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 |
Daewoo Mega 160, Mega 160TC Common Problems This Manual Covers
Daewoo Mega 160 hydraulics feel weak, boom lifts slowly and bucket curls sluggish under load
Check the hydraulic oil level with the bucket flat on the ground; the Mega 160 tank holds 100.0 liters, per page 94. Drain and refill if the fluid looks milky or burnt. Inspect suction hoses for collapse, then retorque any weeping split flange fittings; 1/2 inch flange bolts take 2.1 to 2.5 kg•m per page 74.
Manual Section: Hydraulics p. 347Transmission slips between gears, shifts late and whines under load after fluid gets hot
Read the stored fault codes; definitions for codes 11 through F6 start on page 321. Measure resistance across each proportional solenoid valve, good coils read 19 ohm plus or minus 1.9 ohm at 20°C per page 544. Verify transmission pump pressure against the 16+2 bar value on the schematic, page 224, before pulling the gearbox.
Manual Section: Transmission Error Codes (Zf) p. 321Brake pedal feels soft, wheel loader needs extra pedal travel and brakes fade on grades
Check brake system pressure at the test port; the setting is 37 kg/sq cm on page 350. Test the accumulator nitrogen precharge, 15 kg/sq cm on the Mega 160, page 362, and recharge or replace a dead bladder. Bleed the lines, then follow the axle troubleshooting steps on page 108 if the pedal stays soft.
Manual Section: Axle Troubleshooting p. 108Boom drifts down overnight, bucket cylinder creeps and leaves oil film on the rod
Inspect the cylinder rod for scoring and check the gland for oil past the wiper. Replace piston seals and backup rings; soak the new slipper seal in 60 to 100°C (140 to 212°F) water for five minutes before fitting, per page 382. Cycle the boom several times and recheck for drift with the bucket loaded.
Manual Section: Cylinder TroubleshootingCab air conditioner blows warm air, compressor cycles on and off constantly
Check refrigerant pressure on both sides of the compressor before adding gas. Recover the charge and pull a vacuum, then weigh in 850 plus or minus 20 grams (30 ounces) of R134a on the Mega 160, per page 157. Test for leaks at every fitting; short cycling usually means a low charge, not a bad compressor.
Manual Section: Air-Conditioner p. 157Frequently Asked Questions
What are the torque specifications for the wheel bolts on a Daewoo Mega 160?
The wheel bolt torque for the Daewoo Mega 160 is 88 kg•m (640 ft lbs). p. 343
What are the replacement specifications for O-rings and seals on the Daewoo Mega 160, Mega 160TC wheel loader?
It is recommended to replace all O-rings and oil seals whenever hydraulic assemblies are rebuilt. When installing, ensure joint surfaces are clean and free of corrosion, and follow all bolt torque requirements. p. 58
What is the procedure for checking the brake disc thickness on a Mega 160?
To check the brake disc thickness, insert a feeler gauge into the oil level check hole. The minimum thickness for the Mega 160 is 1.25 mm (0.049 in.). p. 115
What is the specified nitrogen pre-charge pressure for the accumulator on a Mega 160?
The nitrogen pre-charge pressure for the accumulator on a Mega 160 is 30 kg/sq cm (427 psi). p. 362
What is the torque spec for the ZF 4WG130 transmission pump mounting bolts on the Daewoo Mega 160, Mega 160TC?
The transmission pump mounting bolts should be tightened to a torque limit of 4.69 kg•m (33.93 ft lbs). p. 308
What format is this Daewoo Mega 160 manual in?
Immediate download of the complete 600-page searchable Shop Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Can I print specific sections of this Daewoo Mega 160 Shop Manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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