Doosan Mega 200-V, Mega 200-VTC. Operation and Maintenance Manual (2003)

Mega 200-V

Mega 200-VTC

Operation and Maintenance Manual

022-00028AE

S/N 1001 and Up (Tier I & II)

February 2003

Daewoo reserves the right to improve our products in a continuing process to provide the best possible

product to the market place. These improvements can be implemented at any time with no obligation to

change materials on previously sold products. It is recommended that consumers periodically contact their

distributors for recent documentation on purchased equipment.

This documentation may include attachments and optional equipment that is not available in your

machine’s package. Please call your distributor for additional items that you may require.

Illustrations used throughout this manual are used only as a representation of the actual piece of

equipment, and may vary from the actual item.

022-00028AE Operation and Maintenance Manual

TABLE OF CONTENTS

Safety

1-1

To the Operator of a Daewoo Wheel Loader

1-1

General Safety Essentials

1-2

Location of Safety Labels

1-3

Unauthorized Modifications

1-10

Work Site Precautions

1-10

Operation

1-12

Equipment

1-17

Maintenance

1-22

Shipping and Transportation

1-24

Operating Controls

2-1

Component Locations

2-2

Control Identification

2-8

Steering Console and Pedals

2-9

Transmission Display

2-16

Front Instrument Panel

2-18

Right Side Switch Panel

2-27

Various Cabin Locations

2-38

Heater and Air Conditioner Operation

2-42

Stereo

2-47

Seat Adjustment

2-51

Seat Belt

2-53

Door Side Latch

2-54

Fuse Box/Relay

2-55

Window Glass Breaking Tool

2-58

Operation

3-1

Instrument Panel Control Functions

3-1

New Machine Break-in Procedures

3-1

022-00028AE Operation and Maintenance Manual

Table of Contents 1

Engine Start and Stop

3-2

Machine Travel

3-11

Machine Shut Down

3-13

Additional Braking

3-15

Boom Raise Kickout

3-16

Bucket Angle Indicator

3-16

Boom Lower Kickout (Option)

3-17

Adjustment of Bucket Position Switch

3-18

Towing Machine

3-19

If Engine Stalls While Traveling

3-20

Allowable Water Depth

3-20

Inspection, Maintenance and Adjustment

4-1

Table of Recommended Lubricants

4-3

Fluid Capacities

4-5

Maintenance Intervals

4-6

10 Hour / Daily Service

4-8

50 Hour / Weekly Service

4-18

250 Hour / Monthly Service

4-27

500 Hour / 3 Month Service

4-34

1,000 Hour / 6 Month Service

4-37

1,500 Hour / 9 Month Service

4-43

2,000 Hour / Yearly Service

4-45

12,000 Hour / Six Year Service

4-48

Severe Conditions Maintenance

4-49

General Maintenance

4-50

Parking Brake Adjustment

4-52

Check Hydraulic Pressures

4-53

Tires and Wheels

4-57

Electrical System

4-59

Bolt Torque Chart

4-60

Long Term Storage

4-61

2 Table of Contents

022-00028AE Operation and Maintenance Manual

1SAFETY

TO THE OPERATOR OF A 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.

“General Safety Essentials” on page 1-2

“Location of Safety Labels” on page 1-3

“Unauthorized Modifications” on page 1-10

“Work Site Precautions” on page 1-10

“Operation” on page 1-12

“Equipment” on page 1-17

“Maintenance” on page 1-22

“Shipping and Transportation” on page 1-24

022-00028AE Operation and Maintenance Manual

Safety 1-1

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 Daewoo. Lifting-work applications are permitted in approved lift configuration, to

rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for

activities for which it was not intended. Do not use bucket for lifting work, unless lift slings are used in

approved configuration.

1-2 Safety

022-00028AE Operation and Maintenance Manual

WARNING FOR OPERATION, INSPECTION AND MAINTENANCE (4190-2545, 190-00092)

CAUTION!

•

Read manual and labels before

operation and maintenance.

Follow instructions and warnings

in manual and on labels on

machine.

•

Sound horn to alert people

nearby before operating, and

make sure all persons are clear

of area.

•

Always make sure when leaving

operator’s seat to:

ACO1360L

•

Lower bucket or other

working tools to ground.

•

"LOCK" transmission selector in "NEUTRAL."

•

Set park brake.

•

Turn starter switch "OFF." Remove key from switch.

•

If hydraulic components and units are ABNORMAL, consult nearest DAEWOO dealer

or authorized service shop. Do not attempt to make an overhaul.

WARNINGS WHEN OPENING ENGINE HOOD (2190-2525, 190-00095)

WARNING!

Before opening bonnet, shut down

engine.

ACO1420L

1-4 Safety

022-00028AE Operation and Maintenance Manual

WARNING FOR HANDLING ACCUMULATOR (2190-2528, 190-00099)

WARNING!

Explosion hazard:

•

Keep away from flame.

•

Do not weld or drill.

ACO1480L

Accumulator

Wheel loader pilot control system is equipped with an accumulator. Accumulator will store a pressure

charge that may enable hydraulic controls to be activated for a brief period of time after engine has been

shut down. Activation of any controls may enable selected function to operate under force of gravity.

CAUTION!

Any raised attachment will lower to ground if accumulator holds a charge.

When shutting machine down, lower front attachment to ground. After engine has been shut down, turn key

to "ON" position and move joystick controls to release pressure in accumulator. Remove key.

IMPORTANT

Refer to Shop Manual for service procedures. Do not release any pilot lines until pressure within

accumulator has been released.

022-00028AE Operation and Maintenance Manual

Safety 1-5

WARNING FOR HIGH TEMPERATURE COOLANT (2190-2531, 190-00097)

WARNING!

To prevent hot water from spurting out:

•

Turn engine "OFF."

•

Allow water to cool.

•

Slowly loosen cap to relieve

pressure before removing.

ACO1410L

WARNING FOR BATTERY MAINTENANCE (2190-2533, 190-00100)

DANGER!

•

Battery fumes can explode.

Keep sparks and flames away

from batteries.

•

Always avoid storing metals like

tools or inflammable materials

around or on batteries.

Explosion or fire can be caused

by short circuiting batteries.

•

Sulfuric acid in battery is

poisonous. It is strong enough

to burn skin, eat holes in

clothing, and cause blindness if

splashed in eyes.

If you spill acid on yourself:

Flush your skin with water.

ACO1400L

Apply baking soda or lime to

help neutralize acid.

Flush your eyes with water for

10-15 minutes.

Get medical attention immediately.

022-00028AE Operation and Maintenance Manual

Safety 1-7

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 Daewoo representative.

Any modification made without authorization or written approval from Daewoo 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 Daewoo 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 Daewoo for information on available one-way

(single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because Daewoo cannot

anticipate, identify or test all attachments that owners may wish to install on their machines, please contact

Daewoo for authorization and approval of attachments, and their compatibility with options kits.

AVOID HIGH-VOLTAGE CABLES

Serious injury or death can result from contact

or proximity to high-voltage electric lines. The

bucket does not have to make physical contact

with power lines for current to be transmitted.

Use a spotter and hand signals to stay away

from power lines not clearly visible to operator.

Voltage

Minimum Safe Distance

6.6 kV

3 m (9’ 10")

33.0 kV

4 m (13’ 1")

Figure 2

66.0 kV

5 m (16’ 5")

154.0 kV

8 m (26’ 3")

275.0 kV

10 m (32’ 10")

Use these minimum distances as a guideline only. Depending upon voltage in line and atmospheric

conditions, strong current shocks can occur with boom or bucket as far away as 4 - 6 m (13 - 20 ft) from

power line. Very high voltage and rainy weather could further decrease that safety margin.

NOTE: Before starting any type of operation near power lines (either above ground or buried

cable-type) you should always contact power utility directly and work out a safety plan with

them.

1-10 Safety

022-00028AE Operation and Maintenance Manual

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. Overhand 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.

SLOPING TERRAIN REQUIRES CAUTION

Dig evenly around work site whenever possible,

trying to gradually level any existing slope. If it’s

not possible to level area or avoid working on a

slope, reducing size and cycling rate workload is

recommended.

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

always avoid working bucket over downhill side

AJO0580L

of machine when parked perpendicular to slope.

Figure 3

Avoid full extensions of bucket in a downhill

direction. Lifting bucket too high, too close to

machine, while wheel loader is turned uphill can

also be hazardous.

022-00028AE Operation and Maintenance Manual

Safety 1-11

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 4

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.

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 can’t see

clearly and something is happening behind you.

HAOA151L

Replace damaged safety labels and lost or

Figure 5

damaged operator’s manuals.

Do not let anyone operate machine unless

they’ve been fully and completely trained, in

safety and in operation of machine.

1-12 Safety

022-00028AE Operation and Maintenance Manual

BEFORE STARTING ENGINE, DO A "PRE-START" 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.

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 6

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.

HA3O1003

Figure 7

022-00028AE Operation and Maintenance Manual

Safety 1-13

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 8

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

asbestos-laden

atmosphere.

ARO1770L

•

Never use compressed air for

Figure 9

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.

1-14 Safety

022-00028AE Operation and Maintenance Manual

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

Figure 10

other conditions that could produce static

discharge, keep tip of fuel nozzle in constant

contact with neck of fuel filling nozzle, to provide

a ground.

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 11

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 “Starting with

Auxiliary Batteries” on page 3-8.

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.

022-00028AE Operation and Maintenance Manual

Safety 1-15

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 12

TRAVEL PRECAUTIONS

Engage frame lock for long-distance travel. 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 about 440 mm

(17") 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.

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.

1-16 Safety

022-00028AE Operation and Maintenance Manual

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 13

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 14

damage to system requires a complete integrity

reevaluation. Reinstallation, recertification and/

or replacement of system may be necessary.

022-00028AE Operation and Maintenance Manual

Safety 1-17

INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE

Laminate glass protection for the front, side or rear windows may also be recommended depending upon

particular site conditions.

Contact your Daewoo distributor for available safety guards and/or recommendations if there is any danger

of getting hit by objects that could strike the operator’s cab. Make sure that all other work site crew

members are kept well away from wheel loader and safe from potential hazards.

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 15

WINDOW GLASS BREAKING TOOL

This loader is equipped with a glass breaking

tool. It is in the lower right 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!

Figure 16

Protect your eyes when breaking the

glass.

1-18 Safety

022-00028AE Operation and Maintenance Manual

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.

MAINTAIN STANDARD SAFETY EQUIPMENT

IN GOOD CONDITION

Machinery guards and body panel covers must

HAOA080L

be in place at all times. Keep well clear of

Figure 17

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 filler cap.

•

Hydraulic system hoses, especially the pump outlet lines and front and rear pump branch

hoses.

•

Keep mounting brackets and hose and cable routing straps tight. Hose routing should have

gradual bends.

HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT

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

HIGH PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY

Exposed hydraulic hoses on arm or boom could react with explosive force if struck by a falling rock,

overhead obstacle or other 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.

022-00028AE Operation and Maintenance Manual

Safety 1-19

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 18

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.

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

asbestos-laden

atmosphere.

ARO1770L

•

Never use compressed air for

Figure 19

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.

1-20 Safety

022-00028AE Operation and Maintenance Manual

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 listed 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

Figure 20

an explosive spark.

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.

022-00028AE Operation and Maintenance Manual

Safety 1-21

MAINTENANCE

USE WARNING TAG DURING SERVICE

Alert others that service or maintenance is

being performed and tag operator’s cab controls

- and other machine areas if required - with a

warning notice.

Warning tags for controls are available from

WARNING

Daewoo distributors; see Figure 21.

HAOC920L

Figure 21

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

You should always have at least two people working together if engine must be run during service. One

person needs to remain in operator’s seat, ready to work controls or stop machine and shut "OFF" engine.

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 PRIOR TO

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 filler cap for venting

built-up air pressure. Release levers before

trying to take off filler caps and LOOSEN CAPS

SLOWLY, before removal.

HAOA060L

Figure 22

1-22 Safety

022-00028AE Operation and Maintenance Manual

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)”

on page 4-48, for additional European regulations.

HAOA420L

Figure 23

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.

022-00028AE Operation and Maintenance Manual

Safety 1-23

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

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 24

requirements.

CHECK TIRE PRESSURE AND CONDITION

Maintain tire pressure but do not over inflate. Inspect tires and wheels daily. When inflating tires, follow

procedures in Maintenance Section, which include using an extension to allow you to avoid standing in

front of or over a tire. Do not change a tire unless you have both experience and proper equipment.

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. See “Transportation” on page 5-1.

1-24 Safety

022-00028AE Operation and Maintenance Manual

2OPERATING CONTROLS

"Operating Controls" section presented here consists of the following groups:

“Component Locations” on page 2-2

“Control Identification” on page 2-8

“Steering Console and Pedals” on page 2-9

“Transmission Display” on page 2-16

“Front Instrument Panel” on page 2-18

“Right Side Switch Panel” on page 2-27

“Various Cabin Locations” on page 2-38

“Heater and Air Conditioner Operation” on page 2-42

“Stereo” on page 2-47

10.

“Seat Adjustment” on page 2-51

11.

“Seat Belt” on page 2-53

12.

“Door Side Latch” on page 2-54

13.

“Fuse Box/Relay” on page 2-55

14.

“Window Glass Breaking Tool” on page 2-58

Each group is explained with a point location drawing or photo and a brief description of each control,

switch, gauge or valve.

Indicator lights work in addition to gauges on instrument panel. Operators should monitor machine

pressure on instrument panel along with indicator lights. These lights will only give operators an indication

that there is a problem.

WARNING!

Warning lights. When any one or more of the warning lights on the control console turn "ON,"

immediately discontinue operation and shut down unit. Investigate and correct problem before

proceeding with operation.

022-00028AE Operation and Maintenance Manual

Operating Controls 2-1

BUCKET TOOTH

24. RADIATOR

BUCKET

25. GRILL

AIR CONDITIONER CONDENSER

26. FAN

REAR WHEEL COVER

27. FUEL TANK

ENGINE OIL FILTER

28. ENGINE OIL FILLER PIPE

BATTERY BOX

29. ENGINE OIL LEVEL GAUGE

REAR LAMP

30. REMOTE ENGINE OIL DRAIN PORT

COUNTERWEIGHT

31. REAR AXLE PIVOT

10.

TOWING PIN

32. REAR AXLE

11.

TOOL BOX / FUEL PUMP

33. DRIVE SHAFT (REAR)

12.

OIL TANK

34. TRANSMISSION

13.

TILT LEVER

35. TRANSMISSION OIL FILTER

14.

BUCKET CYLINDER

36. CENTER PIN

15.

FRONT WHEEL COVER

37. STEERING WHEEL CYLINDER

16.

HEADLIGHT SUPPORT

38. DRIVE SHAFT (CENTER)

17.

LADDER

39. DRIVE SHAFT (FRONT)

18.

WORKING LAMP

40. PARKING BRAKE

19.

OPERATOR’S CAB

41. FRONT AXLE

20.

AIR CLEANER

42. BOOM CYLINDER

21.

PRE-CLEANER

43. LOADER ARM

22.

MUFFLER

44. LINK

23.

ENGINE

022-00028AE Operation and Maintenance Manual

Operating Controls 2-3

BUCKET TOOTH

23. ENGINE

BUCKET

24. RADIATOR

AIR CONDITIONER CONDENSER

25. GRILL

REAR WHEEL COVER

26. FAN

ENGINE OIL FILTER

27. FUEL TANK

BATTERY BOX

28. ENGINE OIL FILLER PIPE

REAR LAMP

29. ENGINE OIL LEVEL GAUGE

COUNTERWEIGHT

30. REMOTE ENGINE OIL DRAIN PORT

FAN MOTOR

31. REAR AXLE PIVOT

10.

TOWING PIN

32. REAR AXLE

11.

TOOL BOX / FUEL PUMP

33. DRIVE SHAFT (REAR)

12.

OIL TANK

34. TRANSMISSION

13.

TILT LEVER

35. TRANSMISSION OIL FILTER

14.

BUCKET CYLINDER

36. CENTER PIN

15.

FRONT WHEEL COVER

37. STEERING WHEEL CYLINDER

16.

HEADLIGHT SUPPORT

38. DRIVE SHAFT (CENTER)

17.

LADDER

39. DRIVE SHAFT (FRONT)

18.

WORKING LAMP

40. PARKING BRAKE

19.

OPERATOR’S CAB

41. FRONT AXLE

20.

AIR CLEANER

42. BOOM CYLINDER

21.

PRE-CLEANER

43. LOADER ARM

22.

MUFFLER

44. LINK

022-00028AE Operation and Maintenance Manual

Operating Controls 2-5

BUCKET TOOTH

25. GRILL

BUCKET

26. FAN

AIR CONDITIONER CONDENSER

27. FUEL TANK

REAR WHEEL COVER

28. ENGINE OIL FILLER PIPE

ENGINE OIL FILTER

29. ENGINE OIL LEVEL GAUGE

BATTERY BOX

30. REMOTE ENGINE OIL DRAIN PORT

REAR LAMP

31. REAR AXLE PIVOT

COUNTERWEIGHT

32. REAR AXLE

FAN MOTOR

33. DRIVE SHAFT (REAR)

10.

TOWING PIN

34. TRANSMISSION

11.

TOOL BOX / FUEL PUMP

35. TRANSMISSION OIL FILTER

12.

OIL TANK

36. CENTER PIN

13.

FRONT WHEEL COVER

37. STEERING WHEEL CYLINDER

14.

LEVER

38. DRIVE SHAFT (CENTER)

15.

LINK

39. DRIVE SHAFT (FRONT)

16.

HEADLIGHT SUPPORT

40. PARKING BRAKE

17.

LADDER

41. FRONT AXLE

18.

WORKING LAMP

42. LINK

19.

OPERATOR’S CAB

43. LOADER ARM

20.

AIR CLEANER

44. LEVER

21.

PRE-CLEANER

45. LIFT CYLINDER

22.

MUFFLER

46. TILT CYLINDER

23.

ENGINE

47. CONTROL VALVE

24.

RADIATOR

022-00028AE Operation and Maintenance Manual

Operating Controls 2-7

STARTER SWITCH

A four-position starter switch is used to

start or shut down engine for equipment

operation.

O. "OFF" position. Key can be inserted

or removed at this position. When

key is moved to this position, engine

will stop running.

In this position, with engine "OFF,"

alternator light and engine oil light

will turn "ON." In this position with

HAOC340L

engine running, electrical circuits

Figure 6

controlled by this switch are closed.

. Moving switch to this position will crank engine. When engine starts, release key and allow it to

return to "I" (ON) position. Do not crank engine for more than 15 seconds at a time; this could

damage starter motor.

WARNING!

DO NOT USE STARTING FLUIDS. The preheat system could cause the starting fluid to

explode.

. Preheat position. Used to aid engine starting in cold weather. When key is in this position,

engine preheater is operating. When preheat cycle indicator light turns "ON" engine preheat

cycle is complete. Immediately turn key to crank position and start engine.

HORN BUTTON (TWO PLACES)

Pressing the button at the end of the

combination switch (Figure 7) or the left

button at the tip of the pilot control valve

lever

(joystick)

(Figure

8), the horn will

sound.

NOTE: Starter switch must be "ON."

AHO0890L

Figure 7

2-10 Operating Controls

022-00028AE Operation and Maintenance Manual

Figure 8

COMBINATION SWITCH

A. Left Side Directional Switch

Pushing lever forward, activates left

outside directional

lights

and

directional

indicator

light

instrument panel.

B. Right Side Directional Switch

Pulling lever back, activates right

outside directional

lights

and

directional

indicator

light

instrument panel.

AHO0920L

NOTE: When turn is completed the

Figure 9

lever automatically returns to

the

"NEUTRAL" position.

Should it not, it can be manually

returned by hand.

NOTE: Turn signals will function with starter switch in "OFF" position.

C. Window Washer Switch - When the outside area of the lever is pressed, it activates the washer

pump and sprays fluid on the windshield. (Only while being pressed.)

CAUTION!

The washer pump can be damaged if it is activated while there is no fluid in the tank.

The fluid level should be checked regularly and refilled if necessary.

Using soap or other solvents instead of the recommended washer fluid may damage

the wiper blades and the paint finish.

Only use recommended washer fluid or equivalent.

D. Horn Button - The center button on end of lever activates horn. (Only while being pressed.)

E. Wiper Switch - Activates wipers when outside area of lever is rotated.

J: Intermittent Mode - wipes every 5 seconds.

0: Stop (Off).

I: Normal Speed Mode.

II: High Speed Mode.

022-00028AE Operation and Maintenance Manual

Operating Controls 2-11

Push Down - Locks into position and

lights up the high beams.

G. Neutral Position - Normal low beams.

H. Pull Up

- Momentarily turns "ON"

both the low beams and high beams.

(Returns to "NEUTRAL" position

when released.)

NOTE: High and low beams will only

function with the headlight

switch in the "||" position.

HAAA4350

Figure 10

ACCELERATOR PEDAL

Controls the travel speed of loader and

working speed of load handling system.

CAUTION!

The further the pedal is pressed, the

more engine speed increases.

However, do not press the pedal

more than necessary; otherwise it

will increase fuel consumption,

Figure 11

cause short life on the engine, and in

the worst case lead to a serious

accident.

STEERING TILT KNOB

This knob is used to allow steering wheel

to be moved to the most convenient

position for the operator. Loosen knob (2,

Figure

12), while grabbing the steering

wheel (1). Once the steering wheel is in

the proper place, tighten the knob.

HBOI200L

Figure 12

2-12 Operating Controls

022-00028AE Operation and Maintenance Manual

BRAKE PEDAL (RIGHT AND LEFT

PEDALS)

Pressing brake pedal will apply the brakes

to the loader. The brake pedal modes can

be switched over from inching to no-

inching or vice-versa, by using the

Transmission cutoff switch

(See page

2-36).

CAUTION!

When descending on an incline, slow

Figure 13

down the machine by using both the

brake pedal and the engine brake.

Using the brake pedal too often

might lead to insufficient oil

pressure, thus making it difficult to

brake the loader.

IMPORTANT

Do not use brake pedal as a foot rest.

This will cause brake disc to wear

faster than normal, and this could

cause brake failure.

STEERING WHEEL

Rotating steering wheel controls position

of front wheels and this determines

direction of machine travel.

Figure 14

022-00028AE Operation and Maintenance Manual

Operating Controls 2-13

KICK-DOWN SWITCH (TWO PLACES)

When transmission is in

2nd gear,

pressing this switch will shift transmission

into 1st gear. This will allow the driver to

perform a quick digging movement.

NOTE: Kick-down is "RELEASED"

when transmission is placed in

"NEUTRAL" position or the

switch is pressed again.

Kick-down function range:

AHO0900L

•

Automatic: 2nd, 3rd, 4th.

Figure 15

•

Manual: 2nd.

A second kick-down switch (Figure 16) is

on the right button in the tip of the pilot

control valve lever (joystick).

Figure 16

TRANSMISSION LEVER

F Forward - When the lever is pushed

forward,

transmission

"FORWARD." 1st, 2nd, 3rd and 4th

are available.

N Neutral - When the lever is returned

to the center position, between

forward

and

reverse,

the

transmission is in "NEUTRAL."

R Reverse - When the lever is pulled

back, transmission is in "REVERSE"

HAAA3680

1st, 2nd and 3rd are available.

Figure 17

Rotating the switch shifts transmission

between 1st, 2nd, 3rd, or 4th gear.

NOTE: There is a transmission display,

on the dash, that indicates,

gears, direction of travel, error

codes and kick-down activation.

(See page 2-16)

2-14 Operating Controls

022-00028AE Operation and Maintenance Manual

A transmission neutral lever lock is in base

of transmission lever. This neutral lever

lock prevents the transmission lever from

being moved out of "NEUTRAL."

N "NEUTRAL

LOCK"

position.

Prevents lever from being moved out

of "NEUTRAL."

D "DRIVE" position. Allows lever to be

moved from "NEUTRAL" to

"FORWARD and REVERSE."

Figure 18

CAUTION!

"LOCK" transmission lever. When

ever machine is parked, "LOCK"

transmission lever in "NEUTRAL" to

prevent

accidental

machine

movement.

10.

FRONT INSTRUMENT PANEL

See

“Front Instrument Panel” on

page 2-18.

APO0050L

Figure 19

11. TRANSMISSION DISPLAY

See “Transmission Display” on page 2-16.

HAAA3773

Figure 20

022-00028AE Operation and Maintenance Manual

Operating Controls 2-15

TRANSMISSION DISPLAY

A transmission display is to the left of the

steering wheel on the dash. The LCD indicates,

gears, direction of travel, error codes, and

activated kick-down.

Figure 21

Figure 22, shows the transmission display in

detail.

A. Indicates travel direction and gear

selection. See Figure 23 for more detailed

information.

B. Indicates normal operation and error

codes. For a list of error codes. See

“Transmission Error Codes” on page 6-8.

(D)

(A)

(B)

(C)

NOTE: Most codes are only two digits.

C. Indicates that error codes have occurred

HAAA3770

and are stored.

Figure 22

D. Indicates that operation must be stopped

immediately to prevent damage to

transmission and hazardous operating

condition.

The gear range indicator bars will indicate which

gear is selected by displaying the corresponding

FORWARD

number of bars. The forward and reverse

indicator bars will be "OFF" when the

INDICATOR

transmission is in "MANUAL MODE."

GEAR RANGE

When transmission is in "AUTOMATIC MODE,"

all the gear range indicator bars and both travel

INDICATOR BARS

direction indicators will be "ON."

REVERSE

INDICATOR

HAAA3774

Figure 23

2-16 Operating Controls

022-00028AE Operation and Maintenance Manual

GAUGES

FUEL GAUGE

TACHOMETER

SPEEDOMETER

COOLANT TEMP. GAUGE

HOUR METER

TRANSMISSION OIL TEMP. GAUGE

WARNING AND INDICATOR LIGHTS

PREHEAT CYCLE INDICATOR LIGHT

13. HIGH BEAM INDICATOR LIGHT

AIR FILTER INDICATOR LIGHT

14. RIGHT TURN AND HAZARD WARNING

COOLANT TEMPERATURE WARNING

LIGHT

15. WORK LIGHT INDICATOR LIGHT

10. ENGINE OIL PRESSURE WARNING

16. BRAKE FLUID WARNING LIGHT

LIGHT

17. UNUSED LIGHT

11. BATTERY WARNING LIGHT

18. PARKING BRAKE INDICATOR LIGHT

12. LEFT TURN AND HAZARD WARNING

19. EMERGENCY STEERING INDICATOR

LIGHT

LIGHT (OPTION)

SWITCHES

20. HAZARD WARNING LIGHT SWITCH

22. BUCKET FLOAT SWITCH (OPTION)

21. BLANK (EMPTY SWITCH SOCKET)

IMPORTANT

All of gauge and warning lights (except for the turn lights, high beam light, work light and

transmission cutoff light) turn "ON" for two seconds with a warning buzzer sound when the

starter switch is turned to the "I" position.

If any light fails to turn "ON" at this time, check the cause and replace.

FUEL GAUGE

This gauge displays amount of fuel in tank.

"F" means the tank is "full"; "E" means the

tank is "empty." If the pointer comes close

to the "E" (red zone), add fuel as soon as

possible. When the pointer comes close to

the "E" (red zone), approximately 15 liters

(4 U.S. gal.) of fuel remains.

HBOI250L

Figure 25

022-00028AE Operation and Maintenance Manual

Operating Controls 2-19

COOLANT TEMPERATURE GAUGE

This gauge displays temperature of engine

coolant.

CAUTION!

When the pointer indicates "H" mark

(red zone), it means the engine is

overheated. Stop the operation, let

the engine run at low rpm and wait

HBOI260L

for it to cool down.

Figure 29

Do not shut down engine. If engine is

shut down heat surge may occur.

TRANSMISSION OIL TEMPERATURE

GAUGE

This gauge displays temperature of oil in

transmission converter and transmission

circuit.

CAUTION!

When the pointer indicates "H" mark

(red zone), it means the transmission

HBOI270L

is overheated. Stop the operation, let

the engine run at low rpm and wait

Figure 30

for transmission to cool down.

PREHEAT CYCLE INDICATOR LIGHT

When this light turns "ON" it means that

engine preheat cycle is complete. When

radiator temperature is below

10°C

(-12°F), this light will turn

"ON"

approximately

3.5 seconds after starter

switch is turned to preheat position.

HAOA639L

Figure 31

022-00028AE Operation and Maintenance Manual

Operating Controls 2-21

AIR FILTER INDICATOR LIGHT

When this light turns "ON," dirt has built up

in the air filter and is beginning to restrict

flow of air. Clean or replace air filter

element before continuing to operate

machine. To turn indicator light "OFF," turn

starter switch "OFF" and then back "ON."

HAOA660L

Figure 32

COOLANT TEMPERATURE WARNING

LIGHT

If engine coolant overheats, this light will

turns "ON" and an alarm will sound. If light

turns "ON," reduce engine speed until

coolant temperature drops. Do not turn

engine "OFF" because this will cause

coolant temperature to rise and may cause

engine to siege due to heat surge.

HAOD350L

Figure 33

10. ENGINE OIL PRESSURE WARNING

LIGHT

When starter switch is in "ON" position,

this red light should "ON." When engine is

running this red light should turn "OFF." If

light remains "ON" when engine is running,

an alarm will sound. This means that

engine oil pressure has fallen below a safe

level. Never allow engine to run if this light

is "ON." Serious engine damage will result.

Investigate and repair cause of low oil

pressure before running engine.

HAOA620L

Figure 34

11. BATTERY WARNING LIGHT

When starter switch is first turned to "ON"

position, this red light should turn "ON."

When engine is running this red light

should turn "OFF." If light remains "ON"

when engine is running, alternator is

defective.

HAOA610L

Figure 35

2-22 Operating Controls

022-00028AE Operation and Maintenance Manual

12. LEFT TURN AND HAZARD WARNING

LIGHT

This light blinks when left turn signal is

turned "ON." Both lights blink when

warning lights are turned "ON."

NOTE: If left and right turn indicators

blink together, or if they blink

faster than normal, a light bulb

is not operating or flasher

solenoid is damaged.

ACO0240L

Figure 36

13. HIGH BEAM INDICATOR LIGHT

This light turns "ON" when headlights are

turned to "HIGH BEAM."

HAOD394L

Figure 37

14. RIGHT TURN AND HAZARD WARNING

LIGHT

This light blinks when right turn signal is

turned "ON." Both lights blink when

warning lights are turned "ON."

NOTE: If left and right turn indicators

blink together, or if they blink

faster than normal, a light bulb

is not operating or flasher

solenoid is damaged.

ACO0241L

Figure 38

15. WORK LIGHT INDICATOR LIGHT

This light should turn "ON" when the front

work lights are activated.

Figure 39

022-00028AE Operation and Maintenance Manual

Operating Controls 2-23

16. BRAKE FLUID WARNING LIGHT

This light turns "ON" when pressure drops

in brake fluid circuit. When light turns

"ON," an alarm also sounds.

WARNING!

Never operate or travel machine

when this light is "ON" or when alarm

is sounding. Always investigate

HA0O2024

cause of the drop in brake fluid

pressure, and repair problem before

Figure 40

operating or traveling machine.

17.

UNUSED LIGHT

18.

PARKING BRAKE INDICATOR LIGHT

When parking brake is "APPLIED," this

light turns "ON." If vehicle is moved while

parking brake is applied, a warning alarm

will sound.

WARNING!

If vehicle is moved while this light is

turned "ON," it could cause

0717A

premature wear or damage the brake.

Figure 41

Always "RELEASE" parking brake

and make sure this light is "OFF"

before traveling machine.

2-24 Operating Controls

022-00028AE Operation and Maintenance Manual

19. EMERGENCY STEERING INDICATOR

LIGHT (OPTION)

This light turns "ON" when the emergency

steering system is activated due to a

hydraulic

failure.

Immediately stop

operation, stop machine, "APPLY" parking

brake, and shut down engine.

DANGER!

AJO0450L

Emergency steering indicator light. If

Figure 42

this light turns "ON" while operating

machine, discontinue operation

immediately. This light indicates that

there is a severe problem with the

unit.

NOTE: The light will also turn "ON"

when the system is being

tested.

20.

HAZARD WARNING LIGHT SWITCH

This light is used when the equipment is

stopped due to a malfunction or when an

emergency occurs. When this switch is

pressed the directional indicator lights in

front and back of the machine light up and

flash, warning others in the area. At the

same time the directional indicator lights

on the instrument panel will turn "ON" to

warn the operator. The hazard warning

lights operate independent of the starter

switch.

2665C

Figure 43

O. In this position, this switch turns

"OFF" hazard warning lights.

In this position, this switch turns "ON"

all turn signals and they flash

simultaneously.

NOTE: Hazard warning lights will

function with starter switch in

"OFF" position.

022-00028AE Operation and Maintenance Manual

Operating Controls 2-25

21. BLANK (EMPTY SWITCH SOCKET)

A blank socket is provided for addition of

accessory switches.

HAOA734L

Figure 44

22. BUCKET FLOAT SWITCH (OPTION)

Bucket float allows the bucket to follow the

contour of the ground/working surface.

When pressing this switch and setting

work lever to floating position, lever is

locked

(detent) and boom is lowered.

When boom is matched to setting position,

lever locking is released and lever is

turned to "NEUTRAL" position and boom

lowering is stopped.

HA0O2027

O. In this position, this switch turns

"OFF" bucket float.

Figure 45

In this position, this switch turns "ON"

bucket float.

2-26 Operating Controls

022-00028AE Operation and Maintenance Manual

RIGHT SIDE SWITCH PANEL

1B1A

AJO0070L

Figure 46

PILOT CONTROL VALVE LEVER

REAR WORK LIGHT SWITCH

(JOYSTICK)

REAR WIPER SWITCH

1A. PILOT CONTROL VALVE LEVER

ROTATING BEACON SWITCH (OPTION)

(OPTION)

10.

CUP HOLDER

1B. ERGO-II PILOT CONTROL VALVE LEVER

11.

PARKING BRAKE SWITCH

(JOYSTICK) (OPTION)

12.

PILOT CUTOFF SWITCH

KICK-DOWN SWITCH

13.

TRANSMISSION CUTOFF SWITCH

HORN SWITCH

14.

AUTOMATIC TRANSMISSION SWITCH

CIGAR LIGHTER

15.

EMERGENCY STEERING TEST SWITCH

HEADLIGHT SWITCH

(OPTION)

FRONT WORK LIGHT SWITCH

022-00028AE Operation and Maintenance Manual

Operating Controls 2-27

PILOT CONTROL VALVE LEVER

(JOYSTICK)

Used to position bucket and boom. This

lever is capable of raising or lowering

boom, and crowding or dumping bucket.

When machine is being traveled, the lever

(joystick) can be "LOCKED" out, to prevent

any movement of bucket or boom. To

"LOCK" out lever

(joystick), place pilot

cutoff switch in "LOCKED" position.

Pilot control valve lever (joystick) operating

pattern and description of operation.

Figure 47

HL. Hold lever

lower mode

L. Lower

HC. Hold lever in

C. Bucket Crowd

N. Neutral

Bucket Dump

Bucket Crowd

R. Raise

HR. Hold lever

Raise Mode

1A.

PILOT CONTROL VALVE LEVER

(OPTION)

If loader is equipped with log forks this

lever controls boom, bucket and log forks.

The boom and bucket operating pattern of

this lever is the same as above.

A. When the log forks control lever is

pushed forward the log forks are

allowed to open.

B. When the log forks control lever is

AJO0600L

pulled back the log forks are allowed

Figure 48

to close.

2-28 Operating Controls

022-00028AE Operation and Maintenance Manual

1B.

ERGO-II PILOT CONTROL VALVE

LEVER (JOYSTICK) (OPTION)

Ergo-II lever is a pilot control valve lever

that incorporates transmission control

functions. It is used to reduce hand and

arm movement for he otherwise complex

operation of machine.

Forward, Neutral and Reverse

Switches.

"↑" Button

− When pressing this

switch, machine

travels

"FORWARD."

"N" Button

− When pressing this

switch,

machine

AJO0591L

"NEUTRAL."

Figure 49

"↓" Button

− When pressing this

switch,

machine

travels

"REVERSE."

Traveling Speed Changing Switches.

The transmission has 4 speeds in

forward and 3 speeds in reverse.

"+"

Button − When pressing this

switch, machine speed increase.

"-"

Button − When pressing this

switch, machine speed decrease.

Kick-down Switch.

"KD" Button

− When pressing this

switch that is in the rear side, kick-

HAAD3761

down function is selected.

Figure 50

Ergo-II lever switch usage:

•

When Rotating the starter switch to "I" (ON) position, DISPLAY indicates "NN."

•

When DISPLAY indicates "N4" while "N" button of ERGO-II is pressed, start the engine.

•

When DISPLAY indicates "N1" while "-" button is pressed, the machine is in the traveling ready

condition.

•

When "↑" button is pressed at forward traveling while "KD" button is pressed, machine can travel

forward.

•

When "↓" button is pressed at backward traveling while "KD" button is pressed, machine can

travel backward.

•

When machine is travelled, it can convert forward and backward travel without pressing "KD"

button.

NOTE: Travel can be possible while "KD" button is pressed at NEUTRAL condition.

•

"+" Button − Increase speed.

•

"-" Button − Decrease speed.

•

Kick-down switch: "KD" Button.

022-00028AE Operation and Maintenance Manual

Operating Controls 2-29

KICK-DOWN SWITCH (TWO PLACES)

Kick-down Switch Function

- When

transmission is in 2nd gear, pressing this

switch (Figure 52) will shift transmission

into 1st gear. This will allow the driver to

perform a quick digging movement.

Kick-down function range:

•

Automatic: 2nd, 3rd, 4th.

•

Manual: 2nd.

NOTE: Kick-down is "RELEASED"

when transmission is placed in

Figure 51

"NEUTRAL" position or the

switch is pressed again.

A second kick-down switch (Figure 51) is

on the end of the transmission lever.

AHO0900L

Figure 52

2-30 Operating Controls

022-00028AE Operation and Maintenance Manual

HORN BUTTON (TWO PLACES)

Pressing the left button at the tip of the

pilot control valve lever (joystick)

(Figure

53) or the button at the end of the

combination switch (Figure 54) will sound

the horn.

NOTE: Starter switch must be "ON."

Figure 53

AHO0890L

Figure 54

CIGAR LIGHTER

Push the lighter all the way into the socket

and release your hand. After pushing it in,

it will be ejected when it is heated. If it

does not eject after a short time, pull it out

and have it serviced.

IMPORTANT

The cigar lighter is powered by a 24

volt circuit. Never plug any 12 volt

HAOA780L

device into the cigar lighter.

Figure 55

022-00028AE Operation and Maintenance Manual

Operating Controls 2-31

HEADLIGHT SWITCH

O. In this position, this switch turns

"OFF" clearance, tail, instrument

panel, switch and headlights.

NOTE: If the switch is not in this

position with the engine not

running, the pilot buzzer will

sound to warn the operator that

the

batteries

are being

discharged.

In this position, this switch turns "ON"

HAOA720L

clearance, tail, instrument panel and

Figure 56

switch lights.

II.

In this position, this switch turns "ON"

clearance, tail, gauge panel, and

headlights.

CAUTION!

Do not leave clearance, tail,

instrument panel or headlights "ON"

when the engine is not running.

Leaving lights "ON" with the engine

shut down will discharge batteries.

FRONT WORK LIGHT SWITCH

O. In this position, this switch turns

"OFF" work lights mounted on the

front top of cab.

In this position, this switch turns "ON"

work lights mounted on the front top

of cab.

CAUTION!

HAOQ072L

Do not turn "ON" the work light when

Figure 57

traveling on public roads.

2-32 Operating Controls

022-00028AE Operation and Maintenance Manual

REAR WIPER SWITCH

O. In this position, this switch turns

"OFF" windshield wiper mounted on

rear windshield of operator’s cab.

In this position, windshield washer

fluid sprays onto the rear windshield

while running the rear wiper. When

released, the switch returns to the

"O" position.

II.

In this position, this switch turns "ON"

windshield wiper mounted on rear

APO0200L

windshield of operator’s cab.

Figure 59

CAUTION!

The washer pump can be damaged if

it is activated while there is no fluid in

the tank. The fluid level should be

checked regularly and refilled as

necessary.

Using soap or other solvents instead

of the recommended washer fluid

may damage the wiper blades and the

paint

finish.

Only use the

recommended washer fluid or

equivalent.

ROTATING BEACON SWITCH (OPTION)

O. "OFF" position.

When this switch is moved to "ON"

position, it activates the warning light.

10.

CUP HOLDER

Place to put beverages.

HAOA750L

Figure 60

2-34 Operating Controls

022-00028AE Operation and Maintenance Manual

11. PARKING BRAKE SWITCH

O. In this position, the parking brake is

"RELEASED" and the monitor light

on the front instrument panel turns

"OFF."

In this position, the parking brake is

"APPLIED" and the monitor light on

the front instrument panel comes

"ON." This brake can also be used as

an emergency brake.

HA0O2019

Figure 61

WARNING!

Set the parking brake switch in the

"I" (APPLIED) position before leaving

the loader. Make sure to "APPLY" the

parking brake switch before trying to

start the loader.

CAUTION!

Do not use the parking brake to stop

the loader, except in an emergency;

otherwise, it might cause premature

wear or damage of the brake.

AOO0220L

Figure 62

12. PILOT CUTOFF SWITCH

O. In this position the operator cannot

operate the pilot control valve lever

(joystick).

In this position the operator can fully

control the movement of the pilot

control valve lever (joystick).

CAUTION!

HBOI110L

When driving or parking, the pilot

Figure 63

cutoff switch should be changed to

"O" position.

022-00028AE Operation and Maintenance Manual

Operating Controls 2-35

13.

TRANSMISSION CUTOFF SWITCH

This switch changes over the modes of the

brake pedal, inching and no-inching.

O. In this position, the "NO INCHING"

mode is selected.

In the "NO INCHING" mode, the

power transmission line is still

connected when the brake pedal is

pressed, thus, making it easier to

start off on an incline. This mode is

also suitable for traveling, because

HA3O2018

both engine braking and the service

Figure 64

brake can be used in descending

grades.

In this position, the "INCHING" mode is selected.

In this mode, the transmission is put in "NEUTRAL" by pressing the left brake pedal. This mode

is suitable for load handling operation. When the accelerator pedal is pressed under this

condition, more power is concentrated on the load handling system, to quicken the boom lifting

speed.

NOTE:

1) Transmission "CUTOFF" function dose not operate at 3rd and 4th gear for protection of

transmission.

2) Regardless of transmission "CUTOFF" switch, the right brake pedal has braking

function only.

WARNING!

When pressing brake pedal while traveling or working on a slope, set this switch to "O" for

engine brake.

14. AUTOMATIC TRANSMISSION SWITCH

Automatic speed range:

•

Forward: 2nd, 3rd, 4th.

•

Reverse: 2nd, 3rd.

O. When this switch is in "O" (MANUAL)

position, travel mode is switched to

"MANUAL" and allows operator to

choose speeds manually.

When this switch is in "I"

(AUTO)

position,

gears

are

HLB20071L

"AUTOMATICALLY" changed to the

Figure 65

appropriate speed up to the limit set

by the gear lever and according to

travel load and engine rpm.

2-36 Operating Controls

022-00028AE Operation and Maintenance Manual

15. EMERGENCY STEERING TEST SWITCH

(OPTION)

This switch is used to test whether the

emergency steering system is properly

functioning.

The system should be tested during the

start-up procedure ensure that the system

is functioning.

Test emergency steering system using the

following procedure;

AJO0010L

A. Turn starter switch to "I"

(ON)

Figure 66

position.

NOTE: Do not start engine.

B. Press emergency steering test switch and turn steering wheel at the same time. If system is

functioning properly the unit should steer. The emergency steering indicator light should turn

"ON."

NOTE: If unit does not steer, do not operate unit until problem is corrected.

C. Release switch. Switch will automatically return to "O" (OFF) position.

WARNING!

Do not press this switch continuously. Continuously pressing switch will cause heavy

battery discharge. The emergency steering DC-motor uses high consumption of

power.

022-00028AE Operation and Maintenance Manual

Operating Controls 2-37

STORAGE BOX

There is a storage box

(1, Figure

72)

behind the seat. Keep the operation

maintenance manual and other documents

in this compartment.

HBOI431L

Figure 72

WASHER TANK

Contains windshield washer fluid.

HBOM680I

Figure 73

HOT/COLD REFRIGERATOR

There is a hot/cold refrigerator (1, Figure

74) behind and to the left of the seat. Air

conditioner and heating unit must be

operated after starting the engine for this

function. Keep the cover close for proper

function.

HBOI432L

Figure 74

ELECTRIC BOX

Under the seat are two pullout trays that

contain relays for unit.

(See “Fuse Box/

Relay” on page 2-55.)

Figure 75

2-40 Operating Controls

022-00028AE Operation and Maintenance Manual

OPERATION PANEL

HAOA801L

Figure 79

FAN AND AIR CONDITIONER SWITCH

SELECTION SWITCH FOR WIND

BLOWER FAN SWITCHES

DIRECTION

TEMPERATURE CONTROL SWITCH

VENTILATION SELECTION SWITCH

When a switch is selected, the LED above that switch will turn "ON" and give an activation sound.

When the light switch is turned "ON," the panel LED’s will turn "ON."

FAN AND AIR CONDITIONER SWITCH

A. "OFF" Switch

- Turns "OFF" the

heater and air conditioner unit.

B. "A/C" Switch

- Turns "ON" the air

conditioner when one of the blower

switches is activated.

HAOC930L

Figure 80

022-00028AE Operation and Maintenance Manual

Operating Controls 2-43

BLOWER FAN SWITCHES

These switches are used to control the

speed of the blower fan.

A. "LO" Switch - Used for low blower

speed.

B. "MID" Switch - Used for intermediate

blower speed.

C. "HI" Switch - Used for high blower

speed.

NOTE: If you do not select a blower

HAOC940L

speed the heater and air

Figure 81

conditioner will not work.

TEMPERATURE CONTROL SWITCH

The temperature control consists of

stages. An LED is turned "ON" for every

three stages. Whenever pushing it, it

changes in stages. Pushing it continuously,

it changes continuously.

A. "COOL" Switch

Lowers the

temperature.

B. "WARM" Switch

Raises the

temperature.

HAOA860I

LED COLOR STATUS

Figure 82

Green LED - Air conditioner. Full

green, maximum operation of

air conditioner.

Red LED

- Heater. Full red,

maximum operation of heater.

SELECTION SWITCH FOR WIND

DIRECTION

A. Used to direct air flow to upper

portion of operator’s cab.

HBOI320L

Figure 83

2-44 Operating Controls

022-00028AE Operation and Maintenance Manual

MEMORY FUNCTION OF USED MODE

The air conditioner panel has a memory function. When the starter switch is turned "OFF" the settings for

the panel will be stored. When the excavator is started, the last setting will be used.

ADDITIONAL OPERATING INSTRUCTION

A proper indoor temperature in summer is 5 - 6° C (10 - 12°F) less than the outdoor temperature.

Operate the air conditioner from 20 - 30 minutes a week to circulate the refrigerant in the system.

NOTE: The blower switch should be on "LO" speed.

NOTE: The filter should be cleaned out every 500 hours and replaced with a new one every 1,000

hours.

NOTE: In the event that the unit is being operated in a dusty environment, the cleaning and

replacement should be performed more frequently.

If operating the air conditioner or heater for a long time, operate the ventilation switch, and when smoking,

vent the air to the outside to prevent irritation to eyes.

2-46 Operating Controls

022-00028AE Operation and Maintenance Manual

STEREO

Figure 87

ON-OFF / VOLUME CONTROL KNOB

CASSETTE SLOT

BALANCE / FADER CONTROL

8. & 9. PLAY DIRECTION BUTTON

BASS/TREBLE CONTROL

10. AUTOMATIC SELECTION

AM/FM BAND SELECTION

11. DOLBY B SELECTION

AUTOMATIC MEMORY (AME)

12. METAL SELECTION

TAPE EJECT BUTTON

13. LCD DISPLAY PANEL

ON-OFF / VOLUME CONTROL KNOB

When this button is pressed, stereo will be turned "ON."

When this button is pressed a second time, power turns "OFF."

Increase volume by rotating control clockwise.

When stereo is turned "ON," LCD display will indicate radio stations and/or tape functions.

BALANCE / FADER CONTROL

This control adjusts both side to side balance of stereo sound and front to back fading.

Rotating control counterclockwise will increase volume to the left speakers, clockwise increases

volume to the right speakers.

Press on control and it will pop out; you can now adjust the fader (front/rear) balance.

Rotating control counterclockwise increases volume to the rear speakers, clockwise increases

volume to the front speakers.

BASS / TREBLE CONTROL

This control adjust bass and treble tone levels.

To adjust treble tone level rotate control counterclockwise to decrease treble and clockwise to

increase treble.

022-00028AE Operation and Maintenance Manual

Operating Controls 2-47

To adjust bass tone level press on control and it will pop out. Rotate control counterclockwise to

decrease bass and clockwise to increase bass.

AM/FM BAND SELECTION

This button sets radio to either AM-1, AM-2, FM-1 or FM-2 frequency bands. Each frequency bands

will enable the stereo to store 6 preset radio station frequencies. Each time the button is pressed the

stereo will move to the next band.

AUTOMATIC MEMORY (AME)

This function automatically finds the six

strongest radio signals in the frequency

selected and stores them in memory.

Select band (AM-1, AM-2, FM-1, FM-2).

Press and hold AME button for

approximately two seconds and stereo will

search out strongest stations in area.

These stations can then be recalled by

pressing buttons (1 thru 6, Figure 88).

NOTE: To manually store radio station

HAOC990L

settings, use band selector to

Figure 88

select frequency band to be

listened to. Then use tuning

control to select desired station.

Press and hold any preset keys

for approximately 2 seconds; a

beep will sound when station

has been set.

TAPE EJECT BUTTON

Eject tape from cassette deck by pressing this button. Stereo returns to tuner mode.

CASSETTE SLOT

Press "ON/OFF" switch for power. Insert a tape with exposed tape facing right. The tape will start to

play. "TAPE" is displayed on LCD display.

8. & 9. PLAY DIRECTION BUTTON

Pressing this control button to either right or left will fast forward or rewind tape. The button will lock

into this position. To stop action, press opposite side button and tape will return to normal play mode.

Pressing both control buttons at the same time will reverse direction of tape.

10. AUTOMATIC SELECTION

Press this control to change channels manually to either higher or lower frequencies.

11. DOLBY B SELECTION

If the tape being listened to has been recorded with Dolby B, press preset selector button 1 to turn

Dolby B control on. Dolby symbol will appear on display. Press this control a second time to turn

Dolby B control "OFF."

2-48 Operating Controls

022-00028AE Operation and Maintenance Manual

12. METAL SELECTION

If tape being listened to is either a metal or chromium type of tape, press preset selector button 2 to

select "MTL" setting. "MTL" will appear on display. Press this control a second time to turn this setting

"OFF."

13. LCD DISPLAY PANEL

A. Tape Reverse Direction Indicator

B. Tape Forward Direction Indicator

C. Preset Radio Memory Channel

Indicator

D. Radio Station Frequency

E. AM/FM Band Indicator

Stereo Radio Signal

G. Dolby Noise Reduction Indicator

HAOA960L

Figure 89

H. Metal Tape Indicator

CARE OF STEREO

Do not use a tape that has a longer playing time

than C-90 (90 minutes). Avoid use of C-120

tapes because tapes are made of a thinner

material that may break and get tangled inside

stereo.

Figure 90

Make sure tapes are wound tight. If you use a

loose tape, it may cause a problem in a deck. If

they are loose, use a pencil or similar device to

wind up slack.

Do not use poor quality tapes.

Figure 91

022-00028AE Operation and Maintenance Manual

Operating Controls 2-49

Do not store cassette tapes in the following

places or under the following conditions.

Damage to tape and stereo may result.

•

Direct sunlight.

•

Humid place.

•

Dusty place.

•

Around heater or heater vents which

discharge heat.

•

Around speakers and other magnet

devices that generate a strong

HLB2014L

magnetic field (solenoid valves).

Figure 92

Clean head and pinch roller periodically. They

continuously contact the tape. If they are not

kept clean, stereo and tapes may be damaged.

Keep them clean for optimum performance.

Figure 93

If head gets dirty, clean it with a soft cotton swap

through cassette slot.

It is recommended to use a cassette deck

cleaning tape for easy and efficient cleaning of

head, capstan and pinch roller.

When you turn "OFF" power, be sure to take out

cassette tape by pressing eject button.

When not using a cassette tape, keep it stored

in a plastic case.

Figure 94

2-50 Operating Controls

022-00028AE Operation and Maintenance Manual

SEAT ADJUSTMENT

WARNING!

Whenever operator or operating condition

has changed, check to see that seating

position is suitable for the condition at

hand. Always fasten your seat belt while

operating vehicle. Adjust backrest so that

the operator can fully reach and operate

pedals.

HAOB110L

Figure 95

ADJUSTING SEAT FORWARD/

BACKWARD LEVER

Holding lever (3, Figure 96), raise it up,

while pushing or pulling seat to desired

position. Release lever once desired

position is reached. Adjustment range is

160 mm (6.3 in).

2 & 3. ADJUSTING SEAT'S ANGLE AND

HEIGHT LEVER

Pulling left lever (3, Figure 96) up allows

HBOI350L

rear part of seat to be moved up or down.

Figure 96

Pulling lever (2) up allows front part of seat

to be moved up or down. Adjust seat

according to operator’s size and work

conditions. Adjustment range is

60 mm

(2.36 in) for both front and rear.

WEIGHT ADJUSTMENT KNOB

Turning knob (4, Figure 96) to right makes suspension harder. Turning knob to left makes suspension

softer. Adjust according to operator’s weight by checking weight indicator dial. Adjustment range is

from 50 - 120 kg (110 - 265 lb).

BACKREST ADJUSTMENT LEVER

Pulling up right lever (5, Figure 96) allows seat backrest to be moved forward or backward.

022-00028AE Operation and Maintenance Manual

Operating Controls 2-51

SEAT BELT

WARNING!

Seat belt is for operator's safety and should be worn at all times. Before driving machine, adjust

seat to desired position for maximum comfort and machine control, then fasten seat belt. Seat

belts must be worn across pelvic region and adjusted snugly to lessen chance and severity of

injury in event of an accident. Never fasten a seat belt across abdomen.

Under no circumstances should operator be standing in cab when operating wheel loader.

Do not adjust seat position while vehicle is moving because a loss of control may result. Stop

machine, apply parking brake, and then adjust seat.

Always, check condition of seat belt and belt bracket before fastening it. Do not use it with twists

in it. Replace belt or bracket if damaged or worn.

SEAT BELT LOCKING AND UNLOCKING

Insert belt end (1, Figure 98) into buckle (2). Pull

belt to check that belt end is locked into buckle.

Adjust belt length so that it comfortably tight

against operator’s pelvic region (hipbone).

HAOB140L

Figure 98

Press button (3, Figure 99) in center of buckle

(2) and pull out belt (1) to unlock.

HAOB150L

Figure 99

022-00028AE Operation and Maintenance Manual

Operating Controls 2-53

FUSE BOX/RELAY

FUSE BOXES

There are two fuse boxes inside the

cab.

Fuse box one (1, Figure 102) is in the

rear side of right control stand. A usage

diagram of fuses is shown inside of fuse

box. Spare fuses are mounted on the

inside of fuse box cover (10A - Qty. 1,

15A - Qty. 1, 20A - Qty. 1 and 30A - Qty.

1).

Fuse box two (2, Figure 102) is just

above the windshield washer fluid tank.

WARNING!

If any fuse is blown, turn "OFF" the

starter switch and shut off the

power supply. Remedy the cause if

needed and replace the fuse with a

new one.

Figure 102

022-00028AE Operation and Maintenance Manual

Operating Controls 2-55

Fuse Box One

No.

Name

Capacity

Gauge Panel

15A

Transmission

15A

Front Wiper, Horn

15A

Parking Brake,

15A

Pilot Cutoff, Log Fork

(Option)

AJO0470L

Headlight, Stop Light

20A

Figure 103 FUSE BOX ONE

Condenser Fan, Preheat

15A

Emergency Steer (Option),

15A

Spare

Air Conditioner, Heater

30A

Working Light (Front),

15A

Rotating Beacon (Option)

Working Light (Rear)

15A

Turn Signal Light, Hazard

15A

Light, Indicate Light

Stereo, Cab Light,

15A

Fuel Pump, Engine Stop

Memory Backup,

10A

Pilot Buzzer

Starter Switch

10A

Fuse Box Two

No.

Name

Capacity

Cigar Lighter

15A

Rear Wiper

15A

Position Light (Right)

10A

Position Light (Left)

10A

Auto-Detent, LIS (Option)

15A

AJO0480L

Spare

30A

Figure 104 FUSE BOX TWO

2-56 Operating Controls

022-00028AE Operation and Maintenance Manual

RELAY

The relays are in the electrical box under the

seat. If the problem is not solved after replacing

the fuse, check the function of the relay.

APO0210L

Figure 105

Figure 106

CIRCUIT BREAKER

A circuit breaker is next to the relay by the

batteries at back of unit under engine

compartment hood. When a short circuit or an

overload

occurs,

the

circuit

breaker

automatically cuts-off current, thus preventing

electrical wires from burning.

Figure 107

FUSIBLE LINK

A fusible link is in the battery box. If electric

power is not present at the "I" (ON) position of

the starter switch, check the fusible link first.

NOTE: If fuse wire is burnt off, replace

link.

Figure 108

022-00028AE Operation and Maintenance Manual

Operating Controls 2-57

3OPERATION

WARNING!

Before operating any Daewoo wheel loader, read and understand "Operating Controls" section

of this manual.

INSTRUMENT PANEL CONTROL FUNCTIONS

MONITORING SYSTEM

Monitoring system uses network circuits between control system and sensors installed at various machine

system locations to monitor selected conditions. This monitoring systems function is to continually inform

operator of machine’s condition. Displays and gauge readouts on instrument panel provide information

such as engine speed, engine coolant temperature, transmission oil pressure, and electrical charge status.

NEW MACHINE BREAK-IN PROCEDURES

All Daewoo wheel loaders are inspected and adjusted before leaving the factory. However, it is required

that the operator follow these steps during initial break-in period. Failure to follow these steps may result in

damage to equipment or reduced performance.

Make sure to check all fluid levels before starting and every 8 to 10 operating hours.

Do all Daily maintenance and service checks.

For first 50 operational hours, as shown by hour meter on control console, do not exceed 80% of

maximum rated engine speed.

At end of first 50 operational hours, drain engine oil. Replace engine oil filter and engine oil.

022-00028AE Operation and Maintenance Manual

Operation 3-1

Set pilot cutoff switch to "O"

(LOCK)

position. This will "LOCK" pilot control

valve lever (joystick).

HBOI111L

Figure 4

Rotate starter key to "I" (ON) position. All

indicator lights should turn "ON."

NOTE: If unit is equipped with and

emergency steering system.

Test system before starting

engine. If system does not

function properly, do not start

unit. Follow test procedure

given with test switch.

HAOB320L

Figure 5

Rotate starter key to "START" position.

Starter motor should crank immediately,

and engine should start within a few

seconds.

HAOB350L

Figure 6

Release starter key when engine starts.

Key will return to "I" (ON) position.

IMPORTANT

engine does not start after

approximately

seconds of

cranking, release Starter Key. Wait 5

minutes for starter motor to cool

down. Repeat step 6.

After engine starts, check all indicator

HAOB360L

lights and gauges to be certain that all

Figure 7

022-00028AE Operation and Maintenance Manual

Operation 3-3

engine systems (oil pressure, oil temperature, coolant temperature, etc.) are in normal operating

range. If any engine system is not normal, turn starter key to "OFF" position.

Indicator

Instrument Panel Light Or Gauge

Reading

Fuel Gauge

Engine Coolant T

emperature Gauge

WHITE RANGE

Transmission Oil Temperature Gauge

Engine Oil Pressure Warning Light

Charging Warning Light

OFF

Brake Oil Pressure Warning Light

Parking Brake Light

NOTE: Parking brake indicator light turns "ON" or "OFF" according to parking brake operation

regardless of engine starting.

Perform “Hydraulic System Warm-up” on page 3-10

10.

Check color of exhaust smoke.

•

No color or light blue - Engine is running in good condition.

•

Black - Incomplete combustion. Check cause.

•

White or dark blue - Engine is burning engine oil. Check cause.

11.

Check for usual engine vibration and noises. If any are heard or felt, investigate cause.

NOTE: If engine coolant temperature gauge shows red while running, take the following action;

Discontinue work and allow engine to run at "LOW IDLE." Open engine compartment

cover for good ventilation. Once engine temperature gauge returns to the green zone, shut

down engine. After engine has cooled, check coolant level, look for leaks, clogged or dirty

radiator fins (radiator core), and fan belt tension.

3-4 Operation

022-00028AE Operation and Maintenance Manual

COLD WEATHER ENGINE START

Set parking brake switch to the "I"

(APPLIED) position. This will ensure that

the parking brake is "APPLIED."

HA0O2019

Figure 8

Move all control levers to "NEUTRAL"

position.

IMPORTANT

transmission lever is not in

"NEUTRAL" position, engine will not

start.

Figure 9

Make sure transmission neutral lock is in

the "N" (NEUTRAL LOCK) position.

Figure 10

Set pilot cutoff switch to "O" (LOCKED)

position. This will "LOCK" pilot control

valve lever (joystick).

HBOI111L

Figure 11

022-00028AE Operation and Maintenance Manual

Operation 3-5

Release starter key when engine starts.

Key will return to "I" (ON) position.

IMPORTANT

engine does not start after

approximately

seconds of

cranking, release starter key. Wait 5

minutes for starter motor to cool

down. Repeat step 8.

10. After engine starts, check all indicator

HAOB360L

lights and gauges to be certain that all

Figure 15

engine systems

(oil

pressure, oil

temperature, coolant temperature, etc.)

are in normal operating range. If any

engine system is not normal, turn starter

key to "O" (OFF) position.

11. Perform

“Hydraulic System Warm-up

Cold Weather” on page 3-10.

022-00028AE Operation and Maintenance Manual

Operation 3-7

STARTING WITH AUXILIARY BATTERIES

WARNING!

Wear safety glasses.

Never connect negative leads to positive terminals and vice versa.

DO NOT connect auxiliary or booster battery ground terminal directly to battery terminal. Locate

and use a ground point on machine frame.

Depleted batteries generate hydrogen gas. Electrical sparks around or near batteries can cause

an explosion.

Figure 16

AUXILIARY BATTERIES

GROUND AUXILIARY BATTERIES TO

DEPLETED BATTERIES

MACHINE FRAME

If batteries are drained during starting procedures, you can jump start engine using auxiliary or booster

batteries according to following procedures:

Connect positive jumper cable from auxiliary batteries to depleted batteries (Figure 16).

Connect negative jumper cable from auxiliary batteries to a ground point on machine frame. DO NOT

CONNECT DIRECTLY TO NEGATIVE BATTERY TERMINAL.

Follow normal engine starting procedures.

After engine has started, remove negative jumper cable, and then positive cable.

3-8 Operation

022-00028AE Operation and Maintenance Manual

ENGINE STOP

Move transmission lever to "NEUTRAL"

position.

Figure 17

Make sure transmission neutral lock is in

the "N" (NEUTRAL LOCK) position.

Figure 18

Set parking brake switch to the "I"

(APPLIED) position. This will ensure that

the parking brake is "APPLIED."

HA0O2019

Figure 19

Set bucket on ground.

Put pilot cutoff switch to "O"

(LOCK)

position. This will "LOCK" pilot control

valve lever (joystick).

Allow engine to idle for 1 - 2 minutes to

cool down.

HBOI111L

Figure 20

022-00028AE Operation and Maintenance Manual

Operation 3-9

Rotate starter key to "O" (OFF) position.

Remove key.

HAOC342L

Figure 21

HYDRAULIC SYSTEM WARM-UP

Correct operating temperature of hydraulic oil is 50° - 80°C (120° - 175°F). Make sure to follow

procedures listed below for hydraulic fluid warm-up.

Run engine at idle (no load) for 5 minutes.

Run engine for approximately 5 minutes at middle of speed range, without a load.

Cycle bucket until bucket cylinder bottoms out (extended and retracted) without a load to circulate the

oil through the system. Do this for 5 minutes.

NOTE: Do not allow cylinders to pass hydraulic oil over relief valve for more than twenty seconds

at a time.

Cycle boom, and bucket about five times without a load to circulate oil through system.

HYDRAULIC SYSTEM WARM-UP - COLD WEATHER

Follow Steps 1 through 3 in Hydraulic System Warm-up.

Do not operate machine at full speed until system has fully warmed up.

If working speeds continue to be slow, repeat initial hydraulic warm-up procedures again. If repeating

warm-up procedures does not improve working speeds, continue to operate, but use extreme caution

because machine function may be erratic.

3-10 Operation

022-00028AE Operation and Maintenance Manual

MACHINE TRAVEL

WARNING!

If vehicle is moved while parking brake is engaged, serious damage to parking brake disc will

result.

Select a transmission gear that is appropriate for top speed that will be traveled. Choosing a

gear that is too high will reduce acceleration and will unnecessarily heat transmission converter

oil.

Never place transmission in "NEUTRAL" when going down a hill. Over speeding transmission

can damage transmission gears.

Never change direction of vehicle travel at high speed. Serious damage to transmission will

result.

Unlatch frame lock plate between front and

rear frames before traveling. Secure lock

plate to rear frame (Figure 22).

Figure 22

Set pilot cutoff switch to "I" (UNLOCKED)

position. Raise bucket to a height of 20 -30

cm (8 - 12 in) above the ground. Tilt bucket

completely back.

HBOI110L

Figure 23

022-00028AE Operation and Maintenance Manual

Operation 3-11

Place transmission lever in desired gear.

Shift gears one by one. Do not skip from

1st to 3rd, for example.

Shift transmission lever to "FORWARD"

position.

Figure 28

Release the brake pedal while slowly

pressing the accelerator pedal.

WARNING!

When traveling at high speed or on a

steep hill, do not make sharp

changes in direction. This could

cause vehicle to overturn.

When traveling or changing

direction, always look carefully to be

Figure 29

certain that no one is in path of

vehicle.

MACHINE SHUT DOWN

Ease off throttle and apply travel brakes.

Figure 30

022-00028AE Operation and Maintenance Manual

Operation 3-13

Put transmission lever in "NEUTRAL."

Figure 31

Set transmission neutral lock is in the "N"

(NEUTRAL LOCK) position.

CAUTION!

"LOCK" transmission lever. When

ever machine is parked, "LOCK"

transmission lever in "NEUTRAL" to

prevent

accidental

machine

movement.

Figure 32

Set parking brake switch to the "I"

(APPLIED) position. This will ensure that

the parking brake is "APPLIED."

HA0O2019

Figure 33

Set bucket on ground.

Select pilot cutoff switch to "O" (LOCKED)

position. This will lock pilot control valve

lever (joystick).

Allow engine to idle for 1 - 2 minutes to

cool down. Stopping a turbocharged

engine without a cool down period can

seriously damage turbocharger.

HBOI111L

Figure 34

3-14 Operation

022-00028AE Operation and Maintenance Manual

Rotate starter key to "O" (OFF) position.

Remove key.

HAOC342L

Figure 35

If machine is parked on a slope, install

wheel chocks in front of and behind vehicle

wheels.

WARNING!

Always secure machine with wheel

chocks when parked on a slope.

Leaving machine in gear will provide

no braking

effect

because

transmission clutch is hydraulically

operated. When engine is turned

Figure 36

"OFF," there is no hydraulic pressure

in transmission and clutch is not

engaged.

ADDITIONAL BRAKING

Machine hydraulic system can supply additional braking force during travel. To accomplish this, move pilot

control valve lever (joystick) to crowd position and hold it there. Hydraulic pump will be driven to supply

output at maximum pressure (relief pressure). Energy expended to drive pump, will slow engine speed.

Additional braking, along with proper gear selection, can be used to slow a vehicle that is being driven

down an incline.

022-00028AE Operation and Maintenance Manual

Operation 3-15

BOOM RAISE KICKOUT

Placing bucket lever in "Boom Raise Detent"

position will lock bucket lever in raise boom

position. Boom will raise until trip plate

(1,

Figure 37) makes contact with bucket height

limit switch

(2). When limit switch is tripped,

boom will stop raising and bucket lever will

automatically be returned to "NEUTRAL"

position. Trip plate can be adjusted to control

maximum height that boom can be raised.

HBOI441L

Figure 37

IMPORTANT

Trip plate (1, Figure 37) must always be set

to contact limit switch (2) before boom

cylinders reach maximum extension.

Maximum extension causes pump to force

fluid over relief valve.

To raise boom to maximum height, past preset

height, hold boom and bucket lever in "Raise" or

"Hold Raise" position until boom has reached

maximum height. Then remove your hand from

Figure 38

lever. Lever will automatically return to

"NEUTRAL" position. This prevents hydraulic

pump from working against relief valve

(maximum pressure).

BUCKET ANGLE

INDICATOR

Upper right side of bucket includes a bracket

that indicates angle of bottom of bucket. Top of

bracket is parallel with bottom of bucket. If

bottom of bucket is not visible, top of bracket will

be visible.

Figure 39

3-16 Operation

022-00028AE Operation and Maintenance Manual

BOOM LOWER KICKOUT (OPTION)

Placing bucket lever in "L" position will lock

control lever in lower boom position. Boom will

move downward until trip plate (2, Figure 40)

makes contact with bucket lower limit switch (1).

When limit switch is tripped, boom will stop

lowering and bucket lever will automatically be

returned to "NEUTRAL" position. Trip plate can

be adjusted to control maximum height that

boom can be lowered.

IMPORTANT

Trip plate must always be set to contact

Figure 40

limit switch before boom cylinders reach

maximum extension. Maximum extension

causes pump to force fluid over relief

valve.

022-00028AE Operation and Maintenance Manual

Operation 3-17

ADJUSTMENT OF BUCKET POSITION SWITCH

MEGA 200-V

When bucket lever is held in crowd detent position, after bucket has been dumped, bucket will pivot toward

crowd position. Once full crowd position has been reached, bucket lever will automatically return to

"NEUTRAL" position. If bucket is lowered after lever returns to "NEUTRAL," bucket will automatically

position itself to be in a preselected digging position (usually flat). To adjust bucket to desired preselected

digging position, perform the following steps.

Operate controls to place bucket on ground and in desired digging position (usually flat). Return

bucket lever to its "NEUTRAL" position.

Shut down engine.

Loosen bolts (4, Figure 41) on bracket (3).

Position bracket (3, Figure 41) so that end

of arm

(1) is aligned with center of

magnetic switch (2).

Tighten bolts (4, Figure 41).

Start engine. Raise boom, dump bucket,

then move bucket lever into crowd detent

position. Now lower boom and check to

see that bucket has stopped at required

position. A small readjustment of bracket

Figure 41

(3, Figure 41) may be necessary.

MEGA 200-VTC

When bucket lever is held in crowd detent position, after bucket has been dumped, bucket will pivot toward

crowd position. Once full crowd position has been reached, bucket lever will automatically return to

"NEUTRAL" position. If bucket is lowered after lever returns to "NEUTRAL," bucket will automatically

position itself to be in a preselected digging position (usually flat). To adjust bucket to desired preselected

digging position, perform the following steps.

Operate controls to place bucket on ground. Operate controls to place bucket in desired preselected

digging position (usually flat). Return bucket lever to its "NEUTRAL" position.

Shut down engine.

Loosen bolts (4, Figure 42) on bracket (3).

Position bracket (3, Figure 42) so that end

point of arm (1) is aligned with center of

magnetic switch (2).

Tighten bolts (4, Figure 42).

Start engine. Raise boom, dump bucket,

then move bucket lever into crowd detent

position. Now lower boom and check to

see that bucket has stopped at required

position. A small readjustment of bracket

Figure 42

(2, Figure 42) may be necessary.

3-18 Operation

022-00028AE Operation and Maintenance Manual

TOWING MACHINE

When necessary to tow another vehicle, the tow

rope must be tied to the towing pin on the

counterweight at the rear of vehicle.

NOTE: The loader must be used for

towing only in an emergency.

WARNING!

Do not tow machine at a speed over 10 km/

h (6 MPH) and do not tow machine farther

than 10 Km (6 miles). This will prevent

damage to machine transmission that

Figure 43

would result from lack of lubrication.

WARNING!

When towing another vehicle on a public road, take necessary measures to let other vehicles

and people know that you are towing another vehicle. Use a flag, rotating light, or hazard light.

NOTE: There are several requirements you must abide by when towing another vehicle. Learn the

regulations and rules about towing another vehicle and observe them.

If the loader is being towed by another vehicle and the engine will not start, remove the front and rear drive

shafts; otherwise the transmission will rotate without being properly lubricated, causing seizure. Before

removing them, apply the parking brakes and block the wheels securely.

If the engine can be started and the steering wheel and brakes function normally, have someone get on the

loader you are going to tow for steering it.

Before you tow a vehicle make sure you have checked the following:

•

Check the weights of your loader and the vehicle to be towed and make sure you loader has

sufficient braking capacity to stop the towed load.

•

Check if the vehicle to be towed can be braked and steered. If not, do not allow anyone to ride

on the towed vehicle.

•

Check the tow rope or tow bar for damage and make sure it has sufficient strength for the work.

•

When necessary to descend a gradient, another towing vehicle must be used in the rear to

retard.

When towing make sure you are doing the following;

•

Start slowly. A sudden start can lead to a broken tow rope.

•

The tow line must be along the centerline of both your loader and the vehicle to be towed.

•

If you use any other towing device, refer to the Instruction Manual supplied with the towing

device.

•

If it is difficult to tow the loader, transport it by a trailer truck to your nearest repair shop.

•

In addition to the above measures, release the parking brake if the engine will not start or the

hydraulic pumps are defective.

022-00028AE Operation and Maintenance Manual

Operation 3-19

IF ENGINE STALLS WHILE TRAVELING

BRAKE SYSTEM: The brakes can be applied approximately 9 times by pressing the brake pedal due to the

oil pressure stored in the accumulator after engine is turned "OFF" if the engine stalls while traveling,

move to an out of traffic area and park. Do not pump the brake pedal at this time; otherwise the brake

oil pressure will be used up, thus causing the brakes to fail.

ALLOWABLE WATER DEPTH

The water depth is an important factor to take into consideration when the loader is working in swampy

areas. Do not enter water whose depth exceeds the loader’s minimum ground clearance height or is high

enough to wet the bottom of the axle housing. As a rule of thumb, the allowable water depth is about 400

mm. This means that the loader should not be used in a river.

Observe the following conditions:

Check the water depth in advance when crossing across a river.

Use the same precautions before crossing across a swampy area.

Do not enter rivers whose river bed is steep or has a rapid flow.

CAUTION!

Avoid use of the loader in salt water. Salt water will cause the development of rust which will

shorten the life of the loader.

3-20 Operation

022-00028AE Operation and Maintenance Manual

4INSPECTION, MAINTENANCE AND

ADJUSTMENT

Routine maintenance and inspections are

required to keep your machine in the correct

operating condition. The following pages list the

inspection intervals, the system or component

checks and location references.

NOTE: The following pages list the

service checks and their

required intervals. The service

cycles may need to be

shortened depending on the

working conditions. Extremely

hot or dusty conditions will

HA0O2012

require more frequent service.

Figure 44

Operational

hours

are

determined by the amount of

time accumulated on the

engine hour meter on the front

instrument panel in the cab.

SERIAL NUMBERS

There are two serial number plates attached to

the body of wheel loader. Main serial number

plate is on left side of front frame above wheel

cover (Figure 1). The number is also stamped in

the rear frame on the left side just below the cab

(Figure 2).

Figure 1

Figure 2

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-1

The engine name plate (identification label) is

attached to rocker cover (Figure 3). The engine

serial number is stamped on the left rear of the

engine block, under exhaust manifold.

Please make note of these numbers and their

locations. These will be required whenever

warranty service work is requested.

SAFETY PRECAUTIONS

Before performing any maintenance

checks, move pilot cutoff switch to

"LOCKED" position. Place a Warning Tag

Figure 3

on controls so that no one begins to

operate machine while maintenance

checks are being performed.

Clean up all fuel spills. Fuel spills are

hazardous, especially around engine.

Inspect all fuel lines for leakage. Replace

any lines, fittings, O-rings, or filters that

show signs of wear or damage.

If a test procedure requires engine to be

running, use two people and keep all

unnecessary personnel away from

machine.

4-2 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

TABLE OF RECOMMENDED LUBRICANTS

IMPORTANT

Do not use lubricants other than those recommended, without prior written approval from

Daewoo.

NOTE: Refer to Maintenance Intervals Table for application points.

LUBRICANT

HYDRAULIC OIL

ENGINE OIL

AXLE GEAR OIL

MANUFACTURER

GREASE

CALTEX

CALTEX HD32

CALTEX RPM or

MULTIFAC EP

MULTIPURPOSE

EP90

DELO 300

EXXON/ESSO

NUTO (ANTI-

EXXON XD-3

RONEX MP #2

SPARTAN EP220

WEAR)

STRAIGHT

WEIGHT or

HD 32 (BELOW

EXXON GX

15W40

RONEX MP #1

0°C (32°F)) or

80W90

(COLD TEMPS)

HD 46 (ABOVE

0°C (32°F)) or

TERESSTIC

(ANTI-RUST)

MOBIL

DELVAC 1300 or

MOBIL FAW #2

MOBILUBE LS

80W90

DTE 13M (ALL-

SUPER 15W40 or

TEMP) or

DELVAC 1 or

MOBIL FAW #1

DTE 24

(COLD TEMPS)

STRAIGHT

(SUMMER)

WEIGHT

SHELL

TELLUS 32

ROTELLA

ALVANIA EP #2

SPIRAX HD

80W90

T15W40 or

T30 (WINTER) or

T40 (SUMMER)

PENNZOIL

PENNZBELL

LONGLIFE

PENNZOIL 705

PENZOIL

EP #2

MULTIPUPOSE

AW 32 (BELOW

SAE30 or

4092 or

0°C (32°F)) or

SAE40 or

80W90

AW 46 (ABOVE

SAE15W40

0°C (32°F))

DRYDEN

PARADENE

DIESELALL

EP #2 (RED)

AP80W90

PLUS or

AW 32 (BELOW

0°C (32°F)) or

30W or

AW 46 (ABOVE

40W or

0°C (32°F))

15W40

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-3

LUBRICANT

HYDRAULIC OIL

ENGINE OIL

AXLE GEAR OIL

MANUFACTURER

GREASE

CHEVRON

AW MV 32

DELO 400

DELO GREASE

DELO GEAR OIL

(BELOW 0°C

15W40

EP-2

(32°F)) or

RPM UNIV GEAR

AW MV 46

80W90

(ABOVE 0°C

(32°F))

TEXACO

RANDO

URSA SUPER

STAR PLEX 2

MULTIGEAR

PLUS 15W40 or

EPSAE 80W90

HD32 (BELOW

STAR PLEX

0°C (32°F)) or

URSA PREMIUM

PREMIUM

TDX 15W40

HD46 (ABOVE

0°C (32°F))

IDEMITSU

DAPHNE KOSAN

APOROIL

DAPHNE

APOROIL GEAR

KOSAN

46WR

MOTIRE S300

CORRONE #2

HE 90

NIPPON SEIKIYU

SUPER

HIGH D. S3

LIPANOC

NISEKI SP90 or

HIGHLAND S26

STRAIGHT

GREASE

EP90

or 32

WEIGHT

TOTAL

TOTAL EQUIVIS

TOTAL

TOTAL MULTIS

ZS46 - III

XT 15W40

EP #2

FUCHS

85W90LS

LUBRICANT

TRANSMISSION GEAR OIL

MANUFACTURER

Same as engine oil

SAE 15W40

API CD and above

CAUTION!

Do not mix oils from different manufacturers. Daewoo does not endorse specific brands but

does suggest that owners select quality oils whose suppliers provide assurance that required

standards will always be met or exceeded.

IMPORTANT

Fluctuating daily or weekly extremes of temperature, or operation in sub-zero freezing weather

may make it impractical to use straight weight lubricants. Use good judgement in selecting

lubricant types that are appropriate for climate conditions.

4-4 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

FLUID CAPACITIES

Component

Capacity

Engine

Oil Pan with Filter

21 liters

(5.5 U.S. gal.)

NOTE:

The filter holds an additional 1 liter (1

qt) of oil.

Cooling System

31 liters

(8.2 U.S. gal.)

Fuel Tank

260 liters

(69 U.S. gal.)

Hydraulic Oil Tank

150 liters

(40 U.S. gal.)

Transmission

30 liters

(7.9 U.S. gal.)

Axles

Front Differential

16 liters

(4.2 U.S. gal.)

Front Hub Reduction Gear

1.7 liters

(0.4 U.S. gal.) Each end.

Rear Differential

15 liters

(4 U.S. gal.)

Rear Hub Reduction Gear

1.7 liters

(0.4 U.S. gal.) Each end.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-5

MAINTENANCE INTERVALS

10 HOUR / DAILY SERVICE

•

Grease Front Attachment Pins (See page

•

Inspect the Bucket Teeth and Side Cutters

4-8)*

for Signs of Wear (See page 4-14)

•

Inspect All Tires for Correct Tire Pressure

•

Inspect Seat Belt for Proper Operation (See

and Signs of Damage or Abnormal Wear

page 4-15)

(See page 4-8)

•

Inspect the Structure for Cracks and Faulty

•

Check Engine Oil Level (See page 4-8)

Welds (See page 4-15)

•

Check Transmission Oil Level (See page

•

Check the Operation of All Switches (See

4-9)

page 4-15)

•

Check Hydraulic System Oil Level (See

•

Check the Operation of All Exterior Lights,

page 4-10)

Horn and Control Console Indicator and

•

Check for Leaks in the Hydraulic System

Monitor Lights (See page 4-15)

(See page 4-11)

•

Start Engine, Check Starting Ability, and

•

fill Fuel Tank (See page 4-12)

Observe Exhaust Color at Start-up and at

•

Check for Leaks in the Fuel System (See

Normal Operating Temperature. Listen for

page 4-12)

Any Abnormal Sounds (See page 4-15)

•

Drain Fuel Condensation (See page 4-13)

•

Check Operation of All Controls (See page

•

Check Coolant Level (See page 4-13)

4-15)

•

Check Antifreeze Protection Levels (See

•

Inspect Engine Fan Blade (See page 4-16)

page 4-14)

•

Check Engine Drive Belt Wear (See page

•

Check Level of Window Washer Liquid (See

4-16)

page 4-14)

•

Check Air Intake System (See page 4-17)

50 HOUR / WEEKLY SERVICE

•

Perform All 10 Hour / Daily Service Checks

•

Change Engine Oil and Filter (See page

(See page 4-18)

4-25)*

•

Grease Front Attachment Pins (See page

•

Hydraulic Full Flow Filter Replacement

4-18)

(See page 4-25)*

•

Grease Steering Cylinder Rod and Head

•

Check Water Pump Belt Tension (See page

Ends (See page 4-24)

4-25)*

•

Grease Upper and Lower Center Pins (See

•

Clean Exterior of Radiator, Oil Cooler and

page 4-25)

Air conditioner Condenser (See page

4-26)*

250 HOUR / MONTHLY SERVICE

•

Perform All 10 Hour / Daily, 50 Hour Service

•

Drain Water From Hydraulic Oil Tank (See

Checks (See page 4-27)

page 4-31)

•

Change Engine Oil and Filter (See page

•

Check Water Pump Belt Tension (See page

4-25)

4-32)

•

Replace Hydraulic System brake and Pilot

•

Grease Drive Shafts (See page 4-33)

Filter (See page 4-28)

•

Axle Differential and Planetaries Oil

•

Check Engine Air Pre-cleaner (See page

Replacement (after first 250 hours) (See

4-29)

page 4-33)*

•

Hydraulic Full Flow Filter Replacement

•

Replacement Of Transmission Oil and Filter

(See page 4-30)

(After First 250 Hours) (See page 4-33)*

•

Clean Air Cleaner (See page 4-31)

* Break-In

4-6 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

500 HOUR / 3 MONTH SERVICE

•

Perform All 10 Hour / Daily, 50, and 250

•

Clean Exterior of Radiator, Oil Cooler and

Hour Service Checks (See page 4-34)

Air conditioner Condenser (See page 4-35)

•

Replace Fuel Filter (See page 4-34)

•

Clean Air Conditioner Filter (See page

4-36)

1,000 HOUR / 6 MONTH SERVICE

•

Perform All 10 Hour / Daily, 50, 250, and

•

Clean Fuel Injection Priming Pump Strainer

500 Hour Service Checks (See page 4-37)

(See page 4-41)

•

Change Radiator Coolant (See page 4-37)

•

Replace Air Conditioner Filter (See page

•

Drain and Replace Transmission Oil and

4-41)

filter (See page 4-39)

•

Check Air Conditioner Refrigerant (See

•

Clean Fuel Tank and Strainer (See page

page 4-42)

4-40)

•

Check and Adjust Engine (See page 4-42)

1,500 HOUR / 9 MONTH SERVICE

•

Perform All 10, 50, 250, and 500 Hour

•

Axle Differential and Planetaries Oil

Service Checks (See page 4-43)

Replacement (See page 4-43)

•

Replace Outer and Inner Air Cleaner

Elements (See page 4-43)

2,000 HOUR / YEARLY SERVICE

•

Perform All 10 Hour / Daily, 50, 250, 500

•

Replace Pipes and Hoses (See page 4-45)

and 1,000 Hour Service Checks (See page

•

Bleed Brakes (See page 4-45)

4-45)

•

Drain and Replace Hydraulic Oil (See page

•

Check Steering, Brake, Drive Shaft, Engine

4-46)

and Fuel System (See page 4-45)

•

Check Brake Accumulator (See page 4-47)

12,000 HOUR / SIX YEAR SERVICE

•

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN) (See

page 4-48)

* Break-In

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-7

10 HOUR / DAILY SERVICE

GREASE FRONT ATTACHMENT PINS

NOTE: Fittings are greased daily, or every 10 hours, for the first 100 hours of operation to comply

with new machine break-in requirements. After that, greasing should be done every 50

hours. If bucket is being used in water, grease fittings immediately after machine is

removed from water. Follow procedure printed under the 50 hour maintenance interval

“Grease Front Attachment Pins” on page 4-18.

INSPECT ALL TIRES FOR CORRECT TIRE

PRESSURE AND SIGNS OF DAMAGE

OR ABNORMAL WEAR

Inflate tires to proper operating pressure

for working conditions. See

“Tires and

Wheels” on page 4-57.

Figure 4

CHECK ENGINE OIL LEVEL

NOTE: When checking level using a

dipstick always remove and

wipe it clean before making

final level check.

Check level of engine oil every day before

starting engine.

Figure 5

Remove engine oil dipstick. (Figure 5). Oil

level must be between "LOW" and "FULL"

marks.

NOTE: If oil is above "HIGH" mark on

dipstick, some must be drained

to return oil to proper level.

To add oil, remove engine oil fill cap

(Figure 5).

HAOC280L

Figure 6

4-8 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

CHECK TRANSMISSION OIL LEVEL

NOTE: When checking level using a

dipstick always remove and

wipe it clean before making

final level check.

Use two people to perform this operation.

Start engine and move machine to a level

area.

Place transmission lever in "NEUTRAL."

Apply parking brake.

Figure 7

Allow engine to idle until transmission

temperature is between 82°C (180°F) and

93°C (200°F).

Remove transmission dipstick (Figure 7).

Wipe dipstick clean and then insert it back

into transmission.

Remove dipstick and check oil level mark.

Oil level must be between "LOW" and

"FULL" marks (Figure 8).

To add oil, remove transmission fill cap

(Figure 7) from transmission oil filler pipe.

Shut down engine when done.

HAOC280L

Figure 8

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-9

CHECK HYDRAULIC SYSTEM OIL LEVEL

WARNING!

The hydraulic oil will be hot after normal

machine operation. Allow system to cool

before attempting to service any of the

hydraulic components.

The hydraulic tank is pressurized. Turn the

breather cap slowly to allow the

HAOA060L

pressurized air to vent. After the pressure

Figure 9

has been released, it is safe to remove

either the fill cap or service covers.

Move machine to a level area and shut

down engine.

Apply parking brake.

Lower bucket to ground.

Check sight gauge that is attached to

hydraulic reservoir. Oil level must be

between upper limit

(1, Figure

10) and

lower limit (2) shown on gauge.

Figure 10

To add hydraulic oil, turn the breather cap

(1, Figure

11) slowly to allow the

pressurized air to vent.

Remove the upper cover (2, Figure 11) of

the hydraulic oil tank and add oil to proper

level by checking sight glass (Figure 10).

IMPORTANT

Do not fill above "H" mark on sight

gauge. Overfilling can result in

Figure 11

damage to equipment and oil leaking

from hydraulic tank due to

expansion.

4-10 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

The hydraulic oil filler cover also serves as the

hydraulic oil strainer access cover. It is important

to replace this cover and the components in the

proper order and alignment.

The filter element (2, Figure 12), retaining rod

(2) and spring (4) are assembled as shown in

Figure 12. The hole (1) in the base of the filter

element fits over a circular base in the bottom of

the reservoir. The retaining rod (3) screws into

the top of the filter element (2), but the spring (4)

slides over the top of the rod. Be certain that this

spring does not fall into the tank during

reassembly.

Figure 12

If filter assembly was removed, insert

assembly into the reservoir and check to

make sure it is securely in place.

Check O-ring for damages and replace if

necessary. Check position of O-ring at

surface of hole.

Place the cover on the access hole. Make

sure the spring retaining cup (1, Figure 13)

in the lower section of the cover is lined up

with the spring. The filter assembly rod

must be in a vertical position and

perpendicular to the base of the reservoir.

The cover can be rotated to align the rod

into a vertical position.

Tighten mounting bolts to 4.84 kg•m (35 ft

lb).

CHECK FOR LEAKS IN THE HYDRAULIC

Figure 13

SYSTEM

Perform a daily walk-around inspection to

make sure that the hoses, piping, fittings,

cylinders and hydraulic motors are not

showing any signs of leakage. If any is

noted, determine the source of the leak

and repair.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-11

FILL FUEL TANK

WARNING!

Use extreme safety precautions while

refueling to prevent explosions or fire.

Immediately clean up any spilt fuel.

At end of each work day, fill fuel tank. Add

fuel through fuel filler pipe

(Figure

14).

When working at a temperature of 0°C

Figure 14

(32°F) or higher, use ASTM No. 2-D or its

equivalent. At temperatures below

0°C

(32°F) use ASTM No. 1-D or its equivalent.

NOTE: See

“Fluid Capacities” on

page 4-5 for capacity.

Securely tighten cap after fueling.

NOTE: If breather holes in cap are

clogged, a vacuum may form in

the tank preventing proper fuel

flow to engine. Keep holes in

fuel cap clean.

CHECK FOR LEAKS IN THE FUEL SYSTEM

Perform an inspection of engine

compartment to verify that fuel system is

not leaking. If any is noted, determine the

source of leak and repair.

HAOC510L

Figure 15

4-12 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

DRAIN FUEL CONDENSATION

AOO0040L

APO0070L

Figure 16

Figure 17

Open fuel tank drain valve (Figure 16). Allow any condensed water or sediment to drain out of tank.

Also open drain on fuel filter and drain out any water or sediment (Figure 17). Catch drained material

in a container. Properly dispose of drained material.

CHECK COOLANT LEVEL

WARNING!

Never open radiator when it is hot. Scalding liquid inside a hot radiator is under pressure.

Removing cap from a hot radiator could cause a person to be sprayed and burned from liquid

inside. Wait for radiator temperature to cool down before removing cap.

Figure 19

Figure 18

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-13

Remove fill cap from radiator (Figure 19). Check level of coolant inside radiator. If low, add coolant to

fill radiator to a point that is 10 - 20 mm (1/2 - 3/4") below top of overflow pipe. If temperature is

below freezing, see “Check Antifreeze Protection Levels” on page 4-14 for antifreeze protection. Use

the table to calculate a proper mixture of anti-freeze

and

water

provide level of

protection

necessary for expected temperature.

CHECK ANTIFREEZE PROTECTION LEVELS

Ambient Temperature

Cooling Water

Antifreeze

-10°C (15°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-5°F)

67%

33%

-25°C (-15°F)

60%

40%

-30°C (-20°F)

56%

44%

-40°C (-30°F)

50%

CHECK LEVEL OF WINDOW WASHER

LIQUID

Check fluid level in windshield washer

tank, in the storage box of the rear of the

seat.

Open fill cap and add fluid.

NOTE: Use a washer liquid that is rated

for all seasons. This will prevent

freezing during cold weather

operation.

Figure 20

INSPECT THE BUCKET TEETH AND SIDE

CUTTERS FOR SIGNS OF WEAR

On a daily basis, inspect bucket teeth to

make sure that tooth wear or breakage has

not developed.

Do not allow replaceable bucket teeth to

wear down to the point that bucket adapter

is exposed. (Figure 21)

NOTE: These instructions are only for

Daewoo OEM buckets. If you

are using other manufacturers’

buckets, refer to their specific

Figure 21

instructions.

4-14 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

INSPECT SEAT BELT FOR PROPER OPERATION

INSPECT THE STRUCTURE FOR CRACKS AND FAULTY WELDS

During the daily walk-around inspection and when greasing the machine, look for any visible damage

to the machine. Repair or replace any damaged parts before operating machine.

CHECK THE OPERATION OF ALL SWITCHES

Verify working condition of all switches before starting engine.

CHECK THE OPERATION OF ALL EXTERIOR LIGHTS, HORN AND CONTROL CONSOLE

INDICATOR AND MONITOR LIGHTS

Turn engine starter switch to the "ON" position and observe all indicator lights.

Restore operation of any light bulbs that do not turn "ON" at this point.

Sound the horn. Repair or replace if required.

Turn "ON" and inspect all exterior work lights. Replace any monitors, burned out bulbs or cracked or

broken housings or lenses.

START ENGINE, CHECK STARTING ABILITY, AND OBSERVE EXHAUST COLOR AT START-UP

AND AT NORMAL OPERATING TEMPERATURE. LISTEN FOR ANY ABNORMAL SOUNDS

CHECK OPERATION OF ALL CONTROLS

IMPORTANT

Cold weather operation requires that the operator fully warm up the hydraulic oil before

beginning machine operation. Follow all warm up instructions listed in the Operating Instruction

section of this manual. Make sure to cycle oil through all of the components, including all

cylinders, both travel motors and the swing motor. Cold hydraulic oil in the lines and

components needs to be warmed before beginning full operation. If this is not done, damage to

the cylinders or hydraulic motors can occur.

With engine at rated speed, operate all of the controls.

Follow cold weather hydraulic system warm-up procedures.

Note any slow operations or unusual movements. Determine the cause and repair fault before

operating.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-15

INSPECT ENGINE FAN BLADE

WARNING!

Personal injury can result from a fan blade

failure. Never pull or pry on the fan. This

can damage the fan blade(s) and cause

fan failure.

NOTE: Manually rotate the crankshaft

by using a wrench on the

accessory drive pulley nut.

Figure 22

An inspection of the cooling fan is required

daily. check for cracks, loose rivets, bent or

loose blades, and for contact between the

blade tips and the fan shroud. Check the

fan to make sure it is securely mounted.

Tighten the bolts if necessary. Replace

any fan that is damage.

CHECK ENGINE DRIVE BELT WEAR

WARNING!

Keep clear of engine fan and fan drive

belts when the engine is running. Rotating

fan and belt contact can cause injury.

WARNING!

Figure 23

When checking, adjusting or replacing

drive belts, care must be taken to prevent

accidental cranking of the engine. Be sure

the starter switch is in the "OFF" position

and the controls are tagged.

Replace badly worn, greasy or severely cracked belts immediately. These conditions prevent proper

belt function. Visually inspect the belt. Check the belt for intersecting cracks. Transverse (across the

belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with

transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces of material missing.

Before installing new belts, make sure all pulley grooves are clean and not worn. Replace pulley, if

damaged, or if the grooves are worn.

All pulley support bearings, shafts, and brackets must be in working order.

When replacing belts and pulleys, pulley alignment must be checked with belts tensioned and

brackets securely clamped. A misalignment that can be detected by the naked eye is detrimental to

belt performance.

4-16 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

Do not force the belts into the pulley grooves by prying with a screwdriver or pry bar. This will damage

the belt side cords which will cause the belts to turn and result in complete destruction of the belts in

operation.

Belts on new machines and replacement belts lose their tension as they seat into the pulley grooves.

Check the tension of new belts at 20 hour intervals until tension is stabilized and thereafter, every 250

hours. If the tension falls below the required minimum, the belt slips damaging the belts and pulley

grooves.

NOTE: When operating in abrasive conditions, check tension every 100 hours.

CHECK AIR INTAKE SYSTEM

WARNING!

Hot engine components can cause burns.

Avoid contact with hot engine

components.

Park the machine on a level surface, apply

the parking brake, lower the attachment to

HAOA050L

the ground, and shut down engine.

Figure 24

Check the engine intake hose, and hose

bands for damage and tightness.

If damaged, wrinkled or loose, replace or

retighten or contact your nearest Daewoo

loader dealer.

IMPORTANT

Severe engine damage will result

from running with unfiltered air.

Do not operate engine if any leaks or

Figure 25

defects are found on air intake

system.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-17

B: Bucket lever connecting pins,

locations. Lever link connecting pins,

2 locations. Bucket cylinder rod ends,

2 locations. (Figure 42)

Figure 42

C: Bucket cylinder heads, 2 locations.

Arm lever connecting pins,

locations. Lever link connecting pins,

2 locations. (Figure 43)

Link foot pins, 2 locations.

Figure 43

D: Lift cylinder heads

(left, right),

locations. Lift cylinder rod ends,

locations. (Figure 44)

Figure 44

GREASE STEERING CYLINDER ROD AND

HEAD ENDS

Steering cylinder rods, 2 locations, one on

each side of machine.

Figure 45

4-24 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

Steering cylinder head ends, 2 locations.

Use remote grease fittings mounted on

frame.(1,2 Figure 46).

Reference

Remote Grease

Number

Fittings

1 and 2

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

250 Hours

Center Bearing

Figure 46

GREASE UPPER AND LOWER CENTER PINS

Center pins, Upper (Figure 47) and Lower (Figure 48). Two locations on each side of machine.

Figure 47

Figure 48

CHANGE ENGINE OIL AND FILTER

NOTE: Engine oil and filter must be changed after first 50 hours of operation to comply with new

machine break-in requirements. After first change, oil and filter should be changed every

250 hours. Follow procedure under 250 hour maintenance interval. (See page 4-25)

HYDRAULIC FULL FLOW FILTER REPLACEMENT

NOTE: Replace hydraulic full flow filter after first 50 hours of operation and every 250 Hours

thereafter. Follow procedure under 250 hour maintenance interval (See page 4-30)

CHECK WATER PUMP BELT TENSION

Water pump belt tension must be checked after first 50 hours of operation to comply with new

machine break-in requirements. After first check, water pump belt must be checked every 250 hours.

Follow procedure printed under 250 hour maintenance interval “Check Water Pump Belt Tension” on

page 4-32.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-25

250 HOUR / MONTHLY SERVICE

PERFORM ALL 10 HOUR / DAILY, 50 HOUR SERVICE CHECKS

CHANGE ENGINE OIL AND FILTER

NOTE: Change engine oil and filter after first 50 hours on a new machine and every 250 hours

thereafter.

CAUTION!

Never attempt to change oil or filter on a hot engine. Hot oil could splash and cause burns. Allow

engine to cool down before changing oil or filter.

Position a larger container under drain

valve beside left wall of fuel tank. Loosen

drain valve and allow all engine oil to drain

out. Tighten drain valve.

NOTE: Oil warming is good when

replacing oil. If machine is cold,

operate the engine to bring the

coolant temperature up to

about 40°C (104°F). When the

needle

the

coolant

temperature gauge reaches the

middle of the "WHITE ZONE,"

the temperature is about 40°C

Figure 49

(104°F).

Replace engine oil filter (Figure 50). The

engine oil filter is a spin-on type. Remove

and discard filter.

Install new filter. Apply a small amount of

oil around filter gasket. Screw filter on

head until gasket contacts head by hand,

turn filter

3/4

1 turn more with filter

wrench.

NOTE: See

“Fluid Capacities” on

page 4-5 for capacity.

APO0071L

Figure 50

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-27

Fill engine with correct oil through oil fill

port

(2, Figure 51). Refer to Lubrication

Table of this manual for recommended oil

for the operating conditions.

Start engine and check engine oil pressure

light.

Shut down engine. Look for signs of leaks

at filter. Recheck oil level using dipstick (1,

Figure 51).

APO0100L

Figure 51

REPLACE HYDRAULIC SYSTEM BRAKE

AND PILOT FILTER

Replace filter element in pilot filter. Perform the

following steps:

Vent hydraulic oil tank.

Figure 52

Unscrew element cover

(5, Figure

53).

Cover is filled with oil. Dispose of oil.

Remove O-ring (3, Figure 53) and filter

element (4).

Use a nonflammable, nontoxic solvent to

clean out cover (5, Figure 53).

Insert a new filter element (4, Figure 53)

into cover (5). Install a new O-ring (3).

Screw cover (5, Figure 53) onto filter head

(1).

Figure 53

4-28 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

HYDRAULIC FULL FLOW FILTER REPLACEMENT

WARNING!

The hydraulic oil will be hot after normal machine operation. Allow system to cool before

attempting to service any of the hydraulic components.

The hydraulic tank is pressurized. Loosen hydraulic oil fill cap slightly to allow pressurized air to

vent. After pressure has been released, it is safe to remove either the fill cap or service covers or

drain water from the tank.

IMPORTANT

Make sure to clean any dirt or water from top of the hydraulic tank, especially around fill port and

filter ports.

NOTE: Replace hydraulic full flow filter after first 50 hours of operation and every 250 Hours

thereafter.

Loosen breather cap on hydraulic

reservoir. (See Figure 11 on page 4-10).

Clean filter cover

(2, Figure

55) and

reservoir around cover.

Remove bolts (1, Figure 55) from cover

(2).

Lift cover (2, Figure 55) and O-ring (4) off

reservoir. Control spring

(3) that sits

beneath cover. Remove spring (3).

Remove valve (5, Figure

55) and filter

element (6) from reservoir.

Clean underside of cover (2, Figure 55).

Set a new element (6, Figure 55) and valve

(5) down into reservoir. Press element

down onto its base until top of element is

approximately 4 mm (0.157") below edge

of reservoir.

Figure 55

Install a new O-ring (4, Figure 55) on cover

(2). Set spring (3) into place on element

(6).

Set cover (2, Figure 55) into place over

element (6). Install bolts (1) through cover

(2) and tighten them.

10.

Tighten breather cap on reservoir.

4-30 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

DRAIN WATER FROM HYDRAULIC OIL TANK

WARNING!

Be certain that hydraulic oil has cooled before draining water and sediment. Hot oil could splash

and cause burns.

The hydraulic tank is pressurized. Press button in center of breather to allow pressurized air to

vent. After pressure has been released, it is safe to remove either the fill cap or service covers.

Position machine on firm, level ground.

Lower boom and position bucket on

ground. Turn "Off engine.

Position a container under hydraulic

reservoir drain plug. Open reservoir

breather cap (See Figure 11 on page 4-

10). Loosen drain valve from bottom of

reservoir (Figure 56). Allow all water and

sediment to drain out. Tighten drain valve.

AOO0090L

Figure 56

CLEAN AIR CLEANER

CAUTION!

Never remove air cleaner element while

engine is running. This will allow dirt to be

sucked into engine and cause serious

engine damage. Always turn engine "OFF"

before servicing air cleaner.

AOO0230L

Figure 57

Locate the air filter assembly (Figure 58).

Remove access cover and remove outer

element of air filter assembly.

NOTE: If indicator light on instrument

panel comes "ON," this

indicates that air cleaner needs

to be serviced.

NOTE: Replace outer element every

1,500 hours of service.

Figure 58

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-31

Clean outer filter by blowing compressed

air from inside of filter towards the outside.

Do not use more than 205 kPa (30 psi) air

pressure.

Clean the inside of air filter housing and

inside of air filter housing cover.

CAUTION!

Never clean the inside of air filter

HAOC570L

housing while the inner element is

not installed.

Figure 59

Properly reinstall air filter and cover.

Tighten cover wing nut by hand. Do not

use any tools to tighten wing nut.

CHECK WATER PUMP BELT TENSION

Water pump belt tension

control link (A)

IMPORTANT

Adjustable link

A loose water pump belt can cause

for alternator belt

engine overheating, poor charging, and/or

premature belt wear. A belt that is too

tight can cause damage to the water

pump, alternator bearing or belt.

Air-con belt tension

control link (B)

NOTE: Water pump belt tension must

APO0090L

be checked after first 50 hours

Figure 60

of operation to comply with new

machine break-in requirements.

After first tension check, belt

must be checked every

250

hours.

Apply 10 kg (22 lb) of force to midpoint of belt. (Figure 60). The belt should deflect 10 mm (0.4"). If

belt deflects more than this, loosen control link to tighten belt tension until deflection is 10 mm (0.4").

Inspect belt for damage. If belt is damaged, replace it.

4-32 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

GREASE DRIVE SHAFTS

Grease fitting for center bearing,

location. Use remote grease fitting

mounted on frame (3, Figure 61).

Reference

Remote Grease

Number

Fittings

1 and 2

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

250 Hours

Center Bearing

Figure 61

Figure 62

AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT (AFTER FIRST 250 HOURS)

NOTE: The differential and planetaries oil should be drained and refilled after first 250 hours of

operation. There after every 1,500 hours of operation. (See page 4-43)

REPLACEMENT OF TRANSMISSION OIL AND FILTER (AFTER FIRST 250 HOURS)

NOTE: Transmission oil and filter must be changed after first 250 hours of operation to comply

with new machine break-in requirements.

NOTE: After first change, oil and filter should be changed every 1,000 hours. Follow procedure

under 1,000 hour maintenance interval. (See page 4-39)

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-33

500 HOUR / 3 MONTH SERVICE

PERFORM ALL 10 HOUR / DAILY, 50, AND 250 HOUR SERVICE CHECKS

REPLACE FUEL FILTER

WARNING!

Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke.

Locate fuel

filter

inside

engine

compartment.

Position a small container under fuel filter.

Drain filter by opening drain valve on

bottom of filter.

Unscrew fuel filter from head assembly.

Discard fuel filter.

After cleaning filter head, install new fuel

filter. Screw filter on head until gasket

contacts head, turn filter 1/3-1/2 turn more.

APO0070L

NOTE: Coat fuel filter gasket with fuel.

Figure 63

NOTE: Fill fuel filter with clean fuel.

This will help reduce fuel

system priming.

Start engine. After engine has run for a couple of minutes, shut down engine and look for leaks.

If engine does not start, fuel system may need priming. Prime fuel system using the following

procedure:

A. Loosen plug on top of fuel filter head.

B. Unscrew and pump the hand operated primer pump near fuel injection pump. Pump primer until

fuel is present at plug hole in fuel filter head.

C. Tighten plug in fuel filter head.

D. Continue to pump primer pump until a strong resistance is felt. Screw primer pump knob back

into housing.

E. Start engine and look for signs of leaks.

4-34 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

CLEAN EXTERIOR OF RADIATOR, OIL

COOLER AND AIR CONDITIONER

CONDENSER

Dust and dirt accumulation on fins of

radiator and oil cooler (Figure 64), and air

conditioner condenser (Figure 65) greatly

reduce their cooling efficiency. Use

compressed air, water and steam to clean

fins

on radiator, oil cooler, and

transmission cooler.

NOTE: On an especially dusty work

site, clean fins every 50 hours.

Figure 64 (S/N 1001 thru 2000 EUROPE LOW

On other work sites, clean fins

NOISE KIT) and (S/N 2001 and Up)

every 500 hours.

Figure 65 AIR CONDITIONER CONDENSER

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-35

CLEAN AIR CONDITIONER FILTER

The unit is equipped with an air filtration system

which filters out dirt and dust particles from air

being circulated into operator’s cab. The air

conditioner filter is in the right side switch panel

console.

Open access cover on the lower right side

of cab on the outside to gain access to

filter.

Figure 66

Remove filter element and inspect it for

damage.

Use compressed air to clean filter element.

If element is very dirty use a mild soap and

water solution to clean it.

NOTE: If water was used to clean filter

element be sure it is completely

dry before installation.

NOTE: This filter should be cleaned out

every 500 hours and replaced

with a new one every

1,000

hours.

Figure 67

NOTE: In the event that the unit is

being operated in a dusty

environment, the cleaning and

replacement

should

performed more frequently.

WARNING!

All service and inspection of the air-conditioning system should be performed with the

starter switch in the "O" (OFF) position.

4-36 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

1,000 HOUR / 6 MONTH SERVICE

PERFORM ALL 10 HOUR / DAILY, 50, 250, AND 500 HOUR SERVICE CHECKS

CHANGE RADIATOR COOLANT

WARNING!

Allow the engine to cool before releasing

the radiator cap. Make sure to loosen the

cap slowly to release any remaining

pressure.

Radiator cleaning is performed while the

engine is running. Take extreme caution

when working on or near a running

Figure 68

engine. Make sure to lock out and tag the

controls notifying personnel that service

work is being performed.

Do not remove the radiator cap unless it is

required. Observe the coolant level in the

coolant recovery tank.

Slowly open the radiator cap (Figure 68) to

allow any pressure to escape.

NOTE: See

“Fluid Capacities” on

page 4-5 for capacity.

Place a container under the radiator and

open the drain valve (Figure 69).

Figure 69

Open vent on intercooler.

Figure 70

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-37

Remove coolant drain plug

(Figure

71)

from engine.

APO0170L

Figure 71

Open heater shutoff valve (Figure 72) to

allow coolant to drain from heater core.

Install drain plug, and close drain valve

after coolant has completely drained from

system.

Fill cooling system with a flushing solution.

NOTE: When filling engine with

flushing solution, open vent

(Figure

70) on intercooler to

allow air to escape. Close vent

when solution is present.

APO0110L

Figure 72

Run engine at low idle until the coolant

temperature gauge reaches the "GREEN

ZONE." Run engine for another 10 minutes.

Alter allowing engine to cool.

10.

Drain flushing fluid and fill system with water.

11.

Run engine again to allow water to completely circulate.

12.

Drain water and fill system with proper anti-freeze mixture for ambient temperature. Refer to coolant

concentration table (See page 4-14).

NOTE: When filling engine with coolant, open vent (Figure 70) on intercooler to allow air to

escape. Close vent when coolant is present.

13.

Run engine without radiator cap installed, so that all air will be purged from system. Fill radiator to a

point that is 10 - 20 mm (1/2 - 3/4'') below top of overflow pipe.

4-38 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

DRAIN AND REPLACE TRANSMISSION OIL AND FILTER

NOTE: Transmission oil and filter must be changed after first 250 hours of operation to comply

with new machine break-in requirements. After first change, oil and filter must be changed

every 1,000 hours.

Start machine and drive it until transmission fluid has warmed to 82 - 93°C (180 - 200°F). Park

machine on a level area.

Place transmission lever in "NEUTRAL." Apply parking brake. Shut down engine. Block tires.

NOTE: See “Fluid Capacities” on page 4-5 for capacity.

Remove drain plug. Allow all transmission

fluid to drain into a receptacle. Properly

dispose of drained fluid. Clean drain plug

(Figure 73).

Install drain plug in transmission.

Remove inlet strainer.

Use a

nonflammable, nontoxic solvent to clean

strainer.

Inspect gasket on inlet strainer. Replace

gasket if it is damaged. Install inlet strainer.

Remove breather filter. Clean breather

Figure 73

filter and install it.

Rotate

filter

(1,

Figure

74)

counterclockwise to remove it.

Clean filter head.

10.

Grease filter gasket and gasket mating

surface on filter head.

11.

Thread filter onto filter head. Tighten filter

1/2 turn after filter gasket contacts filter

head. Filter should be torqued to 1.6 - 2.1

kg.m (11.5 - 15 ft lb.) (Figure 74).

AOO0140L

Figure 74

12.

Fill transmission with fluid through fluid

supply pipe (3, Figure 74). Add fluid until

fluid level reaches low mark on dipstick (2,

Figure 74).

13.

Start engine. Idle engine for two minutes.

14.

With engine idling, check transmission

fluid level. Add fluid until level reaches high

mark on dipstick.

15.

Idle engine until transmission fluid

temperature reaches 82 - 93°C (180 -

200°F). Check fluid level with engine idling.

Level must reach high mark on dipstick.

Figure 75

16.

Check filter for leaks while engine is

running.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-39

CLEAN FUEL TANK AND STRAINER

WARNING!

Fuel is flammable and harmful to skin.

•

Do not smoke while draining moisture and sediment from fuel tank.

•

Do not drain fuel with engine running.

•

Do not allow fuel to remain on skin for an extended period of time. Wash thoroughly

with soap and water.

NOTE: It is easiest to clean the fuel tank when the fuel is almost empty.

Park the machine on a level surface, apply

the parking brake, lower the attachment to

the ground, and shut down engine.

Open the drain valve (1,Figure 76) on the

bottom of the fuel tank.

Drain the remaining fuel into a suitable

container.

Remove the nuts with a 17mm wrench to

remove the inspection cover (2,Figure 76).

AOO0150L

Figure 76

Clean inside of the tank and suction

stainer (Figure 77).

Install the inspection cover with a new

gasket. Tighten the bolts. Do not

overtighten.

Close drain valve.

Fill fuel tank.

Check for any leaks at cover and plug.

Figure 77

4-40 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

CLEAN FUEL INJECTION PRIMING PUMP STRAINER

Remove fitting, fuel line and strainer from

bottom of priming pump.

Clean strainer.

Position strainer in priming pump and

install fuel line and fitting.

Figure 78

REPLACE AIR CONDITIONER FILTER

NOTE: This unit is equipped with an air filtration system which filters out dirt and dust particles

from air being circulated into operator’s cab. This filter should be cleaned out every 500

hours and replaced with a new one every 1,000 hours. For filter replace See “Clean Air

Conditioner Filter” on page 4-36.

NOTE: In the event that the equipment is being operated in a dusty environment, the cleaning and

replacement should be performed more frequently.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-41

CHECK AIR CONDITIONER REFRIGERANT

WARNING!

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging air-conditioning system.

Apply the parking brake and lower attachment to the ground.

Remove the cover.

Press the "HI" flow control switch to set maximum air flow.

Set the temperature control switch fully to the cool position and fully open the cab doors.

Slightly accelerate the engine to about the middle speed range (compressor speed 1,500-1800 rpm).

Compare the flow of bubbles in the sight glass with the drawings in the following table.

CAUTION!

Overfilling refrigerant may cause dangerous high pressure and poor cooling action; and low

refrigerant level may cause compressor damage.

Always maintain refrigerant at normal level.

Amount of

Appearance of the Sight Glass

Solutions

Refrigerant

Almost clear.

Normal

Any bubbles disappear if the engine

speed is increased to 1,500 rpm.

Contact your local Daewoo loader

dealer

for

inspection

and

High

No bubble is seen.

recharging refrigerant.

Low

A flow of bubbles is visible.

CHECK AND ADJUST ENGINE

Contact your nearest Daewoo loader dealer.

Engine dealer for checking and adjusting the following items:

•

Engine Compression Pressure.

•

Injection Pressure.

•

Injection Timing.

4-42 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

1,500 HOUR / 9 MONTH SERVICE

PERFORM ALL 10, 50, 250, AND 500 HOUR SERVICE CHECKS

REPLACE OUTER AND INNER AIR CLEANER ELEMENTS

CAUTION!

Never remove air cleaner element while engine is running. This will allow dirt to be sucked into

engine and cause serious engine damage. Always turn engine "OFF" before servicing air

cleaner.

Replace inner element when outer element is replaced.

After removing outer element, remove wing nut and inner element.

Clean out inside of air cleaner housing. DO NOT use compressed air to blow out housing.

Install new inner element, and secure it into position with wing nut. DO NOT clean and re-use inner

element.

Install new outer element, and secure it into position with wing nut.

Install air cleaner cover.

NOTE: Make sure that all gaskets on wing nuts and cover are properly installed and seated.

AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT

NOTE: Oil in both front and rear axle must be replaced after first 250 hours of operation to comply

with new machine break-in requirements. After that, axle oil check should be done every

250 hours of operation and replacement should be done every 1,500 hours.

Each axle contains a center differential, and a planetary in each end. The same oil lubricates center

differential and planetaries in axle ends, but oil flows very slowly between these points. When checked, oil

must be checked and refilled at all three places at the same time. To drain and replace oil in an axle,

perform the following steps:

Drive machine onto a level surface.

Position wheels on axle being drained so

that axle end level plugs (1, Figure 79) are

in the lowest position. Apply parking brake.

Block wheels.

Clean area around level plugs on both

ends of axle. Remove plugs.

NOTE: See

“Fluid Capacities” on

page 4-5 for capacity.

Figure 79

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-43

Clean area around level plug (1, Figure 80)

and drain plug (2) on center differential.

Remove level plug and drain plug. Allow oil

to drain into a container.

Install drain plug into center differential,

and tighten it.

Pump oil into plug hole for level plug on

center differential. Add oil until oil level is

even with bottom of plug hole.

Figure 80

Go to level plug holes (1, Figure 81) on

axle ends. Add oil to these openings until

oil level is even with bottom of plug hole.

Recheck level on center differential. Add

oil if necessary. When oil level is

satisfactory at all three level plug holes,

install and tighten level plugs at all three

locations.

Repeat procedure for other axle.

Figure 81

4-44 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

2,000 HOUR / YEARLY SERVICE

PERFORM ALL 10 HOUR / DAILY, 50, 250, 500 AND 1,000 HOUR SERVICE CHECKS

CHECK STEERING, BRAKE, DRIVE SHAFT, ENGINE AND FUEL SYSTEM

REPLACE PIPES AND HOSES

Replace pipes that carry brake fluid to

wheel brakes i.e., service brake pipe (1,

Figure 82) parking brake pipe (2). Also

replace hoses that carry hydraulic fluid to

steering cylinders.

It is difficult to determine condition of many

pipes and hoses. The best way to ensure

safe operation and to maintain maximum

performance is to replace hoses on a

regular basis. If any brake or steering

pipes and hoses become damaged or

Figure 82

appear defective in any way, replace them

immediately regardless of time interval

since their last replacement.

BLEED BRAKES

When brake hoses or brake tubes are replaced, air can be introduced into brake hydraulic system. Air can

cause brakes to operate intermittently, which is a dangerous condition. Never operate machine with air in

brake hydraulic system. A spongy feel when pressing brake pedal is a sign that air is present in brake

hydraulic system.

To bleed air out of brake hydraulic system,

perform the following steps: (Figure 83)

Start engine and place transmission in

"NEUTRAL."

Remove rubber cap from bleeder screw on

wheel.

Place one end of a plastic hose (2) over

bleeder screw (1). Place other end of hose

in a container (3) filled with brake fluid.

Station one person in operator’s cab, and

one person at bleeder screw on wheel

being bled.

HLB3018L

Figure 83

Open bleeder screw (1). Then press down

on brake pedal until it rests on floor of cab.

Hold pedal down on floor of cab. Close bleeder screw while pedal is being held down. After bleeder

screw has been closed, allow brake pedal to return to upright position. Continue to open bleeder

screw and press down pedal as described in this step, until fluid expelled from bleeder hose has no

air bubbles present.

Securely close bleeder screw (1). Install rubber cap on bleeder screw.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-45

Perform bleeding procedure on other three wheels.

DRAIN AND REPLACE HYDRAULIC OIL

CAUTION!

Be certain that hydraulic oil has cooled before draining it. Hot oil could splash and cause burns.

Raise boom to its highest position. Tilt

bucket back as far as possible, and shut

down engine.

NOTE: See

“Fluid Capacities” on

page 4-5 for capacity.

Figure 84

Position a catch tank beneath hydraulic

reservoir drain plug. Release pressurized

air from hydraulic oil tank by rotating air-

breather cap. (See Figure 11 on page 4-

10). Remove drain plug (Figure 85) from

bottom of reservoir. Allow all hydraulic oil

to drain out.

AOO0090L

Figure 85

Figure 86

Figure 87

4-46 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

Without starting engine, operate controls to dump bucket. (Figure 86). Then operate controls to lower

boom. (Figure 87). This will drain oil out of boom and bucket cylinders.

Replace full flow hydraulic filters as described under “Hydraulic Full Flow Filter Replacement” on

page 4-30.

Install reservoir drain plug. Remove upper cover of hydraulic oil tank. Refill reservoir by pouring oil in

through upper cover opening. Install and tighten upper cover.

Figure 88

Figure 89

Start engine and operate controls to raise and lower bucket a few times. (Figure 88). Raise and lower

boom a few times. (Figure 89). Lower bucket to ground.

Check reservoir sight gauge. (See Figure 10 on page 4-10). Oil level must be between upper limit and

lower limit on sight gauge. Remove breather cap and add oil if necessary.

CHECK BRAKE ACCUMULATOR

Test the brake accumulator for proper precharge of Nitrogen gas:

WARNING!

Pressurized Nitrogen gas in brake accumulator may explode causing serious injury or death.

Never service brake accumulator unless properly trained.

Park the machine on a level surface, apply the parking brake, lower the attachment to the ground.

Run the engine at low idle for five minutes to fill the brake accumulator with oil.

Shut down engine.

Turn the starter switch to the "ON" position.

Count the number of times you can depress the right hand brake pedal before the brake warning light

comes on.

If the number counted is less than five (5), there is some problem with the accumulator. Contact your

nearest Daewoo dealer.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-47

12,000 HOUR / SIX YEAR SERVICE

HOSE IN-SERVICE LIFETIME LIMIT (EUROPEAN STANDARD ISO 8331 AND EN982 CEN)

European regulations state that the in-service life of any hydraulic hose may not exceed six years. Daewoo

recommends the following;

•

Hoses at the customer premises can not be stored more than 2 years before being discarded or

installed on a machine.

•

In-service lifetime of hoses fitted on a machine can never exceed 6 years, but replace hoses

described in “Replace Pipes and Hoses” on page 4-45, every year. Always replace hoses

having exceeded the allowed in-service lifetime irrespective of the external appearance/wear.

•

Always store hoses in a dark place at a maximum of 65% relative humidity, between 0°C (32°F)

and 35°C (95°F) but as close as possible to 15°C (59°F) and away from copper, manganese or

tube generating Ozone.

4-48 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

SEVERE CONDITIONS MAINTENANCE

OPERATING CONDITION

REQUIRED MAINTENANCE

Mud, Water, Rain

Check for loose fittings, obvious damage to machine, or any

fluid leakage.

After completing operations, clean mud, rocks, or debris from

machine. Inspect for damage, cracked welds, or loosened

parts.

Perform all daily lubrication and service.

If machine was working in salt water or other corrosive

materials, be sure to flush equipment with fresh water.

Extremely Dusty

Hot

Clean engine air filter on a more frequent basis.

Environment

Clean radiator and oil cooler fins to remove dirt and dust.

Clean fuel system intake strainer and fuel filter more frequently.

Inspect starter motor and alternator, and clean as often as

necessary.

Rocky Terrain

Check wheels, tires, rims, and valve stems for damage or

excessive wear.

Inspect for loose or damaged fittings and bolts.

On a more frequent basis, inspect bucket and boom for

damage or excessive wear.

Install a top guard and front guard as necessary for protection

against falling rock.

Extreme Cold

Use proper grade of fuel for cold temperatures.

Use a gauge to check antifreeze to be sure that it will provide

protection for coldest temperature expected.

Use a hydrometer to check condition of batteries. In extremely

cold weather, remove batteries at night and store them in a

warm area.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-49

GENERAL MAINTENANCE

FUEL TRANSFER PUMP

WARNING!

Do not dry operate fuel pump for more than 15 seconds.

•

Cooling and lubrication of pump is achieved by fuel passing through the pump. If the

pump is dry operated, the heat generated by the moving parts will cause damage to

the pump rotors, vanes and seals. To prevent unnecessary wear and / or damage to

the pump do not dry operate the fuel pump for more than 15 seconds.

Do not operate the pump for more than 15 minutes at a time.

•

Continuous usage of pump over the recommended time interval will cause

overheating of motor result in causing motor damage.

Do not use refueling pump for other types of fuel. (Use only for diesel fuel.)

•

Do not use refueling pump for other types of fuel which have a low flash point.

•

Do not use refueling pump for fuel contaminated with water or high humidity. Moisture

in pump mechanism can cause rust and can create pump failure.

Always operate pump using the strainer installed on the inlet hose. This will prevent any

foreign materials from being introduced into the pump. Always maintain the pump and all of

its components in a clean condition.

•

If dirt or other foreign materials enter the pump, it can become lodged between the

rotor and / or vanes and generate heat which can cause pump damage.

•

Do not remove strainer or use a strainer with larger mesh to increase the flow of fuel.

Be careful not to overfill or spill fuel.

Make sure the direction of check valve is in line with the flow direction of fuel.

If any parts or components of the pump become lost, damaged or inoperable, immediately

replace it with a new one.

IMPORTANT

If there are any sign of leakage while operating transfer pump, inspect the following components

to prevent any fires or hazardous fuel spills.

•

Check all hoses leading to and from the transfer pump.

•

Check all hose clamps.

•

Check transfer pump inlet port.

This transfer pump is used to transfer fuel from a refueling source to fuel tank. A check valve is installed in

the inlet hose to prevent fuel from flowing backward from fuel tank to source. A strainer is installed in inlet

hose to prevent any foreign material from being introduced into transfer pump or fuel tank.

A thermal limiter, built into motor, will automatically shut off the circuit if motor is overheating to protect

motor from damage.

4-50 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

OUT

AHO0790L

Figure 90

Remove strainer cap (4, Figure 90) from inlet hose.

NOTE: Keep strainer cap in a safe location to reseal strainer after refueling is complete.

Insert inlet hose (5, Figure 90) into refueling tank.

Turn fuel pump switch to "ON" position.

NOTE: The transfer pump rate of flow

is approximately

20 liters

minute (5 gpm). Use extra care

not to overfill fuel tank so that

fuel does not over flow.

Once fuel transfer is completed,

immediately turn switch to "OFF" position

to stop pump.

Lift inlet hose from fueling source and turn

switch to "ON" position for 2 - 3 seconds to

drain remaining fuel from hose to fuel tank.

Figure 91

Replace strainer cap (4) to inlet strainer

and return hose to storage position.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-51

PARKING BRAKE ADJUSTMENT

To adjust parking brake, perform the following steps:

Jack up machine enough to allow tires to rotate freely.

Turn “OFF” engine and place transmission lever in “NEUTRAL.” Turn ignition switch to “ON” position.

Move parking brake switch to “UNLOCKED” position.

FRONT AXLE SERVICE BRAKES

Checking clearance between brake pad and

brake disc in the front axle.

Locate the pinion adjusting bolt in the

upper part of the differential housing.

Remove lock bolt

(2, Figure

92) and

bracket (1).

Rotate the square pinion adjusting bolt (3,

Figure 92) in counter clockwise direction

until it stops. At this time the clearance of

brake disk is “0”.

Rotate adjusting bolt

(3, Figure

92)

clockwise four turns (0.25 mm / rotation) to

set the clearance to 1 mm (0.4 in).

Install lock bracket (1, Figure 92) and bolt

(2).

Repeat steps 1-5 for other side.

FRONT AXLE PARKING BRAKE

EMERGENCY RELEASE

Locate parking brake release bolt on the

lower section on both sides of the housing.

Loosen lock nut

(4, Figure

92) from

adjusting bolt (5).

Tighten adjusting bolt (5, Figure 92) until it

stops. This will manually release the

parking brake so that the drive shaft will be

free to turn.

The initial setting of adjusting bolt is 47 mm and

should be readjusted to this length and lock nut

Figure 92

tightened after towing is complete.

REAR AXLE SERVICE BRAKE

There are three adjusting bolts per side at 120° intervals for the rear axle brake adjustment. All three must

be adjusted for proper operation. The adjusting procedure is same as the front brake adjustment method

and must be repeated for both sides.

4-52 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

CHECK HYDRAULIC PRESSURES

Hydraulic pressure for most systems can be

check by using the remote test ports shown in

(Figure 93).

Reference

Description

Number

Main Pump Pressure

Control Lever Activation

Pressure

Steering Pump Pressure

Figure 93

Transmission Clutch Pressure

Brake Charge Pressure

MAIN PUMP PRESSURE

P - From pump

R - To Tank

Attach gauge to port (1, Figure 93).

3A - Boom lower

3B - Boom raise

2A - Bucket dump

2A - Bucket crowd

Relief cartridge for main pump must open

at 205^±5kg/cm²(2,915^±70 psi).

Adjust screw on relief valve cartridge

(Figure

94). Loosen lock nut and turn

screw clockwise to raise relief pressure.

Turn screw counterclockwise to lower relief

pressure.

Tighten lock nut after pressure has been

APO0120L

adjusted.

Figure 94

CONTROL LEVER ACTIVATION PRESSURE

(S/N 1001 thru 2000)

Attach gauge to port (2, Figure 93).

Adjust relief cartridge

(3, Figure

95) on

brake and pilot supply valve (1, Figure 95).

Relief pressure should be set at 28

kg/

-2

+43

cm² (398

-30

psi).

Loosen lock nut on adjusting screw. Turn

adjusting screw clockwise to raise relief

pressure.

Turn

adjusting

screw

APO0130L

counterclockwise to lower relief pressure.

Figure 95

Tighten lock nut after adjustment has been

made.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-53

CONTROL LEVER ACTIVATION PRESSURE

(S/N 1001 thru 2000 Europe Low Noise

Kit)

(S/N 2001 and Up)

Attach gauge to port (2, Figure 93).

Adjust relief cartridge

(3, Figure

96) on

brake and pilot and fan motor supply valve

(1, Figure 96). Relief pressure should be

+43

set at 28

-2

kg/cm² (398

-30

psi).

Loosen lock nut on adjusting screw. Turn

APO0140L

adjusting screw clockwise to raise relief

Figure 96

pressure.

Turn

adjusting

screw

counterclockwise to lower relief pressure.

Tighten lock nut after adjustment has been

made.

STEERING PUMP PRESSURE

Attach gauge to port (3, Figure 93).

Adjust relief valve cartridge on steering

valve

(Figure

97). Cartridge must be

adjusted to open at 200 ±5 kg/cm² (2,845

±70 psi).

Figure 97

Unscrew remove plug and washer. Adjust

screw that is beneath plug. Turn screw

clockwise to raise relief pressure. Turn

screw counterclockwise to lower relief

pressure.

Install plug and washer after pressure has

been adjusted.

Figure 98

TRANSMISSION CLUTCH PRESSURE

Attach gauge to port (4, Figure 93)

It is not impossible to adjust pressure.

+28

•

Transmission clutch pressure: 16

kg/cm² (228

psi)

4-54 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

BRAKE CHARGE PRESSURE (S/N 1001 thru

2000)

Attach gauge to port (5, Figure 93).

Adjust brake charge valve cartridge

(2,

Figure 99) on brake and pilot supply valve

(1, Figure 99). Relief pressure for brake

charging is 140/120 kg/cm²(1,990/1,707

psi).

APO0130L

Figure 99

BRAKE CHARGE PRESSURE

(S/N 1001 thru 2000 Europe Low Noise

Kit)

(S/N 2001 and Up)

Attach gauge to port (5, Figure 92).

Adjust brake charge valve cartridge

(2,

Figure 100) on brake and pilot and fan

motor supply valve (1, Figure 100). Relief

pressure for brake charging is 120±5 kg/

cm²(1,707±70 psi).

APO0140L

Figure 100

SERVICE BRAKE OUTLET PRESSURE

Attach gauge to brake pressure test port

(1, Figure 101) on front axle.

Outlet pressure should be 45±3 kg/cm²

(640±43 psi).

PARKING BRAKE RELEASE PRESSURE

Attach pressure gauge to parking brake

port (2, Figure 101).

APO0150L

Parking brake pressure should be 52 - 65

Figure 101

kg/cm² (740 - 925 psi).

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-55

FAN MOTOR PRESSURE

(S/N 1001 thru 2000 Europe Low Noise

Kit)

(S/N 2001 and Up)

Attach gauge to inlet port of fan motor (1,

Figure 102).

Adjust screw on relief valve cartridge (2,

Figure 102).

NOTE: Outlet pressure should be 87

±5 kg/cm² (1,237 ±70 psi).

Loosen lock nut on adjusting screw. Turn

Figure 102

adjusting screw clockwise to raise relief

pressure.

Turn

adjusting

screw

counterclockwise to lower relief pressure.

NOTE: One turn varies pressure 16.5

kg/cm² (235 psi).

Tighten lock nut after adjustment has been

made.

4-56 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

TIRES AND WHEELS

Properly inflated tire

(2, Figure

103) is an

important factor in determining tire performance

and tire life. A tire that is under-inflated

(1,

Figure 103) does not properly support machine,

and will wear out quickly. Over-inflated tires (3,

Figure 103) have poor traction and puncture

easily.

Use a pressure gauge to measure tire pressure.

Always measure tire pressure before machine

has been working, when tires are cold. Use

table below to determine correct pressure for

front or rear tires when driving machine, or when

working machine.

Figure 103

Check tires for damage and embedded objects.

Check valve stems for damage.

Working Pressure

Driving Pressure

Tire Dimension

Remarks

Front Tire

Rear Tire

Front Tire

Rear Tire

17.5-25-12PR (L2)

Bias Ply Tire

3.25 kg/cm²

3.0 kg/cm²

2.5 kg/cm²

2.0 kg/cm²

(Standard)

(46 psi)

(43 psi)

(36 psi)

(29 psi)

20.5-25-12PR (L2)

3.5 kg/cm²

3.3 kg/cm²

2.8 kg/cm²

2.0 kg/cm²

Bias Ply Tire

(Option)

(50 psi)

(47 psi)

(40 psi)

(29 psi)

(Option)

WHEEL NUT TORQUE

Tighten wheel nuts to 58 - 62 kg•m (420 - 448 ft

lb).

WARNING!

If a wheel and tire must be removed from

machine and replaced, or if a tire must be

replaced on wheel, allow this task to be

performed only by experienced service

personnel. A tire rim could be propelled

off wheel and cause serious bodily injury

Figure 104

or death. See Figure 104.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-57

CHECK TIRE FOR DAMAGE

WARNING!

Improper servicing or changing tires and rims can cause explosion resulting in serious injury or

death.

Do not service or change tires and rims unless properly trained and equipped.

Contact your nearest Daewoo loader dealer or tire manufacturer’s local dealer for tire servicing

or changing.

WARNING!

Overheated tire may explode causing serious injury or death.

If overheated tire is suspected, do not approach tire to distance of less than 15mm (50ft).

Stay away until tire and rim cool down.

If the following defects are found in tires, for

safety reasons the tires should be replaced with

new tires.

For the replacement contact DAEWOO loader

dealer or a tire manufacturer’s local dealer.

•

Bead wire is broken or bent, or the

tire is greatly deformed.

•

Wear is excessive and the carcass

ply (including breaker) is exposed for

more than 1/4 of the circumference.

•

Damage to the carcass exceeds 1/3

Figure 105

of the tire width.

•

Tire layers are separated.

•

Radial cracks reach the carcass.

•

Deformation or damage which makes

the tire unsuitable for use.

4-58 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

ELECTRICAL SYSTEM

CHECK BATTERY CONDITION

WARNING!

Before starting any battery service work, make sure to shut the engine off and turn the starter

switch to the "OFF" position.

The batteries create hydrogen gas. An explosion hazard exists, particularly with a deeply

discharged battery. Make sure that open flames, burning objects or sparks are kept away from

the battery compartment.

Battery electrolyte is diluted sulfuric acid. Take extreme caution when handling the batteries.

The electrolyte can cause severe chemical burns. If any electrolyte gets on your clothing or skin,

wash it off immediately with large quantities of water. If the electrolyte gets into your eyes, flush

them immediately with a large quantity of water and contact a doctor at once.

When installing a battery, wear safety glasses at all times.

When removing a battery, remove the Negative (-) or ground terminal first, and then the Positive

(+) terminal. This will prevent sparks or arcing that could cause an explosion. When installing a

battery, connect the Positive terminal first and then the Negative terminal. Make sure to fully

tighten the terminal clamps.

In colder weather a greater drain is placed on the batteries when they are used for the preheat cycle

and when starting a cold engine. Battery performance decreases as the temperature gets lower.

In extremely cold weather, remove the batteries at night and move them to a warm location. This will

help to keep them at a higher power level.

Inspection of battery electrolyte level.

NOTE: The battery installed at the

factory is a Maintenance Free

(MF) type. Electrolyte under

normal conditions

should

remain at its proper level.

Inspect charge condition of battery by

looking at the indicator light built into

battery.

•

GREEN: Normal.

HJB5002L

•

BLACK: Insufficient charging - check

Figure 106

alternator.

•

TRANSPARENT: Insufficient battery

fluid - replace with new battery.

NOTE: Colors may vary from one battery manufacturer to another. Always refer to instructions on

battery.

The batteries should always be replaced in pairs. Using an old battery with a new one will

shorten the life span of the new battery.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-59

BOLT TORQUE CHART

TIGHTENING TORQUE SPECIFICATIONS FOR METRIC BOLTS (FOR COATED THREADS, PRE-

LUBRICATED ASSEMBLIES)

Grade

Gr. 8.8

Gr. 10.9

Gr. 12.9

Dia.

kg•m

ft lb

kg•m

ft lb

kg•m

ft lb

5 mm x std

0.59

4.3

0.79

5.7

1.0

7.2

6 mm x std

1.00

7.3

1.38

1.66

8 mm x std

2.49

3.46

4.15

8 mm x 1.0

2.76

3.87

4.56

10 mm x std

4.84

6.92

8.30

10 mm x

1.0

4.84

7.05

8.30

12 mm x std

8.57

11.89

14.52

105

12 mm x

1.5

9.00

12.59

14.94

108

14 mm x std

13.55

18.95

137

23.10

167

14 mm x

1.5

14.94

108

21.02

152

24.89

180

16 mm x std

20.88

151

29.46

213

35.54

257

16 mm x

1.5

22.54

163

31.53

228

38.03

275

18 mm x std

28.90

209

40.52

293

48.41

350

18 mm x

1.5

32.50

235

45.92

332

55.04

398

20 mm x std

40.94

296

57.95

419

69.01

499

20 mm x

1.5

46.05

333

64.03

463

77.03

557

22 mm x std

54.90

397

77.86

563

93.08

673

22 mm x

1.5

61.00

441

86.02

622

105.00

759

24 mm x std

71.00

513

100.00

723

120.00

868

24 mm x

2.0

78.00

564

109.95

795

130.00

940

27 mm x

2.0

115.06

832

160.00

1157

195.00

1410

4-60 Inspection, Maintenance and Adjustment

022-00028AE Operation and Maintenance Manual

LONG TERM STORAGE

CLEANING

Pressure wash machine. Inspect machine for any damage or missing parts. Drive machine to check

steering linkage for damage.

HYDRAULIC SYSTEM

Start engine and allow it to idle for a few minutes. Drive machine around for 2 - 3 minutes. Raise and lower

boom 2 - 3 times. Crowd and dump bucket 2 - 3 times. This will circulate hydraulic fluid through all

hydraulic systems.

LUBRICATION

Perform all daily maintenance procedures listed in this section (Section 4.) Grease all grease fittings in

steering linkage. Apply a coating of light oil to all exposed cylinder rods. Apply a coating of light oil to all

control linkages and all control valve spools. Check condition of oil coating each month and add to coating

where necessary.

BATTERY

Disconnect cables from battery, or remove battery from machine. If battery is removed, fully charge battery

and store it.

COOLING SYSTEM CARE

If cooling system does not need antifreeze and is filled with water only, add an anti-rust additive. If

temperatures below freezing are expected, add antifreeze to protect system to level of cold expected. See

antifreeze protection Table 4-1. Use a hydrometer to check level of antifreeze protection once each month.

If desired, cooling system can be completely drained. If system is drained, place a sign in operator’s cab to

warn operator that there is no coolant in engine.

022-00028AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-61

5TRANSPORTATION

LOADING MACHINE ON A TRAILER

When transporting the machine observe the

various road rules, road transportation vehicle

laws and vehicle limit ordinances, etc.

It is a good idea to obtain special platform for

loading and unloading the machine.

Park the trailer on a flat firm roadbed. Keep

a fairly long distance between the road

shoulder and the machine.

Properly apply the brakes of the trailer and

place wheel chocks in front of and behind

the tires to ensure that the trailer does not

move.

Figure 1

Fix the ramp in line with the centers of the

trailer and the machine.

Determine the position of the ramp, then

slowly load the machine onto to the

specified part of the trailer.

NOTE: Have someone in clear view

and in a safe position provide

directions while loading.

Lower the bucket and lock each control

lever using the pilot cutoff switch.

Apply the parking brake and set the

Figure 2

articulation stopper in the "LOCKED"

position.

Tape over the exhaust stack outlet to

prevent turbo "Wind-milling" damage.

Place blocks in front of and behind the

tires to prevent the machine from moving.

Fasten the machine to the trailer with

chains or cables at lower part of the rear

chassis. Additional chains or cables may

be used but do not damage brake lines or

cylinder rods.

IMPORTANT

Figure 3

Brake pipe runs on axle housing.

Do not fasten axle housing.

022-00028AE Operation and Maintenance Manual

Transportation 5-1

10. Determine the route for transporting the machine by taking into account the width, height and weight

of the machine and the truck.

SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING

To make safe lifts, the following items must be

evaluated by operator and work site crew.

•

Condition of ground support.

•

Wheel loader configuration and

attachments.

•

Weight, lifting height and lifting

radius.

•

Safe rigging of load.

•

Proper handling of suspended load.

Taglines on opposite sides of load can be very

Figure 4

helpful in keeping a suspended load secure, if

they are anchored safely to control points on

ground.

5-2 Transportation

022-00028AE Operation and Maintenance Manual

6 TROUBLESHOOTING

ENGINE

Problem

Cause

Remedy

Starter does not operate.

Blown fuse.

Replace fuse.

Low battery power.

Charge battery.

Poor terminal contact.

Clean and tighten connections.

Starter switch failed.

Replace switch.

Starter relay failed.

Replace relay.

Starter control failed.

Replace controller.

Wiring harness faulty.

Replace harness.

Battery relay failed.

Replace relay.

Starter engages, engine

does

Blown fuse.

Replace fuse.

not start.

Fuel gelled in cold weather.

Replace fuel.

Fuel filters plugged.

Replace filters.

Water or dirt in fuel system.

Clean system and add new fuel.

Air in fuel system.

Purge air from system.

Engine stop control failed.

Replace stop control.

Engine stop relay failed.

Replace relay.

Engine starts, runs only at low

Engine oil viscosity incorrect.

Change oil.

speed or shuts down.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine stop motor cable out of

Readjust.

adjustment.

Engine speed control cable out

Readjust.

of adjustment.

022-00028AE Operation and Maintenance Manual

Troubleshooting 6-1

Problem

Cause

Remedy

Engine knocks, runs unevenly or

Low engine oil.

Add oil.

surges.

Plugged air intake system.

Clean system and replace filter.

Injection

pump out of

Contact your Daewoo dealer.

adjustment.

Plugged fuel filter.

Replace fuel filter.

Water or dirt in fuel system.

Clean system and add new fuel.

Clogged or dirty fuel injectors.

Clean injectors.

Engine has poor power.

Plugged air intake system.

Clean system and replace filter.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine speed control cable out

Readjust.

of adjustment.

Injection

pump out of

Contact your Daewoo dealer.

adjustment.

Valve backlash faulty.

Adjust backlash.

Engine runs hot.

Low coolant level.

Add coolant.

Thermostat faulty.

Replace thermostat.

Radiator cap faulty.

Replace radiator cap.

Radiator core plugged.

Clean oil cooler.

Oil cooler core plugged.

Clean oil cooler.

Fan belt loose or damaged.

Tighten or replace as required.

Temperature sensor faulty.

Replace sensor.

Engine oil pressure warning light

Low engine oil level.

Add oil.

turns "ON," and buzzer sounds.

Wrong grade oil for weather

change oil.

conditions.

Clogging oil filter element.

Change filter and oil.

Defective alarm switch.

Contact your Daewoo dealer.

Oil leakage from pipe or joint.

Clogging suction strainer.

Excessive engine wear.

Defective oil pump.

6-2 Troubleshooting

022-00028AE Operation and Maintenance Manual

Problem

Cause

Remedy

Coolant temp, warning light

Low engine coolant level.

Add coolant.

turns "ON."

Loose/slipping/broken fan belt.

Adjust or replace belt.

Clogging radiator fins.

Clean.

Scale or mineral build up inside

Flush or professionally clean.

radiator.

Defective alarm switch (gauge is

Contact your Daewoo dealer.

in green).

Low water pump flow.

Thermostat stuck or missing.

Engine does not start when the

Fuel filter element clogging.

Replace fuel filter.

starter motor is turning.

(Also

Starter motor speed too low.

Booster Battery may be used.

see

ELECTRICAL

TROUBLESHOOTING.)

Defective

engine

shutoff

Contact your Daewoo dealer.

solenoid.

Fuel pump failure.

Incorrect fuel injection timing.

Compression pressure too low.

Defective injectors.

Unstable (rough) idling.

Air in fuel lines.

Tighten fuel connections and

filter.

Fuel filter element clogging.

Replace fuel filter.

Fuel pump failure.

Contact your Daewoo dealer.

Incorrect fuel injection timing.

Insufficient power.

Air cleaner element clogging.

Clean or replace element.

Fuel filer element clogging.

Replace fuel filter.

Throttle linkage adjustment

Check and adjust linkage.

wrong.

Engine oil level too high.

Check dipstick and correct level.

Incorrect valve clearance.

Contact your Daewoo dealer.

Piston ring wear.

Defective injectors.

Fuel pump failure.

022-00028AE Operation and Maintenance Manual

Troubleshooting 6-3

HYDRAULIC SYSTEM

Problem

Cause

Remedy

None of the controls function

Hydraulic pump failed.

Contact your Daewoo

(loud noise from pumps).

dealer.

Low hydraulic oil level.

Add hydraulic oil as

required.

Suction line plugged or damaged.

Clean or replace as

required.

None of the controls function (no

Pilot pump failure.

Contact your Daewoo

noise from pumps).

dealer.

Cutoff solenoid valve failed.

Replace solenoid.

Relief cartridge of pilot parking valve

Clean or replace as

stuck.

required.

Safety limit switch is ON.

Adjust limit switch

clearance.

All actuators have low power.

Low hydraulic oil level.

Add hydraulic oil as

required.

Suction filter clogged.

Clean filter.

Hydraulic pumps faulty.

Contact your Daewoo

dealer.

Main relief pressure too low.

Contact your Daewoo

dealer.

Hydraulic pumps cavitating.

Bleed air from hydraulic

pumps.

Only one or two actuators have

Overload relief pressure too low.

Reset pressure.

little or no power.

Make-up check valve leaking.

Clean or replace as

required.

Control valve spool faulty.

Replace valve spool.

Dirt in valve spool.

Clean or replace as

required.

Actuator failed.

Repair or replace as

required.

Cylinder seal failed.

Repair or replace as

required.

Cylinder rod damaged.

Repair or replace as

required.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

6-4 Troubleshooting

022-00028AE Operation and Maintenance Manual

Problem

Cause

Remedy

Oil temperature too high.

Debris in exterior of cooler.

Clean exterior of cooler.

Oil cooler faulty.

Contact your Daewoo

dealer.

Fan belt loose.

Tighten fan belting as

required.

Actuators on one side of boom

Overload relief valve is not operating

Repair valve or replace.

have little power or do not

properly.

operate.

Damaged hydraulic hose.

Replace hose.

Loose hydraulic fittings.

Tighten fittings.

Internal damage to control valve

Replace control valve.

housing.

Control valve spool damaged.

Replace control valve.

Sediment inside control valve.

Clean and repair valve.

Check valve internal leakage.

Repair or replace valve.

Damaged cylinder or pump.

Repair or replace pump or

cylinder.

Cylinder internal leakage.

Repair or replace cylinder.

Damaged cylinder rod.

Replace rod.

Pilot valve failure.

Replace pilot valve.

022-00028AE Operation and Maintenance Manual

Troubleshooting 6-5

TRAVEL SYSTEM

GENERAL

Problem

Cause

Remedy

Machine will not travel.

Transmission

clutch

pressure

Adjust pressure.

incorrect.

Transmission

charge

pump

Replace pump.

damaged.

Damage to transmission control

Repair wiring.

valve wiring harness.

Burned travel relay or fuse

Replace relay or fuse.

Forward/Reverse

solenoid

for

Clean and repair.

transmission control valve sticking.

Damaged transmission clutch.

Repair or replace clutch.

Damaged drive shaft.

Repair or replace.

Damaged transmission or axle.

Repair or replace.

Wheel brakes not releasing.

Repair brakes.

Parking brake not releasing.

Repair parking brake.

Machine will travel but has little

Fluid pressure low in transmission

Repair clutch.

power.

clutch.

Transmission fluid low.

Add fluid.

Damage to torque converter.

Repair or replace.

Engine malfunction.

See Engine Troubleshooting

Table.

Brake valve.

Disassemble and clean.

Unusual transmission noise.

Low transmission fluid, or low quality

Add fluid or change fluid.

fluid.

Worn transmission parts.

Replace parts.

Broken gears or bearings.

Replace parts.

Transmission fails to operate.

Damaged transmission clutch discs.

Replace discs.

Damaged wires in transmission

Repair wires.

control wire harness.

6-6 Troubleshooting

022-00028AE Operation and Maintenance Manual

Problem

Cause

Remedy

Drive shaft vibration Noisy

Bent drive shaft.

Replace drive shaft.

universal joints.

Loose universal joints.

Tighten bolts that secure

joints.

Worn or damaged universal joint.

Replace universal joint.

Loose universal joints.

Tighten bolts that secure

universal joints.

Lack of lubrication.

Lubricate universal joints.

Worn slip joint spline.

Replace slip joint.

Noisy Front or Rear Axle.

Worn or broken gears.

Replace gears.

Low oil level, poor quality oil.

Add oil, change oil.

Worn bearings.

Replace bearings.

Worn shaft spline.

Replace spline.

022-00028AE Operation and Maintenance Manual

Troubleshooting 6-7

TRANSMISSION ERROR CODES

The first number of the error code is the category that it is grouped into. They are as follows for the first

number.

Digital Input Signals

Analog Input Signals

Speed Signals

Analog Current Output Signals

Digital Output Signals

A Digital Output Signals

B Clutch Errors

D Power Supply

E High Speed Signals

F General Errors

Error Code

Meaning Of Error Code

Remarks

Number

Logical error at gear range signal.

Logical error at direction select signal.

Shot circuit to battery voltage at clutch cutoff input

Short circuit to ground or open circuit at clutch cutoff input.

Short circuit to battery voltage at load sensor input.

Not used.

Short circuit to ground or open circuit at load sensor input.

Not used.

Short circuit to battery voltage or open circuit at temperature sensor

input.

Short circuit to ground at temperature sensor input.

Short circuit to battery voltage at engine speed input.

Short circuit to ground or open circuit at engine speed input.

Logical error at engine speed input.

Short circuit to battery voltage at turbine speed input.

Short circuit to ground or open circuit at turbine speed input

Logical error at turbine speed input

Short circuit to battery voltage at internal speed input.

6-8 Troubleshooting

022-00028AE Operation and Maintenance Manual

Error Code

Meaning Of Error Code

Remarks

Number

Short circuit to ground or open circuit at internal speed input.

Logical error at internal speed input.

Short circuit to battery voltage at output speed input.

Short circuit to ground or open circuit at output speed input.

Logical error at output speed input.

Short circuit to battery voltage at clutch K1.

Short circuit to ground at clutch K1.

Open circuit at clutch K1.

Short circuit to battery voltage at clutch K2.

Short circuit to ground at clutch K2.

Open circuit at clutch K2.

Short circuit to battery voltage at clutch K3.

Short circuit to ground at clutch K3.

Open circuit at clutch K3.

Short circuit to battery voltage at converter clutch.

Not used.

Short circuit to ground at converter clutch.

Not used.

Open circuit at converter clutch.

Not used.

Short circuit to battery voltage at clutch K4.

Short circuit to ground at clutch K4.

Open circuit at clutch K4.

Short circuit to battery voltage at clutch KV.

Short circuit to ground at clutch KV.

Open circuit at clutch KV.

Short circuit to battery voltage at clutch KR.

Short circuit to ground at clutch KR.

Open circuit at clutch KR.

Short circuit to battery voltage at relay reverse warning alarm.

Short circuit to ground at relay reverse warning alarm.

022-00028AE Operation and Maintenance Manual

Troubleshooting 6-9

Error Code

Meaning Of Error Code

Remarks

Number

Open circuit at relay reverse warning alarm.

Short circuit to battery voltage at relay starter interlock.

Short circuit to ground at relay starter interlock.

Open circuit at relay starter interlock.

Short circuit to battery voltage at park brake solenoid.

Short circuit to ground at park brake solenoid.

Open circuit at park brake solenoid.

Slippage at clutch K1.

Slippage at clutch K2.

Slippage at clutch K3.

Slippage at clutch K4.

Slippage at clutch KV.

Slippage at clutch KR.

Short circuit to battery voltage at power supply for sensors.

Short circuit to ground at power supply for sensors.

Low power at battery.

High power at battery.

Error at switch 1 for valve power supply.

Error at switch 2 for valve power supply.

Short circuit to battery at speedometer output.

Not used.

Short circuit to ground or open circuit at speedometer output.

Not used.

Short circuit to battery voltage at display output.

Not used.

Short circuit to ground or open circuit at display output.

Not used.

Error at communication on CAN.

General EEPROM fault.

Configuration lost.

Application error.

6-10 Troubleshooting

022-00028AE Operation and Maintenance Manual

STEERING

Problem

Cause

Remedy

Steering Wheel is hard to turn.

Sediment blocking direction change

Clean and repair.

spool orifice, inside priority valve.

Sediment blocking amplifying spool

Clean and repair.

orifice, inside priority valve.

Sediment blocking load sensing line

Clean and repair.

orifice, inside priority valve.

Priority valve spool sticking, inside

Clean and repair.

steering valve.

Incorrect relief valve pressure drop,

Adjust pressure.

inside priority valve.

Steering pump failure.

Repair or replace.

Leaking steering cylinder.

Repair cylinder.

Rust on steering column bearing

Lubricate.

and spline.

Tire air pressure is low.

Inflate to proper pressure.

High initial

resistance

Air in load sensing line, inside

Bleed system to remove air.

movement of steering wheel.

priority valve.

Sediment blocking orifice of load

Clean and repair.

sensing line, inside priority valve.

Sediment in direction change spool,

Clean and repair.

inside priority valve.

Damage to control spring damping

Replace priority valve.

inside priority valve.

Steering wheel shakes.

Chattering bearing in axle end

Replace bearing.

differential.

Tire pressure not equal in left side

Equalize pressure.

and right side tires.

022-00028AE Operation and Maintenance Manual

Troubleshooting 6-11

BRAKING

Problem

Cause

Remedy

Reduced brake action.

Low secondary pressure in brake

Repair or replace brake

valve.

Worn brake discs.

Replace brake discs.

Damaged brake discs.

Replace brake discs.

Damaged brake valve block.

Replace valve.

Air in brake hydraulics due to leak in

Repair leak, bleed system.

brake hose.

After bleeding brakes, brakes

Damaged brake discs.

Replace discs.

are not fully released.

Damaged brake disc return spring.

Replace return springs.

ELECTRICAL SYSTEM

Problem

Cause

Remedy

Battery has no power and will

Damaged battery plates.

Replace battery.

not accept a charge.

Alternator not charging properly.

Repair or replace alternator.

Bad ground.

Clean and tighten.

Loose electrical connector.

Clean and tighten.

Alternator belt loose or damaged.

Tighten or replace.

Battery will accept a charge but

Internal battery short.

Replace battery.

discharges soon after.

Wiring harness short.

Repair wire.

6-12 Troubleshooting

022-00028AE Operation and Maintenance Manual

7SPECIFICATIONS

MEGA 200-V

GENERAL SPECIFICATIONS

COMPONENT

SPECIFICATION

STD

1.8 m³(2.4 yd³)

STD. Bucket Cap.

OPT

1.9 m³(2.5 yd³)

STD

11,000 kg (24,251 lb)

Vehicle Weight

OPT

11,200 kg (24,692 lb)

Engine

Model

DB58TI

DB58TIS

Emission

Tier I

Tier II

Type

Turbo, Intercooler

Turbo, Charge Air Intercooler

140 ps @ 2,200 rpm

Rated. 145 ps (143 hp) @ 2,200 rpm

Horsepower (see note)

(138 hp @ 2,200 rpm)

Max. 160 ps (158 hp) @ 2,000 rpm

(SAE J 1349 net)

(Gross) (SAE J1995)

57 kg•m @ 1,500 rpm

64 kg•m (463 ft lb) @ 1,600 rpm

Max. Torque (see note)

(412 ft lb @ 1,500 rpm)

(Gross) (SAE J1995)

(SAE J 1349 net)

Transmission

Type

Full Automatic Power Shift

Speeds

4 Forward, 3 Reverse

Brake Systems

Service Brakes

Full Hydraulic, Separate Dual Line Wet Discs

Parking Brake

Spring Applied / Oil Released on Front Axle, Dry Disc

Performance

STD

7.3 - 36 km/h (4.5 - 22.4 MPH)

Travel Speed

OPT

8.2 - 39.5 km/h (5.1 - 24.5 MPH)

Steering Angle

± 40°

NOTE: "High torque rise"

Fuel system deliveries a control increase of fuel as the engine lugs back from rated speed.

This results in horsepower greater than rated power. The combination of increased torque

rise and maximum horsepower improves response, provides greater rimpull, more lift

022-00028AE Operation and Maintenance Manual

Specifications 7-1

Dimension