Daewoo Doosan Mega 500-V (Tier II) shop manual 023-00054E – PDF DOWNLOAD

Daewoo Doosan Mega 500-V (Tier II) shop manual 023-00054E – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan Mega 500-V (Tier II) shop manual 023-00054E – 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 (Tier II) shop manual 023-00054E – 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 (Tier II) S0203075K............................................................ 49
		General Description...................................................................................... 52
		General Specifications................................................................................... 55
		Engine Performance Curves................................................................................ 56
		Working Range and Dimensions............................................................................. 58
		Working Capacities....................................................................................... 61
			Bucket Capacity...................................................................................... 61
			Tipping Load......................................................................................... 61
		Material Weight.......................................................................................... 61
			Approximate Weight of Workload Materials............................................................. 61
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 S0403040K...................................................................................... 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 S0406040K.................................................................................105
		General Description......................................................................................107
			Parts List...........................................................................................107
			Specifications.......................................................................................108
Lower Structure and Chassis......................................................................................111
	Center Joint (Articulation Joint) S0502020K..................................................................113
		General Description......................................................................................115
			Maintenance Standard.................................................................................116
Engine and Drive Train...........................................................................................119
	Axle (ZFAP-420R) S0602170K..................................................................................121
		General Description......................................................................................125
			AP 407 - 420.........................................................................................125
			Specifications.......................................................................................125
			Torque Limits for Screws.............................................................................126
				Torque Limits for Screws (In Nm) According to ZFStandards 148...................................126
				Torque Limits for Locking Screws (In Nm).........................................................127
				Torque Limits for Locking Screws with Locked Toothing (In Nm)....................................127
			Lubrication Instructions.............................................................................128
				Type of Lubrication..............................................................................128
				Oil Level........................................................................................128
				Oil Level Check..................................................................................128
				Oil Change Intervals (Generally).................................................................128
				Brake............................................................................................128
				Point of Grease Lubrication......................................................................128
			List of Lubricants TE-ML 05..........................................................................129
			Examples of Gear-tooth-contact Patterns for the Gleason Gear-tooth System............................131
		Special Tools............................................................................................135
			Final Drive..........................................................................................136
				AP - 407 / 409...................................................................................136
				AP - 411 / 415...................................................................................138
				AP - 417 / 420...................................................................................140
			Differential (Version - Screwed Bearing Caps)........................................................142
				Differential Carrier "CK"........................................................................142
				Differential Carrier "RK"........................................................................144
				Differential Carrier "DK"........................................................................146
			Differential (Version - Cast-on Bearing Caps)........................................................148
				Differential Carrier "DK"........................................................................148
				Differential Carrier "HK"........................................................................150
			Differential (Version - Cast-on and Screwed Bearing Caps)............................................152
				Differential Carrier "LK"........................................................................152
		Planetary Rigid Axle AP 407 - 420 Disassembly............................................................154
			Final Drive..........................................................................................154
		Differential Disassembly (Version - Screwed Bearing Caps)................................................160
			Differential.........................................................................................162
			Drive Unit...........................................................................................163
		Differential Disassembly (Version - Cast-on Bearing Caps)................................................166
			Differential.........................................................................................167
			Drive Unit...........................................................................................170
		Differential Disassembly (Version - Screwed and Cast-on Bearing Caps)....................................172
			Differential.........................................................................................174
			Drive Unit...........................................................................................175
		Final Drive Reassembly...................................................................................178
			Hub Carrier..........................................................................................178
				Check Rolling Resistance of Wheel Bearing........................................................180
			Hub..................................................................................................181
				Complete Internal Gear Carrier...................................................................182
			Internal Gear Carrier................................................................................184
				Adjusting Plate Clearance According To Table.....................................................187
				Determine Sun-gear Shaft Play....................................................................190
			Illustrated Table....................................................................................193
		Differential Reassembly (Version - Screwed Bearing Caps).................................................194
			Determine Thickness of Shim..........................................................................194
			Adjust Rolling Resistance of Drive Pinion Bearing....................................................198
			Differential.........................................................................................201
				Determine Plate Clearance........................................................................204
				Adjustment of Bearing Preload and Backlash.......................................................206
			Illustrated Table....................................................................................209
		Differential Reassembly (Version - Cast-on Bearing Caps).................................................210
			Determine Thickness of Shim..........................................................................210
			Adjustment of Drive Pinion Bearing Rolling Resistance................................................214
			Differential.........................................................................................217
				Determination of Plate Clearance.................................................................220
				Adjustment of Bearing Preload and Backlash.......................................................222
			Illustrated Table....................................................................................225
		Differential Reassembly (Version - Screwed and Cast-on Bearing Caps).....................................226
			Determine Thickness of Shim..........................................................................226
			Adjustment of Drive Pinion Bearing Rolling Resistance................................................228
			Differential.........................................................................................232
				Determination of Plate Clearance.................................................................235
				Adjustment of Bearing Preload and Backlash.......................................................237
			Illustrated Table....................................................................................240
	Air Conditioner S0605050K....................................................................................241
		General Description......................................................................................243
		Refrigerant Circulation..................................................................................244
		Control Panel............................................................................................246
		Control Specifications...................................................................................247
		Temperature Level Control and Display....................................................................248
		Air Discharge According to Path Selection................................................................249
			Vent.................................................................................................249
			Foot.................................................................................................250
			Defroster............................................................................................251
		Airconditioning System Circuit Diagram..................................................................252
		Troubleshooting..........................................................................................254
			Refrigerant Pressure Check...........................................................................254
		Weight of R134a Gas Used In Machines.....................................................................257
		Refrigerant System Repairs...............................................................................259
			Refrigerant Safe Handling Procedures.................................................................259
			Repair and Replacement Procedure.....................................................................260
			Refrigerant Recovery.................................................................................262
			Vacuuming Refrigerant System.........................................................................262
			Leakage Check........................................................................................264
			Refrigerant Charging.................................................................................264
			Inspecting System for Leakage........................................................................266
	Transmission and Torque Converter (ZF4WG-310) S0607080K.....................................................267
		Drive Train Description..................................................................................271
		Transmission and Torque Converter........................................................................272
			Powershift Transmission..............................................................................273
			Transmission Control.................................................................................273
			Schedule of Measuring Points and Connection 4WG-310..................................................274
			Oil Circuit Diagram 4WG-310 Forward 1st Speed........................................................277
		Transmission Electric Components.........................................................................280
			TCU (Transmission Control Unit)......................................................................281
			Transmission Control Valve...........................................................................282
			Transmission Oil Temperature Sensor..................................................................282
			Engine Pickup Sensor.................................................................................283
			Central Gear Pickup Sensor...........................................................................283
			Turbine Pickup Sensor................................................................................283
			Output Speed Sensor..................................................................................284
			Shift Lever Switch (DW-3)............................................................................284
			Auto Selector Switch.................................................................................286
			Display..............................................................................................286
		Transmission Faults Codes................................................................................287
			Fault Display........................................................................................287
			CAN - Message........................................................................................287
			Description of Fault Codes...........................................................................287
			Abbreviations........................................................................................288
			Definition of Operation Modes........................................................................288
				Normal...........................................................................................288
				Substitute Clutch Control........................................................................288
				Limp-home........................................................................................288
				Transmission Shut Down...........................................................................288
				TCU Shut Down....................................................................................288
			Table of Fault Codes.................................................................................289
			Measurement of Resistance at Actuator/sensors and Cable..............................................289
				Actuator.........................................................................................289
				Cable............................................................................................289
		Transmission Electrical Circuits.........................................................................290
			Transmission Controller Circuit......................................................................290
			Traveling Circuits...................................................................................292
				Neutral..........................................................................................292
				Forward First Gear...............................................................................293
				Forward Second Gear..............................................................................294
				Forward Third Gear...............................................................................295
				Forward Fourth Gear..............................................................................296
				Reverse First Gear...............................................................................297
				Reverse Second Gear..............................................................................298
				Reverse Third Gear...............................................................................299
			Downshift............................................................................................300
				Overview.........................................................................................300
				Kick-down: Forward Second Gear to Forward First Gear (Auto Selector Switch "O" - Manual Mode)....300
				Downshift (Auto Selector Switch "I" - Auto Mode).................................................302
			Transmission Cutoff..................................................................................304
		Installation View........................................................................................306
			Inner Section........................................................................................306
			Front View...........................................................................................308
			Side View............................................................................................309
			Rear View............................................................................................310
		Hydraulic Control Unit (HSG-94)..........................................................................311
			Disassembly..........................................................................................312
			Reassembly...........................................................................................316
		Transmission Disassembly.................................................................................324
			Converter-input......................................................................................324
			Drive Shaft Pump Power Take-off......................................................................327
			Transmission Pump....................................................................................329
			Output- Layshaft Assembly............................................................................329
			Multidisk Clutches...................................................................................334
			Power Take-off.......................................................................................335
			Multidisk Clutch - K3/K4.............................................................................336
			Multidisk Clutch KR/K2...............................................................................339
			Multidisk Clutch KV/K1...............................................................................342
		Transmission Reassembly..................................................................................347
			Power Take-off.......................................................................................347
			Reassemble Multidisk Clutch K3/K4....................................................................349
				Multidisk Clutch - K4............................................................................352
				Multidisk Clutch - K3............................................................................356
			Reassemble Multidisk Clutch KR/K2....................................................................360
				Multidisk Clutch - KR............................................................................363
				Multidisk Clutch - K2............................................................................368
			Reassemble Multidisk Clutch KV / K1..................................................................374
				Multidisk Clutch - KV............................................................................377
				Multidisk Clutch - K4............................................................................382
			Install Countershaft Gear and Multidisk Clutches.....................................................387
			Preassemble and Mount Housing Cover..................................................................392
			Install Countershaft Axle............................................................................402
			Hydraulic Pump.......................................................................................404
			Axle Disconnection...................................................................................406
			Filter...............................................................................................407
			Input Shaft (Power Take-off Pump)....................................................................408
			Input – Converter Bell...............................................................................412
			Converter............................................................................................417
			Inductive Transmitters and Speed Sensor..............................................................419
	Transmission Error Codes (ZF) S0607900C......................................................................425
		Introduction.............................................................................................428
		Abbreviations............................................................................................428
		Display..................................................................................................428
			Description of Fault Codes...........................................................................429
		Display During Operation.................................................................................430
		Definition of Operating Modes............................................................................432
			Normal...............................................................................................432
			Substitute Clutch Control............................................................................432
			Limphome............................................................................................432
			Transmission shut Down...............................................................................432
			TCU Shut Down........................................................................................432
		Clutch Pack and Solenoid Valve Crossreference Table.....................................................433
		Table of Fault Codes.....................................................................................434
		Table of Fault Codes  ERGOControl......................................................................456
		Measurement of Resistance at Actuator/ sensors and Cable.................................................459
			Actuator.............................................................................................459
			Cable................................................................................................459
Hydraulics.......................................................................................................461
	Accumulator S0703000.........................................................................................463
		General Description......................................................................................465
			Specifications.......................................................................................466
		Accumulator Charging.....................................................................................469
			Charging the Accumulator with Nitrogen...............................................................469
	Cylinders S0705010...........................................................................................471
		General Description......................................................................................473
			Theory of Operation..................................................................................474
			Parts List...........................................................................................475
				Lift Cylinder....................................................................................475
				Bucket Cylinder..................................................................................476
		Troubleshooting, Testing and Adjustment..................................................................477
		Disassembly..............................................................................................481
		Cleaning and Inspection (Wear Limits and Tolerances).....................................................483
		Reassembly...............................................................................................484
	Fan Drive Hydraulic Motor (Haldex) S0707100K.................................................................493
		General Description......................................................................................495
			Theory of Operation..................................................................................495
			Parts List...........................................................................................497
			Specifications.......................................................................................498
	Pump (Denison T67DB Series) S0708465K........................................................................499
		General Description......................................................................................502
			Theory of Operation..................................................................................502
			Parts List...........................................................................................504
				Main Pump........................................................................................504
				Steering Pump....................................................................................506
				Replacement Parts................................................................................507
			Specification........................................................................................508
		Special Tools............................................................................................508
			Seal Driver..........................................................................................508
			Protective Cone......................................................................................509
		Troubleshooting, Testing and Adjustment..................................................................510
		Disassembly..............................................................................................511
			Pump Disassembly.....................................................................................511
			Camring Replacement, Cartridge Change of Rotation....................................................513
				Unidirectional Cartridge (Examples: 025, 042, 066)...............................................513
				Bidirectional Cartridge (Examples: B06, B25, B42)................................................514
			Shaft Assembly Removal...............................................................................515
			Shaft Seal Removal...................................................................................515
		Cleaning and Inspection (Wear Limits and Tolerances).....................................................516
			Vanes................................................................................................516
			Rotor................................................................................................516
			Camring..............................................................................................516
			Port-plates..........................................................................................517
			Seals................................................................................................517
			Shaft................................................................................................517
			Circuit Inspection...................................................................................518
			Adding Hydraulic Oil to System.......................................................................518
			Adjustments..........................................................................................518
			Lubrication..........................................................................................518
		Reassembly...............................................................................................519
			General Instructions.................................................................................519
			Shaft Assembly Installation..........................................................................519
			Shaft Seal Installation..............................................................................520
			Pump Assembly........................................................................................520
			Porting Change.......................................................................................521
				Bolt Tightening Torque kg•m (ftlb)..............................................................522
				Selection Table..................................................................................522
		Start-up Procedures......................................................................................523
			Prestart Check.......................................................................................523
			Priming..............................................................................................523
	Brake Pedal Valve S0709240K..................................................................................525
		General Description......................................................................................527
			Theory of Operation..................................................................................527
			Specification........................................................................................529
		Brake System.............................................................................................530
		Brake, Pilot and Parking Brake Supply Valve..............................................................531
			Specifications.......................................................................................532
	Main Control Valve (Toshiba) S0709455K.......................................................................533
		General Description......................................................................................535
		Specifications...........................................................................................537
		Operation................................................................................................538
			Neutral..............................................................................................538
			Bucket/option Spool Operation........................................................................538
			Boom Spool Operation.................................................................................539
				Boom Float.......................................................................................539
			Relief Valve.........................................................................................539
				Main Relief Valve................................................................................539
				Port Relief Valve................................................................................539
			Operation (Main Relief Valve)........................................................................540
				Operation in Inoperative State...................................................................540
				Operation (A)....................................................................................540
				Operation (B)....................................................................................540
			Operation (Port Relief Valve)........................................................................541
				In the Inoperative State.........................................................................541
				Operation (A)....................................................................................541
				Operation (B)....................................................................................541
				Operation (C)....................................................................................542
				Sucking Operation................................................................................542
	Pilot Control Valve S0709476K................................................................................543
		General Description......................................................................................546
			Pilot Valve Operation................................................................................546
		Pilot System.............................................................................................548
	Flow Amplifier (Danfoss) S0709665K...........................................................................551
		General Description......................................................................................553
			Parts List...........................................................................................554
			Specifications.......................................................................................555
		Special Tools and Materials..............................................................................556
			Special tools........................................................................................556
		Troubleshooting, Testing and Adjustment..................................................................557
			Steering System with OSQA/B and OSPBXLS.............................................................558
		Disassembly..............................................................................................559
		Cleaning and Inspection (Wear Limits and Tolerances).....................................................579
			Cleaning.............................................................................................579
			Inspection and replacement...........................................................................579
			Lubrication..........................................................................................579
		Reassembly...............................................................................................579
	Power Steering Unit S0709730K................................................................................599
		General Description......................................................................................601
			Power Steering System................................................................................601
				Power Steering Unit..............................................................................601
				Neutral Operation................................................................................603
				Right Turn.......................................................................................603
				Left Turn........................................................................................603
			Gerotor Operation....................................................................................603
			Cushion Valve Operation..............................................................................604
				Function.........................................................................................604
				Working Principle................................................................................604
			Parts List...........................................................................................606
			Specifications.......................................................................................607
		Special Tools............................................................................................608
		Troubleshooting, Testing and Adjustment..................................................................610
		Disassembly..............................................................................................611
		Cleaning and Inspection..................................................................................615
		Reassembly...............................................................................................616
		Installation.............................................................................................627
	Restriction Valve S0709750K..................................................................................629
		General Description......................................................................................631
			Theory of Operation..................................................................................631
			Unloader Cartridge Identification....................................................................632
			Specifications.......................................................................................633
	Hydraulic Schematic (Mega 500-V (Tier II)) S0793065K.........................................................635
		General Description......................................................................................637
		Mega 500-V (Tier II).....................................................................................638
Electrical System................................................................................................641
	Electrical System S0802195K..................................................................................643
		Overview.................................................................................................647
			Electric Wire Color..................................................................................647
		Electric Supply System...................................................................................648
		Engine Starting Circuit..................................................................................650
			Operation During Start Process.......................................................................650
			Operation After Start Process........................................................................652
		Engine Stop and Derating System..........................................................................654
			Operation In Engine Stop.............................................................................654
			Operation in Engine Derating.........................................................................654
		Charging System..........................................................................................656
		Monitoring System........................................................................................657
			Instrument Panel.....................................................................................658
			Function Check.......................................................................................659
			Monitoring System Schematic..........................................................................660
			Operation............................................................................................662
				Instruments......................................................................................662
				Indicator Lights.................................................................................663
				Initial Operation................................................................................664
				Control Unit Operation...........................................................................665
				Characteristic of Operation......................................................................665
		Windshield Wiper.........................................................................................668
			Front Windshield Wiper...............................................................................668
				Front Windshield Wiper Circuit...................................................................668
			Rear Windshield wiper................................................................................669
		Lighting System..........................................................................................672
			Light Circuit........................................................................................672
		Engine Control System....................................................................................675
			ECM Block Diagram....................................................................................675
		ECM Electric Circuit.....................................................................................676
			ECM External Circuit.................................................................................676
			ECM Internal Circuit.................................................................................677
		ECM System Component.....................................................................................678
			ECM (Electronic Control Module)......................................................................678
			Alternate (Switchable) Torque Switch.................................................................678
			Alternate Low Idle Switch............................................................................679
			Idle Speed Control Switch............................................................................679
			Engine Diagnostic Switch.............................................................................680
			Engine Fault Codes...................................................................................680
			Fault Code Information...............................................................................682
		Electronic Accelerator...................................................................................689
			Electric Specification...............................................................................689
			Switch Specification.................................................................................689
			Mechanical Specification (Pedal Sensor)..............................................................690
		Data Link for Engine Communication.......................................................................690
		LIS (Load Isolation System) - Option.....................................................................690
		Aeb Starter..............................................................................................692
			Introduction.........................................................................................692
			List of Abbreviations................................................................................692
			Procedure to Start AEB...............................................................................692
			Display During AEB-mode..............................................................................693
	Electrical Schematic (Mega 500-V (Tier II)) S0893065K........................................................695
		General Description......................................................................................697
		Mega 500-V (Tier II).....................................................................................698
Attachments......................................................................................................701

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