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Daewoo Mega 200-V, Operation And Maintenance Manual

The Daewoo Mega 200-V is a powerful and efficient construction machine designed to handle heavy-duty tasks. To ensure its optimal performance, it is crucial to have the Operation And Maintenance Manual. You can easily download this manual for free from manualshive.com, providing step-by-step instructions and valuable insights for your machine's care and operation.

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Index 8-2  

022-00028AE Operation and Maintenance Manual

Fluid Capacities

 4-5

Front Instrument Panel

 2-18

Front Work Light Switch

 2-32

Fuel Injection Priming Pump Strainer

 4-41

Fuel System

Condensation - Draining

 4-13

Filter-Replace

 4-34

Gauge

 2-19

Refill

 4-12

Tank - Cleaning

 4-40

Transfer Pump

 4-50

Fuse Boxes

 2-55

Fusible Link

 2-57

G

Gauges

Coolant Temperature Gauge

 2-21

Fuel Gauge

 2-19

Hour Meter

 2-20

Speedometer

 2-20

Tachometer

 2-20

Transmission Oil Temperature Gauge

 2-21

General Specifications

 7-1, 7-4

Glass Breaking Tool

 1-18

H

Hazard Warning Light Switch

 2-25

Headlight Switch

 2-32

Heater and Air Conditioner

Additional Operating Instruction

 2-46

Blower Fan Switches

 2-44

Fan and Air-Conditioner Switch

 2-43

Memory Function of Used Mode

 2-46

Selection Switch for Wind Direction

 2-44

Temperature Control Switch

 2-44

Ventilation Selection Switch

 2-45

Heater and Air-conditioner

Control Panel

 2-39

High Beam Indicator Light

 2-23

Horn Button

 2-10, 2-31

Hot/Cold Refrigerator

 2-40

Hour Meter

 2-20

Hydraulic System

Brake Charge Pressure

 4-53

Check Oil Level

 4-10

Control Lever Activation Pressure

 4-53, 4-

54

Fan Motor Pressure

 4-56

Full Flow Filter - Replace

 4-25, 4-30

Hydraulic Oil - Replace

 4-46

Hydraulic Pressures

 4-53

Leaks in the Hydraulic System

 4-11

Long Term Storage

 4-61

Main Pump Pressure

 4-53

Parking Brake Release Pressure

 4-55

Service Brake Outlet Pressure

 4-55

Steering Pump Pressure

 4-54

System Pilot Filter - Replace

 4-28

System Warm-up

 3-10

System Warm-up – Cold Weather

 3-10

Tank Water Draining

 4-31

Transmission Clutch Pressure

 4-54

Troubleshooting

 6-4

I

Indicator Lights

Air Filter Indicator Light

 2-22

Battery Warning Light

 2-22

Brake Fluid Warning Light

 2-24

Coolant Temperature Warning Light

 2-22

Emergency Steering Indicator Light

 2-25

Engine Oil Pressure Warning Light

 2-22

High Beam Indicator Light

 2-23

Left Turn and Hazard Warning Light

 2-23

Parking Brake Indicator Light

 2-24

Preheat Cycle Indicator Light

 2-21

Right Turn and Hazard Warning Light

 2-23

Work Light Indicator Light

 2-23

Inspection, Maintenance and Adjustment

 4-1

Instrument Panel Monitoring System

 3-1

K

Kick-down Switch

 2-14, 2-30

L

Leaks in Fuel System

 4-12

Leaks in Hydraulic System

 4-11

Left Turn and Hazard Warning Light

 2-23

Levers

Adjusting Seat Forward/Backward

 2-51

Adjusting Seat's Angle

 2-51

Angle Adjustment of Armrest

 2-52

Backrest Adjustment

 2-51

Ergo-II Lever (Joystick)

 2-29

Log Forks Control Lever

 2-28

Pilot Control Valve Lever (Joystick)

 2-28

Steering Tilt Knob

 2-12

Transmission Lever

 2-14

Weight Adjustment Knob

 2-51

Lifting Safety Precautions

 5-2

Loading Machine on a Trailer

 5-1

Log Fork Control Lever

 2-28

Long Term Storage

 4-61

Lubricants

 4-3

M

Machine Shutdown

 3-13

Summary of Contents for Mega 200-V

Page 1: ...at consumers periodically contact their distributors for recent documentation on purchased equipment This documentation may include attachments and optional equipment that is not available in your machine s package Please call your distributor for additional items that you may require Illustrations used throughout this manual are used only as a representation of the actual piece of equipment and m...

Page 2: ......

Page 3: ...2 Shipping and Transportation 1 24 Operating Controls 2 1 Component Locations 2 2 Control Identification 2 8 Steering Console and Pedals 2 9 Transmission Display 2 16 Front Instrument Panel 2 18 Right Side Switch Panel 2 27 Various Cabin Locations 2 38 Heater and Air Conditioner Operation 2 42 Stereo 2 47 Seat Adjustment 2 51 Seat Belt 2 53 Door Side Latch 2 54 Fuse Box Relay 2 55 Window Glass Bre...

Page 4: ...ction Maintenance and Adjustment 4 1 Table of Recommended Lubricants 4 3 Fluid Capacities 4 5 Maintenance Intervals 4 6 10 Hour Daily Service 4 8 50 Hour Weekly Service 4 18 250 Hour Monthly Service 4 27 500 Hour 3 Month Service 4 34 1 000 Hour 6 Month Service 4 37 1 500 Hour 9 Month Service 4 43 2 000 Hour Yearly Service 4 45 12 000 Hour Six Year Service 4 48 Severe Conditions Maintenance 4 49 Ge...

Page 5: ...Trailer 5 1 Summary of Safety Precautions for Lifting 5 2 Troubleshooting 6 1 Engine 6 1 Hydraulic System 6 4 Travel System 6 6 Steering 6 11 Braking 6 12 Electrical System 6 12 Specifications 7 1 Mega 200 V 7 1 Mega 200 VTC 7 4 Working Capacities 7 7 Approximate Weight of Workload Materials 7 7 Index 8 1 ...

Page 6: ......

Page 7: ...bels on page 1 3 3 Unauthorized Modifications on page 1 10 4 Work Site Precautions on page 1 10 5 Operation on page 1 12 6 Equipment on page 1 17 7 Maintenance on page 1 22 8 Shipping and Transportation on page 1 24 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 O...

Page 8: ...vities for which it was not intended Do not use bucket for lifting work unless lift slings are used in approved configuration SAFETY ALERT SYMBOL Be Prepared Get to Know All Operating and Safety Instructions This is the Safety Alert Symbol Wherever it appears in this manual or on safety signs on the machine you should be alert to potential for personal injury or accidents Always observe safety pre...

Page 9: ...or replace them with a new label Make sure replacement parts have current 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 4 8 10 3 9 11 1 5 2 7 2 8 4 6 9 APO0190L 9 Figure 1 ...

Page 10: ... on machine Sound horn to alert people nearby before operating and make sure all persons are clear of area Always make sure when leaving operator s seat to Lower bucket or other working tools to ground LOCK transmission selector in NEUTRAL Set park brake Turn starter switch OFF Remove key from switch If hydraulic components and units are ABNORMAL consult nearest DAEWOO dealer or authorized service...

Page 11: ...ny controls may enable selected function to operate under force of gravity When shutting machine down lower front attachment to ground After engine has been shut down turn key to ON position and move joystick controls to release pressure in accumulator Remove key WARNING Explosion hazard Keep away from flame Do not weld or drill CAUTION Any raised attachment will lower to ground if accumulator hol...

Page 12: ...A 4190 1992 190 00120 5 WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL 2190 2529 190 00097 DANGER Keep out of steering turn area WARNING HYDRAULIC OIL To prevent hot oil from spurting out Turn engine off Allow oil to cool Slowly loosen cap to relieve pressure before removing AMO0410L ACO1410L ...

Page 13: ...de Keep sparks and flames away from batteries Always avoid storing metals like tools or inflammable materials around or on batteries Explosion or fire can be caused by short circuiting batteries Sulfuric acid in battery is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed in eyes If you spill acid on yourself 1 Flush your skin with water 2 Apply bakin...

Page 14: ... MACHINE 4190 1989 190 00107 9 WARNING FOR PERFORMING MAINTENANCE ON FRONT ATTACHMENT 4190 2546 190 00105 WARNING For your safety do not stand on ladder when machine is in motion DANGER To avoid injury securely brace lift arm before disassembly of valve or piping AMO0420L AMO0430L ...

Page 15: ...0 WARNING TO USE SAFETY LOCK 4190 1993 190 00121 11 WARNING TAG 2190 2549 190 00098 WARNING Safety lock must be in LOCK position when servicing pivot area or transporting machine WARNING Do not touch when performing inspection or maintenance AMO0440L ACO1450L ...

Page 16: ...LTAGE CABLES Serious injury or death can result from contact or proximity to high voltage electric lines The bucket does not have to make physical contact with power lines for current to be transmitted Use a spotter and hand signals to stay away from power lines not clearly visible to operator Use these minimum distances as a guideline only Depending upon voltage in line and atmospheric conditions...

Page 17: ...NEATH OVERHANGS Digging beneath an overhang is dangerous Overhand could collapse on top of operator and cause serious injury or death Go onto another digging area before steep overhangs are formed Know height and reach limits of wheel loader and plan ahead while working Park wheel loader away from overhangs before work shut down DIGGING BENEATH WHEEL LOADER Digging beneath wheel loader is dangerou...

Page 18: ... operation may be mandated by governing authorities There may also be guidelines standards or restrictions on equipment that may be used to perform certain kinds of work Check and follow all local requirements which may also be related to below ground hazards and power lines OPERATION OPERATE WHILE SEATED AT OPERATOR S STATION ONLY Never reach in through a window to work a control Do not try to op...

Page 19: ...ures could require a warm up or maintenance service before start up Check gauges and monitor displays for normal operation before starting engine Listen for unusual noises and remain alert for other potentially hazardous conditions at start of work cycle Check tire inflation and check tires for damage or uneven wear Perform maintenance before operation NEVER USE ETHER STARTING AIDS An electric gri...

Page 20: ...unconsciousness serious injury and fatal accidents Make sure of adequate ventilation before starting engine in any enclosed area You should also be aware of open windows doors or ductwork into which exhaust may be carried or blown by wind exposing others to danger ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled Materials containing asbestos fiber can ...

Page 21: ...ontact with neck of fuel filling nozzle to provide a ground Keep fuel and other fluid reservoir caps tight and do not start engine until caps have been secured BOOST STARTING OR CHARGING ENGINE BATTERIES Turn OFF all electrical equipment before connecting leads to battery This includes electrical switches on battery charger or boost starting equipment When boost starting from another machine or ve...

Page 22: ...s tilt or more OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES In icy cold weather avoid sudden travel movements and stay away from even very slight slopes Machine could skid off to one side very easily Snow accumulation could hide or obscure potential hazards Use care while operating or while using machine to clear snow Warming up engine for a short period may be necessary to avoi...

Page 23: ...tective Structure reinforcement system Any reinforcement system that is installed on machine must pass safety and certification standards and carry appropriate labeling and rating information For example most often added type of reinforcement system FOPS must meet or exceed Society of Automotive Engineers standard SAE J1356 Performance Criteria for Falling Object Guards for Wheel loaders Never att...

Page 24: ...ds MOVEMENT ALARMS If wheel loader is equipped with an audible travel movement alarm test alarm on a daily basis Audible alarm should sound as soon as travel system is engaged SEAT BELTS SHOULD BE USED AT ALL TIMES Whenever engine is running operator should be seated at the control station with seat belt properly engaged WINDOW GLASS BREAKING TOOL This loader is equipped with a glass breaking tool...

Page 25: ...s as soon as they begin to show any sign of wear or at regular periodic intervals whether or not deterioration is visible Fuel system flexible hoses the tank overflow drain hose and the fuel filler cap Hydraulic system hoses especially the pump outlet lines and front and rear pump branch hoses Keep mounting brackets and hose and cable routing straps tight Hose routing should have gradual bends HYD...

Page 26: ... be immediately apparent Exhaust gases and noise pollution may not be visible but these hazards can cause disabling or permanent injuries ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled Materials containing asbestos fiber can be present on work site Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage To prevent...

Page 27: ...ks from incidental contact or static discharge Turn OFF all switches and engine when working on batteries Keep battery terminals tight Contact between a loose terminal and post can create an explosive spark DISCONNECT BATTERIES BEFORE ELECTRICAL SERVICE OR ELECTRICAL WELDING Remove cable to negative terminal first when disconnecting cable Connect positive terminal cables first when installing a ba...

Page 28: ...supports Do not work under any equipment supported solely by a lift jack DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS Wait for engine to cool off after normal operation Park wheel loader on firm level ground and lower all equipment before shutting down and switching OFF controls When engine lube oil gearbox lubricant or other fluids require change wait for fluid temperatures to d...

Page 29: ...ressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly to prevent vibration rubbing against other parts and excessive heat during operation If any of the following conditions are found replace the part Damage or leakage from hose end Wear damage cutting of covering or exposure of strengthening wire layer ...

Page 30: ... or in metropolitan sewer systems or rural landfills Check state and local regulations for other requirements CHECK TIRE PRESSURE AND CONDITION Maintain tire pressure but do not over inflate Inspect tires and wheels daily When inflating tires follow procedures in Maintenance Section which include using an extension to allow you to avoid standing in front of or over a tire Do not change a tire unle...

Page 31: ...ent on page 2 51 11 Seat Belt on page 2 53 12 Door Side Latch on page 2 54 13 Fuse Box Relay on page 2 55 14 Window Glass Breaking Tool on page 2 58 Each group is explained with a point location drawing or photo and a brief description of each control switch gauge or valve Indicator lights work in addition to gauges on instrument panel Operators should monitor machine pressure on instrument panel ...

Page 32: ...ce Manual COMPONENT LOCATIONS MEGA 200 V Tier I The following figure identifies the location of major machine components 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 29 28 27 26 31 32 33 34 35 36 44 43 42 41 40 39 38 37 APO0010L Figure 1 ...

Page 33: ...L COVER 16 HEADLIGHT SUPPORT 17 LADDER 18 WORKING LAMP 19 OPERATOR S CAB 20 AIR CLEANER 21 PRE CLEANER 22 MUFFLER 23 ENGINE 24 RADIATOR 25 GRILL 26 FAN 27 FUEL TANK 28 ENGINE OIL FILLER PIPE 29 ENGINE OIL LEVEL GAUGE 30 REMOTE ENGINE OIL DRAIN PORT 31 REAR AXLE PIVOT 32 REAR AXLE 33 DRIVE SHAFT REAR 34 TRANSMISSION 35 TRANSMISSION OIL FILTER 36 CENTER PIN 37 STEERING WHEEL CYLINDER 38 DRIVE SHAFT ...

Page 34: ...ual MEGA 200 V Tier II Tier I European low noise kit The following figure identifies the location of major machine components 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 29 28 27 26 31 32 33 34 35 36 44 43 42 41 40 39 38 37 APO0020L 9 Figure 2 ...

Page 35: ...T WHEEL COVER 16 HEADLIGHT SUPPORT 17 LADDER 18 WORKING LAMP 19 OPERATOR S CAB 20 AIR CLEANER 21 PRE CLEANER 22 MUFFLER 23 ENGINE 24 RADIATOR 25 GRILL 26 FAN 27 FUEL TANK 28 ENGINE OIL FILLER PIPE 29 ENGINE OIL LEVEL GAUGE 30 REMOTE ENGINE OIL DRAIN PORT 31 REAR AXLE PIVOT 32 REAR AXLE 33 DRIVE SHAFT REAR 34 TRANSMISSION 35 TRANSMISSION OIL FILTER 36 CENTER PIN 37 STEERING WHEEL CYLINDER 38 DRIVE ...

Page 36: ...and Maintenance Manual MEGA 200 VTC Figure 3 identifies the location of major machine components 15 46 45 44 43 16 14 13 17 18 19 20 21 22 23 24 25 30 29 28 27 26 31 32 33 34 35 36 42 41 40 39 38 37 BFO0010L 47 1 2 3 4 5 6 7 8 10 11 12 9 Figure 3 ...

Page 37: ...PORT 17 LADDER 18 WORKING LAMP 19 OPERATOR S CAB 20 AIR CLEANER 21 PRE CLEANER 22 MUFFLER 23 ENGINE 24 RADIATOR 25 GRILL 26 FAN 27 FUEL TANK 28 ENGINE OIL FILLER PIPE 29 ENGINE OIL LEVEL GAUGE 30 REMOTE ENGINE OIL DRAIN PORT 31 REAR AXLE PIVOT 32 REAR AXLE 33 DRIVE SHAFT REAR 34 TRANSMISSION 35 TRANSMISSION OIL FILTER 36 CENTER PIN 37 STEERING WHEEL CYLINDER 38 DRIVE SHAFT CENTER 39 DRIVE SHAFT FR...

Page 38: ...ce Manual CONTROL IDENTIFICATION Figure 4 identifies controls in operator s cab 1 STEERING CONSOLE AND PEDALS See page 2 9 2 VARIOUS CABIN LOCATIONS See page 2 38 3 RIGHT SIDE SWITCH PANEL See page 2 41 4 SEAT ADJUSTMENT See page 2 51 4 1 3 2 APO0030L Figure 4 ...

Page 39: ...LS 1 STARTER SWITCH 2 HORN BUTTON 3 COMBINATION SWITCH LEVER 4 ACCELERATOR PEDAL 5 STEERING TILT KNOB 6 BRAKE PEDALS 7 STEERING WHEEL 8 KICK DOWN SWITCH 9 TRANSMISSION LEVER 10 FRONT INSTRUMENT PANEL See page 2 18 11 TRANSMISSION DISPLAY See page 2 16 Figure 5 11 5 6 6 4 2 1 3 7 8 10 9 APO0040L ...

Page 40: ...s release key and allow it to return to I ON position Do not crank engine for more than 15 seconds at a time this could damage starter motor Preheat position Used to aid engine starting in cold weather When key is in this position engine preheater is operating When preheat cycle indicator light turns ON engine preheat cycle is complete Immediately turn key to crank position and start engine 2 HORN...

Page 41: ...ition C Window Washer Switch When the outside area of the lever is pressed it activates the washer pump and sprays fluid on the windshield Only while being pressed D Horn Button The center button on end of lever activates horn Only while being pressed E Wiper Switch Activates wipers when outside area of lever is rotated J Intermittent Mode wipes every 5 seconds 0 Stop Off I Normal Speed Mode II Hi...

Page 42: ...of loader and working speed of load handling system 5 STEERING TILT KNOB This knob is used to allow steering wheel to be moved to the most convenient position for the operator Loosen knob 2 Figure 12 while grabbing the steering wheel 1 Once the steering wheel is in the proper place tighten the knob CAUTION The further the pedal is pressed the more engine speed increases However do not press the pe...

Page 43: ...TEERING WHEEL Rotating steering wheel controls position of front wheels and this determines direction of machine travel CAUTION When descending on an incline slow down the machine by using both the brake pedal and the engine brake Using the brake pedal too often might lead to insufficient oil pressure thus making it difficult to brake the loader IMPORTANT Do not use brake pedal as a foot rest This...

Page 44: ...utton in the tip of the pilot control valve lever joystick 9 TRANSMISSION LEVER F Forward When the lever is pushed forward transmission is in FORWARD 1st 2nd 3rd and 4th are available N Neutral When the lever is returned to the center position between forward and reverse the transmission is in NEUTRAL R Reverse When the lever is pulled back transmission is in REVERSE 1st 2nd and 3rd are available ...

Page 45: ...osition Prevents lever from being moved out of NEUTRAL D DRIVE position Allows lever to be moved from NEUTRAL to FORWARD and REVERSE 10 FRONT INSTRUMENT PANEL See Front Instrument Panel on page 2 18 11 TRANSMISSION DISPLAY See Transmission Display on page 2 16 CAUTION LOCK transmission lever When ever machine is parked LOCK transmission lever in NEUTRAL to prevent accidental machine movement Figur...

Page 46: ... Codes on page 6 8 NOTE Most codes are only two digits C Indicates that error codes have occurred and are stored D Indicates that operation must be stopped immediately to prevent damage to transmission and hazardous operating condition The gear range indicator bars will indicate which gear is selected by displaying the corresponding number of bars The forward and reverse indicator bars will be OFF...

Page 47: ...022 00028AE Operation and Maintenance Manual Operating Controls 2 17 ...

Page 48: ...2 18 Operating Controls 022 00028AE Operation and Maintenance Manual FRONT INSTRUMENT PANEL Figure 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 APO0060L 17 ...

Page 49: ...RAKE INDICATOR LIGHT 19 EMERGENCY STEERING INDICATOR LIGHT OPTION SWITCHES 20 HAZARD WARNING LIGHT SWITCH 21 BLANK EMPTY SWITCH SOCKET 22 BUCKET FLOAT SWITCH OPTION 1 FUEL GAUGE This gauge displays amount of fuel in tank F means the tank is full E means the tank is empty If the pointer comes close to the E red zone add fuel as soon as possible When the pointer comes close to the E red zone approxi...

Page 50: ...OUR 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 This shows that the hour meter is working 4 TACHOMETER This meter displays engine speed in revolutions per minute HBOI230L Figure 26 Figure 27 10 1 HA0O2012 HBOI240L Figure 28 ...

Page 51: ...mperature is below 10 C 12 F this light will turn ON approximately 3 5 seconds after starter switch is turned to preheat position 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 for it to cool down Do not shut down engine If engine is shut down heat surge may occur CAUTION When the pointer indicates H ma...

Page 52: ... to rise and may cause engine to siege due to heat surge 10 ENGINE OIL PRESSURE WARNING LIGHT When starter switch is in ON position this red light should ON When engine is running this red light should turn OFF If light remains ON when engine is running an alarm will sound This means that engine oil pressure has fallen below a safe level Never allow engine to run if this light is ON Serious engine...

Page 53: ...damaged 13 HIGH BEAM INDICATOR LIGHT This light turns ON when headlights are turned to HIGH BEAM 14 RIGHT TURN AND HAZARD WARNING LIGHT This light blinks when right turn signal is turned ON Both lights blink when warning lights are turned ON NOTE If left and right turn indicators blink together or if they blink faster than normal a light bulb is not operating or flasher solenoid is damaged 15 WORK...

Page 54: ...icle is moved while parking brake is applied a warning alarm will sound WARNING Never operate or travel machine when this light is ON or when alarm is sounding Always investigate cause of the drop in brake fluid pressure and repair problem before operating or traveling machine WARNING If vehicle is moved while this light is turned ON it could cause premature wear or damage the brake Always RELEASE...

Page 55: ...l indicator lights in front and back of the machine light up and flash warning others in the area At the same time the directional indicator lights on the instrument panel will turn ON to warn the operator The hazard warning lights operate independent of the starter switch O In this position this switch turns OFF hazard warning lights I In this position this switch turns ON all turn signals and th...

Page 56: ... contour of the ground working surface When pressing this switch and setting work lever to floating position lever is locked detent and boom is lowered When boom is matched to setting position lever locking is released and lever is turned to NEUTRAL position and boom lowering is stopped O In this position this switch turns OFF bucket float I In this position this switch turns ON bucket float HAOA7...

Page 57: ...TICK OPTION 2 KICK DOWN SWITCH 3 HORN SWITCH 4 CIGAR LIGHTER 5 HEADLIGHT SWITCH 6 FRONT WORK LIGHT SWITCH 7 REAR WORK LIGHT SWITCH 8 REAR WIPER SWITCH 9 ROTATING BEACON SWITCH OPTION 10 CUP HOLDER 11 PARKING BRAKE SWITCH 12 PILOT CUTOFF SWITCH 13 TRANSMISSION CUTOFF SWITCH 14 AUTOMATIC TRANSMISSION SWITCH 15 EMERGENCY STEERING TEST SWITCH OPTION 10 11 13 9 8 7 6 4 5 12 3 2 1 1A 14 15 AJO0070L 1B F...

Page 58: ...ntrol valve lever joystick operating pattern and description of operation 1A PILOT CONTROL VALVE LEVER OPTION If loader is equipped with log forks this lever controls boom bucket and log forks The boom and bucket operating pattern of this lever is the same as above A When the log forks control lever is pushed forward the log forks are allowed to open B When the log forks control lever is pulled ba...

Page 59: ... switch machine speed decrease C Kick down Switch KD Button When pressing this switch that is in the rear side kick down function is selected Ergo II lever switch usage When Rotating the starter switch to I ON position DISPLAY indicates NN When DISPLAY indicates N4 while N button of ERGO II is pressed start the engine When DISPLAY indicates N1 while button is pressed the machine is in the travelin...

Page 60: ... Figure 52 will shift transmission into 1st gear This will allow the driver to perform a quick digging movement Kick down function range Automatic 2nd 3rd 4th Manual 2nd NOTE Kick down is RELEASED when transmission is placed in NEUTRAL position or the switch is pressed again A second kick down switch Figure 51 is on the end of the transmission lever Figure 51 AHO0900L Figure 52 ...

Page 61: ...Figure 54 will sound the horn NOTE Starter switch must be ON 4 CIGAR LIGHTER Push the lighter all the way into the socket and release your hand After pushing it in it will be ejected when it is heated If it does not eject after a short time pull it out and have it serviced IMPORTANT The cigar lighter is powered by a 24 volt circuit Never plug any 12 volt device into the cigar lighter Figure 53 AHO...

Page 62: ...instrument panel and switch lights II In this position this switch turns ON clearance tail gauge panel and headlights 6 FRONT WORK LIGHT SWITCH O In this position this switch turns OFF work lights mounted on the front top of cab I In this position this switch turns ON work lights mounted on the front top of cab CAUTION Do not leave clearance tail instrument panel or headlights ON when the engine i...

Page 63: ... WORK LIGHT SWITCH O In this position this switch turns OFF work lights mounted on the rear top of cab I In this position this switch turns ON work lights mounted on the rear top of cab CAUTION Do not turn ON the work light when traveling on public roads AHO0851L O I Figure 58 ...

Page 64: ...eld wiper mounted on rear windshield of operator s cab 9 ROTATING BEACON SWITCH OPTION O OFF position I When this switch is moved to ON position it activates the warning light 10 CUP HOLDER Place to put beverages CAUTION The washer pump can be damaged if it is activated while there is no fluid in the tank The fluid level should be checked regularly and refilled as necessary Using soap or other sol...

Page 65: ...annot operate the pilot control valve lever joystick I In this position the operator can fully control the movement of the pilot control valve lever joystick WARNING Set the parking brake switch in the I APPLIED position before leaving the loader Make sure to APPLY the parking brake switch before trying to start the loader CAUTION Do not use the parking brake to stop the loader except in an emerge...

Page 66: ...he accelerator pedal is pressed under this condition more power is concentrated on the load handling system to quicken the boom lifting speed NOTE 1 Transmission CUTOFF function dose not operate at 3rd and 4th gear for protection of transmission 2 Regardless of transmission CUTOFF switch the right brake pedal has braking function only 14 AUTOMATIC TRANSMISSION SWITCH Automatic speed range Forward ...

Page 67: ...itch to I ON position NOTE Do not start engine B Press emergency steering test switch and turn steering wheel at the same time If system is functioning properly the unit should steer The emergency steering indicator light should turn ON NOTE If unit does not steer do not operate unit until problem is corrected C Release switch Switch will automatically return to O OFF position WARNING Do not press...

Page 68: ... CAB LIGHT 2 STEREO 3 HEATER AND AIR CONDITIONER CONTROL PANEL 4 SPEAKERS 5 STORAGE BOX 6 WASHER TANK 7 HOT COLD REFRIGERATOR 8 ELECTRICAL BOX 9 FUSE BOX TWO 10 FUSE BOX ONE BAN D BAL FAD 2 6 1 TU N E M PULL L O V F F O N O H S U P U 4 TRE B A S S 5 AM E 3 1 2 3 4 5 6 7 8 9 10 HAAA3710 Figure 67 ...

Page 69: ...N and OFF by pressing its switch 2 STEREO For operation of stereo see Stereo on page 2 47 3 HEATER AND AIR CONDITIONER CONTROL PANEL For operation of heater and air conditioner see Heater and Air Conditioner Operation on page 2 42 4 SPEAKERS Emits sound generated by stereo HBOI400L Figure 68 HAOA951L Figure 69 HAOA771L Figure 70 HBOM350L Figure 71 ...

Page 70: ...hield washer fluid 7 HOT COLD REFRIGERATOR There is a hot cold refrigerator 1 Figure 74 behind and to the left of the seat Air conditioner and heating unit must be operated after starting the engine for this function Keep the cover close for proper function 8 ELECTRIC BOX Under the seat are two pullout trays that contain relays for unit See Fuse Box Relay on page 2 55 1 HBOI431L Figure 72 HBOM680I...

Page 71: ...use box two is just above the windshield washer fluid tank For a detailed explanation of fuses see Fuse Box Relay on page 2 55 10 FUSE BOX ONE The fuse box one is at the rear side of right control stand For a detailed explanation of fuses Fuse Box Relay on page 2 55 Figure 76 Figure 77 ...

Page 72: ...S AND VENTS 1 OPERATION PANEL 2 FRONT NOZZLE AIR CONDITIONER 3 FRONT NOZZLE DEFROSTER 4 FOOT NOZZLE 5 REAR NOZZLE 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 5 5 4 3 3 2 1 HBOI310L Figure 78 ...

Page 73: ...N 5 VENTILATION SELECTION SWITCH When a switch is selected the LED above that switch will turn ON and give an activation sound When the light switch is turned ON the panel LED s will turn ON 1 FAN AND AIR CONDITIONER SWITCH A OFF Switch Turns OFF the heater and air conditioner unit B A C Switch Turns ON the air conditioner when one of the blower switches is activated HAOA801L Figure 79 HAOC930L Fi...

Page 74: ...ERATURE CONTROL SWITCH The temperature control consists of 24 stages An LED is turned ON for every three stages Whenever pushing it it changes in stages Pushing it continuously it changes continuously A COOL Switch Lowers the temperature B WARM Switch Raises the temperature LED COLOR STATUS Green LED Air conditioner Full green maximum operation of air conditioner Red LED Heater Full red maximum op...

Page 75: ...b C Used to direct air flow for defrosting front window of operator s cab 5 VENTILATION SELECTION SWITCH A A Switch Draws fresh air into operator s compartment B B Switch Recirculates air within the operator s compartment Used to rapidly reduce condensation on windows HBOI330L Figure 84 HBOI340L Figure 85 HAOC981L A B Figure 86 ...

Page 76: ...ess than the outdoor temperature Operate the air conditioner from 20 30 minutes a week to circulate the refrigerant in the system NOTE The blower switch should be on LO speed NOTE The filter should be cleaned out every 500 hours and replaced with a new one every 1 000 hours NOTE In the event that the unit is being operated in a dusty environment the cleaning and replacement should be performed mor...

Page 77: ...ise When stereo is turned ON LCD display will indicate radio stations and or tape functions 2 BALANCE FADER CONTROL This control adjusts both side to side balance of stereo sound and front to back fading Rotating control counterclockwise will increase volume to the left speakers clockwise increases volume to the right speakers Press on control and it will pop out you can now adjust the fader front...

Page 78: ... band to be listened to Then use tuning control to select desired station Press and hold any preset keys for approximately 2 seconds a beep will sound when station has been set 6 TAPE EJECT BUTTON Eject tape from cassette deck by pressing this button Stereo returns to tuner mode 7 CASSETTE SLOT Press ON OFF switch for power Insert a tape with exposed tape facing right The tape will start to play T...

Page 79: ...adio Memory Channel Indicator D Radio Station Frequency E AM FM Band Indicator F Stereo Radio Signal G Dolby Noise Reduction Indicator H Metal Tape Indicator CARE OF STEREO Do not use a tape that has a longer playing time than C 90 90 minutes Avoid use of C 120 tapes because tapes are made of a thinner material that may break and get tangled inside stereo Make sure tapes are wound tight If you use...

Page 80: ...enoid valves Clean head and pinch roller periodically They continuously contact the tape If they are not kept clean stereo and tapes may be damaged Keep them clean for optimum performance If head gets dirty clean it with a soft cotton swap through cassette slot It is recommended to use a cassette deck cleaning tape for easy and efficient cleaning of head capstan and pinch roller When you turn OFF ...

Page 81: ... conditions Adjustment range is 60 mm 2 36 in for both front and rear 4 WEIGHT ADJUSTMENT KNOB Turning knob 4 Figure 96 to right makes suspension harder Turning knob to left makes suspension softer Adjust according to operator s weight by checking weight indicator dial Adjustment range is from 50 120 kg 110 265 lb 5 BACKREST ADJUSTMENT LEVER Pulling up right lever 5 Figure 96 allows seat backrest ...

Page 82: ...EST Adjustment angle of left and right armrest 6 Figure 97 is done by turning a dial in bottom of armrest When you adjust angle manually raise armrest before turning dial 7 HEADREST Headrest 7 Figure 97 can be adjusted forward backward and up down Move it by holding both sides HAOB130L Figure 97 ...

Page 83: ...just seat to desired position for maximum comfort and machine control then fasten seat belt Seat belts must be worn across pelvic region and adjusted snugly to lessen chance and severity of injury in event of an accident Never fasten a seat belt across abdomen Under no circumstances should operator be standing in cab when operating wheel loader Do not adjust seat position while vehicle is moving b...

Page 84: ...e latch 1 Figure 100 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 2 To release door from side of cab push the latch lever Figure 101 down The latch lever is to the left of the operator s seat Figure 100 Figure 101 ...

Page 85: ...rol stand A usage diagram of fuses is shown inside of fuse box Spare fuses are mounted on the inside of fuse box cover 10A Qty 1 15A Qty 1 20A Qty 1 and 30A Qty 1 Fuse box two 2 Figure 102 is just above the windshield washer fluid tank WARNING If any fuse is blown turn OFF the starter switch and shut off the power supply Remedy the cause if needed and replace the fuse with a new one Figure 102 ...

Page 86: ...re 15A 8 Air Conditioner Heater 30A 9 Working Light Front Rotating Beacon Option 15A 10 Working Light Rear 15A 11 Turn Signal Light Hazard Light Indicate Light 15A 12 Stereo Cab Light Fuel Pump Engine Stop 15A 13 Memory Backup Pilot Buzzer 10A 14 Starter Switch 10A Fuse Box Two No Name Capacity 1 Cigar Lighter 15A 2 Rear Wiper 15A 3 Position Light Right 10A 4 Position Light Left 10A 5 Auto Detent ...

Page 87: ...e relay by the batteries at back of unit under engine compartment hood When a short circuit or an overload occurs the circuit breaker automatically cuts off current thus preventing electrical wires from burning FUSIBLE LINK A fusible link is in the battery box If electric power is not present at the I ON position of the starter switch check the fusible link first NOTE If fuse wire is burnt off rep...

Page 88: ...s breaking tool It is in the lower right side of the cab just rear of the door This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the operator s cabin Grip the handle firmly and use the sharp point to break the glass WARNING Protect your eyes when breaking the glass Figure 109 ...

Page 89: ...HINE 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 1 Make sure to check all fluid levels before starting and every 8 to 10 operating hours 2 Do all Daily maintenance and...

Page 90: ...itch to I APPLIED position This will ensure that the parking brake is APPLIED 2 Move all control levers to NEUTRAL position 3 Make sure transmission neutral lock is in the N NEUTRAL LOCK position IMPORTANT If transmission lever is not in NEUTRAL position engine will not start HA0O2019 P O I Figure 1 Figure 2 Figure 3 ...

Page 91: ...start unit Follow test procedure given with test switch 6 Rotate starter key to START position Starter motor should crank immediately and engine should start within a few seconds 7 Release starter key when engine starts Key will return to I ON position 8 After engine starts check all indicator lights and gauges to be certain that all IMPORTANT If engine does not start after approximately 15 second...

Page 92: ...ngine oil Check cause 11 Check for usual engine vibration and noises If any are heard or felt investigate cause NOTE If engine coolant temperature gauge shows red while running take the following action Discontinue work and allow engine to run at LOW IDLE Open engine compartment cover for good ventilation Once engine temperature gauge returns to the green zone shut down engine After engine has coo...

Page 93: ...ake is APPLIED 2 Move all control levers to NEUTRAL position 3 Make sure transmission neutral lock is in the N NEUTRAL LOCK position 4 Set pilot cutoff switch to O LOCKED position This will LOCK pilot control valve lever joystick IMPORTANT If transmission lever is not in NEUTRAL position engine will not start HA0O2019 P O I Figure 8 Figure 9 Figure 10 HBOI111L O I Figure 11 ...

Page 94: ...eater indicator light turns ON preheat cycle is complete 7 Rotate starter key to I ON position All indicator lights should turn ON 8 Rotate starter key to START position Starter motor should crank immediately and engine should start within a few seconds HAOC020L Figure 12 HAOB320L Figure 13 HAOB350L Figure 14 ...

Page 95: ...t all engine systems oil pressure oil temperature coolant temperature etc are in normal operating range If any engine system is not normal turn starter key to O OFF position 11 Perform Hydraulic System Warm up Cold Weather on page 3 10 IMPORTANT If engine does not start after approximately 15 seconds of cranking release starter key Wait 5 minutes for starter motor to cool down Repeat step 8 HAOB36...

Page 96: ... 16 2 Connect negative jumper cable from auxiliary batteries to a ground point on machine frame DO NOT CONNECT DIRECTLY TO NEGATIVE BATTERY TERMINAL 3 Follow normal engine starting procedures 4 After engine has started remove negative jumper cable and then positive cable WARNING Wear safety glasses Never connect negative leads to positive terminals and vice versa DO NOT connect auxiliary or booste...

Page 97: ... N NEUTRAL LOCK position 3 Set parking brake switch to the I APPLIED position This will ensure that the parking brake is APPLIED 4 Set bucket on ground 5 Put pilot cutoff switch to O LOCK position This will LOCK pilot control valve lever joystick 6 Allow engine to idle for 1 2 minutes to cool down Figure 17 Figure 18 HA0O2019 P O I Figure 19 HBOI111L O I Figure 20 ...

Page 98: ... load to circulate the oil through the system Do this for 5 minutes NOTE Do not allow cylinders to pass hydraulic oil over relief valve for more than twenty seconds at a time 5 Cycle boom and bucket about five times without a load to circulate oil through system HYDRAULIC SYSTEM WARM UP COLD WEATHER 1 Follow Steps 1 through 3 in Hydraulic System Warm up 2 Do not operate machine at full speed until...

Page 99: ...f vehicle is moved while parking brake is engaged serious damage to parking brake disc will result Select a transmission gear that is appropriate for top speed that will be traveled Choosing a gear that is too high will reduce acceleration and will unnecessarily heat transmission converter oil Never place transmission in NEUTRAL when going down a hill Over speeding transmission can damage transmis...

Page 100: ...om accidentally moving during travel as a result of accidentally touching pilot control valve lever joystick 4 Press brake pedal 5 Set transmission neutral lock is in the D DRIVE position 6 Set parking brake switch to the O RELEASE position This will RELEASE the parking brake HBOI111L O I Figure 24 Figure 25 Figure 26 HAOP043L P O I Figure 27 ...

Page 101: ...sition 9 Release the brake pedal while slowly pressing the accelerator pedal MACHINE SHUT DOWN 1 Ease off throttle and apply travel brakes WARNING When traveling at high speed or on a steep hill do not make sharp changes in direction This could cause vehicle to overturn When traveling or changing direction always look carefully to be certain that no one is in path of vehicle Figure 28 Figure 29 Fi...

Page 102: ...5 Set bucket on ground 6 Select pilot cutoff switch to O LOCKED position This will lock pilot control valve lever joystick 7 Allow engine to idle for 1 2 minutes to cool down Stopping a turbocharged engine without a cool down period can seriously damage turbocharger CAUTION LOCK transmission lever When ever machine is parked LOCK transmission lever in NEUTRAL to prevent accidental machine movement...

Page 103: ...d hold it there Hydraulic pump will be driven to supply output at maximum pressure relief pressure Energy expended to drive pump will slow engine speed Additional braking along with proper gear selection can be used to slow a vehicle that is being driven down an incline WARNING Always secure machine with wheel chocks when parked on a slope Leaving machine in gear will provide no braking effect bec...

Page 104: ...hold boom and bucket lever in Raise or Hold Raise position until boom has reached maximum height Then remove your hand from lever Lever will automatically return to NEUTRAL position This prevents hydraulic pump from working against relief valve maximum pressure BUCKET ANGLE INDICATOR Upper right side of bucket includes a bracket that indicates angle of bottom of bucket Top of bracket is parallel w...

Page 105: ...es contact with bucket lower limit switch 1 When limit switch is tripped boom will stop lowering and bucket lever will automatically be returned to NEUTRAL position Trip plate can be adjusted to control maximum height that boom can be lowered IMPORTANT Trip plate must always be set to contact limit switch before boom cylinders reach maximum extension Maximum extension causes pump to force fluid ov...

Page 106: ...k to see that bucket has stopped at required position A small readjustment of bracket 3 Figure 41 may be necessary MEGA 200 VTC When bucket lever is held in crowd detent position after bucket has been dumped bucket will pivot toward crowd position Once full crowd position has been reached bucket lever will automatically return to NEUTRAL position If bucket is lowered after lever returns to NEUTRAL...

Page 107: ...op the towed load Check if the vehicle to be towed can be braked and steered If not do not allow anyone to ride on the towed vehicle Check the tow rope or tow bar for damage and make sure it has sufficient strength for the work When necessary to descend a gradient another towing vehicle must be used in the rear to retard When towing make sure you are doing the following Start slowly A sudden start...

Page 108: ...mportant factor to take into consideration when the loader is working in swampy areas Do not enter water whose depth exceeds the loader s minimum ground clearance height or is high enough to wet the bottom of the axle housing As a rule of thumb the allowable water depth is about 400 mm This means that the loader should not be used in a river Observe the following conditions 1 Check the water depth...

Page 109: ...uired intervals The service cycles may need to be shortened depending on the working conditions Extremely hot or dusty conditions will require more frequent service Operational hours are determined by the amount of time accumulated on the engine hour meter on the front instrument panel in the cab SERIAL NUMBERS There are two serial number plates attached to the body of wheel loader Main serial num...

Page 110: ... work is requested SAFETY PRECAUTIONS 1 Before performing any maintenance checks move pilot cutoff switch to LOCKED position Place a Warning Tag on controls so that no one begins to operate machine while maintenance checks are being performed 2 Clean up all fuel spills Fuel spills are hazardous especially around engine 3 Inspect all fuel lines for leakage Replace any lines fittings O rings or filt...

Page 111: ...W 0 C 32 F or HD 46 ABOVE 0 C 32 F or TERESSTIC ANTI RUST EXXON XD 3 STRAIGHT WEIGHT or 15W40 RONEX MP 2 or RONEX MP 1 COLD TEMPS SPARTAN EP220 or EXXON GX 80W90 MOBIL MOBIL DTE 13M ALL TEMP or DTE 24 SUMMER DELVAC 1300 or SUPER 15W40 or DELVAC 1 or STRAIGHT WEIGHT MOBIL FAW 2 or MOBIL FAW 1 COLD TEMPS MOBILUBE LS 80W90 SHELL TELLUS 32 ROTELLA T15W40 or T30 WINTER or T40 SUMMER ALVANIA EP 2 SPIRAX...

Page 112: ...KI SP90 or EP90 TOTAL TOTAL EQUIVIS ZS46 III TOTAL XT 15W40 TOTAL MULTIS EP 2 FUCHS 85W90LS LUBRICANT MANUFACTURER TRANSMISSION GEAR OIL Same as engine oil SAE 15W40 API CD and above CAUTION Do not mix oils from different manufacturers Daewoo does not endorse specific brands but does suggest that owners select quality oils whose suppliers provide assurance that required standards will always be me...

Page 113: ...ter holds an additional 1 liter 1 qt of oil Cooling System 31 liters 8 2 U S gal Fuel Tank 260 liters 69 U S gal Hydraulic Oil Tank 150 liters 40 U S gal Transmission 30 liters 7 9 U S gal Axles Front Differential 16 liters 4 2 U S gal Front Hub Reduction Gear 1 7 liters 0 4 U S gal Each end Rear Differential 15 liters 4 U S gal Rear Hub Reduction Gear 1 7 liters 0 4 U S gal Each end ...

Page 114: ...p and at Normal Operating Temperature Listen for Any Abnormal Sounds See page 4 15 Check Operation of All Controls See page 4 15 Inspect Engine Fan Blade See page 4 16 Check Engine Drive Belt Wear See page 4 16 Check Air Intake System See page 4 17 50 HOUR WEEKLY SERVICE Perform All 10 Hour Daily Service Checks See page 4 18 Grease Front Attachment Pins See page 4 18 Grease Steering Cylinder Rod a...

Page 115: ...p Strainer See page 4 41 Replace Air Conditioner Filter See page 4 41 Check Air Conditioner Refrigerant See page 4 42 Check and Adjust Engine See page 4 42 1 500 HOUR 9 MONTH SERVICE Perform All 10 50 250 and 500 Hour Service Checks See page 4 43 Replace Outer and Inner Air Cleaner Elements See page 4 43 Axle Differential and Planetaries Oil Replacement See page 4 43 2 000 HOUR YEARLY SERVICE Perf...

Page 116: ...rval Grease Front Attachment Pins on page 4 18 INSPECT ALL TIRES FOR CORRECT TIRE PRESSURE AND SIGNS OF DAMAGE OR ABNORMAL WEAR 1 Inflate tires to proper operating pressure for working conditions See Tires and Wheels on page 4 57 CHECK ENGINE OIL LEVEL NOTE When checking level using a dipstick always remove and wipe it clean before making final level check 1 Check level of engine oil every day bef...

Page 117: ... level area 3 Place transmission lever in NEUTRAL 4 Apply parking brake 5 Allow engine to idle until transmission temperature is between 82 C 180 F and 93 C 200 F 6 Remove transmission dipstick Figure 7 Wipe dipstick clean and then insert it back into transmission 7 Remove dipstick and check oil level mark Oil level must be between LOW and FULL marks Figure 8 8 To add oil remove transmission fill ...

Page 118: ...ent 6 Remove the upper cover 2 Figure 11 of the hydraulic oil tank and add oil to proper level by checking sight glass Figure 10 WARNING The hydraulic oil will be hot after normal machine operation Allow system to cool before attempting to service any of the hydraulic components The hydraulic tank is pressurized Turn the breather cap slowly to allow the pressurized air to vent After the pressure h...

Page 119: ...ly 1 If filter assembly was removed insert assembly into the reservoir and check to make sure it is securely in place 2 Check O ring for damages and replace if necessary Check position of O ring at surface of hole 3 Place the cover on the access hole Make sure the spring retaining cup 1 Figure 13 in the lower section of the cover is lined up with the spring The filter assembly rod must be in a ver...

Page 120: ...e Fluid Capacities on page 4 5 for capacity 2 Securely tighten cap after fueling NOTE If breather holes in cap are clogged a vacuum may form in the tank preventing proper fuel flow to engine Keep holes in fuel cap clean CHECK FOR LEAKS IN THE FUEL SYSTEM 1 Perform an inspection of engine compartment to verify that fuel system is not leaking If any is noted determine the source of leak and repair W...

Page 121: ...n out any water or sediment Figure 17 Catch drained material in a container Properly dispose of drained material CHECK COOLANT LEVEL WARNING Never open radiator when it is hot Scalding liquid inside a hot radiator is under pressure Removing cap from a hot radiator could cause a person to be sprayed and burned from liquid inside Wait for radiator temperature to cool down before removing cap AOO0040...

Page 122: ...heck fluid level in windshield washer tank in the storage box of the rear of the seat 2 Open fill cap and add fluid NOTE Use a washer liquid that is rated for all seasons This will prevent freezing during cold weather operation INSPECT THE BUCKET TEETH AND SIDE CUTTERS FOR SIGNS OF WEAR 1 On a daily basis inspect bucket teeth to make sure that tooth wear or breakage has not developed 2 Do not allo...

Page 123: ...r work lights Replace any monitors burned out bulbs or cracked or broken housings or lenses START ENGINE CHECK STARTING ABILITY AND OBSERVE EXHAUST COLOR AT START UP AND AT NORMAL OPERATING TEMPERATURE LISTEN FOR ANY ABNORMAL SOUNDS CHECK OPERATION OF ALL CONTROLS 1 With engine at rated speed operate all of the controls 2 Follow cold weather hydraulic system warm up procedures 3 Note any slow oper...

Page 124: ...nsverse cracks are not acceptable Replace the belt if it is frayed or has pieces of material missing 2 Before installing new belts make sure all pulley grooves are clean and not worn Replace pulley if damaged or if the grooves are worn 3 All pulley support bearings shafts and brackets must be in working order 4 When replacing belts and pulleys pulley alignment must be checked with belts tensioned ...

Page 125: ... falls below the required minimum the belt slips damaging the belts and pulley grooves NOTE When operating in abrasive conditions check tension every 100 hours CHECK AIR INTAKE SYSTEM 1 Park the machine on a level surface apply the parking brake lower the attachment to the ground and shut down engine 2 Check the engine intake hose and hose bands for damage and tightness 3 If damaged wrinkled or lo...

Page 126: ...REASE FRONT ATTACHMENT PINS MEGA 200 V 1 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 D C B A E F APO0080L Figure 26 ...

Page 127: ... Maintenance and Adjustment 4 19 A Bucket hinge pins 2 locations Figure 27 Lever link connecting pin 1 location Figure 28 Bucket link connecting pin 1 location Figure 29 B Arm lever connecting pin 1 location Figure 30 Figure 27 Figure 28 Figure 29 Figure 30 ...

Page 128: ... Adjustment 022 00028AE Operation and Maintenance Manual C Bucket cylinder rod end 1 location Figure 31 D Lift cylinder heads left right 2 locations Figure 32 Lift cylinder rod ends 2 locations Figure 33 Figure 31 Figure 32 Figure 33 ...

Page 129: ...pection Maintenance and Adjustment 4 21 E Remote location points 1 REMOTE FITTINGS FOR LOADER ARM FOOT ENDS 50 HOUR Figure 35 and Figure 36 2 REMOTE FITTINGS FOR BUCKET CYLINDER HEAD 50 HOUR Figure 35 and Figure 37 1 1 2 AJO0150L Figure 34 Figure 35 ...

Page 130: ... each side of machine Greased from two remote grease points 1 Figure 34 2 Bucket cylinder head 1 point Greased from remote grease point 2 Figure 34 F Rear Axle pivot 1 Figure 38 2 locations on each side of machine Use remote grease fittings mounted on frame shown in Figure 38 Figure 36 Figure 37 1 AHO0390L Figure 38 Figure 39 ...

Page 131: ...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 A Bucket hinge pins 2 locations on each side of bucket Arm link connecting pins 2 locations Figure 41 C B D A BFO0030P Figure 40 Figure 41 ...

Page 132: ...tions Figure 42 C Bucket cylinder heads 2 locations Arm lever connecting pins 2 locations Lever link connecting pins 2 locations Figure 43 Link foot pins 2 locations D Lift cylinder heads left right 2 locations Lift cylinder rod ends 2 locations Figure 44 GREASE STEERING CYLINDER ROD AND HEAD ENDS 1 Steering cylinder rods 2 locations one on each side of machine Figure 42 Figure 43 Figure 44 Figure...

Page 133: ...cedure under 250 hour maintenance interval See page 4 25 HYDRAULIC FULL FLOW FILTER REPLACEMENT NOTE Replace hydraulic full flow filter after first 50 hours of operation and every 250 Hours thereafter Follow procedure under 250 hour maintenance interval See page 4 30 CHECK WATER PUMP BELT TENSION 1 Water pump belt tension must be checked after first 50 hours of operation to comply with new machine...

Page 134: ...t accumulation on fins of radiator oil cooler and additional transmission cooler and air conditioner condenser greatly reduce their cooling efficiency Use compressed air water and steam to clean fins on radiator oil cooler and transmission cooler NOTE On an especially dusty work site clean fins every 50 hours On other work sites clean fins every 500 hours See page 4 35 ...

Page 135: ...ld operate the engine to bring the coolant temperature up to about 40 C 104 F When the needle of the coolant temperature gauge reaches the middle of the WHITE ZONE the temperature is about 40 C 104 F 2 Replace engine oil filter Figure 50 The engine oil filter is a spin on type Remove and discard filter 3 Install new filter Apply a small amount of oil around filter gasket Screw filter on head until...

Page 136: ...r Recheck oil level using dipstick 1 Figure 51 REPLACE HYDRAULIC SYSTEM BRAKE AND PILOT FILTER Replace filter element in pilot filter Perform the following steps 1 Vent hydraulic oil tank 2 Unscrew element cover 5 Figure 53 Cover is filled with oil Dispose of oil 3 Remove O ring 3 Figure 53 and filter element 4 4 Use a nonflammable nontoxic solvent to clean out cover 5 Figure 53 5 Insert a new fil...

Page 137: ...E AIR PRE CLEANER 1 The engine is equipped with a pre cleaner Dust insects rainwater etc can be present in the air The pre cleaner collects this material and discharges it This prevents material from being drawn into air cleaner The pre cleaner does not need periodic cleaning or replacement Figure 54 ...

Page 138: ... 5 down into reservoir Press element down onto its base until top of element is approximately 4 mm 0 157 below edge of reservoir 8 Install a new O ring 4 Figure 55 on cover 2 Set spring 3 into place on element 6 9 Set cover 2 Figure 55 into place over element 6 Install bolts 1 through cover 2 and tighten them 10 Tighten breather cap on reservoir WARNING The hydraulic oil will be hot after normal m...

Page 139: ... element of air filter assembly NOTE If indicator light on instrument panel comes ON this indicates that air cleaner needs to be serviced NOTE Replace outer element every 1 500 hours of service WARNING Be certain that hydraulic oil has cooled before draining water and sediment Hot oil could splash and cause burns The hydraulic tank is pressurized Press button in center of breather to allow pressur...

Page 140: ...n requirements After first tension check belt must be checked every 250 hours 1 Apply 10 kg 22 lb of force to midpoint of belt Figure 60 The belt should deflect 10 mm 0 4 If belt deflects more than this loosen control link to tighten belt tension until deflection is 10 mm 0 4 Inspect belt for damage If belt is damaged replace it CAUTION Never clean the inside of air filter housing while the inner ...

Page 141: ...t 250 hours of operation There after every 1 500 hours of operation See page 4 43 REPLACEMENT OF TRANSMISSION OIL AND FILTER AFTER FIRST 250 HOURS NOTE Transmission oil and filter must be changed after first 250 hours of operation to comply with new machine break in requirements NOTE After first change oil and filter should be changed every 1 000 hours Follow procedure under 1 000 hour maintenance...

Page 142: ...h fuel NOTE Fill fuel filter with clean fuel This will help reduce fuel system priming 5 Start engine After engine has run for a couple of minutes shut down engine and look for leaks If engine does not start fuel system may need priming Prime fuel system using the following procedure A Loosen plug on top of fuel filter head B Unscrew and pump the hand operated primer pump near fuel injection pump ...

Page 143: ...il cooler Figure 64 and air conditioner condenser Figure 65 greatly reduce their cooling efficiency Use compressed air water and steam to clean fins on radiator oil cooler and transmission cooler NOTE On an especially dusty work site clean fins every 50 hours On other work sites clean fins every 500 hours Figure 64 S N 1001 thru 2000 EUROPE LOW NOISE KIT and S N 2001 and Up Figure 65 AIR CONDITION...

Page 144: ...ement and inspect it for damage 3 Use compressed air to clean filter element If element is very dirty use a mild soap and water solution to clean it NOTE If water was used to clean filter element be sure it is completely dry before installation NOTE This filter should be cleaned out every 500 hours and replaced with a new one every 1 000 hours NOTE In the event that the unit is being operated in a...

Page 145: ...tor and open the drain valve Figure 69 3 Open vent on intercooler WARNING Allow the engine to cool before releasing the radiator cap Make sure to loosen the cap slowly to release any remaining pressure Radiator cleaning is performed while the engine is running Take extreme caution when working on or near a running engine Make sure to lock out and tag the controls notifying personnel that service w...

Page 146: ... low idle until the coolant temperature gauge reaches the GREEN ZONE Run engine for another 10 minutes 9 Alter allowing engine to cool 10 Drain flushing fluid and fill system with water 11 Run engine again to allow water to completely circulate 12 Drain water and fill system with proper anti freeze mixture for ambient temperature Refer to coolant concentration table See page 4 14 NOTE When filling...

Page 147: ...vent to clean strainer 6 Inspect gasket on inlet strainer Replace gasket if it is damaged Install inlet strainer 7 Remove breather filter Clean breather filter and install it 8 Rotate filter 1 Figure 74 counterclockwise to remove it 9 Clean filter head 10 Grease filter gasket and gasket mating surface on filter head 11 Thread filter onto filter head Tighten filter 1 2 turn after filter gasket cont...

Page 148: ... a suitable container 4 Remove the nuts with a 17mm wrench to remove the inspection cover 2 Figure 76 5 Clean inside of the tank and suction stainer Figure 77 6 Install the inspection cover with a new gasket Tighten the bolts Do not overtighten 7 Close drain valve 8 Fill fuel tank 9 Check for any leaks at cover and plug WARNING Fuel is flammable and harmful to skin Do not smoke while draining mois...

Page 149: ...EPLACE AIR CONDITIONER FILTER NOTE This unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator s cab This filter should be cleaned out every 500 hours and replaced with a new one every 1 000 hours For filter replace See Clean Air Conditioner Filter on page 4 36 NOTE In the event that the equipment is being operated in a dust...

Page 150: ...NE Contact your nearest Daewoo loader dealer Engine dealer for checking and adjusting the following items Engine Compression Pressure Injection Pressure Injection Timing WARNING Mixing of tobacco smoke and freon is deadly Do not smoke while servicing or recharging air conditioning system CAUTION Overfilling refrigerant may cause dangerous high pressure and poor cooling action and low refrigerant l...

Page 151: ...st 250 hours of operation to comply with new machine break in requirements After that axle oil check should be done every 250 hours of operation and replacement should be done every 1 500 hours Each axle contains a center differential and a planetary in each end The same oil lubricates center differential and planetaries in axle ends but oil flows very slowly between these points When checked oil ...

Page 152: ...and tighten it 5 Pump oil into plug hole for level plug on center differential Add oil until oil level is even with bottom of plug hole 6 Go to level plug holes 1 Figure 81 on axle ends Add oil to these openings until oil level is even with bottom of plug hole Recheck level on center differential Add oil if necessary When oil level is satisfactory at all three level plug holes install and tighten ...

Page 153: ...e brakes to operate intermittently which is a dangerous condition Never operate machine with air in brake hydraulic system A spongy feel when pressing brake pedal is a sign that air is present in brake hydraulic system To bleed air out of brake hydraulic system perform the following steps Figure 83 1 Start engine and place transmission in NEUTRAL 2 Remove rubber cap from bleeder screw on wheel 3 P...

Page 154: ...ne NOTE See Fluid Capacities on page 4 5 for capacity 2 Position a catch tank beneath hydraulic reservoir drain plug Release pressurized air from hydraulic oil tank by rotating air breather cap See Figure 11 on page 4 10 Remove drain plug Figure 85 from bottom of reservoir Allow all hydraulic oil to drain out CAUTION Be certain that hydraulic oil has cooled before draining it Hot oil could splash ...

Page 155: ...oir sight gauge See Figure 10 on page 4 10 Oil level must be between upper limit and lower limit on sight gauge Remove breather cap and add oil if necessary CHECK BRAKE ACCUMULATOR Test the brake accumulator for proper precharge of Nitrogen gas 1 Park the machine on a level surface apply the parking brake lower the attachment to the ground 2 Run the engine at low idle for five minutes to fill the ...

Page 156: ...s can not be stored more than 2 years before being discarded or installed on a machine In service lifetime of hoses fitted on a machine can never exceed 6 years but replace hoses described in Replace Pipes and Hoses on page 4 45 every year Always replace hoses having exceeded the allowed in service lifetime irrespective of the external appearance wear Always store hoses in a dark place at a maximu...

Page 157: ...is 2 Clean radiator and oil cooler fins to remove dirt and dust 3 Clean fuel system intake strainer and fuel filter more frequently 4 Inspect starter motor and alternator and clean as often as necessary Rocky Terrain 1 Check wheels tires rims and valve stems for damage or excessive wear 2 Inspect for loose or damaged fittings and bolts 3 On a more frequent basis inspect bucket and boom for damage ...

Page 158: ...motor result in causing motor damage 3 Do not use refueling pump for other types of fuel Use only for diesel fuel Do not use refueling pump for other types of fuel which have a low flash point Do not use refueling pump for fuel contaminated with water or high humidity Moisture in pump mechanism can cause rust and can create pump failure 4 Always operate pump using the strainer installed on the inl...

Page 159: ...o ON position NOTE The transfer pump rate of flow is approximately 20 liters minute 5 gpm Use extra care not to overfill fuel tank so that fuel does not over flow 4 Once fuel transfer is completed immediately turn switch to OFF position to stop pump 5 Lift inlet hose from fueling source and turn switch to ON position for 2 3 seconds to drain remaining fuel from hose to fuel tank 6 Replace strainer...

Page 160: ...s 0 4 Rotate adjusting bolt 3 Figure 92 clockwise four turns 0 25 mm rotation to set the clearance to 1 mm 0 4 in 5 Install lock bracket 1 Figure 92 and bolt 2 Repeat steps 1 5 for other side FRONT AXLE PARKING BRAKE EMERGENCY RELEASE 1 Locate parking brake release bolt on the lower section on both sides of the housing 2 Loosen lock nut 4 Figure 92 from adjusting bolt 5 3 Tighten adjusting bolt 5 ...

Page 161: ...een adjusted CONTROL LEVER ACTIVATION PRESSURE S N 1001 thru 2000 1 Attach gauge to port 2 Figure 93 2 Adjust relief cartridge 3 Figure 95 on brake and pilot supply valve 1 Figure 95 Relief pressure should be set at 28 kg cm2 398 psi 3 Loosen lock nut on adjusting screw Turn adjusting screw clockwise to raise relief pressure Turn adjusting screw counterclockwise to lower relief pressure 4 Tighten ...

Page 162: ...lower relief pressure 4 Tighten lock nut after adjustment has been made STEERING PUMP PRESSURE 1 Attach gauge to port 3 Figure 93 2 Adjust relief valve cartridge on steering valve Figure 97 Cartridge must be adjusted to open at 200 5 kg cm2 2 845 70 psi 3 Unscrew remove plug and washer Adjust screw that is beneath plug Turn screw clockwise to raise relief pressure Turn screw counterclockwise to lo...

Page 163: ...001 and Up 1 Attach gauge to port 5 Figure 92 2 Adjust brake charge valve cartridge 2 Figure 100 on brake and pilot and fan motor supply valve 1 Figure 100 Relief pressure for brake charging is 120 5 kg cm2 1 707 70 psi SERVICE BRAKE OUTLET PRESSURE 1 Attach gauge to brake pressure test port 1 Figure 101 on front axle 2 Outlet pressure should be 45 3 kg cm2 640 43 psi PARKING BRAKE RELEASE PRESSUR...

Page 164: ...an motor 1 Figure 102 2 Adjust screw on relief valve cartridge 2 Figure 102 NOTE Outlet pressure should be 87 5 kg cm2 1 237 70 psi 3 Loosen lock nut on adjusting screw Turn adjusting screw clockwise to raise relief pressure Turn adjusting screw counterclockwise to lower relief pressure NOTE One turn varies pressure 16 5 kg cm2 235 psi 4 Tighten lock nut after adjustment has been made Figure 102 ...

Page 165: ...chine or when working machine Check tires for damage and embedded objects Check valve stems for damage WHEEL NUT TORQUE Tighten wheel nuts to 58 62 kg m 420 448 ft lb Tire Dimension Working Pressure Driving Pressure Remarks Front Tire Rear Tire Front Tire Rear Tire 17 5 25 12PR L2 Standard 3 25 kg cm2 46 psi 3 0 kg cm2 43 psi 2 5 kg cm2 36 psi 2 0 kg cm2 29 psi Bias Ply Tire Standard 20 5 25 12PR ...

Page 166: ...amage to the carcass exceeds 1 3 of the tire width Tire layers are separated Radial cracks reach the carcass Deformation or damage which makes the tire unsuitable for use WARNING Improper servicing or changing tires and rims can cause explosion resulting in serious injury or death Do not service or change tires and rims unless properly trained and equipped Contact your nearest Daewoo loader dealer...

Page 167: ...ways be replaced in pairs Using an old battery with a new one will shorten the life span of the new battery WARNING Before starting any battery service work make sure to shut the engine off and turn the starter switch to the OFF position The batteries create hydrogen gas An explosion hazard exists particularly with a deeply discharged battery Make sure that open flames burning objects or sparks ar...

Page 168: ...0 4 84 35 7 05 51 8 30 60 12 mm x std 8 57 62 11 89 86 14 52 105 12 mm x 1 5 9 00 65 12 59 91 14 94 108 14 mm x std 13 55 98 18 95 137 23 10 167 14 mm x 1 5 14 94 108 21 02 152 24 89 180 16 mm x std 20 88 151 29 46 213 35 54 257 16 mm x 1 5 22 54 163 31 53 228 38 03 275 18 mm x std 28 90 209 40 52 293 48 41 350 18 mm x 1 5 32 50 235 45 92 332 55 04 398 20 mm x std 40 94 296 57 95 419 69 01 499 20 ...

Page 169: ...ing of light oil to all exposed cylinder rods Apply a coating of light oil to all control linkages and all control valve spools Check condition of oil coating each month and add to coating where necessary BATTERY Disconnect cables from battery or remove battery from machine If battery is removed fully charge battery and store it COOLING SYSTEM CARE If cooling system does not need antifreeze and is...

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Page 171: ... the trailer and the machine 4 Determine the position of the ramp then slowly load the machine onto to the specified part of the trailer NOTE Have someone in clear view and in a safe position provide directions while loading 5 Lower the bucket and lock each control lever using the pilot cutoff switch 6 Apply the parking brake and set the articulation stopper in the LOCKED position 7 Tape over the ...

Page 172: ...NS FOR LIFTING To make safe lifts the following items must be evaluated by operator and work site crew Condition of ground support Wheel loader configuration and attachments Weight lifting height and lifting radius Safe rigging of load Proper handling of suspended load Taglines on opposite sides of load can be very helpful in keeping a suspended load secure if they are anchored safely to control p...

Page 173: ...place relay Starter engages engine does not start Blown fuse Replace fuse Fuel gelled in cold weather Replace fuel Fuel filters plugged Replace filters Water or dirt in fuel system Clean system and add new fuel Air in fuel system Purge air from system Engine stop control failed Replace stop control Engine stop relay failed Replace relay Engine starts runs only at low speed or shuts down Engine oil...

Page 174: ...out of adjustment Readjust Injection pump out of adjustment Contact your Daewoo dealer Valve backlash faulty Adjust backlash Engine runs hot Low coolant level Add coolant Thermostat faulty Replace thermostat Radiator cap faulty Replace radiator cap Radiator core plugged Clean oil cooler Oil cooler core plugged Clean oil cooler Fan belt loose or damaged Tighten or replace as required Temperature se...

Page 175: ...ed too low Booster Battery may be used Defective engine shutoff solenoid Contact your Daewoo dealer Fuel pump failure Incorrect fuel injection timing Compression pressure too low Defective injectors Unstable rough idling Air in fuel lines Tighten fuel connections and filter Fuel filter element clogging Replace fuel filter Fuel pump failure Contact your Daewoo dealer Incorrect fuel injection timing...

Page 176: ...rance All actuators have low power Low hydraulic oil level Add hydraulic oil as required Suction filter clogged Clean filter Hydraulic pumps faulty Contact your Daewoo dealer Main relief pressure too low Contact your Daewoo dealer Hydraulic pumps cavitating Bleed air from hydraulic pumps Only one or two actuators have little or no power Overload relief pressure too low Reset pressure Make up check...

Page 177: ...ng properly Repair valve or replace Damaged hydraulic hose Replace hose Loose hydraulic fittings Tighten fittings Internal damage to control valve housing Replace control valve Control valve spool damaged Replace control valve Sediment inside control valve Clean and repair valve Check valve internal leakage Repair or replace valve Damaged cylinder or pump Repair or replace pump or cylinder Cylinde...

Page 178: ...lace Damaged transmission or axle Repair or replace Wheel brakes not releasing Repair brakes Parking brake not releasing Repair parking brake Machine will travel but has little power Fluid pressure low in transmission clutch Repair clutch Transmission fluid low Add fluid Damage to torque converter Repair or replace Engine malfunction See Engine Troubleshooting Table Brake valve Disassemble and cle...

Page 179: ...Worn or damaged universal joint Replace universal joint Loose universal joints Tighten bolts that secure universal joints Lack of lubrication Lubricate universal joints Worn slip joint spline Replace slip joint Noisy Front or Rear Axle Worn or broken gears Replace gears Low oil level poor quality oil Add oil change oil Worn bearings Replace bearings Worn shaft spline Replace spline Problem Cause R...

Page 180: ... signal 21 Shot circuit to battery voltage at clutch cutoff input 22 Short circuit to ground or open circuit at clutch cutoff input 23 Short circuit to battery voltage at load sensor input Not used 24 Short circuit to ground or open circuit at load sensor input Not used 25 Short circuit to battery voltage or open circuit at temperature sensor input 26 Short circuit to ground at temperature sensor ...

Page 181: ... battery voltage at clutch K3 78 Short circuit to ground at clutch K3 79 Open circuit at clutch K3 7A Short circuit to battery voltage at converter clutch Not used 7B Short circuit to ground at converter clutch Not used 7C Open circuit at converter clutch Not used 81 Short circuit to battery voltage at clutch K4 82 Short circuit to ground at clutch K4 83 Open circuit at clutch K4 84 Short circuit ...

Page 182: ...4 B5 Slippage at clutch KV B6 Slippage at clutch KR D1 Short circuit to battery voltage at power supply for sensors D2 Short circuit to ground at power supply for sensors D3 Low power at battery D4 High power at battery D5 Error at switch 1 for valve power supply D6 Error at switch 2 for valve power supply E1 Short circuit to battery at speedometer output Not used E2 Short circuit to ground or ope...

Page 183: ...ressure Steering pump failure Repair or replace Leaking steering cylinder Repair cylinder Rust on steering column bearing and spline Lubricate Tire air pressure is low Inflate to proper pressure High initial resistance to movement of steering wheel Air in load sensing line inside priority valve Bleed system to remove air Sediment blocking orifice of load sensing line inside priority valve Clean an...

Page 184: ...k bleed system After bleeding brakes brakes are not fully released Damaged brake discs Replace discs Damaged brake disc return spring Replace return springs Problem Cause Remedy Battery has no power and will not accept a charge Damaged battery plates Replace battery Alternator not charging properly Repair or replace alternator Bad ground Clean and tighten Loose electrical connector Clean and tight...

Page 185: ...251 lb OPT 11 200 kg 24 692 lb Engine Model DB58TI DB58TIS Emission Tier I Tier II Type Turbo Intercooler Turbo Charge Air Intercooler Horsepower see note 140 ps 2 200 rpm 138 hp 2 200 rpm SAE J 1349 net Rated 145 ps 143 hp 2 200 rpm Max 160 ps 158 hp 2 000 rpm Gross SAE J1995 Max Torque see note 57 kg m 1 500 rpm 412 ft lb 1 500 rpm SAE J 1349 net 64 kg m 463 ft lb 1 600 rpm Gross SAE J1995 Trans...

Page 186: ...imes The maximum horsepower occurs at 2000 rpm when power is needed during the working cycle WORKING RANGE AND DIMENSIONS Figure 1 illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket A D B a b H I F C E G 4 0 O J APO0160L Figure 1 ...

Page 187: ... Width D 2 450 mm 8 0 2 550 mm 8 4 Wheel Base E 2 900 mm 9 6 Tread F 1 930 mm 6 4 Ground Clearance G 370 mm 1 3 450 mm 1 6 Dump Height to tooth H 2 720 mm 8 11 2 730 mm 8 11 Dump Distance to Bucket Edge I 1 000 mm 3 3 870 mm 2 10 Minimum Tire Turning Radius J 4 950 mm 16 3 Bucket Angle Raised a 46 Bucket Angle b Lowered at carry 45 Bucket Angle b Lowered on ground 40 Tire Size 17 5 25 12PR 20 5 25...

Page 188: ...e Weight STD 11 000 kg 24 251 lb OPT 11 200 kg 24 692 lb Engine Model DB58TI DB58TIS Emission Tier I Tier II Type Turbo Intercooler Turbo Charge Air Intercooler Horsepower see note 140 ps 138 hp 2 200 rpm Net SAE J1349 Rated 145 ps 143 hp 2 200 rpm Max 160 ps 158 hp 2 000 rpm Gross SAE J1995 Max Torque see note 57 kg m 412 ft lb 1 500 rpm Net SAE J1349 64 kg m 463 ft lb 1 600 rpm Gross SAE J1995 T...

Page 189: ...nd Maintenance Manual Specifications 7 5 WORKING RANGE AND DIMENSIONS Figure 2 illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket I H B D A E C F BFO0020L Figure 2 ...

Page 190: ...0 5 3 260 mm 10 8 Bucket Width D 2 450 mm 8 0 5 2 550 mm 8 4 Wheel Base E 2 900 mm 9 6 1 Tread F 1 930 mm 6 4 Ground Clearance G 370 mm 1 3 450 mm 1 6 Dump Height to tooth H 2 584 mm 8 6 2 666 mm 8 9 Dump Distance to Bucket Edge I 961 mm 3 1 890 mm 2 11 Dump Height to Bucket Pivot J 3 748 mm 12 4 3 828 12 7 Bucket Angle Raised a 46 Bucket Angle b Lowered 46 Tire Size 17 5 x 25 12PR 20 5 25 12PR Bi...

Page 191: ...erials APPROXIMATE WEIGHT OF WORKLOAD MATERIALS MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry size 449 kg m3 756 lb yd3 Coal bituminous slack piled 801 kg m3 1 350 lb yd3 Coal bitu...

Page 192: ... size 1 522 kg m3 2 565 lb yd3 Gravel DRY packed fragments 1 810 kg m3 3 051 lb yd3 Gravel WET packed fragments 1 922 kg m3 3 240 lb yd3 Limestone graded above 2 1 282 kg m3 2 160 lb yd3 Limestone graded 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1 282 kg m3 2 160 lb yd3 Salt 929 kg m3 1 566 lb yd3 MATERIAL ...

Page 193: ...T Weights are approximations of estimated average volume and mass Exposure to rain snow or ground water settling or compaction due to overhead weight and chemical or industrial processing or changes due to thermal or chemical transformations could all increase value of weights listed in table MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700...

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Page 195: ...rakes Additional Braking 3 15 Bleeding 4 45 Brake Fluid Warning 2 24 Brake Fluid Warning Light 2 24 Brake Pedal 2 13 Troubleshooting 6 12 Bucket Angle Indicator 3 16 Capacity 7 7 Position Switch 3 18 Teeth and Side Cutters 4 14 C Cab Light 2 39 Cigar Lighter 2 31 Circuit Breaker 2 57 Clean Exterior of Radiator Oil Cooler and Air conditioner Evaporator 4 35 Cold Weather Engine Start 3 5 Combination...

Page 196: ...aulic System 4 11 Long Term Storage 4 61 Main Pump Pressure 4 53 Parking Brake Release Pressure 4 55 Service Brake Outlet Pressure 4 55 Steering Pump Pressure 4 54 System Pilot Filter Replace 4 28 System Warm up 3 10 System Warm up Cold Weather 3 10 Tank Water Draining 4 31 Transmission Clutch Pressure 4 54 Troubleshooting 6 4 I Indicator Lights Air Filter Indicator Light 2 22 Battery Warning Ligh...

Page 197: ...akers 2 39 Speedometer 2 20 Starter Switch 2 10 Start up Cold Weather Engine Start 3 5 Engine Start 3 2 Hydraulic System Warm up 3 10 Hydraulic System Warm up Cold Weather 3 10 Starting with Auxiliary Batteries 3 8 Steering Troubleshooting 6 11 Steering Tilt Knob 2 12 Steering Wheel 2 13 Stereo 2 39 2 47 AM FM Band Selection 2 48 Automatic Memory AME 2 48 Automatic Selection 2 48 Balance Fader Con...

Page 198: ...placement 4 33 4 39 Oil Level Check 4 9 Oil Temperature Gauge 2 21 Travel Precautions 1 16 Travel System Troubleshooting 6 6 Troubleshooting 6 1 U Unauthorized Modifications 1 10 V Visibility 1 15 W Washer Tank 2 40 Water Pump Belt Tension 4 25 4 32 Weight of Workload Materials 7 7 Wheel Nut Torque 4 57 Window Glass Breaking Tool 1 18 2 58 Window Washer Liquid 4 14 Work Area 1 12 Work Light Indica...

Page 199: ...REET ADDRESS TELEPHONE CITY FAX STATE PROVINCE COUNTRY NAME MACHINE MODEL SERIAL NUMBER MANUAL NUMBER SHOP MANUAL SECTION NUMBER PROPOSED DESCRIPTION OF CORRECTION AND OR SUGGESTION Use additional paper if needed Please include copy of current manual pages for reference Attach any photos or illustrations If digital photos are available e mail them to Bill Bernhardt dhiac com If possible use 1024 x...

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