Daewoo Doosan Mega Mega 300-V Shop Manual 023-00041AE – PDF DOWNLOAD

Description

Daewoo Doosan Mega Mega 300-V Shop Manual 023-00041AE – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan Mega Mega 300-V Shop Manual 023-00041AE – PDF DOWNLOAD

• Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
• It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package.
• Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item.

TO THE OPERATOR OF A DAEWOO WHEEL LOADER

• Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
• Please respect the importance of taking responsibility for your own safety, and that other people who may be affected by your actions.
• Safety information on the following pages is organized into the following topics.

1. “General Safety Essentials” on page 6.
2. “Location of Safety Labels” on page 6.
3. “Unauthorized Modifications” on page 6.
4. “General Hazard Information” on page 7.
5. “Before Starting Engine” on page 15.
6. “Machine Operation” on page 18.
7. “Maintenance” on page 25.
8. “Battery” on page 33.
9. “Towing” on page 35.
10. “Shipping and Transportation” on page 36.

• Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance.
• Keep this manual in the storage compartment to the rear of the operator’s seat, and have all personnel involved in working on the machine periodically read the manual. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. T
• he 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. I
• f 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 6 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

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

UNAUTHORIZED MODIFICATIONS

Any modification made without authorization or written approval from 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 Mega 300-V Shop Manual 023-00041AE – PDF DOWNLOAD

Safety..............................................................................  7
	Wheel Loader Safety S0103010K...................................................  9
		To the Operator of a Daewoo Wheel Loader.................................... 11
			Learn Signal Words Used with Safety Alert Symbol........................ 13
		General Safety Essentials................................................... 14
			Accessory Applications.................................................. 14
		Location of Safety Labels................................................... 14
		Unauthorized Modifications.................................................. 14
		General Hazard Information.................................................. 15
			Safety Rules............................................................ 15
			Safety Features......................................................... 15
			Inside Operator's Compartment........................................... 16
			Clothing and Personal Protective Items.................................. 16
			Breathing Masks, Ear Protection May Be Required......................... 17
			Asbestos Dust Hazard Prevention......................................... 17
			Mounting and Dismounting................................................ 17
			Fuel, Oil and Hydraulic Fluid Fire Hazards.............................. 18
			Precautions When Handling Fluids at High Temperature.................... 18
			Injury from Work Equipment.............................................. 19
			Fire Extinguisher and First Aid Kit..................................... 19
			Protection from Falling or Flying Objects............................... 20
			Install Additional Safety Equipment If Conditions Require............... 20
			Maintain Standard Safety Equipment in Good Condition.................... 20
			Attachment Precautions.................................................. 21
			Accumulator............................................................. 21
			Engine Ventilation...................................................... 21
			Window Glass Breaking Tool.............................................. 22
		Before Starting Engine...................................................... 23
			Work Site Precautions................................................... 23
			Checks Before Starting Engine........................................... 24
			Engine Starting......................................................... 24
			Before Operating Machine................................................ 25
		Machine Operation........................................................... 26
			Operate While Seated at Operator’s Station ONLY......................... 26
			Seat Belts Should Be Used at All Times.................................. 26
			Movement Alarms......................................................... 26
			Travel Precautions...................................................... 27
			Sloping Terrain Requires Caution........................................ 27
			Avoid High-voltage Cables............................................... 28
			Before Starting to Dig, Contact Authorities............................. 28
			Be Aware of Height Obstacles............................................ 28
			Use Care on Loose Support............................................... 28
			Use Solid Support Blocking.............................................. 29
			Digging Beneath Overhangs............................................... 29
			Digging Beneath Wheel Loader............................................ 29
			Stay Alert for People Moving Through Work Area.......................... 29
			Be Aware of and Conform to Local Regulations............................ 29
			Never Use Ether Starting Aids........................................... 30
			Observe General Safety Rules............................................ 30
			Take Time to Provide Good Visibility.................................... 30
			Keep "Pinch Point" Areas Clear - Use Caution in Reverse................. 31
			Operate Carefully on Snow and Ice and in Very Cold Temperatures......... 31
			Parking Machine......................................................... 31
			Shutdown Control Functions.............................................. 32
			Never Let Anyone Ride on Attachment..................................... 32
		Maintenance................................................................. 33
			Use Warning Tag During Service.......................................... 33
			clean Before Inspection or Maintenance.................................. 33
			Proper Tools............................................................ 34
			Use of Lighting......................................................... 34
			Fire Prevention and Explosion Prevention................................ 34
			Burn Prevention......................................................... 35
			Welding Repairs......................................................... 36
			Precautions for Removal, Installation, and Storage of Attachments....... 36
			Precautions When Working on Machine..................................... 37
			Lock Inspection Covers.................................................. 37
			Crushing Prevention and Cutting Prevention.............................. 37
			Do Not Run Engine If Repairs or Work Are Being Performed Alone.......... 37
			Always Use Adequate Equipment Supports and Blocking..................... 38
			Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems.......... 38
			Hydraulic Cylinder Seals Require Periodic Replacement................... 38
			High Pressure Hydraulic Lines Can Store a Great Deal of Energy.......... 38
			Precautions with High Pressure Line, Tubes and Hoses.................... 39
			Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin...... 39
			Use Correct Replacement Fasteners Tightened to Proper Torque............ 40
			Safety-critical Parts Must Be Replaced Periodically..................... 40
			Dispose of All Petroleum-based Oils and Fluids Properly................. 40
			Check Tire Pressure and Condition....................................... 40
		Battery..................................................................... 41
			Battery Hazard Prevention............................................... 41
			Disconnect Batteries Before Electrical Service or Electrical Welding.... 41
			Use Low Heat Portable Lighting.......................................... 42
			Boost Starting or Charging Engine Batteries............................. 42
		Towing...................................................................... 43
			Precautions When Towing................................................. 43
		Shipping and Transportation................................................. 44
			Obey State and Local Over-the-Road Regulations.......................... 44
			Summary of Safety Precautions for Lifting............................... 44
Specifications...................................................................... 45
	Specifications for Mega 300-V S0203080K......................................... 47
		Component Locations......................................................... 50
		General Specifications...................................................... 52
		Engine Performance Curves................................................... 54
		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
	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
Upper Structure..................................................................... 93
	Counterweight S0403030K......................................................... 95
		Specifications.............................................................. 97
		Counterweight............................................................... 97
	Fuel Transfer Pump S0405500..................................................... 99
		General Description.........................................................101
			Theory of Operation.....................................................101
		Troubleshooting.............................................................102
		Replacement of Rotor and Vane...............................................102
		Replacement of Rear Cover...................................................103
		Replacement of Armature.....................................................104
	Hydraulic Oil Tank S0406050K....................................................105
		General Description.........................................................107
			Parts List..............................................................107
			Specifications..........................................................108
Lower Structure and Chassis.........................................................109
	Center Joint (Articulation Joint) S0502030K.....................................111
		General Description.........................................................113
			Maintenance Standard....................................................114
Engine and Drive Train..............................................................117
	Front Axle (Volvo SLA15/W) S0602180K...........................................119
		General Description.........................................................123
			Outline.................................................................123
			Drive Axle..............................................................123
			Differential (Standard).................................................126
			Parking Brake Operation.................................................127
			Parts List..............................................................129
		Scheduled Maintenance.......................................................138
			After First 250 Hours...................................................138
			Every 150 hours.........................................................138
			Every 1500 Hours........................................................139
			Lubricant Specifications................................................139
		General Disassembly and Reassembly Instructions.............................140
			General Instructions....................................................140
			Assembling Leakproof Components.........................................141
		Axle Disassembly............................................................141
			Drain Oil...............................................................141
			Final Drive.............................................................142
			Differential Assembly...................................................146
			Overhauling Super Max Trac Assembly.....................................149
			Checking Clearance on Assembled Disc Packs..............................149
		Axle Reassembly.............................................................150
			Determining Thickness of Adjustment Shims...............................150
			Inner Oil Recirculation Piping..........................................151
			Differential Assembly...................................................152
			Axial Position of Bevel Pinion..........................................152
			Adjusting Backlash......................................................153
			Adjusting Tooth Contact.................................................154
			Securing Differential to Axle Housing...................................157
			Final Drive.............................................................158
			Determining Space Available to Form Brake Disc Pack.....................160
		Parking Brake (S/N 1001 thru 2000)..........................................162
			Disassembly.............................................................163
			Reassembly..............................................................163
			Adjustment..............................................................163
		Parking Brake (S/N 2001 and Up).............................................164
	Rear Axle (Volvo SLA12/W) S0602190K............................................165
		General Description.........................................................169
			Outline.................................................................169
			Drive Axle..............................................................169
			Differential (Standard).................................................172
			Parts List..............................................................175
		Scheduled Maintenance.......................................................180
			After First 250 Hours...................................................180
			Every 150 hours.........................................................181
			Every 1500 Hours........................................................181
			Lubricant Specifications................................................181
		General Disassembly and Reassembly Instructions.............................182
			General Instructions....................................................182
			Assembling Leakproof Components.........................................183
		Axle Disassembly............................................................183
			Drain Oil...............................................................183
			Final Drive.............................................................184
			Differential Assembly...................................................189
			Overhauling Super Max Trac Assembly.....................................192
			Checking Clearance on Assembled Disc Packs..............................192
		Axle Reassembly.............................................................193
			Determining Thickness of Adjustment Shims...............................193
			Differential Assembly...................................................194
			Axial Position of Bevel Pinion..........................................194
			Adjusting Backlash......................................................195
			Adjusting Tooth Contact.................................................196
			Securing Differential to Axle Housing...................................199
			Final Drive.............................................................200
			Determining Space Available to Form Brake Disc Pack.....................202
	Parking Brake Caliper (Volvo) S0603000..........................................203
		General Description.........................................................205
			Operation...............................................................205
			Parking Brake Applied...................................................206
			Parking Brake Released..................................................206
			Parts List..............................................................207
		Special Tools and Materials.................................................207
			Lubricants and Sealants.................................................207
		Troubleshooting, Testing and Adjustment.....................................208
			Parking Brake System....................................................208
			Checking and Adjusting Parking Brake....................................208
			Measuring Pad Thickness.................................................208
			Measuring Disc / Pad Clearance..........................................208
			Measuring Procedure.....................................................209
			Adjustment..............................................................209
			Releasing the Parking Brake in Emergency Case...........................210
		Disassembly.................................................................211
			General.................................................................211
			Changing Brake Pads.....................................................211
			Work Sequence During Change of Brake Pads...............................211
		Cleaning and Inspection (Wear Limits and Tolerances)........................213
		Reassembly..................................................................215
	Air Conditioner S0605050K.......................................................221
		General Description.........................................................223
		Refrigerant Circulation.....................................................224
		Control Panel...............................................................226
		Control Specifications......................................................227
		Temperature Level Control and Display.......................................228
		Air Discharge According to Path Selection...................................229
		Air-conditioning System Circuit Diagram.....................................232
		Troubleshooting.............................................................234
		Weight of R134a Gas Used In Machines........................................238
		Refrigerant System Repairs..................................................240
			Refrigerant Safe Handling Procedures....................................240
			Repair and Replacement Procedure........................................241
			Refrigerant Recovery....................................................243
			Vacuuming Refrigerant System............................................243
			Leakage Check...........................................................244
			Refrigerant Charging....................................................245
			Inspecting System For Leakage...........................................247
	Transmission and Torque Converter (ZF4WG210) S0607090K........................249
		Drive Train Description.....................................................254
		Transmission and Torque Converter...........................................255
			Powershift Transmission.................................................256
			Transmission Control....................................................256
			Schedule of Measuring Points and Connection 4 WG-210....................258
			Oil Circuit Diagram 4WG-210 Forward 1st Speed...........................260
		Transmission Electrical Components..........................................262
			TCU (Transmission Control Unit).........................................263
			Transmission Control Valve..............................................263
			Transmission Oil Temperature Sensor.....................................264
			Engine Pick-up Sensor...................................................264
			Central Gear Pick-up Sensor.............................................264
			Turbine Pick-Up Sensor..................................................265
			Output Speed Sensor.....................................................265
			Shift Lever Switch (DW-3)...............................................265
			Auto Select Switch......................................................267
			Display.................................................................267
		Transmission Faults Codes...................................................268
			Fault Display...........................................................268
			CAN - Message...........................................................268
			Description of Fault Codes..............................................268
			Abbreviations...........................................................269
			Definition of Operation Modes...........................................269
			Table of Fault Codes....................................................270
			Measurement of Resistance at Actuator/sensors and Cable.................270
		Transmission Electrical Circuits............................................272
			Transmission Controller Circuit.........................................272
			Traveling Circuits......................................................274
			Kick-down...............................................................282
			Transmission Cutoff.....................................................287
			LIS (Load Isolation System) - Option....................................289
		Installation View (S/N 1001 thru 2000)......................................292
			Inner Section...........................................................292
			Front View..............................................................293
			Front View with Disc Brake..............................................294
			Side View...............................................................295
			Side View with Disc Brake...............................................296
			Rear View...............................................................297
			Rear View with Disc Brake...............................................298
		Installation View (S/N 2001 and Up).........................................300
			Inner Section...........................................................300
			Front View..............................................................301
			Front View with Disc Brake..............................................302
			Side View...............................................................303
			Side View with Disc Brake...............................................304
			Rear View...............................................................305
			Rear View with Disc Brake...............................................306
		Special Tools...............................................................307
			Gearshift System........................................................307
			Engine Connection.......................................................309
			Pressure Oil Pump.......................................................310
			Gearbox Housing.........................................................311
			Input...................................................................313
			Coupling................................................................314
			Output..................................................................320
			Power Take-off..........................................................321
		Hydraulic Control Unit (HSG-94).............................................322
			Disassembly.............................................................324
			Reassembly..............................................................327
		Transmission Disassembly....................................................333
			Hydraulic Control Unit (HSG-94) and Duct plate..........................333
			Engine Connection - Converter...........................................334
			Hydraulic Pump..........................................................336
			Converter Back Pressure Valve...........................................337
			Remove Output, Input and Clutches.......................................338
			Disassemble Clutch - KV and KR..........................................343
			Disassemble Clutch - K1, K2 and K3......................................346
			Disassemble Clutch - K4.................................................348
			Disassemble Drive Shaft.................................................349
		Transmission Reassembly.....................................................351
			Install Oil Tube........................................................351
			Reassemble Clutch - KV and KR...........................................353
			Reassemble Clutch - K1, K2 and K3.......................................360
			Reassemble Clutch - K4..................................................367
			Pre-assemble Drive Shaft................................................373
			Pre-assemble and Install Output.........................................374
			Install Pre-assembled Drive Shaft and Clutches..........................376
			Install Pump Shaft (Power Take-off).....................................379
			Install Output Flanges..................................................380
			Converter Back Pressure Valve...........................................382
			Oil Feed Housing - Transmission Pump....................................382
			Engine Connection - Converter...........................................384
			Converter Safety Valve..................................................387
			Mount Duct Plate and Hydraulic Control Unit.............................387
			Install Plugs and Oil Level Tube........................................388
			Speed Sensor and Inductive Transmitters.................................389
	Transmission Error Codes (ZF) S0607900C.........................................391
		Introduction................................................................394
		Abbreviations...............................................................394
		Display.....................................................................394
			Description of Fault Codes..............................................395
		Display During Operation....................................................396
		Definition of Operating Modes...............................................398
			Normal..................................................................398
			Substitute Clutch Control...............................................398
			Limp-home...............................................................398
			Transmission shut Down..................................................398
			TCU Shut Down...........................................................398
		Clutch Pack and Solenoid Valve Cross-reference Table........................399
		Table of Fault Codes........................................................400
		Table of Fault Codes - ERGO-Control.........................................422
		Measurement of Resistance at Actuator/ sensors and Cable....................425
			Actuator................................................................425
			Cable...................................................................425
Hydraulics..........................................................................427
	Accumulator S0703000............................................................429
		General Description.........................................................431
			Specifications..........................................................432
		Accumulator Charging........................................................435
			Charging the Accumulator with Nitrogen..................................435
	Cylinders S0705005K.............................................................437
		General Description.........................................................440
			Theory of Operation.....................................................441
			Parts List..............................................................442
		Troubleshooting, Testing and Adjustment.....................................448
		Disassembly.................................................................452
		Cleaning and Inspection (Wear Limits and Tolerances)........................454
		Reassembly..................................................................455
	Fan Drive Hydraulic Motor (Haldex) S0707100K....................................463
		General Description.........................................................465
			Theory of Operation.....................................................465
			Parts List..............................................................467
			Specifications..........................................................468
	Main Pump (Denison) S0708485K...................................................469
		General Description.........................................................472
			General.................................................................472
			Description.............................................................472
			Theory of Operation.....................................................473
			Parts List..............................................................476
			Specifications..........................................................478
		Special Tools...............................................................479
			Seal Driver.............................................................479
			Protective Cone.........................................................479
		Troubleshooting.............................................................480
		Overhaul....................................................................482
			General.................................................................482
			Changing Rotation.......................................................483
			Changing Cartridges.....................................................484
			Changing Port Locations.................................................484
			Changing Shaft or Shaft Seal............................................485
			Disassembly of Pump.....................................................486
			Reassembly of Pump......................................................487
			Disassembly of "C" Cartridge............................................490
			Reassembly of "C" Cartridge.............................................491
			Disassembly of "D" Cartridge............................................492
			Reassembly of "D" Cartridge.............................................493
		Installation................................................................494
			Mounting................................................................494
			Piping..................................................................494
			Fluids..................................................................495
		Start-up Procedures.........................................................497
			Pre-start Check.........................................................497
			Priming.................................................................497
	Brake Pedal Valve S0709250K.....................................................499
		General Description.........................................................501
			Theory of Operation.....................................................501
			Specification...........................................................502
		Brake System (S/N 1001 thru 2000)...........................................503
		Brake System (S/N 2001 and Up)..............................................504
		Brake, Pilot and Fan Motor Supply Valve.....................................505
			Specifications (S/N 1001 thru 2000).....................................506
			Specifications (S/N 2001 and Up)........................................507
	Main Control Valve (Toshiba) S0709456K..........................................509
		General Description.........................................................511
		Specifications..............................................................513
		Operation...................................................................514
			Neutral.................................................................514
			Bucket/option Spool Operation...........................................514
			Boom Spool Operation....................................................515
			Relief Valve............................................................515
			Operation (Main Relief Valve)...........................................516
			Operation (Port Relief Valve)...........................................517
	Pilot Control Valve S0709477K...................................................519
		General Description (S/N 1001 thru 2000)....................................521
			Pilot Valve Operation...................................................521
		General Description (S/N 2001 and up).......................................523
			Pilot Valve Operation...................................................523
			Standard................................................................524
			Option..................................................................526
		Pilot System................................................................528
	Priority Valve (Danfoss) S0709651K..............................................531
		General Description.........................................................534
			Theory of Operation.....................................................534
			Parts List..............................................................535
			Specifications..........................................................536
		Disassembly.................................................................536
		Reassembly..................................................................539
	Power Steering Unit S0709730K...................................................541
		General Description.........................................................543
			Power Steering System...................................................543
			Gerotor Operation.......................................................545
			Cushion Valve Operation.................................................546
			Parts List..............................................................548
			Specifications..........................................................549
		Special Tools...............................................................550
		Troubleshooting, Testing and Adjustment.....................................552
		Disassembly.................................................................553
		Cleaning and Inspection.....................................................557
		Reassembly..................................................................558
		Installation................................................................569
	Restriction Valve S0709751K.....................................................571
		General Description.........................................................573
			Theory of Operation.....................................................573
			UNLOADING CIRCUIT (S/N 1001 thru 2000)..................................574
			UNLOADING CIRCUIT (S/N 2001 and Up).....................................575
			Unloader Cartridge Identification (S/N 1001 thru 2000)..................576
			Unloader Cartridge Identification (S/N 2001 and Up).....................577
			Specifications..........................................................578
	Hydraulic Schematic (Mega 300-V) S0793070K......................................579
		General Description.........................................................581
		Mega 300-V (Tier I) (S/N 1001 thru 2000)....................................582
		Mega 300-V (Tier II) (S/N 2001 and Up)......................................584
Electrical System...................................................................587
	Electrical System S0802200K.....................................................589
		Overview....................................................................592
		Electric Supply System......................................................594
		Engine Starting Circuit.....................................................596
			Operation During Start Process..........................................596
			Operation After Start Process...........................................598
		Engine Preheating System (S/N 1001 thru 2000)...............................600
			Principle of Operation..................................................600
		Engine Preheating System (S/N 2001 and Up)..................................602
			Principle Of Operation..................................................602
		Engine Stop System..........................................................604
			Operation In Engine Running Mode........................................604
			Operation In Engine Stop Mode...........................................606
		Charging System.............................................................608
		Monitoring System...........................................................609
			Monitoring System (S/N 1001 thru 2000)..................................609
			Instrument Panel (S/N 1001 thru 2000)...................................610
			Function Check (S/N 1001 thru 2000).....................................611
			Monitoring System Schematic (S/N 1001 thru 2000)........................612
			Monitoring System (S/N 2001 and Up).....................................614
			Instrument Panel (S/N 2001 and Up)......................................615
			Function Check (S/N 2001 and Up)........................................616
			Monitoring System Schematic (S/N 2001 and Up)...........................616
			Operation...............................................................618
		Windshield Wiper............................................................624
			Front windshield wiper..................................................624
			Rear Windshield wiper...................................................625
		Lighting System.............................................................628
			Light Circuit (S/N 1001 thru 2000)......................................628
			Light Circuit (S/N 2001 and Up).........................................632
		Emergency Steering System (Option)..........................................636
			Block Diagram...........................................................636
			Emergency Steering System Components....................................637
			Emergency Steering System Electric Circuit..............................639
		Electric Detent System......................................................640
			Electric Circuit........................................................640
			Boom Kick-Out...........................................................640
			Return To Dig...........................................................641
	Electrical Schematic (Mega 300-V) S0893070K.....................................643
		General Description.........................................................645
		Mega 300-V..................................................................646
Attachments.........................................................................649

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