When the ZF 4WG130 flares between shifts or the loader valve bleeds a raised bucket down, a Mega 160 stops earning; this Daewoo Mega 160 shop manual PDF is the 600 page factory book, OEM 023-00035E, covering both the 160 and 160TC wheel loaders. Hydraulic schematics trace pilot oil from the Barnes pilot pump through the Husco main control valve to the bucket cylinders, and ZF fault code tables pair each error with actuator resistance checks so your diagnosis starts at the right connector. Electrical schematics map the starting and monitoring circuits, and the Clark-Hurth axle chapter walks through brake discs, planetary reductions and the self-locking differential. Torque half inch split flange bolts to 15 to 18 ft lbs; verify the transmission bypass valve at 1.5 bar before you swap parts. A loader waiting on answers bills you by the hour. Bookmarked and text searchable, it also prints clean, so send a copy to the bench and let it get dirty.
What's Inside This Daewoo Mega 160, Mega 160TC Manual
| System | Pages | Key Topics |
|---|
| Safety | 9-30 | General Safety Essentials, Work-Site Precautions, Operation |
| Specifications | 31-52 | Component Locations, General Specifications, Working Range and Dimensions, Material Weight |
| General Maintenance | 53-80 | Welding Precautions and Guidelines, Hydraulic System Cleanliness and Oil Leaks, Cleaning and Inspection, Bearing Inspection |
| Upper Structure | 81-96 | Counterweight, Fuel Transfer Pump, Hydraulic Oil Tank |
| Lower Structure and Chassis | 97-104 | Center Joint |
| Axle (Clark-Hurth) | 105-140 | Axle Identification, Brake Disc Maintenance, Safety Brake Adjustment, Planetary Reduction Gears, Self-Locking Differential |
| Air-Conditioner | 141-166 | Refrigerant Circulation, Control Panel, Refrigerant System Repairs, Leakage Check, Refrigerant Charging |
| Transmission (Zf 4WG130) - General and Layout | 167-243 | Transmission Specifications, Drive Train Layout, Gearbox Housing, Coupling Components, Power Takeoff |
| Transmission (Zf 4WG130) - Control and Repair | 244-314 | Electro-Hydraulic Control Unit, Powershift Transmission Disassembly, Clutch Reassembly, Transmission Cutoff, Speed Sensor |
| Transmission Error Codes (Zf) | 315-346 | Fault Code Definitions, Operating Modes, Actuator Resistance Measurement, Cable Troubleshooting |
| Hydraulics | 347-510 | Hydraulic System, Accumulator |
| Electrical System | 511-588 | Electric Supply System, Engine Starting Circuit, Monitoring System, Transmission Electrical Circuit, Lighting System |
| Attachments | 589-600 | Load Handling System, Loader Arm Assembly |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Worm Drive - 1-3/4 in. Open Diameter and Under (Hydraulic System) | 0.5 - 0.6 kg•m (40 - 50 In. Lbs.) | p. 73 |
| Worm Drive - All "Ultra-Tite" (Hydraulic System) | 0.5 - 0.6 kg•m (40 - 50 In. Lbs.) | p. 73 |
| Mega 160 | 850 ±20 grams (30 ±0.7 oz.) | p. 157 |
| Bypass valve pressure | 1.5 bar | p. 224 |
| Bypass-V pressure | 5.5 bar | p. 224 |
| Proportional solenoid valve resistance | 19 ohm ± 1.9 ohm at 20°C | p. 544 |
| Proportional solenoid valve pressure | 0.8 kg/sq cm - 8.3 kg/sq cm | p. 544 |
| Vehicle Weight (with Canopy) | 8,490 kg | p. 38 |
| Vehicle Weight (with Cab) | 8,660 kg | p. 38 |
| Engine Max. Torque | 37 kg•m | p. 38 |
| Safe Operating Load | 2,560 kg | p. 38 |
| Max. Breakout Force | 7,800 kg | p. 38 |
