Daewoo Doosan Mega 300-V Shop Manual K1003701E – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Mega 300-V Shop Manual K1003701E – PDF DOWNLOAD
- DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
- It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package.
- Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item.
TO THE OPERATOR OF A DOOSAN DAEWOO WHEEL LOADER
- Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
- Please respect the importance of taking responsibility for your own safety, and that other people who may be affected by your actions.
- Safety information on the following pages is organized into the following topics
1. “General Safety Essentials” on page 6.
2. “Location of Safety Labels” on page 6.
3. “Unauthorized Modifications” on page 6.
4. “General Hazard Information” on page 7.
5. “Before Starting Engine” on page 15.
6. “Machine Operation” on page 18.
7. “Maintenance” on page 25.
8. “Battery” on page 33.
9. “Towing” on page 35.
10. “Shipping and Transportation” on page 36
- Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance.
- Keep this manual in the storage compartment to the rear of the operator’s seat, and have all personnel involved in working on the machine periodically read the manual. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual.
- 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.
- DOOSAN 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 DOOSAN or your DOOSAN distributor before operating the machine.
LEARN SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL
The words “CAUTION,” “WARNING,” and “DANGER” used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert “Triangle,” no matter which signal word appears next to the “Exclamation Point” symbol
Safety precautions are described in SAFETY from page 6 on.
DOOSAN 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 you are unsure about the safety of some procedures, contact a DOOSAN distributor.
GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
This wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN. 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 DOOSAN 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 DOOSAN part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised.
GENERAL HAZARD INFORMATION SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will interfere with your sense of judgement in emergencies and may cause accidents. When working with another operator or with a person on work site traffic duty, be sure that all personnel know the nature of the work and understand all hand signals that are to be used. Always observe strictly any other rules related to safety.
SAFETY FEATURES
Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as transmission lever neutral lock and the seat belt, and use them properly. Never remove any safety features. Always keep them in good operating condition. Failure to use safety features according to the instructions in the Operation and Maintenance Manual could result in serious bodily injury
TABLE OF CONTENTS:
Daewoo Doosan Mega 300-V Shop Manual K1003701E – PDF DOWNLOAD
Publication Request for Proposed Revision....................................................................... 7 Safety.......................................................................................................... 9 Wheel Loader Safety S0103010K............................................................................... 11 To the Operator of a DOOSAN Daewoo Wheel Loader......................................................... 13 Learn Signal Words Used with Safety Alert Symbol.................................................... 15 General Safety Essentials............................................................................... 16 Accessory Applications.............................................................................. 16 Location of Safety Labels............................................................................... 16 Unauthorized Modifications.............................................................................. 16 General Hazard Information.............................................................................. 17 Safety Rules........................................................................................ 17 Safety Features..................................................................................... 17 Inside Operator's Compartment....................................................................... 18 Clothing and Personal Protective Items.............................................................. 18 Breathing Masks, Ear Protection May Be Required..................................................... 19 Vibration Level Information......................................................................... 19 Asbestos Dust Hazard Prevention..................................................................... 19 Mounting and Dismounting............................................................................ 20 Fuel, Oil and Hydraulic Fluid Fire Hazards.......................................................... 20 Precautions When Handling Fluids at High Temperature................................................ 21 Injury from Work Equipment.......................................................................... 21 Fire Extinguisher and First Aid Kit................................................................. 22 Protection from Falling or Flying Objects........................................................... 22 Install Additional Safety Equipment If Conditions Require........................................... 23 Maintain Standard Safety Equipment in Good Condition................................................ 23 Attachment Precautions.............................................................................. 24 Accumulator......................................................................................... 24 Engine Ventilation.................................................................................. 24 Before Starting Engine.................................................................................. 25 Work Site Precautions............................................................................... 25 Checks Before Starting Engine....................................................................... 26 Engine Starting..................................................................................... 26 Before Operating Machine............................................................................ 27 Machine Operation....................................................................................... 28 Operate While Seated at Operator's Station ONLY..................................................... 28 Seat Belts Must Be Used at All Times................................................................ 28 Movement Alarms..................................................................................... 28 Travel Precautions.................................................................................. 29 Sloping Terrain Requires Caution.................................................................... 29 Avoid High Voltage Cables........................................................................... 30 Before Starting to Dig, Contact Authorities......................................................... 30 Be Aware of Height Obstacles........................................................................ 30 Use Care on Loose Support........................................................................... 30 Use Solid Support Blocking.......................................................................... 31 Digging Beneath Overhangs........................................................................... 31 Digging Beneath Wheel Loader........................................................................ 31 Stay Alert for People Moving Through Work Area...................................................... 31 Be Aware of and Conform to Local Regulations........................................................ 31 Never Use Ether Starting Aids....................................................................... 32 Observe General Safety Rules........................................................................ 32 Take Time to Provide Good Visibility................................................................ 32 Keep "Pinch Point" Areas Clear Use Caution in Reverse............................................. 33 Operate Carefully on Snow and Ice and in Very Cold Temperatures..................................... 33 Parking Machine..................................................................................... 33 Shutdown Control Functions.......................................................................... 34 Never Let Anyone Ride on Attachment................................................................. 34 Maintenance............................................................................................. 35 Use Warning Tag During Service...................................................................... 35 clean Before Inspection or Maintenance.............................................................. 35 Proper Tools........................................................................................ 36 Use of Lighting..................................................................................... 36 Fire Prevention and Explosion Prevention............................................................ 36 Burn Prevention..................................................................................... 37 Welding Repairs..................................................................................... 38 Precautions for Removal, Installation, and Storage of Attachments................................... 38 Precautions When Working on Machine................................................................. 39 Lock Inspection Covers.............................................................................. 39 Crushing Prevention and Cutting Prevention.......................................................... 39 Do Not Run Engine If Repairs or Work Are Being Performed Alone...................................... 39 Always Use Adequate Equipment Supports and Blocking................................................. 40 Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems...................................... 40 Hydraulic Cylinder Seals Require Periodic Replacement............................................... 40 Highpressure Hydraulic Lines Can Store a Great Deal of Energy...................................... 40 Precautions with Highpressure Line, Tubes and Hoses................................................ 41 Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin.................................. 41 Use Correct Replacement Fasteners Tightened to Proper Torque........................................ 42 Safety Critical Parts Must Be Replaced Periodically................................................. 42 Dispose of All Petroleum Based Oils and Fluids Properly............................................. 42 Check Tire Pressure and Condition................................................................... 42 Battery................................................................................................. 43 Battery Hazard Prevention........................................................................... 43 Disconnect Batteries Before Electrical Service or Electrical Welding................................ 43 Use Low Heat Portable Lighting...................................................................... 44 Boost Starting or Charging Engine Batteries......................................................... 44 Towing.................................................................................................. 45 Precautions When Towing............................................................................. 45 Shipping and Transportation............................................................................. 46 Obey State and Local OvertheRoad Regulations...................................................... 46 Summary of Safety Precautions for Lifting........................................................... 46 Specifications for Mega 300V S0203085...................................................................... 47 Component Locations..................................................................................... 50 General Specifications.................................................................................. 53 Engine Performance Curves............................................................................... 54 Working Range and Dimensions............................................................................ 56 Working Capacities...................................................................................... 59 Bucket Capacity..................................................................................... 59 Tipping Load........................................................................................ 59 Material Weight......................................................................................... 59 Approximate Weight of Workload Materials............................................................ 59 Specifications.................................................................................................. 63 General Maintenance............................................................................................. 65 General Maintenance Procedures S0302000..................................................................... 67 Welding Precautions and Guidelines...................................................................... 69 Hydraulic System General Precautions.................................................................. 70 Maintenance Service and Repair Procedure................................................................ 71 General Precautions................................................................................. 71 Hydraulic System Cleanliness and Oil Leaks.............................................................. 72 Maintenance Precautions for Hydraulic System Service................................................ 72 Oil Leakage Precautions............................................................................. 72 Cleaning and Inspection................................................................................. 73 General Guidelines.................................................................................. 73 Bearing inspection.................................................................................. 74 Normal Bearing.................................................................................. 75 Bent Cage....................................................................................... 75 Galling......................................................................................... 75 Abrasive Step Wear.............................................................................. 76 Etching......................................................................................... 76 Misalignment.................................................................................... 76 Indentations.................................................................................... 76 Fatigue Spalling................................................................................ 77 Brinelling...................................................................................... 77 Cage Wear....................................................................................... 77 Abrasive Roller Wear............................................................................ 77 Cracked Inner Race.............................................................................. 78 Smears.......................................................................................... 78 Frettage........................................................................................ 78 Heat Discoloration.............................................................................. 79 Stain Discoloration............................................................................. 79 Standard Torques S0309000................................................................................... 81 Torque Values for Standard Metric Fasteners............................................................. 83 Torque Values for Standard U.S. Fasteners............................................................... 84 Type 8 Phosphate Coated Hardware........................................................................ 86 Torque Values for Hose Clamps........................................................................... 87 Torque Values for Split Flanges......................................................................... 88 Torque Wrench Extension Tools........................................................................... 89 Torque Multiplication............................................................................... 89 Other Uses for Torque Wrench Extension Tools........................................................ 90 Tightening Torque Specifications (Metric)........................................................... 90 I. "Loctite" Fastener Adhesives................................................................. 91 II. "Loctite" Pipe Thread Sealant............................................................... 91 III. "Loctite" gasket/flange sealer............................................................. 91 IV. "Loctite" retaining compounds............................................................... 92 V. "Loctite" Adhesives.......................................................................... 92 Upper Structure................................................................................................. 93 Counterweight S0403030K..................................................................................... 95 Specifications.......................................................................................... 97 Counterweight........................................................................................... 97 Fuel Transfer Pump S0405500................................................................................. 99 General Description.....................................................................................101 Theory of Operation.................................................................................101 Troubleshooting.........................................................................................102 Replacement of Rotor and Vane...........................................................................102 Replacement of Rear Cover...............................................................................103 Replacement of Armature.................................................................................104 Hydraulic Oil Tank S0406055.................................................................................105 General Description.....................................................................................107 Parts List..........................................................................................107 Specifications......................................................................................108 Lower Structure and Chassis.....................................................................................109 Center Joint (Articulation Joint) S0502030K.................................................................111 General Description.....................................................................................113 Maintenance Standard................................................................................114 Engine and Drive Train..........................................................................................117 Front Axle (ZFMTL 3095) S0602250..........................................................................119 General Description.....................................................................................123 Outline.............................................................................................123 Drive Axle..........................................................................................123 Axle Mount......................................................................................123 Differential........................................................................................126 Differential Operation..........................................................................126 Limited Slip Differential Cross Section.........................................................126 Lubrication Instructions............................................................................128 Oil Drain.......................................................................................129 Oil Filling.....................................................................................129 Check...........................................................................................129 Oil Change Intervals............................................................................129 Oil Level Check.................................................................................129 Bleeders........................................................................................129 Brake...........................................................................................129 Brake Bleeding at Vehicle.......................................................................129 Make Wear Measurement on Multidisk Brake............................................................130 Wear measurement Multidisk brake..............................................................130 Inscriptions On Model Identification Plate..........................................................131 Torque Limits for Screws............................................................................132 Torque Limits for Screws (In Nm) According to ZFStandards 148..................................132 Examples of Gear Tooth Contact Patterns for the Gleason Geartooth System...........................133 Special Tool............................................................................................136 List of Special Tools for Disassembly and Reassembly................................................136 ZFMultitrac Rigid Axle MTL 3095.......................................................................145 Disassembly of Output and Brake.....................................................................145 Reassembly of Output and Brake......................................................................154 Disassembly of Differential Carrier and Brake Tubes.................................................167 Disassembly of Differential Carrier.............................................................167 Disassembly of Limited Slip Differential........................................................170 Disassembly of Drive Pinion.....................................................................172 Disassembly of Brake Tubes......................................................................174 Reassembly of Brake Tubes and Differential Carrier..................................................175 Reassembly of Oil Pipes.........................................................................175 Reassembly of Differential Carrier..............................................................178 Determine Shim Thickness for Tooth Contact Pattern..............................................178 Install Drive Pinion............................................................................179 Reassemble of Limited Slip Differential.........................................................183 Determine Disk Clearance 0.2 0.8mm...........................................................185 Adjustment of Backlash and Bearing Preload......................................................188 Parking Brake...........................................................................................191 Functional Characteristics and Maintenance Instructions for Springloaded Sliding Caliper Brakes....191 1. Functional Characteristics of Springloaded Sliding Caliper Brakes...............................191 2. Mounting and Basic Setting Regulations...........................................................192 3. Adjusting Regulations............................................................................192 4. Emergency Release of Parking Brake...............................................................192 5. Maintenance and Repair Work......................................................................193 Maintenance and Exchange of Brake Pads..........................................................193 Changing the Seal...............................................................................194 6. General..........................................................................................194 Rear Axle (ZFMTL 3085) S0602260...........................................................................195 General Description.....................................................................................199 Outline.............................................................................................199 Drive Axle..........................................................................................199 Axle Mount......................................................................................199 Differential (Standard).............................................................................202 Differential Operation..........................................................................202 Limited Slip Differential Cross Section.........................................................202 Lubrication Instructions............................................................................204 Oil Drain.......................................................................................205 Oil Filling.....................................................................................205 Check...........................................................................................205 Oil Change Intervals............................................................................205 Oil Level Check.................................................................................205 Bleeders........................................................................................205 Brake...........................................................................................205 Brake Bleeding at Vehicle.......................................................................205 Make Wear Measurement on Multidisk Brake............................................................206 Wear Measurement of Multidisk Brake.............................................................206 Inscriptions on Model Identification Plate..........................................................207 Torque Limits for Screws............................................................................208 Torque Limits for Screws (In Nm) According to ZFStandards 148..................................208 Examples of Gear Tooth Contact Patterns for the Gleason Geartooth System...........................209 Special Tool............................................................................................212 List of Special Tools for Disassembly and Reassembly................................................212 ZFMultitrac Rigid Axle MTL 3085.......................................................................222 Disassembly of Output and Brake.....................................................................222 Reassembly of Output and Brake......................................................................231 Disassembly of Differential Carrier and Brake Tubes.................................................244 Disassembly of Differential Carrier.............................................................244 Disassembly of Limited Slip Differential........................................................247 Disassembly of Drive Pinion.....................................................................249 Disassembly of Brake Tubes......................................................................251 Reassembly of Brake Tubes and Differential Carrier..................................................252 Reassembly of Brake Tubes.......................................................................252 Reassembly of Differential Carrier..............................................................255 Determine Shim Thickness for Tooth Contact Pattern..............................................255 Install Drive Pinion............................................................................256 Reassemble of Limited Slip Differential.........................................................260 Determine Disk Clearance 0.2 0.8mm...........................................................262 Adjustment of Backlash and Bearing Preload......................................................266 Parking Brake Caliper (ZF) S0603001.........................................................................269 Functional Characteristics and Maintenance Instructions.................................................271 Functional Characteristics of Springloaded Sliding Caliper Brakes..................................271 Mounting and Basic Setting Regulations..............................................................272 Adjusting Regulations...............................................................................272 Emergency release of parking brake..................................................................272 Maintenance and Repair Work.........................................................................273 Maintenance and Exchange of Brake Pads..........................................................273 Changing Seal...................................................................................274 General.............................................................................................274 Air Conditioner S0605050K...................................................................................275 General Description.....................................................................................277 Refrigerant Circulation.................................................................................278 Control Panel...........................................................................................280 Control Specifications..................................................................................281 Temperature Level Control and Display...................................................................282 Air Discharge According to Path Selection...............................................................283 Vent................................................................................................283 Foot................................................................................................284 Defroster...........................................................................................285 Airconditioning System Circuit Diagram.................................................................286 Troubleshooting.........................................................................................288 Refrigerant Pressure Check..........................................................................288 Weight of R134a Gas Used In Machines....................................................................291 Refrigerant System Repairs..............................................................................293 Refrigerant Safe Handling Procedures................................................................293 Repair and Replacement Procedure....................................................................294 Refrigerant Recovery................................................................................296 Vacuuming Refrigerant System........................................................................296 Leakage Check.......................................................................................298 Refrigerant Charging................................................................................298 Inspecting System for Leakage.......................................................................300 Transmission and Torque Converter (ZF4WG210) S0607090K....................................................301 Drive Train Description.................................................................................306 Transmission and Torque Converter.......................................................................308 Powershift Transmission.............................................................................309 Transmission Control................................................................................309 Schedule of Measuring Points and Connection 4 WG210................................................311 Oil Circuit Diagram 4WG210 Forward 1st Speed.......................................................313 Transmission Electrical Components......................................................................316 TCU (Transmission Control Unit).....................................................................317 Transmission Control Valve..........................................................................318 Transmission Oil Temperature Sensor.................................................................318 Engine Pickup Sensor................................................................................319 Central Gear Pickup Sensor..........................................................................319 Turbine Pickup Sensor...............................................................................319 Output Speed Sensor.................................................................................320 Shift Lever Switch (DW3)...........................................................................320 Auto Selector Switch................................................................................322 Display.............................................................................................322 Transmission Faults Codes...............................................................................323 Fault Display.......................................................................................323 CAN Message.......................................................................................323 Description of Fault Codes..........................................................................323 Abbreviations.......................................................................................324 Definition of Operation Modes.......................................................................324 Normal..........................................................................................324 Substitute Clutch Control.......................................................................324 Limphome.......................................................................................324 Transmission Shut Down..........................................................................324 TCU Shut Down...................................................................................324 Table of Fault Codes................................................................................325 Measurement of Resistance at Actuator/sensors and Cable.............................................325 Actuator........................................................................................325 Cable...........................................................................................325 Transmission Electrical Circuits........................................................................326 Transmission Controller Circuit.....................................................................326 Traveling Circuits..................................................................................328 Neutral.........................................................................................328 Forward First Gear..............................................................................329 Forward Second Gear.............................................................................330 Forward Third Gear..............................................................................331 Forward Fourth Gear.............................................................................332 Reverse First Gear..............................................................................333 Reverse Second Gear.............................................................................334 Reverse Third Gear..............................................................................335 Kickdown...........................................................................................336 Overview........................................................................................336 Kickdown: Forward Second Gear to Forward First Gear (Auto Selector Switch "O" Manual Mode)....338 Kickdown (Auto Selector Switch "I" Auto Mode)................................................340 Transmission Cutoff.................................................................................341 LIS (Load Isolation System) Option................................................................343 Installation View (S/N 1001 thru 2000)..................................................................346 Inner Section.......................................................................................346 Front View..........................................................................................347 Front View with Disk Brake..........................................................................348 Side View...........................................................................................349 Side View with Disk Brake...........................................................................350 Rear View...........................................................................................351 Rear View with Disk Brake...........................................................................352 Installation View (S/N 2001 thru 3000, 3001 and Up).....................................................353 Inner Section.......................................................................................353 Front View..........................................................................................354 Front View with Disk Brake..........................................................................355 Side View...........................................................................................356 Side View with Disk Brake...........................................................................357 Rear View...........................................................................................358 Rear View with Disk Brake...........................................................................359 Special Tools...........................................................................................360 Gearshift System....................................................................................360 Engine Connection...................................................................................362 Pressure Oil Pump...................................................................................363 Gearbox Housing.....................................................................................364 Input...............................................................................................366 Coupling............................................................................................367 Output..............................................................................................373 Power Takeoff......................................................................................374 Hydraulic Control Unit (HSG94).........................................................................375 Disassembly.........................................................................................377 Reassembly..........................................................................................380 Transmission Disassembly................................................................................386 Hydraulic Control Unit (HSG94) and Duct plate......................................................386 Engine Connection Converter.......................................................................387 Hydraulic Pump......................................................................................389 Converter Back Pressure Valve.......................................................................390 Remove Output, Input and Clutches...................................................................391 Disassemble Clutch KV and KR......................................................................396 Disassemble Clutch K1, K2 and K3..................................................................399 Disassemble Clutch K4.............................................................................401 Disassemble Drive Shaft.............................................................................402 Transmission Reassembly.................................................................................404 Install Oil Tube....................................................................................404 Reassemble Clutch KV and KR.......................................................................406 Reassemble Clutch K1, K2 and K3...................................................................412 Reassemble Clutch K4..............................................................................419 Preassemble Drive Shaft.............................................................................426 Preassemble and Install Output......................................................................427 Install Preassembled Drive Shaft and Clutches.......................................................429 Install Pump Shaft (Power Takeoff).................................................................432 Install Output Flanges..............................................................................434 Converter Back Pressure Valve.......................................................................435 Oil Feed Housing Transmission Pump................................................................435 Engine Connection Converter.......................................................................437 Converter Safety Valve..............................................................................440 Mount Duct Plate and Hydraulic Control Unit.........................................................440 Install Plugs and Oil Level Tube....................................................................441 Speed Sensor and Inductive Transmitters.............................................................442 Transmission Error Codes (ZF) S0607900C.....................................................................445 Introduction............................................................................................448 Abbreviations...........................................................................................448 Display.................................................................................................448 Description of Fault Codes..........................................................................449 Display During Operation................................................................................450 Definition of Operating Modes...........................................................................452 Normal..............................................................................................452 Substitute Clutch Control...........................................................................452 Limphome...........................................................................................452 Transmission shut Down..............................................................................452 TCU Shut Down.......................................................................................452 Clutch Pack and Solenoid Valve Crossreference Table....................................................453 Table of Fault Codes....................................................................................454 Table of Fault Codes ERGOControl.....................................................................476 Measurement of Resistance at Actuator/ sensors and Cable................................................479 Actuator............................................................................................479 Cable...............................................................................................479 Hydraulics......................................................................................................481 Accumulator S0703000........................................................................................483 General Description.....................................................................................485 Specifications......................................................................................486 Accumulator Charging....................................................................................489 Charging the Accumulator with Nitrogen..............................................................489 Cylinders S0705005K.........................................................................................491 General Description.....................................................................................494 Theory of Operation.................................................................................495 Parts List..........................................................................................496 Bucket Hydraulic Cylinder.......................................................................496 Lift Hydraulic Cylinder.........................................................................498 Steering Hydraulic Cylinder.....................................................................500 Troubleshooting, Testing and Adjustment.................................................................502 Disassembly.............................................................................................506 Cleaning and Inspection (Wear Limits and Tolerances)....................................................508 Reassembly..............................................................................................509 Fan Drive Hydraulic Motor (Haldex) S0707112.................................................................517 General Description.....................................................................................519 Theory of Operation.................................................................................519 Parts List..........................................................................................521 Specifications......................................................................................522 Main Pump (Denison) S0708485K...............................................................................523 General Description.....................................................................................526 General.............................................................................................526 Description.........................................................................................526 Theory of Operation.................................................................................527 Parts List..........................................................................................530 Specifications......................................................................................532 Special Tools...........................................................................................533 Seal Driver.........................................................................................533 Protective Cone.....................................................................................533 Troubleshooting.........................................................................................534 Overhaul................................................................................................536 General.............................................................................................536 Changing Rotation...................................................................................537 Changing Cartridges.................................................................................538 Changing Port Locations.............................................................................538 Changing Shaft or Shaft Seal........................................................................539 Disassembly of Pump.................................................................................540 End Cap.........................................................................................540 Shaft End.......................................................................................541 Shaft...........................................................................................541 Reassembly of Pump..................................................................................541 Shaft End.......................................................................................541 Center Housing and "D" Unitized Cartridge (P1)..................................................542 "C" Unitized Cartridge (P2) and End Cap.........................................................542 Unitized Pumping Cartridges.....................................................................543 Disassembly of "C" Cartridge........................................................................544 Reassembly of "C" Cartridge.........................................................................545 Disassembly of "D" Cartridge........................................................................546 Reassembly of "D" Cartridge.........................................................................547 Installation............................................................................................548 Mounting............................................................................................548 Piping..............................................................................................548 Fluids..............................................................................................549 Type............................................................................................549 Antiwear Additives..............................................................................549 Non Petroleum Base or Fire Resistant Fluids.....................................................549 Operating Temperature...........................................................................549 Pump inlet Conditions...........................................................................550 Startup Procedures.....................................................................................551 Prestart Check......................................................................................551 Priming.............................................................................................551 Brake Pedal Valve S0709250K.................................................................................553 General Description.....................................................................................555 Theory of Operation.................................................................................555 Specification.......................................................................................556 Brake System (S/N 1001 thru 2000).......................................................................557 Brake System (S/N 2001 thru 3000, 3001 and Up)..........................................................558 Brake, Pilot and Fan Motor Supply Valve.................................................................560 S/N 1001 thru 3000..................................................................................560 S/N 3001 and Up.....................................................................................561 Hydraulic Circuit.......................................................................................562 S/N 1001 thru 2000..................................................................................562 S/N 2001 thru 3000, 3001 and Up.....................................................................562 Specifications..........................................................................................563 S/N 1001 thru 2000..................................................................................563 S/N 2001 thru 3000, S/N 3001 and Up.................................................................563 Main Control Valve (Toshiba) S0709456K......................................................................565 General Description.....................................................................................567 Specifications..........................................................................................569 Operation...............................................................................................570 Neutral.............................................................................................570 Bucket/option Spool Operation.......................................................................570 Boom Spool Operation................................................................................571 Boom Float......................................................................................571 Relief Valve........................................................................................571 Main Relief Valve...............................................................................571 Port Relief Valve...............................................................................571 Operation (Main Relief Valve).......................................................................572 Operation in Inoperative State..................................................................572 Operation (A)...................................................................................572 Operation (B)...................................................................................572 Operation (Port Relief Valve).......................................................................573 In the Inoperative State........................................................................573 Operation (A)...................................................................................573 Operation (B)...................................................................................573 Operation (C)...................................................................................574 Sucking Operation...............................................................................574 Pilot Control Valve S07094775...............................................................................575 General Description.....................................................................................577 Pilot Valve Operation...............................................................................577 Mono Lever..........................................................................................578 Pilot System............................................................................................580 Pilot Control Valve (FNR) S07094776.........................................................................583 Joystick Valve Assembly.................................................................................585 HRC6 LV...............................................................................................587 Dual Axis Section...................................................................................588 Single Axis Section.................................................................................589 Dual Axis: Actuation Components and Flange......................................................590 Single Axis: Actuation Components and Flange....................................................591 Spring capsule assemblies and joint plate.......................................................592 Valve Body, Bushing Assembly and Shuttle Valve..................................................593 EHPS (Electric Hydraulic Power Steering) S0709715...........................................................595 Steering Control System.................................................................................598 EHPS Valve..........................................................................................598 Description of operation of EHPS with integrated priority valve.................................599 Steering Spool at Neutral Position..................................................................600 Steering Spool Operated.............................................................................601 1. Turning Left.................................................................................601 2. Turning Right................................................................................602 Pressure Reducing Valves............................................................................603 Pilot Relief Valve..............................................................................604 Function................................................................................................605 Picture of Components in the EHPS...................................................................605 Power Steering Unit S0709735................................................................................607 General Description.....................................................................................609 Steering Unit.......................................................................................609 Function............................................................................................609 Exploded View of a Steering Unit................................................................610 Restriction Valve S0709751K.................................................................................611 General Description.....................................................................................613 Theory of Operation.................................................................................613 UNLOADING CIRCUIT (S/N 1001 thru 2000)..............................................................614 UNLOADING CIRCUIT (S/N 2001 thru 3000, 3001 and Up).................................................615 Unloader Cartridge Identification (S/N 1001 thru 2000)..............................................616 Unloader Cartridge Identification (S/N 2001 thru 3000, 3001 and Up).................................617 Specifications......................................................................................618 Hydraulic Schematic (Mega 300V) S0793070K..................................................................619 General Description.....................................................................................621 Mega 300V (Tier I) (S/N 1001 thru 2000)................................................................622 Mega 300V (Tier II) (S/N 2001 thru 3000)...............................................................624 Mega 300V (S/N 3001 and Up)............................................................................626 Electrical System...............................................................................................629 Electrical System S0802205K.................................................................................631 Overview................................................................................................635 Electric Wire Color.................................................................................635 Electric Supply System..................................................................................636 Engine Starting Circuit.................................................................................638 Operation During Start Process......................................................................638 Operation After Start Process.......................................................................640 Engine Preheating System (S/N 1001 thru 2000)...........................................................642 Principle of Operation..............................................................................642 Engine Preheating System (S/N 3001 and Up)..............................................................644 Principle of Operation..............................................................................644 Engine Stop System......................................................................................646 Operation In Engine Running Mode....................................................................646 Operation In Engine Stop Mode.......................................................................648 Charging System.........................................................................................650 Monitoring System.......................................................................................651 Monitoring System (S/N 1001 thru 2000)..............................................................651 Instrument Panel (S/N 1001 thru 2000)...............................................................652 Function Check (S/N 1001 thru 2000).................................................................653 Monitoring System Schematic (S/N 1001 thru 2000)....................................................654 Monitoring System (S/N 3001 and Up).................................................................656 Instrument Panel (S/N 3001 and Up)..................................................................657 Function Check (S/N 3001 and Up)....................................................................658 Monitoring System Schematic (S/N 3001 and Up).......................................................658 Operation...........................................................................................660 Instruments.....................................................................................660 Indicator Lights................................................................................661 Initial Operation...............................................................................663 Control Unit Operation..........................................................................663 Characteristic of Operation.....................................................................665 Windshield Wiper........................................................................................666 Front windshield wiper..............................................................................666 Front Windshield Wiper Circuit..................................................................666 Rear Windshield wiper...............................................................................667 Lighting System.........................................................................................670 Light Circuit (S/N 1001 thru 2000)..................................................................670 Light Circuit (S/N 3001 and Up).....................................................................674 Emergency Steering System (Option)......................................................................678 Block Diagram.......................................................................................678 Emergency Steering System Components................................................................679 Emergency Steering Timer........................................................................679 Emergency Steering Pump.........................................................................680 Emergency Steering Switch.......................................................................680 Emergency Steering System Electric Circuit..........................................................681 Electric Detent System..................................................................................682 Electric Circuit....................................................................................682 Boom Kickout.......................................................................................682 Return To Dig.......................................................................................683 Proximity Switch................................................................................683 Electrical Schematic (Mega 300V) S0893070K.................................................................685 General Description.....................................................................................687 Mega 300V..............................................................................................688 Attachments.....................................................................................................691
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