Page 1 Serial Number 4001 and Up August 2004 Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
Page 3: Table Of Contents
TABLE OF CONTENTS Safety ..................1-1 To the Operator of a Daewoo Wheel Loader ........1-1 General Safety Essentials ..............1-2 Location of Safety Labels ..............1-3 Unauthorized Modifications .............. 1-11 Work Site Precautions..............1-11 Operation..................1-13 Equipment ..................1-18 Maintenance..................
Page 4 Engine Start and Stop ................ 3-2 Machine Travel (Standard Transmission Controls) ......3-11 Machine Shut Down .................3-13 F/R (Forward/Reverse) Travel Control System (Option) ....3-16 Additional Braking ................3-17 Boom Raise Kick-out................ 3-17 Bucket Angle Indicator ..............3-18 Boom Lower Kick-out (Option) ............3-19 Adjustment of Bucket Position Switch ..........
Page 5 Long Term Storage ................4-68 Parking Brake Adjustment..............4-69 Tires and Wheels ................4-72 Transportation ................5-1 Loading Machine on a Trailer.............5-1 Summary of Safety Precautions for Lifting ......... 5-2 Troubleshooting ............... 6-1 Braking ....................6-1 Electrical System................6-1 Engine ....................6-2 Hydraulic System ................
Page 7: To The Operator Of A Daewoo Wheel Loader
1SAFETY TO THE OPERATOR OF A DAEWOO WHEEL LOADER DANGER! Improper use of wheel loader could cause serious injury or death. Before operating wheel loader, or performing maintenance, operator or technician must read and understand entire Operation and Maintenance Manual.
Page 8: General Safety Essentials
Wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact Daewoo. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended.
Page 9: Location Of Safety Labels
There are other labels in addition to safety labels that follow so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Daewoo distributor. BZO0180L...
Page 10 BZO0190L Figure 2 (S/N 4001 and Up) 1-4 Safety K1000896E Operation and Maintenance Manual...
Page 11 Set park brake. • Turn starter switch "OFF." Remove key from switch. • If hydraulic components and units are ABNORMAL, consult nearest DAEWOO dealer or authorized service shop. Do not attempt to make an overhaul. WARNINGS WHEN OPENING ENGINE HOOD (190-00095) WARNING! Before opening hood, shut down engine.
Page 12 WARNING FOR HANDLING ACCUMULATOR (190-00703, 190-00099) WARNING! Explosion hazard: • Keep away from flame. • Do not weld or drill. ACO1480L Accumulator Wheel loader pilot control system is equipped with an accumulator. Accumulator will store a pressure charge that may enable hydraulic controls to be activated for a brief period of time after engine has been shut down.
Page 13 KEEP OUT OF STEERING TURN AREA (4190-1992A, 190-00120) DANGER! Keep out of steering turn area. AMO0410L WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (190-00691, 190-00097) WARNING! HYDRAULIC OIL To prevent hot oil from spurting out: • Turn engine off. • Allow oil to cool. •...
Page 14 WARNING FOR HIGH TEMPERATURE COOLANT (190-00692, 190-00097) WARNING! To prevent hot water from spurting out: • Turn engine "OFF." • Allow water to cool. • Slowly loosen cap to relieve pressure before removing. ACO1410L WARNING FOR BATTERY MAINTENANCE (2190-2533A, 190-00100) DANGER! •...
Page 15 WARNING FOR PERFORMING MAINTENANCE ON FRONT ATTACHMENT (4190-2546A, 190-00105) DANGER! To avoid injury, securely brace lift arm before disassembly of valve or piping. AMO0430L WARNING TO USE SAFETY LOCK (190-00121) WARNING! Safety lock must be in "LOCK" position when servicing pivot area or transporting machine.
Page 16 10. WARNING TAG (190-00695, 190-00098) WARNING! Do not touch when performing inspection or maintenance. ACO1450L 11. WARNING FOR WHEEL BLOCK (4190-2547A, 190-00207) WARNING! Block wheels prevent machine movement before disengaging park brake. BZO0170L 1-10 Safety K1000896E Operation and Maintenance Manual...
Page 17: Unauthorized Modifications
For safety's sake, replace all OEM parts with correct authorized or genuine Daewoo part. For example, not taking time to replace fasteners, bolts or nuts with correct replacement parts could lead to a condition in which safety of critical assemblies is dangerously compromised.
Page 18 BEFORE STARTING TO DIG, CONTACT AUTHORITIES Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know what's underneath work site before starting to dig. BE AWARE OF HEIGHT OBSTACLES Any type of object in vicinity of boom could represent a potential hazard, or cause operator to react suddenly and cause an accident.
Page 19: Operation
STAY ALERT FOR PEOPLE MOVING THROUGH WORK AREA When loading a truck you should always know where the driver is. Avoid loading over the cab of a truck even if the driver is in a safe spot. Someone else could have gone inside, for any number of reasons.
Page 20 BEFORE STARTING ENGINE, DO A "PRESTART" SAFETY CHECK: • Walk around your machine before getting in operator's cab. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. • All equipment covers and machinery safety guards must be in place, to protect against injury while machine is being operated.
Page 21 OBSERVE GENERAL SAFETY RULES Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be allowed to operate or perform maintenance or service on wheel loader. All personnel at work site should be aware of assigned individual responsibilities and tasks. Communication and hand signals used should be understood by everyone.
Page 22 TAKE TIME TO PROVIDE GOOD VISIBILITY Halt work if visibility is poor. Strong rains, snow, fog and extremely dusty conditions can all obscure visibility so badly that it is best to wait for weather to change or dust to settle before continuing operation. Night work in areas of limited visibility should be halted if installation of extra work lights on machine (or work area) is necessary.
Page 23 KEEP "PINCH POINT" AREAS CLEAR – USE CAUTION IN REVERSE Use a signal person in high traffic areas and whenever operator's view is not clear, such as when traveling in reverse. Anyone standing near wheels, or working assemblies of the attachment, is at risk of being caught between moving parts of machine.
Page 24: Equipment
SHUTDOWN CONTROL FUNCTIONS After bucket has been lowered to overnight storage position, move all switches and controls to "OFF" position. Move parking brake switch to "LOCK" position. This will apply parking brake. Move pilot cutoff switch to "LOCK" position. This will disable bucket control lever. Move key in starter switch to "OFF" position, and remove key from switch.
Page 25 Laminate glass protection for the front, side or rear windows may also be recommended depending upon particular site conditions. Contact your Daewoo distributor for available safety guards and/or recommendations if there is any danger of getting hit by objects that could strike the operator's cab. Make sure that all other work site crew members are kept well away from wheel loader and safe from potential hazards.
Page 26 HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT Check cylinder drift rate at regular intervals. Overhaul seal kits are available through Daewoo. HIGH-PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY Exposed hydraulic hoses on arm or boom could react with explosive force if struck by a falling rock, overhead obstacle or other work site hazard.
Page 27 BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries. NOTE: The equivalent continuous A-weighted sound pressure level at the workstation for this machine is 76 dB(A).
Page 28: Maintenance
– and other machine areas if required – with a warning notice. WARNING Warning tags for controls are available from Daewoo distributors; see Figure 20. HAOC920L Figure 20 DO NOT RUN ENGINE IF REPAIRS OR WORK ARE BEING PERFORMED ALONE You should always have at least two people working together if engine must be run during service.
Page 29 DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS Wait for engine to cool off after normal operation. Park wheel loader on firm, level ground and lower all equipment before shutting down and switching "OFF" controls. When engine lube oil, gearbox lubricant or other fluids require change, wait for fluid temperatures to decrease to a moderate level before removing drain plugs.
Page 30 HAOA420L Figure 22 OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES SKIN WARNING! Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue. USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE Refer to "General Maintenance" section of Shop Manual for information on tightening torques and recommended assembly compounds and always use correct part.
Page 31: Shipping And Transportation
SHIPPING AND TRANSPORTATION OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. Hauling vehicle, trailer and load must all be in compliance with local regulations governing intended shipping route.
Page 33 2OPERATING CONTROLS "Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-2 “Control Identification” on page 2-6 “Steering Console and Pedals” on page 2-7 “Transmission Display” on page 2-15 “Front Instrument Panel” on page 2-16 “Right Side Switch Panel”...
Page 34: Component Locations
COMPONENT LOCATIONS The following figure identifies the location of major machine components. 28(R) 29(R) BZO0090L Figure 1 (S/N 3001 thru 4000) 2-2 Operating Controls K1000896E Operation and Maintenance Manual...
Page 35 BUCKET TOOTH 24. RADIATOR BUCKET 25. GRILLE AIR CONDITIONER CONDENSER 26. FAN REAR WHEEL COVER 27. FUEL TANK ENGINE OIL FILTER 28. ENGINE OIL LEVEL GAUGE (RIGHT BATTERY BOX SIDE) REAR LIGHT 29. ENGINE OIL FILLER PIPE (RIGHT SIDE) COUNTERWEIGHT 30.
Page 36 The following figure identifies the location of major machine components. TURBO-II D100 28(R) 29(R) BZO0010L Figure 2 (S/N 4001 and Up) 2-4 Operating Controls K1000896E Operation and Maintenance Manual...
Page 37 BUCKET TOOTH 24. RADIATOR BUCKET 25. GRILLE AIR CONDITIONER CONDENSER 26. FAN REAR WHEEL COVER 27. FUEL TANK ENGINE OIL FILTER 28. ENGINE OIL LEVEL GAUGE (RIGHT BATTERY BOX SIDE) REAR LIGHT 29. ENGINE OIL FILLER PIPE (RIGHT SIDE) COUNTERWEIGHT 30.
Page 38: Control Identification
CONTROL IDENTIFICATION Figure 3, identifies controls in operator's cab. BSO0141L Figure 3 STEERING CONSOLE AND PEDALS (See RIGHT SIDE SWITCH PANEL (See page page 2-7) 2-39) VARIOUS CABIN LOCATIONS (See page SEAT ADJUSTMENT (See page 2-49) 2-36) 2-6 Operating Controls K1000896E Operation and Maintenance Manual...
Page 39: Steering Console And Pedals
STEERING CONSOLE AND PEDALS BSO0131L Figure 4 STARTER SWITCH STEERING WHEEL HORN BUTTON KICK-DOWN SWITCH COMBINATION SWITCH LEVER TRANSMISSION LEVER ACCELERATOR PEDAL 10. FRONT INSTRUMENT PANEL (See page STEERING WHEEL ADJUSTMENT 2-16) LEVER 11. TRANSMISSION DISPLAY (See page BRAKE PEDALS 2-15) K1000896E Operation and Maintenance Manual Operating Controls 2-7...
Page 40 STARTER SWITCH A four-position starter switch is used to start or shut down engine for operation. "OFF" position. Key can be inserted or removed at this position. When key is moved to this position, engine will stop running. In this position, with engine "OFF," alternator light and engine oil light will turn "ON."...
Page 41 Figure 7 COMBINATION SWITCH Left Side Directional Switch Pushing lever forward, activates left outside directional lights directional indicator light instrument panel. Right Side Directional Switch - Pulling lever back, activates right outside directional lights directional indicator light instrument panel. AHO0920L NOTE: When turn is completed the Figure 8...
Page 42 Push Down - Locks into position and light turns "ON" the high beams. Neutral Position - Normal low beams. Pull Up - Momentarily turns "ON" both the low beams and high beams. (Returns to "NEUTRAL" position when released.) NOTE: High and low beams will only function with headlight...
Page 43 To adjust the steering wheel height, push down on adjustment lever (1, Figure 12) TILTING and move the steering wheel to the TELESCOPIC desired position. Release the adjustment lever (1, Figure 12). The steering wheel will remain in the desired position. BSO0070L Figure 12 BRAKE PEDAL (RIGHT AND LEFT...
Page 44 STEERING WHEEL Rotating steering wheel controls position of front wheels and this determines direction of machine travel. Figure 14 KICK-DOWN SWITCH (TWO PLACES) When transmission is in 2nd gear, pressing this switch will shift transmission into 1st gear. This will allow the driver to perform a quick digging movement.
Page 45 TRANSMISSION LEVER Forward - When the lever is pushed forward, transmission "FORWARD." 1st, 2nd, 3rd and 4th are available. Neutral - When the lever is returned to the center position, between forward reverse, transmission is in "NEUTRAL." Reverse - When the lever is pulled back, transmission is in "REVERSE"...
Page 46 10. FRONT INSTRUMENT PANEL “Front Instrument Panel” page 2-16. AOO0291L Figure 19 11. TRANSMISSION DISPLAY See “Transmission Display” on page 2-15. HAAA3773 Figure 20 2-14 Operating Controls K1000896E Operation and Maintenance Manual...
Page 47: Transmission Display
TRANSMISSION DISPLAY A transmission display is to the left of the steering wheel on the dash. The LCD indicates, gears, direction of travel, error codes, and activated kick-down. Figure 21 Figure 22, shows the transmission display in detail. Indicates travel direction gear selection.
Page 48: Front Instrument Panel
FRONT INSTRUMENT PANEL BSO0500L Figure 24 2-16 Operating Controls K1000896E Operation and Maintenance Manual...
Page 49 GAUGES FUEL GAUGE ENGINE COOLANT TEMPERATURE SPEEDOMETER GAUGE HOUR METER TRANSMISSION OIL TEMPERATURE TACHOMETER GAUGE WARNING AND INDICATOR LIGHTS PREHEAT INDICATOR LIGHT 14. RIGHT TURN AND HAZARD WARNING AIR CLEANER CLOGGED WARNING LIGHT LIGHT 15. WORK LIGHT INDICATOR LIGHT ENGINE COOLANT TEMPERATURE 16.
Page 50 SPEEDOMETER This meter displays speed at which vehicle is traveling. HBOI230L Figure 26 HOUR METER A LCD meter that records total time that starter switch is turned "ON" up to 99,999.9 hours. When engine is running, the hourglass icon blinks every four seconds.
Page 51 ENGINE COOLANT TEMPERATURE GAUGE This gauge displays temperature of engine coolant. CAUTION! When the pointer indicates "H" mark (red zone), it means the engine is overheated. Stop the operation, let the engine run at low rpm and wait HBOI260L Figure 29 for it to cool down.
Page 52 AIR CLEANER CLOGGED WARNING LIGHT When this light turns "ON," dirt has built up in the air filter and is beginning to restrict flow of air. Clean or replace air filter before continuing to operate machine. To turn indicator light "OFF," turn starter switch "OFF"...
Page 53 12. LEFT TURN AND HAZARD WARNING LIGHT This light blinks when left turn signal is turned "ON." Both lights blink when warning lights are turned "ON." NOTE: If left and right turn indicators blink together, or if they blink faster than normal, a light bulb is not operating or flasher solenoid is damaged.
Page 54 16. BRAKE FLUID PRESSURE WARNING LIGHT This light turns "ON" when pressure drops in brake fluid circuit. When light turns "ON," an alarm also sounds. WARNING! Never operate or travel machine when this light is "ON" or when HA0O2024 alarm sounding.
Page 55 19. EMERGENCY STEERING INDICATOR LIGHT (OPTION) This light turns "ON" when the emergency steering system is activated due to a hydraulic failure. Immediately stop operation, stop machine, "APPLY" parking brake, and shut down engine. DANGER! AJO0450L Emergency steering indicator light. If Figure 43 this light turns "ON"...
Page 56 21. LIS (LOAD ISOLATION SYSTEM) SWITCH (OPTION) When this switch is moved to "OFF" position, it does not allow boom cylinders to act as shock absorbers. When this switch is moved to "ON" position, it causes boom cylinders to act as shock absorbers. This reduces machine bouncing when machine is traveling with a loaded bucket.
Page 57: Right Side Switch Panel
RIGHT SIDE SWITCH PANEL BSO0151L Figure 47 PILOT CONTROL VALVE LEVER 10. CUP HOLDER (JOYSTICK) (See page 2-34) 11. PARKING BRAKE SWITCH KICK-DOWN SWITCH 12. PILOT CUTOFF SWITCH HORN BUTTON 13. TRANSMISSION CUTOFF SWITCH CIGAR LIGHTER 14. AUTOMATIC TRANSMISSION SWITCH HEADLIGHT SWITCH 15.
Page 58 PILOT CONTROL VALVE LEVER (JOYSTICK) See “Pilot Control Valve Lever (Joystick)” on page 2-34. Figure 48 KICK-DOWN SWITCH (TWO PLACES) Kick-down Switch Function When transmission is in 2nd gear, pressing this switch (Figure 50) will shift transmission into 1st gear. This will allow the driver to perform a quick digging movement.
Page 59 HORN BUTTON (TWO PLACES) Pressing the left button at the tip of the pilot control valve lever (joystick) (Figure 51) or the button at the end of the combination switch (Figure 52) will sound the horn. NOTE: Starter switch must be "ON." Figure 51 AHO0890L Figure 52...
Page 60 HEADLIGHT SWITCH In this position, this switch turns "OFF" clearance, tail, instrument panel, switch and headlights. NOTE: If the switch is not in this position with the engine not running, the pilot buzzer will sound to warn the operator that batteries being discharged.
Page 61 REAR WORK LIGHT SWITCH In this position, this switch turns "OFF" work lights mounted on the rear top of cab. In this position, this switch turns "ON" work lights mounted on the rear top of cab. CAUTION! AHO0851L Do not turn "ON" the work light when Figure 56 traveling on public roads.
Page 62 ROTATING BEACON LIGHT SWITCH (OPTION) "OFF" position. When this switch is moved to "ON" position, it activates the warning light. 10. CUP HOLDER Place to put beverages. HAOA750L Figure 58 11. PARKING BRAKE SWITCH In this position, the parking brake is "RELEASED"...
Page 63 12. PILOT CUTOFF SWITCH In this position the operator cannot operate the pilot control valve lever (joystick). In this position the operator can fully control the movement of the pilot control valve lever (joystick). CAUTION! HBOI110L When driving or parking, the pilot Figure 61 cutoff switch should be changed to "O"...
Page 64 14. AUTOMATIC TRANSMISSION SWITCH Automatic speed range: • Forward: 2nd, 3rd, 4th. • Reverse: 2nd, 3rd. When this switch is in "O" (MANUAL) position, travel mode is switched to "MANUAL" and allows operator to choose speeds manually. When this switch is in "I" (AUTO) position, gears HLB20071L...
Page 65 16. F/R (FORWARD/REVERSE) SELECTOR SWITCH (OPTION) In this position, the F/R control switch is "OFF." In this position, the F/R control switch is activated. When released the switch returns to the "O" position, but the system is still activated. NOTE: 1) When activating system, the transmission lever and F/R control...
Page 66: Pilot Control Valve Lever (Joystick)
PILOT CONTROL VALVE LEVER (JOYSTICK) The machine can be equipped with several variations of a pilot control valve lever (joystick). The type of lever is dependant upon your local market. Contact your local Daewoo Dealer for the levers that are available in your area.
Page 67 Neutral Switch When this switch is pressed, 2nd gear function will be operated, and then 2nd gear indicator light turns "ON." When 2nd gear function is operated, this switch is pressed, and then machine is neutral. Forward Switch When this switch is pressed at forward traveling while "KD" (5, Figure 68) switch is pressed, machine can travel forward.
Page 68: Various Cabin Locations
VARIOUS CABIN LOCATIONS HAAA3710 Figure 69 CAB LIGHT WASHER TANK STEREO HOT/COLD REFRIGERATOR HEATER AND AIR CONDITIONER ELECTRICAL BOX CONTROL PANEL FUSE BOX TWO SPEAKERS 10. FUSE BOX ONE STORAGE BOX 2-36 Operating Controls K1000896E Operation and Maintenance Manual...
Page 69 CAB LIGHT A cab light is on the front of the ceiling. You can turn the light "ON" and "OFF" by pressing its switch. HBOI400L Figure 70 STEREO For operation of stereo see “Stereo” on page 2-45. HAOA951L Figure 71 HEATER AND AIR CONDITIONER CONTROL PANEL For operation of heater and air conditioner...
Page 70 STORAGE BOX There is a storage box (1, Figure 74) behind the seat. Keep the operation maintenance manual and other documents in this compartment. HBOI431L Figure 74 WASHER TANK Contains windshield washer fluid. HBOM680I Figure 75 HOT/COLD REFRIGERATOR There is a hot/cold refrigerator (1, Figure 76) behind and to the left of the seat.
Page 71 FUSE BOX TWO Fuse box two is just above the windshield washer fluid tank. detailed explanation of fuses see “Fuse Box/Relay” on page 2-53. Figure 78 10. FUSE BOX ONE The fuse box one is at the rear side of right control stand.
Page 72: Heater And Air Conditioner Operation
HEATER AND AIR CONDITIONER OPERATION LOCATION OF CONTROLS AND VENTS BSO0120L Figure 80 OPERATION PANEL FOOT NOZZLE FRONT NOZZLE (AIR CONDITIONER) REAR NOZZLE FRONT NOZZLE (DEFROSTER) The heater and air conditioner are combined into one unit to the right side of the operator's seat. If necessary, the operator can control inner temperature using the operation panel.
Page 73 OPERATION PANEL HAOA801L Figure 81 FAN AND AIR CONDITIONER SWITCH SELECTOR SWITCH FOR WIND BLOWER FAN SWITCHES DIRECTION TEMPERATURE CONTROL SWITCH VENTILATION SELECTOR SWITCH When a switch is selected, the LED above that switch will turn "ON" and give an activation sound. When the light switch is turned "ON,"...
Page 74 BLOWER FAN SWITCHES These switches are used to control the speed of the blower fan. "LO" Switch - Used for low blower speed. "MID" Switch - Used for intermediate blower speed. "HI" Switch - Used for high blower speed. NOTE: If you do not select a blower HAOC940L speed...
Page 75 Used to direct air flow to lower portion of operator's cab. HBOI330L Figure 86 Used to direct air flow for defrosting front window of operator's cab. HBOI340L Figure 87 VENTILATION SELECTOR SWITCH "A" Switch - Draws fresh air into operator's compartment. "B"...
Page 76 MEMORY FUNCTION OF USED MODE The air conditioner panel has a memory function. When the starter switch is turned "OFF" the settings for the panel will be stored. When the excavator is started, the last setting will be used. ADDITIONAL OPERATING INSTRUCTION A proper indoor temperature in summer is 5 - 6°...
Page 77: Stereo
STEREO Figure 89 ON-OFF / VOLUME CONTROL KNOB CASSETTE SLOT BALANCE / FADER CONTROL 8. & 9. PLAY DIRECTION BUTTON BASS/TREBLE CONTROL 10. AUTOMATIC SELECTOR AM/FM BAND SELECTOR 11. DOLBY B SELECTOR AUTOMATIC MEMORY (AME) 12. METAL SELECTOR TAPE EJECT BUTTON 13.
Page 78 To adjust bass tone level press on control and it will pop out. Rotate control counterclockwise to decrease bass and clockwise to increase bass. AM/FM BAND SELECTOR This button sets radio to either AM-1, AM-2, FM-1 or FM-2 frequency bands. Each frequency bands will enable the stereo to store 6 preset radio station frequencies.
Page 79 12. METAL SELECTOR If tape being listened to is either a metal or chromium type of tape, press preset selector button 2 to select "MTL" setting. "MTL" will appear on display. Press this control a second time to turn this setting "OFF."...
Page 80 Do not store cassette tapes in the following places or under the following conditions. Damage to tape and stereo may result. • Direct sunlight. • Humid place. • Dusty place. • Around heater or heater vents which discharge heat. • Around speakers and other magnet devices that generate a strong HLB2014L...
Page 81: Seat Adjustment
SEAT ADJUSTMENT WARNING! Whenever operator or operating condition has changed, check to see that seating position is suitable for the condition at hand. Always fasten your seat belt while operating vehicle. Adjust backrest so that the operator can fully reach and operate pedals.
Page 82 RECOMMENDATIONS FOR LIMITING VIBRATIONS Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a Daewoo genuine part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.
Page 83: Seat Belt
SEAT BELT WARNING! Seat belt is for operator's safety and should be worn at all times. Before driving machine, adjust seat to desired position for maximum comfort and machine control, then fasten seat belt. Seat belts must be worn across pelvic region and adjusted snugly to lessen chance and severity of injury in event of an accident.
Page 84: Door Side Latch
DOOR SIDE LATCH The door side latch (1, Figure 102) is used to secured the door to the side of the cab when it is opened. NOTE: Keep the door closed and locked when machine is not in use. Figure 102 To release door from side of cab, push the latch lever (Figure 103) down.
Page 85: Fuse Box/Relay
FUSE BOX/RELAY FUSE BOXES There are two fuse boxes inside the cab. Fuse box one (1, Figure 104) is in the rear side of right control stand. A usage diagram of fuses is shown inside of fuse box. Spare fuses are mounted on the inside of fuse box cover (10A - Qty.
Page 86 Fuse Box One Name Capacity Gauge Panel Transmission Front Wiper, Horn Parking Brake, Pilot Cutoff, Log Fork (Option) AJO0470L Headlight, Stop Light Figure 105 FUSE BOX ONE Condenser Fan, Preheat Emergency Steer (Option), Spare Air Conditioner, Heater Working Light (Front), Rotating Beacon (Option) Working Light (Rear) Turn Signal Light, Hazard...
Page 87 RELAY The relays are in the electrical box under the seat. If the problem is not solved after replacing the fuse, check the function of the relay. APO0210L Figure 107 Figure 108 CIRCUIT BREAKER A circuit breaker is next to the relay by the batteries back unit...
Page 88 When changing the fusible link, replace the fusible link with the same capacity part. Otherwise, a fire could break out in wiring harness and/or other components of the circuit. Always use original Daewoo parts. HAOB100L Figure 111 2-56 Operating Controls K1000896E Operation and Maintenance Manual...
Page 89: Operation
NEW MACHINE BREAK-IN PROCEDURES All Daewoo wheel loaders are inspected and adjusted before leaving the factory. However, it is required that the operator follow these steps during initial break-in period. Failure to follow these steps may result in damage to equipment or reduced performance.
Page 90: Engine Start And Stop
ENGINE START AND STOP ENGINE START Set parking brake switch to "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 1 Move all control levers to "NEUTRAL" position. IMPORTANT transmission lever "NEUTRAL" position, engine will not start.
Page 91 Set pilot cutoff switch to "O" (LOCK) position. This will "LOCK" pilot control valve lever (joystick). HBOI111L Figure 4 Rotate starter key to "I" (ON) position. All indicator lights should turn "ON." NOTE: If unit is equipped with and emergency steering system.
Page 92 engine systems (oil pressure, oil temperature, coolant temperature, etc.) are in normal operating range. If any engine system is not normal, turn starter key to "OFF" position. Instrument Panel Light or Gauge Indicator Reading Fuel Gauge Engine Coolant Temperature Gauge WHITE RANGE Transmission Oil Temperature Gauge Engine Oil Pressure Warning Light...
Page 93 COLD WEATHER ENGINE START Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 8 Move all control levers to "NEUTRAL" position. IMPORTANT transmission lever "NEUTRAL" position, engine will not start.
Page 94 Turn starter key to "PREHEAT" position. When preheater indicator light turns "ON," preheat cycle is complete. HAOC020L Figure 12 Rotate starter key to "I" (ON) position. All indicator lights should turn "ON." HAOB320L Figure 13 Rotate starter key to "START" position. Starter motor should crank immediately, and engine should start within a few seconds.
Page 95 Release starter key when engine starts. Key will return to "I" (ON) position. IMPORTANT engine does start after approximately seconds cranking, release starter key. Wait 5 minutes for starter motor to cool down. Repeat step 8. 10. After engine starts, check all indicator HAOB360L lights and gauges to be certain that all Figure 15...
Page 96 STARTING WITH AUXILIARY BATTERIES WARNING! Wear safety glasses. Never connect negative leads to positive terminals and vice versa. DO NOT connect auxiliary or booster battery ground terminal directly to battery terminal. Locate and use a ground point on machine frame. Depleted batteries generate hydrogen gas.
Page 97 ENGINE STOP Move transmission lever to "NEUTRAL" position. Figure 17 Make sure transmission neutral lock is in the "N" (NEUTRAL LOCK) position. Figure 18 Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 19 Set bucket on ground.
Page 98 Rotate starter key to "O" (OFF) position. Remove key. HAOC342L Figure 21 HYDRAULIC SYSTEM WARM-UP Correct operating temperature of hydraulic oil is 50° - 80°C (120° - 175°F). Make sure to follow procedures listed below for hydraulic fluid warm-up. Run engine at idle (no load) for 5 minutes. Run engine for approximately 5 minutes at middle of speed range, without a load.
Page 99: Machine Travel (Standard Transmission Controls)
MACHINE TRAVEL (STANDARD TRANSMISSION CONTROLS) WARNING! If vehicle is moved while parking brake is engaged, serious damage to parking brake disk will result. Select a transmission gear that is appropriate for top speed that will be traveled. Choosing a gear that is too high will reduce acceleration and will unnecessarily heat transmission converter oil.
Page 100 Set pilot cutoff switch to "O" (LOCKED) position. This will prevent boom and bucket from accidentally moving during travel, as a result of accidentally touching pilot control valve lever (joystick). HBOI111L Figure 24 Press brake pedal. Figure 25 Set transmission neutral lock is in the "D" (DRIVE) position.
Page 101: Machine Shut Down
Place transmission lever in desired gear. Shift gears one by one. Do not skip from 1st to 3rd, for example. Shift transmission lever to "FORWARD" position. Figure 28 Release the brake pedal while slowly pressing the accelerator pedal. WARNING! When traveling at high speed or on a steep hill, make...
Page 102 Place transmission lever in "NEUTRAL." Figure 31 Set transmission neutral lock is in the "N" (NEUTRAL LOCK) position. CAUTION! "LOCK" transmission lever. When ever machine is parked, "LOCK" transmission lever in "NEUTRAL" to prevent accidental machine movement. Figure 32 Set parking brake switch to the "I" (APPLIED) position.
Page 103 Rotate starter key to "O" (OFF) position. Remove key. HAOC342L Figure 35 If machine is parked on a slope, install wheel chocks in front of and behind vehicle wheels. WARNING! Always secure machine with wheel chocks when parked on a slope. Leaving machine in gear will provide braking effect...
Page 104: F/R (Forward/Reverse) Travel Control System (Option)
F/R (FORWARD/REVERSE) TRAVEL CONTROL SYSTEM (OPTION) An optional F/R (Forward/Reverse) travel control system can be installed as an option on the machine. With this system installed, the operator's left-hand can remain on the steering wheel during operation, and not have to manually move the transmission lever between forward and reverse. To activate system perform the following steps: Place transmission lever in "NEUTRAL."...
Page 105: Additional Braking
The F/R control switch is then used to control the travel direction of the machine. In this position, the machine is in "NEUTRAL." In this position, the machine travels "FORWARD." In this position, the machine travels in "REVERSE." The F/R travel control system will stay activated until one of two things happen.
Page 106: Bucket Angle Indicator
IMPORTANT Trip plate (1, Figure 41) must always be set to contact limit switch (2) before boom cylinders reach maximum extension. Maximum extension causes pump to force fluid over relief valve. To raise boom to maximum height, past preset height, hold boom and bucket lever in "Raise" or "Hold Raise"...
Page 107: Boom Lower Kick-Out (Option)
BOOM LOWER KICK-OUT (OPTION) Placing bucket lever in "L" position will lock control lever in lower boom position. Boom will move downward until trip plate (2, Figure 44) makes contact with bucket lower limit switch (1). When limit switch is tripped, boom will stop lowering and bucket lever will automatically be returned to "NEUTRAL"...
Page 108: Towing Machine
TOWING MACHINE When necessary to tow another vehicle, the tow rope must be tied to the towing pin on the counterweight at the rear of vehicle. NOTE: The loader must be used for towing only in an emergency. WARNING! Do not tow machine at a speed over 10 km/ h (6 MPH) and do not tow machine farther than 10 km (6 miles).
Page 109: If Engine Stalls While Traveling
• In addition to the above measures, release the parking brake if the engine will not start or the hydraulic pumps are defective. IF ENGINE STALLS WHILE TRAVELING BRAKE SYSTEM: The brakes can be applied approximately 9 times by pressing the brake pedal due to the oil pressure stored in the accumulator after engine is turned "OFF"...
Page 111: Preventive Maintenance
4INSPECTION, MAINTENANCE AND ADJUSTMENT PREVENTIVE MAINTENANCE Periodic checks and replacement of oil, grease, filters, etc. must be made at specific intervals, to keep machine in good working condition. The following pages describe items to be checked, lubricants to be used, and time interval between each check.
Page 112 The number is also stamped in the rear frame on the left side just below the cab (Figure 2). Figure 2 Engine Serial Number The engine name plate (identification label) is attached to rocker cover (Figure 3). The engine serial number is stamped on the left rear of the engine block, under exhaust manifold.
Page 113: Table Of Recommended Lubricants
TABLE OF RECOMMENDED LUBRICANTS IMPORTANT Do not use lubricants other than those recommended, without prior written approval from Daewoo. NOTE: Refer to Maintenance Intervals Table for application points. LUBRICANT LUBRICANT HYDRAULIC OIL ENGINE OIL AXLE GEAR OIL MANUFACTURER GREASE −...
Page 114 Others meeting or exceeding ASTM D3306 CAUTION! Do not mix oils from different manufacturers. Daewoo does not endorse specific brands but does suggest that owners select quality oils whose suppliers provide assurance that required standards will always be met or exceeded.
Page 115: Fluid Capacities
FLUID CAPACITIES Capacity Component S/N 3001 thru 4000 S/N 4001 and Up 21 liters 25.4 liters (5.5 U.S. gal.) (6.7 U.S. gal.) Oil Pan with Filter Engine NOTE: The filter holds an additional 1 liter (1 qt) of oil. 50 liters 31 liters Cooling System (13 U.S.
Page 116 Description of Lubrication and Service Chart 250h 500h 1000h 1500h 2000h BZO0210L Figure 4 4-6 Inspection, Maintenance and Adjustment K1000896E Operation and Maintenance Manual...
Page 117 Service Data M250-V Items To Check Service Service Interval Qty. 1000 1500 2000 Front Joint Pin Grease F100 Articulation Pin Grease Rear Axle Pivot Grease Steering Cylinder Grease Front Drive Shaft Grease Bearing Hydraulic Hydraulic Oil Tank 195 L Engine Oil Engine Oil Pan 21 L 15W40...
Page 118: Maintenance Intervals
MAINTENANCE INTERVALS 10 HOUR / DAILY SERVICE • Inspect Seat Belt for Proper Operation (See • Grease Front Attachment Pins (See page 4-10)* page 4-17) • Inspect All Tires for Correct Tire Pressure • Inspect the Structure for Cracks and Faulty and Signs of Damage or Abnormal Wear Welds (See page 4-17) (See page 4-10)
Page 119 500 HOUR / 3 MONTH SERVICE • Perform All Daily, 50 and 250 Hour Service • Hydraulic Full Flow Filter Replacement Checks (See page 4-35) (See page 4-37) • Change Engine Oil and Filter (Tier II • Clean Exterior of Radiator, Oil Cooler and engine) (See page 4-35) Air conditioner Condenser (See page 4-38) •...
Page 120: 10 Hour / Daily Service
10 HOUR / DAILY SERVICE GREASE FRONT ATTACHMENT PINS NOTE: Fittings are greased daily, or every 10 hours, for the first 100 hours of operation to comply with new machine break-in requirements. After that, greasing should be done every 50 hours.
Page 121 Check level of engine oil every day before starting engine. Remove engine oil dipstick (1, Figure 5). Oil level must be between "LOW" and "FULL" marks. NOTE: If oil is above "HIGH" mark on dipstick, some must be drained to return oil to proper level. To add oil, remove engine oil fill cap (2, Figure 5).
Page 122 To add oil, remove transmission fill cap (Figure 8) from transmission oil fill pipe. Refer “Table Recommended Lubricants” on page 4-3, of this manual for recommended operating conditions. Shut down engine when done. COLD HAAD4540 Figure 10 TRANSMISSION SIGHT GAUGE CHECK HYDRAULIC SYSTEM OIL LEVEL WARNING! The hydraulic oil will be hot after normal...
Page 123 To add hydraulic oil, turn breather cap (1, Figure 13) slowly to allow pressurized air to vent. Remove upper cover (2, Figure 13) from hydraulic oil tank and add oil to proper level by checking sight glass (Figure 12). IMPORTANT Do not fill above "H"...
Page 124 FILL FUEL TANK WARNING! Use extreme safety precautions while refueling to prevent explosions or fire. Immediately clean up any spilt fuel. At end of each work day, fill fuel tank. Add fuel through fuel fill cap (Figure 14). When working at a temperature of 0°C (32°F) or Figure 14 higher, ASTM...
Page 125 DRAIN FUEL CONDENSATION Open fuel tank drain valve (Figure 16). Allow any condensed water or sediment to drain out of tank. Also, open drain on fuel filter and drain out any water or sediment (Figure 17 and Figure 18). Catch drained material in a container.
Page 126 CHECK COOLANT LEVEL NOTE: Do not mix ethylene glycol and propylene glycol antifreeze together. If the two are mixed, the protection level will be reduced to the level of the ethylene glycol. See “Antifreeze Concentration Tables” on page 4-61, for further details. NOTE: This unit was factory filled with propylene glycol.
Page 127 Do not allow replaceable bucket teeth to wear down to the point that bucket adapter is exposed. (Figure 22) NOTE: These instructions are only for Daewoo OEM buckets. If you are using other manufacturers' buckets, refer to their specific Figure 22 instructions.
Page 128 START ENGINE, CHECK STARTING ABILITY, AND OBSERVE EXHAUST COLOR AT START-UP AND AT NORMAL OPERATING TEMPERATURE. LISTEN FOR ANY ABNORMAL SOUNDS CHECK OPERATION OF ALL CONTROLS IMPORTANT Cold weather operation requires that the operator fully warm up the hydraulic oil before beginning machine operation.
Page 129 CHECK ENGINE DRIVE BELT WEAR WARNING! Keep clear of engine fan and fan drive belts when the engine is running. Rotating fan and belt contact can cause injury. WARNING! Figure 24 When checking, adjusting or replacing drive belts, care must be taken to prevent accidental cranking of the engine.
Page 130 Figure 25 Check the engine intake hose, and hose bands for damage and tightness. If damaged, wrinkled or loose, replace or retighten or contact your nearest Daewoo loader dealer. IMPORTANT Severe engine damage will result from running with unfiltered air.
Page 131: Hour / Weekly Service
50 HOUR / WEEKLY SERVICE PERFORM ALL DAILY SERVICE CHECKS GREASE FRONT ATTACHMENT PINS Following fittings are greased daily, or every 10 hours, for first 100 hours of operation to comply with new machine break-in requirements. After that, greasing should be done every 50 hours. If bucket is being used in water, grease fittings immediately after machine is removed from water.
Page 132 Bucket hinge pins, locations (Figure 28). Figure 28 Lever link connecting pin, 1 location (Figure 29). Figure 29 Bucket link connecting pin, 1 location (Figure 30). Figure 30 Arm-lever connecting pin, 1 location. (Figure 31). Figure 31 4-22 Inspection, Maintenance and Adjustment K1000896E Operation and Maintenance Manual...
Page 133 Bucket cylinder rod end, 1 location. (Figure 32). Figure 32 Lift cylinder heads (left, right), 2 locations (Figure 33). Figure 33 Lift cylinder rod ends, 2 locations. (Figure 34). Figure 34 K1000896E Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-23...
Page 134 Remote location points. AJO0150L Figure 35 REMOTE FITTINGS FOR LOADER ARM REMOTE FITTINGS FOR BUCKET FOOT ENDS (50 HOUR) (Figure 36 and CYLINDER HEAD (50 HOUR) (Figure 36 Figure 37). and Figure 38). Figure 36 4-24 Inspection, Maintenance and Adjustment K1000896E Operation and Maintenance Manual...
Page 135 Loader foot ends, locations on each side of machine. Greased from two remote grease points (1, Figure 35). Figure 37 Bucket cylinder head, 1 point. Greased from remote grease point (2, Figure 35). Figure 38 Rear Axle pivot (1, Figure 39 and Figure 41), 2 locations on each side of machine.
Page 136 R/AXLE BAO0110L Figure 41 (S/N 4001 and Up) Figure 42 (S/N 4001 and Up) GREASE STEERING CYLINDER ROD AND HEAD ENDS Steering cylinder rods, 2 locations, one on each side of machine. Figure 43 Steering cylinder head ends, 2 locations. Use remote grease fittings mounted on frame.(1,2 Figure 44).
Page 137 GREASE UPPER AND LOWER CENTER PINS Center pins, Upper (Figure 45) and Lower (Figure 46). Two locations on each side of machine. Figure 45 Figure 46 CHANGE ENGINE OIL AND FILTER NOTE: Engine oil and filter must be changed after first 50 hours of operation to comply with new machine break-in requirements.
Page 138: Hour / Monthly Service
250 HOUR / MONTHLY SERVICE PERFORM ALL DAILY AND 50 HOUR SERVICE CHECKS REPLACE HYDRAULIC SYSTEM BRAKE AND PILOT FILTER Replace filter in pilot filter. Perform the following steps: Vent hydraulic oil tank. 15 bar 0.32 l BZO0140L Figure 47 Unscrew element cover (5, Figure 48).
Page 139 CHECK ENGINE AIR INTAKE PRECLEANER The engine is equipped with a precleaner. Dust, insects, rainwater etc., can be present in the air. The precleaner collects this material and discharges it. This prevents material from being drawn into air cleaner. The precleaner does not need periodic cleaning or replacement.
Page 140 Locate the air filter assembly (Figure 52 and Figure 53). Remove access cover and remove outer filter of air filter assembly. NOTE: If indicator light on instrument panel comes "ON," this indicates that air cleaner needs to be serviced. NOTE: Replace outer filter every 1,000 hours of service.
Page 141 CHECK WATER PUMP BELT TENSION Water pump belt IMPORTANT Adjustable link A loose water pump belt can cause for alternator belt Adjustable link engine overheating, poor charging, and/or for Air-con belt premature belt wear. A belt that is too tight can cause damage to the water pump, alternator bearing or belt.
Page 142 GREASE DRIVE SHAFTS Grease fitting for center bearing, 1 location. Use remote grease fitting mounted on frame (3, Figure 57). Reference Remote Grease Number Fittings 1 and 2 Steering Cylinder 50 Hours Head Ends Drive Shaft 250 Hours Center Bearing Figure 57 Figure 58 4-32 Inspection, Maintenance and Adjustment...
Page 143 CHANGE ENGINE OIL AND FILTER (TIER I ENGINE) NOTE: Change engine oil and filter after first 50 hours on a new machine and every 250 hours for Tier I engine and 500 hours for Tier II engine thereafter. CAUTION! Never attempt to change oil or filter on a hot engine. Hot oil could splash and cause burns. Allow engine to cool down before changing oil or filter.
Page 144 Fill engine with correct oil through oil fill port (2, Figure 61). Start engine and check engine oil pressure light. Shut down engine. Look for signs of leaks at filter. Recheck oil level using dipstick (1, Figure 61). AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT (AFTER FIRST 250 HOURS) AOO0030L...
Page 145: Hour / 3 Month Service
500 HOUR / 3 MONTH SERVICE PERFORM ALL DAILY, 50 AND 250 HOUR SERVICE CHECKS CHANGE ENGINE OIL AND FILTER (TIER II ENGINE) NOTE: Change engine oil and filter after first 50 hours on a new machine and every 250 hours for Tier I engine and 500 hours for Tier II engine thereafter.
Page 146 Fill engine with correct oil through oil fill port (2, Figure 64). Start engine and check engine oil pressure light. Shut down engine. Look for signs of leaks at filter. Recheck oil level using dipstick (1, Figure 64). BAO0040L Figure 64 (S/N 4001 and Up) REPLACE FUEL FILTER WARNING! Exchange filter after waiting for engine to cool.
Page 147 Tighten plug in fuel filter head. Continue to pump primer pump until a strong resistance is felt. Screw primer pump knob back into housing. Start engine and look for signs of leaks. HYDRAULIC FULL FLOW FILTER REPLACEMENT WARNING! The hydraulic oil will be hot after normal machine operation. Allow system to cool before attempting to service any of the hydraulic components.
Page 148 Loosen breather hydraulic reservoir. (See Figure 13 on page 4-13). Clean filter cover (2, Figure 67) and reservoir around cover. Remove bolts (1, Figure 67) from cover (2). Lift cover (2, Figure 67) and O-ring (4) off reservoir. Control spring (3) that sits beneath cover.
Page 149 Figure 69 AIR CONDITIONER CONDENSER K1000896E Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-39...
Page 150 CLEAN AIR CONDITIONER FILTER The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator's cab. The air conditioner filter is in the right side switch panel console. Open access cover on the lower right side of cab on the outside to gain access to filter.
Page 151: Hour / 6 Month Service
1,000 HOUR / 6 MONTH SERVICE PERFORM ALL DAILY, 50, 250 AND 500 HOUR SERVICE CHECKS DRAIN AND REPLACE TRANSMISSION OIL AND FILTER NOTE: Transmission oil and filter must be changed after first 250 hours of operation to comply with new machine break-in requirements. After first change, oil and filter must be changed every 1,000 hours.
Page 152 13. Fill transmission with fluid through transmission fill tube. Figure 74 14. Add fluid until fluid level is visible in lower "COLD" portion of sight gauge (Figure 76). 15. Start engine. Idle engine for two minutes. Have a person remain in the cab. 16.
Page 153 AXLE BRAKE DISK WEAR MEASUREMENT NOTE: A wear measurement on the multidisk brake must be made at least once a year, especially in case of a change in braking behavior like, e.g.. • Braking noise. • Braking power reduced. • Deceleration changed.
Page 154 CLEAN FUEL TANK AND STRAINER WARNING! Fuel is flammable and harmful to skin. • Do not smoke while draining moisture and sediment from fuel tank. • Do not drain fuel with engine running. • Do not allow fuel to remain on skin for an extended period of time. Wash thoroughly with soap and water.
Page 155 CLEAN FUEL INJECTION PRIMING PUMP STRAINER Remove fitting, fuel line and strainer from bottom of priming pump. Clean strainer. Position strainer in priming pump and install fuel line and fitting. Figure 81 REPLACE AIR CONDITIONER FILTER NOTE: This unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator's cab.
Page 156 Contact your local Daewoo loader dealer inspection recharging refrigerant. A flow of bubbles is visible. CHECK AND ADJUST ENGINE Contact your nearest Daewoo loader dealer. Engine dealer for checking and adjusting the following items: • Engine Compression Pressure. • Injection Pressure.
Page 157: Hour / 9 Month Service
1,500 HOUR / 9 MONTH SERVICE PERFORM ALL DAILY, 50, 250 AND 500 HOUR SERVICE CHECKS AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT NOTE: Oil in both front and rear axles must be replaced after first 250 hours of operation to comply with new machine break-in requirements.
Page 158 Clean area around level plug (1, Figure drain plug center differential. Remove level plug (1) and drain plug (2). Allow oil to drain into a suitable container. NOTE: Plug Size (1, Figure 83): M36 x 1.5 Tightening Torque: 13.2 kg•m (95 ft lb) Plug Size (2, Figure 83): M24 x 1.5...
Page 159 REPLACE OUTER AND INNER AIR CLEANER ELEMENTS CAUTION! Never remove air cleaner element while engine is running. This will allow dirt to be sucked into engine and cause serious engine damage. Always turn engine "OFF" before servicing air cleaner. Replace inner element when outer element is replaced. After removing outer element, remove wing nut and inner element.
Page 160: Hour / Yearly Service
2,000 HOUR / YEARLY SERVICE PERFORM ALL DAILY, 50, 250, 500 AND 1,000 HOUR SERVICE CHECKS CHECK STEERING, BRAKE, DRIVE SHAFT, ENGINE, AND FUEL SYSTEM REPLACE PIPES AND HOSES Replace hoses that carry brake fluid to wheel brakes. Also, replace hoses that carry hydraulic fluid to steering cylinders.
Page 161 Remove plug (Figure 85) on axle. Increase the height of bleeder (1, Figure 86) by using special tool (4, Figure 86). Place one end of a plastic hose (2, Figure 86) over bleeder screw (1). Place other end of hose in a container (3) filled with brake fluid.
Page 162 Slowly open the radiator cap (Figure 87) to allow any pressure to escape. NOTE: “Fluid Capacities” page 4-5 capacity “Table Recommended Lubricants” on page 4-3. Place a container under the radiator and open the drain valve (Figure 88). Figure 88 Remove coolant drain plug (Figure 89) from engine.
Page 163 Alter allowing engine to cool. Drain flushing fluid and fill system with water. 10. Run engine again to allow water to completely circulate. 11. Drain water and fill system with proper antifreeze mixture ambient temperature. Refer coolant concentration table (See page 4-61) 12.
Page 164 Figure 95 Figure 96 ithout starting engine, operate controls to dump bucket. (Figure 95). Then operate controls to lower boom. (Figure 96). This will drain oil out of boom and bucket cylinders. Replace full flow hydraulic filters as described under “Hydraulic Full Flow Filter Replacement” on page 4-27.
Page 165 Count the number of times you can depress the right-hand brake pedal before the brake warning light comes on. If the number counted is less than five (5), there is some problem with the accumulator. Contact your nearest Daewoo dealer. K1000896E Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-55...
Page 166: Hour / Six Year Service
12,000 HOUR / SIX YEAR SERVICE HOSE IN-SERVICE LIFETIME LIMIT (EUROPEAN STANDARD ISO 8331 AND EN982 CEN) European regulations state that the in-service life of any hydraulic hose may not exceed six years. Daewoo recommends the following; • Hoses at the customer premises cannot be stored more than 2 years before being discarded or installed on a machine.
Page 167: Severe Conditions Maintenance
SEVERE CONDITIONS MAINTENANCE Operating Condition Required Maintenance Mud, Water, Rain Check for loose fittings, obvious damage to machine, or any fluid leakage. After completing operations, clean mud, rocks, or debris from machine. Inspect for damage, cracked welds, or loosened parts. Perform all daily lubrication and service.
Page 168: Bolt Torque Chart
BOLT TORQUE CHART TIGHTENING TORQUE SPECIFICATIONS FOR METRIC BOLTS (FOR COATED THREADS, PRELUBRICATED ASSEMBLIES) Grade Gr. 8.8 Gr. 10.9 Gr. 12.9 Dia. kg•m ft lb kg•m ft lb kg•m ft lb 5 mm x std 0.59 0.79 6 mm x std 1.00 1.38 1.66...
Page 169: Electrical System
ELECTRICAL SYSTEM CHECK BATTERY CONDITION WARNING! Before starting any battery service work, make sure to shut the engine off and turn the starter switch to the "OFF" position. The batteries create hydrogen gas. An explosion hazard exists, particularly with a deeply discharged battery.
Page 170: Engine Cooling System
Ethylene glycol (standard life antifreeze) has been on the market for many years. Its chemical properties do not provide the improved corrosion resistance that propylene glycol (extended life antifreeze) does. Ethylene glycol is also very hazardous to the environment, people and animals. Daewoo recommends that ethylene glycol be replaced with propylene glycol.
Page 171 NOTE: Do not mix ethylene glycol and propylene glycol antifreeze together. If the two are mixed, the protection level will be reduced to the level of the ethylene glycol. ANTIFREEZE CONCENTRATION TABLES Ethylene Glycol - Standard Life Antifreeze (1,000 Hour / 6 Months) Ambient Temperature Cooling Water Antifreeze...
Page 172: Fuel Transfer Pump
FUEL TRANSFER PUMP WARNING! Do not dry operate fuel pump for more than 15 seconds. • Cooling and lubrication of pump is achieved by fuel passing through the pump. If the pump is dry operated, the heat generated by the moving parts will cause damage to the pump rotors, vanes and seals.
Page 173 AHO0790L Figure 100 Remove strainer cap (4, Figure 100) from inlet hose. NOTE: Keep strainer cap in a safe location to reseal strainer after refueling is complete. Insert inlet hose (5, Figure 100) into refueling tank. Turn fuel pump switch to "ON" position. NOTE: The transfer pump rate of flow is approximately 20 liters /...
Page 174: Hydraulic Pressure Checks
HYDRAULIC PRESSURE CHECKS Hydraulic pressure for most systems can be check by using the remote test ports shown in (Figure 102). Reference Description Number Main Pump Pressure Unloading Valve Pressure Steering Pump Pressure Transmission Clutch Pressure Figure 102 Control Lever Activation Pressure Brake Charge Pressure MAIN PUMP PRESSURE...
Page 175 STEERING PUMP PRESSURE Attach gauge to port (3, Figure 102). Adjust relief valve cartridge on EHPS valve (Figure 105). • Steering pump pressure: 200 ±5 kg/ (2,900 ±70 psi). • Relief pressure of EHPS: 175 ~ 180 bar (2,500 - 2,600 psi). Figure 105 Unscrew remove plastic plug.
Page 176 BRAKE CHARGE PRESSURE (S/N 4001 AND Attach gauge to port (5, Figure 102). Adjust brake charge valve cartridge (2, Figure 108) on brake and pilot and fan motor supply valve (1, Figure 108). Relief pressure for brake charging is 120±5 kg/ (1,707 ±70 psi).
Page 177 SERVICE BRAKE OUTLET PRESSURE Attach gauge to brake pressure test port (Figure 111) on front axle. Outlet pressure should be 60±3 kg/cm (853±43 psi). Figure 111 PARKING BRAKE RELEASE PRESSURE Attach pressure gauge to parking brake port. Parking brake pressure. •...
Page 178: Long Term Storage
LONG TERM STORAGE CLEANING Pressure wash machine. Inspect machine for any damage or missing parts. Drive machine to check steering linkage for damage. HYDRAULIC SYSTEM Start engine and allow it to idle for a few minutes. Drive machine around for 2 – 3 minutes. Raise and lower boom 2 –...
Page 179: Parking Brake Adjustment
PARKING BRAKE ADJUSTMENT EMERGENCY RELEASE OF THE PARKING BRAKE Figure 114 If the parking brake cannot be released by normal hydraulic system pressure, or if the engine will not start, it must be manually released before towing can take place. Before releasing parking brake make sure that wheels have wheel chocks placed in front of and behind them, to prevent...
Page 180 Release the screw cap (6, Figure 114 and Figure 116) and unscrew. Release the lock nut (5, Figure 114) and turn adjusting screw counterclockwise until the brake disk is free. Install lock nut (5, Figure 114) and screw cap (6) and tighten both as far as possible. This will protect...
Page 181 Hold the adjusting screw (4, Figure 114) in position with the hexagonal socket wrench and lock with the lock nut (5). Mount the screw cap (6, Figure 114) and tighten as far as possible manually. Actuate the brake valve several times and check the braking efficiency of the parking brake on slope. K1000896E Operation and Maintenance Manual Inspection, Maintenance and Adjustment 4-71...
Page 182: Tires And Wheels
TIRES AND WHEELS Properly inflated tire (2, Figure 117) is an important factor in determining tire performance and tire life. A tire that is under inflated (1, Figure 117) does not properly support machine, and will wear out quickly. Overinflated tires (3, Figure 117) have poor traction and puncture easily.
Page 183 Improper servicing or changing tires and rims can cause explosion resulting in serious injury or death. Do not service or change tires and rims unless properly trained and equipped. Contact your nearest Daewoo loader dealer or tire manufacturer's local dealer for tire servicing or changing. WARNING! Overheated tire may explode causing serious injury or death.
Page 185: Transportation
5TRANSPORTATION LOADING MACHINE ON A TRAILER When transporting the machine observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc. It is a good idea to obtain special platform for loading and unloading the machine. Park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.
Page 186: Summary Of Safety Precautions For Lifting
10. Determine the route for transporting the machine by taking into account the width, height and weight of the machine and the truck. SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING To make safe lifts, the following items must be evaluated by operator and work site crew. •...
Page 187: Troubleshooting
6TROUBLESHOOTING BRAKING Problem Possible Causes Remedies Reduced brake action. Low secondary pressure in brake Repair or replace brake valve. valve. Worn brake disks. Replace brake disks. Damaged brake disks. Replace brake disks. Damaged brake valve block. Replace valve. Air in brake hydraulics due to leak in Repair leak, bleed system.
Page 188: Engine
Low engine oil. Add oil. surges. Plugged air intake system. Clean system and replace filter. Injection pump out of Contact your Daewoo dealer. adjustment. Plugged fuel filter. Replace fuel filter. Water or dirt in fuel system. Clean system and add new fuel.
Page 189 Clogged or dirty fuel injectors. Clean injectors. Fuel filters plugged. Replace filters. Engine speed control cable out Readjust. of adjustment. Injection pump out of Contact your Daewoo dealer. adjustment. Valve backlash faulty. Adjust backlash. Engine runs hot. Low coolant level. Add coolant. Thermostat faulty.
Page 190: Hydraulic System
(Also, Starter motor speed too low. Booster Battery may be used. see ELECTRICAL TROUBLESHOOTING.) Defective engine shutoff Contact your Daewoo dealer. solenoid. Fuel pump failure. Incorrect fuel injection timing. Compression pressure too low. Defective injectors. Unstable (rough) idling.
Page 191 Problem Possible Causes Remedies None of the controls function (no Pilot pump failure. Contact your Daewoo noise from pumps). dealer. Cutoff solenoid valve failed. Replace solenoid. Relief cartridge of pilot parking valve Clean or replace as stuck. required. Safety limit switch is ON.
Page 192 Problem Possible Causes Remedies Actuators on one side of boom Overload relief valve is not operating Repair valve or replace. have little power or do not properly. operate. Damaged hydraulic hose. Replace hose. Loose hydraulic fittings. Tighten fittings. Internal damage to control valve Replace control valve.
Page 193: Steering
STEERING Problem Possible Causes Remedies Steering Wheel is hard to turn. Sediment blocking direction change Clean and repair. spool orifice, inside priority valve. Sediment blocking amplifying spool Clean and repair. orifice, inside priority valve. Sediment blocking load sensing line Clean and repair. orifice, inside priority valve.
Page 194: Travel System
TRAVEL SYSTEM GENERAL Problem Possible Causes Remedies Machine will not travel. Transmission clutch pressure Adjust pressure. incorrect. Transmission charge pump Replace pump. damaged. Damage to transmission control Repair wiring. valve wiring harness. Burned travel relay or fuse. Replace relay or fuse. Forward/Reverse solenoid for Clean and repair.
Page 195 Problem Possible Causes Remedies Drive shaft vibration Noisy Bent drive shaft. Replace drive shaft. universal joints. Loose universal joints. Tighten bolts that secure joints. Worn or damaged universal joint. Replace universal joint. Loose universal joints. Tighten bolts that secure universal joints. Lack of lubrication.
Page 196 TRANSMISSION ERROR CODES The first number of the error code is the category that it is grouped into. They are as follows for the first number. Digital Input Signals Analog Input Signals Speed Signals Speed Signals Analog Current Output Signals Analog Current Output Signals Digital Output Signals Digital Output Signals...
Page 197 Error Code Meaning Of Error Code Remarks Number Short circuit to ground or open circuit at internal speed input. Logical error at internal speed input. Short circuit to battery voltage at output speed input. Short circuit to ground or open circuit at output speed input. Logical error at output speed input.
Page 198 Error Code Meaning Of Error Code Remarks Number Open circuit at relay reverse warning alarm. Short circuit to battery voltage at relay starter interlock. Short circuit to ground at relay starter interlock. Open circuit at relay starter interlock. Short circuit to battery voltage at park brake solenoid. Short circuit to ground at park brake solenoid.
Page 199 K1000896E Operation and Maintenance Manual Troubleshooting 6-13...
Page 200 6-14 Troubleshooting K1000896E Operation and Maintenance Manual...
Page 201: Specifications
7SPECIFICATIONS GENERAL SPECIFICATIONS MEGA 250-V Specification Item S/N 3001 thru 4000 S/N 4001 and Up Standard Bucket Capacity 2.4 m (3.1 yd Vehicle Weight 14,000 kg (30,865 lb) 14,200 kg (31,306 lb) Engine Model Daewoo 1146T DB58TIS Turbo and Charge Air...
Page 202 Bucket Lower Time 3.3 Sec. Bucket Dump Time 1.2 Sec. Max. Breakout Force 13,200 kg (29,100 lb) Static Tipping Load 12,000 / 9,800 kg (26,455 / 21.605 lb) (Straight / Full Turn) Maximum Gradeability 30° (58%) K1000896E Operation and Maintenance Manual -2 Specifications...
Page 203: Working Range And Dimensions
WORKING RANGE AND DIMENSIONS Figure 1, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. B (D) BZO0150L Figure 1 K1000896E Operation and Maintenance Manual Specifications 7-3...
Page 204 Category Dimension Overall Length (A) 7,500 mm (24' - 7") Overall Width (B) 2,740 mm (8' - 12") Overall Height (C) 3,320 mm (10' - 11") Bucket Width (D) 2,740 mm (8' - 12") Wheel Base (E) 3,020 mm (9' - 11") Tread (F) 2,040 mm (6' - 8") Ground Clearance (G)
Page 205: Working Capacities
WORKING CAPACITIES BUCKET CAPACITY Standard toothed bucket has a capacity of 2.4 m (3.1 yd TIPPING LOAD Static Tipping Load with bucket in Over Front position is 12,000 kg (26,455 lb). With bucket in Fully Turned position, Static Tipping Load is 9,800 kg (21,605 lb). MATERIAL WEIGHT The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.
Page 206 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Cement, Portland, DRY 1,362 kg/m --------------------- --------------------- clinkers (2,295 lb/yd...
Page 207 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Snow, light density 529 kg/m --------------------- --------------------- (891 lb/yd Sand, DRY, loose...
Page 209 1INDEX Numerics Bucket 3-18 Angle Indicator 4-41 1,000 Hour / 6 Month Service 4-47 Capacity 1,500 Hour / 9 Month Service 3-19 4-10 Position Switch 10 Hour / Daily Service 4-17 Teeth and Side Cutters 4-56 12,000 Hour / Six Year Service 4-50 2,000 Hour / Annually Service 4-28...
Page 210 4-68 Long Term Storage 4-64 Main Pump Pressure 2-33 F/R (Forward/Reverse) Control Switch 4-67 2-33 Parking Brake Release Pressure F/R (Forward/Reverse) Selector Switch 4-67 Service Brake Outlet Pressure 1-16 Fire Hazard 4-65 Steering Pump Pressure 2-24 Float Kick-out Switch 4-28 System Pilot Filter - Replace Fluid Capacities 3-10...
Page 211 2-51 Lubrication Seat Belt Service Chart Serial Numbers Service Chart 1-25 Shipping and Transportation Shut Down Machine Serial Number Engine Shut Down 3-13 Machine Shutdown 3-13 Machine 3-11 Machine Travel 1-18 Shutdown Control Functions 1-22 Maintenance 1-12 Sloping Terrain Maintenance Intervals 2-37 Speakers Material Weight...
Page 212 2-43 4-34, 4-41 Selector Switch Oil - Drain and Replace 4-34, 4-41 Horn Button Oil Filter Replacement 2-12, 2-26 4-11 Kick-down Switch Oil Level Check 2-24 2-19 Load Isolation System Switch Oil Temperature Gauge 2-30 1-17 Parking Brake Switch Travel Precautions 2-31 Pilot Cutoff Switch Travel System...

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