Daewoo Doosan Mega 500-V shop manual 023-00033E – PDF DOWNLOAD

Description

Daewoo Doosan Mega 500-V shop manual 023-00033E – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan Mega 500-V shop manual 023-00033E – 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 read the manual periodically. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual.
• The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for any others. In no event should you or others engage in prohibited uses or actions as described in this manual.
• Daewoo delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
• If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Daewoo or your Daewoo distributor before operating the machine

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.

Safety precautions are described in SAFETY from page 1-4 on.

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

GENERAL SAFETY ESSENTIALS ACCESSORY APPLICATIONS

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

LOCATION OF SAFETY LABELS

There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs. Make sure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or other harsh chemicals could loosen the adhesive that secures the warning sign. Loose adhesive will allow the warning sign to fall off. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part

UNAUTHORIZED MODIFICATIONS

Any modification made without authorization or written approval from Daewoo can create a safety hazard, for which the machine owner must be held responsible. For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised

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 500-V shop manual 023-00033E – 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................................................................................................... 47
	Specifications for Mega 500-V S0203070K...................................................................... 49
		General Description...................................................................................... 51
		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
General Maintenance.............................................................................................. 63
	General Maintenance Procedures S0302000...................................................................... 65
		Welding Precautions and Guidelines....................................................................... 67
		Hydraulic System  General Precautions................................................................... 68
		Maintenance Service and Repair Procedure................................................................. 69
			General Precautions.................................................................................. 69
		Hydraulic System Cleanliness and Oil Leaks............................................................... 70
			Maintenance Precautions for Hydraulic System Service................................................. 70
			Oil Leakage Precautions.............................................................................. 70
		Cleaning and Inspection.................................................................................. 71
			General Guidelines................................................................................... 71
			Bearing inspection................................................................................... 72
				Normal Bearing................................................................................... 73
				Bent Cage........................................................................................ 73
				Galling.......................................................................................... 73
				Abrasive Step Wear............................................................................... 74
				Etching.......................................................................................... 74
				Misalignment..................................................................................... 74
				Indentations..................................................................................... 74
				Fatigue Spalling................................................................................. 75
				Brinelling....................................................................................... 75
				Cage Wear........................................................................................ 75
				Abrasive Roller Wear............................................................................. 75
				Cracked Inner Race............................................................................... 76
				Smears........................................................................................... 76
				Frettage......................................................................................... 76
				Heat Discoloration............................................................................... 77
				Stain Discoloration.............................................................................. 77
	Standard Torques S0309000.................................................................................... 79
		Torque Values for Standard Metric Fasteners.............................................................. 81
		Torque Values for Standard U.S. Fasteners................................................................ 82
		Type 8 Phosphate Coated Hardware......................................................................... 84
		Torque Values for Hose Clamps............................................................................ 85
		Torque Values for Split Flanges.......................................................................... 86
		Torque Wrench Extension Tools............................................................................ 87
			Torque Multiplication................................................................................ 87
			Other Uses for Torque Wrench Extension Tools......................................................... 88
			Tightening Torque Specifications (Metric)............................................................ 88
				I. "Loctite" Fastener Adhesives.................................................................. 89
				II. "Loctite" Pipe Thread Sealant................................................................ 89
				III. "Loctite" gasket/flange sealer.............................................................. 89
				IV. "Loctite" retaining compounds................................................................ 90
				V. "Loctite" Adhesives........................................................................... 90
Upper Structure.................................................................................................. 91
	Counterweight S0403040K...................................................................................... 93
		Specifications........................................................................................... 95
		Counterweight............................................................................................ 95
	Fuel Transfer Pump S0405500.................................................................................. 97
		General Description...................................................................................... 99
			Theory of Operation.................................................................................. 99
		Troubleshooting..........................................................................................100
		Replacement of Rotor and Vane............................................................................100
		Replacement of Rear Cover................................................................................101
		Replacement of Armature..................................................................................102
	Hydraulic Oil Tank S0406040K.................................................................................103
		General Description......................................................................................105
			Parts List...........................................................................................105
			Specifications.......................................................................................106
Lower Structure and Chassis......................................................................................109
	Center Joint (Articulation Joint) S0502020K..................................................................111
		General Description......................................................................................113
			Maintenance Standard.................................................................................114
Engine and Drive Train...........................................................................................117
	Axle (ZFAP-420R) S0602170K..................................................................................119
		General Description......................................................................................123
			AP 407 - 420.........................................................................................123
			Specifications.......................................................................................123
			Torque Limits for Screws.............................................................................124
				Torque Limits for Screws (In Nm) According to ZFStandards 148...................................124
				Torque Limits for Locking Screws (In Nm).........................................................125
				Torque Limits for Locking Screws with Locked Toothing (In Nm)....................................125
			Lubrication Instructions.............................................................................126
				Type of Lubrication..............................................................................126
				Oil Level........................................................................................126
				Oil Level Check..................................................................................126
				Oil Change Intervals (Generally).................................................................126
				Brake............................................................................................126
				Point of Grease Lubrication......................................................................126
			List of Lubricants TE-ML 05..........................................................................127
			Examples of Gear-tooth-contact Patterns for the Gleason Gear-tooth System............................129
		Special Tools............................................................................................133
			Final Drive..........................................................................................134
				AP - 407 / 409...................................................................................134
				AP - 411 / 415...................................................................................136
				AP - 417 / 420...................................................................................138
			Differential (Version - Screwed Bearing Caps)........................................................140
				Differential Carrier "CK"........................................................................140
				Differential Carrier "RK"........................................................................142
				Differential Carrier "DK"........................................................................144
			Differential (Version - Cast-on Bearing Caps)........................................................146
				Differential Carrier "DK"........................................................................146
				Differential Carrier "HK"........................................................................148
			Differential (Version - Cast-on and Screwed Bearing Caps)............................................150
				Differential Carrier "LK"........................................................................150
		Planetary Rigid Axle AP 407 - 420 Disassembly............................................................152
			Final Drive..........................................................................................152
		Differential Disassembly (Version - Screwed Bearing Caps)................................................158
			Differential.........................................................................................160
			Drive Unit...........................................................................................161
		Differential Disassembly (Version - Cast-on Bearing Caps)................................................164
			Differential.........................................................................................165
			Drive Unit...........................................................................................168
		Differential Disassembly (Version - Screwed and Cast-on Bearing Caps)....................................170
			Differential.........................................................................................172
			Drive Unit...........................................................................................173
		Final Drive Reassembly...................................................................................176
			Hub Carrier..........................................................................................176
				Check Rolling Resistance of Wheel Bearing........................................................178
			Hub..................................................................................................179
				Complete Internal Gear Carrier...................................................................180
			Internal Gear Carrier................................................................................182
				Adjusting Plate Clearance According To Table.....................................................185
				Determine Sun-gear Shaft Play....................................................................188
			Illustrated Table....................................................................................191
		Differential Reassembly (Version - Screwed Bearing Caps).................................................192
			Determine Thickness of Shim..........................................................................192
			Adjust Rolling Resistance of Drive Pinion Bearing....................................................196
			Differential.........................................................................................199
				Determine Plate Clearance........................................................................202
				Adjustment of Bearing Preload and Backlash.......................................................204
			Illustrated Table....................................................................................207
		Differential Reassembly (Version - Cast-on Bearing Caps).................................................208
			Determine Thickness of Shim..........................................................................208
			Adjustment of Drive Pinion Bearing Rolling Resistance................................................212
			Differential.........................................................................................215
				Determination of Plate Clearance.................................................................218
				Adjustment of Bearing Preload and Backlash.......................................................220
			Illustrated Table....................................................................................223
		Differential Reassembly (Version - Screwed and Cast-on Bearing Caps).....................................224
			Determine Thickness of Shim..........................................................................224
			Adjustment of Drive Pinion Bearing Rolling Resistance................................................226
			Differential.........................................................................................230
				Determination of Plate Clearance.................................................................233
				Adjustment of Bearing Preload and Backlash.......................................................235
			Illustrated Table....................................................................................238
	Air Conditioner S0605050K....................................................................................239
		General Description......................................................................................241
		Refrigerant Circulation..................................................................................242
		Control Panel............................................................................................244
		Control Specifications...................................................................................245
		Temperature Level Control and Display....................................................................246
		Air Discharge According to Path Selection................................................................247
			Vent.................................................................................................247
			Foot.................................................................................................248
			Defroster............................................................................................249
		Airconditioning System Circuit Diagram..................................................................250
		Troubleshooting..........................................................................................252
			Refrigerant Pressure Check...........................................................................252
		Weight of R134a Gas Used In Machines.....................................................................255
		Refrigerant System Repairs...............................................................................257
			Refrigerant Safe Handling Procedures.................................................................257
			Repair and Replacement Procedure.....................................................................258
			Refrigerant Recovery.................................................................................260
			Vacuuming Refrigerant System.........................................................................260
			Leakage Check........................................................................................262
			Refrigerant Charging.................................................................................262
			Inspecting System for Leakage........................................................................264
	Transmission and Torque Converter (ZF4WG-310) S0607080K.....................................................265
		Drive Train Description..................................................................................269
		Transmission and Torque Converter........................................................................270
			Powershift Transmission..............................................................................271
			Transmission Control.................................................................................271
			Schedule of Measuring Points and Connection 4WG-310..................................................272
			Oil Circuit Diagram 4WG-310 Forward 1st Speed........................................................275
		Transmission Electric Components.........................................................................278
			TCU (Transmission Control Unit)......................................................................279
			Transmission Control Valve...........................................................................280
			Transmission Oil Temperature Sensor..................................................................280
			Engine Pickup Sensor.................................................................................281
			Central Gear Pickup Sensor...........................................................................281
			Turbine Pickup Sensor................................................................................281
			Output Speed Sensor..................................................................................282
			Shift Lever Switch (DW-3)............................................................................282
			Auto Selector Switch.................................................................................284
			Display..............................................................................................284
		Transmission Faults Codes................................................................................285
			Fault Display........................................................................................285
			CAN - Message........................................................................................285
			Description of Fault Codes...........................................................................285
			Abbreviations........................................................................................286
			Definition of Operation Modes........................................................................286
				Normal...........................................................................................286
				Substitute Clutch Control........................................................................286
				Limp-home........................................................................................286
				Transmission Shut Down...........................................................................286
				TCU Shut Down....................................................................................286
			Table of Fault Codes.................................................................................287
			Measurement of Resistance at Actuator/sensors and Cable..............................................287
				Actuator.........................................................................................287
				Cable............................................................................................287
		Transmission Electrical Circuits.........................................................................288
			Transmission Controller Circuit......................................................................288
			Traveling Circuits...................................................................................290
				Neutral..........................................................................................290
				Forward First Gear...............................................................................291
				Forward Second Gear..............................................................................292
				Forward Third Gear...............................................................................293
				Forward Fourth Gear..............................................................................294
				Reverse First Gear...............................................................................295
				Reverse Second Gear..............................................................................296
				Reverse Third Gear...............................................................................297
			Downshift............................................................................................298
				Overview.........................................................................................298
				Kick-down: Forward Second Gear to Forward First Gear (Auto Selector Switch "O" - Manual Mode)....298
				Downshift (Auto Selector Switch "I" - Auto Mode).................................................300
			Transmission Cutoff..................................................................................302
		Installation View........................................................................................304
			Inner Section........................................................................................304
			Front View...........................................................................................306
			Side View............................................................................................307
			Rear View............................................................................................308
		Hydraulic Control Unit (HSG-94)..........................................................................309
			Disassembly..........................................................................................310
			Reassembly...........................................................................................314
		Transmission Disassembly.................................................................................322
			Converter-input......................................................................................322
			Drive Shaft Pump Power Take-off......................................................................325
			Transmission Pump....................................................................................327
			Output- Layshaft Assembly............................................................................327
			Multidisk Clutches...................................................................................332
			Power Take-off.......................................................................................333
			Multidisk Clutch - K3/K4.............................................................................334
			Multidisk Clutch KR/K2...............................................................................337
			Multidisk Clutch KV/K1...............................................................................340
		Transmission Reassembly..................................................................................345
			Power Take-off.......................................................................................345
			Reassemble Multidisk Clutch K3/K4....................................................................347
				Multidisk Clutch - K4............................................................................350
				Multidisk Clutch - K3............................................................................354
			Reassemble Multidisk Clutch KR/K2....................................................................358
				Multidisk Clutch - KR............................................................................361
				Multidisk Clutch - K2............................................................................366
			Reassemble Multidisk Clutch KV / K1..................................................................372
				Multidisk Clutch - KV............................................................................375
				Multidisk Clutch - K4............................................................................380
			Install Countershaft Gear and Multidisk Clutches.....................................................385
			Preassemble and Mount Housing Cover..................................................................390
			Install Countershaft Axle............................................................................400
			Hydraulic Pump.......................................................................................402
			Axle Disconnection...................................................................................404
			Filter...............................................................................................405
			Input Shaft (Power Take-off Pump)....................................................................406
			Input – Converter Bell...............................................................................410
			Converter............................................................................................415
			Inductive Transmitters and Speed Sensor..............................................................417
	Transmission Error Codes (ZF) S0607900C......................................................................423
		Introduction.............................................................................................426
		Abbreviations............................................................................................426
		Display..................................................................................................426
			Description of Fault Codes...........................................................................427
		Display During Operation.................................................................................428
		Definition of Operating Modes............................................................................430
			Normal...............................................................................................430
			Substitute Clutch Control............................................................................430
			Limphome............................................................................................430
			Transmission shut Down...............................................................................430
			TCU Shut Down........................................................................................430
		Clutch Pack and Solenoid Valve Crossreference Table.....................................................431
		Table of Fault Codes.....................................................................................432
		Table of Fault Codes  ERGOControl......................................................................454
		Measurement of Resistance at Actuator/ sensors and Cable.................................................457
			Actuator.............................................................................................457
			Cable................................................................................................457
Hydraulics.......................................................................................................459
	Accumulator S0703000.........................................................................................461
		General Description......................................................................................463
			Specifications.......................................................................................464
		Accumulator Charging.....................................................................................467
			Charging the Accumulator with Nitrogen...............................................................467
	Cylinders S0705010...........................................................................................469
		General Description......................................................................................471
			Theory of Operation..................................................................................472
			Parts List...........................................................................................473
				Lift Cylinder....................................................................................473
				Bucket Cylinder..................................................................................474
		Troubleshooting, Testing and Adjustment..................................................................475
		Disassembly..............................................................................................479
		Cleaning and Inspection (Wear Limits and Tolerances).....................................................481
		Reassembly...............................................................................................482
	Fan Drive Hydraulic Motor (Haldex) S0707100K.................................................................491
		General Description......................................................................................493
			Theory of Operation..................................................................................493
			Parts List...........................................................................................495
			Specifications.......................................................................................496
	Pump (Denison T67DB Series) S0708465K........................................................................497
		General Description......................................................................................500
			Theory of Operation..................................................................................500
			Parts List...........................................................................................502
				Main Pump........................................................................................502
				Steering Pump....................................................................................504
				Replacement Parts................................................................................505
			Specification........................................................................................506
		Special Tools............................................................................................506
			Seal Driver..........................................................................................506
			Protective Cone......................................................................................507
		Troubleshooting, Testing and Adjustment..................................................................508
		Disassembly..............................................................................................509
			Pump Disassembly.....................................................................................509
			Camring Replacement, Cartridge Change of Rotation....................................................511
				Unidirectional Cartridge (Examples: 025, 042, 066)...............................................511
				Bidirectional Cartridge (Examples: B06, B25, B42)................................................512
			Shaft Assembly Removal...............................................................................513
			Shaft Seal Removal...................................................................................513
		Cleaning and Inspection (Wear Limits and Tolerances).....................................................514
			Vanes................................................................................................514
			Rotor................................................................................................514
			Camring..............................................................................................514
			Port-plates..........................................................................................515
			Seals................................................................................................515
			Shaft................................................................................................515
			Circuit Inspection...................................................................................516
			Adding Hydraulic Oil to System.......................................................................516
			Adjustments..........................................................................................516
			Lubrication..........................................................................................516
		Reassembly...............................................................................................517
			General Instructions.................................................................................517
			Shaft Assembly Installation..........................................................................517
			Shaft Seal Installation..............................................................................518
			Pump Assembly........................................................................................518
			Porting Change.......................................................................................519
				Bolt Tightening Torque kg•m (ftlb)..............................................................520
				Selection Table..................................................................................520
		Start-up Procedures......................................................................................521
			Prestart Check.......................................................................................521
			Priming..............................................................................................521
	Main Pump (Denison T6DMY Series) S0708475K...................................................................523
		General Description......................................................................................525
			Construction.........................................................................................525
				General..........................................................................................525
				Assembly and Construction........................................................................526
			Theory of Operation..................................................................................527
			Parts List...........................................................................................528
			Specifications.......................................................................................529
		Troubleshooting, Testing and Adjustment..................................................................530
		Disassembly..............................................................................................532
			General InstructionS.................................................................................532
			Pump Disassembly.....................................................................................532
			Camring Replacement, Cartridge Change of Rotation....................................................534
				Unidirectional Cartridge (Examples: 025, 042, 066)...............................................534
				Bidirectional Cartridge (Examples: B06, B25, B42)................................................535
			Shaft Assembly Removal...............................................................................536
			Shaft Seal Removal...................................................................................536
		Cleaning and Inspection (Wear Limits and Tolerances).....................................................537
			Vanes................................................................................................537
			Vane Holdout Pins....................................................................................537
			Rotor................................................................................................537
			Camring..............................................................................................537
			Port-plates..........................................................................................538
			Seals................................................................................................538
			Shaft................................................................................................538
		Reassembly...............................................................................................539
			Shaft Assembly Installation..........................................................................539
			Shaft Seal Installation..............................................................................539
			Pump Assembly........................................................................................539
			Porting Change.......................................................................................541
				Bolt Tightening Torque...........................................................................541
				Porting Codes....................................................................................541
				Adapter Porting..................................................................................541
		Start-up Procedures......................................................................................542
			Prestart Check.......................................................................................542
			Priming..............................................................................................542
	Brake Pedal Valve S0709240K..................................................................................543
		General Description......................................................................................545
			Theory of Operation..................................................................................545
			Specification........................................................................................547
		Brake System.............................................................................................548
		Brake, Pilot and Parking Brake Supply Valve..............................................................549
			Specifications.......................................................................................550
	Main Control Valve (Toshiba) S0709455K.......................................................................551
		General Description......................................................................................553
		Specifications...........................................................................................555
		Operation................................................................................................556
			Neutral..............................................................................................556
			Bucket/option Spool Operation........................................................................556
			Boom Spool Operation.................................................................................557
				Boom Float.......................................................................................557
			Relief Valve.........................................................................................557
				Main Relief Valve................................................................................557
				Port Relief Valve................................................................................557
			Operation (Main Relief Valve)........................................................................558
				Operation in Inoperative State...................................................................558
				Operation (A)....................................................................................558
				Operation (B)....................................................................................558
			Operation (Port Relief Valve)........................................................................559
				In the Inoperative State.........................................................................559
				Operation (A)....................................................................................559
				Operation (B)....................................................................................559
				Operation (C)....................................................................................560
				Sucking Operation................................................................................560
	Pilot Control Valve S0709476K................................................................................561
		General Description......................................................................................564
			Pilot Valve Operation................................................................................564
		Pilot System.............................................................................................566
	Flow Amplifier (Danfoss) S0709665K...........................................................................569
		General Description......................................................................................571
			Parts List...........................................................................................572
			Specifications.......................................................................................573
		Special Tools and Materials..............................................................................574
			Special tools........................................................................................574
		Troubleshooting, Testing and Adjustment..................................................................575
			Steering System with OSQA/B and OSPBXLS.............................................................576
		Disassembly..............................................................................................577
		Cleaning and Inspection (Wear Limits and Tolerances).....................................................597
			Cleaning.............................................................................................597
			Inspection and replacement...........................................................................597
			Lubrication..........................................................................................597
		Reassembly...............................................................................................597
	Power Steering Unit S0709730K................................................................................617
		General Description......................................................................................619
			Power Steering System................................................................................619
				Power Steering Unit..............................................................................619
				Neutral Operation................................................................................621
				Right Turn.......................................................................................621
				Left Turn........................................................................................621
			Gerotor Operation....................................................................................621
			Cushion Valve Operation..............................................................................622
				Function.........................................................................................622
				Working Principle................................................................................622
			Parts List...........................................................................................624
			Specifications.......................................................................................625
		Special Tools............................................................................................626
		Troubleshooting, Testing and Adjustment..................................................................628
		Disassembly..............................................................................................629
		Cleaning and Inspection..................................................................................633
		Reassembly...............................................................................................634
		Installation.............................................................................................645
	Restriction Valve S0709750K..................................................................................647
		General Description......................................................................................649
			Theory of Operation..................................................................................649
			Unloader Cartridge Identification....................................................................650
			Specifications.......................................................................................651
	Hydraulic Schematic (Mega 500-V) S0793060K...................................................................653
		General Description......................................................................................655
		Mega 500-V...............................................................................................656
Electrical System................................................................................................659
	Electrical System S0802190K..................................................................................661
		Overview.................................................................................................663
			Electric Wire Color..................................................................................663
		Electric Supply System...................................................................................664
		Engine Starting Circuit..................................................................................666
			Operation During Start Process.......................................................................666
			Operation After Start Process........................................................................668
		Cold Weather Starting Aid System (Option)................................................................670
			Principle of Operation...............................................................................671
		Engine Stop and Derating System..........................................................................672
			Operation In Engine Stop Mode........................................................................672
			Operation in Engine Derating.........................................................................674
		Charging System..........................................................................................676
		Monitoring System........................................................................................677
			Instrument Panel.....................................................................................678
			Function Check.......................................................................................679
			Monitoring System Schematic..........................................................................680
			Operation............................................................................................682
				Instruments......................................................................................682
				Indicator Lights.................................................................................683
				Initial Operation................................................................................685
				Control Unit Operation...........................................................................686
				Characteristic of Operation......................................................................687
		Windshield Wiper.........................................................................................688
			Front Windshield Wiper...............................................................................688
				Front Windshield Wiper Circuit...................................................................688
			Rear Windshield wiper................................................................................689
		Lighting System..........................................................................................692
			Light Circuit........................................................................................692
	Electrical Schematic (Mega 500-V) S0893060K..................................................................695
		General Description......................................................................................697
		Mega 500-V...............................................................................................698
Attachments......................................................................................................701

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