SB 4031 e
SB 4031 e
SB 4031 e
form SB4031E
SB4032E00
Jul. 2000
NOTICE
This form lists the contents of the complete Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers listed with mark(*) are, they are not available for the initial release of the
manual. When items are updated, or supplements added, they will be announced in
preview and should be ordered as they become available.
FOREWORD
ENGINE
VEHICLE
ELECTRIC
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
SB2003E00
A p r. 1 9 9 9
WARNING
SAFETY
machine. If this cannot be done, make sure the
WARNING forks or other im plements are blocked correctly to
prevent them from dropping unexpectedly.
The proper and safe lubrication and malntenance
for this machine, recommended by DAEWOO, are 5. Use steps and grab handles (if applicable)when
outilined in the OPERATION & MAINTENANCE mounting or dismounting a machine. Clean any
GUIDE of this machine. mud or debris from steps, walkways or work
plaftorms before using. Always face machine when
Improper performance of lubrication or maintenance using steps, ladders and walkways. When it is not
procedures is dangerous and could result in injury possible to use the designed access system,
or death. Read and understand the OPERATION & provide ladders, scaffolds, or work platforms to
MAINTENANCE GUIDE before performing any perfom safe repair operations.
lubrication or maintenance.
6. To avoid back injury, use a hoist when lifting
components which weigh 23 kg (50 lb.) or more.
The serviceman or mechanic may be unfamitiar with Make sure all chains, hooks, slings, etc., are in
many of the systems on this machine. This makes it good condition and are of the correct capacity. Be
important to use caution when performing service sure hooks are positioned correctly. Lifting eyes
work A knowledge of the system an/ or components are not to be side loaded during a lifting operation.
is important before the removal or disassembly of
any component. 7. To avoid bums, be alert for hot parts on machines
which have just been stopped and hot fluids in
Because of the size of some of the machine lines, tubes and compartments.
components, the serviceman or mechanic should
check the weights noted in this Manual, Use proper 8. Be careful when removing cover plates. Gradually
lifting procedures when removing any components. back off the last two bolts or nuts located at
opposite ends of the cover or device and pry cover
Following is a list of basic precautions that should loose to relieve any spring or other pressure,
always be observed. before removing the last two bolts or nuts
completely.
1. Read and understand all Waming plates and
decals on the machine before operating, 9. Be careful when removing filler caps, breathers
lubricating or repairing the product. and plugs on the machine. Hold a rage over the
cap or plug to prevent being sprayed or splashed
2. Always wear protective glasses and protective by liquids under pressure. The danger is even
shoes when working around machines. In greater if the machine has just been stopped
particular, wear protective glasses when pounding because fluids can be hot.
on any part of the machine or its attachments with
a hmmer or sledge. Use welders gloves, 10. Always use tools that are in good condition and
hood/goggles, apron and other protective clothing be sure you understand how to use them before
appropriate to the welding job being performed. Do performing any service work.
not wear loose-fitting or tom clothing. Remove all
rings from fingers when working on machinery. 11. Reinstall all fasteners with same part number. Do
not use a lesser quality fastener if replacements
3. Do not work on any machine that is supported only are necessary. Do not mix metric fasteners with
by lift jacks or a hoist. Always use blocks or jack standard nuts and bolts.
stands to support the machine before performing
any disassembly. 12. If possible, make all repairs with the machine
parked on a level, hard surface. Block machine
4. Lower the bucket or other implements to the so it does not roll while working on or under
ground before performing any work on the machine.
WARNING
13. Disconnect battery before starting to work on 20. Do not operate a machine if any rotating part is
machine. Hang Do Not Operate tag in the damaged or contacts any other part during
Operators Compartment. operation. Any high speed rotating component
that has been damaged or altered should be
14. Repairs, which require welding, should be checked for balance before reusing.
performed only with the benefit of the appropriate
reference information and by personnel
adequately trained and knowledgeable in welding
procedures. Determine type of metal being
welded and select correct welding procedure and
electrodes, rods or wire to provide a weld metal
strength equivalent at least to that of parent
metal.
The table of Contents on the preceding pages is your 3) Preparation for disassembly
best tool for finding the service procedure you need.
To save unnecessary work, reserve the necessary
Be certain to observe all Safety information included facilities, tools, and parts racks as well as adequate
in these pages. floor space considering the extent of disassembly.
Keep the area and facilities clean.
7) Safety
Seal
Seal
When tightening bolts on certain designated parts,
tighten them in the prescribed sequence as shown
in the figure, in order to exert even torque on every
bolt. In this method called the template methods.
the bolts are tightened stepwise and sometimes
loosened, so that the bolts and nuts are well seated Guide Jig
or the bearing comes into close and even contact.
Apply engine oil to the screw threads of certain
designated bolts so that smooth and even tightening
of the bolts may be obtained.
With wires, cotter pins or lock washers, securely After press-fitting an oil seal, check for alignment.
lock those bolts and nuts which cannot be checked Allowable limit of misalignment :
from the outside or are used for important parts that 0.2 mm per 100 mm dia. (1/64 per 3 15/16 dia.).
require locking. When applying bonding agent on the circumference
Oil Pressure
Keep the oil seals free from dust, and see that there
is no rust or scratches on their surfaces (especially
on the lips).
Before installation, coat the oil seal with grease as
outlined below, to prevent dry friction which may
occur during the break-in operation of the machine.
Engine
For Skid Steer Loaders
D427 Diesel Engine
1550XL(DSL702)
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
Specifications
Specifications
Fig 1-3
4. Adjust valve clearance when fixing bolts. Intake side : No.3, No.4
Exhaust side : No.2, No.4
3. Adjust the idling speed if the speed is not within Fig 1-8
the specified range.
3. Set measuring instrument to injection pump. Make
sure that the filler end of measuring device is in
contact with plunger head.
Adjustment
Adjust the idling speed by turning the idling adjusting
bolt of the injection pump.
Fig 1-7
Fig 1-10
1. Remove all injection pipes.
2. Remove the head bolt and gasket from the 6. Turn the flywheel clockwise until it reaches TDC,
distributor on the injection pump. lnjection timing is normal if dial gauge indicates
1.00mm at this point.
Adjust if more than 1.00mm.
Fig 1-13
Fig 1-11
1. Warm up the engine thoroughly.
1. If injection timing is not right, then turn the injection 2. Remove the nozzle holders from all cylinders.
pump until the dial gauge indicates 1.00mm.
(1) If cam lift value is less than 1.00mm, turn 3. Install the adapter set and use a pressure gauge
injection pump in direction of engine rotation to of capacity greater than 30 kg/cm2
its maximum, and then adjust the cam lift value
to 1.00mm, by turning it in counter direction. 4. Remove the fuel cut solenoid wiring.
(2) If cam lift value is more than 1.00mm, adjust it
by turning injection pump in counter direction to 5. Crank the engine and measure compression
engine rotation, until value reaches 1.00mm. pressure.
2. Install the bolts and gasket after adjusting. Compression pressure kg/cm2 (lbin2)-rpm
Standard 30(426)-200
CAUTION : Use new head bolts and gasket.
Limit 27(384)-200
3. Install the injection pipes.
CAUTION : If the pressure does not come up to the
specified pressure, check the engine speed.
Fig 1-24
(1) Cylinder head cover. (2) Gasket. (3) Rocker arm. (4) Cylinder head. (5) Gasket. (6) Push rod. (7) Intake valve.
(8) Exhaust valve. (9) Valve guide.
Fig 1-25
(1) Piston ring. (2) Piston. (3) Piston pin. (4) Connecting rod. (5) Connecting rod bearing set. (6) Oil pipe. (7) Set screw.
(8) Oil pump. (9) Oil level gauge. (10) Gasket. (11) Oil pan.
Fig 1-26
(1) Timing case cover. (2) Gasket. (3) Oil deflector. (4) Injection pump cover. (5) Gasket. (6) Locking bolt.
(7) Thrust plate. (8) Idle gear. (9) Spindle. (10) Crankshaft gear. (11) Lock nut. (12) Lock plate.
(13) Cam gear. (14) Lock nut. (15) Lock plate. (16) Injection pump gear. (17) Timing case. (18) Oil seal
Fig 1-27
(1) Main bearing cap. (2) Bearing set. (3) Crankshaft. (4) Thrust plate. (5) Cam shaft. (6) Tappet. (7) Oil seal cap. (8) Gasket.
(9) Oil seal. (10) Cylinder liner. (11) Cylinder block.
11. Disassemble the pulley lock bolts and crankshaft 14. Remove the valve guide, pushing it towards
mounting bolts, preventing flywheel rotation combustion chamber by using the valve guide
prevent the flywheel from rotating and remove the installer.
pully lock bolts and crankshaft mounting bolts.
Fig 1-32
Fig 1-29
Fig 1-30
16. Remove the piston pin by using the piston pin 19. Assemble the piston rings and oil rings onto
remover & installer. piston as shown in the figure.
CAUTIONS :
a) Gaps on the top ring and second ring must be
placed on the opposite side of combustion
chamber.
b) Gap on the top ring should not face thrust side or
counter thrust side.
c) Gap on the top ring should be set on opposite side
(180) of oil ring gap.
Fig 1-34
Fig 1-37
Fig 1-35
21. Adjust valve clearance after assembling. Oil pan 24. Remove the injection pump gear by using the
gasket is composed of side, front and back extractor.
gaskets as shown in the figure.
Fig 1-43
Fig 1-44
26. Insert the oil seal, by using the oil seal puller &
Fig 1-41
installer timing cover.
Fig 1-46
Fig 1-49
27. Remove the cylinder liner, by using cylinder liner
replacer and press.
29. Assemble the main bearing in reverse order of
Cylinder liner assembling pressure :1 ~ 3 tons disassembly carefully not to apply oil on the back
of the bearing.
Fig 1-47
NOTES :
a) If cylinder liner is difficult to remove, then bore the
liner until it comes loose.
b) Check for any damage or scratch on the cylinder
bore wall after removing the liner and, if there is
any defect, repair by using fine sandpaper.
31. Assemble the main bearing cap, directing arrow 35. Replacing valve seal
mark on the top of the cap towards engine front. (1) Remove the valve seal by using the suitable
tools.
32. Assemble the thrust washers on both sides of (2) Insert new seal into valve guide.
center bearing, with their oil grooves facing (3) Assemble the valve seal by using the valve
outwards. seal pusher. Press valve seal pusher until the
valve seal reaches the bottom of valve spring
seat.
Fig 1-51
Fig 1-52
Cylinder Head
Inspection of Cylinder Head
Fig 1-57
Fig 1-58
Fig 1-56
Distortion limit :
A, B : 0.1 mm (0.004 in)
Fig 1-59
C, D, E, F : 0.25 mm (0.010 in)
Fig 1-62
Fig 1-61
Fig 1-65
Fig 1-68
Fig 1-70
Visually inspect the valve for even seating of valve
seat with the center part of the valve, and check for
defect. If any defective part is wide, replace valve Clearance limit
and grind it if defective area is minor. Intake : 0.127mm (0.0050 in)
Exhaust : 0.127mm (0.0050 in)
Dimensions of Valve If the clearance exceeds the limit, replace valve and
valve guide.
Valve Spring
Checking Free Length
Fig 1-69
Fig 1-71
Fig 1-74
Fig 1-72
3. Measure the spring tension when the spring is Place the push rod on a plane surface, and measure
compressed longitudinally. the clearance between the plane surface and rod
with feeler gauge.
Outer spring 40.3 mm(1.587 in) 18.0 L 0.9kg(39.7 L 2.0 lb) 15.9kg(35.1 lb)
Inner spring 37.8 mm(1.488 in) 12.7 L 0.6kg(28.0 L 1.3lb) 11.3kg(24.9 lb)
Checking Perpendicular
Fig 1-75
Fig 1-73
Angle limit
Outter spring : 1.37mm (0.0539 in)
Inner spring : 1.25 mm (0.0492 in)
Inspect tappet for crack or damage, and replace it if 1. Inspect every part of rocker arm assembly for
necessary. Inspect contact point with came, and crack or damage, and replace it if necessary.
replace it if it is worn out.
2. Inspect oil holes of rocker arm and shaft, and
clean them if blocked.
Checking of Clearance Between Tappet and
Tappet Guide
Checking Clearance
Fig 1-77
Fig 1-79
Clearance limit : 0.10 mm (0.0039 in) Clearance limit : 0.07 mm (0.0028 in)
Fig 1-80
Fig 1-82
Fig 1-81
Standard clearance :
0.016 ~ 0.061 mm (0.0006 ~ 0.0024 in )
Fig 1-83
Fig 1-85
Measure the clearance between piston and cylinder Checking clearance Between Piston Ring Groove
liner, and replace piston or cylinder liner if the and Piston Ring
clearance exceeds the limit.
Fig 1-86
Checking Condition Check end play of the big end of the connecting rod,
and replace connecting rod or crankshaft if the play
exceeds the limit.
Fig 1-87
Fig 1-89
Inspect connecting rod at both ends for crack of
damage on the surface, and replace it if necessary.
1. Fit connecting rod to crankshsft.
Checking for Bending & Torsion 2. Measure end play by using a dial gauge with
magnetic base.
Fig 1-88
Fig 1-93
Fig 1-91 When grinding the bushing make sure that the
reamer is precisely inserted to prevent a rough
1. Replace the bushing by using a rod and press. bushing surface always grind in the direction of
cutting. Always be sure not to stop the reamer at
same points. When repairing the small end bushing
with a pin hole horning machine, the bushing hole
tends to incline to one direction, so change the
connecting rod position many times during the
horning process until horning size reaches standard.
Checking Condition
Fig 1-92
Standard clearance :
0.014 ~ 0.044 mm (0.0006 ~ 0.0017 in)
Fig 1-94
Fig 1-96
Fig 1-95
1. Inspect the crankshaft for crack, breakage, or
other damage, and replace it if necessary.
1. Remove oil residue from joural and bearing.
2. Check if oil holes are clogged, and unblock them
2. Set plasti-gauge to axial direction on a journal. by using compressed air or a needle if clogged.
3. Install bearing cap and tighen to the specified torque.
Oil clearance
Standard : 0.059-0.090 mm (0.0023 ~ 0.0035 in)
Limit : 0.12 mm (0.0047 in)
Fig 1-97
Fig 1-98
Fig 1-101
End play
Standard : 0.14 ~ 0.39 mm (0.0055 ~ 0.0154 in)
Limit : 0.4 mm (0.016 in)
Fig 1-102
Fig 1-103
Fig 1-105
Check the cam jounal for wear, and replace the cam
Checking Condition shaft if the wear exceeds the limit.
Fig 1-108
Fig 1-106
Wear
Journal Diameter
limit
1. Repair for replace if necessary. No.1 51.910-51.940mm
2.044 - 2.045 in)
2. Be careful not to change the original shape of the
cam when repairing. No.2 51.660-51.690mm
(2.034-2.035 in) 0.008mm
No.3 51.410-51.440mm (0.0003 in)
Checking Height (2.24-2025 in)
No.4 51.160-51.190mm
(2.014~ 2.015)
Checking Deflection
Fig 1-107
Fig 1-110
Backlash
Checking Journal Oil Clearance
Standard : 0.10 ~ 0.17 mm (0.004 ~ 0.007 in)
Limit : 0.3 mm (0.012 in)
Fig 1-111
Fig 1-115
Oil clearance
Standard : 0.034 ~ 0.048 mm(0.001 ~ 0.003 in)
Limit : 0.15 mm (0.06 in)
Fig 1-117
Outline
Structural View
Fig 2-1
Troubleshooting Guide
Preblem Possible Cause Remedy
OIl leakage Loose drain plug Tighten or replace
Faulty seal oil and cylinder block Replace
Damaged cylinder head cover Replace
Loose oil pump body bolt, cylinder head cover bolt, or oil pan bolt Tighten
Damaged front housing gasket, or cylinder head gasket Replace
Faulty oil seal(s) Replace
Loose oil filter Tighten
Loose or damaged oil pressure switch Tighten or replace
Oil pressure drop Oil leak As described above
Insufficient oil Add oil
Worn and/or damaged oil pump gear Replace
Worn plunger(inside oil pump) or weak spring Replace
Clogged oil strainer Clean it
Excessive lubrication clearance between main bearing and
connecting rod bearing Refer to Group 1
Warning lamp Oil pressure drop As described above
illuminates while Malfunction of oil pressure switch Repair
engine running Problem in electrical system Repair
Fig 2-2
Disassembly
1. Remove the oil pressure switch.
Disassemble in the following sequence :
2. Mount the oil pressure gauge on the cylinder block
hole where oil pressure switch had been installed.
FIG 2-3
(1) Oil pump body. (2) Set screw. (3) Nut. (4) Plunger.
(5) Spring. (6) Plug. (7) Drive shaft. (8) Outer rotor
(9) Inner rotor. (10) Cover. (11) Oil strainer. (12) Oil pipe
Checking Condition
Fig 2-5
Fig 2-8
Clearance Between Inner and Outer Rotor
Fig 2-6 Check wear of relief valve plunger and spring defect.
Installation
Install in the reverse order of removal
Fig 2-9
CAUTION : Install oil pan upper block with its
Assemble in reverse order of disassembly. assembly surface conforming to the cylinder block
under part.
CAUTION : When assembling the rotor on the body,
confirm that the matching marks are in the front of Replace the oil pan gasket with a new one. Apply a
the cover. thin coating of engine oil to gasket between the
cylinder block and the oil pan. Tighten the oil pan
Cover tightening torque : bolts and nuts on the cylinder block to the specified
0.8 ~ 1.2 mkg (5.79 ~ 8.68 ftlb) torque.
Oil Pan
Removal Inspection
1. Remove dust and chips from oil pan.
Fig 2-10
Troubleshooting Guide
Preblem Possible Cause Remedy
Water leakage Damaged radiator core seam Replace
Leakage from radiator hose or heater hose Repair or replace
Leakage from water temperature switch Repair or replace
Leakage from water seal (water pump) Replace
Damaged or loose thermostat cover or gasket Repair or replace
Loose cylinder head bolt Tighten
Damaged cylinder block Replace
Cracked cylinder head Replace
Corrosion Impurities in coolant Clean
Overheating Water passage clogged Clean
Thermostat malfunction Replace
Radiator fins clogged Clean
Water pump malfunction Repair or replace
Insufficient coolant Add
Thermo - modulated cooling fan malfunction Replace
Radiator cap malfunction Replace
Removal
Remove the thermostat in the following sequence.
Fig 3-11
Installation
Install the thermostat in the reverse order of removal.
Notes
Fig 3-10
Fig 3-12
Fig 3-13
Fig 3-15
Removal and Installation
(1) Nut & washer. (2) Bearing housing. (3) Gasket.
Remove the water pump in the numbered order. (4) Pulley boss. (5) Snap ring.
Installation is the reverse order of removal. (6) Shaft, spacer & bearing ass'y. (7) Impeller. (8) Seal ass'y.
(9) Bearing. (10) Spacer. (11) Bearing. (12) Baffle plate.
(13) Dust seal. (14) Snap ring.
Fig 3-14
Fig 3-16
1. Drain the coolant.
1. Remove the pump pulley boss with the fan pulley
2. Remove the radiator cowling.
boss puller and press.
3. Remove the cooling fan.
Fig 3-17
2. Remove the impeller and the shaft from bearing Fig 3-20
housing by using the support block and press.
1. Disassemble scale from within the pump body.
Clean removed parts.
Fig 3-18
V-belt
3. Remove the snap ring by using snap ring pliers,
and push out the water pump shaft from the Inspection
bearing.
Fig 3-21
Fig 3-19
Belt deflection
New belt : 10 ~ 12 mm (0.39 ~ 0.47 in)
Used belt : 13 ~ 16 mm (0.51 ~ 0.63 in)
Diesel Engine D427 45 Cooling System
Fuel System
Outline
Structural View
Fig 4-1
Item Specification
Type VE type
Injection timing ATDC 2
Injection pump
Turning direction Clockwise
Idling speed 1100 L 25
Nozzle type Throttle type
Orifice Dia. XNo. 8mm (0.032 in.)X1
Injection nozzle
Injection pressure 135~140 kg/cm2
Air cleaner Filter paper element type
Fuel Filter Cartridge type with water-detector
Injection order 1-3-4-2
Troubleshooting Guide
Preblem Possible Cause Remedy
Hard starting Clogged fuel filter Replace
Air in fuel filter Air-bleed
Faulty fuel cut valve Replace
Faulty injection timing Adjust
Air in injection pump Air-bleed
Trouble inside of injection pump Replace
Seized needle valve of injection nozzle Clean or replace
Fuel dripping from injection nozzle Adjust
Faulty cold start device Adjust or replace
Rough idling Clogged fuel filter Replace
Air in fuel filter Air-bleed
Faulty fuel cut valve Replace
Faulty injection timing Adjust
Air in injection pump Air-bleed
Trouble inside of injection pump Replace
Seized needle valve of injection nozzle Clean or replace
Faulty injection starting pressure Adjust
Improper mounting to nozzle holder Disassemble and assemble or replace
Leakage at gasker Replace
Crack in injection pipe Replace
Leaking from injection pipe joint Retighten or replace
improper idling speed Adjust
Engine knocking Faulty injection timing Adjust
Low quality fuel Replace
Faulty injection starting pressure Adjust
Seized needle valve of injection nozzle Clean or replace
Fuel dripping from injection nozzle Replace
Engine knockin Faulty injection timing Adjust
Low quality fuel Replace
Faulty injection starting pressure Adjust
Seized needle valve of injection nozzle Clean or replace
Fuel dripping from injection nozzle Replace
Fig 4-10
After installing the filter, remove the air breather 9. Start the engine and check whether fuel us is
screw in order to remove air with the priming the being ejected from injection pipe
filter, remove the air with priming pump, and after
starting the engine, check for leakage
Fig 4-11
(1) Adapter. (2) Cartridge. (3) Level sensor. (4) Drain plug
(5) Air breather.
Structural View
Fig 4-13
Fig 4-18
Fig 4-16
Fig 4-20
Fig 4-23
Fig 4-24
12. Remove the injection pump mounting nut. Also Fig 4-26
remove the spring washer and flat washer.
1. Before installing the key on the drive shaft of
13. Remove the pump shaft and the gear.
injection pump, tap the key hole slightly until the
key is inserted into the key hole completely.
Set the extractor and use M marked side of it.
Disconnect the shaft and the gear by tightening
2. Remove air after installing the injection pump.
extractor bolt.
Drive gear tightening torque :
4.0 ~ 7.0 mkg (28.9 ~ 50.6 ftlb)
Air-Bleeding
Make sure to bleed the air replacing the fuel filter or
cleaning the sedimenter.
Fig 4-28
4. Injection nozzle
5. Washer
Fig 4-27
(1) Nozzle holder body. (2) Pressure Pin. (3) Pressure Spring.
Fig 4-29
(4) Retaining Nut. (5) Distance Piece. (6) Shim. (7) Washer.
(8) Nut. (9) Nozzle.
Fig 4-30
Fig 4-33
Fig 4-34
CAUTIONS :
a) After assembling the injection nozzle, check the
injection starting pressure and atomizing condition.
b) Tighten the nozzle body on the nozzle holder to
the specified torque.
Installation
Install in reverse order of removal.
Fig 4-35
CAUTIONS :
a) The gasket and corrugated gasket and not be
reused.
b) Tighten the injection nozzle on the cylinder head
to the specified torque.
Specifications
Item Specification
Voltage 12V, Negative Ground
Type Alternating
Alternator Output 12V-60A
Regulator Type Transistorized(built-in IC regulator)
Starter Type Electromagnetic push-in-type
Output 12V-2.5kW
Type Sheathed type
Glow plug Voltage 11V
Amperage 52A
Troubleshooting Guide
Preblem Possible Cause Remedy
Starter does not Battery and related parts
turn at all, or its Poor contact of battery terminals Clean and tighten
turning speed is Poor grounding of negative cable Clean and repair
too slow to start Voltage drop caused by discharged battery Recharge
the engine. Insufficient voltage caused by battery malfunction Replace
Magnetic switch and related parts
Loose wiring and / or connectors Repair
Burnt magnetic switch contact plate or improper contact Replace
Broken wire in magnetic switch contact plate or improper contact Replace
plate or improper contact
Broken wire magnetic switch holding coil Replace
Starter and related parts
Poor contact of brushes Adjust contact or replace
Fatigued brush spring Replace
Poor grounding of field coil Replace
Poor soldering of field coil Repair
Commutator malfunction Repair
Grounded armature Replace
Worn parts Replace
Starting problem Insufficient battery capacity Recharge
Starter turns but Tip of overrunning pinion is worn Replace
pinion gear does Fatigued overrunning clutch drive spring Replace
not mesh with Overrunning clutch races Replace
ring gear Improper sliding of spline Adjust contact and repair
Worn bushing Replace
Worn ring gear Replace
Starter turns Sticking contact place of magnetic switch Replace
continuously Layer shorting of coil magnetic switch Replace
(does not stop)
Installation
Install the start in the reverse order of removal, taking
care of the following.
WARNING
Fig 5-7
Fig 5-6
Fig 5-8
Fig 5-11
Fig 5-12
Fig 5-16
1. Pull out the brush and brush lead wire from the
brush holder.
Fig 5-14
3. Replace a new brush in the brush lead wire. Clean
the brush lead wire. Fix the brush lead by inserting
Check the brush for any damage or wear. the lead through the small tapered hole on the
Wear limit : 14 mm (5.51 in) brush.
Attraction Test
Fig 5-19
Fig 5-17
1. Disconnect the lead wire between the terminal and
the starter.
1. Disconnect the lead wire between terminal M and
starter terminal. 2. Connect battery power to terminal M of magnetic
switch and its body.
2. It is normal if the plunger is pulled in and the
pinion jumps out when power is supplied to the 3. Pull and release the pinion. It is normal if the
magnetic switch S and the terminal M. pinion returns quickly to its original position ; but, if
it does not return, replace the magnetic switch.
CAUTION : Do not supply power for more than 10
seconds.
Pinion Jumping-out Condition
Attraction-holding Test
Fig 5-20
Fig 5-18
1. Disconnect the wire from the terminal M.
1. Disconnect the lead wire between the terminal M 2. The pinion jumps out when battery power is
and starter. supplied to terminal S and to starer body. Measure
the clearance between the pinion and stopper.
2. Supply battery power to S terminal of magnetic
switch and switch body, and then pull the pinion by Standard Pinion clearance :
hand. 0 ~ 2.0mm (0 ~ 0.078 in)
3. It is normal if the pinion does not return to its CAUTION : Do not supply power to starter for
original position when the pulled-out pinion is more than 20 seconds.
released.
1. Be sure battery connections are not reversed, 2. Turn the ignition switch OFF.
because this will damage the rectifier.
3. Read the voltage between the L terminal and
2. Do not use high-voltage testers, such as a ground. The alternator is bad if the reading is not 0
Megger, because they will damage the rectifier. V.
3. Remember that battery voltage is always applied 4. Turn the ignition switch ON and read the voltmeter.
to the alternators B terminal. If the reading is 0 V, there is a malfunction of the
alternator or wiring.
4. Do not ground the L terminal while the engine is
running.
Fig 5-25
Fig 5-24
1. Disconnect the negative battery cable.
1. Check to be sure that the battery is fully charged.
2. Connect an ammeter and a voltmeter as shown in
the figure.
2. Connect an ammeter and a voltmeter as shown in
the figure. Be sure that the voltmeter reading is 0 V. 3. Connect the negative battery cable.
3. Turn the ignition key to ON, and then check to be 4. Start the engine.
sure that the voltmeter reading is significantly
lower than the battery voltage(1 ~ 3V). If the 5. Apply a increase the engine speed. and read the
voltmeter reading is the same as the battery output current. If the voltage is higher than the
voltage, there may be a malfunction in the battery voltage and there is an output current,
alternator. there is no problem.
Fig 5-30
LOCK NUT
Disassembly and Assembly
Disassemble in numbered order shown in the figure.
Assembly is the reverse order of disassembly.
Fig 5-31
Fig 5-32
Fig 5-28 Secure the rotor in a vise, and loosen the pulley nut.
Seal Washers
Fig 5-34
Fig 5-37
Inspect the following parts, and repair or replace if a 1. Use a circuit tester to check for continuity between
problem is found. the core and each slip ring.
No-continuity is the normal condition.
Stator
Fig 5-41
Fig 5-39
Use a continuity tester to check the continuity of each Check the front and rear bearings for improper
rectifier. There should be high resistance in one rotation and/or abnormal noise. Replace if an
direction and low resistance in the other direction. abnormal condition is discovered.
There is a short-circuit if the resistance is low in both
directions, and there is a broken wire if the resistance
is high in both directions. In either instance, replace
the rectifier. Glow Plugs
Checking Open Circuit of Glow
Brushes and Spring Plugs
1. Check the force of the brush spring. Measure the Check the continuity between the positive terminal of
force of the brush spring by using a spring the glow plug and cylinder head block with a circuit
pressure gauge, and push the brush into the brush tester. If there is no continuity, replace the glow plug.
holder until the tip projects 2mm (0.079 in).
Fig 5-46
3. Glow plug
Item
Type Diesel, four-cycle
Number and arrangement of cylinders Four cylinders, in-line
Type of combustion chamber Swirl floor type
Bore and Stroke mm B mm(in*in) 92.0 B 101.6 (3.62 B 4.00)
Total piston displacement cc 2701
Compression ratio 21.5 : 1
Valve system Over head valve(0HV)
Valve timing
Intake valve Open(BTDC) 14
Closes(ABDC) 44
Exhaust valve Open(BBDC) 48
Closes(ATDC) 10
Firing order 1-3-4-2
Idling speed 1075 ~ 1125
Cylinder head
Valve clearance(cold) mm(in) Intake 0.30(0.012)
Exhaust 0.30(0.012)
Cylinder head distortion limit mm(in) 0.10(0.0040)
Valve seat
Seat sinking mm(in) Intake standard 48.05(1.892)
(Length L) Limit 49.05(1.931)
Exhaust Standard 48.05(1.892)
Limit 49.05(1.931)
Seat angle Intake 45
Exhaust 30
Seat contact width mm(in) Intake 2.0(0.079)
Exhaust 20(0.079)
Valve stem mm(in) Intake Standard 8.995 ~ 8.989(0.3526 ~ 0.3535)
Limit 8.904(0.3506)
Exhaust Standard 0.038 ~ 0.085(0.0015 ~ 0.0033)
Limit 0.127(0.0050)
Valve stem to guide Intake Standard 0.038 ~ 0.085(0.0015 ~ 0.0033)
clearance mm(in) Limit 0.127(0.0050)
Exhaust Standard 0.058 ~ 0.105(0.0023 ~ 0.0041)
Limit 0.127(0.0050)
Camshaft
Cam height mm(in) Intake Standard 42.580(1.6764)
Wear limit 42.478(1.6724)
Exhaust Standard 42.580(1.6764)
Wear limit 42.478(1.6724)
Journal mm(in) Elliptical limit 0.008(0.0003)
Diameter 1 51.910 ~ 51.940(2.044 ~ 2.045)
2 51.660 ~ 51.690(2.034 ~ 2.035)
3 51.410 ~ 51.440(2.024 ~ 2.025)
4 51.160 ~ 51.190(2.014 ~ 2.015)
Camshaft deflection limit mm(in) 0.8(0.00079 ~ 0.000709)
Camshaft end play mm(in) Standard 0.02 ~ 0.18(0.00079 ~ 0.000709)
Limit 0.3(0.0118)
Item Specification
Lubricating method Force-fed type
Oil Pump
Type Trochoid type
Oil pressure kg/cm2(lb/in2) 3.8(54) or more
Outer rotor and body mm(in) Standard 0.14 ~ 0.25(0.0055 ~ 0.0098)
clearance Limit 0.3(0.0118)
Pump shaft and body mm(in) Standard 0.06 ~ 0.15(0.0024 ~ 0.0059)
clearance Limit 0.1(0.0039)
Cooling System
Item Specification
Fan belt tension New belt 10 ~ 12(0.39 ~ 0.47)
(10kg force mm(in) Used belt 13 ~ 16(0.51 ~ 0.63)
Fan Type Blower
Number of blades 6
Outer diameter mm(in) 430(16.93)
Item Specification
Thermostat Opening temp C(F) 82 L 1.5(179.6 L 34.7)
Full-open temp C(F) 95(203)
Full-open lift mm(in) 8.0(0.31)
Water pump Type Centrifugal, timing belt driven
Radiator Type Corrugated
Cap valve opening 1.0 L 0.15(14.2 L 2.1)
Pressure kg/cm2(lb/in2)
Item Specification
Idle speed rpm 1100 L 25
Injection timing ATDC 2
2 2
Injection pressure kg/cm (lb/in ) 135 ~ 140(1920 ~ 1991)
Item Specification
Charging system
Starting system
Engine
For Skid Steer Loaders
D430 Diesel Engine
1760XL(DSL802)
2060XL(DSL902)
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as
shown below.
WARNING
The Message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most
current information available.
Lubrication System
Lubricating Circuit ..................................................28
Oil Pump ................................................................29
Oil Pressure Relief Valve .......................................31
Oil Pressure Switch ................................................31
Checking Oil Pressure ...........................................31
Oil Filter ..................................................................32
Cooling System
Cooling Circuit .........................................................33
Antifreeze Solution ..................................................34
Radiator Inspection .................................................34
Thermostat ..............................................................34
Water Pump.............................................................35
V Belt and Tension Adjustment .............................37
Engine Disassembly
Disassemble the engine following the order numbered in Figs. 1-4, 1-5, 1-6 and 1-7.
Fig.1-4
(1) Exhaust manifold. (2) Alternator/bracket. (3) Injection pipe/nozzle holder/fuel leak pipe. (4) Oil filter.
(5) Fuel filter/separate mount on frame. (6) Intake manifold. (7) Cooling fan/belt/pulley assembly. (8) Water pump assembly
(9) Oil cooler assembly. (10) Thermostat housing assembly
(12) Hose band. (13) Bleeder hose. (14) Bolt/seal washer. (15) Rocker arm cover/gasket. (16) Cylinder head bolt/washer.
(17) Rocker arm assembly. (18) Push rod. (19) Cylinder head bolt/washer. (20) Cylinder head. (21) Head gasket. (22) Cotter.
(23) Valve spring upper seat. (24) Oil deflector. (25) Valve spring outer. (26) Valve spring inner. (27) Valve spring lower seat.
(28) IN./EX. Valve. (29) Valve Cap.
(29) Crank pulley lock bolt. (30) Crank pulley. (31) Timing gear cover. (32) Oil deflector. (34) Crank shaft gear. (35) Nut. (36) Nut.
(37) Idle gear thrust plate. (38) Idle gear. (39) Injection pump drive gear. (40) Idle gear spindle. (44) Bolt. (45) Washer.
(46) Flywheel. (47) Bolt/washer. (48) Flywheel housing. (49) Bolt/washer. (50) Seal. (51) Oil pan. (52) Gasket.
(54) Bolt/washer. (55) Rear oil seal assembly. (56) Gasket. (57) Bolt/washer. (58) Oil pump lock screw/nut. (59) Oil pump assembly.
(60) Bolt/washer. (61) Cam shaft/gear assembly. (62) Bolt/washer. (63) Timing gear case. (64) Gasket. (65) Tappet.
(66) Connecting rod cap/bearing/bolt/nut. (67) Piston/connecting rod assembly. (68) Main bearing cap bolt. (69) Main bearing cap.
(70) Main bearing/thrust bearing. (71) Crank shaft. (72) Main bearing/thrust bearing.
Remove the injection pump gear, using the gear Remove the piston pin by using the piston pin
puller installer
Fig.1-9
Fig.1-10
Loosen the lock screw of oil pump and remove the oil
pump.
Fig.1-14
Fig.1-13
Fig.1-16
Fig.1-19
Fig.1-17
Check the clearance with a suitably mounted dial
indicator, or feel the clearance by moving the valve
Out of squareness should be less than 3 mm. per
stem back and forth.
100 mm (0.03 in per 1.00 in).
Standard:
IN. 0.046 ~ 0.096 mm (0.0018 ~ 0.0038 in)
Valve Inspection EX. 0.059~ 0.109 mm (0.0023 ~ 0.0043 in)
Limit; 0.127 mm (0.0050 in)
Fig.1-18
Fig 1-21
Fig.1-22
Fig.1-24
Standard:
0.016 ~ 0.061 mm (0.0006 ~ 0.0024 in)
Limit:
0.070 mm (0.0028 in)
Fig.1-25
Fig.1-28
Fig.1-31
Fig.1-29 3. Place the piston in the cylinder bore below the ring
travel, using a piston head to push the ring in
sequarely.
Check the clearance between each piston and
Check the piston ring end gap.
cylinder by measuring the diameter of the piston and
If it exceeds limit, the piston ring must be replaced.
cylinder bore. Refer to Liner Inspection for the bore
measurement procedure. Measure the piston
Limit: 1.5 mm (0.06 in)
diameter at 90 degrees to the pin bore axis and 58.4
mm (2.299 in) below the piston top.
If it is excessive the piston or liner must be replaced.
Checking Piston Pin and Bush
Standard:
0.187 ~ 0.212 mm (0.0074 ~ 0.0084 in)
Fig.1-32
1. Check to see that the fir of the bush and piston pin
is 0.014~0.044 mm (0.001~0.002 in).
If it exceeds limit, the bush or piston pin must be
Fig.1-30 replaced.
Standard:
0.050 ~ 0.096 mm (0.0020 ~ 0.0038 in)
Limit:
0.3 mm (0.012 in)
Fig.1-34
Fig.1-35
Check the connecting rod alignment by using a feeler
gauge and an aligner. The standard deflection is less 2. Measure the diameter of each crankpin and main
than 0.05 mm per 100 mm (0.0020 in per 4 in). If journal. If the wear exceeds limit, the crankshaft
realignment is necessary, correct by using a press should be ground to the under size of 0.254 mm
and applying a gradual pressure to the rod. (0.01 in) or replaced.
3. Check the crankshaft run-out. 2. Measure the diameters of the camshaft journals.
If it is not within the specification, correct with a
press or replace. The permissible diameters of the journals are in
the following table.
Max. allowable run-out 0.05 mm (0.002 in)
Permissible Diameter
Front No. 1 51.902 mm (2.0434 in)
No. 2 51.652 mm (2.0336 in)
Camshaft Inspection No. 3 51.402 mm (2.0237 in)
Rear No. 4 51.152 mm (2.0139 in)
Standard clearance:
0.06~0.12 mm (0.0024~0.0047 in)
Fig.1-37
Fig.1-40
Checking Idle Gear and Spindle Replace if the contact surface of the tappet with the
cam is worn abnormally.
Fig.1-41
Standard: To check the push rod for bend, place the push rod
0.034~0.084 mm (0.0013~0.0033 in) on the surface plate and determine the clearance
Limit: between the push rod and surface plate with a feeler
0.15 mm (0.006 in) gauge. If it exceeds 0.19 mm (0.007 in), repair or
replace with a new one.
Press
Fig.1-44
Installation:
Press
Fig.1-45
NOTE:
1) New liner supplied as spare parts should be
installed with lighter pressure than the removing.
2) There is no necessary to hone the cylinder liner
bore after installation.
Fig.1-46
(1) Piston pin. (2) Clip. (3) Piston ring. (4) Piston/connecting rod assembly. (5) Connecting rod bearing. (6) Tappet.
(7) Main bearing/thrust bearing. (8) Crank shaft. (9) Main bearing cap. (11) Cap bolt. (12) Connecting rod bearing/cap/bolt/nut.
(13) Idle gear spindle. (14) Gasket. (15) Timing gear case. (16) Bolt/washer. (17) Camshaft/gear assembly. (18) Bolt/washer.
(19) Gasket. (20) Rear oil seal assembly. (21) Bolt/washer. (22) Gasket. (23) Oil pump assembly. (24) Bolt/washer.
(25) Lock bolt/nut.
(26) Crank shaft gear. (27) Injection pump drive gear. (28) Idle gear. (29) Idle gear thrust plate. (30) Nut. (31) Nut.
(32) Oil deflector. (33) Gasket. (34) Timing gear cover. (35) Gasket. (36) Oil pan gasket. (37) Oil pan. (39) Bolt/washer.
(40) End plate. (41) Bolt/washer. (42) Flywheel. (43) washer. (44) Bolt. (49) Crank pulley. (50) Bolt.
(51) Valve/spring assembly. (52) Head gasket. (53) Cylinder head. (54) Push rod. (55) Rocker arm assembly.
(56) Cylinder head bolt/washer. (57) Cylinder head bolt/washer. (58) Rocker arm cover/gasket. (59) Bolt/seal washer.
(60) Bleeder hose. (61) Hose band.
(62) Water pump assembly. (63) Thermostat casing assembly. (64) Oil cooler assembly. (65) Intake manifold.
(66) Fuel filter assembly. (67) Oil filter/oil pipe. (68) Injection pipe/nozzle holder/fuel leak pipe. (69) Cooling fan/V belt/fan pulley.
(70) Alternator/bracket. (72) Exhaust manifold.
Fig.1-51
Fig.1-52
Checking main bearing oil clearance. Install the caps to the connecting rods, ensuring that
the identification numbers are matched.
1) Place the plastigauge on the main journal in the
axial direction. NOTE: After tightening the nut turn the crankshaft
2) Tighten the cap bolts to 11.0~11.7 kgm (80~85 and make sure that the rotation is light and smooth.
lbft).
Oil clearance:
New ...........0.059~0.090 mm (0.0023~0.0035 in)
Limit.....................................0.12 mm (0.0047 in)
Fig.1-59
Oil clearance
New ..........0.036~0.076 mm (0.0014~0.0030 in)
Fig.1-57
Limit ....................................0.10 mm (0.0039 in)
Standard:
0.14~0.39 mm (0.006~0.015 in)
Limit:
0.4 mm (0.016 in)
Oversized thrust washer:
0.178 mm (0.007 in)
Check the connecting rod side play with a dial- Install the idle gear spindle, aligning the oil hole.
indicator or feeler gauge.
Standard:
0.239~0.330 mm (0.009~0.013 in)
Limit:
0.4 mm (0.016 in)
Fig.1-63
Fig.1-61
Fig.1-54
Standard:
0.1~0.2 mm (0.004~0.008 in)
Limit:
0.3 mm (0.012 in)
Check the idle gear end play with a feeler gauge. Cut off the excess gaskets along the mounting
surfaces of the oil pan.
Standard:
0.15~0.30 mm (0.006~0.012 in) Before installing the oil pan, make a final internal
inspection.
Apply a thin coat of gasket past on the oil pan.
Fig.1-66
Fig.1-69
Checking Compression
Pressure
Fig.1-70
Compression pressure:
Standard Limit
30.0 kg/cm2 (427 lb/in2) 27.0 kg/cm2 (384 lb/in2)
at 200rpm at 200 rpm
Special Tools :
Lubricating Circuit
Fig.2-1
Fig.2-2
(1) Bolt/washer. (2) Oil pipe. (3) Gasket. (4) Bolt/washer. (5) Oil strainer. (6) Gasket. (7) Bolt/washer.
(8) Cover. (9) Drive gear. (10) Rotor/shaft assembly. (11) Outer rotor. (12) Pin. (13) Inner rotor.
(14) Drive shaft. (15) Relief valve assembly.
Fig.2-5
Fig.2-4
Fig.2-6
Fig.2-8
Fig.2-9
Fig.2-10
4. Start the engine and check that the joints are not
leaking. Top up with oil if necessary.
Cooling Circuit
Fig.3-1
Antifreeze Solution
To prevent freezing, add anti-freeze solution to the
water which lowers the freezing point of the coolant.
Before adding anti-freeze, inspect the cooling system
to be sure it is clean and leaktight.
Removing Thermostat
3
2
1
Fig.3-3
Fig.3-6
Fig.3-8
Installing Thermostat
Follow the removal procedure in the reverse order.
Fill the cooling system. Operate the engine and
check for leaks.
Fig.3-9
Fig.3-10
(1) Nut/washer. (2) Bearing housing. (3) Gasket. (4) Pulley boss. (5) Snap ring. (6) Shaft, spacer/bearing assembly. (7) Impeller.
(8) Seal assembly. (9) Bearing. (10) Spacer. (11) Bearing. (12) Baffle plate. (13) Dust seal.
(14) Snap ring.
Fig.3-12
NOTE:
1) Adjust the belt tension, as discribed in V Belt and
tension adjustment.
b) Fill the cooling system. Operate the engine and
check for leaks.
Fig.4-2
Fig.4-5
Fig.4-8
Fig.4-10
4
3
Fig.4-9
4. Aim the light of the tachometer onto the reflecting 2. Loosen the lock nut 3 of the idle adjust bolt and
tape to confirm the engine speed. adjust the play by turning the idle adjust bolt 4.
5. Adjust the idle speed if the engine speed is not NOTE: Idle speed will increase when the adjust bolt
within the specified value. is turned clockwise and decrease when turned
counter clockwise.
Standard idling speed:
1100 L 25 rpm 3. After the adjustment, race the engine two or three
times to inspect the returning of the accelerator
wire.
Bolt
Fig.4-14
2. Remove the bolt and gasket installed on the 5. When it is confirmed that the dial gauge needle
distributor head of the injection pump. does not deflect, set the needle to O on the
scale.
Fig.4-13
Fig.4-15
3. Set the measuring device on the injection pump.
Make sure that the tip of the feeler needle of the 6. Turn the flywheel in the normal direction until TDC
measuring device is in contact with plunger end at is indicated.
this time. The injection timing is normal when the dial gauge
needle of advanced 1.00 mm ahead of the value
set in the above 5.
Fig.4-16 Fig.4-17
When the cam lift is larger than 1.00 mm, turn the
injection pump all the way in the engine revolving
direction once, and then turn it in the reverse
direction once, adjusting the cam lift to the 1.00 mm
point.
If the cam lift is smaller than 1.00 mm, adjust the lift Key groove
by turning the pump in the direction inverse to the
engine revolving direction. Fig.4-18
NOTE:
Support bracke Before installing the key on the drive shaft of the
injection pump, lightly tap the key groove of the
shaft with a hammer to assure that the key is tightly
inserted in the key groove.
After installing the injection pump, evacuate air.
Fig.4-19
Drive gear tightening torque:
4.0 - 7.0 kgm (29 - 51 lbft).
Fig.4-20
14. Remove the injection pump. 3. Continue to pump until fuel flows from the air
Gradually remove the injection pump by pressing bleeder screw hole free of air bubbles.
the pump gear against the injection pump side,
ensuring not to drop the key into the gear case. 4. Depress the fuel pump priming plunger and close
the fuel filter air bleeder screw. Secure the priming
15. Remove the extractor. plunger by turning clockwise.
Fig.4-22
Fig.4-25
Fig.4-26
(1) Joint bolt & Gasket. (2) Fuel Leak pipe. (3) Injection pipe.
(4) Nut. (5) Nozzle holder. (6) Gasket & Dust seal. Fig.4-27
(1) Nozzle nut. (2) Nozzle. (3) Body. (4) Cap nut. (5) Gasket.
As the function of the injection nozzles greatly (6) Spring adjust screw. (7) Nozzle spring seat.
influences the engine performances, all the injection (8) Nozzle spring. (9) Push rod.
nozzles must be checked at every 3,000 km (2,000
miles) according to the following method. NOTE:
1) Greatest possible care should be taken in handling
the nozzles as they are the parts with high
precision.
Removing Nozzle Holder 2) As the nozzle and the needle valve are in pairs,
mixing up of the original combinations must be
Remove the nozzle holder following order numbered
prevented by disassembling and washing one
in Fig. 4-37.
nozzle assembly after another separately.
3) Carbon deposit on the nozzle body must be
removed with a piece of hard wood. However, it
would be advisable not to clean the surrounding
area of the nozzle orifice to avoid possible
damage to the orifice.
After cleaning, wash the nozzle body in clean
gasoline in a container.
Fig.4-28
Fig.4-30
Fig.4-33
Fig.4-31
Fig.4-32
Summary
Structural View
Fig.5-1
(1) Alternator. (2) Glow plug. (3) External resistor. (4) Glow cord. (5) Battery. (6) Starting motor. (7) Oil pressure switch.
(8) Magnet valve (Fuel cut solenoid). (9) Water temperature gauge unit.
Troubleshooting
Trouble Possible Cause Action to be Taken
Starting motor does Battery and related parts
not turn, or turns too Faulty contact of battery terminals Clean and tighten
slowly to start the Faulty grounding of negative cable Clean and repair
engine Voltage drop caused by discharging Charge
Insufficient voltage caused by faulty battery Charge
Engine switch (ignition switch)
Faulty contact on engine switch Replace
Loose engine switch wiring and connectors Repair
Broken wire between engine switch and magnetic switch Repair or replace
Magnetic switch and related parts
Loose wiring and connectors Repair
Faulty contact of magnetic switch contact plate Replace
Broken wire of magnetic switch pull-in coil Replace
Broken wire of magnetic switch holding coil Replace
Starting motor and related parts
Faulty contact of brushes Repair replace
Fatigued brush spring Replace
Faulty grounding of field coil Replace
Faulty soldering of field coil Repair
Faulty commutator Repair
Faulty grounding of armature Replace
Wear on parts Replace
Starting motor turns, Insufficient battery capacity Charge
but the engine does Quick start system and related parts
not start Faulty glow plug relay control unit Replace
Faulty glow plug relay Replace
Faulty glow plug Replace
Starting motor turns, Tip of overrunning clutch pinion is worn Replace
but pinion gear does Raced overrunning clutch Replace
not mesh with ring Faculty sliding surface of spline Repair or replace
gear Worn bushing Replace
Worn ring gear Replace
Starting motor turns Sticking contact plate of magnetic switch Replace
continuously and Layer short of magnetic switch coil Replace
does not stop Engine (ignition) switch does not return properly Replace
Disassembling Alternator
Fig.5-5
(1) Brush/holder assembly. (4) Rotor/vane. (5) Through bolt. (6) Rear housing assembly. (7) Front housing assembly.
(8) Nut/washer. (9) Pully/fan. (10) Spacer. (11) Front housing. (12) Rotor/bearing. (13) Rear housing. (14) Stator/heat sink.
Separate the rear housing assembly. To check for ground, connect one prod to the core
and the other to each lead wire.
Remove the heat sink attaching screws and remove If a ground is present, the current will flow and the
the heat sink from the rear housing. stator coil must be repaired or replaced.
Alternator Inspection
Fig.5-10
b. Checking rotor
To check for open circuit place both prods of an
Fig.5-8
ohmmeter on the slip rings. If the reading is 5~6
ohms, there is no trouble in the rotor.
a. Checking stator coil
Check the stator coil. To check for open, connect To check for ground, connect one prod to the slip
the prods to each of the two leads. If there is no ring and other prod to the core.
flow of current, the coil is open circuit and must be If the current flows, the rotor must be repaired or
repaired or replaced. replaced.
Fig.5-11
c. Checking diodes
To check diode, read the resistance between the
lead wire and case with a tester.
Fig.5-12
Standard tension
350 L 52.5 gr (0.8 L 0.12 lb)
Fig.5-17
(1) Weak battery. (2) Corroded or loose battery terminal. (3) Loose starting motor terminal.
(4) Broken or loose wires of the starting circuit. (5) Faulty ignition switch.
Fig.5-18
(1) Field strap. (2) Screw. (3) Magnet switch/plunger. (4) Through bolt. (5) Rear cover. (6) Insulator/washer. (7) Yoke assembly.
(8) Rubber ring/spring/driving lever. (9) Center bracket. (10) Armature assembly. (11) Stop ring. (12) Piston stop coller.
(13) Over running clutch/pinion. (14) Screw/pole core. (15) Brush spring/brush.
Fig.5-19
Drive the pinion stop collar toward the armature, and Fig.5-21
remove the stop ring.
Then, slide the stop collar and over-running clutch off Place a armature against the core of the growler
the armature shaft. tester, and hold a steel strip on the armature. Then,
rotate the armature slowly by hand. If the armature
coil is shorted, the steel strip will become magnetized
and vibrate. Replace the armature if a short is found.
Inspecting Starting Motor
b. Checking commutator
a. Checking armature
Ground test:
Fig.5-20 Fig.5-22
Touch one prod of an ohmmeter to each segment If the commutator is dirty, discolored or worn, clean it
and the other prod to the core or shaft. with emery paper and wash with clean solvent. After
An infinite reading should be obtained for each cleaning. undercut the mica between the segment to
segment. the depth of 05 ~ 0.8 mm (0.020 ~ 0.031 in) shown in
If the meter reading is not infinite, the armature Fig. 5-20.
windings are shorted to the core and shaft, and the
armature must be replaced.
Fig.5-23
Fig.5-25
To test the field coil for ground with a tester, place
one prod on the yoke or pole core and the other prod
to the field terminal. (for each prod) Apply the specified voltage (12V) between the S
If it is grounded, the current will no flow, and the field terminal and M terminal. If the magnetic switch is
coil must be repaired or replaced. forcefully attached, the pull-in coil is in good
condition.
d. Checking brushes and brush springs
b. Holding coil test
Fig.5-26
Fig.5-24
Ground the (M) terminal to the magnetic switch body
The brushes should be replaced when one - third of with lead and impose the specified voltage (12V)
the original length is worn away. upon the S terminal to pull in the plunger. If the
plunger remains attracted after disconnecting the
Standard length lead at the (M) terminal, there is no trouble with the
19 mm (0.748 in) holding coil.
Standard tension
2.0 L 0.3 Kg (4.4 L 0.661 lb)
Fig.5-27
Specified current
200A or less at 3,000 rpm. or more
Voltage 3.0V
NOTE: When the magnetic switch is engaged, the Current 1200A or less
clearance between the pinion and stop collar should Torque 3.5 kgm
be 0.5~2.0 mm (0.020~0.079 in).
This clearance can be adjusted by inserting the
adjusting washer between the magnetic switch body
and the driving housing.
Engine switch
Fig.5-31
2. Resistor
4. Glow plug
Valve seat
Valve seat angle
Inlet 45
Exhaust 30
Valve seat width
Inlet 2.0 mm (0.079 in)
Exhaust 2.0 mm (0.079 in)
Valve guide
Protrusion from cylinder head 16.5 mm (0.6496)
Inner diameter 7.988~8.014mm (0.3145~0.3155in)
Stem to guide clearance limit 0.127 mm (0.005 in)
Valve-Inlet
Overall length 114.5 mm (4.5079 in)
Head diameter 40 L 0.1 mm (1.5748 L 0.0039 in)
Face angle 45
Stem diameter
Standard 7.925~7.950mm (0.3120~0.3130in)
Limit 7.880 mm (0.3102 in)
Valve margin
Limit 1.35 mm (0.0532 in)
Valve-Exhaust
Overall length 114.6 mm (4.5118 in)
Head diameter 36 L 0.13 mm (1.4173 L 0.0051 in)
Face angle 30
Stem diameter
Standard 7.912~7.937mm (0.3115~0.3125in)
Limit 7.867 mm (0.3097 in)
Valve margin
Limit 1.35 mm (0.0532 in)
Valve spring-Outer
Wire diameter 4.5 mm (0.177 in)
Outer coil diameter 38.0 mm (1.496 in)
Free length
Standard 45.9 mm (1.807 in)
Limit 43.6 mm (1.717 in)
Fitting length 40.3 mm (1.587 in)
Fitting load
Standard 18.0 L 0.9 Kg (39.7 L 2.0 lb)
Limit 14.5 Kg (32.0 lb)
Oil
4.743~4.763 mm
(0.1867~0.1875 in)
Side clearance
Top
0.050~0.096 mm
(0.0020~0.0038 in)
Second
0.050~0.096 mm
(0.0020~0.0038 in)
Oil
0.050~0.096 mm
(0.0020~0.0038 in)
End gap
Top
0.4~0.6 mm
(0.0157~0.0236 in)
Second
0.4~0.6 mm
(0.0157~0.0236 in)
Oil
0.4~0.53 mm
(0.0157~0.0209 in)
Crankshaft
Main journal diameter
Standard
75.812~75.825 mm
(2.9848~2.9853 in)
Inner diameter
95.025~95.050 mm
(3.7412~3.7422 in)
Outer diameter
98.551~98.576 mm
(3.8800~3.8810 in)
Flywheel
Run-out
Limit 0.20 mm (0.0079 in)
2. LUBRICATING SYSTEM
Oil pressure 3.6 Kg/cm2(51 lb/in2) and more
at 3600rpm
Safe minimum pressure at idle 0.3 L 0.1 Kg/cm2
(4.3 L 1.4 lb/in2)
Oil pump
Outer rotor and body clearance
Standard 0.14~0.20 mm
(0.006~0.008 in)
Limit 0.30 mm (0.012 in)
Clearance between rotor lobes
Standard 0.04~0.20 mm
(0.002~0.008 in)
Limit 0.30 mm (0.012 in)
Rotor end float
Standard 0.04~0.10 mm
(0.002~0.004 in)
Limit 0.15 mm (0.006 in)
Clearance between pump shaft and
body 0.10 mm (0.004 in)
3. COOLING SYSTEM
Fan belt tension (Slack)
New belt 10~13 mm (0.39~0.51 in)
Used belt 13~16 mm (0.51~0.63 in)
Fan
Fan diameter 430 L 2 mm (16.93 L 0.08 in)
Number of blades
6
Ratio of crankshaft and fan
Thermostat 1 : 1.25
Type Wax pellet
Starts to open 82 L 1.5C (180 L 2.7F)
Fully opens at 95C (203F)
Lift 8 mm (0.315 in) or more
5. ELECTRICAL SYSTEM
Alternator
Ground polarity Negative
No load test
Voltage 14 volt
Current 0 amp.
Revolution 950 rpm or less
Load test
Voltage 13.5 volt
Current 56 amp.
Revolution 5000 rpm or less
Starting motor
Lock test
Voltage 3.0 volt
Current 1200 amp. or less
Torque 3.5 kgm
Vehicle Systems
For Skid Steer Loaders
1550XL(DSL702)
1760XL(DSL802)
2060XL(DSL902)
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
1
Index
Specifications
Dimensional & Performance Specifications ..............5
Service Schedule ....................................................12
Special Torque.........................................................13
R S
Q
Q R
T G F S T G
F
O O
K K
M
A M
A
B B
L L C
C
I
I N
J U
N J U H
P
P H E
E D
D
IGAT001I
Spec. Spec.
Item Unit 1550XL 1760XL 2060XL Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902) (DSL702) (DSL802) (DSL902)
Overall Height Dumping
A. Fully Raised in(mm) 145.8(3704) 152.8(3880) 156.2(3967) K. Dump Angle deg 45 40 44
B. To Hinge Pin in(mm) 114.8(2915) 119.1(3026) 122(3100) L. Dump Height in(mm) 87.6(2224) 91.5(2323) 93.6(2378)
C. To Canopy in(mm) 76.9(1954) 79.3(2015) 80.1(2035) Reach
Overall Length M.Fully Raised in(mm) 25.4(645) 22.5(572) 27.3(694)
D. With Bucket in(mm) 126.3(3208) 125.1(3177) 126.0(3200) Rollback
E. Less Bucket in(mm) 99.3(2521) 987(2508) <
------- N. Max. at Ground deg 25 26 <
-------
Overall Width O. Max. Fully Raised deg 94 98 94
F. With Bucket in(mm) 63.4(1611) 67.5(1714) 70(1778) Digging
G. Less Bucket in(mm) 58.5(1486) 65.4(1662) <
------- P. Digging Depth in(mm) 0.6(16) 0.4(10) <
-------
Others Clearance (Circle)
H. Wheel Base in(mm) 42.3(1074.8) 41.8(1061) <
------- Q. Front, Less Bucket in(mm) 51.3(1304) 45.1(1146) <
-------
I. Height of S.I.P. in(mm) 35.8(908.5) 40.9(1040) <
------- R. Front, With Bucket in(mm) 74.8(1901) 74.1(1883) 76.3(1939)
J. Ground Clearance in(mm) 7.5(190) 8.4(218) <
------- S. Rear in(mm) 63.3(1607) 62.7(1593) 61.8(1570)
T. Tread in(mm) 48.1(1222) 53.1(1350) <
-------
U. Departure Angle deg 26 28 <
-------
Overall Operating Height (A) - Fully Raised - The Digging Depth (P) - The vertical distance in inches
vertical distance in inches (millimeters) from the (millimeters) from the ground to the bottom of the
ground to the highest point attainable. bucket cutting edge at the lowest position with the
bucket cutting edge horizontal.
Height to Hinge Pin (B) - Fully Raised - The
vertical distance in inches (millimeters) from the Loader Clearance Circle (Q) - Front No
ground to the centerline of the bucket hinge pin. Attachment - The smallest diameter measured in
inches (millimeters) that the outermost front point on
Overall Height (C) - The vertical distance in inches
the machine will describe measured from a point
(millimeters) from the ground to the highest point on
located at 1/2 the wheelbase (H) and 1/2 the overall
the unit with the bucket on the ground.
width (G) of the machine.
Overall Length (D) - The horizontal distance in
Loader Clearance Circle (R) - Front with Standard
inches (millimeters) with the bucket on the ground
Attachment - The smallest diameter measured in
and level, measured from the foremost point of the
inches (millimeters) that the outermost front point on
bucket cutting edge to the rear most point of the
the machine will describe measured from a point
machine.
located at 1/2 the wheelbase (H) and 1/2 the overall
Overall Length (E) - Without Bucket - The width (G) of the machine.
horizontal distance in inches (millimeters) from the
Loader Clearance Circle (S) - Rear - The smallest
furthest rearward to the furthest point forward.
diameter measured in inches (millimeters) that the
Bucket Width (F) - The maximum outside width in outermost rear point on the machine will describe
inches (millimeters) of the bucket specified. measured from a point located at 1/2 the wheelbase
Overall Width (G) - The maximum outside width in (H) and 1/2 the overall width (G) of the machine.
inches (millimeters) of the machine specified exclusive Tread or Track Gauge (T) - The transverse distance
of bucket. in inches (millimeters) between the centerlines of the
Wheelbase (H) - The vertical distance in inches tires or sprockets. If the front and rear are different,
(millimeters) from the center of the front wheel or both must be specified.
idler to the center of the rear wheel or sprocket. Angle of Departure (U) - The angle in degrees
Height to S.I.P. (I) - The vertical distance in inches taken from a line drawn from the lowest and rear
(millimeters) from the ground to the Seat Index Point. most portion of the rear overhang to the rear bottom
face of the rear tire to the ground.
Ground Clearance (J) - The minimum vertical
distance in inches (millimeters) from the ground to
the lowest point on the machine between the tires or
tracks with the lift arm raised.
Dump Angle (K) - The maximum angle in degrees
that the longest flat section of the inside bottom of
the bucket will rotate below horizontal with the bucket
hinge pin at maximum height.
Dump Height (L) - The vertical distance in inches
(millimeters) from the ground to the lowest point of
the cutting edge with the bucket hinge pin at
maximum height and the bucket at a 45 dump
angle. The angle is less than 45, specify angle.
Reach (M) at Maximum Height - The horizontal
distance in inches (millimeters) from the foremost
point on the machine (including tires, tracks, or
loader frame) to the front most point on the bucket
cutting edge at a 45 angle with the bucket hinge pin
at maximum height. Specify angles less than 45.
Maximum Rollback (N) - at Ground - Maximum
rollback angle in degrees without movement of the lift
arm.
Performance
Spec.
Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Rated Capacity lb(kg) 1500 (680) 1700(771) 2000 (907)
Bucket Capacity ft3(m3) 11.9 (0.34) 13.5(0.38) 14.1 (0.40)
Operating Weight lb(kg) 5849 (2653) 6594(2991) 6777 (3074)
Tipping Load lb(kg) 3946 (1790) 3593(1630) 4647 (2108)
Hydraulic Lifting Capacity lb(kg) 4465 (2025) 5732(2600) 4718 (2140)
Break Out Force - Bucket lb(kg) 2910 (1320) 3770(1710) 3770 (1710)
- Boom lb(kg) 3285 (1490) 3467(2480) 5194 (2356)
Raising Time - W/O Load sec 5.1 3.7 4.6
- W/ Load sec 5.3 3.8 4.7
Lower Time - W/O Load sec 4.4 3.5 5.1
- W/ Load sec 3.8 3.1 4.3
Boom Dump Time - W/O Load sec 3.3 2.3 2.3
- W/ Load sec 2.3 2.2 2.1
Rollback Time - W/O Load sec 1.9 1.8 1.8
- W/ Load sec 2.0 2.2 2.3
Drawbar Pull - W/O Load lb(kg) 4923 (2233) 5291(2400) 5282 (2396)
- W/ Load lb(kg) 5908 (2680) 6305(2860) 6499 (2948)
Forward mph(km/h) 6.7 (10.8) 6.8(11.0) 6.77 (10.9)
Travel Speed
Reverse mph(km/h) 6.7 (10.8) 6.8(11.0) 6.77 (10.9)
Power Unit
Spec.
Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Make - DAEWOO <
------- <
-------
Model - D427 D430 <
-------
Type of Fuel - Diesel <
------- <
-------
Cooling Medium - Water <
------- <
-------
No. of Cylinders ea 4 <
------- <
-------
Displacement in3(cc) 164.8 (2701) 181.7 (2977) <
-------
Bore Size in(mm) 3.62 (92.0) 3.74 (95) <
-------
Stroke in(mm) 4.0 (101.6) 4.13 (105) <
-------
Horsepower Net hp(ps)/rpm 50.2 (51.0)/2400 62.6 (63.5)/2500 <
-------
High Idle rpm 2600 50 265050 <
-------
Low Idle rpm 1100 25 <
------- <
-------
Torque ft.lb(kg.m)/rpm 115.8 (16.0) 130.2 (18.0) <
-------
2000 1800 <
-------
Torque Rise % 3.0 8.6 <
-------
Lubrication - Full Flow <
------- <
-------
Spec.
Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Chain - 2 Chain with 2 Chain with
Super80HT & RS 100HT & <
-------
Super80HT RS 100HT
No. of Teeth
Drive Sprocket (Motor) ea 12 10 <
-------
Drive Sprocket (Axle) ea 32 28 <
-------
Ratio 2.67 2.8 <
-------
Tire
Type - Flotation- <
------- <
-------
Tubeless
Size - 10-16.5, 8PR 12-16.5, 8PR <
-------
2
Pressure psi(kg/cm ) 57 (4.0) 40(2.8) <
-------
Wheel
Size - 8.25 X 16.5 9.75 X 16.5 <
-------
Hole x Pitch Circle Diameter - 8 X 8 <
------- <
-------
Spec.
Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Type - Piston, Variable
Displacement <
------- <
-------
(Manual)
Max. Displacement in3(cc)/rev 2.68 (44) <
------- <
-------
Relief Setting Pressure bar (psi) 250 (3555) 280(4061) <
-------
Internal Charge Pump - None <
------- <
-------
Rotation - clockwise <
------- <
-------
Swash Plate Operating Angle deg 16 <
------- <
-------
Mounting - SAE 2 Bolt B Mount <
------- <
-------
ANSI B92.1-1970
Shaft - Class No.5 <
------- <
-------
30X15X16/32
Standard Pump
Flow (Max) LPM(GPM) 60 (16) 77.7(20.5) <
-------
Relief Pressure (max) psi 300035 <
------- <
-------
at charge pump (2072.4bar) <
------- <
-------
High Flow Option Pump
Flow (max) LPM(GPM) 101(26.7) 131.5(34.8) <
-------
Relief Pressure (max) psi 300035 <
------- <
-------
at charge pump (2072.4bar) <
------- <
-------
Spec.
Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Motor
Type - Orbit, Fixed <
------- <
-------
Displacement
Bi-rotational
Displacement in3(cc)/rev 32.04 (523.6) <
------- <
-------
Mounting - SAE 4 Bolt B Mount <
------- <
-------
Spline Shaft
Pump
Type - Gear <
------- <
-------
Capacity in3(cc)/rev 1.47 (23.0) *1.92(31.5) <
-------
Max. Pressure bar(psi) 230 (3,335) <
------- <
-------
Max. Speed rpm 3,000 <
------- <
-------
Mounting - SAE 2 Bolt A Mount <
------- <
-------
Shaft SAE Spline Shaft <
------- <
-------
Rotation - Clockwise <
------- <
-------
Control Valve
No. of Spool - 3 <
------- <
-------
Relief Setting Pressure psi 2840 (+70) <
------- <
-------
(set by valve supplier) (195 (+5) bar)
Circuit - Series on Lift Float <
------- <
-------
Function with Detent
Series on Tilt
Series on Auxiliary
With Electric
Detent (thumb control)
Spec.
Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Boom Cylinder
Type - Single Rod, <
------- <
-------
Double Acting
Number ea. 2 <
------- <
-------
Cylinder Bore in(mm) 2.17 (55) 2.36(60) <
-------
Cylinder Rod in(mm) 1.58 (40) 1.50(38) 1.57(40)
Stroke in(mm) 39.2 (996) 33.5(850) 42.0(1065)
Mounting - Single Crest Crevice <
------- <
-------
Plating on Rod - Hard Chrome w/15-50 <
------- <
-------
Micron Thickness
Bucket Cylinder
Type - Single Rod, Double Acting <
------- <
-------
Number ea. 2 <
------- <
-------
Cylinder Bore in(mm) 2.36 (60) <
------- <
-------
Cylinder Rod in(mm) 1.10 (28) 1.50(38) 1.57(40)
Stroke in(mm) 14.45 (367) 20.0(507) <
-------
Mounting - Single Crest Crevice <
------- <
-------
Plating on Rod - Hard Chrome w/15-50 <
------- <
-------
Micron Thickness
HRC 52-60 Hardness
Electrical Components
Spec.
Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Alternator - 12V - 60A <
------- <
-------
Battery - 12V-100AH, 700CCA <
------- <
-------
Starter - 12V - 2.5KW <
------- <
-------
Lighting -
Head Lamps each 2 <
------- <
-------
Rear Lamps each 1 <
------- <
-------
Spec.
Item Specifications Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Fuel Tank, Max #2 Diesel recommended for Ambient gal(liter) 14.3(54) 21.1(80) 18.2(69)
Temp above 40 deg. F
#1 Diesel recommended for Ambient
Temp below 40 deg. F
Hydraulic Max Oil Tank SAE 10W20CD; Taxaco TDH; Mobil gal(liter) 8.0 (30) 9.2(35) 11.9(45)
Hydraulic System Capacity Fluid 423; Chevron Tractor Hydraulic gal(liter) 11.1 (42) 12.7(48) <
-------
Fluid; G Automatic Fluids meeting
Caterpillar TO-2 or Allison C3 standards
Chain Case Oil API CC or CD SAE 10W30 gal(liter) 5.9 (22.5) 6.3(24) <
-------
Cooling Fluid Recommended mixture is 50/50 gal(liter) 1.8 (6.9) <
------- <
-------
ethylene glycol and water
Engine Lubrication - w/filter API CC or CD SAE 10W30 for gal(liter) 2.1 (8) <
------- <
-------
w/o filter Ambient Temp above -4 deg. F gal(liter) 2.0 (7.6) <
------- <
-------
API CC or CD SAE 5W30 for
Ambient Temp below -4 deg. F
105 20 N.m
240 40 N.m
55 10 N.m
28 7 N.m 55 10 N.m
USE EXISTING HARDWARD
SUPPLIED WITH ENGINE
USE EXSISTING HARDWARD
SUPPLIED WITH ENGINE
100 30 N.m
& APPLY LOCTITE (NO.271)
55 1 N.m
2 EACH, SIDE
AS REQ'D
54 ~ 68 N.m
Mount gp-Covers
15-25N.m 15-25N.m
Loctite #592
15-25N.m
Loctite #592
Initial Torque 200 20 N.m, and loosen bolt, Loctite #2C(gasket sealant)
then retorgue 50 5 N.m(Loctite #271) on the frange of Motor
Start By :
Start By : 1 2
3
IGAT007P
4
6 5
5 2 3
IGAT005P
IGAT006P
End By :
8 WARNING
End By :
4 12,13
19
6,17
5 7
8,14,15 3 20
1
18
2
9,10,11
21
16
1 WELDMENT 1. Remove the cotter pin, washer, and clevis pin at the
2 ROD AS lever assembly end.
3 WASHER 2. Remove the cotter pin, washer, and clevis pin from the
4 WASHER rod end.
5 NUT ; LOCK 3. Remove the spring pin and separate the wedge, spring,
6 PIN ; COTTER and rod.
7 WASHER
8 PIN
9 PIN ; GUIDE
10 PIN ; SPLIT
11 WASHER ; HARD
12 HANDLE-L.H.
13 HANDLE-R.H.
14 WASHER ; PLAIN
15 PIN ; SPLIT
16 WEDGE
17 NUT
18 SPRING
19 BUSHING
20 WASHER ; HARD
21 NIPPLE ; GREASE
IGAT010P
4
7
IGAT012P IGAT015P
8
5
IGAT016P
IGAT013P
5. Disassemble the hose-RH (7) and the hose-LH
(8). Remove the bucket cylinder (2).
IGAT011P IGAT013P
7. Hoist the bucket cylinder (2) and put the bucket 9. Install the pin assembly (6) and bolt and washer
cylinder (2) in position on inside of the boom. (5).
IGAT015P IGAT012P
End By :
IGAT016P
5
1
IGAT010P
IGAT018P 8 3
2 3
1550XL(DSL702), 2060XL(DSL902)
Spacer (2.3t)
Plate-stopper (6t)
IGAT020P Boom
Rubber
1760XL(DSL802)
IGAT022I
IGAT021P
1
5
4
IGAT027P
IGAT024P 5. Remove ring - retaining (2) and link (3), nuts (4),
then dis connect parking cable assembly (5).
2. Remove the stopper-plastic (1) from the canopy
hinge mtg. bracket (RH, LH).
IGAT025P
6. Remove the cotter pin (8) and pin, then loosen the
nut (9) and disconnect the cable assembly (10).
IGAT032I
IGAT030P
7. Remove the cotter pin (11) and pin (12) from the
gas spring (13) where it attaches to the frame.
IGAT033P
2
3
18-22 ft.lb
IGAT034I
1
4
2 3
VIEW A-A
A A
2
IGAT035I
Adjustment Procedure
Removal
The parking brake system includes the brake lever
assembly, 2 brake assemblies (1 on each side), 2
cable assemblies (1 set of 2 on each side), and
associated linkages, springs, and fasteners.
SPRING
DISC
BELL CRANK(C)
02-8
1) Remove the chain case covers to access the Remove the parking brake
parking brake assemblies.
2) Place the parking brake lever in the release
assemblies (each side).
position.
1) Remove the 2 springs at bellcrank assembly (C).
3) Remove the spring (A) to release tension.
2) Remove the bolts and washers that mount the
4) Remove the cotter pin and clevis pin from the
parking brake assembly to the frame and lift out
clevis at the brake lever.
the brake assembly.
5) Loosen the bolts and clamp that hold the cable
assem-blies to the frame bracket and slide the
cables out of the bracket.
6) Remove the cotter pin and clevis pin from the
clevis at the end of the cable assembly where it
attaches to the seat bar.
7) Unscrew the clevis from the end of the cable.
8) Disconnect the cable where it attaches to the
frame at (B).
9) Remove the remaining fasteners from the cable
and remove the cable assembly from the frame.
m
76m
SPRING
DISC
BELL CRANK(C)
Wire
Position "B"
Stopper Bracket
Upper-Plate
WARNING
1) Lift the frame and support it with jack stands so 2) Remove the upper covers and gaskets on chain
that the tires are off the ground. case.
2) Support the tire and remove the hub nuts. 3) Remove the rectangular covers and gaskets on
the outside frame, 4 Axle covers on the in side
3) Lift the wheel and tire by the rim and pull it free of frame
the wheel studs.
Remove the parking brake components.
Remove the chain case covers.
Follow the procedures under Parking Brake System
Removal.
WARNING
1) Remove the bolt, washer and driven sprocket. CAUTION : Be sure to install the spacer between the
bearing cone and the sprocket.
2) Remove the axle. Bearing cones are removed
from inside the chain case. CAUTION : Check the direction of sprocket
installation. Install the front and rear drive sprockets
CAUTION : Check for damage to the oil seal when according to the marks you made on their faces at
you pull out the axle. disassembly.
For installation, refer to the photos and illustrations 4) Initially, tighten the bolt to 200 L 20 Nm (147 L
with the removal steps, above. 15 ftlbs.).
1) Check the oil seal and the inside and outside 6) Back off the bolt until it will turn by hand.
bearing cups before installing the axle shaft.
Replace any of these components if damaged. 7) Retighten the bolt to 50 L 5 Nm (38 L 4 ftlbs.)
with Loctite#271.
2) Install the axle shaft with outside bearing cone in
place.
Take care not to damage the oil seal in the axle
housing.
1760XL(DSL802)
1550XL(DSL702)
2060XL(DSL902)
A-B 17 ~ 26 18 ~ 27
S(mm)
C-D 26 ~ 39 24 ~ 36
Start By:
IGAT046P
End By : 1550XL(DSL702)
Control Valve
1760XL(DSL802), 2060XL(DSL902)
Remove & Install Hydraulic Control Valve
1. Disconnect hoses and wire.
1 1
IGAT058P
1. Remove 4 bolts and washers (1) from frame.
1760XL(DSL802)
2 3
1
1550XL(DSL702), 2060XL(DSL902)
2. Remove nuts (2) and bolts (3). 2. Remove bolts and nuts, washers (1) at both sides.
4
5
3
2
6
IGAT059P
1760XL(DSL802)
3. Remove nuts and clamp (4), tail tube (5). 3. Remove nuts (2) and washers, shims and rubbers
(3) at both sides.
4. Remove muffler (6).
IGAT060P IGAT061P
1760XL(DSL802) 1760XL(DSL802)
4. Disconnect oil and cooling lines (4). 5. Pull out radiator and oil cooler assembly (5) by two
persons, disconnect radiator-out hose(6).
"A" "A"
IGAT062I
Torque to
206~225 N.m
(Socket Bolt)
(Element as - Insert R)
Clean Assembly
Face of Flywheel
(Element as-Insert A)
(Spring Pin)
(Hub-Spline)
Element As-Element)
Torque to
196~225 N.m
4.0 M AX
IGAT063I
STEP 1 : Make each items and assembling face of STEP 5 : Assemble hub and rubber element on fly
fly wheel clear. wheel with 3 hex socket bolt (tightening w/specified
torque).
STEP 2 : Assemble the spring pins(6ea) on the hub-
spline. (projection height of spring pin : MAX.4mm). *ATTENTION : Hex socket bolt assembly
STEP 3 : Assembling the hub into the rubber 1) Apply very little grease on bolt seat face(never let
element, make sure the spline direction correct, and the thread contaminanted with grease. erf. fig.1).
tighten 3 hex socket bolt with specified torque
aligning spring pin locations. 2) Loctite is coated on hex socket bolt(colored blue)
for anti-loosening.
STEP 4 : Assemble spring pins(3EA) on fly wheel The loctite can be workable within 3 times of
(projection height of spring pin : MAX. 4mm). assemble and disassemble.
WARNING
IGAT064P
2. Loosen the nuts (1) that hold the wheel and tire in
place.
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
Systems Operation
Hydraulic System.......................................................5
HST System...............................................................6
Hydraulic Control Valve .............................................8
Optional Bucket Self-Leveling System ....................13
HST Pump ...............................................................19
HST Motor ...............................................................20
Specifications
Hydrostatic Systems ................................................22
Hydraulic Systems ...................................................23
Hydraulic System
8
To Valve Block
2
1 14
13
IGAT065I
(1) HST Pump. (2) Hydraulic Pump. (4) Control Valve. (5) Boom Cylinder. (6) Bucket Cylinder. (7) Quick Coupling. (8) Quick Coupling.
(13) Suction Strainer. (14) Hydraulic Tank.
The hydraulic pump (2) is driven by a shaft through pressure reaches the setting pressure of relief valve
the hydrostatic (HST) pump (1). The fluid flows from (3000psi), it will open and let the fluid by-pass the
the hydraulic tank to the hydraulic pump (2), then hydraulic circuit internally and go to the valve block.
goes from the hydraulic pump to control valve (4). When the spool goes back to neutral position, there
The pump draws hydraulic oil from the tank and is fluid available for the other sections of the control
charges the hydraulic system with hydraulic power valve (4). Two sections of the control valve can be
converted from engine power. used at the same time as long as the main relief
valve is not open.
When all three spools (boom, bucket, attach) of the
control valve are in neutral position, the fluid goes
through the control valve (4) and the valve block. If
one of the spools is activated by pedal (boom,
bucket) or electric rocker switch (attach), the fluid
goes out respective port and to either the base end
or the rod end of cylinders (5, 6), or attachment is
operated. As the fluid goes into one end of the
cylinders (5, 6), the fluid from the other side of
cylinder flows back into the control valve. The control
valve (4) has an adjustable relief valve. When the
cylinders (5, 6) reach the end of the stroke, the fluid
11 12
From Control Valve
3
9
2
10 14
IGAT066I
Schematic for 1760XL(DSL802) and 2060XL(DSL902)
(1) HST Pump. (2) Hydraulic Pump. (3) HST Motors. (9) Valve Block. (10) Drain Relief Valve. (11) Oil Cooler. (12) Hydraulic Filter.
(14) Hydraulic Tank.
11 12
From Control Valve
3
9
2
10 14
IGAT066I
Schematic for 1550XL(DSL702)
(1) HST Pump. (2) Hydraulic Pump. (3) HST Motors. (9) Valve Block. (10) Drain Relief Valve. (11) Oil Cooler. (12) Hydraulic Filter.
(14) Hydraulic Tank.
There are two parts of hydrostatic pump (1) and two The filter (12) has a by-pass valve (50psi, check
hydrostatic motors (3). One part of hydrostatic pump valve and 40 psi pressure switch) to allow fluid flow
and one of hydrostatic motors work together as a pair when the fluid will not go through the filter element
to drive one side of the loader. The other part of (plugged).
pump and the other motor work as a pair to drive the
opposite side of the loader. The valve block (9) works as a cooler-by-pass valve
and surge valve (for 1760XL/DSL802 and
When the driving levers are in neutral, hydrostatic 2060XL/DSL902). The by-pass valve (20 psi, check
pump (1) and the hydrostatic motors (3) are not valve) of valve block will open when the boom arms
working, but have charge pressure. When the driving are lowered quickly with heavy load in the bucket.
levers are moved, the swashplates in the hydrostatic For 1760XL/DSL802 and 2060XL/DSL902, when the
pump are angled and the fluid is forced out of the pressure which works against the oil cooler is higher
pressure side of hydrostatic pump and goes to than 220 psi at the same condition, the relief valve
hydrostatic motors. (220 psi) of valve block will open to protect the oil
cooler (11) and filter (12). The by-pass valve (20 psi)
of oil cooler (11) will also open when the fluid is cold
and is thick to go through the cooler and filter.
INE
N K L ort
TA p
T
6
5
4 8
orts
P
A
ts
P or
B
RE
2
E SSU ort Monoblock Valve Body
PR P p
IGAT067I
P1 A1 B1 A2 B2 A3 B3 T
SC1
SC3
MV SC2
CV1 CV2 CV2
210 bar 10 bar
3000 psi 145 psi
P
BPV
S1 S2 S3
IGAT068I
1760XL(DSL802)
P1 A1 B1 A2 B2 A3 B3 T
SC1
SC3
MV
SC2
CV1 CV2 CV2
210 bar 10 bar
3000 psi 145 psi
P
BPV
S1 S2 S3
1 0
Tank Passage
Free Line
3 1 0 2
To Next Section
Oil return from work port A B or to Tank
3 1 0 2
To Next Section
A B or to Tank
P T
P T
IGAT070I
A B
A B
0 2
0 3
3 1 0 2
3 1 0 2
A B A B
P T
P T
IGAT071I IGAT072I
When the free line passage is closed, the oil Oil discharged from the pump returns to the valve
discharged from the pump flows to port A. block through the tank line. A and B are connected.
The return oil from port B is returned to the other
section (series) or goes through the free passage.
The spool is retuned to neutral by the return spring
when released.
A1 A2 A3
IN
P OUT
ON OFF ON
B1 B2 B3
12 VDC Battery
IGAT073I
C D
IGAT074I
Boom Cylinder
Port A
Adjustable Orifice
Boom
Pump Input
Port B Spool
Flow Divider Spool Out
Control Valve
with Fixed Orifice Bucket
Spool
Return
Neutral
Unloading
Spool
Port C Port D
Bucket Cylinder
IGAT075I
Boom Cylinder
Port A
Unloading
Spool
Port D
Port C
Bucket Cylinder
Stroked Out
IGAT076I
Boom Cylinder
Port A
Lift Check
Boom
Pump Input Spool
Port B In
Control Valve
Bucket
Return Spool
Neutral
Port C Port D
Bucket Cylinder
IGAT077I
Boom Cylinder
Port A
Boom
Pump Input Spool
Port B
Neutral
Control Valve
Bucket
Spool
Return
Out
Lift Check
Unloading
Spool
Port D
Port C
Bucket Cylinder
IGAT078I
Boom Cylinder
Port A
Boom
Pump Input Spool
Port B Neutral
Control Valve
Bucket
Return Spool
In
Lift Check
Unloading
Spool
Port D
Port C
Bucket Cylinder
IGAT079I
General Description
Case Drain
Bypass Valve
IGAT081P
Above pictures show three positions of the rotor, the
corresponding rotor center movements, and the
locations of pressure and return chambers
respectively.
Hence 1/9 shaft revolution corresponds to 8/9 rotor A simple rotary channel plate guides the fluid so that
center revolution causing the oil from 8 fluid pressure and suction chambers rotate synchronously
chambers to be displaced, i.e. that one shaft with the rotor, thus causing continuous rotation.
revolution gives 8 revolutions of the rotor centre with
displacement of 72 chambers.
Outer Ring
IGAT083P
Disc Valve
Zero Position Channel Plate
Rotor
Revolution of Rotor
Center
1/14 Shaft Rotation
Hydrostatic Systems
Hydrostatic Transmission Pump
IGAT084I
Hydraulic Systems
Hydraulic Pump
Control Valve
Boom Cylinder
Bucket Cylinder
Fluid Capacity
Specification
Item Unit
1550XL(DSL702) 1760XL(DSL802) 2060XL(DSL902)
Fuel Tank (Maximum) gal (liter) 14.3(54) 21.1 (80) 18.2(69)
Hydraulic Maximum Oil Tank gal (liter) 8.0(30) 9.2 (35) 11.9(45)
Hydraulic System Capacity gal (liter) 11.1(42) 12.7 (48) 12.7(48)
Chain Case Oil gal (liter) 5.9(22.5) 6.3(24) 6.3(24)
Cooling Fluid gal (liter) 1.8(6.9) 1.8 (6.9) 1.8(6.9)
Engine Lubrication - with filter gal (liter) 2.1(8.0) 2.1 (8.0) 2.1(8.0)
Without filter gal (liter) 2.0(7.6) 2.0 (7.6) 2.0(7.6)
Oil Type
WARNING
There is leakage of oil inside the The piston seals are worn and Replace seals. Or replace cylinder
cylinder or loss of boom or let oil go through. assembly.
bucket power. Cylinder has damage. Replace cylinder assembly.
Foreign material behind the The wiper rings show wear and do Replace wiper rings.
wiper rings which causes not remove dirt and foreign material.
scratches on the cylinder rod.
Too much drift. Defective boom cylinder seals. Inspect and replace seals.
Defective control valve. Replace spool. Or replace control
valve assmbly (with changing oil).
OK
Check Control Input Check System Pressure
(Linkage, Pressure, Differential
Current)
More Than
Defective
50 PSI
Repair or Adjust
Replace Swashplate Neutral
OK
Replace
Pump
OK High
Low
Fill to Proper Repair or
Level Replace
Reduce
Transmission
Inspect Load
Inspect OK OK Inspect
Charge Relief
Charge Pump Inlet Filter
Valve
Replace
Repair or Repair or
Replace
Replace Replace
Transmission
(Pump & Motor)
Inspect System
Replace
Check Control OK Check/Relief OK
Transmission
Linkage Valves or Charge
(Pump and Motor)
Check Valves
Defective Defective
Repair or Repair or
Replace Replace
OK
Low in Neutral & Forward
or Reverse
Inspect Defective
Inspect OK OK Inspect
Charge Relief
Charge Pump Inlet Filter
Valve
OK
Repair or
Defective Defective Clogged Replace
OK
Repair or Repair or
Replace
Replace Replace
Replace
Transmission
(Pump & Motor)
Lock nut
Check & Adjusting Procedure of Relief Pressure
of Control Valve
A1 A2 A3
1. If attachment is installed on the truck, take it out
from truck. OUT
IN
2. Check the engine speed. It should be 2640 L 50
rpm (1550XL/DSL702) or 2730 L 50rpm
(1760XL/DSL802 and 2060XL/DSL902), if it is not
adjusted. B1 B2 B3
Bypass Valve
HST Pump
NOTE : Only trained personnel should disassemble.
When making repairs on hydrostatic systems, clean
the work area before disassembly and keep all parts
clean. Mark the match points on housing.
5
IGAT090P
1
2 3
IGAT088P
4 16
IGAT091P
1
7 8 9 10
11
IGAT089P
IGAT092P
12
IGAT093P IGAT096P
6. Remove screws (12) from the pump. 9. Remove the valve plate (17) from the end cap
Separate the front and rear sections of pump. (16).
(Front pump is engine side and rear pump is
hydraulic pump side).
19
14
13 18
IGAT097P
24
7. Remove coupling (13) and O-ring (14) from the 22
front pump.
21 23
15
IGAT098P 20
8. Remove screws (15) and the end cap (16) with the
valve plate from the front pump.
19
25
31
30
IGAT099P IGAT102P
12. Remove the retaining ring (25) from the housing 16. Remove the screws (30) and the trunnion covers
(19) using plier. (31) (mark the position of cover for re-assembly).
27
28
32
IGAT103P
IGAT100P
17. Remove both bearings (32).
28 33
34
29
IGAT104P
IGAT105P
IGAT106P
IGAT107P IGAT110P
4. Remove O-ring (3) and channel plate (4) from the 7. Remove valve drive (7).
valve housing (2).
IGAT111P
IGAT108P
6
10
IGAT109P IGAT112P
6. Remove balance plate (6) from the valve housing. 9. Remove O-ring (10) from gear wheel set (8).
Apply some clean oil for removal, if needed.
16
IGAT113P IGAT116P
10. Remove cardan shaft (11) from bearing housing 14. Remove shaft and bearing assembly (16) from
(9). bearing housing.
11. Separate bearing housing from the vise. Followings are procedures for assembly of HST
motor.
12
16
13
IGAT114P
IGAT116P
12. Remove six screws (12) and front cover (13) from
bearing housing. 15. Install shaft and bearing assembly (16) to bearing
housing (9).
14
14
15
15
13
13
IGAT115P
IGAT115P
13. Remove shaft seal (14) and O-ring (15) from front
cover (13). 16. Install shaft seal (14) and O-ring (15) to front
cover (13).
13 8
IGAT119P IGAT111P
17. Install front cover (13) to bearing housing (9) and 20. Install gear wheel set (8) to bearing housing (9).
tighten six screws (12) with torque of 24 L 2 Nm
(210 L 17 lbin).
7
8
10
IGAT110P
IGAT112P
21. Install valve drive (7) to gear wheel set (8).
11
IGAT124P
IGAT113P
22. Install channel plate (4) with O-ring to gear wheel
set.
19. Install cardan shaft (11) to bearing housing (9).
IGAT125P IGAT105P
23. Install disc valve (5) to channel plate (4). 26. Tighten four bolts with the torque of 140 L 5 Nm
(100 L 4 lbft).
1
2
IGAT109P
2
IGAT129P
2
IGAT106P
IGAT130P
23 19
5 22
21
IGAT131P IGAT134P
3. Remove boot (5) and coil (6). 7. Remove joint (19), piston (21), flange (22), O-ring
(23), spool control kit (20) and end cap (24).
11 9 16
28
27
25
26
15 14 13 12 10 8 7
IGAT132P
IGAT135P
26
18 28
IGAT136P
6. Remove flange (17) and O-ring (18). 10. Remove back-pressure valve body from the
control valve.
30
29
43
IGAT137P IGAT139P
11. Remove main relief valve (29) from the control 15. Remove load check valve (43) from the control
valve. valve.
12. Remove four screws (30) and float detent spool 16. Assemble control valve in the reverse order of
control kit (31). disassembly. Refer to following torques when
installing.
34
38 Main relief valve.........................42 Nm (31 lbft).
Back-pressure valve ..................42 Nm (31 lbft).
33 39 Load check valve .......................24 Nm (18 lbft).
35 40
41
36
32
42
37
IGAT138P
IGAT140I
1. Place the boom cylinder in a vice and remove the 6. Remove the bushing (17) from the knuckle and
rod cover (3). head cover.
2. Remove rod assembly (2) from the cylinder 7. Assemble the boom cylinder in the reverse order
assembly. of disassembly.
IGAT140I
1. Place the boom cylinder in a vice and remove the 6. Remove the bushing (17) from the knuckle and
rod cover (3). head cover.
2. Remove rod assembly (2) from the cylinder 7. Assemble the boom cylinder in the reverse order
assembly. of disassembly.
IGAT141I
1. Place the bucket cylinder in a vice and remove the 6. Remove the bushing (19) from the knuckle and
rod cover (3). head cover.
2. Remove rod assembly (2) from the cylinder 7. Assemble the bucket cylinder in the reverse order
assembly. of disassembly.
IGAT141I
1. Place the bucket cylinder in a vice and remove the 6. Remove the bushing (18) from the knuckle and
rod cover (3). head cover.
2. Remove rod assembly (2) from the cylinder 7. Assemble the bucket cylinder in the reverse order
assembly. of disassembly.
14
2
ITEM COMPONENTS
1 HST PUMP
2 HYDRAULIC PUMP
3 HST MOTOR
4 CONTROL VALVE
5 BOOM CYLINDER
6 BUCKET CYLINDER
7 QUICK COUPLING
8 QUICK COUPLING
9 VALVE BLOCK
10 DRAIN RELIEF VALVE
10
15 11 OIL COOLER
12 HYDRAULIC FILTER
13 13 SUCTION STRAINER
14 ONE DIRECTIONAL RESTRICTOR
15 CONNECTOR WITH SCREEN FILTER
51
Hydraulic Schematic for 1760XL(DSL802) 8
7
6
11
12 14
5
OPTIONAL SELF LEVELING
B2
A2
BUCKET
CYL.
4
BOOM
B1 CYL.
A1
3 1
2 ITEM COMPONENTS
1 HST PUMP
2 HYDRAULIC PUMP
3 HST MOTOR
4 CONTROL VALVE
5 BOOM CYLINDER
3 6 BUCKET CYLINDER
7 QUICK COUPLING
8 QUICK COUPLING
9 VALVE BLOCK
15
10 DRAIN RELIEF VALVE
10 11 OIL COOLER
12 HYDRAULIC FILTER
13 SUCTION STRAINER
13 14 ONE DIRECTIONAL RESTRICTOR
15 CONNECTOR WITH SCREEN FILTER
52
Hydraulic Schematic for 2060XL(DSL902) 8
7
6
11 9
14
12
5
OPTIONAL SELF LEVELING
B2
A2
4 BUCKET
CYL.
BOOM
B1 CYL.
A1
1
3
2
ITEM COMPONENTS
1 HST PUMP
2 HYDRAULIC PUMP
3 HST MOTOR
4 CONTROL VALVE
5 BOOM CYLINDER
6 BUCKET CYLINDER
7 QUICK COUPLING
8 QUICK COUPLING
3
9 VALVE BLOCK
15
10 DRAIN RELIEF VALVE
10
11 OIL COOLER
13 12 HYDRAULIC FILTER
13 SUCTION STRAINER
14 ONE DIRECTIONAL RESTRICTOR
15 CONNECTOR WITH SCREEN FILTER
53
SB4038E00
Jul. 2000
Electric Systems
For Skid Steer Loaders
1550XL(DSL702)
1760XL(DSL802-D430)
2060XL(DSL902)
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
The Preheat Controller controls the operation of the Glow Plugs to give better starts to a cold engine.
The controller will turn ON the Preheat Lamp for 5 seconds and also activate the Preheat Relay for 7 seconds.
According to the temperature which is sensed by Thermal Sender, the time of After Heating will be set after starting.
Electric Systems
3. Preheating & Charging System (1550XL(DSL702), 2060XL(DSL902))
5
Preheating & Charging System
The Preheat Controller controls the operation of the Glow Plugs to give better starts to a cold engine.
The controller will turn ON the Preheat Lamp for 5 seconds and also activate the Preheat Relay for 7 seconds.
According to the temperature which is sensed by Thermal Sender, the time of After Heating will be set after starting.
4. Instrument Panel Layout (1760XL(DSL802-D430))
9 10 8 11 14 13 12 15
2 3 4 5 6 7 1 16 17 18 19
A C B D E
15 3 4 2 5 14 11 E D
B
12 10 8 6 9 7 13 A C
- Relay, solenoid valve, spool motion of control valve and direction of pump flow to attachment quick coupler port
D2 relay
Pushing switch(D) -Keep depressing ON relay FWD solenoid Spool-out Down side
left handside F1 relay
of button, F2 relay
-After that D1 relay
releasing button D2 relay
control & detent control
Pushing switch(D) -Keep depressing ON relay REV solenoid Spool-in Upper side
right hand side R1 relay
of button, R2 relay
-After that D1 relay
releasing button D2 relay
Pushing button(C) Pushing switch(E) Either way - - - -
Available Options
Strobe light
Horn
Back up buzzer
Heater
Cigar lighter
The light turns on when the temperature of the The light turns on when the temperaturre of the
engine cooling water exceeds 110C (230 F). hydraulic oil to drive HST goes up to 100C (212 F).
The light turns on when the engine oil pressure is The light turns on when the pressure of the HST
below 0.5 kg/cm2(15 psi). pump oil falls below 6.0 kg/cm2 (85 psi).
If the oil filter becomes clogged, the light turns on. The light turns ON when the water exceeds 100cc
in the fuel filter.
The light turns on simultaneously with Charge HST Step 1 : Two front lights turn on.
oil temperature, HST pressure and oil filter warning Step 2 : Two front lights and one rear light turn on
lights. simultaneously.
The light turns on simultaneously with water When the key is turned to the IGN position, the
temperature and engine oil pressure warning lights. glowplug relay turns on this light.
Raising the hand lever, the parking brake is The buzzer is activated simultaneously with water
engaged and the light turns on. temperature and engine oil pressurre warning lights.
13.1. Test Equipment NOTE 1 : The DSL has no electrical shutdowns, only
visual and auditory indicators.
The following items should be sufficient to allow you
to perform most electrical troubleshooting operations NOTE 2 : The lighting, instrument panel, and start
on the electrical system. (key switch) fuses (and horn fuse-optional, if
equipped) located in the right-side instrument panel
Volt/ohmmeter (Multimeter) are all 15-amp tube-type fuses.
Jumper wires (variety of lengths) with alligator clip
ends The following troubleshooting guide presents
Needle tips possible causes and actions in a logial order from
External 12-volt source simplest/most likely to more complex/less likely
Wiring diagrams (more drastic). For any symptom, if a given action
does not identify the problem, proceed to the next
action.
WIRING SCHEMATIC-ELECTRIC
MODEL : 1760XL(DSL802)
(FOR D430 E/G)
2
WIRING SCHEMATIC-ELEC
MODEL : 1550XL(DSL702), 2060XL(DSL902)
WARNING
Do not start, operate or service this machine unless you have read and understood these instructions
and received proper training.
Unsafe or improper use of the machine may cause serious injury or death.
Operators and maintenance personnel must read this manual and receive training before operating or
maintaining the machine.
This manual should be kept with the machine for reference and periodically reviewed by the machine
operator and by all personnel who will come into contact with it.
The following warning is povided pursuant to California Health & Safety Code Sections 25247.5 et, seq,
WARNING
California Proposition 65
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
S-1
FOREWORD
This manual explains the safety rules, lubrication, testing and controls to operate and maintain the DAEWOO Skid
Steer Loader for safe and optimal performance.
The operator should be familiar with all of the contents of this manual before starting the vehicle to insure maxi-
mum performance, safety and economy.
Descriptions explain the testing, starting, operation, and stop procedures in detail.
To maintain the vehicle in top condition, the operator should periodically check the vehicle in accordance with the
service schedule.
The periodic maintenance intervals in this manual are based on the service hour meter.
Environment Management
Note that DAEWOO INDUSTRIAL VEHICLE DIVISION is ISO 14001 certified which is harmonized with ISO 9001
Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by
internal and external inspection entities. LIFE - CYCLE ANALYSIS has also been made through out the total prod-
uct life. ENVIRONMENT MANAGEMENT SYSTEM includes DESIGN FOR ENVIRONMENT from the initial stage
of the design.
ENVIRONMENT MANAGEMENT SYSTEM considers environmental laws & regulations, reduction or elimination of
resource consumption as well as environmental emission or pollution from industrial activities, energy saving, envi-
ronment - friendly product design(lower noise, vibration, emission, smoke, heavy metal free, ozone depleting sub-
stance free, etc.), recycling, material cost reduction, and even environmentally oriented education for the employee.
S-2
SAFETY INFORMATION
HA0OA00I
S-3
SIGNAL WORDS
S-4
WARNING SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual and all safety labels
on your machine. Keep safety labels in good condition. Replace missing or CAU
TIO
N
NING
damaged safety labels. Be sure new equipment components and WAR
repair parts include the current safety labels. Learn how to operate the
machine and how to use controls properly. Do not let anyone operate
the machine without instruction. Keep your machine in proper working
condition. Unauthorized modifications to the machine may impair operator
safety and well being and/or machine life and function.
HA0OA01I
ONLY trained and authorized personnel should operate and maintain the machine.
Use common sense and follow all safety rules, precautions and instructions when operating or perform-
ing maintenance on the machine.
When working with another person, be sure all hand signals to be used are understood.
Certain operating conditions may require reference to applicable OSHA, ANSI, ISO, EEC or other local
and national regulations. Consult your supervisor or safety coordinator to be sure all applicable stan-
dards are being followed, and for special operating conditions.
Never operate equipment under the influence of drugs or alcohol. Certain prescription and over-the-
counter medications can affect alertness and coordination. Follow instructions on labels and/or consult
your physician. Notify your supervisor or consult your physician for clarification.
S-5
CONTENTS
S-7
cont. 2.0 SAFETY INFORMATION
S-8
S-9
cont. 6.0. OPERATING INSTRUCTIONS
S-10
S-11
cont. 7.0 PERIODIC MAINTENANCE
S-12
1. OWNER/OPERATOR SAFETY also includes establishing daily inspections
OVERVIEW and scheduled maintenance practices to
ensure the equipments ongoing safe operat-
1.1. Safety Message for Owners and ing condition.
Operators
The manual you are reading now is intended
Your DAEWOO equipment has been designed to help you meet your responsibilities. It iden-
with the safety of the persons who will operate tifies warning labels on the equipment and
and service it in mind. However, our care in explains what they mean. It describes some
designing this equipment does not guarantee of the general and specific hazards to be
that it will be used in a safe manner. Safe aware of when operating the equipment. It
operating practice is where your responsibility also offers some suggestions for establishing
and the responsible actions of the persons workplace rules and operator training pro-
who operate this equipment take over. grams.
-1-
options. This section of the manual discuss- Recognize and avoid potential hazards in
es these issues as well. your workplace.
At the end of this overview, we list specific Understand and abide by the Warning labels
OSHA, ANSI, and other published resources attached to the equipment.
you can consult for ways to help you comply Inspect the equipment for its serviceability at
with safety requirements for the use of this the beginning of each shift.
equipment in your workplace. Report immediately any service problems you
notice before you use the equipment or that
1.1.2. Operator Responsibility develop while you are using it.
Report immediately any unsafe workplace
If your job includes operating this equipment,
conditions that threaten your safety or the
you should first get formal training in how to
safety of others.
operate it properly and safely. Furthermore,
Avoid horseplay or other reckless actions that
you should ensure that your workplace is
you know endanger yourself or others.
maintained to assure your continued safety
and the safety of others around whom you
In short, every operator of this equipment has
work.
the responsibility to use common sense at all
times and to make safety his or her number
In addition, you, the operator, have the
one job priority.
responsibility to:
-2-
1.2. Maintaining a Safe Workplace
As we said, operators should recognize and When the equipment is driven onto trailers, use
avoid hazards in the workplace. Although some wheel chocks and jack supports if necessary to
injuries occur because of unsafe operating prevent creeping and possible collapse.
practices, many result from unnecessary work- Develop - and enforce - workplace safety rules
place hazards. To maintain a safe workplace for all employees.
environment for this equipment, do the follow- Post these rules conspicuously in the areas
ing: where they apply.
Remove physical hazards where the equipment Many appropriate workplace rules are published
will be operated, in either the plant or the yard. by OSHA, ANSI, and the National Safety
Separate pedestrian and equipment traffic Council. (See the list below under Information
wherever possible. Resources for Operation, Maintenance, and
Place convex mirrors at blind intersections. Safety.) We recommend that you consult
Require the use of horns at intersections or these publications as you develop and update
when approaching pedestrian areas. the safety rules for your workplace.
Establish equipment speed limits.
Install and maintain backup alarms and flashing
caution lights on equipment.
Use edge guards, levelers and trailer locks on
docks.
-3-
-4-
1.4. Maintenance Practices 1.5. Operator Safety Training
Well maintained equipment is safer equipment. Although this manual contains much informa-
A regular program of scheduled maintenance tion about safety practices, it is not meant to be
should be part of your facilitys ongoing safety a training manual for new operators. An
program. Daily inspections or inspections at employers responsibility extends beyond hand-
the start of every shift are required by OSHA. ing an employee this or any other document
Your DAEWOO dealer can help you train your and saying read this to learn how to operate
operators for this task and provide you with this equipment.
genuine replacement parts and service equip-
ment when scheduled (or unscheduled) main- 1.5.1. Formal Training
tenance and repairs are needed.
OSHA and ANSI require formal training for
new operators and refresher training for ex-
Although operators have a daily responsibility
perienced operators, along with appropriate
to inspect and report service problems, OSHA
on-the-job supervision. Furthermore, training
and ANSI standards require that equipment
must be tailored to the specific conditions of
maintenance and repair be performed by au-
your workplace and the workplace rules you
thorized mechanics only. Understand what is
have developed to protect your employees.
reasonable to expect in this area, and leave the
Whenever work conditions change in ways
serious maintenance and repair tasks to pro-
that affect operator safety, training for the new
fessional mechanics and technicians.
conditions must be provided. Of course,
before any employee can be selected to
-5-
operate industrial or construction type equip- In what areas of our workplace does operating
ment, the employee must meet the employ- the equipment pose hazards to pedestrians?
ers specific visual, auditory, physical and What hazards must operators be trained to
mental ability standards. deal with?
Does our workplace have any one-way aisles,
1.5.2. Inspection Training speed zones, high noise, low light, or fire haz-
ard areas?
OSHA furthermore requires that operators be
What are the specific features of our loading
trained to conduct daily equipment safety
docks, ramps, or railcar loading facilities?
inspections. The goal of these inspections is
What specialized attachments are used on our
to prevent any piece of equipment in need of
equipment?
repairs from being placed into service and
What personal protective equipment or special
thereby endangering personnel. Your DAE-
clothing is necessary to operate the equipment
WOO dealer can help you develop training to
in our work environment? (hard hats, seat
comply to this and to other OSHA/ANSI re-
restraints, respirators, protective shoes or
quirements.
gloves, etc.)
Are operators conducting daily inspections
1.5.3. Training Program Development
prior to shift start?
As noted above, OSHA/ANSI requires your Does our equipment require any special refu-
training to be designed around the conditions eling procedures?
present in your operation. To ensure this, ask
yourself specific questions: One additional recommendation: ask those
-6-
employees who work around (but do not op- 1.6. Information Resources for
erate) the equipment for suggestions about Operation, Maintenance, and
what the operators should be taught. Safety
-7-
ANSI/ASME B56.1-1988: Safety Standard for Pedestrian. Available from: National Safety
Low Lift and High Lift Trucks (Safety Code of Council, 444 North Michigan Avenue, Chicago,
Powered Industrial Trucks). Available from: IL 60611.
Society of Mechanical Engineers, United
Accident Prevention Manual for Industrial Opera-
Engineering Center, 345 E. 47Th Street, New
York, NY 10017. tions: Two volumes: Administration and
EN474-1: Earth - moving Machinery - Safety - Programs and Engineering and Technology.
General Requirements , Available from: National Safety Council, 444
EN474-3 : Earth - moving Machinery - Safety - North Michigan Avenue, Chicago, IL 60611.
Requirements for Loaders . Publications Concerning Safe Handling and
Available from: European Committee for Storage of LP Gas: Available from: National LP
Standardization, rue de Stassart, 36 B - 105C Gas Association, 1301 West 22nd Street,
Brussels.
Oakbrook, IL 60521
NFPA 58: Storage and Handling of Liquified
Other OSHA regulations which may be applica-
Petroleum Gases. Available from: National Fire
ble to the place of use.
Protection Association, Inc., Batterymarch Park,
Quincy, MA 02269. You can receive help in applying information
Skid-Steer Loader Safety Manual. Available from from these sources to your workplace by con-
the Equipment Manufacturers Institute, 10 S tacting OSHA or your Workers Compensation
Riverside Plaza, Chicago, Illinois 60606-3710. Insurance Company.
National Safety Council Data Sheets: 1-664 -
Writing and Publishing Employee Safety
Regulations; 479 - Liquified Petroleum Gases
for Industrial Trucks; 195.71 - The In-Plant
-8-
2. SAFETY INFORMATION
The following section of this manual discusses rules or take obvious precautions. Often you can
some of the general and specific safety issues avoid an accident by recognizing situations that
for your equipment. It gives you basic safety pre- might be hazardous. Furthermore, anyone who
cautions. It also shows you where to find warn- operates, maintains, or repairs this equipment
ing labels used on this equipment. The warnings should have the necessary training, skills, and
themselves are reproduced here for you to read. tools.
Before you operate or perform any maintenance Improper operation, maintenance, or repair of
on this equipment, read this Safety Information this equipment can be dangerous and could
section carefully. Also carefully read the opera- result in injury or death.
tion and other sections of this manual and heed
all of the safety information they contain. Also Do not operate or perform any lubrication, main-
locate, read, and understand the warning decals tenance, or repair on this equipment until you
on the equipment itself. have read and understood the operation, main-
tenance, and repair information in this manual.
-9-
Hazards are identified by the exclamation point every possible circumstance that might involve a
(!) Safety Alert Symbol followed by words such hazard. You must ensure that your operating
as DANGER, WARNING, or CAUTION. techniques, tools, and work procedures are safe
for you and others. You should also make sure
that the equipment will not be damaged or made
unsafe by your chosen operation, maintenance,
DANGER or repair procedures.
- 10 -
sentation that the OSHA rules and regulations 2.2. Rated Operating Load Plate
have been reproduced verbatim.
DO NOT exceed machine rated operating load
as described on the rated operating load plate
The best method for preventing serious injury or
attached to your machine.
death is for the operator to be familiar with the
proper operation of the equipment. Be alert and
avoid actions or conditions that can result in an
accident.
DAEWOO HEAVY INDUSTRIES LTD.
MADE IN KOREA
MACHINE NAME
SERIAL NUMBER
IA0OA02I
- 11 -
CAUTION
Always keep safety and information labels clean. If they are lost or damaged, attach them again or
replace them with a new label. Safety labels are available in languages other than ENGLISH. Please
contact your dealer or DAEWOO if you need non-English labels.
E E
D
2
3 4 5 6 D
1 DAEWOO HEAVY INDUSTRIES LTD. CO.
THIS STRUCTURE (CANOPY WELDMENT : DSL601-D415200.
1760XL/DSL802-D416447) HAS BEEN TESTED
AND MEETS THE FOLLOWING STANDARDS :
ROPS - ROLLOVER PROTECTIVE STRUCTURE
ISO 3471 FEB '94 AND SAE J1040 MAY '94
FOPS - 3471 FALLING OBJECT PROTECTIVE STRUCTURE
ISO 3449 MAY '92 AND SAE J1043 SEP '87
C
B
C B
A
7
A
IA4O2001
- 12 -
2.3.2. Label Descriptions
1 Danger warning for Boom lock 3 Warning for canopy latch
IA0OA12I
- 13 -
N D422635
I IA0OA07I
IA0OA09I
- 14 -
WARNING DANGER
8
9 10
3
8 Warning for general safety rules. 9 Warning for fastening seat belt and seat bar.
WARNING
WARNING
AVOID DEATH OR SERIOUS INJURY
READ AND UNDERSTAND THE OPERATOR'S MANUAL PRIOR ALWAYS WEAR SEAT BELT.
TO OPERATING THIS MACHINE FAILURE TO FOLLOW THESE ALWAYS OPERATE WITH SEAT
PRECAUTIONS CAN CAUSE INJURY OR DEATH.
CARRY LOAD LOW.
BAR IN DOWN POSITION.
AVOID STEEP SLOPES AND HIGH SPEED TURNS. AVOID SUDDEN AND ABRUPT
TRAVEL SLOWLY OVER ROUGH TERRAIN. MACHINE OPERATION.
NEVER CARRY MORE THAN RATED OPERATING LOAD.
NEVER PLACE ANY PART OF YOUR BODY UNDER BOOM NEVER CARRY RIDERS.
OR ATTACHMENTS.
KEEP BOTH FEET ON PEDALS AND BOTH HANDS ON
NEVER USE LOADER AS
CONTROLS WHILE OPERATING MACHINE. MANLIFT OR WORK
D416620
PLATFORM.
D415532
IA0OA15I IA0OA13I
- 15 -
DANGER FRAME
IA0OA14I
11 Service Shedule label
View "E-E" IA0OA18P
- 16 -
2.4. General Safety and Hazard Information
2.4.1. Unauthorized Modification
Any modification made without authorization from DAEWOO can create hazards.
Before making a modification, consult your DAEWOO dealer.
Improper modification could result in injury or death.
Improper use of safety features could result in serious bodily harm or death.
- 17 -
NEVER jump on or off the machine. NEVER get on or off a moving machine.
When mounting or dismounting, always face the machine and use the handrails.
Do not grasp or come in contact with any control levers when getting on or off the machine.
Ensure safety by always maintaining at least three-point contact of hands and feet with the
handrails and steps.
Always remove any oil or mud from the handrails, steps and shoes.
NEVER mount or dismount the machine with engine running.
HA0OA03I
- 18 -
2.4.4. Fire Prevention and Hazardous Fluids and Vapors
Fuel, oil, antifreeze, and other flammable fluids and combustibles can be ignited by a flame or hot sur-
faces. Vapors can be particularly FLAMMABLE and can be HAZARDOUS.
Keep open flame and hot surfaces away from flammable fluids and combustibles.
Stop the engine and do not smoke when refueling.
Tighten all fuel and oil caps securely.
Refueling and oiling should be done in well ventilated areas.
Keep oil and fuel in a designated area and do not allow unauthorized persons to enter.
Thoroughly remove wood chips, leaves, paper and other flammable items accumulated in the engine
compartment .
Check fuel and hydraulic systems for leaks prior to starting or using vehicle.
Have any leaks repaired before operating the machine.
Wipe up any excess oil, fuel or other flammable fluids.
Be sure a fire extinguisher is present and working and that personnel are properly trained in extin-
guisher operation.
Never use ether or other starting aids on any engine with glow plugs or other engine preheating devices.
See OSHA Class 1910.178.
Avoid skin contact, injestion and excessive breathing of vapors from fuel, oil, antifreeze, and other fluids.
See California Proposition 65 in the front of this book.
HA0OA04I
- 19 -
Before starting the engine, thoroughly check the area for any
unusual conditions that could pose a hazard.
Before starting the engine, examine the terrain and soil condi-
tions of the work site. Determine the best and safest method
of operation.
- 20 -
2.5.2. Operators Cab
Do not leave tools or spare parts lying around in the operators compartment. They may damage,
break, or interfere with the control levers or switches.
Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
Always check the seat belt, seat bar, and hardware for damage or wear. Replace any worn or dam-
aged parts. Always use seat belts and seat bar when operating your machine.
- 21 -
DANGER
,,,
VENTILATION FOR ENCLOSED AREAS
,,,
adequate ventilation. Exhaust fumes from the engine can KILL.
HA0OA07I
A standard loader or a loader equipped with a spark arrestor/spark arresting muffler cannot be
operated in these areas. Use of these machines in flammable/explosive atmospheres can result in
fires and/or explosions which could cause serious injury or death.
See Code of Federal Regulations (OSHA) 29CFR Part 1910.178, to determine where machines
which are approved and labeled as G, GS, D, DS, DY, LP, LPS, G/LP, or GS/LPS are permitted to
operate.
- 22 -
2.5.6. Precautions for Mirrors, Windows, and Lights
Always remove all dirt from the surface of the windows and lights to ensure that you can see well.
Check that the head lamps and working lamps are installed to match the operating conditions.
Check also that they light up properly.
When working in dark places, install working lamps and head lamps, and set up lighting in the
work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or other cause, and wait for con-
ditions to improve to a level that allows the operation to be carried out safely.
- 23 -
DANGER CHECK THAT NO ONE IS NEAR THE MACHINE BEFORE MOVING, TURNING,
TRAVELING IN REVERSE OR OPERATING ANY ATTACHMENTS
Keep all parts of the machine or load far away from all
electric lines.
IA0OA22S
- 24 -
2.5.10. Operating on Snow
When working on snow or icy or wet roads, even a slight slope may cause the machine to slip to
the side, so always travel at low speed and avoid sudden starting, stopping, or turning.
When there has been heavy snow, the road and objects placed beside the road are buried in the
snow and cannot be seen, so always carry out snow-clearing operations carefully.
Avoid operating your machine too close to the edge of cliffs, overhangs, loading docks, deep
ditches, and other uneven surfaces or drop-offs. If these areas collapse or you get too close to
the edge, your machine could fall or tip over and result in serious injury or death. Remember that
the soil after heavy rain or blasting is weakened in these areas.
Earth laid on the ground and the soil near ditches are loose. It can collapse under the weight or
vibration of your machine.
- 25 -
Never enter, or put your hand or arm or any other part of your body between movable parts such
as between the work equipment and cylinders, or between the machine and work equipment. If the
machine or work equipment is operated or moved, the clearance will change and this may lead to
serious damage or personal injury.
ALWAYS keep both feet on pedals and both hands on controls when operating loader.
The cab structure of the 1340XL/ DSL602 complies with the following ROPS (Rollover Protective
Structure) and FOPS (Falling Object Protective Structure) criteria. -ROPS per ISO 3471 -FOPS per
ISO 3449 Level I
Never operate without a ROPS/ FOPS approved cab.
2.5.13. Parking
- 26 -
2.5.14. Precautions for Attachments
When installing/using an optional attachment, read the instruction manual for the attachment and
the information related to attachments in the manual.
Never use attachments that are not authorized by DAEWOO or your DAEWOO dealer. Use of
unauthorized attachments could create a safety problem and adversely affect the proper operation
and useful life of the machine.
NEVER attempt to engage or disengage the Universal Attachment System (Quik-tach) levers with
the engine running.
WARNING
Load, unload and turn on flat level ground. Do not exceed machine rated operating load shown
on the rated operating load name plate attached to your machine. Failure to obey warnings can
cause the machine to tip or roll over and cause injury or death.
WARNING
Never dump over an obstruction that can enter the operator cab. The machine could tip forward
and cause injury or death.
- 27 -
WARNING
1. Never attempt to service a machine unless you are authorized and qualified to do so.
2. Before attempting any service on this machine, familiarize yourself with all instructions and warn-
ings in the operators manual and all machine decals.
3. Do not attempt to service machine unless you have the necessary skill, information, safety gear,
and tools and equipment to perform the procedure correctly.
4. While service is being performed ensure a warning tag is installed on or near the ignition key switch
and clearly visible to prevent inadvertent starting of the machine during service.
5. If a service procedure necessitates running the engine, the control levers must remain in the neu-
tral position and the emergency brake must be fully engaged. Failure to do so can result in injury
or death.
6. After completing service check for: proper operation of all controls, correct torque on all fasteners
and fittings, any fluid leaks (prior to and after starting engine), all tools and equipment must be
removed from the machine.
7. Ensure all hoisting and supporting equipment is in good repair and of adequate capacity to support
loader.
8. Failure to follow safety precautions and proper service procedures can lead to machine malfunction
or damage, injury to operator or bystanders, or death.
- 28 -
2.6.2. Precautions for High Temperature Operations
- 29 -
- 30 -
2.6.4. Precautions for High Pressure Oil
Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked
piping, tubes or hoses. They may burst during use.
Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
Be aware that the machine hydraulic circuits are always under pressure.
Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the
internal pressure.
If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil
hits your skin or enters your eyes. It also can be extremely hot. Always wear safety glasses and
appropriate gloves, and use a piece of cardboard or a sheet of wood to check for oil leakage. The
stream of oil may not be visible.
If your skin is punctured by a jet of high-pressure oil, seek a doctor immediately for medical atten-
tion.
IA0OA26I
- 31 -
Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If
you spill acid on yourself, immediately flush the area with water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into eyes, flush them
immediately with large quantities of water and see a doctor immediately.
If you accidentally swallow battery acid, drink a large quantity of water or milk, beaten egg or veg-
etable oil. Call a doctor or poison prevention immediately.
When working with batteries, ALWAYS wear safety glasses, goggles, or face shield.
Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a
small spark or flame.
Before working with batteries, stop the engine and turn the starting switch to the OFF position.
Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as
tools, across the terminals or between the hot (+) post and frame or other grounding surface.
Keep the battery terminals tightened securely. Loose terminals can generate sparks and lead to an
explosion.
When repairing the electrical system or when carrying out electrical welding, remove the negative
(-) terminal of the battery to stop the flow of current.
NEVER attempt to charge or jump start a frozen battery. An explosion may occur.
IA0OA27I
- 32 -
2.6.6. Waste Material Precautions
Always put oil drained from your machine in containers. Never drain
oil directly on the ground.
Obey appropriate state, local, and federal laws and regulations when
disposing of harmful liquids, objects, or wastes such as oil, fuel,
coolant, solvent, acids, filters, batteries and others.
HA0O1043I
Keep away from all moving or rotating parts and be careful not to let
anything get caught in them.
Never touch any rotating parts. If your body or tools touch the fan
blades or fan belt, they may be cut off or sent flying or it may pull you
into the equipment.
IA0OA28I
- 33 -
DANGER
Tires should only be mounted/dismounted from rims or repaired by trained and authorized personnel
using the proper equipment and procedures. Death or serious injury could result. See OSHA
1910.177.
- 34 -
3. SERIAL NUMBER LOCATIONS
3.1. Vehicle Serial Number 3.2. Engine Serial Number
MODEL
OUTPUT PS
DAEWOO HEAVY INDUSTRIES LTD. RPM
MADE IN KOREA
DISPLACEMENT
MACHINE TYPE SKID-STEER LOADER ENGINE NO
SERIAL NUMBER
IA0OA02I
The engine serial number tag is riveted to the
top of engine valve cover.
The vehicle serial number plate is riveted on
the inner side of left-hand mast. If you need parts, service or information for
your engine, you must give the complete
engine number to your Yanmar distributor.
- 35 -
4. MACHINE COMPONENTS
4.1. Identification of Machine Parts
Hoist points
Canopy lock
Drive levers
Seat belts
Engine
Rear door
hood
handle
Bucket
cylinder Rear door
Anti-skid
Bucket
Draw/Tiedown eyes
IA4O4001
- 36 -
Head lamps
Grab handles Seat bar Boom lock
Seat belt
Boom cylinder Seat belt Throttle Anti-skid Drive lever Brake lever Boom
cylinder
IA4O4002
- 37 -
5. CONTROLS AND INSTRUMENTS
5.1. Instrument Panel
(9) (10) (8) (11) (14) (13) (15)
STOP
FUEL
(2) (3) (4) (5) (6) (7) (1) (16) (17) (12) (18) (19)
IA0OA32I IA0OA33I
- 38 -
- 39 -
(6) HST pressure warning light (9) Stop light
The light turns on when The light turns on simulta-
the pressure of the HST neously with water tem-
pump oil falls down below STOP perature and engine oil
3.51 kg/cm2 (50psi). pressure warning lights.
(10) Buzzer
(7) Oil filter warning light
The buzzer is activated
If the oil filter becomes
simultaneously with water
clogged, the light turns on.
temperature and engine oil
pressure warning lights.
- 40 -
- 41 -
5.2. Controls 5.2.1. Drive control lever( 1 2 )
(8)
(7)
IA4O5001 IA4O5002
(1) Drive Control Lever(RH) (6) Seat Bar The steering levers are on the left and right sides in
(2) Drive Control Lever(LH) (7) Parking Brake front of the seat. The levers are independent of each
(3) Boom Pedal (Released Position) other.
(4) Attachment Pedal (8) Throttle Lever FORWARD MOVE : Push both levers forward.
(5) Bucket Pedal (9) Horn Button(Option) BACKWARD MOVE : Pull both levers back-
ward.
STOP : Hold both levers at neutral position.
- 42 -
5.2.2. Pedals ( 3 4 5 )
Boom up
Neutral
Boom down
(3) (4) (5) Floating
position
- 43 -
floating status, press the rear part of the pedal.
5.2.5. Attachment Pedal( 4 )
Float position should only be used with vehi-
cle in reverse. This pedal is used to operate the auxiliary
hydraulics(attachments) instead of the stan-
5.2.4. Bucket Pedal ( 5 ) dard bucket.
This is the pedal to tilt the bucket forward or Note: Press the right part of the pedal fully to
backward. The speed is controlled both for for- the bottom, then the pedal will be locked
ward and backward tilting by the degree of the to detent position, which makes the
pedal pressing. attachment operate in succession.
To release the attachment from detent posi-
tion, press the left part of pedal.
Neutral Neutral
Backward Forward
tilting
Forward tilting
Forward
tilting Reverse
Backward tilting
Detent position
IA4O5006
IA0OA38I
- 44 -
IA4O5005
Raised Position
- 46 -
6. OPERATING INSTRUCTIONS
IA0OA42P
IA4O6001
IA4O6002
- 47 -
(3) Fasten the seat belt and adjust it snugly across (1) Be sure all controls (the foot pedals and drive
the hips. control levers) are in neutral position.
(2) Set the throttle lever at half-throttle position.
(3) When the key is turned to the PREHEAT
position, the light turns on and preheating of air
begins. The light goes off automatically after 30
seconds. Then start the engine by turning the
key to the start position.
IA0OA18P
6.3. Starting
IA4O6003
CAUTION
Refer to section 7.3 for pre-start maintenance
checks.
- 48 -
DANGER Cold Temperature Starting and Operation
Before any Daewoo skid steer loader is operated in cold ambient temperatures (below 45 F), the
hydrostatic system needs to be properly warmed up to assure precise drive operation. This is espe-
cially crucial due to the fact it has a servo controlled hydrostatic drive system.
To properly warm up the hydraulic system you should: 1. Disconnect any attachment lines from the
auxiliary hydraulic couplings. 2. Following all proper procedures as outlined in this manual, start the
engine and run at high idle (full throttle position). 3. Set the auxiliary hydraulic pedal in the full oper-
ational position. 4. Depending on ambient temperature proper warm up time will vary from 3 to 15
minutes. This procedure should be continued until both A) The outside of the hydraulic tank is warm
to the touch and B) Using short slow movements the drive controls react normally to inputs. Caution
should be taken during the initial control movements as warm oil may be delayed in reaching the
control servos.
- 49 -
IA0OA46I
CAUTION
When traveling or steering, always lower the
boom to the carry position.
Forward Backward
IA0OA45I
- 50 -
Sharp Turning 6.5 Operation
Push one lever forward and pull another leverback-
ward.
CAUTION
For safe and economical handling with the
DAEWOO skid steer loader, the operator must
have a thorough knowledge of safety instruc-
tions and a good grasp of the construction and
performance features of the vehicle. Then he
must choose the operating approach best
matched to the actual conditions.
IA0OA47I
(1) Bucket filling
CAUTION
Be alert for tail swing.
IA4O6004
- 51 -
IA4O6005 IA4O6006
Move the vehicle forward slowly with the bucket IMPORTANT Do not shake the buck-
held parallel to the ground or tilted down slightly. et unnecessarily to dislodge sticky material. Vibra-
When the bucket is sufficiently full, roll back and tions put excess stress on the bucket cylinder and
raise the bucket simultaneously. stopper, which in turn will reduce machine life.
- 52 -
(4) Leveling the ground Also, leveling jobs can be performed by using
Drive forward or backward with the bucket tilted the floating position for the boom according to
and raised slightly off the ground to perform lev- operating conditions. Make the bucket parallel to
eling. the ground as much as possible.
IA4O6007
CAUTION
Do not drive forward with the boom in float po-
sition.
- 53 -
(2) Parking
Stop the loader on level ground.
Lower the boom and put the bucket cutting edge
IA4O6008 on the ground.
- 54-
Pull the throttle lever all the way back. 6.7. Towing Procedures
Engage the parking brake.
Turn the key to the OFF position.
Make sure that all controls in operator cabin are WARNING
in stop position.
Raise the seat bar all the way up to the roof. Towing loaders without following the procedures
listed below can result in damage to machine
Disconnect the seat belt.
and injury to personnel
Remove the key from the switch.
Front Rear
DANGER
NEVER exit machine with boom arms raised
unless secured by safety locks.
IA0OA52I
- 55 -
WARNING
Opening of bypass valves will result in a loss of
hydrostatic braking capacity. Take precautions
to prevent machine movement when opening
the valves, and after valves are opened.
(4) Tow loader using the two draw eyes located at IA0OA53S
lower rear portion of frame.
(5) After towing, tighten valves to 9.5-14 Nm (7-10
ft/lbs.)
Damage to units may result from over-torquing WARNING
valves.
Lifting may shift the load and could result in
(6) DAEWOO Skid Steer Loader can draw another death or serious injury.
machine using the 2 drawing eyes on rear frame.
Specified draw bar forces are as follows:
1340 XL : 2,110Kg(w/load) 1,800Kg (w/o load)
- 56 -
1. Use proper rated cables and slings for lifting. 6.9. Transportation
(min. durable force of cable/sling = 1,400Kgf)
2. Lifting cables should have sufficient length to
prevent contact with the machine.
3. Use the 4 holes for lifting i.e. 2 holes in front up-
per frame and 2 holes in rear inner mast with U-
clamp or strap. 15 or less
IA0OA55I
U-Clamp
or Strap
- 57 -
Fix the skid loader tightly to the transport truck 6.10. Bucket and Attachments
bed with an approved securing device. The ma-
The loader is equipped with a Universal
chine has 3 fixing points, i.e. 1 holes in front up-
Attachment System (Quick-tach) in front of the
per frame and 2 holes in lower rear frame.
vehicle for rapid replacement of bucket or var-
Use wheel blocks to prevent vehicle from moving
ious attachments.
during transportation.
(1) Installation
Wire Rope
Wire Rope
IA4O6012
IA4O6011 <Figure 1>
IA4O6013 IA4O6014
<Figure 2> <Figure 3>
- 59 -
IA4O6015 IA4O6016
(2) Removal
(1) Lower the boom thoroughly and tilt the
bucket down until the bucket cutting edge
touches to ground.
(2) Pull out both handles and disengage the
locking pin. (Figure 5)
IA4O6012
<Figure 6>
- 60 -
6.11. Boom Lock Operation
DANGER
When working on a machine with the boom up,
always engage the boom lock.
IA0OA24P
<Figure 2>
IA0OA23P
<Figure 1>
IA0OA25P
<Figure 3>
- 61 -
- 62 -
7. PERIODIC MAINTENANCE
7.1. Safety Warnings
WARNING
1. Never attempt to service a machine unless you are authorized and qualified to do so.
2. Before attempting any service on this machine, familiarize yourself with all instructions and warn-
ings in the operators manual and all machine decals.
3. Do not attempt to service machine unless you have the necessary skill, information, safety gear,
and tools and equipment to perform the procedure correctly.
4. While service is being performed ensure a warning tag is installed on or near the ignition key
switch and clearly visible to prevent inadvertent starting of the machine during service.
5. If a service procedure necessitates running the engine, the control levers must remain in the neu-
tral position and the emergency brake must be fully engaged. Failure to do so can result in injury
or death.
6. After completing service check for: proper operation of all controls, correct torque on all fasteners
and fittings, any fluid leaks (prior to and after starting engine), all tools and equipment must be
removed from the machine.
7. Ensure all hoisting and supporting equipment is in good repair and of adequate capacity to support
loader.
8. Failure to follow safety precautions and proper service procedures can lead to machine malfunction
or damage, injury to operator or bystanders, or death.
- 63 -
7.2. Access to Items Requiring Service NOTE: The rear door can by locked by placing
a pad lock on the hasp provided on the handle.
IA4O7001
IA0OA62P
More service space can be obtained if opera-
Push the door handle forward to close the rear tor opens up the engine hood after opening the
door. rear door.
- 64 -
7.2.2. Canopy Tilting
IA0OA65P
IA4O7004
- 65 -
- 66 -
service manual for proper adjustment pro-
WARNING cedure.
b. Check for proper operation of boom, buck-
If any of the following pre/post start checks
et, and accessories (if attached).
indicate that service may be required, have
such service performed before using the c. Insure that the boom, bucket, attachment
machine. pedals are locked with the seat bar raised.
- 67 -
Fuel System Clean and replace fuel filter element. (Replace (Clean) (Replace)
First time)
Engine Check cooling level and add as needed.
Cooling Check for leaks
System
Check and adjust the tension of fan belt
Check the indicator.
(Clean or replace the outer element when the red ring shows.)
Air
Clean the dust cover.
Cleaner
Replace the outer element.
(Replace the inner element every third time the outer
(Clean) (Replace)
element is replaced).
- 68 -
SERVICE SCHEDULE HOURS
ITEM SERVICE REQUIRED every every every every every every
day 50 100 250 500 1000
Tires Check air pressure and for damage to tires.
Wheel Nuts Tighten to correct torque if loose.
Seat Belt Check the condition of seat belt.
Seat Bar Check the seat bar for correct operation.
Safety Signs Check for damaged signs and replace if needed.
Pivots Grease pivots as needed.
Check the water level and battery cables for corrosion.
Battery Check whether battery cables are tightly clamped.
Check covers.
Check the oil level and add as needed.
Hydraulic Fluid (First time)
Replace the fluid
Hydraulic Check for damage and leaks and replace as needed.
Tubes and Hoses
Chain Case Oil Replace the oil.
(First time)
Hydraulic Filter Replace the filter.
Hydraulic Replace the hydraulic oil.
Oil Tank
Spark Arrestor Clean the spark chamber
for Muffler
(First time)
Suction filter in tank Inspect and clean or change
Air breather cap Inspect and clean or change
- 69 -
4 5
IA4O7006
- 70 -
1. Bucket cylinder pivot 3. Upper bucket cylinder pivot
IA4O7007 IA4O7009
IA4O7008 IA4O7010
- 71 -
IA4O7011
IA4O7012
- 72 -
(8) (7) (8)
IA4O7013
- 73 -
IA4O7031
IA0OA77P
- 74 -
7.6.1. Lubrication 7.7. Engine Lubrication
All seat bar mounting points (right shown-left
in mirror position) should be checked for secu-
rity, cleaned of any dirt and debris, and lubri-
cated daily. Use either a spray lubricant or a
light machine oil at the points marked on the
illustration. Lubrication for the pedal lock link-
age is covered in the previous section (7.5).
7.6.2. Function
Drain Plug Cap Bottom Cover
Sit in seat and fasten seat belt. Check the seat
IA4O7015
belt for security at mounting points. With the
seat bar up, check for full engagement of the
pedal locks (right and left) into the correspond-
ing slots under the pedal assembly. Lower the
seat bar. Pedal lock assemblies should fully
disengage from pedals.
Oil Filter
IA4O7016
- 75 -
Dip Stick
7.7.3. Remove/Replace Engine Oil Filter
Raise and secure operators cab. Filter is located
on left side of engine block. Using a strap type or
IA0OA81P other style filter wrench, remove the engine oil
filter. Before installing new filter, coat the rubber
gasket on the filter with clean oil. Install filter BY
HAND and tighten until gasket fully contacts the
mounting surface. Once this tighten another 2/3
turn to fully seat the gasket.
- 76 -
7.8. Engine Cooling System tubing to the nipple on the petcock to allow fluid
to drain outside of the chassis. Collect the fluid
NOTE: Check the cooling water level while the
and discard it in accordance with local/federal
engine is cold.
environmental rules and regulations.
Accurate coolant level check is not guaranteed
when engine is hot, because a hot radiator can
flow coolant to sub-tank.
Check the coolant level on the sub-tank. Re-
move the top cap of the sub-tank and fill to the
FULL mark if coolant level is below LOW
mark on sub-tank.
IA4O7018
FULL
Fuel Tank
CAUTION
LOW
(1) Steam or hot liquid may spurt out if the
radiator cap is removed soon after the
engine is stopped.
(2) When removing the radiator cap, turn your
IA0OA82I face away from cap and cover the cap with
a cloth. Turn the cap slowly to release the
NOTE: The radiator drain petcock is located on
pressure inside the radiator.
the right radiator tank. Attach a section of 5/16
- 77 -
IA0OA85S
IA0OA84S
- 78 -
7.10. Two Stage Air Filter
Primary Element
Indiccator
IA4O7021
- 79 -
7.10.3. Installation
Installation is simply the reverse of the above 7.11.1. General
procedures. Ensure that the element and
This vehicle is equipped with a U.S.D.A.
gasket are not damaged during replacement.
Forestry Service approved spark arrestor
The air cleaner will not function properly if the
muffler. To keep it in working condition, the
gaskets do not seat completely.
spark chamber must be emptied every 100
hours of operation.
- 80 -
7.11.2. Maintenance 7.12. Battery
The engine must be completely cool before
attempting to clean the spark chamber.
NEVER attempt to empty the spark chamber
on a hot engine. Raise and support the
loader and open and secure the operators
cab. Remove the clean out plug from the
spark chamber. Ensure that the individuals
performing this operation are wearing safety
glasses with side shields. Start the engine IA4O7023
and run for approximately 10 seconds while
the second individual wearing protective
7.12.1. Remove and Install
gloves holds a piece of wood over the
exhaust outlet. Re-install plug and lower and Removal: The battery is located in the right
secure cab. rear corner of the chassis. Access to battery
is gained through the rear service door.
Disconnect the negative (-) battery cable
first, then disconnect the positive (+) cable.
Remove the wing nuts from the battery hold
down clamp, and remove the clamp assem-
bly. Remove the battery from the loader.
Installation: Installation procedure is the
- 81 -
reverse of the removal procedure. Before jumper battery to the negative (-) terminal on
beginning installation, clean the battery ter- the loader frame. Once loader has started,
minals and cable ends with a wire brush. Be remove the ground cable from the frame first.
sure to connect the negative (-) cable last to
minimize the potential for sparking. Coat the NOTE: Ensure the jumper battery being used
terminals and cable ends with grease to pre- is a 12 volt battery or electrical system dam-
vent corrosion. age will result.
- 82 -
7.13. Fuel System/Filters 7.13.1. Removal/Installation-Fuel Filter
1. Fuel filter Open and secure the operators cab. Facing
the loader, the fuel filter is located above the
right corner of the engine. Use a spanner
wrench to remove the retaining ring from the
filter head and remove the filter bowl. Follow
the service schedule for replacement/cleaning
intervals. Clean the filter using a light grade
machine oil and compressed air. NEVER use
gasoline to clean filter. Align the filter bowl and
IA4O7024 tighten the retaining ring by hand until snug.
Finish tightening using the spanner wrench.
2. Water Separator When complete, refer to section 7.14 for fuel
system priming.
IA4O7025
- 83 -
IA0OA93P IA4O7026
IA4O7027
- 84 -
accomplished by loosening the vent joint (A) 7.15. Hydraulic System Maintenance
and pumping the priming lever (B) until air is
bled from the system. Tighten vent joint (A) 7.15.1. Oil Level Indicator
when complete. The hydraulic oil level indicator and filler neck
are located on the right hand side of the loader
inside the rear service door. To daily check the
fluid level, the loader should be on level ground
with the boom completely lowered and the
Quick-tach assembly tilted back. The fluid level
as indicated on the sight gauge should read
between the two red lines. Refer to specifica-
tions section 8.2.9 for complete information on
fluid capacities and requirements.
IA4O7032
OIL LEVEL INDICATOR
- 85 -
INSTALLATION
Before installation you must coat the rubber
IA4O7028
seal on the new filter with a light coat of
Hydraulic filter hydraulic oil. Spin on filter by hand turning
clockwise until the rubber filter seal makes
complete contact with the filter head assembly.
- 86 -
At this point, turn the filter an additional 3/4 sis. Before draining, the loader should be on
turn to fully tighten. When complete, run the level ground with the boom completely low-
loader and check the hydraulic oil level indi- ered and the Quick-tach tilted back. Once the
cator. Add fluid as needed. Discard the used loader is drained, oil should be disposed of
filter in accordance with local/federal environ- into an approved waste oil container in accor-
mental rules and regulations. dance with local/federal rules and regula-
tions.
IA0OA99P
- 87 -
IA4O7030
- 88 -
7.17. Parking Brake Adjustment
IA0OB02P
- 89 -
Overall Height
A. Fully Raised in(mm) 142.4 (3617)
B. To Hinge Pin in(mm) 112.0 (2845)
C. To Canopy in(mm) 76.1 (1934) O
Overall Length
D. With Bucket in(mm) 115.5 (2924) K
E. Less Bucket in(mm) 90.4 (2296)
Overall Width A M
F. With Bucket in(mm) 61.5 (1562)
B
G. Less Bucket in(mm) 58.5 (1486) L C
Others
I
H. Wheel Base in(mm) 37.9 (962) N
I. Height of S.I.P. in(mm) 37.8 (959) J U
P H
J. Ground Clearance in(mm) 7.5 (190) E
T. Tread in(mm) 48.1 (1222) D
U. Departure Angle deg 27 IA0OB04I
- 91 -
Q
R
Item Unit Spec.
F S T G
Dumping
K. Dump Angle deg 55
L. To Hinge Pin in(mm) 86.3 (2192)
Reach O
M. Fully Raised in(mm) 20.4 (518)
Rollback K
N. Max. at Ground deg 25
O. Max. Fully Raised deg 94 A M
Digging
B
P. Digging Depth in(mm) 0.5 (13) L C
Clearance (Circle)
I
Q. Front, Less Bucket in(mm) 46.6 (1183) N
R. Front, With Bucket in(mm) 71.0 (1804) J U
P H
S. Rear in(mm) 57.7 (1465)
E
D
IA0OB04I
- 92 -
Definitions: (Daewoo Skid Steer Loader)
Refer to sketches on pages 88 or 90 of this section.
Overall Operating Height (A) - Fully Raised - The vertical distance in inches (millimeters) from the ground to
the highest point attainable.
Height to Hinge Pin (B) - Fully Raised - The vertical distance in inches (millimeters) from the ground to the
centerline of the bucket hinge pin.
Overall Height (C) - The vertical distance in inches (millimeters) from the ground to the highest point on the unit
with the bucket on the ground.
Overall Length (D) - The horizontal distance in inches (millimeters) with the bucket on the ground and level,
measured from the foremost point of the bucket cutting edge to the rear most point of the machine.
Overall Length (E) - Without Bucket - The horizontal distance in inches (millimeters) from the furthest rearward
to the furthest point forward.
Bucket Width (F) - The maximum outside width in inches (millimeters) of the bucket specified.
Overall Width (G) - The maximum outside width in inches (millimeters) of the machine specified exclusive of bucket.
Wheelbase (H) - The vertical distance in inches (millimeters) from the center of the front wheel or idler to the
center of the rear wheel or sprocket.
Height to S.I.P. (I) - The vertical distance in inches (millimeters) from the ground to the Seat Index Point.
Ground Clearance (J) - The minimum vertical distance in inches (millimeters) from the ground to the lowest
point on the machine between the tires or tracks with the lift arm raised.
Dump Angle (K) - The maximum angle in degrees that the longest flat section of the inside bottom of the bucket
will rotate below horizontal with the bucket hinge pin at maximum height.
Dump Height (L) - The vertical distance in inches (millimeters) from the ground to the lowest point of the cutting
- 93 -
edge with the bucket hinge pin at maximum height and the bucket at a 45 dump angle. The angle is less than
45, specify angle.
Reach (M) at Maximum Height - The horizontal distance in inches (millimeters) from the foremost point on the
machine (including tires, tracks, or loader frame) to the front most point on the bucket cutting edge at a 45 angle
with the bucket hinge pin at maximum height. Specify angles less than 45.
Maximum Rollback (N) - at Ground - Maximum rollback angle in degrees without movement of the lift arm.
Maximum Rollback (O) - Fully Raised - The angle in degrees from the bucket cutting edge level position to the
maximum rollback position.
Digging Depth (P) - The vertical distance in inches (millimeters) from the ground to the bottom of the bucket cut-
ting edge at the lowest position with the bucket cutting edge horizontal.
Loader Clearance Circle (Q) - Front No Attachment - The smallest diameter measured in inches (millimeters)
that the outermost front point on the machine will describe measured from a point located at 1/2 the wheelbase
(H) and 1/2 the overall width (G) of the machine.
Loader Clearance Circle (R) - Front with Standard Attachment - The smallest diameter measured in inches
(millimeters) that the outermost front point on the machine will describe measured from a point located at 1/2 the
wheelbase (H) and 1/2 the overall width (G) of the machine.
Loader Clearance Circle (S) - Rear - The smallest diameter measured in inches (millimeters) that the outermost
rear point on the machine will describe measured from a point located at 1/2 the wheelbase (H) and 1/2 the over-
all width (G) of the machine.
Tread or Track Gauge (T) - The transverse distance in inches (millimeters) between the centerlines of the tires
or sprockets. If the front and rear are different, both must be specified.
Angle of Departure (U) - The angle in degrees taken from a line drawn from the lowest and rear most portion of
the rear overhang to the rear bottom face of the rear tire to the ground.
- 94 -
8.2. Operational Specification (Per SAE J732 Feb 80)
8.2.1. Performance 8.2.2. Power Unit
- 95 -
- 96 -
8.2.5. Hydraulic System
- 97 -
- 98 -
8.2.7. Instrument Features 8.2.8. Seat
- 99 -
- 100 -
WARNING
Do not start, operate or service this machine unless you have read and understand these instruc-
tions and received proper training.
Unsafe or improper use of the machine may cause serious injury or death.
Operators and maintenance personnel must read this manual and receive training before operat-
ing or maintaining the machine.
This manual should be kept with the machine for reference and periodically reviewed by the
machine operator and by all personnel who will come into contact with it.
- 101 -
When servicing this lift truck, use an authorized servicing area and an approved container to collect coolant, oil,
fuel, grease, electrolyte and any other potential environmental pollutant before any lines, fittings or related items
are disconnected or removed. After servicing, dispose of those materials in an authorized place and container.
When cleaning the lift truck, be sure to use an authorized area.
- 102 -
WARNING
Do not start, operate or service this machine unless you have read and understand these instructions
and received proper training.
Unsafe or improper use of the machine may cause serious injury or death.
Operators and maintenance personnel must read this manual and receive training before operating or
maintaining the machine.
This manual should be kept with the machine for reference and periodically reviewed by the machine
operator and by all personnel who will come into contact with it.
The following warning is provided pursuant to California Health & Safety Code Sections 25247.5
et, seq,
WARNING
California Proposition 65
Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals
known to the State of California to cause cancer birth defects of other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known
to the State of California to cause cancer and birth defects or other reproductive harm.
WASH HANDS AFTER HANDLING.
FOREWORD
This manual explains the safety rules, lubrication, testing and controls to operate and maintain the DAEWOO Skid
Steer Loader for safe and optimal performance.
The operator should be familiar with all of the contents of this manual before starting the vehicle to insure maxi-
mum performance, safety and economy.
Descriptions explain the testing, starting, operation, and stop procedures in detail.
To maintain the vehicle in top condition, the operator should periodically check the vehicle in accordance with the
service schedule.
The periodic maintenance intervals in this manual are based on the service hour meter.
Environment Management
Note that DAEWOO INDUSTRIAL VEHICLE DIVISION is ISO 14001 certified which is harmonized with ISO 9001
Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by
internal and external inspection entities. LIFE - CYCLE ANALYSIS has also been made through out the total prod-
uct life. ENVIRONMENT MANAGEMENT SYSTEM includes DESIGN FOR ENVIRONMENT from the initial stage
of the design.
ENVIRONMENT MANAGEMENT SYSTEM considers environmental laws & regulations, reduction or elimination of
resource consumption as well as environmental emission or pollution from industrial activities, energy saving, envi-
ronment - friendly product design(lower noise, vibration, emission, smoke, heavy metal free, ozone depleting sub-
stance free, etc.), recycling, material cost reduction, and even environmentally oriented education for the employee.
S-1
SAFETY INFORMATION
S-2
SIGNALWORDS
S-3
WARNING SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual and all safety labels
on your machine. Keep safety labels in good condition. Replace missing or CAU
TIO
N
NING
damaged safety labels. Be sure new equipment components and WAR
repair parts include the current safety labels. Learn how to operate the
machine and how to use controls properly. Do not let anyone operate
the machine without instruction. Keep your machine in proper working
condition. Unauthorized modifications to the machine may impair operator
safety and well being and/or machine life and function.
HA0OA01I
ONLY trained and authorized personnel should operate and maintain the machine.
Use common sense and follow all safety rules, precautions and instructions when operating or perform-
ing maintenance on the machine.
When working with another person, be sure all hand signals to be used are understood.
Certain operating conditions may require reference to applicable OSHA, ANSI, ISO, EEC or other local
and national regulations. Consult your supervisor or safety coordinator to be sure all applicable stan-
dards are being followed, and for special operating conditions.
Never operate equipment under the influence of drugs or alcohol. Certain prescription and over-the-
counter medications can affect alertness and coordination. Follow instructions on labels and/or consult
your physician. Notify your supervisor or consult your physician for clarification.
S-4
CONTENTS
S-5
S-6
cont. 2.0 SAFETY INFORMATION
S-7
S-8
cont. 7.0 PERIODIC MAINTENANCE
S-9
S-10
1. OWNER / OPERATOR SAFETY OVERVIEW
1.1. Safety Message for Owners and Your responsibility also includes establishing
Operators daily inspections and scheduled maintenance
practices to ensure the equipments ongoing
Your DAEWOO equipment has been designed safe operating condition.
with the safety of the persons who will operate
and service it in mind. However, our care in The manual you are reading now is intended
designing this equipment does not guarantee to help you meet your responsibilities.
that it will be used in a safe manner. It identifies warning labels on the equipment
Safe operating practice is where your responsi- and explains what they mean.
bility and the responsible actions of the per- It describes some of the general and specific
sons who operate this equipment take over. hazards to be aware of when operating the
equipment.It also offers some suggestions for
1.1.1. Owner/Employer Responsibility establishing workplace rules and operator
training programs.
Both the Occupational Safety and Health Act
(OSHA) and the American National Stan- As the owner/employer, you also have the
dards Institute (ANSI) make you, the employ- responsibility to be certain that the equipment
er, responsible for providing formal training you have placed into service is capable of
and a safe workplace environment for the doing its intended job.
use of this equipment.
-1-
This includes matching equipment design to In addition, you, the operator, have the responsi-
working conditions, capacity to the size of bility to :
loads it will be handling, and selecting suit- Follow the safety practices in which you are
able attachments and options. This section trained - every day.
of the manual discusses these issues as well. Recognize and avoid potential hazards in
At the end of this overview, we list specific your workplace.
OSHA, ANSI, and other published resources Understand and abide by the Warning labels
you can consult for ways to help you comply attached to the equipment.
with safety requirements for the use of this Inspect the equipment for its serviceability at
equipment in your workplace. the beginning of each shift.
Report immediately any service problems you
1.1.2. Operator Responsibility notice before you use the equipment or that
develop while you are using it.
If your job includes operating this equipment,
Report immediately any unsafe workplace
you should first get formal training in how to
conditions that threaten your safety or the
operate it properly and safely. Furthermore,
safety of others.
you should ensure that your workplace is
Avoid horseplay or other reckless actions that
maintained to assure your continued safety
you know endanger yourself or others.
and the safety of others around whom you
In short, every operator of this equipment has
work.
the responsibility to use common sense at all
times and to make safety his or her number one
job priority.
-2-
1.2. Maintaining a Safe Workplace
As we said, operators should recognize and When the equipment is driven onto trailers,
avoid hazards in the workplace. Although some use wheel chocks and jack supports if nec-
injuries occur because of unsafe operating essary to prevent creeping and possible col-
practices, many result from unnecessary work- lapse.
place hazards. To maintain a safe workplace Develop - and enforce - workplace safety
environment for this equipment, do the follow- rules for all employees.
ing: Post these rules conspicuously in the areas
where they apply.
Remove physical hazards where the equip-
ment will be operated, in either the plant or Many appropriate workplace rules are published
the yard. by OSHA, ANSI, and the National Safety
Separate pedestrian and equipment traffic Council. (See the list below under Information
wherever possible. Resources for Operation, Maintenance, and
Place convex mirrors at blind intersections. Safety.) We recommend that you consult
Require the use of horns at intersections or these publications as you develop and update
when approaching pedestrian areas. the safety rules for your workplace.
Establish equipment speed limits.
Install and maintain backup alarms and
flashing caution lights on equipment.
Use edge guards, levelers and trailer locks
on docks.
-3-
-4-
1.4. Maintenance Practices 1.5. Operator Safety Training
Well maintained equipment is safer equipment. Although this manual contains much informa-
A regular program of scheduled maintenance tion about safety practices, it is not meant to be
should be part of your facilitys ongoing safety a training manual for new operators. An
program. Daily inspections or inspections at employers responsibility extends beyond hand-
the start of every shift are required by OSHA. ing an employee this or any other document
Your DAEWOO dealer can help you train your and saying read this to learn how to operate
operators for this task and provide you with this equipment.
genuine replacement parts and service equip-
ment when scheduled (or unscheduled) main- 1.5.1. Formal Training
tenance and repairs are needed.
OSHA and ANSI require formal training for
new operators and refresher training for ex-
Although operators have a daily responsibility
perienced operators, along with appropriate
to inspect and report service problems, OSHA
on-the-job supervision. Furthermore, training
and ANSI standards require that equipment
must be tailored to the specific conditions of
maintenance and repair be performed by au-
your workplace and the workplace rules you
thorized mechanics only. Understand what is
have developed to protect your employees.
reasonable to expect in this area, and leave the
Whenever work conditions change in ways
serious maintenance and repair tasks to pro-
that affect operator safety, training for the new
fessional mechanics and technicians.
conditions must be provided.
-5-
Of course, before any employee can be To ensure this, ask yourself specific questions:
selected to operate industrial or construction In what areas of our workplace does operating
type equipment, the employee must meet the the equipment pose hazards to pedestrians?
employers specific visual, auditory, physical What hazards must operators be trained to
and mental ability standards. deal with?
Does our workplace have any one-way aisles,
1.5.2. Inspection Training speed zones, high noise, low light, or fire haz-
ard areas?
OSHA furthermore requires that operators be
What are the specific features of our loading
trained to conduct daily equipment safety
docks, ramps, or railcar loading facilities?
inspections. The goal of these inspections is
What specialized attachments are used on our
to prevent any piece of equipment in need of
equipment?
repairs from being placed into service and
What personal protective equipment or special
thereby endangering personnel. Your DAE-
clothing is necessary to operate the equipment
WOO dealer can help you develop training to
in our work environment? (hard hats, seat
comply to this and to other OSHA/ANSI re-
restraints, respirators, protective shoes or
quirements.
gloves, etc.)
15.3. Training Program Development Are operators conducting daily inspections
prior to shift start?
As noted above, OSHA/ANSI requires your Does our equipment require any special refu-
training to be designed around the conditions eling procedures?
present in your operation.
-6-
1.6. Information Resources for
One additional recommendation: ask those Operation, Maintenance, and
employees who work around (but do not op- Safety
erate) the equipment for suggestions about
The following publications contain information,
what the operators should be taught.
instructions, and standards for various operation,
1.5.4. Practical Training maintenance, and safety issues related to your
DAEWOO equipment.
The questions above and others like them
can help you design an appropriate training General Industry Standards, OSHA 2206: OSHA
course for your operators. But above all, be Safety and Health Standards (29 CFR 1910),
sure that your training incorporates a signifi- Subpart N - Materials Handling and Storage; 29
cant portion of practical experience. CFR 1910.178 powered industrial trucks;
1910.177 - Servicing Multi-Piece and Single Rim
1.5.5. Recognition
Wheels. Available from: Superintendent of
A key part of any training program is recogni- Documents, U.S. Government Printing Office,
tion. Think of ways you can recognize the Washington, DC 20402.
achievement of those who successfully com-
plete this important training. Certificates, National Fire Protection (NFPA) 505, Powered In-
licenses, patches, authorization cards and the dustrial Trucks, Type Designation, Areas of Use,
like set these individuals apart and help cre- Maintenance, and Operation. Available from: Su-
ate a lasting attitude of commitment to the perintendent of Documents, U.S. Government
job. Printing Office, Washington, DC 20402.
-7-
ANSI/ASME B56.1-1988: Safety Standard for Accident Prevention Manual for Industrial Opera-
Low Lift and High Lift Trucks (Safety Code of tions: Two volumes: Administration and
Powered Industrial Trucks). Available from: Programs and Engineering and Technology.
Society of Mechanical Engineers, United Available from: National Safety Council, 444
Engineering Center, 345 E. 47Th Street, New North Michigan Avenue, Chicago, IL 60611.
York, NY 10017.
Publications Concerning Safe Handling and
NFPA 58: Storage and Handling of Liquified Storage of LP Gas: Available from: National LP
Petroleum Gases. Available from: National Fire Gas Association, 1301 West 22nd Street,
Protection Association, Inc., Batterymarch Park, Oakbrook, IL 60521
Quincy, MA 02269.
Other OSHA regulations which may be applica-
Skid-Steer Loader Safety Manual. Available from ble to the place of use.
the Equipment Manufacturers Institute, 10 S
Riverside Plaza, Chicago, Illinois 60606-3710. You can receive help in applying information
from these sources to your workplace by con-
National Safety Council Data Sheets: 1-664 - tacting OSHA or your Workers Compensation
Writing and Publishing Employee Safety Insurance Company.
Regulations; 479 - Liquified Petroleum Gases
for Industrial Trucks; 195.71 - The In-Plant
Pedestrian. Available from: National Safety
Council, 444 North Michigan Avenue, Chicago,
IL 60611.
-8-
2. SAFETY INFORMATION
The following section of this manual discusses rules or take obvious precautions. Often you can
some of the general and specific safety issues avoid an accident by recognizing situations that
for your equipment. It gives you basic safety pre- might be hazardous. Furthermore, anyone who
cautions. It also shows you where to find warn- operates, maintains, or repairs this equipment
ing labels used on this equipment. The warnings should have the necessary training, skills, and
themselves are reproduced here for you to read. tools.
Before you operate or perform any maintenance Improper operation, maintenance, or repair of
on this equipment, read this Safety Information this equipment can be dangerous and could
section carefully. Also carefully read the opera- result in injury or death.
tion and other sections of this manual and heed
all of the safety information they contain. Also Do not operate or perform any lubrication, main-
locate, read, and understand the warning decals tenance, or repair on this equipment until you
on the equipment itself. have read and understood the operation, main-
tenance, and repair information in this manual.
-9-
Hazards are identified by the exclamation point every possible circumstance that might involve a
(!) Safety Alert Symbol followed by words such hazard. You must ensure that your operating
as DANGER, WARNING, or CAUTION. techniques, tools, and work procedures are safe
for you and others. You should also make sure
that the equipment will not be damaged or made
unsafe by your chosen operation, maintenance,
DANGER or repair procedures.
- 10 -
They are paraphrased without representation 2.2. Rated Operating Load Plate
that the OSHA rules and regulations have been
DO NOT exceed machine rated operating load
reproduced verbatim.
as described on the rated operating load plate
attached to your machine.
The best method for preventing serious injury or
death is for the operator to be familiar with the
proper operation of the equipment. Be alert and
avoid actions or conditions that can result in an
accident. DAEWOO HEAVY INDUSTRIES LTD.
MADE IN KOREA
MACHINE NAME
SERIAL NUMBER
IA0OA02I
- 11 -
CAUTION
Always keep safety and information labels clean. If they are lost or damaged, attach them again or
replace them with a new label. Safety labels are available in languages other than ENGLISH.
Please contact your dealer or DAEWOO if you need non-English labels.
2
1
14 5
D D 15 15
4 6
C B
C B
A
A
IC0O001I
- 12 -
2.3.2. Label Descriptions
1 Danger warning for Boom lock 3 Warning for canopy latch
IA0OA12I
- 13 -
W
A
R
N
I IC0O047I
ALWAYS ASSURE
5 THAT LATCHED ARE
Warning for high temperature muffler FULLY ENGAGED.
D415534
IA0OA09I
- 14 -
WARNING DANGER
10
ALWAYS WEAR SEAT BELT. BEFORE LEAVING SEAT :
ALWAYS OPERATE WITH SEAT LOWER BOOM OR ATTACHMENTS
BAR IN DOWN POSITIONL TO THE GROUND.
AVOID SUDDEN AND ABRUPT STOP ENGINE.
MACHINE OPERATION.
SET PARKING BRAKE.
NEVER CARRY RIDERS. RAISE THE SEAT BAR.
NEVER USE LOADER AS TO EXIT WHILE THE BOOM IS IN A
MANLIFT OR WORK
PLATFORM.
D415532 D415535
8 9
3 11
View "B-B"
(Inside of Canopy RH)
IA0OA04I View "C-C"
(Inside of Canopy. LH) IA0OA17I
8 Warning for general safety rules. 9 Warning for fastening seat belt and seat bar.
WARNING
WARNING
AVOID DEATH OR SERIOUS INJURY
READ AND UNDERSTAND THE OPERATOR'S MANUAL PRIOR ALWAYS WEAR SEAT BELT.
TO OPERATING THIS MACHINE FAILURE TO FOLLOW THESE ALWAYS OPERATE WITH SEAT
PRECAUTIONS CAN CAUSE INJURY OR DEATH.
CARRY LOAD LOW.
BAR IN DOWN POSITION.
AVOID STEEP SLOPES AND HIGH SPEED TURNS. AVOID SUDDEN AND ABRUPT
TRAVEL SLOWLY OVER ROUGH TERRAIN. MACHINE OPERATION.
NEVER CARRY MORE THAN RATED OPERATING LOAD.
NEVER PLACE ANY PART OF YOUR BODY UNDER BOOM NEVER CARRY RIDERS.
OR ATTACHMENTS.
KEEP BOTH FEET ON PEDALS AND BOTH HANDS ON
NEVER USE LOADER AS
CONTROLS WHILE OPERATING MACHINE. MANLIFT OR WORK
D416620
PLATFORM.
D415532
IA0OA15I IA0OA13I
- 15 -
DANGER GREASE
STOP ENGINE.
SET PARKING BRAKE.
RAISE THE SEAT BAR.
BE SURE PEDALS ARE LOCKED.
TO EXIT WHILE THE BOOM IS IN A
RAISED POSITION, THE BOOM
LOCK MUST BE ENGAGED. (SEE
INSTRUCTIONS ON OUTSDE OF
BOOM LOCK OR OPERATION
MANUAL.)
D415535
D423402
IA0OA14I IC0O050I
11 Service Shedule label 2060XL/DSL902
CHAIN CASE
COOLANT
12 Anti-Skid surface
GREASE
CHAIN CASE
HYDRAULIC TANK
GREASE
GREASE
D423400
IC0O049I View
View D-D
"E-E"
1550XL/DSL702 IC0O003P
- 16 -
13 Extinguisher
IC0O059P
Right Side
IA0OA76I
15 Warning for Boom
14 Warning for pinch point
IC0O058P
- 17 -
Any modification made without authorization from DAEWOO can create hazards.
Before making a modification, consult your DAEWOO dealer.
Improper modification could result in injury or death.
Improper use of safety features could result in serious bodily harm or death.
- 18 -
2.4.3. Mounting and Dismounting
NEVER jump on or off the machine. NEVER get on or off a moving machine.
When mounting or dismounting, always face the machine and use the handrails.
Do not grasp or come in contact with any control levers when getting on or off the machine.
Ensure safety by always maintaining at least three-point contact of hands and feet with the
handrails and steps.
Always remove any oil or mud from the handrails, steps and shoes.
NEVER mount or dismount the machine with engine running.
HA0OA03I
- 19 -
Fuel, oil, antifreeze, and other flammable fluids and combustibles can be ignited by a flame or hot sur-
faces. Vapors can be particularly FLAMMABLE and can be HAZARDOUS.
Keep open flame and hot surfaces away from flammable fluids and combustibles.
Stop the engine and do not smoke when refueling.
Tighten all fuel and oil caps securely.
Refueling and oiling should be done in well ventilated areas.
Keep oil and fuel in a designated area and do not allow unauthorized persons to enter.
Thoroughly remove wood chips, leaves, paper and other flammable items accumulated in the engine
compartment .
Check fuel and hydraulic systems for leaks prior to starting or using vehicle.
Have any leaks repaired before operating the machine.
Wipe up any excess oil, fuel or other flammable fluids.
Be sure a fire extinguisher is present and working and that personnel are properly trained in extin-
guisher operation.
Never use ether or other starting aids on any engine with glow plugs or other engine preheating devices.
See OSHA Class 1910.178.
Avoid skin contact, injestion and excessive breathing of vapors from fuel, oil, antifreeze, and other fluids.
See California Proposition 65 in the front of this book.
HA0OA04I
- 20 -
2.5. Operating Safety
2.5.1. Work Site Safety
Before starting the engine, thoroughly check the area for any
unusual conditions that could pose a hazard.
Before starting the engine, examine the terrain and soil condi-
tions of the work site. Determine the best and safest method
of operation.
- 21 -
Do not leave tools or spare parts lying around in the operators compartment. They may damage,
break, or interfere with the control levers or switches.
Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
Always check the seat belt, seat bar, and hardware for damage or wear. Replace any worn or dam-
aged parts. Always use seat belts and seat bar when operating your machine.
- 22 -
2.5.4. Ventilation for Enclosed Areas
DANGER
,,,
VENTILATION FOR ENCLOSED AREAS
,,,
adequate ventilation. Exhaust fumes from the engine can KILL.
HA0OA07I
A standard loader or a loader equipped with a spark arrestor/spark arresting muffler cannot be
operated in these areas. Use of these machines in flammable/explosive atmospheres can result in
fires and/or explosions which could cause serious injury or death.
See Code of Federal Regulations (OSHA) 29CFR Part 1910.178, to determine where machines
which are approved and labeled as G, GS, D, DS, DY, LP, LPS, G/LP, or GS/LPS are permitted to
operate.
- 23 -
Always remove all dirt from the surface of the windows and lights to ensure that you can see well.
Check that the head lamps and working lamps are installed to match the operating conditions.
Check also that they light up properly.
When working in dark places, install working lamps and head lamps, and set up lighting in the
work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or other cause, and wait for con-
ditions to improve to a level that allows the operation to be carried out safely.
- 24 -
2.5.8. Traveling in Reverse, Sate Working Zone
DANGER CHECK THAT NO ONE IS NEAR THE MACHINE BEFORE MOVING, TURNING,
TRAVELING IN REVERSE OR OPERATING ANY ATTACHMENTS
Keep all parts of the machine or load far away from all
electric lines.
IA0OA22S
- 25 -
When working on snow or icy or wet roads, even a slight slope may cause the machine to slip to
the side, so always travel at low speed and avoid sudden starting, stopping, or turning.
When there has been heavy snow, the road and objects placed beside the road are buried in the
snow and cannot be seen, so always carry out snow-clearing operations carefully.
Avoid operating your machine too close to the edge of cliffs, overhangs, loading docks, deep
ditches, and other uneven surfaces or drop-offs. If these areas collapse or you get too close to
the edge, your machine could fall or tip over and result in serious injury or death. Remember that
the soil after heavy rain or blasting is weakened in these areas.
Earth laid on the ground and the soil near ditches are loose. It can collapse under the weight or
vibration of your machine.
- 26 -
2.5.12. Preventing Crushing or Cutting
Never enter, or put your hand or arm or any other part of your body between movable parts such
as between the work equipment and cylinders, or between the machine and work equipment.
If the machine or work equipment is operated or moved, the clearance will change and this may
lead to serious damage or personal injury.
ALWAYS keep both feet on pedals and both hands on controls when operating loader.
The cab structure of the 1550XL, 2060XL complies with the following ROPS (Rollover Protective
Structure) and FOPS (Falling Object Protective Structure) criteria. -ROPS per ISO 3471 -FOPS per
ISO 3449 Level I
Never operate without a ROPS/FOPS approved cab.
2.5.13. Parking
- 27 -
When installing/using an optional attachment, read the instruction manual for the attachment and
the information related to attachments in the manual.
Never use attachments that are not authorized by DAEWOO or your DAEWOO dealer. Use of
unauthorized attachments could create a safety problem and adversely affect the proper operation
and useful life of the machine.
NEVER attempt to engage or disengage the Universal Attachment System (Quick-tach) levers with
the engine running.
WARNING
Load, unload and turn on flat level ground. Do not exceed machine rated operating load shown
on the rated operating load name plate attached to your machine. Failure to obey warnings can
cause the machine to tip or roll over and cause injury or death.
WARNING
Never dump over an obstruction that can enter the operator cab. The machine could tip forward
and cause injury or death.
- 28 -
2.5.16. Precautions for Stopping the engine.
CAUTION
When the engine stops and the seat bar (pedal locking device/parking) is secured in place (lowered).
if the pedal is depressed, then the boom or the bucket descends.
CAUTION
When the pedal is kept depressing, then even though the seat bar (pedal locking device/parking) is
raised, the boom or the bucket keeps moving regardless of engines running or not.
- 29 -
WARNING
1. Never attempt to service a machine unless you are authorized and qualified to do so.
2. Before attempting any service on this machine, familiarize yourself with all instructions and warn-
ings in the operators manual and all machine decals.
3. Do not attempt to service machine unless you have the necessary skill, information, safety gear,
and tools and equipment to perform the procedure correctly.
4. While service is being performed ensure a warning tag is installed on or near the ignition key switch
and clearly visible to prevent inadvertent starting of the machine during service.
5. If a service procedure necessitates running the engine, the control levers must remain in the neu-
tral position and the emergency brake must be fully engaged. Failure to do so can result in injury
or death.
6. After completing service check for: proper operation of all controls, correct torque on all fasteners
and fittings, any fluid leaks (prior to and after starting engine), all tools and equipment must be
removed from the machine.
7. Ensure all hoisting and supporting equipment is in good repair and of adequate capacity to support
loader.
8. Failure to follow safety precautions and proper service procedures can lead to machine malfunction
or damage, injury to operator or bystanders, or death.
- 30 -
2.6.2. Precautions for High Temperature Operations
- 31 -
- 32 -
2.6.4. Precautions for High Pressure Oil
Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked
piping, tubes or hoses. They may burst during use.
Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
Be aware that the machine hydraulic circuits are always under pressure.
Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the
internal pressure.
If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil
hits your skin or enters your eyes. It also can be extremely hot. Always wear safety glasses and
appropriate gloves, and use a piece of cardboard or a sheet of wood to check for oil leakage. The
stream of oil may not be visible.
If your skin is punctured by a jet of high-pressure oil, seek a doctor immediately for medical atten-
tion.
IA0OA26I
- 33 -
Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If
you spill acid on yourself, immediately flush the area with water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into eyes, flush them
immediately with large quantities of water and see a doctor immediately.
If you accidentally swallow battery acid, drink a large quantity of water or milk, beaten egg or veg-
etable oil. Call a doctor or poison prevention immediately.
When working with batteries, ALWAYS wear safety glasses, goggles, or face shield.
Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a
small spark or flame.
Before working with batteries, stop the engine and turn the starting switch to the OFF position.
Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as
tools, across the terminals or between the hot (+) post and frame or other grounding surface.
Keep the battery terminals tightened securely. Loose terminals can generate sparks and lead to an
explosion.
When repairing the electrical system or when carrying out electrical welding, remove the negative
(-) terminal of the battery to stop the flow of current.
NEVER attempt to charge or jump start a frozen battery. An explosion may occur.
IA0OA27I
- 34 -
2.6.6. Waste Material Precautions
Always put oil drained from your machine in containers. Never drain
oil directly on the ground.
Obey appropriate state, local, and federal laws and regulations when
disposing of harmful liquids, objects, or wastes such as oil, fuel,
coolant, solvent, acids, filters, batteries and others.
HA0O1043I
Keep away from all moving or rotating parts and be careful not to let
anything get caught in them.
Never touch any rotating parts. If your body or tools touch the fan
blades or fan belt, they may be cut off or sent flying or it may pull you
into the equipment.
IA0OA28I
- 35 -
DANGER
Tires should only be mounted/dismounted from rims or repaired by trained and authorized personnel
using the proper equipment and procedures. Death or serious injury could result. See OSHA
1910.177.
- 36 -
3. SERIAL NUMBER LOCATIONS
3.1. Vehicle Serial Number 3.2. Engine Serial Number
MACHINE NAME
SERIAL NUMBER
IA0OA02I
The engine number is stamped on a plate on
the right side of the cylinder block.
The vehicle serial number plate is riveted on
the inner side of left-hand mast. If you need parts, service or information for
your engine, you must give the complete
engine number to your Daewoo distributor.
- 37 -
4. MACHINE COMPONENTS
4.1. Identification of Machine Parts
Canopy
Head lamps ( ROPS & FOPS ) Rear lamp Strobe light (CE Option)
Seat bar
Canopy lock
Rear door
Drive levers handle
Seat belts
- 38 -
Head lamp
Grab Handles
Seat bar
Drive levers
Boom cylinder
Anti - skid
Boom cylinder
IC0O005P
- 39 -
5. CONTROLS AND INSTRUMENTS
5.1. Instrument Panel
1 2 3 4 5 6 14 15
7 8 9 10 11 12 13
IC0O006I IC0O007I
- 40 -
(2) Engine oil pressure warning light (5) HST oil temperature warning light
The light turns on when The light turns on when
the engine oil pressure is the temperature of the hy-
below 0.5kg/cm2 (15 psi). draulic oil to drive HST
goes up to 100C (212F).
- 41 -
(7) Pre-heat light (10) HST pressure warning light
When the key is turned to The light turns on when
the PREHEAT position, the pressure of the HST
the light turns on and pre- pump oil falls down below
heating of air begins. 5.97 kg/cm2 ( 85 psi )
Light turns off automatical-
ly after 30 seconds. (11) Stop light
The light turns on simulta-
(8) Diesel engine water in fuel filter indicator
neously with water tem-
light
perature and engine oil
Indicates when the engine
pressure warning lights.
is running, there is water in
the fuel filter exceeds
(12) Oil filter warning light
100cc.
If the oil filter becomes
clogged, the light turns on.
(9) Warning light
The light turns on simulta-
neously with charge, HST
oil temperature, HST pres-
sure and oil filter warning
lights.
- 42 -
- 43 -
5.2. Controls 5.2.1. Drive control lever( 1 2 )
(10)
IA0OA34I IA0OA35I
(1) Drive control lever(RH) (7) Parking Brake The steering levers are on the left and right sides in
(2) Drive control lever(LH) (Released Position) front of the seat. The levers are independent of each
(3) Boom pedal (8) Auxiliary Hydraulic other.
(4) Bucket pedal Thumb Control FORWARD MOVE : Push both levers forward.
(5) Throttle Lever (9) Horn Button BACKWARD MOVE : Pull both levers backward.
(6) Seat Bar (10) Pressure Relief STOP : Hold both levers at neutral position.
- 44 -
IA0OA37I
- 45 -
floating status, press the rear part of the pedal. 5.2.5. Auxiliary Hydraulics Thumb Control (6)
Float position should only be used with vehi-
cle in reverse. (4) (5)
Neutral
Backward
tilting IA0OA39I
Forward tilting
CAUTION
Forward When using an attachment other than the stan-
tilting
dard bucket, follow the instructions for each
Backward tilting separate attachment.
IA0OA38I
- 46 -
- 47 -
5.2.7. Seat Bar
The seat bar is installed to help protect the op-
erator.
IA0OA17P IA0OA18P
Raised Position Raised Position
NOTE: The pedals are locked if the seat bar is NOTE: 1550XL, 2060XL are equipped with a
in the raised position. Lower the seat bar to seat bar safety interlock that sets the park
operate the pedals. brake with the seat bar raised. The seat bar
must be lowered for travel.
- 48 -
6. OPERATING INSTRUCTIONS
IA0OA42P
IA0OA41P
IA0OA43P
- 49 -
(3) Fasten the seat belt and adjust it snugly across (1) Be sure all controls (the foot pedals and drive
the hips. control levers) are in neutral position.
(2) Set the throttle lever at half-throttle position.
(3) When the key is turned to the PREHEAT
position, the light turns on and preheating of air
begins. The light goes off automatically after 30
seconds. Then start the engine by turning the
key to the start position.
IA0OA18P
6.3. Starting
A
IC0O008P
CAUTION
Refer to section 7.3 for pre-start maintenance
checks.
- 50 -
DANGER Cold Temperature Starting and Operation
Before any Daewoo skid steer loader is operated in cold ambient temperatures (below 45 F), the
hydrostatic system needs to be properly warmed up to assure precise drive operation. This is espe-
cially crucial due to the fact it has a servo controlled hydrostatic drive system.
To properly warm up the hydraulic system you should: 1. Disconnect any attachment lines from the
auxiliary hydraulic couplings. 2. Following all proper procedures as outlined in this manual, start the
engine and run at high idle (full throttle position). 3. Set the auxiliary hydraulic pedal in the full oper-
ational position. 4. Depending on ambient temperature proper warm up time will vary from 3 to 15
minutes. This procedure should be continued until both A) The outside of the hydraulic tank is warm
to the touch and B) Using short slow movements the drive controls react normally to inputs. Caution
should be taken during the initial control movements as warm oil may be delayed in reaching the
control servos.
- 51 -
IA0OA46I
CAUTION
When traveling or steering, always lower the
boom to the carry position.
Forward Backward
IA0OA45I
- 52 -
Sharp Turning 6.5 Operation
Push one lever forward and pull another leverback-
ward.
CAUTION
For safe and economical handling with the
DAEWOO skid steer loader, the operator must
have a thorough knowledge of safety instruc-
tions and a good grasp of the construction and
performance features of the vehicle. Then he
must choose the operating approach best
matched to the actual conditions.
IA0OA47I
(1) Bucket filling
CAUTION
Be alert for tail swing.
IC0O011I
- 53 -
IC0O012I IC0O013I
Move the vehicle forward slowly with the bucket IMPORTANT Do not shake the buck-
held parallel to the ground or tilted down slightly. et unnecessarily to dislodge sticky material. Vibra-
When the bucket is sufficiently full, roll back and tions put excess stress on the bucket cylinder and
raise the bucket simultaneously. stopper, which in turn will reduce machine life.
- 54 -
(4) Leveling the ground Also, leveling jobs can be performed by using
Drive forward or backward with the bucket tilted the floating position for the boom according to
and raised slightly off the ground to perform lev- operating conditions. Make the bucket parallel to
eling. the ground as much as possible.
IC0O014I
CAUTION
Do not drive forward with the boom in float po-
sition.
- 55 -
(2) Parking
Stop the loader on level ground.
Lower the boom and put the bucket cutting edge
IC0O063P on the ground.
- 56 -
Pull the throttle lever all the way back. 6.7. Towing Procedures
Engage the parking brake.
Turn the key to the OFF position.
Make sure that all controls in operator cabin are WARNING
in stop position.
Raise the seat bar all the way up to the roof. Towing loaders without following the procedures
listed below can result in damage to machine
Disconnect the seat belt.
and injury to personnel
Remove the key from the switch.
Front Rear
DANGER
NEVER exit machine with boom arms raised
unless secured by safety locks.
IA0OA52I
- 57 -
WARNING
Opening of bypass valves will result in a loss of
hydrostatic braking capacity. Take precautions
to prevent machine movement when opening
the valves, and after valves are opened.
ft/lbs.)
Damage to units may result from over-torquing
valves.
WARNING
(6) DAEWOO Skid Steer Loader can draw another Lifting may shift the load and could result in
machine using the 2 drawing eyes on rear frame. death or serious injury.
Specified draw bar forces are as follows:
1550XL (DSL 702) : 2,680Kg (w/ load)
2,233Kg (w/o load)
2060XL (DSL 902) : 2,948Kg (w/ load)
2,494Kg (w/o load)
- 58 -
1. Use proper rated cables and slings for lifting. 6.9. Transportation
(min. durable force of cable/sling = 1,400Kgf)
2. Lifting cables should have sufficient length to
prevent contact with the machine.
3. Use the 4 holes for lifting i.e. 2 holes in front side
frame and 2 holes in inside mast with U-clamp or
strap. 15 or less
U - Clamp or Strap
IA0OA55I
BOOM
- 59 -
Fix the skid loader tightly to the transport truck 6.10. Bucket and Attachments
bed with an approved securing device. The ma-
The loader is equipped with a Universal
chine has 3 fixing points, i.e. 1 holes in front up-
Attachment System (Quick-Tach) in front of the
per frame and 2 holes in lower rear frame.
vehicle for rapid replacement of bucket or var-
Use wheel blocks to prevent vehicle from moving
ious attachments.
during transportation.
(1) Installation
Wire Rope
Wire Rope
IA0OA57P
IC0O046I <Figure 1>
- 60 -
edge of the Quick-tach is completely insert- backward until the back of bucket becomes
ed to the flange of the bucket.(Figure 1) perpendicular to ground.(Figure 2)
IA0OA58P IA0OA59P
<Figure 2> <Figure 3>
- 61 -
IA0OA60P IA0OA61P
(2) Removal
(1) Lower the boom thoroughly and tilt the
bucket down until the bucket cutting edge
touches to ground.
(2) Pull out both handles and disengage the
locking pin. (Figure 5)
IA0OA57P
<Figure 6>
- 62 -
6.11. Boom Lock Operation
DANGER
When working on a machine with the boom up,
always engage the boom lock.
IA0OA24P
<Figure 2>
IA0OA23P
<Figure 1>
IA0OA25P
<Figure 3>
- 63 -
- 64 -
7. PERIODIC MAINTENANCE
7.1. Safety Warnings
WARNING
1. Never attempt to service a machine unless you are authorized and qualified to do so.
2. Before attempting any service on this machine, familiarize yourself with all instructions and warn-
ings in the operators manual and all machine decals.
3. Do not attempt to service machine unless you have the necessary skill, information, safety gear,
and tools and equipment to perform the procedure correctly.
4. While service is being performed ensure a warning tag is installed on or near the ignition key
switch and clearly visible to prevent inadvertent starting of the machine during service.
5. If a service procedure necessitates running the engine, the control levers must remain in the neu-
tral position and the emergency brake must be fully engaged. Failure to do so can result in injury
or death.
6. After completing service check for: proper operation of all controls, correct torque on all fasteners
and fittings, any fluid leaks (prior to and after starting engine), all tools and equipment must be
removed from the machine.
7. Ensure all hoisting and supporting equipment is in good repair and of adequate capacity to support
loader.
8. Failure to follow safety precautions and proper service procedures can lead to machine malfunction
or damage, injury to operator or bystanders, or death.
- 65 -
7.2. Access to Items Requiring Service NOTE: The rear door can be locked by placing
a pad lock on the hasp provided on the rear
IC0O016P
IC0O015P
More service space can be obtained if opera-
Push the door handle forward to close the rear tor opens up the engine hood after opening the
door. rear door.
- 66 -
7.2.2. Canopy Tilting
IA0OA64P IA0OA65P
Remove attaching hardware
Stop the loader on level ground and lower the
boom all the way.
Turn off skid loader
Set park brake
Loosen both mounting bolts at the front cor-
ners of the canopy.
IA0OA66P
- 67 -
- 68 -
7.3.2. After Starting-Before Operation
WARNING 1. Start the engine and observe the intial exhaust
If any of the following pre/post start checks color at start and at normal operating temper-
indicate that service may be required, have atures. Excessively black, blue, or white
such service performed before using the
exhaust is an indication of a problem. Listen
machine.
for any abnormal sounds.
2. Check the operation of all exterior lights,
instrument panel indicator lights and installed
optional equipment.
3. Check the operation of all switches.
4. Check the operation of all controls.
Check loader for movement with controls in
neutral. Should movement occur refer to
service manual for proper adjustment
procedure.
a. Check for proper operation of boom, buck-
et, and accessories ( if attached ).
b. Insure that the boom and bucket pedals are
locked with the seat bar raised.
- 69 -
- 70 -
SERVICE SCHEDULE HOURS
ITEM SERVICE REQUIRED every every every every every every
day 50 100 250 500 1000
Tires Check air pressure and for damage to tires.
Wheel Nuts Tighten to correct torque if loose.
Seat Belt Check the condition of seat belt.
Seat Bar Check the seat bar for correct operation.
Safety Signs Check for damaged signs and replace if needed.
Pivots Grease pivots as needed.
Check the water level and battery cables for corrosion.
Battery Check whether battery cables are tightly clamped.
Check covers.
Check the oil level and add as needed.
Hydraulic Fluid (First time)
Replace the fluid
Hydraulic Check for damage and leaks and replace as needed.
Tubes and Hoses
Chain Case Oil Replace the oil.
(First time)
Hydraulic Filter Replace the filter.
Hydraulic Replace the hydraulic oil.
Oil Tank
Spark Arrestor Clean the spark chamber
for Muffler
(First time)
Suction filter in tank Inspect and clean or change
Air breather cap Inspect and clean or change
- 71 -
7 8 9
4
3
1
2
5
IC0O018I
- 72 -
1. Bucket cylinder pivot 3. Upper bucket cylinder pivot
IC0O019P IC0O021P
IC0O020P IC0O022P
- 73 -
IC0O052P IC0O025P
IC0O024P IC0O026P
1550XL/DSL702
- 74 -
9. Rear boom pivot
IC0O027P
2060XL/DSL902 IC0O028P
1550XL/DSL702
IC0O029P
2060XL/DSL902
- 75 -
8 7 8
IA0OA75I
- 76 -
7. Pedal assembly grease fittings 7.6. Operator Restraint Lubrication and
Maintenance
1. Seat bar mounting points
IA0OA76P
IA0OA78P
IA0OA77P
- 77 -
IC0O030I
7.6.2. Function
Sit in seat and fasten seat belt. Check the seat
belt for security at mounting points. With the
seat bar up, check for full engagement of the
pedal locks (right and left) into the correspond-
ing slots under the pedal assembly. Lower the
seat bar. Pedal lock assemblies should fully
disengage from pedals.
IC0O031P
- 78 -
7.7.1. General
Engine oil level should be checked daily.
After draining oil and changing filter approximate refill amounts is 2.1gallon(8 liter) for the 1550XL,
2060XL. Run loader briefly and check oil level on dipstick before returning the loader to service.
See section 8.2.9 (page 111) for fluid recommendations.
IC0O032P IC0O032P
- 79 -
7.7.2. Draining Engine Oil 7.7.3. Remove/ Replace Engine Oil Filter
Remove the four bolts from the access plate locat- Raise and secure operators cab.
ed on the left bottom corner of the chassis. Filter is located on left side of engine block.
Remove the drain plug by either reaching through Using a strap type or other style filter wrench,
the opening between the radiator and the chassis remove the engine oil filter. Before installing new
or through the access plate. Drain oil into an filter, coat the rubber gasket on the filter with
approved waste oil receptacle. Inspect drain plug clean oil.
gasket and if serviceable, replace drain plug. Install filter BY HAND and tighten until gasket
If gasket is deformed or torn, replace gasket and fully contacts the mounting surface.
re-install drain plug. Discard oil in accordance with Tighten 1/2 to 3/4 of a turn, by hand only.
local environmental rules and regulations.
- 80 -
7.8. Engine Cooling System tubing to the nipple on the petcock to allow fluid
NOTE: Check the cooling water level while the to drain outside of the chassis. Collect the fluid
engine is cold. and discard it in accordance with local/federal
Accurate coolant level check is not guaranteed environmental rules and regulations.
when engine is hot, because a hot radiator can
flow coolant to sub-tank.
Check the coolant level on the sub-tank. Re-
move the top cap of the sub-tank and fill to the
HOT mark if coolant level is below COLD
mark on sub-tank.
IC0O033P
Fuel Tank
Hot
CAUTION
Cold (1) Steam or hot liquid may spurt out if the
radiator cap is removed soon after the
engine is stopped.
IA0OA82I (2) When removing the radiator cap, turn your
face away from cap and cover the cap with
a cloth. Turn the cap slowly to release the
NOTE: The radiator drain petcock is located on
pressure inside the radiator.
the right radiator tank. Attach a section of 5/16
- 81 -
IA0OA84S IA0OA85S
- 82 -
7.10. Two Stage Air Filter
IA0OA87P
- 83 -
7.10.3. Installation
Installation is simply the reverse of the above 7.11.1. General
procedures. Ensure that the element and
This vehicle is equipped with a U.S.D.A.
gasket are not damaged during replacement.
Forestry Service approved spark arrestor
The air cleaner will not function properly if the
muffler. To keep it in working condition, the
gaskets do not seat completely.
spark chamber must be emptied every 100
hours of operation.
- 84 -
7.11.2. Maintenance 7.12. Battery
The engine must be completely cool before
attempting to clean the spark chamber.
NEVER attempt to empty the spark chamber
on a hot engine. Raise and support the
loader and open and secure the operators
cab. Remove the clean out plug from the
spark chamber. Ensure that the individuals
performing this operation are wearing safety
glasses with side shields. Start the engine IC0O035P
- 85 -
Installation: Installation procedure is the Next, connect from the negative (-) terminal
reverse of the removal procedure. Before on the jumper battery to the negative (-) ter-
beginning installation, clean the battery ter- minal on the loader frame. Once loader has
minals and cable ends with a wire brush. Be started, remove the ground cable from the
sure to connect the negative (-) cable last to frame first.
minimize the potential for sparking. Coat the
terminals and cable ends with grease to pre- NOTE: Ensure the jumper battery being used
vent corrosion. is a 12 volt battery or electrical system dam-
age will result.
7.12.2. Jump Starting the Loader
(See caution pg. 34-frozen battery)
- 86 -
7.13. Fuel System/Filters
1. Fuel filter & Water Separator
IC0O053P IC0O054P
1550XL/DSL702 2060XL/DSL902
- 87 -
- 88 -
7.13.2. Fuel Tank Drain
The fuel tank drain plug is located directly behind the 1550XL ( right ), 2060XL ( left ) rear tire on the
chassis. Fuel drained should be disposed of into an approved waste oil container. Discard the fuel in
accordance with local/federal environmental rules and regulations.
IC0O038P IC0O039P
1550XL/DSL702 2060XL/DSL902
- 89 -
FUEL FILLER
IC0O040P IC0O041P
1550XL/DSL702 2060XL/DSL902
- 90 -
7.14. Injection Pump Priming
If air enters the fuel system, it must be elimi- 1. Loosen the vent plug (A1) on the side of
nated before the engine can be started. the fuel injection pump.
2. Operate the priming lever (A2) of the fuel
Air can enter the system if: lift pump until fuel, free from air, comes
The fuel tank is drained during normal operation. from the vent point. Tighten the vent plug.
The low-pressure fuel pipes are disconnected. 3. Turn the start key on the ON position.
A part of the low-pressure fuel system leaks 4. Operate the starter motor for intervals of
during engine operation. 15 seconds until the engine starts. If the
engine runs correctly for a short time and
In order to eliminate air from the fuel system,
then stops or runs roughly, check for air in
proceed as follows:
the fuel system. If there is air in the fuel
system, there is probably a leakage in the
low pressure system. Stop the engine and
turn the start key to the OFF position.
IA0OA94S
- 91 -
IA0OA95P IC0O056P
REMOVAL INSTALLATION
Access to the 1550XL, 2060XL filter are Before installation you must coat the rubber
through the rear service door. Remove the fil- seal on the new filter with a light coat of
ter by turning counterclockwise. Drain the hydraulic oil. Spin on filter by hand turning
hydraulic oil into an approved waste oil con- clockwise until the rubber filter seal makes
tainer. While draining, check fluid and filter complete contact with the filter head assem-
base for signs of particle contaminants. bly. At this point, turn the filter an additional
3/4 turn to fully tighten. When complete, run
the loader and check the hydraulic oil level
indicator. Add fluid as needed. Discard the
used filter in accordance with local/federal
environmental rules and regulations.
- 93 -
INTERVAL OF REPLACEMENT
Replace the fluid according to service sched-
ule(7.4)
It may be nessary to change more frequently
then the normal interual if the fluid becomes
with foreigu material(dirt, water, grease, etc)
or if the fluid has beer subjected to tempera-
ture levels greater than the maximum IC0O043P
recommeded. 2060XL/DSL902
- 94 -
7.16. Chain Case Drain and Refill
1. Chain case drain plugs
TO DRAIN CHAIN CASE:
1) Remove drain plugs and drain case oil into
an approved waste oil container.
IC0O057P
- 95 -
Loosen the jam nut (B), remove bolt (C), and rotate
the clevis on the linkage to adjust the cable tension
until parking brake engages fully and interlock func-
IA0OB02P
tions properly.
- 96 -
7.18. Tire Maintenance 7.18.2. Inflation Pressures
1550XL/DSL702 - 57 psi ( 4.0 kg/cm2 )
7.18.1. General Information
2060XL/DSL902 - 50 psi ( 3.5 kg/cm2 )
Tires should be checked regularly for wear,
damage, and proper inflation. When replacing 1
tires, ensure that the size matches those 3 6
Overall Height
F
A. Fully Raised in(mm) 145.8 (3704) 156.2 (3967)
B. To Hinge Pin in(mm) 114.8 (2915) 122 (3100)
C. To Canopy in(mm) 76.9 (1954) 80.1 (2035)
Overall Length
D. With Bucket in(mm) 126.3 (3208) 126.0 (3200) O
E. Less Bucket in(mm) 99.3 (2521) 98.7 (2508)
Overall Width K
IC0O045I
- 98 -
Spec.
R S
Item Unit 1550XL 2060XL Q
DSL702 DSL902
F
Dumping
K. Dump Angle deg 45 44
L. Dump Height in(mm) 87.6 (2224) 93.6 (2378)
Reach
M. Fully Raised in(mm) 25.4 (645) 27.3 (694) O
Rollback
N. Max. at Ground deg 25 26 K
IC0O045I
- 99 -
Definitions: (Daewoo Skid Steer Loader)
Refer to sketches on pages 98 or 99 of this section.
Overall Operating Height (A) - Fully Raised - The vertical distance in inches (millimeters) from the ground to
the highest point attainable.
Height to Hinge Pin (B) - Fully Raised - The vertical distance in inches (millimeters) from the ground to the
centerline of the bucket hinge pin.
Overall Height (C) - The vertical distance in inches (millimeters) from the ground to the highest point on the unit
with the bucket on the ground.
Overall Length (D) - The horizontal distance in inches (millimeters) with the bucket on the ground and level,
measured from the foremost point of the bucket cutting edge to the rear most point of the machine.
Overall Length (E) - Without Bucket - The horizontal distance in inches (millimeters) from the furthest rearward
to the furthest point forward.
Bucket Width (F) - The maximum outside width in inches (millimeters) of the bucket specified.
Overall Width (G) - The maximum outside width in inches (millimeters) of the machine specified exclusive of bucket.
Wheelbase (H) - The vertical distance in inches (millimeters) from the center of the front wheel or idler to the
center of the rear wheel or sprocket.
Height to S.I.P. (I) - The vertical distance in inches (millimeters) from the ground to the Seat Index Point.
Ground Clearance (J) - The minimum vertical distance in inches (millimeters) from the ground to the lowest
point on the machine between the tires or tracks with the lift arm raised.
Dump Angle (K) - The maximum angle in degrees that the longest flat section of the inside bottom of the bucket
will rotate below horizontal with the bucket hinge pin at maximum height.
Dump Height (L) - The vertical distance in inches (millimeters) from the ground to the lowest point of the cutting
- 100 -
edge with the bucket hinge pin at maximum height and the bucket at a 45 dump angle. The angle is less than
45, specify angle.
Reach (M) at Maximum Height - The horizontal distance in inches (millimeters) from the foremost point on the
machine (including tires, tracks, or loader frame) to the front most point on the bucket cutting edge at a 45 angle
with the bucket hinge pin at maximum height. Specify angles less than 45.
Maximum Rollback (N) - at Ground - Maximum rollback angle in degrees without movement of the lift arm.
Maximum Rollback (O) - Fully Raised - The angle in degrees from the bucket cutting edge level position to the
maximum rollback position.
Digging Depth (P) - The vertical distance in inches (millimeters) from the ground to the bottom of the bucket cut-
ting edge at the lowest position with the bucket cutting edge horizontal.
Loader Clearance Circle (Q) - Front No Attachment - The smallest diameter measured in inches (millimeters)
that the outermost front point on the machine will describe measured from a point located at 1/2 the wheelbase
(H) and 1/2 the overall width (G) of the machine.
Loader Clearance Circle (R) - Front with Standard Attachment - The smallest diameter measured in inches
(millimeters) that the outermost front point on the machine will describe measured from a point located at 1/2 the
wheelbase (H) and 1/2 the overall width (G) of the machine.
Loader Clearance Circle (S) - Rear - The smallest diameter measured in inches (millimeters) that the outermost
rear point on the machine will describe measured from a point located at 1/2 the wheelbase (H) and 1/2 the over-
all width (G) of the machine.
Tread or Track Gauge (T) - The transverse distance in inches (millimeters) between the centerlines of the tires
or sprockets. If the front and rear are different, both must be specified.
Angle of Departure (U) - The angle in degrees taken from a line drawn from the lowest and rear most portion of
the rear overhang to the rear bottom face of the rear tire to the ground.
- 101 -
8.2. Operational Specification (Per SAE J732 Feb 80)
8.2.1. Performance
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Rated Capacity lb(kg) 1500 (680) 2000 (907)
Bucket Capacity ft3(m3) 11.9 (0.34) 14.1 (0.40)
Operating Weight lb(kg) 5849 (2653) 6777 (3074)
Tipping Load lb(kg) 3946 (1790) 4647 (2108)
Hydraulic Lifting Capacity lb(kg) 4465 (2025) 4718 (2140)
Break Out Force - Bucket lb(kg) 2910 (1320) 3770 (1710)
- Boom lb(kg) 3285 (1490) 5194 (2356)
- 102 -
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Make - DAEWOO DAEWOO
Model - D427 D430
Type of Fuel - Diesel Diesel
Cooling Medium - Water Water
No. of Cylinders ea 4 4
3
Displacement in (cc) 164.8 (2701) 181.7 (2977)
Bore Size in(mm) 3.62 (92.0) 3.74 (95)
Stroke in(mm) 4.0 (101.6) 4.13 (105)
Horsepower Net hp(ps)/rpm 50.2 (51.0)/2400 62.6 (63.5)/2500
High Idle rpm 260050 265050
Low Idle rpm 90025 90025
Torque ft.lb(kg.m)/rpm 115.8 (16.0) 130.2 (18.0)
2000 1800
Torque Rise % 3.0 8.6
Lubrication - Full Flow Full Flow
- 103 -
8.2.3. Final Drive Components
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Chain - 2 Chain with 2 Chain with
Super80HT & Super100HT &
Super80HT Super100HT
No. of Teeth
Drive Sprocket (Motor) ea 12 10
Counter Sprocket ea
Drive Sprocket (Axle) ea 32 28
Tire
Type - Flotation- Flotation-
Tubeless Tubeless
Size - 10-16.5, 8PR 12-16.5, 8PR
Pressure psi (kg/cm2) 57 (4.0) 50 (3.5)
Wheel
Size - 8.25 X 16.5 9.75 X 16.5
Hole x Pitch Circle Diameter - 8 X 8 8 X 8
- 104 -
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Type - Piston, Variable Piston, Variable
Displacement Displacement
3
(Manual) (Manual)
Max. Displacement in (cc)/rev 2.68 (44) 2.68 (44)
Relief Setting Pressure bar (psi) 250 (3555) 250 (3555)
Internal Charge Pump - None None
Rotation - clockwise clockwise
Swash Plate Operating Angle deg 16 16
Mounting - SAE 2 Bolt B SAE 2 Bolt B
- Mount Mount
Shaft ANSI B92.1-1970 ANSI B92.1-1970
Class No.5 Class No.5
30X15X16/32 30X15X16/32
Standard Pump
Flow (Max) LPM(GPM) 60 (16) 77.7 (20.5)
Relief Pressure (max) psi- 300035 300035
at charge pump (2072.4bar) (2072.4bar)
High Flow Option Pump
Flow (max) LPM(GPM) 101(26.7) 131.5(34.8)
Relief Pressure (max) psi 300035 300035
at charge pump (2072.4bar) (2072.4bar)
- 105 -
8.2.5. Hydraulic System
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Motor
Type - Orbit, Fixed Orbit, Fixed
Displacement Displacement
Bi-rotational Bi-rotational
Displacement in3(cc)/rev 32.04 (523.6) 32.04 (523.6)
Mounting - SAE 4 Bolt B Mount SAE 4 Bolt B Mount
Spline Shaft Spline Shaft
Pump
Type - Gear Gear
3
Capacity in (cc)/rev 1.47 (23.0) *1.92 (31.5)
Max. Pressure bar(psi) 230 (3,335) 230 (3,335)
Max. Speed rpm 3,000 3,000
Mounting - SAE 2 Bolt A Mount SAE 2 Bolt A Mount
Shaft SAE Spline Shaft SAE Spline Shaft
Rotation - Clockwise Clockwise
Control Valve
No. of Spool - 3 3
Relief Setting Pressure psi 2840 (+70) 2840 (+70)
(set by valve supplier) (195 (+5) bar) (195 (+5) bar)
Circuit - Series on Lift Float Series on Lift Float
Function with Detent Function with Detent
Series on Tilt Series on Tilt
Series on Auxiliary Series on Auxiliary
With Electric Detent With Electric Detent
(thumb control) (thumb control)
3
* European Truck (CE Area) : 1.77 (29.0) in (cc)/rev
- 106 -
Models
Item Unit
1550XL/DSL702 2060XL/DSL902
Boom Cylinder
Type - Single Rod, Double Acting Single Rod, Double Acting
Number ea. 2 2
Cylinder Bore in(mm) 2.17 (55) 2.36 (60)
Cylinder Rod in(mm) 1.58 (40) 1.57 (40)
Stroke in(mm) 39.2 (996.0) 42.0 (1065)
Mounting - Single Crest Crevice Single Crest Crevice
Plating on Rod - Hard Chrome w/15-50 Hard Chrome w/15-50
Micron Thickness Micron Thickness
Bucket Cylinder
-
Type Single Rod, Double Acting Single Rod, Double Acting
Number ea. 2 2
Cylinder Bore in(mm) 2.36 (60) 2.36 (60.0)
Cylinder Rod in(mm) 1.10 (28) 1.57 (40)
Stroke in(mm) 14.45 (367) 20.0 (507)
Mounting - Single Crest Crevice Single Crest Crevice
Plating on Rod - Hard Chrome w/15-50 Hard Chrome w/15-50
Micron Thickness Micron Thickness
HRC 52-60 Hardness HRC 52-60 Hardness
- 107 -
Models
Item Unit
1550XL/DSL702 2060XL/DSL902
Hydraulic Filter
Type - Full Flow Spin-On Full Flow Spin-On
Filter Rating - 13 Micron Beta Rating 13 Micron Beta Rating
of 20 of 20
Rated Flow I(gal)/min 132.5 (35) 132.5 (35)
By-Pass Valve Closing PR50 PSID Closing PR50 PSID
( Normally Open Type ) ( Normally Open Type )
- 108 -
Spec
Item Unit
1550XL/DSL702 2060XL/DSL902
Alternator - 12V - 60A 12V - 60A
Battery - 12V-100AH, 700CCA 12V-100AH, 700CCA
Starter 12V - 2.5KW 12V - 2.5KW
Lighting -
Head Lamps each 2 2
Rear Lamps each 1 1
- 109 -
8.2.7. Instrument Features 8.2.8. Seat
- 110 -
Models
Item Specifications Unit
1550XL/DSL702 2060XL/DSL902
Fuel Tank, Max #2 Diesel recommended for Ambient gal (liter) 14.3 (54) 18.2 (69)
Temp above 40 deg. F
#1 Diesel recommended for Ambient
Temp below 40 deg. F
Hydraulic Max Oil Tank SAE 10W20CD; Taxaco TDH; Mobil gal (liter) 8.0 (30) 11.9 (45)
Hydraulic System Capacity Fluid 423; Chevron Tractor Hydraulic gal (liter) 11.1 (42) 12.7 (48)
Fluid; G Automatic Fluids meeting
Caterpillar TO-2 or Allison C3 standards
Chain Case Oil API CC or CD SAE 10W30 gal (liter) 5.9 (22.5) 6.3 (24)
Cooling Fluid Recommended mixture is 50/50 gal (liter) 1.8 (6.9) 1.8 (6.9)
ethylene glycol and water
Engine Lubrication - w/filter API CC or CD SAE 10W30 for gal (liter) 2.1 (8) 2.1 (8)
w/o filter Ambient Temp above -4 deg. F gal (liter) 2.0 (7.6) 2.0 (7.6)
API CC or CD SAE 5W30 for
Ambient Temp below -4 deg. F
- 111 -
ENVIRONMENT PROTECTION SECTION
When servicing this lift truck, use an authorized servicing area and an approved container to collect coolant, oil,
fuel, grease, electrolyte and any other potential environmental pollutant before any lines, fittings or related items
are disconnected or removed. After servicing, dispose of those materials in an authorized place and container.
When cleaning the lift truck, be sure to use an authorized area.
- 112 -
WARNING
Do not start, operate or service this machine unless you have read and understand these instructions
and received proper training.
Unsafe or improper use of the machine may cause serious injury or death.
Operators and maintenance personnel must read this manual and receive and receive training before
operating or maintaining the machine.
This manual should be kept with the machine for reference and periodically reviewed by the machine
operator and by all personnel who will come into contact with it.
The following warning is povided pursuant to California Health & Safety Code Sections 25247.5 et, seq,
WARNING
WARNING
California Proposition 65
Engine Exhaust, some of its consituents, and certain vehicle components contain or emit chemi-
cals known to the State of California to cause cancer and birth defects or other reproductive
harm.
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and birth defects or other reproductive harm.
WASH HANDS AFTER HANDLING.
S-1
FOREWORD
This manual explains the safety rules, lubrication, testing and controls to operate and maintain the DAEWOO Skid
Steer Loader for safe and optimal performance.
The operator should be familiar with all of the contents of this manual before starting the vehicle to insure maxi-
mum performance, safety and economy.
Descriptions explain the testing, starting, operation, and stop procedures in detail.
To maintain the vehicle in top condition, the operator should periodically check the vehicle in accordance with the
service schedule.
The periodic maintenance intervals in this manual are based on the service hour meter.
Environment Management
Note that DAEWOO INDUSTRIAL VEHICLE DIVISION is ISO 14001 certified which is harmonized with ISO 9001
Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by
internal and external inspection entities. LIFE - CYCLE ANALYSIS has also been made through out the total prod-
uct life. ENVIRONMENT MANAGEMENT SYSTEM includes DESIGN FOR ENVIRONMENT from the initial stage
of the design.
ENVIRONMENT MANAGEMENT SYSTEM considers environmental laws & regulations, reduction or elimination of
resource consumption as well as environmental emission or pollution from industrial activities, energy saving, envi-
ronment - friendly product design(lower noise, vibration, emission, smoke, heavy metal free, ozone depleting sub-
stance free, etc.), recycling, material cost reduction, and even environmentally oriented education for the employee.
S-2
SAFETY INFORMATION
HA0OA00I
S-3
SIGNAL WORDS
S-4
WARNING SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual and all safety labels
on your machine. Keep safety labels in good condition. Replace missing or CAU
TIO
N
NING
damaged safety labels. Be sure new equipment components and WAR
repair parts include the current safety labels. Learn how to operate the
machine and how to use controls properly. Do not let anyone operate
the machine without instruction. Keep your machine in proper working
condition. Unauthorized modifications to the machine may impair operator
safety and well being and/or machine life and function.
HA0OA01I
ONLY trained and authorized personnel should operate and maintain the machine.
Use common sense and follow all safety rules, precautions and instructions when operating or perform-
ing maintenance on the machine.
When working with another person, be sure all hand signals to be used are understood.
Certain operating conditions may require reference to applicable OSHA, ANSI, ISO, EEC or other local
and national regulations. Consult your supervisor or safety coordinator to be sure all applicable stan-
dards are being followed, and for special operating conditions.
Never operate equipment under the influence of drugs or alcohol. Certain prescription and over-the-
counter medications can affect alertness and coordination. Follow instructions on labels and/or consult
your physician. Notify your supervisor or consult your physician for clarification.
S-5
CONTENTS
S-7
cont. 2.0 SAFETY INFORMATION
S-8
S-9
6.0. OPERATING INSTRUCTIONS
6.1. Inspection Before Boarding ................................................................................................................48
6.2. Boarding the Loader ............................................................................................................................48
6.3. Starting..................................................................................................................................................49
6.4. Traveling and Steering ........................................................................................................................51
6.5. Operation ............................................................................................................................................52
6.6. Traveling on a Slope, Parking ............................................................................................................55
6.7. Towing Procedures ..............................................................................................................................56
6.8. Lifting ..................................................................................................................................................57
6.9. Transportation ......................................................................................................................................58
6.10. Bucket and Attachments ......................................................................................................................59
6.11. Boom Lock Operation.......................................................................................................................... 62
S-10
WORLDWIDE NETWORK
S-12
1. OWNER/OPERATOR SAFETY also includes establishing daily inspections
OVERVIEW and scheduled maintenance practices to
ensure the equipments ongoing safe operat-
1.1. Safety Message for Owners and ing condition.
Operators
The manual you are reading now is intended
Your DAEWOO equipment has been designed to help you meet your responsibilities. It iden-
with the safety of the persons who will operate tifies warning labels on the equipment and
and service it in mind. However, our care in explains what they mean. It describes some
designing this equipment does not guarantee of the general and specific hazards to be
that it will be used in a safe manner. Safe aware of when operating the equipment. It
operating practice is where your responsibility also offers some suggestions for establishing
and the responsible actions of the persons workplace rules and operator training pro-
who operate this equipment take over. grams.
-1-
options. This section of the manual discuss- Recognize and avoid potential hazards in
es these issues as well. your workplace.
At the end of this overview, we list specific Understand and abide by the Warning labels
OSHA, ANSI, and other published resources attached to the equipment.
you can consult for ways to help you comply Inspect the equipment for its serviceability at
with safety requirements for the use of this the beginning of each shift.
equipment in your workplace. Report immediately any service problems you
notice before you use the equipment or that
1.1.2. Operator Responsibility develop while you are using it.
Report immediately any unsafe workplace
If your job includes operating this equipment,
conditions that threaten your safety or the
you should first get formal training in how to
safety of others.
operate it properly and safely. Furthermore,
Avoid horseplay or other reckless actions that
you should ensure that your workplace is
you know endanger yourself or others.
maintained to assure your continued safety
and the safety of others around whom you
In short, every operator of this equipment has
work.
the responsibility to use common sense at all
times and to make safety his or her number
In addition, you, the operator, have the
one job priority.
responsibility to:
-2-
1.2. Maintaining a Safe Workplace
As we said, operators should recognize and When the equipment is driven onto trailers, use
avoid hazards in the workplace. Although some wheel chocks and jack supports if necessary to
injuries occur because of unsafe operating prevent creeping and possible collapse.
practices, many result from unnecessary work- Develop - and enforce - workplace safety rules
place hazards. To maintain a safe workplace for all employees.
environment for this equipment, do the follow- Post these rules conspicuously in the areas
ing: where they apply.
Remove physical hazards where the equipment Many appropriate workplace rules are published
will be operated, in either the plant or the yard. by OSHA, ANSI, and the National Safety
Separate pedestrian and equipment traffic Council. (See the list below under Information
wherever possible. Resources for Operation, Maintenance, and
Place convex mirrors at blind intersections. Safety.) We recommend that you consult
Require the use of horns at intersections or these publications as you develop and update
when approaching pedestrian areas. the safety rules for your workplace.
Establish equipment speed limits.
Install and maintain backup alarms and flashing
caution lights on equipment.
Use edge guards, levelers and trailer locks on
docks.
-3-
-4-
1.4. Maintenance Practices 1.5. Operator Safety Training
Well maintained equipment is safer equipment. Although this manual contains much informa-
A regular program of scheduled maintenance tion about safety practices, it is not meant to be
should be part of your facilitys ongoing safety a training manual for new operators. An
program. Daily inspections or inspections at employers responsibility extends beyond hand-
the start of every shift are required by OSHA. ing an employee this or any other document
Your DAEWOO dealer can help you train your and saying read this to learn how to operate
operators for this task and provide you with this equipment.
genuine replacement parts and service equip-
ment when scheduled (or unscheduled) main- 1.5.1. Formal Training
tenance and repairs are needed.
OSHA and ANSI require formal training for
new operators and refresher training for ex-
Although operators have a daily responsibility
perienced operators, along with appropriate
to inspect and report service problems, OSHA
on-the-job supervision. Furthermore, training
and ANSI standards require that equipment
must be tailored to the specific conditions of
maintenance and repair be performed by au-
your workplace and the workplace rules you
thorized mechanics only. Understand what is
have developed to protect your employees.
reasonable to expect in this area, and leave the
Whenever work conditions change in ways
serious maintenance and repair tasks to pro-
that affect operator safety, training for the new
fessional mechanics and technicians.
conditions must be provided. Of course,
before any employee can be selected to
-5-
operate industrial or construction type equip- In what areas of our workplace does operating
ment, the employee must meet the employ- the equipment pose hazards to pedestrians?
ers specific visual, auditory, physical and What hazards must operators be trained to
mental ability standards. deal with?
Does our workplace have any one-way aisles,
1.5.2. Inspection Training speed zones, high noise, low light, or fire haz-
ard areas?
OSHA furthermore requires that operators be
What are the specific features of our loading
trained to conduct daily equipment safety
docks, ramps, or railcar loading facilities?
inspections. The goal of these inspections is
What specialized attachments are used on our
to prevent any piece of equipment in need of
equipment?
repairs from being placed into service and
What personal protective equipment or special
thereby endangering personnel. Your DAE-
clothing is necessary to operate the equipment
WOO dealer can help you develop training to
in our work environment? (hard hats, seat
comply to this and to other OSHA/ANSI re-
restraints, respirators, protective shoes or
quirements.
gloves, etc.)
Are operators conducting daily inspections
1.5.3. Training Program Development
prior to shift start?
As noted above, OSHA/ANSI requires your Does our equipment require any special refu-
training to be designed around the conditions eling procedures?
present in your operation. To ensure this, ask
yourself specific questions: One additional recommendation: ask those
-6-
employees who work around (but do not op- 1.6. Information Resources for
erate) the equipment for suggestions about Operation, Maintenance, and
what the operators should be taught. Safety
-7-
ANSI/ASME B56. 1 : Safety Standard for Low NFPA 58: Storage and Handling of Liquified
Lift and High Lift Trucks (Safety Code of Petroleum Gases. Available from: National Fire
Powered Industrial Trucks). Available from: Protection Association, Inc., Batterymarch Park,
Society of Mechanical Engineers, United Quincy, MA 02269.
Engineering Center, 345 E. 47Th Street, New
National Safety Council Data Sheets: 1-664 -
York, NY 10017.
Writing and Publishing Employee Safety
EN474 - 1 : Earth - moving Machinery - Safety Regulations; 479 - Liquified Petroleum Gases
-General Requirements , for Industrial Trucks; 195.71 - The In-Plant
EN474 - 3 : Earth - moving Machinery - Safety Pedestrian. Available from: National Safety
-Requirements for Loaders. Council, 444 North Michigan Avenue, Chicago,
Available from : European Committee for IL 60611.
Standardization, rue de Stassart, 36 B - 1050
Publications Concerning Safe Handling and
Brussels.
Storage of LP Gas: Available from: National LP
Skid - Steer Loader Safety Manual. Available Gas Association, 1301 West 22nd Street,
from the Equipment Manufacturers Institute, 10 S Oakbrook, IL 60521
Riverside Plaza, Chicago, Illinois 60606-3710.
Other OSHA regulations which may be applica-
Accident Prevention Manual for Industrial Opera- ble to the place of use.
tions : Two volumes: Administration and
You can receive help in applying information
Programs and Engineering and Technology.
from these sources to your workplace by con-
Available from : National Safety Council, 444
tacting OSHA or your Workers Compensation
North Michigan Avenue, Chicago, IL 60611.
Insurance Company.
-8-
2. SAFETY INFORMATION
The following section of this manual discusses rules or take obvious precautions. Often you can
some of the general and specific safety issues avoid an accident by recognizing situations that
for your equipment. It gives you basic safety pre- might be hazardous. Furthermore, anyone who
cautions. It also shows you where to find warn- operates, maintains, or repairs this equipment
ing labels used on this equipment. The warnings should have the necessary training, skills, and
themselves are reproduced here for you to read. tools.
Before you operate or perform any maintenance Improper operation, maintenance, or repair of
on this equipment, read this Safety Information this equipment can be dangerous and could
section carefully. Also carefully read the opera- result in injury or death.
tion and other sections of this manual and heed
all of the safety information they contain. Also Do not operate or perform any lubrication, main-
locate, read, and understand the warning decals tenance, or repair on this equipment until you
on the equipment itself. have read and understood the operation, main-
tenance, and repair information in this manual.
-9-
Hazards are identified by the exclamation point every possible circumstance that might involve a
(!) Safety Alert Symbol followed by words such hazard. You must ensure that your operating
as DANGER, WARNING, or CAUTION. techniques, tools, and work procedures are safe
for you and others. You should also make sure
that the equipment will not be damaged or made
unsafe by your chosen operation, maintenance,
DANGER or repair procedures.
- 10 -
sentation that the OSHA rules and regulations 2.2. Rated Operating Load Plate
have been reproduced verbatim.
DO NOT exceed machine rated operating load
(marked ) as described on the rated operat-
The best method for preventing serious injury or
ing load plate attached to your machine.
death is for the operator to be familiar with the
proper operation of the equipment. Be alert and
avoid actions or conditions that can result in an
accident.
DAEWOO HEAVY INDUSTRIES LTD.
MADE IN KOREA
MACHINE NAME
SERIAL NUMBER
IA0OA02I
- 11 -
CAUTION
Always keep safety and information labels clean. If they are lost or damaged, attach them again or
replace them with a new label. Safety labels are available in languages other than ENGLISH. Please
contact your dealer or DAEWOO if you need non-English labels.
2 D
F D
1 5 3
6
F 4 C
B
E E C B
A A
IA0OA03I
- 12 -
2.3.2. Label Descriptions
1 Danger warning for Boom lock 3 Warning for canopy latch
IA0OA12I
- 13 -
W
A
R
N View
View F-F
I (Inside
(Inside of
"F-F"
of Canopy
Canopy LH)
LH)
N IA0OA07I
G D415545
ALWAYS ASSURE
View
View A-A
"A-A"
HOT EXHUAUST AND MUFFLER IA0OA05I
D415546
IA0OA09I
- 14 -
WARNING DANGER
8
9 10
3
View "B-B" View "C-C"
(Inside of Canopy RH) (Inside of Canopy. LH)
IA0OA04I IA0OA17I
8 Warning for general safety rules. 9 Warning for fastening seat belt and seat bar.
WARNING
WARNING
AVOID DEATH OR SERIOUS INJURY
READ AND UNDERSTAND THE OPERATOR'S MANUAL PRIOR ALWAYS WEAR SEAT BELT.
TO OPERATING THIS MACHINE FAILURE TO FOLLOW THESE ALWAYS OPERATE WITH SEAT
PRECAUTIONS CAN CAUSE INJURY OR DEATH.
CARRY LOAD LOW.
BAR IN DOWN POSITION.
AVOID STEEP SLOPES AND HIGH SPEED TURNS. AVOID SUDDEN AND ABRUPT
TRAVEL SLOWLY OVER ROUGH TERRAIN. MACHINE OPERATION.
NEVER CARRY MORE THAN RATED OPERATING LOAD.
NEVER PLACE ANY PART OF YOUR BODY UNDER BOOM NEVER CARRY RIDERS.
OR ATTACHMENTS.
KEEP BOTH FEET ON PEDALS AND BOTH HANDS ON
NEVER USE LOADER AS
CONTROLS WHILE OPERATING MACHINE. MANLIFT OR WORK
D416620
PLATFORM.
D415532
IA0OA15I IA0OA13I
- 15 -
DANGER
BEFORE LEAVING SEAT :
LOWER BOOM OR ATTACHMENTS
TO THE GROUND. Pedal
STOP ENGINE.
SET PARKING BRAKE.
RAISE THE SEAT BAR.
BE SURE PEDALS ARE LOCKED.
TO EXIT WHILE THE BOOM IS IN A
RAISED POSITION, THE BOOM
LOCK MUST BE ENGAGED. (SEE
INSTRUCTIONS ON OUTSDE OF
BOOM LOCK OR OPERATION
MANUAL.)
D415535
Spark Arres-
Clean the spork chamber.
tor Muffler
Tires Check air pressure and damage to tires.
Wheel Nuts Tighten to correct torque if loose.
Seat Belt Check the condition of seat belt.
Seat Bar Check the seat bor for correct operation.
Safety Signs Check for damaged signs and replace damaged signs.
Pivots Grease pivots as needed.
- 16 -
2.4. General Safety and Hazard Information
2.4.1. Unauthorized Modification
Any modification made without authorization from DAEWOO can create hazards.
Before making a modification, consult your DAEWOO dealer.
Improper modification could result in injury or death.
Improper use of safety features could result in serious bodily harm or death.
- 17 -
NEVER jump on or off the machine. NEVER get on or off a moving machine.
When mounting or dismounting, always face the machine and use the handrails.
Do not grasp or come in contact with any control levers when getting on or off the machine.
Ensure safety by always maintaining at least three-point contact of hands and feet with the
handrails and steps.
Always remove any oil or mud from the handrails, steps and shoes.
NEVER mount or dismount the machine with engine running.
HA0OA03I
- 18 -
2.4.4. Fire Prevention and Hazardous Fluids and Vapors
Fuel, oil, antifreeze, and other flammable fluids and combustibles can be ignited by a flame or hot sur-
faces. Vapors can be particularly FLAMMABLE and can be HAZARDOUS.
Keep open flame and hot surfaces away from flammable fluids and combustibles.
Stop the engine and do not smoke when refueling.
Tighten all fuel and oil caps securely.
Refueling and oiling should be done in well ventilated areas.
Keep oil and fuel in a designated area and do not allow unauthorized persons to enter.
Thoroughly remove wood chips, leaves, paper and other flammable items accumulated in the engine
compartment .
Check fuel and hydraulic systems for leaks prior to starting or using vehicle.
Have any leaks repaired before operating the machine.
Wipe up any excess oil, fuel or other flammable fluids.
Be sure a fire extinguisher is present and working and that personnel are properly trained in extin-
guisher operation.
Never use ether or other starting aids on any engine with glow plugs or other engine preheating devices.
See OSHA Class 1910.178.
Avoid skin contact, injestion and excessive breathing of vapors from fuel, oil, antifreeze, and other fluids.
See California Proposition 65 in the front of this book.
HA0OA04I
- 19 -
Before starting the engine, thoroughly check the area for any
unusual conditions that could pose a hazard.
Before starting the engine, examine the terrain and soil condi-
tions of the work site. Determine the best and safest method
of operation.
- 20 -
2.5.2. Operators Cab
Do not leave tools or spare parts lying around in the operators compartment. They may damage,
break, or interfere with the control levers or switches.
Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
Always check the seat belt, seat bar, and hardware for damage or wear. Replace any worn or dam-
aged parts. Always use seat belts and seat bar when operating your machine.
- 21 -
DANGER
,,,
VENTILATION FOR ENCLOSED AREAS
,,,
adequate ventilation. Exhaust fumes from the engine can KILL.
HA0OA07I
A standard loader or a loader equipped with a spark arrestor/spark arresting muffler cannot be
operated in these areas. Use of these machines in flammable/explosive atmospheres can result in
fires and/or explosions which could cause serious injury or death.
See Code of Federal Regulations (OSHA) 29CFR Part 1910.178, to determine where machines
which are approved and labeled as G, GS, D, DS, DY, LP, LPS, G/LP, or GS/LPS are permitted to
operate.
- 22 -
2.5.6. Precautions for Mirrors, Windows, and Lights
Always remove all dirt from the surface of the windows and lights to ensure that you can see well.
Check that the head lamps and working lamps are installed to match the operating conditions.
Check also that they light up properly.
When working in dark places, install working lamps and head lamps, and set up lighting in the
work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or other cause, and wait for con-
ditions to improve to a level that allows the operation to be carried out safely.
- 23 -
DANGER CHECK THAT NO ONE IS NEAR THE MACHINE BEFORE MOVING, TURNING,
TRAVELING IN REVERSE OR OPERATING ANY ATTACHMENTS
Keep all parts of the machine or load far away from all
electric lines.
IA0OA22S
- 24 -
2.5.10. Operating on Snow
When working on snow or icy or wet roads, even a slight slope may cause the machine to slip to
the side, so always travel at low speed and avoid sudden starting, stopping, or turning.
When there has been heavy snow, the road and objects placed beside the road are buried in the
snow and cannot be seen, so always carry out snow-clearing operations carefully.
Avoid operating your machine too close to the edge of cliffs, overhangs, loading docks, deep
ditches, and other uneven surfaces or drop-offs. If these areas collapse or you get too close to
the edge, your machine could fall or tip over and result in serious injury or death. Remember that
the soil after heavy rain or blasting is weakened in these areas.
Earth laid on the ground and the soil near ditches are loose. It can collapse under the weight or
vibration of your machine.
- 25 -
Never enter, or put your hand or arm or any other part of your body between movable parts such
as between the work equipment and cylinders, or between the machine and work equipment. If the
machine or work equipment is operated or moved, the clearance will change and this may lead to
serious damage or personal injury.
ALWAYS keep both feet on pedals and both hands on controls when operating loader.
The cab structure of the 1760XL complies with the following ROPS (Rollover Protective Structure) and
FOPS (Falling Object Protective Structure) criteria. -ROPS per ISO 3471 -FOPS per ISO 3449 Level I
Never operate without a ROPS/FOPS approved cab.
2.5.13. Parking
- 26 -
2.5.14. Precautions for Attachments
When installing/using an optional attachment, read the instruction manual for the attachment and
the information related to attachments in the manual.
Never use attachments that are not authorized by DAEWOO or your DAEWOO dealer. Use of
unauthorized attachments could create a safety problem and adversely affect the proper operation
and useful life of the machine.
NEVER attempt to engage or disengage the Universal Attachment System (Quik-tach) levers with
the engine running.
WARNING
Load, unload and turn on flat level ground. Do not exceed machine rated operating load shown
on the rated operating load name plate attached to your machine. Failure to obey warnings can
cause the machine to tip or roll over and cause injury or death.
WARNING
Never dump over an obstruction that can enter the operator cab. The machine could tip forward
and cause injury or death.
- 27 -
CAUTION
When the engine stops and the seat bar (pedal locking device/parking) is secured in place (lowered).
if the pedal is depressed, then the boom or the bucket descends.
CAUTION
When the pedal is kept depressing, then even though the seat bar (pedal locking device/parking) is
raised, the boom or the bucket keeps moving regardless of engines running or not.
- 28 -
2.6. Maintenance Safety
2.6.1. Periodic Maintenance
WARNING
1. Never attempt to service a machine unless you are authorized and qualified to do so.
2. Before attempting any service on this machine, familiarize yourself with all instructions and warn-
ings in the operators manual and all machine decals.
3. Do not attempt to service machine unless you have the necessary skill, information, safety gear,
and tools and equipment to perform the procedure correctly.
4. While service is being performed ensure a warning tag is installed on or near the ignition key switch
and clearly visible to prevent inadvertent starting of the machine during service.
5. If a service procedure necessitates running the engine, the control levers must remain in the neu-
tral position and the emergency brake must be fully engaged. Failure to do so can result in injury
or death.
6. After completing service check for: proper operation of all controls, correct torque on all fasteners
and fittings, any fluid leaks (prior to and after starting engine), all tools and equipment must be
removed from the machine.
7. Ensure all hoisting and supporting equipment is in good repair and of adequate capacity to support
loader.
8. Failure to follow safety precautions and proper service procedures can lead to machine malfunction
or damage, injury to operator or bystanders, or death.
- 29 -
- 30 -
2.6.3. Maintaining and Inspecting Hydraulic Equipment
- 31 -
Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked
piping, tubes or hoses. They may burst during use.
Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
Be aware that the machine hydraulic circuits are always under pressure.
Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the
internal pressure.
If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil
hits your skin or enters your eyes. It also can be extremely hot. Always wear safety glasses and
appropriate gloves, and use a piece of cardboard or a sheet of wood to check for oil leakage. The
stream of oil may not be visible.
If your skin is punctured by a jet of high-pressure oil, seek a doctor immediately for medical atten-
tion.
IA0OA26I
- 32 -
2.6.5. Preventing Battery Hazards
Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If
you spill acid on yourself, immediately flush the area with water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into eyes, flush them
immediately with large quantities of water and see a doctor immediately.
If you accidentally swallow battery acid, drink a large quantity of water or milk, beaten egg or veg-
etable oil. Call a doctor or poison prevention immediately.
When working with batteries, ALWAYS wear safety glasses, goggles, or face shield.
Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a
small spark or flame.
Before working with batteries, stop the engine and turn the starting switch to the OFF position.
Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as
tools, across the terminals or between the hot (+) post and frame or other grounding surface.
Keep the battery terminals tightened securely. Loose terminals can generate sparks and lead to an
explosion.
When repairing the electrical system or when carrying out electrical welding, remove the negative
(-) terminal of the battery to stop the flow of current.
NEVER attempt to charge or jump start a frozen battery. An explosion may occur.
IA0OA27I
- 33 -
Always put oil drained from your machine in containers. Never drain
oil directly on the ground.
Obey appropriate state, local, and federal laws and regulations when
disposing of harmful liquids, objects, or wastes such as oil, fuel,
coolant, solvent, acids, filters, batteries and others.
HA0O1043I
Keep away from all moving or rotating parts and be careful not to let
anything get caught in them.
Never touch any rotating parts. If your body or tools touch the fan
blades or fan belt, they may be cut off or sent flying or it may pull you
into the equipment.
IA0OA28I
- 34 -
2.6.8. Tire Maintenance
Tires should be checked regularly for wear, premature wear and damage to drive train
damage, and proper inflation. When replacing components. If tires are replaced in pairs,
tires, ensure that the size matches those they should be mounted on the same side of
already on the vehicle. Mismatched tire sizes the vehicle to minimize stress on the drive
can change vehicle performance and cause train.
DANGER
Tires should only be mounted/dismounted from rims or repaired by trained and authorized personnel
using the proper equipment and procedures. Death or serious injury could result. See OSHA
1910.177.
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3. SERIAL NUMBER LOCATIONS
3.1. Vehicle Serial Number 3.2. Engine Serial Number
MACHINE NAME
SERIAL NUMBER
IA0OA02I
The engine number is stamped on a plate on
the right side of the cylinder block.
The vehicle serial number plate is riveted on
the inner side of left-hand mast. If you need parts, service or information for
your engine, you must give the complete
engine number to your DHI distributor.
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4. MACHINE COMPONENTS
4.1. Identification of Machine Parts
IA0OA30P
- 37 -
IA0OA31P
- 38 -
5. CONTROLS AND INSTRUMENTS
5.1. Instrument Panel
(9) (10) (8) (11) (15) (13) (16)
STOP
(2) (3) (4) (5) (6) (7) (1) (17) (18) (12) (14) (19) (20)
IA0OC02I IA0OC03I
- 39 -
- 40 -
(6) HST pressure warning light (9) Stop light
The light turns on when The light turns on simulta-
the pressure of the HST neously with water tem-
pump oil falls down below STOP perature and engine oil
5.97 kg/cm2 (85psi). pressure warning lights.
(10) Buzzer
(7) Oil filter warning light
The buzzer is activated
If the oil filter becomes
simultaneously with water
clogged, the light turns on.
temperature and engine oil
pressure warning lights.
- 41 -
(10)
IA0OC05I IA0OC06I
- 43 -
IA0OC08I
- 44 -
floating status, press the rear part of the pedal. 5.2.5. Auxiliary Hydraulics Thumb Control (6)
Float position should only be used with vehi-
cle in reverse.
RH Dir. Cont.
IA0OA39I
Neutral
Backward
tilting
CAUTION
Forward tilting
When using an attachment other than the stan-
dard bucket, follow the instructions for each
Forward separate attachment.
tilting
Backward tilting
IA0OC09I
- 45 -
The Auxiliary Hydraulics Thumb Control 5.2.6. Engine Control & Auxiliary Hydraulic
system is activated by pushing the on button Attachment Bleed Off
(1) on the forward control panel. The green
light (2) on the panel will illuminate when the
A
system is active. This system can be operat-
ed in two modes by utilizing the rocker switch
(4) (5) on control panel. B
Momentary control: This system is activated
with the rocker switch (5) in the down position.
The auxiliary hydraulics will only operate when
the thumb button (6) on the drive control han-
dle is depressed. IA0OC10P
Detent control: This system is activated with
the rocker switch (4) in the down position. The
Throttle lever (A) controls the engine speed.
thumb button (6) controls the direction of flow
Push the throttle lever forward to increase the
in this mode but it cannot stop or pause flow
engine rpm and pull backward to decrease the
once the system is activated. Auxiliary
engine rpm.
hydraulics will remain active until the off but-
When auxiliary hydraulic attachment has
ton (3) on the panel is pushed or the key
residual pressure, so you cannot remove
switch is turned to off.
attachment from machine, you must recipro-
cate the knob(B) up and down to bleed off the
attachment.
- 46 -
5.2.7. Seat Bar
The seat bar is installed to help protect the op-
erator.
IA0OA17P IA0OA18P
Raised Position Raised Position
NOTE: The pedals are locked if the seat bar is NOTE: 1760XL/ DSL802 is equipped with a
in the raised position. Lower the seat bar to seat bar safety interlock that sets the park
operate the pedals. brake with the seat bar raised. The seat bar
must be lowered for travel.
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6. OPERATING INSTRUCTIONS
IA0OA42P
IA0OA41P
IA0OA43P
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(3) Fasten the seat belt and adjust it snugly across (1) Be sure all controls (the foot pedals and drive
the hips. control levers) are in neutral position.
(2) Set the throttle lever at half-throttle position.
(3) When the key is turned to the PREHEAT
position, the light turns on and preheating of air
begins. The light goes off automatically after 30
seconds. Then start the engine by turning the
key to the start position.
IA0OA18P
6.3. Starting
IA0OC11P
CAUTION
Refer to section 7.3 for pre-start maintenance
checks.
- 49 -
DANGER Cold Temperature Starting and Operation
Before any Daewoo skid steer loader is operated in cold ambient temperatures (below 45 F), the
hydrostatic system needs to be properly warmed up to assure precise drive operation. This is espe-
cially crucial due to the fact it has a servo controlled hydrostatic drive system.
To properly warm up the hydraulic system you should: 1. Disconnect any attachment lines from the
auxiliary hydraulic couplings. 2. Following all proper procedures as outlined in this manual, start the
engine and run at high idle (full throttle position). 3. Set the auxiliary hydraulic pedal in the full oper-
ational position. 4. Depending on ambient temperature proper warm up time will vary from 3 to 15
minutes. This procedure should be continued until both A) The outside of the hydraulic tank is warm
to the touch and B) Using short slow movements the drive controls react normally to inputs. Caution
should be taken during the initial control movements as warm oil may be delayed in reaching the
control servos.
- 50 -
IA0OA46I
CAUTION
When traveling or steering, always lower the
boom to the carry position.
Forward Backward
IA0OA45I
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Sharp Turning 6.5 Operation
Push one lever forward and pull another leverback-
ward.
CAUTION
For safe and economical handling with the
DAEWOO skid steer loader, the operator must
have a thorough knowledge of safety instruc-
tions and a good grasp of the construction and
performance features of the vehicle. Then he
must choose the operating approach best
matched to the actual conditions.
IA0OA47I
(1) Bucket filling
CAUTION
Be alert for tail swing.
IA0OA48I
- 52 -
IA0OA49I IA0OA50I
Move the vehicle forward slowly with the bucket IMPORTANT Do not shake the
held parallel to the ground or tilted down slightly. bucket unnecessarily to dislodge sticky material.
When the bucket is sufficiently full, roll back and Vibrations put excess stress on the bucket cylinder
raise the bucket simultaneously. and stopper, which in turn will reduce machine life.
- 53 -
(4) Leveling the ground Also, leveling jobs can be performed by using
Drive forward or backward with the bucket tilted the floating position for the boom according to
and raised slightly off the ground to perform lev- operating conditions. Make the bucket parallel to
eling. the ground as much as possible.
IA0OA51I
CAUTION
Do not drive forward with the boom in float po-
sition.
- 54 -
(2) Parking
Stop the loader on level ground.
Lower the boom and put the bucket cutting edge
IA0OA20P on the ground.
- 55-
Pull the throttle lever all the way back. 6.7. Towing Procedures
Engage the parking brake.
Turn the key to the OFF position.
Make sure that all controls in operator cabin are WARNING
in stop position.
Raise the seat bar all the way up to the roof. Towing loaders without following the procedures
listed below can result in damage to machine
Disconnect the seat belt.
and injury to personnel
Remove the key from the switch.
Front Rear
DANGER
NEVER exit machine with boom arms raised
unless secured by safety locks.
IA0OA52I
- 56 -
WARNING
Opening of bypass valves will result in a loss of
hydrostatic braking capacity. Take precautions
to prevent machine movement when opening
the valves, and after valves are opened.
(4) Tow loader using the two draw eyes located at IA0OA53S
lower rear portion of frame.
(5) After towing, tighten valves to 9.5-14 Nm (7-10
ft/lbs.)
Damage to units may result from over-torquing WARNING
valves.
Lifting may shift the load and could result in
(6) DAEWOO Skid Steer Loader can draw another death or serious injury.
machine using the 2 drawing eyes on rear frame.
Specified draw bar forces are as follows:
1760XL/ DSL802 : 2,644 Kg ( w/load )
2,066 Kg ( w/o load )
- 57 -
1. Use proper rated cables and slings for lifting. 6.9. Transportation
(min. durable force of cable/sling = 1,400Kgf)
2. Lifting cables should have sufficient length to
prevent contact with the machine.
3. Use the 4 holes for lifting i.e. 2 holes in front up-
per frame and 2 holes in rear inner mast with U-
clamp or strap. 15 or less
IA0OA55I
U-Clamp
or Strap
- 58 -
Fix the skid loader tightly to the transport truck 6.10. Bucket and Attachments
bed with an approved securing device. The ma-
The loader is equipped with a Universal
chine has 3 fixing points, i.e. 1 holes in front up-
Attachment System (Quik-tach) in front of the
per frame and 2 holes in lower rear frame.
vehicle for rapid replacement of bucket or var-
Use wheel blocks to prevent vehicle from moving
ious attachments.
during transportation.
(1) Installation
Wire Rope
Wire Rope
IA0OA57P
IA0OA56I <Figure 1>
- 59 -
of the Quik-tach is completely inserted to ward until the back of bucket becomes per-
the flange of the bucket.(Figure 1) pendicular to ground.(Figure 2)
IA0OA58P IA0OA59P
<Figure 2> <Figure 3>
- 60 -
IA0OA60P IA0OA61P
(2) Removal
(1) Lower the boom thoroughly and tilt the
bucket down until the bucket cutting edge
touches to ground.
(2) Pull out both handles and disengage the
locking pin. (Figure 5)
IA0OA57P
<Figure 6>
- 61 -
6.11. Boom Lock Operation
DANGER
When working on a machine with the boom up,
always engage the boom lock.
IA0OA24P
<Figure 2>
IA0OA23P
<Figure 1>
IA0OA25P
<Figure 3>
- 62 -
- 63 -
7. PERIODIC MAINTENANCE
7.1. Safety Warnings
WARNING
1. Never attempt to service a machine unless you are authorized and qualified to do so.
2. Before attempting any service on this machine, familiarize yourself with all instructions and warn-
ings in the operators manual and all machine decals.
3. Do not attempt to service machine unless you have the necessary skill, information, safety gear,
and tools and equipment to perform the procedure correctly.
4. While service is being performed ensure a warning tag is installed on or near the ignition key
switch and clearly visible to prevent inadvertent starting of the machine during service.
5. If a service procedure necessitates running the engine, the control levers must remain in the neu-
tral position and the emergency brake must be fully engaged. Failure to do so can result in injury
or death.
6. After completing service check for: proper operation of all controls, correct torque on all fasteners
and fittings, any fluid leaks (prior to and after starting engine), all tools and equipment must be
removed from the machine.
7. Ensure all hoisting and supporting equipment is in good repair and of adequate capacity to support
loader.
8. Failure to follow safety precautions and proper service procedures can lead to machine malfunction
or damage, injury to operator or bystanders, or death.
- 64 -
7.2. Access to Items Requiring Service NOTE: The rear door can by locked by placing
a pad lock on the hasp provided on the handle.
IA0OC12P
IA0OA62P
More service space can be obtained if opera-
Push the door handle forward to close the rear tor opens up the engine hood after opening the
door. rear door.
- 65 -
7.2.2. Canopy Tilting
IA0OA65P
IA0OA66P
- 66 -
CAUTION 11. Check the loader tires for proper inflation and
unusual wear
Never operate without canopy lowered and 12. Check the fuel level.
properly secured. 13. Check the condition and security of the opera-
tor seat belt and seat bar.
- 67 -
7.3.2. After Starting-Before Operation
WARNING 1. Start the engine and observe the intial exhaust
If any of the following pre/post start checks color at start and at normal operating temper-
indicate that service may be required, have atures. Excessively black, blue, or white
such service performed before using the
exhaust is an indication of a problem. Listen
machine.
for any abnormal sounds.
2. Check the operation of all exterior lights,
instrument panel indicator lights and installed
optional equipment.
3. Check the operation of all switches.
4. Check the operation of all controls.
a. Check for proper function of the motion
interlock system. With the loader running,
lift the seat-bar to the raised position.
Move the control levers in either direction.
The engine should shut off with less than
1 inch of movement in either direction.
Adjust as necessary.
b. Check for proper operation of boom,
bucket, and accessories ( if attached ).
c. Insure that the boom and bucket pedals are
locked with the seat bar raised.
- 68 -
- 69 -
SERVICE SCHEDULE HOURS
ITEM SERVICE REQUIRED every every every every every every
day 50 100 250 500 1000
Tires Check air pressure and for damage to tires.
Wheel Nuts Tighten to correct torque if loose.
Seat Belt Check the condition of seat belt.
Seat Bar Check the seat bar for correct operation.
Safety Signs Check for damaged signs and replace if needed.
Pivots Grease pivots as needed.
Check the water level and battery cables for corrosion.
Battery Check whether battery cables are tightly clamped.
Check covers.
Check the oil level and add as needed.
Hydraulic Fluid (First time)
Replace the fluid
Hydraulic Check for damage and leaks and replace as needed.
Tubes and Hoses
Chain Case Oil Replace the oil.
(First time)
Hydraulic Filter Replace the filter.
Hydraulic Replace the hydraulic oil.
Oil Tank
Spark Arrestor Clean the spark chamber
for Muffler
(First time)
Suction filter in tank Inspect and clean or change
Air breather cap Inspect and clean or change
- 70 -
5
3
IA0OA68I
- 71 -
1. Bucket cylinder pivot 3. Upper bucket cylinder pivot
IA0OA69P IA0OA71P
IA0OA70P IA0OA72P
- 72 -
IA0OA73P IA0OA74P
- 73 -
8 7 8
IA0OC14I
- 74 -
IA0OA77P
IA0OA78P
- 75 -
7.6.1. Lubrication 7.7. Engine Lubrication
All seat bar mounting points (right shown-left
in mirror position) should be checked for secu-
rity, cleaned of any dirt and debris, and lubri-
cated daily. Use either a spray lubricant or a
light machine oil at the points marked on the
illustration. Lubrication for the pedal lock link-
age is covered in the previous section (7.5).
IA0OA101
7.6.2. Function
Sit in seat and fasten seat belt. Check the seat
belt for security at mounting points. With the
seat bar up, check for full engagement of the
pedal locks (right and left) into the correspond-
ing slots under the pedal assembly. Lower the
seat bar. Pedal lock assemblies should fully
disengage from pedals.
IA0OC16P
- 76 -
- 77 -
7.8. Engine Cooling System tubing to the nipple on the petcock to allow fluid
NOTE: Check the cooling water level while the to drain outside of the chassis. Collect the fluid
engine is cold. and discard it in accordance with local/federal
Accurate coolant level check is not guaranteed environmental rules and regulations.
when engine is hot, because a hot radiator can
flow coolant to sub-tank.
Check the coolant level on the sub-tank. Re-
move the top cap of the sub-tank and fill to the
HOT mark if coolant level is below COLD
mark on sub-tank.
IA0OA83P
Fuel Tank
Hot
CAUTION
Cold (1) Steam or hot liquid may spurt out if the
radiator cap is removed soon after the
engine is stopped.
IA0OA82I (2) When removing the radiator cap, turn your
face away from cap and cover the cap with
a cloth. Turn the cap slowly to release the
NOTE: The radiator drain petcock is located on
pressure inside the radiator.
the right radiator tank. Attach a section of 5/16
- 78 -
IA0OC19P
- 79 -
7.10. Two Stage Air Filter
IA0OC22P
- 80 -
7.10.3. Installation
Installation is simply the reverse of the above 7.11.1. General
procedures. Ensure that the element and
This vehicle is equipped with a U.S.D.A.
gasket are not damaged during replacement.
Forestry Service approved spark arrestor
The air cleaner will not function properly if the
muffler. To keep it in working condition, the
gaskets do not seat completely.
spark chamber must be emptied every 100
hours of operation.
- 81 -
7.11.2. Maintenance 7.12. Battery
The engine must be completely cool before
attempting to clean the spark chamber.
NEVER attempt to empty the spark chamber
on a hot engine. Raise and support the
loader and open and secure the operators
cab. Remove the clean out plug from the
spark chamber. Ensure that the individuals
performing this operation are wearing safety
glasses with side shields. Start the engine IA0OA90P
and run for approximately 10 seconds while
the second individual wearing protective
7.12.1. Remove and Install
gloves holds a piece of wood over the
exhaust outlet. Re-install plug and lower and Removal: The battery is located in the right
secure cab. rear corner of the chassis. Access to battery
is gained through the rear service door.
Disconnect the negative (-) battery cable
first, then disconnect the positive (+) cable.
Remove the wing nuts from the battery hold
down clamp, and remove the clamp assem-
bly. Remove the battery from the loader.
Installation: Installation procedure is the
- 82 -
reverse of the removal procedure. Before jumper battery to the negative (-) terminal on
beginning installation, clean the battery ter- the loader frame. Once loader has started,
minals and cable ends with a wire brush. Be remove the ground cable from the frame first.
sure to connect the negative (-) cable last to
minimize the potential for sparking. Coat the NOTE: Ensure the jumper battery being used
terminals and cable ends with grease to pre- is a 12 volt battery or electrical system dam-
vent corrosion. age will result.
- 83 -
7.13. Priming the Fuel System
7.13.1. Bleeding the Fuel System
After changing the fuel filter cartridge assem-
bly, or after having serviced any part of the
fuel system, make sure that the air is bled
from the system.
IA0OC24P
- 84 -
7.13.2. Draining the Water From the Fuel Filter 7.13.3. Fuel Tank Drain
IA0OC25P IA0OA93P
1. Turn the wing nut counter clockwise to The fuel tank drain plug is located directly
open the drain valve on the bottom of the behind the left rear tire on the chassis. fuel
fuel filter. drained should be disposed of into an
2. Drain some fuel (and any water) until approved waste oil container. Discard the
clean fuel flows from the filter. fuel in accordance with local/federal environ-
mental rules and regulations.
- 85 -
7.14. Hydraulic System Maintenance
7.14.1. Oil Level Indicator
The hydraulic oil level indicator and filler neck
are located on the right hand side of the loader
inside the rear service door. To daily check the
fluid level, the loader should be on level ground
with the boom completely lowered and the
IA0OC26P
Quik-tach assembly tilted back. The fluid level
HYDRAULIC FLUID FILTER NECK
as indicated on the sight gauge should read
between the two red lines. Refer to specifica-
tions section 8.2.9 (pg. 93) for complete infor-
mation on fluid capacities and requirements. 7.14.2. Filter Replacement
Replace the filter accordiy to service sched-
ule(7.4)
The filter should be changed whenever the
fluid is changed or whenever the filter indica-
tor shows that it is necessary to change the
filter(a red warning lamp on the instrument
pannel is lit)
IA0OA95P
OIL LEVEL INDICATOR
- 86 -
REMOVAL
Access to the 1760XL(H) / DSL802(H) filter is
through the rear service door. Remove the fil-
ter by turning counterclockwise. Drain the
hydraulic oil into an approved waste oil con-
tainer. While draining, check fluid and filter
base for signs of particle contaminants.
IA0OC27P
INSTALLATION
HYDRAULIC OIL FILTER
Before installation you must coat the rubber
seal on the new filter with a light coat of
7.14.3. Hydraulic fluid replacement
hydraulic oil. Spin on filter by hand turning
clockwise until the rubber filter seal makes
complete contact with the filter head assem-
bly. At this point, turn the filter an additional
3/4 turn to fully tighten. When complete, run
the loader and check the hydraulic oil level
indicator. Add fluid as needed. Discard the
used filter in accordance with local/federal
environmental rules and regulations.
IA0OA99P
- 87 -
TO REPLACE THE FLUID 7.15. Chain Case Drain and Refill
The hydraulic tank drain plug is located
1. Chain case drain plugs
directly behind the right rear tire on the chas-
sis. Before draining, the loader should be on
level ground with the boom completely low-
ered and the Quik-tach tilted back. Once the
loader is drained, oil should be disposed of
into an approved waste oil container in accor-
dance with local/federal rules and regula-
tions.
IA0OB00P
INTERVAL OF REPLACEMENT
Replace the fluid according to service sched-
ule(7.4) 2. Fill plug
It may be nessary to change more frequently
then the normal interual if the fluid becomes
with foreigu material(dirt, water, grease, etc)
or if the fluid has beer subjected to tempera-
ture levels greater than the maximum
recommeded.
IA0OB01P
- 88 -
- 89 -
7.17. Tire Maintenance
and re-connect spring when completed with the 7.17.1. General Information
adjustment procedure. Inability to achieve proper Tires should be checked regularly for wear,
adjustment using this procedure is indicative of more damage, and proper inflation. When replacing
serious problem and should be referred to your DAE- tires, ensure that the size matches those
WOO dealer. already on the vehicle. Mismatched tire sizes
can change vehicle performance and cause
premature wear and damage to drive train
components. If tires are replaced in pairs, they
should be mounted on the same side of the
vehicle to minimize stress on the drive train.
DANGER
Tires should only be mounted/dismounted from
rims or repaired by trained and authorized per-
sonnel using the proper equipment and proce-
dures. Death or serious injury could result.
See OSHA 1910.177.
- 90 -
- 91 -
8. DIMENSIONAL & PERFORMANCE SPECIFICATIONS
8.1. Dimensional Specifications
Q
R
Item Unit Spec.
F S T G
Overall Height
A. Fully Raised in(mm) 152.8 (3880)
B. To Hinge Pin in(mm) 119.1 (3026)
C. To Canopy in(mm) 79.3 (2015) O
Overall Length
D. With Bucket in(mm) 125.1 (3177) K
E. Less Bucket in(mm) 98.7 (2508)
Overall Width A M
F. With Bucket in(mm) 67.5 (1714)
B
G. Less Bucket in(mm) 65.4 (1662) L C
Others
H. Wheel Base in(mm) 41.5 (1057) I
N
I. Height of S.I.P. in(mm) 40.9 (1040) J U
P H
J. Ground Clearance in(mm) 8.6 (218)
E
T. Tread in(mm) 53.1 (1350) D
U. Departure Angle deg 28 IA0OB04I
- 92 -
Q
R
Item Unit Spec.
F S T G
Dumping
K. Dump Angle deg 40
L. To Hinge Pin in(mm) 91.5 (2323)
Reach O
- 93 -
8.2. Operational Specification (Per SAE J732 Feb 80)
8.2.1. Performance 8.2.2. Power Unit
- 94 -
- 95 -
8.2.5. Hydraulic System
- 96 -
- 97 -
8.2.7. Instrument Features 8.2.8. Seat
- 98 -
- 99 -
Definitions: (Daewoo Skid Steer Loader)
Refer to sketches on pages 91 or 92 of this section.
Overall Operating Height (A) - Fully Raised - The vertical distance in inches (millimeters) from the ground to
the highest point attainable.
Height to Hinge Pin (B) - Fully Raised - The vertical distance in inches (millimeters) from the ground to the
centerline of the bucket hinge pin.
Overall Height (C) - The vertical distance in inches (millimeters) from the ground to the highest point on the unit
with the bucket on the ground.
Overall Length (D) - The horizontal distance in inches (millimeters) with the bucket on the ground and level,
measured from the foremost point of the bucket cutting edge to the rear most point of the machine.
Overall Length (E) - Without Bucket - The horizontal distance in inches (millimeters) from the furthest rearward
to the furthest point forward.
Bucket Width (F) - The maximum outside width in inches (millimeters) of the bucket specified.
Overall Width (G) - The maximum outside width in inches (millimeters) of the machine specified exclusive of bucket.
Wheelbase (H) - The vertical distance in inches (millimeters) from the center of the front wheel or idler to the
center of the rear wheel or sprocket.
Height to S.I.P. (I) - The vertical distance in inches (millimeters) from the ground to the Seat Index Point.
Ground Clearance (J) - The minimum vertical distance in inches (millimeters) from the ground to the lowest
point on the machine between the tires or tracks with the lift arm raised.
Dump Angle (K) - The maximum angle in degrees that the longest flat section of the inside bottom of the bucket
will rotate below horizontal with the bucket hinge pin at maximum height.
Dump Height (L) - The vertical distance in inches (millimeters) from the ground to the lowest point of the cutting
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edge with the bucket hinge pin at maximum height and the bucket at a 45 dump angle.
The angle is less than 45, specify angle.
Reach (M) at Maximum Height - The horizontal distance in inches (millimeters) from the foremost point on the
machine (including tires, tracks, or loader frame) to the front most point on the bucket cutting edge at a 45 angle
with the bucket hinge pin at maximum height. Specify angles less than 45.
Maximum Rollback (N) - at Ground - Maximum rollback angle in degrees without movement of the lift arm.
Maximum Rollback (O) - Fully Raised - The angle in degrees from the bucket cutting edge level position to the
maximum rollback position.
Digging Depth (P) - The vertical distance in inches (millimeters) from the ground to the bottom of the bucket
cutting edge at the lowest position with the bucket cutting edge horizontal.
Loader Clearance Circle (Q) - Front No Attachment - The smallest diameter measured in inches (millimeters)
that the outermost front point on the machine will describe measured from a point located at 1/2 the wheelbase
(H) and 1/2 the overall width (G) of the machine.
Loader Clearance Circle (R) - Front with Standard Attachment - The smallest diameter measured in inches
(millimeters) that the outermost front point on the machine will describe measured from a point located at 1/2 the
wheelbase (H) and 1/2 the overall width (G) of the machine.
Loader Clearance Circle (S) - Rear - The smallest diameter measured in inches (millimeters) that the outermost
rear point on the machine will describe measured from a point located at 1/2 the wheelbase (H) and 1/2 the
overall width (G) of the machine.
Tread or Track Gauge (T) - The transverse distance in inches (millimeters) between the centerlines of the tires
or sprockets. If the front and rear are different, both must be specified.
Angle of Departure (U) - The angle in degrees taken from a line drawn from the lowest and rear most portion of
the rear overhang to the rear bottom face of the rear tire to the ground.
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ENVIRONMENT PROTECTION SECTION
When servicing this lift truck, use an authorized servicing area and an approved container to collect coolant, oil,
fuel, grease, electrolyte and any other potential environmental pollutant before any lines, fittings or related items
are disconnected or removed. After servicing, dispose of those materials in an authorized place and container.
When cleaning the lift truck, be sure to use an authorized area.
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