Mega 500-V (Tier II)

Shop Manual
023-00054E
Serial Number 2001 and Up

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

023-00054E Shop Manual

 Pub.No. 023-00054E
Serial Number 2001 and Up
Mega 500-V (Tier II)
Product Label

Instructions

Trim Out The Label Along

The Lines And Insert Into
Pocket On The Binder Spine

Pub. No. 023-00054E

 1TABLE OF CONTENTS
Return to Master Table of Contents

Safety
Wheel Loader Safety .......................................................................... S0103010K

Specifications
Specifications for Mega 500-V (Tier II) ............................................... S0203075K

General Maintenance
General Maintenance Procedures .........................................................S0302000
Standard Torques ..................................................................................S0309000

Upper Structure
Counterweight..................................................................................... S0403040K
Fuel Transfer Pump ...............................................................................S0405500
Hydraulic Oil Tank .............................................................................. S0406040K

Lower Structure and Chassis

Center Joint (Articulation Joint)........................................................... S0502020K

Engine and Drive Train

Axle (ZF AP-420R) ............................................................................. S0602170K
Air Conditioner .................................................................................... S0605050K
Transmission and Torque Converter (ZF 4WG-310) .......................... S0607080K
Transmission Error Codes (ZF) .......................................................... S0607900C

Hydraulics
Accumulator...........................................................................................S0703000
Cylinders................................................................................................S0705010
Fan Drive Hydraulic Motor (Haldex) ................................................... S0707100K
Pump (Denison T67DB Series) .......................................................... S0708465K

Table of Contents
Page 1
 Brake Pedal Valve .............................................................................. S0709240K
Main Control Valve (Toshiba) ............................................................. S0709455K
Pilot Control Valve .............................................................................. S0709476K
Flow Amplifier (Danfoss)..................................................................... S0709665K
Power Steering Unit............................................................................ S0709730K
Restriction Valve................................................................................. S0709750K
Hydraulic Schematic (Mega 500-V (Tier II)) ....................................... S0793065K

Electrical System
Electrical System ................................................................................ S0802195K
Electrical Schematic (Mega 500-V (Tier II))........................................ S0893065K

Attachments

Table of Contents
Page 2
1SAFETY
 S0103010K

2WHEEL LOADER
SAFETY

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

WHEEL LOADER SAFETYS0103010K

MODEL SERIAL NUMBER RANGE
Mega 200-V 1001 and Up
Mega 250-V 1001 and Up
Mega 300-V 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Wheel Loader Safety S0103010K

Page 1
TABLE OF CONTENTS

To the Operator of a Daewoo Wheel Loader .................................................. 3

General Safety Essentials .............................................................................. 6
Location of Safety Labels ............................................................................... 6
Unauthorized Modifications ............................................................................ 6
General Hazard Information ........................................................................... 7
Before Starting Engine ................................................................................. 15
Machine Operation ....................................................................................... 18
Maintenance................................................................................................. 25
Battery.......................................................................................................... 33
Towing .......................................................................................................... 35
Shipping and Transportation ........................................................................ 36

S0103010K Wheel Loader Safety

Page 2
TO THE OPERATOR OF A DAEWOO WHEEL LOADER

DANGER!
Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures,
maintenance and equipment practices or traveling or shipping methods that do not follow the
safety guidelines on the following pages could cause serious, potentially fatal injuries or
extensive damage to the machine or nearby property.

Please respect the importance of taking responsibility for your own safety, and that other people who may
be affected by your actions.
Safety information on the following pages is organized into the following topics.
1. “General Safety Essentials” on page 6.
2. “Location of Safety Labels” on page 6.
3. “Unauthorized Modifications” on page 6.
4. “General Hazard Information” on page 7.
5. “Before Starting Engine” on page 15.
6. “Machine Operation” on page 18.
7. “Maintenance” on page 25.
8. “Battery” on page 33.
9. “Towing” on page 35.
10. “Shipping and Transportation” on page 36.

Wheel Loader Safety S0103010K

Page 3
 WARNING!
Improper operation and maintenance of this machine can be hazardous and could result in
serious injury or death.
Operator and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in the storage compartment to the rear of the operator’s seat, and have all
personnel involved in working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the machine can cause a serious
accident, if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the
machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for any others. In no event should you or others engage in prohibited uses
or actions as described in this manual.
Daewoo delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether
your product complies with the applicable standards and regulations of your country, consult
Daewoo or your Daewoo distributor before operating the machine.

S0103010K Wheel Loader Safety

Page 4
 SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety Instructions
This is the Safety Alert Symbol. Wherever it appears - in this manual or on safety signs on the
machine - you should be alert to potential for personal injury or accidents. Always observe
safety precautions and follow recommended procedures.

LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL

Words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on labels on machine
indicate hazards or unsafe practices. All three statements indicate that safety is involved. Observe
precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears
next to the "Exclamation Point" symbol.

CAUTION!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert
against a generally unsafe practice.

WARNING!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in serious injury or death. It may also be used to alert
against a highly unsafe practice.

DANGER!
This word is used on safety messages and safety labels and indicates imminent hazard of a
situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also
be used to alert against equipment that may explode or detonate if handled or treated carelessly.

Safety precautions are described in SAFETY from page 6 on.

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

Wheel Loader Safety S0103010K

Page 5
GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for
other object handling, contact Daewoo. Lifting-work applications are permitted in approved lift
configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use
machine for activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are
used in approved configuration.

LOCATION OF SAFETY LABELS

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

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

S0103010K Wheel Loader Safety

Page 6
GENERAL HAZARD INFORMATION
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel
sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will
interfere with your sense of judgement in emergencies and may cause accidents.
When working with another operator or with a person on work site traffic duty, be sure that all personnel
know the nature of the work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.

SAFETY FEATURES
Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety features such as transmission lever neutral lock
and the seat belt, and use them properly.
Never remove any safety features. Always keep them in good operating condition.
Failure to use safety features according to the instructions in the Operation and Maintenance Manual could
result in serious bodily injury.

Wheel Loader Safety S0103010K

Page 7
INSIDE OPERATOR'S COMPARTMENT
When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If
you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and
this may cause a serious accident.
Clean grease and dirt from pedals and controls. This contributes to safe operation. Cleaning also provides
an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems
result.
Keep cab floor and consoles free of tools and personal items.
After using the ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to
close the ashtray. If the ashtray is left open, there is danger of fire.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not leave lighters laying around the operator's compartment. If the temperature inside the operator's
compartment becomes high, there is danger that the lighter may explode.
Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
There is danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or explosive items into the operator's cab.
To ensure safety, do not use the radio or music headphones when operating the machine. There is danger
that this may lead to a serious accident.
When operating the machine, do not put your hands or head out of the window.
When standing up from the operator's seat, always place transmission neutral lock lever in the "LOCK"
position and set pilot cutoff switch to "O" (OFF) position. If you accidentally touch the work equipment
levers when they are not locked, the machine may suddenly move and cause serous injury or damage.
When leaving the machine, lower the work equipment completely to the ground, set transmission neutral
lock lever in the "LOCK" position, set pilot cutoff switch to "O" (OFF) position, "APPLY" parking brake, and
shut down engine. Use the key to lock all the equipment. Always remove the key and take it with you.

CLOTHING AND PERSONAL PROTECTIVE

ITEMS
Contain long hair, and avoid loose clothing and
jewelry. They can catch on controls or in
protruding parts and cause serious injury or
death.
Do not wear oily clothes. They are highly
flammable.
Full eye protection, a hard hat, safety shoes and
gloves may be required at the work site.
HAOA020L
While working on the machine, never use
Figure 1
inadequate tools. They could break or slip,
causing injury, or they may not adequately
perform intended functions.

S0103010K Wheel Loader Safety

Page 8
BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED
Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise
pollution may not be visible, but these hazards can cause disabling or permanent injuries.
NOTE: Sound level in closed operator’s cab is 75 dB(A). Additional information on machine sound
and vibration levels can be found in Shop Manual.

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be HAZARDOUS to your
health if it is inhaled.
If you handle materials containing asbestos
fibers, follow these guidelines as given below:
• Use an approved respirator.
• Never use compressed air for
cleaning.
• Use water for cleaning to keep down
the dust. ARO1770L
Figure 2
• Work on the machine or component
with the wind at your back whenever
possible.
• Always observe any rules and
regulations related to the work site
and working environment.

MOUNTING AND DISMOUNTING

Before getting on or off the machine, if there is
any oil. grease, or mud on the handrails, steps,
or track shoes, wipe it off immediately. Always
keep these parts clean. Repair any damage and
tighten any loose bolts.
Never get on or off a moving machine. In
particular, never get on or off a moving machine.
These actions may lead to serious injury.
When getting on or off the machine, always face
the machine, and maintain a three-point contact HA3O1003
(both feet and one hand or one foot and both Figure 3
hands) with the handholds and steps to ensure
that you support yourself securely.
Never hold any control levers when getting on or
off the machine.
Never get up from operator’s seat or leave
operator’s station and dismount machine if
engine is running.

Wheel Loader Safety S0103010K

Page 9
FUEL, OIL AND HYDRAULIC FLUID FIRE
HAZARDS
Fuel, oil and antifreeze will catch fire if it is
brought close to a flame. Fuel is particularly
flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the
machine only in a well-ventilated area. The
machine must be parked with controls, lights
and switches turned "OFF." The engine must be
"OFF" and any flames, glowing embers,
auxiliary heating units or spark-causing
equipment must be doused, turned off and/or
kept well clear of the machine.
Static electricity can produce dangerous sparks
at the fuel filling nozzle. In very cold, dry Figure 4
weather or other conditions that could produce a
static discharge, keep the tip of the fuel nozzle
in constant contact with the neck of the fuel
filling nozzle, to provide a ground.
Keep fuel and other fluid reservoir caps tight and
do not start the engine until caps have been
secured.

PRECAUTIONS WHEN HANDLING FLUIDS

AT HIGH TEMPERATURE
Immediately after operations are stopped, the
coolant, engine oil, and hydraulic oil are at high
temperature and the radiator and hydraulic tank
are still under pressure. Attempting to remove
the cap, drain the oil or coolant, or replace the
filters may lead to serious burns. Always wait for
the temperature to go down, and follow the
specified procedures when carrying out these
operations.
HAOA050L
Figure 5
To prevent hot coolant from spurting out, stop
the engine, wait for the coolant to cool, then
loosen the cap slowly to relieve the pressure.
To prevent hot oil from spurting out, stop the
engine, wait for the oil to cool, then loosen the
cap slowly to relieve the pressure.

HAOA060L
Figure 6

S0103010K Wheel Loader Safety

Page 10
INJURY FROM WORK EQUIPMENT
Do not enter or put your hand, arm or any other
part of your body between movable parts, such
as between the work equipment and cylinders,
or between the machine and work equipment.
If the control levers are operated, the clearance
between the machine and the work equipment
will change and this may lead to serious
damage or personal injury.
If going between movable parts is necessary,
always position and secure the work equipment HDO1010L
so that it cannot move. Figure 7

FIRE EXTINGUISHER AND FIRST AID KIT

As a precaution if any injury or fire should occur,
always do the following.
• Be sure that fire extinguishers have
been provided and read the labels to
ensure that you know now to use
them. It is recommended that an
appropriately sized (2.27 kg [5 lb] or
larger) multipurpose "A/B/C" fire
extinguisher be mounted in the cab.
Check and service the fire HDO1009L
extinguisher at regular intervals and
Figure 8
make sure that all work site crew
members are adequately trained in
its use.
• Provide a first aid kit in the storage compartment and keep another at the work site. Check the
kit periodically and make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance service, hospital and fire department near
your telephone.
If the machine catches fire, it may lead to serious personal injury or death. If a fire occurs during operation,
escape from the machine as follows;
• Turn the starter switch "OFF" and stop the engine.
• If there is time, use the fire extinguisher to extinguish as much of the fire as possible.
• Use the handrails and steps to escape from the machine.
The above is the basic method for escaping from the machine, but changing the method may be necessary
according to the conditions, so carry out practice drills at the work site.

Wheel Loader Safety S0103010K

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PROTECTION FROM FALLING OR FLYING
OBJECTS
On work sites where there is danger that falling
objects or flying objects may hit the operator's
cab select a guard to match the operating
conditions to protect the operator.
Work in mines, tunnels, deep pits or on loose or
wet surfaces could produce danger of falling
rock, roll over or hazardous flying objects.
Additional protection for operator’s cab could be
required in form of a FOPS/Falling Object
HAOA110L
Protective Structure and/or ROPS/Roll Over
Protective Structure reinforcement system. Figure 9

Any reinforcement system that is installed on

machine must pass safety and certification
standards and carry appropriate labeling and
rating information. For example, most often
added type of reinforcement system, FOPS,
must meet or exceed Society of Automotive
Engineers standard SAE J1356, "Performance
Criteria for Falling Object Guards for Wheel
loaders."
Never attempt to alter or modify any type of
protective structure reinforcement system, by
drilling holes, welding or remounting or HAOA100L
relocating fasteners. Any serious impact or Figure 10
damage to system requires a complete integrity
reevaluation. Reinstallation, recertification and/
or replacement of system may be necessary.

INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE

Laminate glass protection for the front, side or rear windows may also be recommended depending upon
particular site conditions.
Contact your Daewoo distributor for available safety guards and/or recommendations if there is any danger
of getting hit by objects that could strike the operator’s cab. Make sure that all other work site crew
members are kept well away from wheel loader and safe from potential hazards.

MAINTAIN STANDARD SAFETY EQUIPMENT IN GOOD CONDITION

Machinery guards and body panel covers must be in place at all times. Keep well clear of rotating parts.
Pinch point hazards such as cooling fan and alternator drive belts could catch hair, jewelry or oversize or
very loose clothing.
Safety labels must be replaced if they are damaged or become unreadable. Information on labels gives
work crew members an important safety reminder. Part numbers for each decal and required mounting
locations are shown on pages 1-2 through 1-4 of this section.

S0103010K Wheel Loader Safety

Page 12
ATTACHMENT PRECAUTIONS
Options kits are available through your dealer. Contact Daewoo for information on available one-way
(single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because Daewoo cannot
anticipate, identify or test all attachments that owners may wish to install on their machines, please contact
Daewoo for authorization and approval of attachments, and their compatibility with options kits.

ACCUMULATOR
The pilot control system is equipped with an accumulator. For a brief period of time after the engine has
been shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be
activated. Activation of any controls may enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the hydraulic pressure in the system must be
released as describe in Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas, so it is extremely dangerous if it is handled in
the wrong way. Always observe the following precautions;
• Do not drill or make any holes in the accumulator or expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching anything to it.
• When carrying out disassembly or maintenance of the accumulator, or when disposing of the
accumulator, the charged gas must be properly released. Contact your Daewoo distributor.
• Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious injuries.

ENGINE VENTILATION
Engine exhaust gases can cause loss of
judgment, loss of alertness, and loss of motor
control. These gases can also cause
unconsciousness, serious injury and fatal
accidents.
Make sure of adequate ventilation before
starting engine in any enclosed area.
You should also be aware of open windows,
doors or ductwork into which exhaust may be
carried, or blown by wind, exposing others to ARO1770L
danger. Figure 11

Wheel Loader Safety S0103010K

Page 13
WINDOW GLASS BREAKING TOOL
This loader is equipped with a glass breaking
tool. It is on the lower right side of the cab
beside the operator’s seat. This tool can be
used in case of an emergency situation which
requires the breaking of glass to exit from the
operator’s cab. Grip the handle firmly and use
the sharp point to break the glass.

WARNING!
Protect your eyes when breaking the Figure 12 RIGHT SIDE
glass.

S0103010K Wheel Loader Safety

Page 14
BEFORE STARTING ENGINE
WORK SITE PRECAUTIONS
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work site, and determine the best and safest method of
operation.
Make the ground surface as hard and horizontal as possible before carrying out operations. If there is a lot
of dust and sand on the work site, spray water before starting operations.
If you need to operate on a street, protect
pedestrians and cars by designating a person
for work site traffic duty or by erecting fences
and posting "No Entry" signs around the work
site.
Erect fences, post "No Entry" signs, and take
other steps to prevent people from coming close
to or entering the work site. If people come
close to a moving machine, they may be hit or
caught by the machine, and this may lead to
serious personal injury or death.
Water lines, gas lines, phone lines and high-
Figure 13
voltage electrical lines may be buried under the
work site. Contact each utility and identify their
locations. Be careful not to damage or cut any of
these lines.
NEVER be in water that is in excess of the permissible water depth. Refer to "Operation Manual."
Any type of object in the vicinity of the boom could represent a potential hazard, or cause the operator to
react suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines,
work site scaffolds, or other obstructions.
Minimum levels of insurance coverage, work permits or certification, physical barriers around the work site
or restricted hours of operation may be mandated by governing authorities. There may also be regulations,
guidelines, standards or restrictions on equipment that may have to be followed for local requirements.
There may also be regulations related to performing certain kinds of work. If there is any question about
whether your machine and work site complies with the applicable standards and regulations contact your
local authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine to escape.
Avoid operating your machine to close to the edge of cliffs, overhangs, and deep ditches. The ground may
be weak in such areas. If the ground should collapse, the machine could fall or tip over and this could result
in serious injury or death.
Remember that the soil after heavy rain, blasting or after earthquakes, is weakened in these areas.
Earth laid on the ground and the soil near ditches is loose. It can collapse under the weight of vibration of
your machine and cause your machine to tip over.
Install the head guard (FOPS) if working in areas where there is danger of falling rocks.

Wheel Loader Safety S0103010K

Page 15
CHECKS BEFORE STARTING ENGINE
Every day before starting the engine for the first time, carry out the following checks. If these checks are
not carried out properly, there is danger of serious injury.
• Completely remove all wood chips, leaves, grass, paper and other flammable materials
accumulated in the engine compartment and around the battery. They could cause a fire.
Remove any dirt from the window glass, mirrors, handrails, and steps.
• Do not leave tools or spare parts laying around in the operator's compartment. The vibration of
the machine when traveling or during operations may cause them to fall and damage or break
the control levers or switches. They may also get caught in the gap of the control levers and
cause the work equipment to malfunction or move dangerously. This may lead to unexpected
accidents.
• Check the coolant level, fuel level, and hydraulic tank oil level, and check for clogged air cleaner
and damage to the electrical wiring.
• Adjust the operator's seat to a position where it is easy to operate the machine, and check the
seat belt and mounts for damage and wear.
• Check the operation of the gauges and the angle of the mirrors, and check that the safety lever
is in "LOCKED" position.
• If any abnormalities are found in the above checks, carry out repairs immediately.

ENGINE STARTING
• Walk around your machine before getting in operator’s cab. Look for evidence of leaking fluid,
loose fasteners, misaligned assemblies or any other indications of possible equipment hazard.
• All equipment covers and machinery safety guards must be in place, to protect against injury
while machine is being operated.
• Look around work site area for potential hazards, or people or property that could be at risk
while operation is in progress.
• NEVER start engine if there is any indication that maintenance or service work is in progress, or
if a warning tag is attached to controls in cab.
• A machine that has not been used recently, or is being operated in extremely cold temperatures,
could require a warm-up or maintenance service before start up.
• Check gauges and monitor displays for normal operation before starting engine. Listen for
unusual noises and remain alert for other potentially hazardous conditions at start of work cycle.
• Check tire inflation and check tires for damage or uneven wear. Perform maintenance before
operation.
• Do not short circuit the starting motor to start the engine. This is not only dangerous, but may
also damage the machine.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.

S0103010K Wheel Loader Safety

Page 16
BEFORE OPERATING MACHINE
If checks are not carried out properly after starting the engine, it may result in a delay in discovering
abnormalities in the machine, and this may lead to personal injury or damage to the machine.
Carry out the checks in an open area where there are no obstructions. Do not let anyone near the machine
when carrying out the checks.
• Check the operating condition of the equipment, and the actuation of the bucket, boom, and
travel systems.
• Check the machine for any abnormal noise, vibration, heat, smell, or abnormality with the
gauges. Check also for leakage of air, oil, and fuel.
• If any abnormality is found, repair the problem immediately. If the machine is used without
repairing the problems, it may lead to unexpected injury or failure.
• Clear all personnel from directly around machine and from the area.
• Clear all obstacles from the machine's path. Beware of hazards.
• Be sure that all windows are clean. Secure the doors and the windows in the open position or in
the shut position.
• Adjust the rear view mirrors for best visibility close to the machine. Make sure that the horn, the
travel alarm (if equipped), and all other warning devices are working properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before operating machine.
• Before moving the machine, check the position of undercarriage. The normal travel position is
with idler wheels to the front under the cab and the drive sprockets to the rear. When the
undercarriage is in the reversed position, the travel controls must be operated in opposite
directions.

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Page 17
MACHINE OPERATION
IMPORTANT
If you need more information or have any questions or concerns about safe operating
procedures or working the wheel loader correctly in a particular application or in the specific
conditions of your individual operating environment, please consult your local Daewoo
representative.

OPERATE WHILE SEATED AT OPERATOR’S

STATION ONLY
Never reach in through a window to work a
control. Do not try to operate wheel loader
unless you’re in command position - seated at
controls. You should stay alert and focused on
your work at all times. Do not twist out of seat if
job activity behind you (or to the side) requires
your attention.
Use a spotter or signal person if you cannot see
clearly and something is happening behind you.
HAOA151L
Replace damaged safety labels and lost or Figure 14
damaged operator’s manuals.
Do not let anyone operate machine unless
they’ve been fully and completely trained, in
safety and in operation of the machine.

SEAT BELTS SHOULD BE USED AT ALL

TIMES
Whenever engine is running, operator should be
seated at the control station with seat belt
properly engaged.

Figure 15

MOVEMENT ALARMS
If wheel loader is equipped with an audible travel movement alarm, test alarm on a daily basis. Audible
alarm should sound as soon as travel system is engaged.

S0103010K Wheel Loader Safety

Page 18
TRAVEL PRECAUTIONS
When traveling, wheel loader always keeps lights on; make sure that you are in compliance with all state
and local regulations concerning warning flags and signs.
Never turn the starter switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops
when the machine is traveling. It will be impossible to operate the steering unless the unit is equipped with
an emergency steering system.
Pilot control valve lever (joystick) should not be operated while traveling.
Lower work equipment so that it is 400 mm (16 in) above ground.
Never travel over obstacles or slopes that will cause machine to tilt severely. Travel around any slope or
obstacle that causes 10 degrees tilt, or more.
Do not operate the steering suddenly. The work equipment may hit the ground and cause the machine to
lose its balance, and this may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.
Always keep to the permissible water depth.
When traveling over bridges or structures on private land, check first that the bridge or structure can
withstand the weight of the machine. When traveling on public roads, check with the local authorities and
follow their instructions.

SLOPING TERRAIN REQUIRES CAUTION

Dig evenly around work site whenever possible,
trying to gradually level any existing slope. If it’s
TURBO-II

not possible to level area or avoid working on a

)
slope, reducing size and cycling rate workload is m(16''
recommended. 400 m
TURBO-II

On sloping surfaces, use caution when

positioning wheel loader before starting a work
cycle. Stay alert for instability situations to avoid
getting into them. For example, you should 400 m
m(16
always avoid working bucket over downhill side '')
AHO0970L
of machine when parked perpendicular to slope.
Avoid full extensions of bucket in a downhill Figure 16
direction. Lifting bucket too high, too close to
machine, while wheel loader is turned uphill can
also be hazardous.

Wheel Loader Safety S0103010K

Page 19
AVOID HIGH-VOLTAGE CABLES
Serious injury or death can result from contact
or proximity to high-voltage electric lines. The
bucket does not have to make physical contact
with power lines for current to be transmitted.
Use a spotter and hand signals to stay away
from power lines not clearly visible to operator.

VOLTAGE MINIMUM SAFE

DISTANCE
6.6 kV 3 m (9’ 10")
33.0 kV 4 m (13’ 1") Figure 17
66.0 kV 5 m (16’ 5")
154.0 kV 8 m (26’ 3")
275.0 kV 10 m (32’ 10")

Use these minimum distances as a guideline only. Depending upon voltage in line and atmospheric
conditions, strong current shocks can occur with boom or bucket as far away as 4 - 6 m (13 - 20 ft) from
power line. Very high voltage and rainy weather could further decrease that safety margin.
NOTE: Before starting any type of operation near power lines (either above ground or buried
cable-type) you should always contact power utility directly and work out a safety plan with
them.

BEFORE STARTING TO DIG, CONTACT AUTHORITIES

Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know
what’s underneath work site before starting to dig.

BE AWARE OF HEIGHT OBSTACLES

Any type of object in vicinity of boom could represent a potential hazard, or cause operator to react
suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines, work
site scaffolds, or other obstructions.

USE CARE ON LOOSE SUPPORT

Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load
conditions and possible tipover and injury. Travel without a load or balanced load may also be hazardous.
If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen
ground. Stay away from ditches, overhangs and all other weak support surfaces. Halt work and install
support mats or blocking if work is required in an area of poor support.

S0103010K Wheel Loader Safety

Page 20
USE SOLID SUPPORT BLOCKING
Never rely on lift jacks or other inadequate
supports when work is being done. Block
wheels fore and aft to prevent any movement.

DIGGING BENEATH OVERHANGS

Digging beneath an overhang is dangerous.
Overhand could collapse on top of operator and
cause serious injury or death. Go on to another
digging area before steep overhangs are
formed. Know height and reach limits of wheel HDO1042L
loader and plan ahead while working. Park Figure 18
wheel loader away from overhangs before work
shutdown.

DIGGING BENEATH WHEEL LOADER

Digging beneath wheel loader is dangerous. Earth beneath could collapse. This could cause wheel loader
to tip, which could cause serious injury or death to operator. Working around deep pits, trenching or along
high walls may require support blocks, especially after heavy rainfalls or during spring thaws.

STAY ALERT FOR PEOPLE MOVING

THROUGH WORK AREA
When loading a truck you should always know
where the driver is.
Avoid loading over the cab of a truck even if the
driver is in a safe spot. Someone else could
have gone inside, for any number of reasons.
Avoid working where unseen passersby might
be.
Slow down work cycle and use slower travel
speeds in congested or populated areas. Use a HAOA171L
commonly understood signal so that other Figure 19
members of work crew can warn operator to
slow or halt work in an impending hazardous
situation.

BE AWARE OF AND CONFORM TO LOCAL REGULATIONS

Minimum levels of insurance coverage, work permits or certification, physical barriers around work-site or
restricted hours of operation may be mandated by governing authorities. There may also be guidelines,
standards or restrictions on equipment that may be used to perform certain kinds of work. Check and
follow all local requirements, which may also be related to below ground hazards and power lines.

Wheel Loader Safety S0103010K

Page 21
NEVER USE ETHER STARTING AIDS
An electric-grid type manifold heater is used for
cold starting. Glowing heater element can cause
ether or other starting fluid to detonate, causing
injury.

Figure 20

OBSERVE GENERAL SAFETY RULES

Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be
allowed to operate or perform maintenance or service on wheel loader.
All personnel at work site should be aware of assigned individual responsibilities and tasks.
Communication and hand signals used should be understood by everyone.
Terrain and soil conditions at job site, approaching traffic, weather-related hazards and any above or below
ground obstacles or hazards should be observed and monitored by all work crew members.

TAKE TIME TO PROVIDE GOOD VISIBILITY

Be careful not to go close to the edge of a cliff by mistake.
Use the machine only for its main purpose. Using it for other purposes will cause failures.
To ensure an ample view, do as follows:
• When working in dark areas, attach working lights and front lights to the machine. If necessary,
set up lighting at the work site.
• Stop operations when the visibility is poor, such as in fog, mist, snow, and rain. Wait for the
visibility to improve to a level which causes no problems for the operation.
• Keep dirt and dust off of windows and off lens surfaces of work lights. Stop working if lights,
windows or mirrors need cleaning or adjustment.
To avoid hitting the work equipment, always do the following;
• When working in tunnels, on bridges, under electric wires, or when parking the machine or
carrying out other operations in places with limited height, be extremely careful not to hit the
bucket or other parts.
• To prevent collisions, operate the machine at a safe speed when working in confined spaces,
indoors, or in crowded areas.
• Do not pass the bucket over the heads of workers or over the operator's compartment of dump
truck.

S0103010K Wheel Loader Safety

Page 22
KEEP "PINCH POINT" AREAS CLEAR - USE
CAUTION IN REVERSE
Use a signal person in high traffic areas and
whenever operator’s view is not clear, such as
when traveling in reverse.
Anyone standing near wheels, or working
assemblies of the attachment, is at risk of being
caught between moving parts of machine.
Never allow anyone to ride on any part of
machine or attachment, including any part of
operator’s cab. HAOA191L
Figure 21

OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES

In icy cold weather avoid sudden travel movements and stay away from even very slight slopes. Machine
could skid off to one side very easily.
Snow accumulation could hide or obscure potential hazards. Use care while operating or while using
machine to clear snow.
Warming up engine for a short period may be necessary, to avoid operating with sluggish or reduced
working capacity. Jolting shocks and impact loads caused by bumping or bottoming boom or attachment
are more likely to cause severe stress in very cold temperatures. Reducing work cycle rate and work load
may be necessary.
When the temperature rises, frozen road surfaces become soft, so the machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare hands. If you touch a metal surface in
extremely cold weather, your skin may freeze to the metal surface.

PARKING MACHINE
Avoid making sudden stops, or parking machine wherever it happens to be at the end of the work day. Plan
ahead so that the wheel loader will be on a firm, level surface away from traffic and away from high walls,
cliff edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable,
block wheels to prevent movement. Lower bucket or other working attachment completely to ground, or to
an overnight support saddle. There should be no possibility of unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs
to ensure that passing traffic can see the machine clearly, and park the machine so that the machine, flags,
and fences do not obstruct traffic.

Wheel Loader Safety S0103010K

Page 23
SHUTDOWN CONTROL FUNCTIONS
After bucket has been lowered to overnight storage position, move all switches and controls to "OFF"
position. Pull parking brake knob to "APPLIED" position. This will apply parking brake. Move pilot cutoff
switch to "LOCK" position. This will disable pilot control valve lever (joystick). Move key in starter switch to
"OFF" position, and remove key from switch.
Engage all lock-down security equipment that may have been installed on machine.

IMPORTANT
When hydraulic system maintenance or service work must be performed, be aware that
accumulators in system store fluid under pressure after system has been shutdown. To release
hydraulic pressure in accumulators, operate control with engine "OFF" until accumulator
pressure is completely dissipated.

NEVER LET ANYONE RIDE ON

ATTACHMENT
Never let anyone ride on any work attachment,
such as the bucket, crusher, grapple, or
clamshell (grab bucket). There is a danger of the
person falling and suffering serious injury.

HAAD4050
Figure 22

S0103010K Wheel Loader Safety

Page 24
MAINTENANCE
USE WARNING TAG DURING SERVICE
Alert others that service or maintenance is
being performed and tag operator’s cab controls
- and other machine areas if required - with a
warning notice.
Warning tags for controls are available from WARNING
Daewoo distributors; see Figure 23.

CLEAN BEFORE INSPECTION OR

MAINTENANCE
HAOC920L
Clean the machine before carrying out
inspection and maintenance. This prevents dirt Figure 23
from getting into the machine and also ensures
safety during maintenance.
If inspection and maintenance are carried out when the machine is dirty, it will become more difficult to
locate the problems, and also there is danger that you may get dirt or mud in your eyes or that you may slip
and injure yourself.
When washing the machine, do the following;
• Wear shoes with non-slip soles to prevent yourself from slipping and falling on wet places.
• Wear safety glasses and protective clothing when washing the machine with high-pressure
steam.
• Take action to prevent touching high-pressure water and cutting your skin or having mud fly into
your eyes.
• Do not spray water directly on electrical components (sensors, connector) (1, Figure 24). If
water gets into the electrical system, there is danger that it will cause defective operation and
malfunction.

Figure 24

Pick up any tools or hammers that are laying in the work place, wipe up any grease or oil or any other
slippery substances, and clean the area to make it possible to carry out the operation in safety. If the work
place is left untidy, you may trip or slip and suffer injury.

Wheel Loader Safety S0103010K

Page 25
PROPER TOOLS
Use only tools suited to the task. Using
damaged, low qualify, faulty, or makeshift tools
could cause personal injury. There is danger
that pieces from, chisels with crushed heads, or
hammers, may get into your eyes and cause
blindness.

HDO1037L
Figure 25
USE OF LIGHTING
When checking fuel, oil, battery electrolyte, or
window washing fluid, always use lighting with
anti-explosion specifications. If such lighting
equipment is not used, there is danger of
explosion.
If work is carried out in dark places without
using lighting, it may lead to injury, so always
use proper lighting.
Even if the place is dark, never use a lighter or
flame instead of lighting. There is danger of fire. HDO1040L
There is also danger that the battery gas may Figure 26
catch fire and cause and explosion.

FIRE PREVENTION AND EXPLOSION PREVENTION

All fuels, most lubricants and some coolant mixtures are flammable. Leaking fuel or fuel that is spilled onto
hot surfaces or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons.
Store oily rags and other flammable material in a protective container.
Do not smoke while you refuel the machine or while you are in a refueling area.
Do not smoke in battery charging areas or in areas the contain flammable material.
Clean all electrical connections and tighten all electrical connections. Check the electrical wires daily for
wires that are loose of frayed. Tighten all lose electrical wires before you operate the machine. Repair all
frayed electrical wires before you operate the machine.
Remove all flammable materials before the flammable materials accumulate on the machine.
Do not weld on pipes or on tubes that contain flammable fluids. Do not flame cut on pipes or on tubes that
contain flammable fluids. Before you weld on pipes or on tubes or before you flame cut on pipes or on
tubes, clean the pipes or tubes thoroughly with a nonflammable solvent.

S0103010K Wheel Loader Safety

Page 26
BURN PREVENTION
When checking the radiator coolant level, stop the engine, let the engine and radiator cool down, then
check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit,
there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.

ARO1360L
Figure 27

If the coolant level in the coolant recovery tank is below the lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Allow cooling system components to cool before you drain the cooling system.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact
the skin.
Remove the hydraulic tank filter plug only after the engine has been stopped. Make sure that the hydraulic
tank filter plug is cool before you remove it with your bare hand. Remove the hydraulic tank filter plug slowly
to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel system, or in the cooling system before you
disconnect any lines, fittings, or related items.
Batteries give off flammable fumes that can explode.
Do not smoke while you are checking the battery electrolyte levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or
the eyes.
Always wear protective glasses when you work on batteries.

Wheel Loader Safety S0103010K

Page 27
WELDING REPAIRS
When carrying out welding repairs, carry out the welding in a properly equipped place. The welding should
be performed by a qualified worker. During welding operations, there is the danger of, generation of gas,
fire, or electric shock, so never let an unqualified worker do welding.
The qualified welder must do the following;
• To prevent explosion of the battery, disconnect the battery terminals and remove batteries.
• To prevent generation of gas, remove the paint from the location of the weld.
• If hydraulic equipment, piping or places close to them are heated, a flammable gas or mist will
be generated and there is danger of it catching fire. To avoid this, never subject these places to
heat.
• Do not weld on pipes or on tubes that contain flammable fluids. Do not flame cut on pipes or on
tubes that contain flammable fluids. Before you weld on pipes or on tubes or before you flame
cut on pipes or on tubes, clean the pipes or tubes thoroughly with a nonflammable solvent.
• If heat is applied directly to rubber hoses or piping under pressure, they may suddenly break so
cover them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and provide a fire extinguisher.

PRECAUTIONS FOR REMOVAL,

INSTALLATION, AND STORAGE OF
ATTACHMENTS
Before starting removal and installation of
attachments, decide the team leader.
Do not allow anyone except the authorized
workers close to the machine or attachment.
Place attachments that have been removed
from the machine in a safe place so that they do
not fall. Put up a fence around the attachments
and take other measures to prevent HDO1041L
unauthorized persons from entering. Figure 28

S0103010K Wheel Loader Safety

Page 28
PRECAUTIONS WHEN WORKING ON
MACHINE
When carrying out maintenance operations on
the machine, keep the area around your feet
clean and tidy to prevent you from falling.
Always do the following;
• Do not spill oil or grease.
• Do not leave tools laying about.
• Watch your step when walking.
Never jump down from the machine. When ARO1380L
getting on or off the machine, use the steps and Figure 29
handrails, and maintain a three-point contact
(both feet and one hand or both hands and one
foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when
working on the hood or covers, never use any
part except the inspection passage fitted with
non-slip pads.

LOCK INSPECTION COVERS

When carrying out maintenance with the inspection cover open, lock the cover securely in position with the
lock bar.
If maintenance work is carried out with the inspection cover open but not locked, there is danger that it may
suddenly close and cause injury if there is a gust of wind.

CRUSHING PREVENTION AND CUTTING PREVENTION

You should always have at least two people working together if the engine must be run during service. One
person needs to remain in the operator’s seat, ready to work the controls or stop the machine and shut off
the engine.
Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the
engine is running.
Stay clear of all rotating parts and moving parts.
Keep objects away from moving fan blades. The fan blades will throw objects and the fan blades can cut
objects.
Do not use a wire rope cable that is kinked or flayed. Wear gloves when you handle a wire rope cable.
When you strike a retainer pin, the retainer pin might fly out. The loose retainer pin can injure personnel.
Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear
protective glasses when you strike a retainer pin.

DO NOT RUN ENGINE IF REPAIRS OR WORK ARE BEING PERFORMED ALONE

You should always have at least two people working together if engine must be run during service. One
person needs to remain in operator’s seat, ready to work controls or stop machine and shut "OFF" engine.

Wheel Loader Safety S0103010K

Page 29
ALWAYS USE ADEQUATE EQUIPMENT SUPPORTS AND BLOCKING
Do not allow weight or equipment loads to remain suspended. Lower everything to ground before leaving
operator’s seat. Do not use hollow, cracked or unsteady, wobbling weight supports. Do not work under any
equipment supported solely by a lift jack.

DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS

Wait for engine to cool off after normal operation. Park wheel loader on a firm, level surface and lower all
equipment before shutting down and switching "OFF" controls. When engine lube oil, gearbox lubricant or
other fluids require change, wait for fluid temperatures to decrease to a moderate level before removing
drain plugs.
NOTE: Oil will drain more quickly and completely if it is warm. Do not drain fluids at temperatures
exceeding 95°C (203°F), however do not allow full cool-down.

HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT

Check cylinder drift rate at regular intervals. Overhaul seal kits are available through Daewoo.

HIGH PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY

Exposed hydraulic hoses on arm or boom could react with explosive force if struck by a falling rock,
overhead obstacle or other job site hazard. Extra safety guards may be required. NEVER allow hoses to be
hit, bent or interfered with during operation.

S0103010K Wheel Loader Safety

Page 30
PRECAUTIONS WITH HIGH PRESSURE LINE, TUBES AND HOSES
When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released
form the circuit. Failure to release the pressure may lead to serious injury. Always do the following;
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized components can be difficult to see but
pressurized oil has enough force to pierce the skin and cause serious injury. Always use a piece
of wood or cardboard to check for suspected hydraulic leaks. Never use your hands or expose
your fingers.
• Do not bend high pressure lines. Do not strike high pressure lines. Do not install lines, tubes or
hoses that are bent or damaged.
• Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration,
rubbing against other parts, and excessive heat during operation.
– If any of the following conditions are found, replace the part.
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure of strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.

X X O

HAOA420L
Figure 30

OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES SKIN.

WARNING!
Failure to obtain prompt medical assistance could result in gangrene or other serious damage to
tissue.

Wheel Loader Safety S0103010K

Page 31
USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE
Refer to "General Maintenance" section of Shop Manual for information on tightening torques and
recommended assembly compounds and always use correct part.
Poor or incorrect fastener connections can dangerously weaken assemblies.

SAFETY-CRITICAL PARTS MUST BE REPLACED PERIODICALLY

Replace following fire-related components as soon as they begin to show any sign of wear, or at regular
periodic intervals, whether or not deterioration is visible:
• Fuel system flexible hoses, the tank overflow drain hose and the fuel filler cap.
• Hydraulic system hoses, especially the pump outlet lines and front and rear pump branch
hoses.
• Keep mounting brackets and hose and cable routing straps tight. Hose routing should have
gradual bends.

DISPOSE OF ALL PETROLEUM-BASED OILS

AND FLUIDS PROPERLY
Physical contact with used motor oil may pose a
X
health risk. Wipe oil from your hands promptly
and wash off any remaining residue.
Used motor oil is an environmental contaminant
and may only be disposed of at approved
collection facilities. To prevent pollution of the
environment, always do the following;
• Never dump waste oil in a sewer
system, rivers, etc. HAOA470L

• Always put oil drained from your Figure 31

machine in containers. Never drain
oil directly onto the ground.
• Obey appropriate laws and
regulations when disposing of
harmful materials such as oil, fuel,
solvent, filters, and batteries.

CHECK TIRE PRESSURE AND CONDITION

Maintain tire pressure but do not over inflate. Inspect tires and wheels daily. When inflating tires, follow
procedures in Maintenance Section, which include using an extension to allow you to avoid standing in
front of or over a tire. Do not change a tire unless you have both experience and proper equipment.

S0103010K Wheel Loader Safety

Page 32
BATTERY
BATTERY HAZARD PREVENTION
Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is
highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems,
always do the following;
• Do not smoke or bring any flame near the battery.
• When working with batteries, ALWAYS wear safety glasses and rubber gloves.
• If you spill battery electrolyte on yourself or your clothes, immediately flush the area with water.
• If battery electrolyte gets into your eyes, flush them immediately with large quantities of water
and see a doctor at once.
• If you accidentally drink battery electrolyte, drink a large quantity of water or milk, raw egg or
vegetable oil. Call a doctor or poison prevention center immediately.
• When cleaning the top surface of the battery, wipe it with a clean, damp cloth. Never use
gasoline, thinner, or any other organic solvent or detergent.
• Tighten the battery caps securely.
• Explosive battery gas can be set off by sparks from incidental contact or static discharge. Turn
"OFF" all switches and engine when working on batteries. Keep battery terminals tight. Contact
between a loose terminal and post can create an explosive spark.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with power from
another source. There is danger that the battery may catch fire.
• When charging the battery or starting with power from another source, let the battery electrolyte
melt and check that there is no leakage of battery electrolyte before starting the operation.
• Always remove the battery from the machine before charging.

Figure 32

DISCONNECT BATTERIES BEFORE ELECTRICAL SERVICE OR ELECTRICAL WELDING

Remove cable to negative terminal first when disconnecting cable. Connect positive terminal cables first
when installing a battery.

Wheel Loader Safety S0103010K

Page 33
USE LOW HEAT PORTABLE LIGHTING
Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.

BOOST STARTING OR CHARGING ENGINE

BATTERIES
If any mistake is made in the method of
connecting the booster cables, it may cause an
explosion or fire. Always do the following;
• Turn off all electrical equipment
before connecting leads to the
battery. This includes electrical
switches on the battery charger or
boost starting equipment.
• When boost-starting from another HAOA310L
machine or vehicle do not allow the Figure 33
two machines to touch. Wear safety
glasses or goggles while required
battery connections are made.
• 24 volt battery units consisting of two series-connected twelve volt batteries have a cable
connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the
other battery. Booster or charger cable connections must be made between the non-series-
connected positive terminals and between the negative terminal of the booster battery and the
metal frame of the machine being boosted or charged. Refer to the procedure and illustration in
Operation and Maintenance Manual.
• Connect positive cable first when installing cables and disconnect the negative cable first when
removing them. The final cable connection, at the metal frame of the machine being charged or
boost-started, should be as far away from the batteries as possible.

S0103010K Wheel Loader Safety

Page 34
TOWING
PRECAUTIONS WHEN TOWING
If any mistake is made in the method of selecting or inspecting the towing wire or in the method of towing,
it may lead to serious personal injury. Always do the following;
• Always use the method of towing given in this Operation and Maintenance Manual. Do not use
any other method.
• Use leather gloves when handling the wire rope.
• When carrying out the preparation work for towing with two or more workers, determine the
signals to use and follow these signals correctly.
• If the engine on the problem machine will not start or there is a failure in the brake system.
always contact your Daewoo distributor.
• Never go between the towing machine and the towed machine during the towing operation.
• It is dangerous to carry out towing on slopes, so select a place where the slope is gradual. If
there is no place where the slope is gradual, carry out operations to reduce the angle of the
slope before starting the towing operation.
• When towing a problem machine, always use a wire rope with a sufficient towing capacity.
• Do not use a frayed, kinked rope or a rope with any loss of diameter.

Wheel Loader Safety S0103010K

Page 35
SHIPPING AND TRANSPORTATION
OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS
Check state and local restrictions regarding weight, width and length of a load before making any other
preparation for transport.
Hauling vehicle, trailer and load must all be in compliance with local regulations governing intended
shipping route.
Partial disassembly or tear-down of wheel loader may be necessary to meet travel restrictions or particular
conditions at work site.
Refer to the section "Transportation" section of operation manual.

SUMMARY OF SAFETY PRECAUTIONS FOR

LIFTING

WARNING!
Improper lifting can allow load to shift and
cause personal injury or damage to the
machine

To make safe lifts, the following items must be

evaluated by operator and work site crew.
Figure 34
• Condition of ground support.
• Wheel loader configuration and
attachments.
• Weight, lifting height and lifting
radius.
• Safe rigging of load.
• Proper handling of suspended load.
Taglines on opposite sides of load can be very
helpful in keeping a suspended load secure, if
they are anchored safely to control points on
ground.

S0103010K Wheel Loader Safety

Page 36
1SPECIFICATIONS
 S0203075K

1SPECIFICATIONS FOR
MEGA 500-V (TIER II)

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

SPECIFICATIONS FOR MEGA 500-V (TIER II)S0203075K

MODEL SERIAL NUMBER RANGE
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Specifications for Mega 500-V (Tier II) S0203075K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
General Specifications ................................................................................... 5
Engine Performance Curves .......................................................................... 6
Working Range and Dimensions.................................................................... 8
Working Capacities ...................................................................................... 11
Bucket Capacity .................................................................................... 11
Tipping Load ......................................................................................... 11
Material Weight ............................................................................................ 11
Approximate Weight of Workload Materials .......................................... 11

S0203075K Specifications for Mega 500-V (Tier II)

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GENERAL DESCRIPTION
Figure 1 identifies the location of major machine components.

1 2

5
3
4

7
9

10 8

16
17
20
18 21
19
15
22
24 25
23 26
12 13 14
27

11

44

30 28
31
34 29
43 42 41 40 39 38 37 36 35 33 32

AQO0190L

Figure 1

Specifications for Mega 500-V (Tier II) S0203075K

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1. BUCKET TOOTH 23. ENGINE
2. BUCKET 24. CAC COOLER
3. OPERATOR’S CAB 25. RADIATOR
4. AIR CONDITIONING CONDENSER 26. FAN
5. BATTERY BOX (R.H.) 27. GRILL
6. FAN MOTOR 28. FUEL TANK
7. COUNTERWEIGHT 29. FUEL FILLER PIPE
8. BATTERY BOX (L.H.) 30. ENGINE OIL LEVEL GAUGE
9. OIL TANK 31. ENGINE OIL FILLER PIPE
10. FULL FLOW FILTER 32. REAR AXLE PIVOT
11. TILT LEVER 33. REAR AXLE
12. BUCKET CYLINDER 34. TRANSMISSION OIL FILTER
13. CONTROL VALVE 35. WHEEL CHOCK
14. FRONT WHEEL COVER 36. TRANSMISSION
15. STEERING WHEEL 37. CENTER PIN
16. ROPS 38. STEERING CYLINDER
17. WORK LEVER 39. BOOM CYLINDER
18. SEAT 40. DRIVE SHAFT
19. REAR WHEEL COVER 41. PARKING BRAKE
20. PRE-CLEANER 42. FRONT AXLE
21. AIR CLEANER 43. LOADER ARM
22. MUFFLER 44. LINK

S0203075K Specifications for Mega 500-V (Tier II)

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GENERAL SPECIFICATIONS
MEGA 500 TIER II

Item Specification

Standard Bucket Capacity 4.8 m3 (6.3 yd3)

Vehicle Weight (W/ROPS CANOPY) 28,800 (29,600) kg (63.493 (65.257) lb)

Engine

Type Cummins N14-C

Horsepower 340 ps (335 hp) @ 2,100 rpm

Max. Torque 174 kg•m (1,255 ft lb) @ 1,400 rpm

Transmission

Full Automatic Power -Shift Full Automatic Power Shift

Speeds 4 Forward, 3 Reverse

Brake Systems

Travel Brakes 4 Wheel, Wet Disk

Parking Brake SHAR, Dry Disc Type

Performance

Travel Speed 7 – 35 km/h (4.35 - 21.75 MPH)

Steering Angle ± 40°

Min. Tire Turning Radius 6,140 mm (20' 2'')

Safe Operating Load 8,640 kg (19,050 lb)

Max. Breakout Force 27,000 kg (59,520 lb)

Bucket Rise Time 6.5 Sec

Bucket Dump Time 1.3 Sec

Bucket Descent Time 3.4 Sec

Maximum Gradeability 30° (58%)

Specifications for Mega 500-V (Tier II) S0203075K

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ENGINE PERFORMANCE CURVES

1300

1200 1600

Torque (lb ft)

1100

Torque (Nm)
1400
1000

900 1200
800
1000
700
800 1000 1200 1400 1600 1800 2000

Engine Speed (RPM)

250
300
Power (hp)

Power (kW)
200

200 150

100
100
800 1000 1200 1400 1600 1800 2000

Engine Speed (RPM)

0.45
Fuel Consumption (lb/hp-hr)

Fuel Consumption (gm/kW-hr)

250
0.40

0.35
200
0.30

0.25
1400 1600 1800 2000

Engine Speed (RPM)

AWS0600L
Figure 2

S0203075K Specifications for Mega 500-V (Tier II)

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 Performance standard SAE J1995
Power (Maximum / rpm 340 ps @ 2,100 rpm (335 hp @ 2,100 rpm)
Maximum Torque 174 kg•m / 1,400 rpm
(1,255 ft lb @ 1,400 rpm)
Fuel Consumption 153 g/ps•h (5.39 oz/hp•h)

NOTE: Barometric Pressure: 760 mm (30") Mercury

Temperature: 20°C (68°F)
W/ Cooling Fan
Alternator: 24 V, 70 amp
Exhaust System: Complete, attached
Air Cleaner; Installed

Specifications for Mega 500-V (Tier II) S0203075K

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WORKING RANGE AND DIMENSIONS
Figure 3, illustrates exterior machine dimensions and working range of machine when it is equipped with a
standard bucket.

C
H

G
B
E
D
A F

I
H

AHO0830L

Figure 3

S0203075K Specifications for Mega 500-V (Tier II)

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 Category Dimension

Overall Length (A) 9,320 mm (30’ 7")

Overall Width, without bucket (B) 3,190 mm (10’ 6")

Overall Height (C) 3,780 mm (12’ 5")

Bucket Width (D) 3,480 mm (11’ 5")

Wheel Base (E) 3,600 mm (11’ 10")

Tread (F) 2,420 mm (7’ 11")

Ground Clearance (G) 490 mm (1’ 7")

Dump Height, to tooth (H) 3,080 mm (10’ 1")

Dump Distance, to Bucket Edge (I) 1,380 mm (4’ 6")

Dump Height to Bucket Pivot 4,470 mm (14’ 8")

Bucket Angle, Raised (a) 47°

Bucket Angle (b), Lowered (at carry) 48°

Tire Size 29.5-25-22 PR(L3)

Specifications for Mega 500-V (Tier II) S0203075K

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Figure 4 and Figure 5, illustrate working range when machine is equipped with optional Pallet or Log Fork.

F E

a
A

b
D AHS3690L
Figure 4

Reference Reference
Dimension Dimension
Number Number
A 1,785 mm (5’ 10") E 1,800 (5’ 11")
B 2,185 mm (7’ 2") F 1,025 (3’ 4")
C 4,260 mm (13’ 12") a 16°
D 9,870 mm (32’ 5") b 22°

B
b

AHS3740L
Figure 5

Reference Reference
Dimension Dimension
Number Number
A 2,016 mm (6’ 7") a 45°
B 2,785 mm (9’ 2") b 33°

S0203075K Specifications for Mega 500-V (Tier II)

Page 10
WORKING CAPACITIES
BUCKET CAPACITY

Standard toothed bucket has a capacity of 4.8 m3 (6.3 yd3). An optional bucket equipped with a cutting
edge and no teeth has a capacity of 4.8 m3 (6.3 yd3).

TIPPING LOAD
Static Tipping Load with bucket in Over Front position is 22,000 kg (48,500 lb). With bucket in Fully Turned
position, Static Tipping Load is 19,000 kg (41,890 lb).

MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.

APPROXIMATE WEIGHT OF WORKLOAD MATERIALS

LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR

DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS

Charcoal 401 kg/m3

--------------------- ---------------------
(695 lb/yd3)

Coke, blast furnace 433 kg/m3

size --------------------- ---------------------
(729 lb/yd3)

Coke, foundry size 449 kg/m3

--------------------- ---------------------
(756 lb/yd3)

Coal, bituminous slack, 801 kg/m3

piled --------------------- ---------------------
(1,350 lb/yd3)

Coal, bituminous r. of 881 kg/m3

m., piled --------------------- ---------------------
(1,485 lb/yd3)
Coal, anthracite 897 kg/m3
--------------------- ---------------------
(1,512 lb/yd3)

Clay, DRY, in broken 1,009 kg/m3

lumps --------------------- ---------------------
(1,701 lb/yd3)

Clay, DAMP, natural 1,746 kg/m3

bed --------------------- ---------------------
(2,943 lb/yd3)

Specifications for Mega 500-V (Tier II) S0203075K

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 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS

Cement, Portland, DRY 1,506 kg/m3

granular --------------------- ---------------------
(2,583 lb/yd3)

Cement, Portland, DRY 1,362 kg/m3

clinkers --------------------- ---------------------
(2,295 lb/yd3)

Dolomite, crushed 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)

Earth, loamy, DRY, 1,202 kg/m3

loose --------------------- ---------------------
(2,025 lb/yd3)

Earth, DRY, packed 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)

Earth, WET, muddy 1,762 kg/m3

--------------------- ---------------------
(2,970 lb/yd3)

Gypsum, calcined, 961 kg/m3

(heated, powder) --------------------- ---------------------
(1,620 lb/yd3)

Gypsum, crushed to 3 1,522 kg/m3

inch size --------------------- ---------------------
(2,565 lb/yd3)

Gravel, DRY, packed 1,810 kg/m3

fragments --------------------- ---------------------
(3,051 lb/yd3)

Gravel, WET, packed 1,922 kg/m3

fragments --------------------- ---------------------
(3,240 lb/yd3)

Limestone, graded 1,282 kg/m3

above 2 --------------------- ---------------------
(2,160 lb/yd3)

Limestone, graded 1,362 kg/m3

1-1/2 or 2 --------------------- ---------------------
(2,295 lb/yd3)

Limestone, crushed 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)

Limestone, fine 1,602 kg/m3

--------------------- ---------------------
(2,705 lb/yd3)
Phosphate, rock 1,282 kg/m3
--------------------- ---------------------
(2,160 lb/yd3)

S0203075K Specifications for Mega 500-V (Tier II)

Page 12
 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS

Salt 929 kg/m3

--------------------- ---------------------
(1,566 lb/yd3)

Snow, light density 529 kg/m3

--------------------- ---------------------
(891 lb/yd3)

Sand, DRY, loose 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)

Sand, WET, packed 1,922 kg/m3

--------------------- ---------------------
(3,240 lb/yd3)

Shale, broken 1,362 kg/m3

--------------------- ---------------------
(2,295 lb/yd3)

Sulphur, broken 529 kg/m3

--------------------- ---------------------
(1,620 lb/yd3)

IMPORTANT
Weights are approximations of estimated average volume and mass. Exposure to rain, snow or
ground water; settling or compaction due to overhead weight and chemical or industrial
processing or changes due to thermal or chemical transformations could all increase value of
weights listed in table.

Specifications for Mega 500-V (Tier II) S0203075K

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S0203075K Specifications for Mega 500-V (Tier II)
Page 14
1GENERAL MAINTENANCE
 Return to Master Table of Contents

S0302000
R1

1GENERAL
MAINTENANCE
PROCEDURES
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

GENERAL MAINTENANCE PROCEDURESS0302000

MODEL SERIAL NUMBER RANGE

ALL MODELS ALL RANGES

Copyright 2002 Daewoo

May 2002

General Maintenance Procedures S0302000

Page 1
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TABLE OF CONTENTS

Welding Precautions and Guidelines ............................................................. 3

Hydraulic System - General Precautions ....................................................... 4
Maintenance Service and Repair Procedure ................................................. 5
General Precautions ............................................................................... 5
Hydraulic System Cleanliness and Oil Leaks................................................. 6
Maintenance Precautions for Hydraulic System Service ........................ 6
Oil Leakage Precautions ......................................................................... 6
Cleaning and Inspection................................................................................. 7
General Guidelines ................................................................................. 7
Bearing inspection .................................................................................. 8

S0302000 General Maintenance Procedures

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WELDING PRECAUTIONS AND GUIDELINES

IMPORTANT
To avoid accidents, personal injury and the possibility of causing damage to the machine or to
components, welding must only be performed by properly trained and qualified personnel, who
possess the correct certification (when required) for the specific welding fabrication or
specialized repair being performed.

WARNING!
Structural elements of the machine may be built from a variety of steels. These could contain
unique alloys or may have been heat treated to obtain particular strength characteristics. It is
extremely important that welding repairs on these types of steel are performed with the proper
procedures and equipment. If repairs are performed incorrectly, structural weakening or other
damage to the machine (that is not always readily visible) could be caused. Always consult
Daewoo After Sales Service before welding on integral components (loader arm, frames, car
body, track frames, turntable, attachment, etc.) of the machine. It is possible that some types of
structurally critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make
sure there are no hidden cracks or damage, before the machine can be returned to service.

CAUTION!
Always perform welding procedures with the proper safety equipment on hand. Adequate
ventilation and a dry work area are absolutely essential. Keep a fire extinguisher nearby and
always wear protective clothing and the recommended type of eye protection.

General Maintenance Procedures S0302000

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CAUTION!
Observe the following safety precautions:
1. Use extra caution and adequate safety shielding when welding near fuel and oil tanks,
batteries, hydraulic piping lines or other fire hazards.
2. Never weld when the engine is running. Battery cables must be disconnected before the
welding procedure is started.
3. Never weld on a wet or damp surface. The presence of moisture causes hydrogen
embrittlement and structural weakening of the weld.
4. If welding procedures are being performed near cylinder rods, operator’s cab window areas
or any other assemblies that could be damaged by weld spatters, use adequate shielding
protection in front of the assembly.
5. During equipment setup, always attach ground cables directly to the area or component
being welded to prevent arcing through bearings, bushings, or spacers.
6. Always use correct welding rods for the type of weld being performed and observe
recommended precautions and time constraints. AWS Class E7018 welding rods for low
alloy to medium carbon steel must be used within two hours after removal from a freshly
opened container. Class E11018G welding rods for T-1 and other higher strength steel must
be used within 1/2 hour.

HYDRAULIC SYSTEM - GENERAL PRECAUTIONS

Always maintain oil level in the system at recommended levels. Assemblies that operate under heavy
loads, at high speed, with extremely precise dimensional tolerances between moving parts - pistons and
cylinders, or shoes and swash plates, for example - can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very short time when piping or hoses are
disconnected to repair leaks and/or replace damaged components. Hoses that are inadvertently switched
during disassembly (inlet for outlet and vice versa), air introduced into the system or assemblies that are
low on oil due to neglect or careless maintenance, could all produce sufficient fluid loss to cause damage.
When starting the engine (particularly after long layoff or storage intervals), make sure that all hydraulic
controls and operating circuits are in neutral, or "OFF." That will prevent pumps or other components that
may be temporarily oil-starved from being run under a load.
Replacement of any hydraulic system component could require thorough cleaning, flushing, and some
amount of pre-filling with fresh, clean oil if the protective seal on replacement parts has obviously been
broken or if seal integrity may have been compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts carefully, before they are installed. If the
replacement part is bone dry (with no trace of factory pre-lube) or has been contaminated by dirt or by
questionable oils, flushing and pre-filling with clean hydraulic fluid is recommended.
Vibration, irregular or difficult movement or unusual noise from any part of the hydraulic system could be
an indication of air in the system (and many other types of problems). As a general precaution (and to help
minimize the risk of potential long-term damage), allow the engine to run at no-load idle speed immediately
after initial start-up. Hydraulic fluid will circulate, releasing any air that may have been trapped in the
system before load demands are imposed.
A daily walk-around pre-start equipment safety inspection, including a quick visual scan for any exterior
evidence of leaking hydraulic fluid, can help extend the service life of system components.

S0302000 General Maintenance Procedures

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IMPORTANT
Hydraulic system operating conditions (repetitive cycling, heavy work loads, fluid circulating
under high pressure) make it extremely critical that dust, grit or any other type of contamination
be kept out of the system. Observe fluid and filter change maintenance interval
recommendations and always pre-clean any exterior surface of the system before it is exposed
to air. For example, the reservoir filler cap and neck area, hoses that have to be disassembled,
and the covers and external surfaces of filter canisters should all be cleaned before
disassembly.

MAINTENANCE SERVICE AND REPAIR PROCEDURE

GENERAL PRECAUTIONS
Fluid level and condition should always be checked whenever any other type of maintenance service or
repair is being performed.
NOTE: If the unit is being used in an extreme temperature environment (in sub-freezing climates
or in high temperature, high humidity tropical conditions), frequent purging of moisture
condensation from the hydraulic reservoir drain tap should be a regular and frequent part
of the operating routine. In more moderate, temperate climates, draining reservoir
sediment and moisture may not be required more than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring or visible fluid contamination at every oil
change. Abrasive grit or dust particles will cause discoloration and darkening of the fluid. Visible
accumulations of dirt or grit could be an indication that filter elements are overloaded (and will require more
frequent replacement) or that disintegrating bearings or other component failures in the hydraulic circuit
may be imminent or have already occurred. Open the drain plugs on the main pump casings and check
and compare drain oil in the pumps. Look for evidence of grit or metallic particles.
Vibration or unusual noise during operation could be an indication of air leaking into the circuit (Refer to the
appropriate Troubleshooting section for component or unit for procedures.), or it may be evidence of a
defective pump. The gear-type pilot pump could be defective, causing low pilot pressure, or a main pump
broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown on the multidisplay digital gauge on
the Instrument Panel ("F-Pump" and "R-Pump") will be reduced as a result of a
mechanical problem inside the pump. However, pressure loss could also be due to
cavitation or air leakage, or other faults in the hydraulic system.
Check the exterior case drain oil in the main pumps. If no metallic particles are found, make sure there is
no air in the system. Unbolt and remove the tank return drain line from the top part of the swing motor, both
travel motors and each main pump. If there is air in any one of the drain lines, carefully pre-fill the
assembly before bolting together the drain line piping connections. Run the system at low rpm.

General Maintenance Procedures S0302000

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HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS

MAINTENANCE PRECAUTIONS FOR HYDRAULIC SYSTEM SERVICE
Whenever maintenance, repairs or any other type of troubleshooting or service is being performed, it’s
important to remember that the hydraulic system - including both the interior and exterior surfaces of
assemblies, and every drop of operating fluid - must be protected from contamination.
Dust and other foreign contaminants are major contributors to premature wear in hydraulic circuits. The
narrow tolerances, rapidly moving parts and high operating pressures of the system require that fluid be
kept as clean as possible. The performance and dependability of the machine (and the service lift of
individual components) can be noticeably reduced if proper precautions are not observed:
• Use a safe, non-combustible, evaporative-type, low-residue solvent and thoroughly clean
exterior surfaces of assemblies before any part of the circuit is opened up or disassembled.
NOTE: It’s just as important to clean the cap and reservoir top before routine fluid changes or
quick checks as it is before major repairs. (Accumulated dirt attracts moisture, oil and
other fluids - and more dirt.)
• Keep dismantled parts covered during disassembly. Use clean caps, plugs or tape to protect the
disconnected openings of flanges, manifolds and piping.
• Do not allow cleaning solvents or other fluids to mix with the oil in the system. Use clean oil to
flush any traces of solvent or other residue before reassembly.
• If metal or rubber fragments are found in the system, flush and replace all fluid in the system
and troubleshoot the circuit to identify the source of contamination.

IMPORTANT
Make sure that cleaning solvents will be compatible with rubber materials used in the hydraulic
system. Many petroleum based compounds can cause swelling, softening, or other deterioration
of system sealing elements, such as O-rings, caps and other seals.

OIL LEAKAGE PRECAUTIONS

Oil that is visibly seeping from joints or seals should always serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew that air, water and dirt have an open, free
passageway through which to enter the circuit. Harsh, corrosive salt air, freezing and thawing
condensation cycles and working environments that are full of fine dust are especially hazardous. Clogging
of valve spools or external piping (especially pilot circuit piping) can gradually diminish or very suddenly
put a complete stop to normal hydraulic function. You can prevent having to make these types of repairs by
following recommended assembly procedures:
1. Use new O-rings and oil seals whenever hydraulic assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking alignment and flatness. Clean and repair
corrosion or any other damage.
3. Follow bolt torque recommendations and all other assembly requirements.

S0302000 General Maintenance Procedures

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NOTE: Grease lip seals before

assembly.

Figure 1

CLEANING AND INSPECTION

GENERAL GUIDELINES
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or
foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting
parts such as thrust bearing, matched parts, etc.

WARNING!
Care should be exercised to avoid inhalation of vapors, exposure to skin and creating fire
hazards when using solvent type cleaners.

1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign
materials are dissolved and parts are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then
remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified
particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation
until bearings are thoroughly clean. To dry bearings, use moisture-free compressed air. Be careful to
direct air stream across bearing to avoid spinning bearings that are not lubricated. DO NOT SPIN
BEARINGS WHEN DRYING; bearings may be rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine
condition. Do not replace a bearing cone or cup individually without replacing mating cup or cone at
the same time. After inspection, dip bearings in light weight oil and wrap in clean lintless cloth or
paper to protect them until installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation,
scoring, pitting, cracked or chipped races. If any of these defects are found, replace bearings. Also
inspect defective bearing housing and/or shaft for grooved, galled or burred conditions that indicate
bearing has been turning in its housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for
replacement items. Be extremely careful when installing sealing members, to avoid cutting or

General Maintenance Procedures S0302000

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scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite
#120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme
care not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle
and allow leakage.
When replacing lip type seals, make sure spring loaded side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye.
Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all
gears showing cracks or spots where case hardening has worn through. Small nicks may be
removed with suitable hone. Inspect shafts and quills to make certain they have not been sprung,
bent, or splines twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or
worn.
6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves
and dirt. Remove any scratches and burrs with crocus cloth. Remove foreign material. Replace any
parts that are deeply grooved or scratched which would affect their operation.

BEARING INSPECTION
The conditions of the bearing are vital to the smooth and efficient operation of the machinery. When any
component containing bearings is disassembled, always carefully examine the condition of the bearings
and all of its components for wear and damage.
Once the bearing is removed, clean all parts thoroughly using a suitable cleaning solution. If the bearing is
excessively dirty soak the bearing assembly in a light solution and move the bearing around until all
lubricants and or foreign materials are dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be used. Be careful not to direct the air in a
direction which will force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully inspect all bearing rollers, cages and cups for
wear, chipping or nicks. If the bearing cannot be removed and is to be inspected in place, check foe
roughness of rotation, scoring, pitting, cracked or chipped races. If any of these defects are found replace
the whole bearing assembly. NEVER replace the bearing alone without replacing the mating cup or the
cone at the same time.
After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper
and protect them from moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that
indicate that the bearing has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for cracks that are not visible to the naked eye.
The following illustrations will aid in identifying and diagnosing some of the bearing related problems.
NOTE: The illustrations will only show tapered roller bearings, but the principles of identifying,
diagnosing and remedying the defects are common to all styles and types of bearings.

S0302000 General Maintenance Procedures

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Normal Bearing
Smooth even surfaces with no discoloration or
marks.

Figure 2
Bent Cage
Cage damage due to improper handling or tool
usage.
Replace bearing.

Figure 3

Figure 4
Galling
Metal smears on roller ends due to overheat,
lubricant failure or overload.
Replace bearing - check seals and check for
proper lubrication.

Figure 5

General Maintenance Procedures S0302000

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Abrasive Step Wear

Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts
and housings, check seals and bearings and
replace if leaking, rough or noisy.

Figure 6
Etching
Bearing surfaces appear gray or grayish black
in color with related etching away of material
usually at roller spacing.
Replace bearings - check seals and check for
proper lubrication.

Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make
sure races are properly seated.

Figure 8
Indentations
Surface depressions on race and rollers caused
by hard particles of foreign materials.
Clean all parts and housings, check seals and
replace bearings if rough or noisy.

Figure 9

S0302000 General Maintenance Procedures

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Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.

Figure 10
Brinelling
Surface indentations in raceway caused by
rollers either under impact loading or vibration
while the bearing is not rotating.
Replace bearing if rough or noisy.

Figure 11
Cage Wear
Wear around outside diameter of cage and roller
pockets caused by abrasive material and
inefficient lubrication.
Replace bearings - check seals.

Figure 12
Abrasive Roller Wear
Pattern on races and rollers caused by fine
abrasives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or noisy.

Figure 13

General Maintenance Procedures S0302000

Page 11
 Return to Master Table of Contents

Cracked Inner Race

Race cracked due to improper fit, cocking or
poor bearing seat.
Replace all parts and housings, check seals and
bearings and replace if leaking.

Figure 14
Smears
Smearing of metal due to slippage caused by
poor fitting, lubrication, overheating, overloads
or handling damage.
Replace bearings, clean related parts and check
for proper fit and lubrication.
Replace shaft if damaged.

Figure 15
Frettage
Corrosion set up by small relative movement of
parts with no lubrication.
Replace bearing. Clean all related parts. Check
seals and check for proper lubrication.

Figure 16

S0302000 General Maintenance Procedures

Page 12
 Return to Master Table of Contents

Heat Discoloration
Heat discoloration can range from faint yellow to
dark blue resulting from overload or incorrect
lubrication.
Excessive heat can cause softening of races or
rollers.
To check for loss of temper on races or rollers, a
simple file test may be made. A file drawn over a
tempered part will grab and cut metal, whereas
a file drawn over a hard part will glide readily
with no metal cutting.
Figure 17
Replace bearing if over heating damage is
indicated. Check seals and other related parts
for damage.

Stain Discoloration
Discoloration can range from light brown to
black caused by incorrect lubrication or
moisture.
if the stain can be removed by light polishing or
if no evidence of overheating is visible, the
bearing can be reused.
Check seals and other related parts for damage.

Figure 18

General Maintenance Procedures S0302000

Page 13
 Return to Master Table of Contents

S0302000 General Maintenance Procedures

Page 14
 S0309000
R1

1STANDARD TORQUES

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

STANDARD TORQUESS0309000
MODEL SERIAL NUMBER RANGE
ALL MODELS ALL RANGES

Copyright 2002 Daewoo

May 2002

Standard Torques S0309000

Page 1
TABLE OF CONTENTS

Torque Values for Standard Metric Fasteners ................................................ 3

Torque Values for Standard U.S. Fasteners.................................................... 4
Type 8 Phosphate Coated Hardware ............................................................. 6
Torque Values for Hose Clamps ..................................................................... 7
Torque Values for Split Flanges...................................................................... 8
Torque Wrench Extension Tools ..................................................................... 9
Torque Multiplication ............................................................................... 9
Other Uses for Torque Wrench Extension Tools ................................... 10
Tightening Torque Specifications (Metric) ............................................. 10

S0309000 Standard Torques

Page 2
TORQUE VALUES FOR STANDARD METRIC
FASTENERS
NOTE: The units for the torque values are kg•m (ft lb).

Grade
Dia. x
Pitch (mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)

Standard Torques S0309000

Page 3
TORQUE VALUES FOR STANDARD U.S. FASTENERS
S.A.E. BOLT HEAD
TYPE DESCRIPTION
GRADE MARKING

WILL HAVE NO MARKINGS IN THE CENTER OF THE

HEAD.
1 1 OR 2
Low or Medium Carbon Steel Not Heat Treated.

WILL HAVE THREE RADIAL LINES.

5 5
Quenched and Tempered Medium Carbon Steel.

WILL HAVE 6 RADIAL LINES.

8 8
Quenched and Tempered Special Carbon or Alloy Steel.

Recommended torque, in foot pounds, for all Standard Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE-30 engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 when finished jam nuts are used.
0.70 when Molykote, white lead or similar mixtures are used as lubricants.
0.75 when parkerized bolts or nuts are used.
0.85 when cadmium plated bolts or nuts and zinc bolts w/waxed zinc nuts are used.
0.90 when hardened surfaces are used under the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use minimum torque values.

S0309000 Standard Torques

Page 4
The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are
not given

NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED

(WET) THREADS; VALUES SHOULD BE INCREASED 1/3 FOR NON-LUBRICATED
(DRY) THREADS.

HEAT TREATED MATERIAL GRADE 5 AND GRADE 8

GRADE 5 GRADE 8
THREAD SIZE
(3 RADIAL DASHES ON HEAD) (6 RADIAL DASHES ON HEAD)
NEWTON
FOOT POUNDS FOOT POUNDS NEWTON METER
METER
(ft lb) (ft lb) (Nm)
(Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less than what the chart states, it is
recommended that the loose bolt and/or nut be replaced with a new one.

Standard Torques S0309000

Page 5
TYPE 8 PHOSPHATE COATED HARDWARE
This chart provides tightening torque for general purpose applications using original equipment standard
hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases,
original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru
hardened flat washers (Rockwell "C" 38 - 45), all phosphate coated and assembled without supplemental
lubrication (as received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or gray iron.
2. Phosphate coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted
threads or plastic inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine
required torque.

STANDARD TORQUE ±10%

NOMINAL THREAD
DIAMETER
KILOGRAM METER FOOT POUNDS
(kg•m) (ft lb)

1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2 522.8 3780

S0309000 Standard Torques

Page 6
TORQUE VALUES FOR HOSE CLAMPS
The following chart provides the tightening torques for hose clamps used in all rubber applications
(radiator, air cleaner, operating lever boots, hydraulic system, etc.).

TORQUE

RADIATOR, AIR CLEANER,

HYDRAULIC SYSTEM
BOOTS, ETC.
CLAMP TYPE AND SIZE

KILOGRAM KILOGRAM
INCH POUNDS INCH POUNDS
METER METER
(in lb) (in lb)
(kg•m) (kg•m)

"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------

Worm Drive - Under 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50

44 mm (1-3/4 in) Open
Diameter

Worm Drive - Over 44 mm 0.5 - 0.6 40 - 50 ------- ------

(1-3/4 in) Open Diameter

Worm Drive - All "Ultra- 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50

Tite"

Standard Torques S0309000

Page 7
TORQUE VALUES FOR SPLIT FLANGES
The following chart provides the tightening torques for split flange connections used in hydraulic systems.
Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly.
NOTE: Over torquing bolts will damage the flanges and/or bolts, which may cause leakage.

BOLT TORQUE
FLANGE BOLT
SIZE (*) SIZE KILOGRAM METER FOOT POUNDS
(kg•m) (ft lb)

1/2" 5/16" 2.1 - 2.5 15 - 18

3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133

(*) - Inside diameter of flange on end of hydraulic tube or hose fitting.

NOTE: Values stated in chart are for Standard Pressure Series (Code 61) Split Flanges.

S0309000 Standard Torques

Page 8
TORQUE WRENCH EXTENSION TOOLS
Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning
force to achieve recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of the torque wrench.
• Specialized sockets do not fit the adapter on the front end (nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the torque wrench impossible.
• A unique application requires fabrication of an adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one of the proceeding needs or situations, if
the right extension tool is used or fabricated.

TORQUE MULTIPLICATION
A wrench extension tool can be used to
increase the tightening force on a high capacity
nut or bolt.
For example, doubling the distance between the
bolt and the back (handle) end of the torque
wrench doubles the tightening force on the bolt.
It also halves the indicated reading on the scale
or dial of the torque wrench. To accurately
adjust or convert indicated scale or dial
readings, use the following formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench Figure 1
scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque).
A = Length of the torque wrench (between the center of the nut or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque wrench, and the indicated torque on the dial
reads "150 ft lb," the real force applied to the bolt is 300 ft lb:

AxT 12 x 300 3600

I= = = = 150
A+B 12 + 12 24

NOTE: The formula assumes that there is no added deflection or "give" in the joint between the
extension and torque wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly straight (for example, an extension
made to go around an obstruction, to allow access to a difficult to tighten fastener), the
materials and methods used must be solid enough to transmit full tightening torque.

Standard Torques S0309000

Page 9
OTHER USES FOR TORQUE WRENCH EXTENSION TOOLS
Torque wrench extensions are sometimes made up for reasons other than increasing leverage on a
fastener.
For example, a torque wrench and extension can be used to measure adjustment "tightness" of a linkage
or assembly. Specially fabricated extensions can be used to make very precise checks of the force
required to engage or disengage a clutch mechanism, release a spring-applied brake assembly, or "take
up" free play in most any movable linkage.
Once the value of the adjustment force is established, repeated checks at regular intervals can help to
monitor and maintain peak operating efficiency. These types of adjustment checks are especially useful if
physical measurements of linkage travel are difficult to make or will not provide the needed degree of
precision and accuracy.
To allow the assembly or mechanism to accept a torque wrench, welding a nut or other adapter on the end
of a linkage shaft or other leverage point will allow turning the shaft or assembly manually.

TIGHTENING TORQUE SPECIFICATIONS (METRIC)

(For coated threads, prelubricated assemblies.)

CAUTION!
Disassembly, overhaul and replacement of components on the machine, installation of new or
replacement parts and/or other service-related maintenance may require the use of thread or
flange sealing assembly compound.
Use the information on this page as a general guide in selecting specific formulas that will meet
the particular requirements of individual assembly installations. Daewoo does not specifically
endorse a specific manufacturer or brand name but the following table of "Loctite" applications
is included for which cross-references to other makers’ products should also be widely
available.

IMPORTANT
Use primer "T" or "N" for all cold weather assembly of fastener adhesives, with Thread locker
sealers 222, 242/243, 262, 271, 272, or 277.

S0309000 Standard Torques

Page 10
I. "Loctite" Fastener Adhesives

Break-away
Cure Strength
Product Application Color Removal
(in lb) of Sealer
Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
242 or Medium strength for 6 mm (1/4") and
Blue Hand tools 80
243 larger fasteners.
High strength for high grade Heat/260°C (500°F)
262 fasteners subject to shock, stress Red Remove HOT 160
and vibration. (NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.

II. "Loctite" Pipe Thread Sealant

Product Application Color Removal Required Setup

"No-filler/non-clog" formula for high-
4 Hours (or 1/2 hour
pressure hydraulic systems. Over-
545 Purple Hand tools with Locquic "T"
application will not restrict or foul system
Primer)
components.
4 Hours (or 1/2 hour
Solvent-resistant, higher viscosity tapered
656 White Hand tools with Locquic "T"
thread sealer.
Primer)

III. "Loctite" gasket/flange sealer

Product Application Color Notes

Gasket eliminator specifically made for Use Locquic "N" primer for fast
518 aluminum flanges/surfaces. For hydraulic Red (1/2 - 4 hours) setup. Unprimed
systems to 34,475 kPa (5,000 psi). setup 4 - 24 hours.
Low pressure/wide-gap gasket eliminator Use Locquic "N" primer for
504 compound. Fills gaps to 0.0012 mm (0.030"), Orange faster (1/2 - 4 hours) setup.
cures to rigid seal. Unprimed setup 4 - 24 hours.
General purpose, fast setup, flexible-cure Use Locquic "N" primer for
515 gasket eliminator. For non-rigid assemblies Purple faster (1/4 - 2 hours) setup.
subject to shock, vibration or deflection. Unprimed setup 1 - 12 hours.

Standard Torques S0309000

Page 11
IV. "Loctite" retaining compounds

Product Application Color Notes

For bushings, sleeves, press-fit bearings, Use Locquic "N" primer for
609 splines and collars. For gaps to 0.0002 mm Green increased bond strength and all
(0.005"), temperatures to 121°C (250°F). cold temperature applications.
620 For high temperatures to 232°C (450°F). Green Same as 609, above.
For high strength bonds and tight clearance
680 Green Same as 609, above.
gaps, to 0.00008 mm (0.002").

V. "Loctite" Adhesives

Product Application Color Notes

Black Max instant adhesive for shock and May take 120 hours to reach full
380 Black
vibration-resistant bonds. cure strength.
454 Adhesive for porous surfaces. Clear Full strength in 24 hours.
Increased strength (+50%), shock and
480 Black Full strength in 24 hours.
vibration-resistant.

S0309000 Standard Torques

Page 12
1UPPER STRUCTURE
 S0403040K

1COUNTERWEIGHT

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

COUNTERWEIGHT S0403040K
MODEL SERIAL NUMBER RANGE
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Counterweight S0403040K
Page 1
TABLE OF CONTENTS

Specifications ................................................................................................. 3
Counterweight ................................................................................................ 3

S0403040K Counterweight
Page 2
SPECIFICATIONS
NOTE: Weight

Mega 500-V 1,920 kg (4,233 lb)

COUNTERWEIGHT

AHS3700L
Figure 1
NOTE: 1) 110 kg•m (796 ft lb)

Counterweight S0403040K
Page 3
S0403040K Counterweight
Page 4
 S0405500

1FUEL TRANSFER PUMP

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

FUEL TRANSFER PUMPS0405500

MODEL SERIAL NUMBER RANGE
Mega 130 0001 and Up
Mega 160 0001 and Up
Mega 200-III 1001 and Up
Mega 200-V 1001 and Up
Mega 250-III 1001 and Up
Mega 250-V 1001 and Up
Mega 300-V 1001 and Up
Mega 400-III PLUS 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Solar 170LC-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 220LC-V 0001 and Up
Solar 220LL 1001 and Up
Solar 220N-V 1001 and Up

Models continued on back of cover.

Copyright 2002 Daewoo

June 2002

Fuel Transfer Pump S0405500

Page 1
 MODEL SERIAL NUMBER RANGE
Solar 250LC-V 1001 and Up
Solar 290LC-V 0001 and Up
Solar 290LL 1001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 1001 and Up
Solar 330LC-V 1001 and Up
Solar 340LC-V 1001 and Up
Solar 400LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up

TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Troubleshooting .............................................................................................. 4
Replacement of Rotor and Vane .................................................................... 4
Replacement of Rear Cover ........................................................................... 5
Replacement of Armature .............................................................................. 6

S0405500 Fuel Transfer Pump

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION

Figure 1

Reference Reference
Description Description
Number Number
1 Motor 3 Inlet Hose
2 Pump 4 Outlet Hose
2-1 Pump Cover 5 Check Valve
2-2 Rotor and Vane 6 Strainer Cap

Fuel pump consists of motor, pump, switch and

hose assembly.

Figure 2

Fuel Transfer Pump S0405500

Page 3
TROUBLESHOOTING
On some pumps the ON-OFF switch is installed separately at a remote location.
A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it
from damage.
NOTE: OPEN TEMP: 150 ±5°C (302 ±41°F). After circuit is automatically shut off due to
overheating the pump will stop running. When temperature drops below 143°C (289°F) the
circuit will reactivate allowing the pump to restart.

Figure 3 WITH TOGGLE SWITCH Figure 4 WITHOUT TOGGLE SWITCH

Check resistance at connectors "A." If reading is zero, or very close to zero, the motor is bad and must be
replaced.
On units equipped with a toggle switch, check the resistance through the toggle switch, while the switch is
in the "ON" position. If continuity is not present, the switch is bad. Be sure to check resistance through the
motor.

REPLACEMENT OF ROTOR AND VANE

If dirt or other foreign materials enter pump
during operation, it can become lodged between
the rotor and/or vanes and generate heat which
can cause pump damage.
Remove the pump cover and check the rotor
and vane. If any pump parts or components
become lost, damaged or inoperable,
immediately replace them with a new ones.

Figure 5 WITHOUT TOGGLE SWITCH

S0405500 Fuel Transfer Pump

Page 4
Insert vane, with the circled edge of vane facing
in the counterclockwise direction. (Detail A)
Insert O-ring again at reassembly of pump
cover.

Figure 6

REPLACEMENT OF
REAR COVER
Brush assembly and a thermal limiter are
installed in the rear cover. If you find any
damage, replace them with new ones.
Remove the switch cover and screw (M5 x L95)
from the rear cover.
Remove cover.
At reassembly of rear cover, widen the space of
brush and insert it to the armature. Then fit the Figure 7
hole of screw in the housing.
Be careful when installing screw. The cover
screw may be attracted by the motor magnet.

Fuel Transfer Pump S0405500

Page 5
REPLACEMENT OF
ARMATURE
You can replace only the armature in case motor
was damaged by a short circuit.
Remove the switch cover and rear cover, than
remove the armature from the housing.
Remove the pump cover and remove the rotor
and vane.
Insert a new armature into the housing.
Figure 8
Refer to “Replacement of Rear Cover” on page
5, for installation of rear cover.
Fit the rotor in the shaft flute of armature. Insert
vane to the rotor being careful for the direction.
Refer to “Replacement of Rotor and Vane” on
page 4.

S0405500 Fuel Transfer Pump

Page 6
 S0406040K

1HYDRAULIC OIL TANK

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

HYDRAULIC OIL TANKS0406040K

MODEL SERIAL NUMBER RANGE
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Hydraulic Oil Tank S0406040K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Parts List ................................................................................................. 3
Specifications .......................................................................................... 4

S0406040K Hydraulic Oil Tank

Page 2
GENERAL DESCRIPTION
PARTS LIST

SECTION A

SECTION B

AHS3710L
Figure 1

Reference Reference
Description Description
Number Number
1 Return Filter 5 Air Breather
2 By-pass Valve 6 Level Gauge
3 Spring 7 Drain Plug
4 Suction Filter

Hydraulic Oil Tank S0406040K

Page 3
SPECIFICATIONS

Mega 500-V
Type Pressurized Sealing
Capacity (System) 300 liters
(79 U.S. gal.)
Air breather
Open Pressure 0.40 kg/cm2
(5.7 psi)
Vacuum pressure 0.035 kg/cm2 @ 900 l/min.
(0.5 psi @ 238 gpm)
Return Filter
Filtration rating 10 µ
Pressure drop 0.2 kg/cm2 @ 600 l/min.
(3 psi @ 159 gpm)
Suction Filter 177 µ

S0406040K Hydraulic Oil Tank

Page 4
1LOWER STRUCTURE AND CHASSIS
 S0502020K

1CENTER JOINT
(ARTICULATION JOINT)

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

CENTER JOINT (ARTICULATION JOINT)S0502020K

MODEL SERIAL NUMBER RANGE
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Center Joint (Articulation Joint) S0502020K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Maintenance Standard ............................................................................ 4

S0502020K Center Joint (Articulation Joint)

Page 2
GENERAL DESCRIPTION
The loader frame is an articulated type: the front frame is joined to the rear frame with two hinge pins
around which the loader pivots for steering.

CAUTION!
When the loader is steered, the area near
the center hinge pins becomes so narrow
that you might get caught between the
front and rear frames. Before trying to
service the loader, make sure to set the
frame lock plate.
Prior to moving (traveling) the loader,
make sure the frame lock plate is set to
the original position. Figure 1

Center Joint (Articulation Joint) S0502020K

Page 3
MAINTENANCE STANDARD

11 2 1
18 7 9 3
6
13
15

13
14

12
4
8 5 16 17

UPPER HINGE LOWER HINGE

AHS3730L

Figure 2

S0502020K Center Joint (Articulation Joint)

Page 4
 Unit: mm
No. Check item Criteria Remedy
Clearance between lower Standard Tolerance Standard Clearance
hinge pin and rear frame. size clearance limit
1
100 -0.030 +0.071 0.030 - -
-0.076 +0.036 0.130
2 Clearance between lower 100 -0.030 +0.060 0.060 - -
hinge pin and spacer -0.076 +0.030 0.136
(small).
3 Clearance between lower 100 -0.030 0 0.015 - -
hinge pin and bearing. -0.076 -0.015 0.076
4 Clearance between lower 100 -0.030 +0.060 0.060 - -
hinge pin and spacer -0.076 +0.030 0.136
(large).
5 Clearance between rear 115 -0.036 +0.071 0.072 - -
frame and spacer (large). -0.090 +0.036 0.161
Replace
6 Clearance between front 180 0 -0.048 -0.023 - -
frame and upper hinge -0.025 -0.088 -0.088
bearing.
7 Clearance between upper 100 -0.030 +0.054 0.030 - -
hinge pin and rear frame. -0.076 0 0.130
8 Clearance between upper 100 -0.030 0 0.015 - -
hinge pin and bearing. -0.076 -0.015 0.076
9 Clearance between front 180 0 -0.048 -0.023 - -
frame and upper hinge -0.025 -0.088 -0.088
bearing.
11 Height of lower hinge 42 - - 0 0
spacer (small).
12 Height of lower hinge 81.5 - - 0 0
spacer (large).
13 Shim thickness for lower 0.8 - 1.14 - - - -
hinge and retainer (front
frame).
14 Shim thickness for lower 2.99 - 3.5 - - - -
hinge and retainer (rear
frame).
Tightening torque of upper When adjusting with shim: 8±0.2 kg•m
15 hinge retainer mounting
bolt. Final value: 30±1.0 kg•m
Tightening torque of upper When adjusting with shim: 8±0.2 kg•m
16 hinge retainer mounting Final value: 30±1.0 kg•m Retight-
bolt. en
17 Tightening torque of upper 13±1.0 kg•m
hinge pin mounting bolt.
18 Tightening torque of lower 30±1.0 kg•m
hinge pin mounting bolt.

Center Joint (Articulation Joint) S0502020K

Page 5
S0502020K Center Joint (Articulation Joint)
Page 6
1ENGINE AND DRIVE TRAIN
 S0602170K

1AXLE
(ZF AP-420R)

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

AXLE (ZF AP-420R) S0602170K

MODEL SERIAL NUMBER RANGE
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Axle (ZF AP-420R) S0602170K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 5
AP 407 - 420 ........................................................................................... 5
Specifications .......................................................................................... 5
Torque Limits for Screws ......................................................................... 6
Torque Limits for Screws (In Nm) According to ZF-Standards 148 .. 6
Torque Limits for Locking Screws (In Nm)........................................ 7
Torque Limits for Locking Screws with Locked Toothing (In Nm). .... 7
Lubrication Instructions ........................................................................... 8
Type of Lubrication........................................................................... 8
Oil Level ........................................................................................... 8
Oil Level Check ................................................................................ 8
Oil Change Intervals (Generally)...................................................... 8
Brake................................................................................................ 8
Point of Grease Lubrication ............................................................. 8
List of Lubricants TE-ML 05 .................................................................... 9
Examples of Gear-tooth-contact Patterns
for the Gleason Gear-tooth System ...................................................... 11
Special Tools ................................................................................................ 15
Final Drive ............................................................................................. 16
AP - 407 / 409 ................................................................................ 16
AP - 411 / 415 ................................................................................ 18
AP - 417 / 420 ................................................................................ 20
Differential (Version - Screwed Bearing Caps)...................................... 22
Differential Carrier "CK" ................................................................. 22
Differential Carrier "RK" ................................................................. 24
Differential Carrier "DK" ................................................................. 26
Differential (Version - Cast-on Bearing Caps) ....................................... 28
Differential Carrier "DK" ................................................................. 28
Differential Carrier "HK" ................................................................. 30
Differential (Version - Cast-on and Screwed Bearing Caps) ................. 32
Differential Carrier "LK".................................................................. 32

S0602170K Axle (ZF AP-420R)

Page 2
 Planetary Rigid Axle AP 407 - 420 Disassembly ......................................... 34
Final Drive ............................................................................................. 34
Differential Disassembly (Version - Screwed Bearing Caps)........................ 40
Differential ............................................................................................. 42
Drive Unit .............................................................................................. 43
Differential Disassembly (Version - Cast-on Bearing Caps) ......................... 46
Differential ............................................................................................. 47
Drive Unit .............................................................................................. 50
Differential Disassembly (Version - Screwed and Cast-on Bearing Caps) ... 52
Differential ............................................................................................. 54
Drive Unit .............................................................................................. 55
Final Drive Reassembly ............................................................................... 58
Hub Carrier ........................................................................................... 58
Check Rolling Resistance of Wheel Bearing ................................. 60
Hub........................................................................................................ 61
Complete Internal Gear Carrier ..................................................... 62
Internal Gear Carrier ............................................................................. 64
Adjusting Plate Clearance According To Table .............................. 67
Determine Sun-gear Shaft Play ..................................................... 70
Illustrated Table ..................................................................................... 73
Differential Reassembly (Version - Screwed Bearing Caps) ........................ 74
Determine Thickness of Shim ............................................................... 74
Adjust Rolling Resistance of Drive Pinion Bearing................................ 78
Differential ............................................................................................. 81
Determine Plate Clearance............................................................ 84
Adjustment of Bearing Preload and Backlash................................ 86
Illustrated Table ..................................................................................... 89
Differential Reassembly (Version - Cast-on Bearing Caps).......................... 90
Determine Thickness of Shim ............................................................... 90
Adjustment of Drive Pinion Bearing Rolling Resistance........................ 94
Differential ............................................................................................. 97
Determination of Plate Clearance ................................................ 100
Adjustment of Bearing Preload and Backlash.............................. 102

Axle (ZF AP-420R) S0602170K

Page 3
 Illustrated Table ................................................................................... 105
Differential Reassembly (Version - Screwed and Cast-on Bearing Caps).. 106
Determine Thickness of Shim ............................................................. 106
Adjustment of Drive Pinion Bearing Rolling Resistance...................... 108
Differential ........................................................................................... 112
Determination of Plate Clearance ................................................ 115
Adjustment of Bearing Preload and Backlash.............................. 117
Illustrated Table ................................................................................... 120

S0602170K Axle (ZF AP-420R)

Page 4
GENERAL DESCRIPTION
AP 407 - 420

Figure 1

SPECIFICATIONS

Specifications Mega 500-V Front Axle Mega 500-V Rear Axle

Maker ZF ZF
Model AP420R AP420R
Type Fully floating planetary drive Fully floating planetary drive
Drive Unit Limited Slip Differential Limited slip differential
Final Drive Planetary gear train Planetary gear train
Overall Reduction Ratio 27:1 27:1
Axle Load 14,900 kg 14,000 kg
(Travel Condition) (32,850 lb) (30,860 lb)
Axle Load 27,000 kg 10,500 kg
(Working Condition) (59,520 lb) (23,150 lb)
- Wet disc - Wet disc
Brake Type - Multidisk brake with hydraulic - Multidisk brake with hydraulic
control control
3,960 kg @ 50 kg/cm2 3,960 kg @ 50 kg/cm2
Brake Torque
(8,730 lb @ 711 psi) (8,730 lb @ 711 psi)
Steering Angle 40° 40°
Differential Carrier Version Screwed Bearing Caps - Differential Carrier Type "RK"

Axle (ZF AP-420R) S0602170K

Page 5
TORQUE LIMITS FOR SCREWS

Torque Limits for Screws (In Nm) According to ZF-Standards 148

Coefficient of friction: m total 0.12 for screws and nuts without after treatment and for phosphated
nuts.
NOTE: Tighten by hand.
Torque limits, if not especially indicated, can be taken from the following list:

Metric ISO-Standard Thread Metric ISO-Fine Thread

DIN 13, (See page 60) DIN 13, (See page 60)
Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2.8 4.1 4.8 M8x1 24.5 36 43
M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14.0 16.5 M 10 x 1 52 76 89
M7 15.5 23.0 27.0 M 10 x 1, 25 49 72 84
M8 23 34 4. M 12 x 1, 25 87 125 150
M 10 46 68 79 M 12 x 1, 5 83 122 145
M 12 79 117 135 M 14 x 1, 5 135 200 235
M 14 125 185 215 M 16 x 1, 5 205 300 360
M 16 195 280 330 M 18 x 1, 5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490
M 20 390 560 650 M 20 x 1, 5 430 620 720
M 22 530 750 880 M 22 x 1, 5 580 820 960
M 24 670 960 1,120 M 24 x 1, 5 760 1,090 1,270
M 27 1,000 1,400 1,650 M 24 x 2 730 1,040 1,220
M 30 1,350 1,900 2,250 M 27 x 1, 5 1,110 1,580 1,850
M 33 1,850 2,600 3,000 M 27 x 2 1,070 1,500 1,800
M 36 2,350 3,300 3,900 M 30 x1, 5 1,540 2,190 2,560
M 39 3,000 4,300 5,100 M 30 x 2 1,490 2,120 2,480
M 33 x 1, 5 2,050 2,920 3,420
M 33 x 2 2,000 2,800 3,300
M 36 x 1, 5 2,680 3,820 4,470
M 36 x 3 2,500 3,500 4,100
M 39 x 1, 5 3,430 4,890 5,720
M 39 x 3 3,200 4,600 5,300

S0602170K Axle (ZF AP-420R)

Page 6
Torque Limits for Locking Screws (In Nm).

Metric ISO-Standard Thread Metric ISO-Fine Thread

DIN 13, (See page 60) DIN 13, (See page 60)
Size 10.8 12.9 Size 10.8 12.9
M5 7.8 10.8 M8x1 34 47
M6 13.2 18.2 M 10 x 1 68 94
M7 22.0 30.0 M 10 x 1, 25 65 89
M8 32 44 M 12 x 1, 25 118 163
M 10 61 84 M 12 x 1, 5 113 155
M 12 108 148 M 14 x 1, 5 185 254
M 14 169 233 M 16 x 1, 5 280 385
M 16 263 362 M 18 x 1, 5 405 556
M 18 358 493 M 20 x 2 536 737
M 20 508 698

Torque Limits for Locking Screws with Locked Toothing (In Nm).

Metric ISO-Standard Thread Metric ISO-Fine Thread

DIN 13, (See page 60) DIN 13, (See page 60)
Size 12.9 Size 12.9
M5 10.5 M8x1 46
M6 17.5 M 10 x 1, 25 86
M8 42.0 M 10 x 1 91
M 10 81 M 12 x 1, 5 150
M 12 140 M 12 x 1, 25 155
M 14 225 M 14 x 1, 5 245
M 16 350 M 16 x 1, 5 375
M 18 470 M 18 x 2 500
M 20 680 M 18 x 1, 5 530
M 20 x 2 710
M 20 x 1, 5 750

Axle (ZF AP-420R) S0602170K

Page 7
LUBRICATION INSTRUCTIONS
Valid for ZF Axles with and without ZF-Locking differential.
The basis for a correct lubrication of all axles and their parts is a horizontal plane of installation in
every direction. (An inclined position of the differential carrier up to 5° is tolerable). In case of
variations, ZF must be asked for advice.
Place the vehicle in a horizontal position. All lubricating points must b cleaned carefully before
refilling.
Drain oil only immediately after a longer run.

Type of Lubrication
See “List of Lubricants TE-ML 05” on page 9.

Oil Level
Wheel end: Turn wheel hubs until the word "Oil level" can be read in a horizontal position. Fill up oil to
the overflow on the level plug.
Axle housing: Fill up oil, to the overflow on the level plug or the oil filler opening resp., installed in the
center.
Differential carrier, not installed in a ZF - Axle: Fill up oil 20 mm (0.7874 in) below the middle of the
crown wheel.

Oil Level Check

After a few minutes, if oil level has dropped fill up to the correct level until level remains constant. Oil
level check monthly. Especially before you start a vehicle with new or repaired axles or their
components resp.

Oil Change Intervals (Generally)

1st oil change after 500 operating hours. Further oil changes must be made every 1,000 operating
hours, or at least once a year.

Brake
For the pneumatic - hydraulic or memory controlled brake actuation are admitted.
Motor oils SAE 10W according to specifications MIL-L-2104 C, MIL-L-46152, API-CC, CD, SC, SD,
SE, SF.
ATF-Oils (Type A / Suffix A, Dexron IID).
NOTE: Other brake fluids may be not used.

Point of Grease Lubrication

At greasing points, use a multipurpose grease with following properties: Lithium soap, drop point 170
C, NLGI Class 2.
The grease must be anti-corrosive, water-resistant and walk stable.
Re-grease all pressure grease fittings monthly.

S0602170K Axle (ZF AP-420R)

Page 8
LIST OF LUBRICANTS TE-ML 05
NOTE: Axles for cars, commercial vehicles and off-road vehicles.

Axles Approved Lubricants

Axles and axle-center reduction gears. Gear oils with or without limited-slip additives.
Wheel hubs and half-shafts. API GL-5
Axle differentials. MIL-L 2105 D
SAE 80 W-90
SAE 85 W--90
SAE 85 W-140
SAE 90
For commercial products see A12 and A13
Axles and axle-center reduction gears with multidisc Gear oils with or without limited-slip additives.
limited-slip differentials.
API GL-5
MIL-L 2105 D
SAE 80 W-90
SAE 85 W-90
SAE 85 W-140
SAE 90
For commercial products see A12 and A13
Axles and axle-center reduction gears with wet Gear oils with limited-slip additives.
multidisc brakes.
API GL-5
MIL-L 2105 D
SAE 80 W-90
SAE 85 W-90
SAE 85 W-140
SAE 90

When using multigrade gear oils, the base oil must not contain more than 2% by weight of dissolved
additives (VI improver, pour point depressant etc.) in addition to EP additives.
At greasing points, use a multipurpose grease with the following properties:
Lithium soap, drop point above 170°C (338°F), NLGI Class 2.
The grease must be anti-corrosive, water-resistant and walk stable.
Note to lubricant suppliers: Please inform ZF immediately of any changes to the composition of trade
names of approved products, and of differences between Germany and other countries.

Axle (ZF AP-420R) S0602170K

Page 9
 IMPORTANT
Check correct torque limit of all screwed joints within regular intervals. (First check after 50
operating hours). Axle with ZF-multidisk self-locking differentials: a slight noise could be noted,
when oil without limited slip additives have been filled in. This noise can be regarded as
harmless. In case of heavy noise or when the tire is jerking, use EP-gear lubricants with Limited-
Slip additives. You will find the corresponding products on the list of lubricants TE-ML-05 for the
above mentioned units.

S0602170K Axle (ZF AP-420R)

Page 10
EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS
FOR THE GLEASON GEAR-TOOTH SYSTEM
Ideals Tooth-contact Pattern I.E. Pinion Distance Is Correct
Coast side (concave).

Figure 2
Drive side (convex).

Figure 3
Pinion Distance must be increased.

Figure 4

Axle (ZF AP-420R) S0602170K

Page 11
Pinion distance must be decreased.

Figure 5

Figure 6

Figure 7

Figure 8

S0602170K Axle (ZF AP-420R)

Page 12
 Figure 9

S0602170K Axle (ZF AP-420R)

Page 13
S0602170K Axle (ZF AP-420R)
Page 14
SPECIAL TOOLS
The following illustrations show special tools required to service the axle assembly.
Many of these tools are common tools used by most service personnel.
It is advised that the service person review these illustrations and make their determination of what is
required in their particular case.
All tools are listed throughout the text of the manual with an; (S), Name of the tool, and a ZF part number.
All tools are available through ZF.

Axle (ZF AP-420R) S0602170K

Page 15
FINAL DRIVE

AP - 407 / 409

Figure 10

S0602170K Axle (ZF AP-420R)

Page 16
 Disassembly Reassembly Subject-No. Denomination /Application Special Tool (S)
Figure 18 5370 350 000 Assembly car compl. with tilting device
5870 350 055 Support
Figure 21 5870 970 003 Two-leg puller
Figure 134,
Figure 24 5870 900 010 Clamping pliers
Figure 142
Figure 27,
5870 400 001 Adjustment device
Figure 33
Figure 111,
Figure 28 5870 401 084 Hook spanner
Figure 125
Figure 28 Figure 111 5870 912 012 Centering bracket
Figure 30,
Figure 123 5870 375 036 Pry bar (set of 2)
Figure 35
Figure 30 Figure 110 5870 281 033 Lifting bracket
Figure 31 5870 281 016 Expanding claw
Figure 32 Figure 123 5870 281 034 Spring hook
Figure 34 5870 028 006 Grab sleeve "super"
Figure 34 5870 028 010 Grab sleeve "super"
Figure 103 5870 204 026 Adjusting screw Ml8 (set of 2)
Figure 104 5870 610 001 Wheel stud puller - Basic set
5870 610 002 Insert M22 x 1.5
Figure 105 5870 050 004 Driver
Figure 105 5870 050 010 Driver
5870 260 004 Driver
Figure 110,
Figure 115, 5870 651 048 Installer M90 x 1.5
Figure 125
Figure 112 5870 230 007 Spring scale O - 200 N
Figure 114 5870 051 025 Driver
5870 260 004 Driver
Figure 114 5870 051 026 Driver (AP-9)
Figure 119 5870 651 042 Installer inner ∅ 260 mm (10.2362 in)
Figure 121 5870 654 018 Clamping plate
5870 970 006 Two-leg puller
Figure 150 5870 287 007 HP-Pump

Axle (ZF AP-420R) S0602170K

Page 17
AP - 411 / 415

Figure 11

S0602170K Axle (ZF AP-420R)

Page 18
 Disassembly Reassembly Subject-No. Denomination /Application Special Tool (S)
Figure 18 5870 350 000 Assembly car compl. with tilting device
5870 350 008 Support
Figure 21 5870 970 004 Two-leg puller
Figure 134,
Figure 24 5870 900 010 Clamping pliers
Figure 142
Figure 27,
5870 400 001 Adjustment device
Figure 33
Figure 111,
Figure 28 5870 401 097 Hook spanner
Figure 125
5870 912 Ol2 Centering bracket
Figure 30,
5870 345 036 Pry bar (set of 2)
Figure 35
Figure 30 Figure 110 5870 281 033 Lifting bracket
Figure 31 5870 281 016 Expanding claw
Figure 32 Figure 123 5870 281 034 Spring hook
Figure 34 5870 028 007 Grab sleeve "super"
Figure 103 5870 204 044 Adjusting screw M20 x 1.5 (set of 2)
Figure 104 5870 610 001 Wheel stud puller - Basic set
5870 610 002 Insert M22 x 1.5
Figure 105 5870 050 004 Driver
5870 260 004 Driver
Figure 105 5870 050 011 Driver
5870 260 004 Driver
Figure 110,
Figure 115, 5870 651 049 Installer M110 x 1.5
Figure 125
Figure 112 5870 230 007 Spring scale O - 200 N
Figure 114 5870 051 023 Driver
5870 260 004 Driver
Figure 119 5870 651 042 Installer ∅ 260 mm (10.2362 in)
5870 651 043 Installer ∅ 315 mm (12.4016 in)
Figure 121 5870 654 Ol8 Clamping plate
5870 970 006 Two-leg puller
Figure 150 5870 287 007 HP-Pump

Axle (ZF AP-420R) S0602170K

Page 19
AP - 417 / 420

Figure 12

S0602170K Axle (ZF AP-420R)

Page 20
 Disassembly Reassembly Subject-No. Denomination /Application Special Tool (S)
Figure 18 5870 350 000 Assembly car compl. with tilting device
5870 350 053 Support
Figure 21 5870 080 030 Cross bracket
5870 027 032 Cover and spindle
5870 080 031 Puller hook # 2 pieces needed
Figure 134,
Figure 24 5870 900 024 Clamping pliers
Figure 142
Figure 27 5870 400 001 Adjustment device 2 Pieces needed
Figure 111,
Figure 28 5870 401 098 Hook spanner
Figure 125
5870 912 012 Centering bracket
Figure 28 Figure 111 5870 401 106 Hook spanner
5870 912 012 Centering bracket
Figure 28 Figure 111 5870 401 097 Hook spanner AP 417
Figure 30,
5870 345 036 Pry bar (set of 2)
Figure 35
Figure 30 Figure 110 5870 281 033 Lifting bracket
Figure 31 5870 281 016 Expanding claw
Figure 32 Figure 123 5870 281 034 Spring hook
Figure 34 5870 028 008 Grab sleeve "super"
Figure 34 5870 028 011 Grab sleeve "super"
Figure 103 5870 204 045 Adjusting screw M24 (set of 2)
Figure 104 5870 610 001 Wheel stud puller - Basic set
5870 610 002 Basic set M22 x 1.5
Figure 105 5870 050 011 Driver
5870 260 004 Driver
Figure 110,
Figure 115, 5870 651 041 Installer M130 x 1.5
Figure 125
Figure 110,
Figure 115, 5870 651 049 Installer M110 x 1.5
Figure 125
Figure 112 5870 230 007 Spring scale O - 200 N
Figure 114 5870 051 023 Driver
5870 260 004 Driver
Figure 119 5870 651 042 Installer ∅ 260 mm (10.2362 in)
5870 651 043 Installer ∅ 315 mm (12.4016 in)
Figure 121 5870 654 018 Clamping plate
5870 970 006 Two-leg puller
Figure 150 5870 287 007 HP-Pump

Axle (ZF AP-420R) S0602170K

Page 21
DIFFERENTIAL (VERSION - SCREWED BEARING CAPS)

Differential Carrier "CK"

Figure 13

S0602170K Axle (ZF AP-420R)

Page 22
 Disassembly Reassembly Subject-No. Denomination /Application Special Tool (S)
Figure 39 5870 240 016 Back-off screws M18 (set of 2)
Figure 41 5870 900 010 Clamping pliers
Figure 42 Figure 194 5870 204 022 Adjusting screws M14 (set of 2)
Figure 43 5870 350 000 Assembly car compl. with tilting device
5870 350 004 Support
5870 350 005 Insert "BK/CK"
Figure 44 5870 345 036 Pry bar (set of 2)
Figure 47 5870 026 001 Grab sleeve "Super"
5870 506 058 Pressure piece
5870 026 100 Back-off insert
Figure 47 5870 027 025 Grab sleeve "Super"
5870 506 058 Pressure piece
5870 027 000 Basic set
Figure 164,
Figure 53 Figure 166, 5870 240 025 Clamping yoke
Figure 169
Figure 58 5870 027 004 Grab sleeve "Super"
Figure 154 5870 500 001 Measuring shaft
5870 500 028 Adjusting piece
5870 351 016 Measuring pin
5870 351 010 Stop washer
5870 351 011 Spacer
Figure 168 5870 048 118 Driver
Figure 187 5870 200 055 Magnetic base
Figure 189 5870 200 057 Dial indicator
Figure 192 5870 900 023 Wire pincers

Axle (ZF AP-420R) S0602170K

Page 23
Differential Carrier "RK"

Figure 14

S0602170K Axle (ZF AP-420R)

Page 24
 Disassembly Reassembly Subject-No. Denomination /Application Special Tool (S)
Figure 39 5870 204 016 Back-off screws M18 (set of 2)
Figure 39 5870 204 019 Back-off screws M20 (set of 2)
Figure 41 5870 900 010 Clamping pliers
Figure 42 Figure 194 5870 204 022 Adjusting screws M14 (set of 2)
Figure 43 5870 350 000 Assembly car compl. with tilting device
5870 350 004 Support
Figure 44 5870 345 036 Pry bar (set of 2)
Figure 46 5870 281 013 Grip tongs
Figure 47 5870 029 003 Grab sleeve "Super"
5870 029 014 Reduction
5870 027 000 Basic set
Figure 47 5870 287 002 HP-Pump
5870 287 008 Hydro-cylinder LZM 25/200
5870 285 018 Sleeve M110 x 3 / M68 x 2
5870 285 015 Bayonet catch M125 x 3
Figure 164,
Figure 53 Figure 166, 5870 240 025 Clamping yoke
Figure 169
Figure 58 5870 029 008 Grab sleeve "Super"
5870 285 017 Pressing ring M125 x 3
Figure 154 5870 500 001 Measuring shaft
5870 500 008 Adjusting piece (set of 2)
5870 351 016 Measuring pin
5870 351 014 Stop washer
5870 351 015 Spacer
Figure 158 5870 050 007 Driver
5870 260 004 Driver
Figure 160 5870 340 009 Measuring ring
Figure 168 5870 048 089 Driver
Figure 185 5870 281 013 Grip tongs
Figure 187 5870 200 055 Magnetic base
Figure 189 5870 200 057 Dial indicator
Figure 192 5870 900 023 Wire pincers

Axle (ZF AP-420R) S0602170K

Page 25
Differential Carrier "DK"

S0602170K Axle (ZF AP-420R)

Page 26
 Disassembly Reassembly Subject-No. Denomination /Application Special Tool (S)
Figure 39 5870 204 016 Back-off screws M18 (set of 2)
Figure 42 5870 204 022 Adjusting screws M14 (set of 2)
Figure 41 5870 900 010 Clamping pliers
Figure 43 5870 350 000 Assembly car compl. with tilting device
5870 350 004 Support
5870 350 006 Insert D-DK-DST
Figure 44 5870 345 036 Pry bar (set of 2)
Figure 46 5870 281 013 Grip tongs
Figure 47 5870 026 001 Grab sleeve "Super"
5870 506 058 Pressure piece
5870 026 100 Back-off insert
Figure 47 5870 027 025 Grab sleeve "Super"
5870 506 058 Pressure piece
5870 027 000 Basic set
Figure 164,
Figure 53 Figure 166, 5870 240 025 Clamping yoke
Figure 169
Figure 58 5870 027 004 Grab sleeve "Super"
5870 027 000 Basic set
Figure 154 5870 500 001 Measuring shaft
5870 500 028 Adjusting piece (set of 2)
5870 351 016 Measuring pin
5870 351 012 Stop washer
Figure 160 5870 340 001 Measuring ring
Figure 168 5870 048 118 Driver
Figure 185 5870 281 013 Grip tongs
Figure 187 5870 200 055 Magnetic base
Figure 189 5870 200 057 Dial indicator
Figure 192 5870 900 023 Wire pincers
Figure 194 5870 204 021 Adjusting screws M12 (set of 2)

Axle (ZF AP-420R) S0602170K

Page 27
DIFFERENTIAL (VERSION - CAST-ON BEARING CAPS)

Differential Carrier "DK"

Figure 15

S0602170K Axle (ZF AP-420R)

Page 28
 Disassembly Reassembly Subject-No. Denomination /Application Special Tool (S)
Figure 60 5870 204 016 Back-off screws M18 (set of 2)
Figure 63 5870 900 010 Clamping pliers
Figure 64 5870 204 012 Back-off screws M12 (set of 2)
Figure 64 5870 350 000 Assembly car compl. with tilting device
5870 350 006 Support
Figure 69 5870 027 029 Grab sleeve "Super" 33 281
Figure 69 5870 027 030 Grab sleeve "Super" JM 714 249
5870 027 000 Basic set
Figure 70 5870 345 036 Pry bar (set of 2)
Figure 76 Figure 208, 5870 240 025
Clamping yoke
Figure 212
Figure 81 5870 027 021 Grab sleeve "Super" 31 313
Figure 198 5870 500 001 Measuring shaft
5870 500 006 Adjusting piece (set of 2)
5870 351 016 Measuring pin
5870 351 013 Stop washer
Figure 202 5870 058 060 Drive
Figure 204 5870 340 001 Measuring ring
Figure 211 5870 048 118 Driver
Figure 234 5870 200 055 Magnetic base
Figure 235 5870 200 057 Dial indicator
Figure 239 5870 057 025 Driver
Figure 240 5870 204 021 Adjusting screws M14 (set of 2)
5870 260 002 Handle

Axle (ZF AP-420R) S0602170K

Page 29
Differential Carrier "HK"

Figure 16

S0602170K Axle (ZF AP-420R)

Page 30
 Disassembly Reassembly Subject-No. Denomination /Application Special Tool (S)
Figure 60 5870 204 016 Back-off screws M18 (set of 2)
Figure 63 5870 900 010 Clamping pliers
Figure 64 5870 204 030 Back-off screws M14 (set of 3)
Figure 64 5870 350 000 Assembly car compl. with tilting device
5870 350 007 Support
Figure 69 5870 027 027 Grab sleeve "Super" 27 695
Figure 69 5870 027 028 Grab sleeve "Super" 47 686
5870 027 000 Basic set
Figure 70 5870 345 036 Pry bar (set of 2)
Figure 208,
Figure 76 5870 240 025 Clamping yoke
Figure 212
Figure 198 5870 500 001 Measuring shaft
5870 500 007 Adjusting piece (set of 2)
5870 351 016 Measuring pin
5870 351 018 Stop washer
Figure 208,
Figure 76 5870 401 093 Hook spanner
Figure 212
Figure 81 5870 027 021 Grab sleeve "Super" JW 7049
Figure 204 5870 340 026 Measuring ring
Figure 211 5870 048 089 Driver
Figure 211 5870 048 118 Driver
Figure 232,
5870 200 055 Magnetic base
Figure 235
5870 200 057 Dial indicator
Figure 239 5870 057 025 Driver
Figure 240 5870 204 021 Adjusting screws M14 (set of 2)
Figure 240 5870 204 022 Adjusting screws M16 (set of 2)
5870 260 002 Handle

Axle (ZF AP-420R) S0602170K

Page 31
DIFFERENTIAL (VERSION - CAST-ON AND SCREWED BEARING CAPS)

Differential Carrier "LK"

Figure 17

S0602170K Axle (ZF AP-420R)

Page 32
 Disassembly Reassembly Subject-No. Denomination /Application Special Tool (S)
Figure 82 5870 204 016 Back-off screws M18 (set of 2)
Figure 84 5870 900 010 Clamping pliers
Figure 85 5870 204 023 Adjusting screws M16 (set of 2)
Figure 86 5870 350 000 Assembly car compl. with tilting device
5870 350 004 Support
Figure 88 5870 345 036 Pry bar (set of 2)
Figure 90 5870 281 013 Grip tongs
Figure 91 5870 027 010 Grab sleeve "Super"
5870 027 000 Basic set
Figure 91 5870 027 031 Grab sleeve "Super"
5870 027 000 Basic set
Figure 96 Figure 254, 5870 240 025 Clamping yoke
Figure 256,
Figure 259
Figure 96 Figure 254, 5870 401 093 Hook spanner
Figure 256,
Figure 259
5870 912 015 Centering disk
Figure 101 5870 027 023 Grab sleeve "Super"
5870 027 000 Basic set
Figure 244 5870 500 001 Measuring shaft
5870 500 030 Adjusting piece (set of 2)
5870 500 022 Adjusting piece (set of 2)
5870 351 016 Measuring pin
5870 351 019 Stop washer
Figure 248 5870 051 012 Driver
5870 260 004 Handle
Figure 250 5870 340 026 Measuring ring
Figure 258 5870 048 089 Driver
Figure 278 5870 281 013 Grip tongs
Figure 281, 5870 200 055 Magnetic base
Figure 283
5870 200 057 Dial indicator
Figure 287 5870 057 025 Driver
5870 260 002 Handle

Axle (ZF AP-420R) S0602170K

Page 33
PLANETARY RIGID AXLE AP 407 - 420 DISASSEMBLY
Figure 18, shows the total view of the axle.
NOTE: See “Special Tools” on page 15.

Figure 18
FINAL DRIVE
1. Remove oil drain plug and drain oil.

Figure 19
2. Remove hex. head screws and lift off the
planetary carrier.

Figure 20

S0602170K Axle (ZF AP-420R)

Page 34
3. Squeeze out retaining ring and pull off the
planetary gears.
4. Remove thrust washer.
NOTE: See “Special Tools” on page 15.

Figure 21
5. Pull sun gear along with inner plate carrier
from the stab shaft, resp. out of the plate
pack.

Figure 22
6. Remove locking screws and remove ring
from the inner plate carrier.

Figure 23
7. Squeeze out retaining ring.
NOTE: See “Special Tools” on page 15.

Figure 24

Axle (ZF AP-420R) S0602170K

Page 35
8. Remove backing plate and plate pack.

Figure 25
9. Remove thrust washer.

Figure 26
10. Remove lock plate.
NOTE: See “Special Tools” on page 15.

Figure 27
11. Loosen and remove slotted nut.
NOTE: See “Special Tools” on page 15.

Figure 28

S0602170K Axle (ZF AP-420R)

Page 36
12. Pull stub shaft out of the axle housing.

Figure 29
13. Separate complete hub from hub carrier.
NOTE: See “Special Tools” on page 15.

Figure 30
14. Lift internal gear and internal gear carrier
out of the hub.
15. Remove released spacer.
NOTE: See “Special Tools” on page 15.

Figure 31
16. Unhook return springs.
NOTE: See “Special Tools” on page 15.

Figure 32

Axle (ZF AP-420R) S0602170K

Page 37
17. Take out the piston and remove sealing
components.
NOTE: See “Special Tools” on page 15.

Figure 33
18. Pull off tapered roller bearing from the
internal gear carrier.
NOTE: See “Special Tools” on page 15.

Figure 34
19. Pry shaft seal out of the hub and remove
the inner bearing race.
NOTE: See “Special Tools” on page 15.

Figure 35
20. If required drive out and remove the two
outer bearing races.

Figure 36

S0602170K Axle (ZF AP-420R)

Page 38
21. Remove bleeder valve.

Figure 37
22. Remove hex. head screws and separate
the hub carrier from the axle housing.

Figure 38

Axle (ZF AP-420R) S0602170K

Page 39
DIFFERENTIAL DISASSEMBLY (VERSION - SCREWED
BEARING CAPS)
NOTE: Remove the two stub shafts
before separate the differential
carrier from the axle housings.
See Figure 39 - Figure 41.
1. Drain oil from the final drive and the axle
housing.
2. Remove hex. head screws and separate
planetary carrier from the hubs using eye
hook.
NOTE: See “Special Tools” on page 15.

Figure 39
3. Pull inner plate carrier (along with sun
gear) from the stub shaft.

Figure 40
4. Pull stub shaft out of the axle housing.
Squeeze out retaining ring and remove the
plate pack.
NOTE: This step is necessary to make
the later installation of the inner
plate carrier possible.
NOTE: See “Special Tools” on page 15.

Figure 41

S0602170K Axle (ZF AP-420R)

Page 40
5. Remove hex. head screws and separate
the differential carrier from the axle
housing.
NOTE: See “Special Tools” on page 15.

Figure 42
6. Fasten the differential carrier in the
assembly jig.
7. Remove lock wire and drive roll pins out.
NOTE: See “Special Tools” on page 15.

Figure 43
8. Loosen adjusting nuts.
NOTE: See “Special Tools” on page 15.

Figure 44
9. Remove hex. head screws and remove the
two bearing caps.
NOTE: Match mark bearing caps with
housings, see Arrow.

Figure 45

Axle (ZF AP-420R) S0602170K

Page 41
10. Remove adjusting nuts.
11. Remove differential assembly from the
axle carrier.
NOTE: See “Special Tools” on page 15.

Figure 46
DIFFERENTIAL
1. Pull the two inner bearing races of the
tapered roller bearing from the differential
case halves.
NOTE: See “Special Tools” on page 15.

Figure 47
2. Match mark housing cover with differential.
3. Clamp the differential case halves, remove
the locking screws.

Figure 48
4. Back off the cover.
NOTE: Pay attention to the released
thrust washer.

Figure 49

S0602170K Axle (ZF AP-420R)

Page 42
5. Take all components of the multidisk self
locking differential out of the differential
case.

Figure 50
6. Press crown wheel from the differential
case.

Figure 51
DRIVE UNIT
1. Unlock slotted nut or hex. head screw
(according to the Version) and remove lock
plate.

Figure 52
2. Loosen slotted nut or hex. nut (according
to the Version) and remove it along with
washer.
NOTE: See “Special Tools” on page 15.

Figure 53

Axle (ZF AP-420R) S0602170K

Page 43
3. Pull off the drive flange.

Figure 54
4. Pry out the shaft seal.

Figure 55
5. Press drive pinion out of the axle carrier.
NOTE: Pay attention to the released
tapered roller bearing.

Figure 56
6. Remove spacer from the drive pinion end.

Figure 57

S0602170K Axle (ZF AP-420R)

Page 44
7. Press tapered roller bearing from the drive
pinion, using grab sleeve (see Arrow).
NOTE: See “Special Tools” on page 15.

Figure 58
8. If necessary, drive the two outer bearing
races out of the axle carrier bores.

Figure 59

Axle (ZF AP-420R) S0602170K

Page 45
DIFFERENTIAL DISASSEMBLY (VERSION - CAST-ON
BEARING CAPS)
NOTE: Remove the two stub shafts
before separate the differential
carrier from the axle housing,
see Figure 60 - Figure 63.
1. Drain oil from the final drive and the axle
housing.
2. Remove hex. head screws and separate
planetary carrier from the hubs, using eye
bolt.
NOTE: See “Special Tools” on page 15.

Figure 60
3. Pull inner plate carrier (along with sun
gear) from the stub shaft.

Figure 61
4. Pull stub shaft out of the axle housing.

Figure 62

S0602170K Axle (ZF AP-420R)

Page 46
5. Squeeze out retaining ring and remove
plate pack.
NOTE: This step is necessary to allow
the later installation of the inner
plate carrier.
NOTE: See “Special Tools” on page 15.

Figure 63
6. Remove hex. head screws and separate
differential carrier from the axle housing,
using back-off screws.
NOTE: See “Special Tools” on page 15.

Figure 64
DIFFERENTIAL
1. Fasten the differential carrier in the
assembly jig.
2. Drive out the roll pin on the crown wheel
side.
NOTE: See “Special Tools” on page 15.

Figure 65
3. Loosen and remove adjusting nut.

Figure 66

Axle (ZF AP-420R) S0602170K

Page 47
4. Lift differential and remove outer bearing
race.

Figure 67
5. Tilt axle carrier 180°.
6. Drive out roll pin (opposite the crown
wheel side), remove adjusting nut and
outer bearing race (See Figure 68).

Figure 68
7. Pull off inner bearing race from the
housing cover, resp. differential case.
NOTE: See “Special Tools” on page 15.

Figure 69
8. Match mark housing cover with differential
case.
9. Remove locking screws.
NOTE: See “Special Tools” on page 15.

Figure 70

S0602170K Axle (ZF AP-420R)

Page 48
10. Separate housing cover from differential
case and pull it out of the axle carrier.

Figure 71
11. Lift differential carrier out of the axle
carrier.

Figure 72
12. Take all components of the multidisk self-
locking differential out of the differential
case.

Figure 73
13. Clamp the differential housing.
14. Remove locking screws and separate the
crown wheel from the differential case.

Figure 74

Axle (ZF AP-420R) S0602170K

Page 49
DRIVE UNIT
1. Unlock slotted nut or hex. nut (according to
the Version) and remove lock plate.

Figure 75
2. Loosen slotted nut or hex. nut (according
to the Version) and remove it along with
washer.
NOTE: See “Special Tools” on page 15.

Figure 76
3. Pull off drive flange.

Figure 77
4. Pry out shaft seal.

Figure 78

S0602170K Axle (ZF AP-420R)

Page 50
5. Drive the drive pinion out of the axle
carrier.
NOTE: Pay attention to the released
tapered roller bearing. If
necessary drive the two outer
bearing races out of the axle
carrier bores.

Figure 79
6. Pull spacer from the drive pinion end.

Figure 80
7. Press tapered roller bearing from drive
pinion using grab sleeved (See Arrow).
NOTE: See “Special Tools” on page 15.

Figure 81

Axle (ZF AP-420R) S0602170K

Page 51
DIFFERENTIAL DISASSEMBLY (VERSION - SCREWED
AND CAST-ON BEARING CAPS)
NOTE: Remove the two stub shafts
before separate the differential
carrier from the axle housing,
see Figure 82 - Figure 84.
1. Drain oil from the final drive and the axle
housing.
2. Remove hex. head screws and separate
planetary carrier from the hub, using eye
bolt.
NOTE: See “Special Tools” on page 15.

Figure 82
3. Pull inner plate carrier along with the sun
gear from the stub shaft.

Figure 83
4. Pull stub shaft out of the axle housings
squeeze out retaining ring and remove the
plate pack.
NOTE: This step is necessary to allow
the later installation of the inner
plate carrier.
NOTE: See “Special Tools” on page 15.

Figure 84

S0602170K Axle (ZF AP-420R)

Page 52
5. Remove hex. head screws and separate
the differential carrier from the axle
housing.
NOTE: See “Special Tools” on page 15.

Figure 85
6. Fasten differential carrier in the assembly
jig.
7. Drive out the roll pin.
NOTE: See “Special Tools” on page 15.

Figure 86
8. Remove lock wire and lock plate.

Figure 87
9. Loosen and remove the two adjusting
nuts.
NOTE: See “Special Tools” on page 15.

Figure 88

Axle (ZF AP-420R) S0602170K

Page 53
10. Remove hex. head screws and remove
bearing caps.

Figure 89
11. Lift the differential assembly out of the axle
carrier.
NOTE: Pay attention to the released
outer bearing races.
NOTE: See “Special Tools” on page 15.

Figure 90
DIFFERENTIAL
1. Pull off the two inner bearing races from
the housing cover, resp. differential case.
NOTE: See “Special Tools” on page 15.

Figure 91
2. Match mark housing cover with differential
case.
3. Remove locking screws.

Figure 92

S0602170K Axle (ZF AP-420R)

Page 54
4. Take all components of the multidisk self-
locking differential out of the differential
case.

Figure 93
5. Clamp the differential case half.
6. Remove locking screws and separate the
crown wheel from the differential case.

Figure 94
DRIVE UNIT
1. Unlock slotted nut and remove lock plate.

Figure 95
2. Loosen slotted nut or hex. nut (according
to the Version) and remove it along with
washer.
NOTE: See “Special Tools” on page 15.

Figure 96

Axle (ZF AP-420R) S0602170K

Page 55
3. Pull off drive flange.

Figure 97
4. Pry out shaft seal.

Figure 98
5. Press drive flange out of the axle carrier.
NOTE: Pay attention to the released
tapered roller bearing.

Figure 99
6. Pull spacer from the drive pinion end.

Figure 100

S0602170K Axle (ZF AP-420R)

Page 56
7. Separate the tapered roller bearing from
the drive pinion.
NOTE: See “Special Tools” on page 15.

Figure 101
8. If necessary, drive the two outer bearing
races out of the axle carrier.

Figure 102

Axle (ZF AP-420R) S0602170K

Page 57
FINAL DRIVE REASSEMBLY
HUB CARRIER
1. Fasten hub carrier on the axle housing
using hex. head screws.
NOTE: See “Torque Limits for Screws”
on page 6.
NOTE: See “Special Tools” on page 15.

CAUTION!
Pay attention to the installation
position. Figure 103

Cover flange-mounted surface with

sealing compound.

2. Pull the wheel studs into the hub bores,

using a special device.
NOTE: See “Special Tools” on page 15.

Figure 104
3. Drive both outer bearing races firmly
against shoulder.
NOTE: See “Special Tools” on page 15.

Figure 105

S0602170K Axle (ZF AP-420R)

Page 58
4. Guide the inner bearing race over the end
of the hub carrier until contact is obtained.

Figure 106
5. Guide hub over the end of the hub carrier.

Figure 107
6. Heat inner bearing race and place it firmly
against shoulder.

Figure 108
7. Assemble spacer s = 5.4 mm (0.2126 in)
(empirical value).
NOTE: If hub carriers hub and internal
gear carrier are not replaced we
recommend to install the
existing spacer again. Decisive,
however, is the rolling
resistance of the wheel bearing,
See Figure 112.

Figure 109

Axle (ZF AP-420R) S0602170K

Page 59
8. Screw installer (S) over the threads of the
hub carrier.
9. Guide complete internal gear over the hub
carrier splines and fix the hub.
NOTE: See “Special Tools” on page 15.

Figure 110
10. Tighten slotted nut while continuously
turning of the hub.
NOTE: Torque limit:
AP-407/409 = 800 - 1000 Nm
(590 - 740 ft lb)
AP-411/415 = 1370 - 7570 Nm
(1,010 - 5,585 ft lb)
AP-417/420 = 2000 - 2200 Nm
(1,475 - 1,620 ft lb)
NOTE: See “Special Tools” on page 15.

Figure 111
Check Rolling Resistance of Wheel Bearing
T = F x R, from that result: Tractive Force
T
F = ---
R

T = Rolling resistance in Nm (Newton

meter)
F = Tractive Force in N (Newton)
R = Radius in m (meter)
NOTE: See “Special Tools” on page 15.
1. Nominal value / Bearing rolling moment.
NOTE: AP - 407/409/411/415 = 11 - 18 Figure 112
Nm (8.1 - 13.3 ft lb)
AP - 417/420 = 14 - 20 Nm
(10.3 - 14.7 ft lb)
NOTE: For already run-in bearings try
to find the lower value.
NOTE: If the required rolling resistance
is not obtained, correct using a
corresponding spacer, see
Figure 109.
NOTE: After adjustment of the wheel
bearing remove hub again.

S0602170K Axle (ZF AP-420R)

Page 60
HUB
1. Insert inner bearing race into the hub.

Figure 113
2. Cover outside of shaft seal with Loctite
#578 and drive it in.
NOTE: Installation depth 7.0 - 7.8 mm
(0.2756 - 0.3071 in) is
determined by the special tool.
If necessary, (according to the
Version) heat cover plate before
assemble the hub and install it.
NOTE: See “Special Tools” on page 15.

Figure 114
3. Carefully guide hub over the hub carrier
end against shoulder.
NOTE: See “Special Tools” on page 15.

Figure 115

Axle (ZF AP-420R) S0602170K

Page 61
Complete Internal Gear Carrier
1. Figure 116, shows the installation position
of the backup sealing elements.

Reference
Description
Number
1 Backup Ring
2 Packing Ring
3 U-section Ring

Figure 116
2. Clean the piston with mineral spirits. Stick
on support ribbons at two points using
Loctite #496.
3. The support ribbons must adhere exactly
around the whole circumference. Remove
any sticking residues.

Figure 117
4. Install packing rings (2) and U-section
lings (3).
NOTE: Pay attention to the installation
position, see Figure 116.

Figure 118

S0602170K Axle (ZF AP-420R)

Page 62
5. Insert piston into the installer (S).
NOTE: Lubricate sealing and backup
elements, (Use W-10 oil).
NOTE: See “Special Tools” on page 15.

Figure 119
6. Insert piston with installer into the internal
gear carrier.
NOTE: Pay attention to the radial
installation position, (openings
for return springs).
With installed condition, the
support ribbon openings must
face upwards.

Figure 120
7. Press piston carefully against shoulder,
using clamping plate (S) and two-leg puller
(S).
NOTE: See “Special Tools” on page 15.

Figure 121
8. Engage return springs (with lug facing
outwards) on the retaining ring and
assemble it in the internal gear carrier.
NOTE: Pay attention to the radial
installation position of the
retaining ring (see Arrow).

Figure 122

Axle (ZF AP-420R) S0602170K

Page 63
9. Insert 2nd retaining ring and engage
return springs.
NOTE: Pay attention to the radial
installation position of the
retaining ring.
NOTE: See “Special Tools” on page 15.

Figure 123
10. Insert O-ring into the groove of the internal
gear carrier and grease it slightly.
11. Mark the location of the oil supply holes on
the face, (see Arrow).

Figure 124
INTERNAL GEAR CARRIER
1. Screw installer (S) over the threads of the
hub carrier.
2. Assemble the spacer determined in Figure
109.
NOTE: See “Special Tools” on page 15.

Figure 125
3. Guide O-ring over the hub carrier and
insert it into the groove.
4. Mark the radial location of the oil supply
bores on the face (see Arrows).

Figure 126

S0602170K Axle (ZF AP-420R)

Page 64
5. Guide the complete internal gear over the
splines of the hub carrier. At the same time
pay attention to the overlapping of the oil
holes (hub carrier, internal gear carrier),
(see Arrows).
NOTE: During these steps it is
absolutely necessary to respect
the centric location of the hub to
make a correct reassembly of
the internal gear - internal gear
carrier possible, and to avoid a
damage of the two O-rings.
Figure 127
6. Tighten slotted nut while continuously
turning of the hub.
NOTE: Torque limit:
AP-407/409 = 800 - 1,000 Nm
(590 - 740 ft lb)
AP-411/415 = 1,300 - 1,500 Nm
(960 - 1,105 ft lb)
AP-417/420 = 2,000 - 2,200 Nm
(1,475 - 1,620 ft lb)
NOTE: See “Special Tools” on page 15.

Figure 128
7. Install lock plate and secure slotted nut.

Figure 129
8. Assemble stub shaft until contact is
obtained.

Figure 130

Axle (ZF AP-420R) S0602170K

Page 65
9. Attach oil seal to inner plate carrier.
NOTE: Torque limit:
AP 407 - 420 = 50 Nm (37 ft lb)

Figure 131
10. Install thrust washer.

Figure 132
11. Guide the inner plate carriers (along with
the sun gear) on the stub shaft splines.

Figure 133

S0602170K Axle (ZF AP-420R)

Page 66
Adjusting Plate Clearance According To Table

Plate clearance - piston stroke in

Number of inner plate Number of friction faces
mm in.
2 4 1.6 - 2.0 0.0630 -0.0787
3 6 2.4 - 2.8 0.0945 - 0.1102
4 8 3.2 - 3.6 0.1260 - 0.1417
5 10 4.0 - 4.4 0.1575 - 0.1732

1. Determine piston stroke (Nominal value

2.4 - 2.8 mm) (0.0945 - 0.1102 in).
2. Squeeze in retaining ring and place it
against shoulder towards the outside.
3. Determine dimension A from the flange-
mounted surface / hub to the plane surface
/ piston.
• Dimension A e.g. 121.50 mm (4.7835
in).
NOTE: Pay attention to the correct
location of the piston against
the internal gear carrier. Figure 134

NOTE: See “Special Tools” on page 15.

4. Measure dimension B from the flange-
mounted surface/hub to the inner plane
surface of the retaining ring.
• Dimension B e.g. 75.20 mm (2.9606
in).

Figure 135
5. Outer plate: 4 x 4.5 mm (0.1575 x 0.1772
in).
• Dimension C e.g. 18.00 mm (0.7087
in).

Figure 136

Axle (ZF AP-420R) S0602170K

Page 67
6. Inner plate: 3 x 4.5 mm (0.1181 x 0.1772
in).
• Dimension D e.g. 13.50 mm (0.5315
in).

Figure 137
7. Dimension E = Backing plate.
• Dimension E e.g. 12.00 mm (0.4724
in).

Figure 138

EXAMPLE
Dimension A 121.50 mm (4.7835 in)
Dimension B - 75.20 mm (2.9606 in)
Dimension C - 18.00 mm (0.7080 in)
Dimension D - 13.50 mm (0.5315 in)
Dimension E - 12.00 mm (0.4724 in)
Difference = Plate clearance = 2.80 mm (0.1102 in)

NOTE: If the required plate clearance according the table, (See page 67) is not obtained, correct
with corresponding outer plates. If necessary, mount thinner outer plates on the piston
side, resp. backing plate side.

S0602170K Axle (ZF AP-420R)

Page 68
8. Install alternating outer and Inner plates
(starting with one outer plate).

Figure 139
9. Figure 140, shows the required
arrangement of the outer plates.

Figure 140
10. Insert backing plate - stepped plane
surface is facing outwards.

Figure 141
11. Hold plate pack into position using
retaining ring.
NOTE: See “Special Tools” on page 15.

Figure 142

Axle (ZF AP-420R) S0602170K

Page 69
12. Heat planetary gear and place it on the
planetary carrier.
NOTE: Pay attention to the installation
position, large radius of the
inner bearing race must be
facing the planetary carrier
(downwards).

Figure 143
13. Squeeze in retaining ring.

Figure 144
Determine Sun-gear Shaft Play
Normal value 0. 3 - 0.6 mm (0.0118 - 0.0236 in),
try to fine the higher value.
1. Place sun gear and plate carrier against
shoulder.
• Dimension A e.g. 6.00 mm (0.2362
in).

Figure 145
2. Determine dimension B from the flange-
mounted surface to the thrust washer.
• Dimension B e.g. 5.50 mm (0.2165
in).
NOTE: For the measurement, lay
thrust washer into the planetary
carrier.

Figure 146

S0602170K Axle (ZF AP-420R)

Page 70
 EXAMPLE

Dimension A 6.00 mm (0.2362 in)

Dimension B - 5.50 mm (0.2165 in)
Required end play of the sun-gear shaft = 0.50 mm (0.0197 in)

NOTE: Remove thrust washer again and make it adhere with Loctite #270.
3. Insert new O-ring into the ring groove of
the planetary carrier (Arrow).

Figure 147
4. Assemble planetary carrier until contact is
obtained.

Figure 148
5. Tighten hex. head screws.
NOTE: See “Torque Limits for Screws”
on page 6.

Figure 149

Axle (ZF AP-420R) S0602170K

Page 71
6. Check tightness of the brake hydraulic
system

CAUTION!
Bleed the brake.
After having applied the brake for
about 10 times carry out the
following pressure test.
Using a suitable pressure apparatus
(Lukas or similar) with stopcock Figure 150
build up an actuating pressure of 120
bar.
Close the stopcock and pressurize
the brake for 5 minutes with this
pressure. After this timer the
pressure may have dropped to 117
bar (1,700 psi) only.

A. Afterwards, build up a pressure of 5

bar (70 psi) and close the stopcock.
B. Within 5 minutes there may be no
pressure break.
C. Install bleeder valve.
NOTE: See “Special Tools” on page 15.
D. Tighten oil drain plug.
NOTE: Torque limit 50 Nm (37 ft lb).
NOTE: Before the Axle is put into
service, follow the “Lubrication
Instructions” on page 8

Figure 151

S0602170K Axle (ZF AP-420R)

Page 72
ILLUSTRATED TABLE

Figure 152

Axle (ZF AP-420R) S0602170K

Page 73
DIFFERENTIAL REASSEMBLY (VERSION - SCREWED
BEARING CAPS)
NOTE: If crown wheel or drive pinion are damaged, the two parts must be replaced as a set. If a
new complete crown wheel set is installed, pay attention that crown wheel and drive pinion
have the same mating numbers.
NOTE: When replacing a complete crown wheel set or axle carrier, pay attention to the Figure
153.

DETERMINE THICKNESS OF SHIM

NOTE: The following measuring operations must be carried out with utmost care. Inexact
measurements would cause an incorrect contact pattern and require replacement of the
drive pinion and the differential (partial) after the contact pattern has been taken. See
“Examples of Gear-tooth-contact Patterns for the Gleason Gear-tooth System” on page
11.
1. Install adjusting pieces (3) and temporarily
fasten the two bearing caps Install stop
washer (2) and measuring pin (1) and
introduce measuring shaft (4). (See Figure
153.)
CK-Drive

Reference
Description
Number
1 Measuring Pin
2 Stop Washer
3 Adjusting Piece
4 Measuring Shaft

Figure 153

S0602170K Axle (ZF AP-420R)

Page 74
2. Determine gap (Dimension b) between
measuring pin and measuring shaft with
feeler gauge.
• Dimension b e.g. 0.70 mm (0.0276
in).
NOTE: See “Special Tools” on page 15.

Figure 154

EXAMPLE I

Dimension a (measuring piston) 166.80 mm (6.5669 in)

Dimension b + 0.70 mm (0.0276 in)
Dimension C (1/2 ∅ measuring shaft) + 15.00 mm (0.5906 in)
Gives Dimension "X" = 182.50 mm (7.1850 in)

3. Measure bearing width.

• Bearing width e.g. 33.50 mm (1.3189
in).

Figure 155

Axle (ZF AP-420R) S0602170K

Page 75
4. Read pinion dimension.
• Pinion dimension e.g. 147.80 mm
(5.8189 in).
5. Now, remove bearing caps, shims,
measuring shaft and measuring pin again.

Figure 156
EXAMPLE II

Bearing width 33.50 mm (1.3189 in)

Pinion dimension + 147.80 mm (5.8189 in)
Gives Dimension "X" 1 = 181.30 mm (7.1378 in)

EXAMPLE III

Dimension "X" 182.50 mm (7.1457 in)

Dimension "X" 1 - 182.30 mm (7.1772 in)
Difference = Shim thickness s= 1.20 mm (0.0472 in)

6. Lay shim (s = 1.20 mm (0.0472 in)) into the

housing bore.

Figure 157
7. Freeze outer bearing race and press it
firmly against shoulder.
8. Install the drive flange side outer bearing
race correspondingly.
NOTE: See “Special Tools” on page 15.

Figure 158

S0602170K Axle (ZF AP-420R)

Page 76
9. Heat inner bearing race, guide it over the
drive pinion end until contact is obtained.
NOTE: Pay attention to a correct
contact, reset after the cooling.

Figure 159

Axle (ZF AP-420R) S0602170K

Page 77
ADJUST ROLLING RESISTANCE OF DRIVE
PINION BEARING
Nominal Value

DK / CK 1.1 - 2.3 Nm
(9.7 - 20.3 in lb)
HK 1.5 - 3.0 Nm
(13.2 - 17.7 in lb)
LK / RK 3.0 - 4.5 Nm
(17.7 - 39.8 in lb)

1. Lay measuring ring over the drive pinion

collar. Figure 160
NOTE: Configuration and description of
the measuring ring, See Figure 161.
NOTE: See “Special Tools” on page 15.

Figure 161

S0602170K Axle (ZF AP-420R)

Page 78
2. If necessary (according to the version),
install hex. head screws into the drive
flange bores and press the dust shield on
the collar of the drive flange.

Figure 162
3. Insert the drive pinion into the axle carrier
and assemble the heated inner bearing
race until contact is obtained.

Figure 163
4. Guide drive flange over the drive pinion
splines.
5. Install washer and tighten slotted nut until
the required rolling resistance is obtained.
NOTE: When tightening, make several
full revolutions of the drive
pinion in both directions, and
check the rolling resistance
continuously.
NOTE: See “Special Tools” on page 15.
6. Remove slotted nut, pull off drive flange
and remove the pinion again. Figure 164

Axle (ZF AP-420R) S0602170K

Page 79
7. Take off measuring ring and determine
dimension "X" see Figure 161.
• Dimension "X" e.g. s = 8.55 mm
(0.3366 in).
NOTE: Dimension "X" corresponds to
the thickness of the spacer to
be installed.
NOTE: Lay spacer (e.g. s = 8.55 mm
(0.3366 in)) instead of the
measuring ring over the drive
pinion end. Install drive pinion
again. Figure 165
8. Replace drive flange, install washer and
tighten slotted nut
NOTE: Torque limit:
RK 1,100 Nm (810 ft lb)
LK 1,200 Nm (885 ft lb)
CK 700 Nm (515 ft lb)
NOTE: When tightening, mate several
full revolutions of the drive
pinion in both directions.

Figure 166
9. Check rolling resistance
NOTE: If the required rolling resistance
is not obtained correct again
with one corresponding spacer.

Figure 167

S0602170K Axle (ZF AP-420R)

Page 80
10. Remove the drive flange and install the
shaft seal.

CAUTION!
Pay attention to the contact.
If the shaft seal outer diameter is
lubber-coated, the sealing face must
be wetted with mineral spirits.
Otherwise use sealing compound
Loctite #586. Figure 168
Fill cavity between sealing lip and
dust lip with grease.

NOTE: See “Special Tools” on page 15.

11. Replace drive flange, assemble washer
and tighten slotted nut, resp. hex. nut
(according to the Version) finally.
NOTE: Torque limit:
RK 1,100 Nm (810 ft lb)
LK 1,200 Nm (885 ft lb)
CK 700 Nm (515 ft lb)
NOTE: The securing of the slotted nuts
resp. hex. nut (according to the
Version) is carried out after the
contact pattern is taken.
NOTE: See “Special Tools” on page 15. Figure 169

DIFFERENTIAL
1. Heat the crown wheel, center and
temporarily fasten it into position.

Figure 170

Axle (ZF AP-420R) S0602170K

Page 81
2. Insert the two thrust washers into the
differential case half.
NOTE: Mount the brass washer on top
with the lubricating groove
facing the side gear.

Figure 171
3. Insert retaining ring and install drive pin.

Figure 172
4. Assemble alternating outer and inner
plates, starting with one outer plate.
NOTE: Number and installation
position of the outer and inner
plates, see corresponding
spare parts list (according tO
the Version). The total height
(thickness) of the plate pack
must be equal on both
differential sides. Plate
thickness of outer plates may
be different.
Figure 173
5. Mount pressure ring.

Figure 174

S0602170K Axle (ZF AP-420R)

Page 82
6. Insert side gear and assemble inner plates
at the same time.

Figure 175
7. Insert the complete differential spider.

Figure 176
8. Install the second side gear.
NOTE: Pay attention to the radial
installation position of the
pressure ring.

Figure 177
9. Install the second pressure ring and insert
all drive pins.
NOTE: Pay attention to the radial
installation position of the
pressure ring.

Figure 178

Axle (ZF AP-420R) S0602170K

Page 83
10. Assemble alternating inner and outer
plates, starting with one inner plate.
NOTE: Number and installation
position of the inner and outer
plates, see corresponding list of
spare parts (according to the
Version).

Figure 179
Determine Plate Clearance
1. Differential case
Measure dimension A from the flange-
mounted surface to the outer plate.
• Dimension A e.g. 3.40 mm (0.1339
in).

Figure 180
2. Housing cover
Determine dimension B from the contact
face (outer plate) to the flange-mounted
surface.
• Dimension B e.g. 3.10 mm (0.1220
in).
NOTE: The proscribed end play (=
plate clearance) is 0.2 - 0.8 mm
(0.0079 - 0.0315 in), whilst the
lower value should be found.
The end play is corrected by
installing outer plates of Figure 181
corresponding thickness, whilst
the plate thickness must be
equal on both differential sides.
EXAMPLE
Dimension A 3.40 mm (0.1339 in)
Dimension B - 3.10 mm (0.1220 in)
Difference = Plate clearance = 0.30 mm (0.0118 in)

S0602170K Axle (ZF AP-420R)

Page 84
 A. Make the two thrust washers adhere
with grease in the housing cover.
NOTE: Mount the brass washer on top
with the lubricating groove
facing the side gear.

Figure 182
B. Fasten the housing cover using
locking screws.
NOTE: Pay attention to the installation
position see Figure 182. Only
use of the locking screws one
time. Do not reuse them.
NOTE: See “Torque Limits for Screws”
on page 6.

Figure 183
C. Heat the two inner bearing races and
place them against shoulder.

Figure 184
D. Install the two outer bearing races
and insert the differential assembly
into the housing.
E. Secure the differential using the
adjusting nuts.
NOTE: See “Special Tools” on page 15.

Figure 185

Axle (ZF AP-420R) S0602170K

Page 85
 F. Install the two bearing caps and
tighten them using hex. head screws.
NOTE: Pay attention to the match
marks, see Figure 186.
NOTE: See “Torque Limits for Screws”
on page 6.

Figure 186
Adjustment of Bearing Preload and
Backlash
1. Attach dial indicator right angled on the
outer diameter of the tooth flank / crown
wheel. Adjust the adjusting nut on the
crown wheel side until the required
backlash - see value engraved on the
crown wheel outer diameter - is obtained.
NOTE: See “Special Tools” on page 15.

Figure 187
2. Screw in the adjusting nut (opposite the
crown wheel side) until the differential
bearing is free of play. Now, tighten
adjusting nut further for 2 notches to obtain
the required bearing preload of the
differential bearing 3 - 4 Nm (26.5 - 35.4 in
lb).
3. Check backlash again and correct if
necessary.
NOTE: At this step make several full
revolutions of the differential.
NOTE: Determine yoke width e.g. "CK" Figure 188
258 +0.1 mm (10.1575 +
0.0039 in).

S0602170K Axle (ZF AP-420R)

Page 86
4. Attach dial indicator on the plane face /
crown wheel, make at least one revolution
of the crown wheel and record the run-out.
NOTE: Admitted run-out max. 0.08 mm
(0.0031 in).
NOTE: See “Special Tools” on page 15.

Figure 189
5. Check contact pattern on the crown wheel.
A. Cover some tooth flanks of the crown
wheel with gear marking compound.
B. Roll the crown wheel over the drive
pinion back and forth.
C. Check the contact pattern and
compare it with “Examples of Gear-
tooth-contact Patterns for the
Gleason Gear-tooth System” on
page 11.

Figure 190
D. In case of a greater contact pattern
deviation a spacing error has been
made during the reassembly of the
drive pinion which must be corrected.
E. Lock the two adjusting nuts using roll
pins, resp. cotter pins (according to
the version).

Figure 191
F. Secure hex. head screws of the
bearing cap fastening against getting
loose using lock wire (ø 1.6 mm
(0.0630 in)).
NOTE: See “Special Tools” on page 15.

Figure 192

Axle (ZF AP-420R) S0602170K

Page 87
 G. Tilt differential carrier.
H. Insert lock plate firmly against
shoulder and caulk it on the drive
flange, using a suitable tool.

Figure 193
I. Cover flange-mounted surface with
sealing compound Loctite #573.
J. Screw in two adjusting screws and
place the differential carrier against
the axle housing until contact is
obtained.
NOTE: See “Special Tools” on page 15.

Figure 194
K. Fasten differential carrier on the axle
housing using hex. head screws.
NOTE: Cover hex. head screws with
sealing compound Loctite #573.
NOTE: See “Torque Limits for Screws”
on page 6.
NOTE: Now, install the stub shafts
again and complete the final
drive.
NOTE: Before the axle is put into
service, follow the “Lubrication
Instructions” on page 8. Figure 195

S0602170K Axle (ZF AP-420R)

Page 88
ILLUSTRATED TABLE

Figure 196

Axle (ZF AP-420R) S0602170K

Page 89
DIFFERENTIAL REASSEMBLY (VERSION - CAST-ON
BEARING CAPS)
NOTE: If crown wheel or drive pinion are damaged, the two parts must be replaced as a set. If a
new complete crown wheel set is installed, pay attention that crown wheel and drive pinion
have the same mating numbers.
NOTE: When replacing a complete crown wheel set or axle carrier, pay attention to the Figure
197.

DETERMINE THICKNESS OF SHIM

NOTE: The following measuring operations must be carried out with utmost care. Inexact
measurements would cause an incorrect contact pattern and require a replacement of the
drive pinion and the differential (partial) after the contact pattern has been taken. See
“Examples of Gear-tooth-contact Patterns for the Gleason Gear-tooth System” on page
11.
1. Install adjusting pieces (3) and temporarily
fasten the two bearing caps. Install thrust
washer (2) and measuring pin (1) and
introduce measuring shaft (7), see Figure
197.
NOTE: See “Special Tools” on page 15.

Figure 197

S0602170K Axle (ZF AP-420R)

Page 90
2. Determine gap (Dimension b) between
measuring pin and measuring shaft with
feeler gauge.
• Dimension b e.g. 0.70 mm (0.0276
in).

Figure 198
EXAMPLE I

Dimension a (=measuring pin) 226.00 mm (8.8976 in)

Dimension b + 0.70 mm (0.0276 in)
Dimension c (1/2 ∅ measuring shaft) + 15.00 mm (0.5906 in)
Gives Dimension "X" = 241.70 mm (9.5157 in)

3. Measure bearing width.

• Bearing width e.g. 42.45 mm (1.6713
in).

Figure 199

Axle (ZF AP-420R) S0602170K

Page 91
4. Read pinion dimension.
• Pinion dimension e.g. 198 - 0.1=
197.90 mm (7.7913 in).

Figure 200

EXAMPLE II

Bearing width 42.45 mm (1.6712 in)

Pinion dimension + 197.90 mm (7.7913 in)
Gives Dimension X1 = 240.35 mm (9.4626 in)

EXAMPLE III

Dimension X 241.70 mm (9.5157 in)

Dimension X1 - 240.35 mm (9.4626 in)
Difference = Shim thickness s= 1.35 mm (0.0531 in)

5. Lay shim (according to the Example s =

1.35 mm (0.0531 in)) into the housing
bore.

Figure 201
6. Freeze outer bearing race and press it
firmly against shoulder.
7. Install the drive flange side outer bearing
race correspondingly.
NOTE: See “Special Tools” on page 15.

Figure 202

S0602170K Axle (ZF AP-420R)

Page 92
8. Heat inner bearing race, guide it over the
drive pinion end until contact is obtained.

Figure 203

Axle (ZF AP-420R) S0602170K

Page 93
ADJUSTMENT OF DRIVE PINION BEARING
ROLLING RESISTANCE
Nominal Value

DK / CK 1.1 - 2.3 Nm
(9.7 - 20.3 in lb)
HK 1.5 - 3.0 Nm
(13.2 - 17.7 in lb)
LK / RK 3.0 - 4.5 Nm
(17.7 - 39.8 in lb)

1. Lay measuring ring over the drive pinion

collar. Figure 204
NOTE: Configuration and description of
the measuring ring, See Figure 205.
NOTE: See “Special Tools” on page 15.

Figure 205

S0602170K Axle (ZF AP-420R)

Page 94
2. If necessary (according to the Version),
insert hex. head screws into the drive
flange bores and press the dust shield on
the collar of the drive flange.

Figure 206
3. Insert the drive pinion into the axle carrier
and assemble the heated inner bearing
race until contact is obtained.

Figure 207
4. Tighten washer and tighten slotted nut the
required rolling resistance is obtained.
NOTE: When tightening, make several
full revolutions of the drive
pinion in both directions, and
check the rolling resistance
continuously.
NOTE: See “Special Tools” on page 15.
5. Loosen slotted nut, tighten drive flange
and remove the pinion again.

Figure 208

Axle (ZF AP-420R) S0602170K

Page 95
6. Take off measuring ring and determine
dimension "X" (see Figure 205).
• Dimension "X" e.g. s = 7.79 m
(0.3067 in).
NOTE: Dimension "x" corresponds to
the thickness of the spacer to
be installed.
NOTE: Lay spacer (e.g. s = 7.79 mm
(0.3067 in)) instead of the
measuring ring over the drive
pinion end. Install thrive pinion
again. Figure 209
7. Replace thrive flange, install washer and
tighten slotted nut.
NOTE: Torque limit:
RK 1,100 Nm (810 ft lb)
HK/LK 1,200 Nm (885 ft lb)
DK/CK 700 Nm (515 ft lb)
NOTE: When tightening, make several
full revolutions of the drive
pinion in both directions.
8. Check rolling resistance
NOTE: If the required rolling resistance
is not obtained correct again
with a corresponding spacer.

Figure 210
9. Install shaft seal.
10. If the outer diameter of the shaft seal is
rubber-coated, wet the sealing lip with
mineral spirits, otherwise use the sealing
compound Loctite #586. Fill cavity
between sealing lip and dust lip with
grease.
NOTE: Without figure, place dust
shield over the isle carrier collar
(ø160 mm (6.2992 in)) until
contact is obtained.
NOTE: For Version with additional dust Figure 211
shield only.
NOTE: See “Special Tools” on page 15.

S0602170K Axle (ZF AP-420R)

Page 96
11. Replace drive flange. Assemble washer
and tighten slotted nuts resp. hex. nut
(according to the Version) finally.
NOTE: Torque Limit:
RK 1,100 Nm (810 ft lb)
HK/LK 1,200 Nm (885 ft lb)
DK/CK 700 Nm (515 ft lb)
NOTE: The securing of the slotted nuts
resp. hex. nut (according to the
Version) is carried out after the
contact pattern is taken.
Figure 212
DIFFERENTIAL
1. Heat the crown wheel and place it against
the differential case half until contact is
obtained.
2. Clamp differential case using press.
3. Tighten locking screws.
NOTE: Only single use of the locking
screws is admitted.

Figure 213
4. Press inner bearing race firmly against
shoulder.

Figure 214
5. Lay the two thrust washers into the
differential case half.
NOTE: Mount brass washer on top with
the lubricating groove facing
the side gear.

Figure 215

Axle (ZF AP-420R) S0602170K

Page 97
6. Lay snap ring into the ring groove, see
Figure 216.

Figure 216
7. Insert drive pin, see Figure 217.

Figure 217
8. Assemble alternating outer and inner
plates, starting with one outer plate.
NOTE: For number and installation
position of outer and inner
plates, see corresponding List
of Spare Parts (according to the
Version). The total height
(thickness) of the plate pack
must be equal on both
differential sides. Plate
thickness of outer plates may
be different.
Figure 218
9. Replace pressure ring.

Figure 219

S0602170K Axle (ZF AP-420R)

Page 98
10. Insert side gear and assemble inner plates
at the same time.

Figure 220
11. Insert the differential spider assembly.

Figure 221
12. Install second side gear.

Figure 222
13. Install second pressure ring and insert all
drive pins.
NOTE: Pay attention to the radial
installation position of the
pressure ring.

Figure 223

Axle (ZF AP-420R) S0602170K

Page 99
14. Assemble alternating inner and outer
plates, starting with one inner plate.
NOTE: Number and installation
position of inner and outer
plates, see corresponding List
of Spare Parts (according to the
Version).

Figure 224
Determination of Plate Clearance
1. Differential case
Measure dimension A from the flange-
mounted surface to the outer plate.
• Dimension A e.g. 4.00 mm (0.1575
in).

Figure 225
2. Housing cover
Determine dimension B from the contact
face (outer plate) to the flange-mounted
surface.
• Dimension B e.g. 3.80 mm (0.1496
in).
NOTE: The proscribed end play (=
plate clearance) is 0.2 - 0.8 mm
(0.0079 - 0.0315 in), whilst the
lower value should be found.
The end play is corrected by
the installation of outer plates of Figure 226
corresponding thickness whilst
the plate thickness must be
equal on both differential sides.
EXAMPLE
Dimension A 4.00 mm (0.1575 in)
Dimension B - 3.80 mm (0.1496 in)
Differential = Plate clearance = 0.20 mm (0.0079 in)

S0602170K Axle (ZF AP-420R)

Page 100
3. Insert pre-assembled differential case half
in the axle carrier.

Figure 227
4. Make the two thrust washers adhere with
grease in the housing cover.
NOTE: Mount brass washer on top with
the lubricating groove facing
the side gear.

Figure 228
5. Lay housing cover over the differential
case.
NOTE: Pay attention to the installation
position (see Figure 229).

Figure 229
6. Fasten the housing cover using locking
screws.
NOTE: Only use locking screws one
time. Do not reuse them.
NOTE: See “Special Tools” on page 15.

Figure 230

Axle (ZF AP-420R) S0602170K

Page 101
7. Heat inner bearing race and place it
against the housing cover until contact is
obtained.

Figure 231
8. Insert outer bearing race into the bearing
bore and hold it in place using adjusting
nut.

Figure 232
9. Tilt idle carrier 180°.
10. Insert the crown wheel side outer bearing
race into the bearing bore and temporarily
hold it in position with the second adjusting
nut.

Figure 233
Adjustment of Bearing Preload and
Backlash
1. Attach dial indicator right angled on the
outer diameter of the tooth flank/crown
wheel.
2. Adjust adjusting nut on the crown wheel
side until the required backlash - see value
engraved on the crown wheel outer
diameter - is obtained.

Figure 234

S0602170K Axle (ZF AP-420R)

Page 102
3. Screw in adjusting nut (opposite the crown
wheel side) until the differential bearing
has no endplay.
4. Now, tighten adjusting nut further for 2
notches to obtained the required bearing
preload of the differential bearing 3 - 4 Nm
(26.5 - 35.4 in lb).
5. Check backlash again and correct if
necessary.
NOTE: At this step make several
revolutions of the differential.
Determine yoke width. Figure 235
6. Attach dial indicator on the plane face/
crown wheel, make at least one revolution
of the crown wheel and record the run-out.
NOTE: Admitted run-out max. 0.08 mm
(0.0031 in).
NOTE: See “Special Tools” on page 15.

Figure 236
7. Check contact pattern on the crown wheel
A. Cover some tooth flanks of the crown
wheel with gear marking compound.
B. Roll the clown wheel over the drive
pinion back and forth.
C. Take the contact pattern and
compare it with “Examples of Gear-
tooth-contact Patterns for the
Gleason Gear-tooth System” on
page 11.
D. In case of a greater contact pattern
deviation, a spacing error has been Figure 237
made during the reassembly of the
drive pinion, which must be
corrected.

Axle (ZF AP-420R) S0602170K

Page 103
 E. Secure the two adjusting nuts.

Figure 238
F. Tilt differential carrier.
G. Insert lock plate until contact is
obtained and caulk it on the drive
flange.
NOTE: See “Special Tools” on page 15.

Figure 239
H. Cover flange-mounted surface with
the sealing compound Loctite #573.
I. Screw in the two adjusting screws
and place the differential carrier
against the axle housing until contact
is obtained.
NOTE: See “Special Tools” on page 15.

Figure 240
J. Fasten differential carrier on the axle
housing using hex. head screws.
NOTE: Cover threads of hex. head
screws with sealing compound.
NOTE: Now, install stub shafts again
and complete the final drive.
NOTE: Before the Axle is put into
Service follow the “Lubrication
Instructions” on page 8

Figure 241

S0602170K Axle (ZF AP-420R)

Page 104
ILLUSTRATED TABLE

Figure 242

Axle (ZF AP-420R) S0602170K

Page 105
DIFFERENTIAL REASSEMBLY (VERSION - SCREWED
AND CAST-ON BEARING CAPS)
NOTE: If crown wheel or drive pinion are damaged, the two parts must be replaced as a set. If a
new complete crown wheel set is installed, pay attention that crown wheel and drive pinion
have the same mating numbers.
NOTE: When replacing a complete crown wheel set or axle carrier, pay attention to the Figure
243.

DETERMINE THICKNESS OF SHIM

NOTE: The following measuring operations must be carried out with utmost care. Inexact
measurements would cause an incorrect contact pattern and require a replacement of the
drive pinion and the differential (partial) after the contact pattern has been taken.
1. Install adjusting pieces (3) and temporarily
fasten the two bearing caps. Install stop
washer (2) and measuring pin (1) and
introduce measuring shaft (4) (see Figure
243.
Special Tools

Reference
Description
Number
1 Measuring Pin
2 Stop Washer
3 Adjusting Piece
4 Measuring Shaft

Figure 243
2. Determine gap (Dimension b) between
measuring piston and measuring shaft
with feeler gauge.
• Dimension b e.g. 2.50 mm (0.0984
in).

Figure 244
EXAMPLE I

Dimension a (measuring piston) 224.00 mm (8.8189 in)

Dimension b + 2.50 mm (0.0984 in)
Dimension C (1/2 ∅ measuring shaft) + 15.00 mm (0.5906 in)
Gives Dimension "X" = 241.50 mm (9.5079 in)

S0602170K Axle (ZF AP-420R)

Page 106
3. Measure bearing width.
• Bearing width e.g. 42.45 mm (1.6713
in).

Figure 245
4. Read pinion dimension.
• Pinion dimension e.g. 197.85 mm
(7.7894 in).

Figure 246

EXAMPLE II
Bearing width 42.45 mm (1.6713 in)
Pinion dimension + 197.85 mm (7.7894 in)
Gives Dimension "X" 1 = 240.30 mm (9.4606 in)

EXAMPLE III

Dimension "X" 241.50 mm (9.5079 in)

Dimension "X" 1 - 240.30 mm (9.4606 in)
Difference = Shim thickness s= 1.20 mm (0.0472 in)

5. Lay shim (according to the Example s =

1.20 mm (0.0472 in)) into the housing
bore.

Figure 247

Axle (ZF AP-420R) S0602170K

Page 107
6. Freeze outer bearing race and place it
firmly against shoulder.
7. Install the drive flange side outer bearing
race accordingly.
NOTE: See “Special Tools” on page 15.

Figure 248
8. Heat inner bearing race, guide it over the
drive pinion end until contact is obtained.

Figure 249
ADJUSTMENT OF DRIVE PINION BEARING
ROLLING RESISTANCE
Nominal Value
DK / CK 1.1 - 2.3 Nm
(9.7 - 20.3 in lb)
HK 1.5 - 3.0 Nm
(13.2 - 17.7 in lb)
LK / RK 3.0 - 4.5 Nm
(17.7 - 39.8 in lb)

1. Lay measuring ring over the drive pinion

collar. Figure 250
NOTE: Configuration and description of
the measuring ring, see Figure
251.
NOTE: See “Special Tools” on page 15.

S0602170K Axle (ZF AP-420R)

Page 108
 Figure 251
2. If necessary (according to the Version).
insert hex. head screws into the drive
flange bores and press dust shield over
the drive flange collar.

Figure 252
3. Insert drive pinion into the axle carrier and
assemble heated inner bearing race until
contact is obtained.

Figure 253

Axle (ZF AP-420R) S0602170K

Page 109
4. Guide drive flange over the drive pinion
splines. Install washer and tighten slotted
nuts resp. hex. nut (according to the
Version) until the required rolling
resistance is obtained.
NOTE: When tightening, make several
revolutions of the thrive pillion
in both directions and check
rolling resistance continuously.
NOTE: See “Special Tools” on page 15.
5. Remove slotted nut, pull off drive flange
and remove pinion again. Figure 254
6. Remove measuring ring and determine
dimension "X" (see Figure 251).
• Dimension "X" e.g. s = 7.97 mm
(0.3138 in).
NOTE: Dimension "X corresponds to
the thickness of the spacer to
be installed.
NOTE: Lay spacer (e.g. S. = 7.97 mm
(0.3138 in)) instead of the
measuring ring over the drive
pinion end. Install drive pinion
again. Figure 255
7. Replace drive flange, mount washer and
tighten slotted nut.
NOTE: Torque limit:
DK/CK 700 Nm (515 ft lb)
RK 1,100 Nm (810 ft lb)
HK/LK 1,200 Nm (885 ft lb)
NOTE: When tightening, make several
revolutions of the drive pinion in
both directions.

Figure 256

S0602170K Axle (ZF AP-420R)

Page 110
8. Check rolling resistance.
NOTE: If the required rolling resistance
is not obtained correct again
with a corresponding spacer.

Figure 257
9. Remove drive flange and install shaft seal.
NOTE: Pay attention to the contact.
NOTE: If the outer diameter of the shaft
seal is rubber-coated,
wet the sealing face with
mineral spirits. Otherwise use
the sealing compound Loctite
#586.
NOTE: Fill the cavity between sealing
lip and dust lip with grease.
NOTE: See “Special Tools” on page 15.
Figure 258
10. Replace drive flange.
11. Assemble washer and tighten slotted nut,
resp. hex. nut (according to the Version)
finally
NOTE: Torque limit:
DK/CK 700 Nm (515 ft lb)
RK 1,100 Nm (810 ft lb)
HK/LK 1,200 Nm (885 ft lb)
NOTE: The securing of the slotted nut,
resp. hex. nut (according to the
Version) is carried out after the
contact pattern is taken. Figure 259
NOTE: See “Special Tools” on page 15.

Axle (ZF AP-420R) S0602170K

Page 111
DIFFERENTIAL
1. Heat crown wheel and place it against the
differential case half until contact is
obtained.
2. Clamp the differential case using a press
and tighten locking screws.
NOTE: See “Torque Limits for Screws”
on page 6.
NOTE: Only single use of the locking
screws is admitted.
Figure 260
3. Press the inner bearing race firmly against
shoulder.

Figure 261
4. Lay the two thrust washers into the
differential case half.
NOTE: Mount brass washer on top with
the lubricating groove facing
the side gear.

Figure 262
5. Lay snap ring into the ring groove, see
Figure 263.

Figure 263

S0602170K Axle (ZF AP-420R)

Page 112
6. Insert drive pin, see Figure 264.

Figure 264
7. Assemble alternating outer and inner
plates, starting with one outer plate.
NOTE: Number and installation
position of outer and inner
plates, see corresponding list of
spare parts. The total height
(thickness) of the plate pack
must be equal on both
differential sides. Plate
thickness of outer plates may
be different.

Figure 265
8. Replace pressure ring.

Figure 266
9. Insert side gear and assemble inner plates
at the same time.

Figure 267

Axle (ZF AP-420R) S0602170K

Page 113
10. Insert the differential spider assembly.

Figure 268
11. Install second side gear.

Figure 269
12. Install second pressure ring and insert all
drive pins.
NOTE: Pay attention to the radial
installation position of the
pressure ring.

Figure 270
13. Assemble alternating inner and outer
plates, starting with one inner plate.
NOTE: Number and installation
position of inner and outer
plates, see corresponding list of
spare parts.

Figure 271

S0602170K Axle (ZF AP-420R)

Page 114
Determination of Plate Clearance
1. Differential case
Measure dimension A from the flange-
mounted surface to the outer plate.
• Dimension A e.g. 4.20 mm (0.1654
in).

Figure 272
2. Housing cover
Determine dimension B from the contact
face (outer plate) to the flange-mounted
surface.
• Dimension B e.g. 3.80 mm (0.1496
in).
NOTE: The proscribed end play (=
plate clearance) is 0.2 - 0.8 mm
(0.0079 - 0.0315 in), whilst the
lower value should be found.
The end play is corrected by the
installation of outer plates of Figure 273
corresponding thickness whilst
the plate thickness must be
equal on both differential sides.
EXAMPLE
Dimension A 3.40 mm (0.1339 in)
Dimension B - 3.10 mm (0.1221 in)
Differential = Plate clearance = 0.30 mm (0.0118 in)

3. Make the two thrust washers adhere with

grease in the housing cover.
NOTE: Mount the brass washer on top
wish the lubricating groove
facing the side gear.

Figure 274

Axle (ZF AP-420R) S0602170K

Page 115
4. Lay housing cover over the differential
case and fasten it using locking screws.
NOTE: See “Torque Limits for Screws”
on page 6.
NOTE: Pay attention to the installation
position, see Figure 275. Only
single use of locking screws is
admitted.

Figure 275
5. Heat inner bearing race and position it on
the housing cover until contact is obtained.

Figure 276
6. Insert 1st outer bearing race into the
housing and hold it temporarily using
adjusting nut.

Figure 277
7. Mount 2nd outer bearing race and insert
the differential assembly into the axle
carrier.
NOTE: See “Special Tools” on page 15.

Figure 278

S0602170K Axle (ZF AP-420R)

Page 116
8. Temporarily secure the crown wheel side
outer bearing race using the second
adjusting nut.

Figure 279
9. Replace bearing caps and tighten hex.
head screws.
NOTE: See “Torque Limits for Screws”
on page 6.

Figure 280
Adjustment of Bearing Preload and
Backlash
1. Attach dial indicator right angled on the
outer diameter of the tooth flank/crown
wheel.
2. Adjust adjusting nut on the crown wheel
side until the required backlash (see value
engraved on the crown wheel outer
diameter) is obtained.
NOTE: See “Special Tools” on page 15.

Figure 281
3. Screw in adjusting nut (opposite the crown
wheel side) until the differential bearing is
free of play.
4. Now, tighten adjusting nut further for 2
notches to obtain the required bearing
preload of the differential bearing 3 - 4 Nm
(26.5 - 35.4 in lb). Check backlash again
and correct if necessary.
NOTE: At this step make several
revolutions of the differential.
5. Determine yoke width. Yoke width e.g.
358.00 +0.05 mm(14.0945 +0.0020 in) max. Figure 282

Axle (ZF AP-420R) S0602170K

Page 117
6. Attach dial indicator on the plane face/
crown wheel.
7. Make at least one revolution of the crown
wheel and record the run-out.
NOTE: Admitted run-out max. 0.08 mm
(0.0031 in).
NOTE: See “Special Tools” on page 15.

Figure 283
8. Cover some tooth flanks of the crown
wheel wish gear marking compound.
9. Roll the crown wheel over the drive pinion
back and forth.
10. Check the contact pattern and compare it
with “Examples of Gear-tooth-contact
Patterns for the Gleason Gear-tooth
System” on page 11.
11. In case of a greater contact pattern
deviation, a spacing error has been made
during the reassembly of the drive pinions
which must be corrected. Figure 284
12. Secure adjusting nut.

Figure 285
13. Secure adjusting nut and hex. head
screws according to the Figure 286.

Figure 286

S0602170K Axle (ZF AP-420R)

Page 118
14. Tilt differential carriers.
15. Insert lock plate until contact is obtained
and caulk on the drive flange.

Figure 287
16. Cover flange-mounted surface with sealing
compound Loctite #573.
17. Screw in the two adjusting screws and
place the differential carrier against the
axle housing until contact is obtained.
NOTE: See “Torque Limits for Screws”
on page 6.
NOTE: Now, install stub shafts again
and complete the final drive.
Before the Axle is put into
Service, follow the “Lubrication
Instructions” on page 8 Figure 288

Axle (ZF AP-420R) S0602170K

Page 119
ILLUSTRATED TABLE

Figure 289

S0602170K Axle (ZF AP-420R)

Page 120
 Return to Master Table of Contents

S0605050K

1AIR CONDITIONER

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

AIR CONDITIONER S0605050K

MODEL SERIAL NUMBER RANGE
Mega 130 0001 and Up
Mega 160 0001 and Up
Mega 200-V 1001 and Up
Mega 250-V 1001 and Up
Mega 300-V 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Air Conditioner S0605050K

Page 1
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TABLE OF CONTENTS

General Description........................................................................................ 3
Refrigerant Circulation.................................................................................... 4
Control Panel.................................................................................................. 6
Control Specifications..................................................................................... 7
Temperature Level Control and Display.......................................................... 8
Air Discharge According to Path Selection..................................................... 9
Air-conditioning System Circuit Diagram...................................................... 12
Troubleshooting ............................................................................................ 14
Weight of R134a Gas Used In Machines ..................................................... 17
Refrigerant System Repairs ......................................................................... 19
Refrigerant Safe Handling Procedures ................................................. 19
Repair and Replacement Procedure..................................................... 20
Refrigerant Recovery ............................................................................ 22
Vacuuming Refrigerant System............................................................. 22
Leakage Check ..................................................................................... 23
Refrigerant Charging............................................................................. 24
Inspecting System For Leakage............................................................ 26

S0605050K Air Conditioner

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GENERAL DESCRIPTION

AJS0880L

Figure 1

The heater and air conditioner are combined into one blower unit in the right control stand of operator’s
seat. If necessary, the operator can control inner temperature using the operation panel installed in the top
of the right side door.
The unit is equipped with an air filtration system
which filters out dirt and dust particles from air
being circulated into the operator’s cab. This
filter (1, Figure 2) should be cleaned out at 1
approximately every 500 hours and replaced
with a new one every 1000 hours.
NOTE: In the event that the unit is
being operated in a dusty
environment, cleaning and
replacement should be
performed more frequently.

WARNING!
AJS0530L
All service and inspection of the air-
conditioning system should be performed Figure 2
with the starter switch in the "O" (OFF)
position.

NOTE: Refer to appropriate operation

and maintenance manual for
latest service intervals.

Air Conditioner S0605050K

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REFRIGERANT CIRCULATION

4
7

3
HBOI020L

Figure 3

Reference Reference
Description Description
Number Number
1 Evaporator 5 Compressor
2 Expansion Valve 6 Blower Fan
3 Condenser 7 Receiver Dryer
4 Condenser Fan

S0605050K Air Conditioner

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Shading Temperature Refrigerant State

High High Pressure Gas

High High Pressure Liquid

Low Low Pressure Liquid

High High Pressure Gas/Liquid

Low Low Pressure Gas

• Refrigerant (R134a) is compressed to approximately 15 kg/cm2 (213 psi) within the compressor.
• The compressed refrigerant flows into the condenser at high temperature (approximately 80°C
(176°F)).
• The refrigerant in the condenser is cooled to approximately 60° by the condenser fan. At this
time the refrigerant changes from the gas to the liquid state, even though the temperature has
only been reduced 20°C (68°F). (From 80° - 60°C (176° - 140°F)).
• The refrigerant in its liquid form is injected into the evaporator through the expansion valve. At
this time the pressure is reduced by approximately 2 kg/cm2 (28 psi) and the temperature is also
reduced. As a result, the refrigerant absorbs the heat from the air surrounding the evaporator
creating a cooling effect and changes from the gas to the liquid state.
• The refrigerant once again flows into the compressor in the gaseous state and the process is
repeated.

WARNING!
Refrigerant gas is pressurized and sealed in the air-conditioning system. Special
precautions are required for the proper recharging or release of refrigerant. Release of
refrigerant into the atmosphere is strictly regulated by law. Make sure that you are in
compliance with all mandated federal, state and municipality requirements, before starting
any service or repair of the air conditioner. Refrigerant gas used in the system must meet
or exceed specifications for R134a refrigerant, or any subsequently issued
environmentally-mandated standard.

Air Conditioner S0605050K

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CONTROL PANEL

OFF A/C

LO MID HI COOL WARM

HDA6047L
Figure 4

INPUT CONTROL OUTPUT

PANEL

DISPLAY
TEMPERATURE
SENSOR
LOW SPEED RELAY

OFF SW MID SPEED RELAY BLOWER

MOTOR
A / C SW
VENT SW HIGH SPEED RELAY
DEF. SW
HEAT SW A/C TEMP. CONTROL MIX DOOR
ACTUATOR
FRE SW CONTROL
REC SW PANEL VENT ACTUATOR VENT CONTROL
LOW SW
MID SW DEF. ACTUATOR FOOT / DEF.
HI SW
COOL SW INTAKE RECYCLE/FRESH
ACTUATOR AIR CONTROL
WARM SW
TEMPERATURE COMP. RELAY COMPRESSOR
CONTROL ACTUATOR
CONDENSER CONDENSER
FAN RELAY FAN

HDA6048L
Figure 5

S0605050K Air Conditioner

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CONTROL SPECIFICATIONS

Control Item Control Switch Control Specifications

Temperature "COOL" Switch
MAX COOL
Control
"WARM" Switch 100%

50%

MAX HOT
0%

HDA6049L
Figure 6

Temperature control switch consists of a 24 step

variable selector. The display uses 7, Green / Red two-
color LED’s to display the selected temperature.
Blower Fan "OFF" Switch
Speed Control
"LOW" Switch
"MID" Switch
HI RELAY
"HI" Switch
MID RELAY

LOW RELAY

OFF LOW MID HI

HDA6050L
Figure 7

Compressor Temperature Sensor

Control
COMP ON

COMP OFF

1.5 C 4.0 C

HDA6051L
Figure 8

Air Conditioner S0605050K

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TEMPERATURE LEVEL CONTROL AND DISPLAY

Position
Step LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Sensor Remark
Voltage
0 Green Green Green Green Green Green Green 4.50 V ±0.2 MAX. COOL
1 Green Green Green Green Green Green Green 4.33 V ±0.2
2 Green Green Green Green Green Green Green 4.15 V ±0.2
3 Red Green Green Green Green Green Green 3.98 V ±0.2
4 Red Green Green Green Green Green Green 3.80 V ±0.2
5 Red Green Green Green Green Green Green 3.63 V ±0.2
6 Red Red Green Green Green Green Green 3.46 V ±0.2
7 Red Red Green Green Green Green Green 3.28 V ±0.2
8 Red Red Green Green Green Green Green 3.11 V ±0.2
9 Red Red Red Green Green Green Green 2.93 V ±0.2
10 Red Red Red Green Green Green Green 2.76 V ±0.2
11 Red Red Red Green Green Green Green 2.59 V ±0.2
12 Red Red Red Red Green Green Green 2.41 V ±0.2
13 Red Red Red Red Green Green Green 2.24 V ±0.2
14 Red Red Red Red Green Green Green 2.07 V ±0.2
15 Red Red Red Red Red Green Green 1.89 V ±0.2
16 Red Red Red Red Red Green Green 1.72 V ±0.2
17 Red Red Red Red Red Green Green 1.54 V ±0.2
18 Red Red Red Red Red Red Green 1.37 V ±0.2
19 Red Red Red Red Red Red Green 1.20 V ±0.2
20 Red Red Red Red Red Red Green 1.02 V ±0.2
21 Red Red Red Red Red Red Red 0.85 V ±0.2
22 Red Red Red Red Red Red Red 0.67 V ±0.2
23 Red Red Red Red Red Red Red 0.50 V ±0.2 MAX. HOT

S0605050K Air Conditioner

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AIR DISCHARGE ACCORDING TO PATH SELECTION

Vent

AJS0540L

Figure 9

Reference Reference
Description Description
Number Number
1 Select Switch 3-2 Rear Vent (L)
2 Front Vent 4 Heater Core
2-1 Front Vent (R) 5 Evaporator Core
2-2 Front Vent (L) 6 Air Filter
3 Rear Vent 7 Blower Motor
3-1 Rear Vent (R)

Air Conditioner S0605050K

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Foot

4 5
1

6
7

3-1
3-2

2
AJS0551L

Figure 10

Reference Reference
Description Description
Number Number
1 Select Switch 4 Heater Core
2 Foot Vent 5 Evaporator Core
3 Rear Vent 6 Air Filter
3-1 Rear Vent (R) 7 Blower Motor
3-2 Rear Vent (L)

S0605050K Air Conditioner

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Defroster

4 5

6
7

3-1
3-2

2
AJS0561L

Figure 11

Reference Reference
Description Description
Number Number
1 Select Switch 4 Heater Core
2 Defroster Vent 5 Evaporator Core
3 Rear Vent 6 Air Filter
3-1 Rear Vent (R) 7 Blower Motor
3-2 Rear Vent (L)

Air Conditioner S0605050K

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AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM

AJS0570L

Figure 12

S0605050K Air Conditioner

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Reference Reference
Description Description
Number Number
1 Battery 14 A/C Control Panel
2 Battery Relay 15 A/C Unit
3 Fusible Link 15-1 Blower Motor
4 Circuit Breaker 15-2 Resister
5 Fuse Box 15-3 High Speed Relay
6 Headlight Switch 15-4 Mid Speed Relay
7 Condenser Fan Relay 15-5 Low Speed Relay
8 Condenser Fan Motor 15-6 Recirculate / Fresh Air
9 Compressor Relay Control Actuator
10 Foot / Defrost Control 15-7 Vent Actuator
Actuator 15-8 Temperature Control
11 Receiver Drier Actuator
12 Diode 15-9 Temperature Sensor
(Evaporator)
13 Compressor

Air Conditioner S0605050K

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TROUBLESHOOTING
Refrigerant Pressure Check

LO HI

HDA6074L
Figure 13

1. Open all doors and windows.

2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 - 2,000 rpm.
4. Check high / low pressure of refrigerant.

High Pressure: 8 - 10 kg/cm2 (114 - 142 psi)

1
Low Pressure: Approximately 1 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
Reassemble using correct
Yes
1 Check for traces of refrigerant oil. tightening torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major No Recharge system to correct
components and joints. pressure.

High Pressure: Over 23 kg/cm2 (327 psi)

2
Low Pressure: Approximately 2.5 - 3.0 kg/cm2 (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser
Step Inspection Item Remedy
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.

S0605050K Air Conditioner

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High Pressure: Approximately 20 - 25 kg/cm2 (284 - 356 psi)

3
Low Pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.

4 High Pressure: Over 6 kg/cm2 (85 psi)

Low Pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
Step Inspection Item Remedy
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace
Yes
receiver dryer.
3. Set blower switch to HIGH position.
4. Turn air conditioner OFF and wait 10
1 minutes.
Contaminated system, replace
5. Recheck high / low pressure readings. expansion valve.
No
High Pressure: 13 - 19 kg/cm2 (185 - 270 psi) (Replace evaporator core
assembly.)
Low Pressure: 1.5 - 3.3 kg/cm2 (21 - 47 psi)

5 High Pressure: Over 6 - 18 kg/cm2 (85 - 256 psi)

Low Pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful
readings should be made to determine whether pressure is in normal range.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.

High Pressure: Over 22 - 23 kg/cm2 (313 - 327 psi)

6
Low Pressure: 2.5 kg/cm2 (36 psi)
Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor.
Step Inspection Item Remedy
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.

Air Conditioner S0605050K

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High Pressure: Over 7 - 11 kg/cm2 (100 - 156 psi)

7
Low Pressure: 4 - 6 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression
Inspect and replace compressor if necessary.

S0605050K Air Conditioner

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WEIGHT OF R134A GAS USED IN MACHINES

Model Weight of Gas

Mega 130 850 ±20 grams (30 ±0.7 oz.)
Mega 160 850 ±20 grams (30 ±0.7 oz.)
Mega 200-III 850 ±20 grams (30 ±0.7 oz.)
Mega 200-V 850 ±20 grams (30 ±0.7 oz.)
Mega 250-III 850 ±20 grams (30 ±0.7 oz.)
Mega 250-V 850 ±20 grams (30 ±0.7 oz.)
Mega 300-III 950 ±20 grams (33 ±0.7 oz.)
Mega 300-V 850 ±20 grams (30 ±0.7 oz.)
Mega 400-III 950 ±20 grams (33 ±0.7 oz.)
Mega 400-III PLUS 850 ±20 grams (30 ±0.7 oz.)
Mega 400-V 850 ±20 grams (30 ±0.7 oz.)
Mega 500-V 850 ±20 grams (30 ±0.7 oz.)
Solar 130-III 950 ±20 grams (33 ±0.7 oz.)
Solar 130LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 130W-III 950 ±20 grams (33 ±0.7 oz.)
Solar 130W-V 850 ±20 grams (30 ±0.7 oz.)
Solar 170LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 170W-III 1100 ±20 grams (38 ±0.7 oz.)
Solar 200W-III 1100 ±20 grams (38 ±0.7 oz.)
Solar 200W-V 850 ±20 grams (30 ±0.7 oz.)
Solar 220LC-III 950 ±20 grams (33 ±0.7 oz.)
Solar 220LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 220LL 850 ±20 grams (30 ±0.7 oz.)
Solar 250LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 280LC-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 290LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 290LL 850 ±20 grams (30 ±0.7 oz.)
Solar 300LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 300LL 850 ±20 grams (30 ±0.7 oz.)
Solar 330-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 330LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 340LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 400LC-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 400LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 420LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 450LC-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 450LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 470LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 70-III 800 ±20 grams (28 ±0.7 oz.)

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S0605050K Air Conditioner

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REFRIGERANT SYSTEM REPAIRS

WARNING!
Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in
contact with the skin or eyes, immediately flush with clean, running water and consult a
physician.
Select a clean and well-ventilated area to work.
The refrigerant container is under high pressure and should be stored below 40°C (104°F). Be
careful not to drop the container from a high location
The contents are under high pressure and should not be used with compressed air or near an
open flame.

REFRIGERANT SAFE HANDLING PROCEDURES

UNION NUT

TORQUE WRENCH

CORRECT WRONG
WRONG

WRONG

CORRECT

O - RING POSITION

CAP & PLUG CORRECT WRONG WRONG

HDA6066L
Figure 14

The following procedures should be observed for safe handling of refrigerant during vacuum and charging
process.
1. Use an approved recovery / charging device which can safely perform vacuum and charge work
simultaneously.
2. The new refrigerant has improved cooling characteristics than the old type and care should be used
not to overcharge the system.
3. Do not over tighten connections when working on refrigerant system.
4. The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to
use equipment use in servicing the old refrigerant system.

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5. The new refrigerant oil (PAG type) has a high moisture absorption characteristic. When the
refrigerant system vacuum seal has been broken, immediately plug up all openings to prevent
moisture from entering into the system.
6. When joining unions which use O-ring seals, lightly coat O-rings with refrigerant oil. Be careful not to
drip oil on the threads of the nut.
7. Be certain the O-rings are seated properly on the refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine running, do not open the high pressure valve
on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose.
10. When releasing the high pressure hose after completing the charging process, quickly disconnect the
hose to minimize refrigerant released to the air.

REPAIR AND REPLACEMENT PROCEDURE

1. Work Procedure.
A. Before repairing or replacing any refrigerant components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition.
A. Run engine at maximum engine speed.
B. Select "HI" blower fan speed and select A/C switch to "ON."
C. Set the temperature control switch for maximum cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary depending on the outdoor temperatures.

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INSTALL REPAIR TOOL

RECOVER REFRIGERANT

REPAIR / REPLACE DEFECTIVE PARTS

VACUUM SYSTEM (OVER 5 MINUTES)

CHECK SYSTEM FOR AIR LEAKAGE REPAIR

VACUUM SYSTEM (OVER 20 MINUTES)

CHARGE SYSTEM (APPROXIMATELY 100 g)

CHECK SYSTEM FOR REFRIGERANT LEAKAGE

CHARGE SYSTEM TO PROPER LEVEL

(Standard Capacity less Initial Charge)

CHECK SYSTEM FOR REFRIGERANT LEAKAGE

CHECK FOR PROPER REFRIGERANT LEVEL

RUN SYSTEM

RECOVER REFRIGERANT IN CHARGING HOSE

REMOVE REPAIR TOOLS

HDA6067L
Figure 15

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REFRIGERANT RECOVERY

Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low Pressure Side
3 High Pressure Side
4 From Receiver
5 Refrigerant Recovery Tank

1. Attach the manifold gauges and the

refrigerant recovery unit to the refrigerant 5
lines as shown. HDA6067L
Figure 16
NOTE: Be careful not to switch the
connections for the low and
high pressure valves.
2. Open the high pressure valve slowly to release the refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see that refrigerant is not leaking out.

3. When the manifold gauge dial falls below 3.5 kg/cm2 (50 psi), slowly open the low pressure valve.

4. Open both the high and low pressure valves slowly until the manifold gauge dials indicates 0 kg/cm2
(0 psi).

VACUUMING REFRIGERANT SYSTEM

Reference 2 3
Description
Number 1 4
1 To Compressor
2 Low Pressure Side
3 High Pressure Side
4 From Receiver
5 Vacuum Pump

1. Vacuuming Procedure. 5
HDA6068L
NOTE: When the A/C system has been Figure 17
exposed to the air, it must be
vacuumed out. Perform vacuum
process for 30 minutes for
complete moisture and air
evacuation.
A. Attach the manifold gauges and vacuum pump to the refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low pressure gauge shows approximately 710 mmHg, close both valves and turn off
vacuum pump.

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2. Check system for vacuum leak.

Allow system to sit for 10 minutes and
check whether the system is holding the
pressure. If the pressure has dropped, it
must be repaired before proceeding to the
next step.
3. Vacuuming Procedure.
If the system is holding the pressure and it
has not changed for 10 minutes, vacuum
out the system for an additional 20
minutes. HDA6069L
Figure 18
A. Turn on the vacuum pump and slowly
open both valves.
B. Allow vacuum pump to run for additional 20 minutes until the low pressure gauge dial reads
approximately 750 mmHg.
C. Close both valves and stop the vacuum pump.
4. Installation of Refrigerant Container.

Reference 1
Description
Number
1 Handle
2 Hose Connection
3 Mounting Disk 2

A. Before mounting valve on the 3

container, make sure the handle is in
the counterclockwise most position,
with the puncture pin retracted and HDA6070L
the mounting disk is in the raised Figure 19
position.
B. Attach the manifold gauge center
hose to the valve assembly.
C. Turn the disc in the clockwise direction and securely mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in the counter clockwise direction so the
refrigerant can flow into the manifold gauge center hose. At this time, do not open the low and
high pressure valves of the manifold gauge.
F. Press the manifold gauge low side valve to eliminate the trapped air in the hose.

LEAKAGE CHECK
NOTE: Perform the leakage check after completing vacuuming process.
1. After attaching the manifold gauge, open the high side valve.

2. Charge system until the low side gauge dial indicates a pressure of 1 kg/cm2 (14 psi) and close the
high side valve.

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3. Using a refrigerant leak detector or soapy

water check each joint for leakage.
1
Reference
Description
Number
Refrigerant Leak
1
Detection Device

4. If a leak is detected, check for O-ring

damage or correct tightening torque and
replace or repair as necessary.
5. If no leaks are detected, proceed with the HDA6071L
charging process. Figure 20

WARNING!
For accurate refrigerant leak
detection, perform leak detection
procedure in a well-ventilated area.

REFRIGERANT CHARGING
1. Perform the vacuuming procedure, vacuum holding and leaking tests as described in the proceeding
headings.
NOTE: First charge the refrigerant system with 100 g (3.5 ounces) of refrigerant with the engine
off. Then using the manifold gauges as a guide fully charge the system with the engine
running.
When exchanging refrigerant containers, press the manifold gauge low side valve to
eliminate air from the charging hose.

Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low Pressure Side
3 High Pressure Side
4 From Receiver
5 Refrigerant Supply
Container

2. Charge the system by opening the manifold 5

gauge low side valve. HDA6072L
Figure 21
Initial charge amount: 100 g (3.5 ounces).

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3. If refrigerant does not flow freely into system, try starting engine first before operating air conditioner.
• Temperature control switch setting: Maximum Cooling
• Blower Speed Setting: Hi (3 step)
• Engine Speed: 1,300 - 1,500 rpm

WARNING!
When charging refrigerant system with the engine running;
• Always keep refrigerant supply container in the upright position.
• Never open the high side pressure valve.

4. Open the manifold gauge low side valve and charge system to standard capacity.

Gauge Dial Standard Reading

High Side Gauge 13 - 20 kg/cm2

(185 - 285 psi)

Low Side Gauge 1.5 - 3.5 kg/cm2

(21 - 50 psi)

NOTE: These standards are for outside temperatures between 30° - 35°C (86° - 95°F). The gauge
readings may vary for extreme temperature conditions.

WARNING!
• When outside temperature is low, warm the refrigerant supply container with
warm water not exceeding 40°C (104°F). Do not allow water to come in contact
with the charging adapter valve handle.
• When outside temperature is high, cool off refrigerant supply container and
condenser to aid the refrigerant charging process.

5. Close low pressure side valve.

6. Shut off engine and close refrigerant supply container adapter valve. Disconnect manifold gauge
hoses from vehicle.

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INSPECTING SYSTEM FOR LEAKAGE

After completing charging procedures, clean all
joints and connections with a clean dry cloth.
Using a refrigerant leak detecting device or
soapy water, inspect system for leaks starting 2
from the high pressure side. 1
NOTE: When the refrigerant circulation
has been stopped the high
pressure will start to decrease
and the low pressure will start 3
to increase until they are
equalized. Starting the
4
inspection from the high side HDA6073L
will result in a accurate test. Figure 22

Reference
Description
Number
1 Pressure
2 High Pressure
3 Low Pressure
4 Compressor Stop

Inspection Procedure
1. High pressure side.
Compressor outlet → condenser inlet → receiver dryer inlet → air conditioner unit inlet
2. Low pressure side.
Compressor inlet → air conditioner unit outlet
3. Compressor.
Compressor shaft area, bolt hole area and magnetic clutch area.
4. Receiver dryer.
Pressure switch and plug area.
5. Connection valve area.
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air conditioner unit.
After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds
minimum.)
NOTE: When inspecting leakage from the air conditioner unit, perform the inspection in a well-
ventilated area.

S0605050K Air Conditioner

Page 26
 S0607080K

1TRANSMISSION AND
TORQUE CONVERTER
(ZF 4WG-310)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

TRANSMISSION AND TORQUE CONVERTER (ZF 4WG-310)S0607080K

MODEL SERIAL NUMBER RANGE
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 1
TABLE OF CONTENTS

Drive Train Description ................................................................................... 5

Transmission and Torque Converter............................................................... 6
Powershift Transmission.......................................................................... 7
Transmission Control............................................................................... 7
Schedule of Measuring Points and Connection 4WG-310 ...................... 8
Oil Circuit Diagram 4WG-310 Forward 1st Speed ................................ 11
Transmission Electric Components .............................................................. 14
TCU (Transmission Control Unit) .......................................................... 15
Transmission Control Valve ................................................................... 16
Transmission Oil Temperature Sensor .................................................. 16
Engine Pick-Up Sensor ......................................................................... 17
Central Gear Pick-Up Sensor................................................................ 17
Turbine Pick-Up Sensor......................................................................... 17
Output Speed Sensor............................................................................ 18
Shift Lever Switch (DW-3) ..................................................................... 18
Auto Select Switch ................................................................................ 19
Display .................................................................................................. 19
Transmission Faults Codes .......................................................................... 21
Fault Display.......................................................................................... 21
CAN - Message..................................................................................... 21
Description of Fault Codes .................................................................... 21
Abbreviations ........................................................................................ 22
Definition of Operation Modes............................................................... 22
Normal ........................................................................................... 22
Substitute Clutch Control ............................................................... 22
Limp-home ..................................................................................... 22
Transmission Shut Down................................................................ 22
TCU Shut Down ............................................................................. 22
Table of Fault Codes.............................................................................. 23
Measurement of Resistance at Actuator/sensors and Cable ................ 23

S0607080K Transmission and Torque Converter

Page 2 (ZF 4WG-310)
 Actuator.......................................................................................... 23
Cable.............................................................................................. 23
Transmission Electrical Circuits.................................................................... 24
Transmission Controller Circuit ............................................................. 24
Traveling Circuits ................................................................................... 26
Neutral ........................................................................................... 26
Forward First Gear ......................................................................... 27
Forward Second Gear.................................................................... 28
Forward Third Gear........................................................................ 29
Forward Fourth Gear ..................................................................... 30
Reverse First Gear......................................................................... 31
Reverse Second Gear.................................................................... 32
Reverse Third Gear........................................................................ 33
Downshift .............................................................................................. 34
Overview ........................................................................................ 34
Kick-down: Forward Second Gear to Forward First Gear
(Auto Selector Switch "O" - Manual Mode) ................................... 34
Downshift (Auto Selector Switch "I" - Auto Mode).......................... 36
Transmission Cutoff............................................................................... 38
Installation View ........................................................................................... 40
Inner Section ......................................................................................... 40
Front View ............................................................................................. 42
Side View .............................................................................................. 43
Rear View.............................................................................................. 44
Hydraulic Control Unit (HSG-94) .................................................................. 46
Disassembly.......................................................................................... 47
Reassembly .......................................................................................... 51
Transmission Disassembly ........................................................................... 59
Converter-Input ..................................................................................... 59
Drive Shaft Pump Power Take-off ......................................................... 62
Transmission Pump ............................................................................... 64
Output- Layshaft Assembly ................................................................... 64
Multidisk Clutches ................................................................................. 69

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 3
 Power Take-off....................................................................................... 70
Multidisk Clutch - K3/K4 ........................................................................ 71
Multidisk Clutch KR/K2.......................................................................... 74
Multidisk Clutch KV/K1.......................................................................... 77
Transmission Reassembly............................................................................ 82
Power Take-off....................................................................................... 82
Reassemble Multidisk Clutch K3/K4 ..................................................... 84
Multidisk Clutch - K4 ...................................................................... 87
Multidisk Clutch - K3 ...................................................................... 91
Reassemble Multidisk Clutch KR/K2..................................................... 96
Multidisk Clutch - KR...................................................................... 98
Multidisk Clutch - K2 .................................................................... 103
Reassemble Multidisk Clutch KV / K1................................................. 110
Multidisk Clutch - KV.................................................................... 112
Multidisk Clutch - K4 .................................................................... 117
Install Countershaft Gear and Multidisk Clutches ............................... 123
Pre-assemble and Mount Housing Cover ........................................... 128
Install Countershaft Axle ..................................................................... 139
Hydraulic Pump................................................................................... 140
Axle Disconnection.............................................................................. 142
Filter .................................................................................................... 143
Input Shaft (Power Take-off Pump) ..................................................... 144
Input – Converter Bell ......................................................................... 148
Converter ............................................................................................ 153
Inductive Transmitters and Speed Sensor........................................... 155

S0607080K Transmission and Torque Converter

Page 4 (ZF 4WG-310)
DRIVE TRAIN DESCRIPTION
Figure 1, shows layout of drive train assemblies. The engine (1, Figure 1) drives a torque converter (2),
which drives a power shift transmission (3). Two output shafts extend out of the transmission. Each output
shaft has a drive shaft attached to it. Front drive shaft (4) drives a final drive shaft (6) that drives the front
differential (7).
A parking brake (8, Figure 1) is mounted on the front differential input shaft. The front differential is
enclosed in the front axle housing (9). Each end of the front axle housing contains reduction gearing (10).
Each end of the front axle housing also contains a service brake (11). Rear drive shaft (5) drives the rear
differential (12). The rear differential is enclosed in the rear axle housing (13). Each end of the rear axle
housing contains reduction gearing (10). Each end of the rear axle housing also contains a service brake
(11).

Figure 1

Reference Reference
Description Description
Number Number
1 Engine 8 Parking Brake
2 Torque Converter 9 Front Axle Housing
3 Transmission 10 Reduction Gearing
4 Front Drive Shaft 11 Service Brake
5 Final Drive Shaft 12 Rear Differential
6 Rear Drive Shaft 13 Rear Axle Housing
7 Front Differential

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 5
TRANSMISSION AND TORQUE CONVERTER
The machine contains a powershift transmission that has four forward speeds and three speeds in
reverse. Gear changes are made by an elector-hydraulic control valve that is mounted on transmission.
Moving gear select lever in cab, generates an electrical signal that is transmitted to the control valve. The
control valve contains proportional valves that direct pressurized fluid to various clutches that control the
forward and reverse gears.

Item Mega 500-V

Torque Converter Model 4WG-310 (Full Auto)
Type 3-Element, 1-Stage, Single-phase,
E/G mounted with flexible plate
Oil Cooler Water-cooled (multiplate) and Air-cooled
Charging Pump 130 l/min at 2,000 rpm
Hydraulic Pump P.T.O 1:1
T/C Size ∅ 370 mm (14.5669 in)
Stall Ratio 2,985
Safety Relief 11 Bar (160 psi)
Transmission Type Full Power Shift, Counter shaft
Speeds 4 Forward / 3 Reverse
Ratio F: 3.73 / 2.206 / 1.969 / 0.624
R: 3.73 / 2.206 / 0.969
Power Shift Control 16 - 18 Bar (232 - 261 psi)
Pressure
Shift Control Electric Shift with Proportional Valve
Oil Capacity 50 l (13.2 U.S. gal)
Dry Weight 750 kg (1,653 lb)
Output Flange Front 9C Mechanics
Rear 9C Mechanics

S0607080K Transmission and Torque Converter

Page 6 (ZF 4WG-310)
POWERSHIFT TRANSMISSION
The multispeed reversing transmission in countershaft design is power shiftable by hydraulically actuated
multidisk clutches.
All gears are constantly meshing and carried on antifriction bearings.
The gear wheels, bearings and clutches are cooled and lubricated with oil.
The 4-speed reversing transmission is equipped with 6 multidisk clutches.
At the shifting, the actual plate pack is compressed by a piston, movable in axial direction, which is
pressurized by pressure oil.
A compression spring takes over the pushing back of the piston, thus the release of the plate pack. As to
the layout of the transmission and the specifications of the closed clutches in the single speeds, See
“Schedule of Measuring Points and Connection 4WG-310” on page 8. and “Oil Circuit Diagram 4WG-310
Forward 1st Speed” on page 11.

TRANSMISSION CONTROL
Transmission control, See “Schedule of Measuring Points and Connection 4WG-310” on page 8., Electro-
hydraulic unit on page 10 and “Oil Circuit Diagram 4WG-310 Forward 1st Speed” on page 11.
The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is
sitting in the transmission on the engine-dependent input shaft.
The feed rate of the pump is Q = 130 l/min. at nEngine = 2000 min-1.
This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the ZF-Fine filter - the
filters is fitted externally from the transmission - to the main pressure valve.
ZF-Fine filter
Filtration ratio according to ISO 4572: β30 ≥ 75 β15 = 25 β10 = 5.0
Filter surface at least: 2 x 6,700 cm2 = 13,400 cm2
Dust capacity according to ISO 4572 at least: 17 g
The six clutches of the transmission are selected via the 6 proportional valves P1 to P6.
The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y6). follow-on
slide and vibration damper.
The control pressure of 9 bar (130 psi) for the actuation of the follow-on slides is created by the pressure
reducing valve. The pressure oil (16+2 bar (232+29 psi)) is directed via the follow-on slide to the respective
clutch.
Due to the direct proportional selection with separated pressure modulation for each clutch, the pressure
to the clutches, which are engaged in the gear change, will be controlled. In this way, a hydraulic
intersection of the clutches to be engaged and disengaged becomes possible. This is creating
spontaneous shifts without traction force interruption.
At the shifting, the following criteria will be considered:
• Speed of engine, turbine, central gear train and output.
• Transmission temperature.
• Shifting mode (up-, down-, reverse shifting and speed engagement out of Neutral).
• Load condition (full and part load, traction, overrun inclusive consideration of load cycles during
the shifting).

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 7
The main pressure valve is limiting the max. control pressure to 16+2 bar (232+29 psi) and releases the
main stream to the converter and lubricating circuit.
In the inlet to the converter, a converter safety valve is installed which protects the converter from high
internal pressure (opening pressure 11 bar (160 psi).
Within the converter, the oil serves to transmit the power according to the well-known hydro-dynamic
principle.
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter pressure backup valve, rear-mounted to the converter, with an opening
pressure of at least 5 bar (73 psi).
The oil, escaping out of the converter, is directed to a heat exchanger.
From the heat exchanger, the oil is directed to the transmission and there to the lubricating oil circuit, so
that all lubricating points are supplied with cooled oil.
The allocation of the pressure regulators to the single speeds can be seen on the “Schedule of Measuring
Points and Connection 4WG-310” on page 8 and “Oil Circuit Diagram 4WG-310 Forward 1st Speed” on
page 11.

SCHEDULE OF MEASURING POINTS AND CONNECTION 4WG-310

The marked positions (e.g. 53) correspond with the positions on the “Oil Circuit Diagram 4WG-310
Forward 1st Speed” on page 11.
The measurements have to be carried out at hot transmission (about 80° - 90°C).
Marking on the
No. Denomination of the Position Connection
Valve Block
Measuring Points for Pressure Oil and Temperature
51 In front of the converter - Opening pressure 11 bar M10 x 1 H
52 Behind the converter - Opening pressure 5 bar M14 x 1.5
53 Clutch Forward 16 + 2 bar (232+29 psi) KV M10 x 1 B
55 Clutch Reverse 16 + 2 bar (232+29 psi) KR M10 x 1 E
56 Clutch Reverse 16 + 2 bar (232+29 psi) K1 M10 x 1 D
57 Clutch Reverse 16 + 2 bar (232+29 psi) K2 M10 x 1 A
58 Clutch Reverse 16 + 2 bar (232+29 psi) K3 M10 x 1 C
60 Clutch Reverse 16 + 2 bar (232+29 psi) K4 M10 x 1 F
63 Behind the Converter
M14 x 1.5
Temperature 100°C, Short-time 120°C
65 System Pressure 16 + 2 bar (232+29 psi) K4 M10 x 1 K
10 Breather M10 x 1
15 Connection to the Heat Exchanger -------
16 Connection from the Heat Exchanger -------
28 To the Filter M42 x 2
29 From the Filter M42 x 2
30 From the Filter Bypass M42 x 2
36 Oil Filter Plug M42 x 2
49 Plug Connection on the Electrohydraulic Control Unit
68 System Pressure (Option) M16 x 1.5 G
69 Control System (Option) M16 x 1.5 J

S0607080K Transmission and Torque Converter

Page 8 (ZF 4WG-310)
 Marking on the
No. Denomination of the Position Connection
Valve Block
Inductive Transmitters and Speed Sensor
5 Inductive Transmitter n Turbine M18 x 1.5
9 Inductive Transmitter n Central Gear Train M18 x 1.5
13 Speed Sensor n Output and Speedometer -------
14 Inductive Transmitter n Engine M18 x 1.5

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 9
Figure 2

S0607080K Transmission and Torque Converter

Page 10 (ZF 4WG-310)
OIL CIRCUIT DIAGRAM 4WG-310 FORWARD 1ST SPEED
The marked positions (e.g. 53) correspond with the positions on “Schedule of Measuring Points and
Connection 4WG-310” on page 8.

Reference
Positions
Number
WT Heat Changer
WGV Converter Back Pressure Valve 5 bar (73 psi)
WSV Converter Safety Valve 11 bar (160 psi)
HDV Main Pressure Valve 16+2 bar (232+29 psi)
RV-9 Pressure Reducing Valve 9 bar (131 psi)
NFS Follow-on Slide
D Vibration Damper
B Orifice
P1 Proportional Valve - Clutch KR
P2 Proportional Valve - Clutch K4
P3 Proportional Valve - Clutch K1
P4 Proportional Valve - Clutch K3
P5 Proportional Valve - Clutch KV
P6 Proportional Valve - Clutch K2
Y1 -Y6 Pressure Regulator
TEMP Temperature Sensor

Figure 3

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 11
 P1 P2 P3 P4 P5 P6

ZF-FINE FILTER
FILTER GRADE ACCORDING ISO 4572:
β30>75 β15=25 β10=5.0
DUST CAPACITY ACCORDING ISO 4572:
min. 17g
2
FILTER SURFACE cm
WT 2 x 6,700 = 13,400
(SCOPE OF SUPPLY
CUSTOMER) TRANSMISSION PUMP
LEGEND: p = 16+2 bar
= MAIN PRESSURE Qp= 130 l/min-1 at
n = ENGINE 2000 min-1
= REGULATED MAIN PRESSURE
BYPASS-
= PILOT PRESSURE COARSE FILTER
VALVE
= CONVERTER INPUT PRESSURE ∆p=1.5bar MESH WIDTH µm : 450
= CONVERTER OUTPUT PRESSURE FILTER SURFACE cm2 1000
= LUBRICATION
= RETURN INTO THE SUMP
AJS0871L
Figure 4

S0607080K Transmission and Torque Converter

Page 12 (ZF 4WG-310)
S0607080K Transmission and Torque Converter
Page 13 (ZF 4WG-310)
TRANSMISSION ELECTRIC COMPONENTS

21
13

10
18

19

14 17
20
8

15
1

16
3
9
2
11
12 4
6 7
5

AJS0190L
Figure 5

S0607080K Transmission and Torque Converter

Page 14 (ZF 4WG-310)
 Reference Reference
Description Description
Number Number
1 Transmission Control Unit 11 Transmission Cutoff Switch
(TCU) 12 Transmission Cutoff Pressure
2 Transmission Control Valve Switch
3 Transmission Oil Temperature 13 Downshift Switch
Sensor 14 Safety Starter Switch
4 Engine Pick-Up Sensor 15 Fuse Box
5 Central Gear Pick-up Sensor 16 Parking Brake Switch
6 Turbine Pick-up Sensor 17 Control Unit
7 Output Speed Sensor 18 Starter Controller
8 Shift Lever Switch 19 LIS Switch (Option)
9 Auto Select Switch 20 LIS Solenoid Valve
10 Display 21 Speedometer

TCU (TRANSMISSION CONTROL UNIT)

1. Sending a control signal transmitted from
the shift lever to the control valve,
generates a speed.
2. At the auto mode, transmits the appreciate
signals to the control valves according to
the load and engine rpm.
3. Detecting a fault, controls various
clutches.

Figure 6

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 15
TRANSMISSION CONTROL VALVE
1. The transmission control valve contains a
temperature sensor and proportional
solenoid valves (Y1 - Y6) that direct
pressurized fluid to various clutches that
generates a speed with control the shift
gears.
2. Specification of the proportional solenoid
valve.
• Resistance: 19 ±1.9 ohm at 20°C
(68°F) AJS0210L
Figure 7
• Pressure: 0.8 kg/cm2 → 8.3 kg/cm2
3. The contained temperature sensor detects
the temperature of the control valve and
transmits the electrical signal to the TCU,
and serves TCU determines gears to
change.
• Neutral: At temperature less than -
30°C (-22°F)
• 1st or 2nd gear: At temperature less
than -10°C (14°F)
• Normal Operation: At temperature
greater than -10°C (14°F)

TRANSMISSION OIL TEMPERATURE

SENSOR
1. Detecting a oil temperature of transmission
and send a control signal to transmission
oil temperature gauge.
2. Specification
• Resistance
216 ±30 Ohm (at 60°C (140°F))
81.2 ±10 Ohm (at 90°C (194°F))
AJS0220L
36.5 ±3.5 Ohm (at 120°C (248°F)) Figure 8
18.7 ±2.1 Ohm (at 150°C (302°F))

S0607080K Transmission and Torque Converter

Page 16 (ZF 4WG-310)
ENGINE PICK-UP SENSOR
1. Detect a revolution of gear array in engine
side.
2. Specification
• Resistance: 1050Ω ± 10% (at 20°C
(68°F)).
• Fasten torque: 30 Nm (22 ft lb).
• Gap: 0.5 + 0.3 mm (0.0197 + 0.0118
in).
AJS0230L
• Output: 4 Pulse/Rev.
Figure 9

CENTRAL GEAR PICK-UP SENSOR

1. Detect a revolution of central gear array
2. Specification
• Resistance: 1050Ω ±10% (at 20°C
(68°F)).
• Fasten torque: 30 Nm (22 ft lb).
• Gap: 0.5 + 0.3 mm (0.0197 + 0.0118
in).
• Output: 91 Pulse/Rev. AJS0240L
Figure 10
TURBINE PICK-UP SENSOR
1. Detect a revolution of gear array in turbine
side.
2. Specification
• Resistance: 1050Ω ± 10% (at 20°C
(68°F)).
• Fasten torque: 30 Nm (22 ft lb).
• Gap: 0.5 + 0.3 mm (0.0197 + 0.0118
in).
AJS0250L
• Output: 59 Pulse/Rev. Figure 11

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 17
OUTPUT SPEED SENSOR
3(+)
1. Detect a revolution of gear array in
transmission output side 2(SIG)
1(-)
2. Specification
• Voltage Supply: 20 V - 32 V.
• Operation Frequency: 2 Hz - 5 KHz.
• Fasten torque (M8): 23 Nm (17 ft lb).
• Gap: 1.0 + 0.5 mm (0.0394 + 0.0197 1.5 40
in). AJS0260L
• Output: 60 Pulse/Rev. Figure 12

SHIFT LEVER SWITCH (DW-3)

1. Forward, Reverse and Shift F
• F: Forward
• N: Neutral
N KD
• R: Reverse
• 1,2,3,4: Shift Step SHIFT SWITCH
* Forward shift range: 1 - 4 LEVER LOCK KEY
R (N/D)
* Reverse shift range: 1 - 3
AJS0270L
2. Kick-Down (Down Shift) Switch Figure 13
• KD: Kick-Down Switch
3. Lever Lock Key
• N: Neutral (The lever is not moved.)
• D: Driving (The lever is released.)
4. Switch Circuit
B A AD3 (B3)
1 2 G B AD2 (B2)
1 2 L X1
C AD1 (B1)
1 2 V
D AD7 (KD)
R A ED1 (+/VP)
2 Gr
1 D AD6 (N)
3 2
1
3 Y B AD4 (F) X2
1 2
3 P C AD5 (R)
AJS0280L
Figure 14

S0607080K Transmission and Torque Converter

Page 18 (ZF 4WG-310)
5. Terminal position and color
TERMINAL COLOR
(AD6) GREY

D C B A
(AD5) PINK
X2
(AD4) YELLOW
(VP) RED

(AD7) VIOLET

D C B A
(AD1) BLUE
X1
(AD2) GREEN
(AD3) BLACK
AJS0290L
Figure 15

6. Switch Connection

GEAR FORWARD REVERSE NEUTRAL KICK

DOWN
TERMINAL 1 2 3 4 1 2 3 4 1 2 3 4
ED1 VP
AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7 KD
AJS0300L
Figure 16

AUTO SELECT SWITCH

1. This is an auto/manual select switch.
2. When the switch is in the "I" - (AUTO)
position, gears are "AUTOMATICALLY"
changed to the appropriate speed up to O
A

the limit set by the gear lever and

according to travel load and engine rpm
3. Automatic shifting takes place between
I
gears.
• Forward: 2nd - 3rd - 4th
HLB20071L
• Reverse: 2nd - 3rd Figure 17
4. When the switch is in the "O" - (Manual)
position, travel mode is switched to
"MANUAL" and allows operator to choose
speeds manually.

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 19
DISPLAY
Fault codes are given in a separate section "Transmission Error Codes (ZF)."

S0607080K Transmission and Torque Converter

Page 20 (ZF 4WG-310)
TRANSMISSION FAULTS CODES
The transmission has a monitoring system that indicates when a malfunction is occurring.

FAULT DISPLAY left right

h f e d character character
If a fault is detected, the display shows a
spanner symbol (g) for a fault. The display
shows the fault code, if the gear selector is in S
neutral.
T
If more than one fault is detected, each fault O
code is shown for about 1 second.
P

CAN - MESSAGE
a b c g

The TCU sends the fault code of a detected (special symbols a-h) HBOE630L
fault in the specified CAN - message, while the
fault is active. Figure 18

If more than one fault is detected, the fault code

scrolls.

DESCRIPTION OF FAULT CODES

First Number Meaning of Number

1 Hex Digital Input Signal
2 Hex Analog Input Signal
3 Hex Speed Signal
4 Hex Can Signal Error
5 Hex Can Signal Error
6 Hex Can Signal Error
7 Hex Analog Current Output Signal
8 Hex Analog Current Output Signal
9 Hex Digital Output Signal
A Hex Digital Output Signal
B Hex Transmission Fault, Clutch Error
C Hex Logical Fault
D Hex Power Supply
E Hex High Speed Signal
F Hex General Fault

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 21
ABBREVIATIONS
Throughout this section the following abbreviations are used to indicate various conditions.

Abbreviations
O.C. Open Circuit
S.C. Short Circuit
OP-Mode OPeration Mode
TCU Transmission Control Unit
ABS Anti Blocking System
ASR Anti Slipping Regulation
EEC Electronic Engine Controller
PTO Power Take Off
CCO Clutch Cut Off

DEFINITION OF OPERATION MODES

Normal
There is no failure detected in transmission system or failure has no or slight effects on transmission
control. TCU will work without or in special cases with little limitations. (see following table)

Substitute Clutch Control

TCU cannot change gears or direction under control of normal clutch modulation. TCU uses substitute
strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25)

Limp-home
The detected failure in the system has strong limitations to transmission control. TCU can engage only one
gear in each direction. In some cases only one direction will be possible. TCU will shift the transmission
into neutral at the first occurrence of the failure. First, the operator must shift the gear selector into neutral
position. If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector
into forward or reverse, the TCU will select the limp-home gear. If output speed is less than a threshold for
reversal speed and TCU has changed into the limp-home gear and the operator selects a shuttle shift,
TCU will shift immediately into the limp-home gear of the selected direction. If output speed is greater than
the threshold, TCU will shift the transmission into neutral. The operator has to slow down the vehicle and
must shift the gear selector into neutral position.

Transmission Shut Down

TCU has detected a severe failure that disables control of the transmission. TCU will shut off the solenoid
valves for the clutches and also the common power supply (VPS1). Transmission shifts to Neutral. The
park brake will operate normally, also the other functions which use ADM 1 to ADM 8. The operator has to
slow down the vehicle. The transmission will stay in neutral.

TCU Shut Down

TCU has detected a severe failure that disables control of system. TCU will shut off all solenoid valves and
also both common power supplies (VPS1, VPS2). The park brake will engage, also all functions are
disabled which use ADM 1 to ADM 8. The transmission will stay in neutral.

S0607080K Transmission and Torque Converter

Page 22 (ZF 4WG-310)
TABLE OF FAULT CODES
Fault codes are given in a separate section "Transmission Error Codes (ZF)."

MEASUREMENT OF RESISTANCE AT ACTUATOR/SENSORS AND CABLE

Actuator
open circuit:R12 ≈ R1G ≈ R2G ≈ ∞
1
short cut to ground:R12 ≈ R;R1G ≈ 0, R2G ≈ R or
R1G ≈ R, R2G ≈ 0(for S.C. to ground, G is
R
connected to vehicle ground)
short cut to battery:R12 ≈ R;R1G ≈ 0, R2G ≈ R or
R1G ≈ R, R2G ≈ 0(for S.C. to battery, G is 2
G
connected to battery voltage).
HBOE640I

Figure 19
Cable
UBat
open circuit:
R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞
P (power supply)

short cut to ground: TCU

Actuator /
1 2
R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞ Sensor

short cut to battery: C (chassis)

R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0

Gnd

HBOE650I
Figure 20

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 23
TRANSMISSION ELECTRICAL CIRCUITS
TRANSMISSION CONTROLLER CIRCUIT

AHS0130L

Figure 21

S0607080K Transmission and Torque Converter

Page 24 (ZF 4WG-310)
 Reference Reference
Description Description
Number Number
1 Transmission Controller 10 Safety Starter Switch
2 Transmission Selector Switch 11 Output Speed Sensor
3 Transmission Control Valve 12 Speed Pick-up
4 Fuse Box 1 13 LIS Select Switch
5 Auto Selector Switch 14 LIS Solenoid
6 Transmission Cutoff Selector 15 Speedometer
Switch 16 Parking Brake Switch
7 Transmission Cutoff Pressure 17 Control Unit
Switch
18 Starter Controller
8 Display
19 Fuse Box 2
9 Downshift Switch

The transmission proportioning solenoid valves are shown here as (Y1 thru Y6, Figure 21).

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 25
TRAVELING CIRCUITS

Neutral

AHS0140L
Figure 22

Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
17 Control Unit
8 Display
18 Starter Controller

S0607080K Transmission and Torque Converter

Page 26 (ZF 4WG-310)
When all transmission solenoid valves are de-energized (OFF) the transmission is in "NEUTRAL."

Forward First Gear

AHS0150L
Figure 23

Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
17 Control Unit
8 Display
18 Starter Controller

Transmission solenoid valves (Y3 and Y5, Figure 23) are energized when in forward first gear.

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 27
Forward Second Gear

AHS0160L
Figure 24

Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
17 Control Unit
8 Display
18 Starter Controller

Transmission solenoid valves (Y5 and Y6, Figure 24) are energized when in forward second gear.

S0607080K Transmission and Torque Converter

Page 28 (ZF 4WG-310)
Forward Third Gear

AHS0170L

Figure 25

Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
17 Control Unit
8 Display
18 Starter Controller

Transmission solenoid valves (Y4 and Y5, Figure 25) are energized when in forward third gear.

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 29
Forward Fourth Gear

AHS0180L
Figure 26

Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
17 Control Unit
8 Display
18 Starter Controller

Transmission solenoid valves (Y2 and Y4, Figure 26) are energized when in forward fourth gear.

S0607080K Transmission and Torque Converter

Page 30 (ZF 4WG-310)
Reverse First Gear

AHS0190L
Figure 27

Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
17 Control Unit
8 Display
18 Starter Controller

Transmission solenoid valves (Y1 and Y3, Figure 27) are energized when in reverse first gear.

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 31
Reverse Second Gear

AHS0200L
Figure 28

Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
17 Control Unit
8 Display
18 Starter Controller

Transmission solenoid valves (Y1 and Y6, Figure 28) are energized when in reverse second gear.

S0607080K Transmission and Torque Converter

Page 32 (ZF 4WG-310)
Reverse Third Gear

AHS0210L

Figure 29

Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
17 Control Unit
8 Display
18 Starter Controller

Transmission solenoid valves (Y1 and Y4, Figure 29) are energized when in reverse third gear.

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 33
DOWNSHIFT

Overview
1. There are two downshift switches down
Figure 30, and it is possible for operators
to select one of them according to the
condition.
2. If the downshift switch is depressed during
the machine moving, downshifting takes
place automatically. As a result, fast
digging and moving is possible. But at the
manual mode the kick-down can only be
activated.
AJS0400L
3. If a change or traveling direction takes Figure 30
place or the downshift switch is depressed
a second time, downshifting is released
automatically.

Kick-down: Forward Second Gear to Forward First Gear

(Auto Selector Switch "O" - Manual Mode)

AHS0220L
Figure 31

S0607080K Transmission and Torque Converter

Page 34 (ZF 4WG-310)
 Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
8 Display

With the auto selector switch (Figure 32) is in

the "O" (MANUAL) and the forward second gear
is selected, if either downshift switch (Figure 30)
is activated, a pulse is sent to the "22"
transmission controller. This signal energizes
solenoid valves, (Y3 and Y5), which shifts the O
transmission to the forward first gear. When

A
either switch (Figure 30) is selected a second
time, the transmission pulse signal of the "22"
terminal is interrupted and solenoid valve, Y5
I
and Y6, are energized and the transmission
returns to the forward second gear.
HLB20072L
Figure 32

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 35
Downshift (Auto Selector Switch "I" - Auto Mode)

AHS0230L
Figure 33

Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
8 Display

When the auto selector switch (Figure 33) is in the "I" position, the "29" terminal of transmission controller
is energized. This allows the transmission to automatically upshift and downshift gears depending on the
load and on the engine speed.
If either downshift switch (Figure 30) is activated, a pulse signal is sent to the "22" terminal of transmission
controller. This signal shifts the transmission to the next lowest gear.

S0607080K Transmission and Torque Converter

Page 36 (ZF 4WG-310)
 Automatic
Downshift Switch "Activated"
Gear Selection
Fourth Gear Downshift to Third Gear
Third Gear Downshift to Second Gear
Second Gear Downshift to First Gear
First Gear Remains in First Gear

When either downshift (Figure 30) is depressed a second time, the transmission pulse signal of the "22" is
interrupted and the transmission returns to normal operation.
NOTE: The fourth to the third gear changes without any rpm change when the downshift switch is
pressed.
NOTE: The third to the second gear, and the third to the first gear, changes occur when the rpm is
reduced 200 - 300 rpm from current setting.

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 37
TRANSMISSION CUTOFF
When the brake pedal is depressed while
transmission cutoff switch (Figure 34) is in the
"I" position, the transmission cutoff pressure
switch turns "ON" and current is supplied to the
"66" terminal of the transmission controller.
All current being supplied to the transmission
O
solenoid valves (Y1 thru Y6) is cut off and the
transmission is in "NEUTRAL."
I
NOTE: To protect transmission,
transmission cutoff switch does
not function in third and fourth HA3O2018
gears. Figure 34

CAUTION!
When the machine is traveling or working in the place of inclination, the transmission cutoff
switch (Figure 34) must be placed in position 'O' for the purse of using engine braking and the
normal braking function at the same time.

AHS0240L
Figure 35

S0607080K Transmission and Torque Converter

Page 38 (ZF 4WG-310)
 Reference Reference
Description Description
Number Number
1 Transmission Controller 9 Downshift Switch
2 Transmission Selector Switch 10 Safety Start Switch
3 Transmission Control Valve 11 Output Speed Sensor
4 Fuse Box 12 Speed Pick-up
5 Auto Selector Switch 13 LIS Select Switch
6 Transmission Cutoff Selector 14 LIS Solenoid
Switch 15 Speedometer
7 Transmission Cutoff Pressure 16 Parking Brake Switch
Switch
17 Control Unit
8 Display
18 Starter Controller

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 39
INSTALLATION VIEW
INNER SECTION

Figure 36

S0607080K Transmission and Torque Converter

Page 40 (ZF 4WG-310)
 Reference Reference
Description Description
Number Number
1 Engine Connection - Direct 8 Clutch K1
Mounting 9 Clutch K2
2 Converter 10 Clutch K3
3 Breather 11 Output - Front Axle
4 Drive 12 Output - Rear Axle
5 Electro-hydraulic Shift 13 Layshaft
Control
14 Clutch K4
6 1st Power Take Off
15 Clutch Kr
7 Converter Charge and
16 Clutch Kv
Control Pressure Pump

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 41
FRONT VIEW

Figure 37

Reference Reference
Description Description
Number Number
1 Lifting Lugs 7 Coarse Filter
2 Breather 8 Oil Drain Plug
3 Electro-hydraulic Shift Control 9 Attachment Possibility for Oil
4 Diaphragms - Direct Mounting Filter Tube with Oil Dipstick
(Converter-side)
5 Converter
10 Oil Filler Tube with Oil Dipstick
6 Output Flange (Converter-side)
(Rear-side)

S0607080K Transmission and Torque Converter

Page 42 (ZF 4WG-310)
SIDE VIEW

Figure 38

Reference Reference
Description Description
Number Number
1 Diaphragms for Direct Mounting 7 Output Flange (Rear -side)
2 Converter 8 Oil Filler Tube with Oil Dipstick
3 Converter Bell (Rear-side)
4 Lifting Lug 9 Cover
5 Breather 10 Gearbox Housing
6 Electro-hydraulic Shift Control 11 Output Flange (Converter-side)
12 Transmission Suspension M20

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 43
REAR VIEW

Figure 39

Reference Reference
Description Description
Number Number
1 1st Power Take-off 9 Attachment Possibility for
2 Pressure Line Clutch KV Emergency Steering Pump
3 2nd Power Take-off 10 Oil Filter Tube With Oil Dipstick
4 Lifting Lug 11 Model Identification Plate
5 Pressure Oil Line Clutch K1 12 Output Flange (Rear-side)
6 Pressure Oil Line Clutch K4 13 Lubricating Oil Line "S2" Clutch
K4 / K3
7 Pressure Oil Line Clutch K3
14 Pressure Oil Line Clutch KR
8 Lubricating Oil Line "S1" Clutch
KR / K2 15 Pressure Oil Line Clutch K2

S0607080K Transmission and Torque Converter

Page 44 (ZF 4WG-310)
Transmission and Torque Converter S0607080K
(ZF 4WG-310) Page 45
HYDRAULIC CONTROL UNIT (HSG-94)
Figure 40, shows a sectional view of the HSG-94.

IMPORTANT
Different versions in relation to the position of the cable harness are possible.
In this connection, pay attention to the Specifications of the Vehicle Manufacturer.

Figure 40

S0607080K Transmission and Torque Converter

Page 46 (ZF 4WG-310)
Section A -A

Figure 41

DISASSEMBLY
1. Loosen socket head screws and remove
selector housing.

Figure 42

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 47
2. Separate hose lines from the intermediate
plate.
3. Loosen socket head screws and separate
intermediate plate and gaskets and
intermediate sheet from gearbox housing.

Figure 43
4. Mark installation position of the cable
harness to the valve block.

Figure 44
5. Loosen socket head screws.
6. Separate duct plate, gaskets and
intermediate sheet from the valve block.

Figure 45
7. Remove retaining clip.

Figure 46

S0607080K Transmission and Torque Converter

Page 48 (ZF 4WG-310)
8. Loosen socket head screws and remove
cover.
9. Remove opposite cover.

Figure 47
10. Demount pressure regulator and remove
cable harness.

Figure 48
11. Loosen socket head screws, remove
retaining plates and demount pressure
regulator.

Figure 49
12. Loosen two socket head screws and locate
the housing provisionally using adjusting
screws. (Housing is spring-loaded). Now,
loosen the remaining socket head screws.

Figure 50

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 49
13. Separate housing from valve body by
uniform loosening of the adjusting screws.

Figure 51
14. Remove components.

Figure 52
15. Remove opposite pressure regulators,
housing and components accordingly.

Figure 53

S0607080K Transmission and Torque Converter

Page 50 (ZF 4WG-310)
REASSEMBLY
NOTE: Check all components for
damage and replace if
necessary. Prior to installation,
check free travel of all moving
parts in housing. Spools can be
exchanged individually. Oil
components before reassembly
according to ZF-List of
lubricants TE-ML 03.
Insert diaphragms with concave
side facing upward until contact
is obtained. Figure 54

NOTE: Installation position, see

arrows.
1. Figure 55, shows the following
components:

Reference
Description
Number
1 Vibration Damper (3x
Spool and
Compression Spring)
2 Follow On Site (3x
Spool And
Compression Spring)
3 Pressure Reducing
Valve (1x Spool And Figure 55
Compression Spring)

2. Install components according to Figure 55.

NOTE: Preload compression spring of
the follow-on slides and locate
spool provisionally using
cylindrical pins Ø 5.0 mm
(0.1969 in) (assembly aid), See
Figure 56.

Figure 56

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 51
3. Install two adjusting screws.
4. Line up flat gasket (Arrow) and housing
cover (Figure 57). Now, bring housing
cover using adjusting screws uniformly
against shoulder (Figure 58).

Figure 57

Figure 58
5. Preload spool and remove the cylindrical
pins (assembly aid) again.

Figure 59
6. Fasten housing cover using socket head
screws.
NOTE: Torque limit 5.5 Nm (4 ft lb).

Figure 60

S0607080K Transmission and Torque Converter

Page 52 (ZF 4WG-310)
7. Introduce pressure regulators and secure
them using retaining plates and socket
head screws.
NOTE: Install retaining plates, with the
claw facing downward. Pay
attention to the radial
installation position of the
pressure regulators, Figure 61.
NOTE: Torque limit 5.5 Nm (4 ft lb).

Figure 61
8. Pre-assemble opposite side.
A. Figure 62, shows the following
components:

Reference
Description
Number
1 Main Pressure Valve
(1x Spool and
Compression Spring.)
2 Follow On Slide (3x
Spool and
Compression Spring)
Figure 62
3 Vibration Damper (3x
Spool and
Compression Spring)

B. Install components according to

Figure 62.
C. Preload compression springs of the
follow-on slides and secure the
spools provisionally with cylindrical
pins aid), see arrows.
D. Install two adjusting screws.
E. Line up flat gasket (1, Figure 63) and
housing cover and bring them
uniformly against shoulder, using
adjusting screws.
F. Now, fasten housing cover using Figure 63
socket head screws.
NOTE: Torque limit 5.5 Nm (4 ft lb).
G. Remove cylindrical pins (assembly
aid) again.

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 53
 H. Introduce pressure regulators and
secure them using retaining plates
and socket head screws.
NOTE: Install retaining plates, with the
claw facing downward.
I. Pay attention to radial installation
position of pressure regulators, see
Figure 64.
NOTE: Torque limit 5.5 Nm (4 ft lb).

Figure 64
J. Install cable harness and connect
pressure regulators (6x).
NOTE: Pay attention to installation
position of cable harness, see
markings (Figure 43).

Figure 65
K. Mount flat gasket (Figure 66).
L. Introduce female connector, with the
groove facing the guide nose of the
cover, until contact is obtained.
M. Fasten cover with socket head
screws.
NOTE: Torque limit 0.56 kg•m (4.06 ft
lb).

Figure 66
N. Locate the female connector using
retaining clip.
O. Install opposite cover.

Figure 67

S0607080K Transmission and Torque Converter

Page 54 (ZF 4WG-310)
 P. Install two adjusting screws and
mount gasket I.
NOTE: Pay attention to different
gaskets, see Figure 68 and
Figure 71.

Figure 68
9. Intermediate plate-version with screens:
A. Insert screens (6x) flash mounted
into bore of intermediate plate, see
Figure 69.
NOTE: Pay attention to installation
position- screens are facing
upward (facing duct plate).

Figure 69
B. Mount intermediate plate, with the
strainers facing upward.

Figure 70
C. Mount gasket II.

Figure 71

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(ZF 4WG-310) Page 55
 D. Mount duct plate and fasten it
uniformly using socket head screws.
NOTE: Torque limit 9.5 Nm (7 ft lb).

Figure 72
E. Equip screw plugs (8x) with new O-
rings and install them.
NOTE: Torque limit 6 Nm (4.4 ft lb).

Figure 73
10. Attach Hydraulic control unit (HSG-94)
(Figure 74 - Figure 84).
A. Screw orifice into the housing bore
(Figure 74) and secure it using
center punch.

Figure 74
B. Install connecting fittings 1- 6.
C. Install screw plugs 7.
NOTE: Torque limit Screw plugs
(M10x1) 6 Nm (4.4 ft lb).
NOTE: Install always new O-rings.

Figure 75

S0607080K Transmission and Torque Converter

Page 56 (ZF 4WG-310)
 D. Install two adjusting screws (M8) and
mount housing gasket.

CAUTION!
At the following steps (Figure 75 -
Figure 81), pay attention to the
installation positions of the different
gaskets.

Figure 76
E. Mount intermediate plate.

Figure 77
F. Mount 2nd gasket.

Figure 78
G. Mount plate and fasten it uniformly
using socket head screws.
NOTE: Torque limit (M8/10.9) 23 Nm
(17 ft lb).

Figure 79

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(ZF 4WG-310) Page 57
 H. Install 2 adjusting screws (M6).
I. Mount gasket (Figure 80).

Figure 80
J. Fasten complete valve block
uniformly with socket head screws (2
pieces M6 x 105 and 21 pieces M6 x
80 mm).

CAUTION!
Pay attention to the position of the
two socket head screws (M6 x 105),
see Allows.

NOTE: Torque limit 9.5 Nm (7 ft lb). Figure 81

S0607080K Transmission and Torque Converter

Page 58 (ZF 4WG-310)
TRANSMISSION DISASSEMBLY
1. Fasten transmission on an appropriate
support stand.

Figure 82
2. Disassemble complete shift control,
remove pressure lines and duct plate.

Figure 83
CONVERTER-INPUT
1. Separate torque converter from
transmission, using lifting device.

Figure 84

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(ZF 4WG-310) Page 59
2. Loosen hex. head screws and lift complete
retarder along with converter out of the
converter bell, using lifting device.

Figure 85
3. Pull oil feed flange out of converter bell,
using special device (S).

Figure 86
4. Remove converter safety valve (ball and
spring, see Figure 87).

Figure 87
5. Loosen screw connection (M8 and M12).
Separate converter bell from the
transmission, using lifting device.

Figure 88

S0607080K Transmission and Torque Converter

Page 60 (ZF 4WG-310)
6. Remove shim.

Figure 89
7. Remove both rectangular rings (Figure
90).

Figure 90
8. Press input shaft out of the spur gear
bearing.
9. Remove released inner bearing race and
spur gear.

Figure 91
10. Press inner bearing race from the input
shaft.

Figure 92

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(ZF 4WG-310) Page 61
11. Remove converter pressure backup valve.

Figure 93
DRIVE SHAFT PUMP POWER TAKE-OFF
1. Pull the complete input shaft out of the
gearbox housing, resp. out of the pump.

Figure 94
2. Squeeze rectangular ring out (Figure 95).

Figure 95
3. Separate spur gear from the shaft and
squeeze retaining ring out (Figure 96).

Figure 96

S0607080K Transmission and Torque Converter

Page 62 (ZF 4WG-310)
4. Pull inner bearing race from spur gear.

Figure 97
5. Pull inner bearing race from spur gear.

Figure 98
6. Pull inner bearing race and drive from
shaft.
NOTE: Support puller on end face/
drive shaft. Pay attention to
released shims.

Figure 99
7. Separate inner bearing race from driver.
NOTE: Pay attention to released shim.
8. If necessary, squeeze snap rings (3x) out.

Figure 100

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(ZF 4WG-310) Page 63
TRANSMISSION PUMP
1. Tilt gearbox housing 180°.
2. Loosen hex. head screws and remove
both pump flanges.

Figure 101
3. Loosen socket head screws (M8) and
position Puller device (s).
4. Pull transmission pump out of housing
bore
NOTE: Tapping housing face is a help
during extraction operation.

Figure 102
OUTPUT- LAYSHAFT ASSEMBLY
1. Loosen screw connection and remove
brake caliper.

Figure 103
2. Unlock and loosen hex. head screws, tap
brake disk loose and separate it from
output shaft.

Figure 104

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Page 64 (ZF 4WG-310)
3. Pry shaft seal out of housing bore.

Figure 105
4. Tilt gearbox housing.
5. Remove sealing covers (Figure 106)

Figure 106
6. Loosen hex. head screws.

Figure 107
7. Pull idler shaft using puller out of housing
bore.

Figure 108

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(ZF 4WG-310) Page 65
8. Tilt gearbox housing 180°.
9. Loosen hex. head screws and pull bearing
cover -K1/KV out of housing bore.

Figure 109
10. Loosen hex. head screws and remove
bearing cover KR/K2 and K3/K4.

Figure 110
11. Squeeze rectangular rings (3 pieces/axle)
out, see Figure 111.

Figure 111
12. Squeeze snap ring and remove released
washers.

Figure 112

S0607080K Transmission and Torque Converter

Page 66 (ZF 4WG-310)
13. Support output flange against gearbox
housing, see Figure 113.

Figure 113
14. Loosen hex. head screws and separate
housing cover from gearbox housing,
using forcing screws and lifting device.

Figure 114
15. Unlock and loosen hex. head screws.
16. Remove output flange and pry shaft seal
out of housing.

Figure 115
17. Loosen hex. head screws and remove oil
baffle.

Figure 116

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(ZF 4WG-310) Page 67
18. Remove output gear along with shaft.

Figure 117
19. Separate output shaft from spur gear.

Figure 118
20. Pull inner bearing race from output gear.

Figure 119
21. Remove plate.

Figure 120

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Page 68 (ZF 4WG-310)
22. Drive roller bearing out of housing bore
and remove it.

Figure 121
MULTIDISK CLUTCHES
1. Disassemble clutch K4/K3, KR/K2 and KV/
K1 using lifting device.
NOTE: At the disassembly of the clutch
K4/K3, lift clutch KR/K2 slightly
and displace it in arrow
direction, see Figure 122.

Figure 122
2. Figure 123, shows the clutches in
disassembled condition.

Figure 123
3. Remove countershaft gear.

Figure 124

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(ZF 4WG-310) Page 69
POWER TAKE-OFF
1. Squeeze retaining ring out and remove
shims.

Figure 125
2. Lift output shaft using pry bar until the
outer bearing race is free.

Figure 126
3. Take output shaft out of the housing.

Figure 127
4. Pull outer bearing race out of the housing
bore.

Figure 128

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Page 70 (ZF 4WG-310)
5. Pull inner bearing race from the shaft
(Figure 129).
6. Press opposite inner bearing race from the
shaft.
NOTE: The separation of shaft and
gear is not possible (shrink fit).

Figure 129
MULTIDISK CLUTCH - K3/K4
1. Fasten clutch using clamping ring (S) on
the assembly car.

Figure 130
2. Pull roller bearing from plate carrier.

Figure 131
3. Separate spur gear K3 from plate carrier.

Figure 132

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(ZF 4WG-310) Page 71
4. Pull inner bearing race from plate carrier.

Figure 133
5. Squeeze snap ring out.
6. Disassemble end shim and plate pack K3.

Figure 134
7. Tilt plate carrier 90°.
8. Loosen slotted nut.

CAUTION!
Slotted nut is secured with Loctite.
To prevent a damage of the thread,
heat the slotted nut before loosen it
(about 120°C (248°F))

Figure 135
9. Tilt plate carrier 90°.
10. Pull off the tapered roller bearing.

Figure 136

S0607080K Transmission and Torque Converter

Page 72 (ZF 4WG-310)
11. Pull spur gear K4 from plate carrier.

Figure 137
12. Remove adjusting ring.

Figure 138
13. Pull off tapered roller bearing.

Figure 139
14. Squeeze snap ring out.
15. Disassemble end shim and plate pack K4.

Figure 140

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(ZF 4WG-310) Page 73
16. Preload compression spring using Special
device (S). Squeeze snap ring out and
remove the released components.
17. Disassemble opposite components (K3-
side) accordingly.

Figure 141
18. Separate both pistons using compressed
air from the plate carrier.

Figure 142
MULTIDISK CLUTCH KR/K2
1. Fasten clutch using clamping ring (Figure
143) on the assembly car.

Figure 143
2. Tilt plate carrier 90°.
3. Loosen slotted nut.

CAUTION!
Slotted nut is secured with Loctite.
To prevent a damage of the thread,
heat the slotted nut before loosen it
(about 120°C (248°F)).

Figure 144

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Page 74 (ZF 4WG-310)
4. Pull tapered roller bearing from plate
carrier.

Figure 145
5. Press spur gear K2 from the plate carrier.

CAUTION!
Pay attention to the released plate
carrier.

Figure 146
6. Secure plate carrier using clamping ring
(S).
7. Remove shim.

Figure 147
8. Pull tapered roller bearing from plate
carrier.

Figure 148

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(ZF 4WG-310) Page 75
9. Squeeze snap ring out.
10. Disassemble end shim and plate pack K2.

Figure 149
11. Tilt plate carrier 90°.
12. Loosen slotted nut.

CAUTION!
Slotted nut is secured with Loctite.
To prevent a damage of the thread,
heat the slotted nut before loosen it
(about 120°C (248°F)).

Figure 150
13. Pull tapered roller bearing from plate
carrier.

Figure 151
14. Pull tapered roller bearing from plate
carrier.

Figure 152

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Page 76 (ZF 4WG-310)
15. Remove adjusting rings.

Figure 153
16. Squeeze snap ring out.
17. Disassemble end shim and plate pack KR.

Figure 154
18. Pull tapered roller bearing from plate
carrier.
19. Disassemble both pistons, as described at
Figure 141and Figure 142.

Figure 155
MULTIDISK CLUTCH KV/K1
1. Fasten clutch using clamping ring on the
assembly car.
2. Loosen slotted nut (Figure 156).

CAUTION!
Slotted nut is secured with Loctite.
To prevent a damage of the thread,
heat the slotted nut before loosen it
(about 120°C (248°F)). Figure 156

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 77
3. Pull tapered roller bearing from plate
carrier.

Figure 157
4. Remove disk.

Figure 158
5. Pull spur gear K1 from plate carrier.

Figure 159
6. Figure 160, shows the spur gear bearing
K1.
7. The bearing (1) is only as sub-assembly
available.

CAUTION!
If the disassembly of the plate pack-
side ball bearing (Arrow, resp. Figure
162 and Figure 163) is necessary, the
complete bearing (1) must be Figure 160
replaced.

S0607080K Transmission and Torque Converter

Page 78 (ZF 4WG-310)
8. Remove bush.

Figure 161
9. Pull ball bearing from plate carrier (Figure
162 and Figure 164).
NOTE: Pay attention to the released
balls.

Figure 162

Figure 163
10. Squeeze snap ring out.
11. Disassemble end shim and plate pack K1.

Figure 164

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 79
12. Tilt plate carrier 90°.
13. Loosen slotted nut.

CAUTION!
Slotted nut is secured with Loctite.
To prevent a damage of the thread,
heat the slotted nut before loosen it
(about 120°C (248°F)).

Figure 165
14. Pull tapered roller bearing from plate
carrier.

Figure 166
15. Pull spur gear KV from plate carrier.

Figure 167
16. Remove shim and ring.

Figure 168

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Page 80 (ZF 4WG-310)
17. Pull tapered roller bearing from plate
carrier (Figure 169).
18. Squeeze snap ring out.
19. Disassemble end shim and plate pack KV.
20. Disassemble both pistons (as described at
Figure 141 and Figure 142).

Figure 169

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(ZF 4WG-310) Page 81
TRANSMISSION REASSEMBLY
1. Install studs (Figure 170).
NOTE: Wet thread with Loctite #243

CAUTION!
According to the transmission
version, differences concerning
number and length of the studs are
possible. See in this connection the
corresponding Spare Parts List.
Figure 170
2. Line up O-ring (Figure 171).
3. Insert bush into the housing bore until
contact is obtained and fasten it.

Figure 171
POWER TAKE-OFF
1. Supercool the shaft (about -80°C (-
112°F)), heat gear (about 120°C (248°F))
and line it up, resp. press it against
shoulder.

Figure 172

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Page 82 (ZF 4WG-310)
2. Press inner bearing race against shoulder.
3. Press opposite inner bearing race against
shoulder.

Figure 173
4. Insert outer bearing race (Figure 174) into
the housing bore until contact is obtained.

Figure 174
5. Position pre-assembled PTO shaft in the
housing, and insert outer bearing race until
contact is obtained.

Figure 175
6. Adjust Axial play – Power take-off bearing
– max. 0.10 mm (0.0039 in) using shim(s)
and retaining ring.

Figure 176

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(ZF 4WG-310) Page 83
7. Tilt gearbox housing 180°.
8. Insert sealing disk (Figure 177), with the
concave side facing downward, into the
housing bore until contact is obtained.
NOTE: Wet contact face with Loctite
#262

IMPORTANT
Do not damage the centric orifice
hole ∅0.8 mm (0.0315 in) during the Figure 177
installation of the sealing disk

REASSEMBLE MULTIDISK CLUTCH K3/K4

1. Lift plate carrier, with the K4-side facing
downward, into the clamping ring (S) and
secure it. Now, tilt plate carrier 180°.
2. Insert both roll pins (6x24 and 3.5x24)
flush-mounted into the end face-side bore
of the plate carrier, see Arrow in Figure
178.

Figure 178
3. Tilt plate carrier 180°.
4. Wet both roll pins (Figure 179) with Loctite
#262 and install them.

Figure 179

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Page 84 (ZF 4WG-310)
5. Insert purge valve (Figure 180) flush-
mounted, with the chamfer facing
downward.

Figure 180
6. Insert both O-rings scrollfree into the ring
grooves of the piston, see Figure 181.

Figure 181
7. Oil O-rings and piston bearing surfaces.
8. Insert piston K3 uniformly until contact is
obtained.
NOTE: Pay attention to the installation
position of the piston, see
Figure 182.

Figure 182
9. Introduce intermediate washer and
compression spring.

Figure 183

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(ZF 4WG-310) Page 85
10. Lay guide ring, with the chamfer (Figure
184) facing upward, over the compression
spring and line up the snap ring.
11. Lift plate carrier out of the clamping ring.

Figure 184
12. Preload compression spring using Special
device (S) and squeeze snap ring into the
annular groove of the plate carrier, see
Figure 186.
13. Install purge valve, spool and compression
spring on the opposite side (Clutch K4)
accordingly, see Figure 180 - Figure 185.
14. Now, lift plate carrier, with the K4-side
facing downward, into the clamping ring
and secure it. Tilt plate carrier 180°.

Figure 185

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Page 86 (ZF 4WG-310)
Multidisk Clutch - K4
Figure 186, shows the plate stacking and the installation position of the components.

K4 K3

X Y
3 4 3 2 1

6 5

AHS1460S
Figure 186

Item Denomination Quantity s (mm) Comment

1 Plate Carrier 1
2 Piston 1
3 Outer Plate 2 1.85 (0.0728 in) One-side Coated
4 Outer Plate 5 2.5 (0.0984 in) Coated On Both Sides
5 Inner Plate 5 3.5 (0.1378 in)
6 Inner Plate 1 2.5 - 4.0 (0.0984 - 0.1575 in) Optional
7 Snap Ring 1 2.55 - 3.10 (0.1004 - 0.1220 in) Optional
8 End Shim 1
Number of friction surfaces: 12
Plate clearance: 2.2 - 2.4 mm (0.0866 - 0.0945 in)

NOTE: Install outer plates Item 3, with the uncoated side facing the piston, resp. the end shim.
The respective clutch side can be recognized by the length of the plate carrier, see Figure
186.
K4 = Dimension X (short plate-carrier side)
K3 = Dimension Y (long plate-carrier side)

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 87
1. Check Plate Clearance - K4 (2.2 - 2.4 mm
(0.0866 - 0.0945 in)) (Figure 187- Figure
189).
NOTE: To ensure a faultless measuring
result, install the plate pack for
the present without oil
A. Install the plate pack according to
Figure 186.

Figure 187
B. Introduce the end shim and secure it
using snap ring.

Figure 188
C. Press end shim on with about 100 N
(10 kg) and set dial indicator to
"Zero" (Figure 189).
D. Now, press end shim against the
snap ring (upward) and read the
plate clearance on the dial indicator.
E. After the performed adjustment of the
plate clearance, disassemble the
plate pack, oil the plates according to
ZF-List of lubricants TE-ML 03, and
install them again.
Figure 189

IMPORTANT
In case of a deviation from the required plate clearance (2.2 - 2.4 mm (0.0866 - 0.0945 in)),
correct with corresponding inner plate Item 6 (optional s = 2.5 - 4.0 mm (0.0984 - 0.1575 in))
or and snap ring Item 7 (optional).

S0607080K Transmission and Torque Converter

Page 88 (ZF 4WG-310)
2. Pre-assemble and install Spur gear K4
(Figure 190 - Figure 196).
A. Figure 190, shows the components
of spur gear K4.

Reference
Description
Number
1 Inner Bearing Race
2 Outer Bearing Race
3 Shim (Optional, Empirical
Value s=5.4 mm (0.2126
in))
Figure 190
4 Spur Gear

B. Check Axial play – Spur gear bearing

0.0 - 0.05 mm (0.0 - 0.0020 in).
C. Install components, according to
Figure 190. Preload tapered roller
bearing with about 50,000 N (5.5
ton), and determine axial play with
dial indicator.
NOTE: In case of deviations from the
required axial play, correct with
corresponding shim (Item 3/
Figure 190).
Figure 191
D. Heat inner bearing race and line it up
until contact is obtained.

Figure 192

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(ZF 4WG-310) Page 89
 E. Line up the determined shim (see
Figure 190 and Figure 191), with the
oil groove facing upward.

Figure 193
F. Introduce spur gear until all inner
plates are accommodated.

Figure 194
G. Heat inner bearing race (spur gear
bearing) and position it against
shoulder.

CAUTION!
Use protective gloves.

Figure 195
H. Heat inner bearing race (spur gear
bearing) and position it against
shoulder.

CAUTION!
Use protective gloves.

Figure 196

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Page 90 (ZF 4WG-310)
Multidisk Clutch - K3
Figure 197, shows the plate stacking and the installation position of the components.

K4 K3

X Y
1 2 3 4 3

8
9

5 6 57

AHS1470S
Figure 197

Item Denomination Quantity s (mm) Comment

1 Plate Carrier 1
2 Piston 1
3 Outer Plate 2 1.85 (0.0728 in) One-side Coated
4 Outer Plate 8 2.5 (0.0984 in) Coated On Both Sides
5 Inner Plate 3 2.5 (0.0984 in)
6 Inner Plate 5 3.0 (0.1181 in)
7 Inner Plate 1 2.5 - 4.0 (0.0984 - 0.1575 in) Optional
8 Snap Ring 1 2.55 - 3.10 (0.1004 - 0.1220 in) Optional
9 End Shim 1
Number of friction surfaces: 18
Plate clearance: 2.6 - 2.8 mm (0.1024 - 0.1102 in)

NOTE: Install outer plates Item 3, with the uncoated side facing the piston, resp. the end shim.
The respective clutch side can be recognized by the length of the plate carrier, see Figure
197.
K4 = Dimension X (short plate-carrier side)
K3 = Dimension Y (long plate-carrier side)

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 91
1. Check plate clearance K3 = 2.6 - 2.8 mm
(Figure 198 - Figure 200).
NOTE: To ensure a faultless measuring
result, install the plates for the
present without oil.
A. Install the plate pack according to
Figure 197.

Figure 198
B. Introduce the end shim and secure it
using snap ring.

Figure 199
C. Press the end shim on with about
100 N (10 kg) and set the dial
indicator to "Zero" (Figure 200).
D. Now, press the end shim against the
snap ring (upward), and read the
plate clearance on the dial indicator.
E. After the performed adjustment of the
plate clearance, disassemble the
plate pack, oil plates according to ZF-
List of lubricants TE-ML 03 and
install them again.
Figure 200

IMPORTANT
In case of a deviation from the required plate clearance (2.2 - 2.4 mm (0.0866 - 0.0945 in)),
correct with corresponding inner plate Item 6 (optional s = 2.5 - 4.0 mm (0.0984 - 0.1575 in))
or and snap ring Item 7 (optional).

S0607080K Transmission and Torque Converter

Page 92 (ZF 4WG-310)
2. Heat inner bearing race and line it up until
contact is obtained.

CAUTION!
Use protective gloves.

Figure 201
3. Lift plate carrier out of the clamping ring
(S).
4. To ensure the exact contact of the
components, preload the bearing with 100
000 N (10 ton) (Figure 202).

CAUTION!
Support on the lower and on the
upper inner bearing race.
Use pressure pieces (S). Figure 202

5. Lift plate carrier, with the K4-side facing

downward, into the clamping ring (S) and
secure it.
6. Tilt plate carrier 90°.
7. Wet thread of slotted nut with Loctite #262
and install slotted nut (Figure 203).
NOTE: Install slotted nut, with the collar
(∅60 mm (2.3622 in) facing the
inner bearing race.

Figure 203

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(ZF 4WG-310) Page 93
8. Insert outer bearing race into the spur gear
K3 until contact is obtained.

Figure 204
9. Heat roller bearing and position it against
shoulder.

Figure 205
10. Tighten slotted nut.

CAUTION!
Use protective gloves.

Figure 206
11. Introduce inner bearing race.

Figure 207

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Page 94 (ZF 4WG-310)
12. Check function of clutch using compressed
air.
NOTE: At correctly installed
components, the closing resp.
opening of the clutches is
clearly audible.

Figure 208
13. Squeeze in and engage rectangular rings
(3x, Figure 209).

Figure 209

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(ZF 4WG-310) Page 95
REASSEMBLE MULTIDISK CLUTCH KR/K2
1. Lift plate carrier, with the KR-side facing
downward, into the clamping ring and
secure it.
2. Tilt plate carrier 180°.
3. Insert both roll pins (6x24 and 3.5x24)
flush-mounted into the spur gear-side bore
(Figure 210) of the plate carrier.

Figure 210
4. Tilt plate carrier 180°.
5. Wet both set screws (Figure 211) with
Loctite #262 and install them.

Figure 211
6. Insert purge valve (Figure 212) flush-
mounted, with the chamfer facing
downward.

Figure 212
7. Lay both O-rings scrollfree into the ring
grooves of the piston, see Arrows.

Figure 213

S0607080K Transmission and Torque Converter

Page 96 (ZF 4WG-310)
8. Oil O-rings and piston bearing surfaces.
Insert K2 piston uniformly until contact is
obtained.
NOTE: Pay attention to the installation
position of the piston, see /
Figure 214.

Figure 214
9. Introduce intermediate plate and
compression spring.

Figure 215
10. Lay guide ring, with the chamfer (Arrow)
facing upward, over the compression
spring and line up the snap ring.

Figure 216
11. Lift plate carrier out of the clamping ring
(S). Preload compression spring using
Special device (S) and squeeze snap ring
into the annular groove of the plate carrier
(Arrow), see Figure 217.
12. Install purge valve, spool and compression
spring on the opposite side (KR clutch)
accordingly as Figure 212 - Figure 217.
13. Now, lift plate carrier, with the KR-side
facing downward into the clamping ring (S)
and secure it.
Figure 217

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(ZF 4WG-310) Page 97
Multidisk Clutch - KR
Figure 218, shows the plate stacking and the installation position of the components.

KR K2

3 4 3 2 1

6 5

AHS1780S
Figure 218

Item Denomination Quantity s (mm) Comment

1 Plate Carrier 1
2 Piston 1
3 Outer Plate 2 1.85 (0.0728 in) One-side Coated
4 Outer Plate 11 2.5 (0.0984 in) Coated On Both Sides
5 Inner Plate 11 2.5 (0.0984 in)
6 Inner Plate 1 3.0 (0.1181 in) Optional
7 Snap Ring 1 2.5 - 4.0 (0.0984 - 0.1575 in) Optional
8 End Shim 1
Number of friction surfaces: 24
Plate clearance: 2.8 - 3.0 mm (0.1102 - 0.1181 in)

NOTE: Install outer plates Item 3, with the uncoated side facing the piston, resp. the end shim.
The respective clutch side can be recognized by the length of the plate carrier, see Figure
218.
KR = Dimension Y (long plate-carrier side)
K2 = Dimension X (short plate-carrier side)

S0607080K Transmission and Torque Converter

Page 98 (ZF 4WG-310)
1. Check Plate clearance KR = 2.8 - 3.0 mm
(0.1102 - 0.1181 in) (Figure 219 - Figure
221).
NOTE: To ensure a faultless measuring
result, install the plates for the
present without oil.
A. Install plate pack according to Figure
218.

Figure 219
B. Introduce end shim and secure it
using snap ring.

Figure 220
C. Press the end shim on with about
100 N (10 kg) and set the dial
indicator to "Zero." Now, press the
end shim against the snap ring
(upward) and read the plate
clearance on the dial indicator.
D. After the performed adjustment of the
plate clearance, disassemble the
plate pack, oil plates according to ZF-
List of lubricants TE-ML 03 and
install them again.

Figure 221

IMPORTANT
In case of deviations from the required plate clearance = 2.8 - 3.0 mm (0.1102 - 0.1181 in), correct
with corresponding inner plate Item 6 (optional 2.5 - 4.0 mm (0.0984 - 0.1575 in)) or and snap ring
Item 7 (optional).

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 99
2. Pre-assemble and install Spur gear KR
(Figure 222 - Figure 230)
A. Figure 222, shows the components
of spur gear KR.

Reference
Description
Number
1 Inner Bearing Race
2 Shim s=3.0 and
s=3.10 mm
(∑=6.10 mm / Empirical
Value)
Figure 222
3 Spur Gear
4 Inner Bearing Race

B. Check Axial play – Spur gear bearing

0.0 - 0.05 mm (0.0 - 0.0020 in).
C. Place spur gear over the inner
bearing race.

Figure 223
D. Introduce shims (2 pieces/s = 3.0
(0.1181 in) and s = 3.10 mm (0.1220
in)).

Figure 224

S0607080K Transmission and Torque Converter

Page 100 (ZF 4WG-310)
 E. Mount inner bearing race.

Figure 225
F. Preload the tapered roller bearing
with about 50 000 N (5 ton) and
determine the axial play with dial
indicator.
NOTE: In case of deviations from the
required axial play, correct with
corresponding shims (Item 2/
Figure 222).

Figure 226
G. Heat inner bearing race and position
it against shoulder.

CAUTION!
Use protective gloves.

Figure 227
H. Introduce the spur gear until all inner
plates are accommodated.

Figure 228

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 101
 I. Introduce determined shims (see
Figure 223 to Figure 226).

Figure 229
J. Heat inner bearing race (spur gear
bearing) and position it against
shoulder.

CAUTION!
Use protective gloves.

Figure 230
K. Heat inner bearing race (spur gear
bearing) and position it against
shoulder.

CAUTION!
Use protective gloves.

Figure 231

S0607080K Transmission and Torque Converter

Page 102 (ZF 4WG-310)
Multidisk Clutch - K2
Figure 232, shows the plate stacking and the installation position of the components.

KR K2

Y X
1 2 3 4 3

5 6 5 7

AHS1790S
Figure 232

Item Denomination Quantity s (mm) Comment

1 Plate Carrier 1
2 Piston 1
3 Outer Plate 2 1.85 (0.0728 in) One-side Coated
4 Outer Plate 8 2.5 (0.0984 in) Coated On Both Sides
5 Inner Plate 3 2.5 (0.0984 in)
6 Inner Plate 5 3.0 (0.1181 in)
7 Inner Plate 1 2.5 - 4.0 (0.0984 - 0.1575 in) Optional
8 Snap Ring 1 2.55 - 3.10 (0.1004 - 0.1220 in) Optional
9 End Shim 1
Number of friction surfaces: 18
Plate clearance: 2.6 - 2.8 mm (0.1024 - 0.1102 in)

NOTE: Install outer plates Item 3, with the uncoated side facing the piston, resp. the end shim.
The respective clutch side can be recognized by the length of the plate carrier, see Figure
232.
KR = Dimension Y (long plate-carrier side)
K2 = Dimension X (short plate-carrier side)

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 103
1. Check Plate clearanceK2 = 2.6 - 2.8 mm
(Figure 233 - Figure 235).
NOTE: To ensure a faultless measuring
result, install the plates for the
present without oil.
A. Install the plate pack according to
Figure 232.

Figure 233
B. Introduce end shim and secure it
using snap ring.

Figure 234
C. Press the end shim on with about
100 N (10 kg) and set the dial
indicator to "Zero."
D. Now, press the end shim against the
snap ring (upward) and read the
plate clearance on the dial indicator.
E. After the performed adjustment of the
plate clearance, disassemble the
plate pack, oil the plates according to
ZF-List of lubricants TE-ML 03 and
install them again.
Figure 235

IMPORTANT
In case of deviations from the required plate clearance = 2.6 - 2.8 mm (0.1024 - 0.1102 in), correct
with corresponding inner plate Item 7 (optional s = 2.5 - 4.0 mm (0.0984 - 0.1575 in)) or and snap
ring Item 8 (optional).

S0607080K Transmission and Torque Converter

Page 104 (ZF 4WG-310)
2. Pre-assemble and install Spur gear K2
(Figure 236 - Figure 245)
A. Supercool gear wheel 1 (about -80°C
(-112°F)) and heat gear wheel 2
(about 120°C (248°F)). Squeeze
snap ring in (Arrow), preload, and
join both parts together using
hydraulic press until the snap ring
snaps into the annular groove of the
gear wheel 2.

Figure 236
B. Adjust Axial play – Spur gear bearing
0.05 - 0.15 mm (0.0020 - 0.0059 in)
(Figure 237 - Example C).
C. Figure 237, shows the components
of the spur gear bearing.

Reference
Description
Number
1 Bearings Inner Race
2 Shim (Optional)
3 Spur Gear Compl.
4 Inner Bearing Race Figure 237
D. Place spur gear over the inner
bearing race.

Figure 238

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 105
 E. Introduce inner bearing race.

Figure 239
F. Determine Dimension I (bearing
dimension).
NOTE: Dimension I e.g. 76.270 mm
(3.0028 in)

Figure 240
G. Determine Dimension II (shaft
dimension).
NOTE: Dimension II e.g. 74.14 mm
(3.0028 in)

Figure 241
EXAMPLE C:

Dimension I e.g. 76.27 mm (3.0028 in)

Dimension II e.g. - 74.14 mm (2.9189 in)
Difference = 2.13 mm (0.0839 in)
Axial Play e.g. + 0.07 mm (0.0028 in)
Gives Shim = 2.20 mm (0.0866 in)

S0607080K Transmission and Torque Converter

Page 106 (ZF 4WG-310)
3. Heat inner bearing race and line it up until
contact is obtained.

CAUTION!
Use protective gloves.

Figure 242
4. Introduce spur gear until all inner plates
are accommodated.

Figure 243
5. Line up shim (e.g. s = 2.20 mm (0.0866 in),
see Example/page 106).

Figure 244
6. Heat inner bearing race (spur gear
bearing) and line it up until contact is
obtained.

CAUTION!
Use protective gloves.

Figure 245

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 107
7. Heat inner bearing race (clutch bearing)
and position it against shoulder.

CAUTION!
Use protective gloves.

Figure 246
8. Lift plate carrier out of the clamping ring
(S).
9. To ensure the exact contact of the
components, preload bearing with 100 000
N (10 ton) (Figure 247).

CAUTION!
Support on the lower and on the
upper bearing race. Use pressure
pieces (S).
Figure 247
10. Lift plate carrier into the clamping ring (S)
and secure it.
A. Tilt clutch 90°.
B. K2-Side: Wet thread of slotted nut
with Loctite #262 and install it (Figure
317).
NOTE: Install slotted nut with the
chamfer facing the inner
bearing race.
NOTE: Torque limit 800 Nm (590 ft lb).
Figure 248
C. KR-Side: Wet thread of slotted nut
with Loctite #262 and install it.
NOTE: Install slotted nut, with the collar
(∅ 70 mm (2.7560 in)) facing
the inner bearing race.
NOTE: Torque limit 800 Nm (590 ft lb).

Figure 249

S0607080K Transmission and Torque Converter

Page 108 (ZF 4WG-310)
 D. D. Check function of clutches K3 and
K4 using compressed air (Figure
250).
NOTE: At correctly installed
components, the closing, resp.
opening of the clutches is
clearly audible.
E. Squeeze in and engage rectangular
ring (3x – see Arrows).

Figure 250

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(ZF 4WG-310) Page 109
REASSEMBLE MULTIDISK CLUTCH KV / K1
1. Lift plate carrier, with the KV-side facing
downward, into the clamping ring (S) and
secure it.
2. Tilt plate carrier 180°.
3. Insert both roll pins (6x24 and 3.5x24)
flush-mounted into the end face-side bore
of the plate carrier (Figure 251).

Figure 251
4. Tilt plate carrier 180°.
5. Wet both set screws (Figure 252) with
Loctite #262 and install them.

Figure 252
6. Drive purge valve (Arrow) flush-mounted
in, with the chamfer facing downward.

Figure 253
7. Lay both O-rings scrollfree into the ring
grooves of the piston, see Figure 254.

Figure 254

S0607080K Transmission and Torque Converter

Page 110 (ZF 4WG-310)
8. Oil O-rings and piston bearing surfaces.
9. Insert K1-piston uniformly against
shoulder.
NOTE: Pay attention to the installation
position of the piston, see
Figure 255.

Figure 255
10. Introduce intermediate washer and
compression spring.

Figure 256
11. Lay guide ring, with the chamfer (Figure
257) facing upward, over the compression
spring and line up the snap ring.

Figure 257
12. Lift the plate carrier out of the clamping
ring. Preload compression spring using
Special device (S) and squeeze snap ring
into the annular groove of the plate carrier
(Arrow) – seeFigure 258.
13. Install purge valve, spool and compression
spring on the opposite side (KV-clutch)
accordingly.
14. Now, lift the plate carrier, with the KV-side
facing downward, into the clamping ring
(S) and secure it. Tilt plate carrier 180°.
Figure 258

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(ZF 4WG-310) Page 111
Multidisk Clutch - KV
Figure 259, shows the plate stacking and the installation position of the components.

KV K1
Y X
3 4 3 2 1

6 5

AHS2190S
Figure 259

Item Denomination Quantity s (mm) Comment

1 Plate Carrier 1
2 Piston 1
3 Outer Plate 2 1.85 (0.0728 in) One-side Coated
4 Outer Plate 11 2.5 (0.0984 in) Coated On Both Sides
5 Inner Plate 11 2.5 (0.0984 in)
6 Inner Plate 1 3.0 (0.1181 in) Optional
7 Snap Ring 1 2.5 - 4.0 (0.0984 - 0.1575 in) Optional
8 End Shim 1
Number of friction surfaces: 24
Plate clearance: 2.8 - 3.0 mm (0.1102 - 0.1181 in)

NOTE: Install outer plates Item 3, with the uncoated side facing the piston, resp. the end shim.
The respective clutch side can be recognized by the length, resp. ∅ of the plate carrier,
see Figure 259.
KV = Dimension Y (long plate-carrier side, resp. great ∅)
K1 = Dimension X (short plate-carrier side, resp. small ∅)

S0607080K Transmission and Torque Converter

Page 112 (ZF 4WG-310)
1. Check plate clearance KV = 2.8 - 3.0 mm
(0.1102 - 0.1181 in) (Figure 260 - Figure
262).
NOTE: To ensure a faultless measuring
result, install the plates for the
present without oil.
A. Install the plate pack according to
Figure 259.

Figure 260
B. Introduce the end shim and secure it
using snap ring.

Figure 261
C. Press the end shim on with about
100 N (10 kg) and set the dial
indicator to "Zero."
D. Now, press the end shim against the
snap ring (upward), and read the
plate clearance on the dial indicator.

Figure 262

IMPORTANT
In case of deviations from the required plate clearance = 2.8 - 3.0 mm (0.1102 - 0.1181 in),
correct with corresponding inner plate Item 6 (optional s = 2.5 - 4.0 (0.0984 - 0.1575 in)) or
and snap ring (optional).
After the performed adjustment of the plate clearance disassemble the plate pack, oil plates
according to ZF-List of lubricants TE-ML 03 and install them again.

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 113
2. Pre-assemble and install Spur gear KV
(Figure 263 - Figure 271):
A. Figure 263, shows the components
of spur gear KV.

Reference
Description
Number
1 Inner Bearing Race
2 Outer Bearing Race
3 Ring
4 Shim(s) Optional,
Empirical Value s = 1.70 Figure 263
mm (0.0669 in)
5 Spur Gear

B. Check Axial play – Spur gear bearing

0.0 - 0.05 mm (0.0 - 0.0020 in).
C. Install both outer bearing races (2)
and place spur gear over the inner
bearing race.

Figure 264
D. Introduce shim(s) 4 and ring 3.

Figure 265

S0607080K Transmission and Torque Converter

Page 114 (ZF 4WG-310)
 Figure 266
E. Preload the tapered roller bearing
with about 50,000 N (5.5 ton) and
determine axial play using dial
indicator.
NOTE: In case of deviations from the
required axial play, correct with
corresponding shim (Item 4/
Figure 263).

Figure 267
F. Heat inner bearing race and position
it against shoulder.

CAUTION!
Use protective gloves.

Figure 268
G. Line up shim (see Figure 263 -Figure
267) and ring.

Figure 269

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 115
 H. Introduce spur gear until all inner
plates are accommodated.

Figure 270
I. Heat inner bearing race (spur gear
bearing) and position it against
shoulder.

CAUTION!
Use protective gloves.

Figure 271
J. Heat inner bearing race (clutch
bearing) and position it against
shoulder.

CAUTION!
Use protective gloves.

K. Tilt plate carrier 180°.

Figure 272

S0607080K Transmission and Torque Converter

Page 116 (ZF 4WG-310)
Multidisk Clutch - K4
Figure 273, shows the plate stacking and the installation position of the components.

KV K1
Y X
1 2 3 4 3
7
8

5 6

AHS2330S
Figure 273

Item Denomination Quantity s (mm) Comment

1 Plate Carrier 1
2 Piston 1
3 Outer Plate 2 1.85 (0.0728 in) One-side Coated
4 Outer Plate 8 2.5 (0.0984 in) Coated On Both
Sides
5 Inner Plate 8 3.5 (0.1378 in)
6 Inner Plate 1 2.5 - 3.5 (0.0984 - 0.1378 in) Optional
7 Snap Ring 1 2.1 - 2.5 (0.0827 - 0.0984 in) Optional
8 End Shim 1
Number of friction surfaces: 18
Plate clearance: 2.6 - 2.8 mm (0.1024 - 0.1102 in)

NOTE: Install outer plates Item 3, with the uncoated side facing the piston, resp. the end shim.
The respective clutch side can be recognized by the length, resp. ∅ of the plate carrier,
see Figure 273.
KV = Dimension Y (long plate-carrier side, resp. great ∅)
K1 = Dimension X (short plate-carrier side, resp. small ∅)

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 117
1. Check plate clearance K1 = 2.6 - 2.8 mm
(0.1024 - 0.1102 in) (Figure 274 - Figure
276).
NOTE: To ensure a faultless measuring
result, install the plates for the
present without oil.
A. Install plate pack according to Figure
273.

Figure 274
B. Introduce the end shim and secure it
using snap ring.

Figure 275
C. Press the end shim on with about
100 N (10 kg) and set the dial
indicator to "Zero."
D. Now, press the end shim against the
snap ring (upward), and read the
plate clearance on the dial indicator.
E. After the performed adjustment of the
plate clearance, disassemble the
plate pack, oil plates according to ZF-
List of lubricants TE-ML 03 and
install them again.
Figure 276

IMPORTANT
In case of deviations from the required plate clearance = 2.6 - 2.8 mm (0.1024 - 0.1102 in), correct
with corresponding inner plate Item 6 (optional 2.5 - 3.5 mm (0.0984 - 0.1378 in)) or and snap ring
Item 7 (optional).

S0607080K Transmission and Torque Converter

Page 118 (ZF 4WG-310)
2. Pre-assemble and install Spur gear K1
(Figure 277 - Figure 284).
A. Figure 277, shows the components
of spur gear K1.

Reference
Description
Number
1 Ball Bearing (Compl.)
2 Snap Ring
3 Spur Gear

Figure 277
NOTE: Prior to assemble the
components, align plate pack
using the spur gear radially and
center it, see Figure 278.

Figure 278
B. Install snap ring.

Figure 279
C. Introduce bush, with the end face-
side collar (Arrow) facing the snap
ring.

Figure 280

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 119
 D. Press ball bearing in until contact is
obtained.
NOTE: Install ball bearing, with the
lubricating groove (Arrow)
facing downward. Apply the
pressing-in tool only on the
outer bearing race.

Figure 281
E. Heat ball bearing and line it up until
contact is obtained.
NOTE: Lubricating groove (Arrow)
must face upward.

CAUTION!
Use protective gloves.

Figure 282
F. Line up the bush.

Figure 283
G. Heat spur gear about 120°C (248°F)
and introduce it until all inner plates
are accommodated.

CAUTION!
Use protective gloves.

Figure 284

S0607080K Transmission and Torque Converter

Page 120 (ZF 4WG-310)
 NOTE: Line up shim = 1.2 mm (0.0472
in).

Figure 285
3. Heat inner bearing race and line it up until
contact is obtained.

CAUTION!
Use protective gloves.

Figure 286
4. Lift plate carrier out of the clamping ring
(S). To ensure the exact contact of the
components, preload bearing with 100 000
N (10 ton) (Figure 287).

CAUTION!
Support on the lower and on the
upper inner bearing race. Use
pressure pieces (S).

Figure 287
5. Lift plate carrier into the clamping ring (S),
secure and tilt it 90°. Wet thread of slotted
nut with Loctite #262 and install slotted
nut.
NOTE: Install slotted nut, with the collar
facing the inner bearing race.
NOTE: Torque limit 550 Nm (405 ft lb).
6. Install opposite slotted nut (KV-side)
accordingly.

Figure 288

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 121
7. Check function of the clutches KV and K1
using compressed air.
NOTE: At correctly installed
components, the closing, resp.
opening of the clutches is
clearly audible.

Figure 289
8. Squeeze in and engage rectangular rings
(3x, see Arrows).

Figure 290

S0607080K Transmission and Torque Converter

Page 122 (ZF 4WG-310)
INSTALL COUNTERSHAFT GEAR AND
MULTIDISK CLUTCHES
1. Adjust axial play of the countershaft gear
bearing 0.0 - 0.05 mm (0.0 - 0.0020 in)
(Figure 291 - Example D2).
2. Determine Dimension I (shaft dimension).
NOTE: Dimension I e.g. 61.57 mm
(2.4240 in).

Figure 291
3. Measure Dimension II (housing
dimension) from the locating face of the
inner bearing race to the locating face of
the axle.
NOTE: Dimension II e.g. 0.52 mm
(0.0205 in).

Figure 292

EXAMPLE D1:

Dimension I e.g. 61.57 mm (2.4240 in)

Dimension II e.g. - 0.52 mm (0.0205 in)
Gives Dimension X 61.05 mm (2.4035 in)
Required Axial Play e.g. - 0.03 mm (0.0012 in)
Gives Installation Dimension Y e.g. = 61.02 mm (2.4024 in)

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 123
4. Install both inner bearing races. Lay pre-
assembled countershaft gear upon the
surface plate and determine Dimension III
(bearing dimension).
NOTE: Dimension III e.g. 59.52 mm
(2.3433 in).

EXAMPLE D2: Figure 293

Dimension Y (installation dimension) 61.02 mm (2.4024 in)

Dimension III (bearing dimension) - 59.52 mm (2.3433 in)
Gives Shim e.g. s = 1.50 mm (0.0591 in)

NOTE: The assembly of the shim and

of the countershaft axle can be
performed only after the
installation of the clutches
(page 139).
5. Position countershaft gear (along with
inner bearing races), see Figure 294.

Figure 294
6. Insert outer bearing races KV/K1, KR/K2
and K3/K4 into the housing bores until
contact is obtained, see Arrows.

Figure 295

S0607080K Transmission and Torque Converter

Page 124 (ZF 4WG-310)
7. Position clutch KV/K1, using lifting device.

Figure 296
8. Position clutch KR/K2.

Figure 297
9. Check installation position of the
countershaft gear (Arrow) once more and
correct if necessary.

Figure 298
10. Locate the spur gear K3 using Special
device and eye bolt (Arrow) axially.
NOTE: The securing of spur gear
prevents the slipping out of the
plates during the lifting into
position of the clutch.

Figure 299

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 125
11. Lift clutch KR/K2 slightly, displace it in
direction of arrow, and position clutch K3/
K4.
12. Now, remove the Special device again.

Figure 300
13. Cool down outer bearing race and insert in
into housing bore until contact is obtained.

Figure 301
14. Heat inner bearing race and assemble it
until contact is obtained.

Figure 302
15. Position oil baffle.

Figure 303

S0607080K Transmission and Torque Converter

Page 126 (ZF 4WG-310)
16. Install output gear.

Figure 304
17. Insert second oil baffle and fasten both
plates using hex. head screws (mount
plain washer).
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(16.96 ft lb).
NOTE: Secure hex. head screws with
Loctite #262.

Figure 305
18. Cool down output shaft and install it until
contact is obtained.
NOTE: Pay attention to installation
position, see Figure 306.

Figure 306

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(ZF 4WG-310) Page 127
PRE-ASSEMBLE AND MOUNT HOUSING
COVER
1. Mount components.

Reference
Description
Number
1 Sealing Cover (Use
Loctite #262)
2 Connecting Piece (Install
New Sealing Ring)
3 Cover Plate (Install New
Gasket)
Figure 307
4 Sealing Cover (Use
Loctite #262)

NOTE: According to the transmission

version, differences concerning
components and their
installation positions are
possible. In this connection, see
the respective Spare Parts List.
2. Drive the roll pin (2x8 mm (0.0787 x
0.3150 in) flush-mounted in (1, Figure
308).
3. Equip screw plug with new O-ring and
install it (2, Figure 308).

Figure 308
4. Squeeze both snap rings (Arrow) into the
recess.

Figure 309

S0607080K Transmission and Torque Converter

Page 128 (ZF 4WG-310)
5. Expand the two snap rings. Introduce ball
bearing, with the annular groove facing
upward, until the upper snap ring snaps
into the groove of the ball bearing.

Figure 310
6. Insert gear wheel until contact is obtained.

Figure 311
7. Secure gear wheel using retaining ring.

Figure 312
8. Cover mounting face with sealing
compound Loctite #574).
9. Install two adjusting screws and position
the housing cover on the gearbox housing
until contact is obtained, using lifting de-
vice.

Figure 313

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(ZF 4WG-310) Page 129
10. Insert both cylindrical pins (1 and 2, Figure
314) until contact is obtained.
11. Fasten housing cover using screw
connection.
12. Drive roll pin (3, Figure 314) flush-mounted
in.
NOTE: Torque limit (M10/8.8) 46 Nm
(34 ft lb).

Figure 314
13. Insert ball bearing until contact is obtained.

Figure 315
NOTE: Introduce shim s = 4.0 mm
(0.1575 in).

Figure 316
14. Secure ball bearing free play, using shim
and retaining ring.

Figure 317

S0607080K Transmission and Torque Converter

Page 130 (ZF 4WG-310)
15. Install shaft seal, with the sealing lip facing
the oil chamber.
NOTE: At application of the prescribed
driver (S), the exact installation
position is obtained. Grease
sealing lip.

CAUTION!
According to the version, different
shaft seals can have been applied.
Outer diameter rubber-coated – wet Figure 318
with mineral spirits.
Outer diameter metallic - wet with
sealing compound (Loctite #574).

16. Press screening plate against shoulder.

Figure 319
17. Line up output flange.
18. Wet contact face of the shim with sealing
compound Loctite #574 and fasten output
flange with hex head screws.
NOTE: Torque limit (M10/8.8) 46 Nm
(34 ft lb).

Figure 320

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 131
19. Secure hex. head screws using lock plate.

Figure 321
20. Adjust bearing preload – Clutch K3/K4 =
0.00 - 0.15 mm (0.00 - 0.0059 in) (Figure
322 - Figure 324).
A. Insert inner bearing race into the
outer race.
Housing dimension: Press the inner
bearing race uniformly on, and
determine Dimension I from the
mounting face to the inner bearing
race.
NOTE: Dimension I e.g. 43.85 mm
(1.7264 in). Figure 322
NOTE: Apply several measuring points
and determine the average value.
Cover dimension: Determine
Dimension II from the mounting face
to the con-tact / inner bearing race.
NOTE: Dimension II e.g. 42.15 mm
(1.6594 in).

Figure 323

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Page 132 (ZF 4WG-310)
 B. Line up the shim.

Figure 324
EXAMPLE F:

Dimension I e.g. 43.85 mm (1.7264 in)

Dimension II e.g. - 42.15 mm (1.6594 in)
Difference = 1.70 mm (0.0669 in)
Bearing Preload e.g. + 0.10 mm (0.0039 in)
Gives Shim (s) s = 1.80 mm (0.0709 in)

21. Heat inner bearing race and position it

against shoulder.

CAUTION!
Use protective gloves.

Figure 325
22. Install and grease O-ring (Figure 326).
23. Heat inner diameter of the bearing cover
(bearing seat).

Figure 326

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 133
24. Grease and align rectangular rings (3x,
Figure 327) and align them centrically.

Figure 327
25. Install two adjusting screws. Line up the
bearing cover using hex. head screws and
pull it uniformly against shoulder.
NOTE: Torque limit (M10/8.8) 46 Nm
(34 ft lb).
NOTE: Pay attention to the radial
installation position, see
markings (Arrows).

Figure 328
26. Adjust bearing preload of Clutch KR/K2 =
0.20 - 0.25 mm (0.0079 - 0.0098 in)
(Figure 329 - Figure 332).
A. Insert outer bearing race until contact
is obtained.

Figure 329
Housing dimension: Determine
Dimension I from outer bearing race
to mounting face.
NOTE: Dimension I e.g. 15.68 mm
(0.6173 in).

Figure 330

S0607080K Transmission and Torque Converter

Page 134 (ZF 4WG-310)
 Cover dimension: Determine
Dimension II from the contact/outer
bearing race to the mounting face.
NOTE: Dimension II e.g. 17.46 mm
(0.6874 in).

Figure 331
B. Make shim adhere with assembly
grease in the cover. Install O-ring
(Arrow).

Figure 332
EXAMPLE G:

Dimension I e.g. 17.46 mm (0.6874 in)

Dimension II e.g. - 15.68 mm (0.6173 in)
Difference = 1.78 mm (0.0701 in)
Bearing Preload e.g. + 0.22 mm (0.0079 in)
Gives Shim (s) s = 2.00 mm (0.0787 in)

27. Grease and align rectangular rings (Figure

333) centrically.

Figure 333

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 135
28. Pull bearing cover uniformly against
shoulder.
NOTE: Torque limit (M10/8.8) 46 Nm
(34 ft lb).
NOTE: Pay attention to the radial
installation position, see
markings (Figure 334).

Figure 334
29. Adjust Bearing preload of the Clutch KV/
K1= 0.15 - 0.20 mm (0.0059 - 0.0079 in)
(Figure 335 - Figure 338).
A. Lay outer bearing race over the inner
bearing race.
Housing dimension: Press the outer
bearing race uniformly on, and determine
Dimension I from the mounting face to the
outer bearing race.
NOTE: Dimension I e.g. 52.67 mm
(2.0736 in).
NOTE: Apply several measuring points Figure 335
and determine the average
value.
B. Insert ring, with the chamfer facing
downward, into the bearing cover.

Figure 336

S0607080K Transmission and Torque Converter

Page 136 (ZF 4WG-310)
 Cover dimension: Determine Dimension II
from the mounting face to the ring.
NOTE: Dimension II e.g. 50.75 mm
(1.9980 in).

Figure 337
C. Insert shim.

Figure 338
EXAMPLE H:

Dimension I 52.67 mm (2.0736 in)

Dimension II - 50.75 mm (1.9980 in)
Difference 1.92 mm (0.0076 in)
Bearing Preload e.g. + 0.18 mm (0.0071 in)
Gives Shim (s) s = 2.10 mm (0.0827 in)

30. Insert outer bearing race until contact is

obtained.
31. Line up O-ring (Figure 339).

Figure 339

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 137
32. Grease and align the rectangular rings
(Figure 340) centrically.

Figure 340
33. Insert the bearing cover until contact is
obtained and fasten using hex. head
screws.
NOTE: Torque limit (M10/8.8) 46 Nm
(34 ft lb).
NOTE: Pay attention to the radial
installation position, see
markings (Arrows).

Figure 341

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Page 138 (ZF 4WG-310)
INSTALL COUNTERSHAFT AXLE
1. Tilt gearbox housing 180°.
2. Align countershaft gear centrically.
3. Install adjusting screw (Figure 342).

Figure 342
4. Supercool pin.
5. Make determined shim (see also page
123) adhere with grease.

Figure 343
6. Insert pin until contact is obtained.

CAUTION!
Use protective gloves.

Figure 344
7. Remove adjusting screw and secure bolt
using hex. head screw.
NOTE: Torque limit (M10/8.8) 46 Nm
(34 ft lb).
NOTE: Wet thread of hex. head screw
with Loctite #243.

Figure 345

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 139
8. Drive the sealing covers (Figure 346) in,
with the concave side showing downward,
flush-mounted to the housing face.
NOTE: Wet contact face with Loctite
#262.

Figure 346
HYDRAULIC PUMP
1. Press needle sleeve (Figure 347) against
shoulder, with the reinforced shell facing
the pressing-in tool.

Figure 347
2. Insert disk s = 1.3 mm (0.0512 in) and
position outer bearing race against
shoulder.

Figure 348
3. Install and grease O-ring (Figure 349).

Figure 349

S0607080K Transmission and Torque Converter

Page 140 (ZF 4WG-310)
4. Supercool the pump to about -80°C
(-112°F).
5. Install two adjusting screws and introduce
pump until contact is obtained.
NOTE: Pay attention to the radial
installation position.

CAUTION!
Use protective gloves.
Figure 350
6. Install O-ring (Figure 351) and mount
pump flange.

Figure 351
7. Fasten pump flange, resp. the pump using
hex. head screws.
NOTE: Torque limit (M12/8.8) 79 Nm
(58 ft lb).
NOTE: Wet thread of the two hex. head
screws, (Position, see Arrows)
with Loctite #243 (through
holes).

Figure 352
8. Insert O-ring (Figure 353) into the annular
groove and grease it. Fasten pump flange
(power take-off) with hex. head screws.
NOTE: Torque limit (M14/8.8) 125 Nm
(92 ft lb).

Figure 353

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(ZF 4WG-310) Page 141
AXLE DISCONNECTION
1. Install shaft seal (Arrow), with the sealing
lip facing the oil chamber.
NOTE: At application of the prescribed
driver (S), the exact installation
position is obtained. Grease
sealing lip.

CAUTION!
According to the version, different Figure 354
shaft seals may be applied: Outer
diameter rubber-coated – wet with
mineral spirits.
Outer diameter metallic - wet with
sealing compound Loctite #574.

2. Press screening plate (Figure 355) against

shoulder.

Figure 355
3. Line up output flange.
4. Wet contact face of the disk with sealing
compound Loctite #574 and fasten output
flange with hex. head screws.
NOTE: Torque limit (M10/8.8) 46 Nm
(34 ft lb).

Figure 356

S0607080K Transmission and Torque Converter

Page 142 (ZF 4WG-310)
5. Secure hex. head screws using lock plate.

Figure 357
FILTER
1. Introduce filter (compl.) into the housing
bore.
NOTE: Oil sealing ring (Arrow).

Figure 358
2. Fasten cover using hex. head screws
(mount flat washers).
3. Install new O-ring (Arrow).
NOTE: Torque limit (M8/8.8) 23 Nm (17
ft lb).

Figure 359
4. Equip screw plugs (1 and 2, Figure 360)
with new O-ring and install them.
5. Mount gasket and fasten cover plate (3,
Figure 360) using hex. head screws.
NOTE: Torque limit (screw plugs) 140
Nm (103 ft lb).
NOTE: Torque limit (M8/8.8) 23 Nm (17
ft lb).

Figure 360

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(ZF 4WG-310) Page 143
INPUT SHAFT (POWER TAKE-OFF PUMP)
1. Tilt gearbox housing 180°.
2. Squeeze V-rings (3x) into the recess of the
driver (internal splines). Install fitting key
(Figure 361).

Figure 361
3. Adjust Gap Dimension = 0.50 mm (0.0197
in) (Driver/ Input shaft) (Figure 362 -
Figure 366).

Reference
Description
Number
1 Driver
2 Input Shaft

Figure 362
A. Line up the disk s = 1.90 mm (0.0748
in) and position inner bearing race
against shoulder.

Figure 363
B. Determine Dimension I from the
inner bearing race to the end face/
driver.
NOTE: Dimension I e.g. 9.64 mm
(0.3795 in).

Figure 364

S0607080K Transmission and Torque Converter

Page 144 (ZF 4WG-310)
 C. Determine Dimension II (A – B).
NOTE: Dimension II e.g. 10.64 mm
(0.4189 in).

EXAMPLE J: Figure 365

Dimension II 10.64 mm (0.4189 in)

Dimension I - 9.64 mm (0.3795 in)
Difference = 1.00 mm (0.0394 in)
Required Gap Dimension + 0.50 mm (0.0197 in)
Gives Shim (s) = 1.50 mm (0.0591 in)

D. Line up shim(s).

Figure 366
4. Position driver against shoulder and
secure it using clamping disk and socket
head screw.
NOTE: Torque limit (M10/8.8, DIN
6912) 32 Nm (24 ft lb).

Figure 367

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 145
5. Press inner bearing race against shoulder.

Figure 368
6. Squeeze retaining ring in (Figure 369) and
line up the drive gear.

Figure 369
7. Squeeze retaining ring in (Figure 370) and
engage it.

Figure 370
8. Introduce pre-assembled input shaft until
contact is obtained.
NOTE: Pay attention to the overlapping
of the fitting key with the fitting
key groove.

Figure 371

S0607080K Transmission and Torque Converter

Page 146 (ZF 4WG-310)
9. Adjust Axial Play of the Input Shaft
Bearing = 0.0 - 0.05 mm (0.0000 - 0.0020
in) (Figure 372 - Figure 374).
A. Mount flat gasket. Mount outer
bearing race, press it uniformly on
and determine Dimension I from the
mounting face (gasket) to the outer
bearing race.
NOTE: Dimension I e.g. 128.50 mm
(5.0591 in).
NOTE: Apply several measuring points
and determine the average Figure 372
value.
B. Measure Dimension II from the
mounting face/converter bell to the
locating face/outer bearing race.
NOTE: Dimension II e.g. 127.46 mm
(5.0181 in).

Figure 373
C. Insert shim and position outer
bearing race until contact is obtained.

Figure 374

EXAMPLE K:

Dimension I 128.50 mm (5.0591 in)

Dimension II - 127.46 mm (5.0181 in)
Difference 1.04 mm (0.0409 in)
Axial Play e.g. - 0.04 mm (0.0016 in)
Gives Shim (s) = 1.00 mm (0.0394 in)

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 147
INPUT – CONVERTER BELL
1. Insert outer bearing race into the housing
bore until contact is obtained and install
inner bearing race, see Figure 375.

Figure 375
2. Introduce spur gear (Figure 376). starting
from the side, with the long collar facing
upward, and bring it in position.

Figure 376
3. Insert both roll pins (ø 2.5 mm (10.0984 in)
and ø 1.5 mm (0.0591 in)) flush-mounted
into the bore (Arrow) of the input shaft.

Figure 377
4. Supercool the input shaft and introduce it
until contact is obtained.

CAUTION!
Use protective gloves.

Figure 378

S0607080K Transmission and Torque Converter

Page 148 (ZF 4WG-310)
5. Heat inner bearing race and line it up until
contact is obtained.

CAUTION!
Use protective gloves.

Figure 379
6. Position outer bearing race against
shoulder.

Figure 380
7. Adjust Axial play of the Drive gear bearing
= 0.03 - 0.07 mm (0.0012 - 0.0028 in)
(Figure 381 - EXAMPLE L).
A. Measure Dimension I from the
mounting face to the outer bearing
race.
NOTE: Dimension I e.g. 59.60 mm
(2.3465 in).
B. Mount gasket (Arrow) and determine
Dimension II from the mounting face
to the locating face of the outer
bearing race. Figure 381
NOTE: Dimension II e.g. 58.50 mm
(2.3031 in).
EXAMPLE L:

Dimension I 59.60 mm (2.3465 in)

Dimension II - 58.50 mm (2.3031 in)
Difference = 1.10 mm (0.0433 in)
Axial Play (0.03 - 0.07) e.g. - 0.05 mm (0.0020 in)
Gives Shim (s) = 1.05 mm (0.0413 in)

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 149
 Figure 382
8. Insert needle sleeve (Figure 383), with the
reinforced shell facing the pressing-in tool
until contact is obtained.

Figure 383
9. Install two adjusting screws and mount
gasket (1, Figure 384).
10. Install converter safety valve (disk,
compression spring and ball), see (2,
Figure 384). Squeeze both rectangular
rings into the annular grooves of the input
shaft and engage them (3, Figure 384).
11. Now, grease rectangular rings and align
them centrically.

Figure 384
12. Supercool oil feed flange, (about -80°C
(-112°F)) and make shim s = 1.05 mm
(0.0413 in) (see Example, page 149)
adhere with assembly grease in the
bearing bore.

Figure 385

S0607080K Transmission and Torque Converter

Page 150 (ZF 4WG-310)
13. Introduce supercooled oil feed flange until
contact is obtained.
NOTE: Pay attention to the radial
installation position.

CAUTION!
Use protective gloves.

Figure 386
14. Mount flat gasket (Arrow) and install
bearing cover.
NOTE: Pay attention to the radial
installation position.
NOTE: Torque limit (M10/8.8) 46 Nm
(34 ft lb).

Figure 387
15. Wet thread of the screw-in sleeves (1 and
2, Figure 388) with Loctite #262 and install
the two screw-in sleeves.
16. Equip screw plugs (3 and 4, Figure 388)
with new O-rings and install them.
NOTE: Torque limit (10x1) 25 Nm (18 ft
lb).
NOTE: Torque limit (M14x1,5) 35 Nm
(26 ft lb).

Figure 388
17. Converter Pressure Backup Valve (Figure
389 and Figure 390).
A. Drive roll pin (6 x 50 mm) (0.2362 x
1.9685 in) into the bore until contact
is obtained.

Figure 389

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(ZF 4WG-310) Page 151
 B. Introduce spool and compression
spring.
C. Equip screw plug with new O-ring
and install it.
NOTE: Torque limit 130 Nm (96 ft lb).

Figure 390
18. Remove input shaft and heat housing bore
(about 120°C (248°F)).
NOTE: Carry out the following steps
(Figure 392 - Figure 394) in
immediate chronological order.

Figure 391
19. Grease rectangular ring (Arrow) and align
it centrically. Introduce input shaft until
contact is obtained.
NOTE: Pay attention to the overlapping
of the fitting key with the fitting
key groove.

Figure 392
20. Install two adjusting screws and mount flat
gasket (1, Figure 393).
21. Lay O-ring (2, Figure 393) into the annular
groove.

Figure 393

S0607080K Transmission and Torque Converter

Page 152 (ZF 4WG-310)
22. Introduce converter bell using lifting device
until contact is obtained.
NOTE: Slight rotary motions of the
input shaft will facilitate the
sliding in. Protect the splines
from damage. Pay attention to
the radial installation position.

Figure 394
CONVERTER
1. Fasten diaphragms (3x) on converter,
using hex. head screws (mount plain
washer).
NOTE: Insert hex. head screws with
Loctite #243.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (33.93 ft lb).

Figure 395
2. Squeeze in and engage rectangular ring
(Figure 396). Now, grease rectangular and
align it centrically.

Figure 396
3. Install converter using lifting drive until
contact is obtained.

Figure 397

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 153
4. Tilt transmission 90°.
5. Insert pot flush-mounted to the housing
face.
NOTE: Wet sealing surface with Loctite
#262.

Figure 398
6. Install breather (Figure 399).

Figure 399
7. Equip screw plug (1, Figure 400) with new
O-ring and install it. Install the two
retaining plates (2, Figure 400).
8. Mount hydraulic control unit (HSG-94), see
page 56 - page 58.
9. Install all oil lines.

CAUTION!
The line routing is different
according to the design. In this Figure 400
connection, pay attention to the
Perspective Illustrations of the
corresponding Spare Parts List.

S0607080K Transmission and Torque Converter

Page 154 (ZF 4WG-310)
INDUCTIVE TRANSMITTERS AND SPEED
SENSOR 14
1. The figures show the installation position
of the single inductive transmitters and the
speed sensor.

Reference
Description
Number
6 Inductive Transmitter
N – Turbine
14 Inductive Transmitter
N – Engine
39 Inductive Transmitter 6
N – Central Gear Train 6
31 Speed Sensor N – Output
And Speedometer 39 39

AHS3460S
Figure 401

31

AHS3470S
Figure 402

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 155
2. The following illustrations describe the
reassembly, resp. the setting of the
Inductive transmitter N engine (14, Figure
401). The reassembly of the Inductive
transmitter N turbine (6, Figure 401) and N
central gear train (39, Figure 401) has to

"S"
"A"
be carried out accordingly.

I
X
AHS3480S
Figure 403

IMPORTANT
Pay attention to the different Setting dimensions "X."
Inductive transmitter N-Engine (14) X = 0.5 + 0.3 mm (0.0197 + 0.0118 in)
Inductive transmitter N-Turbine (6) X = 0.5 + 0.3 mm (0.0197 + 0.0118 in)
Inductive transmitter N-Central gear train (39) X = 0.3 ±0.1 mm (0.0118 + 0.0039 in)

3. Set Dimension X using adjusting disk(s)

(Figure 404 - Figure 410).
A. Measure Dimension I from the
contact face to the screw-in face on
the inductive transmitter.
NOTE: Dimension I e.g. 30.00 mm
(1.1811 in).

Figure 404
B. Rotate counting disk radially until one
tooth tip is central to the inductive
transmitter bore.
C. Screw the plug gauge in until contact
is obtained. Position anvil on the
tooth tip until contact is obtained and
lock it using set screw (Figure
405and Figure 406).

Figure 405

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Page 156 (ZF 4WG-310)
 II
AHS3510S
Figure 406
D. Screw the plug gauge out and
determine Dimension II (see also
Figure 405).
NOTE: Dimension II e.g. 30.10 mm
(1.1850 in).

Figure 407
EXAMPLE M1:

Dimension II e.g. 30.10 mm (1.1850 in)

Dimension X (0.5 + 0.3
mm (0.0197
+ 0.0118
in)) e.g. - 0.60 mm (0.0236 in)
Gives Installation Dimension A = 29.50 mm (1.1614 in)

EXAMPLE M2:

Dimension I e.g. 30.10 mm (1.1850 in)

Installation Dimension A e.g. - 29.50 mm (1.1614 in)
Gives Adjusting Disk (s) = 0.50 mm (0.0197 in)

E. Line up the corresponding adjusting

disk(s) and wet thread (Arrow) with
Loctite #574.

Figure 408

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(ZF 4WG-310) Page 157
 F. Install inductive transmitter N-Engine
(14), see Figure 409.
NOTE: Torque limit 30 Nm (22 ft lb).
NOTE: Set and install the inductive
transmitter n-Turbine (6) and n-
Central gear train (39)
accordingly.
NOTE: Pay attention to the different
setting dimensions. Installation
position of the single inductive
transmitters, see also page
160. Figure 409
4. Install Speed sensor N-Output/
Speedometer (31) (Figure 410 - Figure X
415).
2
NOTE: Setting dimension X = 1.0 + 0.5
31
mm (0.0394 + 0.0197 in).
1

AHS3550S
Figure 410
A. Figure 411, shows the speed sensor
(Hall sensor).

Reference
Description
Number
1 Speed Sensor
2 O-ring
3 Setting Plate(s)

Figure 411
B. Determine Dimension I from the
housing face to the spur gear K3.
NOTE: Dimension I e.g. 39.20 mm
(1.5433 in).

Figure 412

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Page 158 (ZF 4WG-310)
 C. Measure Dimension II from the
contact face to the mounting face.
NOTE: Dimension II e.g. 39.00 mm
(1.5354 in).

Figure 413
D. Line up setting plates (2x, s = 0.5 mm
(0.0197 in)) and grease O-ring.

Figure 414

EXAMPLE N1:

Dimension I e.g. 39.20 mm (1.5433 in)

Dimension X (1.0 + 0.3 mm (0.0394 + 0.0118 in) e.g. - 1.20 mm (0.0472 in)
Gives Adjusting Disk (s) = 38.00 mm (1.4961 in)

EXAMPLE N2:

Dimension I e.g. 39.00 mm (1.5354 in)

Installation Dimension A e.g. - 38.00 mm (1.4961 in)
Gives Setting Plate (s) = 1.00 mm (0.0394 in)

Transmission and Torque Converter S0607080K

(ZF 4WG-310) Page 159
5. Fasten speed sensor using socket head
screw.
NOTE: Torque limit (M8/8.8) 23 Nm (17
ft lb).
NOTE: Installation position of the
speed sensor, see also page
155.

CAUTION!
Prior to the commissioning of the Figure 415
Transmission, carry out the oil filling
according to the Operating
Instructions.

S0607080K Transmission and Torque Converter

Page 160 (ZF 4WG-310)
 S0607900C
R2

1TRANSMISSION ERROR
CODES (ZF)

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

TRANSMISSION ERROR CODES (ZF)S0607900C

MODEL SERIAL NUMBER RANGE
Mega 130 1003 and Up
Mega 160 1021 and Up
Mega 200-V 1001 and Up
Mega 250-V 1001 and Up
Mega 300-V 1001 and Up
Mega 400-III PLUS 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Transmission Error Codes (ZF) S0607900C

Page 1
TABLE OF CONTENTS

Introduction..................................................................................................... 3
Abbreviations.................................................................................................. 3
Display............................................................................................................ 3
Description of Fault Codes ...................................................................... 4
Display During Operation ............................................................................... 5
Definition of Operating Modes........................................................................ 7
Normal .................................................................................................... 7
Substitute Clutch Control ........................................................................ 7
Limp-home .............................................................................................. 7
Transmission shut Down ......................................................................... 7
TCU Shut Down ...................................................................................... 7
Clutch Pack and Solenoid Valve Cross-reference Table................................. 8
Table of Fault Codes....................................................................................... 9
Table of Fault Codes - ERGO-Control .......................................................... 31
Measurement of Resistance at Actuator/sensors and Cable ....................... 34
Actuator................................................................................................. 34
Cable..................................................................................................... 34

S0607900C Transmission Error Codes (ZF)

Page 2
INTRODUCTION
The "WG" series of ZF Transmissions use an electronic control system called "ZF-Ergopower."
The Ergo System (for short) allows the transmission to function either in a manual powershift mode, or in a
fully automatic mode.
An LCD display (Figure 1) is in the cab. This display gives the machine operator a continuos status of the
operating condition of the system. It displays normal operational codes, and fault codes.

ABBREVIATIONS
Throughout this section the following abbreviations are used to indicate various conditions.

Abbreviations
ABS Anti Blocking System
ADM (1 - 6) Ausgeschaltet Digital Minus
(Switched Off Digital Minus)
AFP Automatic Filling Parameter
Adjustment
CAN Controller Area Network
LIS (1 and 2) Load Isolation System
(Solenoids 1 and 2)
O.C. Open Circuit
OP-Mode OPeration Mode
S.C. Short Circuit
TCU Transmission Control Unit
VPS (1 and 2) Variable Power Supply

DISPLAY h f e d
left
character
right
character

If a fault is detected, the display shows a

spanner symbol (g) for a fault. The display
shows the fault code, if the gear selector is in
S
neutral position. T
O
If more than one fault is detected, each fault
code is shown for about 1 second. P

Reference Description a b c g
Letter
(special symbols a-h) HBOE630L
a, f Automatic Range (Upshifting
and Downshifting) Figure 1

b, c, d, e Preselected Gear
g EST-37 has detected an
error and is flashing.
h This character will not be
used at the EST-37.

Transmission Error Codes (ZF) S0607900C

Page 3
DESCRIPTION OF FAULT CODES
The first number of the error code is the category that it is grouped into. They are as follows for the first
number.

First Number Meaning of Number

1 Hex Digital Input Signal
2 Hex Analog Input Signal
3 Hex Speed Signal
4 Hex CAN Signal Error
5 Hex CAN Signal Error
6 Hex CAN Signal Error
7 Hex Analog Current Output Signal
8 Hex Analog Current Output Signal
9 Hex Digital Output Signal
A Hex Digital Output Signal
B Hex Transmission Fault, Clutch Error
C Hex Logical Fault
D Hex Power Supply
E Hex High Speed Signal
F Hex General Fault

S0607900C Transmission Error Codes (ZF)

Page 4
DISPLAY DURING OPERATION

Symbol Meaning Remarks

1F, 1R Actual gear and direction. ---------------
2F, 2R Left digit shows actual gear.
3F, 3R Right digit shows actual direction.
4F
5F
6F
LF, LR Limp home gear.
F or R, no gear Clutch Cut Off. ---------------
F or R flashing Only 6WG. ---------------
Direction F or R selected while turbine
speed is too high.
CAUTION: Gear will engage if turbine
speed drops.
NN Not neutral, waiting for neutral after Go engage a gear, first move shift selector to
power up or a severe fault. neutral position and again to F or R position.
** Oil temperature too low, no gear Warm up engine / transmission.
available.
*N Oil temperature low, only one gear Warm up engine / transmission.
available.
1 bar (special Manual mode 1. gear. ---------------
symbol)
2 bars Manual mode 2. gear. ---------------
3 bars Manual mode 3. gear. ---------------
4 bars Manual mode 4. gear. ---------------
4 bars and 2 Automatic mode. ---------------
arrows
Bars flashing 6 WG: converter lockup clutch open. Difference of engine and turbine speed above a
certain limit and lockup clutch not activated.
4 WG: Downshift mode active.
Spanner At least one fault active. Select neutral to get fault code displayed.
Fault code See fault code list (See page 9). ---------------
WS Warning sump temperature. Changes between actual gear/direction while
driving, in neutral only displayed if no fault is
detected (spanner).
WR Warning retarder temperature. Changes between actual gear/direction while
driving, in neutral only displayed if no fault is
detected (spanner).
WE Warning high engine speed. Changes between actual gear/direction while
driving, in neutral only displayed if no fault is
detected (spanner).
PN Direction F or R selected while parking Transmission in neutral until parking brake is
brake engaged. released.
CAUTION: Vehicle starts to move after release of
parking brake.

Transmission Error Codes (ZF) S0607900C

Page 5
 Symbol Meaning Remarks
F or R flashing Direction F or R selected while turbine ---------------
speed is to high.
CAUTION: Gear will engage if turbine
speed drops.
EE flashing No communication with display. Checked wiring from TCU to display.

S0607900C Transmission Error Codes (ZF)

Page 6
DEFINITION OF OPERATING MODES
NORMAL
There is no failure detected in transmission system or failure has no or slight effects on transmission
control. TCU will work without or in special cases with little limitations. (See “Table of Fault Codes” on page
9.)

SUBSTITUTE CLUTCH CONTROL

TCU cannot change gears or direction under control of normal clutch modulation. TCU uses substitute
strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25.)

LIMP-HOME
The detected failure in the system has strong limitations to transmission control. TCU can engage only one
gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift
the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into
forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear
and the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected
direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has
to slow down the vehicle and must shift the gear selector into neutral position.

TRANSMISSION SHUT DOWN

TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).
Transmission shifts to Neutral. The park brake will operate normally, also the other functions which use
ADM 1 to ADM 6.
The operator has to slow down the vehicle. The transmission will stay in neutral.

TCU SHUT DOWN

TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake
will engage, also all functions are disabled which use ADM 1 to ADM 6.
The transmission will stay in neutral.
NOTE: VPS2: is the LIS (option power supply).

Transmission Error Codes (ZF) S0607900C

Page 7
CLUTCH PACK AND SOLENOID VALVE CROSS-
REFERENCE TABLE
Throughout the fault codes, references are made to various clutch packs within the transmission. These
clutch pack references are indicated as K1, K2, etc.
Clutch pack charge pressure is controlled by proportional valves that contain a solenoid valve.
The following chart identifies which solenoid valve corresponds to each clutch pack.

Solenoid Valve (Proportioning Valve) Number

Mega 400-III PLUS

Mega 250-V

Mega 300-V

Mega 400-V

Mega 500-V
Clutch Pack
Mega 130

Mega 160
4WG-100

4WG-130

4WG-190

4WG-210

4WG-260

4WG-260

4WG-310
K1 Y3 Y3 Y3 Y3 Y3 Y3 Y3
K2 Y6 Y6 Y6 Y6 Y6 Y6 Y6
K3 Y4 Y4 Y4 Y4 Y4 Y4 Y4
K4 Y1 Y1 Y1 Y1 Y2 Y2 Y2
KR Y2 Y2 Y2 Y2 Y1 Y1 Y1
KV Y5 Y5 Y5 Y5 Y5 Y5 Y5

S0607900C Transmission Error Codes (ZF)

Page 8
TABLE OF FAULT CODES
The fault codes shown in this table are a complete list of codes that are common to more than one version
of the transmission. Some of the versions are 4WG (four speed) and 6WG (six speed).
NOTE: This fault code list is valid for the ZF Software Versions V 53.x to V58.0

Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
11 Logical error at gear range TCU shifts Check cables from Failure cannot be
signal. transmission to TCU to shift lever. detected in systems
neutral. with DW2/DW3 shift
TCU detected a wrong signal Check signal
lever.
combination for gear range. OP-Mode: combinations of shift
transmission shut lever positions for Fault is taken back if
• Cable from shift lever to TCU
down. gear range. TCU detects a valid
is broken.
signal for position.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
12 Logical error at direction TCU shifts Check cables from Fault is taken back if
select signal. transmission to TCU to shift lever. TCU detects a valid
neutral. signal for direction at
TCU detected a wrong signal Check signal
shift lever.
combination for direction. OP-Mode: combinations of shift
transmission shut lever positions
• Cable from shift lever to TCU
down. F-N-R.
is broken.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
17 ** S.C. to ground at Solenoid Customer specific. Check cable from 1) See
LIS1 (Function No. 1). TCU to Solenoid “Measurement of
LIS1 (Function No. Resistance at
TCU detected a wrong
1) device. Actuator/sensors
voltage at output pin, that
looks like a S.C. to vehicle Check connectors and Cable” on page
ground. from Solenoid LIS1 34.
(Function No. 1) to
• Cable is defective and is
TCU.
contacted to vehicle ground.
Check resistance of
• Solenoid LIS1 (Function No.
Solenoid LIS1
1) device has an internal
(Function No. 1)
defect.
device.
• Connector pin is contacted
to vehicle ground.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 9
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
18 ** S.C. to battery voltage at Customer specific. Check cable from 1) See
Solenoid LIS1 (Function No. TCU to Solenoid “Measurement of
1). LIS1 (Function No. Resistance at
1) device. Actuator/sensors
TCU detected a wrong
voltage at output pin, that Check connectors and Cable” on page
looks like a S.C. to battery from Solenoid LIS1 34.
voltage. (Function No. 1) to
TCU.
• Cable is defective and is
contacted to battery voltage. Check resistance of
Solenoid LIS1
• Solenoid LIS1 (Function No.
(Function No. 1)
1) device has an internal
device.
defect.
• Connector pin is contacted
to battery voltage.
19 ** O.C. at Solenoid LIS1 Customer specific. Check cable from 1)See
(Function No. 1). TCU to Solenoid “Measurement of
LIS1 (Function No. Resistance at
TCU detected a wrong
1) device. Actuator/sensors
voltage at output pin, that
looks like a O.C. for this output Check connectors and Cable” on page
pin. from Solenoid LIS1 34.
(Function No. 1)
• Cable is defective and has
device to TCU.
no connection to TCU.
Check resistance of
• Solenoid LIS1 (Function No.
Solenoid LIS1
1) device has an internal
(Function No. 1)
defect.
device.
• Connector has no
connection to TCU.
1A ** S.C. to ground at Solenoid Customer specific. Check cable from 1)See
LIS2 (Function No. 2). TCU to Solenoid “Measurement of
LIS2 (Function No. Resistance at
TCU detected a wrong
2) device. Actuator/sensors
voltage at output pin, that
looks like a S.C. to vehicle Check connectors and Cable” on page
ground. from Solenoid LIS2 34.
(Function No. 2)
• Cable is defective and is
device to TCU.
contacted to vehicle ground.
Check resistance of
• Solenoid LIS2 (Function No.
Solenoid LIS2
2) device has an internal
(Function No. 2)
defect.
device.
• Connector pin is contacted
to vehicle ground.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 10
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
1B ** S.C. to battery voltage at Customer specific. Check cable from 1) See
Solenoid LIS2 (Function No. TCU to Solenoid “Measurement of
2). LIS2 (Function No. Resistance at
2) device. Actuator/sensors
TCU detected a wrong
voltage at output pin, that Check connectors and Cable” on page
looks like a S.C. to battery from Solenoid LIS2 34.
voltage. (Function No. 2)
device to TCU.
• Cable is defective and is
contacted to battery voltage. Check resistance of
Solenoid LIS2
• Solenoid LIS2 (Function No.
(Function No. 2)
2) device has an internal
device.
defect.
• Connector pin is contacted
to battery voltage.
1C ** O.C. at Solenoid LIS2 Customer specific. Check cable from 1)See
(Function No. 2). TCU to Solenoid “Measurement of
LIS2 (Function No. Resistance at
TCU detected a wrong
2) device. Actuator/sensors
voltage at output pin, that
looks like a O.C. for this output Check connectors and Cable” on page
pin. from Solenoid LIS2 34.
(Function No. 2)
• Cable is defective and has
device to TCU.
no connection to TCU.
Check resistance of
• Solenoid LIS2 (Function No.
Solenoid LIS2
2) device has an internal
(Function No. 2)
defect.
device.
• Connector has no
connection to TCU.
25 S.C. to battery voltage or O.C. No reaction, Check cable from ---------------
at transmission sump TCU to sensor.
TCU uses default
temperature sensor input.
temperature. Check connectors.
The measured voltage is too
OP-Mode: normal. Check temperature
high:
sensor.
• Cable is defective and is
contacted to battery voltage.
• Cable has no connection to
TCU.
• Temperature sensor has an
internal defect.
• Connector pin is contacted
to battery voltage or is broken.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 11
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
26 S.C. to ground at transmission No reaction, Check cable from ---------------
sump temperature sensor TCU to sensor.
TCU uses default
input.
temperature. Check connectors.
The measured voltage is too
OP-Mode: normal. Check temperature
low:
sensor.
• Cable is defective and is
contacted to vehicle ground.
• Temperature sensor has an
internal defect.
• Connector pin is contacted
to vehicle ground.
31 S.C. to battery voltage or O.C. OP-Mode: substitute Check cable from ---------------
at engine speed input. clutch control. TCU to sensor.
TCU measures a voltage Check connectors.
higher than 7.00 V at speed
Check speed sensor.
input pin.
• Cable is defective and is
contacted to battery voltage.
• Cable has no connection to
TCU.
• Speed sensor has an
internal defect.
• Connector pin is contacted
to battery voltage or has no
contact.
32 S.C. to ground at engine OP-Mode: substitute Check cable from ---------------
speed input. clutch control. TCU to sensor.
TCU measures a voltage less Check connectors.
than 0.45V at speed input pin.
Check speed sensor.
• Cable / connector is
defective and is contacted to
vehicle ground.
• Speed sensor has an
internal defect.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 12
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
33 Logical error at engine speed OP-Mode: substitute Check cable from This fault is reset
input. clutch control. TCU to sensor. after power up of
TCU.
TCU measures a engine Check connectors.
speed over a threshold and
Check speed sensor.
the next moment the
measured speed is zero. Check sensor gap.
• Cable / connector is
defective and has bad
contact.
• Speed sensor has an
internal defect.
• Sensor gap is incorrect.
34 S.C. to battery voltage or O.C. OP-Mode: substitute Check cable from ---------------
at turbine speed input. clutch control. TCU to sensor.
TCU measures a voltage If a failure is existing Check connectors.
higher than 7.00 V at speed at output speed,
Check speed sensor.
input pin.
TCU shifts to neutral.
• Cable is defective and is
OP-Mode: limp
contacted to battery voltage.
home.
• Cable has no connection to
TCU.
• Speed sensor has an
internal defect.
• Connector pin is contacted
to battery voltage or has no
contact.
35 S.C. to ground at turbine OP-Mode: substitute Check cable from ---------------
speed input. clutch control. TCU to sensor.
TCU measures a voltage less If a failure is existing Check connectors.
than 0.45V at speed input pin. at output speed,
Check speed sensor.
• Cable / connector is TCU shifts to neutral.
defective and is contacted to
OP-Mode: limp
vehicle ground.
home.
• Speed sensor has an
internal defect.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 13
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
36 Logical error at turbine speed OP-Mode: substitute Check cable from This fault is reset
input. clutch control. TCU to sensor. after power up of
TCU.
TCU measures a turbine If a failure is existing Check connectors.
speed over a threshold and at at output speed,
Check speed sensor.
the next moment the
TCU shifts to neutral.
measured speed is zero. Check sensor gap.
OP-Mode: limp
• Cable / connector is
home.
defective and has bad
contact.
• Speed sensor has an
internal defect.
• Sensor gap is incorrect.
37 S.C. to battery voltage or O.C. OP-Mode: substitute Check cable from ---------------
at internal speed input. clutch control. TCU to sensor.
TCU measures a voltage Check connectors.
higher than 7.00 V at speed
Check speed sensor.
input pin.
• Cable is defective and is
contacted to battery voltage.
• Cable has no connection to
TCU.
• Speed sensor has an
internal defect.
• Connector pin is contacted
to battery voltage or has no
contact.
38 S.C. to ground at internal OP-Mode: substitute Check cable from ---------------
speed input. clutch control. TCU to sensor.
TCU measures a voltage less Check connectors.
than 0.45V at speed input pin.
Check speed sensor.
• Cable / connector is
defective and is contacted to
vehicle ground.
• Speed sensor has an
internal defect.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 14
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
39 Logical error at internal speed OP-Mode: substitute Check cable from This fault is reset
input. clutch control. TCU to sensor. after power up of
TCU.
TCU measures a internal Check connectors.
speed over a threshold and at
Check speed sensor.
the next moment the
measured speed is zero. Check sensor gap.
• Cable / connector is
defective and has bad
contact.
• Speed sensor has an
internal defect.
• Sensor gap is incorrect.
3A S.C. to battery voltage or O.C. Special mode for Check cable from ---------------
at output speed input. gear selection; TCU to sensor.
TCU measures a voltage OP-Mode: substitute Check connectors.
higher than 12.5 V at speed clutch control.
Check speed sensor.
input pin.
If a failure is existing
• Cable is defective and is at turbine speed,
contacted to battery voltage.
TCU shifts to neutral.
• Cable has no connection to
OP-Mode: limp
TCU.
home.
• Speed sensor has an
internal defect.
• Connector pin is contacted
to battery voltage or has no
contact.
3B S.C. to ground at output Special mode for Check cable from ---------------
speed input. gear selection. TCU to sensor.
TCU measures a voltage less OP-Mode: substitute Check connectors.
than 1.00V at speed input pin. clutch control.
Check speed sensor.
• Cable / connector is If a failure is existing
defective and is contacted to at turbine speed,
vehicle ground.
TCU shifts to neutral.
• Speed sensor has an
OP-Mode: limp
internal defect.
home.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 15
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
3C Logical error at output speed Special mode for Check cable from This fault is reset
input. gear selection. TCU to sensor. after power up of
TCU.
TCU measures a output OP-Mode: substitute Check connectors.
speed over a threshold and at clutch control.
Check speed sensor.
the next moment the
If a failure is existing
measured speed is zero. Check sensor gap.
at turbine speed,
• Cable / connector is
TCU shifts to neutral.
defective and has bad
contact. OP-Mode: limp
home.
• Speed sensor has an
internal defect.
• Sensor gap is incorrect.
3E Output speed zero doesn’t fit Special mode for Check sensor signal This fault is reset
to other speed signals. gear selection. of output speed after power up of
sensor. TCU.
If transmission is not neutral OP-Mode: substitute
and the shifting has finished, clutch control. Check sensor gap of
output speed sensor.
TCU measures output speed If a failure is existing
zero and turbine speed or at turbine speed, Check cable from
internal speed not equal to TCU to sensor.
TCU shifts to neutral.
zero.
OP-Mode: limp
• Speed sensor has an
home.
internal defect.
• Sensor gap is incorrect.
71 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1)See
clutch K1. TCU to gearbox. “Measurement of
OP-Mode: limp
The measured resistance home. Check connectors Resistance at
value of valve is out of limit, from TCU to Actuator/sensors
If failure at another and Cable” on page
voltage at K1 valve is too high. gearbox.
clutch is pending. 34.
• Cable / connector is Check regulator
TCU shifts to neutral.
defective and has contact to resistance. 1)
battery voltage. OP-Mode: TCU shut
down. Check internal wire
• Cable / connector is harness of gearbox.
defective and has contact to
another regulator output of
TCU.
• Regulator has an internal
defect.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 16
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
72 S.C. to ground at clutch K1. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit, home. Check connectors Resistance at
voltage at K1 valve is too low. from gearbox to Actuator/sensors
If failure at another and Cable” on page
TCU.
• Cable / connector is clutch is pending. 34.
defective and has contact to Check regulator
TCU shifts to neutral.
vehicle ground. resistance. 1)
OP-Mode: TCU shut
• Regulator has an internal Check internal wire
down.
defect. harness of gearbox.
73 O.C. at clutch K1. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit. home. Check connectors Resistance at
from gearbox to Actuator/sensors
• Cable / connector is If failure at another and Cable” on page
TCU.
defective and has no contact clutch is pending. 34.
to TCU. Check regulator
TCU shifts to neutral.
• Regulator has an internal resistance. 1)
OP-Mode: TCU shut
defect. Check internal wire
down.
harness of gearbox.
74 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1)See
clutch K2. TCU to gearbox. “Measurement of
OP-Mode: limp
The measured resistance home. Check connectors Resistance at
value of valve is out of limit, from gearbox to Actuator/sensors
If failure at another and Cable” on page
voltage at K2 valve is too high. TCU.
clutch is pending. 34.
• Cable / connector is Check regulator
TCU shifts to neutral.
defective and has contact to resistance. 1)
battery voltage. OP-Mode: TCU shut
down. Check internal wire
• Cable / connector is harness of gearbox.
defective and has contact to
another regulator output of
TCU.
• Regulator has an internal
defect.
75 S.C. to ground at clutch K2. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit, home. Check connectors Resistance at
voltage at K2 valve is too low. from gearbox to Actuator/sensors
If failure at another and Cable” on page
TCU.
• Cable / connector is clutch is pending. 34.
defective and has contact to Check regulator
TCU shifts to neutral.
vehicle ground. resistance. 1)
OP-Mode: TCU shut
• Regulator has an internal Check internal wire
down.
defect. harness of gearbox.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 17
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
76 O.C. at clutch K2. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit. home. Check connectors Resistance at
from gearbox to Actuator/sensors
• Cable / connector is If failure at another and Cable” on page
TCU.
defective and has no contact clutch is pending. 34.
to TCU. Check regulator
TCU shifts to neutral.
• Regulator has an internal resistance. 1)
OP-Mode: TCU shut
defect. Check internal wire
down.
harness of gearbox.
77 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1) See
clutch K3. TCU to gearbox. “Measurement of
OP-Mode: limp
The measured resistance home. Check connectors Resistance at
value of valve is out of limit, from gearbox to Actuator/sensors
If failure at another and Cable” on page
voltage at K3 valve is too high. TCU.
clutch is pending. 34.
• Cable / connector is Check regulator
TCU shifts to neutral.
defective and has contact to resistance. 1)
battery voltage. OP-Mode: TCU shut
down. Check internal wire
• Cable / connector is harness of gearbox.
defective and has contact to
another regulator output of
TCU.
• Regulator has an internal
defect.
78 S.C. to ground at clutch K3. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit, home. Check connectors Resistance at
voltage at K3 valve is too low. from gearbox to Actuator/sensors
If failure at another and Cable” on page
TCU.
• Cable / connector is clutch is pending. 34.
defective and has contact to Check regulator
TCU shifts to neutral.
vehicle ground. resistance. 1)
OP-Mode: TCU shut
• Regulator has an internal Check internal wire
down.
defect. harness of gearbox.
79 O.C. at clutch K3. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit. home. Check connectors Resistance at
from gearbox to Actuator/sensors
• Cable / connector is If failure at another and Cable” on page
TCU.
defective and has no contact clutch is pending. 34.
to TCU. Check regulator
TCU shifts to neutral.
• Regulator has an internal resistance. 1)
OP-Mode: TCU shut
defect. Check internal wire
down.
harness of gearbox.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 18
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
7D S.C. to ground at engine Engine derating will Check cable from 1) See
derating device. be on until TCU TCU to engine “Measurement of
power down even if derating device. Resistance at
• Cable is defective and is
fault vanishes (loose Actuator/sensors
contacted to vehicle ground. Check connectors
connection). and Cable” on page
from engine derating
• Engine derating device has 34. (Only Mega
OP-Mode: normal. device to TCU.
an internal defect. 500-V)
• Connector pin is contacted Check resistance 1)
to vehicle ground. of engine derating
device.
7E S.C. to battery voltage at No reaction. Check cable from Only Mega 500-V
engine derating device. TCU to engine
OP-Mode: normal.
derating device.
• Cable / connector is
defective and is contacted to Check connectors
battery voltage. from backup alarm
device to TCU.
• Engine derating device has
an internal defect. Check resistance 1)
of backup alarm
device.
7F O.C. at engine derating No reaction. Check cable from 1)See
device. TCU to engine “Measurement of
OP-Mode: normal.
derating device. Resistance at
TCU detected a wrong
voltage at output pin, that Check connectors Actuator/sensors
looks like a O.C. for this output from engine derating and Cable” on page
pin. device to TCU. 34. (Only Mega
500-V)
• Cable is defective and has Check resistance 1)
no connection to TCU. of engine derating
• Engine derating device has device.
an internal defect.
• Connector has no
connection to TCU.
81 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1) See
clutch K4. TCU to gearbox. “Measurement of
OP-Mode: limp
The measured resistance home. Check connectors Resistance at
value of valve is out of limit, from gearbox to Actuator/sensors
If failure at another and Cable” on page
voltage at K4 valve is too high. TCU.
clutch is pending. 34.
• Cable / connector is Check regulator
TCU shifts to neutral.
defective and has contact to resistance. 1)
battery voltage. OP-Mode: TCU shut
down. Check internal wire
• Cable / connector is harness of gearbox.
defective and has contact to
another regulator output of
TCU.
• Regulator has an internal
defect.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 19
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
82 S.C. to ground at clutch K4. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit, home. Check connectors Resistance at
voltage at K4 valve is too low. from gearbox to Actuator/sensors
If failure at another and Cable” on page
TCU.
• Cable / connector is clutch is pending. 34.
defective and has contact to Check regulator
TCU shifts to neutral.
vehicle ground. resistance. 1)
OP-Mode: TCU shut
• Regulator has an internal Check internal wire
down.
defect. harness of gearbox.
83 O.C. at clutch K4. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit. home. Check connectors Resistance at
from gearbox to Actuator/sensors
• Cable / connector is If failure at another and Cable” on page
TCU.
defective and has no contact clutch is pending. 34.
to TCU. Check regulator
TCU shifts to neutral.
• Regulator has an internal resistance. 1)
OP-Mode: TCU shut
defect. Check internal wire
down.
harness of gearbox.
84 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1)See
clutch KV. TCU to gearbox. “Measurement of
OP-Mode: limp
The measured resistance home. Check connectors Resistance at
value of valve is out of limit, from gearbox to Actuator/sensors
If failure at another and Cable” on page
voltage at KV valve is too TCU.
clutch is pending. 34.
high.
Check regulator
TCU shifts to neutral.
• Cable / connector is resistance. 1)
defective and has contact to OP-Mode: TCU shut
battery voltage. down. Check internal wire
harness of gearbox.
• Cable / connector is
defective and has contact to
another regulator output of
TCU.
• Regulator has an internal
defect.
85 S.C. to ground at clutch KV. TCU shifts to neutral. Check cable from 1)See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit, home. Check connectors Resistance at
voltage at KV valve is too low. from gearbox to Actuator/sensors
If failure at another and Cable” on page
TCU.
• Cable / connector is clutch is pending. 34.
defective and has contact to Check regulator
TCU shifts to neutral.
vehicle ground. resistance. 1)
OP-Mode: TCU shut
• Regulator has an internal Check internal wire
down.
defect. harness of gearbox.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 20
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
86 O.C. at clutch KV. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit. home. Check connectors Resistance at
from gearbox to Actuator/sensors
• Cable / connector is If failure at another and Cable” on page
TCU.
defective and has no contact clutch is pending. 34.
to TCU. Check regulator
TCU shifts to neutral.
• Regulator has an internal resistance. 1)
OP-Mode: TCU shut
defect. Check internal wire
down.
harness of gearbox.
87 S.C. to battery voltage at TCU shifts to neutral. Check cable from 1) See
clutch KR. TCU to gearbox. “Measurement of
OP-Mode: limp
The measured resistance home. Check connectors Resistance at
value of valve is out of limit, from gearbox to Actuator/sensors
If failure at another and Cable” on page
voltage at KR valve is too TCU.
clutch is pending. 34.
high.
Check regulator
TCU shifts to neutral.
• Cable / connector is resistance. 1)
defective and has contact to OP-Mode: TCU shut
battery voltage. down. Check internal wire
harness of gearbox.
• Cable / connector is
defective and has contact to
another regulator output of
TCU.
• Regulator has an internal
defect.
88 S.C. to ground at clutch KR. TCU shifts to neutral. Check cable from 1) See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit, home. Check connectors Resistance at
voltage at KR valve is too low. from gearbox to Actuator/sensors
If failure at another and Cable” on page
TCU.
• Cable / connector is clutch is pending. 34.
defective and has contact to Check regulator
TCU shifts to neutral.
vehicle ground. resistance. 1)
OP-Mode: TCU shut
• Regulator has an internal Check internal wire
down.
defect. harness of gearbox.
89 O.C. at clutch KR. TCU shifts to neutral. Check cable from 1)See
TCU to gearbox. “Measurement of
The measured resistance OP-Mode: limp
value of valve is out of limit. home. Check connectors Resistance at
from gearbox to Actuator/sensors
• Cable / connector is If failure at another and Cable” on page
TCU.
defective and has no contact clutch is pending. 34.
to TCU. Check regulator
TCU shifts to neutral.
• Regulator has an internal resistance. 1)
OP-Mode: TCU shut
defect. Check internal wire
down.
harness of gearbox.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 21
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
91 ** S.C. to ground at relay reverse Backup alarm will be Check cable from 1) See
warning alarm. on until TCU power TCU to backup “Measurement of
down even if fault alarm device. Resistance at
TCU detected a wrong
vanishes (loose Actuator/sensors
voltage at output pin, that Check connectors
connection). and Cable” on page
looks like a S.C. to vehicle from backup alarm
ground. OP-Mode: normal. device to TCU. 34.

• Cable is defective and is Check resistance 1)

contacted to vehicle ground. of backup alarm
• Backup alarm device has an device.
internal defect.
• Connector pin is contacted
to vehicle ground.
92 ** S.C. to battery voltage at relay No reaction. Check cable from 1)See
reverse warning alarm. TCU to backup “Measurement of
OP-Mode: normal.
alarm device. Resistance at
TCU detected a wrong
voltage at output pin, that Check connectors Actuator/sensors
looks like a S.C. to battery from backup alarm and Cable” on page
voltage. device to TCU. 34.

• Cable is defective and is Check resistance 1)

contacted to battery voltage. of backup alarm
• Backup alarm device has an device.
internal defect.
• Connector pin is contacted
to battery voltage.
93 ** O.C. at relay reverse warning No reaction. Check cable from 1)See
alarm. TCU to backup “Measurement of
OP-Mode: normal.
alarm device. Resistance at
TCU detected a wrong
voltage at output pin, that Check connectors Actuator/sensors
looks like a O.C. for this output from backup alarm and Cable” on page
pin. device to TCU. 34.

• Cable is defective and has Check resistance 1)

no connection to TCU. of backup alarm
• Backup alarm device has an device.
internal defect.
• Connector has no
connection to TCU.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 22
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
94 ** S.C. to ground at relay starter No reaction. Check cable from 1) See
interlock. TCU to starter “Measurement of
OP-Mode: normal.
interlock relay. Resistance at
TCU detected a wrong
voltage at output pin, that Check connectors Actuator/sensors
looks like a S.C. to vehicle from starter interlock and Cable” on page
ground. relay to TCU. 34.

• Cable is defective and is Check resistance 1)

contacted to vehicle ground. of starter interlock
• Starter interlock relay has an relay.
internal defect.
• Connector pin is contacted
to vehicle ground.
95 * O.C. at LIS1 solenoid valve. No reaction. Check the cable from If fault code 95 and
TCU to the valve. 98 are both being
The measured resistance OP-Mode: normal.
displayed for about
value of the valve is out of Check the
one second each,
limit. connectors from
see combined fault
valve to TCU.
• Cable/connector is defective code.
and has no contact to TCU. Check the valve
resistance.
• Valve has an internal defect.
95 ** S.C. to battery voltage at relay No reaction. Check cable from 1)See
starter interlock. TCU to starter “Measurement of
OP-Mode: normal.
interlock relay. Resistance at
TCU detected a wrong
voltage at output pin, that Check connectors Actuator/sensors
looks like a S.C. to battery from starter interlock and Cable” on page
voltage. relay to TCU. 34.

• Cable is defective and is Check resistance 1)

contacted to battery voltage. of starter interlock
• Starter interlock relay has an relay.
internal defect.
• Connector pin is contacted
to battery voltage.
95 * S.C. battery voltage or ground No reaction. Check the cable from ---------------
98 * at LIS1 solenoid valve or LIS2 TCU to the valve.
OP-Mode: normal.
solenoid valve.
Each Check the connector.
fault • Cable is defective and is
Check the valve.
code contacted to vehicle ground or
shown vehicle ground.
for about
• Cable has no connection to
one
TCU.
second.
• Valve has an internal defect.
• Connector pin is contacted
to battery voltage or is broken.
• Connector pin is contacted
to vehicle ground.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 23
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
96 ** O.C. at relay starter interlock. No reaction. Check cable from 1) See
TCU to starter “Measurement of
TCU detected a wrong OP-Mode: normal.
interlock relay. Resistance at
voltage at output pin, that
looks like a O.C. for this output Check connectors Actuator/sensors
pin. from starter interlock and Cable” on page
relay to TCU. 34.
• Cable is defective and has
no connection to TCU. Check resistance 1)
• Starter interlock relay has an of starter interlock
internal defect. relay.

• Connector has no
connection to TCU.
98 * O.C. at LIS2 solenoid valve. No reaction. Check the cable from If fault code 95 and
TCU to the valve. 98 are both being
The measured resistance OP-Mode: normal.
displayed for about
value of the valve is out of Check the
one second each,
limit. connectors from
see combined fault
valve to TCU.
• Cable/connector resistance code.
and has no contact to TCU. Check the valve
resistance.
• Valve has an internal defect.
B1 Slippage at clutch K1. TCU shifts to neutral. Check pressure at ---------------
clutch K1.
TCU calculates a differential OP-Mode: limp
speed at closed clutch K1. If home. Check main
this calculated value is out of pressure in system.
If failure at another
range, TCU interprets this as
clutch is pending. Check sensor gap at
slipping clutch.
internal speed
TCU shifts to neutral.
• Low pressure at clutch K1. sensor.
OP-Mode: TCU shut
• Low main pressure. Check sensor gap at
down.
output speed sensor.
• Wrong signal at internal
speed sensor. Check signal at
internal speed
• Wrong signal at output
sensor.
speed sensor.
Check signal at
• Sensor gap is incorrect.
output speed sensor.
• Clutch is defective.
Replace clutch.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 24
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
B2 Slippage at clutch K2. TCU shifts to neutral. Check pressure at ---------------
clutch K2.
TCU calculates a differential OP-Mode: limp
speed at closed clutch K2. If home. Check main
this calculated value is out of pressure in system.
If failure at another
range, TCU interprets this as
clutch is pending. Check sensor gap at
slipping clutch.
internal speed
TCU shifts to neutral.
• Low pressure at clutch K2. sensor.
OP-Mode: TCU shut
• Low main pressure. Check sensor gap at
down.
output speed sensor.
• Wrong signal at internal
speed sensor. Check signal at
internal speed
• Wrong signal at output
sensor.
speed sensor.
Check signal at
• Sensor gap is incorrect.
output speed sensor.
• Clutch is defective.
Replace clutch.
B3 Slippage at clutch K3. TCU shifts to neutral. Check pressure at ---------------
clutch K3.
TCU calculates a differential OP-Mode: limp
speed at closed clutch K3. If home. Check main
this calculated value is out of pressure in system.
If failure at another
range, TCU interprets this as
clutch is pending. Check sensor gap at
slipping clutch.
internal speed
TCU shifts to neutral.
• Low pressure at clutch K3. sensor.
OP-Mode: TCU shut
• Low main pressure. Check sensor gap at
down.
output speed sensor.
• Wrong signal at internal
speed sensor. Check signal at
internal speed
• Wrong signal at output
sensor.
speed sensor.
Check signal at
• Sensor gap is incorrect.
output speed sensor.
• Clutch is defective.
Replace clutch.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 25
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
B4 Slippage at clutch K4. TCU shifts to neutral. Check pressure at ---------------
clutch K4.
TCU calculates a differential OP-Mode: limp
speed at closed clutch K4. If home. Check main
this calculated value is out of pressure in system.
If failure at another
range, TCU interprets this as
clutch is pending. Check sensor gap at
slipping clutch.
internal speed
TCU shifts to neutral.
• Low pressure at clutch K4. sensor.
OP-Mode: TCU shut
• Low main pressure. Check sensor gap at
down.
turbine speed
• Wrong signal at internal
sensor.
speed sensor.
Check signal at
• Wrong signal at turbine
internal speed
speed sensor.
sensor.
• Sensor gap is incorrect.
Check signal at
• Clutch is defective. turbine speed
sensor.
Replace clutch.
B5 Slippage at clutch KV. TCU shifts to neutral. Check pressure at ---------------
clutch KV.
TCU calculates a differential OP-Mode: limp
speed at closed clutch KV. If home. Check main
this calculated value is out of pressure in system.
If failure at another
range, TCU interprets this as
clutch is pending. Check sensor gap at
slipping clutch.
internal speed
TCU shifts to neutral.
• Low pressure at clutch KV. sensor.
OP-Mode: TCU shut
• Low main pressure. Check sensor gap at
down.
turbine speed
• Wrong signal at internal
sensor.
speed sensor.
Check signal at
• Wrong signal at turbine
internal speed
speed sensor.
sensor.
• Sensor gap is incorrect.
Check signal at
• Clutch is defective. turbine speed
sensor.
Replace clutch.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 26
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
B6 Slippage at clutch KR. TCU shifts to neutral. Check pressure at ---------------
clutch KR.
TCU calculates a differential OP-Mode: limp
speed at closed clutch KR. If home. Check main
this calculated value is out of pressure in system.
If failure at another
range, TCU interprets this as
clutch is pending. Check sensor gap at
slipping clutch.
internal speed
TCU shifts to neutral.
• Low pressure at clutch KR. sensor.
OP-Mode: TCU shut
• Low main pressure. Check sensor gap at
down.
turbine speed
• Wrong signal at internal
sensor.
speed sensor.
Check signal at
• Wrong signal at turbine
internal speed
speed sensor.
sensor.
• Sensor gap is incorrect.
Check signal at
• Clutch is defective. turbine speed
sensor.
Replace clutch.
B7 Overtemp sump. No reaction. Cool down machine. ---------------
TCU measured a temperature OP-Mode: normal. Check oil level.
in oil sump that is over
Check temperature
allowed threshold.
sensor.
D1 S.C. to battery voltage at See fault codes No. Check cables and Fault codes No. 21 to
power supply for sensors. 21 - 2C. connectors to No. 2C may be a
sensors, which are reaction of this fault.
TCU measures more than 6V
supplied from AU1.
at the pin AU1 (5V sensor
supply). Check the power
supply at the pin AU1
(should be
approximately 5V).
D2 S.C. to ground at power See fault codes No. Check cables and Fault codes No. 21 to
supply for sensors. 21 - 2C. connectors to No. 2C may be a
sensors, which are reaction of this fault.
TCU measures less than 4V
supplied from AU1.
at the pin AU1 (5V sensor
supply). Check the power
supply at the pin AU1
(should be
approximately 5V).
D3 Low power at battery. Shift to neutral. Check power supply ---------------
battery.
Measured voltage at power OP-Mode: TCU shut
supply is lower than 18 V. down. Check cables from
batteries to TCU.
Check connectors
from batteries to
TCU.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 27
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
D4 High power at battery. Shift to neutral. Check power supply ---------------
battery.
Measured voltage at power OP-Mode: TCU shut
supply is higher than 32 V. down. Check cables from
batteries to TCU.
Check connectors
from batteries to
TCU.
D5 Error at switch 1 for valve Shift to neutral. Check fuse. ---------------
power supply VPS1.
OP-Mode: TCU shut Check cables from
TCU switched on VPS1 and down. gearbox to TCU.
measured VPS1 is off or TCU
Check connectors
switched off VPS1 and
from gearbox to
measured VPS1 is still on.
TCU.
• Cable or connectors are
Replace TCU.
defect and are contacted to
battery voltage.
• Cable or connectors are
defect and are contacted to
vehicle ground.
• Permanent power supply
KL30 missing.
• TCU has an internal defect.
D6 Error at switch 2 for valve Shift to neutral. Check fuse. ---------------
power supply VPS2.
OP-Mode: TCU shut Check cables from
TCU switched on VPS2 and down. gearbox to TCU.
measured VPS2 is off or TCU
Check connectors
switched off VPS2 and
from gearbox to
measured VPS2 is still on.
TCU.
• Cable or connectors are
Replace TCU.
defect and are contacted to
battery voltage.
• Cable or connectors are
defect and are contacted to
vehicle ground.
• Permanent power supply
KL30 missing.
• TCU has an internal defect.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 28
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
E3 S.C. to battery voltage at No reaction. Check the cable from ---------------
display output. TCU to the display.
OP-Mode: normal.
TCU sends data to the display Check the
and measures always a high connectors at the
voltage level on the connector. display.
• Cable or connectors are Change display.
defective and are contacted to
battery voltage.
• Display has an internal
defect.
E4 S.C. to ground at display No reaction. Check the cable from ---------------
output. TCU to the display.
OP-Mode: normal.
TCU sends data to the display Check the
and measures always a high connectors at the
voltage level on the connector. display.
• Cable or connectors are Change display.
defective and are contacted to
vehicle ground.
• Display has an internal
defect.
F1 General EEPROM fault. Transmission stay Replace TCU. Often shown
neutral. together with fault
TCU cannot read non volatile
code F2.
memory. OP-Mode: TCU shut
down.
• TCU is defective.
F2 Configuration lost. Transmission stay Reprogram the ---------------
neutral. correct configuration
TCU has lost the correct
for the vehicle (e.g.
configuration and can't control OP-Mode: TCU shut
with cluster
the transmission. down.
controller,...).
• Interference during saving
data on non volatile memory.
• TCU is brand new or from
another vehicle.
F3 Application error. Transmission stay Replace TCU! This fault occurs only
neutral. if an test engineer
Something of this application
did something wrong
is wrong. OP-Mode: TCU shut
in the application of
down.
the vehicle.
F5 ** Clutch failure. Transmission stay Check clutch. TCU shows also the
neutral. affected clutch on
AFP was not able to adjust
the Display.
clutch filling parameters. OP-Mode: TCU shut
down.
• One of the AFP-Values is out
of limit.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

Transmission Error Codes (ZF) S0607900C

Page 29
 Fault Meaning of the Fault Code Reaction of the Possible Steps to Remarks
Code (Possible reason for fault TCU Repair
(hex) detection.)
F6 ** Clutch Adjustment Data lost. No reaction, Execute AFP. ---------------
TCU was not able to read Default values = 0 for
correct clutch adjustment AFP offsets used.
parameters.
OP-Mode: normal.
• Interference during saving
data on non volatile memory.
• TCU is brand new.
* Only Mega 400-III PLUS
** Only Series "V"
Gray shaded boxes are error codes for other applications. They are only given for general reference purposes.

S0607900C Transmission Error Codes (ZF)

Page 30
TABLE OF FAULT CODES - ERGO-CONTROL
Error Code
Meaning of Error Code Remarks
Number

11 Logical error at gear range signal.

12 Logical error at direction select signal.

21 Short circuit to battery voltage at clutch cutoff input.

22 Short circuit to ground or open circuit at clutch cutoff input.

23 Short circuit to battery voltage at load sensor input. Not used.

24 Short circuit to ground or open circuit at load sensor input. Not used.

25 Short circuit to battery voltage or open circuit at temperature sensor

input.

26 Short circuit to ground at temperature sensor input.

31 Short circuit to battery voltage at engine speed input.

32 Short circuit to ground or open circuit at engine speed input.

33 Logical error at engine speed input.

34 Short circuit to battery voltage at turbine speed input.

35 Short circuit to ground or open circuit at turbine speed input.

36 Logical error at turbine speed input.

37 Short circuit to battery voltage at internal speed input.

38 Short circuit to ground or open circuit at internal speed input.

39 Logical error at internal speed input.

3A Short circuit to battery voltage at output speed input.

3B Short circuit to ground or open circuit at output speed input.

3C Logical error at output speed input.

71 Short circuit to battery voltage at clutch K1.

72 Short circuit to ground at clutch K1.

73 Open circuit at clutch K1.

74 Short circuit to battery voltage at clutch K2.

75 Short circuit to ground at clutch K2.

76 Open circuit at clutch K2.

Transmission Error Codes (ZF) S0607900C

Page 31
 Error Code
Meaning of Error Code Remarks
Number

77 Short circuit to battery voltage at clutch K3.

78 Short circuit to ground at clutch K3.

79 Open circuit at clutch K3.

7A Short circuit to battery voltage at converter clutch. Not used.

7B Short circuit to ground at converter clutch. Not used.

7C Open circuit at converter clutch. Not used

81 Short circuit battery voltage at clutch K4.

82 Short circuit to ground at clutch K4.

83 Open circuit at clutch K4.

84 Short circuit to battery voltage at clutch KV.

85 Short circuit to ground at clutch KV.

86 Open circuit at clutch KV.

87 Short circuit to battery voltage at clutch KR.

88 Short circuit to ground at clutch KR.

89 Open circuit at clutch KR.

91 Short circuit battery voltage at relay reverse warning alarm.

92 Short circuit to ground at relay reverse warning alarm.

93 Open circuit at relay reverse warning alarm.

94 Short circuit to battery voltage at relay starter interlock.

95 Short circuit to ground at relay starter interlock.

96 Open circuit at relay starter interlock.

97 Short circuit to battery voltage at park brake solenoid.

98 Short circuit ground at park brake solenoid.

99 Open circuit at park brake solenoid.

B1 Slippage at clutch K1.

B2 Slippage at clutch K2.

B3 Slippage at clutch K3.

B4 Slippage at clutch K4.

S0607900C Transmission Error Codes (ZF)

Page 32
 Error Code
Meaning of Error Code Remarks
Number

B5 Slippage at clutch KV.

B6 Slippage at clutch KR.

D1 Short circuit to battery voltage at power supply for sensors.

D2 Short circuit to ground at power supply for sensors.

D3 Low power at battery.

D4 High power at battery.

D5 Error at switch 1 for valve power supply.

D6 Error at switch 2 for valve power supply.

E1 Short circuit to battery at speedometer output. Not used.

E2 Short circuit to ground or open circuit at speedometer output. Not used.

E3 Short circuit to battery voltage at display output. Not used.

E4 Short circuit to ground or open circuit at display output. Not used.

E5 Error at communication on CAN.

F1 General EEPROM fault.

F2 Configuration lost.

F3 Application error.

Transmission Error Codes (ZF) S0607900C

Page 33
MEASUREMENT OF RESISTANCE AT ACTUATOR/
SENSORS AND CABLE
ACTUATOR
Open circuit:R12 ≈ R1G ≈ R2G ≈ ∞
1
Short cut to ground:R12 ≈ R;R1G ≈ 0, R2G ≈ R or
R1G ≈ R, R2G ≈ 0(for S.C. to ground, G is
R
connected to vehicle ground)
Short cut to battery:R12 ≈ R;R1G ≈ 0, R2G ≈ R or
R1G ≈ R, R2G ≈ 0(for S.C. to battery, G is 2
G
connected to battery voltage.
HBOE640I

Figure 2
CABLE
UBat
open circuit:
R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞
P (power supply)

short cut to ground: TCU

Actuator /
1 2
R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞ Sensor

short cut to battery: C (chassis)

R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0

Gnd

HBOE650I
Figure 3

S0607900C Transmission Error Codes (ZF)

Page 34
1HYDRAULICS
 Return to Master Table of Contents

S0703000
R3

1ACCUMULATOR

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

ACCUMULATOR S0703000
MODEL SERIAL NUMBER RANGE
Mega 130 0001 and Up
Mega 160 0001 and Up
Mega 200-III 1001 and Up
Mega 200-V 1001 and Up
Mega 250-III 1001 and Up
Mega 250-V 1001 and Up
Mega 300-V 1001 and Up
Mega 400-III PLUS 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Solar 170LC-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 220LC-V 0001 and Up
Solar 220LL 1001 and Up
Solar 220N-V 1001 and Up

Models continued on back of cover.

Copyright 2002 Daewoo

June 2002

Accumulator S0703000
Page 1
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MODEL SERIAL NUMBER RANGE

Solar 250LC-V 1001 and Up
Solar 290LC-V 0001 and Up
Solar 290LL 1001 and Up
Solar 330LC-V 1001 and Up
Solar 400LC-V 1001 and Up
Solar 450LC-V 1001 and Up

TABLE OF CONTENTS

General Description........................................................................................ 3
Specifications .......................................................................................... 4
Accumulator Charging.................................................................................... 7
Charging the Accumulator with Nitrogen................................................. 7

S0703000 Accumulator
Page 2
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GENERAL DESCRIPTION
The accumulator is a gas-charged storage
device designed to hold a reserve quantity of
hydraulic fluid under pressure. Accumulators are
used in hydraulic circuits in much the same way
that condensers (or capacitors) are used to
collect, store and maintain electrical charge in a
circuit.
In a hydraulic circuit, minor variations or lags in
pump output that might otherwise cause
unsteady or irregular operation are made up
from the supply of pressurized oil in the
accumulator.

Reference
Description
Number
1 Screw Plug
2 Sealing Ring
3 Diaphragm
4 Fluid Valve
5 Steel Pressure Vessel Figure 1
Accumulators are solidly constructed to resist
the high operating pressures of the fluids they contain. There are only three main moving parts: a valve
assembly at the top allows adding or expelling gas from the compressible, pre-charged upper chamber; a
valve assembly at the bottom of the accumulator for passing hydraulic fluid in and out, and an elastic
diaphragm to separate the two chambers. The flexible diaphragm changes shape to conform to the
changing pressures and volumes of the two fluids in the upper and lower chambers.
There are six possible positions the diaphragm
can be in and they are as follows:
1. With no gas charge in the upper chamber
0 bar (0 psi, empty) and no oil in the
bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the pre-pressure charge of gas
(usually nitrogen) is introduced through the
valve at the top of the accumulator, the
diaphragm expands to maximum size. The
valve button in the center of the diaphragm
pushes into the fluid opening in the bottom
chamber, sealing off the lower valve. If the
pressure of the gas charge exceeds
system oil pressure, no fluid enters the
accumulator. The button also keeps the
diaphragm from protruding into the lower
valve opening.

Figure 2

Accumulator S0703000
Page 3
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NOTE: Pre-charge pressure is referred to as the "P1" pressure. The accumulator manufacturer’s
"P1" rated pressure should be stamped or marked on the accumulator’s rating plate.
Annual checks of actual pre-charge pressure should be made by tapping a hydraulic
pressure gauge (and 3-way adapter coupling) into the valve on the bottom of the
accumulator. When hydraulic fluid is pushed out the lower valve opening by the pressure
of the gas charge on the other side of the diaphragm - and there is no counter-pressure
from system oil - the valve button on the bottom of the diaphragm eventually seals off the
lower oil passage. Just after the needle on the gauge reaches its highest point (when there
is 0 bar (0 psi) resistance from hydraulic system pressure) pressure on the gauge will drop
sharply to zero, as the accumulator is completely emptied of oil and the diaphragm button
closes.
Record the highest gauge reading and compare to the "P1" rated pre-charge pressure on the
accumulator manufacturer’s data label. Repeat this test at least once a year to verify proper
functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator pre-charge pressure, the flexible diaphragm
begins to retract upward.
4. When system oil is at highest working pressure and the accumulator fills to maximum reserve
capacity, the flexible diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as the "P3" pressure and can also be
referenced on the manufacturer’s data label on the exterior of the accumulator.
5. If system oil pressure begins to fall off or is momentarily checked or interrupted, the energy stored on
the other side of the diaphragm, in the form of compressed gas, pushes oil back out of the lower
chamber, maintaining oil pressure of the circuit.
6. With minimal system pressure, an equilibrium point may be reached in which accumulator pre-charge
pressure and hydraulic system oil pressure achieve a rough balance. In this condition a minimal
amount of oil is stored in the accumulator.

SPECIFICATIONS

Charge
Model Serial Number System Volume
Pressure
15 kg/cm2 320 cc
Mega 130 S/N 0001 - 1003 Pilot
(210 psi) (19.53 in3)
9 kg/cm2 500 cc
Mega 130 S/N 0001 and Up Brake System
(130 psi) (30.51 in3)
8 kg/cm2 500 cc
Mega 160 S/N 0001 - 1020 Brake System
(115 psi) (30.51 in3)
15 kg/cm2 320 cc
Mega 160 S/N 0001 - 1020 Pilot
(210 psi) (19.53 in3)
30 kg/cm2 750 cc
Mega 160 S/N 1021 and Up Brake System
(430 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 200-III S/N 1001 - 1386 Brake System
(210 psi) (19.53 in3)
15 kg/cm2 320 cc
Mega 200-III S/N 1001 - 1386 Pilot
(210 psi) (19.53 in3)

S0703000 Accumulator
Page 4
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Charge
Model Serial Number System Volume
Pressure
40 kg/cm2 750 cc
Mega 200-III S/N 1387 and Up Brake System
(570 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 200-V S/N 1001 and Up Brake System
(210 psi) (19.53 in3)
Brake / Pilot 30 kg/cm2 750 cc
Mega 250-III S/N 1001 and Up
System (430 psi) (45.77 in3)
Brake / Pilot 15 kg/cm2 320 cc
Mega 250-V S/N 1001 and Up
System (210 psi) (19.53 in3)
30 kg/cm2 750 cc
Mega 300-V S/N 1001 and Up Brake System
(430 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 300-V S/N 1001 and Up Pilot
(210 psi) (19.53 in3)
Mega 400-III S/N 1001 and Up Brake System
Mega 400-III S/N 1001 and Up Pilot
Brake / Pilot 30 kg/cm2 750 cc
Mega 400-III PLUS S/N 1001 and Up
System (430 psi) (45.77 in3)
30 kg/cm2 750 cc
Mega 400-V S/N 1001 and Up Brake System
(430 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 400-V S/N 1001 and Up Pilot
(210 psi) (19.53 in3)
S/N 1001 thru 30 kg/cm2 750 cc
Mega 500-V Brake System
2000 (430 psi) (45.77 in3)
S/N 1001 thru 15 kg/cm2 320 cc
Mega 500-V Pilot
2000 (210 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 130LC-V S/N 0001 and Up Pilot / Travel
(140 psi) (19.53 in3)
30 kg/cm2 750 cc
Solar 130W-V S/N 0001 and Up Brake System
(430 psi) (45.77 in3)
10 kg/cm2 320 cc
Solar 130W-V S/N 0001 and Up Pilot
(140 psi) (19.53 in3)
8 kg/cm2 750 cc
Solar 130W-V S/N 0001 and Up Transmission
(115 psi) (45.77 in3)
10 kg/cm2 320 cc
Solar 170LC-V S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)
30 kg/cm2 750 cc
Solar 170W-V S/N 1001 and Up Brake System
(430 psi) (45.77 in3)
10 kg/cm2 320 cc
Solar 170W-V S/N 1001 and Up Pilot
(140 psi) (19.53 in3)

Accumulator S0703000
Page 5
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Charge
Model Serial Number System Volume
Pressure
8 kg/cm2 750 cc
Solar 170W-V S/N 1001 and Up Transmission
(115 psi) (45.77 in3)
30 kg/cm2 750 cc
Solar 200W-V S/N 0001 and Up Brake System
(430 psi) (45.77 in3)
10 kg/cm2 320 cc
Solar 200W-V S/N 0001 and Up Pilot
(140 psi) (19.53 in3)
8 kg/cm2 750 cc
Solar 200W-V S/N 0001 and Up Transmission
(115 psi) (45.77 in3)
10 kg/cm2 320 cc
Solar 220LC-V S/N 0001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 220LL S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 220N-V S/N 1001 and Up
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 250LC-V S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 290LC-V S/N 0001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 290LL S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 330LC-V S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 400LC-V S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 450-V S/N 1001 and Up Pilot / Travel
(140 psi) (19.53 in3)

S0703000 Accumulator
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ACCUMULATOR CHARGING

WARNING!
In the event of a diaphragm or upper valve failure, or any type of accident or handling fault, the
upper chamber of the accumulator could at some point require re-pressurization. Depending
upon the specific procedures and safety precautions recommended for the type and model
accumulator that has been installed on your machine, a specialized adapter and/or filling tool
may be required to perform the procedure. Consult your dealer or Daewoo After Sales Service
for more information and follow recommended procedures carefully. All accumulators may
contain gas held under high pressure. Careless handling or improper disassembly could release
explosive stored energy, resulting in an accident or injury.

NOTE: Some machines use 320 cc (19.53 in3) Bosch Accumulators with a nitrogen precharge
(P1) pressure of 15 kg/cm2 (213 psi). Always verify pre-charge pressure by checking the
manufacturer’s data label on the exterior of the accumulator.

CHARGING THE ACCUMULATOR WITH NITROGEN

1. Remove the protective cap (10, Figure 3) and the protective plug (11) from the accumulator (6).

Figure 3

Accumulator S0703000
Page 7
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Reference Reference
Description Description
Number Number
1 Nitrogen Cylinder Fitting 7 Cylinder to Accumulator
2 Hose, 3 Meters (10 ft) Long Adapter
3 Check Valve 8 Nitrogen Bleeder Valve
4 Pressure Gauge 9 Nut O-ring
5 Sealing Nut 10 Protective Cap
6 Accumulator 11 Protective Plug
12 Sealing Ring

2. Clean area around seal ring (12).

3. Thread the sealing nut (5, Figure 3) of adapter (7) onto accumulator. Tighten adapter securely. Close
nitrogen bleeder vale (8).
4. Thread nitrogen cylinder fittings (1, Figure 3) onto nitrogen cylinder.
5. Open valve on nitrogen cylinder and charge accumulator to a appropriate pressure (P1). Close valve
on nitrogen cylinder.
NOTE: Wait 2 or 3 minutes for nitrogen to warm to ambient temperature. This will stabilize
pressure.
6. Slowly open nitrogen bleeder valve (8). Open valve (8) until gauge (4) reading is equal to primary
pressure. Close bleeder valve.
7. Unscrew adapter (7, Figure 3) from accumulator (6).
8. Thread protective plug (11, Figure 3) into accumulator. Tighten to 3 kg•m (22 ft lb).
9. Check for nitrogen leaks around protective plug (11, Figure 3). Coat area around protective plug (11)
with soapy water. If soap bubbles form, retighten protective plug (11).
10. Install protective cap (10, Figure 3) on accumulator.

WARNING!
Accumulator store nitrogen under high pressure. Before replacing an accumulator, install
an adapter (7) with a bleeder valve (8) on the accumulator. Slowly and carefully bleed off all
nitrogen before removing the accumulator from the hydraulic system.

NOTE: After an accumulator has been installed, or after an accumulator has been recharged with
(P1) after the first week of operation. Check for a pressure drop due to leaks. If no
pressure drop is found after the first week, check again after 3 more weeks. If no pressure
drop is found after 3 weeks, check after one year.

S0703000 Accumulator
Page 8
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S0705010

1CYLINDERS

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

CYLINDERS S0705010
MODEL SERIAL NUMBER RANGE
Mega 130 0001 and Up
Mega 160 0001 and Up
Mega 200-III 1001 and Up
Mega 200-V 1001 and Up
Mega 250-III 1001 and Up
Mega 250-V 1001 and Up
Mega 300-V 1001 and Up
Mega 400-III PLUS 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Cylinders S0705010
Page 1
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TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 4
Parts List ................................................................................................. 5
Troubleshooting, Testing and Adjustment....................................................... 7
Disassembly ................................................................................................. 11
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 13
Reassembly.................................................................................................. 14

S0705010 Cylinders
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GENERAL DESCRIPTION
The machine contains boom cylinders, buckets cylinders and steering cylinders. Each cylinder contains a
cylinder tube, piston rod, piston, and cylinder head. See Figure 1. The piston is held to piston rod by a nut.
A dust seal protects the U-ring and oil seal from dirt and also prevents oil from leaking out of the cylinder.

Figure 1

Reference Reference
Description Description
Number Number
1 Retaining Ring 10 Seal O-ring
2 Dust Seal 11 Piston
3 U-Ring 12 Spring
4 Seat O-ring 13 Cylinder Tube
5 Port (A) 14 O-ring, Backup Ring
6 Cushion Plate 15 Bushing
7 Wear Ring 16 Cylinder Head
8 Piston Nut 17 Bolt
9 Port (B) 18 Piston Rod

Cylinders S0705010
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THEORY OF OPERATION

Reference
Description
Number
1 Piston
2 Oil Path A
3 Oil Path B

Cylinder piston rods are extended or retracted

by oil flow to back side of cylinder (shown as "oil
path A") or to front of cylinder ("oil path B").
The cylinder rod is extended as oil flow is
pumped through the circuit to the back side of
the piston. The force (F1) of the piston stroke
can be expressed by the formula below, where P
= circuit oil pressure and the inside diameter of
Figure 2
the cylinder is expressed by B (Figure 2).

F1 = P x πB2
4

(P: Pressure, π = 3.14, B: Cylinder Inside Diameter)

Reference
Description
Number
1 Cylinder Inside Diameter - B
2 Oil Path A
3 Oil Path B
4 Rod Diameter

When the cylinder rod is retracted, oil flow Figure 3

through the circuit from the pump to the front
side of the cylinder generates a force (F2) that
can be expressed by the formula in which the
diameter of the piston rod is expressed by R,
and the other two terms are the same as in the
preceding expression.

F2 = P x π(B2-R2)
4

Because the volume of oil needed to lengthen

the cylinder rod (Q1) is greater than the volume
of oil required to retract the cylinder rod, it takes
more time to decrease cylinder stroke length
than it does to lengthen it.

Q1 = S x π(B2)
4
Figure 4
Q2 = S x π(B2-R2)
4

Q1 > Q2

S0705010 Cylinders
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PARTS LIST

Boom Hydraulic Cylinder

Figure 5

Reference Reference
Description Description
Number Number
1 Cylinder Tube 11 Piston Ring
2 Cylinder Rod 12 U-Ring
3 Cylinder Head 13 U-Ring Holder
4 Bushing 14 Stopper
5 Snap Ring 15 U-nut
6 Packing Header 16 Lock Washer
7 U-Ring 17 Pin Bushing
8 Wiper Ring 18 Pin Bushing
9 Snap Ring 19 Grease Flitting
10 Piston 20 O-ring

Cylinders S0705010
Page 5
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Bucket Hydraulic Cylinder

Figure 6

Reference Reference
Description Description
Number Number
1 Cylinder Tube 12 U-ring Holder
2 Cylinder Rod 13 U-ring Holder
3 Cylinder Head 14 Stopper
4 Bushing 15 Castle Nut
5 Snap Ring 16 Shim
6 Packing Header 17 Dividing Pin
7 U-ring 18 Lock Washer
8 Wiper Ring 19 Pin Bushing
9 Piston 20 O-ring
10 Piston Ring 21 O-ring
11 U-ring 22 Plug

S0705010 Cylinders
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TROUBLESHOOTING, TESTING AND ADJUSTMENT

Problem Possible Cause Remedy
Oil leaking between cylinder Foreign material in U-ring (3). Remove foreign material.
head (16) and piston rod (18). Scratches in U-ring (3). Replace U-ring (3).
(Index nos. refer to Figure 1)
Damage to U-ring (3). Replace U-ring (3).
Foreign material in dust seal (2). Remove foreign material.
Scratches to dust seal (2). Replace dust seal.
Damage to dust seal (2). Replace dust seal.
Foreign material in seal O-ring Remove foreign material.
(4).
Scratches in seal O-ring (4). Replace O-ring (4).
Damage to seal O-ring (4). Replace O-ring (4).
Scratches on sealing surface of If scratches are not deep, hone
piston rod (18). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface Replace Bushing.
of bushing (15).
Oil leaking between cylinder Damage to O-rings (14). Replace O-rings (14).
head (16) and cylinder tube (13).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).

Cylinders S0705010
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Problem Cause Remedy

Oil leaking between cylinder Foreign material in U-ring (3, Remove foreign material.
head (16) and piston rod (18). Figure 1)
(Index nos. refer to Figure 1). Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to U-ring (3, Figure 1). Replace U-ring (3).
Foreign material in dust seal (2, Remove foreign material.
Figure 1).
Scratches in dust seal (2, Figure Replace dust seal (2).
1).
Damage to dust seal (2, Figure Replace dust seal (2).
1).
Foreign material in seal O-ring Remove foreign material.
(4, Figure 1).
Scratches in seal O-ring (4, Replace O-ring (4).
Figure 1).
Damage to seal O-ring (4, Replace O-ring (4).
Figure 1).
Scratch on sealing surface of If scratches are not deep, hone
piston rod (18, Figure 1). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface Replace bushing.
of bushing (15, Figure 1).
Oil leaking between cylinder Damage to O-rings (14, Figure Replace O-rings (14).
head (16) and cylinder tube (13). 1).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
Cylinder drops from pull of Light scratches on sealing Hone out scratches with oil
gravity. surface of cylinder tube (13, stone.
Figure 1).
Deep scratches on sealing Replace cylinder tube (13).
surface of cylinder tube (13,
Figure 1).
Deep scratches on sealing Replace O-rings (10).
surface of piston O-rings (10,
Figure 1).
Foreign material in U-ring (3, Remove foreign material.
Figure 1).
Scratches in U-ring (3, Figure 1). Replace U-ring (3).

Damage to U-ring (3, Figure 1). Replace U-ring (3).

Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
twisted.
Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
scratched.
Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
have other damage.

S0705010 Cylinders
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Problem Cause Remedy

Slow bucket and boom Reduced oil flow due to dirty Disassemble and clean parts.
movements. filter or dirty intake line.
Air drawn into circuit through Tighten intake connections.
loose connections.
Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Damaged pump shaft or pump Replace damaged parts.
drive sleeve.
Pump worn or damaged Replace worn or damaged parts.
internally.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Air in pressure line. Perform cylinder bleeding
procedure to remove air. Tighten
or replace pressure line.
Damaged pipe or hose. Replace pipe or hose.
Worn cylinder seals. Replace worn parts.
Low pressure, shown by weak Reduced oil flow due to dirty Disassemble and clean parts.
upward movement of boom and filter or dirty intake line.
bucket. Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Pump worn or damaged Replace worn or damaged parts.
internally.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Worn cylinder seals. Replace worn parts.
Low pump output due to dirty Remove and clean pump
discharge pipes. discharge pipes.
Relief valve spring is weak. Replace worn parts.
Relief valve poppet worn.
Cylinder drops when control Worn plunger in control valve. Replace plunger.
valve is in neutral. Stuck overload relief valve due Replace worn parts.
to worn seat surface.
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic Replace seal.
cylinder.
Vibration or excessive noise. Excessive resistance in pump Inspect intake line and clean or
intake line. replace as necessary.
Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.

Cylinders S0705010
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Problem Cause Remedy

Air bubbles in oil. Wrong type of operating oil. Drain and fill with proper type of
oil.
Oil level too low. Raise to proper level.
Air trapped in system. Perform cylinder bleeding
procedure to remove air.
Frequent rubber hose damage. System pressure too high. Adjust relief valve pressure.
Hoses breaking due to contact Restrain hoses to prevent
with another machine parts. contact.

S0705010 Cylinders
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DISASSEMBLY
NOTE: Keep on hand a container large enough to hold all of the oil in cylinder being repaired.
When cylinder rod and head are removed, oil will run out of cylinder.
1. Use an allen wrench to remove bolts that
hold cylinder head to cylinder tube. See
Figure 7.

Figure 7
2. Support cylinder rod with a lifting sling.
See Figure 8. Slide cylinder rod out of
cylinder tube. Rotate cylinder rod slightly
as it is being pulled from cylinder tube.
This will make it easier to pull rod out of
tube.

Figure 8
3. Set cylinder rod assembly in a repair
fixture and secure rod in place. See Figure
9. Use a power wrench and socket to
remove nut that holds piston on rod.

Figure 9

Cylinders S0705010
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4. Remove piston nut (1, Figure 10), piston

assembly (2), cushion flange (3), and
cylinder head assembly (4).

Reference
Description
Number
1 Piston Nut
2 Piston Assembly
3 Cushion Flange
4 Cylinder Head
Assembly

Figure 10
5. Do not remove slipper seal, backup ring,
and back ring from piston. If these three
items are not scratched or damaged. See
Figure 11. Once these 3 items are
removed from piston, they must be
replaced. They cannot be reused. Exercise
caution when removing slipper seal to
prevent damage to piston O-ring groove.
Remove wear rings from piston.

Figure 11
6. When disassembling cylinder head do not
remove slipper seal, backup ring, back
ring, or dust seal unless items are
scratched or damaged. If seals are
removed from head, they must be
replaced. They cannot be reused. Remove
snap ring, (1, Figure 12). Use a
screwdriver to remove dust seal (2) from
head.

Reference
Description
Number
1 Snap Ring
Figure 12
2 Dust Seal

S0705010 Cylinders
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7. Use caution to prevent damage to any

parts of U-packing (1, Figure 13). Remove
U-packing (1). Remove O-ring (2), and ring
(3).

Reference
Description
Number
1 U-Packing
2 O-Ring
3 Ring

Figure 13

CLEANING AND INSPECTION (WEAR LIMITS AND

TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.

Cylinders S0705010
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REASSEMBLY
NOTE: Check cylinder head grooves
for U-packing and dust seal. If
edges of grooves are sharp or
have burns, use an oil stone to
smooth surface. See Figure 14.

Figure 14
1. Apply grease to inner part of cylinder head
and to U-packing groove. See Figure 15.

Figure 15
2. Install split backup ring into its groove by
compressing ring. See Figure 16. Make
sure that ends of ring do not overlap.
NOTE: The U-packing can be installed
by hand or by using a seal
installing jig. The jig should be
made of copper, aluminum, or
plastic. If a jig is used, be sure
that jig does not have sharp
edges that could damage U-
packing.

Figure 16

S0705010 Cylinders
Page 14
 Return to Master Table of Contents

3. Insert one side of U-packing in its groove.

See Figure 17.

Figure 17
4. Carefully push down on other side of U-
packing until entire U-packing is seated in
its groove. See Figure 18.

Figure 18
5. Check to be sure that U-packing and
backup ring are correctly installed by
pushing with your hand on inner diameter
of U-packing. See Figure 19.
NOTE: There are 2 backup rings used
on outside of cylinder head.
One backup ring is continuous.
The other backup ring is open,
split by an angled cut.

Figure 19
6. Use grease or an adhesive to hold split
backup ring (1, Figure 20) in place. Install
split backup ring (1) in groove closets to
flange on cylinder head.

Reference
Description
Number
1 Split Backup Ring
2 Continuous Backup
Ring

Figure 20

Cylinders S0705010
Page 15
 Return to Master Table of Contents

7. Place continuous backup ring in warm

water. See Figure 21. Water temperature
should be 30 - 50°C (86 - 122°F). Leave
ring in water for 2 - 3 minutes. Slide
continuous backup ring (2, Figure 20) over
cylinder head and into its groove.

Figure 21
8. Install an O-ring over each of backup
rings. See Figure 22.

Figure 22
9. Use a seal installing jig to install dust seal
into cylinder head. See Figure 23. Install
snap ring.

Figure 23

S0705010 Cylinders
Page 16
 Return to Master Table of Contents

10. On piston, check corners of grooves that

piston rings will be mounted in. See Figure
24. If any burrs, roughness, or sharp
edges (1) are present, use an oil stone to
smooth roughened areas and dull sharp
edges.

Figure 24
11. Apply grease or hydraulic oil to corner of
piston at position A. See Figure 25.

Figure 25
12. Insert one end of backup ring into its
groove. See Figure 26. Use your hand to
slide other end of ring into groove.

Figure 26
13. Use warm water to expand slipper seal.
See Figure 27. This will make seal easier
to install. Set slipper seal in 60 -100
degree C (140 - 212 degree F) water for 5
minutes or longer.

Figure 27

Cylinders S0705010
Page 17
 Return to Master Table of Contents

14. Insert one end of slipper seal, (1, Figure

28) into its groove. Use your hand to slide
other end of slipper seal into groove.

WARNING!
Before piston is inserted into
cylinder tube, make sure that slipper
seal is no longer expanded. If seal is
still expanded, it could catch on
threaded portion of cylinder tube. An
expanded seal could also jam inside Figure 28
cylinder tube.

15. Install two backup rings, (1, Figure 29).

One ring fits on either side of slipper seal
(2).

Reference
Description
Number
1 Backup Ring
2 Slipper Seal

Figure 29

S0705010 Cylinders
Page 18
 Return to Master Table of Contents

16. Install wear ring (1, Figure 30) on piston.

Figure 30
17. Set cylinder rod (1, Figure 31) into a repair
fixture (2). Securely clamp rod to fixture.
Exercise caution to prevent nicks or
scratches to chrome plated areas of rod.
chrome plated area is oil sealing surface of
rod.

Reference
Description
Number
1 Cylinder Rod
2 Repair Fixture

Figure 31
18. Slide cylinder head assembly (1, Figure
32) onto cylinder rod (2). Use caution to
prevent threads on rod from damaging
seal inside cylinder head.

Reference
Description
Number
1 Cylinder Head
2 Cylinder Rod

Figure 32

Cylinders S0705010
Page 19
 Return to Master Table of Contents

19. Install cushion flange (1, Figure 33) on

cylinder rod (2). Slide piston assembly (3)
onto cylinder rod (2).

Reference
Description
Number
1 Cushion Flange
2 Cylinder Rod
3 Piston Assembly

Figure 33
20. Install piston nut (1, Figure 34) and tighten
it with an impact wrench. Then use a
torque wrench to tighten nut (1) to
specified torque.
After nut has been tightened, check to see
that cushion flange moves.

Figure 34
21. Slide rod assembly into cylinder tube.
Align punch mark (1, Figure 35) with port
(2) in cylinder tube. This will align hole (3)
in cylinder head with port (2).

Reference
Description
Number
1 Punch Mark
2 Port
3 Hole

Figure 35

S0705010 Cylinders
Page 20
 Return to Master Table of Contents

22. Install bolts in cylinder head and tighten

them to torque specified in bolt torque
chart. See Figure 36. Double check to
make sure that hole in cylinder head is
align with port in cylinder tube.
NOTE: After rebuilding a cylinder, or
after loosening a cylinder
hydraulic line, air must be bled
from hydraulic system. To bleed
air from system, first extend
and retract a cylinder (or pair of
cylinders) about 5 times at low
engine rpm. Stop cylinder about Figure 36
100 mm (4 in) short of full
extension and full retraction.
Then fully extend and retract
cylinder about 5 times, also at
low engine rpm.

Cylinders S0705010
Page 21
 Return to Master Table of Contents

S0705010 Cylinders
Page 22
 S0707100K

2FAN DRIVE
HYDRAULIC MOTOR
(HALDEX)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

FAN DRIVE HYDRAULIC MOTOR (HALDEX)S0707100K

MODEL SERIAL NUMBER RANGE
Mega 300-V 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Fan Drive Hydraulic Motor (Haldex) S0707100K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 5
Specifications .......................................................................................... 6

S0707100K Fan Drive Hydraulic Motor (Haldex)

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION

AJS0770L

Figure 1 Fan Drive System Schematic

Reference Reference
Description Description
Number Number
1 Pump (Brake, Pilot, Fan Drive) 4 Fan Motor
2 Supply Valve 5 Fan
(Brake, Pilot, Fan motor) 6 Relief Valve
3 Sequency Valve 7 Oil Cooler

The main components of the fan drive system are pump (1), motor (4), brake / pilot / fan motor supply
valve (2), fan (5) and oil cooler (7). Oil is drawn from tank through pump (1) and brake / pilot filter, to the
brake valve and accumulators, at the same time to the sequency valve (3) of brake / pilot / fan motor
supply valve (2). In case that the pressure of brake circuit rise up to 120.0 kg/cm2 (1,710 psi), the
sequency valve (3) allows oil to flow fan motor (4). From fan motor (4), oil flows through oil cooler (7) and
to the tank.
Fan drive pump (common as brake and pilot pump) is a fixed displacement, vane pump. The pump is
attached to the end of steering pump and common suction port as steer pump.

Fan Drive Hydraulic Motor (Haldex) S0707100K

Page 3
On the fan drive motor, at engine speed of 1,620

FAN RPM
rpm and above 1,620 rpm, the relief valve on
the fan drive pump opens to dump excess flow

1,300
back to hydraulic tank and thus the fan motor const
speed will constantly be 1,300 rpm. At low idle
engine speed (between 975 and 1,620 rpm), the
fan speed will be approximately between 750

750
and 1,300 rpm.
Fan speed can be changed by adjusting the
relief valve on the fan drive pump.
970 1,620 2,350
E/G RPM AJS0790L

Figure 2

S0707100K Fan Drive Hydraulic Motor (Haldex)

Page 4
PARTS LIST

2
3
4
5
7

1 6
7
5
10
9
8
4
3
2
13
14

12
16

AJS0780L

Figure 3

Reference Reference
Description Description
Number Number
1 Front Bearing 9 Drive Gear
2 Back Up Ring 10 Coupling
3 Seal 11 Cover
4 Bearing Block 12 Bolt
5 O-ring 13 Plug
6 Gear Housing 14 Spring
7 Dowel Pin 15 Ball
8 Idler Gear 16 Relief Valve Cartridge

Fan Drive Hydraulic Motor (Haldex) S0707100K

Page 5
SPECIFICATIONS

Item Specification
Fan Motor Displacement 31.0 cc (1.89 in3)
Relief Valve Setting 70 ± 5 kg/cm2 (1000 ±70 psi)
∆ p/1 turn
16.5 kg/cm2 (235 psi)
Maker (Model) HALDEX (WM9A1-31...)
Fan Fan Size ∅812 (32")
Type Sucker, plastic -8 driven by hydraulic motor
Fan rpm 1,300 rpm @ 70 ± 5 kg/cm2
(at motor relief ∆ p) (1000 ±70 psi))
Fan Drive Pump 24.9 cc
(1.52 in3)

S0707100K Fan Drive Hydraulic Motor (Haldex)

Page 6
 S0708465K

3PUMP
(DENISON T67DB
SERIES)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

PUMP (DENISON T67DB SERIES)S0708465K

MODEL SERIAL NUMBER RANGE
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Pump (Denison T67DB Series) S0708465K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 4
Theory of Operation ................................................................................ 4
Parts List ................................................................................................. 6
Specification.......................................................................................... 10
Special Tools ................................................................................................ 10
Seal Driver ............................................................................................ 10
Protective Cone..................................................................................... 11
Troubleshooting, Testing and Adjustment..................................................... 12
Disassembly ................................................................................................. 13
Pump Disassembly ............................................................................... 13
Camring Replacement, Cartridge Change of Rotation ......................... 15
Shaft Assembly Removal ...................................................................... 17
Shaft Seal Removal .............................................................................. 17
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 18
Vanes .................................................................................................... 18
Rotor ..................................................................................................... 18
Camring ................................................................................................ 18
Port-plates............................................................................................. 19
Seals ..................................................................................................... 19
Shaft...................................................................................................... 19
Circuit Inspection................................................................................... 20
Adding Hydraulic Oil to System............................................................. 20
Adjustments .......................................................................................... 20
Lubrication ............................................................................................ 20
Reassembly.................................................................................................. 21
General Instructions .............................................................................. 21
Shaft Assembly Installation ................................................................... 21
Shaft Seal Installation ........................................................................... 22
Pump Assembly .................................................................................... 22
Porting Change ..................................................................................... 23

S0708465K Pump (Denison T67DB Series)

Page 2
 Start-up Procedures ..................................................................................... 25
Pre-start Check ..................................................................................... 25
Priming.................................................................................................. 25

Pump (Denison T67DB Series) S0708465K

Page 3
GENERAL DESCRIPTION
THEORY OF OPERATION
The operating principle of a vane pump is illustrated in Figure 1. A slotted rotor is splined to the drive shaft
and turns inside a cam ring. Vanes are fitted to rotor slots and follow inner surface of cam ring as the rotor
turns. Centrifugal force and pressure under vanes hold them out against the cam ring. Pumping chambers
are formed between the vanes and cam ring and are enclosed by two end plates.
The pump is a balanced intra-vane design. See Figure 1. Outlet pressure is constantly applied to small
intra-vane area of the vane. As the pump vane rotates through high and low quadrants, outlet pressure is
alternately applied to the rest of under vane area. This varying pressure under the vane reduces wear and
increases pump efficiency.

Figure 1 VANE PUMP OPERATION

S0708465K Pump (Denison T67DB Series)

Page 4
Pump (Denison T67DB Series) S0708465K
Page 5
PARTS LIST
Denison Hydraulics recommends to use primarily service kits, whenever possible. Spare parts lists shown
in “Parts List” on page 6 are for reference, and may not be available individually.
Parts must be kept clean at all time. If cleaning is needed, solvent must be used. Cleaning is needed for
visual inspection. Lightly coat inner parts with oil before assembly.
If replacement of parts with multiple numbers or sets, such as vanes and holdout pins, all the parts must be
changed.

Main Pump

Figure 2 Mega 500-V (Tier II)

S0708465K Pump (Denison T67DB Series)

Page 6
 Reference Reference
Description Description
Number Number
1 End Cap (Standard) Metric 20 Round Section Ring
2 Sq. Section Seal 21 Mounting Cap (Metric)
3 Sq. Section Seal 22 Port Plate-pressure (C.C.W)
4 Back-up Ring 23 Rotor Insert Assembly
5 Sq. Section Seal 24 Back-up Ring
6 Rotor Insert Assembly 25 Dowel Pin
7 Screw 26 Housing (Standard) Metric
8 Lock Washer Internal Tooth 27 Dowel Pin
9 Rear Port Plate (C.C.W) 28 Bush
10 Cam Ring 038 29 Dowel Pin
11 Vane 30 Rear Port Plate
12 Sq. Section Seal 31 Pin-vane Holdout
13 Sq. Section Seal 32 Cam Ring 008
14 Pin-vane Holdout 33 Dowel Pin
15 Sq. Section Seal 34 Vane
16 Retaining Ring 35 Port Plate-pressure
17 Ball Bearing 36 Screw
18 Shaft Seal (S-1, 0.7 bar) 37 Screw
19 Shaft (Splined Code 3) 38 Screw

Pump (Denison T67DB Series) S0708465K

Page 7
Steering Pump

Figure 3 Mega 500-V and Mega 500-V (Tier II)

S0708465K Pump (Denison T67DB Series)

Page 8
 Reference Reference
Description Description
Number Number
1 End Cap (Standard) Metric 20 Round Section Ring
2 Sq. Section Seal 21 Mounting Cap (Metric)
3 Sq. Section Seal 22 Port Plate-pressure (C.W)
4 Back-up Ring 23 Rotor Insert Assembly
5 Sq. Section Seal 24 Back-up Ring
6 Rotor Insert Assembly 25 Dowel Pin
7 Screw 26 Housing (Standard) Metric
8 Lock Washer Internal Tooth 27 Dowel Pin
9 Rear Port Plate (C.W) 28 Bush
10 Cam Ring 035 29 Dowel Pin
11 Vane 30 Rear Port Plate
12 Sq. Section Seal 31 Pin-vane Holdout
13 Sq. Section Seal 32 Cam Ring 006
14 Pin-vane Holdout 33 Dowel Pin
15 Sq. Section Seal 34 Vane
16 Retaining Ring 35 Port Plate-pressure
17 Ball Bearing 36 Screw
18 Shaft Seal (S-1, 0.7 bar) 37 Screw
19 Shaft (Splined Code 3) 38 Screw

Replacement Parts
1. Reliable operation throughout specified
operating range is assured only if genuine
Denison parts are used (available through
your Daewoo distributor). Sophisticated
design process and material are used in
the manufacture of these parts.
NOTE: Substitute replacement parts
may result in early failure of
pump assembly.
2. Commonly replaced parts are usually
provided in the form of repair kits available Figure 4 PREASSEMBLED CARTRIDGE KIT
through your Daewoo distributor. It is
strongly recommended to use repair kits
when a pump is overhauled.

Pump (Denison T67DB Series) S0708465K

Page 9
SPECIFICATION

Specifications
Item
Model Type Displacement Max. Flow Rate Remark
Main and Fan 120.3 + 24.9 cc/rev 277 + 57 liter/min.
T67DB-038 Vane M500-V (Tier II)
Motor Pump (7.34 + 1.52 in3/rev) (73.2 + 15.1 gpm)
Steering and 111 + 19.8 cc/rev 255 + 46 liters/min. M500-V,
T67DB-035 Vane
Brake Pump (6.77 + 1.21 in3/rev) (67.4 + 12.2 gpm) M500-V (Tier II)

SPECIAL TOOLS
SEAL DRIVER
A seal driver is required to install shaft seal in C
Length 19mm to have a
the pump front-cap. 10-20√
full length, with a
smooth intersection
2 0.127
1. Material: 4140 or equivalent. between chamfer and -A-
A dia. 19
2. Remove all burrs and break sharp edges:
0.25/0.13 R. 15°
A dia. B dia.
3. Length 19 mm (0.75 in).
4. "A dia." to be heat treated Rc 50/55.
A 0.127
Item Dimension AWS0400L
34.90 - 34.75 mm dia. Figure 5
A
(13.74 - 13.68 in dia.)
57.10 - 56.92 mm dia.
B
(22.48 - 22.41 in dia.)
C 145 mm (57.09 in dia.)
Tool Ref. SS2

S0708465K Pump (Denison T67DB Series)

Page 10
PROTECTIVE CONE
A
A protective cone is to be used when installing 15
30°
shaft assembly in the front-cap. The protective 10°
cone prevents damaging the lips of the shaft
seal during insertion. B dia. C dia. 4 dia.
1. Material: TEFLON preferred.
2. Remove all burrs and break sharp edges:
0.13 - 0.25 mm R (0.005 - 0.010 in R.).
10-20√
full length. No tools marks or scratches
permissible. Smooth intersection between
Item Dimension 15° Chamfer and A dia.

60 mm dia. AWS0410L
A
(23.62 in dia.) Figure 6
35.00 - 34.95 mm dia.
B
(13.78 - 13.76 in dia.)
31.33 - 31.25 mm dia.
C
(12.34 - 12.30 in dia.)
Tool Ref. CP14

Pump (Denison T67DB Series) S0708465K

Page 11
TROUBLESHOOTING, TESTING AND ADJUSTMENT
Table below lists the common difficulties experienced with vane pumps and hydraulic systems. It indicates,
possible causes and remedies for each of the problems listed.

Problem Possible Cause Remedy

Excessive noise in pump. Low oil level in reservoir. Fill reservoir to proper level with
recommended fluid.
Air in system. Open reservoir cap and operate
system until purged.
Bleed hydraulic lines at highest
point down stream of pump while
system is under pressure.
Vacuum condition. Check inlet (suction) line and
fittings for air leaks.
Oil too thick. Be certain correct type of oil is
used in system. Warm up pump in
cold weather until noise
disappears.
Damaged or missing pump seals at Locate and replace damaged or
mating surfaces. missing seals.
Cartridge kit not assembled Reassemble cartridge kit.
properly.
Pump inlet/outlet lines reversed. Reconnect lines to proper port
connections.
Pump overheating. Internal leakage. If excessive internal leakage
exists, return to shop for complete
overhaul.
Heat exchanger not functioning. Locate trouble and repair or
replace.
System not developing Relief valve open. Repair or replace.
pressure. Loss of fluid internally (slippage). Return to shop for evaluation and
repair.
Cartridge kit not assembled Reassemble kit.
properly.
Cartridge kit assembled for Reassemble kit to proper rotation.
opposite rotation.
Pump inlet/outlet lines reversed. Reconnect lines to proper port
connections.
Disconnected or broken drive Locate and repair.
mechanism.
Loss of fluid. Ruptured hydraulic lines. Locate and repair.
Leaking or missing seals. Locate and repair.

S0708465K Pump (Denison T67DB Series)

Page 12
DISASSEMBLY
PUMP DISASSEMBLY
1. Securely hold the pump in a vise or similar 28 1
equipment, at front-cap (13, Figure 7)
level.
P2 24
2. Unscrew end-cap bolts (28).
3. Note porting then remove end-cap (1) and
cartridge (P2) together.
4. Remove seal (24).

13

AWS0230L
Figure 7
5. Remove cartridge (P2, Figure 8) from end-
cap (1), using a gear puller or by prying
P2
upward. Care must be taken not to
damage parts.

AWS0240L
Figure 8
6. Unscrew four bolts (29, Figure 9).
7. Note location of ports, then remove central 8
housing (8).
8. Remove seal (12).

12

29
AWS0250L
Figure 9

Pump (Denison T67DB Series) S0708465K

Page 13
9. Remove cartridge (P1, Figure 10) from
front-cap (13), using a gear puller or by
prying upward. Care must be taken not to P1
damage the parts.

13

AWS0260L
Figure 10

S0708465K Pump (Denison T67DB Series)

Page 14
CAMRING REPLACEMENT, CARTRIDGE CHANGE OF ROTATION

Unidirectional Cartridge
(Examples: 025, 042, 066) 20
1. Camring change; 22

A. Unscrew two bolts (20, Figure 11) 6

holding cartridge together.
B. Remove rear plate (6), save dowel
pin (23a). 23a

C. Take out camring (5) carefully, save 5

dowel pin (23b). Leave rotor and
vane in place.
D. Install dowel pin (23b) in pressure-
plate (2) orifice.
NOTE: Rotation should match arrow in
port cutout (a) closest to dowel 23b
pin. 2
E. Install new camring. a

NOTE: Arrow on camring size should 25

be as per required rotation.
F. Install dowel pin (23a) on camring.
G. Install back rear-plate (6), then AWS0270L
tighten bolts (20). Make sure dowel Figure 11
pin (22) is in place.
H. Replace back-up ring (25). Change
other seals if damaged.
2. Change rotation;
A. Proceed as per above for
disassembly.
B. Save camring (5, Figure 11), remove
rotor, vanes and pins.
NOTE: Change of rotation requires
exchange of port-plates.
C. Carefully install rotor, vanes and pins
on new pressure-plate (2, Figure 11).
D. Flip camring from previous position.
Then proceed to reassemble as per
above, with new rear-plate.

Pump (Denison T67DB Series) S0708465K

Page 15
Bidirectional Cartridge
(Examples: B06, B25, B42) 20
1. Camring change; 22

A. Unscrew the two bolts (20, Figure 12) 6

holding the cartridge together.
B. Remove rear plate (6), save dowel
pin (23a). 23

C. Take out camring (5) carefully, save 5

dowel pin (23b). Leave rotor and
vane in place.
D. Install dowel pin (23b) in pressure-
plate (2) orifice.
NOTE: There are two dowel pin orifices
in port-plate. Use orifice closest 23b
to the arrow in the port cutout 2
(a) as per required direction of a
rotation.
25
E. Install new camring.
NOTE: Arrow on the camring size
should be as per required
rotation. AWS0280L

F. Install dowel pin (23a) on camring. Figure 12

G. Install back rear-plate (6), then

tighten the bolts (20). Make sure
dowel pin (22) is in place.
H. Replace back-up ring (25). Change
other seals if damaged.
2. Change rotation;
A. Proceed as per above for
disassembly.
B. Remove dowel pin (23b, Figure 12) in
pressure plate (6) and install it back
in the other orifice.
NOTE: There are 2 dowel pin orifices in
port-plate. Use orifice closest to
the arrow in the port cutout (a)
as per required direction of
rotation.
C. Flip camring from previous position.
Then proceed re-assembly as per
above.

S0708465K Pump (Denison T67DB Series)

Page 16
SHAFT ASSEMBLY REMOVAL
16
1. Remove circlip (19, Figure 13) from front-
13
cap (13).
2. Gently tap shaft-end with a plastic hammer
to remove shaft assembly.
NOTE: Unless pump is new, when
changing the shaft assembly
always install a new shaft seal
(16).
19
AWS0290L

Figure 13
SHAFT SEAL REMOVAL
1. Remove shaft seal (16) from front-cap
(13).
NOTE: Removed shaft seal should not
be re-used. It must be disposed
of as per local environmental
regulation.

16 13
AWS0310L
Figure 14

Pump (Denison T67DB Series) S0708465K

Page 17
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.

VANES
The faces and edges should be free of
Industrial Series Mobile Series
scratches from contamination. Vanes should Solid pins Hollow pin
move smoothly in the rotor slots, without
Vane
excessive clearance. Edges may be stoned with
a fine India stone to remove burrs.
Rotor
Vane holdout pins: Holdout pins should
have no mating marks. Pin

AWS0050L
Figure 15
ROTOR
Industrial Series Mobile Series
Side surfaces and vane slots should be free of
3 side feed holes 5 blind holes
scratches. Side feeds, vane slots and holdout-
pin orifices should be free of contamination.
Serration (driving splines) should not be
deformed by the shaft.

AWS0060L
Figure 16
CAMRING
No scratches or vane shock marks (waves)
should be seen. Visual axial waves on new
camring are from grinding process and therefore
normal.

AWS0070L
Figure 17

S0708465K Pump (Denison T67DB Series)

Page 18
PORT-PLATES
Faces should not be scratched. No cavitation /
aeration / fretting corrosion marks should be
seen. The bronze bushing should be clean, with
no abnormal signs of wear.
NOTE: Bidirectional cartridges use
same port-plates for CW and
CCW rotation. Unidirectional
cartridges require different port-
plates.
AWS0080L
Figure 18
SEALS
All oil seals must be free of wear, cuts or marks.
When servicing a pump from field operation, it is Backup ring Seal
recommended to change all seals. All seals VV
should be lightly coated with grease before
assembly.
Use seal driver tool to install shaft seal, and
protective cone to install shaft assembly.
Backup rings (1) on pressure plates must be
replaced, anytime a cartridge is taken out of the
pump. Backup rings are to be installed behind AWS0090L
the square seal See Figure 19. Figure 19

SHAFT
Key-way should not be damaged and not worn
on the sides by excessive torque. No fretting 2 1
corrosion due to poor coupling should be visible.
On spline shaft, splines should not be deformed.
No axial scratches should be on the sealing
area (1, Figure 19). The shaft seal lip contact
line may be visible, but should not be a groove. 4 3
Bronze bushing contact area (2) should not be
damaged and cylindrical, without scratch marks.
AWS0220L
Ball bearing (3) should turn freely and snap ring
Figure 20
(4) should be in place. Some shaft assemblies
have two snap rings, on each side of ball
bearing.
NOTE: Never insert a snap ring from
shaft seal end, to avoid
scratching the sealing surface.
Use protective cone to install shaft assembly. If
not available, make sure not to damaged the
shaft seal lips.

Pump (Denison T67DB Series) S0708465K

Page 19
CIRCUIT INSPECTION
NOTE: Periodic inspection of hydraulic fluid condition and tube or pipe line connections can save
time consuming breakdowns and unnecessary and expensive repairs.
1. All hydraulic connections must be kept tight. A loose connection in a pressure line will permit fluid to
leak out. If hydraulic oil level becomes so low as to uncover inlet pipe opening in reservoir, extensive
damage to pump can result. In suction or return lines, loose connections permit air to be drawn into
system, resulting in noisy and/or erratic operation.
2. Clean hydraulic oil is the best insurance for long service life. Therefore, the reservoir should be
checked periodically for dirt and other contaminants. If hydraulic oil becomes contaminated, the
system should be drained and reservoir thoroughly cleaned before adding new oil.
3. Filter elements should be checked and replaced at regular service intervals. A clogged filter element
results in a higher pressure drop. This can force particles through the filter which would ordinarily be
trapped, or can cause the by-pass to open, resulting in a partial or complete loss of filtration.
4. Air bubbles in the reservoir can cause damage to pump and other components. If bubbles are seen,
locate source of air and seal the leak.
5. A pump which is running excessively hot or noisy is a potential failure. Should a pump become noisy
or overheated, immediately shut down the machine and correct problem.

ADDING HYDRAULIC OIL TO SYSTEM

1. When hydraulic oil is added to replenish the system, it should be poured through a clean wire screen
(200 mesh or finer), or preferably pumped through a 10 micron (absolute) filter.
2. It is important that hydraulic oil be clean and free of any substance which could cause improper
operation or wear pumps and other hydraulic components. Therefore, use of cloth to strain hydraulic
oil should be avoided to prevent lint from entering system.

ADJUSTMENTS
1. No periodic adjustments are required, other than to maintain proper shaft alignment with driving
medium.

LUBRICATION
1. Internal lubrication is provided by the hydraulic oil in the system. Coat shaft splines with a dry
lubricant (Molycoat or equivalent) to prevent wear.

S0708465K Pump (Denison T67DB Series)

Page 20
REASSEMBLY
GENERAL INSTRUCTIONS
Any servicing work done on Denison Hydraulics
vane pumps must be done in a clean 1 3
environment to prevent potential contamination 3 1

by foreign particles.
5 6
Appropriate tools and equipment are required in
order to insure proper disassembly and re-
assembly in suitable conditions. In case of 7 4
repetitive service, a specific working bench is 4 2 2
recommended: contact Denison Hydraulics for
details. AWS0210L
To prevent oil leakage and body tilting during Figure 21
assembly, housing bolts are to be tightened as
per the following pattern:
Denison Hydraulics vane pumps are precision
equipment and must be handle accordingly.

SHAFT ASSEMBLY INSTALLATION

1. Install protective cone (A, Figure 22) on 16
the shaft end (14). Grease external
surface of protective cone.
2. Apply a small amount of grease on lip of
shaft seal.
3. Insert very carefully the shaft assembly
with protective cone in the front-cap (13).
13
NOTE: Do not damage the seal lips 14
(16). 4 A
AWS0300L
4. Complete insertion using a constant press Figure 22
load on the bearing outer ring.
NOTE: Do not use hammer.
5. Install circlip (19) in front-cap (13).

Pump (Denison T67DB Series) S0708465K

Page 21
SHAFT SEAL INSTALLATION
1. Carefully install shaft seal (16) on seal B
driver (B).
NOTE: Grease seal driver and seal lips
(16) to prevent damage.
NOTE: Make sure seal is mounted as
16
shown in Figure 23.
2. With the shaft seal securely installed on
the seal driver, insert the shaft seal (16) in 13
the front-cap (13). AWS0320L
3. Complete insertion using a constant press Figure 23
load (10,000 N max.).
NOTE: Do not use hammer.

PUMP ASSEMBLY
1. Securely hold pump in a vise or similar P1
device, at central housing (8, Figure 24) 12
level (light grip).
2. Carefully Insert cartridge (P1).
NOTE: If not new, seals and backup
ring are to be replaced.
NOTE: Make sure the dowel pin (22) is
properly inserted in the
22
corresponding hole in the
central housing (8). 8
AWS0330L
3. Install new seal (12) in central housing (8).
Figure 24
4. Carefully insert front-cap + shaft assembly
(A). Shaft should go through cartridge (P1)
smoothly. A 29

NOTE: When inserting cartridge (P1)

in front-cap, make sure the 25
white Teflon back-up ring (25) is
not damaged and securely in
place.
P1
5. Use bolts (29) to insure front-cap goes
down straight and does not tilt.
6. Tighten bolts (29). AWS0340L
Figure 25
NOTE: Tightening torque: 19 kg•m
(140 ft lb).

S0708465K Pump (Denison T67DB Series)

Page 22
7. Rotate pump then securely hold it again in P2 27
vise level at front-cap.
8. Carefully insert cartridge (P2). 8
24
NOTE: Install new, seals and backup
ring. 22

NOTE: Make sure the dowel pin (22) is

properly inserted in
corresponding hole in central
housing (8).
9. Make sure seal (27) is on cartridge (P2). AWS0350L
10. Install seal (24) in central housing (8). Figure 26
11. Insert end-cap (1) carefully on cartridge 28 1
(P2).
25
NOTE: When inserting cartridge (P2)
in end-cap, make sure the white P2
Teflon back-up ring (25) is not
damaged and securely in place.
12. Use the bolts (28) to insure the end-cap
goes down straight and does not tilt.
13. Tighten bolts (28).
NOTE: Tightening torque: 7 kg•m (50 ft AWS0360L
lb).
Figure 27
14. Final check: shaft must rotate when turned
by hand.

PORTING CHANGE
1. Unscrew housing bolts (from part list: P1->#29, P2->#28).
NOTE: Do not change all ports position simultaneously, but each port individually.
2. Open housing no more then 1 - 2 mm (0.04 - 0.08 in), to make sure cartridge dowel pin stays in place
(refer to pump assembly procedure about dowel pin).
3. Turn housing to obtain required porting (ex: T6CC-025-020-1R00-C100). Below are porting position
codification table and a selection table.
4. Tight back the housing bolts to appropriate torque.

Pump (Denison T67DB Series) S0708465K

Page 23
Bolt Tightening Torque kg•m (ft lb)
T7BB T67CB T6CC T67DB T6DC T6EE
Bolt T6DDS T67EB T6EC T6ED
T7BBS T67CBW T6CCW T67DBW T6DCW T6EES
19 16 16 19 19 19 19 19 19 30
P1
(140) (117) (117) (140) (140) (140) (140) (140) (140) (220)
6 6 6 7 7 19 68 7 19 30
P2
(45) (45) (45) (50) (50) (140) (140) (50) (140) (220)

Selection Table

Selection Table
T6CC, T6DC, T6EC
All Double Vane Pumps T67CB, T67DB, T67EB
T7BB
P1 00 12 05 15 16 17 18 19
P1,P2 P1 P1 P1 P1 P2 P1 P1 P2 P1

P2 P2

S S S S,P2 S S S P2 P2 S S
11 01 04 10 23 20 21 22
P2 P2 P2
P1
P1
P1 P1 P2 P1 P1 P1 P1 P1
P2
S
S S S,P2 S S S P2 P2 S S
08 09 02 07 26 27 24 25
P2 P2 P2

P2 P2
S P1
S,P1 S,P1 S,P1,P2 S,P1 S,P1 S,P1 P2 P2 S,P1 S,P1
13 14 06 03 29 30 31 28
P2 P2 P2
P1
P1
P1 P1 P2 P1 P1 P1 P1 P1
P2
S
S S S,P2 S S S P2 P2 S S

AWS0370L

S0708465K Pump (Denison T67DB Series)

Page 24
START-UP PROCEDURES
PRE-START CHECK
Before operating the pump, the following points must be checked:
• Pump rotation is as per electric motor or engine.
• All fittings are properly connected and tight. No oil-leak and/or air intake being allowed.
• If any, valve on suction line is to be fully opened.

PRIMING
When engine is started up, the pump should prime immediately. However, depending on installation and
amount of air in the discharge lines, priming may take a few seconds. If priming does not occur within 15
seconds, equipment should be switched off at once. Then:
• Manually fill the pump housing with fluid.
• Bleed off air that may be trapped in the pump.
• Check air bleed-off valves.
• Start rotation in a jogging manner until a prime is picked up.
NOTE: Some specific tools are needed, especially shaft seal driver and protective cones. Consult
Denison Hydraulics for details.

Pump (Denison T67DB Series) S0708465K

Page 25
S0708465K Pump (Denison T67DB Series)
Page 26
 S0709240K

1BRAKE PEDAL VALVE

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

BRAKE PEDAL VALVES0709240K

MODEL SERIAL NUMBER RANGE
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Brake Pedal Valve S0709240K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Specification............................................................................................ 5
Brake System ................................................................................................. 6
Brake, Pilot and Parking Brake Supply Valve ................................................. 7
Specifications .......................................................................................... 8

S0709240K Brake Pedal Valve

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
The brake pedal valve is attached to, and operated by, the brake pedal (Figure 1). The valve contains two
spools (Figure 2). One spool ports fluid to the brake pistons in the front axle, and the other spool ports fluid
to the brake pistons in the rear axle. Maximum system operating pressure is 60 bars (870 psi). If something
in one of the circuits should fail, the other circuit will continue to operate.

AHS3750L
Figure 1

Brake Pedal Valve S0709240K

Page 3
When the brake pedal is depressed, force is applied to the working element (6, Figure 2). This force is
transferred to the primary control spool (1) and the secondary control spool (2) by the main control spring
(5). This causes the control spool lands to close the path from the supply ports (P1 and P2) to the tank
ports (T1 and T2). Simultaneously, the spool then opens a path from the brake circuit ports (Br1 and Br2)
to the supply ports (P1 and P2). Drilled passages in control spools (1 and 2) allow fluid pressure in ports
P1 and P2 to act against the main control spring (5). This allows brake pressure in both circuits to rise
proportionally to the force applied to the brake pedal.
As the force applied to the brake pedal becomes constant, the control spools (1 and 2) move into a
balanced position and hold the braking pressure constant.
When force is removed from the brake pedal, this removes force from the control spring. The return
springs (3 and 4) now move the control spools (1 and 2) to the upward. The spools open a path from the
brake circuit ports (B1 and B2) to the tank ports (T1 and T2) and this releases the pressure from the brake
circuits.

Figure 2

Reference Reference
Description Description
Number Number
1 Primary Control Spool 4 Upper Spring
2 Secondary Control Spool 5 Main Control Spring
3 Lower Spring 6 Working Element

S0709240K Brake Pedal Valve

Page 4
SPECIFICATION

Item Specification
Braking Pressure 60.0 bar (870 psi)
Pedal Force 24 ±2.0 kg
(53 ±4.4 lb)
Operating Angle 18 ±2°

Brake Pedal Valve S0709240K

Page 5
BRAKE SYSTEM
Multiple wet disc brakes for stopping vehicle movement are contained in the axle-end planetary gear sets.
A brake pump (10, Figure 3) supplies pressurized fluid to the brake hydraulic system. Force on the brake
pedal (5) moves two spools in the brake valve (9). The spools are proportional. The farther the brake pedal
is pushed, the greater the amount of fluid that passes through each spool. One spool ports fluid to brake
pistons in the front axle (3). The other spool ports fluid to brake pistons in the rear axle (1). Pressure on the
brake pistons applies pressure to the brake discs, and this stops axle shaft and wheel rotation.
The brake hydraulic system also contains four accumulators (8). The accumulators hold a volume of
pressurized fluid large enough to allow the brakes to be applied nine times with full pressure, after the
engine has been turned off.
The brake hydraulic system includes a pressure operated transmission cutoff switch (2, Figure 3). Pressing
the brake pedal (5) will open cutoff switch (2). When the transmission cutoff switch in the operator’s cab is
selected, this will cut off current to a solenoid operated hydraulic valve in the transmission. This prevents
operation of the forward clutch in the transmission. This prevents the transmission from driving the wheels
forward when the brake pedal is pressed.

AHS3770L

Figure 3 BRAKE HYDRAULIC CIRCUIT

Reference Reference
Description Description
Number Number
1 Rear Axle 9 Brake Valve
2 Transmission Cutoff Switch 10 Pilot Pump
3 Front Axle 11 Pilot Supply Line
4 Brake 12 Low Pressure Warning Switch
5 Brake Pedal 13 Pilot and Parking Valve
6 Stop Light Switch 14 Low Pressure Warning Switch
7 Parking Brake 15 Brake and Pilot Filter
8 Accumulators: Brake

S0709240K Brake Pedal Valve

Page 6
BRAKE, PILOT AND PARKING BRAKE SUPPLY VALVE
This valve controls oil flow to the brake pedal valve for braking, to the pilot controller for operation of bucket
and boom and to the parking brake.

2-φ11DR' THRO
MOUNT HOLES

AHS3780L
Figure 4 VALVE CARTRIDGE IDENTIFICATION AND PILOT LOCATION

Reference Reference
Description Description
Number Number
1 Body (200 x 120 x 79) 4 Solenoid (C4, C5)
2 Relief (C1) 5 Coil (C4, C5)
3 Check (C2, C3) 6 Plug

Brake Pedal Valve S0709240K

Page 7
 AHS3790L

Figure 5 HYDRAULIC CIRCUIT

SPECIFICATIONS

Item Specifications
System Flow 41 l/min @ 37 bar
(10.8 gpm @ 535 psi)
Setting Pressure C1 37 ±2 kg/cm2 @ 20 l/min
(526 ±28 psi @ 5.3 gpm)
Port Size T1 PF 1/2 O-ring
TP PF 1/4 O-ring
All other ports PF 3/8 O-ring

S0709240K Brake Pedal Valve

Page 8
 Return to Master Table of Contents

S0709455K

1MAIN CONTROL VALVE

(TOSHIBA)

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

MAIN CONTROL VALVE (TOSHIBA)S0709455K

MODEL SERIAL NUMBER RANGE
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Main Control Valve (Toshiba) S0709455K

Page 1
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TABLE OF CONTENTS

General Description........................................................................................ 3
Specifications ................................................................................................. 5
Operation........................................................................................................ 6
Neutral..................................................................................................... 6
Bucket/option Spool Operation................................................................ 6
Boom Spool Operation............................................................................ 7
Boom Float....................................................................................... 7
Relief Valve ............................................................................................. 7
Main Relief Valve ............................................................................. 7
Port Relief Valve............................................................................... 7
Operation (Main Relief Valve) ................................................................. 8
Operation in Inoperative State ......................................................... 8
Operation (A) ................................................................................... 8
Operation (B) ................................................................................... 8
Operation (Port Relief Valve)................................................................... 9
In the Inoperative State.................................................................... 9
Operation (A) ................................................................................... 9
Operation (B) ................................................................................... 9
Operation (C) ................................................................................. 10
Sucking Operation ......................................................................... 10

S0709455K Main Control Valve (Toshiba)

Page 2
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GENERAL DESCRIPTION
The main control valve controls the operation of the bucket, boom, and option cylinders. The bucket spool
has priority over the boom spool.
Pump output flows to port P on the main control valve. See Figure 1. Maximum pressure is prevented from
exceeding the desired level by the main relief valve (1). See hydraulic schematic (Figure 2). When all
spools on the main control valve are in the neutral position (when the pilot valve is not being operated), oil
passes through port P, the bucket spool, the boom spool, the option spool, and passes out T, the tank port.
Oil that passes out the tank port passes through a filter and returns to tank.
Two overload relief valve (2) are installed in the bucket circuit to protect circuit components in the event of
abnormally high pressure. One valve works as a relief valve while the other valve works as an
anticavitation valve to provide additional oil flow to the opposite side of the bucket cylinders.
Boom spool has two important roles in loader work at the floating position. One is that it is possible to lower
the boom by its weight without oil supply from the pump, and that, at the same time, the oil from the pump
makes it possible to combine with the bucket crowd at the max. height of bucket through the bucket line.
Another is that boom and bucket are positioned at the level as the cylinder ports A and B are open as a
leveling function of ground. There is a suction check valve (3) in the boom power port. When the boom is
dropped suddenly by its weight, the cylinder bottom has a cavitation with a lack of oil supply. The check
valve supplements oil to prevent the cavitation.

Figure 1

Main Control Valve (Toshiba) S0709455K

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AJS0660L
Figure 2 Control valve hydraulic circuit

Reference Reference
Description Description
Number Number
a3 Option Valve Port B3 Option Cylinder Port
a1 Bucket Crowd Valve Port (to Option Cylinder Tube)
b2 Boom Down Valve Port B1 Bucket Dump Port
(to Bucket Cylinder Rod)
b3 Option Valve Port
A2 Boom Up Port
b1 Bucket Dump Valve Port
(to Boom Cylinder Tube)
a2 Boom Up Valve Port
P Pump Port
f Float Valve Port
R Tank Port
A1 Bucket Crowd Port
A3 Option Cylinder Port
(to Bucket Cylinder Tube)
(to Option Cylinder Rod)
(1) Main Relief Valve
(2) Overload Relief Valve
B2 Boom Lower Port
(3) Anticavitation Check Valve
(to Boom Cylinder Rod)

S0709455K Main Control Valve (Toshiba)

Page 4
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SPECIFICATIONS

2-Spool (STD.) 3-Spool (OPT.)

Name MRT40D1F1 - 56 MRT40D1F1D1 - 52
Type Pilot Control with Float spool
Spool Diameter ø 40.0 mm (1.5748 in)
Spool Arrangement Bucket - Boom Bucket - Boom - Auxilary
Main relief pressure 200 kg/cm @ 210 l/min.
2

(2,840 psi @ 55.4 gpm)

Overload relief pressure 240 kg/cm2 @ 20 l/min.
(3,400 psi @ 5.3 gpm)

Main Control Valve (Toshiba) S0709455K

Page 5
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OPERATION
NEUTRAL
When the spools of the bucket section and the boom section are in neutral, both the cylinder ports A (rod
side) and B (tail side) are closed by the spools.
The pressure oil which has reached the control valve flows through the inlet section, past the neutral oil
passages in the bucket section and the boom section to the outlet section from which it is directed to the
low-pressure oil passage and leaves the control valve through the exhaust port of the inlet section.

BUCKET/OPTION SPOOL OPERATION

Figure 3 OPERATION IN BUCKET/OPTION

Reference Reference
Description Description
Number Number
1 Load Check 4 Tank Passage
2 Port A1 5 Center By-pass Passage
3 Port B1

When the bucket spool moves in the direction indicated by the arrow
The neutral oil passage is closed by the spool and the pressure oil pushes open the load check valve to
flow to the cylinder port (A1) from which it is directed into the bucket cylinder rod side.
The oil discharged from the bucket cylinder tail side flows through the cylinder port (B1) to the low pressure
oil passage.

S0709455K Main Control Valve (Toshiba)

Page 6
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BOOM SPOOL OPERATION

Boom Float

Figure 4 OPERATION IN BOOM FLOAT

Reference Reference
Description Description
Number Number
1 Port A2 4 Center By-pass Passage
2 Port B2 5 Tank Passage
3 Tank Passage

When the control lever is further pushed down from the "Down" position to the "Float" position, the boom
spool moves as indicated in the illustration.
Due to this motion the neutral passage is opened. The pressure oil flows as if in neutral position. The
cylinder ports (A2) and (B2) are connected to the low-pressure oil passage. As a result, the booms float
over the ground surface according to its irregularities. The oil discharged from the boom cylinder rod side is
sent to the tail side and the oil forced out from its tail side is sent to the rod side respectively through the
low-pressure oil passage in the control valve.

RELIEF VALVE

Main Relief Valve

The main relief valve is between the neutral oil passage and the low pressure oil passage (return oil
passage) in the inlet section.

Port Relief Valve

The port relief valve is between the rod side cylinder port and the low-pressure oil passage (return oil
passage) in the bucket spool section.
The combination valve, used as the port relief valve, serves both as the relief valve and an anticavitation
valve.

Main Control Valve (Toshiba) S0709455K

Page 7
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OPERATION (MAIN RELIEF VALVE)

Operation in Inoperative State

The pressure oil in the neutral oil passage (HP)
flows through the throttle hole (2) in the main
poppet (1) to fill the internal cavity (3). Owing to
the difference in area on which the hydraulic
pressure acts, the main poppet (1) closely seats
to the sleeve (4).

Figure 5 IN INOPERATIVE STATE

Operation (A)
When the pressure in the neutral oil passage
(HP) rises and exceeds the relief pressure
setting. the pilot poppet (5) opens. The pressure
oil flows from the pilot poppet into the low
pressure oil passage (LP). passing between the
sleeve (4) and the housing (6).

Figure 6 OPERATION (A)

Operation (B)
As the pilot poppet (5) opens, the pressure in
the internal cavity (3) lowers to move the main
poppet (1) so that the pressure oil in the neutral
oil passage (HP) flows directly into the low
pressure oil passage (LP).

Figure 7 OPERATION (B)

S0709455K Main Control Valve (Toshiba)

Page 8
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OPERATION (PORT RELIEF VALVE)

In the Inoperative State

The pressure oil at the cylinder port (HP) flows
through the hole in the piston poppet (1) to act
from the opposite sides of the check valve
poppet (2) and relief valve poppet (3). Owing to
the difference in area on which the hydraulic
pressure acts, both poppets close to seat the
same time.

Figure 8 IN INOPERATIVE STATE

Operation (A)
When the pressure at the cylinder port (HP)
rises and exceeds the relief pressure setting,
the pilot poppet (4) opens. The pressure oil
flows from the pilot poppet into the low-pressure
oil passage (LP), passing between the check
valve poppet (2) and the housing (5).

Figure 9 OPERATION (A)

Operation (B)
As the pilot poppet (4) opens, the pressure at
the back of the piston poppet (1) lowers to move
the piston poppet (1). As a result, the hole in the
piston poppet (1) is closed so that the pressure
at the back of the relief valve poppet (3) drops
further.

Figure 10 OPERATION (B)

Main Control Valve (Toshiba) S0709455K

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Operation (C)
The pressures across the relief valve poppet (3)
loses balance. Due to pressure differential, the
relief valve poppet moves so that the pressure
oil at the cylinder port (HP) flows directly to the
low-pressure oil passage (LP).

Figure 11 OPERATION (C)

Sucking Operation
If the pressure at the cylinder port (HP)
becomes lower than that at the low-pressure oil
passage (LP) due to the development of
cavitation, the check valve poppet (2) moves
depending upon the difference in area on which
negative pressure acts across the check valve
poppet. Consequently, oil is supplied from the
low-pressure oil passage (LP) to the cylinder
port side (HP) to eliminate the cavitation.

Figure 12 SUCKING OPERATION

S0709455K Main Control Valve (Toshiba)

Page 10
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S0709476K

1PILOT CONTROL
VALVE

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

PILOT CONTROL VALVES0709476K

MODEL SERIAL NUMBER RANGE
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Pilot Control Valve S0709476K

Page 1
 Return to Master Table of Contents

S0709476K Pilot Control Valve

Page 2
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TABLE OF CONTENTS

General Description........................................................................................ 4
Pilot Valve Operation............................................................................... 4
Pilot System ................................................................................................... 6

Pilot Control Valve S0709476K

Page 3
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GENERAL DESCRIPTION
When no force is applied to lever (1, Figure 1), return spring (4) positions lever at "NEUTRAL" position.
When lever is moved, plunger (5) is moved, which pushes down return spring (4). At this time, spool (2) is
moved by spring (3). When spool (2) moves down, a groove (6) in spool (2) opens the pilot pressure line to
the line that the lever controls. This allows pilot pressure to flow to the boom or bucket control valve, where
pilot pressure operates the control valve. When the lever is completely moved in one direction, solenoid (7)
energizes electromagnet (8) and holds the lever in the fully moved position.

PILOT VALVE OPERATION

The lever handle is positioned on the right side of the operator’s seat. This single lever controls the
following machine functions: raise boom, lower boom, bucket crowd, and bucket dump. The lever positions
are identified as follows:
F-Float
L-Lower
N-Neutral
R-Raise
H-Hold Position
C-Bucket Crowd
D-Bucket Dump
HR-Holds lever in Raise Mode.

S0709476K Pilot Control Valve

Page 4
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Figure 1

Reference Reference
Description Description
Number Number
1 Lever 5 Plunger
2 Valve Spool 6 Spool Groove
3 Regulating Spring 7 Solenoid
4 Return Spring 8 Electromagnet

Pilot Control Valve S0709476K

Page 5
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PILOT SYSTEM
The pilot system uses low pressure oil to operate the main control valves. The main components of the
pilot system are pump (1), pressure relief valve (3), accumulator (4), pilot cutoff valve (5) and pilot valves (6
and 7).
With the engine running, oil flows from hydraulic tank to pilot pump (1) The oil flows from the pump through
pressure relief valve (3) to pilot cutoff valve (5). The pressure relief valve maintains pilot system pressure at
37 kg/cm2 (450 psi).
From the pilot cutoff valve the oil flows into the pilot control valves. Pilot valve (6) is a closed center valve.
The oil cannot flow through the valve when it is in the HOLD position because it is a closed center valve.
When the control lever is moved to the DUMP position, oil flows through oil lines to the ends of the bucket
spool of main control valve (8). This causes the main control valve spool to move. Movement of the spool
opens passages for attachment pressure oil to flow to the rod end of the bucket cylinder (9).
Spool movement also opens a passage for return oil from the head end of the bucket cylinder to flow back
to hydraulic tank. Attachment pressure oil acts on the rod end of the bucket cylinder and, because the
head end of the cylinder is now vented to tank, the bucket will dump.
When the control lever is moved to the CROWD position, oil flows through oil lines to the ends of the
bucket spool of main control valve (8). This causes the main control valve spool to move in the opposite
direction.
Movement of the spool in this direction opens passages for pressure oil to flow to the head end of the tilt
cylinder. Spool movement also opens a passage for return oil from the rod end of the tilt cylinder to flow
back to the hydraulic tank. Attachment pressure oil acts on head end of the tilt cylinder and because the
rod end of the cylinder is now vented to tank, the bucket will crowd.

S0709476K Pilot Control Valve

Page 6
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AHS3800L
Figure 2

Reference Reference
Description Description
Number Number
1 Pilot Pump 6 Pilot Valve (Mono, STD.)
2 Brake and Pilot Filter 7 Solenoid Valve (OPT.)
3 Pressure Relief Valve 8 Main Control Valve
4 Accumulator: Pilot 9 Bucket Cylinder
5 Pilot Cutoff Valve 10 Boom Cylinder

Pilot Control Valve S0709476K

Page 7
 Return to Master Table of Contents

S0709476K Pilot Control Valve

Page 8
 S0709665K

1FLOW AMPLIFIER
(DANFOSS)

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

FLOW AMPLIFIER (DANFOSS)S0709665K

MODEL SERIAL NUMBER RANGE
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Flow Amplifier (Danfoss) S0709665K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Special Tools and Materials............................................................................ 6
Special tools............................................................................................ 6
Troubleshooting, Testing and Adjustment....................................................... 7
Steering System with OSQA/B and OSPBX-LS ..................................... 8
Disassembly ................................................................................................... 9
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 29
Cleaning ................................................................................................ 29
Inspection and replacement .................................................................. 29
Lubrication ............................................................................................ 29
Reassembly.................................................................................................. 29

S0709665K Flow Amplifier (Danfoss)

Page 2
GENERAL DESCRIPTION

Figure 1

Flow Amplifier (Danfoss) S0709665K

Page 3
PARTS LIST

Figure 2

S0709665K Flow Amplifier (Danfoss)

Page 4
 Reference Reference
Description Description
Number Number
1 O-ring 22 Stopper
2 O-ring 23 Stopper
3 O-ring 24 Guide; Spring
4 O-ring 25 Screw; Drive
5 Washer 26 Plate; Name
6 Washer 27 Orifice
7 O-ring 28 Spring
8 O-ring 29 Spring
9 Housing 30 Spring
10 Check Valve 31 Plug
11 Screw 32 Washer
12 Washer; Spring 34 Orifice
13 Screw 35 Orifice
14 Washer; Spring 36 Orifice
15 End Cover 37 Throttle Check Valve
16 End Cover 38 Plug
17 Relief Valve 40 Spring
20 Plug 41 Spring
21 Shock and Suction Valve

SPECIFICATIONS

Flow Amplifier Specification

Type Contains a directional valve, an amplification stage, a priority
valve, a pilot pressure relief valve and suction valve.
Amplification Factor 8
Control Pressure 10.50 kg/cm2 (149.35 psi)
LS Relief Valve Setting 185.0 ±5.0 bar (2,683.24 ±72.52 psi))
Max. Oil Flow to Steering 125.0 l/min. (33.0 U.S. gpm)

Flow Amplifier (Danfoss) S0709665K

Page 5
SPECIAL TOOLS AND MATERIALS
SPECIAL TOOLS
Guide screws Material: M8 x 1
Hook Material: Wire

Figure 3

S0709665K Flow Amplifier (Danfoss)

Page 6
TROUBLESHOOTING, TESTING AND ADJUSTMENT

Figure 4 Flow Amplifier Circuit

Flow Amplifier (Danfoss) S0709665K

Page 7
STEERING SYSTEM WITH OSQA/B AND OSPBX-LS

Problem Possible Causes Remedies

Amplification too large Dirty, leaky or missing check valve (1). Clean or replace check valve.
Piston (2) sticks in the open position. Clean and check that the piston
moves easily.
Amplification too small Piston (2) sticks in the closed position. Clean and check that the piston
moves easily.
Piston (2) incorrectly installed (only Rotate the piston 180° on its
OSQA/B-5). axle.
Heavy turning of Dirty orifices (3) in directional valve. Clean or replace orifice.
steering wheel and Dirty orifices (4) in the combi-valve Clean or replace orifice.
slow increase of spool.
amplification
Dirty orifices (5) in housing. Clean or replace orifice.
Dirty orifices (6) in LS-port. Clean or replace orifice.
Dirty orifices in throttle/check valve (7) in Clean or replace throttle/check
PP-port. valve.
No end stop in one or One or both shock valves (8) set too low. Setting takes a long time without
both directions. special equipment. Contact the
nearest service shop.
One or both anti-cavitation valves (9) Clean or replace completely
leaky, or sticks. shock/anti-cavitation valve(s).
Missing end-stop plate(s) pos. 10 for Fit end-stop plates.
directional valve.
"Hard" point when Air in LS and/or PP pipes. Bleed pipes.
starting to turn the Spring force in the built in priority valve Replace spring with one which is
steering wheel too weak (11). more powerful. (There are three
sizes: 4, 7 and 10 bar).
Orifices in respectively LS-(6) or PP-(7) Take out and clean orifices.
ports blocked.
No pressure build-up LS-pressure limitation valve (12) Remove plug and set to
adjusted too low. specified pressure.
Spool and sleeve in OSPBX steering Take out spool set and turn the
unit put together incorrectly. inner spool 180° in the outer
sleeve. (See service manual)
Emergency control ball in steering unit Install new ball.
missing.
Pump does not run or is defective. Repair or replace pump.

S0709665K Flow Amplifier (Danfoss)

Page 8
DISASSEMBLY
1. Dismantling counter pressure valve.
A. Unscrew plug with O-ring. (Hexagon
socket for 8 mm internal hexagon.)

Figure 5
B. Remove small spring (hook).

Figure 6
C. Remove ball (magnetic rod).

Figure 7

Flow Amplifier (Danfoss) S0709665K

Page 9
 D. Remove piston.

Figure 8
E. Remove spring.

Figure 9
F. Counter pressure valve shown
dismantled.

Figure 10

S0709665K Flow Amplifier (Danfoss)

Page 10
 G. Counter pressure valve with orifice
shown dismantled.

Figure 11
2. Removing pressure relief valve.
A. Unscrew plug with washer (hexagon
socket for 8 mm internal hexagon).

Figure 12
B. Screw pressure relief valve out (10
mm hexagon key).

Figure 13
C. Remove washer (magnetic rod).

Figure 14

Flow Amplifier (Danfoss) S0709665K

Page 11
3. Dismantling pressure relief valve.
A. Hold cartridge and screw adjustment
screw out (5 mm hexagon key).

Figure 15
B. Pressure relief valve shown
dismantled.

Figure 16
4. Removing end cover at PP-connection.
A. Unscrew screws with spring washer
hexagon socket for 13 mm external
hexagon and 10 mm internal
hexagon.

Figure 17

S0709665K Flow Amplifier (Danfoss)

Page 12
 B. Remove end cover.

Figure 18

C. Remove stop and 2 springs.

Figure 19

D. Remove spring.

Figure 20

Flow Amplifier (Danfoss) S0709665K

Page 13
 E. Remove plate and six O-rings.

Figure 21

F. Remove spring guide.

Figure 22

5. Removing end cover at LS-connection.

A. Unscrew screws with spring washer
using hexagon socket for 13 mm
external hexagon and 10 mm internal
hexagon.

Figure 23

S0709665K Flow Amplifier (Danfoss)

Page 14
 B. Remove end cover.

Figure 24

C. Remove stop and two springs.

Figure 25
D. Remove stop and spring.

Figure 26

Flow Amplifier (Danfoss) S0709665K

Page 15
 E. Remove plate and four O-ring.

Figure 27
F. Remove spring guide.

Figure 28
6. Removing spools.
A. Remove directional spool.

Figure 29

S0709665K Flow Amplifier (Danfoss)

Page 16
 B. Remove amplifier spool.

Figure 30
C. Remove priority valve spool.

Figure 31
7. Removing orifice and throttle check valve.
A. Unscrew orifice in LS-connection
with 6 mm hexagon key.

Figure 32

Flow Amplifier (Danfoss) S0709665K

Page 17
 B. Unscrew throttle check valve in PP-
connection with 6 mm hexagon key.

Figure 33
C. Unscrew orifice in housing with 4 mm
hexagon key.

Figure 34
8. Removing shock valves.
A. Remove shock valve with
screwdriver and hexagon key.

Figure 35

S0709665K Flow Amplifier (Danfoss)

Page 18
9. Overview of dismantled parts.
A. Housing and end cover with
accessories.

Figure 36
B. Spool with accessories.

Figure 37
10. Dismantling of directional spool.
A. Unscrew orifice with 4 mm hexagon
key. Use a mandrel.

Figure 38

Flow Amplifier (Danfoss) S0709665K

Page 19
 B. Directional spool shown dismantled.

Figure 39
11. Dismantling of priority valve spool.
A. Unscrew plug or throttle check valve
with 8 mm hexagon key.

Figure 40
B. Priority valve spool with plug for
external PP shown dismantled.

Figure 41

S0709665K Flow Amplifier (Danfoss)

Page 20
 C. Priority valve spool with throttle
check valve for internal PP shown
dismantled.

Figure 42
12. Dismantling of amplifier spool.
A. Carefully remove spring from recess
with 3 mm screwdriver.
NOTE: Avoid damage to spring ring.

Figure 43
B. Carefully guide spring ring back.

Figure 44

Flow Amplifier (Danfoss) S0709665K

Page 21
 C. Carefully take spring ring from recess
and guide it back with 3 mm
screwdriver.
NOTE: Avoid damage to spring ring.

Figure 45
D. Press pin out gently with finger.

Figure 46
E. Remove plug.

Figure 47

S0709665K Flow Amplifier (Danfoss)

Page 22
 F. Remove spring.

Figure 48
G. Remove pin with 3 mm screwdriver.

Figure 49
H. Remove inner spool.

Figure 50

Flow Amplifier (Danfoss) S0709665K

Page 23
 I. Unscrew check valve with hexagon
socket for 17 mm external hexagon
and mandrel in pin hole.

Figure 51
J. Unscrew orifice out of plug with 4 mm
hexagon key. Use a mandrel.

Figure 52
K. Amplifier spool shown dismantled.

Figure 53

S0709665K Flow Amplifier (Danfoss)

Page 24
13. Dismantling of check valve.
A. Unscrew plug with 4 mm hexagon
key and hexagon socket for 17 mm
external hexagon.

Figure 54
B. Check valve shown dismantled.

Figure 55
14. Dismantling of shock valve / suction valve.
A. Unscrew lock nut with hexagon
socket for 13 mm external hexagon.
Use a mandrel.
NOTE: When readjusting shock valve
hold lock nut with 13 mm ring
spanner.

Figure 56

Flow Amplifier (Danfoss) S0709665K

Page 25
 B. Remove disc and spring.

Figure 57
C. Remove housing.

Figure 58
D. Unscrew pilot valve with hexagon
socket for 19 mm external hexagon.
Use a mandrel.

Figure 59

S0709665K Flow Amplifier (Danfoss)

Page 26
 E. Remove pilot valve and spring.

Figure 60
F. Remove spool.

Figure 61
G. Unscrew adjustment screw and
remove spring and ball.

Figure 62

Flow Amplifier (Danfoss) S0709665K

Page 27
 H. Shock valve/suction valve shown
dismantled.

Figure 63

S0709665K Flow Amplifier (Danfoss)

Page 28
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.

CLEANING
Clean all parts carefully with low aromatic kerosine.

INSPECTION AND REPLACEMENT

Replace all gaskets and sealing washers. Check al other parts carefully and replace if necessary.

LUBRICATION
Before assembly, lubricate all parts with hydraulic oil.

REASSEMBLY
1. Assemble shock valve/suction valve.
A. Guide spring with cone into housing.

Figure 64

Flow Amplifier (Danfoss) S0709665K

Page 29
 B. Install adjustment screw.

Figure 65
C. Install spool.

Figure 66
D. Install spring.

Figure 67

S0709665K Flow Amplifier (Danfoss)

Page 30
 E. Install pilot valve. Remember O-ring.

Figure 68
F. Tighten with torque wrench for 19
mm external hexagon. Use a
mandrel. Tightening torque: 2 ±0.5
daNm. (175 ±45 in lb).

Figure 69
G. Install housing.

Figure 70

Flow Amplifier (Danfoss) S0709665K

Page 31
 H. Install spring.

Figure 71
I. Fir disc.

Figure 72
J. Install lock nut. Tighten torque 1.5
±0.2 daNm. (135 ±20 in lb).

Figure 73

S0709665K Flow Amplifier (Danfoss)

Page 32
2. Assemble check valve.
A. Install ball, spring and plug.
B. Tightening torque: 0.5 ±1 daNm. (45
±90 in lb).

Figure 74
3. Assembly of amplifier spool.
A. Install orifice in plug. Tightening
torque: 0.5 ±1 daNm. (45 ±90 in lb).

Figure 75
B. Install check valve. Tightening
torque: 2 ±0.3 daNm. (175 ±25 in lb).
NOTE: Avoid damaging spool surface.
Remember O-ring.

Figure 76

Flow Amplifier (Danfoss) S0709665K

Page 33
 C. Place inner spool in correct position.
NOTE: When assembling OSQA 5 and
OSQB 5 there are two ways of
installing inner spool. Only one
is correct. The pilot channel
which is faced upwards must be
lined up with one of five
amplification holes in the outer
spool.

Figure 77
D. Guide inner spool in.

Figure 78
E. Install pin.

Figure 79

S0709665K Flow Amplifier (Danfoss)

Page 34
 F. Push spring ring into position. Place
spring ring into recess with ends
facing away from pin plate.

Figure 80
G. Install spring.

Figure 81
H. Install plug.

Figure 82

Flow Amplifier (Danfoss) S0709665K

Page 35
 I. Install pin.

Figure 83
J. Push spring ring into position. pLace
spring ring into recess with ends
facing away from pin holes.

Figure 84
4. Assembly of priority valve spool.
A. Install plug or throttle check valve.
B. External pp: plug.
C. External pp: throttle check valve.
D. Tightening torque: 1 ±0.03 daNm. (90
±25 in lb).

Figure 85

S0709665K Flow Amplifier (Danfoss)

Page 36
5. Assembly of directional spool.
A. Screw in orifice.
B. Tightening torque: 0.5 ±0.1 daNm.
(45 ±10 in lb).

Figure 86
6. Installation of orifice and throttle check
valve.
A. Install orifice in housing.
B. Tightening torque: 0.5 ±0.1 daNm (45
±10 in lb).

Figure 87
C. Install orifice in LS-connection.
D. Tighten torque: 1 ±0.3 daNm. (90
±25 in lb.).

Figure 88

Flow Amplifier (Danfoss) S0709665K

Page 37
 E. Install throttle check valve in PP-
connection.
F. Tighten torque: 1 ±0.3 daNm. (90
±25 in lb.).
7. Comments on flow amplifiers with internal
PP:
A. 1/4 BSP.F in PP-connection: Install
washer and plug. Tightening torque 4
±0.3 daNm (355 ±25 in lb).
B. 7/116 - 20 UNF in PP-connection:
Install O-ring and plug. Tightening
torque: 1.5 ±0.5 daNm (135 ±45 in
lb).
Figure 89
8. Installation of shock valves.
A. Guide shock valve in and secure it by
hand. Remember O-ring.

Figure 90
9. Assembly of pressure relief valve.
A. Guide adjustment screw, spring and
cone up into cartridge.

Figure 91

S0709665K Flow Amplifier (Danfoss)

Page 38
 B. Screw adjustment screw so far in
that 10 mm hexagon key fully
engages.

Figure 92
10. Installation of pressure relief valve.
A. Let washer drop into hole.

Figure 93
B. Install pressure relief valve. Tighten
torque: 3 ±0.3 daNm. (265 ±25 in lb).

Figure 94

Flow Amplifier (Danfoss) S0709665K

Page 39
 C. Install plug with washer. Tighten
torque: 6 ±0.5 daNm. (530 ±45 in lb).

Figure 95
11. Installation of back pressure valve.
A. First Install spring in piston with
Vaseline. Install assembled piston
and spring.

Figure 96
B. Let ball drop down.

Figure 97

S0709665K Flow Amplifier (Danfoss)

Page 40
 C. Install spring in plug with Vaseline.
Install assembled plug and spring.
Remember O-ring. Tightening torque
2.5 ±0.03 daNm (220 ±25 in lb).

Figure 98
12. Installation of spools.
A. Install directional spool. Install
priority valve spool.
NOTE: Spring control must be placed
in correct position against LS-
connection.

Figure 99
B. Install spring.
NOTE: Spring must be by LS-
connection.

Figure 100

Flow Amplifier (Danfoss) S0709665K

Page 41
 C. Install amplifier spool.
NOTE: The orifice must be placed in
correct position against LS-
connection.

Figure 101
13. Installation of end cover at PP-connection.
A. Install spring with Vaseline on
amplifier spool.
NOTE: The spring must be installed at
PP-connection.

Figure 102
B. Install spring guide with Vaseline.

Figure 103

S0709665K Flow Amplifier (Danfoss)

Page 42
 C. Install large and small springs with
Vaseline.

Figure 104
D. Install guide screws.

Figure 105
E. Install four large and two small O-
rings.

Figure 106

Flow Amplifier (Danfoss) S0709665K

Page 43
 F. Guide plate in.

Figure 107
G. Install stop (thickness: 5 mm) in end
cover with Vaseline.

Figure 108
H. Guide end cover in.

Figure 109

S0709665K Flow Amplifier (Danfoss)

Page 44
 I. Install screw with spring washer.

Figure 110
J. Install screw with spring washer.
Tightening torque: 2.5 ±0.5
daNm.(220 ±45 in lb).

Figure 111
14. Installation of end cover at LS-connection.
A. Install guide screws.
B. Install remote control valve with
Vaseline.

Figure 112

Flow Amplifier (Danfoss) S0709665K

Page 45
 C. Install large and small springs with
Vaseline.

Figure 113
D. Guide in plate with four O-rings.

Figure 114
E. Install stop priority valve spool.
F. (thickness: 8 mm) with Vaseline.

Figure 115

S0709665K Flow Amplifier (Danfoss)

Page 46
 G. Install stop for directional spool
(thickness: 5 mm) with Vaseline.

Figure 116
H. Guide in end cover.

Figure 117
I. Install large screw with spring
washer.

Figure 118

Flow Amplifier (Danfoss) S0709665K

Page 47
 J. Install screws with spring washers.
Tightening torque: 2.5 ±0.5 daNm.
(220 ±45 in lb). Tightening torque for
large screw: 8 ±1 daNm (710 ±90 in
lb).

Figure 119
K. Install plastic plugs.

Figure 120

S0709665K Flow Amplifier (Danfoss)

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S0709730K
R1

1POWER STEERING
UNIT

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

POWER STEERING UNITS0709730K

MODEL SERIAL NUMBER RANGE
Mega 300-V 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Power Steering Unit S0709730K

Page 1
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TABLE OF CONTENTS

General Description........................................................................................ 3
Power Steering System........................................................................... 3
Gerotor Operation ................................................................................... 5
Cushion Valve Operation......................................................................... 6
Parts List ................................................................................................. 8
Specifications .......................................................................................... 9
Special Tools ................................................................................................ 10
Troubleshooting, Testing and Adjustment..................................................... 12
Disassembly ................................................................................................. 13
Cleaning and Inspection............................................................................... 17
Reassembly.................................................................................................. 18
Installation .................................................................................................... 29

S0709730K Power Steering Unit

Page 2
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GENERAL DESCRIPTION
POWER STEERING SYSTEM

Power Steering Unit.

The machine contains a fully hydraulic steering unit. See Figure 1. Rotating the steering wheel controls
hydraulic flow through the steering valve. Figure 2, shows the hydraulic schematic for the steering system.
The steering valve meters the volume of pump flow that is supplied to the steering cylinders

Reference
Description
Number
1 Bearing
2 Centering Springs
3 Sleeve
4 Center Pin
5 Check Valve
6 Gerotor
7 End Cap
8 Spool
9 Drive Shaft
10 Housing

The steering unit contains a gerotor. This allows

the operator to steer the machine when the
engine is not running or when the steering pump
has failed. The gerotor functions as a manual
hydraulic pump that is powered by the rotation of
the steering wheel. Rotating the steering wheel Figure 1
will cause the gerotor to draw oil from the
hydraulic tank and send this oil to the steering
cylinders.
The shaft that is rotated by the steering wheel is attached to the spool (8, Figure 1) by the engagement of
a spline. The spool is surrounded by a sleeve (3). The spool and sleeve are connected by the centering
spring (2). At the steering wheel neutral position, the center pin does not contact the spool. A drive shaft
(9) extends through the spool. The upper end of the drive shaft engages the center pin (4). The lower end
of the drive shaft engages the spline in the gerotor (6).

Power Steering Unit S0709730K

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AJS0700L
Figure 2 STEERING CIRCUIT

Reference Reference
Description Description
Number Number
1 Steering Unit 5 Valve block
2 Priority Valve 6 Steer Pump
3 Steering Cylinder 7 Supply Line to Main Control
4 Cushion Valve Valve

S0709730K Power Steering Unit

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Neutral Operation
With the steering wheel in the neutral position (wheels turned neither right nor left), the spool (2, Figure 3)
and sleeve (1) are stationary at the position where the center pin (6) becomes centered in the spool space
by the centering springs (3). Oil flow through the load sensing line (LS), port L, port R, and port T are
bypassed to the tank line and the oil supply (P) is blocked by the directional spool in the steering unit (1,
Figure 2). Even if an external force is applied to the steering cylinder, the steering unit is protected because
the oil path is blocked by the directional spool.

Reference
Description
Number
1 Sleeve
2 Spool
3 Centering Spring
4 Spool
5 Sleeve
6 Center Pin
7 Drive shaft

Figure 3

Right Turn
The spool (2, Figure 3) is engaged with the spline of the steering shaft. When the steering wheel is turned
to the right, the spool turns. The sleeve (1) is connected to the spool (2) by centering springs (3). When
spool turns, the sleeve turns. The sleeve turning angle is about 10° less than the spool turning angle. This
allows the longitudinal slots in the spool to align with the ports in the sleeve. Oil from port P on the steering
unit (1, Figure 2) travels through the control spool and is directed to port R which directs the oil to the
steering cylinders (3, Figure 2). The amount of flow metered to port R is controlled by the amount of
steering wheel rotation. Excess oil flow through port P that is not metered to port R, is directed by the spool
to port T and is then directed through the il cooler and into the tank.

Left Turn
The spool (2, Figure 3) is engaged with the spline of the steering shaft. When the steering wheel is
connected to the spool (2) by centering springs (3). When the spool turns, the sleeve turns. The sleeve
turning angle is about 10° less than the spool turning angle. This allows the longitudinal slots in the spool
to align with the ports in the sleeve. When the steering wheel is turned to the left, oil from port P on the
steering unit (1, Figure 2) is directed through the control spool in the steering unit, out port L and into the
steering cylinders (3, Figure 2). The amount of oil flow metered to port L is controlled by the amount of
steering wheel rotation. Excess oil flow through port P that is not metered to port L, is directed by the spool
to port T and is then directed through the oil cooler and into the tank.

GEROTOR OPERATION
If the engine or pump is not operating, the steering unit (1, Figure 2) works as a manual pump when the
steering wheel is turned. The gerotor will work when the input torque to the steering wheel is less than 12
kg•m (87 ft lb). If the necessary input torque is greater than this, the gerotor will not function. When the
steering wheel is turned, the gerotor creates a vacuum that draws oil from port T. See Figure 2. The
gerotor pumps this oil through the control spool and into the steering cylinders. Return oil flows back to the
spool and is used to lubricate the steering unit (1, Figure 2). The return oil then flows back into the tank line
and is recirculated back to the gerotor and the steering cylinders.

Power Steering Unit S0709730K

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CUSHION VALVE OPERATION

Function
The cushion valve absorbs any excessive peak pressure that my be generated during initial movement of
the steering wheel or during a change in steering direction. The cushion valve also prevents excessive
high pressure and shock that can result from steering load inertia.

Working Principle
If a high pressure oil is fed back to the port R, it pushes the spring (3) and opens the poppet (2). And this
operation directs the high pressure oil to the port L through the center hole in the spool (12) and the check
valve poppet in the port L part. At the same time, oil reaches the pressure room of the plug through the
orifice (8). This operation closes the passage from the port R to the port L. This releases the pressure and
prevents machine shock by intercepting oil. If a low pressure oil flows, the cushion operation is not
necessary. It is due that the speed of the closing the spool (12) is faster than the speed of the opening the
poppet (2), therefore, the cushion valve does not work.

Figure 4

S0709730K Power Steering Unit

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Power Steering Unit S0709730K

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PARTS LIST
An exploded view of the steering unit is shown in Figure 5.

Figure 5

S0709730K Power Steering Unit

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Reference Reference
Description Description
Number Number
1 Seal Ring 16 Spacer - 25 mm (If
2 Housing equipped)
3 Spool 17 Spacer Bushing (If
equipped)
4 Sleeve
18 O-ring 80.5 x 1.5 mm
5 Ball
19 Middle Plate
6 Threaded Bushing
20 Distributor Plate
7 O-ring
21 Rotor
8 Backing Ring (If equipped)
22 O-ring - 79.92 x 1.78 mm
9 Thrust Washers
23 Cylinder Gear
10 Thrust Bearing
24 End Cover
11 Spacer Ring
25 Washer
12 Cross Pin
26 Roll Pin 2.5 x 32 mm
13 Neutral Springs
27 Bolt
14 Shaft
15 Spacer - 13.8 mm (If
equipped)

SPECIFICATIONS

Specification
Steering Unit Mega 500-V
Mega 300-V Mega 400-V
Mega 500-V (Tier II)
Type Load Sensing, Dynamic Signal, Non-reaction
Gerotor Displacement 1,000 cc/rev 200 cc/rev 315 cc/rev
(61 in3/rev) (12.2 in3/rev) (19.2 in3/rev)

Power Steering Unit S0709730K

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SPECIAL TOOLS
The tools necessary for steering unit repair are illustrated below.
1. Stabilizing base. See Figure 6.

Figure 6
2. O-ring assembly tool. See Figure 7.

Figure 7
3. Seal driver. See Figure 8.

Figure 8

S0709730K Power Steering Unit

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4. Torque wrench, 0 - 5 kg•m (0 - 35 ft lb).

See Figure 9. 13 mm socket. Ratchet
handle. 12 mm screwdriver. 6 mm
screwdriver. 2 mm screwdriver. Plastic
hammer.

Figure 9

Power Steering Unit S0709730K

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TROUBLESHOOTING, TESTING AND ADJUSTMENT

Problem Cause Remedy
Steering wheel does not operate Broken or damaged oil pump. Replace pump.
smoothly Stuck or damaged relief valve. Repair or replace.
Stuck, damaged or worn out Clean, repair or replace.
steering valve.
Restricted hose or pipe. Leaking Clean, repair or replace.
or restricted hose, pipe, or
connection.
Mechanical defect in steering Repair or replace.
gear.
Steering wheel has a heavy feel. Oil level low in reservoir. Add oil.
Low oil pressure due to broken Replace pump.
or damaged oil pump.
Steering valve stuck. Clean, repair or replace.
Low oil level in steering gearbox. Inspect oil level, fill to proper
level.
Damaged bolt and nut in Replace damaged parts.
steering gearbox.
Difficult to drive in a straight line Defective spool in steering valve. Tighten lock nut.
Stuck or damaged steering valve Repair or replace.
or damaged or defective spring.
Improper fit of track line. Repair or replace.
Noise during steering Low oil level in reservoir. Add oil.
Restricted inlet pipe or filter. Clean or replace
Steering system leaking oil Worn or damaged O-ring and oil Replace worn or damaged
seal of pipe and steering valve. parts.

S0709730K Power Steering Unit

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DISASSEMBLY
It is very important to keep the inside of the steering unit clean. Make sure that the outside of the steering
unit is clean before opening the unit. Use a wire brush and solvent to clean the entire unit.
1. Remove steering column from steering
unit. Bolt steering unit to stabilizing base.
Bolt base to work bench.
2. Remove bolts from steering unit end cover.
See Figure 10.

Figure 10
3. Remove end cover from unit. See Figure
11.

Figure 11
4. Lift cylinder gear off unit. See Figure 12.
Remove two O-rings.

Figure 12

Power Steering Unit S0709730K

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5. Remove spacer bushing and spacer from

cylinder gear (If equipped). See Figure 13.
NOTE: Refer to parts manual for our
unit to determine if these parts
are installed.

Figure 13
6. Remove shaft from housing. See Figure
14.

Figure 14
7. Remove distributor plate from housing.
See Figure 15.

Figure 15
8. Remove O-ring from top of middle plate.
See Figure 16.

Figure 16

S0709730K Power Steering Unit

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9. Lift middle plate off housing. See Figure

17.

Figure 17
10. Remove O-ring from housing. See Figure
18.

Figure 18
11. Unscrew threaded bushing and remove it.
See Figure 19.

Figure 19
12. Remove cross pin. See Figure 20.

Figure 20

Power Steering Unit S0709730K

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13. Shake ball out of housing. See Figure 21.

Figure 21
14. Pull sleeve and spool out of housing. See
Figure 22.

Figure 22
15. Remove thrust bearing and thrust washers
from sleeve. See Figure 23. Remove
spacer ring. Be sure to remove spacer
ring. It can stick in sleeve.

Figure 23
16. Carefully slide control spool out of sleeve.
See Figure 24.

Figure 24

S0709730K Power Steering Unit

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17. Push neutral position springs out of groove

in spool. See Figure 25.

Figure 25
18. Remove dust seal from housing. See
Figure 26. Remove O-ring and backup ring
from inside housing.

Figure 26
19. Figure 27, shows all parts removed from
steering unit. Clean all parts before
assembly. Use only new O-rings and seals.

Figure 27

CLEANING AND INSPECTION

For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.

Power Steering Unit S0709730K

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REASSEMBLY
NOTE: Use bolt torque chart that follows to tighten bolts as steering unit is assembled.

Bolt Torque Chart

Bolt Size Torque Value
M10 4.8 kg•m (35 ft lb)
3/8 - 16 NC 4.8 kg•m (35 ft lb)

1. Install springs in spool slot. See Figure 28.

Springs must be positioned as shown in
Figure 29.

Figure 28

Figure 29
2. Position springs so that amount of spring
protruding out of spool is equal on both
sides. See Figure 30.

Figure 30

S0709730K Power Steering Unit

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3. Insert spool into sleeve. See Figure 31.

Use care so that sleeve and spool are
correctly assembled. The spring slot in
sleeve must align with spring slot in spool.
Also, one of the T shaped slots (A) in the
spool must align with one of the small
holes (B) in sleeve. See Figure 32.

Figure 31

Figure 32
4. Center springs in sleeve. See Figure 33.

Figure 33

Power Steering Unit S0709730K

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5. Install seal ring on sleeve. See Figure 34.

Burnish seal ring with a smooth object until
seal does not protrude past diameter of
sleeve.

Figure 34
6. Rotate seal ring. See Figure 35. It must
rotate freely without resistance.

Figure 35
7. Turn sleeve 180°. Install cross pin into
sleeve and spool. See Figure 36.

Figure 36

S0709730K Power Steering Unit

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8. Install two thrust washers and thrust

bearing over end of spool. See Figure 37.
The sequence of the parts installation is
shown in Figure 38.

Figure 37
Reference
Description
Number
1 Thrust Washer
2 Thrust Bearing
3 Thrust Washer
4 Spool
5 Sleeve

Figure 38
9. Oil O-ring and backup ring and then install
them on an O-ring assembly tool. See
Figure 39.

Figure 39

Power Steering Unit S0709730K

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10. Insert assembly tool down into bore of

steering unit. See Figure 40.

Figure 40
11. Use assembly tool to install O-ring and
backup ring into bore. See Figure 41.

Figure 41
12. Unbolt housing from stabilizing base. Hold
housing in a horizontal position. See
Figure 42. Insert sleeve and spool into
bore.

Figure 42

S0709730K Power Steering Unit

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13. The sleeve will push the O-ring and

backup ring into correct position. See
Figure 43.

Figure 43
14. Bolt housing back into stabilizing base.
See Figure 44.

Figure 44
15. Insert ball into hole. See Figure 45.

Figure 45

Power Steering Unit S0709730K

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16. Install threaded bushing into hole that ball

was placed into. See Figure 46. Lightly
tighten bushing. The top of the bushing
must be lower than the surface of housing.

Figure 46
17. Lubricate O-ring with 20 weight mineral oil
and install it in groove. See Figure 47.

Figure 47
18. Install middle plate onto housing. See
Figure 48. Be sure to properly align plate
holes with holes in housing.

Figure 48
19. Lubricate O-ring with 20 weight mineral oil
and install it in groove. See Figure 49.

Figure 49

S0709730K Power Steering Unit

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20. Install distributor plate. See Figure 50. Be

sure to properly align plate holes with
holes in middle plate.

Figure 50
21. Install shaft into bore of housing. See
Figure 51. Position slot in shaft to engage
cross pin.

Figure 51
22. Position rotor so that cross pin is between
two teeth as shown by position of
screwdriver. See Figure 52.

Figure 52

Power Steering Unit S0709730K

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23. Lubricate two O-rings with 20 weight

mineral oil and install them in grooves of
cylinder gear. Slide cylinder gear into
position on housing. See Figure 53.

Figure 53
24. Use a bolt to align holes in cylinder gear
with bolt holes in housing. See Figure 54.

Figure 54
25. Install spacer bushing. See Figure 55.
Remove bolt that was installed in previous
step (If equipped.).
OSPL 630:1 = 3.80 mm (0.1496 in) (15,
Figure 5)
OSPL 800 (16, Figure 5)
OSPL 1000 (16, Figure 5)
NOTE: Refer to parts manual for our
unit to determine if these parts
are installed.
Figure 55

S0709730K Power Steering Unit

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26. Use a screwdriver to install OSPL 800 and

1000 spacers (If equipped.). See Figure
56.
NOTE: Refer to parts manual for our
unit to determine if these parts
are installed.

Figure 56
27. Install end cover. See Figure 57.

Figure 57
28. Install a washer and roll pin into hole
shown in Figure 58.

Figure 58
29. Install six remaining bolts and tighten
them. See Figure 59. Cross tighten bolts
and roll pin to 48.1 Nm (35 ft lb).

Figure 59

Power Steering Unit S0709730K

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30. Turn steering unit over and work from

opposite side. Set dust seal in position on
housing. See Figure 60.

Figure 60
31. Use a seal driver and a plastic hammer to
install dust seal. See Figure 61.

Figure 61
32. Install plastic plugs to prevent dirt from
entering steering unit. See Figure 62.

Figure 62

S0709730K Power Steering Unit

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33. Figure 63, shows port identification for

steering unit.
L = Left pressure port.
R = Right pressure port
T = Tank port
P = Pressure from pump.

Figure 63

INSTALLATION
The following table shows torque specifications for hydraulic fittings used to install steering unit.

Tightening Torque
kg•m (ft lb)
Type of 1/4 RG 1/2 RG

Screw Fitting 1/4 BSP.F 1/2 BSP.F

7/16-20UNF
R 1/4 R 1/2
G l/4 G 1/2
Cutting Edge 4 (29) 10 (72)
Copper Washer 2 (15) 3 (22)
Aluminum Washer 3 (22) 8 (58)
O-ring 2 (15)

Power Steering Unit S0709730K

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S0709730K Power Steering Unit

Page 30
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S0709750K

1RESTRICTION VALVE

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

RESTRICTION VALVES0709750K
MODEL SERIAL NUMBER RANGE
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Restriction Valve S0709750K

Page 1
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TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Unloader Cartridge Identification ............................................................ 4
Specifications .......................................................................................... 5

S0709750K Restriction Valve

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GENERAL DESCRIPTION
THEORY OF OPERATION
The restriction valve is made up of one cartridge C1 and four bypass check valves C2, C3, C4, and C5.
Output from the steering pump passes through the priority valve that is part of the flow amplifier. See the
hydraulic schematic (Figure 1). This flow then passes out of the flow amplifier and enters the restriction
valve at port EF. This allows output from the steering pump to join flow from the main pump to supply the
boom, bucket and option control valves.

AHS3820L
Figure 1 RESTRICTION CIRCUIT

Restriction Valve S0709750K

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UNLOADER CARTRIDGE IDENTIFICATION

AHS3830L

Figure 2 VALVE CARTRIDGE IDENTIFICATION

Reference
Description Remark
Number
1 Body 125 × 99 × 184
2 Sub Block 125 × 99 × 79
3 Check Valve C3
4 Check Valve C4, 5, 6, 7
5 O-ring

S0709750K Restriction Valve

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SPECIFICATIONS

Item Specification
Maximum Rated Pressure 210.0 bar
(3,045.84 psi)
Rated Flow Ports to R1,R3,C 200 l/min. (52.8 gpm)
Rated Flow Ports to R2 700 l/min. (184.8 gpm)
Setting Pressure C4, 5, 6, 7 0.7 ± 0.1 Bar
(10 ±1.5 psi) Cracking Pressure
R1, R2 2" SAE Flange Port (M12, 1.75)
P1, EF, P3 1-1/4" SAE Flange Port (M12, 1.75)
HT 1" PF O-ring
Port Size
TPM 1/4" PF O-ring
R3 1/4" PF O-ring (Supplied Plugged)
C 3/4" PF O-ring

Restriction Valve S0709750K

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S0709750K Restriction Valve

Page 6
 S0793065K

1HYDRAULIC
SCHEMATIC
(MEGA 500-V (TIER II))
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

HYDRAULIC SCHEMATIC (MEGA 500-V (TIER II))S0793065K

MODEL SERIAL NUMBER RANGE
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Hydraulic Schematic (Mega 500-V (Tier II)) S0793065K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Mega 500-V (Tier II) ....................................................................................... 4

S0793065K Hydraulic Schematic (Mega 500-V (Tier II))

Page 2
GENERAL DESCRIPTION
Schematic(s) presented in this section are laid out on facing pages.
An overlapping edge has been taken into consideration so that a photocopy can be made and pasted
together to make a complete schematic.

Figure 1

Hydraulic Schematic (Mega 500-V (Tier II)) S0793065K

Page 3
MEGA 500-V (TIER II)

REAR AXL

40B 40B 8B

BRAKE PEDAL V/V

BR1 BR2

S1

3/4"
T1

65 BAR
LP S2
31ccr

1/2"

Fan motor

10 Abs

2* 3 4

24.9ccr
57.8 LM at 6.9B at 2321 rpm (FAN MOTOR)
0.75"

DENISON
D
280 LM at 6.9B at 2321 rpm (MAIN) P3
1.25"
3"
120.3ccr
TPM T O.5"
0.25"
P O.5"
EF
1.25 1.25 L O.5"
19.8ccr
45.9 LM at 6.9B at 2321 rpm (BRAKES) R 0.5 "
0.75"
3"
DENISON R2 20
258 LM at 6.9B at 2321 rpm (STEER)
2"
1.25" HT
111ccr 1.0
STEERING SENSOR
L M C4 CR 1.0"
S
< C R1
1.5
SW HP K 0.75" 1
CL 1.0"

< RESTRICTION VALVE

LS O.25"
CHECK VALVE
P PP CF EF LS
0.75

PRIORITY VALVE (OSQB S/F PORTS)

HP 1.25"

FLOW AMPLIFIER

OPTIONAL EMERGENCY STEERING SYSTEM (INC. PIPING)

Figure 2

S0793065K Hydraulic Schematic (Mega 500-V (Tier II))

Page 4
 AXLE
JOYSTICK VALVE

DUMP TURN

65 BAR
LPWS
T
P 3
BRAKE PEDAL V/V
BR1 BR2

P1 P2
37B
C1
T1
T U4 U3 SP
TP
ACC.2
S2

T3

PSR
O2 R L F

OPTION SOLEN. V/V

PILOT ACC.1 PARK

PILOT PARKING V/V

FROM PUMP

STEER VALVE
T O.5" (315x8=2520ccr)
P O.5"

L O.5" L P

R 0.5 "
R
OPTION BUCKET
T
20 LS

240B
CR 1.0" JERK B2
B3 A3 A2 B1 A1 " AUTO RETURN
SOFTENER
S TO DIG "
CONTROL V/V 300 mm HEIGHT

PS.'F'
CL 1.0" PS,'R'
ps.'F'

LS O.25"

0.75" 0.75"

BOOM CYLINDER BUCKET CYLINDER

SQB S/F PORTS)
OPTION DEVICE(INC. PIPING)

SOLENOID V/V

LIS SYSTEM
OPTION DEVICE(INC. PIPING)

TO TANK

Mega 500-V (Tier II)

AWS0420L

Hydraulic Schematic (Mega 500-V (Tier II)) S0793065K

Page 5
S0793065K Hydraulic Schematic (Mega 500-V (Tier II))
Page 6
1ELECTRICAL SYSTEM
 S0802195K

1ELECTRICAL SYSTEM

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

ELECTRICAL SYSTEMS0802195K
MODEL SERIAL NUMBER RANGE
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Electrical System S0802195K

Page 1
TABLE OF CONTENTS
Overview ........................................................................................................ 4
Electric Supply System .................................................................................. 6
Engine Starting Circuit ................................................................................... 8
Operation During Start Process .............................................................. 8
Operation After Start Process ............................................................... 10
Engine Stop and Derating System ............................................................... 12
Operation In Engine Stop...................................................................... 12
Operation in Engine Derating................................................................ 12
Charging System.......................................................................................... 14
Monitoring System ....................................................................................... 15
Instrument Panel ................................................................................... 16
Function Check ..................................................................................... 17
Monitoring System Schematic .............................................................. 18
Operation .............................................................................................. 20
Windshield Wiper ......................................................................................... 24
Front Windshield Wiper ......................................................................... 24
Rear Windshield wiper .......................................................................... 25
Lighting System............................................................................................ 28
Light Circuit ........................................................................................... 28
Engine Control System................................................................................. 31
ECM Block Diagram .............................................................................. 31
ECM Electric Circuit ..................................................................................... 32
ECM External Circuit............................................................................. 32
ECM Internal Circuit.............................................................................. 33
ECM System Component............................................................................. 34
ECM (Electronic Control Module).......................................................... 34
Alternate (Switchable) Torque Switch ................................................... 34
Alternate Low Idle Switch...................................................................... 35
Idle Speed Control Switch..................................................................... 35
Engine Diagnostic Switch...................................................................... 36
Engine Fault Codes............................................................................... 36

S0802195K Electrical System

Page 2
 Fault Code Information.......................................................................... 38
Electronic Accelerator .................................................................................. 45
Electric Specification ............................................................................. 45
Switch Specification .............................................................................. 45
Mechanical Specification (Pedal Sensor).............................................. 46
Data Link ...................................................................................................... 46
LIS (Load Isolation System) - Option ........................................................... 46
Aeb Starter ................................................................................................... 48
Introduction ........................................................................................... 48
List of Abbreviations .............................................................................. 48
Procedure to Start AEB......................................................................... 48
Display During AEB-mode .................................................................... 49

Electrical System S0802195K

Page 3
OVERVIEW
The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24
volts with the exception of the car stereo and the air-conditioning control actuator. The system contains two
12 volt batteries connected in series and a three phase AC generator with a rectifier. The electric wiring
used in the system is easily identifiable by the insulator color. The color symbols used in the electrical
system are listed in the following chart.

Electric Wire Color

Symbol Color Symbol Color

W White R Red
G Green Gr Gray
Or Orange P Pink
B Black Y Yellow
L Blue Br Brown
Lg Light Green V Violet

NOTE: RW: Red wire with White stripe

R - Base Color, W - Stripe Color

NOTE: 0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2 (0.03 in2)

S0802195K Electrical System

Page 4
Electrical System S0802195K
Page 5
ELECTRIC SUPPLY SYSTEM
The electric power circuit supplies electric current to each electric component. It consists of a battery,
battery relay, starter switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle body.
Even when the starter switch is in the "OFF" position, electric current is supplied to the following
components through battery → fusible link → fuse circuit.
1. Cabin light, fuel pump switch, No. 1 terminal of DC-DC converter (back up for car stereo memory).
2. "B" terminal of starter switch and No. 22 terminal of air conditioner control panel.
3. Power terminal "B" of engine stop motor.
When the starter switch is in the preheat, on and start positions, the current flows from the battery →
fusible link → fuse → starter switch "B" terminal/starter switch "BR" terminal → diode → battery relay "BR"
terminal which activates the coil of the battery relay and the electric supply system is energized.
When the battery relay’s contacts are connected, all electric devices can be operated.
While the engine is not running, the electric power for all electric devices are supplied by the battery. Once
the engine is started the power is supplied from the alternator.

S0802195K Electrical System

Page 6
 AHS0030L
Figure 1 ELECTRICAL POWER CIRCUIT DIAGRAM

Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode

Electrical System S0802195K

Page 7
ENGINE STARTING CIRCUIT
OPERATION DURING START PROCESS
When the starter switch is turned to the start position, the safety relay (14) is opened by the current flow
from the connected "52" and "67" terminals of the transmission controller (13) and the "S" and "E"
terminals of the starter controller (7) are connected. At this time the contacts in the starter relay (8) are
closed by the current flow from the battery (1), to the fusible link (3), to the "B" terminal of the starter switch
(5), to the "C" terminal of the starter relay (8), to the "D" terminal of the starter relay (8), to the "S" terminal
of starter controller (7), to the "E" terminal of the starter controller, and then to the ground.
When the contact point "B" and "PP" of starter relay (8) are connected, the pinion gear of the starter (9) is
pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter
are connected.
The current flows from the battery (1), to the "A" terminal of the battery relay (2), to the "B" terminal of the
battery relay (2), and then to the "B" terminal of the starter (9). The starter motor is rotated and the engine
is started.
The engine can be cranked only when the transmission selector switch (11) is the neutral position. If the
transmission selector switch (11) is in forward or reverse, the current that flows the switch (11) to the starter
controller (7) opens the path to ground for the starter relay (8). This prevents the starter relay (8) from
closing.

S0802195K Electrical System

Page 8
 AHS0040L
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING

Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker Transmission Selector
11
5 Starter Switch Switch
6 Fuse Box 12 Diode
7 Starter Controller 13 Transmission Controller
14 Safety Start Relay

Electrical System S0802195K

Page 9
OPERATION AFTER START PROCESS
Once the engine has been started, the belt driven alternator (10) generates a current. The output
generated by the alternator is a square wave pulse voltage through the "P" terminal and the frequency of
the pulse voltage is proportional to the rotation of the alternator. The starter controller (7) monitors the
frequency of the output current. Once the frequency equivalent to 500 rpm is sensed the connection
between "S" and "E" terminals and the connection between "B" and "PP" terminals are opened. As a result
the rotation of the starter (9) is stopped. Once the engine is running, the starter (9) will not operate even if
the starter switch (5) is moved to the start position, preventing possible damage to the starter (9).

AHS0050L
Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START

Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Transmission Selector Switch
5 Starter Switch 12 Diode
6 Fuse Box 13 Transmission Controller
7 Starter Controller 14 Safety Starter Switch

S0802195K Electrical System

Page 10
Electrical System S0802195K
Page 11
ENGINE STOP AND DERATING SYSTEM
OPERATION IN ENGINE STOP
The engine stop is achieved by the "open" or "closed" operation of the fuel shutoff valve controlled by ECM
(Electronic Control Module).

OPERATION IN ENGINE DERATING

For the purpose of reducing the input torque during the clutch slip when a shuttle shift is done, engine
derating is to be used.
When the shuttle shift is occurring, the contacts points "30" and "87" of the engine derating relay (7) are
closed due to the signal of the transmission controller (10). Then the control signal flows from the No.23
terminal of ECM (8) to the No.9 and 10 terminals.
In accordance with this, the engine RPM will be dropped down for maximum 0.7 seconds. (The operating
time is set automatically in dependent of vehicle speed.)

S0802195K Electrical System

Page 12
 3

6
ACC C

5 2
B 4
R2 B A
BR
R1 9
BR
E
23

7
30
87a 9 8
87 10
86 85 - + - +
1

11
43 6
F
N
64
R 10

AWS0440L
Figure 4 ENGINE DERATING CIRUIT

Reference Reference
Description Description
Number Number
1 Battery 7 Engine Derating Relay
2 Battery Relay 8 ECM (Electronic Control
3 Fusible Link Module)
4 Circuit Breaker 9 Diode
5 Starter Switch 10 TCU (Transmission Controller)
6 Fuse Box 11 Shift Lever Switch

S0802195K Electrical System

Page 13
CHARGING SYSTEM
When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of
the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this
condition the alternator (7) starts charging. The current flows from the "B+" terminal of alternator (7), to the
circuit breaker (4), to the battery relay (2), and to the battery (1).
The alternator also supplies electric current to other electrical components. When the alternator (7) starts
to operate, a current flows from the "R" terminal of alternator to the diode (8) and then to the battery relay
(2) coil securing a path for the charging current to the battery (1). Thus, preventing the possibility of a high
voltage build up and possible damage to the electrical system.

AHS0080L
Figure 5 CHARGING CIRCUIT

Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode

S0802195K Electrical System

Page 14
MONITORING SYSTEM

17
2
+

16

15

14
5

13

12 10 11 9
8
AWS0450L
Figure 6

Reference Reference
Description Description
Number Number
1 Instrument Panel 10 Turn Signal Light Switch
2 Battery 11 High Beam Switch
3 Alternator 12 Work Light Switch
4 Speed Sensor 13 Brake Oil Pressure Switch
5 Coolant Temperature 14 Parking Brake Pressure
Sensor Switch
6 Fuel Sensor 15 Transmission Cut-off
7 Transmission Oil Switch
Temperature Sensor 16 Control Unit
8 Air Cleaner Indicator 17 ECM (Electronic Control
9 Hazard Warning Light Module)
Switch 18 Control Unit

The monitoring system displays the various data and warning signals onto the instrument panel by
processing the information gathered from the various sensors throughout the equipment.

Electrical System S0802195K

Page 15
INSTRUMENT PANEL

9 10 11 12 13 14 15 16 17

8 20
30 15 18
20
10
40
25
7 10 5

0 50 0 30
Km/h
x100r/min

4 1 3 2 5 6

4 1

11 10 8 7 14

(CN1) (CN2)
AWS0460L
Figure 7

Reference Reference
Description Description
Number Number
1 Speed Meter 10 Engine Stop Light
2 Tachometer 11 Charging Warning Light
3 Hour Meter 12 Turn and Hazard Warning Light
4 Fuel Gauge 13 High Beam Indicator
5 Engine Coolant Temperature 14 Turn and Hazard Warning Light
Gauge 15 Work Light Indicator
6 Transmission Oil Temperature 16 Brake Oil Pressure Warning
Gauge Light
7 Preheat Indicator 17 Engine Maintenance Light
8 Air Cleaner Clogging Warning 18 Parking Brake Indicator
Light
9 Engine Check Light

S0802195K Electrical System

Page 16
FUNCTION CHECK
When the starter switch is turned to the "ON" position, all displays, switch lights and warning lights except
turn and hazard warning light, high beam indicator and working light indicator will be lit for two seconds and
the warning buzzer will sound.
Any lights which do not light up during the function check should be replaced.

Electrical System S0802195K

Page 17
MONITORING SYSTEM SCHEMATIC

23 22
B A

BR
1 17 E
CN1 AMP MIC 13P
+
9 I R B
SIG CN1-4 1
SPEED - CN1-5 2
E
+ S CN1-3
CN1-13 - + - +
21
+ S CN1-6
- 10 F- F+
+ CN1-7
- 11
+
25
S CN1-8
E
- 12 24
1 3 CN1-2
19
2
ILLUMINATION

CN1-9
CN1-1
18
CHARGE CN2-5 3 1
L5
4 2 87a
TIME DELAY 30
ENGINE WARNING 5 87
BUZZER CIRCUIT
BRAKE OIL PRESS 6 85 86

7 8
3
AIR CLEANER
PREHEAT 10 9
4 20
MAINTENANCE 13

CN2-16 CN1 AMP MIC 13P

WORKING
L9
CN2-9 8
TURN SIGNAL (R)
L8
CN2-8 7
L6
CN2-6 6
HI BEAM
L7
CN2-7 5
L13
CN2-17 CN7-04
CN2 AMP MIC 17P CN7-05
CN7-11
13 CN7-06
14
16 CN7-16

15
AWS0470L
Figure 8

S0802195K Electrical System

Page 18
 Reference Reference
Description Description
Number Number
1 Instrument Panel ECM (Electronic Control
14
2 Head Light Switch Module)
3 Forward Lever Switch 15 Brake Oil Pressure Switch
4 Reverse Lever Switch 16 Parking Brake Pressure Switch
5 High Beam Switch 17 Alternator
6 Left Turn Light Switch 18 Control Unit
7 Right Turn Light Switch 19 Alarm Buzzer
8 Working Light Switch 20 Alarm Relay
9 Speedometer 21 Battery
10 Coolant Temperature Sensor 22 Battery Relay
11 Fuel Sensor 23 Circuit Breaker
Transmission Oil Temperature 24 Fuse Box
12
Sensor 25 Fusible Link
Air Cleaner Clogging Warning
13
Light

Electrical System S0802195K

Page 19
OPERATION

Instruments

Sensor Specification
Function Display Input
Input Specification
Terminal
10 km/h- 905 Hz
20 km/h- 1,811 Hz
30 km/h- 2,716 Hz
CN1-4 40 km/h- 3,622 Hz
Speedometer
CN1-5 *F = 90.55 V [Hz]
F : Frequency of
transmission controller
V: Speed (km/h)
500 rpm - 100 Hz
1000 rpm - 200 Hz
1500 rpm - 300 Hz
2000 rpm - 400 Hz
2500 rpm - 500 Hz
Tachometer CN1-3
3000 rpm - 600 Hz
*F = 0.2 N [Hz]
F : Frequency of alternator
"P" terminal
N: Engine rpm

ALTERNATOR "I" Terminal

Hour Meter CN1-2
voltage (24V)

0012

EMPTY - Above 90 Ohm

Fuel Level
CN1-7 1/2 - 38 Ohm
Gauge
FULL - Below 10 Ohm

S0802195K Electrical System

Page 20
 Sensor Specification
Function Display Input
Input Specification
Terminal

50°C - Above 188.2 Ohm

Engine Coolant 67°C - 102 Ohm
Temperature CN1-6
Gauge 105°C - 32 Ohm
125°C - Below 19.8 Ohm

50°C - Above 322.8 Ohm

Transmission Oil
Temperature CN1-8 120°C - 36.5 Ohm
Gauge
150°C - Below 18.6 Ohm

Indicator Lights

Input
Symbol Description Operation Remarks
Terminal
Lights up while the air
heater is heated.
Preheat CN2-11
(when the terminal input
HAOA639L
is grounded.)
Lights up when the air
cleaner is clogged.
Air Cleaner CN2-2
HAOA660L

Lights up when the non- In the diagnostic mode, will

Engine fatal system error flash after the engine stop
CN2-3
Check occurred at the engine light completes the three-
AQO0040L
itself or peripherals. digit fault code.
Lights up when the fatal Also used to flash out the
system error happened fault code number in the
Engine Stop CN2-4
to the engine itself or diagnostic mode.
AQO0050L
peripherals.
Lights up when not Under normal conditions,
charging. start up and unlighted once
Charging CN2-5 engine is running.
(And "R" terminal output
HAOA610L

of the alternator drops

below 24 V.)

Electrical System S0802195K

Page 21
 Input
Symbol Description Operation Remarks
Terminal
Lights up when the left
Left Turn and turn signal or hazard light
CN2-6 switch is applied.
Hazard Light
ACO0240L

(Terminal input is to 24 V)
Lights up when the right
Right Turn turn signal or hazard light
and Hazard CN2-8 switch is applied.
Light
ACO0241L
(Terminal input is to 24 V)
Lights up when the high
beam switch is applied.
High Beam CN2-7
(Terminal input is to 24 V)
HAOD394L

Lights up when the front

or rear working light
Working Light CN2-9 switch is applied.
(Terminal input is to 24 V)
Unlighted when the brake Under normal conditions,
oil pressure increase will be alight before engine
over 65 kgf/cm2 and start up and unlighted once
lights up when the brake engine is running.
HA0O2024

Brake Oil
CN2-10 oil pressure drops below
Pressure
60 kgf/cm2.
(When the input terminal
is grounded)
Lights up when the
concerned of engine
maintenance or service
Maintenance CN2-11 is required.
AQO0060L

(When the input terminal

is grounded)
Lights up when the Under any conditions, will
Parking parking brake switch is be alight before engine
CN2-12 applied. start up.
P Brake
0717A

(Terminal input is to 24 V)

Initial Operation

Input
Item Output (Operation and initial setting mode)
(Terminal)
Initial Operation CN 1-1 • All indicator lights are turned on and turned off after 2
seconds. (Except for turn signal indicator, high beam
indicator and working light indicator.)
• Warning buzzer is activated and turned off after 2
seconds.
• Monitoring system displays present condition.

S0802195K Electrical System

Page 22
Control Unit Operation

5
2
1
6
7 8
CHARGE 3 1
L5
ENGINE STOP 4 2 I

ENGINE WARNING 5
BRAKE OIL PRESS
L3
6
BUZZER CIRCUIT 3
L10
PARK BRAKE 7 8
L12
AIR CLEANER 87a
30 4
PREHEAT 10 9 87
L1
MAINTENANCE 13 85 86
L11
CN1 AMP MIC 13P

13
11
AMP MIC 13P
12 6 5 3 1

13 12 9 7

AWS0480L
Figure 9

Reference Reference
Description Description
Number Number
1 Instrument Panel 7 Warning Buzzer
2 Starter Switch 8 Alternator
3 Forward Lever Switch 11 Brake Oil Pressure Switch
4 Reverse Lever Switch 12 Parking Brake Pressure
5 Fuse Box Switch
6 Control Unit 13 Alarm Relay

Characteristic of Operation

Input Output
All indicator lights are turned on and
turned off after 2 - 2.5 seconds. At
1 When starter switch is "ON."
this time the warning buzzer will
sound.
is below 12 ±1 V. The charging light,L5, will be alight.
When "I" terminal
2 The charging light,L5, will be
voltage of alternator. is above 12 ±1 V.
unlighted.
Brake oil pressure switch is Warning buzzer sounds
When "I" terminal "ON." immediately.
3 voltage of alternator is Forward and reverse lever
above 12 ±1 V. Warning buzzer sounds
switch is "ON" and parking brake
immediately.
pressure switch is "ON."

Electrical System S0802195K

Page 23
WINDSHIELD WIPER
FRONT WINDSHIELD WIPER
You can control windshield wiper by operating wiper washer switch (2).
1. Low speed wiper action (1st)
Wiper acts in low speed through fuse box (1) to the 15,53 terminal of wiper switch (2) to the L,E
terminal of wiper motor (5).
2. High speed wiper action (2nd)
Wiper acts in high speed through Fuse box (1) to the 15,53b terminal of wiper switch (2) to the H,E
terminal of wiper motor (5).
3. When you turn off switch during Low speed wiper action (1st) or High speed wiper action (2nd),
electric currents flow through Fuse box (1) to the B,S terminal of wiper motor (5) to the 87a,30
terminal of wiper relay (3) to the 31b,53 terminal of wiper switch (2) - L,E terminal of wiper motor (5).
Wiper acts until wiper rotates to the stop position, than the wiper stops.
4. Intermittent wiper action
Fuse box (1) to the 15,J terminal of wiper switch (2) to the 1,4 terminal of wiper timer (4) are
connected intermittently, and electric current flow into 86,85 terminal of wiper relay (3) than 87
terminal and 30 terminal are connected.
Therefore, electric current flow through fuse box (1) to the 87,30 terminal of wiper relay (3) to the
31b,53 terminal of wiper switch (2) to the L,E terminal of wiper motor (5), and wiper operates
intermittently in low speed.

Front Windshield Wiper Circuit

Figure 10

S0802195K Electrical System

Page 24
 Reference Reference
Description Description
Number Number
1 Fuse Box 5 Wiper Motor
2 Wiper Washer Switch 6 Washer Tank
3 Wiper Relay 7 Diode
4 Wiper Timer

REAR WINDSHIELD WIPER

You can control rear windshield wiper by pressing wiper washer switch (2) in the switch panel.
1. 1st wiper action (Wiper and washer activate the same time, automatic return)
Fuse box (1), to the washer tank (4), to the 5,7 terminal of switch (20) are connected, then activates
windshield washers. Also fuse box (1), to the B,L terminal of wiper motor (3), to the diode (5), to the
5,7 terminal of switch (2) are connected, then activates wiper.

3
2

6 5
5
4

AJS0170L

Figure 11 REAR WINDSHIELD WIPER 1ST ACTION CIRCUIT

Reference Reference
Description Description
Number Number
1 Fuse Box 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor 6 Diode

2. 2nd wiper action (Only wiper action)

Fuse box (1), to the B,L terminal of wiper motor (3), to the 4,2 terminal of switch (2) are connected,
then activates wiper.
3. When you turn off windshield wiper switch in 1st or 2nd position, electric current flows fuse box (1), to
the B,L terminal of wiper motor (3), to the 4,6 terminal of wiper switch (2), to the diode (6), to the S,E
terminal of wiper motor (3).

Electrical System S0802195K

Page 25
 1

3
2

6 5
5
4
AJS0160L

Figure 12 REAR WINDSHIELD WIPER STOP CIRCUIT

Reference Reference
Description Description
Number Number
1 Fuse Box 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor 6 Diode

S0802195K Electrical System

Page 26
Electrical System S0802195K
Page 27
LIGHTING SYSTEM
LIGHT CIRCUIT

22
28 29
23
20 19 21

24 27
18 18

17
1

26
2
7
8 3
12 10 11 13

6
18
4

25

14 16 15
5
AJS0180L

Figure 13 LIGHT CIRCUIT

S0802195K Electrical System

Page 28
 Reference Reference
Description Description
Number Number
1 Fuse Box 1 15 Rear Combination Light (R)
2 Blinker Unit 16 License Plate Light
3 Headlight Switch 17 Instrument Panel
4 Combination Switch 18 Diode
5 Shift Lever Switch 19 Front Working Light Switch
6 Hazard Switch 20 Front Working Light
7 Stop Light Switch 21 Rear Working Light Switch
8 Headlight Relay 22 Working Light Relay
9 Reverse Relay 23 Rear Working Light 1
10 Headlight (L) 24 Rear Working Light 2
11 Headlight (R) 25 Fuse Box 2
12 Front Combination Light (L) 26 Starter Switch
13 Front Combination Light (R) 27 Pilot Buzzer
14 Rear Combination Light (L) 28 Alarm Relay 1
29 Alarm Relay 2

The lighting system consists of the headlight, the position light, the turn signal light, the hazard light, the
stop light, the license plate light, the working light, the rotating beacon light (option) and the switches,
which are used to turn on the lights.
1. When the headlight switch (3) is in the first step, through the fuse box 1 (1) to the "2," "6" terminal of
headlight switch (3), the following lights will be "ON."
A. The front combination light (L)(12) and rear combination light (L) through the fuse box 2 (23).
B. The front combination light (R)(13) and rear combination light (R) through the fuse box 2 (23).
C. The illumination lights through the "9" terminal of all kind of rocker switches include the
headlight switch (3), the front working light switch (19), the rear working light (21) and the
hazard switch (6).
D. The license plate light (16).
2. When the headlight switch (3) is in the second step, the current flows through the fuse box 1 (1), to
the "2," "3" terminal of headlight switch (3) and to the "86," "85" terminal of headlight relay (8), and the
"30," "87" terminal of headlight relay (8) is connected. As a result, through the fuse box 1 (1) to the
"30," "87" terminal of headlight relay (8), the voltage is applied to the "56" terminal of combination
switch (R)(4).
A. At this time if the combination switch (4) is in the "0" position, the current flows to the "56b"
terminal and it allow the low light, which is in the headlight (L)(10) and the headlight (R)(11), to
be turned "ON."
B. Also if the combination switch (4) is in the "t" position, the current flows to the "56a" terminal and
it allow the high light, which is in the headlight (L)(10) and the headlight (R)(11), to be "ON." At
the same time the current flows to the "CN2-7" terminal of instrument panel (17) and the
headlight indicator L7 will be "ON,"
C. And if the combination switch (4) is in the "s" position, the current flows to the "56b" terminal and
it allows the low light, which is in the headlight (L)(10) and the headlight (R)(11), to be "ON."
At the same time another current flows from the fuse box 1 (1) to the "15/1," "56b" terminal of
combination switch (4) and the high light, which is in the headlight (L)(10) and the headlight

Electrical System S0802195K

Page 29
 (R)(11) will be turned "ON," and the other current flows to the "CN2-7" terminal of instrument
panel (17) and the headlight indicator will be "ON."
The combination switch (4) is returned automatically.
3. When the combination switch (4) is in the "←" (or "→") position, the current flows from the fuse box 1
(1), to the blinker unit (2), to the "L" (or "R") terminal through "49a" terminal of combination switch (4),
to the "C" terminal of front combination light (L)(12) and the rear combination light (L)(14) (or to the
front combination light (R)(13) and the rear combination light (R)(15)). This current makes the turn
signal light turn "ON." At the same time the current flows to the "CN2-6" terminal (or to the CN2-8
terminal) of instrument panel and the turn signal light indicator L6 (or L8) will be "ON."
4. If you operates the hazard light switch (6), the current flows from to the fuse box 1 (1), to the blinker
unit (2), to the "5," "1" terminal of hazard switch (6), to the diode (18), to the front combination light
(L)(12) and the front combination light (R)(13), to the "C" terminal of rear combination light (L)(14)
and rear combination light (R)(15). This current makes the turn signal light turn "ON."
At the same time through the "2," "6" terminal of hazard switch (6), the voltage is applied to the "9"
terminal and the illumination light used to symbol light will be "ON." Also the current flows to the
"CN2-6," "CN2-8" terminal of instrument panel (17) and the turn signal light indicator "L,"" "L8" will be
"ON."
5. When the shift lever switch (5) is in the "R" position, the contact points "30" and "87" of the reverse
relay (9) are closed due to current flowing from the fuse box 2 (23), to the shift lever switch (5), to the
"86" terminal of reverse relay (9) and to the ground. Thus the current flows from fuse box 2 (23), to
the reverse relay (9) and to the "D" terminal of rear combination light (L)(14) and rear combination
light (R)(15). And the reverse light will be "ON."
6. When the brake pedal is depressed and at the same time the stop light switch (7) is turned "ON," the
current flows the from fuse box 1 (1), to the stop light switch (7) and to the "F" terminal of rear
combination light (L)(14) and rear combination light (R)(15). And the stop light will be "ON."
7. When the front working light switch (19) is in the "ON" position, the current flows from the fuse box 1
(1), to the "5," "1" terminal of front working light switch (19) and to the front working light (20).
This current makes the front working lights turn "ON." At the same time the working light indicator,
L9," is turned "ON" due to the current flowing from the diode (8) to the "CN2-9" terminal of instrument
panel (17).
8. When the rear working light switch (21) is in the second step, the contact points "30" and "87" of the
working light relay (22) is closed due to the flowing current from the fuse box 1 (1), to the "2" and "6"
terminal of the working light switch (21), to the "86" terminal of the working light relay (22) and to the
ground. Thus the current flows from the fuse box 1 (1), to the working light relay (22) and to the rear
working light 1 (23) mounted on radiator guard. As a result the rear working light (23) turns "ON". At
the same time the working light indicator "L9" turns "ON" due to the current flowing from the diode
(18) to the "CN2-9" terminal of the instrument panel.
9. When the rear working light switch (21) is in the second step, the contact points "30" and "87" of the
working light relay (22) is closed due to the flowing current from the fuse box 1 (1), to the "2" and "6"
and "3" terminal of the working light switch (21), the rear working (23) is operated like being described
above clause "8" and the rear working light (24) mounted on the cabin turns "ON" at the same time.
10. When the headlight switch (3) is in the first step or in the second step while the starter switch (26) is
in the "OFF" position, the contact point "30," "87" of alarm relay 1 (28) is closed due to the excited
current, which flows to the coil of alarm relay 1 (28) and the pilot buzzer (27) will sound. But when the
headlight switch (3) is in the first step or in the second step while the starter switch (26) is in the "ON"
position, the contact point "3," "87" of alarm relay 2 (29) is closed due to the excited current, which
flows to the coil of alarm relay 2 (29). At the same time the current is not supplied to the "30" terminal
of alarm relay 1 (28) and the pilot buzzer will not sound any more.

S0802195K Electrical System

Page 30
ENGINE CONTROL SYSTEM
ECM BLOCK DIAGRAM

2 3 4

30
5
14

6
13

12
Insite

11 ECM
1

10

9
7

AWS0490L

Figure 14

Reference Reference
Description Description
Number Number
1 ECM (Electronic Control 8 Electronic Accelerator Pedal
Module) 9 Fuse Box
2 Engine Check Warning Light 10 Engine Disgnostic Switch
3 Engine Stop Warning Light 11 Idle Speed Control Switch
4 Engine Maintenance Light 12 Alternate Low Idle Switch
5 Engine Derating Relay 13 Alternate Torque Switch
6 TCU (Transmission Control 14 Taco Meter
Unit)
7 Data Link Harness

Electrical System S0802195K

Page 31
ECM ELECTRIC CIRCUIT
ECM EXTERNAL CIRCUIT

ECM TERMINAL NO

OEM SENSOR OEM

PORT PORT PORT CONNECTOR(ECM CN-7)

THROTTLE POSITION +5 V SUPPLY 0.85R

48
THROTTLE POSITION SIGNAL 0.85G
47
THROTTLE POSITION RETURN 0.85B
49
IDLE OFF IDLE VALIDATION SWITCH 0.85Or
03
ON IDLE VALIDATION SWITCH 0.85V
13
D 0.85Y PANEL GROUND 0.85BL
09
FOOT PEDAL
UNUSED PIN 16
6
PANEL GROUND 0.85BL
10
TACHOMETER
OEM CONNECTOR(CN-7) S 0.85WG TACHOMETER 0.85WG
11
+24V + RPM -

1
11 0.85BL
21
31
87a
41 30 0.85BrL INTERMEDIATE SPEED CONTROL 1 0.85BrL
87 23

86 0.5W 6
ZF
TCU

E/G DERATING RELAY

31P OEM CONNECTOR

ALTERNATE 0.85GL ALTERNATE TORQUE CURVE SELECT 0.85GL

02
TORQUE 0.85BL
SWITCH

0.85YL ALTERNATE IDLE SWITCH 0.85YL

ALTERNATE IDLE 45
SWITCH 0.85BL

1.25WR 0.85BrW 0.85Lq DIAGNOSTICS INCREMENT 0.85Lq

INCREMENT 14
0.85BY /DECREMENT 0.85LqW DIAGNOSTICS DECREMENT 0.85LqW
24
SWITCH 0.85BL

TML R1 R2 C ACC
DIAGNOSTIC
OFF 0.85BW / USER-ENGAGED SNAPSHOT 0.85BW
LAMP 44
PREHEAT CHECK 0.85BL
SWITCH

START

STARTER SWITCH

FUSE 1(14) 10A

ENGINE STOP LAMP RED 0.85BY 0.85BY ENGINE STOP LAMP 0.85BY
06
ENGINE WARNING LAMP AMBER 0.85YB 0.85YB ENGINE WARNING LAMP 0.85YB
16
FUSIBLE FUSE 1(6) BLUE 0.85LW 0.85LW MAINTENANCE LAMP
0.5G

0.5LR MAINTENANCE LAMP 05

LINK AMBER 0.85LB 0.85LB PREHEAT LAMP 0.85LB
15A PREHEAT LAMP 04

FUSE 1(1)
1.25BrW 1.25R
15A

0.85BrW 0.85Br 0.85Br KEY SWITCH (KEY) 0.85Br

38
ECM POWER (+) 0.85RW
BATTERY 18
FUSE 2(5)
RELAY 1.25WR 0.85RW
28
10A 0.85RW
07
0.85RW
08
85R 85R 15R 1.25RW
17
10A
B C
8W 3W

PREHEAT
STARTER RELAY
STARTER RELAY 4 PIN DATA LINK
C B
CONTROLLER CONNECTOR
- B D 3Y BATTERY (+)
BATTERY N BATTERY (-)
24V + PP
P SAE J1708 DATA LINK (+) 0.85R
26
SAE J1708 DATA LINK (-) 0.85G
27
0.85BR

-
B

R STARTER
ST2001
B 24V 25KW M
1.25B

I
E
E

22SI-350
ECM POWER RETURN (-) 0.85B
29
30
ECM POWER RETURN (-) 0.85B
39
ECM POWER RETURN (-) 0.85B
40
ECM POWER RETURN (-) 0.85B
50

31 PIN-OEM
CONNECTOR

0.85R
COOLANT 05
LEVEL SENSOR 0.85RL
SHORTING 07
PLUG
19

0.85BrY
10
0.85BR
11

AWS0500L
Figure 15

S0802195K Electrical System

Page 32
ECM INTERNAL CIRCUIT

CUMMINS QSM11 ENGINE ECM (ELECTRONIC CONTROL MODULE) ASS'Y

SENSOR
CONNECTOR

47
ENGINE 48
POSITION
SENSOR 50
49
ECM TERMINAL NO
AMBIENT AIR PRESSURE +5 VOLT SUPPLY
AMBIENT AIR
PRESSURE C
06 OEM ACTUATOR SENSOR
SENSOR
31
PORT PORT PORT

45
OIL PRESSURE /
44
TEMPERATURE
SENSOR 42
OIL PRESSURE / TEMPERATURE RETURN
43

COOLANT COOLANT TEMPERATURE RETURN

03
TEMPERATURE COOLANT TEMPERATURE INPUT
SENSOR 02

07 UNUSED PIN 16
6
26
PWM CONNECTOR
ACTUATOR CONNECTOR
RETURN

5
B A INTAKE MANIFOLD PRESSURE +5 VOLT SUPPLY
37
INTAKE MANIFOLD (BOOST) C
PRESSURE SENSOR 39
40

INTAKE MANIFOLD TEMPERATURE RETURN 49 48 47 46 02 44 43 42 41

INTAKE MANIFOLD (BOOST)
TEMPERATURE SENSOR INTAKE MANIFOLD TEMPERATURE INPUT
38

WATER IN FUEL SIGNAL RETURN

10 SENSOR CONNECTOR
WATER IN WATER IN FUEL SIGNAL
31 PIN-OEM FUEL SENSOR
CONNECTOR
SPARE TEMPERATURE 5 2 1
23 28
SPARE SWITCH INPUT 12 11

SPARE
24 46
SPARE
25 21
04 12
OEM TEMPERATURE RETURN
03 13
COOLANT LEVEL HIGH SWITCH
05 24
COOLANT LEVEL LOW SWITCH
06 22
COOLANT LEVEL SWITCH +5 VOLT SUPPLY
07 25
COOLANT LEVEL RETURN
OEM SWITCH INPUT
31 16
OEM PRESSURE SUPPLY +5 VOLT SUPPLY
1 1 18 31P OEM CONNECTOR
SWITCHED 19
OUTPUT A SWITCHED 20
SHORTING OUTPUT A
PLUG 6 14
4 11
27
OEM SWITCH RETURN
28 32
SWITCH OUTPUT B
08 45

GRID HEATER ACTULATOR SIGNAL

10 34
GRID HEATER / SWITCHED OUTPUT RETURN
11 43
12 05
FAN CLUTCH ACTULATOR RETURN
13 42
SPARE SUPPLY
SPARE INPUT
15 18
AIRCONDOTIONER PRESSURE SWITCH
17 13
AIRCONDOTIONER PRESSURE SWITCH RETURN
SPARE
20 46
SPARE
29 25
21 40
SHAFT SPEED (-) / FREQUENCY THROTTLE (+) /TRANSMISSION SYNCHRONIZATION (+)
22 30
FREQUENCY THROTTLE RETURN
16 17

B A FUEL INLET RESTRICTION +5 VOLT SUPPLY

29
FUEL INLET
C
RESTRICTION 28
SENSOR 27

WASTEGATE ACTUATOR 1
24
WASTEGATE WASTEGATE ACTUATOR 2
23

REAL TIME CLOCK BATTERY BACKUP SUPPLY (+)

REAL TIME CLOCK 1 20
BATTERY BACKUP MODULE REAL TIME CLOCK BATTERY BACKUP RETURN (-)
2 47

FUEL SHUTOFF VALVE FUEL SHUTOFF ACTUATOR

33

CYLINDER NO.1 ACTUATOR SUPPLY (+)

1 10
CYLINDER NO.1 CYLINDER NO.1 ACTUATOR RETURN (-)
2 09
3 08
CYLINDER NO.2 CYLINDER NO.2 ACTUATOR RETURN (-)
4 07
CYLINDER NO.3 ACTUATOR SUPPLY (+)
CYLINDER NO.3 CYLINDER NO.3 ACTUATOR RETURN (-)
16
CYLINDER NO.4 ACTUATOR SUPPLY (+)
26
CYLINDER NO.4

CYLINDER NO.5 ACTUATOR SUPPLY (+)

9 04
CYLINDER NO.5 CYLINDER NO.5 ACTUATOR RETURN (-)
10 03
A 11 02
CYLINDER NO.6 CYLINDER NO.6 ACTUATOR RETURN (-)
B 12 01
SPARE
13 44
SPARE
14 15
SPARE
15 31
1
15 PIN PASS THROUCH
CONNECTOR 2
ACTUATOR
CONNECTOR

AWS0510L
Figure 16

Electrical System S0802195K

Page 33
ECM SYSTEM COMPONENT
ECM (ELECTRONIC CONTROL MODULE)
1. The ECM (Electronic Control Module) is
the control center of the system. It
processes all of the inputs and sends
commands fuel system, vehicle and
engine control devices.
2. The ECM performs diagnostic tests on
most of its circuit and will activate a fault
code if a problem is detected in one of
these circuits. Along with the fault code
identifying the problem, a snapshot of
engine operating parameters at the time of
fault activation is also stored in memory. AWS0520L
Figure 17

ALTERNATE (SWITCHABLE) TORQUE SWITCH

The alternate torque switch provides the ability to select up to additional derated torque curves. This
alternate torque feature allows the operator to switch between 100% throttle torque curves and up to
derated torque curve (80%) and improves operating efficiency in loaded versus unloaded conditions.

100%
ECM
Torque

O
02
80%
I

Engine Speed
AWS0530L
Figure 18

S0802195K Electrical System

Page 34
ALTERNATE LOW IDLE SWITCH
The alternate low idle switch allows operator to select an alternate idle speed (about 1,200 rpm). This
feature is activated whenever the normally open alternate low idle switch is closed and 0 volts are detected
by the ECM on the alternate low idle signal line. This is convenient to use when operator wants to decrease
warm-up time in the winter.

1
ECM

Torque
45 2
I

Engine Speed
AWS0540L
Figure 19

Reference
Description
Number
1 Low Idle Speed Setting
2 Alternate Low Idle Speed Setting

IDLE SPEED CONTROL SWITCH

The idle speed control switch allows the idle
speed to be adjusted in 25-rpm increments by
pressing the rocker switch. The switch will only
work from 800 to 900 rpm.
Pressing the "I" position of the switch will
O O
increase (+) engine rpm.
Pressing the "II" position of the switch will
I II
decrease (-) engine rpm.
This switch is also used to view the next or
AQO0110L
previous fault code in the diagnostic mode.
Figure 20

Electrical System S0802195K

Page 35
ENGINE DIAGNOSTIC SWITCH
If the engine check light (Yellow) or the engine
stop light (Red) or the engine maintenance light
(Blue) comes on when the engine is running, it
means a fault code has been recorded. O
During this time, the engine diagnostic switch
allows the operator to view the fault codes.
I
The severity of the fault will determine the light
that will come "ON" and the active fault codes
can be viewed using the engine stop light as
described below. AQO0120L
Figure 21
To view the fault codes:
1. Engine must be shut off (not running)
2. Starter switch must be in the "ON"
position.
3. Engine diagnostic switch must be in the "I"
position.
The engine stop and check lights flash if there
are any fault codes to display. If there are no
fault codes to display, the engine stop and check
lights will remain lit.

ENGINE FAULT CODES

If there are fault codes to be displayed, the
engine check light will flash momentarily. Then
the engine stop light will flash the first, second 1 2 3
and third digits of the fault code.
1. Engine Stop Light (Red)
2. Engine Check Light (Yellow) CHECK
STOP
3. Engine Maintenance Light (Blue)

AWS0550L
Figure 22

S0802195K Electrical System

Page 36
 • Example:
NOTE: The engine check light will flash
between each fault code.
Fault Code 423 (example)
This pattern repeats itself until the fault is
cleared or the diagnostic switch is turned "OFF."
To view the next or previous fault code, press
the idle speed control switch (Figure 20) in the
"I" position or "II" position.
: Flash : Pause

AQO0010L
Figure 23

Electrical System S0802195K

Page 37
FAULT CODE INFORMATION

Fault Code J1587 PID(P) J1939

Reason Effect
Light SID(S) FMI SPN FMI
111 S254 629 Error internal to the ECM related to Engine will not start.
Red 12 12 memory hardware failures or
internal ECM voltage supply
circuits.
115 P190 190 No engine speed signal detected at Engine will die and will not
Red 2 2 both engine position sensor circuits. start
121 P190 190 No engine speed signal detected None on performance.
Yellow 10 10 from one of the engine position
sensor circuits.
122 P102 102 High voltage detected on the intake Derate in power output of the
Yellow 3 3 manifold pressure circuit. engine
123 P102 102 Low voltage detected on the intake Derate in power output of the
Yellow 4 4 manifold pressure circuit. engine
131 P091 91 High voltage detected at the throttle Severe derate (power and
Red 3 3 position signal circuit. speed). Limp home power
only.
132 P091 91 Low voltage detected at the throttle Severe derate (power and
Red 4 4 position signal circuit. speed). Limp home power
only.
133 P029 974 High voltage detected at the remote None on performance if
Red 3 3 throttle position signal circuit. remote throttle is not used.
134 P029 974 Low voltage detected at the remote None on performance if
Red 4 4 throttle position signal circuit. remote throttle is not used.
135 P100 100 High voltage detected at the oil No engine protection for oil
Yellow 3 3 pressure circuit. pressure
141 P100 100 Low voltage detected at the oil No engine protection for oil
Yellow 4 4 pressure circuit. pressure
143 P100 100 Oil Pressure signal indicates oil Progressive power and
Yellow 1 18 pressure below the low oil pressure speed derate with increasing
engine protection limit. time after alert. If Engine
Protection Shutdown 30
seconds after red light starts
flashing.
144 P110 110 High voltage detected at the coolant Possible white smoke. Fan
Yellow 3 3 temperature circuit. will stay on if controlled by the
electronic control module
(ECM). No engine protection
for coolant temperature.
145 P110 110 Low voltage detected at the coolant Possible white smoke. Fan
Yellow 4 4 temperature circuit. will stay on if controlled by
electronic control module
(ECM). No engine protection
for coolant temperature.
147 P110 91 A frequency of less than 100Hz was Calibration dependent power
Red 4 8 detected at the frequency throttle and speed derate.
signal pin of the actuator harness
connector at the ECM.
148 P091 91 A frequency of more than 100Hz Calibration dependent power
Red 8 8 was detected at the frequency and speed derate.
throttle signal pin of the actuator
harness connector at the ECM.

S0802195K Electrical System

Page 38
 Fault Code J1587 PID(P) J1939
Reason Effect
Light SID(S) FMI SPN FMI
151 P110 110 Coolant temperature signal Progressive power derate
Red 0 0 indicates coolant temperature with increasing time after
above 104°C [220°F]. alert. If Engine Protection
shutdown feature is enabled,
engine will shut down 30
seconds after red light starts
flashing.
153 P105 105 High voltage detected at the intake Possible white smoke. Fan
Yellow 3 3 manifold temperature circuit. will stay on if controlled by
electronic control module
(ECM). No engine protection
for coolant temperature.
154 P105 105 Low voltage detected at the intake Possible white smoke. Fan
Yellow 4 4 manifold temperature circuit. will stay on if controlled by
electronic control module
(ECM). No engine protection
for coolant temperature.
155 P105 105 Intake Manifold temperature signal Progressive power derate
Red 0 0 indicates temperature above with increasing time after
87.7°C [190°F]. alert. If Engine Protection
shutdown feature is enabled,
engine will shut down 30
seconds after red light starts
flashing.
187 S232 620 Low voltage detected on the ECM Engine will run derated. No
Yellow 4 4 voltage supply line to some sensors engine protection for oil
(VSEN2 supply). pressure and coolant level.
211 A216 1484 Additional OEM or Vehicle None on engine
None 11 31 diagnostic codes have been logged. performance.
Check other ACME’s for diagnostic
codes.
212 P175 175 High voltage detected at the oil No engine protection for oil
Yellow 3 3 temperature circuit. temperature.
213 P175 175 Low voltage detected at the oil No engine protection for oil
Yellow 4 4 temperature circuit. temperature.
214 P175 175 Oil temperature signal indicates oil Progressive power derate
Red 0 0 temperature above123.9°C [255°F] with increasing time after
alert. If Engine Protection
shutdown feature is enabled,
engine will shut down 30 sec.
after red light starts flashing.
219 P017 1380 Low oil level was detected in the None performance. Centinel
Maintenance 1 17 Centinel makeup oil tank. deactivated.
221 P108 108 High voltage detected at the Derate in power output of the
Yellow 3 3 ambient air pressure circuit. engine
222 P108 108 Low voltage detected at the Derate in power output of the
Yellow 4 4 ambient air pressure circuit. engine
223 P085 1265 Incorrect voltage detected at the None n performance.
Yellow 4 4 Centinel actuator circuit by the Centinel deactivated.
ECM.
227 P232 620 High voltage detected on the ECM Engine will run derated. No
Yellow 3 3 voltage supply line to some sensors engine protection for oil
(VSEN2 supply). pressure and coolant level.

Electrical System S0802195K

Page 39
 Fault Code J1587 PID(P) J1939
Reason Effect
Light SID(S) FMI SPN FMI
234 P190 190 Engine speed signal indicates Fuel shutoff valve closes until
Red 0 0 engine speed is greater than 2730 engine speed fails to 2184
rpm. rpm.
235 P111 111 Coolant level signal indicates Progressive power derate
Red 1 1 coolant level is below the normal with increasing time after
range. alert. If Engine Protection
shutdown feature is enabled,
engine will shut down 30 sec.
after red light starts flashing.
237 S030 644 Duty cycle of the throttle input All engines (primary and
Yellow 2 2 signal to the primary or secondary secondary) are shut down
engine for multiple unit with increasing time after
synchronization is less than alert if harscoupled. Only
3percent or more than 97 percent. secondary engine are shut
down with increasing time
after alert if soft coupled.
241 P084 84 2 The ECM lost the vehicle speed Engine speed limited to
Yellow 2 signal. Maximum Engine Speed
without vehicle speed sensor
parameter value cruise
control, gear-down protection
and road speed governor will
not work (automotive only)
242 P084 84 Invalid or inappropriate vehicle Engine speed limited to
Yellow 10 10 speed signal detected. Signal Maximum Engine Speed
indicates an intermittent connection without vehicle speed sensor
or VSS tampering. valve cruise control, gear-
down protection and road
speed governor will not work
(automotive only
245 S033 647 Less than 6 VDC detected at fan The fan may stay on at all
Yellow 4 4 clutch circuit when on. Indicates an times.
excessive current draw from the
ECM or faulty ECM output circuit.
254 S017 632 Less than 6 VDC detected at FSO The ECM turns off the FSO
Red 4 4 circuit when on. Indicates an supply voltage. The engine
excessive current draw from the will shut down.
ECM or a faulty ECM output circuit.
255 S017 632 Externally supplied voltage None on performance. Fuel
Yellow 3 3 detected going to the fuel shutoff shutoff valve stays open.
solenoid supply circuit.
285 S231 639 The ECM expected information At least one multiplexed
Yellow 9 9 from a multiplexed device but did device will not operate
not receive it soon enough or did properly.
not receive it at all.
286 S231 639 The ECM expected info from a At least one multiplexed
Yellow 13 13 multiplexed device but only receive device will not operate
a portion of the necessary properly.
information.
287 S091 91 The OEM vehicle electronic control The engine will only idle.
Red 2 19 unit (VECU) detected a fault with its
throttle pedal.

S0802195K Electrical System

Page 40
 Fault Code J1587 PID(P) J1939
Reason Effect
Light SID(S) FMI SPN FMI
288 S029 974 The OEM vehicle electronic control The engine will not respond
Red 2 19 unit (VECU) detected a fault with its to the remote throttle.
remote throttle.
293 S154 1083 High voltage detected at the OEM No engine protection for
Yellow 3 3 temperature sensor signal pin of the OEM temperature.
31-pin OEM connector.
294 S154 1083 Low voltage detected at the OEM No engine protection for
Yellow 4 4 temperature sensor signal pin of the OEM temperature.
31-pin OEM connector.
295 S108 108 An error in the ambient air pressure Engine is derated to no air
Yellow 2 2 sensor signal was detected by the setting.
ECM.
297 S223 1084 High voltage detected at the OEM No engine protection for
Yellow 3 3 pressure sensor signal pin of the OEM pressure
31-pin OEM connector.
298 S223 1084 Low voltage detected at the OEM No engine protection for
Yellow 4 4 pressure sensor signal pin of the OEM pressure
31-pin OEM connector.
299 S117 1384 Engine shutdown by device other No action taken by the ECM.
Yellow 11 31 than key switch before proper
engine cool down resulting in
filtered load factor above maximum
shutdown threshold.
311 S001 651 Current detected at No.1 injector Current to injector is shut off.
Yellow 6 6 when voltage is turned off.
312 S005 655 Current detected at No.5 injector Current to injector is shut off.
Yellow 6 6 when voltage is turned off.
313 S003 653 Current detected No.3 injector Current to injector is shut off.
Yellow 6 6 when voltage is turned off.
314 S006 656 Current detected No.6 injector Current to injector is shut off.
Yellow 6 6 when voltage is turned off.
315 S002 652 Current detected No.2 injector Current to injector is shut off.
Yellow 6 6 when voltage is turned off.
319 S251 251 Real time clock lost power. None on performance. Data
Maintenance 2 2 in the ECM will not have
accurate time and data
information.
321 S004 654 Current detected No.4 injector Current to injector is shut off.
Yellow 6 6 when voltage is turned on.
322 S001 651 No current detected at No.1 injector Current to injector is shut off.
Yellow 5 5 when voltage is turned on.
323 S005 655 No current detected at No.5 injector Current to injector is shut off.
Yellow 5 5 when voltage is turned on.
324 S003 653 No current detected at No.3 injector Current to injector is shut off.
Yellow 5 5 when voltage is turned on.
325 S006 656 No current detected at No.6 injector Current to injector is shut off.
Yellow 5 5 when voltage is turned on.
331 S002 652 No current detected at No.2 injector Current to injector is shut off.
Yellow 5 5 when voltage is turned on.
332 S004 654 No current detected at No.4 injector Current to injector is shut off.
Yellow 5 5 when voltage is turned on.

Electrical System S0802195K

Page 41
 Fault Code J1587 PID(P) J1939
Reason Effect
Light SID(S) FMI SPN FMI
341 S253 630 Severe loss of data from the ECM. Possible no noticeable
Yellow 2 2 performance effects OR hard
starting. Fault information.
Trip information, and
maintenance monitor data
may be inaccurate.
343 S254 629 Internal ECM error. Possible none on
Yellow 12 12 performance or severe
darate.
349 S191 191 A frequency greater than calibrated Calibration dependent power
Yellow 0 16 threshold was detected at the tail and speed derate.
shaft governor signal pin of the 31-
pin OEM connector.
352 S232 1079 Low voltage detected on the ECM Engine is derated to no air
Yellow 4 4 voltage supply line to some sensors setting.
(VSEN1 supply).
386 S232 1079 High voltage detected on the ECM Engine is derated to no air
Yellow 3 3 voltage supply line to some sensors setting.
(VSEN1 supply).
387 S221 1043 High voltage detected on the ECM Engine will only idle.
Yellow 3 3 voltage supply line to the throttle(s)
(VTP supply).
415 P100 100 Oil Pressure signal indicates oil Progressive power derate
Red 1 18 pressure below the very low oil with increasing time from
pressure engine protection limit. alert. If engine protection
shutdown feature is enabled,
engine will shut down 30
seconds after red light starts
flashing.
418 S097 97 Water has been detected in the fuel Possible white smoke. loss of
Maintenance 0 15 filter. power, or hard starting.
419 S102 1319 An error in the intake manifold Engine is derated to no air
Yellow 0 2 pressure sensor signal was setting.
detected by the ECM.
422 S111 111 Voltage detected simultaneously on No engine protection for
Yellow 2 2 both the coolant level high and low coolant level.
signal circuits OR no voltage
detected on both circuits.
426 S231 639 Communication between the ECM None on performance. J1939
None 2 2 and the J1939 data link has been devices may not operate.
lost.
428 S097 97 High voltage detected at water-in- None on performance.
Yellow 3 3 fuel sensors.
429 S097 97 Low voltage detected at water-in- None on performance.
Yellow 4 4 fuel sensors.
431 S23 558 Voltage detected simultaneously on None on performance.
Yellow 02 2 both the idle validation off-idle and
on-idle circuits.

S0802195K Electrical System

Page 42
 Fault Code J1587 PID(P) J1939
Reason Effect
Light SID(S) FMI SPN FMI
432 S230 558 Voltage detected at idle validation Engine will only idle.
Red 13 13 on-idle circuit when voltage at
throttle position circuit indicates the
pedal is not at idle OR voltage
detected at idle validation off-idle
circuit when voltage at throttle
position circuit indicates the pedal is
at i
433 P102 102 Voltage signal at intake manifold Derate to no air setting.
Yellow 2 2 pressure circuit indicates high
intake manifold pressure but other
engine characteristics indicate
intake manifold pressure must be
low.
434 P251 627 Supply voltage to the ECM fell Possible no noticeable
Yellow 2 2 below 6.2 VDC for a fraction of a performance effects OR
second OR the ECM was not possibility of engine dying OR
allowed to power down correctly hard starting. Fault
(retain battery voltage for 30 information, Trip information,
seconds after key off.) and maintenance monitor
data may be inaccurate.
435 P100 100 An error in the oil pressure sensor None on performance. No
Yellow 2 2 signal was detected by the ECM. engine protection for oil
pressure.
441 P168 168 Battery voltage below normal Possible no noticeable
Yellow 1 18 operating level. performance effects OR
possibility of rough idle.
442 P168 168 Battery voltage above normal None on performance.
Yellow 0 16 operating level.
443 P221 1043 Low voltage detected on the ECM Engine will only idle.
Yellow 4 4 voltage supply line to throttle(s)
(VTP supply).
489 P191 191 Auxiliary speed frequency on input Engine will only idle.
Yellow 1 18 pin indicated that the frequency is
below a calibration dependent
threshold.
527 P040 702 Less than 17.0 VDC detected at the No action taken by the ECM.
Yellow S1543 3 dual output A signal pin of the 31-
pin OEM connector.
528 P093 93 Less than 17.0 VDC detected at the No action taken by the ECM
Yellow 2 2 dual output B signal pin of the 31-
pin OEM connector.
529 S051 703 Less than 17.0 VDC detected at the No action taken by the ECM.
Yellow 3 3 dual output B signal pin at the ECM.
551 S230 558 No voltage detected simultaneously Engine will only idle.
Yellow 4 4 on both the idle validation off-idle
and on-idle circuits.
581 P105 1381 High voltage detected at the fuel Fuel inlet restriction monitor
Yellow 3 3 inlet restriction sensor signal pin. deactivated.
582 P105 1381 Low voltage detected at the fuel Fuel inlet restriction monitor
Yellow 4 4 inlet restriction sensor signal pin. deactivated.
583 P105 1381 Restriction has been detected at Fuel inlet restriction monitor
Yellow 1 18 the fuel pump inlet. warning is set.

Electrical System S0802195K

Page 43
 Fault Code J1587 PID(P) J1939
Reason Effect
Light SID(S) FMI SPN FMI
596 P167 167 High battery voltage detected by Yellow light will be lit until high
Yellow 0 16 the battery voltage monitor feature. battery voltage condition is
corrected.
597 P167 167 ICON has restarted the engine Yellow light will be lit until low
Yellow 1 18 three times within three hours due battery voltage condition is
to low battery voltage (automotive corrected. The ECM may
only) OR low battery voltage increase idle speed and
detected by the battery voltage deactivate idle decrement
monitor feature switch if idle speedup is
enabled. The engine will run
continuously if ICON is active
(automotive only).
598 P167 167 Very low battery voltage detected Red light lit until very low
Red 1 1 by the battery voltage monitor battery voltage condition is
feature. corrected.
611 S151 1383 Engine shutdown by operator No action taken by the ECM.
None 11 31 before proper engine cool down
resulting in filtered load factor
above maximum shutdown
threshold.
951 P166 166 A power in balance between Engine may have rough idle
None 2 2 cylinders was detected by the ECM. or misfire.

S0802195K Electrical System

Page 44
ELECTRONIC ACCELERATOR

ACCELERATOR CIRCUIT
A 0.5R
POSITION PT B 0.5G
SENSOR
C 0.5B
IDLE E 0.5Or
VALIDATION
F 0.5V
D 0.85Y

DETAIL "A"

D A

E B

F C

SEE DETAIL "A" PEDAL SENSOR

BLACK GREEN RED

OV C B A +VE
C.W.

PEDAL SENSOR

PIN IDLE VALIDATION SW.

E DESCRIPTION COLOR
LOCATION
D VIOLET YELLOW ORANGE
A THROTTLE POSITION + V SUPPLY RED
F D
B THROTTLE POSITION SIGNAL GREEN F E
A C THROTTLE POSITION RETURN BLACK C.W.
B D COMMON YELLOW
C E OFF IDLE POSITION (NO) ORANGE
F ON IDLE POSITION (NC) VIOLET
IDLE ON IDLE OFF

AWS0560L
Figure 24

ELECTRIC SPECIFICATION
1. Total Resistance: 2.5K Ohm ± 10% (at 20°C)
2. Linerity: ± 2% over 5% ~ 85% of output
3. Power Rating: 0.15W (at 85°C)

SWITCH SPECIFICATION
1. Idle Validation Sw.2: IVS3 - (0.5° ~ 3.5°) (Normally Closed)
2. Idle Validation Sw.3: 13° ± 2° (Normally Open)
3. Continuos Limit Current: Max. 20mA

Electrical System S0802195K

Page 45
MECHANICAL SPECIFICATION (PEDAL SENSOR)
1. Rotating Angle: 83° ± 2°
2. Spring Return Force: 150 ~ 200 Nm at 40° ± 2°

DATA LINK
The ECM (Electronic Control Module)
communicates with service tools through an
SAE J1939 data link or SAE J1708 datalink.
Insite
Using Insite, the data link permits limited
modification of ECM features and parameters,
and downloading of entire ECM calibrations.
NOTE: To use a Insite, you need a data
link harness designed by DHIM.
4P 9P
NOTE: The 4-pin AMP connector, is 4

1
F
E

G
D

H
C

J
B

used as engine-side data link, Datalink Harness

is located in the electric box. AWS0570L
Figure 25

LIS (LOAD ISOLATION SYSTEM) - OPTION

Excessive bucket pitching is drastically reduced
and good floatation is maintained for minimum
operator fatigue and maximum productivity. LIS
is useful for sites where frequent cycles of
loading and carry are needed or rough terrain.
When the LIS switch is in the "I" position and
O
vehicle speed is above 8 km/h, the LIS solenoid
valves(14) are energized and the LIS system is
"ON".
I
When the LIS switch is in the "I" position and
vehicle speed is below 6 km/h, the LIS solenoid HA0O2026
is de-energized and the LIS system is "OFF".
Figure 26
NOTE: If the switch is in the '0' position,
regardless of the vehicle speed
the LIS solenoid valves (14) de-
energized and the LIS system
is not operating.

S0802195K Electrical System

Page 46
 AWS0590L
Figure 27

Reference Reference
Description Description
Number Number
1 Transmission Controller 11 Output Speed Sensor
2 Shift Lever Switch 12 Speed Pick-up (3)
4 Fuse Box 1 13 LIS Switch (Option)
5 Auto Selector Switch 14 LIS Solenoid Valve
8 Display 15 Speedometer
9 Downshift Switch 16 Parking Brake Switch
10 Safety Start Switch 19 Fuse Box 2

Electrical System S0802195K

Page 47
AEB STARTER
INTRODUCTION
The AEB - Starter is s tool to start the AEB of
ergo power transmissions by an easy way. It’s
useful to work with the ZF - Display because you
Insite
get all messages about the AEB state via the
ZF-Display. The AEB - Starter itself doesn’t
show any informations.
The AEB-starter works with the diagnostic plug
which is in the electric box.
4P 9P
To insure the highest level of shift quality, AEB 4

3
F
E
D

A
C
B
2

must be done under following conditions:

J
G
1 H

Datalink Harness
• Before putting the vehicle into AWS0570L
service Figure 28
• When the transmission or TCU been
replaced.
NOTE: The error code "F6" will be shown in the display as long as the AEB is not done.

LIST OF ABBREVIATIONS
AEB: Automatic Filling Parameter Adjustment
TCU: Transmission Control Unit

PROCEDURE TO START AEB

Step to do Display message Remarks

1 Warm up transmission Normal operating messages
2 Turn off starter switch Nothing
3 Plug in AEB-starter
4 Bring shift lever to "N" position.
Engage park brake.
5 Start engine "PL" TCU must recognize PL for at
least 2s before you can press
the button
6 Put engine speed to 800 rpm "PL" if start conditions are
ok
7 Press button of the AEB-Starter "ST" if start conditions are The button must not be
ok released before TCU has
started the AEB or quit whit an
error code
8 Hold button until AEB has "K1" … (Information about TCU has started the AEB, and
started the AEB state) goes on adjusting K1, K2, …,
KR. (Button may be released)
9 Wait until AEB has finished "OK" (AEB has been
successful)

S0802195K Electrical System

Page 48
 Step to do Display message Remarks
10 Turn off starter switch and Nothing
unplug AEB-Starter

DISPLAY DURING AEB-MODE

Symbol Meaning Remarks

AEB - Starter is plugged at the
PL
diagnostic plug
ST AEB-Starter-button is pressed
K1… K4,KV,KR Calibrating clutch K1… K4,KV,KR
Wait for start, initialization of clutch Kx,
- and Kx
x: 1, 2, 3, 4, V, R
≡ and Kx Fast fill time determination of clutch Kx
Compensating pressure determination
= and Kx
of clutch Kx
Calibration for all clutches finished Transmissions stays in neutral, you have
OK to restart the TCU (starter switch off/on)
after removing AEB-Starter
AEB canceled (activation stopped) Transmissions stays in neutral, you have
STOP
to restart the TCU (starter switch off/on)
AEB stopped, clutch Kx can’t be Transmissions stays in neutral, you have
STOP and Kx
calibrated to restart the TCU (starter switch off/on)
Kx couldn’t be calibrated, AEB Transmissions stays in neutral, you have
Spanner and Kx
finished to restart the TCU (starter switch off/on)
Engine speed too low, → raise engine
↑E
speed
Engine speed too high, → lower
↓E
engine speed
Transmission oil temperature too low
↑T
→ heat up transmission
Transmission oil temperature too high
↓T
→ cool down transmission
Transmission temperature not in Transmissions stays in neutral, you have
FT
defined range during calibration to restart the TCU (starter switch off/on)
Operating mode not NORMAL or Transmissions stays in neutral, you have
transmission temperature sensor to restart the TCU (starter switch off/on)
FB
defective or storing of calibrated
values to EEPROM-has failed.
Output speed_not_zero Transmissions stays in neutral, you have
FO
to restart the TCU (starter switch off/on)
Shift lever not in Neutral position Transmissions stays in neutral, you have
FN
to restart the TCU (starter switch off/on)
Parking brake_not_applied Transmissions stays in neutral, you have
FP
to restart the TCU (starter switch off/on)
AEB - Starter was used incorrect or is Transmissions stays in neutral, you have
STOP
defective to restart the TCU (starter switch off/on)

Electrical System S0802195K

Page 49
 NOTE: To prevent the transmission oil temperature from falling down while AEB operating, keep
the transmission oil temperature about 80°C before starting AEB. (Temperature Range:
60°C ~ 90°C)

S0802195K Electrical System

Page 50
 S0893065K

1ELECTRICAL
SCHEMATIC
(MEGA 500-V (TIER II))
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

ELECTRICAL SCHEMATIC (MEGA 500-V (TIER II))S0893065K

MODEL SERIAL NUMBER RANGE
Mega 500-V (Tier II) 2001 and Up

Copyright 2002 Daewoo

June 2002

Electrical Schematic (Mega 500-V (Tier II)) S0893065K

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Mega 500-V (Tier II) ....................................................................................... 4

S0893065K Electrical Schematic (Mega 500-V (Tier II))

Page 2
GENERAL DESCRIPTION
Schematic(s) presented in this section are laid out on facing pages.
An overlapping edge has been taken into consideration so that a photocopy can be made and pasted
together to make a complete schematic.

Figure 1

Electrical Schematic (Mega 500-V (Tier II)) S0893065K

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MEGA 500-V (TIER II)

ECM CN1-14 0.85RG

0.85Lg (2534-9049C)x4 ALARM RELAY 1
(INCREMENT)
0.85BL
ECM CN7-10 (OPTION) FRONT 0.85B
24V 70W
87
30 1.25RY (2544-9033 )
(PANEL GROUND) WORKING LAMP 0.85RW 1.25RW 87a
CN1 AMP MIC 13P ECM CN7-24
(DECREMENT) 0.
0.85RG 0 85B 5B 85 0.5RG 0.5B
+ SIG 10 0.5WR 24V 70W
HELLA 0.85B
SPEED - 0.85R 86 0.5
REAR LAMP SW
+ (549-00069) 1.25RG (2549-9109 )
S CN1-3 0.85WG REAR LAMP RELAY
+(2190-2584D10) +(2190-2036D20) 0.5B
TACHO - 1 (2544-9033 )
ECM CN7-11 1.25RG
1 5 0
2 1.25RY
0.85L W/TEMP SENSOR 5 0.85RY
(2547-6028) 1.25B
TEMP 9
(17) 10 0.5WR
+ 9 0.5WR
EL SENSOR FRONT LAMP SW 0.85RW (18)
FUEL 47-00020) (2549-9098) (CL) 0.85B
+(2190-2036D5) 2RY
+
CN1-8 0.85GR ANSMISSION OIL 1.25RY
- TEMP SENSOR
TEMP
0501-311-444)
1 3 0.5RW 0.5RW 0.5RW 0.5RW
CN1-2
0.85WR 0.85WR
1.25R 1.25R 1.25R 1.25R
ILLUMINATION
0.85G 0.85G 0.5BrW 0.5BrW

ECM CN7-05 (MAINTENANCE)

CN1-9 0.85WR CONTROL UNIT 0.85L 0.85L
(543-00001)
CN1-1 1.25R
B 0.85L CIGAR LIGHTER
+
CHARGE 0.5W 0.5W 3 1 0.85R 0.85B (545-00001)
L5
ENGIN 0.85BY 4 2 0.5RW 0.85L 0.85B
ECM CN7-06 (STOP) TIME DELAY -
-
0.85YB 5 S 0.85Y +
ECM CN7-16 (WARNING) BUZZER CIRCUIT
0.85W
PREH 0.85LB 0.5WR
ECM CN7-04 (PREHEAT)
0.5YL 0.5YL 6 8 0.5BrW 0.85G

PARK 0.5Lg 0.5Lg 7 B

0.85L
0.85LR 0.85LB BLINKER
L11
0.85RW 1 UNIT
AIR CLEANER 0.85B 13
L2 (2525-1011 )
15A
3W
CN1 +
P 9 7 0.85WR
WORKING 0.5RL 0.5RL
L9 FUSE BOX 2 0.85RY
0.5GR 0.5GR + (F)
TURN SIGNAL (R) HORN (H)
L8 0.5GL 0.5GL (2516-9015)
1.25WR
TURN SIGNAL (L) CN2-6 0.5R 0.5R
L6 0.85BR 0.85B 10 0.85WR
0.85YL 10A
L7 (13)
1.25RB
SPARE CN2-13 3 HORN (L)
L13 0.85Lg 0.85RW (2516-9016)
ECM CN7-18 (POWER,+)

0 85WR
CN2-17 0.85RW

1.25RW
5R ECM CN7-07 (POWER,+) 0.85RW
CN2 AMP MIC 17P ECM CN7-48
0.85B 5G ECM CN7-08 (POWER,+) 0.85RW 3W
GAUGE PANEL ASS'Y ECM CN7-47 DATALINK(1)
(539-00030) ECM CN7-17 (POWER,+) 0.85RW 0.85RW 1.25WR
FOOT PEDAL ECM CN7-49
0.85RW 0.85RW
ECM CN7-03
2RL 2RL
0.85V ECM CN7-13 0.85BR 0.85RY
ECM CN7-09 0.85WL
FLOAT KICK-OUT ASS'Y (OPTION) STD 0.85RB
0.85GW 0.85GY 0.85GY
0.85RB 0.85RB
FLOAT KICK-OUT SW OPT (FLOAT KICK-OUT)
0.85WR
0.85R STOP LAMP SWITCH
1 0.85RY
(549-00010) HORN RELAY
1 FRONT FRONT
(2544-9033 )
5 RAISE RELAY COMBI LAMP(L) HEAD LAMP(L) HEAD LAMP(R) COMBI LAMP(R)
FLOAT 30
75/70W 87
0.5B 10 9 30
0.85B
85 86
86
(RAISE)

0.85LY
+ 0.5B
(position)

(position)
0.85WR

0.85WR
0.85WL
0.85RW

0.85WL
0.85GL

0.85BR
0.85RB

0.5BrW

0.85RY
0.5GR
0.85G

0.5GL
0.5R

2RL

-
RETURN TO DIG 0.5LB 0.5BrY
MAGNET RETURN TO DIG RELAY 0.85RB
1 3
(5)
3 0.85G 87a
6 DISPLAY ILL RELAY
30 0.85RB 0.5GR 0.85GR
(2544-9033 )
87
87a 0.85GL 0.85GL
- 85 86 0.85RB 0.85RW
87
0.85R 0.85R
85 0.85WR
0.85WG
0.85GW
0.85RB
0.85RY 0.5LB
LIS ASS'Y (OPTION) 0.5WR
0.85BR
0.85WR

LIS SELECT SW 0.5BrW

WIPER MOTOR
(position)

sition)
k up)

(2549-9098 )
(turn sig)

(turn sig)
0.85RL
5GW

5GW
top)

top)

0.85GR
WR
0.85RY

5RY
0.85GL

SAFETY START
0.85WL
0.85GW

0.85GW

+(2190-2036D3) (4538-9017)
RELAY BACK UP RELAY 0 85B 0 85B
0.85RY 1 (2544-9033 ) H 0.85RY
(2544-9033 )
5 0.85RB 87a 87a L
0.5BrW
30 0.5RL 0.85RL 30 A C
87 87 0.85RY S 0.85Y
9 0.5WR LO
0.5Gr 85 86 0.5RL 0.5P 85 86 0.5RL 0.85LB
21W 10W W 21W
0.85RY
B 0.85L

0.85LY + BACK BUZZER

0.5Gr 52 5 0.5P - (2516-1124) E
LOG FORK (OPTION) 0.85B
0.85RY 30 0.85RL 1-4 0.5BY
(1)
0.85LY 8 PARKING BRAKE SW
14 0.85WG 2-1 2-3 0.5L
0.85LY 0.85LY 53 (2549-9098 )
DOWN SHIFT SW +(2190-2036D16)
0.85BL 57 LOG FORK / LOG FORK SW 1
0.85BR 11 SOL-VALVE (2) 0.85W 0.85WL 5 0.5B
4 2 7 0.85Or
15 0.85GW 2 0.85V
0.85R 12 18 0.85BrL 4 9 10
7 0.85R 13
0.85G

4WG- T/M SELECTOR SWITCH

2RL

CHECK CONN (4549-6072)

TRANSM TRANSMISSION 0.85V 0.85Or
(ZF 0501 210 702)
VALVE A 1 0.85YG 10 CONTROLLER 0.
EST-37 CC-TV
3 4
0.85LW 4P CONN(4) F N R
STEP 0.85Or
0.85GL (543-00008) 45 0.85RL 0.85RL X2-A VP (8)
0.85WB 67 0.85Gr 0.85Gr X2-D
0.85GR 9 DW-3 0.85BW X1-A 0.85B
AD3
0.85WL 51 0.85V X1-D AD7
0.85L X1-C
8 0.85LB 39 0.85G X1-B
(543-000 ) AD2 COMPRESSOR
9 0.85Br 46 0.85Y X2-B RECE
AD4 (4208-6018) (2204
ERGO-II (OPT) 0.85P X2-C AD5
0.85LgR 19 0.85Or 0.85LW
(ENGINE) 0.85Lg 0.85W
PILOT CUT OFF SW
SPEED 41
PICK-UP (TURBINE) 5 0.85RL 5
0.85RL
(ZF 0501 7
209 688)x3 42 0.85BW
(CENTRAL 5 0.85WL
GEAR CHAIN) 3 9 0.5WR 0.5WR
1 0.85B
2 0.85B 9 0.5WR
62 0.85B
4 6
CN6 AMP 67P +(2190-2036D15) 0.5W +(2190-2036D9) 0.5W
0.85RL 0.5WR

Figure 2

S0893065K Electrical Schematic (Mega 500-V (Tier II))

Page 4
 ALARM RELAY 1 FUSE 2(6)
(2544-9033 ) ALARM RELAY 2
DATA LINK ECM CN7-29
87a (2544-9033 ) ANTENNA SPEAKER TML
CONNECTOR ECM CN7-26 PST B BR R2 ACC
0.5WL 0.5G
0.5B 30 ECM CN7-27 OFF
0.5WB (LH) (RH) NOTE.
PREHEAT
86 0.5WR 1. DIODE PART NO.
EAR LAMP SW ON
86 0.5LR - DIODE (11)~(19) : 2548-1026
2549-9109 ) + - + - START
90-2036D20) 3 7 0.85GrR - DIODE (1)~(9) : 2548-1027
0.5B TERMINAL NO
CAR
0 10 1 0.85BY
2 1.25RY
(2541-9019 ) 0.85GrL
PILOT BUZZER 4 2 0.85BW
10 0.5WR (2516-1102A)
0.85WB -
0.85B 0.85BR
0.85RW +
11 0.85L 0.85L
2RY
0.85WR
1.25RY
STEREO RELAY
(2544-9033 )
0.5RW 87a WARNING CHECK SW
30 0.85L
0.85LW
1.25R
0.5BrW 0.5B 86 0.5LR 5

0.85L 0.5WR 9 ECM CN7-10

0.85BL
(PANEL GRO
CIGAR LIGHTER ECM CN7-44
(545-00001) (DIAGNOSTIC) S
0.5BrW 0.5BrW N S 0.8

- 0.85B 0.5WR 0.5WG P B

+ 0.5LR 3W
(3)
0.85W 0.5RW
0.5WR 0.85RW 0.5RW
0.85G 0.85G
2RY 1.25WR
B (ALTERNATE IDLE)
1.25RY
(ALTERNATE TORQUE)
BLINKER ALTERNATE IDLE SW ALTERNATE TORQUE SW
1 UNIT (2549-9098) (2549-9098)
(2525-1011 ) +(2190-2584D11) +(2190-2584D12)
15A 1.25WR
3W
7 17 18 19 5 5
0.85WR 2WR
7 0.85BL
3W
2 0.85RY
HORN (H) 0.5WR 9 0.5WR 9 10 0.5B
1.25WR (2516-9015) 5W
15 0.85BL FUEL PUMP (2401-1278A)
0.85WR 5W
ECM CN7-10 1.25RW 1.25R
10A P
1.25WR (PANEL GROUND)
3 HORN (L) 1 2
2WR
(2516-9016)
0.85WR
0.85RW
0.85GY

0.5LR 0.85BY
0.85WL

4P CONN(1)
1.25LR
0.85LB

1.25R 5W 3W 0.85RW 10W

2RL

3W 3W 1.25WG
DATALINK(1) 8W FUSIBLE LINK
1.25WR 1.25WR 0.5RW 15R
0.85RW 0.85RG 0.85WR 2WR

1.25WR

0.85BY
2RL 2RL
SP
2LR 0.5LR 2R
CIRCUIT BREAKER
0.85RY 0.85LB 1.25LR 85R
ACC C B A
0.85WL 0.85WL 0.5RW 8W 8W
0.85GY 0.85GY 0.85RG 0.85RG B
0.85WR 0.85WR 0.85WR
R2 1.25BrW
0.85RY 0.85GY BR
1.25WG

HORN RELAY HEAD LAMP RELAY R1

1.25LR

(2544-9033 ) (2544-9033)
2LR

0.85LY 1 0.85RG 1.25BrW

85R
0.85GY BATTERY RELAY
30 7 30
87 87 (2544-9024)
0.85WY
6 2
2 ECM CN7-38 0.85Br
85 86 0.5LY 85 86 85B 85R
0.5B 0.5WY (2)
(KEY IN)
0.5WR 9 10
0.5WL
0.85LY

0.5B 0.5B 9 1.25WG 1.25RW

0.85WR
0.85WL

0.85BR

0.5B - + - +
0.5RW
HAZARD SWITCH 12V 150AH 12V 150AH
0.5LB 0.5BrY SW HEAD LAMP
1 3 (2549-9138 )
(5) N 0.85BrL ECM CN7-23
(E/G DERATING)
0.85GR 87a AVX 8W
30 AVX 1.25WG
0.85GL
COMBINATION
0.85RW ECM CN7-10 2RW
SWITCH (R)
86 85 (PANEL GROUND)
0.85R (4549-9418)
0.5W
0.5LR

E
0.5LB E/G DERATING RELAY
0.85BR (2544-9033)

PREHEAT RELAY 15L

WIPER MOTOR H
ECM 31P-10 (544-00008)
(4538-9017) J (PREHEAT RELAY) B
H 0.85RY F- F+
L 0.85YB

87a 0.85BrL AIR GRID HEATER

S 0.85Y ECM 31P-11
LO 30 0.85BrL AH 2008
(PREHEAT RELAY) 24V 90A
0.85LB
SW WIPER ALTERNATOR E
E (CUMMINS)
86 85 0.5B 8B
B 0.85L 15B EE 2050, 22SI

1.25LR AIRCON UNIT

E WIPER RELAY (4920-9050A)
0.85B 2LR
(2544-9033) CLUTCH
3
PARKING BRAKE SW 4 1 2LR
0.5L A/C CONTROL PANEL KV Y5
(2549-9098 )
(2543-9031A) 0.5RW 0.85LR KR Y1
+(2190-2036D16) WIPER TIMER 2
1 22
5 0.5B 5 3 0.5BL
WL
7 K2 Y6
0.85Or
13 1.25LR K3 Y4
9 10 CONDENSER FAN RELAY
(2544-9033)
87a
0.85Or 30 3 0.5LB 11 HIG
0.85LR
0.85B - + 87 5 0.5LY 12 M
8 LO
0.85Or 0.5YB 85 86 KICK
0.5LR F R N T+ T-
18 RE
(8) X2-A + VP
INTAKE X2-D
0.85B 0.5YB 10 AD7 AS
ACTUATOR
M X1-A AD3 B3
X1-D AD8 KD
X1-C AD1 B1
COMPRESSOR RELAY 20 0.5OrW
COMPRESSOR RECEIVER DRIER (2544-9033 ) VENT X1-B AD2 B2
(4208-6018) (2204-6039A) 87a ACTUATOR
M X2-B AD5 V
0.85LR X2-C
0.85LW 0.85BW 87 AD6 R
14

0.5RB 85 15
0.5LR M
MIX
ACTUATOR
0.5RB 9
L
0.5WR 11
0.5W STOR
R
DUCT/DEF 26 1.25B
DEF 0.5G 7
ACTUATOR
DUCT 3 0.5GW 6
(2213-9002 ) M CN3 HRS 26P CN1 AMP MIC 13P + 250 4P
R

Mega 500-V (Tier II)

AWS0430L

Electrical Schematic (Mega 500-V (Tier II)) S0893065K

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S0893065K Electrical Schematic (Mega 500-V (Tier II))
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1ATTACHMENTS