DOOSAN DX210WMH EXCAVATOR MATERIAL HANDER SHOP MANUAL 950106-01410NA – PDF DOWNLOAD

Description

DOOSAN DX210WMH EXCAVATOR MATERIAL HANDER SHOP MANUAL 950106-01410NA – PDF DOWNLOAD

DESCRIPTION:

DOOSAN DX210WMH EXCAVATOR MATERIAL HANDER SHOP MANUAL 950106-01410NA – PDF DOWNLOAD

GENERAL

Safe Operation is Operator’s Responsibility

Only trained and authorized personnel should operate and maintain the machine.

Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.

• • Do not operate machine if you are under the influence of drugs or alcohol.
• An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine. •
• When working with other personnel on a work site, be sure that all personnel know nature of work and understand all hand signals that are to be used.
• • Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged. •
• Be sure that you understand the use and maintenance of all safety features such as safety lock lever and seat belt. Use them properly. •
• Never remove, modify or disable any safety features. Always keep them in good operating condition.
• • Always check for and know the location of underground and overhead utility lines before excavating
• . • Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury.

Know Your Machine

Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine.

TABLE OF CONTENTS:

DOOSAN DX210WMH EXCAVATOR MATERIAL HANDER SHOP MANUAL 950106-01410NA – PDF DOWNLOAD

sm-950106-01410 NA_DX210WMH_2014-05-20......................................................................................................................................................................................................................................   0
	Safety..................................................................................................................................................................................................................................................................   9
		Wheel Material Handler Maintenance Safety SP002195NA................................................................................................................................................................................................................  11
			Safety Precautions..............................................................................................................................................................................................................................................  15
			Applicable Models...............................................................................................................................................................................................................................................  15
			Safety Messages.................................................................................................................................................................................................................................................  16
				Signal Words................................................................................................................................................................................................................................................  16
			Safety Decals...................................................................................................................................................................................................................................................  17
			General.........................................................................................................................................................................................................................................................  17
				Safe Operation is Operator's Responsibility.................................................................................................................................................................................................................  17
				Know Your Machine...........................................................................................................................................................................................................................................  17
				Proper Work Tools and Attachments...........................................................................................................................................................................................................................  18
				Pressurized Fluids..........................................................................................................................................................................................................................................  18
				Flying or Falling Objects...................................................................................................................................................................................................................................  19
				Personal Protective Equipment (PPE).........................................................................................................................................................................................................................  20
				Correction of Machine Problems..............................................................................................................................................................................................................................  20
				Crushing and Cutting........................................................................................................................................................................................................................................  20
				Hot Coolant and Oils - Burn Prevention......................................................................................................................................................................................................................  21
				Fire and Explosion Prevention...............................................................................................................................................................................................................................  22
				Fire Extinguisher and First-Aid Kit (Emergency Medical Kit).................................................................................................................................................................................................  25
				Electrical System and Electrical Shock......................................................................................................................................................................................................................  26
			Transportation..................................................................................................................................................................................................................................................  29
				Obey State and Local Over-the-Road Regulations..............................................................................................................................................................................................................  29
				Loading and Unloading.......................................................................................................................................................................................................................................  29
				Transporting Machine........................................................................................................................................................................................................................................  30
			Operation.......................................................................................................................................................................................................................................................  31
				Before Engine Starting......................................................................................................................................................................................................................................  31
				Work Site...................................................................................................................................................................................................................................................  32
				Mounting/Dismounting........................................................................................................................................................................................................................................  33
				Cleaning....................................................................................................................................................................................................................................................  34
				Operator Station............................................................................................................................................................................................................................................  34
				Seat Belt...................................................................................................................................................................................................................................................  35
				Visibility Information......................................................................................................................................................................................................................................  36
				Boost Starting or Charging Engine Batteries.................................................................................................................................................................................................................  37
				Starting Engine.............................................................................................................................................................................................................................................  38
				Swinging or Traveling.......................................................................................................................................................................................................................................  39
				Lifting.....................................................................................................................................................................................................................................................  41
				Towing......................................................................................................................................................................................................................................................  42
				Attachment..................................................................................................................................................................................................................................................  43
				Lowering Elevating Cab with Engine Stopped..................................................................................................................................................................................................................  44
				Engine Stop.................................................................................................................................................................................................................................................  44
				Parking Machine.............................................................................................................................................................................................................................................  45
				Service Brake...............................................................................................................................................................................................................................................  46
				Preservation/Storing Machine................................................................................................................................................................................................................................  47
			Maintenance.....................................................................................................................................................................................................................................................  49
				Cleaning....................................................................................................................................................................................................................................................  53
				Proper Tools and Clothing...................................................................................................................................................................................................................................  53
				Disassembling Precautions...................................................................................................................................................................................................................................  53
				Use of Lighting.............................................................................................................................................................................................................................................  54
				Fire and Explosion Prevention...............................................................................................................................................................................................................................  54
				Burn Prevention.............................................................................................................................................................................................................................................  55
				Rubber That Contains Fluorides..............................................................................................................................................................................................................................  56
				Rubber and Plastics.........................................................................................................................................................................................................................................  57
				Welding Repairs.............................................................................................................................................................................................................................................  58
				Warning for Counterweight and Front Attachment Removal......................................................................................................................................................................................................  59
				Lock Inspection Covers......................................................................................................................................................................................................................................  60
				Working on Machine..........................................................................................................................................................................................................................................  60
				Accumulator.................................................................................................................................................................................................................................................  61
				Compressed Air..............................................................................................................................................................................................................................................  61
				Supports and Blocking for Work Equipment....................................................................................................................................................................................................................  61
				High-pressure Lines, Tubes and Hoses........................................................................................................................................................................................................................  62
				Battery.....................................................................................................................................................................................................................................................  63
			Environment and Circumstances...................................................................................................................................................................................................................................  65
				Work Site Areas Requiring Extra Caution.....................................................................................................................................................................................................................  65
				High-voltage Cables.........................................................................................................................................................................................................................................  66
				Working in Water............................................................................................................................................................................................................................................  67
				Working in Contaminated Environment.........................................................................................................................................................................................................................  67
				Operation in Extreme Conditions.............................................................................................................................................................................................................................  68
				Exhaust Ventilation.........................................................................................................................................................................................................................................  72
				Asbestos Information........................................................................................................................................................................................................................................  72
				Silica Dust Information.....................................................................................................................................................................................................................................  73
				Disposal of Hazardous Materials.............................................................................................................................................................................................................................  73
	Specifications..........................................................................................................................................................................................................................................................  75
		Specification SP000957NA............................................................................................................................................................................................................................................  77
			Safety Precautions..............................................................................................................................................................................................................................................  81
			Applicable Models...............................................................................................................................................................................................................................................  81
			General Description.............................................................................................................................................................................................................................................  83
			Component Locations.............................................................................................................................................................................................................................................  84
			General Dimensions..............................................................................................................................................................................................................................................  87
				One - Piece Boom............................................................................................................................................................................................................................................  87
			Working Range...................................................................................................................................................................................................................................................  88
				One - Piece Boom............................................................................................................................................................................................................................................  88
			General Specifications..........................................................................................................................................................................................................................................  89
			Hydraulic System Component Specifications.......................................................................................................................................................................................................................  90
			System Component Specifications.................................................................................................................................................................................................................................  91
			Performance Tests and Standards.................................................................................................................................................................................................................................  95
			Material Handler Performance Standards..........................................................................................................................................................................................................................  96
				Test Conditions.............................................................................................................................................................................................................................................  96
				Travel Speed Tests..........................................................................................................................................................................................................................................  96
				Swing Speed and Deceleration Force Test.....................................................................................................................................................................................................................  98
				Cylinder Performance Tests.................................................................................................................................................................................................................................. 100
	General Maintenance..................................................................................................................................................................................................................................................... 101
		General Maintenance Procedures SP000016NA........................................................................................................................................................................................................................... 103
			Safety Precautions.............................................................................................................................................................................................................................................. 107
			Applicable Models............................................................................................................................................................................................................................................... 107
			Welding Precautions and Instructions............................................................................................................................................................................................................................ 108
			Hydraulic System - General Precautions.......................................................................................................................................................................................................................... 109
			Maintenance Service and Repair Procedure........................................................................................................................................................................................................................ 111
				General Precautions......................................................................................................................................................................................................................................... 111
			Hydraulic System Cleanliness and Oil Leaks...................................................................................................................................................................................................................... 112
				Maintenance Precautions for Hydraulic System Service........................................................................................................................................................................................................ 112
				Oil Leakage Precautions..................................................................................................................................................................................................................................... 113
			Cleaning and Inspection......................................................................................................................................................................................................................................... 114
				General Instructions........................................................................................................................................................................................................................................ 114
				Bearing Inspection.......................................................................................................................................................................................................................................... 115
		Standard Torques SP000813NA......................................................................................................................................................................................................................................... 123
			Safety Precautions.............................................................................................................................................................................................................................................. 127
			Applicable Models............................................................................................................................................................................................................................................... 127
			Torque Values for Standard Metric Fasteners..................................................................................................................................................................................................................... 128
			Torque Values for Standard U.S. Fasteners....................................................................................................................................................................................................................... 129
			Type 8 Phosphate Coated Hardware................................................................................................................................................................................................................................ 131
			Torque Values for Hose Clamps................................................................................................................................................................................................................................... 132
			Torque Values for Split Flanges................................................................................................................................................................................................................................. 133
			Torque Wrench Extension Tools................................................................................................................................................................................................................................... 134
				Torque Multiplication....................................................................................................................................................................................................................................... 134
				Other Uses for Torque Wrench Extension Tools................................................................................................................................................................................................................ 135
				Tightening Torque Specifications (Metric)................................................................................................................................................................................................................... 136
	Upper Structure......................................................................................................................................................................................................................................................... 139
		Cabin SP002191NA.................................................................................................................................................................................................................................................... 141
			Safety Precautions.............................................................................................................................................................................................................................................. 145
			Applicable Models............................................................................................................................................................................................................................................... 145
		Counterweight SP002207NA............................................................................................................................................................................................................................................ 153
			Safety Precautions.............................................................................................................................................................................................................................................. 157
			Applicable Models............................................................................................................................................................................................................................................... 157
			General......................................................................................................................................................................................................................................................... 158
				Warning for Counterweight and Front Attachment Removal...................................................................................................................................................................................................... 158
			Installation.................................................................................................................................................................................................................................................... 162
		Fuel Tank SP002208NA................................................................................................................................................................................................................................................ 163
			Safety Precautions.............................................................................................................................................................................................................................................. 167
			Applicable Models............................................................................................................................................................................................................................................... 167
			General Description.............................................................................................................................................................................................................................................   0
				Specifications.............................................................................................................................................................................................................................................. 169
		Fuel Transfer Pump SP000021NA....................................................................................................................................................................................................................................... 179
			Safety Precautions.............................................................................................................................................................................................................................................. 183
			Applicable Models............................................................................................................................................................................................................................................... 183
			Troubleshooting................................................................................................................................................................................................................................................. 186
			Replacement of Rotor and Vane................................................................................................................................................................................................................................... 186
		Swing Bearing SP001869NA............................................................................................................................................................................................................................................ 189
			Safety Precautions.............................................................................................................................................................................................................................................. 193
			Applicable Models............................................................................................................................................................................................................................................... 193
			Swing Bearing Maintenance....................................................................................................................................................................................................................................... 194
				Operating Recommendation.................................................................................................................................................................................................................................... 194
				Measuring Swing Bearing Axial Play.......................................................................................................................................................................................................................... 194
				Measuring Bearing Lateral Play.............................................................................................................................................................................................................................. 194
				Swing Bearing Basic Operation............................................................................................................................................................................................................................... 195
				Disassembly................................................................................................................................................................................................................................................. 195
				Assembly.................................................................................................................................................................................................................................................... 197
					1. Clean (degrease) the seal groove for the outer and inner seals (7)................................................................................................................................................................................... 197
					2. Hoist the outer race by crane horizontally and match it with the inner race coaxially................................................................................................................................................................ 197
					3. Top plug (4) into outer race (1) and then, drive pin (3) into the pin hole........................................................................................................................................................................... 197
		Swing Reduction Gear SP002204NA..................................................................................................................................................................................................................................... 199
			Safety Precautions.............................................................................................................................................................................................................................................. 203
			Applicable Models............................................................................................................................................................................................................................................... 203
			General Description............................................................................................................................................................................................................................................. 205
				Theory of Operation......................................................................................................................................................................................................................................... 205
				Parts List.................................................................................................................................................................................................................................................. 206
				Specifications.............................................................................................................................................................................................................................................. 207
			Disassembly..................................................................................................................................................................................................................................................... 210
				1. Remove bolts and motor from swing reduction case......................................................................................................................................................................................................... 210
				2. Remove No. 1 sun gear from No. 1 carrier................................................................................................................................................................................................................. 210
				3. Remove No. 1 carrier..................................................................................................................................................................................................................................... 211
				4. Remove washer and No. 2 sun gear......................................................................................................................................................................................................................... 211
				5. Remove bolt in No. 2 carrier............................................................................................................................................................................................................................. 212
				6. Install eye bolts in No. 2 carrier and remove it from ring gear.......................................................................................................................................................................................... 212
				7. Install eye bolts in ring gear and remove it............................................................................................................................................................................................................. 213
				8. Use a rollover machine to turn assembly over............................................................................................................................................................................................................. 214
				9. Remove cover plate....................................................................................................................................................................................................................................... 214
				10. Use a rollover machine to turn case over and place a jig on drive shaft. Use a press to remove drive shaft from case.................................................................................................................................... 215
				11. Remove bearing from case................................................................................................................................................................................................................................ 215
				12. Put drive shaft in press, and remove bearing and spacer................................................................................................................................................................................................. 216
			Cleaning and Inspection (Wear Limits and Tolerances)............................................................................................................................................................................................................ 216
			Reassembly...................................................................................................................................................................................................................................................... 217
				Shaft and S/R Bearing Heat-fit.............................................................................................................................................................................................................................. 217
				Assembly of Carrier Subassemblies........................................................................................................................................................................................................................... 219
					1. Put No. 1 carrier on assembly jig as shown in Figure 29.............................................................................................................................................................................................. 219
					2. Assemble the pin ass,y 1 and the washer into planet gear 1 and arrange it on the pin hole of the carrier 1........................................................................................................................................... 219
					3. Put the jig, while keeping the pin assembly 1 perpendicular, and push it with a press................................................................................................................................................................ 220
					4. After its pressure insert, check the state of the pressure insert visually........................................................................................................................................................................... 220
					5. Insert the 2 remaining parts with pressure in the same way........................................................................................................................................................................................... 221
					6. Engage the snap ring (for .ı 38 axis) to each thread of the pin 1 and check if gear turns smooth by turning it....................................................................................................................................... 221
					1. Put No. 2 carrier on assembly jig as shown in Figure 39.............................................................................................................................................................................................. 222
					2. Insert No. 2 bushing into No. 2 planetary gear, and position a No. 2 thrust washer on it............................................................................................................................................................. 222
					3. Turn over gear assembly and insert it into No. 2 carrier. Align bushing hole with carrier holes...................................................................................................................................................... 222
					4. Align spring pin hole in No. 2 shaft with spring pin hole of No. 2 carrier. Insert shaft into carrier and No. 2 bushing.............................................................................................................................. 223
					5. Install three remaining No. 2 gears in same manner................................................................................................................................................................................................... 223
					6. After all four shafts are installed, align spring pin (.ı 10x25L) with carrier hole and drive it into position using a hammer........................................................................................................................ 223
					7. Using a hammer and punch, calking spring pin into position........................................................................................................................................................................................... 224
					8. Repeat procedure for other three spring pins. Make sure that gears properly rotate................................................................................................................................................................... 224
				Assembly of Main Case....................................................................................................................................................................................................................................... 225
					1. Insertion of shaft subassembly:...................................................................................................................................................................................................................... 225
						A. Set gear case as shown in Figure 51.............................................................................................................................................................................................................. 225
						B. Using a suitable lifting device, lower shaft subassembly into case............................................................................................................................................................................... 225
						C. Using special jig, keep bearing level and press it into case..................................................................................................................................................................................... 225
					1. Position case so that pinion gear is pointing down................................................................................................................................................................................................... 226
					2. Make sure that there is no foreign substance left on seal assembly, apply grease to and around lip of oil seal (TC5001300) as in Figure 59 and Loctite #609 to its external part..................................................................... 227
					3. Using seal installation jig, press seal into case, keeping it level during installation. Make sure that seal is fully seated......................................................................................................................... 227
					4. Using seal installation jig, position bearing on end of shaft, with bearing trade mark on inner race facing up. Press bearing firmly into place, making sure it is properly seated................................................................... 229
					5. Rotate pinion by hand and check if it turns properly................................................................................................................................................................................................. 230
					6. Install plugs into PT1/2 and PT1/4 drain ports....................................................................................................................................................................................................... 230
					1. Insertion of lock pin................................................................................................................................................................................................................................ 231
					2. Apply liquid gasket (Three Bond #1104) evenly to ring gear assembly of casing........................................................................................................................................................................ 231
					3. Lift ring gear with hoist, wipe its mating surface clean with cloth, match and align holes after checking its assembling direction, and press assembled parts firmly by tightening special bolts (M12x150) on which no Loctite has been applied...... 232
					1. Using a suitable lifting device, lower No. 2 carrier assembly into ring gear, making sure that planetary gears are engaged. Continue to lower carrier and engaging it onto splines of pinion shaft. Make sure that carrier is resting on bearing..... 232
					2. Place a tongued washer on the thrust washer 3 of the carrier assembly 2 and engage a hexagon bolt (M16x25L, torque: 3,000kgf.cm) applied Loctite (#262) with it...................................................................................... 233
					3. After tightening the bolt, fix the carrier assembly 2 and use a torque wrench to tighten it up to the standard torque. After checking the torque, bend the longer part of the tongued washer until it sticks to the head of the hexagon bolt......... 234
					4. Install No. 2 sun gear in No. 2 carrier.............................................................................................................................................................................................................. 234
					5. Lift the carrier assembly 1, and turn it clockwise or anticlockwise gently for it to engage with the spline of the sun gear 2 and the ring gear...................................................................................................... 234
					6. Assemble the sun gear 1.............................................................................................................................................................................................................................. 235
					1. Remove the compression bolts of the ring gear, wipe out the motor assembly with clean cloth, and apply liquid (#1104) gasket evenly.................................................................................................................. 236
					2. Use a hoist to lift the prepared motor, wipe out the assembly, and engage the snap ring on the shaft................................................................................................................................................. 236
					3. Put the motor on the reduction gear carefully with the adjustment of its direction as shown in the figure below (care should ........................................................................................................................ 236
					4. Apply Loctite (#2652) to 16 socket bolts (M12x150L, torque: 1,440 kgf.cm), insert into holes, and tighten with an impact wrench...................................................................................................................... 237
					5. Engage the level gauge pipe sealed with Teflon tape to the level gauge port of the port with a pipe wrench........................................................................................................................................... 238
					1. Open the oil inlet lid and supply gear oil (EP80W/90) of 3.8ߧ....................................................................................................................................................................................... 239
					2. After the supply of oil, stick the level gauge into tank and check the oil level..................................................................................................................................................................... 239
					3. Put the nipple to supply grease in the PT1/4 tap hole and start to supply grease until it flows out of the opposite PT1/ 4 hole...................................................................................................................... 240
					4. After the completion of supplying grease, release and remove cokes, assemble the PT1/4 plug sealed with Teflon tape (torque: ........................................................................................................................ 240
			Installation.................................................................................................................................................................................................................................................... 242
			Start-up Procedures............................................................................................................................................................................................................................................. 242
	Lower Structure and Chassis............................................................................................................................................................................................................................................. 243
		Ram Lock Valve SP000923NA........................................................................................................................................................................................................................................... 245
			Safety Precautions.............................................................................................................................................................................................................................................. 249
			Applicable Models............................................................................................................................................................................................................................................... 249
			Sectional Drawing and Part Names................................................................................................................................................................................................................................ 250
			Hydraulic Circuit............................................................................................................................................................................................................................................... 250
			Operational Principle........................................................................................................................................................................................................................................... 251
				In Case of No Pilot Pressure at PI Port..................................................................................................................................................................................................................... 251
				In Case of Pilot Pressure (Approx. 20 kg.cm2) at PI Port.................................................................................................................................................................................................... 251
			Disassembly and Assembly........................................................................................................................................................................................................................................ 251
				General Cautions............................................................................................................................................................................................................................................ 251
				Assembly and Disassembly of Chocking Valve.................................................................................................................................................................................................................. 252
			Performance Test................................................................................................................................................................................................................................................ 253
				Oil Leakage Test............................................................................................................................................................................................................................................ 253
				Operational Test............................................................................................................................................................................................................................................ 253
		Selector Valve SP000926NA........................................................................................................................................................................................................................................... 255
			Safety Precautions.............................................................................................................................................................................................................................................. 259
			Applicable Models............................................................................................................................................................................................................................................... 259
			Sectional Drawing and Part Names................................................................................................................................................................................................................................ 260
			Hydraulic Circuit............................................................................................................................................................................................................................................... 260
			Operational Principle........................................................................................................................................................................................................................................... 261
				Neutral Position: A Æ B..................................................................................................................................................................................................................................... 261
				Selective Position: A Æ C................................................................................................................................................................................................................................... 261
			Disassembly and Assembly........................................................................................................................................................................................................................................ 262
				General Cautions............................................................................................................................................................................................................................................ 262
				Assembly and Disassembly of Selector Valve.................................................................................................................................................................................................................. 262
			Performance Test................................................................................................................................................................................................................................................ 264
				Oil Leakage Test............................................................................................................................................................................................................................................ 264
				Operational Test............................................................................................................................................................................................................................................ 264
		Double Pilot Check Valve SP000927NA................................................................................................................................................................................................................................. 265
			Safety Precautions.............................................................................................................................................................................................................................................. 269
			Applicable Models............................................................................................................................................................................................................................................... 269
			Sectional Drawing & Parts....................................................................................................................................................................................................................................... 270
			Hydraulic Diagram............................................................................................................................................................................................................................................... 271
			Operational Principle........................................................................................................................................................................................................................................... 272
				A Æ C, D Æ B................................................................................................................................................................................................................................................ 272
				B Æ D, C Æ A................................................................................................................................................................................................................................................ 272
			Disassembly and Assembly........................................................................................................................................................................................................................................ 273
				General Cautions............................................................................................................................................................................................................................................ 273
				Assembly and Disassembly of Double Pilot Check Valve........................................................................................................................................................................................................ 274
			Performance Test................................................................................................................................................................................................................................................ 276
				Cracking Pressure Test for Check Cartridge Ass'y............................................................................................................................................................................................................ 276
				Pilot Cracking Pressure Test................................................................................................................................................................................................................................ 276
				Oil Leakage Test............................................................................................................................................................................................................................................ 277
		Solenoid Valve SP000928NA........................................................................................................................................................................................................................................... 279
			Safety Precautions.............................................................................................................................................................................................................................................. 283
			Applicable Models............................................................................................................................................................................................................................................... 283
			Single Solenoid Valve Diagram................................................................................................................................................................................................................................... 284
			Functions of Single Solenoid Valve.............................................................................................................................................................................................................................. 285
				Functions of Each Valve..................................................................................................................................................................................................................................... 285
			Disassembly and Reassembly Diagrams............................................................................................................................................................................................................................. 286
			Troubleshooting of Each Part.................................................................................................................................................................................................................................... 287
			Double Solenoid Valve Diagram................................................................................................................................................................................................................................... 288
			Functions of Double Solenoid Valve.............................................................................................................................................................................................................................. 289
				Functions of Each Valve..................................................................................................................................................................................................................................... 289
			Disassembly and Reassembly Diagrams............................................................................................................................................................................................................................. 290
			Troubleshooting of Each Part.................................................................................................................................................................................................................................... 291
		Front Axle SP000929NA............................................................................................................................................................................................................................................... 293
			Safety Precautions.............................................................................................................................................................................................................................................. 297
			Applicable Models............................................................................................................................................................................................................................................... 297
				Examples of Gear-Tooth-Contact Patterns for the Gleason Gear-Tooth System................................................................................................................................................................................... 298
			Lubrication and Maintenance Specifications for Axle MS- E 3050/3060/3070........................................................................................................................................................................................ 300
				1. Oil Drain From Axle...................................................................................................................................................................................................................................... 300
				2. Oil Drain From Outputs................................................................................................................................................................................................................................... 300
				3. Oil Filling of Axle...................................................................................................................................................................................................................................... 301
					Tightening torque (M36x1.5) MA = 50 N.m................................................................................................................................................................................................................. 301
				4. Check.................................................................................................................................................................................................................................................... 301
					Tightening torque (M36x1.5) MA = 50 N.m................................................................................................................................................................................................................. 301
					Tightening torque (M36x1.5) MA = 50 N.m................................................................................................................................................................................................................. 301
				1. Motor oils SAE 10 W acc. to specification MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE.............................................................................................................................................................. 301
				2. ATF. oils type A, Suffic A, Dexron von II D.............................................................................................................................................................................................................. 301
			Brake Wear Measurement on Axles of MT/MS-E 3050/ 3060/3070 Range................................................................................................................................................................................................ 302
				Tightening torque(M36x1.5) MA = 50 N.m...................................................................................................................................................................................................................... 303
			Disassembly..................................................................................................................................................................................................................................................... 304
				Steering.................................................................................................................................................................................................................................................... 304
					1. View - Steering installed in axle.................................................................................................................................................................................................................... 304
					2. Loosen hex nuts on both tie rods..................................................................................................................................................................................................................... 304
					4. Separate both tie rods (ass’y) from piston rod....................................................................................................................................................................................................... 305
					5. Disassemble both elbows (see arrows) or screw necks, depending on version............................................................................................................................................................................ 305
					6. Loosen threaded joint of steering / axle drive housing............................................................................................................................................................................................... 306
					7. Steering cylinder is fixed with locking compound - disassembly is more difficult!.................................................................................................................................................................... 306
					8. Drive out steering cylinder ass’y from axle drive housing by means of a plastic / aluminium hammer................................................................................................................................................... 306
					9. Unsnap the circlip and remove flange................................................................................................................................................................................................................. 306
					10. Unsnap retaining ring............................................................................................................................................................................................................................... 307
					11. Drive the guide into the cylinder tube (direction of arrow) until the circlip can be removed (see Figure 26)........................................................................................................................................ 307
					12. Unsnap circlip...................................................................................................................................................................................................................................... 307
					13. Drive out piston rod together with guide from cylinder tube......................................................................................................................................................................................... 307
					14. Pull off guide from piston rod...................................................................................................................................................................................................................... 308
				Output...................................................................................................................................................................................................................................................... 308
					1. Loosen screw plug and drain oil from the axle........................................................................................................................................................................................................ 308
					2. Please take the required work steps (such as dismantling the tie rod-, bearing pins ecc. ...) from chapters.......................................................................................................................................... 309
					1. Loosen both cylinder screws and separate planetary carrier from hub.................................................................................................................................................................................. 309
					2. Unsnap circlip....................................................................................................................................................................................................................................... 309
					3. Pull off planetary gear by means of a two-armed puller............................................................................................................................................................................................... 309
					4. Unsnap circlip and remove washer..................................................................................................................................................................................................................... 310
					1. Unsnap retaining ring and remove both thrust washers................................................................................................................................................................................................. 310
					2. Remove slotted nut mount (cylinder screw)............................................................................................................................................................................................................ 310
					3. Loosen slotted nut................................................................................................................................................................................................................................... 310
					4. Press off ring gear with piston...................................................................................................................................................................................................................... 311
					5. Loosen hex. screws, remove spring sleeves and compression springs.................................................................................................................................................................................... 311
					6. Press off piston from ring gear...................................................................................................................................................................................................................... 311
					7. Remove sealing elements (arrows) from ring gear...................................................................................................................................................................................................... 311
					8. Remove plate pack.................................................................................................................................................................................................................................... 312
					9. Remove O-ring (arrow) and lift-off disc carrier with lever, then remove releasing O-ring............................................................................................................................................................. 312
					10. Pull hub from hub carrier by means of pressure piece and two armed puller........................................................................................................................................................................... 312
					11. Lift-off shaft seal (arrow) with lever and remove both bearing outer rings from hub................................................................................................................................................................. 312
					12. Just for axle type MS-E 3060 :...................................................................................................................................................................................................................... 313
					13. Pull bearing inner ring from hub.................................................................................................................................................................................................................... 313
					1. Legend to the sketch................................................................................................................................................................................................................................. 313
					2. Loosen threaded connection and remove upper bearing pin.............................................................................................................................................................................................. 313
					3. Secure knuckle housing by means of lifting device and dismantle lower bearing pin.................................................................................................................................................................... 314
					4. Remove bearing inner ring (7), O-ring (5), sealing cap (6) and brake connection screw neck (8) from bearing pin (1).................................................................................................................................. 314
					5. Separate knuckle housing with double u-joint shaft from axle housing................................................................................................................................................................................. 314
					6. Pull out double u-joint shaft from knuckle housing................................................................................................................................................................................................... 314
					7. Pull out seal ring and afterwards the bushing behind from the knuckle housing........................................................................................................................................................................ 315
					8. Pull out seal ring and afterwards the bushing behind from the axle housing........................................................................................................................................................................... 315
					9. Pull out both bearing outer rings from the swivel bearing holes...................................................................................................................................................................................... 315
				Differential - Input........................................................................................................................................................................................................................................ 316
					1. Fix axle housing part / II by means of a lifting strap, loosen threaded joint of axle housing half on crown wheel side (differential) and separate axle housing half part / II from axle drive housing............................................... 316
					2. Remove bearing outer ring (arrow1) and the shim behind as well as O ring (arrow 2) from axle housing part / II....................................................................................................................................... 316
					3. Lift off the differential from the axle drive housing................................................................................................................................................................................................ 317
					4. Pull out bearing outer ring and the shim behind from the bearing hole of axle housing part / I....................................................................................................................................................... 317
					1. The illustration shows version "D-500"............................................................................................................................................................................................................... 317
					2. Loosen threaded joint (position "X")................................................................................................................................................................................................................. 317
						A. Version "D-500".................................................................................................................................................................................................................................. 318
						B. Version "D-750".................................................................................................................................................................................................................................. 318
					1. Legend to Figure 69.................................................................................................................................................................................................................................. 319
					4. Lift-off seal ring with lever........................................................................................................................................................................................................................ 320
					5. Drive out input pinion............................................................................................................................................................................................................................... 320
					6. Remove spacer ring................................................................................................................................................................................................................................... 320
					7. Press off bearing inner ring from input pinion....................................................................................................................................................................................................... 320
					8. Extract outside bearing outer ring................................................................................................................................................................................................................... 321
					9. Drive out bearing outer ring from the inner bearing hole - pay attention to the shim behind.......................................................................................................................................................... 321
				Pivot Bearing............................................................................................................................................................................................................................................... 321
			Reassembly...................................................................................................................................................................................................................................................... 322
				Input....................................................................................................................................................................................................................................................... 322
					Tightening torque MA = 390 N.m (M 18/10.9).............................................................................................................................................................................................................. 322
					1. Read dimension "I" (Position - see arrow) from axle drive housing.................................................................................................................................................................................... 322
						Dimension "I" e.g 149.09 mm......................................................................................................................................................................................................................... 322
					2. Read pinion dimension (basic distance) "X" from pinion (see arrow) or measure it in case of a + or - deviation of the pinion dimension caused by the production (value concerned is marked by hand on the pinion, e.g.+ 0.1)......................... 323
						Dimension "II" (Pinion basic distance) e.g. 116.00 mm............................................................................................................................................................................................... 323
					3. Since the installed roller bearing is subject to a pre-load in installation position, consider an experience deduction of - 0.1mm!................................................................................................................... 323
						Dimension "I" 149.09 mm............................................................................................................................................................................................................................. 323
						Dimension "II + III" (116.00 + 31.90) -148.10 mm.................................................................................................................................................................................................... 323
						Result = 1.01 mm.................................................................................................................................................................................................................................... 323
						Shim required "S" 1.00 mm........................................................................................................................................................................................................................... 323
					4. Insert the determined shim (e.g. "S" = 1.00 mm) into the inner bearing hole / pinion bearing......................................................................................................................................................... 323
					5. Super-cool bearing outer ring (see arrow) and bring it into contact position in the inner bearing hole / pinion bearing by means of the fixture...................................................................................................... 324
					6. Instal outside bearing outer ring / pinion bearing................................................................................................................................................................................................... 324
					7. Mount heated bearing inner ring until contact is obtained and readjust after cooling-down............................................................................................................................................................ 324
					1. Mount spacer ring (s = optional)..................................................................................................................................................................................................................... 324
					2. Insert the preassembled drive pinion, mount the heated bearing inner ring until contact is obtained.................................................................................................................................................. 325
					3. Mount flange, fix with washer and hex. nut........................................................................................................................................................................................................... 325
						Tightening torque (M27x1.5) MA = 600 N.m............................................................................................................................................................................................................ 325
					4. Check rolling moment of pinion bearing............................................................................................................................................................................................................... 325
					1. Illustration shows version "D-500"................................................................................................................................................................................................................... 326
					2. Assembly Specification:.............................................................................................................................................................................................................................. 326
					3. Press differential carrier until contact is obtained................................................................................................................................................................................................. 326
					4. Insert thrust washer and axle bevel gear............................................................................................................................................................................................................. 326
					5. Install differential bevel gears and thrust washers on differential spider and insert in differential carrier half I................................................................................................................................. 327
					6. Insert second axle bevel gear........................................................................................................................................................................................................................ 327
					7. Stick thrust washer with grease (assembly aid) into differential carrier half II..................................................................................................................................................................... 327
					8. Fasten differential carrier halves with cylinder. screws and washers (D-500, Pos. X) and with hex. screws (D-750, Pos.X)............................................................................................................................. 327
						A. Version "D-500".................................................................................................................................................................................................................................. 328
						B. Version "D-750".................................................................................................................................................................................................................................. 328
							Tightening torque (M 12x1.5/12.9) MA = 145 N.m.................................................................................................................................................................................................. 328
							Tightening torque (M 12x1.5/10.9) MA = 122 N.m.................................................................................................................................................................................................. 328
							Tightening torque (M 16x1.5/10.9) MA = 300 N.m.................................................................................................................................................................................................. 328
					9. Wet some tooth flanks of the crown wheel with marking ink (for contact pattern check - See Figure 112 on page -40)................................................................................................................................... 328
					1. Insert shim (backlash) into hole of axle housing / part I and install bearing outer ring until contact is obtained................................................................................................................................... 329
					2. Insert pre-assembled differential.................................................................................................................................................................................................................... 329
					3. Place bearing outer ring............................................................................................................................................................................................................................. 329
					4. Determine dimension "I", from mounting face of axle drive housing to bearing contact................................................................................................................................................................. 330
						Dimension "I" e.g. 18.10 mm......................................................................................................................................................................................................................... 330
					5. Determine dimension "II", from mounting face of axle housing part II to contact face / bearing outer ring............................................................................................................................................ 330
						Dimension "II" e.g. 17.20 mm........................................................................................................................................................................................................................ 330
						Dimension "I" e.g. 18.10 mm......................................................................................................................................................................................................................... 330
						Dimension "II" e.g. - 17.20 mm...................................................................................................................................................................................................................... 330
						Difference = 0.90 mm................................................................................................................................................................................................................................ 330
						requ. bearing preload (0.10 ~ 0.15mm) + 0.13 mm..................................................................................................................................................................................................... 330
						Result = 1.03 mm.................................................................................................................................................................................................................................... 330
						Required shim "S" Æ = 1.05 mm....................................................................................................................................................................................................................... 330
					6. Insert determined shim(s) e.g. "S" = 1.05 mm into bearing hole of axle housing / part II and instal bearing outer ring so that contact is obtained................................................................................................... 331
					7. Locate preassembled axle housing /part II (without O-ring) (observe radial installation position) and temporarily fix with hex. screws............................................................................................................... 331
					1. Place dial indicator at right angles to a tooth flank of the crown wheel (within the outer diameter area) through oil drain hole and check backlash.................................................................................................. 331
					Backlash................................................................................................................................................................................................................................................ 331
						2. Rotate drive pinion in both directions several times over crown wheel / differential (contact pattern impression - in this connection see Figure 112)............................................................................................ 332
						3. Remove differential.............................................................................................................................................................................................................................. 332
						4. Oil O-ring and mount on collar (arrow) of axle housing half / part II............................................................................................................................................................................ 332
						5. Reinstall differential........................................................................................................................................................................................................................... 333
						6. Instal pre-assembled axle housing half (observe radial installation position), fix with hex. screws and washers.................................................................................................................................. 333
							Tightening torque (M18/10.9) MA = 390 N.m....................................................................................................................................................................................................... 333
						7. Disassemble flange............................................................................................................................................................................................................................... 333
				Input Flange................................................................................................................................................................................................................................................ 334
					1. Place seal ring (6), considering the required installation position (dimension "X") - see Figure 118................................................................................................................................................. 334
					2. Press screen / thrust plate (5) on the input flange until contact is obtained - also see Figure 118.................................................................................................................................................. 335
					3. Install pre-assembled input flange (4+5) and washer (3), fix with hex. nut (2)....................................................................................................................................................................... 335
						Tightening torque (M27x1.5) MA = 600 N.m............................................................................................................................................................................................................ 335
				Output...................................................................................................................................................................................................................................................... 335
					1. Comment on Figure 122................................................................................................................................................................................................................................ 335
					2. Mount just for cpl. output - Figure 123.............................................................................................................................................................................................................. 335
					1. Legend on Figure 124 ~ Figure 128.................................................................................................................................................................................................................... 336
					2. Flush-mount bushing in the axle housing hole, considering the installation position (see detailed sketch)............................................................................................................................................ 336
					3. Flush-mount seal ring (item 3 - See Figure 124) into axle housing hole, with seal lip showing to oil chamber......................................................................................................................................... 336
					4. Mount both bearing outer rings (Item 4- See Figure 124) into pivot bearing holes of the axle housing................................................................................................................................................. 337
					1. Just for assembly of a new knuckle housing (Figure 130):............................................................................................................................................................................................. 337
					2. Legend to Figure 131 ... Figure 134:................................................................................................................................................................................................................. 338
					3. Flush-mount bushing into knuckle housing hole, considering the installation position (See Figure 131 and detailed sketch)............................................................................................................................ 338
					4. Mount seal ring (item 3 - See Figure 131) into knuckle housing hole - considering installation dimension "E" (See Figure 131) and installation position (seal lip showing to oil chamber)............................................................ 338
					5. Legend to Figure 136 .... Figure 139:................................................................................................................................................................................................................ 339
					6. Mount sealing cap.................................................................................................................................................................................................................................... 340
					7. Instal O-ring (arrow - 1) and apply anti-corrosive agent, "Weicon Anti Seize" (Never Seez) ZF-order no. 0671 196001 on bearing pin collar (arrow-2).................................................................................................. 340
					8. Just on lower bearing pin:........................................................................................................................................................................................................................... 340
					9. Instal pre-assembled lower bearing pin and fix with hex. screws...................................................................................................................................................................................... 340
					10. Instal O-ring....................................................................................................................................................................................................................................... 341
					11. Instal pre-assembled upper bearing pin (Figure 137 and Figure 138).................................................................................................................................................................................. 341
					12. Fix both bearing pins definitively.................................................................................................................................................................................................................. 341
						Tightening torque (M 16/10.9) MA = 280 N.m.......................................................................................................................................................................................................... 341
					13. Mount lubrication nipple (arrow-I) in both bearing pins and provide pivot bearing with grease (grease acc. to ZF- lubrication list "TE-ML 05", e.g. RENOLIT 283 EP 2)............................................................................... 341
						Tightening torque (M 6xl) MA = 6 N.m................................................................................................................................................................................................................ 341
						Tightening torque (M l4x1.5) MA = 35N.m............................................................................................................................................................................................................. 341
						Tightening torque (M l4x1.5) MA = 20N.m............................................................................................................................................................................................................. 341
					14. Check rolling moment of pivot bearing............................................................................................................................................................................................................... 342
					1. Install heated bearing inner ring until contact is obtained.......................................................................................................................................................................................... 342
					2. Just for axle type MS-E 3060:........................................................................................................................................................................................................................ 343
					3. Mount wheel bolts (l)................................................................................................................................................................................................................................ 343
					4. Mount shaft seal, considering installation position (marking OUT - SIDE looking upward / outward) and installation dimension "X" - see detailed sketch............................................................................................... 343
						A. Version MT-E 3050/3060........................................................................................................................................................................................................................... 343
						B. Version MT-E 3070................................................................................................................................................................................................................................ 344
					5. Install preassembled hub until contact is obtained and fix with heated outer bearing inner ring...................................................................................................................................................... 344
					6. Oil a-rings and locate in annular groove (arrow) of knuckle housing.................................................................................................................................................................................. 344
					7. Bring hub bearing into contact position (Figure 155 ~ 157):.......................................................................................................................................................................................... 345
					8. Bring hub bearing into contact position - for this purpose tighten slotted nut with a tightening torque of max. 1400 N.m............................................................................................................................. 345
					9. Loosen slotted nut again and remove ring gear........................................................................................................................................................................................................ 345
					1. Install disc pack alternately starting with an outer disc............................................................................................................................................................................................ 346
					2. Installation position of inner discs:................................................................................................................................................................................................................ 346
					3. Oil O-ring and locate in annular groove of disc carrier.............................................................................................................................................................................................. 346
					4. Oil sealing elements and locate in annular grooves (arrows) of the ring gear - as shown in the detailed sketch....................................................................................................................................... 347
					5. Just for "assembly of new parts" or if disassembled:................................................................................................................................................................................................. 347
					6. Install piston on preassembled ring gear............................................................................................................................................................................................................. 347
						Tightening torque (M 6/8.8) MA = 11 N.m............................................................................................................................................................................................................. 348
					7. Mount preassembled ring gear considering the installation position (markings 0 in 12 o’clock position - see arrows, detail "B")...................................................................................................................... 348
					8. Oil O-ring and insert in recess (arrow).............................................................................................................................................................................................................. 349
					9. Fix ring gear with slotted nut....................................................................................................................................................................................................................... 349
					Make Leakage Test of Multi-disc Brake................................................................................................................................................................................................................... 349
					Adjust and Check Disc Clearance/Piston Stroke........................................................................................................................................................................................................... 350
						Build up braking pressure (100 bar) and find dimension "A", from face / ring gear (1) through measuring hole (2) - See Figure 172 and Figure 173 - to face / piston (3)............................................................................. 350
						Dimension "A" e.g. = 83.50 mm....................................................................................................................................................................................................................... 350
						Dimension "B" e.g. = 82.10 mm....................................................................................................................................................................................................................... 350
						Dimension "A" e.g. 83.50 mm......................................................................................................................................................................................................................... 350
						Dimension "B" e.g. - 82.10 mm....................................................................................................................................................................................................................... 350
						Result Æ disc clearance = 1.40 mm................................................................................................................................................................................................................... 350
						Tightening torque (M 14 x 1.5) MA = 23 N.m.......................................................................................................................................................................................................... 351
						Tightening torque (M 10/8.8) MA = 32 N.m............................................................................................................................................................................................................ 351
						1. Determine dimension I from mounting face of planetary carrier to contact face of thrust washer................................................................................................................................................... 352
							Dimension I, e.g. 260.65 mm..................................................................................................................................................................................................................... 352
						2. Determine dimension II, from face (arrow) of sun gear to mounting face of hub.................................................................................................................................................................... 352
							Dimension II, e.g. 255.70 mm.................................................................................................................................................................................................................... 352
							Dimension I e.g. 260.65 mm...................................................................................................................................................................................................................... 352
							Dimension II e.g. - 255.70 mm................................................................................................................................................................................................................... 352
							Difference. 4.95 mm............................................................................................................................................................................................................................. 352
							Required axial play (average) e.g. - 0.65 mm.................................................................................................................................................................................................... 352
							Result = requir.thrust washer(s) e.g. s = 4.30 mm............................................................................................................................................................................................... 352
						3. Insert thrust washer(s) (e.g. s = 4.30 mm) into planetary carrier and press into contact position................................................................................................................................................ 352
						4. Preassemble planetary gear - depending on version - as shown in the figure beside................................................................................................................................................................ 352
						5. Warm up bearing inner ring and install pre-assembled planetary gear until contact is obtained.................................................................................................................................................... 353
						6. Fix planetary gear by means of retaining ring.................................................................................................................................................................................................... 353
						7. Install preassembled planetary carrier and fix with cylinder screws.............................................................................................................................................................................. 353
							Tightening torque (MI2/8.8) MA = 55 N.m......................................................................................................................................................................................................... 353
						8. Install screw plug with new O-ring............................................................................................................................................................................................................... 354
							Tightening torque (M 36 x 1.5) MA = 50 N.m...................................................................................................................................................................................................... 354
				Pivot Bearing............................................................................................................................................................................................................................................... 354
				Steering.................................................................................................................................................................................................................................................... 355
					1. Mount U-ring (6) and wiper (7) in the steering cylinder (l).......................................................................................................................................................................................... 355
					2. Position inner installer (S1) on piston rod (3), install O-ring (4b) and press with inner installer (S2) into annular groove (arrow) of piston (3)................................................................................................... 356
					3. Install form seal ring (4a) and press with inner installer (S2) into annular groove (arrow) of piston (3)............................................................................................................................................ 356
					4. Calibrate form seal ring (4a) by means of calibration bush (S3)...................................................................................................................................................................................... 357
					5. Place both guide rings (5) into annular grooves of the piston rod.................................................................................................................................................................................... 357
					6. Insert preassembled piston rod in the preassembled steering cylinder................................................................................................................................................................................. 357
					7. Insert u-ring(6), rod wiper (7) and dual ring (8) in brake head(2)................................................................................................................................................................................... 358
					8. Install preassembled brake head...................................................................................................................................................................................................................... 358
					9. Push brake head into the steering cylinder (arrow) so that the circlip (9) can be mounted............................................................................................................................................................ 358
					10. Bring the inserted brake head (8) into contact position (arrow) on the snapped circlip (9).......................................................................................................................................................... 359
					11. Fix brake head (8) with retaining ring (11)......................................................................................................................................................................................................... 359
					12. Install flange (12) and snap circlip (13)........................................................................................................................................................................................................... 359
					13. Provide both contact faces (steering cylinder/axle drive housing) with sealing agent (Loctite-Nr. 574).............................................................................................................................................. 359
					14. Insert preassembled steering cylinder and fix with hex. screws...................................................................................................................................................................................... 360
						Tightening torque (M 12/8.8) MA = 79 N.m............................................................................................................................................................................................................ 360
					15. If required - preassemble both tie rods............................................................................................................................................................................................................. 360
					16. Do not tighten the screw of the clamp before setting the track...................................................................................................................................................................................... 360
						Tightening torque (M 12x1.5) MA = 75 N.m............................................................................................................................................................................................................ 360
					17. Provide connection - axial joint/piston rod (appr. 3 threads)- with locking agent (Loctite-no. 243)................................................................................................................................................. 360
					18. Fix both tie rods on steering....................................................................................................................................................................................................................... 360
						Tightening torque (M 30xl.5) MA = 450 N.m........................................................................................................................................................................................................... 360
					19. Hang up tie rod and fix with "new" locking nut...................................................................................................................................................................................................... 360
						Tightening torque (M 27xl.5) MA = 100 N.m + 200.................................................................................................................................................................................................... 360
					Basic Track Setting..................................................................................................................................................................................................................................... 362
						Piston (rod) stop / l-h in cylinder "Dimension I" z.B. 215 mm....................................................................................................................................................................................... 362
						Piston (rod) stop / r-h in cylinder "Dimension II" z.B. . 25 mm..................................................................................................................................................................................... 362
						Result = 190mm ¸ 2.................................................................................................................................................................................................................................. 362
						Dimension "X" z.B. = 95mm........................................................................................................................................................................................................................... 362
						Tightening torque (M 12x1.5) MA = 75 N.m............................................................................................................................................................................................................ 362
					Steering Angle Setting.................................................................................................................................................................................................................................. 363
						Tightening torque (MI8/10.9) MA = 390 N.m........................................................................................................................................................................................................... 363
						Tightening torque (MI8/10.9) MA = 170 N.m........................................................................................................................................................................................................... 363
				Oil Drain-Oil Filler and Oil Control Plugs and Grease Lubrication Points.................................................................................................................................................................................... 364
					1. Mount oil drain plug with solenoid insert (1) - fitted with "new" O-ring............................................................................................................................................................................. 364
					2. Mount oil filler and oil control plug (2) - fitted with "new" O- ring................................................................................................................................................................................ 364
						Tightening torque (M 36 x 1.5) MA = 50 N.m.......................................................................................................................................................................................................... 364
					3. Mount oil drain, oil filler and oil control plug with solenoid insert (3) - fitted with "new" O-ring - in both outputs............................................................................................................................... 364
						Tightening torque (M 36 x 1.5) MA = 50 N.m.......................................................................................................................................................................................................... 364
		Rear Axle SP000930NA................................................................................................................................................................................................................................................ 365
			Safety Precautions.............................................................................................................................................................................................................................................. 369
			Applicable Models............................................................................................................................................................................................................................................... 369
				Examples of Gear-Tooth-Contact Patterns for the Gleason Gear-Tooth System................................................................................................................................................................................... 370
			Lubrication and Maintenance Specifications for Axle MT- E 3050/3060/3070........................................................................................................................................................................................ 372
				1. Oil Drain from Axle...................................................................................................................................................................................................................................... 372
				2. Oil Drain from Outputs................................................................................................................................................................................................................................... 372
				3. Oil Filling of Axle...................................................................................................................................................................................................................................... 373
					Tightening torque (M36x1.5) MA = 50 N.m................................................................................................................................................................................................................. 373
				4. Check.................................................................................................................................................................................................................................................... 373
					Tightening torque (M36x1.5) MA = 50 N.m................................................................................................................................................................................................................. 373
					Tightening torque (M36x1.5) MA = 50 N.m................................................................................................................................................................................................................. 373
				1. Motor oils SAE 10 W acc. to specification MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE.............................................................................................................................................................. 373
				2. ATF. oils type A, Suffic A, Dexron of II D............................................................................................................................................................................................................... 373
			Brake Wear Measurement on Axles of MT/MS-E 3050/ 3060/3070 Range................................................................................................................................................................................................ 374
				Tightening torque(M36x1.5) MA = 50 N.m...................................................................................................................................................................................................................... 375
			Disassembly..................................................................................................................................................................................................................................................... 376
				1. Mount the axle to the assembly truck..................................................................................................................................................................................................................... 376
				2. Loosen oil drain plug and drain oil from the axle - use suitable collecting basin........................................................................................................................................................................ 376
					For this purpose secure output ass’y by means of lifting bracket, loosen threaded connections and separate output ass’y from axle housing............................................................................................................... 377
				3. Secure planetary carrier by means of lifting strap, loosen both cylinder screws (arrows) and separate planetary carrier from hub......................................................................................................................... 377
				4. Unsnap retaining ring.................................................................................................................................................................................................................................... 377
				5. Pull off planetary gear by means of two-armed puller..................................................................................................................................................................................................... 377
					A. Version MT-E 3060/3070............................................................................................................................................................................................................................... 378
					B. Version MT-E 3050.................................................................................................................................................................................................................................... 378
				6. Remove slotted nut mount (cylinder screw)................................................................................................................................................................................................................ 378
				7. Loosen slotted nut....................................................................................................................................................................................................................................... 378
				8. Remove sun gear shaft and stub shaft..................................................................................................................................................................................................................... 379
				9. Press off ring gear with piston.......................................................................................................................................................................................................................... 379
				10. Loosen hex screws, remove spring sleeves and compression springs........................................................................................................................................................................................ 379
				11. Press piston from ring gear............................................................................................................................................................................................................................. 379
				12. Remove sealing elements (arrows) from ring gear......................................................................................................................................................................................................... 380
				13. Remove plate pack....................................................................................................................................................................................................................................... 380
				14. Remove O-ring (arrow) and lift-off disc carrier with lever, then remove releasing O-ring................................................................................................................................................................ 380
				15. Secure hub by means of lifting bracket, pull hub from hub carrier by means of pressure piece and two-armed puller....................................................................................................................................... 380
				16. Lift-off shaft seal (arrow) with lever and remove both bearing outer rings from hub..................................................................................................................................................................... 381
				17. Only for axle type MT-E 3060 :.......................................................................................................................................................................................................................... 381
				18. Pull bearing inner ring from hub........................................................................................................................................................................................................................ 381
				19. Fix hub carrier by means of a strap, loosen threaded connection and separate hub carrier from axle housing.............................................................................................................................................. 381
			Reassembly...................................................................................................................................................................................................................................................... 382
				Hub Carrier / Hub........................................................................................................................................................................................................................................... 382
					1. Oil O-ring (1) and install on hub carrier............................................................................................................................................................................................................ 382
					2. Install pre-assembled hub carrier to axle housing, considering the installation position - stamped circle in 12 o’clock position (see arrow) - fix with hex screws and washers....................................................................... 382
						Tightening torque (M16/10.9) MA = 280 N.m........................................................................................................................................................................................................... 382
					3. Install heated bearing inner ring until contact...................................................................................................................................................................................................... 382
					4. Only for axle type MT-E 3060:........................................................................................................................................................................................................................ 383
					5. Mount wheel bolts (1)................................................................................................................................................................................................................................ 383
					6. Mount shaft seal, considering installation position (marking OUT-SIDE looking upward / outward) and rim offset "X" - see detailed sketch............................................................................................................. 383
					7. Legend to Figure 42 and detail sketch................................................................................................................................................................................................................ 383
						A. Version MT-E 3050/3060........................................................................................................................................................................................................................... 384
						B. Version MT-E 3070................................................................................................................................................................................................................................ 384
					8. Install preassembled hub until contact and fix with heated outer bearing inner ring.................................................................................................................................................................. 384
					9. Oil O-ring and locate in annular groove (arrow) of disc carrier...................................................................................................................................................................................... 384
					10. Bring hub bearing into contact position (Figure 47 ~ 50): Install ring gear (without sealing elements).............................................................................................................................................. 385
					11. Insert stub shaft and sun gear shaft................................................................................................................................................................................................................ 385
					12. Bring hub bearing into contact position. for this purpose tighten slotted nut with a tightening torque of max. 1,400 N.m............................................................................................................................ 385
					13. Loosen slotted nut again and remove ring gear....................................................................................................................................................................................................... 385
				Multi Disc Brake............................................................................................................................................................................................................................................ 386
					1. Install disc pack alternately starting with an outer disc............................................................................................................................................................................................ 386
					2. Installation position of inner discs................................................................................................................................................................................................................. 386
					3. Oil O-ring and locate in annular groove of disc carrier.............................................................................................................................................................................................. 386
					4. Oil sealing elements and locate in annular grooves (arrows) of ring gear as shown in the detailed sketch............................................................................................................................................. 387
					5. Just for. assembly of new parts. or if disassembled.................................................................................................................................................................................................. 387
					6. Install piston on preassembled ring gear............................................................................................................................................................................................................. 387
					7. Fix piston with spring sleeve (2), compression springs (3 and 4) and. new. hex. screws (1)........................................................................................................................................................... 388
						Tightening torque (M6/8.8) MA = 11 N.m.............................................................................................................................................................................................................. 388
					8. Mount preassembled ring gear, considering installation position (markings O in 12 o’clock position - see arrows, Detail "B")......................................................................................................................... 388
					9. Oil the O-ring and insert it in recess (arrow)....................................................................................................................................................................................................... 389
					10. Fix ring gear with slotted nut...................................................................................................................................................................................................................... 389
						Tightening torque (M110 x 1.5) MA = 1,400+ 200 N.m.................................................................................................................................................................................................. 389
					1. Mount breather valve (arrow) and connect HP-pump (to connection hole on input side / hub carrier).................................................................................................................................................... 389
					Test media.............................................................................................................................................................................................................................................. 389
						A. High pressure test............................................................................................................................................................................................................................... 389
						B. Low pressure test................................................................................................................................................................................................................................ 389
						1. Disc clearance / piston travel "X" = 1.2~ 1.8 mm................................................................................................................................................................................................. 390
							Dimension A. e.g. = 83.50 mm.................................................................................................................................................................................................................... 390
							Dimension "B" z.B. = 82.10 mm................................................................................................................................................................................................................... 390
							Dimension "A" z.B. 83.50 mm..................................................................................................................................................................................................................... 390
							Dimension "B" z.B. - 82.10 mm................................................................................................................................................................................................................... 390
							Result Æ disc clearance = 1.40 mm............................................................................................................................................................................................................... 390
						2. Dismantle HP-pump and mount screw neck with O-ring. (Just for transport protection - mount protection cap with O- ring on screw neck)............................................................................................................ 391
							Tightening torque (M 14x1.5) MA = 23 N.m........................................................................................................................................................................................................ 391
						3. Secure slotted nut with cylinder screw - in this connection refer to note on Figure 63!.......................................................................................................................................................... 391
							Tightening torque (M 10/8.8) MA = 32 N.m........................................................................................................................................................................................................ 391
				Planetary Carrier........................................................................................................................................................................................................................................... 391
					1. Determine dimension I, from mounting face of planetary carrier to contact face of thrust washer...................................................................................................................................................... 391
						Dimension I, e.g. 260.65 mm......................................................................................................................................................................................................................... 391
					2. Determine dimension II, from front face (arrow) of sun gear to mounting face of hub.................................................................................................................................................................. 391
						Dimension II, e.g. 255.70 mm........................................................................................................................................................................................................................ 391
						Dimension I e.g. 260.65 mm.......................................................................................................................................................................................................................... 391
						Dimension II e.g. - 255.70 mm....................................................................................................................................................................................................................... 391
						Difference = 4.95 mm................................................................................................................................................................................................................................ 391
						Required axial play (average) e.g. - 0.75 mm........................................................................................................................................................................................................ 391
						Result = requ. thrust washer(s) e.g. s = 4.20 mm.................................................................................................................................................................................................... 391
					3. Insert thrust washer(s) (e.g. s = 4.20 mm) into planetary carrier and press into contact position.................................................................................................................................................... 392
					4. Preassemble planetary gear, as shown in the figure beside - see different versions................................................................................................................................................................... 392
					5. Warm up bearing inner ring and install pre-assembled planetary gear until contact.................................................................................................................................................................... 392
					6. Fix planetary gear by means of retaining ring........................................................................................................................................................................................................ 393
					7. Install planetary carrier and fix with cylindrical screws............................................................................................................................................................................................ 393
						Tightening torque (M12/8.8) MA = 55 N.m............................................................................................................................................................................................................. 393
				Assembly of An Output Ass’y (Figure 78)..................................................................................................................................................................................................................... 393
					Tightening torque (M16/10.9) MA = 280 N.m............................................................................................................................................................................................................... 393
			Disassembly..................................................................................................................................................................................................................................................... 394
				Differential / Input........................................................................................................................................................................................................................................ 394
					1. Loosen oil drain plug and drain oil from the axle - use suitable collecting basin.................................................................................................................................................................... 394
					2. Secure output ass’y by means of lifting bracket, loosen threaded connection and separate output ass’y from axle housing.............................................................................................................................. 394
				Input - HL Transmission..................................................................................................................................................................................................................................... 395
					1. Fix HL transmission by means of a lifting strap and loosen threaded connection. (HL-transmission / axle drive housing)............................................................................................................................... 395
					2. Separate HL-transmission from axle................................................................................................................................................................................................................... 395
					3. Loosen threaded connection of axle housing half on crown wheel side.................................................................................................................................................................................. 395
					4. Carefully separate axle housing half................................................................................................................................................................................................................. 395
					5. Lift off differential ass’y from axle drive housing.................................................................................................................................................................................................. 396
					6. Pull bearing outer ring out of hole by means of a striker and remove shim behind (backlash).......................................................................................................................................................... 396
					7. Remove bearing outer ring and shim behind (rolling torque differential bearing) from second axle housing half........................................................................................................................................ 396
				Differential Type "D 500" and "D-750"....................................................................................................................................................................................................................... 397
					1. Illustration shows differential version "D-500"...................................................................................................................................................................................................... 397
					2. Loosen threaded connection (see position "X")........................................................................................................................................................................................................ 397
						A. Version "D-500".................................................................................................................................................................................................................................. 397
						B. Version "D-750".................................................................................................................................................................................................................................. 397
					3. Separate differential carrier halves and remove releasing single components.......................................................................................................................................................................... 398
					4. Push crown wheel off from differential carrier half.................................................................................................................................................................................................. 398
			Reassembly...................................................................................................................................................................................................................................................... 399
				Differential / Input........................................................................................................................................................................................................................................ 399
					1. Illustration shows differential version "D-500"...................................................................................................................................................................................................... 399
					Assembly Specifications................................................................................................................................................................................................................................. 399
						2. Insert two adjusting screws into crown wheel and press differential carrier until contact........................................................................................................................................................ 399
						3. Insert thrust washer and axle bevel gear......................................................................................................................................................................................................... 400
						4. Instal differential bevel gears and thrust washers on differential spider and insert in differential carrier half I.............................................................................................................................. 400
						5. Insert second axle bevel gear.................................................................................................................................................................................................................... 400
						6. Stick thrust washer with grease (assembly aid) into differential carrier half II................................................................................................................................................................. 400
						7. Fasten differential carrier halves with cylinder. screws and washers (version D-500, pos. X) resp. with hex. screws (version D-750, pos. X)...................................................................................................... 401
							Tightening torque (M 12x1.5/12.9) MA = 145 N.m.................................................................................................................................................................................................. 401
							Tightening torque (M 12x1.5/10.9) MA = 122 N.m.................................................................................................................................................................................................. 401
							Tightening torque (M 16x1.5/10.9) MA = 300 N.m.................................................................................................................................................................................................. 401
						8. Instal both bearing inner rings (arrows)......................................................................................................................................................................................................... 402
						9. Wet some tooth flanks of the crown wheel with marking ink (for contact pattern check - See Figure 119 on page -43)............................................................................................................................... 402
					Backlash................................................................................................................................................................................................................................................ 402
						Tightening torque (M18/10.9) MA = 390 N.m........................................................................................................................................................................................................... 403
						1. Insert shim (backlash) into hole of axle housing half and install bearing outer ring until contact............................................................................................................................................... 403
						2. Instal shim ring (arrow, Æ = 160 mm) and determine dimension "A" - See Figure 107, then remove shim ring......................................................................................................................................... 403
							Dimension "A" e.g. 39.92 mm..................................................................................................................................................................................................................... 403
							Dimension "A" z.B. 39.92 mm..................................................................................................................................................................................................................... 403
							Dimension "B" 80.00 mm.......................................................................................................................................................................................................................... 403
							Result = Dimension "X" = 119.92 mm.............................................................................................................................................................................................................. 403
						3. Install pre-assembled differential............................................................................................................................................................................................................... 403
							Dimension "C" e.g. 48.98 mm..................................................................................................................................................................................................................... 404
							Corrective value - 0.07 mm...................................................................................................................................................................................................................... 404
							Result = 48.91 mm............................................................................................................................................................................................................................... 404
						5. Read dimension "D" (distance) from crown wheel, or measure it in case of a + or - deviation of the distance due to production (the concerned value is marked by hand on the crown wheel)......................................................... 404
							Distance "D" (without a + or - deviation) = 71.0 mm............................................................................................................................................................................................. 404
							Distance "D" with an indicated + 0.1 deviation = 71.1 mm........................................................................................................................................................................................ 404
							Distance "D" with an indicated - 0.1 deviation = 70.9 mm........................................................................................................................................................................................ 404
							Dimension "X" z.B. 119.92 mm.................................................................................................................................................................................................................... 404
							Dimension "C"(48.91)+ "D"(71.00) = 119.91 mm.................................................................................................................................................................................................... 404
							Result = 0.01 mm................................................................................................................................................................................................................................ 404
						6. Determine dimension "Y" - from mounting face / axle drive housing to front face / bearing outer ring (take measurements at several points and determine mean value).............................................................................. 404
							Dimension "Y" e.g. 18.11 mm..................................................................................................................................................................................................................... 404
						7. Determine dimension "Z" - from mounting face / axle housing to bearing hole / bearing outer ring contact......................................................................................................................................... 405
							Dimension "Z" e.g. 17.25 mm..................................................................................................................................................................................................................... 405
							Dimension "Y" e.g. 18.11 mm..................................................................................................................................................................................................................... 405
							Dimension "Z" e.g. - 17.25 mm................................................................................................................................................................................................................... 405
							Difference 0.86 mm.............................................................................................................................................................................................................................. 405
							Bearing preload (0.15 ^ 3.0 ... 4.0 N.m + 0.15 mm............................................................................................................................................................................................... 405
							Result = 1.01 mm................................................................................................................................................................................................................................ 405
							Required shim (s) = 1.00 mm..................................................................................................................................................................................................................... 405
						8. Insert the determined shim (e.g. s = 1.00 mm) into bearing hole and instal bearing outer ring until contact...................................................................................................................................... 405
						9. Instal pre-assembled axle housing half (pay attention to radial installation position), fix with hex. screws and washers......................................................................................................................... 405
							Tightening torque (M18/10.9) MA = 390 N.m....................................................................................................................................................................................................... 405
						10. Position HL transmission on the axle and fix it................................................................................................................................................................................................. 406
							Tightening torque (M12/8.8) MA = 79 N.m......................................................................................................................................................................................................... 406
						1. Place dial indicator through oil drain hole at right angles to a tooth flank of the crown wheel (in the outer diameter area) and check backlash.................................................................................................. 406
					Backlash................................................................................................................................................................................................................................................ 406
						2. Disassemble HL transmission again................................................................................................................................................................................................................ 406
						3. Remove differential.............................................................................................................................................................................................................................. 407
						4. Reinstall differential........................................................................................................................................................................................................................... 407
						5. Oil O-ring and install on axle housing half (arrow).............................................................................................................................................................................................. 407
						6. Bring axle housing half into correct position (pay attention to correct installation position), fix with hex screws and washers.................................................................................................................. 407
							Tightening torque (M18/10.9) MA = 390 N.m....................................................................................................................................................................................................... 407
				Reassembly of Output Ass’y (Figure 123 ~ 125)............................................................................................................................................................................................................... 408
					1. Install plug shaft into toothing of axle bevel gear.................................................................................................................................................................................................. 408
					2. Bring output ass’y on axle housing into correct position, by mounting the plug shaft into the sun gear shaft......................................................................................................................................... 408
					3. Fix output unit with hex screws and washers.......................................................................................................................................................................................................... 408
						Tightening torque (M16/10.9) MA = 280 N.m........................................................................................................................................................................................................... 408
					4. Mount the second drive in the same way............................................................................................................................................................................................................... 408
	Engine and Drive Train.................................................................................................................................................................................................................................................. 409
		Transmission SP000962NA............................................................................................................................................................................................................................................. 411
			Safety Precautions.............................................................................................................................................................................................................................................. 415
			Applicable Models............................................................................................................................................................................................................................................... 415
			Layout 2 HL 250/270/290 Axle Attachment......................................................................................................................................................................................................................... 416
			Layout 2 HL 250/270/290 Separate Installation................................................................................................................................................................................................................... 417
			Measuring Points and Connections or Installation View 2 HL 250/ 270/290 Layout "Axle Attachment"................................................................................................................................................................ 418
			Measuring Points and Connections on the 2 HL 250/270/290 Transmission - Version "Separate Installation"......................................................................................................................................................... 420
			Notes to the Required Oil Quality and Oil Filling Capacity...................................................................................................................................................................................................... 421
			Separate the HL- Transmission from the Axle Casing.............................................................................................................................................................................................................. 422
				1. Drain oil from the axle casing........................................................................................................................................................................................................................... 422
				2. Pick-up the HL-Transmission by means of the lifting tackle, loosen the bolt connection and the complete HL- Transmission from the axle casing............................................................................................................ 422
			Disassembly - Brake / Clutch / Planet Carrier................................................................................................................................................................................................................... 423
				1. Mount the transmission to the assembly truck............................................................................................................................................................................................................. 423
				2. Loosen the screw plug and drain the oil - use a suitable collector....................................................................................................................................................................................... 423
				Lube Oil Pump/Downshift Interlock........................................................................................................................................................................................................................... 423
				Speed Transmitter........................................................................................................................................................................................................................................... 424
				Emergency Release (Parking Brake)........................................................................................................................................................................................................................... 424
					1. Remove the bleeder................................................................................................................................................................................................................................... 424
					2. Remove the compression spring and the ball........................................................................................................................................................................................................... 424
					3. Remove the threaded element (see Detail "X") with O-ring from the bore............................................................................................................................................................................... 424
					4. Remove the lubrication nipple, both screw plugs and the bleeder valve - see arrow.................................................................................................................................................................... 425
				Input Housing and Modulation Valve.......................................................................................................................................................................................................................... 425
					1. Take off the input housing and remove the O-ring (arrow)............................................................................................................................................................................................. 425
					2. Modulation valve:.................................................................................................................................................................................................................................... 426
					3. Pull the complete piston out of the bore............................................................................................................................................................................................................. 426
				Brake / Clutch.............................................................................................................................................................................................................................................. 426
					1. Remove the cup springs from the brake................................................................................................................................................................................................................ 426
					2. Remove the cup springs from the clutch............................................................................................................................................................................................................... 427
					3. Remove the piston.................................................................................................................................................................................................................................... 427
					4. Pull off both cyl. pins (arrows)..................................................................................................................................................................................................................... 427
					5. Remove both seals (arrows) from the piston........................................................................................................................................................................................................... 428
					6. Remove the axial roller cage with both thrust washers................................................................................................................................................................................................ 428
					7. Remove the pressure piece and the compression spring................................................................................................................................................................................................. 428
					8. Remove the gasket and O-rings from the pressure ring / ring.......................................................................................................................................................................................... 429
					9. Take the disc set of the brake with end shim(s) out of the housing................................................................................................................................................................................... 429
					10. Unsnap the retaining ring........................................................................................................................................................................................................................... 429
					11. Remove the snap ring and the shim................................................................................................................................................................................................................... 430
					12. Take the disc set of the clutch (with end shim/s) out of the internal gear.......................................................................................................................................................................... 430
					13. Remove the cpl. input shaft with internal gear from the housing..................................................................................................................................................................................... 430
					14. Unsnap the retaining ring........................................................................................................................................................................................................................... 430
					15. Press the input shaft out of the ball bearing/internal gear......................................................................................................................................................................................... 431
					16. Unsnap the retaining ring........................................................................................................................................................................................................................... 431
					17. Press the centering disc from the input shaft....................................................................................................................................................................................................... 431
					18. Unsnap the retaining ring and remove the ball bearing............................................................................................................................................................................................... 431
				Planet Carrier.............................................................................................................................................................................................................................................. 432
					1. Remove the axial needle cage with both thrust washers................................................................................................................................................................................................ 432
					2. If not yet disassembled before, remove the lube oil pump or the downshift interlock (depending on the version) (illustration shows - version - "Lube Oil Pump")...................................................................................... 432
					3. Loosen the bolt connection and remove the washer - fasten the output flange by means of the fixture.................................................................................................................................................. 432
					4. Press the cpl. planet carrier out of the roller bearing.............................................................................................................................................................................................. 432
					5. Pull the second bearing inner ring from the planet carrier........................................................................................................................................................................................... 433
					6. If required - expel both bearing outer rings (arrow) from the bearing bore........................................................................................................................................................................... 433
					7. Unsnap the retaining ring............................................................................................................................................................................................................................ 433
					8. Remove the planetary gear by means of lever action - pay attention to the released shim and the cylindrical rollers.................................................................................................................................. 433
					9. Pull off the bearing inner ring ñ in case of an extremely fixed seat heat the bearing inner ring..................................................................................................................................................... 434
					10. Remove both seals (1)............................................................................................................................................................................................................................... 434
					11. Only for the Version "Transmission Installation Position Horizontal" (Figure 51 and Figure 52)...................................................................................................................................................... 434
					12. Remove the screen sheet (2) from the planet carrier (1)............................................................................................................................................................................................. 435
			Disassembly - Output............................................................................................................................................................................................................................................ 436
				Version - Axle Attachment................................................................................................................................................................................................................................... 436
					1. Loosen the bolt connection, remove the cover and the O- ring......................................................................................................................................................................................... 436
					2. Pull off the flange.................................................................................................................................................................................................................................. 436
					3. Remove the shaft seal by lever action................................................................................................................................................................................................................ 436
					4. Fasten the pinion by means of the device and press it off............................................................................................................................................................................................ 436
					5. Remove the O-ring (arrow) and the bush from the pinion............................................................................................................................................................................................... 437
					6. Pull off and press off respectively the bearing inner ring........................................................................................................................................................................................... 437
					7. Pull the bearing outer ring out of the bearing cover................................................................................................................................................................................................. 437
					8. Pull off the bearing cover........................................................................................................................................................................................................................... 438
					9. Remove the O-rings (arrows).......................................................................................................................................................................................................................... 438
					10. Remove the shaft seal............................................................................................................................................................................................................................... 438
					11. Lift the output gear with oil baffle plate out of the housing....................................................................................................................................................................................... 438
					12. Remove the screen sheet............................................................................................................................................................................................................................. 439
					13. Expel the bearing outer ring from the housing bore (arrow).......................................................................................................................................................................................... 439
					14. Remove the stud bolts, if necessary................................................................................................................................................................................................................. 439
				Version - "Separate Installation"........................................................................................................................................................................................................................... 440
					1. Legend to Figure 67.................................................................................................................................................................................................................................. 440
					2. Fasten the output flange by means of the fixture..................................................................................................................................................................................................... 441
					3. Press off the shaft seal by lever action............................................................................................................................................................................................................. 441
					4. Loosen the bolt connection........................................................................................................................................................................................................................... 441
					5. By means of lifting tackle separate the output gear with cover from the transmission housing......................................................................................................................................................... 441
					6. Press the output gear out of the ball bearing/cover. remove the released oil baffle plate............................................................................................................................................................ 442
					7. Unsnap the retaining ring and expel the ball bearing from the cover.................................................................................................................................................................................. 442
					8. Remove both O-rings (arrows) from the cover.......................................................................................................................................................................................................... 442
					9. Remove the screen sheet from the transmission housing................................................................................................................................................................................................ 442
					10. Expel the ball bearing from the housing bore........................................................................................................................................................................................................ 443
			Reassembly - Output............................................................................................................................................................................................................................................. 444
				Version - Axle Attachment................................................................................................................................................................................................................................... 444
					1. Install the stud bolts............................................................................................................................................................................................................................... 444
						Tightening torque MA = 20 N.m....................................................................................................................................................................................................................... 444
					2. Insert the bearing outer ring until contact.......................................................................................................................................................................................................... 444
					3. Insert the slotted pin (arrow)....................................................................................................................................................................................................................... 444
					4. Position the screen sheet - with slotted pin (See Figure 80) into the fixing bore (arrow)............................................................................................................................................................ 445
					5. Insert the output gear - Observe the installation position........................................................................................................................................................................................... 445
					6. Contact face (external shell of the shaft seal) if:.................................................................................................................................................................................................. 445
					7. Exact installation position of the shaft seal is guaranteed by use of the specified mounting tool.................................................................................................................................................... 446
					1. Legend to Figure 85 ~ 96:............................................................................................................................................................................................................................ 446
					2. Determine the auxiliary dimension "A"................................................................................................................................................................................................................ 447
					3. Read pinion dim. "X" on the pinion (see arrow) or measure it in case of manufacturing-specific + or - deviation from the pinion dim. (relating value is marked by hand on the pinion e.g. + 0.1)..................................................... 447
					4. Determine Dim. "D" bearing width, paying attention that the rollers are seated without clearance (aligning of rollers - rotate the bearing inner ring in both directions several times).............................................................. 447
					5. Determine Dim. "D" (contact surface / bearing cover to contact / bearing bore)....................................................................................................................................................................... 447
						Dim. "D" = e.g. 34.50 mm............................................................................................................................................................................................................................ 447
						Dim. "Z" 189.00 mm.................................................................................................................................................................................................................................. 448
						Dim. "X" z.B. - 116.00 mm........................................................................................................................................................................................................................... 448
						Result Æ Dim. "E" = 73.00 mm........................................................................................................................................................................................................................ 448
						Dim. "E" 73.00 mm................................................................................................................................................................................................................................... 448
						Dim. "B+D" (e.g. 36.55 + 34.50) - 71.05 mm.......................................................................................................................................................................................................... 448
						Result Æ required shim "S" = 1.95 mm................................................................................................................................................................................................................ 448
					6. Insert the determined shim(s) "S" = e.g. 1.95 mm and install the bearing outer ring subsequently until contact is obtained........................................................................................................................... 448
					7. Oil the O-rings (arrows) and insert them into the ring grooves of the bearing cover.................................................................................................................................................................. 448
					8. Bend the edges of the fixing straps of the oil baffle plate slightly - assembly aid (sheet is fixed to the bearing cover - See Figure 93)............................................................................................................ 448
					9. Mount the oil baffle plate on the bearing cover...................................................................................................................................................................................................... 449
					10. Oil the contact face/oil baffle plate/housing (assembly aid)........................................................................................................................................................................................ 449
					11. Mount the heated bearing inner ring until contact and after cooling-down install it subsequently until contact is obtained.......................................................................................................................... 449
					12. Mount the bush, oil the O-ring (arrow) and put it into the ring groove.............................................................................................................................................................................. 450
					13. Mount the preassembled pinion....................................................................................................................................................................................................................... 450
					14. Fasten the pinion by means of the clamping bar...................................................................................................................................................................................................... 450
					1. Rotate the transmission by 180°...................................................................................................................................................................................................................... 451
					2. Mount the heated bearing inner ring and install it subsequently until contact........................................................................................................................................................................ 451
					3. Mount the flange..................................................................................................................................................................................................................................... 451
					4. Put on the washer and fasten the flange with hexagon screws.......................................................................................................................................................................................... 451
						Tightening torque (M 10/8.8) MA = 46 N.m............................................................................................................................................................................................................ 451
					5. Turn back the pinion fastening and remove the clamping bar respectively.............................................................................................................................................................................. 452
					1. Bearing rolling moment (without shaft seal) 1.5 ~ 3.0 N.m (When using new roller bearings - upper value should be achieved).......................................................................................................................... 452
					2. Remove the flange again.............................................................................................................................................................................................................................. 452
					1. Contact face (external shell of the shaft seal) if................................................................................................................................................................................................... 453
					2. Only for installation of a new flange or if stud bolts were removed (Figure 108) Install the stud bolts.............................................................................................................................................. 453
						Tightening torque (M10x1) MA = 20 N.m............................................................................................................................................................................................................... 453
					3. Only for installation of a new flange/screen sheet or if removed (Figure 109) Install the screen sheet (2), considering the required installation position (Dim. "N" - See Figure 107)............................................................... 454
					4. Mount the preassembled flange and put the O-ring into the recess..................................................................................................................................................................................... 454
					5. Place the washer and fasten it by means of hexagon screws............................................................................................................................................................................................ 454
						Tightening torque (M 10/8.8) MA = 46 N.m............................................................................................................................................................................................................ 454
					1. Position the ball [use ø = 7 mm Æ ball ø like for the determination of auxiliary dimension "A"] into the centering bore of the pinion and determine Dim. "C" (See Figure 85), from the contact surface/bearing cover to the ball..................... 454
						Reference dimension "C" e.g. 115.58 mm.............................................................................................................................................................................................................. 454
						Auxiliary dimension "A" (See Figure 86) e.g - 42.56 mm.............................................................................................................................................................................................. 454
						Result (Dim. "E") = 73.02 mm........................................................................................................................................................................................................................ 454
					2. For a correction of the shim/pinion gap, a counter correction of the adjusting ring of the rolling moment / pinion gap - Figure 99 is also to be considered.......................................................................................... 455
					1. Insert ball bearing (2) until contact is obtained.................................................................................................................................................................................................... 457
					2. Rotate the transmission by 180°...................................................................................................................................................................................................................... 457
					3. Position the screen sheet - with slotted pin (See Figure 115) into the fixing bore (arrow)........................................................................................................................................................... 457
					4. Insert the ball bearing into the cover and fasten it by means of the retaining ring.................................................................................................................................................................. 457
					5. Oil both O-rings (arrows) and put it into the ring grooves of the planet carrier..................................................................................................................................................................... 458
					6. Bend the edges of the fixing straps of the oil baffle plate slightly - assembly aid (sheet is fixed to the bearing cover - See Figure 120)........................................................................................................... 458
					7. Mount the oil baffle plate on the bearing cover...................................................................................................................................................................................................... 458
					8. Press the output gear into the ball bearing/bearing cover............................................................................................................................................................................................ 458
					9. Heat the bearing inner ring of the ball bearing...................................................................................................................................................................................................... 459
					10. Attach two adjusting screws (M12) and mount the preassembled bearing cover/output gear until contact is obtained.................................................................................................................................... 459
					11. Fasten the bearing cover by means of hexagon screws................................................................................................................................................................................................. 459
						Tightening torque (M 12/8.8) MA = 80 N.m............................................................................................................................................................................................................ 459
					1. Legend to the sketch:................................................................................................................................................................................................................................ 460
					2. Contact face (external shell of the shaft seal) if................................................................................................................................................................................................... 460
					3. Only for installation of a new flange or if stud bolts were removed (Figure 128)..................................................................................................................................................................... 461
						Tightening torque (M10x1) MA = 20 N.m............................................................................................................................................................................................................... 461
					4. Only for installation of a new flange/screen sheet or if removed (Figure 129)........................................................................................................................................................................ 461
					5. Mount the preassembled output flange................................................................................................................................................................................................................. 461
					6. Insert the O-ring.................................................................................................................................................................................................................................... 461
					7. Position the washer and fasten the output flange by means of hexagon screws.......................................................................................................................................................................... 462
			Reassembly - Brake / Clutch / Planet Carrier.................................................................................................................................................................................................................... 463
				Planet Carrier.............................................................................................................................................................................................................................................. 463
					1. Illustration shows the HL-Version "Axle Attachment".................................................................................................................................................................................................. 463
					2. Rotate transmission by 180°.......................................................................................................................................................................................................................... 463
					3. Only for the Version "Transmission Installation Position Horizontal" (Figure 135 and 144)............................................................................................................................................................ 463
					4. Install the screen sheet (2) considering the installation dimension "X" (see detail sketch) onto the planet carrier (1).............................................................................................................................. 464
					5. Insert the slotted pins (6x), considering the installation dimension "X" = 28.0 - 1.0 mm and the installation position - See Figure 139 (slot is showing to the center).............................................................................. 464
					6. Position the planetary gear (2) - with the marking showing downwards................................................................................................................................................................................. 465
					7. Position the cyl. rollers (3) onto the planetary gear (2)............................................................................................................................................................................................ 465
					8. By means of the mounting tool press the cyl. rollers (2) into the planetary gear (2)................................................................................................................................................................. 466
					9. Press the planetary gear (bearing inner ring) until contact.......................................................................................................................................................................................... 466
					10. Mount the shim (4). marking showing upwards. and snap in the retaining ring......................................................................................................................................................................... 466
					11. Press the bearing inner ring onto the planet carrier until contact is obtained...................................................................................................................................................................... 467
					12. Insert the preassembled planet carrier.............................................................................................................................................................................................................. 467
					13. Fasten the planet carrier by means of pressure plate and clamping bar............................................................................................................................................................................... 467
					14. Rotate the transmission by 180°..................................................................................................................................................................................................................... 468
					15. Mount the heated bearing inner ring until contact................................................................................................................................................................................................... 468
					16. Position the shim and attach the hexagon screws by hand (fixing of the planet carrier).............................................................................................................................................................. 468
					17. Fasten the fixture to the output flange............................................................................................................................................................................................................. 469
						Tightening torque (M 10/8.8) MA = 46 N.m............................................................................................................................................................................................................ 469
				Brake/Clutch................................................................................................................................................................................................................................................ 469
					1. Mount the heated centering disc and press it until contact is obtained............................................................................................................................................................................... 469
					2. Fasten the centering disc by means of the retaining ring............................................................................................................................................................................................. 469
					3. Insert the ball bearing into the internal gear and fasten it by means of the retaining ring.......................................................................................................................................................... 470
					4. Heat the bearing inner ring of the ball bearing...................................................................................................................................................................................................... 470
					5. Mount the preassembled internal gear to the input shaft until contact is obtained.................................................................................................................................................................... 470
					6. Snap in the retaining ring........................................................................................................................................................................................................................... 470
					7. Rotate the transmission by 180°...................................................................................................................................................................................................................... 471
					8. Mount the preassembled input shaft (with internal gear).............................................................................................................................................................................................. 471
					1. Version "2 HL-290"................................................................................................................................................................................................................................... 471
					2. Version "2 HL-270"................................................................................................................................................................................................................................... 472
					3. Version "2 HL-250":.................................................................................................................................................................................................................................. 472
						A. Brake............................................................................................................................................................................................................................................ 472
						B. Insert the end shim (2).......................................................................................................................................................................................................................... 473
						C. Insert the disc set (outer / inner discs) - beginning with an outer disc - alternately........................................................................................................................................................... 473
						D. Clutch:.......................................................................................................................................................................................................................................... 473
					1. Mount the pressure piece (without compression spring)................................................................................................................................................................................................ 473
					2. Oil the axial roller cage and mount it with both thrust washers (1x each, positioned underneath and onto the axial needle cage respectively - see Figure)............................................................................................ 474
					3. Insert the piston (brake) - without sealing elements installed....................................................................................................................................................................................... 474
					4. Insert the piston (clutch) - without sealing elements installed...................................................................................................................................................................................... 474
					5. Insert both cup springs / clutch..................................................................................................................................................................................................................... 474
					6. Insert both cup springs / brake...................................................................................................................................................................................................................... 475
						Tightening torque (M 12/8.8) MA = 80 N.m............................................................................................................................................................................................................ 475
					7. Determine Dim. "A" (Measuring bore "I") from mounting face / housing to the face / piston (clutch)................................................................................................................................................... 476
						Dim. "A" e.g. = 22.45 mm............................................................................................................................................................................................................................ 476
					8. Determine Dim. "C" (Measuring bore "II") from mounting face / housing to the face / piston (brake)................................................................................................................................................... 476
						Dim. "C" e.g. = 11.85 mm............................................................................................................................................................................................................................ 476
					9. Determine Dim. "B" from mounting face / housing to clutch piston contact / housing................................................................................................................................................................... 476
						Dim. "B" e.g. = 19.95 mm............................................................................................................................................................................................................................ 476
						Dim. "A" e.g. 22.45 mm.............................................................................................................................................................................................................................. 476
						Dim. "B" e.g. - 19.95 mm............................................................................................................................................................................................................................ 476
						Result = 2.50 mm.................................................................................................................................................................................................................................... 476
					10. Determine Dim. "D" from mounting face / housing to brake piston contact / housing................................................................................................................................................................... 477
						Dim. "D" e.g. = 9.95mm.............................................................................................................................................................................................................................. 477
						Dim. "C" e.g. 11.85 mm.............................................................................................................................................................................................................................. 477
						Dim. "D" e.g. - 9.95 mm............................................................................................................................................................................................................................. 477
						Result = 1.90 mm.................................................................................................................................................................................................................................... 477
					11. Remove the measuring fixture again. loosen the screws equally....................................................................................................................................................................................... 477
					12. Insert the oil baffle plate into the disc carrier and fix it with the snap ring..................................................................................................................................................................... 477
					13. Oil the sealing faces and the O-ring................................................................................................................................................................................................................ 478
					14. By means of the mounting tool locate the ring until contact is obtained............................................................................................................................................................................. 478
					15. Oil the sealing faces and the sealing elements...................................................................................................................................................................................................... 478
					16. Insert the seal (1) with the sealing lip showing to the oil sump. also see detail sketch............................................................................................................................................................ 478
					17. By means of the mounting tool locate the pressure ring until contact................................................................................................................................................................................ 479
					18. Insert the compression spring....................................................................................................................................................................................................................... 479
					19. Insert the pressure piece........................................................................................................................................................................................................................... 479
					21. Oil the sealing faces and the sealing elements...................................................................................................................................................................................................... 480
					22. Legend to Figure 192 as well as Figure 191 and Figure 193:.......................................................................................................................................................................................... 480
					23. Oil the sealing faces and the sealing elements...................................................................................................................................................................................................... 480
					24. Insert the preassembled piston / brake until contact is obtained.................................................................................................................................................................................... 481
					25. By means of the mounting tool locate the piston until contact....................................................................................................................................................................................... 481
					26. Insert both cyl. pins (arrow)....................................................................................................................................................................................................................... 481
					27. Insert the piston / clutch.......................................................................................................................................................................................................................... 481
					28. Press the piston axially, contrary to the compression spring preload, and seal the pressure oil supply bore by means of scre........................................................................................................................ 482
					29. Insert both cup springs/clutch...................................................................................................................................................................................................................... 482
					30. Insert both cup springs/brake....................................................................................................................................................................................................................... 482
				Modulation Valve and Input Housing.......................................................................................................................................................................................................................... 482
					1. Insert the modulation valve (cpl. - can only be replaced as unit).................................................................................................................................................................................... 482
					2. Place the O-ring (arrow) and insert the compression spring........................................................................................................................................................................................... 483
					3. Input housing:....................................................................................................................................................................................................................................... 483
					4. Position the cup springs centrically - assembly aid.................................................................................................................................................................................................. 483
						Tightening torque (M 12/8.8) MA = 80 N.m............................................................................................................................................................................................................ 483
				Emergency Release (Parking Brake)........................................................................................................................................................................................................................... 484
					1. Install the threaded element (4) with O-ring (3)..................................................................................................................................................................................................... 484
						Tightening torque (M 10x1) MA = 24 N.m.............................................................................................................................................................................................................. 484
					2. Insert the ball (5).................................................................................................................................................................................................................................. 484
					3. Insert the compression spring (6).................................................................................................................................................................................................................... 485
					1. Install both bleeder valves (1), screw plugs (2) with sealing ring and screw plugs (3) with O-ring................................................................................................................................................... 486
						Bleeder valve (M 10x1) MA = 22 N.m.................................................................................................................................................................................................................. 486
						Screw plug (M 10x1 with sealing ring) MA = 15 N.m................................................................................................................................................................................................... 486
						Screw plug (M 10x1 with O-ring) MA = 25 N.m......................................................................................................................................................................................................... 486
					2. Install the bleeder valve (1), screw plugs (2) with O-ring screw plug (3) with O-ring and compressed air connection piece (4)........................................................................................................................ 487
						Bleeder valve (M 10x1) MA = 22 N.m.................................................................................................................................................................................................................. 487
						Screw plug (M 10x1 with O-ring) MA = 25 N.m......................................................................................................................................................................................................... 487
						Screw plug (M 18x1.5 with O-ring) MA = 35 N.m....................................................................................................................................................................................................... 487
						Compr.air connect. piece (M 10x1) w. seal. ring) MA = 15 N.m........................................................................................................................................................................................ 487
					3. Pressurize the emergency release with compressed air p = 5 + 1bar and close the shut-off valve....................................................................................................................................................... 487
					4. Remove the screw plug and the compressed air connection piece (See Figure 212)....................................................................................................................................................................... 487
						Lubrication nipple (M 10x1) MA = 22 N.m............................................................................................................................................................................................................. 487
						Bleeder (M 18x1.5) MA = 22 N.m...................................................................................................................................................................................................................... 487
					1. Multi-disc brake:.................................................................................................................................................................................................................................... 488
					2. Closing pressure test (Cup spring preloading force):................................................................................................................................................................................................. 488
					3. Multi-disc clutch:................................................................................................................................................................................................................................... 489
					4. Closing pressure test (Cup spring preloading force):................................................................................................................................................................................................. 489
				Speed Transmitter........................................................................................................................................................................................................................................... 489
					Tightening torque (M 8/8.8) MA = 23 N.m................................................................................................................................................................................................................. 489
				Lube Oil Pump/Downshift Interlock........................................................................................................................................................................................................................... 490
					1. Install the lube oil pump (with O-rings) or the downshift interlock - depending on the version - (Illustration shows - Version "Lube Oil Pump")...................................................................................................... 490
						Tightening torque (M 8/10.9) MA = 23 N.m............................................................................................................................................................................................................ 490
			Disassembly - Lube Oil Pump/Downshift Interlock................................................................................................................................................................................................................. 491
				Version "with" Lube Oil Pump................................................................................................................................................................................................................................ 491
					1. Loosen the bolt connection and pull off the cpl. lube oil pump....................................................................................................................................................................................... 491
					2. Loosen the cover bolt connection, remove the cover (1) with gasket (2) and the filter (3) from the housing (4)....................................................................................................................................... 491
					3. Remove the cpl. pressure limiting valve and both O-rings (arrows).................................................................................................................................................................................... 491
					4. Loosen the pump cover bolt connection, keep the housing in vertical position - disassembly aid (also see Figure 226)................................................................................................................................. 492
					5. Then pull the pump in vertical position out of the housing - pay attention to possibly released balls/compression springs (See Figure 226 and 236)................................................................................................... 492
					6. Remove the outer (1) and internal rotor (2) and take the released ball [(3) driver] out of the control housing (4)................................................................................................................................... 492
					8. Unsnap the retaining ring............................................................................................................................................................................................................................ 493
					9. Pull the cpl. pump shaft out of the pump cover....................................................................................................................................................................................................... 493
					10. Unsnap the retaining ring and press the ball bearing from the shaft................................................................................................................................................................................. 493
					11. Pull the needle sleeve out of the housing bore...................................................................................................................................................................................................... 493
				Version "with" hydr. Downshift Interlock.................................................................................................................................................................................................................... 494
					1. Disassemble both oil tubes........................................................................................................................................................................................................................... 494
					2. Loosen the bolt connection of the shift interlock (3 x cap screws) and remove the cpl. shift interlock............................................................................................................................................... 494
					3. Loosen the cover bolt connection, remove the cover and flat gasket (also see Figure 236)............................................................................................................................................................. 494
					4. Take the filter out of the housing................................................................................................................................................................................................................... 494
					5. Loosen pump cover bolt connection.................................................................................................................................................................................................................... 495
					6. Then pull the pump in vertical position out of the housing - pay attention to possibly released balls/compression springs (See Figure 239 and 248)................................................................................................... 495
					7. Remove the outer (1) and internal rotor (2) and take the released ball [(3) driver] out of the control housing (4)................................................................................................................................... 495
					8. Remove the control housing and the released balls and compression springs (3 pcs. each).............................................................................................................................................................. 495
					9. Unsnap the retaining ring............................................................................................................................................................................................................................ 496
					10. Pull the cpl. pump shaft out of the pump cover...................................................................................................................................................................................................... 496
					11. Unsnap the retaining ring and press the ball bearing from the shaft................................................................................................................................................................................. 496
					12. Pull the needle sleeve out of the housing bore...................................................................................................................................................................................................... 496
					13. Remove the O-rings and all single parts/valves...................................................................................................................................................................................................... 497
				Version "with" electr. Downshift Interlock- mounted to Transmission......................................................................................................................................................................................... 497
					1. Loosen the fixing bolts and remove the cpl. downshift interlock...................................................................................................................................................................................... 497
					2. Remove both O-rings (arrow).......................................................................................................................................................................................................................... 497
			Reassembly - Lube Oil Pump/Downshift Interlock.................................................................................................................................................................................................................. 498
				Version "with" Lube Oil Pump................................................................................................................................................................................................................................ 498
					1. Mount the ball bearing onto the shaft and fasten it by means of the retaining ring................................................................................................................................................................... 498
					2. Press the preassembled pump shaft into the pump cover and fasten it by means of the retaining ring................................................................................................................................................... 498
					3. Insert the compression springs (1) and ball (2) into the bores (see arrows - 3x)..................................................................................................................................................................... 498
					4. Mount the control housing............................................................................................................................................................................................................................ 499
					5. Position the ball - see arrow -(drive for internal rotor) with grease (assembly aid) into the recess of the pump shaft............................................................................................................................... 499
					6. Mount the internal rotor............................................................................................................................................................................................................................. 499
					7. Assemble the outer rotor............................................................................................................................................................................................................................. 499
					8. Check passage of the orifice / oil bore in the housing bottom........................................................................................................................................................................................ 500
					9. Keep the preassembled pump in "vertical" position (See Note Figure 250) and put on the housing....................................................................................................................................................... 500
					10. Rotate the housing by 180° and fasten the pump with hexagon screws.................................................................................................................................................................................. 500
					11. Fasten the pump finally............................................................................................................................................................................................................................. 501
						Tightening torque (M6/8.8) MA = 9.5 N.m............................................................................................................................................................................................................. 501
					12. Functional test of the lube oil pump:............................................................................................................................................................................................................... 501
					13. Oil both O-rings (arrows) and put them into the ring groove of the housing.......................................................................................................................................................................... 501
					14. Check the O-rings (arrows) of the pressure limiting valve and replace them, if necessary............................................................................................................................................................ 501
					15. Insert the pressure limiting valve.................................................................................................................................................................................................................. 502
						Tightening torque MA = 20 N.m....................................................................................................................................................................................................................... 502
					16. Secure the pressure limiting valve by blows with the center punch (2x).............................................................................................................................................................................. 502
					17. Insert the filter. Observe the installation position................................................................................................................................................................................................ 502
					18. Place the gasket.................................................................................................................................................................................................................................... 502
					19. Place the cover and fasten it with hexagon screws and washers....................................................................................................................................................................................... 503
						Tightening torque (M8/8.8) MA = 23 N.m.............................................................................................................................................................................................................. 503
					20. Insert the screw plug with O-ring................................................................................................................................................................................................................... 503
						Tightening torque (M10x1) MA = 15 N.m............................................................................................................................................................................................................... 503
					21. Mount the cpl. lube oil pump and fasten it with cap screws and washers.............................................................................................................................................................................. 503
						Tightening torque (M8/10.9) MA = 23 N.m............................................................................................................................................................................................................. 503
				Version "with" hydr. Downshift Interlock.................................................................................................................................................................................................................... 504
					1. Put the O-ring (see arrow) into the ring groove of the piston........................................................................................................................................................................................ 504
					2. Calibrate the plastic ring by means of the bush...................................................................................................................................................................................................... 504
					3. Insert the compression spring, oil and mount the preassembled piston................................................................................................................................................................................. 505
					4. Fix the piston with screw plug (1- with O-ring)...................................................................................................................................................................................................... 505
						Screw plug (M24x1.5) MA = 50 N.m.................................................................................................................................................................................................................... 505
						Screw plug (M10x1) MA = 15 N.m...................................................................................................................................................................................................................... 505
					5. Install the single parts according to the illustration on the left................................................................................................................................................................................... 505
						1 = Pressure limiting valve (cpl.) MA = 10 N.m...................................................................................................................................................................................................... 505
						2 = Check valve (cpl.) MA = 10 N.m.................................................................................................................................................................................................................. 505
						3 = Check valve (cpl.) MA = 10 N.m.................................................................................................................................................................................................................. 505
						4 = Check valve (cpl.) MA = 10 N.m.................................................................................................................................................................................................................. 505
					6. Secure the check valves and the pressure limiting valve by two blows each with the center punch...................................................................................................................................................... 506
					7. Check passage of the orifice / oil bore in the housing bottom........................................................................................................................................................................................ 506
					8. Mount the ball bearing onto the shaft and fasten it with the retaining ring.......................................................................................................................................................................... 506
					9. Press the preassembled pump shaft into the pump cover and fasten it with the retaining ring.......................................................................................................................................................... 507
					10. Insert the compression springs (1) and ball (2) into the bores (see arrows - 3x).................................................................................................................................................................... 507
					11. Mount the control housing........................................................................................................................................................................................................................... 507
					12. Position the ball - see arrow -(drive for internal rotor) with grease (assembly aid) into the recess of the pump shaft.............................................................................................................................. 508
					13. Mount the internal rotor............................................................................................................................................................................................................................ 508
					14. Assemble the outer rotor............................................................................................................................................................................................................................ 508
					15. Keep the preassembled pump in "vertical" position (see Instructions Figure 279) and put on the housing.............................................................................................................................................. 508
						Tightening torque (M6/8.8) MA = 9.5 N.m............................................................................................................................................................................................................. 509
					16. Insert the screen filter - Observe the installation position........................................................................................................................................................................................ 509
					17. Place the gasket.................................................................................................................................................................................................................................... 509
					18. Position the cover, fasten it with hexagon screws and washers....................................................................................................................................................................................... 509
						Tightening torque (M8/10.9) MA = 23 N.m............................................................................................................................................................................................................. 509
					19. Oil both O-rings (arrows) and put them into the ring grooves of the housing......................................................................................................................................................................... 510
					20. Mount the preassembled downshift interlock and fasten it with cap screws and washers................................................................................................................................................................ 510
						Tightening torque (M8/10.9) MA = 23 N.m............................................................................................................................................................................................................. 510
					21. Install both screw-in sleeves and the screw plug (see arrows) - with O-rings........................................................................................................................................................................ 510
						Screw-in sleeve (M 16 x 1.5) MA = 23 N.m............................................................................................................................................................................................................ 510
						Screw plug (M 18 x 1.5) MA = 35 N.m................................................................................................................................................................................................................. 510
					22. Install both oil tubes.............................................................................................................................................................................................................................. 511
						Union screw (M 14 x1.5) MA = 25 N.m................................................................................................................................................................................................................. 511
						Union screw (M 16 x1.5) MA = 45 N.m................................................................................................................................................................................................................. 511
				Version "with" electr. Downshift Interlock - mounted to the Transmission.................................................................................................................................................................................... 511
					1. Position both O-rings (arrows)....................................................................................................................................................................................................................... 511
					2. Fasten the cpl. downshift interlock with cap screws and washers...................................................................................................................................................................................... 511
						Tightening torque (M8/10.9) MA = 23 N.m............................................................................................................................................................................................................. 511
			Attach the HL- Transmission to the Axle......................................................................................................................................................................................................................... 512
				1. Position the cpl. HL-Transmission to the axle............................................................................................................................................................................................................ 512
				2. Fasten the HL-Transmission to the axle by means of hexagon screws and nuts............................................................................................................................................................................... 512
					Tightening torque (M12/8.8) MA = 79 N.m................................................................................................................................................................................................................. 512
		Drive Coupling (Main Pump) SP000963NA............................................................................................................................................................................................................................... 513
			Safety Precautions.............................................................................................................................................................................................................................................. 517
			Applicable Models............................................................................................................................................................................................................................................... 517
			Drive Coupling.................................................................................................................................................................................................................................................. 519
			Special Tools................................................................................................................................................................................................................................................... 521
			Drive Coupling Installation..................................................................................................................................................................................................................................... 522
				Installation Procedure...................................................................................................................................................................................................................................... 524
					1. Install spring pin (1) and attach insert (2) with bolt (3) to engine flywheel (4).................................................................................................................................................................... 524
					2. Install two spring pins (5) and attach insert (6) to hub (7) bolts (8)............................................................................................................................................................................... 524
					3. Attach flywheel cover to the main pump with bolts. (S300LC-V, S340LC-V only.)........................................................................................................................................................................ 524
					4. Slide hub (7) into place on pump shaft (9) as specified in the "Table 2" for "Measurement H" and secure it in position with clamping screws (10)..................................................................................................... 524
					5. Install element (11) between inserts (2) on engine flywheel (4)...................................................................................................................................................................................... 524
					6. Install main pump and hub (7) by pushing it softly into element (11)................................................................................................................................................................................. 524
					7. Attach flywheel cover / pump housing to flywheel housing with bolts.................................................................................................................................................................................. 524
	Hydraulics.............................................................................................................................................................................................................................................................. 525
		Hydraulic System Troubleshooting, Testing and Adjustment SP002227NA................................................................................................................................................................................................. 527
			Safety Precautions.............................................................................................................................................................................................................................................. 531
			Applicable Models............................................................................................................................................................................................................................................... 531
			Hydraulic System - General Notes................................................................................................................................................................................................................................ 532
			Hydraulic Schematic............................................................................................................................................................................................................................................. 533
				General Notes............................................................................................................................................................................................................................................... 533
			Operation of Working Components................................................................................................................................................................................................................................. 535
				Boom Operating Circuit...................................................................................................................................................................................................................................... 535
				Boom Up Circuit............................................................................................................................................................................................................................................. 535
				Boom Down Circuit........................................................................................................................................................................................................................................... 535
				Arm Operating Circuit....................................................................................................................................................................................................................................... 536
				Arm Crowd Circuit........................................................................................................................................................................................................................................... 536
				Arm Dump Circuit............................................................................................................................................................................................................................................ 536
				Attachment Operating Circuit................................................................................................................................................................................................................................ 537
				Attachment Close Circuit.................................................................................................................................................................................................................................... 537
				Attachment Open Circuit..................................................................................................................................................................................................................................... 537
				Swing Operating Circuit..................................................................................................................................................................................................................................... 538
				Right Swing Operating Circuit............................................................................................................................................................................................................................... 538
				Left Swing Operating Circuit................................................................................................................................................................................................................................ 538
				Swing Relief Valve and Makeup Valve......................................................................................................................................................................................................................... 538
				Elevating Cab Operating Circuit............................................................................................................................................................................................................................. 539
				Elevating Cab Raising Circuit............................................................................................................................................................................................................................... 539
				Elevating Cab Lowering Circuit.............................................................................................................................................................................................................................. 539
				Elevating Cab Emergency Lowering Valve...................................................................................................................................................................................................................... 539
			Procedural Troubleshooting Baseline Recommendations............................................................................................................................................................................................................. 540
				Initial Checks and Tests to Establish Operating Condition of the Material Handler........................................................................................................................................................................... 540
			Pilot Pressure.................................................................................................................................................................................................................................................. 542
				Adjustment and Testing...................................................................................................................................................................................................................................... 542
			Power Mode Valve................................................................................................................................................................................................................................................ 543
				Current Signal and Hydraulic Pressure Adjustments........................................................................................................................................................................................................... 543
			Pressure Up Valve............................................................................................................................................................................................................................................... 545
				Checks and Adjustments...................................................................................................................................................................................................................................... 545
			Pump Input Power Control........................................................................................................................................................................................................................................ 547
				Pump Regulator Adjustment................................................................................................................................................................................................................................... 547
			Flow Meter and Flow Meter Kit Installation and Testing.......................................................................................................................................................................................................... 550
			Swing System Troubleshooting.................................................................................................................................................................................................................................... 552
				Precautions/Initial Checks.................................................................................................................................................................................................................................. 552
				Swing Relief Valve Checking and Adjustment.................................................................................................................................................................................................................. 553
			Troubleshooting - Swing Gearbox................................................................................................................................................................................................................................. 555
			Troubleshooting - Hydraulic Problems............................................................................................................................................................................................................................ 556
			Troubleshooting - Control Valve................................................................................................................................................................................................................................. 558
			Troubleshooting - Travel Control Valve.......................................................................................................................................................................................................................... 559
			Troubleshooting - Joystick Control Valve........................................................................................................................................................................................................................ 560
		Accumulator SP000984NA.............................................................................................................................................................................................................................................. 561
			Safety Precautions.............................................................................................................................................................................................................................................. 565
			Applicable Models............................................................................................................................................................................................................................................... 565
			General Description.............................................................................................................................................................................................................................................   0
				Specifications.............................................................................................................................................................................................................................................. 568
		Center Joint (Swivel) SP000919NA.................................................................................................................................................................................................................................... 569
			Safety Precautions.............................................................................................................................................................................................................................................. 573
			Applicable Models............................................................................................................................................................................................................................................... 573
			General Description............................................................................................................................................................................................................................................. 574
				Parts List.................................................................................................................................................................................................................................................. 575
			Troubleshooting, Testing and Adjustment......................................................................................................................................................................................................................... 576
				Inspection.................................................................................................................................................................................................................................................. 576
				Testing..................................................................................................................................................................................................................................................... 576
			Disassembly..................................................................................................................................................................................................................................................... 577
			Reassembly...................................................................................................................................................................................................................................................... 581
		Cylinders SP001098NA................................................................................................................................................................................................................................................ 583
			Safety Precautions.............................................................................................................................................................................................................................................. 587
			Applicable Models............................................................................................................................................................................................................................................... 587
			General Description............................................................................................................................................................................................................................................. 588
				Theory of Operation......................................................................................................................................................................................................................................... 588
			Special Tools and Materials..................................................................................................................................................................................................................................... 594
				Piston Nut.................................................................................................................................................................................................................................................. 594
				Piston Jig.................................................................................................................................................................................................................................................. 595
				Slipper Seal Jig............................................................................................................................................................................................................................................ 598
				Slipper Seal Straightening Jig.............................................................................................................................................................................................................................. 599
			Disassembly..................................................................................................................................................................................................................................................... 600
			Reassembly...................................................................................................................................................................................................................................................... 605
		Main Control Valve SP000966NA....................................................................................................................................................................................................................................... 609
			Safety Precautions.............................................................................................................................................................................................................................................. 613
			Applicable Models............................................................................................................................................................................................................................................... 613
			Control Valve Operation......................................................................................................................................................................................................................................... 614
				Arm Priority Circuit........................................................................................................................................................................................................................................ 615
				Attachment (Junction) Circuit............................................................................................................................................................................................................................... 616
				Main Relief Valve........................................................................................................................................................................................................................................... 617
				Overload Relief Valve....................................................................................................................................................................................................................................... 618
				Arm Load Holding Valve...................................................................................................................................................................................................................................... 620
				Boom Load Holding Valve..................................................................................................................................................................................................................................... 623
				Arm Regeneration............................................................................................................................................................................................................................................ 625
				Boom Regeneration........................................................................................................................................................................................................................................... 627
				Foot Relief Valve........................................................................................................................................................................................................................................... 628
				Parts List.................................................................................................................................................................................................................................................. 629
				Specifications.............................................................................................................................................................................................................................................. 637
			Control Valve Drawing and Hydraulic Circuit..................................................................................................................................................................................................................... 638
			Disassembly and Reassembly...................................................................................................................................................................................................................................... 642
				General Disassembly......................................................................................................................................................................................................................................... 642
				General Reassembly.......................................................................................................................................................................................................................................... 642
				Plunger Replacement......................................................................................................................................................................................................................................... 642
				Main Plunger Element - Disassembly and Assembly............................................................................................................................................................................................................. 643
				Tool........................................................................................................................................................................................................................................................ 643
				Main Relief Valve........................................................................................................................................................................................................................................... 646
				Overload Relief Valve....................................................................................................................................................................................................................................... 648
				Arm Load Holding Valve...................................................................................................................................................................................................................................... 650
				Boom Load Holding Valve..................................................................................................................................................................................................................................... 652
				Arm Regeneration Valve...................................................................................................................................................................................................................................... 653
				Attachment Unity Check...................................................................................................................................................................................................................................... 654
				Foot Relief Valve........................................................................................................................................................................................................................................... 655
				Center Bypass Valve (CB Valve).............................................................................................................................................................................................................................. 656
				Boom Parallel Switch Valve.................................................................................................................................................................................................................................. 657
				Boom Unity Check Valve...................................................................................................................................................................................................................................... 658
				Check Valve - Locations..................................................................................................................................................................................................................................... 659
				Check Valve................................................................................................................................................................................................................................................. 660
		Swing Motor SP000985NA.............................................................................................................................................................................................................................................. 665
			Safety Precautions.............................................................................................................................................................................................................................................. 669
			Applicable Models............................................................................................................................................................................................................................................... 669
			Instruction Manual.............................................................................................................................................................................................................................................. 670
				Indication of Type.......................................................................................................................................................................................................................................... 670
				Specifications.............................................................................................................................................................................................................................................. 671
				Construction & Principles of Working........................................................................................................................................................................................................................   0
					Parts No. & Names....................................................................................................................................................................................................................................... 673
					Motor Part.............................................................................................................................................................................................................................................. 674
					Valve Casing Part....................................................................................................................................................................................................................................... 675
						1. Anticavitation Check Valve....................................................................................................................................................................................................................... 675
				Precaution in Use........................................................................................................................................................................................................................................... 679
				Troubleshooting............................................................................................................................................................................................................................................. 684
			Maintenance Manual.............................................................................................................................................................................................................................................. 687
				Disassembling & Assembling.................................................................................................................................................................................................................................. 687
					19. Install swing reactionless valve ass'y (105) to valve casing (101).................................................................................................................................................................................. 698
					21. Assemble brake valve (400) to casing (301) and tightening the hex socket bolts to specified torque.................................................................................................................................................. 699
					22. The assembly is completed........................................................................................................................................................................................................................... 699
				Maintenance Standards....................................................................................................................................................................................................................................... 700
		Travel Motor SP001110NA............................................................................................................................................................................................................................................. 701
			Safety Precautions.............................................................................................................................................................................................................................................. 705
			Applicable Models............................................................................................................................................................................................................................................... 705
			General Repair Guidelines....................................................................................................................................................................................................................................... 707
				3. Check all seal and sliding surfaces for wear............................................................................................................................................................................................................. 707
			Seal Kits and Sub- assemblies................................................................................................................................................................................................................................... 708
				Replace Seal Nut............................................................................................................................................................................................................................................ 710
			Disassembly..................................................................................................................................................................................................................................................... 711
				Sealing the Drive Shaft..................................................................................................................................................................................................................................... 711
				Seal of the Control Parts................................................................................................................................................................................................................................... 712
				Seal of the Relief Valve / Counter-balance Valve............................................................................................................................................................................................................ 714
				Spare Parts List............................................................................................................................................................................................................................................ 716
				Disassembly of the Port Plate............................................................................................................................................................................................................................... 718
				Remove of the Positioning Piston............................................................................................................................................................................................................................ 719
				Remove Rotary Group......................................................................................................................................................................................................................................... 721
				Exchanging of the Rotary Group.............................................................................................................................................................................................................................. 722
				Inspection Notes............................................................................................................................................................................................................................................ 723
			Assembly........................................................................................................................................................................................................................................................ 726
				Rotary Group Assembly....................................................................................................................................................................................................................................... 726
				Rotary Group Adjustment (See Service Information)........................................................................................................................................................................................................... 728
				Assembly of the Port Plate.................................................................................................................................................................................................................................. 730
			Tightening Torques.............................................................................................................................................................................................................................................. 732
				Shaft Bolts................................................................................................................................................................................................................................................. 732
				Locking Screws VSTI......................................................................................................................................................................................................................................... 732
				Seal-Lock Nuts.............................................................................................................................................................................................................................................. 733
				Cross-slotted Lens Head Screws DIN 7985..................................................................................................................................................................................................................... 733
			Test Procedure.................................................................................................................................................................................................................................................. 734
				Hydraulics Schematic........................................................................................................................................................................................................................................ 736
		Counterbalance Valve SP000991NA..................................................................................................................................................................................................................................... 737
			Safety Precautions.............................................................................................................................................................................................................................................. 741
			Applicable Models............................................................................................................................................................................................................................................... 741
			General Description............................................................................................................................................................................................................................................. 742
				While Operating to Run Forward.............................................................................................................................................................................................................................. 742
				While Operating to Stop..................................................................................................................................................................................................................................... 742
				While Operating to Back..................................................................................................................................................................................................................................... 743
				Adjustment of Relief Valve.................................................................................................................................................................................................................................. 744
			Troubleshooting................................................................................................................................................................................................................................................. 745
			Counterbalance Valve............................................................................................................................................................................................................................................ 746
				Recommended Tools........................................................................................................................................................................................................................................... 746
				Disassembly................................................................................................................................................................................................................................................. 746
				Order of Disassembly and Torque Values...................................................................................................................................................................................................................... 747
				Reassembly.................................................................................................................................................................................................................................................. 748
		Main Pump & PTO SP000988NA.......................................................................................................................................................................................................................................... 753
			Safety Precautions.............................................................................................................................................................................................................................................. 757
			Applicable Models............................................................................................................................................................................................................................................... 757
			Section......................................................................................................................................................................................................................................................... 759
			General Repair Guidelines....................................................................................................................................................................................................................................... 760
			Seal Kits and Sub- assemblies................................................................................................................................................................................................................................... 761
			Disassembly..................................................................................................................................................................................................................................................... 765
				Sealing the Drive Shaft..................................................................................................................................................................................................................................... 765
				Gear Pump Sealing........................................................................................................................................................................................................................................... 767
				Control Housing............................................................................................................................................................................................................................................. 768
				Control Module LR........................................................................................................................................................................................................................................... 771
				Control Module H............................................................................................................................................................................................................................................ 772
				Controller.................................................................................................................................................................................................................................................. 773
				Rotary Groups............................................................................................................................................................................................................................................... 775
				Intermediate Wheel.......................................................................................................................................................................................................................................... 778
				Auxiliary Drive............................................................................................................................................................................................................................................. 780
			Inspection Hints................................................................................................................................................................................................................................................ 783
			Assembly........................................................................................................................................................................................................................................................ 788
				Rotary Group................................................................................................................................................................................................................................................ 788
				Pump........................................................................................................................................................................................................................................................ 789
				Hydraulic Component - Measurement "D"....................................................................................................................................................................................................................... 792
				Control Housing............................................................................................................................................................................................................................................. 795
				Intermediate Wheel.......................................................................................................................................................................................................................................... 798
				Gear Pump................................................................................................................................................................................................................................................... 799
				Cover / Auxiliary Drive..................................................................................................................................................................................................................................... 800
			Assembly Guidelines for Tightening Torques...................................................................................................................................................................................................................... 801
				Bolts (to N 08.001)......................................................................................................................................................................................................................................... 801
				Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)............................................................................................................................................................................................. 802
				Seal-Lock - Sealing Nuts (to N 02.100)...................................................................................................................................................................................................................... 802
		Gear Pump SP000989NA................................................................................................................................................................................................................................................ 803
			Safety Precautions.............................................................................................................................................................................................................................................. 807
			Applicable Models............................................................................................................................................................................................................................................... 807
			Single Gear Pump................................................................................................................................................................................................................................................ 808
				Disassembly................................................................................................................................................................................................................................................. 808
				Reassembly.................................................................................................................................................................................................................................................. 810
			Double Gear Pump................................................................................................................................................................................................................................................ 814
				Disassembly................................................................................................................................................................................................................................................. 814
				Reassembly.................................................................................................................................................................................................................................................. 816
		Service Brake Supply Valve SP000990NA............................................................................................................................................................................................................................... 821
			Safety Precautions.............................................................................................................................................................................................................................................. 825
			Applicable Models............................................................................................................................................................................................................................................... 825
				Diagram of Brake Supply Valve Assembly Package.............................................................................................................................................................................................................. 827
				Functions of Brake Supply Valve Assembly Package............................................................................................................................................................................................................ 828
				Exploded View and Tools..................................................................................................................................................................................................................................... 830
				Cautions for Disassembly and Re-assembly.................................................................................................................................................................................................................... 831
				Troubleshooting Guide....................................................................................................................................................................................................................................... 832
				How to Check Brake Pressure................................................................................................................................................................................................................................. 833
		Steering Valve SP000993NA........................................................................................................................................................................................................................................... 835
			Safety Precautions.............................................................................................................................................................................................................................................. 839
			Applicable Models............................................................................................................................................................................................................................................... 839
			General Description............................................................................................................................................................................................................................................. 840
				Theory of Operation......................................................................................................................................................................................................................................... 841
				OSPC / OSPF................................................................................................................................................................................................................................................. 842
			TOOLS........................................................................................................................................................................................................................................................... 844
			Disassembly..................................................................................................................................................................................................................................................... 846
				Dismantling the Shock Valves for OSPC/ OSPC LS.............................................................................................................................................................................................................. 850
				Dismantling the Pressure Relief Valve for OSPC.............................................................................................................................................................................................................. 851
				Dismantling the Pressure Relief Valve (cartridge) for OSPC LS/OSPC LSR...................................................................................................................................................................................... 852
				Cleaning.................................................................................................................................................................................................................................................... 853
				Inspection and Replacement.................................................................................................................................................................................................................................. 853
				Lubrication................................................................................................................................................................................................................................................. 853
			Assembly........................................................................................................................................................................................................................................................ 854
				Assembly Pattern for Standard Bearing....................................................................................................................................................................................................................... 856
				Assembly Pattern for Double Bearing......................................................................................................................................................................................................................... 857
				Installation Instructions for O-ring/Kin-ring /Roto Glyd.................................................................................................................................................................................................... 857
				Installation Instructions for Lip Seal...................................................................................................................................................................................................................... 858
				Assembly of the Pressure Relief Valve for OSPC.............................................................................................................................................................................................................. 863
				Assembly of the Shock Valves for OSPC/ OSPC LS/OSPC LSR..................................................................................................................................................................................................... 864
				Hydraulic Connections....................................................................................................................................................................................................................................... 866
		Accelerator Pedal Valve (Hydraulic) SP000964NA...................................................................................................................................................................................................................... 869
			Safety Precautions.............................................................................................................................................................................................................................................. 873
			Applicable Models............................................................................................................................................................................................................................................... 873
			Structure....................................................................................................................................................................................................................................................... 874
			Parts List...................................................................................................................................................................................................................................................... 874
			Performance Curve............................................................................................................................................................................................................................................... 875
			Hydraulics Symbol............................................................................................................................................................................................................................................... 875
			Disassembly & Assembly Tools.................................................................................................................................................................................................................................... 875
			Disassembly..................................................................................................................................................................................................................................................... 876
			Assembly........................................................................................................................................................................................................................................................ 877
		One Spool Valve SP000996NA.......................................................................................................................................................................................................................................... 879
			Safety Precautions.............................................................................................................................................................................................................................................. 883
			Applicable Models............................................................................................................................................................................................................................................... 883
			Outside Drawing................................................................................................................................................................................................................................................. 885
			Hydraulic Circuit............................................................................................................................................................................................................................................... 885
			Operational Principle........................................................................................................................................................................................................................................... 886
				In the Neutral Condition.................................................................................................................................................................................................................................... 886
				Spool Operation............................................................................................................................................................................................................................................. 886
			Disassembly and Assembly........................................................................................................................................................................................................................................ 887
				General Cautions............................................................................................................................................................................................................................................ 887
				Replacement of Spool Ass'y (Pilot Type)..................................................................................................................................................................................................................... 888
				Replacement of Main Relief Valve............................................................................................................................................................................................................................ 890
				Replacement of Overload Relief Valve........................................................................................................................................................................................................................ 891
				Replacement of Sub-Block Ass'y.............................................................................................................................................................................................................................. 892
		Remote Control Valve (Work Lever / Joystick) SP000069NA............................................................................................................................................................................................................. 895
			Safety Precautions.............................................................................................................................................................................................................................................. 899
			Applicable Models............................................................................................................................................................................................................................................... 899
			General Description............................................................................................................................................................................................................................................. 901
				Theory of Operation......................................................................................................................................................................................................................................... 901
					1. Neutral Position..................................................................................................................................................................................................................................... 901
					2. Control Switch....................................................................................................................................................................................................................................... 901
				Parts List.................................................................................................................................................................................................................................................. 902
				Specifications.............................................................................................................................................................................................................................................. 904
				Torques..................................................................................................................................................................................................................................................... 904
			Tools and Materials............................................................................................................................................................................................................................................. 904
			Disassembly..................................................................................................................................................................................................................................................... 905
			Cleaning and Inspection (Wear Limits and Tolerances)............................................................................................................................................................................................................ 909
			Reassembly...................................................................................................................................................................................................................................................... 909
			Start-up Procedures............................................................................................................................................................................................................................................. 915
		Service Brake Pedal Valve SP001006NA................................................................................................................................................................................................................................ 917
			Safety Precautions.............................................................................................................................................................................................................................................. 921
			Applicable Models............................................................................................................................................................................................................................................... 921
			Functions of Brake Pedal........................................................................................................................................................................................................................................ 923
			Internal Structure and Operation Principles..................................................................................................................................................................................................................... 924
				Internal Structure.......................................................................................................................................................................................................................................... 924
				Operation Principles........................................................................................................................................................................................................................................ 926
			Disassembly..................................................................................................................................................................................................................................................... 927
			Reassembly...................................................................................................................................................................................................................................................... 927
				Reassembly of the Lower Part................................................................................................................................................................................................................................ 927
				Reassembly of the Upper Part................................................................................................................................................................................................................................ 929
				Assembly of Pedal Plate..................................................................................................................................................................................................................................... 932
		Solenoid Valve Assembly SP000997NA.................................................................................................................................................................................................................................. 939
			Safety Precautions.............................................................................................................................................................................................................................................. 943
			Applicable Models............................................................................................................................................................................................................................................... 943
			2-Solenoid Valve................................................................................................................................................................................................................................................ 945
				Diagram of 2-Solenoid Valve Assembly Package................................................................................................................................................................................................................ 945
				Exploded View and Tools..................................................................................................................................................................................................................................... 946
				Cautions for Disassembly and Re- assembly................................................................................................................................................................................................................... 947
				Troubleshooting Guide....................................................................................................................................................................................................................................... 948
			6-Solenoid Valve................................................................................................................................................................................................................................................ 949
				Diagram of 6-Solenoid Valve Assembly Package................................................................................................................................................................................................................ 949
				Functions of 6-Solenoid Valve Assembly Package.............................................................................................................................................................................................................. 950
				Exploded View and Tools..................................................................................................................................................................................................................................... 952
				Cautions for Disassembly and Re- assembly................................................................................................................................................................................................................... 953
				Troubleshooting Guide....................................................................................................................................................................................................................................... 954
			4-Solenoid Valve................................................................................................................................................................................................................................................ 956
				Diagram of 4-Solenoid Valve Assembly Package................................................................................................................................................................................................................ 956
				Functions of 4 Solenoid Valve Assembly Package.............................................................................................................................................................................................................. 957
				Exploded View and Tools..................................................................................................................................................................................................................................... 959
				Cautions for Disassembly and Re- assembly................................................................................................................................................................................................................... 960
				Troubleshooting Guide....................................................................................................................................................................................................................................... 962
			3-Solenoid...................................................................................................................................................................................................................................................... 963
				Diagram of 3-Solenoid Valve Assembly Package................................................................................................................................................................................................................ 963
				Functions of 3 Solenoid Valve Assembly Package.............................................................................................................................................................................................................. 964
				Exploded View and Tools..................................................................................................................................................................................................................................... 966
				Cautions for Disassembly and Re- Assembly................................................................................................................................................................................................................... 967
				Troubleshooting Guide....................................................................................................................................................................................................................................... 969
		Hydraulic Schematic SP001107NA...................................................................................................................................................................................................................................... 971
			Safety Precautions.............................................................................................................................................................................................................................................. 975
			Applicable Models............................................................................................................................................................................................................................................... 975
			DX210WMH........................................................................................................................................................................................................................................................ 979
			DX210WMH Elevating Cab And Attachment........................................................................................................................................................................................................................... 981
	Electrical System....................................................................................................................................................................................................................................................... 983
		Electrical System SP002210NA........................................................................................................................................................................................................................................ 985
			Safety Precautions.............................................................................................................................................................................................................................................. 990
			Applicable Models............................................................................................................................................................................................................................................... 990
			Introduction.................................................................................................................................................................................................................................................... 991
			Electrical Supply System........................................................................................................................................................................................................................................ 992
				1. Terminal "1" of DC-DC converter (for memory backup of stereo)............................................................................................................................................................................................ 992
				2. Terminal "B" of starter switch........................................................................................................................................................................................................................... 992
				3. Hour meter............................................................................................................................................................................................................................................... 992
				4. Engine controller........................................................................................................................................................................................................................................ 992
				5. Fuel feeder pump switch.................................................................................................................................................................................................................................. 992
				6. Terminal "6" of wiper motor.............................................................................................................................................................................................................................. 992
				7. Terminal "13" of wiper controller........................................................................................................................................................................................................................ 992
				8. Terminal "CN6-11" of instrument panel.................................................................................................................................................................................................................... 992
				9. Terminal "CN9-6" of air conditioner panel................................................................................................................................................................................................................ 992
				10. Pilot buzzer............................................................................................................................................................................................................................................ 992
			Engine Starting Circuit.........................................................................................................................................................................................................................................   0
				After Start................................................................................................................................................................................................................................................. 996
			Engine Preheating System........................................................................................................................................................................................................................................ 998
			Engine Stop.....................................................................................................................................................................................................................................................1000
			Monitoring System...............................................................................................................................................................................................................................................   0
				Instrument Panel............................................................................................................................................................................................................................................   0
					22. Home Selector Button................................................................................................................................................................................................................................1005
					23. Camera Selector Button..............................................................................................................................................................................................................................1005
			Warning and Indicator Lights....................................................................................................................................................................................................................................   0
				Indication of Multifunction Gauge and Letter Information Area...............................................................................................................................................................................................1011
			Initial Operation...............................................................................................................................................................................................................................................1013
			Mode Selector Switch............................................................................................................................................................................................................................................1014
			Graphic Information Area Display................................................................................................................................................................................................................................   0
				Main Menus for the Graphic Display Area.....................................................................................................................................................................................................................1016
				Menu Selector Buttons.......................................................................................................................................................................................................................................1016
					5. Home Button (HOME, 5 on Figure 12): Move a screen to default menu....................................................................................................................................................................................1016
			Power Mode Control..............................................................................................................................................................................................................................................1040
				Operation...................................................................................................................................................................................................................................................1042
			Power Mode Control - Circuit Diagram............................................................................................................................................................................................................................1045
			Engine Control System...........................................................................................................................................................................................................................................1046
			Engine Control Dial.............................................................................................................................................................................................................................................1047
			Acceleration pedal..............................................................................................................................................................................................................................................1048
			Automatic Deceleration Control (Auto Idle Control)..............................................................................................................................................................................................................1050
			cruise control..................................................................................................................................................................................................................................................   0
				Cruise Control Circuit......................................................................................................................................................................................................................................1059
			Automatic Travel Speed Control..................................................................................................................................................................................................................................1060
			Self-diagnostic Function........................................................................................................................................................................................................................................1063
				e-EPOS Controller...........................................................................................................................................................................................................................................1063
			Wiper System....................................................................................................................................................................................................................................................   0
				Wiper operation.............................................................................................................................................................................................................................................1066
			Lighting System.................................................................................................................................................................................................................................................1068
				Lighting System Circuit Diagram.............................................................................................................................................................................................................................1068
				Type........................................................................................................................................................................................................................................................1069
				Operation...................................................................................................................................................................................................................................................1069
			Overload Warning Device.........................................................................................................................................................................................................................................1070
				Overload Warning Device Circuit Diagram.....................................................................................................................................................................................................................1070
			Audio Controller................................................................................................................................................................................................................................................1071
				Audio Controller Circuit Diagram............................................................................................................................................................................................................................1071
			ram lock device.................................................................................................................................................................................................................................................1072
				Ram Lock Control Circuit....................................................................................................................................................................................................................................1072
				Operation...................................................................................................................................................................................................................................................1073
			Air Conditioner System..........................................................................................................................................................................................................................................1074
				Outline.....................................................................................................................................................................................................................................................1074
				Internal and External Filters...............................................................................................................................................................................................................................1075
				Air-Conditioning System Layout..............................................................................................................................................................................................................................1077
				Air Conditioner/Heater Circuit Diagram......................................................................................................................................................................................................................1078
				Air Conditioner/Heater Unit.................................................................................................................................................................................................................................1079
				Relay - Blower..............................................................................................................................................................................................................................................1083
				Relay - A/C.................................................................................................................................................................................................................................................1083
				Duct Sensor.................................................................................................................................................................................................................................................1083
				Water Temp Sensor...........................................................................................................................................................................................................................................1084
				Internal Air Temp Sensor....................................................................................................................................................................................................................................1084
				Ambient Air Temperature Sensor..............................................................................................................................................................................................................................1084
				Compressor..................................................................................................................................................................................................................................................1092
				Receiver Dryer..............................................................................................................................................................................................................................................1092
		Electrical Schematic SP002201NA.....................................................................................................................................................................................................................................1093
			Safety Precautions..............................................................................................................................................................................................................................................1097
			Applicable Models...............................................................................................................................................................................................................................................1097
			DX210WMH........................................................................................................................................................................................................................................................1099
	Attachments.............................................................................................................................................................................................................................................................1101
		Boom and Arm SP001255NA.............................................................................................................................................................................................................................................1103
			Safety Precautions..............................................................................................................................................................................................................................................1107
			Applicable Models...............................................................................................................................................................................................................................................1107
			Front Attachment Pin Specifications.............................................................................................................................................................................................................................1108
				DX210WMH....................................................................................................................................................................................................................................................1109
			Front Attachment - Removal and Installation.....................................................................................................................................................................................................................1110
				Arm Removal Procedure.......................................................................................................................................................................................................................................1110
					13. Shut off the engine and release hydraulic system pressure, See Operation and Maintenance Manual for proper process..................................................................................................................................1113
					14. Exit material handler and manually vent residual hydraulic pressure in the tank by tipping the cap on top of the reservoir..........................................................................................................................1113
					31. Remove lifting device from arm lifting lugs (1, Figure 15)..........................................................................................................................................................................................1116
				Boom Removal Procedure......................................................................................................................................................................................................................................1117
					28. Remove lifting device from boom lifting lugs (4, Figure 30).........................................................................................................................................................................................1121
			Installation....................................................................................................................................................................................................................................................1123
				Boom Installation Procedure.................................................................................................................................................................................................................................1123
				Arm Installation Procedure..................................................................................................................................................................................................................................1130
			Start-up Procedures.............................................................................................................................................................................................................................................1135
		Attachment SP001001NA...............................................................................................................................................................................................................................................1137
			Safety Precautions..............................................................................................................................................................................................................................................1141
			Applicable Models...............................................................................................................................................................................................................................................1141
			Attachments.....................................................................................................................................................................................................................................................1142
				Installation and Removal....................................................................................................................................................................................................................................1142
	Blank Page..............................................................................................................................................................................................................................................................1143------

DOOSAN DX210WMH EXCAVATOR MATERIAL HANDER SHOP MANUAL 950106-01410NA – PDF DOWNLOAD:

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