Operation & Maintenance - M400-III

S0602080
1REAR AXLE
(GRAZIANO)
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 are in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
REAR AXLE (GRAZIANO)S0602080

MODEL SERIAL NUMBER RANGE
Mega 400-III 0001 and Up
Mega 400-III PLUS 1001 and Up
Copyright DOOSAN 1999

February 1999
Rear Axle (Graziano) S0602080

Page 1
TABLE OF CONTENTS
General Description........................................................................................ 4
Outline..................................................................................................... 4
When Moving Straight Forward............................................................... 5
When Slowing ......................................................................................... 5
Parts List ................................................................................................. 6
Rear Axle ......................................................................................... 6
Rear Axle Housing ........................................................................... 7
Rear Axle Differential ....................................................................... 8
Rear Axle Planetary Gear Set ....................................................... 10
Scheduled Maintenance............................................................................... 12
After First 200 Hours ............................................................................. 12
Every 150 hours .................................................................................... 13
Every 1,500 Hours ................................................................................ 13
Lubricant Specifications ........................................................................ 13
General Disassembly and Reassembly Instructions .................................... 14
General Instructions .............................................................................. 14
Assembling Leakproof Components ..................................................... 15
Axle Disassembly ......................................................................................... 15
Drain Oil ................................................................................................ 15
Final Drive ............................................................................................. 16
Differential Assembly............................................................................. 20
Overhauling Super Max Trac Assembly ................................................ 22
Checking Clearance on Assembled Disk Packs.................................... 23
Axle Reassembly.......................................................................................... 24
Determining Thickness of Adjustment Shims........................................ 24
Axial Position of Bevel Pinion ................................................................ 25
Adjusting Backlash................................................................................ 26
Adjusting Tooth Contact ........................................................................ 27
Correct Pattern............................................................................... 27
Increase Pinion Distance ............................................................... 27
S0602080 Rear Axle (Graziano)

Page 2
Decrease Pinion Distance.............................................................. 28
Securing Differential to Axle Housing.................................................... 29
Final Drive ............................................................................................. 30
Determining Space Available to Form Brake Disk Pack........................ 32

Page 3
GENERAL DESCRIPTION
Figure 1
OUTLINE
• The motive force from engine is
transmitted to front and rear axles via
torque converter, transmission, and
drive shaft.
• In the axle, motive force is
transmitted from pinion gear (1) to
bevel gear (2), shifted 90° and
reduced, and transmitted to sun gear
shaft (3) via differential gear (4).
• Motive force of sun gear is further
reduced by planetary gear type final Figure 2
drive, and transmitted to axle shaft
and wheel.

Page 4
WHEN MOVING STRAIGHT FORWARD
• When moving straight forward, the
speed of rotation of left and right
wheels is equal, so pinion gear (5) in
differential assembly does not rotate,
and motive force of carrier (6) is
transmitted equally to left and right
sun gear shaft (7) via pinion gear (5)
and side gear (8).
Figure 3
WHEN SLOWING
• When slowing, the speed of rotation
of left and right wheels is unequal, so
pinion gear (5) and side gear (8) in
differential assembly rotate according
to the difference in left and right
rotation speeds, and motive force of
carrier (6) is transmitted to sun gear
shafts (7).
Figure 4

Page 5
PARTS LIST
Rear Axle
Figure 5
Reference Reference
Description Description
Number Number
1 Differential 3 Planetary Gear Sets
2 Axle Housing

Page 6
Rear Axle Housing
Figure 6
Reference Reference
Number Number
1 Oil Fill Plug - M27 x 2 4 Axle Vent - M10 x 1
2 Oil Drain Plug - M27 x 2 5 Axle Shaft
3 Rear Axle Housing

Page 7
Rear Axle Differential
Figure 7

Page 8
Reference Reference
Number Number
1 Pin - 8 mm dia x 40 mm Shim - 100.0 mm
2 Bearing - 95 x 145 x 32 mm Shim - 0.1025 mm
3 Bearing Adjusting Nut Shim - 1.050 mm
4 Cap Screw - M18 x 1.5 x 45 Shim - 1.075 mm
5 Outer Clutch Disk Shim - 1.100 mm
6 Sun Gear Shim - 1.125 mm
7 Cross Shim - 1.150 mm
8 Planetary Gear Shim - 1.175 mm
9 Thrust Washer Shim - 1.200 mm
10 Middle Clutch Disk Shim - 1.225 mm
11 Cap Screw - Shim - 1.250 mm
M12 x 120 mm Shim - 1.275 mm
12 Shim - 3.00 mm Shim - 1.300 mm
Shim - 3.10 mm Shim - 1.325 mm
14 Plate Shim - 1.450 mm
15 Rivet Shim - 1.475 mm
16 Bearing Shim - 1.500 mm
17 Shim - 3.5 mm 22 Nut
Shim - 3.6 mm 23 Flange
Shim - 3.7 mm 24 Bearing - 30311
Shim - 3.8 mm 25 Seal - 85 mm dia x 120 x 1/
Shim - 3.9 mm 24
Shim - 4.0 mm 26 Washer
Shim - 4.1 mm 110 Differential Support
Shim - 4.2 mm Assembly
Shim - 4.3 mm 120 Ring and Pinion Gear
Assembly
Shim - 4.4 mm
130 Differential Carrier
Shim - 4.5 mm
Assembly
18 Spacer
140 Spacer Assembly
19 Shim - 0.5 mm

Page 9
Rear Axle Planetary Gear Set
Figure 8

Page 10
Reference Reference
Number Number
1 Housing Cover 26 Retaining Ring - 92 mm dia
2 Cover Gasket - 27 Thrust Washer
3.35 mm x 278.99 dia 28 Bearing - 170 mm
3 Shaft Thrust Plate dia x 230 x 38
4 Cap Screw - M10 x 25 29 Ring Gear Support
5 Planetary Housing 30 Ring Gear
6 Pin 31 Wheel Hub
7 Plug - M22 x 1.5 32 Stud Bolt
8 Plug Gasket 33 Piston Seal -
9 Thrust Washer - 1.5 mm 5.33 x 109.5 mm
10 Bearing 34 Piston
11 Bearing Spacer 35 Piston Seal -
5.33 x 133.7 mm
12 Differential Pinion Gear
36 Inner Bearing - 140 mm
13 Thrust Washer - 3.0 mm
dia x 195 x 29
14 Differential Side Gear
* 37 Wheel Seal -
15 Retaining Ring 178 mm x 205 x 20
16 Brake Disk Hub 38 Right Side Hub and Spindle
17 Brake Disk Assembly.
18 Steel Disk - 4.0 mm 39 Bleeder Screw
Steel Disk - 4.25 mm 40 Cap Screw - M8 x 25
Steel Disk - 4.5 mm 41 Housing Seal Ring -
Steel Disk - 5.0 mm 3.53 x 430.66 mm
19 Pin 42 Left Side Hub and Spindle
Assembly
20 Retaining Ring
43 Cap Screw -
21 Pressure Plate
M22 x 1.5 x 70 mm
22 Spring
44 Nut
23 Spring Insert
45 Spacer Ring
24 Lockplate
46 Washer
25 Hub Nut
110 Housing Assembly

Page 11
SCHEDULED MAINTENANCE
Figure 9
AFTER FIRST 200 HOURS

Replace oil in axle assembly as Follows:
1. Differential Unit.
• Remove fill plug (1) and drain oil from drain plug (2)
• Replace drain plug (2) and refill through plug (1) until oil if overflowing.
2. Side Final Drives.
• Position plug (3) at bottom, remove plug and drain oil.
• Refill by rotating hub 90° (so "OIL LEVEL" writing is horizontal) and add oil until it overflows,
replace plug (3).

Page 12
EVERY 150 HOURS
Check oil in axle assembly as Follows:
• With axle positioned horizontal, remove fill plug (1) and check oil level. Oil level should reach
edge of fill plug seat. Add oil as required.
• Check oil by rotating hub 90° (so "OIL LEVEL" writing is horizontal), remove plug (3) and check
oil. Oil should edge of fill plug seat. Add oil as required, replace plug (3).
EVERY 1,500 HOURS

Replace oil in axle assembly as Follows:
replace plug (3).
LUBRICANT SPECIFICATIONS
For differential and final drive units:
• Oil specification: Mil - L - 2105B
API GL 5
• Corresponding to: SAE 90 or SAE 80W90 rating.
NOTE: DOOSAN recommends oils with LIMITED-SLIP (LS) additives to prevent noise when
brakes are actuated.

Page 13
GENERAL DISASSEMBLY AND REASSEMBLY
INSTRUCTIONS
WARNING!
Never use gasoline, solvents, or other flammable fluids to clean components. Only use
approved commercial solvents that are nonflammable and nontoxic.
IMPORTANT
Use only GENUINE DOOSAN SPARE PARTS to warrant proper operations and prevent
interchangeability problems.
GENERAL INSTRUCTIONS
1. Thoroughly clean and dry axle before disassembly.
2. All components should be thoroughly cleaned and dried before reassembly. Dirt, chips, and foreign
material may cause failures.
3. All ducts and castings should be thoroughly cleaned and dried to remove dirt, chips, and foreign
material to prevent damage after reassembly.
4. Reassembly should be done in a clean shop, and should be as dust free as possible.
5. Make sure tools and equipment are at hand.
6. When reassembling DOOSAN strongly recommends to replace the following parts with new.
• Seal Rings
• O-rings
• Gaskets
• Threaded rings with notched collar
• Any component damaged during disassembly
7. When mounting heat fitted components, make sure of their proper position and direction of assembly,
after they have cooled.
8. To heat bearings, use proper heating plates, piping, or suitable ovens.
NOTE: Never heat parts by using a torch. Oil bath, heated by a torch, maybe used to warm
components.
9. Lubricate all sections concerned when reassembling shafts, bearings, etc.
10. Lubricate O-rings before installing them in relevant seats to prevent kinking during assembly, such a
position would impair proper sealing.
11. Replace gears only in matched sets to make sure of proper tooth mating.

Page 14
ASSEMBLING LEAKPROOF COMPONENTS
1. Use of proper sealing compounds is recommended when assembling matched parts to be sealed
against fluid leakage (oil or water), and no sealing gasket is used.
2. Best results are reached, with said compounds, when matching surfaces are thoroughly cleaned,
degreased, and dried before spreading a uniform coat over contact area.
3. DOOSAN suggests to use the following compounds:
• Loctite Plastic Gasket
• Rhodorsil CAF 1
• Silastic 732 RTV
AXLE DISASSEMBLY
Figure 10
DRAIN OIL

Page 15
FINAL DRIVE
Figure 11

Page 16
WARNING!
Lift and handle all heavy components by using proper equipment. Make sure that assemblies or
components are lifted and held with the use of proper slings and hooks. Use specific lifting
eyes. Always make sure that people are out of the way when lifting.
1. Remove six cover mounting screws (1), then remove final drive cover (2).
NOTE: Cover (2) is provided with three threaded holes for puller screws.
2. Remove O-ring (3).
3. Using a puller screw, remove axle shaft backing plate (4).
4. Provide suitable support for side gear carrier (6), then remove screws (5) fixing side gear carrier to
wheel hub (7), and pry side gear carrier (6) to separate from wheel hub (7).
5. Pull side gear carrier (6) out of wheel hub.
6. Remove lock ring (9) retaining sun gear (10), and remove sun gear from wheel shaft (14).
7. Remove disk carrier hub (11) along with thrust washer (12) resting against wheel hub sleeve.
8. Remove solid and lined brake disks (13).
9. Remove wheel shaft (14).
10. Remove lock ring (15) securing lock (16), then remove ring nut (17).

Page 17
Figure 12
Spring Retainer Installed

A Spring Retainer
17 Ring Nut
18 Pressure Plate
19 Return Spring
NOTE: Install a spring retainer (A), secured thru three threaded holes of disk pressure plate (18),
to compress return spring (19) and allow removal of ring nut (17).
11. Unlock and remove ring nut (17) from sleeve (27).
12. Remove pressure plate (18) along with brake return spring retainer (A).
13. Provide suitable support for wheel hub (7) and pull ring gear unit (21) and support (22) from hub.
14. Remove six rods (24) in seats on ring gear support (22).
15. Using a screwdriver, pry off lock ring (23) from ring gear (21).
16. Disassemble ring gear support (22) from ring gear (21).
NOTE: Should replacement of outer wheel bearing (25) inner race be mandatory, old part can be
removed by a proper puller, or by a remover that can be inserted in specific holes of ring
gear support (22).
17. Remove brake return spring retainer (A) and disassemble return spring (19), retaining cup (20), and
pressure plate (18).

Page 18
18. Using compressed air thru brake oil port, remove brake actuating piston (26) from wheel hub sleeve
(27).
19. Remove and replace with new two O-rings (28 and 29) in seats on brake actuating piston.
20. Remove complete wheel hub (7)
22. Pry off seal (30) from wheel hub (7), and remove inner race with roller cage of inner wheel bearing
(31).
23. Using a proper remover, push out outer races of inner and outer wheel bearings (25 and 30) from
wheel hub (7).
NOTE: Should sleeve (27) be damaged, it can be removed by undoing relevant screws (32). At
reassembly, smear proper sealing compound on axle case joining flange, then tighten
screws. Torque to 90 ±4.5 Nm (9.18 ±0.46 kg•m / 66 ±3 ft lb)
24. Mark side gear pins (33), various components and seats (34) for identification of original position at
reassembly.
25. Arrange side gear carrier (6) on wooden blocks and push out pins (33) with proper remover.
26. Pick up all needle rollers (35).
NOTE: It is important to keep matched needle rollers (35) and thrust washers (36) with relevant
pin (33), this is consequent to predetermined assembly tolerance limits.
27. Remove side gears (37) and relevant thrust washers (38).
NOTE: No gear can be removed before having released all of them.

Page 19
DIFFERENTIAL ASSEMBLY
Figure 13
1. Remove screws (1) retaining differential assembly, then remove differential assembly from axle case.

Page 20
Figure 14
2. Hammer out spring pins (2) locking slotted rings (3).

3. Mark caps (4) to match parts at reassembly.
4. Remove screws (5), caps (4), and slotted rings (3).
5. Remove differential case assembly from support (11).
6. Straighten locking notches on pinion nut collar (6), position reaction tool on drive flange to unlock nut
(6), release pinion nut, remove drive flange (9) from pinion shank along with washer (8).
7. Pry seal (10) from drive flange.

Page 21
8. Remove bevel pinion (7) from differential support (11), hammer pinion shank with a proper removal
tool.
NOTE: Be careful not to damage threads on pinion (7).
9. Pick up inner race of pinion shank bearing (13).
10. Remove outer races of outer and inner pinion bearings (13 and 14) from differential support (11), pick
up shims (15).
NOTE: Be careful not to loose shims (15) for pinion axial position adjustment, store in a safe place
for reassembly.
11. Remove spacer (16) with shims (17) for bearing preload adjustment, using a proper puller remove
inner race of pinion under head bearing (14).
NOTE: Be careful not to loose shims for bearing preload adjustment, store in a safe place for
reassembly.
12. Mark differential half cases (18 and 19) for reference at reassembly, then remove screws (19a) and
separate half cases (18 and 19).
13. Make a visual and dimensional check of wear on sun gears (21), side gears (20), thrust washers (22
and 23), friction disks (22a), backing disks (22), and spider (24).
14. Using a proper puller, remove bearings (25) from half cases (18 and 19).
15. Clamp ring gear (26) in a vise fitted with soft caps, then remove screws (27) securing ring gear (26) to
half case (18).
16. Fit inner races of differential bearings (25) on half cases (18 and 19)
NOTE: This operation should be carried out by heating equipment or use a proper installer.
17. Mount bevel ring gear (26) on half case (18), secure with screws (27).
NOTE: Torque to 48 ±2.4 Nm (4.89 ±0.25 kg•m / 35 ±2 ft lb).
18. Position differential components in their proper seats.
OVERHAULING SUPER MAX TRAC

ASSEMBLY
1. Select backing disks (22) to reach, as
assembling is completed, prescribed
clearance of 0.05 - 0.10 mm (0.0020 -
0.0039") all around both disk packs.
NOTE: When packing friction and
backing disk, pay particular
care to position of first disk
(22a), it is molybdenum plated
on one side only. Disk (22a) is
in contact with sun gear (21),
and molybdenum plated side Figure 15
must face backing disk (22).
2. Join half cases (18 and 19) matching
reference marks made at disassembly.
3. Mount and secure case halves (18 and 19) with screws (19a).

Page 22
NOTE: Torque to 12 ±0.6 Nm (1.22 ±0.061 kg•m / 8.85 ±0.44 ft lb).
CHECKING CLEARANCE ON ASSEMBLED

DISK PACKS
1. Check should be carried out all around at
points placed at 120° to one another on
both disk packs to prevent mileacting
recording of values due to spider and sun
gear play.
NOTE: Should recorded clearance not
be as specified, disk packs
must be reformed to prescribed
value of 0.05 - 0.10 mm (0.0020
- 0.0039")
Figure 16

Page 23
AXLE REASSEMBLY
DETERMINING THICKNESS OF ADJUSTMENT SHIMS
Figure 17
1. Some dimensions should be recorded before starting reassembly of bevel pinion to determine
thickness of spacer to be fitted between inner (under head) pinion bearing and backing of relevant
seat in differential support.
2. Record dimension from ring gear axis to seat inner (under head) pinion bearing (that will be identified
as "A").
• Example: "A" = 266.1 mm.
3. A number "X" prefix by symbol " ±" is marked on bevel pinion face. This value is expressed in tenth of
millimeter, indicates deviation from theoretical distance from pinion under head to ring gear axis.
• Example: +1 = +0.1 mm.
4. Consequently, the true distance (identified as "B") will be: B = 208 ±deviation.
• Example: B = 208 + 0.1 = 208.1 mm.
5. Measure thickness of pinion head bearing and identify as "D."
• Example: "D" = 54.15 mm.
6. Compute thickness of shim "S" for proper axial position of bevel pinion: S = A - (B + D).
• Example: S = 266.1 - (208.1 + 54.15) = 3.85 mm.
7. Increase by 0.05 mm the computed thickness value to compensate subsequent bearing preload.
Round off to nearest tenth of millimeter to computed thickness value.
• Example: 4.02 rounded off = 4 mm.
3.88 rounded off = 3.9 mm.

Page 24
Figure 18
AXIAL POSITION OF BEVEL PINION

1. Press fit inner race of inner (under head) bearing (14) on pinion by using heating equipment or use of
proper installer.
2. Position shim (15), see "Determining Thickness of Adjustment Shims," in its seat and press fit outer
races of inner (under head) and outer bearings (13 and 14) of pinion.
3. Fit spacer (16) on pinion along with shims (17) for bearing preload adjustment, then mount inner race
of pinion outer bearing (13).

Page 25
NOTE: To facilitate proper preload computation, it is advisable to mount as many shims as
required to warrant a pinion end play and not a preload (that could be excessive) on
bearings.
4. Fit drive flange (9) on pinion (7), position specific reaction tool and tighten nut (6). Remove reaction
tool.
NOTE: Torque from 57 - 63 Nm (5.81 - 6.42 kg•m / 42 - 46 ft lb).
5. Check pinion end play using a dial gauge, then disassemble and change shims to eliminate all end
play and reach intended preload.
6. Reassembly components, check that proper preload of bearing corresponding to a revolving torque
(no seal installed).
NOTE: Revolving torque of 0.20 - 0.40 Nm (0.02 - 0.04 kg•m / 0.15 - 0.30 ft lb).
7. As the prescribed preload of bearings has been reached, remove drive flange (9) and fit lip seal (10)
into its proper seat.
8. Remount drive flange (9) and tighten to specified torque.
9. Position differential assembly with ring gear on support (11), insert ring nut (3), and temporarily adjust
back lash.
10. Mount caps (4), being careful not to invert position, secure support to differential with screws (5).
NOTE: Torque to 620 - 680 Nm (455 - 500 ft lb).
11. Check differential end play with a dial gauge.
12. Screw in a ring nut to have a notch aligned against slot of lockplate, and actuate opposite nut up to
eliminate end play.
NOTE: When end play is eliminated, set bearing preload by screwing in ring nut one more notch.
ADJUSTING BACKLASH
1. Position a dial gauge perpendicular to ring
gear (26) tooth, with pinion steady check
backlash.
• Standard backlash of bevel gear set:
0.15 - 0.20 mm (0.0059 - 0.0079")
• To obtain backlash within specified
range, rotate both ring nuts (3),
displacing them same number of
notches.
• Moving toward ring gear to pinion, if
backlash is too LARGE. Figure 19
• Moving away ring gear to pinion, if

backlash is too SMALL.

Page 26
ADJUSTING TOOTH CONTACT
1. Coat face of 7 or 8 teeth of bevel gear
lightly with red lead. Hold bevel gear by
hand to act as a brake, rotate pinion gear
forward and backward, then inspect
pattern left on teeth.
Correct Pattern
Drive Side.
Figure 20
Neutral Side.
Figure 21
Increase Pinion Distance
Drive Side.
Figure 22
Neutral Side.
Figure 23

Page 27
Decrease Pinion Distance
Drive Side.
Figure 24
Neutral Side.
Figure 25
NOTE: When adjusting bevel gear, do not change preload of bearing. Adjust by rotating both ring
nuts the same number of notches.
2. Fit spring pins (2) to lock differential ring nuts.
3. Make two lock notches on pinion nut collar (6).

Page 28
SECURING DIFFERENTIAL TO AXLE HOUSING
Figure 26
1. Thoroughly clean mating surfaces, apply sealing compound and mount differential assembly on axle
housing, and secure with screws (1).
NOTE: Torque to 33 ±1.65 Nm (3.37 ±0.169 kg•m / 24 ±1 ft lb)

Page 29
FINAL DRIVE
Figure 27

Page 30
1. Reinstall wheel hub (7), first fit outer races of wheel inner and outer bearings (25 and 31), making
sure they rest against seats.
2. Position inner race with roller cage of wheel inner side bearing (31) before fitting lip seal (31).
3. Install O-ring (8).
4. Install wheel inner bearing (31) into sleeve (27).
NOTE: Support wheel hub (7) during assembly stage to prevent damage to seal.
5. Lubricate seals (28 and 29) on piston (26), then insert at travel end on wheel hub sleeve (27).
6. Using heating equipment or proper installer, fit inner race of wheel outer bearing (25) on ring gear
support (22), then mount support (22) in ring gear (21) and secure with lock ring (23).
7. Mount ring gear (21) and support (22) unit onto sleeve (27).
8. Fit six rods (24) into seats on ring gear support (22).
9. Install spring retainer and compress spring (19) with retaining cup (20) onto pressure plate (18).
10. Mount pressure plate and spring assembly onto ring gear support (22).
11. Hand screw ring nut (17) onto wheel hub sleeve (27).
12. With a wrench, tighten ring nut (17) to the prescribed preload for wheel bearings and corresponding
to a revolving torque, checking alignment of lock plates (16).
NOTE: Revolving Torque: 1.5 - 3 Nm (0.15 - 0.31 kg•m / 1.11 - 2.21 ft lb).
NOTE: To prevent recording wrong torque values, it is advisable to seat bearing properly before
checking, by revolving wheel hub repeatedly.
13. Remove spring retainer compressing brake actuator return spring.
14. Insert lock plates (16) securing ring nut and install lock ring (15).
15. Arrange three side gear gears (37) in proper seats of side gear carrier (6).
NOTE: Two rows of needle rollers of same selection class should be used for replacement in each
single side gear pin.
16. Insert outer thrust washers (36), apply grease to pin lower portion (head end) and position the first
row of needle rollers, insert spacer and apply grease to upper portion of pin, then position second row
of needle rollers (35).
17. Position outer thrust washers (38) of side gear on side gear carrier and align holes.
18. Insert and force fit complete pins (33).
NOTE: Avoid any bump or knock that could cause rollers to fall.
19. Insert wheel shaft (14).
20. Insert thrust washer (39).
21. Mount disk carrier hub (11) onto wheel shaft (14).
22. Mount brake disks, alternating solid disks and lined disks. (See "Determining Space Available to
Form Brake Disk Pack").
NOTE: Insert a solid disk (outer teeth) facing pressure plate (12).
23. Insert sun gear (10) and secure with lock ring (9).
24. Mount side gear carrier (6) on side gear unit and secure onto wheel hub (7) with screws (5).
NOTE: Torque to: 7 ±0.35 Nm (0.71 ±0.04 kg•m / 5.16 ±0.26 ft lb).

Page 31
25. Force fit wheel shaft backing plate (4).
26. Mount O-ring seal (3) on edge.
27. Rotate and align pins (33) to allow mounting of cover (2), which also acts as a pin lock to prevent their
rotation.
28. Fit side final drive cover (2).
29. Apply sealing compound to screws (1) and secure cover (2).
NOTE: Torque to 3.5 ±0.175 Nm (0.36 ±0.018 kg•m / 2.58 ±0.129 ft lb).
DETERMINING SPACE AVAILABLE TO

FORM BRAKE DISK PACK
1. Record depth from seating surface of side
gear carrier on wheel hub to outer edge of
ring gear, identify value as "A."
2. Record depth from ring gear outer edge to
brake pressure plate, identify value as "B."
3. Subtract value "B" from value "A" and
identify as value "D."
• Example: A - B = D.
Figure 28
4. Record depth from disk reaction face to
outer edge of side gear carrier, identify
value as "C."
5. Add value "C" to value "D" to provide
space available to form brake disk pack.
• Example: C + D = X
Figure 29
6. To form disk packs, compute thickness of
disk pack (solid disks + lined disks), it is
necessary to subtract clearance of 1 mm
(0.0394") for each brake disk plus the total
thickness of the lined disks from space
available for remaining clearance with solid
disks (outer teeth) of proper thickness with
a tolerance of ±0.25 mm (0.0098").
Figure 30

Page 32
S0607020
R1
1TRANSMISSION AND
TORQUE CONVERTER
(ZF 4WG-260)
CAUTION!
TRANSMISSION AND TORQUE CONVERTER (ZF 4WG-260)S0607020


February 2001
Transmission and Torque Converter (ZF 4WG- S0607020

260) Page 1
TABLE OF CONTENTS
Drive Train Description ................................................................................... 5

Transmission .................................................................................................. 6
Transmission Faults Codes ............................................................................ 7
Fault Display............................................................................................ 7
CAN - Message....................................................................................... 7
Description of Fault Codes ...................................................................... 7
Abbreviations .......................................................................................... 7
Definition of Operation Modes................................................................. 8
Normal ............................................................................................. 8
Substitute Clutch Control ................................................................. 8
Limp-home ....................................................................................... 8
Transmission Shut Down ................................................................. 9
TCU Shut Down ............................................................................... 9
Table of Fault Codes ............................................................................... 9
Measurement of Resistance at Actuator/sensors and Cable .................. 9
Actuator............................................................................................ 9
Cable................................................................................................ 9
Transmission Electrical Circuits.................................................................... 11
T/M Controller Circuit ............................................................................ 11
Traveling Circuits ................................................................................... 12
Neutral ........................................................................................... 12
Forward First Gear ......................................................................... 13
Forward Second Gear.................................................................... 14
Forward Third Gear........................................................................ 15
Forward Fourth Gear ..................................................................... 16
Reverse First Gear......................................................................... 17
Reverse Second Gear.................................................................... 18
Reverse Third Gear........................................................................ 19
Kick-down: Forward Second Gear to Forward First Gear
(Automatic Switch "OFF"- Manual Mode) ...................................... 20
Downshift (Automatic Switch "ON" - Auto Mode)........................... 22
S0607020 Transmission and Torque Converter (ZF 4WG-

Page 2 260)
Transmission Cutoff............................................................................... 24
LIS (Load Isolation System) Option ...................................................... 25
Mechanical Layout 4 WG-260 ...................................................................... 26
Hydraulic Control Unit (HSG-84) .................................................................. 27
Disassembly.......................................................................................... 28
Reassembly .......................................................................................... 31
Transmission Disassembly ........................................................................... 38
Converter-input ..................................................................................... 38
Drive Shaft Pump Power Take-off ......................................................... 41
Transmission Pump............................................................................... 43
Output- Layshaft Assembly ................................................................... 43
Disassemble Clutches and Layshaft Gear ............................................ 48
Disassemble Power Take-off II .............................................................. 49
Disassemble Clutches........................................................................... 50
Clutch - K3/K4................................................................................ 50
Clutch - KR/K2 ............................................................................... 53
Clutch - KV/K1 ............................................................................... 56
Transmission Reassembly............................................................................ 59
Power Take-off II ................................................................................... 59
Clutch K3/K4 ......................................................................................... 61
Clutch K3 ....................................................................................... 61
General Instructions for Plate Installation ...................................... 63
Clutch - K4 ..................................................................................... 67
Clutch KR/K2......................................................................................... 71
Clutch - KV/K1....................................................................................... 79
Install Multidisk Clutches, Layshaft Gear and Output Gear................... 87
Install Filter.......................................................................................... 101
Hydraulic Pump................................................................................... 102
Drive Shaft (Power Take-off Pump) ..................................................... 104
Input - Converter ................................................................................. 107
Converter ............................................................................................ 112
Mount Hydraulic Control Unit (HSG-94).............................................. 113
Inductive Transmitter and Speed Sensor ............................................ 117

260) Page 3
Setting Inductive Transmitter ............................................................... 118
Speed Sensor (Hall Sensor) N Output and Speedometer .................. 120

Page 4 260)
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
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

260) Page 5
TRANSMISSION
The machine contains a powershift transmission that has four forward speeds and three speeds in reverse.
Gear changes are made by an electrohydraulic 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 solenoid valves that direct pressurized fluid to various clutches that control the forward and
reverse gears.

Page 6 260)
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 on 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 fault (special symbols a-h) HBOE630L
in the specified CAN - message, while the fault
is active. Figure 2
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
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
ABBREVIATIONS
Throughout this section the following abbreviations are used to indicate various conditions.
Abbreviations
O.C. Open Circuit
S.C. Short Circuit

260) Page 7
Abbreviations
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.

Page 8 260)
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.
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 3
Cable
UBat
open circuit:
R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞
P (power supply)
short cut to ground: TCU

Actuator /
R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞
1 2
Sensor
short cut to battery: C (chassis)
R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0

Gnd
HBOE650I
Figure 4

260) Page 9
Page 10 260)
TRANSMISSION ELECTRICAL CIRCUITS
T/M CONTROLLER CIRCUIT
4WG-260 TRANSMISSION CONNECTION

FORWARD REVERSE
CLUTCH SOLENOID
1 2 3 4 1 2 3
KV Y5
KR Y1
K1 Y3
K2 Y6
K3 Y4
K4 Y2
LIS SELECT SW
0.85RY 1
5 0.85RW FUSE
7
CONTROL UNIT (21) SAFETY START
RELAY 0.5B 10 9 0.5WR
STARTER CONTROLLER (N) 0.5BrW 87a
30 0.85RL FUSE
87
LIS ASS'Y (OPTION)
0.5B 85 86
LIS SOL-VALVE 0.85RL
0.85LY DISPLAY
(1)
2-4 1-4 0.5BY
0.85RY 30
0.85LY 8 14 0.85WG 2-1 2-3 0.85B
0.85LY 0.85LY 53 23 0.85RW
(2)
68 0.85RW 0.85RW FUSE BATT
0.85BL 57
0.85BR 11 36 0.85RG SPEEDOMETER (4)
SIG.
21 0.85Or PARKING BRAKE SWITCH
0.85R 12 DOWN SHIFT SW
VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
T/M SELECTOR SWITCH DW-3
VALVE ASS'Y Y1 1 0.85YG 10
HSG-94 KICK 1 2 3 4
Y2 2 0.85LW 56 F N R
DOWN STEP STEP STEP STEP
Y3 3 0.85GL 32 45 0.85RL X2-A
VP
Y4 4 0.85WB 55 TRANSMISSION 67 0.85Gr X2-D AD6
Y5 5 0.85GR 9 CONTROLLER 20 0.85BW X1-A AD3
EST-37
Y6 6 0.85WL 51 22 0.85V X1-D AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B
AD4
64 0.85P X2-C AD5
0.85LgR 19
(ENGINE) 0.85Lg 0.85RL
0.85LgW 41 29 0.85W 0.85W

SPEED
PICK-UP (TURBINE) 0.85Lg
66 0.85RY 0.85LB 1 1 (AUTO)
0.85LgB 42
(CENTRAL 5 0.85LY 0.85RL 5
GEAR CHAIN) 0.85Lg 3 7 7 (MANU)
T/M CUT OFF SW 1
1 0.85B 0.5B 10 9 0.5WR 0.5WR 9 10 0.5B

2 0.85YR 62
1 0.85RB 4 2 0.85B
AUTO
T/M CUT OFF SW 2
3 0.85RL SELECT SW
SPEED SENSOR
HBOE010L
Figure 5
The transmission proportioning solenoid valves are shown here as (Y1 thru Y6, Figure 5).

260) Page 11
TRAVELING CIRCUITS
Neutral
SAFETY START
RELAY
CONTROL UNIT (21) 0.5BrW 87a
30 0.85RL FUSE
STARTER CONTROLLER (N) 87
0.5B 85 86
0.85RL
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57
11 36 0.85RG SPEEDOMETER (4)
SIG.

VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
VALVE ASS'Y T/M SELECTOR SWITCH DW-3
Y1 1 0.85YG 10
HSG-94 KICK
Y2 2 0.85LW 56 1 2 3 4
DOWN STEP STEP STEP STEP F N R
Y3 3 0.85GL 32 45 0.85RL X2-A
VP
Y5 5 0.85GR 9 CONTROLLER 20 0.85BW X1-A
EST-37 AD3
Y6 6 0.85WL 51 22 0.85V X1-D
AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B
AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B
AD4
64 0.85P X2-C AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W
SPEED
(TURBINE) 0.85Lg
PICK-UP
0.85LgB 42 66 1 (AUTO)
(CENTRAL 0.85RL 5
GEAR CHAIN) 0.85Lg 3 7 (MANU)
0.5WR 9 10 0.5B
2 0.85YR 62 1 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 0.85RL SELECT SW
SPEED SENSOR
HBOE020L
Figure 6
When all transmission solenoid valves are de-energized (OFF) the transmission is in "NEUTRAL."

Page 12 260)
Forward First Gear
SAFETY START
RELAY
30 0.85RL FUSE
0.5B 85 86
0.85RL
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57
11 36 0.85RG SPEEDOMETER (4) SIG.

VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
Y1 1 0.85YG 10
HSG-94 KICK
Y2 2 0.85LW 56 1 2 3 4
Y3 3 0.85GL 32 45 0.85RL X2-A
VP
EST-37 AD3
Y6 6 0.85WL 51 22 0.85V X1-D
AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B AD4
64 0.85P X2-C AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W
SPEED
(TURBINE) 0.85Lg
PICK-UP
42 66 1 (AUTO)
0.85LgB
(CENTRAL 0.85RL 5
0.5WR 9 10 0.5B
2 0.85YR 62 1 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 0.85RL SELECT SW
SPEED SENSOR
HBOE030L
Figure 7
Transmission solenoid valves (Y3 and Y5, Figure 7) are energized when in forward first gear.

260) Page 13
Forward Second Gear
SAFETY START
RELAY
30 0.85RL FUSE
0.5B 85 86
0.85RL
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57
SIG.

VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
Y1 1 0.85YG 10
HSG-94 KICK
Y2 2 0.85LW 56 1 2 3 4
Y3 3 0.85GL 32 45 0.85RL X2-A
VP
EST-37 AD3
Y6 6 0.85WL 51 22 0.85V X1-D
AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B
AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B
AD4
64 0.85P X2-C AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W
SPEED
(TURBINE) 0.85Lg
PICK-UP
42 66 1 (AUTO)
0.85LgB
(CENTRAL 0.85RL 5
0.5WR 9 10 0.5B
2 0.85YR 62 1 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 0.85RL SELECT SW
SPEED SENSOR
HBOE040L
Figure 8
Transmission solenoid valves (Y5 and Y6, Figure 8) are energized when in forward second gear.

Page 14 260)
Forward Third Gear
SAFETY START
RELAY
30 0.85RL FUSE
0.5B 85 86
0.85RL
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57

VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
Y1 1 0.85YG 10
HSG-94 KICK
Y2 2 0.85LW 56 1 2 3 4
Y3 3 0.85GL 32 45 0.85RL X2-A
VP
EST-37 AD3
Y6 6 0.85WL 51 22 0.85V X1-D
AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B AD4
64 0.85P X2-C AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W
SPEED
(TURBINE) 0.85Lg
PICK-UP
42 66 1 (AUTO)
0.85LgB
(CENTRAL 0.85RL 5
0.5WR 9 10 0.5B
2 0.85YR 62 1 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 0.85RL SELECT SW
SPEED SENSOR
HBOE050L
Figure 9
Transmission solenoid valves (Y4 and Y5, Figure 9) are energized when in forward third gear.

260) Page 15
Forward Fourth Gear
SAFETY START
RELAY
30 0.85RL FUSE
0.5B 85 86
0.85RL
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57
SIG.

VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
Y1 1 0.85YG 10
HSG-94 KICK
Y2 2 0.85LW 56 1 2 3 4
Y3 3 0.85GL 32 45 0.85RL X2-A
VP
EST-37 AD3
Y6 6 0.85WL 51 22 0.85V X1-D
AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B
AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B
AD4
64 0.85P X2-C AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W
SPEED
(TURBINE) 0.85Lg
PICK-UP
42 66 1 (AUTO)
0.85LgB
(CENTRAL 0.85RL 5
0.5WR 9 10 0.5B
2 0.85YR 62 1 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 0.85RL SELECT SW
SPEED SENSOR
HBOE060L
Figure 10
Transmission solenoid valves (Y2 and Y4, Figure 10) are energized when in forward fourth gear.

Page 16 260)
Reverse First Gear
SAFETY START
RELAY
30 0.85RL FUSE
0.5B 85 86
0.85RL
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57

VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
Y1 1 0.85YG 10
HSG-94 KICK
Y2 2 0.85LW 56 1 2 3 4
Y3 3 0.85GL 32 45 0.85RL X2-A
VP
EST-37 AD3
Y6 6 0.85WL 51 22 0.85V X1-D
AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B AD4
64 0.85P X2-C AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W
SPEED
(TURBINE) 0.85Lg
PICK-UP
42 66 1 (AUTO)
0.85LgB
(CENTRAL 0.85RL 5
0.5WR 9 10 0.5B
2 0.85YR 62 1 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 0.85RL SELECT SW
SPEED SENSOR
HBOE070L
Figure 11
Transmission solenoid valves (Y1 and Y3, Figure 11) are energized when in reverse first gear.

260) Page 17
Reverse Second Gear
SAFETYRELAY
START
30 0.85RL FUSE
0.5B 85 86
0.85RL
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57 68 0.85RW 0.85RW FUSE BATT
SIG.

VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
Y1 1 0.85YG 10
HSG-94 KICK 1 2 3 4
Y2 2 0.85LW 56 F N R
Y3 3 0.85GL 32 45 0.85RL X2-A VP
Y5 5 0.85GR 9 CONTROLLER 20 0.85BW X1-A AD3
EST-37
Y6 6 0.85WL 51 22 0.85V X1-D AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B AD4
64 0.85P X2-C
AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W

SPEED
66 1 (AUTO)
0.85LgB 42
(CENTRAL 0.85RL 5
1 0.5WR 9 10 0.5B
2 0.85YR 62 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 0.85RL SELECT SW
SPEED SENSOR
HBOE080L
Figure 12
Transmission solenoid valves (Y1 and Y6, Figure 12) are energized when in reverse second gear.

Page 18 260)
Reverse Third Gear
SAFETY START
RELAY
30 0.85RL FUSE
0.5B 85 86
0.85RL
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57
SIG.

VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
Y1 1 0.85YG 10
HSG-94 KICK
Y2 2 0.85LW 56 1 2 3 4
DOWN STEP STEP F N R
STEP STEP
Y3 3 0.85GL 32 45 0.85RL X2-A
VP
Y4 4 0.85WB 55 TRANSMISSION 67 0.85Gr X2-D
AD6
EST-37 AD3
Y6 6 0.85WL 51 22 0.85V X1-D
AD7
63 0.85L X1-C
AD1
TEMP 8 0.85LB 39 65 0.85G X1-B
AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B AD4
64 0.85P X2-C
AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W
SPEED
66 1 (AUTO)
0.85LgB 42
(CENTRAL 0.85RL 5
0.5WR 9 10 0.5B
2 0.85YR 62 1 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 0.85RL SELECT SW
SPEED SENSOR
HBOE090L
Figure 13
Transmission solenoid valves (Y1 and Y4, Figure 13) are energized when in reverse third gear.

260) Page 19
Kick-down: Forward Second Gear to Forward First Gear
(Automatic Switch "OFF"- Manual Mode)
0.85RL FUSE
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57
SIG.

VPS1 7 0.85R 13 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION TRANSMISSION
VALVE ASS'Y CONTROLLER T/M SELECTOR SWITCH DW-3
Y1 1 0.85YG 10
HSG-94 EST-37 KICK
Y2 2 0.85LW 56 1 2 3 4
DOWN STEP STEP F N R
STEP STEP
Y3 3 0.85GL 32 45 0.85RL X2-A VP
Y4 4 0.85WB 55 67 0.85Gr X2-D AD6
Y5 5 0.85GR 9 20 0.85BW X1-A AD3
Y6 6 0.85WL 51 22 0.85V X1-D AD7
63 0.85L X1-C
AD1
TEMP 8 0.85LB 39 65 0.85G X1-B
AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B
AD4
64 0.85P X2-C
AD5
0.85LgR 19
SPEED 0.85LgW 41 29 0.85W 0.85W

66 0.85RY 0.85LB 1 1 (AUTO)
0.85LgB 42
T/M CUT OFF SW 1
0.5B 10 9 0.5WR 0.5WR 9 10 0.5B

2 0.85YR 62 1 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 T/M CUT OFF SW 2
0.85RL SELECT SW
SPEED SENSOR
HBOE100L
Figure 14
With the automatic switch (Figure 15) "OFF"

and forward second gear selected, if either
downshift switch (Figure 16) is depressed to the
"ON" position, a pulse signal is sent to the
transmission controller terminal (22, Figure 14). OFF
This signal energizes solenoid valves (Y3 and
A
Y5) which shifts transmission from forward

second gear to forward first gear. ON
HBOJ010I
Figure 15

Page 20 260)
When either switch (Figure 16) is depressed a
second time, the transmission pulse signal to
terminal (22, Figure 14) is turned "OFF" and
solenoid valves (Y5 and Y6) are energized and
the transmission returns to forward second gear.
NOTE: If the forward/reverse lever is
moved to or passes through
"NEUTRAL" the kick-down
function is turned "OFF."
Figure 16

260) Page 21
Downshift (Automatic Switch "ON" - Auto Mode)
0.85RL FUSE
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57
VPS1 7 0.85R 13 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION TRANSMISSION
VALVE ASS'Y CONTROLLER T/M SELECTOR SWITCH DW-3
Y1 1 0.85YG 10
HSG-94 EST-37
Y2 2 0.85LW 56 KICK 1 2 3 4
F N R
Y3 3 0.85GL 32 45 0.85RL X2-A
VP
Y4 4 0.85WB 55 67 0.85Gr X2-D AD6
Y5 5 0.85GR 9 20 0.85BW X1-A
AD3
Y6 6 0.85WL 51 22 0.85V X1-D AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B AD4
64 0.85P X2-C AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W

SPEED
66 0.85RY 0.85LB 1 1 (AUTO)
0.85LgB 42
T/M CUT OFF SW 1
0.5B 10 9 0.5WR 0.5WR 9 10 0.5B

2 0.85YR 62 1 0.85B
1 0.85RB 4 2 0.85B
AUTO
T/M CUT OFF SW 2
3 0.85RL SELECT SW
SPEED SENSOR
HBOE110L
Figure 17
With the automatic switch (Figure 15) "ON"

transmission controller terminal (29, Figure 17)
is energized. This allows the transmission to
automatically shift gears depending upon load
and speed. OFF
A
ON
HBOJ011I
Figure 18

Page 22 260)
If either downshift switch (Figure 16) is
depressed to the "ON" position, a pulse signal is
sent to the transmission controller terminal (22,
Figure 17). This signal shifts the transmission to
the next lowest gear.
Automatic
Downshift Switch "ON"
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
Figure 19
When either switch (Figure 16) is depressed a
second time, the transmission pulse signal to
terminal (22, Figure 17) is turned "OFF" and
transmission returns to normal operation.
NOTE: If the forward/reverse lever is moved too or passes through "NEUTRAL" the kick-down
function is turned "OFF."
NOTE: Fourth to third gear changes without any rpm change when switch is pressed.
NOTE: Third to second gear, and second to first gear, changes occur when the rpm is reduced
200 - 300 rpm from current setting.

260) Page 23
TRANSMISSION CUTOFF
CONTROL UNIT (21) SAFETY START

RELAY
STARTER CONTROLLER (N) 0.5BrW 87a
30 0.85RL FUSE
87
0.5B 85 86
0.85RL
DISPLAY
2-4 1-4 0.5BY
30
8 14 0.85WG 2-1 2-3 0.85B
53 23 0.85RW
57
VPS1 7 0.85R 13 0.5Gr 0.85V 0.85WL FUSE
4WG-260 +
TRANSMISSION
Y1 1 0.85YG 10
HSG-94 KICK
Y2 2 0.85LW 56 1 2 3 4
F N R
Y3 3 0.85GL 32 45 0.85RL X2-A VP
EST-37 AD3
Y6 6 0.85WL 51 22 0.85V X1-D AD7
63 0.85L X1-C AD1
TEMP 8 0.85LB 39 65 0.85G X1-B AD2
TEMP 9 0.85Br 46 43 0.85Y X2-B AD4
64 0.85P X2-C AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W

SPEED
42 66 0.85RY 0.85LB 1 1 (AUTO)
0.85LgB
T/M CUT OFF SW 1
2 62 1 0.85B 0.5B 10 9 0.5WR 0.5WR 9 10 0.5B

0.85YR
1 0.85RB 4 2 0.85B
AUTO
T/M CUT OFF SW 2
3 0.85RL SELECT SW
SPEED SENSOR
HBOE120L
Figure 20
When the brake pedal is depressed while

transmission cutoff switch (Figure 21) (T/M
CUTOFF SW2, Figure 20) is "ON," (T/M
CUTOFF SW1) turns "ON" and current is
supplied to the transmission controller terminal OFF
(66). All current being supplied to the
transmission solenoid valves (Y1 thru Y6) is cut
off and the transmission is then in "NEUTRAL."
ON
NOTE: To protect transmission,
transmission cutoff switch does
not function in third and fourth
gears. HBOJ030I
Figure 21

Page 24 260)
LIS (LOAD ISOLATION SYSTEM) OPTION
LIS SELECT SW
0.85RY 1
FUSE
5 0.85RW
7
0.5B 10 9 0.5WR
87a
30 0.85RL FUSE
87
LIS ASS'Y (OPTION)
0.5B 85 86
LIS SOL-VALVE 0.85RL
0.85LY DISPLAY
(1)
2-4 1-4 0.5BY
0.85RY 30
0.85LY 8 14 0.85WG 2-1 2-3 0.85B
0.85LY 0.85LY 53 23 0.85RW
(2)
0.85BL 57
0.85BR 11 36 0.85RG SPEEDOMETER (4) SIG.
DOWN SHIFT SW
0.5Gr 0.85V 0.85WL FUSE
T/M SELECTOR SWITCH DW-3

KICK 1 2 3 4
F N R
45 0.85RL X2-A VP
TRANSMISSION 67 0.85Gr X2-D AD6
CONTROLLER 20 0.85BW X1-A
EST-37 AD3
22 0.85V X1-D AD7
63 0.85L X1-C AD1
65 0.85G X1-B AD2
43 0.85Y X2-B AD4
64 0.85P X2-C AD5
0.85LgR 19
0.85LgW 41 29 0.85W 0.85W

SPEED
42 66 1 (AUTO)
0.85LgB
(CENTRAL 0.85RL 5
1 0.5WR 9 10 0.5B
2 0.85YR 62 0.85B
1 0.85RB 4 2 0.85B
AUTO
3 0.85RL SELECT SW
SPEED SENSOR
HBOE130L
Figure 22
When the LIS selector switch (Figure 23) is

"ON" and the unit is traveling faster than 8 km/h
(4.97 MPH) the LIS solenoids (1 and 2, Figure
22) are energized and the LIS system is "ON."
When the LIS selector switch is "ON" and the OFF
unit is traveling slower than 6 km/h (3.73 MPH)
the LIS solenoids (1 and 2, Figure 22) are de-
energized and the LIS system is "OFF." ON
When the LIS selector switch is "OFF" and the
unit is traveling despite speed, the LIS solenoids
(1 and 2, Figure 22) are de-energized and the
2667C
LIS system is "OFF."
Figure 23

260) Page 25
MECHANICAL LAYOUT 4 WG-260
Figure 1
Reference Reference
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 Electrohydraulic 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

Page 26 260)
HYDRAULIC CONTROL UNIT (HSG-84)
The following illustration shows a sectional view of the HSG-94.
IMPORTANT
Different versions in relation to the position of cable harness are possible.
In this connection, pay attention to the Specifications of the Vehicle Manufacturer.
Figure 2

260) Page 27
Section A - A
Figure 3
DISASSEMBLY
1. Illustration on right shows complete
Control unit.
Figure 4

Page 28 260)
2. Mark installation position of different
covers, housing and cable harness with
valve housing.
Figure 5
3. Loosen socket head screws.
4. Separate duct plate, 1st gasket,
intermediate plate and 2nd gasket from
valve housing.
Figure 6
5. Remove retaining clip.
Figure 7
6. Loosen socket head screws.
7. Separate cover from housing and cable
harness.
Figure 8

260) Page 29
8. Disassemble opposite cover.
9. Disconnect pressure regulator and remove
cable harness.
Figure 9
10. Loosen socket head screws, remove fixing
plate and pressure regulators (3x).
Figure 10
11. Loosen two socket head screws and locate
housing provisionally, using adjusting
screws. (Housing is under spring preload).
Now, loosen remaining socket and screws.
Figure 11
12. Separate housing from valve housing by
loosening adjusting screws uniformly.
Figure 12

Page 30 260)
13. Remove components (Figure 13).
14. Remove opposite pressure regulators,
housing and components accordingly
(Figure 14).
Figure 13
Figure 14
REASSEMBLY
NOTE: Check all components for
damage and renew if
necessary. Before 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 showing upward until
contact is obtained. Figure 15
NOTE: Installation position, see

arrows.

260) Page 31
1. Illustration on left 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 16
Compression Spring)
2. Install components according to Figure 16.

NOTE: Preload compression spring of
the follow on sitie slides and
locate spool provisionally using
cylindrical pins Ø 5.0 mm
(assembly aid), See Figure 17.
Figure 17
3. Install two adjusting screws.
4. Assemble gasket (1, Figure 18) and
housing cover (Figure 18). Now, position
housing cover uniformly, using adjusting
screws, until contact is obtained and
remove cylindrical pins (assembly aid)
again (Figure 18).
NOTE: Pay attention to different
housing covers.
5. Install recess Ø 15 mm (2, Figure 18),
facing spring of pressure reducing valve.
Figure 18

Page 32 260)
Figure 19
6. Fasten housing cover using socket head
screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb)
Figure 20
7. Install pressure regulators and attach
using fixing plates and socket head
screws.
NOTE: Install fixing plate, with claw
showing downward. Pay
attention to radial installation
position of pressure regulators,
see Figure 21.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
Figure 21

260) Page 33
8. Preassemble opposite side.
A. Illustration on left side 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 22
3 Vibration Damper (3x
Spool and
Compression Spring)
B. Install components according to

Figure 22.
C. Preload compression springs of the
follow on slides and locate spool
provisionally using cylindrical pins Ø
5 mm (assembly aid). See arrows.
D. Install two adjusting screws.
E. Assemble gasket (1, Figure 23) and
housing cover, and position them
uniformly against shoulder, using
adjusting screws.
housing covers, install the
recess Ø 19 mm (2, Figure 23),
facing the main pressure valve.
F. Down, fasten housing cover using
socket head screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb). Figure 23
G. Remove cylindrical pins (assembly

aid) again.
H. Install pressure regulators and attach
using fixing plates and socket head
screws.
NOTE: Install fixing plates, with claw
showing downward.
I. Pay attention to radial installation
position of pressure regulators, see
Figure 24.
NOTE: Torque limit 5.5 N.
Figure 24

Page 34 260)
J. Install cable harness and connect
pressure regulators (6x).
NOTE: Pay attention to installation
position of cable harness, see
also markings (Figure 5).
Figure 25
K. Install female connector against
shoulder, with groove facing guide
nose of cover.
L. Install gaskets (Figure 26) and fasten
cover using socket head screws.
Figure 26
M. Install female connector using
retaining clamp, see Figure 27.
N. Install opposite cover.
Figure 27
O. Install two adjusting screws and
mount gasket I.
gaskets, see Figure 28 and
Figure 31.
Figure 28

260) Page 35
9. Intermediate plate-version with screens:
A. Insert screens (6x) flash -mounted
into bore of intermediate plate, see
Figure 29.
position- screens are showing
upward (facing duct plate).
Figure 29
B. Mount intermediate plate, with
screens with screens showing
upward.
Figure 30
C. Mount gasket II.
Figure 31
D. Mount duct plate and fasten it
uniformly using socket head screws.
Figure 32

Page 36 260)
E. Equip screw plugs (8x) with new O-
rings and install them.
NOTE: The installation of hydraulic
control unit is described in
following section, “Mount
Hydraulic Control Unit (HSG-
94)” on page 113.
Figure 33

260) Page 37
TRANSMISSION DISASSEMBLY
1. Fasten transmission on an appropriate
support stand.
Figure 34
2. Disassemble complete shift control,
remove pressure lines and duct plate.
Figure 35
CONVERTER-INPUT
1. Separate torque converter from
transmission, using lifting device.
Figure 36

Page 38 260)
2. Loosen screw connection.
3. Separate bearing cover from converter
bell, using three jacking screws.
Figure 37
4. Pull oil feed flange out of converter bell,
using special device.
Figure 38
5. Remove converter safety valve (composed
of ball, spring and disk.).
Figure 39
6. Separate converter bell from gearbox
housing, using lifting device and pry bar.
Figure 40

260) Page 39
7. Remove shim.
Figure 41
8. Remove rectangular ring (Figure 42)
Figure 42
9. Press drive shaft out of spur gear bearing.
Remove released inner bearing race and
spur gear.
10. If necessary, drive outer bearing race out
of housing bores.
Figure 43
11. Press inner bearing race from drive shaft.
Figure 44

Page 40 260)
12. Remove converter pressure valve.
Figure 45
DRIVE SHAFT PUMP POWER TAKE-OFF
1. Pull complete drive shaft out of gearbox
housing (pump).
Figure 46
2. Remove rectangular ring (Figure 47).
Figure 47
3. Separate spur gear from shaft and
squeeze retaining ring (Figure 48) out.
Figure 48

260) Page 41
4. Pull inner bearing race from spur gear.
Figure 49
5. Loosen socket head screw and remove it
along with clamping plate.
Figure 50
6. Pull inner bearing race and drive from
shaft.
NOTE: Support puller on end face/
drive shaft. Pay attention to
released shims.
Figure 51
7. Separate inner bearing race from driver.
NOTE: Pay attention to released shim.
8. Squeeze retaining rings (3x) out.
Figure 52

Page 42 260)
TRANSMISSION PUMP
1. Tilt gearbox housing 180°.
2. Loosen hex. head screws and remove
both pump flanges.
Figure 53
3. Loosen socket head screws (M8) and
position Puller device.
4. Pull transmission pump out of housing
bore.
NOTE: Tapping housing face is a help
during extraction operation.
Figure 54
OUTPUT- LAYSHAFT ASSEMBLY
1. Loosen screw connection and remove
brake caliper.
Figure 55
2. Unlock and loosen hex. head screws, tap
brake disk loose and separate it from
output shaft.
Figure 56

260) Page 43
3. Pry shaft seal out of housing bore.
Figure 57
4. Tilt gearbox housing.
5. Remove sealing covers (Figure 58)
Figure 58
6. Loosen hex. head screws.
Figure 59
7. Pull idler shaft using puller out of housing
bore.
Figure 60

Page 44 260)
9. Loosen hex. head screws and pull bearing
cover -K1/KV out of housing bore.
Figure 61
10. Loosen hex. head screws and remove
bearing cover KR/K2 and K3/K4.
Figure 62
11. Squeeze rectangular rings (3 pieces/axle)
out, see Figure 63.
Figure 63
12. Squeeze retaining ring and remove
released washers.
Figure 64

260) Page 45
13. Support output flange against gearbox
housing, see Figure 65.
Figure 65
14. Loosen hex. head screws and separate
housing cover from gearbox housing,
using forcing screws and lifting device.
Figure 66
15. Unlock and loosen hex. head screws.
16. Remove output flange and pry shaft seal
out of housing.
Figure 67
17. Loosen hex. head screws and remove oil
baffle.
Figure 68

Page 46 260)
18. Remove output gear along with shaft.
Figure 69
19. Separate output shaft from spur gear.
Figure 70
20. Pull inner bearing race from output gear.
Figure 71
21. Remove plate.
Figure 72

260) Page 47
22. Drive roller bearing out of housing bore
and remove it.
Figure 73
DISASSEMBLE CLUTCHES AND LAYSHAFT
GEAR
1. Remove clutches - K3/K4, KR/K2 and KV/
K1- using lifting device.
NOTE: At the removal of the clutch -
K3/K4, displace clutch - KR/K2
in direction of arrow (Figure 74).
Figure 74
2. Illustration on right shows clutches in
removed condition.
Figure 75
3. Remove layshaft gear.
Figure 76

Page 48 260)
DISASSEMBLE POWER TAKE-OFF II
1. Squeeze retaining ring out and remove
shim(s).
Figure 77
2. Pull PTO shaft using internal puller out of
housing bore until outer bearing race is
released.
Figure 78
3. Take shaft out of housing.
Figure 79
4. Pull inner bearing race from shaft (Figure
80).
5. Press opposite inner bearing race from
shaft.
NOTE: Separation of shaft and gear is
not possible.
Figure 80

260) Page 49
DISASSEMBLE CLUTCHES
Clutch - K3/K4
1. Remove three rectangular rings (Figure
81)
Figure 81
2. Loosen slotted nut.
NOTE: Slotted nut is secured with
Loctite.
To prevent damage of thread,
heat slotted nut before loosen it
(about 120°C).
Figure 82
3. Remove taped roller bearing.
Figure 83
4. Removed flanged disk.
Figure 84

Page 50 260)
5. Remove upper roller bearing.
Figure 85
6. Remove angle ring, squeeze retaining ring
out and remove thrust ring.
Figure 86
7. Press spur gear K3 from plate carrier and
remove released roller bearing.
Figure 87
8. Remove split ring.
Figure 88

260) Page 51
compl. Plate pack K3.
Figure 89
10. Tilt clutch 180°.
NOTE: Slotted nut is secured with
Loctite. To prevent damage of
thread, heat slotted nut before
loosen it (about 120°C)
Figure 90
12. Remove tapered roller bearing.
Figure 91
13. Pull spur gear from plate carrier.
Figure 92

Page 52 260)
14. Remove oil feed ring and pull ball bearing
from plate carrier.
Figure 93
compl. plate pack - K4.
Figure 94
16. Preload compression spring using Special
device. Squeeze retaining ring (Figure 95)
out and remove released components.
17. Now, separate piston from plate carrier,
using compressed air.
18. Disassemble opposite piston accordingly.
Figure 95
Clutch - KR/K2
1. Locate clutch using Special device and
loosen slotted nut.
2. Loosen opposite slotted nut (Figure 96)
accordingly.
NOTE: The slotted nuts are secured
with Loctite heat before loosen
them.
Figure 96

260) Page 53
Figure 97
4. Press spur gear K-2 from shaft.
5. Remove released shim and bush.
Figure 98
Figure 99
7. On opposite side, pull off tapered roller
bearing.
Figure 100

Page 54 260)
8. Pull spur gear KR from shaft.
9. Remove released inner bearing race,
disassemble both outer bearing races and
retaining ring.
Figure 101
10. Remove adjusting ring.
Figure 102
11. Remove tapered bearing (spur gear
bearing).
Figure 103
12. Disassemble plate packs KR and K2 and
compression springs and piston
(accordingly as at clutch K3/K4.
Figure 104

260) Page 55
Clutch - KV/K1
2. Loosen opposite slotted nut (Figure 105)
accordingly.
NOTE: The slotted nuts are secured
with Loctite and require heating
before loosen them.
Figure 105
Figure 106
4. Remove shim.
Figure 107
5. Using a suitable puller remove spur gear
K1.
6. Now, squeeze retaining ring out and drive
ball bearing out of spur gear bore.
Figure 108

Page 56 260)
7. Remove both rings.
Figure 109
8. Using a suitable puller second ball bearing
(spur gear bearing).
Figure 110
9. On opposite side, pull off tapered roller
bearing.
Figure 111
10. Pull spur gear KV from shaft.
11. Remove released inner bearing race,
disassemble both outer bearing race and
retaining ring.
Figure 112

260) Page 57
12. Remove adjusting ring.
Figure 113
13. Remove tapered roller bearing (spur gear
bearing).
14. Now, remove plate pack KV and K1 and
compression springs and piston
(accordingly as at clutch K3/K4.
Figure 114

Page 58 260)
TRANSMISSION REASSEMBLY
POWER TAKE-OFF II
1. Cool shaft down (about 80°C) and heat
gear (about 120°C) and assemble, resp.
press it against shoulder.
Figure 115
2. Press inner bearing race against shoulder.
Press opposite inner bearing race against
shoulder until contract is obtained.
Figure 116
3. Insert outer bearing race (Figure 117) into
housing bore until contact is obtained.
Figure 117

260) Page 59
4. Position preassembled PTO shaft in
housing.
Figure 118
5. Insert outer bearing race until contact is
obtained-bearing must have free play.
Figure 119
6. Adjust PTO bearing free play, using disk(s)
and retaining ring.
Figure 120
8. Insert sealing disk (Figure 121) into
housing bore until contact is obtained.
NOTE: Cover contact surfaces with
Loctite #262).
IMPORTANT
Do not damage centric orifice hole Ø
0.8 mm during installation of sealing
disk. Figure 121

Page 60 260)
CLUTCH K3/K4
1. Install plate carrier using clamping ring(s).
2. Close both bores (Figure 122) using set
screws.
NOTE: Insert set screws with Loctite
#262.
Figure 122
Clutch K3
1. Insert purge valve (Figure 123) until
contact is obtained.
Figure 123
2. Insert both O-rings into ring grooves of
piston, see Figure 124.
Figure 124
3. Oil O-rings and piston race, and insert
piston until contact is obtained.
position of piston, see Figure
125.
Figure 125

260) Page 61
4. Install disk (Figure 126) and compression
spring.
5. Lay guide ring upon compression spring
and assemble retaining ring (Figure 126).
position of guide ring install
chamber (Figure 126) showing
upward.
Figure 126
6. Now, preload compression spring and
install it by engaging retaining ring (Figure
128).
Figure 127
Figure 128

Page 62 260)
General Instructions for Plate Installation
In principle, stacking of outer and inner plates has to be carried out alternately. The piston side has to be
started with a one sided coated outer plate. At clutch-KR and KV, a one sided coated outer plate has to be
additionally installed on the end shim side. The uncoated side must be always installed facing the piston,
resp. the end shim. At plates with different thickness (inner plates), the thinner plates must be installed on
the end shim side.
Number and installation position of plates, see also the corresponding Spare-Parts List. The respective
clutch side can be identified on the length of the plate carrier, see Draft Dimension X.
Install Plate pack - K3, see Draft and Figure 130, EXAMPLE A:
Plate arrangement - K3 (long plate carrier side):
Active number of the friction surfaces = 14.
1 outer plate (one sided coated)
7 outer platess = 2.5 mm
3 inner platess = 3.5 mm
3 inner platess = 3.0 mm
1 inner plate (optional)s = 2.0 - 4.0 mm
Draft:
K4 K3
X
HLA2130L
Figure 129

260) Page 63
1. Install plate pack, mount end shim and
attach it using retaining ring.
Figure 130
2. Check plate clearance - K3 = 2.2 - 2.4 mm
(Figure 131, EXAMPLE A).
A. Determined Dimension I from end
face of plate carrier to end shim.
NOTE: Dimension I, e.g. 2.40 mm
Figure 131
B. Position end shim against retaining
ring (toward upward) until contact is
obtained and determine Dimension
II.
NOTE: Dimension II, e.g. 0.20 mm
EXAMPLE A:
Dimension I 2.40 mm
Dimension II - 0.20 mm
Difference = Plate = 2.20 mm
clearance
Figure 132
IMPORTANT
In case of a deviation from the required plate clearance, correction can be carried out with
corresponding inner plates. (optional s = 2,0 - 4,0 mm) or with different retaining rings
(Figure 130).

Page 64 260)
3. Tilt clutch into horizontal position and
install spur gear K3 until all inner plates
are accommodated.
NOTE: This step will facilitate later spur
gear installation. Now, tilt clutch
again into vertical position and
pull spur gear carefully out of
plate pack.
Figure 133
4. Insert split ring (Figure 134) with grease
into recess.
NOTE: Pay attention to exact contact of
split ring in bottom of recess.
NOTE: Carry out following steps of
Figure 135 and Figure 136
immediately in chronological
order to prevent a cooling down
of heated components.
5. Heat bearing bore of spur gear (Figure
135) and inner bearing race of roller
bearing (Figure 136) to about 120°C. Figure 134
6. Install heated spur gear until all inner
plates are accommodated.
Figure 135
7. Insert heated inner bearing race until
Figure 136

260) Page 65
8. Install disk, lift spur gear slightly and
squeeze retaining ring into annular groove
of spur gear.
Figure 137
9. Install angle ring, with stepped face facing
retaining ring.
Figure 138
10. Install inner bearing race and mount
flanged disk.
NOTE: Install flanged disk, with
chamfer on inner diameter
showing upward.
Figure 139
11. Heat inner bearing race and place it
against shoulder.
Figure 140

Page 66 260)
Clutch - K4
Install purge valve, piston and compression spring accordingly as at clutch K3 (Figure 129).
Install plate pack K4 and check plate clearance.
Plate arrangement K4 (short plate carrier side):
Active number of the friction surfaces = 12
1 inner plates = 3.0 mm
i1 inner plate (optional)s = 2.0 - 4.0 mm
IMPORTANT
Pay attention to the General Instructions for the Plate Installation (See page -63)
Check plate clearance - K4 = 2.2 - 2.4 mm accordingly as at clutch K3 (See page -61).
1. Tilt clutch into horizontal position and install spur gear K4 until all inner plates are accommodated.
NOTE: This step will facilitate the later
reassembly of spur gear.
2. Now, tilt clutch again into vertical position
and pull spur gear carefully out of plate
pack.
Figure 141

260) Page 67
3. Spur gear K4
IMPORTANT
The following steps (Figure 142 thru
Figure 145) are describing
reassembly of spur gear bearing-K4.
Version with ball bearing.
At the version with the tapered roller
bearing, the reassembly has to be
carried out accordingly as at spur
gear-KR. In this connection pay Figure 142
attention to steps of Figure 153 thru
Figure 163.
4. Heat ball bearing and assemble it until

contact is obtained, see Figure 142.
NOTE: Before install the spur gear
(Figure 143), cool ball bearing.
5. Mount Oil feed ring (Figure 143).
Figure 143
IMPORTANT
Carry out steps of Figure 144 and
Figure 145 in immediate sequence, to
prevent a cooling down of the
components. Heat bearing bore of
the spur gear (Figure 144) and ball
bearing (Figure 145) to about 120°C.
6. Install heated spur until all inner plates are

accommodated.
Figure 144

Page 68 260)
7. Insert heated ball bearing until contact is
obtained.
Figure 145
8. Heat tapered roller bearing and assemble
it until contact is obtained.
Figure 146
9. Preload complete clutch pack through both
inner bearing races (Figure 147) with 100
000 N (10 ton). In this way, the exact
contact of the components, resp. the
settling of the complete bearing is ensure.
Figure 147
10. Mount disk. Wet thread of slotted nut with
Loctite #262 and install slotted nut with
chamfer showing downward (Figure 148).
Figure 148

260) Page 69
11. Tighten slotted nut.
NOTE: Torque limit 56 kg•m (406 ft lb).
Figure 149
12. Tilt clutch 180° (K3-side).
13. Wet thread of slotted nut with Loctite #262
and install slotted nut with chamfer
showing downward.
Figure 150
14. Check function of clutch using compressed
air:
A. For this purpose, squeeze
rectangular rings in, engage them
and assemble bearing cover.
NOTE: At correctly installed
components, the closing resp.
opening of the clutches is
clearly audible.
B. Now, remove bearing cover again.
Figure 151

Page 70 260)
CLUTCH KR/K2
Install purge valves, piston and compression spring (each clutch side 1 set of the components) accordingly
as at multidisk clutch K3 (Figure 123 thru Figure 128)
Install plate pack KR and K2 and check plate clearance, see also following Draft.
Draft:
KR K2
Figure 152
Plate arrangement - KR (long plate carrier side):

Active number of the friction surfaces = 24.
2 outer plates (one sided coated)
11 outer plates (s) = 2.5 mm
11 inner plates (s) = 2.5 mm
1 inner plate (optional) (s) = 2.0 mm
IMPORTANT
Pay attention to the General Instructions for the Plate Installation (See page -63).
Check Plate clearance - K2 = 2.8 - 3,0 mm accordingly as at clutch K-3 (See page -61).
Plate arrangement - K2 (short plate carrier side):
Active number of friction surfaces = 16.
1 inner plate (optional) (s) = 2.0 - 4.0 mm

260) Page 71
IMPORTANT
Pay attention to the General Instructions for the plate installation (See page -63).
Check Plate clearance- K2 = 2.2 mm accordingly as at clutch K3 (See page -61).

Spur gear KR
Components:
Reference
Description
Number
1 Inner Bearing Race
2 Outer Bearing Race
3 Spur Gear
4 Retaining Ring
5 Adjusting Ring (Optional)
Figure 153
1. Determines axial play of the spur gear
bearing 0,03 - 0,08 mm (Figure 154,
EXAMPLE B:
A. Squeeze retaining ring (4) in and
place outer bearing race (2) against
shoulder.
Figure 154
B. Place spur gear upon inner bearing
race.
NOTE: Support inner bearing race.
Figure 155

Page 72 260)
C. Measure Dimension I from end face
to inner bearing race.
NOTE: Dimension I, e.g. 24.95 mm.
Figure 156
D. Determine Dimension II from end
face to retaining ring.
Figure 157
E. Determine differential dimension
from outer bearing race to inner
bearing race on upper tapered roller
bearing.
NOTE: Figure 158, shows two tapered
roller bearings with different
measuring results.
NOTE: Dimension III (Differential
dimension) in the actual case,
e.g. 0.15 mm
HLA2159L
Figure 158

260) Page 73
EXAMPLE B:
Dimension I 24.95 mm
Dimension II -20.85 mm
Intermediate result 4.10 mm
Dimension III + 1.15 mm
Result = Differential = 4.25 mm
dimension - zero
required axial play (0,03 - + 0,05 mm
0,08) e.g
Result = adjusting ring = 4.30 mm
Figure 159
F. Select adjusting ring with
corresponding thickness.
2. Check axial play (Figure 160).

A. Install upper outer bearing race.
Insert adjusting ring, e.g. s =
4.30 mm and inner bearing race.
Preload spur gear bearing with about
50 000 N (5 to). Determine axial play.
NOTE: At deviations from the required
axial play 0,03 - 0,08 mm
correct with corresponding
adjusting ring.
Figure 160
3. Heat lower tapered roller bearing and
assemble it until contact is obtained.
Figure 161

Page 74 260)
4. Install spur gear KR into preassembled
plate carrier until all inner plates are
accommodated.
Figure 162
5. Assemble adjusting ring, e.g. s = 4.30 mm
(See EXAMPLE B).
position of oil feed grooves.
They should be showing
upward.
6. Now, heat upper inner bearing race (spur
gear bearing) and assemble it until contact
is obtained.
Figure 163
7. Heat inner bearing race (clutch bearing)
and assemble it until contact is obtained.
Figure 164
Spur gear K2
Reference
Description
Number
1 Tapered Roller Bearing
2 Bushing
3 Shim
4 Spur Gear
Figure 165

260) Page 75
8. Adjust axial play of spur gear bearing 0.05
- 0.15 mm (Figure 166 thru Figure 169):
A. Place spur gear upon inner bearing
race.
NOTE: Support inner bearing race.
Figure 166
B. Install bushing and shim (s= 3.80 mm
/ empirical value) and align it
centrically.
Figure 167
C. Install upper tapered roller bearing.
Figure 168
D. Preload spur gear bearing with about
50,000 N (5 ton) and determined
axial play.
NOTE: At a deviation from required
axial play 0,05 - 0.15 mm,
correct with corresponding shim
(Figure 165).
Figure 169

Page 76 260)
9. Heat inner bearing race and assemble it
until contact is obtained.
Figure 170
10. Install spur gear K2 until all inner plates
are accommodated.
Figure 171
11. Install bushing and corresponding shim.
Figure 172
12. Heat second tapered roller bearing of spur
gear bearing and assemble it until contact
is obtained.
Figure 173

260) Page 77
and place it against shoulder.
Figure 174
000 N (10 ton) In this way, an exact contact
of components, resp. the setting of the
complete bearing is ensure.
Figure 175
15. Install and tighten both slotted nuts.
position of slotted nuts chamfer
is always facing inner bearing
race. Secure slotted nuts with
Loctite #262.
Figure 176

Page 78 260)
CLUTCH - KV/K1
Install purge valves, piston and compression spring (each clutch side 1 set of the components) accordingly
as at clutch (Figure 123 thru Figure 128).
Install plate pack - KV and K1 and check plate clearance, see also Draft.
Draft.
KV K1
HLA2178L
Figure 177
Plate arrangement - KV (long plate carrier side):

Active number of friction surfaces = 24.
2 outer plates (one sided coated)
1 inner plate (optional) (s) = 2.5 - 4.0 mm
IMPORTANT
Pay attention to General Instructions for Plate Installation (See page -63).

260) Page 79
1. Check plate clearance- K1 = 2.2 - 2.4 mm
accordingly as at clutch - K3 (See page
-61).
2. Close both bores (Figure 178) using set
screws.
NOTE: Insert set screws with Loctite
#262).
Figure 178
Spur gear - KV
Reference
Description
Number
1 Bearings Inner Race
2 outer bearing Race
3 Spur Gear
4 Retaining Ring
5 Ring (Optional)
Figure 179
3. Determine axial play of spur gear bearing
0.03 - 0.08 mm (Figure 180, EXAMPLE C).
A. Squeeze retaining ring (4) in place
outer bearing race (2) against
shoulder.
Figure 180
B. Place spur gear upon inner bearing
race.
NOTE: Support inner bearing races.
Figure 181

Page 80 260)
C. Measure Dimension I from end face
to inner bearing race.
Figure 182
D. Determine Dimension II from end
face to retaining ring.
Figure 183
E. Determine Differential dimension
from outer bearing race to inner
bearing race on upper tapered roller
bearing.
NOTE: The illustration on right shows
two tapered roller bearings with
different measuring results.
NOTE: Dimension III (Differential
dimension) in actual case, e.g.
+0.15 mm.
HLA2159L
Figure 184

260) Page 81
EXAMPLE C
Dimension II -20.85 mm
Result A 4.10 mm
Dimension III +0.15 mm
Result = Differential 4.25 mm
Dimension - Zero
Required Axial Play. + 0.05 mm
(0,03 - 0,08)
Result = Adjusting Ring = 4.30 mm
Figure 185
NOTE: Select adjusting ring with
corresponding thickness.
4. Check axial play (Figure 186):
A. Install upper outer bearing race.
B. Insert adjusting ring, e.g. s =
4.30 mm and inner bearing race.
Preload spur gear bearing with about
50 000 N (5 ton) Determine axial
play.
NOTE: At deviations from the required
axial play 0,03 - 0,08 mm
correct with corresponding
adjusting ring.
Figure 186
5. Heat lower inner bearing race and
assemble it until contact is obtained.
Figure 187

Page 82 260)
6. Install spur gear KR into preassembled
plate carrier until all inner plates are
accommodated.
Figure 188
7. Assemble adjusting ring, e.g. s = 4.30 mm
(See EXAMPLE C).
position - oil feed grooves are
showing upward.
8. Now, heat upper inner bearing race (spur
gear bearing) and assemble it until contact
is obtained.
Figure 189
and assemble it until contact is obtained).
Figure 190
Spur Gear - K1
Reference
Description
Number
1 Ball Bearing
2 Ring (Optional)
3 Splash Ring
4 Retaining Ring
5 Spur Gear
6 Ball Bearing
Figure 191

260) Page 83
10. Adjust axial play of spur gear bearing =
0.01 - 0.04 mm (Figure 192 and Figure
193):
A. Determine thickness of splash ring
(3), e.g. s= 17.15 mm
Figure 192
NOTE: Total dimension of retaining ring
4 and ring 2 (optional) must be
selected 0.01 - 0.04 mm
thinner.
NOTE: Total dimension of retaining ring
and ring therefore 17.14 -
17.11 mm.
Figure 193
11. Heat ball bearing and assemble it until
contact is obtained. Now, cool ball bearing
down to room temperature, to allow later
installation of spur gear (Figure 197).
Figure 194
12. Assemble ring (optional) and splash ring.
Figure 195

Page 84 260)
13. Squeeze retaining ring into annular groove
of spur gear.
Figure 196
IMPORTANT
Carry out steps of Figure 197 and
Figure 198, in immediate sequence to
prevent cooling down of
components.
14. Heat bearing bores of spur gear (Figure

197) and ball bearing (Figure 198). Install
spur gear until all inner plates are
accommodated.
Figure 197
15. Install heated ball bearing until contact is
obtained.
Figure 198
16. Assemble spacer (s= 1.50 mm). Heat
tapered roller bearing and place it against
shoulder.
Figure 199

260) Page 85
000 N (10 to). In this way, an exact contact
of components, resp. the setting of the
complete bearing is ensure.
Figure 200
18. Secure clutch pack using disks (Figure
201) and slotted nuts.
position of slotted nuts, chamfer
is always facing inner bearing
race. Wet thread of slotted nuts
with Loctite #262.
Figure 201
19. Tighten both slotted nuts.
Figure 202
20. Install and engage rectangular rings (3x,
see Figure 203).
Figure 203

Page 86 260)
21. Assemble bearing cover and check
function of clutches using compressed air.
NOTE: At correctly installed
components, the closing resp.
opening of the clutches is
clearly audible. Now, remove
bearing cover gain.
Figure 204
INSTALL MULTIDISK CLUTCHES,
LAYSHAFT GEAR AND OUTPUT GEAR
1. Squeeze retaining rings in see Figure 205.
Figure 205
2. Install spacer ring.
Figure 206
obtained.
NOTE: Install spacer rings, resp. outer
bearing races of clutch KR.K2
and KV/K1 accordingly, see
Figure 207.
Figure 207

260) Page 87
4. Install roll pin.
Figure 208
5. Adjust axial play of layshaft gear bearing =
0,0 - 0,05 mm (Figure 209, EXAMPLE D):
A. Determine Dimension I, see Figure
209.
Figure 209
B. Install both inner bearing races and
determine Dimension I: (total height
of layshaft bearing).
Figure 210

Page 88 260)
C. Determine Dimension III from contact
face of inner bearing race to contact
face of axle.
NOTE: Dimension III, e.g. 0.60 mm
EXAMPLE D:
Dimension II. 53.95 mm

Dimension III + 0.60 mm
Intermediate Result A = 54.55 mm
Intermediate Result A - 54.55 mm
Figure 211
Result = Differential = 2.55 mm
Dimension - Zero
NOTE: At a required axial play of 0,0 -

0,05 mm, the shim has
therefore to be selected thinner
for max. 0,05 mm.
D. Shim thickness therefore 2.55 -
2.50 mm.
6. Position shim and layshaft gear.

NOTE: The installation of layshaft gear
can be carried out only after
installation of clutch.
Figure 212
7. Position clutch KV/K1 using lifting device.
Figure 213

260) Page 89
8. Install clutch KR/K2.
Figure 214
9. Displace clutch KR/K2 in direction of arrow
(Figure 215) and position clutch K3/K4.
Figure 215
10. Cool down outer bearing race and insert in
into housing bore until contact is obtained.
Figure 216
Figure 217

Page 90 260)
12. Position oil baffle.
Figure 218
13. Install output gear.
Figure 219
14. 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
(17 ft lb).
NOTE: Secure hex. head screws with
Loctite #262.
Figure 220
15. Cool down output shaft and install it until
position, see Figure 221.
Figure 221

260) Page 91
16. Wet mounting face with sealing compound
(Loctite #574).
17. Install two adjusting screws and position
housing cover using lifting device on
gearbox housing until contact is obtained.
Figure 222
18. Install both cylindrical pins (1 and 2, Figure
223) and roll pin (3).
Figure 223
19. Fasten housing cover using socket head
screws (2 pieces) and hex. head screws.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (34 ft lb).
NOTE: Pay attention to position of two
socket head screws, see Figure
224.
Figure 224
20. Adjust axial play of outer bearing = 0.3 -
0.5 mm (Figure 225 thru Figure 227):
A. Determine Dimension I from plane
face/housing to end face/output
shaft.
NOTE: Dimension I e.g 53.20 mm.
Figure 225

Page 92 260)
B. Measure Dimension II from plane
face/housing to contact face of ball
bearing.
EXAMPLE E:
Dimension Ii - 50.40 mm
Difference = 2.80 mm
Required Axial Play (0.3 - 0.40 mm
- 0.5), e.g.
Gives Shim S = 2.40 mm Figure 226
21. Assemble shim (e.g s = 2.40 mm).
Figure 227
22. Insert bearing until contact is obtained.
Figure 228

260) Page 93
23. Secure ball bearing using disk (s =
4,00 mm) shim (optional) and retaining
ring free play.
Figure 229
24. Install shaft seal with sealing lip showing
downward.
NOTE: At the use of the prescribed
driver, the exact installation
depth is obtained. Cover outer
diameter with sealing
compound Loctite #547.
Grease sealing lip.
Figure 230
25. Assemble output flange.
Figure 231
26. Wet contact face of disk with sealing
compound. Mount disk and fasten output
flange using hex. head screws.
kg•m (34 ft lb).
Figure 232

Page 94 260)
27. Secure hex. head screws using lock plate.
Figure 233
28. If necessary, install studs, insert O-ring
into annular groove (Figure 234) and
fasten cover using hex. nuts.
kg•m (17 ft lb).
NOTE: Insert studs with Loctite #262.
Figure 234
29. Install screw plug (1, Figure 235). Mount
gasket and fasten cover (2) using hex.
head screws.
kg•m (17 ft lb).
Figure 235
30. Fasten brake assemble (according to
version) on housing, using hex. head
screws.
NOTE: Torque limit (M14/10.9) 19 kg•m
(136 ft lb).
IMPORTANT
At works on the brake assembly, the
Specifications of the Brake
Manufacturer, resp. Vehicle
Manufacturer are binding. Figure 236

260) Page 95
31. Cool down outer bearing races (clutches
K3/K4 and KR/K2) and insert them into
housing bores until contact is obtained.
Figure 237
32. Adjust bearing preload - clutch K3/K4 =
0.15 - 0.20 mm (Figure 238 thru Figure
241):
A. Align clutches centrically by rotating
output flange and place outer bearing
race carefully against shoulder.
IMPORTANT
Bearing must not be preload -
Bearing cage, resp. bearing rollers
are stilled easy to be moved. Figure 238
B. Determine Dimension I from outer

bearing race to mounting face.
NOTE: Apply several measuring points
and determine average.
Figure 239

Page 96 260)
C. Measure Dimension I from mounting
face/cover to contact face/outer
bearing race.
EXAMPLE F:
Dimension II 7.13 mm
Dimension I - 5.70 mm
Difference required 1.43 mm
bearing preload
(0.15 - 0.20) + 0.17 mm
Result = shim, e.g. = 1.60 mm Figure 240
33. Insert shim (e.g. s = 1.60 mm) with grease

into bearing cover. Insert O-ring into
annular groove (Figure 241) and grease it.
Figure 241
34. Squeeze rectangular rings (3 pieces, see
Figure 242) in and engage them. Now,
grease rectangular rings and align them
centrically.
Figure 242

260) Page 97
35. Pull cover using hex. head screws
uniformly against shoulder.
kg•m (34 ft lb).
36. Mount bearing cover KR/K2 accordingly.
NOTE: Bearing preload KR/K2 = 0,02 -
0.25 mm.
Figure 243
37. Close both bores of bearing cover KV/K1
using slotted plug.
NOTE: Insert slotted plug with Loctite
#262.
Figure 244
38. Adjust bearing preload clutch KV/K1 =
0.15 - 0.20 mm (Figure 245, EXAMPLE
G).
A. Install outer bearing race.
Figure 245
B. Press outer bearing race uniformly
on and determine Dimension I from
mounting face to outer bearing race.
ad determine average.
Figure 246

Page 98 260)
C. Measure Dimension II from mounting
face of cover (Figure 247) to contact
face/outer bearing race.
NOTE: Dimension II, e.g. 63.90 mm.
EXAMPLE G:
Difference 1,05 mm
Required Bearing + 0.15 mm
Preload (0.15 - 0.20),
e.g. Figure 247
Result = Shim S = 1.20 mm
39. Install shim (e.g s= 1.20 mm) cool down

outer bearing race and insert it until
contact is obtained. Insert O-ring into
annular groove (Figure 248) and grease it.
Figure 248
40. Squeeze rectangular rings (3 pieces) into
annular grooves of clutch shaft (Figure
249) and engage them. Now, grease
rectangular rings and align them
centrically.
Figure 249

260) Page 99
41. Install two adjusting screws, install bearing
cover and pull it uniformly against
shoulder, using hex. head screws.
kg•m (34 ft lb).
Figure 250
42. Tilt housing 180°. Align layshaft gear and
shim centrically, cool down preassembled
bolt and insert it until contact is obtained.
NOTE: Pay attention to overlapping of
roll pin with bore in housing.
Figure 251
43. Fix bolt axially using hex. head screw.
kg•m (34 ft lb).
Figure 252
NOTE: Wet thread of hex. head screw
Drive in sealing covers (1 thru
4, Figure 253) flush-mounted,
with end face showing
downward. Install sealing cover
(5) with recess showing
upward.
NOTE: Wet thread surfaces with
Loctite #262.
Figure 253

Page 100 260)
44. Install shaft seal (Figure 254) with sealing
lip showing downward.
NOTE: At the use of the prescribed
driver, the exact installation
position is obtained. Cover
outer diameter with sealing
compound Loctite #534).
Grease sealing lip.
Figure 254
45. Assemble output flange. Wet contact face
of disk with sealing compound Loctite
#574 and secure output flange using hex.
head screws.
kg•m (34 ft lb).
Figure 255
46. Secure hex. head screws using lock plate.
Figure 256
INSTALL FILTER
1. Mount filter (compl.).
NOTE: Grease sealing ring (Figure
257).
Figure 257

260) Page 101
2. Fasten cover using hex. head screws
(mount plain washers).
NOTE: Install new O-rings (Figure
258).
(17 ft lb)
Figure 258
3. Equip screw plug (1, Figure 259) with new
O-ring and instal it. Mount gasket and
fasten cover plate using hex. head screws
(2).
(17 ft lb).
Figure 259
HYDRAULIC PUMP
1. Press needle sleeve in, with reinforced
shell facing press-in tool until contact is
obtained.
Figure 260
obtained.
Figure 261

Page 102 260)
3. Cool pump to about 80°C. Clean area of
suction and pressure port (1, Figure 262)
again and wet it with Loctite #262.
Assemble and oil O-ring (2).
Figure 262
4. Install two adjusting screws and install
pump until contact is obtained.
NOTE: Pay attention to radial
installation position.
Figure 263
5. Install O-ring (Figure 264) and fasten
pump flange, resp. pump using hex. head
screws.
kg•m (58 ft lb).
Figure 264
6. Insert O-ring (Figure 265) into annular
groove of pump flange (power take off) and
oil it. Mount two adjusting screws and
fasten flange using hex. head screws.
(92 ft lb).
Figure 265

260) Page 103
DRIVE SHAFT (POWER TAKE-OFF PUMP)
1. Squeeze V-rings (3x) into recess of driver
(internal gearing) Mount fitting key (Figure
266).
Figure 266
2. Adjust gap = 0.5 mm (driver-drive shaft)
Figure 267 thru Figure 271:
Figure 267
3. Assemble disk s = 1.90 mm and place
inner bearing race against shoulder.
Figure 268
A. Determine Dimension I from inner
bearing race to end face/driver.
Figure 269

Page 104 260)
B. Determine Dimension II (A-B)
EXAMPLE H:
Dimension II 10.60 mm
Dimension I - 9.60 mm
Difference 1,00 mm
Required Gap + 0.50 mm
Gives Shim (S) = 1.50 mm
Figure 270
4. Assemble shim e.g s = 1.50 mm and
position driver, resp. inner bearing race
against shoulder.
Figure 271
5. Attach driver using clamping disk and
socket head screw.
NOTE: Insert socket head screw with
Loctite #242.
NOTE: Torque limit (M10/8.8 DIN
6912) 3.26 kg•m (24 ft lb).
Figure 272
6. Press inner bearing race upon collar of
drive gear power take off.
Figure 273

260) Page 105
7. Squeeze retaining ring in (Figure 274) and
assemble drive gear.
Figure 274
8. Install and engage rectangular ring (Figure
275).
Figure 275
9. Install preassembled drive shaft until
NOTE: Pay attention to overlapping of
fitting key/fitting key groove.
Figure 276
10. Adjust axial play of drive shaft bearing =
0,0 - 0,05 mm Figure 277 thru Figure 279).
11. Mount gasket. Mount outer bearing race,
press it uniformly on and determine
Dimension I from mounting face (gasket)
to outer bearing race.
and determine average.
Figure 277

Page 106 260)
12. Measure Dimension II from mounting face/
converter bell to contact face/outer bearing
race.
Figure 278
NOTE: Shims are available in 0,05 mm
graduation.
13. Insert shim, e.g. s = 2.10 mm and position
outer bearing race against shoulder.
Figure 279
INPUT - CONVERTER
1. Insert outer bearing race into housing bore
until contact is obtained and install bearing
race, see Figure 280.
Figure 280
2. Install spur gear (Figure 281) starting from
side, with long collar showing, and position
it.
Figure 281

260) Page 107
3. Insert both roll pins (Ø 2.5 and Ø 1.5 mm)
flush-mounted into bore (Figure 282) of
drive shaft.
Figure 282
4. Cool down drive shaft and install it until
Figure 283
Figure 284
6. Place outer bearing race against shoulder.
NOTE: Spur gear bearing must have
free play.
Figure 285

Page 108 260)
7. Adjust bearing preload of drive gear
bearing 0,0 - 0,07 mm (Figure 286,
EXAMPLE K:
A. Measure Dimension I from mounting
face to outer bearing race.
Figure 286
B. Mount gasket (Figure 287) and
determine Dimension II from
mounting face to contact face of
outer bearing race.
EXAMPLE K:
Difference = 1.25 mm
Bearing Preload (0.9 - + 0.05 mm
0,07 mm) e.g Figure 287
Gives Shim = 1.30 mm
NOTE: Reassemble of shim, see

Figure 291.
8. Insert needle bearing until contact is

obtained Insert shaft seal flush mounted,
with sealing lip showing downward.
NOTE: Wet outer diameter of shaft seal
with sealing compound Loctite
#574. Grease sealing lip.
Figure 288

260) Page 109
9. Install two adjusting screws and mount
gasket. Install converter safety valve,
composed of disk, compression spring and
ball (1, Figure 289).
10. Squeeze rectangular ring into annular
groove of drive shaft and engage it (2,
Figure 289). Now, grease rectangular ring
and align it centrically.
Figure 289
IMPORTANT
Carry out following steps (Figure 290
thru Figure 293) immediately within
short chronological order.
11. Cool down oil feed flange about - 80°C

Clean area of suction and pressure port
(Figure 290) again and wet it with Loctite
#241.
Figure 290
12. Make shim, e.g. s = 1.30 mm (See
EXAMPLE K.). adhere with grease in
bearing bore.
Figure 291
13. Install oil feed flange until contact is
obtained.
Figure 292

Page 110 260)
14. Mount gasket (Figure 293) and install
bearing cover.
kg•m (34 ft lb).
Figure 293
15. Insert roll pin until contact is obtained.
Figure 294
16. Install converter pressure valve. Install
temperature sensor (1, Figure 295) and
screw plug (2).
NOTE: Install new O-ring each time.
Figure 295
17. Heat housing bore (about 120°C).
Figure 296

260) Page 111
18. Install two adjusting screws and mount
gasket (1, Figure 297) Install converter bell
using lifting device until contact is obtained
and fasten it using hex. head screws.
installation position. Slight
rotary motions of drive shaft will
facilitate insertion.
kg•m (25 ft lb).
(85 ft lb). Figure 297
CONVERTER
1. Fasten diaphragms (3x) on converter,
using hex. head screws (mount plain
washer).
NOTE: Insert hex. head screws with
Loctite #243.
kg•m (34 ft lb).
Figure 298
2. Install and engage rectangular ring (Figure
299) Now, grease rectangular and align it
centrically.
Figure 299

Page 112 260)
3. Install converter using lifting drive until
Figure 300
4. Tilt transmission 90°. Install breather
(Figure 301) Insert pot flush mounted to
housing surface.
NOTE: Wet sealing surface with Loctite
#262.
Figure 301
5. Equip screw plug (1 and 2, Figure 302)
with new O-rings and install them. Install
both fixing plates (3).
NOTE: Torque limit (screw plug
M42x2) 15 kg•m (107 ft lb).
(144 ft lb).
Figure 302
MOUNT HYDRAULIC CONTROL UNIT (HSG-
94)
1. Preassemble and mount plate (Figure 303
thru Figure 307).
2. Equip fittings (1 thru 6, Figure 303) with
new O-rings and install them. Install screw
plug (7 and 8).
NOTE: Install new O-rings each time.
Figure 303

260) Page 113
3. Install two adjusting screws (M6) and
mount housing gasket.
NOTE: At the following steps (Figure
304 thru Figure 308) pay
attention to installation position
of different gaskets.
Figure 304
4. Mount intermediate plate.
Figure 305
5. Mount 2nd gasket.
Figure 306
6. Mount plate and fasten it uniformly using
socket head screws.
Figure 307

Page 114 260)
7. Mount gasket.
Figure 308
8. Assemble complete control unit and fasten
it uniformly using socket head screws (2x
M6x105 and 21x M6x80 mm).
NOTE: Pay attention to position of two
socket head screws M6x105,
see Figure 309.
NOTE: Torque limit 9.5 mm.
Figure 309

260) Page 115
9. Install pressure lines according to following
draft.
IMPORTANT
The arrangement of lines is different
according to the Version. In this
connection, pay attention to the
Perspective Illustration in the
corresponding Spare-Parts List.
Reference
Description
Number
KV Hydraulic Line Clutch
KV
KR Hydraulic Line Clutch
KR
K1 Hydraulic Line Clutch
K1
K2
K3
K4 Hydraulic Line Clutch Figure 310
K4
S1 Lubricating Oil Line
Clutch KR/K2
S2 Lubricating Oil Line
Clutch K4/K3

Page 116 260)
INDUCTIVE TRANSMITTER AND SPEED
SENSOR
1. The following illustrations show installation
position of single inductive transmitters
and speed sensor.
Reference
Description
Number
5 Inductive
Transmission N-
central Gear Train
9 Inductive
Transmission N-
engine
14 Inductive
Transmission N-
turbine
13 Speed Sensor N-
output and
Speedometer
Figure 311
Figure 312

260) Page 117
SETTING INDUCTIVE TRANSMITTER
1. The following illustrations describe the reassembly, resp. the setting of the Inductive transmitter N
engine (9, Figure 311). The reassembly of the Inductive transmitter N turbine (14) and N central gear
train (5) has to be carried out accordingly.
IMPORTANT
Pay attention to different setting dimensions. Setting dimension corresponds to distance
between contact face-inductive transmitter and tooth tip, see Figure 313.
2. Setting dimensions - Inductive transmitter

N engine (9, Figure 311) and n turbine (14,
Figure 311) =0.5 +0.3 mm.
3. Setting dimension - Inductive transmitter N
central gear train (5, Figure 311) = 0.3
+0.1
mm
Figure 313
4. Turn counting disk radially until one tooth
tip is situated centrally to inductive
transmitter hole.
5. Insert measuring pin (S) until end face has
got contact on tooth tip, resp. the retaining
ring on screw - in face of housing.
Figure 314

Page 118 260)
6. Remove measuring pin and measure
Dimension I from end face/measuring pin
to retaining ring.
7. Measure Dimension II from contact face-
inductive transmitter to contact face.
EXAMPLE L:
Required Gap (0.5 - 0.60 mm
Figure 315
+0.3 mm) e.g
Gives Installation = 29.50 mm
Dimension
EXAMPLE L:
Dimension II 30,00 mm
Installation Dimension - 29.50 mm
Difference = Shim = 0.5 mm
8. Assemble corresponding shim and wet

thread (Figure 316) with Loctite #574.
Figure 316
9. Install inductive transmitter N engine
(9Figure 317), N turbine (14) and N central
gear train (5).
10. Now, install screw plugs (Figure 317).
NOTE: Equip screw plugs with new O-
ring.
NOTE: Torque limit (M26x1.5) 8.16
kg•m (59 ft lb).
NOTE: Torque limit (M18 x 1.5) 5.1
kg•m (37 ft lb). Figure 317

260) Page 119
SPEED SENSOR (HALL SENSOR) N
OUTPUT AND SPEEDOMETER
1. Illustration on right shows speed sensor
13.
Reference
Description
Number
1 Speed Sensor
2 Plate
3 O-ring
Figure 318
2. Grease O-ring and fasten speed sensor
(Figure 319) using socket head screw.
(17 ft lb).
IMPORTANT
Before putting transmission into
service, carry out oil filling according
to Operation and Maintenance
Manual.
Figure 319

Page 120 260)
S0702040
1HYDRAULIC SYSTEM
CAUTION!
HYDRAULIC SYSTEMS0702040

February 1999
Hydraulic System S0702040

Page 1
TABLE OF CONTENTS
Brake System ................................................................................................. 3

Main Control Valve ......................................................................................... 4
Main Relief Valve............................................................................................ 7
Overload Relief Valve ..................................................................................... 8
Restriction Valve........................................................................................... 10
Unloading Valve ........................................................................................... 12
Manually Controlled Pilot Valve .................................................................... 14
Pilot Valve Operation............................................................................. 14
Hydraulic Pressure Adjustments .................................................................. 16
Relief Valve ........................................................................................... 16
Unloading Valve .................................................................................... 17
Brake Pressure Checks......................................................................... 17
Transmission Clutch Pressure............................................................... 17
S0702040 Hydraulic System

Page 2
BRAKE SYSTEM
Multiple wet disk brakes for stopping vehicle movement are contained in the axle-end planetary gear sets.
A brake pump (10, Figure 1) 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 disks, and this stops axle shaft and wheel rotation.
The brake hydraulic system also contains six 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 1). 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.
Figure 1
Reference Reference
Number Number
1 Rear Axle 8 Accumulators
2 Transmission Cutoff Switch 9 Brake Valve
3 Front Axle 10 Pump
4 Brake 11 Pilot Cutoff Line
5 Brake Pedal 12 Safety Valve
6 Brake Pedal Switch 13 Low-pressure Warning Switch
7 Parking Brake 14 Parking Brake Valve

Page 3
MAIN CONTROL VALVE
The main control valve controls the operation of the boom, bucket, and option cylinders. The bucket spool
and the option spool have priority over the boom spool.
Pump output flows to port P on the main control valve. See Figure 2. Maximum pressure is prevented from
exceeding the desired level by the main relief valve (10). See Figure 3. 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. See hydraulic schematic in
appropriate section of this manual. Oil that passes out the tank port passes through a filter and returns to
tank.
Two safety valves 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.
Figure 2

Page 4
Reference Reference
Number Number
PA1 Option Valve Port (from 3A Bucket Lower Port (to
Option Solenoid Valve D2) Boom Cylinder Rod)
PA2 Bucket Crowd Valve Port 1B Option Cylinder Port (to
(from Remote Valve Port 4) Option Cylinder Tube)
PA3 Bucket Down Valve Port 2B Bucket Dump Port (to
(from Remote Valve Port 1) Bucket Cylinder Rod)
PB1 Option Valve Port (from 3B Boom Up Port (to Boom
Option Solenoid Valve D1) Cylinder Tube)
PB2 Bucket Dump Valve Port P Pump Port
(from Remote Valve Port 2) R Main Pressure Relief Valve
PB3 Boom Up Valve Port (from Port
Remote Valve Port 3) T Tank Port
PC Float Valve Port (from 4B Option Cylinder Port (to
Remote Valve Port 5) Option Cylinder Rod)
2A Bucket Crowd Port (to
Bucket Cylinder Tube)

Page 5
Figure 3

Page 6
Reference Reference
Number Number
1 Float Spool Return Spring 8 Bucket Dump Stroke
2 Boom Spool Return Spring Limiter
3 Load Check Valve Return 9 Option Spool
Spring 10 Main Relief Valve
4 Load Check Valve 11 Control Valve Body
5 Restriction Valve 12 Overload Relief Valve
6 Boom/Float Spool 13 Anticavitation Check Valve
7 Bucket Spool
A relief valve is installed at the boom-up port. An intake valve is installed at the boom-down port. The relief
valve will open to protect circuit components when pressure in the boom-up circuit increases beyond the
desired level. During the boom-down cycle, when the weight of the boom and load causes the boom to
drop at a fast rate, the intake valve supplies additional oil to the rod side of the cylinder to prevent
cavitation.
A restriction is included in the return-to-tank path in the main control valve. When all the spools in the main
control valve are in neutral, return oil from the main control valve does not pass through the restriction. This
oil flows freely back to tank. When the bucket spool in the main control valve is being used, return oil from
the bucket cylinder is directed through the restriction. This raises the pressure in the return line and this
opens the anticavitation valve. The anticavitation valve then directs return oil to the other side of the bucket
cylinder.
MAIN RELIEF VALVE

The main relief valve is positioned at the point where pump flow enters the main control valve. The relief
valve opens to prevent system pressure from ever exceeding the level that the relief valve is set for. This
protects circuit components from being damaged from high-pressure. When pressure falls below the
opening pressure of the relief valve, the relief valve closes and will maintain any system pressure lower
than the opening pressure.
Port A is attached to the pump output line. See Figure 4. Port B is connected to the tank line. Oil pressure
that is present at port A is also present at the main poppet (1). Pressurized oil also passes through orifice
(4) and is present in chamber C. Initially, oil pressure at 1 and C are equal. When the oil pressure in
chamber C exceeds the spring force of spring (6), poppet (5) opens. Oil in chamber C flows to chamber D.
Due to the venturi effect of orifice (4), pressure in chamber C drops. Oil pressure on the main poppet (1)
has remained the same. The difference in oil pressure causes the main poppet (1) to shift toward chamber
C. This opens a path between port A and port B. This allows pump flow from port A to be directed to tank.
The main relief valve opening pressure can be controlled by adjusting the pilot poppet spring (6). Loosen
the lock nut (8). Turn the adjusting screw (7) clockwise to increase the pressure level at which the relief
valve opens. Turn the adjusting screw (7) counterclockwise to decrease the pressure level at which the
relief valve opens. Tighten the lock nut (8) to prevent the adjusting screw (7) from moving.

Page 7
OVERLOAD RELIEF VALVE
The overload relief valve protects hydraulic circuit components by venting to tank, the destructive high-
pressure oil that can be generated by external forces applied to the boom and bucket.
Oil from the actuator enters port P, passage Q, and enters the overload relief valve at port A. See Figure 5.
Pressurized oil acts on the nose of spool (7), and flows up through passage B to orifice C and into passage
D. Spring E keeps pilot poppet (6) closed. Initially, oil pressure at points P, Q, B, C, and D is equal. Because
of its greater area exposed to the oil pressure, the force at C is greater than the force applied to the nose of
the spool (7) at A. This keeps the spool (7) seated on F.
When oil pressure rises above the spring force of spring E, pilot poppet (6) moves down and off its seat. Oil
now flows through passage D, around the pilot poppet (6), through port R, and returns to tank. When pilot
poppet (6) moves off its seat due to high-pressure, oil pressure at C drops due to the venturi effect of the
small passage at B. This allows the oil pressure at A to lift the spool (7) off its seat (F). This allows oil at A
to flow through seat (F) and port R and return to tank.
Figure 4
Reference Reference
Number Number
1 Main Poppet 7 Adjusting Screw
2 Main Poppet Spring 8 Lock Nut
3 Valve Sleeve 9 Pump Port
4 Orifice 10 Tank Port
5 Pilot Poppet 11 Pressure Chamber
6 Pilot Poppet Spring 12 Relief Chamber

Page 8
Figure 5
Reference Reference
Number Number
1 Valve Body B Orifice Passage
2 Control Valve Block C Port
3 Cylinder Control Spool D Passage
4 Valve Adjusting Screw E Spring
5 Lock Nut F Spool Seat
6 Pilot Poppet P Control Valve Port
7 Valve Spool Q Passage
A Valve Port R Port

Page 9
RESTRICTION VALVE
The restriction valve is at the tank port of the control valve. This valve creates a constant pressure in the
return line when any of the control valves are being operated. If no control valve is being operated, the oil
that flows through the open centers of the control valves passes through the restriction valve without being
restricted. See hydraulic schematic in appropriate section of this manual.
Port A of the restriction valve is connected to the oil return line of the control valve. See Figure 6. Port B is
connected to the center bypass line of the control valve. When all the control valves are in neutral, the oil
returns through port B and is returned to tank without being restricted.
If any spool is being operated, the center bypass line is blocked. Return oil must now pass through the
control valve oil return line and port A of the restriction valve. Oil passing through port A must overcome
the spring force (1) of the poppet (2) to pass through the restriction valve. See Figure 7. This creates
pressure in the return oil circuit all the way back to the cylinder that is being operated.
Figure 6
Reference Reference
Number Number
1 Poppet Spring 2 Poppet

Page 10
Figure 7

Page 11
UNLOADING VALVE
The unloading valve is made up of three cartridges C1, C2, and C3. When pressure in the main pump
output line is low, the unloading valve diverts output from the steering pump and directs it to the main pump
output line. This line supplies the boom, bucket, and option control valves. This additional fluid creates
faster cycle times. When pressure in the main pump output line is high, the unloading valve directs steering
pump flow to tank.
Output from the steering pump passes through the priority valve that is part of the flow amplifier. See the
hydraulic schematic in appropriate schematic section of this manual. This flow then passes out of the flow
amplifier and enters the unloader valve at port EF. This flow is present at port A of C3 and present at port B
of C2. See Figure 8. This flow raises the check spool (1) at C3 when the pressure in the output line from
the main pump is below 160 kg/cm2 (2,275 psi.) at port P2. This allows output from the steering pump to
join flow from the main pump to supply the boom, bucket, and option control valves.
The pressure at port B of C2 is also present at port C of C2. When pressure in the main pump output line
is above 160 kg/cm2, this pressure forces spool (5) of C1 to move against the force of spring (6), which
allows the oil in chamber C of C2 to flow through port D of C1 and back to tank. When oil in chamber C
flows to tank through port D, the pressure in chamber C drops due to the venturi effect of the orifice (7) in
check spool (4). This allows the pressure at B to lift check spool (4) off its seat. This allows the oil that is
flowing into port B to flow past check spool (4) to tank. This is the output from the steering pump that is
being directed back to tank.

Page 12
Figure 8 UNLOADING VALVE CARTRIDGES
Reference Reference
Number Number
1 C3 Spring C2 Valve Cartridge
2 C3 Check Spool C3 Valve Cartridge
3 C2 Spring D C1 Port
4 C4 Check Spool E C1 Port
5 C1 Check Spool EF Unloading Valve Port
6 C1 Spring P1 C3 Port
7 Orifice P2 C3 Port
C C2 Spool Chamber T Tank
C1 Valve Cartridge

Page 13
MANUALLY CONTROLLED PILOT VALVE
When no force is applied to the lever (1, Figure 9), the return spring (4) positions the lever at the
"NEUTRAL" position. When the lever is moved, plunger (5) is moved, which pushes down the return spring
(4). At the same time, spool (2) is moved by spring (3). When spool (2) moves down, a groove (6) in the
spool opens the pilot pressure line to the line that the lever controls. This allows the pilot pressure to flow to
the boom or bucket control valve, where the pilot pressure operates the control valve. When the lever is
completely moved in one direction, the solenoid (7) energizes the 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.

Page 14
Figure 9
Reference Reference
Number Number
1 Lever 5 Plunger
2 Valve Spool 6 Spool Groove
3 Regulating Spring 7 Solenoid
4 Return Spring 8 Electromagnet

Page 15
HYDRAULIC PRESSURE ADJUSTMENTS
CAUTION!
Whenever hydraulic pressure is being checked for the purpose of adjusting the pressure setting
of any hydraulic valves, the hydraulic oil must be at operating temperature. Operating
temperature is 50 ±5°C (122 ±41°F).
RELIEF VALVE
In the hydraulic circuit that is supplied by the main pump, maximum pressure is limited to 195+50 kg/cm2
(2773+711 psi). Pressure is limited by the relief valve cartridge that is installed at the inlet of the main
control valve. See the hydraulic schematic in appropriate section of this manual. The cartridge can be
adjusted to obtain the correct pressure. Turning the relief valve adjusting screw clockwise will raise the
relief pressure. Turning the screw counterclockwise will lower the relief pressure. Pressure can be
monitored at the main pump outlet. See Figure 10.
Figure 10
Reference Reference
Number Number
1 Hydraulic Reservoir 3 Steering Pump (Opposite
2 Main Pump Gauge Port Side)

Page 16
UNLOADING VALVE
The unloading valve in the steering pump circuit is set to unload at 160 ±5 kg/cm2 (2275 ±71 psi). See
hydraulic schematic in appropriate section of this manual. The unloading valve cartridge C1 can be
adjusted to obtain the correct unloading pressure. Turning the C1 adjusting screw clockwise will raise the
unloading pressure. Turning the screw counterclockwise will lower the unloading pressure. Pressure can
be monitored at the steering pump outlet.
BRAKE PRESSURE CHECKS
The maximum loading and unloading pressure in the brake pilot valve is 120 - 140 kg/cm2 (1,706 - 1,991
psi). This pressure can be checked at gauge port ULTP which is at the upper part of the brake pilot valve.
See the hydraulic schematic in appropriate section of this manual.
Service brake outlet pressure is 60 ±5 kg/cm2 (853 ±71 psi). Pressure can be checked at the gauge port
on the outlet side of the brake pedal valve.
Pressure to the lever controlled pilot valves should be 30 ±5 kg/cm2 (427 ±71 psi). Pressure can be
checked at the TP port on the brake pilot valve. See the hydraulic schematic in appropriate section of this
manual.
TRANSMISSION CLUTCH PRESSURE
Clutch shift pressure in the transmission is 16 - 18 kg/cm2 (228 - 256 psi). This pressure can be checked at
the gauge port (1) on the top of the transmission. See Figure 11.
Reference
Description
Number
1 Clutch Gauge Port
Figure 11

Page 17
Page 18
S0793020
1HYDRAULIC
SCHEMATIC
(MEGA 400-III PLUS)
CAUTION!
HYDRAULIC SCHEMATIC (MEGA 400-III PLUS)S0793020


February 1999
Hydraulic Schematic (Mega 400-III PLUS) S0793020

Page 1
TABLE OF CONTENTS
Mega 400-III PLUS......................................................................................... 4
S0793020 Hydraulic Schematic (Mega 400-III PLUS)

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

Page 3
MEGA 400-III PLUS
REAR 67.16 cc
WORN CLOSE 3B
BR1 BR2
OPENS
60B
P1 T P2
0.7L 0.7
0.7L 0.7L 0.7L
HYDRAULIC
A4 A1 A1 P1 P2 T2 PARK A2 A
TANK ULTP C1 C2
C3
C6
C4
C8 60B
100LM PARK
C9
2
* 3/4 - 14
VICKERS
35VQ 218.4 LM at 6.9B at 2321 rpm (MAIN) P1
2" 30AM 1.25" 1.25"
81.6ccr C3
T 0.5"
TPS P 0.5"
0.25"
C2 L 0.5" L
42 LM at 6.9B at 2321 rpm (BRAKES) R 0.5"

18ccr R
0.75"
3"
VICKERS R2 20 20
218.4 LM at 6.9B at 2321 rpm (STEER)
3520V.QS 2"
30AM5 1.75" HT HT
97ccr STEERING SENSOR 1.0 1.0
240
CR 1.0" JERK
C4 C5 C6 C7
SOFTEN
C R1
240
0.75" 1.5
SW HP 1.5 ~ 2.5B
CL 1.0"
UNLOADER VALVE
LS 0.25"
CHECK VALVE
P PP CF EF LS
0.75" 0.75
185
OSQA 8 CN (CIRCUIT)
PRIORITY VALVE HP 1.25"
(OSQB S/ F PORTS)
FLOW AMPLIFIER 90x50, 4536 cc lock to lock

(90x60, 4172 cc lock to lock)
GROUND DRIVE
EMERGENCY PUMP
OPTIONAL EMERGENCY VKLU2B

STEERING SYSTEM (INC. PIPING)
Figure 2

Page 4
FROLT 94.46 cc
CLOSE 3B WORN
BR1 BR2
OPENS 25B
60B
31.9 cc JOYSTICK VALVE

T P2 WORN
P1
OPTION
0.7L 0.7L 0.7L
DUMP CROWD AUTO RETURN RAISE LOWER

TO DIG
P1 P2 T2 PARK A2 A2 TP D.C D.R D.F
A3
C1 C2
9WATT SOLNS
22
C7 T
C3 P 2 4 3 1 5
C6
T U2 U1 U4 U3 SP
TP
C4
PILOT 20 LM
37B at 35 BAR
C8 60B
C10
PSC PSR
SAFETY
D O1 C O2 R F
PARK
C9 OPTION SOLEN. V/V
BRAKE PILOT SUPPLY V/V
STEER VALVE
T 0.5" (200x8 = 1600 ccr)
P 0.5"
L 0.5" L P FROM PUMP
R 0.5"
R
T 200B
20 20 LS
b3 a3 b2 a2 b1 a1
240
CR 1.0" JERK
SOFTENER
OPTION BOOM BUCKET
240
CL 1.0"
240B
LS 0.25" 240B
B3 A3 B2 A2 B1 A1 " AUTO RETURN
0.75" 0.75" HEIGHT TO DIG "
CONTROL V/V 300 mm
ADJUSTABLE
PS, 'R' PS, 'F'
PS, 'F'
185
OSQA 8 CN (CIRCUIT)
(OSQB S/ F PORTS)
OPTION DEVICE(INC. PIPING)
ER 90x50, 4536 cc lock to lock

(90x60, 4172 cc lock to lock)
BOOM CYLINDER BUCKET CYLINDER
VKLU2B
Name MEGA 400-III PLUS
HYDRAULIC SCHEMATIC
NO.
REVISED
05/30/99 DAEWOO HEAVY INDUSTRIES LTD.
HATF630

Page 5
Page 6
S0893020
1ELECTRICAL
SCHEMATIC
(MEGA 400-III PLUS)
CAUTION!
ELECTRICAL SCHEMATIC (MEGA 400-III PLUS)S0893020


February 1999
Electrical Schematic (Mega 400-III PLUS) S0893020

Page 1
TABLE OF CONTENTS
Mega 400-III PLUS......................................................................................... 4
S0893020 Electrical Schematic (Mega 400-III PLUS)

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

Page 3
MEGA 400-III PLUS
1
SPEEDO-METER 0.5R3 SPEED 4 0.85RG
2 0.5B
5
3 1 87a
TACHO METER 0.5R TACHO 4 0.5WG 0.5RG 30 1.25RY 1.25RY
BEAM LAMP RELAY 2 0.5B 0.85RG 1.25RG 87
87a (FR) 0.85B 0.85RG 86 0.5RG 1
30 0.5RY WATER TEMP 5 0.5WR 0.5B 85
2 0.85L WATER TEMP SENSOR (RR) 5 0.5RY
0.5B 87 0.85B 7
& FUEL GAUGE 0.5R 1 WATER
TEMP 3 0.5B 0.85RG
85 86 0.5R (FL) 9
FUEL 4 0.85YR 0.85B
FUEL SENSOR 0.85B 0.85RG WORKING LAMP RELAY 0.5B 10 0.5WR
0.5B 5 0.5WR (RL) 0.85B
TRANSMISSION 4 0.85GY TRANSMISSION OIL FRONT WORKING LAMP WORKING LAMP SW
OIL PRESS 0.5R 1 TRANS
PRESS 3 0.5B 24V 55W
& CONVERTER PRESS SENSOR REAR WORKING LAMP
CONVERT 2 0.85GR
TEMP GAUGE TEMP CONVERTER OIL 0.85WR 24V 55W 0.85WR
5 0.85WR TEMP SENSOR 0.85WR 0.85WR
PILOT LAMP (A) 1.25R 1.25R
1 T/SIG (L) 2 0.85WG 0.85WG
A1 CONTROL UNIT 0.85BrW 0.85BrW
CHARGE A2 3 1 0.85R 0.85L 0.85L
ENG OIL PRESS 4 11
A3 13 0.85Y CIGAR LIGHTER
BEAM 5 0.5RY 0.5BrB 10 0.5WG REAR WIPER MOTOR
A4 0.85L B S
6 0.5RY 2 15 0.5GL M 0.85B 1 - 0.85B
5 0.5WR
0.5GR 3 16 0.5Lg P 7
PILOT LAMP (B) 0.5BY 4 17 0.5RG + 0.85W
0.85LW 10 9 0.5WR 0.5WR
1 PREHEAT 2 5 E
B1 18 0.85G
PARK BRAKE 3 19 0.5Or 0.85B 0.5B REAR WIPER SW
B2 6 B
WORKING 4 BLINKER
B3 20 0.5GW UNIT E 0.85B
T/SIG (R) 5 05BY 27 21 ROTATING BEACON (OPTION)
B4 0.5BrW
6 05BY 28 22 0.5BG 0.85R 1
0.5GB 29 5 0.85RW L
23 0.5BW 0.85B 7 0.85GY
0.85RW
PILOT LAMP (C) 7 24 0.5B 10 9 0.5WR 0.5WR
1 WATER TEMP C1 2 0.5YB 25 ROTATING BEACON
0.85L/0.85W
8
AIR CLEANER 3 0.85BW 26 BEACON SW
C2 9 PILOT BUZZER
0.85WR
0.85GY
1 25RY
0.85LB
4 0.85GB
1.25R
HYD OIL PRESS 0.85LR 12 14 0.85R
C3
5
C4
6 0.85LR 0.85B 0.85RY 1
0.85GB 5 0.85RW
0.85B 7
HYD OIL PRESS SWITCH
0.85B 0.5B 10 9 0.5WR
0.85GL
PARK BRAKE PRESS SWITCH
0.5BY LIS SELECT SW
0.5LB
0.5R
0.85RB 0.85RB 0.85RB
RETURN STOP LAMP SWITCH 0.85Br/0.85WL
TO DIG
87a 0.85GW 0.85GY
0.85G 30 0.85RB 1.25RL/0.85LY 1.25RL/0.85YL
MAGNET 87
+ 0.85RB 0.5BG 0.5BG
PROXIMITY SW O 0.85WG 0.85B 0.85WG 85 86 0.85RB 0.5BW 0.5BW
- 0.85B RETURN TO DIG RELAY 0.5LB 0.5LB
RAISE 0.50R 0.85WR
(RETURN TO DIG) MAGNET 0.85R 87a 0.85RY HORN SWITCH 2
0.85B 87 30 0.85RB FRONT
COMBI LAMP(L) FRONT
1.25RL/0.85LY
+ 0.85RB 21W 10W COMBI LAMP(R) 0.85BrY (ON JOYSTICK)-F

PROXIMITY SW O 0.85WR 0.85WR 85 86 0.85RB HEAD LAMP(L) HEAD LAMP(R) 10W 21W 0.85BrY
- 0.85B
0.85BrW
RAISE RELAY 75/70W

0.85GW
75/70W
0.85RW
0.85RG
0.85RY
0.85YB
FLOAT HORN (R) H.F

0.5Lg
(turn sig) 0.85WR

0.5R
MAGNET 0.85B
(clearanc)
(RAISE) 0.85RG 87a
0.85GL
0.85RW (low)
0.85B 30 0.85RB (5
0.85RW (low)
0.85BrY
0.85R (high)
87
0.5GL
(high)
(clearanc)
+ 0.85RB
0.85B
0.85B
HORN (L) L.F
(turn sig)
O 0.85W 0.85W 85 86 0.85RB 0.85WR
0.85B
0.85Lg
PROXIMITY SW
0.85R
- 0.85B FLOAT RELAY 0.5GL 0.85GL

(FLOAT) 0.85Lg 0.85Lg
0.58rW 0.58rW 0.85RW
0.85R 0.85R
SAFTY START RELAY BACKUP RELAY 0.85WR
0.58rW 87a 87a 0.85GW
30 0.5RL 0.85RL 30
0.85GL
0.85WR
0.85GR 0.85LB
0.85GW
87 87 0.5GR 0.85BR
0.85WR
0.85GR
0.85Lg
0.85GW
0.85GR
+
LIS ASS'Y (OPTION) 85 86 0.5Gr 85 86 0.5P
(back up)
0.5B WINDOW WASHER

0.85WR
(clearanc)
(turn sig)
(back up)
(18) P FRONT
(clearanc)
LIS SOL - VALVE

(turn sig)
(stop)
(stop)
0.5B 0.85B 0.85B - WIPER MOTOR

0.85LY C B A D E E D A B C 0.85B
(1) 0.85RL 0.85LB 53a
0.85RY 30 M
0.85LY 8 0.85R 53e LO
DISPLAY 25W 10/25W 25W 3Wx2 25W25/10W 25W
(2) 0.85LY 0.85LY 53 0.85RL 2-4 1-4 0.85BY REAR COMBI LAMP(L) LICENCE LAMP REAR COMBI LAMP(R) WIPER RELAY
0.85BL 57 87a 0.85B 31b
0.85BR 11 14 0.85WG 2-1 2-3 0.85B 30 0.85BrL
0.85LB 87
TRANSMISSION VALE 12 0.85GR +
0.85R
23 0.85B - BACK BUZZER 0.5B 85 86 4
ASS'Y + VPS1 0.85R 13 TRANSMISSION 0.85RW
68 0.85RW 0.5L 5 WIPER TIME
10 CONTROLLER KICK 1 2 3 4
Y1 0.85YG 36 0.85RG DOWN STEP STEP STEP STEP
F N R
Y2 0.85LW 56 45 0.85RL 0.85RL X2-A
VP 0.5WR 0.5B
Y3 0.85GL 32 67 0.85Gr 0.85Gr X2-D AD6
Y4 0.85WB 55 20 0.85BW 0.85BW X1-A 0.85Br 0.85Or (C8)
9 22 AD3
Y5 0.85GR 0.85Y 0.85Y X1-D AD7
Y6 0.85WL 51 63 0.85L 0.85L X1-C AD1 PARKING BRAKE SW 0.85B PA
65 0.85G 0.85G X1-B (C9)
TEMP 0.85LB 39 43 0.85Y 0.85Y X2-B AD2 0.5Or
0.85Br 46 64 AD4
TEMP 0.85P 0.85P X2-C AD6 PILOT CUT OFF SW
21 0.850r 0.850r
0.85LgR 19 0.85Y 0.85WL 0.85BW 0.85B (C10) PI
SPEED ENGINE 0.85Lg 29 0.85W 0.85W KICK DOWN SW
PICK / LOG FORK SW
0.85LgW 41 0.85W 0.85B
UP TURBINE 0.85Lg 66 0.85RY 0.85LB 1 1 (AUTO) 0.85WL
5 0.85LY 0.85RL 5
0.85LgB 42 7 7 (MANU) (ON JOYSTICK)-R (1)
CENTRAL GEAR 0.85Lg 3 T/M CUT OFF SW 1
CHAIN 10 9 0.5WR 0.5WR 9 10 0.85W 0.85W
1 0.85B 0.5B 0.85B LOG
2 0.85YR 62 0.5B LOG FORK
(OP
1 0.85RB 4 2 0.85B 0.85W (2) SOL-VALVE
T/M CUT OFF SW 2
3 0.85RL
0.85B
SPEED SENSOR
Figure 1

Page 4
ANTENNA
SPEAKER
(LH) (RH)
CLUTCH FORWARD REVERSE
87a CAR SOLENOID 1 2 3 4 1 2 3
- + -
87
30 1.25RY 1.25RY 3 STEREO 0.85GrR + KV Y2
4 7 KR Y6
1 0.85BY
85 86 0.5RG 1 10 0.85GrL K1 Y4
5 0.5RY 0.85BR 8 K2 Y1
7 9 2 0.85BW
0.85L K3 Y3
9 11
KING LAMP RELAY 0.5B 10 0.5WR 0.85L K4 Y5
0.85B 4
WORKING LAMP SW 3
2 0.85L
DC / DC
0.85WR 1 CONVERTER
0.85WR STARTER CONTROLLER STARTER RELAY
0.85WR ROOM LAMP
1.25R S 0.85BW 0.85BW D PP 2Y
0.85WG 0.85RW N 0.85BrW B
0.85BrW 0.85BY C 2W
(7)
0.85L 10W B P E
0.5WG
0.85B
0.5LR
0.85Y CIGAR LIGHTER 50
0.85WG 0.85WG
- 0.85B 0.85BrW
5 0.5WR 0.5R ENG STOP MOTOR
+ 0.85W
9 0.5WR 0.5WR A 0.85L 30
0.85G P1 0.85LY ENG STOP RELAY
R WIPER SW 15R
B 0.85LB B 0.85LR 87a
30
0.85WR/0.85RW
BLINKER 87
UNIT E 0.85B 0.85WR A P2 0.85LW
86 A
E 0.85B 85
0.85WR
0.85RW
0.85LR
0.85LB
0.85G
0.85RW L
0.85GY 31
0.85RW 0.5B 85B STARTER
0.85LR 24V 6KW
0.5WR 0.5WR 9 10 11 12 13 14 0.85WR
10A 10A 10A 10A 10A 10A 0.5LR 85R
0.85L/0.85W
0.85WR 0.5LR
18 19 20 0.85WR 2WR 2WR 2WR
17
0.85WR
0.85GY
1.25RY
0.85LB
2WR 2W
1.25R
0.85W
FUSE BOX 5W 8W 8W
0.85RY 1 15 16 FUEL PUMP SWITCH
5 0.85RW CIRCUIT BREAKER
0.85WR
15A 15A 15A 15A 15A 15A 15A 15A 0.5R 2R 2WR
0.85BY
7
0.5LR
9 1 2 3 4 5 6 7 8
0.5B 10 0.5WR
0.85L/0.85W
1
0.85GY/0.85GR
0.85RB/0.85RW
1.25LR/0.85LW
1.25RY
0.85Br/0.85WL
2 C P FUEL PUMP 2WR

STARTER ACC
1.25R
0.5B H HOUR METER

LIS SELECT SW 3 SWITCH B
0.85RL
8W 0.5G
R2 BR FUSIBLE LINK
0.85RB R1
0.85Br/0.85WL 0.5BG
0.5BW
0.85Br
0.85GY
1.25RL/0.85YL 8W 2R
0.5BG 8W B A
0.5BW
0.5LB 0.5LB BR
0.5BG
0.5BW
0.85Br 0.85BrW 0.85BrW

0.85WR 0.85WR 0.85WR
HORN SWITCH 2 0.85WY 0.5WY E
87a 0.5LB 4 8 (1) 15R 0.85B
0.85GY 30 85R
T 87 7 PREHEAT 2 0.5WG BATTERY RELAY
MP(R) 0.85BrY (ON JOYSTICK)-F M L E
W HAZARD SWITCH 86 OFF 85 1 CONTROLLER 5 0.85BrY
0.85BrY 85B 85R
0.85LY 1 1 0.5B 0.85LW (2)
HORN (R) H.F 0.85B 5 2
7 3 6 (3) C
0.85GL
B
0.85YB
HEAD LAMP RELAY LAMP SWITCH 0.85B 0.85B - + - +

0.85BrY (5) (6) 10 9
12V 150AH 12V 150AH
)
HORN (L) L.F 0.5WR SW TURN SIGNAL HEAD LAMP

(turn sig)
0.85B 0.5B 0.85GY CN1-8 TML N BATTERY

PREHEAT
49a 8W
0.85GL 0.85GL CN1-4 R THERMO RELAY
(
0.85Lg 0.85Lg CN1-1 L COMBINATION SWITCH H 0.85WG

0.85RW 0.85WY CN1-5 56 15L 0.85RW
0.85R CN1-6 56b SWITCH (R)
0.85RW
0.85R CN1-7 56a
0.85GR CN1-9 15/1 AIR HEATER REGULATOR
0.85GL
0.85LB 0.85LB CN2-6 15(53a) R

+ 0.85BR 0.85BR CN2-8 53c 22V 2.6KW D- DF D+
0.85BrY CN1-2 -
WINDOW WASHER H W
(turn sig)
(18) P FRONT 0.5BL CN2-7 J

WIPER MOTOR 0.85BW CN2-3 53b 15B V U
- +
C 0.85B 0.85BY CN2-1 53
0.85RW
HI 53b 0.85BrL CN2-4 31b
0.85LB 53a
M TML J 0 I II OFF ON OFF ON
0.85R 53e LO 53 SW WIPER WASHER HORN B- ALTERNATOR
5W E
AMP(R) WIPER RELAY 1.25LR 8B
0.85B 31b 24V 50A
87a 0.5RW RECEIVER DRIER COMPRESSOR
30 0.85BrL 0.85BrL NOTE.
0.85LB 87
1 0.5BL AIRCON CONTROLLER LOW PRESS HIGH PRESS MAGNET 1. DIODE PART NO.
0.5B 85 86 4 CUT OFF SW CUT OFF SW 0.85LW CLUTCH
0.85LR DIODE (1) ˜(12) : 2548-1014
2 0.5BL 3 2 0.85BW DIODE (13)˜(18) : 2548-1015
0.5L 5 WIPER TIMER 3 0.5BL 0.5RB 1 AIRCON SWITCH
4 0.5B 2. MARKED (*) : CE OPTION PART NO.
5 6
0.5WR 0.5B 0.5WR 1 0.5RB AIR HANDLING UNIT (4)
0.5RW 5
0.85Br 0.85Or (C8) 7 0.85B
(1) 0.5YG 4
0.5WR 9 10 0.5RB
0.5YW 5
0.85B TERMINAL NO FOR CONTROL UNIT
PARKING BRAKE SW 0.85B PARKING BRAKE 0.5B
(C9) SOL-VALVE 0.85LW 1 AMP MIC 17P AMP MIC 13P
0.5Or 1.25LR 1.25LR 0.85LY 2 30 28 26 24 21 19 17 15 13 11 9 6 4 2
(2)
PILOT CUT OFF SW 0.85LB 3
FAN RELAY + M - 0.85B
0.85WL 0.85BW 0.85B (C10) PILOT CUT OFF 87a 0.85L
W 30 29 27 25 23 22 20 18 16 14 12 10 8 7 5 3 1
W SOL-VALVE 87 0.85L E L M H
0.85B 0.85LR
0.85WL 85 86 OFF +
ICK)-R
0.85W
(1)
0.5B
0.5RB
1
(12) 2
3
STARTER SWITCH CONNECTION
PST TML B BR R1 R2 C ACC
NAME - MEGA 400-III
0.85B LOG FORK 0.85B BLOWER SWITCH OFF
LOG FORK
0.85W (2) SOL-VALVE (OPTION) CONDENSER FAN
PREHEAT WIRING DIAGRAM
ON
0.85B START NO. 4599-1102
DAEWOO HEAVY INDUSTRIES LTD.
HATF620

Page 5
Page 6
S0103000
R1
1WHEEL LOADER
SAFETY
CAUTION!
WHEEL LOADER SAFETYS0103000

Mega 130 0001 and Up

January 2000
Wheel Loader Safety S0103000

Page 1
TABLE OF CONTENTS
To the Operator of a DOOSAN Daewoo Wheel Loader ................................. 3

General Safety Essentials .............................................................................. 4
Location of Safety Labels ............................................................................... 5
Unauthorized Modifications ............................................................................ 5
Work Site Precautions.................................................................................... 5
Operation........................................................................................................ 8
Equipment .................................................................................................... 12
Maintenance................................................................................................. 17
Shipping and Transportation ........................................................................ 20
S0103000 Wheel Loader Safety

Page 2
TO THE OPERATOR OF A DOOSAN DAEWOO WHEEL
LOADER
DANGER!
Improper use of wheel loader could cause serious injury or death. Before operating wheel
loader, or performing maintenance, operator or technician must read and understand entire
Operation and Maintenance Manual.
Any operation, maintenance, traveling or shipping methods that do not follow safety guidelines
printed in this manual could cause serious injury or death.
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 4
2. “Location of Safety Labels” on page 5
3. “Unauthorized Modifications” on page 5
4. “Operation” on page 8
5. “Equipment” on page 12
6. “Maintenance” on page 17
7. “Shipping and Transportation” on page 20

Page 3
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!
Indicates 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!
Indicates 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!
Indicates a hazardous 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.
GENERAL SAFETY ESSENTIALS

ACCESSORY APPLICATIONS
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.

Page 4
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.
Always replace damaged or faded decals.
UNAUTHORIZED MODIFICATIONS
IMPORTANT
If you need more information or have any questions or concerns about safe operating
procedures or working wheel loader correctly in a particular application or in specific conditions
of your individual operating environment, please consult your local DOOSAN representative.
Any modification made without authorization or written approval from DOOSAN can create a safety
hazard, for which machine owner must be held responsible.
For safety's sake, replace all OEM parts with correct authorized or genuine DOOSAN part. For example,
not taking time to replace fasteners, bolts or nuts with correct replacement parts could lead to a condition
in which safety of critical assemblies is dangerously compromised.
WORK SITE PRECAUTIONS

ATTACHMENT PRECAUTIONS
Options kits are available through your dealer. Contact DOOSAN for information on available one-way
(single-acting) and two-way (double-acting) piping/valving/ auxiliary control kits. Because DOOSAN cannot
anticipate, identify or test all attachments that owners may wish to install on their machines, please contact
DOOSAN for authorization and approval of attachments, and their compatibility with options kits.
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")
66.0 kV 5 m (16' 5") Figure 1
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")

Page 5
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.
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. Overhang could collapse on top of operator and cause serious
injury or death. Go onto another digging area before steep overhangs are formed. Know height and reach
limits of wheel loader and plan ahead while working. Park wheel loader away from overhangs before work
shut down.
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.

Page 6
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 0 cm
recommended. 20 ~ 3
TURBO-II
On sloping surfaces, use caution when

positioning wheel loader before starting a work
cycle. Stay alert for unstable situations to avoid
getting into them. For example, you should 20 ~
30 cm
always avoid working bucket over downhill side
HAOA211L
of machine when parked perpendicular to slope.
Avoid full extensions of bucket in a downhill Figure 2
direction. Lifting bucket too high, too close to
machine, while wheel loader is turned uphill can
also be hazardous.
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 3
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.

Page 7
OPERATION
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 but 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 4
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.
BEFORE STARTING ENGINE, DO A "PRESTART" SAFETY CHECK:

• 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.

Page 8
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 5
MOUNTING AND DISMOUNTING
Never get on or off a moving machine. Do not
jump on/off. Entry/egress path should be clear
of mud, oil and spills and mounting hardware
must be kept tight and secure.
Always use handholds or steps and maintain at
least 3-point contact of hands and feet. Never
use controls as handholds.
Never get up from operator's seat or leave
operator's station and dismount machine if
engine is running. HLB1003L
Figure 6
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 work 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.
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 HAOA070L
danger. Figure 7

Page 9
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your
health if it is inhaled. Materials containing
asbestos fiber can be present on work site.
Breathing air that contains asbestos fiber can
ultimately cause serious or fatal lung damage.
To prevent lung damage from asbestos fiber,
observe following precautions;
• Use a respirator that is approved for
use in an asbestos-laden
atmosphere. ARO1770L
• Never use compressed air for Figure 8
cleaning.
• Use water for cleaning to keep down
the dust.
• 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.
TAKE TIME TO PROVIDE GOOD VISIBILITY

Halt work if visibility is poor. Strong rains, snow, fog and extremely dusty conditions can all obscure visibility
so badly that it is best to wait for weather to change or dust to settle before continuing operation.
Night work in areas of limited visibility should be halted if installation of extra work lights on machine (or
work area) is necessary.
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.
FUEL, OIL AND HYDRAULIC FLUID FIRE

HAZARDS
Add fuel, oil, antifreeze and hydraulic fluid to
machine only in a well ventilated area. Machine
must be parked with controls, lights and
switches turned "OFF." 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 machine.
Static electricity can produce dangerous sparks
HAOA120L
at fuel filling nozzle. In very cold, dry weather or
other conditions that could produce static Figure 9
discharge, keep tip of fuel nozzle in constant
contact with neck of fuel filling nozzle, to provide
a ground.

Page 10
Keep fuel and other fluid reservoir caps tight and do not start engine until caps have been secured.
BOOST STARTING OR CHARGING ENGINE

BATTERIES
Turn "OFF" all electrical equipment before
connecting leads to battery. This includes
electrical switches on battery charger or boost
starting equipment.
When boost starting from another machine or
vehicle do not allow two machines to touch.
Wear safety glasses or goggles while required
parallel battery connections - positive to positive
and negative to negative - are made.
HAOA310L
24 volt battery units consisting of two series Figure 10
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 nonseries connected positive terminals and between negative terminal of booster battery
and metal frame of machine being boosted or charged. Refer to procedure and illustration in Operation and
Maintenance Manual.
Connect positive cable first when installing cables and disconnect negative cable first when removing
them. Final cable connection, at metal frame of machine being charged or boost started, should be as far
away from batteries as possible.
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 11
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.
Attachment control levers should not be operated while traveling.
Fold in work equipment so that outer end of boom is as close to machine as possible, and is 200 mm -
300 mm (8" - 12") 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.

Page 11
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.
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 firm, level ground 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.
SHUTDOWN CONTROL FUNCTIONS

After bucket has been lowered to overnight storage position, move all switches and controls to "OFF"
position. Move parking brake switch to "LOCK" position. This will apply parking brake. Move pilot cutoff
switch to "LOCK" position. This will disable bucket control lever. 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 shut down. To release
hydraulic pressure in accumulators, operate control with engine "OFF" until accumulator
pressure is completely dissipated.
EQUIPMENT
ROUGH OPERATION MAY REQUIRE USE OF
CERTIFIED SAFETY EQUIPMENT
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
Protective Structure and/or ROPS/Roll Over
Protective Structure reinforcement system.
HAOA110L
Figure 12

Page 12
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 13
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

When working with a breaker or in some shear work applications, a front guard over windshield may be
required. Windshield guard may or may not be OPS/certified, depending upon the specific application and
working situation.
Laminate glass protection for the front, side or rear windows may also be recommended depending upon
particular site conditions.
Contact your DOOSAN 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.
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.
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 14

Page 13
WINDOW GLASS BREAKING TOOL
This loader is equipped with a glass breaking
tool. It is in the lower left side of the cab just rear
of the door. This tool can be used in case of an
emergency situation which requires the
breaking of glass to exit from the operator's
cabin. Grip the handle firmly and use the sharp
point to break the glass.
WARNING!
Protect your eyes when breaking the Figure 15
glass.
KEEP A FIRE EXTINGUISHER AT HAND

It is recommended that an appropriately sized
(2.27 kg [5 lb] or larger) multipurpose "A/B/C"
fire extinguisher be mounted in cab. Check and
service fire extinguisher at regular intervals and
make sure that all work site crew members are
adequately trained in its use.
HAOA080L
Figure 16
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.
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 fill 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.

Page 14
HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT
Check cylinder drift rate at regular intervals. Overhaul seal kits are available through DOOSAN.
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 work site hazard. Extra safety guards may be required. NEVER allow hoses to
be hit, bent or interfered with during operation.
OPERATOR'S CAB SHOULD BE KEPT CLEAN

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.
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 17
inadequate tools. They could break or slip,
causing injury, or they may not adequately
perform intended functions.
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: The equivalent continuous A-weighted sound pressure level at the workstation for this
machine is given in the operation manual.
Measurement is obtained on a dynamic machine following the procedures and cab
conditions as described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the machinery for this machine is given in
the operation manual.
Measurement is obtained on a dynamic machine with the procedures as described in
2000/14/EC.

Page 15
BATTERY ELECTROLYTE AND EXPLOSIVE
GASES CAN BE LETHAL
Flush eyes with water for 10 - 15 minutes if acid
is splashed in face. Anyone who swallows acid
must have immediate medical aid. Call Poison
Control listing in the front cover of the telephone
directory.
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 HAOA440L
between a loose terminal and post can create
an explosive spark. Figure 18
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.
USE LOW HEAT PORTABLE LIGHTING

Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.

Page 16
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
DOOSAN distributors; see Figure 19.
DO NOT RUN ENGINE IF REPAIRS OR

WORK ARE BEING PERFORMED
ALONE HAOC920L
You should always have at least two people Figure 19

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.
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 firm, level ground 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.
COOL DOWN IS REQUIRED BEFORE

RADIATOR OR RESERVOIR CHECKS
Shut down engine and allow heat to dissipate
before performing service on engine radiator or
hydraulic fluid reservoir. Both assemblies have
air vent levers at or near fill cap for venting built-
up air pressure. Release levers before trying to
take off fill caps and LOOSEN CAPS SLOWLY,
before removal.
HAOA060L
Figure 20

Page 17
PRECAUTIONS WITH HIGH-PRESSURE LINE, TUBES AND HOSES
When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released
from 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.
NOTE: Refer to "Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)"
in Operation and Maintenance Manual, for additional European regulations.
X X O
HAOA420L
Figure 21
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.

Page 18
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.
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. Never drain any petroleum
based product on ground or dispose of old oil in
municipal waste collection containers, or in
metropolitan sewer systems or rural landfills. HAOA470L
Check state and local regulations for other Figure 22
requirements.
CHECK TIRE PRESSURE AND CONDITION

Maintain tire pressure but do not overinflate. Inspect tires and wheels daily. When inflating tires, follow
procedures in Maintenance Section of Operation and Maintenance Manual, 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.

Page 19
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 23
• Condition of ground support.
• Wheel loader configuration and
attachments.
• Weight, lifting height and lifting
radius.
• Safe rigging of load.
• Proper handling of suspended load.
Tag lines 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.

Page 20
S0203020
1SPECIFICATIONS FOR
MEGA 400-III PLUS
CAUTION!
SPECIFICATIONS FOR MEGA 400-III PLUSS0203020


February 1999
Specifications for Mega 400-III PLUS S0203020

Page 1
S0203020 Specifications for Mega 400-III PLUS
Page 2
TABLE OF CONTENTS
Component Locations .................................................................................... 4

General Specifications ................................................................................... 7
Engine Performance Curves .......................................................................... 8
Working Range and Dimensions.................................................................. 10
Working Capacities ...................................................................................... 13
Bucket Capacity .................................................................................... 13
Tipping Load ......................................................................................... 13
Material Weight ............................................................................................ 13
Approximate Weight of Workload Materials .......................................... 13

Page 3
COMPONENT LOCATIONS
Figure 1 identifies the location of major machine components.
1 3 4
2
6
5 7
15 17 18 19
13 14
16 21
11 12 20 22 23 24
25
10
9
8 26 27
28
40 39 38 37 36 34 32 31 30
33 29
35
HAPO010L
Figure 1

Page 4
Reference Reference
Number Number
1 Battery Box (LH) 21 Front Wheel Cover
2 Oil Filter 22 Control Valve
3 Oil Tank 23 Tilt Cylinder
4 Operator's Cab 24 Lift Cylinder
5 Counterweight 25 Tilt Lever
6 Battery Box (RH) 26 Loader Arm
7 Air Conditioner Condenser 27 Bucket
8 Fan 28 Tooth
9 Radiator 29 Link
10 Engine Oil Fill Cap 30 Front Axle
11 Engine Oil Level Dipstick 31 Parking Brake
12 Muffler 32 Drive Shaft
13 Engine 33 Center Pin
14 Air Cleaner 34 Transmission Filter Cap
15 Engine Air Intake 35 Transmission
Precleaner 36 Transmission Oil Level
16 Rear Wheel Cover Dipstick
17 Seat 37 Rear Axle
18 Operator's Controls 38 Rear Pivot
19 Steering Wheel 39 Fuel Filter Cap
20 Wheel Chock 40 Fuel Tank

Page 5
Page 6
GENERAL SPECIFICATIONS
MEGA 400-III PLUS
Item Specification
Standard Bucket Capacity 3.90 m3 (5.10 yd3)
Vehicle Weight 21,900 kg (48,281 lb)
Engine
Type DE12TI
Horsepower 260 ps @ 2,100 rpm
(256 hp @ 2,100 rpm)
Max. Torque 113 kg•m / 1,300 rpm
(817.33 ft lb @ 1,300 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 Drive Shaft Brake
Performance
Travel Speed 7 - 37 km/h (4.35 - 23 MPH)
Steering Angle + 40°
Min. Tire Turning Radius 5,929 mm (19' 5")
Safe Operating Load 7,020 kg (15,476 lb)
Max. Breakout Force 21,900 kg (29,101 lb)
Bucket Rise Time 6.1 Seconds
Bucket Dump Time 1.3 Seconds
Bucket Descent Time 3.4 Seconds
Maximum Gradeability 58% (30°)

Page 7
ENGINE PERFORMANCE CURVES
Figure 2

Page 8
Performance standard Ks-R1004
Power (Maximum / RPM 260 ps @ 2,100 rpm (256 hp @ 2,100 rpm)
Maximum Torque 113 kg•m / 1,300 rpm
(817 ft lb @ 1,300 rpm)
Fuel Consumption 166 g/ps•h
NOTE: Barometric Pressure: 760 mm (30") Mercury

Temperature: 20°C (68°F)
Cooling Fan: 838 mm (33 in) Blower Fan
Alternator: 24 V, 60 amp
Exhaust System: Complete, Attached
Air Cleaner; Installed

Page 9
WORKING RANGE AND DIMENSIONS
Figure 3, illustrates exterior machine dimensions and working range of machine when it is equipped with a
standard bucket.
Figure 3

Page 10
Category Dimension
Overall Length (A) 8,425 mm (27' 8")
Overall Width, without bucket (B) 2,985 mm (9' 10")

Overall Height (C) 3,566 mm (11' 8")
Bucket Width (D) 3,280 mm (10' 9")
Wheel Base (E) 3,500 mm (11' 6")
Tread (F) 2,300 mm (7' 7")
Ground Clearance (G) 500 mm (1' 8")
Dump Height, to tooth (H) 3,022 mm (9' 11")

Dump Distance, to Bucket Edge (I) 1,195 mm (3' 11")
Dump Height to Bucket Pivot 3,886 mm (12' 9")
Bucket Angle, Raised (a) 47°
Bucket Angle (b), Lowered (at carry) 42°
Tire Size 26.5-25-20 PR(L3)

Page 11
Figure 4 and Figure 5, illustrate working range when machine is equipped with optional Pallet or Log Fork.
Figure 4
Reference Reference
Dimension Dimension
Number Number
A 2,503 mm (8' 3") a 14°
B 3,676 mm (12' 1") b 26°
C 4,108 mm (13' 6")
Figure 5
Reference Reference
Dimension Dimension
Number Number
A 1,655 mm (5' 5") b 45°
B 2,840 mm (9' 4") c 22°
a 47°

Page 12
WORKING CAPACITIES
BUCKET CAPACITY
Standard toothed bucket has a capacity of 3.9 m3 (5.1 yd3). An optional bucket equipped with a cutting
edge and no teeth has a capacity of 3.9 m3 (5.1 yd3).
TIPPING LOAD
Static Tipping Load with bucket in Over Front position is 16,420 kg (36,200 lb). With bucket in Fully Turned
position, Static Tipping Load is 14,016 kg (30,900 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
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
Coke, blast furnace 433 kg/m3

--------------------- ---------------------
size (729 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(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)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(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)

Page 13
LESS LESS LESS
Cement, Portland, 1,506 kg/m3

--------------------- ---------------------
DRY granular (2,583 lb/yd3)
Cement, Portland, 1,362 kg/m3

--------------------- ---------------------
DRY clinkers (2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
Earth, loamy, DRY, 1,202 kg/m3

--------------------- ---------------------
loose (2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy --------------------- ---------------------
(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)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)

Page 14
LESS LESS LESS
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulphur, broken --------------------- ---------------------
(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.

Page 15
Page 16
S0302000
R1
1GENERAL
MAINTENANCE
PROCEDURES
CAUTION!
GENERAL MAINTENANCE PROCEDURESS0302000

ALL MODELS ALL RANGES

May 2002
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
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
DOOSAN 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.
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 prefilling 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 prelube) or has been contaminated by dirt or by
questionable oils, flushing and prefilling 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 prestart 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.
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 preclean any exterior surface of the system before it is exposed to
air. For example, the reservoir fill 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 subfreezing 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 filters 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 prefill the assembly
before bolting together the drain line piping connections. Run the system at low rpm.
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, noncombustible, 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.
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 retaining 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
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.
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
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
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
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
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
S0309000
R1
1STANDARD TORQUES
CAUTION!
STANDARD TORQUESS0309000
ALL MODELS ALL RANGES

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 Pitc
h (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)

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.

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 NONLUBRICATED
(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
130 176 185 251
5/8" - 18
205 278 290 393
3/4" - 10
240 312 320 434
3/4" - 16
305 414 455 617
7/8" - 9
334 454 515 698
7/8" - 14
455 617 695 942
1" - 8
510 691 785 1064
1" - 14
610 827 990 1342
1 1/8" - 7
685 929 1110 1505
1 1/8" - 12 860 1166 1400 1898
1 1/4" - 7 955 1295 1550 2102
1 1/4" - 12 1130 1532 1830 2481
1 3/8" - 6 1290 1749 2085 2827
1 3/8" - 12 1400 2034 2430 3295
1 1/2" - 6 1690 2291 2730 3701
1 1/2" - 12 2370 3213 3810 5166
1 3/4" - 5 3550 4813 5760 7810
2" - 4 1/2
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.

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
279.4 2020
1 - 1/2"
347.1 2510
1 - 3/4"
522.8 3780
2

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 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50

"Ultra-Tite"

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.

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.

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. DOOSAN 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.

Page 10
I. "Loctite" Fastener Adhesives
Breakaway Cure
Product Application Color Removal Strength (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/nonclog" formula for high-pressure 4 Hours (or 1/2 hour
545 hydraulic systems. Over application will not Purple Hand tools with Locquic "T"
restrict or foul system components. Primer)
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 faster
504 compound. Fills gaps to 0.0012 mm (0.030"), Orange (1/2 - 4 hours) setup. Unprimed
cures to rigid seal. setup 4 - 24 hours.
General purpose, fast setup, flexible-cure Use Locquic "N" primer for faster
515 gasket eliminator. For nonrigid assemblies Purple (1/4 - 2 hours) setup. Unprimed
subject to shock, vibration or deflection. setup 1 - 12 hours.

Page 11
IV. "Loctite" retaining compounds

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

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.

Page 12
S0405500
1FUEL TRANSFER PUMP
CAUTION!
FUEL TRANSFER PUMPS0405500

Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier I) 1001 thru 2000
Mega 250-V (Tier II) 2001 and Up
Mega 300-V (Tier I) 1001 thru 2000
Mega 300-V (Tier II) 2001 thru 3000
Mega 300-V 3001 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
Models continued on back of cover.

January 2004
Fuel Transfer Pump S0405500

Page 1
Solar 220LL 1001 and Up
Solar 220N-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 55W-V PLUS 1001 and Up
TABLE OF CONTENTS
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
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
The fuel pump consists of a motor, pump,

switch, and hose assembly.
Figure 2

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 being damaged.
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 the pump
during operation, it can become lodged between
the rotor and/or vanes and generate heat which
can cause the 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 new ones.
Figure 5 WITHOUT TOGGLE SWITCH

Page 4
Insert vane, with the circled edge of vane facing
in the counterclockwise direction. (Detail A)
Insert a new O-ring again at reassembly of the
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
the brush and insert it to the armature. Then fit Figure 7
the hole of screw in the housing.
Be careful when installing the screw. The cover
screw may be attracted by the motor magnet.

Page 5
REPLACEMENT OF
ARMATURE
You can replace only the armature in case the
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 the rear cover.
Fit the rotor into the shaft flute of the armature.
Insert vane to the rotor being careful of the
direction. Refer to “Replacement of Rotor and
Vane” on page 4.

Page 6
S0602070
1FRONT AXLE
(GRAZIANO)
CAUTION!
FRONT AXLE (GRAZIANO)S0602070


February 1999
Front Axle (Graziano) S0602070

Page 1
TABLE OF CONTENTS
Outline..................................................................................................... 4
When Moving Straight Forward............................................................... 5
When Slowing ......................................................................................... 5
Parking Brake................................................................................... 5
Parts List ................................................................................................. 6
Front Axle Housing .......................................................................... 6
Limited Slip Differential Cross Section ............................................. 7
Front Axle Differential....................................................................... 8
Front Planetary Gear Set ............................................................... 10
Parking Brake................................................................................. 12
Scheduled Maintenance............................................................................... 14
After First 200 Hours ............................................................................. 14
Every 150 hours .................................................................................... 15
Every 1,500 Hours ................................................................................ 15
Lubricant Specifications ........................................................................ 15
General Disassembly and Reassembly Instructions .................................... 16
General Instructions .............................................................................. 16
Assembling Leakproof Components ..................................................... 17
Axle Disassembly ......................................................................................... 17
Drain Oil ................................................................................................ 17
Final Drive ............................................................................................. 18
Overhauling Super Max Trac Assembly ................................................ 25
Checking Clearance on Assembled Disk Packs.................................... 25
Axle Reassembly.......................................................................................... 26
Determining Thickness of Adjustment Shims........................................ 26
Inner Oil Recirculation Piping................................................................ 27
Axial Position of Bevel Pinion ................................................................ 28
Adjusting Backlash................................................................................ 29
S0602070 Front Axle (Graziano)

Page 2
Adjusting Tooth Contact ........................................................................ 30
Correct Pattern............................................................................... 30
Increase Pinion Distance ............................................................... 30
Decrease Pinion Distance.............................................................. 31
Securing Differential to Axle Housing.................................................... 32
Final Drive ............................................................................................. 34
Determining Space Available to Form Brake Disk Pack........................ 36
Parking Brake ............................................................................................... 38
Disassembly.......................................................................................... 39
Reassembly .......................................................................................... 39
Adjustment ............................................................................................ 39

Page 3
GENERAL DESCRIPTION
Figure 1
OUTLINE
• The motive force from engine is
transmitted to front and rear axles via
torque converter, transmission, and
drive shaft.
• In the axle, motive force is
transmitted from pinion gear (1) to
bevel gear (2), shifted 90° and
reduced, and transmitted to sun gear
shaft (3) via differential gear (4).
• Motive force of sun gear is further
reduced by planetary gear type final Figure 2
drive, and transmitted to axle shaft
and wheel.

Page 4
WHEN MOVING STRAIGHT FORWARD
• When moving straight forward, the
speed of rotation of left and right
wheels is equal, so pinion gear (5) in
differential assembly does not rotate,
and motive force of carrier (6) is
transmitted equally to left and right
sun gear shaft (7) via pinion gear (5)
and side gear (8).
Figure 3
WHEN SLOWING
• When slowing, the speed of rotation
of left and right wheels is unequal, so
pinion gear (5) and side gear (8) in
differential assembly rotate according
to the difference in left and right
rotation speeds, and motive force of
carrier (6) is transmitted to sun gear
shafts (7).
Figure 4
Parking Brake
A disk type parking brake is attached to the input shaft on the front axle. See Figure 12. This brake is
spring applied and hydraulically released. When the parking brake switch in the operator's cab is moved to
the brake release position, the parking brake solenoid valve opens and directs fluid from the brake pump to
the brake cylinder (18).
Maximum parking brake hydraulic pressure set spring is 100 bar. The brake cylinder retracts the brake set
spring (22) and releases the brake.
If the electrical supply to the parking brake is solenoid valve is interrupted, or if the engine is shut off, the
parking brake is automatically applied.
As a safety feature, the transmission forward/reverse gear selector must be in the neutral position and the
parking brake switch must be in the "ON" position, to start the engine.
When the parking brake switch is On, a warning light turns "ON." If either forward/reverse is selected on
the transmission while the parking brake switch is on, a buzzer will sound.

Page 5
PARTS LIST
Front Axle Housing
Figure 5
Reference Reference
Number Number
1 Oil Fill Plug - M27 x 2 7 Oil Tube
2 Oil Drain Plug - M27 x 2 8 Cap Screw - M8 x 22
3 Front Axle Housing 9 Retaining Ring - 20 mm dia
4 Axle Vent - M10 x 1 10 Oil Pipe, Right Side
5 Axle Shaft 11 Oil Pipe, Left Side
6 Tube Gasket - 12 Cap Screw - M8 x 40
2.62 x 26.65 mm dia

Page 6
Limited Slip Differential Cross Section
Figure 6, shows a cross-sectional view of the parts contained in the limited slip differential.
Reference
Description
Number
1 Ring Gear
2 Bevel Pinion
3 Cross
4 Upper Thrust Ring
5 Outer Disk
6 Inner Disk
7 Cover
8 Clutch Disk
9 Sun Gear
10 Lower Thrust Ring
Figure 6

Page 7
Front Axle Differential
Figure 7

Page 8
Reference Reference
Number Number
1 Pin - 8 mm dia x 40 mm Shim - 1.000 mm
2 Bearing - JHM 720249/ Shim - 1.025 mm
720210 Shim - 1.050 mm
3 Bearing Adjusting Nut Shim - 1.075 mm
5 Outer Clutch Disk Shim - 1.125 mm
6 Sun Gear Shim - 1.150 mm
7 Cross Shim - 1.175 mm
8 Planetary Gear Shim - 1.200
9 Thrust Washer Shim - 1.225 mm
* 10 Shim - 3.5 mm Shim - 1.250 mm
11 Cap Screw - M14 Shim - 1.350 mm
x1.5 x 140 mm
Shim - 1.375 mm
12 Middle Clutch Disk
Shim - 1.400 mm
13 Cap Screw -
Shim - 1.425 mm
M16 x 1.5 x 55 mm
Shim - 1.450 mm
14 Plate
Shim - 1.475 mm
15 Rivet
Shim - 1.500 mm
16 Bearing H916600
22 Nut
17 Shim - 3.5 mm
23 Flange Assembly
Shim - 3.6 mm
24 Bearing - JW70
Shim - 3.7 mm
25 Seal - 105 x 140 x 13 mm
Shim - 3.9 mm
26 Washer
Shim - 4.0 mm
110 Differential Support
Shim - 4.1 mm
Assembly
Shim - 4.2 mm
120 Ring and Pinion Gear
Shim - 4.4 mm 130 Differential Carrier
18 Pump 140 Spacer Assembly
19 Shim - 0.5 mm

Page 9
Front Planetary Gear Set
Figure 8

Page 10
Reference Reference
Number Number
1 Housing Cover 27 Thrust Washer
2 Cover Gasket - 28 Bearing - 180 mm
3.53 x 304.4 dia x 250 x 45
3 Shaft Thrust Plate 29 Ring Gear Support
4 Cap Screw - M10 x 25 30 Ring Gear
5 Planetary Housing 31 Wheel Hub
6 Pin 32 Stud Bolt
7 Plug - M22 x 1.5 33 Piston Seal -
8 Plug Gasket 5.33 x 117.5 mm
9 Thrust Washer - 3 mm 34 Piston
10 Bearing 35 Piston Seal -
5.34 x 142.9 mm
11 Bearing Spacer
36 Inner Bearing - 170 mm
12 Differential Pinion Gear
dia x 230 x 38
13 Thrust Washer - 4.7 mm
37 Wheel Seal -
14 Differential Side Gear 190 mm x 230 x 21.3
15 Retaining Ring 38 Right Side Hub and Spindle
16 Brake Disk Hub Assembly
17 Brake Disk 39 Bleeder Screw
18 Steel Disk - 4.0 mm 40 Cap Screw - M x 25
Steel Disk - 4.25 mm 41 Housing Seal Ring -
Steel Disk - 4.5 mm 3.53 x 430.66 mm
Steel Disk - 5.0 mm 42 Left Side Hub Assembly
19 Pin 43 Cap Screw -
M22 x 1.5 x 70 mm
20 Retaining Ring
44 Nut
21 Pressure Plate
45 Pin
22 Spring
46 Ring
23 Spring Insert
47 Seal Ring
24 Lockplate
48 Washer
25 Hub Nut
110 Housing Assembly
26 Retaining Ring

Page 11
Parking Brake
Figure 9

Page 12
Reference Reference
Number Number
1 Ball Socket 18 Washer
2 Ball Socket 19 Cylinder
3 Lock Nut 20 Guide Ring
4 Adjusting Rod 21 Gasket
5 Adjusting Sleeve 22 Seal
6 Lock Nut - M14 x 2 23 Spring
7 Protective Cap 24 Flange
8 Joint Cover 25 Nut
9 Dowel Pin 26 Caliper Assembly
10 Tension Rod 27 Cap Screw - M10 x 40
11 Stem 28 Washer
12 Mounting late Assembly 29 Brake Disk
13 Seal 30 Cap Screw - M10 x 40
14 Gasket 31 Cap Screw -
15 Guide Ring M12 x 35 x 1.75
16 Threaded Stud 32 Cotter Pin
17 Nut - M x 10+ 33 Gasket Kit - Contains items
12, 13, 14, 19, 20 and 21

Page 13
SCHEDULED MAINTENANCE
Figure 10
AFTER FIRST 200 HOURS

Replace oil in axle assembly as follows:

replace plug (3).

Page 14
EVERY 150 HOURS
Check oil in axle assembly as follows:
• With axle positioned horizontal, remove fill plug (1) and check oil level. Oil level should reach
edge of fill plug seat. Add oil as required.
• Check oil by rotating hub 90° (so "OIL LEVEL" writing is horizontal), remove plug (3) and check
oil. Oil should edge of fill plug seat. Add oil as required, replace plug (3).
EVERY 1,500 HOURS

Replace oil in axle assembly as follows:
replace plug (3).
LUBRICANT SPECIFICATIONS
For differential and final drive units:
• Oil specification: Mil - L - 2105B
API GL 5
• Corresponding to: SAE 90 or SAE 80W90 rating.
NOTE: DOOSAN recommends oils with LIMITED-SLIP (LS) additives to prevent noise when
brakes are actuated.

Page 15
GENERAL DISASSEMBLY AND REASSEMBLY
INSTRUCTIONS
WARNING!
Never use gasoline, solvents, or other flammable fluids to clean components. Only use
approved commercial solvents that are nonflammable and nontoxic.
IMPORTANT
Use only GENUINE DOOSAN SPARE PARTS to warrant proper operations and prevent
interchangeability problems.
GENERAL INSTRUCTIONS
1. Thoroughly clean and dry axle before disassembly.
2. All components should be thoroughly cleaned and dried before reassembly. Dirt, chips, and foreign
material may cause failures.
3. All ducts and castings should be thoroughly cleaned and dried to remove dirt, chips, and foreign
material to prevent damage after reassembly.
4. Reassembly should be done in a clean shop, and should be as dust free as possible.
5. Make sure tools and equipment are at hand.
6. When reassembling DOOSAN strongly recommends to replace the following parts with new.
• Seal Rings
• O-rings
• Gaskets
• Threaded rings with notched collar
• Any component damaged during disassembly
7. When mounting heat fitted components, make sure of their proper position and direction of assembly,
after they have cooled.
8. To heat bearings, use proper heating plates, piping, or suitable ovens.
NOTE: Never heat parts by using a torch. Oil bath, heated by a torch, maybe used to warm
components.
9. Lubricate all sections concerned when reassembling shafts, bearings, etc.
10. Lubricate O-rings before installing them in relevant seats to prevent kinking during assembly, such a
position would impair proper sealing.
11. Replace gears only in matched sets to make sure of proper tooth mating.

Page 16
ASSEMBLING LEAKPROOF COMPONENTS
1. Use of proper sealing compounds is recommended when assembling matched parts to be sealed
against fluid leakage (oil or water), and no sealing gasket is used.
2. Best results are reached, with said compounds, when matching surfaces are thoroughly cleaned,
degreased, and dried before spreading a uniform coat over contact area.
3. DOOSAN suggests to use the following compounds:
• Loctite Plastic Gasket
• Rhodorsil CAF 1
• Silastic 732 RTV
AXLE DISASSEMBLY
Figure 11
DRAIN OIL

Page 17
FINAL DRIVE
Figure 12

Page 18
WARNING!
Lift and handle all heavy components by using proper equipment. Make sure that assemblies or
components are lifted and held with the use of proper slings and hooks. Use specific lifting
eyes. Always make sure that people are out of the way when lifting.
1. Remove six cover mounting screws (1), then remove final drive cover (2).
NOTE: Cover (2) is provided with three threaded holes for puller screws.
3. Using a puller screw, remove axle shaft backing plate (4).
4. Provide suitable support for side gear carrier (6), then remove screws (5) fixing side gear carrier to
wheel hub (7), and pry side gear carrier (6) to separate from wheel hub (7).
5. Pull side gear carrier (6) out of wheel hub.
6. Remove lock ring (9) retaining sun gear (10), and remove sun gear from wheel shaft (14).
7. Remove disk carrier hub (11) along with thrust washer (12) resting against wheel hub sleeve.
8. Remove solid and lined brake disks (13).
9. Remove wheel shaft (14).
10. Remove lock ring (15) securing lock (16), then remove ring nut (17).

Page 19
Figure 13
Spring Retainer Installed

A Spring Retainer
17 Ring Nut
18 Pressure Plate
19 Return Spring
NOTE: Install a spring retainer (A), secured thru three threaded holes of disk pressure plate (18),
to compress return spring (19) and allow removal of ring nut (17).
11. Unlock and remove ring nut (17) from sleeve (27).
12. Remove pressure plate (18) along with brake return spring retainer (A).
13. Provide suitable support for wheel hub (7) and pull ring gear unit (21) and support (22) from hub.
14. Remove six rods (24) in seats on ring gear support (22).
15. Using a screwdriver, pry off lock ring (23) from ring gear (21).
16. Disassemble ring gear support (22) from ring gear (21).
NOTE: Should replacement of outer wheel bearing (25) inner race be mandatory, old part can be
removed by a proper puller, or by a remover that can be inserted in specific holes of ring
gear support (22).
17. Remove brake return spring retainer (A) and disassemble return spring (19), retaining cup (20), and
pressure plate (18).

Page 20
18. Using compressed air thru brake oil port, remove brake actuating piston (26) from wheel hub sleeve
(27).
19. Remove and replace with new two O-rings (28 and 29) in seats on brake actuating piston.
20. Remove complete wheel hub (7)
22. Pry off seal (30) from wheel hub (7), and remove inner race with roller cage of inner wheel bearing
(31).
23. Using a proper remover, push out outer races of inner and outer wheel bearings (25 and 30) from
wheel hub (7).
NOTE: Should sleeve (27) be damaged, it can be removed by undoing relevant screws (32). At
reassembly, smear proper sealing compound on axle case joining flange, then tighten
screws. Torque to 90 ±4.5 Nm (9.18 ±0.46 kg•m / 66 ±3 ft lb)
24. Mark side gear pins (33), various components and seats (34) for identification of original position at
reassembly.
25. Arrange side gear carrier (6) on wooden blocks and push out pins (33) with proper remover.
26. Pick up all needle rollers (35).
NOTE: It is important to keep matched needle rollers (35) and thrust washers (36) with relevant
pin (33), this is consequent to predetermined assembly tolerance limits.
27. Remove side gears (37) and relevant thrust washers (38).
NOTE: No gear can be removed before having released all of them.

Page 21
Figure 14
1. Release and remove six screw (1) that secure outer recirculation piping (2) and three seals (3).
2. Check wear condition of components and repair or replace as required.
3. Unlock and remove screws (4) retaining differential assembly, then remove differential assembly from
axle case.

Page 22
Figure 15
4. Hammer out spring pins (2) locking slotted rings (3).

5. Mark caps (4) to match parts at reassembly.
6. Remove screws (5), caps (4), and slotted rings (3).
7. Remove differential case assembly from support (11).
8. Straighten locking notches on pinion nut collar (6), position reaction tool on drive flange to unlock nut
(6), release pinion nut, remove drive flange (9) from pinion shank along with washer (8).
9. Pry seal (10) from drive flange.

Page 23
10. Remove bevel pinion (7) from differential support (11), hammer pinion shank with a proper removal
tool.
NOTE: Be careful not to damage threads on pinion (7).
11. Pick up inner race of pinion shank bearing (13).
12. Remove outer races of outer and inner pinion bearings (13 and 14) from differential support (11), pick
up shims (15).
NOTE: Be careful not to loose shims (15) for pinion axial position adjustment, store in a safe place
for reassembly.
13. Remove spacer (16) with shims (17) for bearing preload adjustment, using a proper puller remove
inner race of pinion under head bearing (14).
NOTE: Be careful not to loose shims for bearing preload adjustment, store in a safe place for
reassembly.
14. Mark differential half cases (18 and 19) for reference at reassembly, then remove screws (19a) and
separate half cases (18 and 19).
15. Make a visual and dimensional check of wear on sun gears (21), side gears (20), thrust washers (22
and 23), friction disks (22a), backing disks (22), and spider (24).
16. Using a proper puller, remove bearings (25) from half cases (18 and 19).
17. Clamp ring gear (26) in a vise fitted with soft caps, then remove screws (27) securing ring gear (26) to
half case (18).
18. Fit inner races of differential bearings (25) on half cases (18 and 19)
NOTE: This operation should be carried out by heating equipment or use a proper installer.
19. Mount bevel ring gear (26) on half case (18), secure with screws (27).
NOTE: Torque to 90 ±4.5 Nm (9.18 ±0.46 kg•m / 66 ±3 ft lb).
20. Position differential components in their proper seats.

Page 24
OVERHAULING SUPER MAX TRAC
ASSEMBLY
1. Select backing disks (22) to reach, as
assembling is completed, prescribed
clearance of 0.05 - 0.10 mm (0.0020 -
0.0039") all around both disk packs.
NOTE: When packing friction and
backing disk, pay particular
care to position of first disk
(22a), it is molibdenum plated
on one side only. Disk (22a) is
in contact with sun gear (21),
and molybdenum plated side Figure 16
must face backing disk (22).
2. Join half cases (18 and 19) matching
reference marks made at disassembly.
3. Mount and secure case halves (18 and 19)
with screws (19a).
NOTE: Torque to 22 ±1.1 Nm
(2.24 ±0.112 kg•m /
16 ±0.8 ft lb).
CHECKING CLEARANCE ON ASSEMBLED DISK PACKS

1. Check should be carried out all around at
points placed at 120° to one another on
both disk packs to prevent mileacting
recording of values due to spider and sun
gear play.
NOTE: Should recorded clearance not
be as specified, disk packs
must be reformed to prescribed
value of 0.05 - 0.10 mm (0.0020
- 0.0039")
Figure 17

Page 25
AXLE REASSEMBLY
DETERMINING THICKNESS OF ADJUSTMENT SHIMS
Figure 18
1. Some dimensions should be recorded before starting reassembly of bevel pinion to determine
thickness of spacer to be fitted between inner (under head) pinion bearing and backing of relevant
seat in differential support.
2. Record dimension from ring gear axis to seat inner (under head) pinion bearing (that will be identified
as "A").
• Example: "A" = 290.6 mm.
3. A number "X" prefix by symbol " ±" is marked on bevel pinion face. This value is expressed in tenth of
millimeter, indicates deviation from theoretical distance from pinion under head to ring gear axis.
• Example: +1 = +0.1 mm.
4. Consequently, the true distance (identified as "B") will be: B = 321.7 ±deviation.
• Example: B = 231.7 + 0.1 = 231.8 mm.
5. Measure thickness of pinion head bearing and identify as "D."
• Example: "D" = 54.85 mm.
6. Compute thickness of shim "S" for proper axial position of bevel pinion: S = A - (B + D).
• Example: S = 290.6 - (231.8 + 54.85) = 3.95 mm.
7. Increase by 0.05 mm the computed thickness value to compensate subsequent bearing preload.
Round off to nearest tenth of millimeter to computed thickness value.
• Example: 4.02 rounded off = 4 mm.
3.88 rounded off = 3.9 mm.

Page 26
INNER OIL RECIRCULATION PIPING
Figure 19
1. Remove pipes (A and B), remove seals (C) from axle housing.
2. Check wear condition of pipes (A and B), replace with new if required.
3. Replace seals (C) with new.

Page 27
Figure 20
AXIAL POSITION OF BEVEL PINION

1. Press fit inner race of inner (under head) bearing (14) on pinion by using heating equipment or use of
proper installer.
2. Position shim (15), see "Determining Thickness of Adjustment Shims," in its seat and press fit outer
races of inner (under head) and outer bearings (13 and 14) of pinion.
3. Fit impeller (16) on pinion along with shims (17) for bearing preload adjustment, then mount inner
race of pinion outer bearing (13).

Page 28
NOTE: To facilitate proper preload computation, it is advisable to mount as many shims as
required to warrant a pinion end play and not a preload (that could be excessive) on
bearings.
4. Fit drive flange (9) on pinion (7), position specific reaction tool and tighten nut (6). Remove reaction
tool.
5. Check pinion end play using a dial gauge, then disassemble and change shims to eliminate all end
play and reach intended preload.
6. Reassembly components, check that proper preload of bearing corresponding to a revolving torque
(no seal installed).
NOTE: Revolving torque of 0.20 - 0.40 Nm (0.02 - 0.04 kg•m / 0.15 - 0.30 ft lb).
7. As the prescribed preload of bearings has been reached, remove drive flange (9) and fit lip seal (10)
into its proper seat.
8. Remount drive flange (9) and tighten to specified torque.
9. Position differential assembly with ring gear on support (11), insert ring nut (3), and temporarily adjust
back lash.
10. Mount caps (4), being careful not to invert position, secure support to differential with screws (5).
NOTE: Torque from 880 - 920 Nm (650 - 680 ft lb).
11. Check differential end play with a dial gauge.
12. Screw in a ring nut to have a notch aligned against slot of lockplate, and actuate opposite nut up to
eliminate end play.
NOTE: When end play is eliminated, set bearing preload by screwing in ring nut one more notch.
ADJUSTING BACKLASH
1. Position a dial gauge perpendicular to ring
gear (26) tooth, with pinion steady check
backlash.
• Standard backlash of bevel gear set:
0.30 - 0.41 mm (0.0118 0.0161")
• To obtain backlash within specified
range, rotate both ring nuts (3),
displacing them same number of
notches.
• Moving toward ring gear to pinion, if
backlash is too LARGE. Figure 21
• Moving away ring gear to pinion, if

backlash is too SMALL.

Page 29
ADJUSTING TOOTH CONTACT
1. Coat face of 7 or 8 teeth of bevel gear
lightly with red lead. Hold bevel gear by
hand to act as a brake, rotate pinion gear
forward and backward, then inspect
pattern left on teeth.
Correct Pattern
Drive Side.
Figure 22
Neutral Side.
Figure 23
Increase Pinion Distance
Drive Side.
Figure 24
Neutral Side.
Figure 25

Page 30
Decrease Pinion Distance
Drive Side.
Figure 26
Neutral Side.
Figure 27
NOTE: When adjusting bevel gear, do not change preload of bearing. Adjust by rotating both ring
nuts the same number of notches.
2. Fit spring pins (2) to lock differential ring nuts.
3. Make two lock notches on pinion nut collar (6).

Page 31
SECURING DIFFERENTIAL TO AXLE HOUSING
Figure 28
1. Thoroughly clean mating surfaces, apply sealing compound and mount differential assembly on axle
housing, and secure with screws (4).
NOTE: Torque to 33 ±1.65 Nm (3.37 ±0.169 kg•m / 24 ±1.22 ft lb)
2. Install outer oil recirculation piping (2) with new seals (3), and secure with six screws (1).

Page 32
Page 33
FINAL DRIVE
Figure 29

Page 34
1. Reinstall wheel hub (7), first fit outer races of wheel inner and outer bearings (25 and 31), making
sure they rest against seats.
2. Position inner race with roller cage of wheel inner side bearing (31) before fitting lip seal (31).
3. Install O-ring (8).
4. Install wheel inner bearing (31) into sleeve (27).
NOTE: Support wheel hub (7) during assembly stage to prevent damage to seal.
5. Lubricate seals (28 and 29) on piston (26), then insert at travel end on wheel hub sleeve (27).
6. Using heating equipment or proper installer, fit inner race of wheel outer bearing (25) on ring gear
support (22), then mount support (22) in ring gear (21) and secure with lock ring (23).
7. Mount ring gear (21) and support (22) unit onto sleeve (27).
8. Fit six rods (24) into seats on ring gear support (22).
9. Install spring retainer and compress spring (19) with retaining cup (20) onto pressure plate (18).
10. Mount pressure plate and spring assembly onto ring gear support (22).
11. Hand screw ring nut (17) onto wheel hub sleeve (27).
12. With a wrench, tighten ring nut (17) to the prescribed preload for wheel bearings and corresponding
to a revolving torque, checking alignment of lock plates (16).
NOTE: Revolving Torque: 1.5 - 3 Nm (0.15 - 0.31 kg•m / 1.11 - 2.21 ft lb).
NOTE: To prevent recording wrong torque values, it is advisable to seat bearing properly before
checking, by revolving wheel hub repeatedly.
13. Remove spring retainer compressing brake actuator return spring.
14. Insert lock plates (16) securing ring nut and install lock ring (15).
15. Arrange three side gear gears (37) in proper seats of side gear carrier (6).
NOTE: Two rows of needle rollers of same selection class should be used for replacement in each
single side gear pin.
16. Insert outer thrust washers (36), apply grease to pin lower portion (head end) and position the first
row of needle rollers, insert spacer and apply grease to upper portion of pin, then position second row
of needle rollers (35).
17. Position outer thrust washers (38) of side gear on side gear carrier and align holes.
18. Insert and force fit complete pins (33).
NOTE: Avoid any bump or knock that could cause rollers to fall.
19. Insert wheel shaft (14).
20. Insert thrust washer (39).
21. Mount disk carrier hub (11) onto wheel shaft (14).
22. Mount brake disks, alternating solid disks and lined disks. (See "Determining Space Available to
Form Brake Disk Pack").
NOTE: Insert a solid disk (outer teeth) facing pressure plate (12).
23. Insert sun gear (10) and secure with lock ring (9).
24. Mount side gear carrier (6) on side gear unit and secure onto wheel hub (7) with screws (5).
NOTE: Torque to: 7 ±0.35 Nm (0.71 ±0.04 kg•m / 5.16 ±0.26 ft lb).

Page 35
25. Force fit wheel shaft backing plate (4).
26. Mount O-ring seal (3) on edge.
27. Rotate and align pins (33) to allow mounting of cover (2), which also acts as a pin lock to prevent their
rotation.
28. Fit side final drive cover (2).
29. Apply sealing compound to screws (1) and secure cover (2).
NOTE: Torque to: 3.5 ±0.175 Nm (0.36 ±0.018 kg•m / 2.58 ±0.129 ft lb).
DETERMINING SPACE AVAILABLE TO

FORM BRAKE DISK PACK
1. Record depth from seating surface of side
gear carrier on wheel hub to outer edge of
ring gear, identify value as "A."
2. Record depth from ring gear outer edge to
brake pressure plate, identify value as "B."
3. Subtract value "B" from value "A" and
identify as value "D."
• Example: A - B = D.
Figure 30
4. Record depth from disk reaction face to
outer edge of side gear carrier, identify
value as "C."
5. Add value "C" to value "D" to provide
space available to form brake disk pack.
• Example: C + D = X
Figure 31

Page 36
6. To form disk packs, compute thickness of
disk pack (solid disks + lined disks), it is
necessary to subtract clearance of 1 mm
(0.0394") for each brake disk plus the total
thickness of the lined disks from space
available for remaining clearance with solid
disks (outer teeth) of proper thickness with
a tolerance of ±0.25 mm (0.0098").
Figure 32

Page 37
PARKING BRAKE
Figure 33

Page 38
DISASSEMBLY
1. Unlock right and left counter nuts (1) of adjustment sleeve (2).
2. Remove nuts (3) retaining hydraulic cylinder (5) to bracket (4), then undo sleeve (2) and remove
cylinder (5).
3. Undo two screws (7) securing caliper to support, then remove brake caliper assembly (6).
4. Undo eight screws (8) and remove brake disk (9) from drive flange.
5. Remove split pin (10) from stem (14), unscrew spring reaction nut (11), then remove thrust washer
(13) and spring (12).
NOTE: In case of leaks, remove stem (14) to replace seals (15) seated in cylinder body (5).
REASSEMBLY
1. Reassembly hydraulic cylinder (5).
2. Mount brake disk (9) on drive flange and lock eight screws (8).
NOTE: Torque from 6.2 - 6.8 Nm (0.63 - 0.69 kg•m / 4.5 - 5 ft lb)
3. Mount caliper assembly (6) to support and lock two screws (7).
NOTE: Torque from 18.5 - 20.5 Nm (1.89 - 2.09 kg•m / 14 - 15 ft lb)
4. Mount hydraulic cylinder (5) on support (4) with lock washer and two nuts (3).
NOTE: Torque from 4.3 - 4.87 Nm (0.44 - 0.50 kg•m / 3 - 3.5 ft lb)
5. Connect linkage thru adjustment sleeve (2).
ADJUSTMENT
1. Apply pressure to cylinder (5) of 75 - 80 bar (1,087 - 1,160 psi), checking that stem (14) is at travel
end (about 65 mm {2.56"} of spring compression.
2. Actuate sleeve (2) to adjust disk (9) to pad clearance up to 0.15 mm (0.006") reach on each side.
NOTE: For fine adjustment of clearance on each side of pads it is necessary to undo counter nut
(16) and actuate screw (17).
3. Release pressure and check that stem (14) return travel is about 40 mm (1.58").
4. Restore pressure and check that clearance and travel remain unchanged (repeating many times).
5. Lock counter nuts (1 and 16) of pad adjustment screws (17) and sleeve (2).

Page 39
Page 40

Operation & Maintenance - M400-III

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S0602080

REAR AXLE (GRAZIANO)S0602080

Copyright DOOSAN 1999

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

AFTER FIRST 200 HOURS

S0602080 Rear Axle (Graziano)

EVERY 1,500 HOURS

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

Spring Retainer Installed

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

2. Hammer out spring pins (2) locking slotted rings (3).

Rear Axle (Graziano) S0602080

OVERHAULING SUPER MAX TRAC

S0602080 Rear Axle (Graziano)

CHECKING CLEARANCE ON ASSEMBLED

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

AXIAL POSITION OF BEVEL PINION

Rear Axle (Graziano) S0602080

• Moving away ring gear to pinion, if

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

S0602080 Rear Axle (Graziano)

Rear Axle (Graziano) S0602080

DETERMINING SPACE AVAILABLE TO

S0602080 Rear Axle (Graziano)

TRANSMISSION AND TORQUE CONVERTER (ZF 4WG-260)S0607020

Copyright DOOSAN 2001

Transmission and Torque Converter (ZF 4WG- S0607020

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

S0607020 Transmission and Torque Converter (ZF 4WG-

Transmission and Torque Converter (ZF 4WG- S0607020

S0607020 Transmission and Torque Converter (ZF 4WG-

Transmission and Torque Converter (ZF 4WG- S0607020

S0607020 Transmission and Torque Converter (ZF 4WG-

FAULT DISPLAY left right

If more than one fault is detected, the fault code

DESCRIPTION OF FAULT CODES

First Number Meaning of Number

Transmission and Torque Converter (ZF 4WG- S0607020

DEFINITION OF OPERATION MODES

Substitute Clutch Control

S0607020 Transmission and Torque Converter (ZF 4WG-

TCU Shut Down

TABLE OF FAULT CODES