SB 4031 e

For use in service manual
form SB4031E
SB4032E00
Jul. 2000
SERVICE MANUAL CONTENTS
NOTICE
This form lists the contents of the complete Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers listed with mark(*) are, they are not available for the initial release of the
manual. When items are updated, or supplements added, they will be announced in
preview and should be ordered as they become available.
TITLE FORM NUMBER
Service Manual Contents SB4032E00
FOREWORD
Safety & Foreword SB4033E00
ENGINE
D427 Diesel Engine (1550XL(DSL702)) SB4034E00

D430 Diesel Engine (1760XL(DSL802), 2060XL(DSL902)) SB4035E00
VEHICLE
Vehicle Systems SB4036E00
HYDRAULIC & HYDROSTATIC
Hydraulic & Hydrostatic Systems SB4037E00
ELECTRIC
Electric Systems SB4038E00
OPERATION & MAINTENANCE
Operation & Maintenance Manual SB2313E00

(1550XL(DSL702), 2060XL(DSL902))
Operation & Maintenance Manual SB2308E00
(1760XL(DSL802-D430))
Models ; 1550XL(DSL702), 1760XL(DSL802), 2060XL(DSL902)

SB4033E00
Jul. 2000
Satety & Foreword

For Skid Steer Loaders
1550XL(DSL702)
1760XL(DSL802)
2060XL(DSL902)
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. DAEWOO dealers have the most current information
available.
SB2003E00
A p r. 1 9 9 9
WARNING
SAFETY
machine. If this cannot be done, make sure the
WARNING forks or other im plements are blocked correctly to
prevent them from dropping unexpectedly.
The proper and safe lubrication and malntenance
for this machine, recommended by DAEWOO, are 5. Use steps and grab handles (if applicable)when
outilined in the OPERATION & MAINTENANCE mounting or dismounting a machine. Clean any
GUIDE of this machine. mud or debris from steps, walkways or work
plaftorms before using. Always face machine when
Improper performance of lubrication or maintenance using steps, ladders and walkways. When it is not
procedures is dangerous and could result in injury possible to use the designed access system,
or death. Read and understand the OPERATION & provide ladders, scaffolds, or work platforms to
MAINTENANCE GUIDE before performing any perfom safe repair operations.
lubrication or maintenance.
6. To avoid back injury, use a hoist when lifting
components which weigh 23 kg (50 lb.) or more.
The serviceman or mechanic may be unfamitiar with Make sure all chains, hooks, slings, etc., are in
many of the systems on this machine. This makes it good condition and are of the correct capacity. Be
important to use caution when performing service sure hooks are positioned correctly. Lifting eyes
work A knowledge of the system an/ or components are not to be side loaded during a lifting operation.
is important before the removal or disassembly of
any component. 7. To avoid bums, be alert for hot parts on machines
which have just been stopped and hot fluids in
Because of the size of some of the machine lines, tubes and compartments.
components, the serviceman or mechanic should
check the weights noted in this Manual, Use proper 8. Be careful when removing cover plates. Gradually
lifting procedures when removing any components. back off the last two bolts or nuts located at
opposite ends of the cover or device and pry cover
Following is a list of basic precautions that should loose to relieve any spring or other pressure,
always be observed. before removing the last two bolts or nuts
completely.
1. Read and understand all Waming plates and
decals on the machine before operating, 9. Be careful when removing filler caps, breathers
lubricating or repairing the product. and plugs on the machine. Hold a rage over the
cap or plug to prevent being sprayed or splashed
2. Always wear protective glasses and protective by liquids under pressure. The danger is even
shoes when working around machines. In greater if the machine has just been stopped
particular, wear protective glasses when pounding because fluids can be hot.
on any part of the machine or its attachments with
a hmmer or sledge. Use welders gloves, 10. Always use tools that are in good condition and
hood/goggles, apron and other protective clothing be sure you understand how to use them before
appropriate to the welding job being performed. Do performing any service work.
not wear loose-fitting or tom clothing. Remove all
rings from fingers when working on machinery. 11. Reinstall all fasteners with same part number. Do
not use a lesser quality fastener if replacements
3. Do not work on any machine that is supported only are necessary. Do not mix metric fasteners with
by lift jacks or a hoist. Always use blocks or jack standard nuts and bolts.
stands to support the machine before performing
any disassembly. 12. If possible, make all repairs with the machine
parked on a level, hard surface. Block machine
4. Lower the bucket or other implements to the so it does not roll while working on or under
ground before performing any work on the machine.
WARNING
13. Disconnect battery before starting to work on 20. Do not operate a machine if any rotating part is
machine. Hang Do Not Operate tag in the damaged or contacts any other part during
Operators Compartment. operation. Any high speed rotating component
that has been damaged or altered should be
14. Repairs, which require welding, should be checked for balance before reusing.
performed only with the benefit of the appropriate
reference information and by personnel
adequately trained and knowledgeable in welding
procedures. Determine type of metal being
welded and select correct welding procedure and
electrodes, rods or wire to provide a weld metal
strength equivalent at least to that of parent
metal.
15. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will it
be damaged in operation by contacting sharp
corners, or by rubbing against some object or hot
surface. Do not connect wiring to a line
containing fluid.
16. Be sure all protective devices including guards

and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.
17. Loose or damaged fuel, lubricant and hydraulic

lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Pin hole (very small) leaks can
result in a high velocity oil stream that will be
invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.
18. Tighten connections to the correct torque. Make

sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat,
vibration or rubbing against other parts during
operation. Shields that protect against oil spray
onto hot exhaust components in event of a line,
tube or seal failure must be installed correctly.
19. Relieve all pressure in air, oil or water systems

before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
Foreword Amount of dirt in air cleaner elements and air
leakage.
How to Use This Manual Oil levels in the engine oil pan and status of oil
(viscosity, color and mixed impurities).
This manual provides information for servicing the Water mixed in the oil and oil leakage.
1760XL(DSL802) skid steer loader. All service Clogging of the oil filter element.
procedures are broken down into detailed steps, Deviations from designated adjusting points.
listed in their recommended sequence. The manual Damaged parts and loosening of tightening fittings.
uses both photographs and drawings to help locate Maintenance conditions of the machine in service, if
and itemize components. possible.
The table of Contents on the preceding pages is your 3) Preparation for disassembly
best tool for finding the service procedure you need.
To save unnecessary work, reserve the necessary
Be certain to observe all Safety information included facilities, tools, and parts racks as well as adequate
in these pages. floor space considering the extent of disassembly.
Keep the area and facilities clean.
Precautions For Disassembly

General Precautions For Disassembly
1) Removal of parts
Preparations before disassembly
Proceed with the disassembly by confirming the
1) Wash the machine before moving it to into the
fitting conditions of the relative parts, their positions
repair shop.
fore-and aft, left-and-right, upper-and-lower, and the
sequence of their removal.
Prior to moving the machine into the repair shop
remove dust and dirt thoroughly by washing the
Confirm match marks for mating joints before
machine. Dirt brought into the shop will degrade the
separating parts and where necessary, punch match
cleanliness of the parts handled in the shop, will
marks to clearly identify their relative position to
produce scratches, and can contaminate the inside of
prevent confusion during reassembly.
reassembled units.
For disassembly of certain designated parts, use
specified special tools.
2) Checking and inspection before disassembly.
When a part, after removal of fastening nuts and
bolts, is still found to be unremovable, never force
Before attempting to disassemble, check thoroughly
the part. Carefully check for the cause of the
to determine the cause of the problem, and record it.
tightness and remove the cause.
This will not only prevent needless disassembly and
Keep the disassembled parts in an orderly condition.
losses from needless replacement parts and
Take special care to identify similar parts by
manhour costs, but will also prevent repetition of the
attaching tags or markings.
same problem.
See that standard parts such as bolts and nuts are
stored in good order with reference to quantity and
It is important to keep records of problems and
where they are to be used.
replacements in order to advise serviceman how to
prevent trouble. Items to be checked and recorded
2) Checking and inspecting during disassembly.
are as follows:
The cause of the actual trouble is often discovered
Model, machine serial number and service meter
in the course of disassembly. Thus careful checking
readings.
of sliding surfaces for any signs of seizing or
Reason for disassembly.
interference, and their mating conditions, is
Components replaced.
important.
Measure and record during disassembly the various
Check for symptom, location and cause of problem. If
end clearances, backflashes and protrusions that
necessary, try repeating the same problem.
are necessary to determine the trouble.
Foreword 5 How to Use This Manual

3) Maintaining clearance adjustmnets Procesures after disassembly
Keep each set of shims or washers stored in an 1) Cleaning

orderly manner so that its original arrangement with
the same clearances can be obtained at reassembly. Wash disassembled parts clean, neatly arrange the
parts according to each assembly, and keep in
4) Maintaining linkage adjustments storage, free from dust and dirt.
Special care should be taken to remove sludge and
Be careful to maintain the original adjustment of the dust thoroughly from oil holes in the parts and from
rods unless some readjustment is necessary. When it the interior of the tubes.
is necessary to remove the rod end for disassembly, More effective cleaning can be achieved by use of
measure and record the length of the rod before two vessels filled with detergent, one for washing
disassembly. dirty parts and the other for rinsing.
When washing special parts, increase the number of
5) disassembly of taper-fitted or force-fitted parts vessels and keep the dirty detergent away from
these parts.
Remove any scars or dents, clean well and Kerosene or neutral-anhydride light oil is a suitable
reassemble. detergent for cleaning viscous bearing oils.
When looseness of fit exists in taper-fitted or force- When washing a large casting, immerse it in a
fitted parts, carefully check for the cause of the vessel filled with detergent (alkalinity pH10 to 12,
faulty fit, remove the cause and reassemble. temperature 50 to 70 C) (122 to 158 F) for up 10
minutes. Then, rinse it thoroughly with water.
6) Disassembly of bearings If harmful chemical agents are used as the
detergent, take care to protect the skin and eyes. Do
Do not attempt to remove a bearing by force, but not attempt to drain waste fluid into the sewage
remove it with a suitable puller such as shown in the system.
figure below.
2) Dust-proofing
Cover washed parts in storage to keep them free

from dust and dirt. Cap all pipes.
Apply suitable rust-preventive treatment to the parts
if they are to be kept an extended period of time in
storage before reassembly.
7) Safety
Keep the area where the machine is to be

disassembled clean and orderly.
When loosening a bolt or nut, use a correct size
wrench and always pull the wrench toward you. Use
of a mis-matched wrench because of confusion
between the inch and metric system, or pushing the
wrench away from your body may cause accidents
through slipping of the wrench or the hand.
For jobs involving two or more persons, keep close
contact by mutual checking and exchange of
necessary signals.
Foreword 6 General Precautions For Disassembly

General Precautions for Assembly Remove remnants of loctite or any thread bonding
agent from the removed bolts with appropriate
Preparations before disassembly solvent. Apply 2 or 3 drops of fresh loctite before
retightening bolts.
1) Installation of parts
(3) Check in the course of assembly
Thoroughly clean all parts before assembly. Check
for scratches and nicks on the surfaces of the parts, During assembly, check and record end clearances,
and repair if necessary. end plays, protrusions, steps and backflashes at
Special care should be paid to the sliding surfaces each stage of assembly.
of parts which, if left soiled, will cause reduced
machine life. (4) Reinsertion of shims
Use detergent to remove any rust preventive before
assembly. Insert stored sets of shims or washers in their
Make sure to align match marks of those parts that positions in the same order as disassembly.
are marked before attempting to assemble. After inserting, check for correct values of
Use the correct or a press-fitting tool or driver when clearances.
assembling bearings, bushings and oil seals. Also,
use the prescribed special tool for assembly of (5) Assembly of control linkage
certain designated parts.
Coat the surface parts to be press-fitted with moly Assemble each control link to the same length as
bdenum disulfide grease. disassembly, unless adjustments are necessary.
Reassemble and properly adjust.
(2) Tightening bolts and nuts
(6) Assembly of taper-fitted or force-fitted parts
Tighten the bolts and nuts fastening parts together
by alternately (left-and-right and upper-and-lower) Repair scratches and nicks, and thoroughly clean
turning symmetrically opposite nuts and bolts, to the parts before fitting.
apply even tightening force. If proper fit cannot be obtained between the taper-
fitted parts, carefully check for the cause.
Check and see that there is no dust, rust or
scratches found on the surface of the shaft on which
an oil seal is to be fitted and coat the shaft with
grease or lubricating oil so that the oil seal can be
installed smoothly.
When installing an oil seal, use a suitable guide and
jig as shown in the figure below to prevent oil seal
damages.
Seal
Seal
When tightening bolts on certain designated parts,
tighten them in the prescribed sequence as shown
in the figure, in order to exert even torque on every
bolt. In this method called the template methods.
the bolts are tightened stepwise and sometimes
loosened, so that the bolts and nuts are well seated Guide Jig
or the bearing comes into close and even contact.
Apply engine oil to the screw threads of certain
designated bolts so that smooth and even tightening
of the bolts may be obtained.
With wires, cotter pins or lock washers, securely After press-fitting an oil seal, check for alignment.
lock those bolts and nuts which cannot be checked Allowable limit of misalignment :
from the outside or are used for important parts that 0.2 mm per 100 mm dia. (1/64 per 3 15/16 dia.).
require locking. When applying bonding agent on the circumference
Foreword 7 General Precautions For Assembly

of an oil seal, avoid contact of the lip surface with
the onding agent.
Remove excess bonding agent on the guide and jig Jig
before using them to install another oil seal.
(7) Handling of bearings

Pressure
Pay special attention to the following
instructions so as not to damage bearing
assemblies :
a. Leave the bearings in their original package until

just before installation.
Keep bearings free from dust and dirt. Dust affects
bearing life significantly.
b. Avoid impact loads and do not apply shocks to the (8) Handling of snap rings
bearings. Absolutely avoid such unreasonable
handling like rotating a bearing excessively by When removing or installing snap rings, use a
blowing compressed air to remove detergent from suitable ring plier, taking care not to over expand the
the bearing. snap ring.
Make sure the snap ring is properly seated in its
Observe the following precautions when groove.
installing the bearings :
(9) Assembly of keys and keyways
a. Do not attempt to hammer the bearing assembly
or damage may occur.
Check for looseness of the key in its keyway and for
b. When installing a bearing assembly, use a suitable
the contact of the keyhead.
jig as shown in the figure below to apply pressure
If the keyhead contacts with keyway, remove the
to the inner race.
excess keyhead.
Apply the shrink fit method to the bearings
requiring large interference. Do not heat any
(10) Safety
bearings requiring large interference. Do not heat
any bearing assemblies to over 120C(248F).
Keep the working area, tools, workers hands, etc.
Excessively high temperature will deteorate the
clean and orderly during assembly work.
hardness of the heat treated bearing surface.
Use the correct size wrench when tightening a bolt
or nut to reduce the risk of injury and equipment
damage.
For jobs involving two or more persons, keep close
Outer Race Jig contact by mutual checking and the exchange of
necessary signs.
Pressure Handling of Common Parts
(1) Handling of packings and O-ring
Inner Race Replace all packings, gaskets O-rings, and copper

packings.
Coat certain gaskets designated in this manual with
recommended sealant.
c. When installing a non-split type bearing with
(2) Handling of O-rings
necesary interferences of the inner and outer
races, use a suitable jig as shown in the figure
Use only the O-rings prescribed in the Service Parts
below to apply the necessary pressure to both the
Manual. Special care should be paid to the O-rings
inner and outer races.
subjected to engine lubrication oil, since they are
made of thermal resistant, aging-free special
materials such as silicon rubber and cannot be

replaced by any other ordinary O-rings.
Coat the O-rings with oil to protect them from
scratching during installation. Be careful not to
expand the silicon rubber O-rings excessively, or
they will be easily cracked.
(3) Handling of oil seals
Be careful to see that the oil seal lips face the

proper directions.
Oil Pressure
Main Lip Main LipDust Sealing Lip
Keep the oil seals free from dust, and see that there
is no rust or scratches on their surfaces (especially
on the lips).
Before installation, coat the oil seal with grease as
outlined below, to prevent dry friction which may
occur during the break-in operation of the machine.
a. In case of a single-lip type oil seal:

Uniformly and lightly coat grease around the lip on
the opposite side of the sealing surface of the lip.
b. In case of a double-lip type oil seal :

Uniformly coat grease over the surface between
the two lips so that about half of the space of the
hollow found between the lips is filled with grease.

SB4034E00
Jul. 2000
Engine
D427 Diesel Engine
1550XL(DSL702)
WARNING
in injury or death.
publication.
available.
Engine 1 2.1. General Information

Index
Engine Cooling System

Specifications ............................................................5 Specifications ..........................................................42
Troubleshooting Guide ..............................................6 Troubleshooting Guide ............................................42
Adjustment of Cylinder Head Valve Clearance/Idling....8 Thermostat
Adjustment of Valve Clearance .................................8 Removal ..............................................................43
Idling Inspection............................................................43
Inspection..............................................................9 Installation ...........................................................43
Adjustment ............................................................9 Water Pump
Injection Timing On-Vehicle Inspection .........................................44
Inspection..............................................................9 Removal and Inspection .....................................44
Adjustment ..........................................................10 Disassembly and Assembly ................................44
Checking of Compression Pressure........................10 Inspection............................................................45
Disassembly and Assembly.....................................11 V-Belt
Inspection and Adjustment Inspection............................................................45
Cylinder Head .....................................................21
Valve....................................................................24
Valve Spring ........................................................24 Fuel System
Push Rod ............................................................25
Tappet .................................................................26 Outline .....................................................................46
Rocker Arm .........................................................26 Structural View ....................................................46
Piston and Piston Ring........................................27 Specifications ......................................................47
Connectng Rod ...................................................29 Troubleshooting Guide ............................................47
Connectng Rod Bearing......................................30 Fuel Filter
Crankshaft...........................................................31 Removal and Installation.....................................49
Main Bearing .......................................................32 Air Bleeding.........................................................49
Cylinder Block .....................................................33 Water-Drain .........................................................50
Cylinder liner .......................................................33 Replacement .......................................................50
Camshaft.............................................................34 Injection pump
Gears ..................................................................35 Structural View ....................................................51
Oil Seal................................................................36 On-Vehicle Inspection and Adjustment ...............52
Removal ..............................................................53
Installation ...........................................................54
Lubrication System Air-Bleeding.........................................................54
Injection Nozzle
Outline Structural View ....................................................55
Structural View ....................................................37 Removal ..............................................................55
Specifications ......................................................38 Inspection and Adjustment..................................55
Troubleshooting Guide ............................................38 Assembly.............................................................57
Inspection Installation ...........................................................57
Checking Oil Pressure ........................................39
Oil Pump
Removal and Installation.....................................39
Disassembly ........................................................39
Inspection............................................................40
Assembly.............................................................41
Oil Pan
Removal ..............................................................41
Installation ...........................................................41
Inspection............................................................41
Diesel Engine D427 3 Index

Engine Electrical System
Specifications ..........................................................58
Troubleshooting Guide ............................................58
Starter
On-Vehicle Inspection .........................................60
Removal ..............................................................60
Installation ...........................................................60
Free Running Test...............................................60
Disassembly ........................................................61
Inspection............................................................62
Alternator
Circuit Diagram ...................................................65
Charging system cautions...................................65
On-Vehicle Inspection .........................................65
Checking No-Load Adjustment Voltage ..............66
Checking Output .................................................66
Removal ..............................................................66
Installation ...........................................................67
Disassembly and Assembly ................................67
Inspection............................................................69
Glow Plugs
Checking Open Circuit of Glow plugs .................70
Removal and Installation.....................................70
Technical Data ..............................................72
Diesel Engine D427 4 Index

Engine
Specifications
Specifications
Engine model D427

Type Diesel, four-cycle
Number and arrangement of cylinders Four cylinders, in-line
Displacement cc 2701
Type of combustion chamber Swirl floor type
Valve system Over head valve(O.H.V)
Bore and stroke mm X mm(in X in) 92.0 X 101.6(3.62 X 4.00)
Compression ratio 21.5 : 1
Open BTDC 14
Intake valve
Closed ABDC 44
Valve timing
Open BBDC 48
Exhaust valve
Closed ATDC 10
Injection Timing ATDC 2
Intake 0.30(0.012)
Valve clearance mm(in)
Exhaust 0.30(0.012)
Idling speed rpm 1100 L 25
Firing order 1-3-4-2
Diesel Engine D427 5 Engine

Troubleshooting Guide
Problem Possible Cause Remedy

Insufficient power Insufficient compression
improper valve clearance Adjust
Compression leakage from valve seat Repair
(grind the valve seat)
Seized valve stem Replace
Weak or broken valve spring Replace
Cracked or distorted cylinder head Replace
Sticking, damaged, or worn piston ring Replace
Cracked or worm piston Replace
Malfunction of fuel svstem Refer to Group 4
Excessive oil Oil working up
consumption Worn or sticking piston ring or piston ring groove Replace
Worn piston or cylinder Replace or repair
Oil working down
Bad valve seal Replace
Worn valve stem or guide Replace
Oil leakage Refer to Group 2
Difficult starting Malfunction of engine-related components
Burned valve Replace
Worn piston, piston ring, or cylinder Replace or repair
Burned cylinder head gasket Replace
Malfunction of fuel system Refer to Group 4
Malfunction of electrical system Refer to Group 5
Abnormal Malfunction of engine related components
combustion improper valve clearance Adjust
Sticking or burned valve Replace
Weak or broken valve spring Replace
Carbon accumulation in combustion chamber Eliminate the carbon
Poor idling Malfunction of engine-related components
Improper valve clearance Adjust
Poor valve to valve seat contact Repair or replace
Failure of cylinder head gasket Replace

Problem Possible Cause Remedy
Engine noise Crankshaft or bearing-related parts
Excessive main bearing oil clearance Replace or repair
Main bearing seized or heat-damaged Replace
Excessive crankshaft end play Replace or repair
Excessive connecting rod bearing oil clearance Replace or repair
Connecting rod bearing seized or heat-damaged Replace
Piston-related parts
Worn cylinder Replace of repair
Worn piston or piston pin Replace
Seized piston Replace
Damaged piston ring Replace
Bent connecting rod Replace
Valves or related parts
Excessive valve clearance Adjust
Broken valve spring Replace
Excessive clearance between valve stem and guide Replace
Others
Malfunction of water pump bearing Replace
Improper drive-belt tension Adjust
Malfunction of alternator bearing Replace
Exhaust gas leakage Repair
Malfunction of timing belt tensioner Replace

Adjustment of Cylinder Head Adjustment of Valve
Valve Clearance/Idling Clearance
Adjustment of Cylinder Head
Fig 1-3
Fig 1-2 1. Remove the cylinder head cover.
2. With the No. 1 cylinder piston at TDC, check and

1. Remove the cylinder head cover. adjust piston clearance as follows :
2. Remove the head bolts. Intake side : No.1, No.2

Exhaust side : No.1, No.3
3. Tighten head bolts to the specified torque, in the Valve clearance(under cold engine condition)
numbered order shown in the figure. Use the Intake & Exhaust : 0.30 mm (0.012in)
torque wrench.
3. Set the No.1 cylinder to compression TDC by
Tightening torque(under cold engine condition) : turning crankshaft, and then check and adjust
11.0 ~ 11.7 mkg (78.6 ~ 84.6 ftlb) piston clearance as follows :
4. Adjust valve clearance when fixing bolts. Intake side : No.3, No.4
Exhaust side : No.2, No.4
4. Assemble the cylinder head cover.

Idling
Inspection
1. Warm up the engine thoroughly.
2. Run the engine at idle.
Standard ldling speed : 1100 L 25
3. Adjust the idling speed if the speed is not within Fig 1-8
the specified range.
3. Set measuring instrument to injection pump. Make
sure that the filler end of measuring device is in
contact with plunger head.
Adjustment
Adjust the idling speed by turning the idling adjusting
bolt of the injection pump.
1. Remove the lock nut of the idling adjusting bolt.
2. Turn the idling adjusting bolt until the idling speed

reaches standard valve.
3. Tighten the lock nut.
4. Run the engine for about 2-3 minutes and check if

the idling speed is at standard value. Fig 1-9
4. With the flywheel ring gear in proximity to BTDC

30 find the point where needle of dial gauge
Injection Timing stands still, even when the flywheel is being turned.
Inspection 5. When it is confirmed that the needle of dial guage

is not moving, then set the needle of the dial
gauge to O
Fig 1-7
Fig 1-10
1. Remove all injection pipes.
2. Remove the head bolt and gasket from the 6. Turn the flywheel clockwise until it reaches TDC,
distributor on the injection pump. lnjection timing is normal if dial gauge indicates
1.00mm at this point.
Adjust if more than 1.00mm.
Cam lift for optimal injection timing : 1.00 mm (0.039 in)

Adjustment Checking of Compression
Injection timing is too early when cam lift value is Pressure
more that 1.00mm, and too late when it is less than
1.00mm.
Fig 1-13
Fig 1-11
1. Warm up the engine thoroughly.
1. If injection timing is not right, then turn the injection 2. Remove the nozzle holders from all cylinders.
pump until the dial gauge indicates 1.00mm.
(1) If cam lift value is less than 1.00mm, turn 3. Install the adapter set and use a pressure gauge
injection pump in direction of engine rotation to of capacity greater than 30 kg/cm2
its maximum, and then adjust the cam lift value
to 1.00mm, by turning it in counter direction. 4. Remove the fuel cut solenoid wiring.
(2) If cam lift value is more than 1.00mm, adjust it
by turning injection pump in counter direction to 5. Crank the engine and measure compression
engine rotation, until value reaches 1.00mm. pressure.
2. Install the bolts and gasket after adjusting. Compression pressure kg/cm2 (lbin2)-rpm
Standard 30(426)-200
CAUTION : Use new head bolts and gasket.
Limit 27(384)-200
3. Install the injection pipes.
CAUTION : If the pressure does not come up to the
specified pressure, check the engine speed.
At normal engine speed, if compression pressure is

less or more than the standard, and the pressure
differences in each cylinder are more than 3 kg/cm2,
it is necessary to disassemble and readjust the
engine.

Disassembly and Assembly
Disassemble in the following sequence. Assembly is
the reverse order of disassembly.
1. Remove the Fuel pipes.
2. Remove the Starter motor.
3. Remove the Engine mounting bracket.
4. Remove coupler from the engine.
5. Set the engine on the engine hanger
6. Remove the following parts from the engine :

(1) Alternator (7) Exhaust manifold
(2) V-belt (8) Ventilation pipe
(3) Crankshaft pulley (9) Injection pipe
(4) Flywheel (10) Oil filter
(5) End plate (11) Intake manifold
(6) Water hose (12) Thermostat case

7. Remove the cylinder head parts in the numbered order shown in the figure.
Fig 1-24
(1) Cylinder head cover. (2) Gasket. (3) Rocker arm. (4) Cylinder head. (5) Gasket. (6) Push rod. (7) Intake valve.
(8) Exhaust valve. (9) Valve guide.

8. Disassemble the piston and oil pan in the numbered order shown in the figure.
Fig 1-25
(1) Piston ring. (2) Piston. (3) Piston pin. (4) Connecting rod. (5) Connecting rod bearing set. (6) Oil pipe. (7) Set screw.
(8) Oil pump. (9) Oil level gauge. (10) Gasket. (11) Oil pan.

9. Disassemble the timing gear and the related parts in the numbered order shown in the figure.
Fig 1-26
(1) Timing case cover. (2) Gasket. (3) Oil deflector. (4) Injection pump cover. (5) Gasket. (6) Locking bolt.
(7) Thrust plate. (8) Idle gear. (9) Spindle. (10) Crankshaft gear. (11) Lock nut. (12) Lock plate.
(13) Cam gear. (14) Lock nut. (15) Lock plate. (16) Injection pump gear. (17) Timing case. (18) Oil seal

10. Disassemble the crankshaft, cylinder block and the parts in the numbered order shown in the figure.
Fig 1-27
(1) Main bearing cap. (2) Bearing set. (3) Crankshaft. (4) Thrust plate. (5) Cam shaft. (6) Tappet. (7) Oil seal cap. (8) Gasket.
(9) Oil seal. (10) Cylinder liner. (11) Cylinder block.

Fig 1-28 Fig 1-31
11. Disassemble the pulley lock bolts and crankshaft 14. Remove the valve guide, pushing it towards
mounting bolts, preventing flywheel rotation combustion chamber by using the valve guide
prevent the flywheel from rotating and remove the installer.
pully lock bolts and crankshaft mounting bolts.
Fig 1-32
Fig 1-29
15. Assemble the valve guide in the following order.

12. Remove crankshaft pulley by using the taper ring
remover (1) Set valve guide on the opposite side of the
combustion chamber and tap down by using
the valve guide installer, until the height of the
valve guide comes near to the level of the
valve guide installer scale.
(2) Check the part of the valve guide protruding
after assembling.
Standard Height of protruding part above the

cylinder head : 16.5 mm (0.650 in)
Fig 1-30
13. Remove the taper sleeve after compressing the

valve spring by using valve spring lifter and pivot

Fig 1-33 Fig 1-36
16. Remove the piston pin by using the piston pin 19. Assemble the piston rings and oil rings onto
remover & installer. piston as shown in the figure.
CAUTIONS :
a) Gaps on the top ring and second ring must be
placed on the opposite side of combustion
chamber.
b) Gap on the top ring should not face thrust side or
counter thrust side.
c) Gap on the top ring should be set on opposite side
(180) of oil ring gap.
Fig 1-34
17. Assemble the piston and connecting rod, after

inserting connecting rod into piston as shown in
the figure.
Fig 1-37
20. Install the piston into cylinder block by using the

piston ring compressor, and make sure that the
piston is placed as shown in the figure. (Install
the piston so that F mark on the piston faces
the front side of the engine).
Fig 1-35
18. Assemble the piston rings after checking that the

Y marked surfaces of the rings appear on the
upper side of the rings.

Fig 1-39 Fig 1-42
21. Adjust valve clearance after assembling. Oil pan 24. Remove the injection pump gear by using the
gasket is composed of side, front and back extractor.
gaskets as shown in the figure.
CAUTION : Use new oil pan gasket.
Fig 1-43
25. Install the idling gear with its reference mark

Fig 1-40
(punched mark) meeting those of other pears.
22. Remove the timing gear by using the bearing

puller set
Fig 1-44
26. Insert the oil seal, by using the oil seal puller &
Fig 1-41
installer timing cover.
23. Remove the cam gear by using the timing gear

case cover mounting bolts and bearing puller set.

Fig 1-45
Fig 1-48
CAUTIONS 28. Install the cylinder liner, and measure cylinder

a) Position the bearing cap and bearing according to inner diameter and height of liner protruding part.
their numbers.
b) Line up thrust washers upright, and be careful not Standard cylinder bore dia :
to alter bearing combination. 92.025 ~ 92.050 mm (3.623 ~ 3.624 in )
Protrusion height above cylinder block :
-0.101 ~ 0 mm (-0.004 ~ 0 in)
Fig 1-46
Fig 1-49
27. Remove the cylinder liner, by using cylinder liner
replacer and press.
29. Assemble the main bearing in reverse order of
Cylinder liner assembling pressure :1 ~ 3 tons disassembly carefully not to apply oil on the back
of the bearing.
30. Apply the grease on crankshaft main journal and

crank pin.
Fig 1-47
NOTES :
a) If cylinder liner is difficult to remove, then bore the
liner until it comes loose.
b) Check for any damage or scratch on the cylinder
bore wall after removing the liner and, if there is
any defect, repair by using fine sandpaper.

Fig 1-50 Fig 1-53
31. Assemble the main bearing cap, directing arrow 35. Replacing valve seal
mark on the top of the cap towards engine front. (1) Remove the valve seal by using the suitable
tools.
32. Assemble the thrust washers on both sides of (2) Insert new seal into valve guide.
center bearing, with their oil grooves facing (3) Assemble the valve seal by using the valve
outwards. seal pusher. Press valve seal pusher until the
valve seal reaches the bottom of valve spring
seat.
Fig 1-51
33. Apply engine oil to connecting rod bearing, and

make sure that the weight marks on the
connecting rod and bearing cap meet each other.
Fig 1-52
34. Check to make sure that the end of push rod is

set at the hollow point of the tappet.

Inspection and Adjustment Replacement of Insert
Cylinder Head
Inspection of Cylinder Head
Fig 1-57
Inspect insert for damage and crack. If a problem is

found, replace the part.
Fig 1-55
1. Inspect for distortion, damage and cracks. If a

problem is found, repair or replace the part.
2. Measure cylinder surface (combustion chamber

side) for distortion with straight edge and filler
gauge.
Fig 1-58
1. Romove insert by hitting round steel rod with a

hammer after inserting the round steel rod into
glow plug hole or nozzle holder hole.
Fig 1-56
3. Measure cylinder head for distortion in the six

directions shown in the figure. If cylinder head
distortion exceeds the limit, replace the cylinder
head.
Distortion limit :
A, B : 0.1 mm (0.004 in)
Fig 1-59
C, D, E, F : 0.25 mm (0.010 in)
2. Set the insert at the specified position on cylinder

head, adjust so that it connects with welsh washer.
Set it facing towards cylinder head gasket and set
the welsh washer at its original positon.
3. Tap the center of the welsh washer slightly, to fix it.

Inspection of Valve and Valve Seat Contact Repair of Valve and Valve Seat Surface
Surface
Inspect contact surface of valve and valve seat as

follows :
Fig 1-62
1. If the problem is slight, grind the valve with a valve

grinder and compound.
Fig 1-60
1. Apply Prussian blue on contact area of valve seat.
2. Press down valve onto valve seat.
3. Check how Prussian blue adheres to the valve,

and see if it is properly in contact with valve seat.
Inspection of Valve seat Contact Position

Fig 1-63
Check the surface which contacts the valve face. The
valve contact position in relation to the valve seat
must be at the center of the circumference. 2. If the problem is a little serious, repair the valve
seat to the specifid angle with a valve cutter.
Valve seat angle

Intake valve : 45
Exhaust valve : 30
Valve seat contact with :
Intake valve : 2.0 mm (0.079 in )
Exhaust valve : 2.0 mm (0.079 in )
Fig 1-61
Standard valve seat contact width :

2.0 mm (0.079 in)

Fig 1-64 Fig 1-66
3. Grind the valve, with 3 valve grinder and

compound.
4. Check lenght L before adjusting.
Projection Length of Valve Stem Above Cylinder

Head(Length L)
Measure the projection length of the valve stem above

the cylinder head (lenght L ) and, if more than Fig 1-67
standard, adjust according to the following instructions :
(2) 0.5mm ~ 1.5mm long
Standard lenght L 48.05 mm (1.89 in) Place a washer (inner dia. 12.8mm, outer dia. 39
mm) under the lower spring seat. Adjust length L
as standard valve.
(3) 1.5mm above

Replace new one, and then measure length L.
Fig 1-65
(1) 0 ~ 0.5mm long

Use without adjusting.

Valve Clearance Between Valve Stem and Valve Guide
Checking Condition Measure the clearance of max-wear piston between

valve stem and valve guide with a dial gauge, by
turning valve and moving valve stem horizontally.
Fig 1-68
Fig 1-70
Visually inspect the valve for even seating of valve
seat with the center part of the valve, and check for
defect. If any defective part is wide, replace valve Clearance limit
and grind it if defective area is minor. Intake : 0.127mm (0.0050 in)
Exhaust : 0.127mm (0.0050 in)
Dimensions of Valve If the clearance exceeds the limit, replace valve and
valve guide.
Valve Spring
Checking Free Length
Measure uncompressed length with calipers.
Fig 1-69
Fig 1-71
Thickness of head (valve verge)

Standard : Uncompressed length limit
Intake : 1.7 mm (0.0669 in) Outer spring : 52.9 mm (2.083 in)
Exhaust : 1.5 mm (0.0591 in) Inner spring : 42.0 mm (1.654 in)
DIA. of valve stem :
Standard: Replace the spring if shorter than uncompressed
Intake : 8.955 ~ 8.980mm (0.3526 ~ 0.3535 in) length limit.
Exhaust : 8.935 ~ 8.960mm (0.3518 ~ 0.3528 in)
Limit :
Intake : 8.904mm (0.3506 in)
Exhaust : 8.884mm (0.3498 in)

Checking Tension Push Rod
Measure tension of assembled valve spring by using Checking Condition
valve spring tester.
Fig 1-74
Fig 1-72
Inspect both ends of push rod for wear or damage,

1. Place valve spring on a valve spring tester. and replace if necessary.
2. Compress the valve spring to assembled lenght.

(Compress several times). Checking Deflection
3. Measure the spring tension when the spring is Place the push rod on a plane surface, and measure
compressed longitudinally. the clearance between the plane surface and rod
with feeler gauge.
Spring Assembled length Standard, tension Allowable tension

of assembled spring
Outer spring 40.3 mm(1.587 in) 18.0 L 0.9kg(39.7 L 2.0 lb) 15.9kg(35.1 lb)
Inner spring 37.8 mm(1.488 in) 12.7 L 0.6kg(28.0 L 1.3lb) 11.3kg(24.9 lb)
Checking Perpendicular
Place the spring on a surface, and measure the

variation form perpendicular at the top of the spring.
Fig 1-75
Deflection limit : 0.19 mm (0.075 in)
If the deflection exceeds the limit straighten or

replace.
Fig 1-73
Angle limit
Outter spring : 1.37mm (0.0539 in)
Inner spring : 1.25 mm (0.0492 in)

Tappet Rocker Arm
Checking Condition Checking Condition
Fig 1-76 Fig 1-78
Inspect tappet for crack or damage, and replace it if 1. Inspect every part of rocker arm assembly for
necessary. Inspect contact point with came, and crack or damage, and replace it if necessary.
replace it if it is worn out.
2. Inspect oil holes of rocker arm and shaft, and
clean them if blocked.
Checking of Clearance Between Tappet and
Tappet Guide
Checking Clearance
Fig 1-77
Fig 1-79
Measure the clearance between tappet and tappet

guide, and replace tapper or cylinder block if the Measure the clearance between rocker arm shaft and
clearance exceeds the limit. rocker arm bushing with a dial gauge.
Clearance limit : 0.10 mm (0.0039 in) Clearance limit : 0.07 mm (0.0028 in)
Replace the rocker arm shaft and bushing, if the

clearance exceeds the limit.

Replacement of Rocker Arm Bushing Piston and Piston Ring
Checking Condition
Fig 1-80
Fig 1-82
1. Inspect sliding surface, ring groove, and other

parts for crack or damage, and replace if
necessary.
2. Inspect for breakage, burning, wear and other

defects on the rings, and replace if necessary.
Fig 1-81
1. Remove the bushing by using press and round

steel rod of proper diameter.
2. Press into the bushing by aligning the oil hole of

rocker arm bushing.
3. Bore the bushing by using expansion reamer and

pin hole grinder, in order to be within standard
clearance between bushing and shaft after
installing.
Standard clearance :
0.016 ~ 0.061 mm (0.0006 ~ 0.0024 in )

Checking Clearance Checking Piston Ring end Gap
Measure piston ring end gap after inserting piston

ring into a cylinder liner.
Fig 1-83
Fig 1-85
(1) When reusing the piston ring :

Measure the gap, placing the ring at the point
where the cylinder liner is most worn.
(2) When replacing the piston ring :

Measure the gap, placing the ring at the point
where the cylinder liner is least worn.
Fig 1-84 End gap limit : 1.5 mm (0.059 in)
Measure the clearance between piston and cylinder Checking clearance Between Piston Ring Groove
liner, and replace piston or cylinder liner if the and Piston Ring
clearance exceeds the limit.
Piston and cylinder liner clearance limit :

0.044 ~ 0.070 mm (0.0017 ~ 0.0028 in)
Measure the piston outer diameter in the thrust

direction, 18mm (0.71 in) above the bottom of piston.
Standard piston outer diameter :

91.967 ~ 91.993mm (3.621 ~ 3.622 in)
Fig 1-86
1. Install the piston ring into the piston.
2. Measure clearance between piston ring groove

and piston ring with a filler gauge. Replace piston
or piston ring if the clearance exceeds the limit.
Clearance limit : 0.3 mm (0.012 in)

Connecting Rod Checking end Play of Big end
Checking Condition Check end play of the big end of the connecting rod,
and replace connecting rod or crankshaft if the play
exceeds the limit.
Fig 1-87
Fig 1-89
Inspect connecting rod at both ends for crack of
damage on the surface, and replace it if necessary.
1. Fit connecting rod to crankshsft.
Checking for Bending & Torsion 2. Measure end play by using a dial gauge with
magnetic base.
End play limit : 0.40 mm (0.016 in)
Checking Clearance Between Piston Pin and

Bushing
Fig 1-88
Check for banding or torsion of connecting rod by

using connecting rod aligner, and modify the
connecting rod with a press, replace it.
Bending limit : 0.05 mm (per 100mm) Fig 1-90
Measure the clearance between piston pin and

bushing as shown in the figure, and replace piston
pin or bushing if the clearance exceeds the limit.

Replacement of Small end Bushing
Fig 1-93
Fig 1-91 When grinding the bushing make sure that the
reamer is precisely inserted to prevent a rough
1. Replace the bushing by using a rod and press. bushing surface always grind in the direction of
cutting. Always be sure not to stop the reamer at
same points. When repairing the small end bushing
with a pin hole horning machine, the bushing hole
tends to incline to one direction, so change the
connecting rod position many times during the
horning process until horning size reaches standard.
Connecting Rod Bearing
Checking Condition
Fig 1-92
2. Push the bushing with a press, confirming that the

oil holes of connecting rod and bushing are in
alignment with each other.
3. Adjust bushing hole with a reamer so that the

clearance between piston pin and bush is within
standard.
Standard clearance :
0.014 ~ 0.044 mm (0.0006 ~ 0.0017 in)
Fig 1-94
Check connecting rod bearing for burning, melting

and other damage, and replace if necessary.

Checking Clearance Crankshaft
Measure the oil clearance between crankshaft journal Checking Condition
and connecting rod bearing with a plasti-gauge, in
the follwing order.
Fig 1-96
Fig 1-95
1. Inspect the crankshaft for crack, breakage, or
other damage, and replace it if necessary.
1. Remove oil residue from joural and bearing.
2. Check if oil holes are clogged, and unblock them
2. Set plasti-gauge to axial direction on a journal. by using compressed air or a needle if clogged.
3. Install bearing cap and tighen to the specified torque.
Cap bolt tightening torque : Checking Wear

7.6 ~ 8.3 mkg (55.0 ~ 6.0 ftlb)
4. Measure the clearance by using the plastigauge

after removing the cap.
Oil clearance
Standard : 0.059-0.090 mm (0.0023 ~ 0.0035 in)
Limit : 0.12 mm (0.0047 in)
If the oil clearance exceeds the standard value, grind

the crank pin use undersized bearing.
Fig 1-97
1. Inspect the crankshaft for wear.
2. Inspect crankshaft pin and main journal in all

directions (front and rear, diagonal directions), and
if wear and tear of the crankshaft is beyond
allowance limits, grind it to undersize and use
undersized main bearing.

Checking Deflection Main Bearing
Checking Condition
Fig 1-98
1. Place and secure both ends of the crankshaft on Fig 1-100

V-blocks.
Check the main bearing for wear, melting and other
2. Measure the deflection by placing a dial gauge on damage and replace it if necessary.
the center of main journal and crankshaft slowly.
Replace crankshaft if the value exceeds the limit.
Read the maximum value on the dial gauge. Checking Clearance
Checking end Play
Fig 1-101
Measure oil clearance between main journal and

main bearing by using plasti-gauge.
Fig 1-99
Oil clearance
Standard : 0.059 ~ 0.090 mm (0.0023 ~ 0.0035 in)
Measure crankshaft end play by placing a dial gauge Limit : 0.12 mm (0.0047 in)
on crankshaft rear end and by moving crankshaft
back and forth in the axial direction. If the value If oil clearance exceeds the limit, grind the main
exceeds the limit, replace the thrust washer, which is jounal and use the undersized bearing.
inserted to the center bearing with 0.718 mm
oversized one.
End play
Standard : 0.14 ~ 0.39 mm (0.0055 ~ 0.0154 in)
Limit : 0.4 mm (0.016 in)

Cylinder Block Cylinder Liner
Checking Condition Checking Wear
Measure the inner diameter of cylinder liner, and

check for wear, and its extent. Measure the inner
diameter at 3 positions, of top, middle and buttom at
sections X-X, and Y-Y, as shown in the figure
Fig 1-102
1. Inspect the cylinder block for crack, breakage,

damage or other defects, and repair or replace if
necessary.
Fig 1-104
2. Check if oil holes and coolant passages are

clogged, and pierce with compressed air or Wear limit
needles as necessary. Wear=Measured highest value-Standard highest
value
Checking Distortion Standard cylinder liner :

92.025 ~ 92.050 mm (3.623 ~ 3.624 in)
Fig 1-103
Fig 1-105
Measure the distortion of top surface of the cylinder

block, and repair or replace if the distortion exceeds If the wear exceeds 2.0 mm ( 0.079 in), replace the
the limit. cylinder liner.
Distortion limit one-sided wear limit

A B : 0.10 mm (0.004 in) One-sided wear=Measured highest value -
C D : 0.25 mm (0.010 in) Measured lowest valve
If the one-sided wear exceeds 2.0mm (0.079 in),
replace the cylinder liner.

Camshaft Checking The Cam Journal Wear
Check the cam jounal for wear, and replace the cam
Checking Condition shaft if the wear exceeds the limit.
Inspect camshaft for crack, breakage, damage of

other defects, and replace it necessary.
Fig 1-108
Fig 1-106
Wear
Journal Diameter
limit
1. Repair for replace if necessary. No.1 51.910-51.940mm
2.044 - 2.045 in)
2. Be careful not to change the original shape of the
cam when repairing. No.2 51.660-51.690mm
(2.034-2.035 in) 0.008mm
No.3 51.410-51.440mm (0.0003 in)
Checking Height (2.24-2025 in)
No.4 51.160-51.190mm
(2.014~ 2.015)
Checking Deflection
Fig 1-107
Check the height of the cam, and replace if lower

than minimum height.
Cam height limit : (42.478 mm) (1.672 in)

Fig 1-109
Minor cam surface defects can be repaired by using
a fine abrasive compound, but be careful not to Support both ends of the camshaft with V-blocks.
change the original of the cam when repairing. Measure in deflection with dial gauge on journal by
turning the camshaft slowly. If the deflecetion
exceeds the limit, replace the camshaft.

Checking end Play Gears(Cam Shaft Gear, Idling Gear,
Cam Gear, Injection Pump Gear)
Checking Condition
Fig 1-110
Measure the end play, and replace thrust plate if the

value exceeds the limit. Fig 1-113
1. Mount thrust plate and camshaft gear on

Replace gear if the gear teeth have been cracked or
camshaft.
damaged.
2. Tighten the lock bolt to the specified torque.
Checking Backlash
Bolt tightening torque :
6.2 ~ 7.0 mkg (44.8 ~ 50.6 ftlb)
Measure backlash between idling gear and other
End play limit : 0.3 mm (0.012 in)
gears with a dial gauge.
Backlash
Checking Journal Oil Clearance
Standard : 0.10 ~ 0.17 mm (0.004 ~ 0.007 in)
Limit : 0.3 mm (0.012 in)
Checking Idle Gear end Play
Fig 1-111
Check the oil clearance by measuring inner diameter

of camshaft bearing, and outer diameter of cam
journal. If the oil clearance exceeds the limit, replace Fig 1-114
the camshaft or cylinder block.
Measure the end play by inserting a filler gauge
Oil clearance limit : 0.145 mm (0.006 in)
bewteen idling gear and thrust.
Standard end play :

0.15 ~ 0.28 mm (0.006 ~ 0.011 in)

Checking Oil Clearance Between Idling Gear and Oil Seal (Timing Gear Cover Oil
Spindle
Seal, Rear Oil Seal)
Checking
Fig 1-115
Measure the oil clearance by checking inner diameter Fig 1-116

of idling gear and outer diameter of spindle. If the oil
clearance exceeds limit, replace idling gear bushing
and spindle.
Oil clearance
Standard : 0.034 ~ 0.048 mm(0.001 ~ 0.003 in)
Limit : 0.15 mm (0.06 in)
Fig 1-117
Inspect oil seals for wear, breakage and damage,

and replace defective oil seals.

Lubrication System
Outline
Structural View
Fig 2-1
Diesel Engine D427 37 Lubrication Systems

Specifications
Lubrication System Force-feed type

Type Trochoid type
Oil pump
Oil pressure control valve opening pressure 3.8 kg/cm2(56.9 lb/in2)
Type Full-flow type, paper filter
Oil Filter
Oil filter relief valve opening pressure 0.8~1.2kg/cm2(11.4~17.1 lb/cn2)
Oil cooler Type water cooled type
Oil warning lamp activation pressure 0.2~0.4kg/cm2(2.8~5.7 lb/in2)
Preblem Possible Cause Remedy
OIl leakage Loose drain plug Tighten or replace
Faulty seal oil and cylinder block Replace
Damaged cylinder head cover Replace
Loose oil pump body bolt, cylinder head cover bolt, or oil pan bolt Tighten
Damaged front housing gasket, or cylinder head gasket Replace
Faulty oil seal(s) Replace
Loose oil filter Tighten
Loose or damaged oil pressure switch Tighten or replace
Oil pressure drop Oil leak As described above
Insufficient oil Add oil
Worn and/or damaged oil pump gear Replace
Worn plunger(inside oil pump) or weak spring Replace
Clogged oil strainer Clean it
Excessive lubrication clearance between main bearing and
connecting rod bearing Refer to Group 1
Warning lamp Oil pressure drop As described above
illuminates while Malfunction of oil pressure switch Repair
engine running Problem in electrical system Repair

Inspection Oil Pump
Checking Oil Pressure Rremoval and Installation
Remove each part in the following order, lnstallation
is the reverse order of removal.
1. Drain engine oil.
2. Remove the oil pan.
3. Remove the oil pipe.
4. Remove the oil pump.
Fig 2-2
Disassembly
1. Remove the oil pressure switch.
Disassemble in the following sequence :
2. Mount the oil pressure gauge on the cylinder block
hole where oil pressure switch had been installed.
3. Start the engine and warm it up to an appropriate

temperature.
4. Read the gauge, holding the engine speed

steady(High idle).
Oil pressure limit : 3.8kgcm2 (54.1 lbin2)
IF the oil pressure exceeds the limit, each part and

repair if necessary.
FIG 2-3
(1) Oil pump body. (2) Set screw. (3) Nut. (4) Plunger.
(5) Spring. (6) Plug. (7) Drive shaft. (8) Outer rotor
(9) Inner rotor. (10) Cover. (11) Oil strainer. (12) Oil pipe

Inspection Clearance Between Outer Rotor and Pump Doby
Checking Condition
Check all parts visually, and replace if necessary.

Carefully check the sliding surface of the pump
cover, and replace if significantly of the pump cover,
and replace if significantly defective (Repair minor
defects by grinding with grinding compound).
Clearance Between Pump Body And Shaft

Fig 2-7
Measure clearance between outer rotor and pump

body with a leaf gauge. If the clearance exceeds the
limit, replace the rotor or pump body.
Clearance Between Rotor and Pump Cover
Fig 2-5
Measure the clearance with a dial gauge and

magnetic base.
If the clearance exceeds the limit, replace the pump

drive shaft, inner rotor, pump body and drive gear.
Fig 2-8
Clearance Between Inner and Outer Rotor
Check the end float of the rotor. Place a flat ruler

across the pump body and measure the clearance
between ruler and rotor. If the clearance exceeds the
limit, replace the drive gear, drive shaft, inner rotor,
outer rotor and pump body.
Free Length of Plunger Spring
Fig 2-6 Check wear of relief valve plunger and spring defect.
Free length of spring : 40 mm (1.57 in)

Measure the clearance with a leaf gauge. Replace
both rotors if the clearance exceeds the limit.

Assembly
7. Remove the gasket.
8. Remove the level switch from the oil pan (if

installed).
9. Remove oil level gauge pipe from the oil pan

upper bock.
Installation
Install in the reverse order of removal
Fig 2-9
CAUTION : Install oil pan upper block with its
Assemble in reverse order of disassembly. assembly surface conforming to the cylinder block
under part.
CAUTION : When assembling the rotor on the body,
confirm that the matching marks are in the front of Replace the oil pan gasket with a new one. Apply a
the cover. thin coating of engine oil to gasket between the
cylinder block and the oil pan. Tighten the oil pan
Cover tightening torque : bolts and nuts on the cylinder block to the specified
0.8 ~ 1.2 mkg (5.79 ~ 8.68 ftlb) torque.
Tightening torque : 1.6 ~ 2.3 mkg (11.6 ~ 16.6 ftlb)
Oil Pan
Removal Inspection
1. Remove dust and chips from oil pan.
2. Inspect the oil pan for cracking, and check the

drain plug spiral part for damage. Check bolt hole
for any damage due to excessive tightening.
Repair such damaged part, and replace if difficult
to repair.
Fig 2-10
1. Drain engine oil.
2. Remove the hose between the vacuum pump and

the oil pan upper block.
3. Remove the oil level gauge pipe from the rubber

hose.
4. Remove the oil level switch coupler (if installed).
5. Remove the oil pan.
6. Remove the gasket.

Cooling System
Specifications
Cooling Method Water-cooled
Type Wax type(2 stage)
Opening temp 82 L 1.5C
Full-open temp 95C
Full-open lift 8.0mm (0.31 in) or more
Water pump type Type Centrifugal, timing belt driven
Radiator Type Corrugated
Cap valve opening pressure 1.0 L 0.15 kg/cm2(14.2 L 2.1 lb/in2)
Water leakage Damaged radiator core seam Replace
Leakage from radiator hose or heater hose Repair or replace
Leakage from water temperature switch Repair or replace
Leakage from water seal (water pump) Replace
Damaged or loose thermostat cover or gasket Repair or replace
Loose cylinder head bolt Tighten
Damaged cylinder block Replace
Cracked cylinder head Replace
Corrosion Impurities in coolant Clean
Overheating Water passage clogged Clean
Thermostat malfunction Replace
Radiator fins clogged Clean
Water pump malfunction Repair or replace
Insufficient coolant Add
Thermo - modulated cooling fan malfunction Replace
Radiator cap malfunction Replace
Diesel Engine D427 42 Cooling System

Thermostat Inspection
Removal
Remove the thermostat in the following sequence.
Fig 3-11
Put the thermostat and a thermometer in water, heat

the water temperature gradually and raise the
Fig 3-9 temperature, both when the thermostat valve starts to
open and when it is fully open. If the temperature
values are lower than the specified values, replace
the thermostat.
Opening temp Full-open temp Full-open lift

82C L 1.5C 95C 8mm(0.3in) or more
Installation
Install the thermostat in the reverse order of removal.
Notes
Fig 3-10
1. Remove the coolant. Drain the coolant until the

coolant level drops below the thermostat case.
2. Remove the radiator upper hose.
3. Remove the thermostat.
Fig 3-12
a) Replace the gasket whenever installing the

thermostat cover.
b) Set the thermostat with its air hole on top.
c) After installing the thermostat, fill the coolant, start

the engine, and check for any leakage.

Water Pump Disassembly and Assembly
Disassemble in the numbered sequence shown in
On-Vehicle Inspection the figure, and assemble in reverse order of
disassembly.
Fig 3-13
Check the water pump for leakage, noise and

looseness to the shaft or bearing. Clattering noise,
when the fan blades are pushed up and down,
indicates that the bearing is worn-out and defective,
in the hole of pump body is leaking, disassemble
hole of the pump and replace the seal.
Fig 3-15
Removal and Installation
(1) Nut & washer. (2) Bearing housing. (3) Gasket.
Remove the water pump in the numbered order. (4) Pulley boss. (5) Snap ring.
Installation is the reverse order of removal. (6) Shaft, spacer & bearing ass'y. (7) Impeller. (8) Seal ass'y.
(9) Bearing. (10) Spacer. (11) Bearing. (12) Baffle plate.
(13) Dust seal. (14) Snap ring.
Fig 3-14
Fig 3-16
1. Drain the coolant.
1. Remove the pump pulley boss with the fan pulley
2. Remove the radiator cowling.
boss puller and press.
3. Remove the cooling fan.
4. Remove the V-belt.
5. Remove the cooling fan pulley.
6. Remove the water hose.
7. Remove the water pump.

Inspection
Fig 3-17
2. Remove the impeller and the shaft from bearing Fig 3-20
housing by using the support block and press.
1. Disassemble scale from within the pump body.
Clean removed parts.
2. Inspect all pump parts, and replace any part which

is cracked or damaged.
3. Check the water pump for noise and looseness,
and replace if necessary.
4. Always use a new water seal after disassembling

the water pump. Replace the impeller if there are
defects in water seal and impeller contact surface.
Fig 3-18
V-belt
3. Remove the snap ring by using snap ring pliers,
and push out the water pump shaft from the Inspection
bearing.
Fig 3-21
Fig 3-19
1. Check the V-belt for breakage or wear, and

4. Apply or inject grease to the following parts : replace if necessary.
CAUTIONS : 2. If there is any noise, check tension of the belt and

a) Fill 1/3 of the bearing space with lithium grease alignment of the pulleys.
(NLGI NO2).
b) Apply grease on water seal surface contacting the 3. V-belt should depress by a given amount when
impeller. 10kg power is applied to it.
Belt deflection
New belt : 10 ~ 12 mm (0.39 ~ 0.47 in)
Used belt : 13 ~ 16 mm (0.51 ~ 0.63 in)
Fuel System
Outline
Structural View
Fig 4-1
Diesel Engine D427 46 Fuel Systems

Specifications
Item Specification
Type VE type
Injection timing ATDC 2
Injection pump
Turning direction Clockwise
Idling speed 1100 L 25
Nozzle type Throttle type
Orifice Dia. XNo. 8mm (0.032 in.)X1
Injection nozzle
Injection pressure 135~140 kg/cm2
Air cleaner Filter paper element type
Fuel Filter Cartridge type with water-detector
Injection order 1-3-4-2
Hard starting Clogged fuel filter Replace
Air in fuel filter Air-bleed
Faulty fuel cut valve Replace
Faulty injection timing Adjust
Air in injection pump Air-bleed
Trouble inside of injection pump Replace
Seized needle valve of injection nozzle Clean or replace
Fuel dripping from injection nozzle Adjust
Faulty cold start device Adjust or replace
Rough idling Clogged fuel filter Replace
Trouble inside of injection pump Replace
Faulty injection starting pressure Adjust
Improper mounting to nozzle holder Disassemble and assemble or replace
Leakage at gasker Replace
Crack in injection pipe Replace
Leaking from injection pipe joint Retighten or replace
improper idling speed Adjust
Engine knocking Faulty injection timing Adjust
Low quality fuel Replace
Fuel dripping from injection nozzle Replace
Engine knockin Faulty injection timing Adjust
Low quality fuel Replace

High fuel consumption Faulty injection timing Adjust
High idling speed Adjust
Leakage of gasket Replace
Clogged fuel filter Replace
Clogged air cleaner Clean or replace
Poor acceleration Clogged air cleaner Clean or replace
Fuel dripping form injection nozzle Replace
Trouble inside of pump Replace
Crack of injection pipe Replace
Clogged fuel filter replace
Excessive Clogged air cleaner Clean of replace
exhaust smoke Improper injection timing Adjust
Faulty injection nozzle Adjust or replace

Fuel Filter Air Bleeding
Fig 4-7 Fig 4-9
The fuel filter is installed between the fuel tank and

the injection pump, and it filters out all impurities from
the fuel system.
Fig 4-10
1. Loosen the air breather on the fuel filter.
2. Operate the priming pump in the fuel filter until the

pure fuel comes out.
3. After bleeding all the between fuel tank and fuel

filter, fuel comes out.
Fig 4-8
4. Loosen the overflow pipe of injection pump.

Remove as the following sequence. Install the filter in
the reverse order of removal. 5. Supply fuel to pump compartment in the injection
pump by operating the priming pump.
1. Drain fuel from the filter.
6. Start the engine, and bleed air in the injection
2. Remove the element, sealing, 0-ring and bow pump.
downwards from the body.
7. Tighten the overflow pipe connector.
NOTE: Apply fuel to the sealing (top & base) and
0ring-before installing. 8. Loosen the injection pipe on injection nozzle side.
After installing the filter, remove the air breather 9. Start the engine and check whether fuel us is
screw in order to remove air with the priming the being ejected from injection pipe
filter, remove the air with priming pump, and after
starting the engine, check for leakage

Water-Drain Replacement
1. When removing the fuel filter, be careful not to
spoil the fuel by holding the fuel filter upright.
Fig 4-11
Drain water when indicating lamp comes on or when

float level reaches standard level.
1. Loosen the drain plug.
2. Loosen the air breather if water does not come out

easily.
3. After draining water, supply fuel by operating the

priming pump on the filter.
4. DO air-bleeding. Fig 4-12
(1) Adapter. (2) Cartridge. (3) Level sensor. (4) Drain plug
(5) Air breather.
2. Apply a small amount of diesel on the packing.
3. Install the cartridge to adapter and tighten securely

by hand.
4. Install the sensor and drain plug to the cartridge.
5. Bleed air in the filter.
6. Start the engine and check whether there is any

leakage.

Injection Pump
If the inside of the injection pump is disassembled for
maintenance, be sure to properly use the checking device
such as the injection tester, and carefully inspect each
component.
Structural View
Fig 4-13

On-Vehicle Inspection and Checking Injection Timing
Adjustment
Checking Idling Speed
1. Warm up the engine.
2. Put the tachometer
3. Idle the engine.
4. Check the engine speed.

Fig 4-17
5. Adjust the idling-speed if the idling speed a with

the specified range. 1. Disconnect the fuel injection pipes from the
injection pump.
Standard idling speed : 1100 L 25
2. Remove the bolt and gasket from distributor head
of the injection pump.
Adjusting Idling Speed
Fig 4-18
Fig 4-16
3. Mount the measuring device on the injection

1. Confirm the accelerator cable deflection. If the pump. Make sure that the tip of the tester feeler
deflection is not suitable, adjust it by turning needle touches the plunger end of pump.
accelerator cable lock nuts.
2. Loosen the lock nut of the idle adjusting bolt and

adjust the idling speed by turning the idle adjusting
bolt.
NOTE : Idle speed will increase when the adjusting

bolt is turned clockwise and decrease when turned
counter-clockwise.
3. After adjusting, press the accelerator pedal 2 ~

3times, and check the return of the accelerator
cable
Fig 4-19
4. Set the flywheel ring gear BTDC 30 and find a

position where the pointer of dial gauge fixed.
5. After confirming the stability of the dial gauge

pointer, set the dial gauge pointer to O point.

Removal
Fig 4-20
6. Turn the flywheel clockwise until indicator pointer Fig 4-22

comes to TDC. The injection timing is right if the
pointer is increased 1mm.
Cam lift at optimal injection timing :

1.00 mm (0.039 in)
7. Adjust injection timing if the cam lift exceeds 1mm.
Adjusting Injection Pump
Fig 4-23
1. Remove the (+) (-) terminals from the battery.
2. Remove the upper cover and the cooling fan.
3. Disconnect the air hose.
4. Disconnect the fuel pipe and the injection pipe.
Fig 4-21 5. Remove the accelerator cable from the injection

pump.
1. If the injection timing is not correct, turn the
6. Remove the fuel-cut solenoid wire.l
injection pump, and set at a position where the dial
gauge pointer indicates 1.00 mm (0.039 in).
7. Remove the injection pump cover.
If the cam lift value is more than 1mm, adjust so
8. Loosen the lock nut.
that the cam lift becomes 1.00mm, by turning the
injection pump one full turn clockwise(in direction
9. Remove the plane washer. Be sure not to drop the
of engine rotation) and counter-clockwise it as
washer into the gear case by using a wire.
necessary again.
If the cam lift is less than 1mm, adjust the cam
10. When checking the shaft key of the injection
lift by turning the injection pump counter-
pump, turn the flywheel through the timing hole
clockwise.
on the clutch cover until the key arrives at the
position.
2. After adjustment, install the gasket and tighten the
head bolt.
NOTE : When adjusting, use a new head bolt and

gasket.

Installation
Install the injection pump in the reverse order of
removal, paying attention to the following points :
Fig 4-24
11. Remove the bolt on the auxiliary bracket, which

fixes the lower part of the injection pump.
12. Remove the injection pump mounting nut. Also Fig 4-26
remove the spring washer and flat washer.
1. Before installing the key on the drive shaft of
13. Remove the pump shaft and the gear.
injection pump, tap the key hole slightly until the
key is inserted into the key hole completely.
Set the extractor and use M marked side of it.
Disconnect the shaft and the gear by tightening
2. Remove air after installing the injection pump.
extractor bolt.
Drive gear tightening torque :
4.0 ~ 7.0 mkg (28.9 ~ 50.6 ftlb)
Air-Bleeding
Make sure to bleed the air replacing the fuel filter or
cleaning the sedimenter.
1. Loosen the air bolt on fuel filter.
2. Pump with feed pump until fuel comes out.

Fig 4-25
3. Tighten the air bolt with pressing the feed pump.

14. Remove the injection pump. Remove the injection
pump in turn by pushing other pump gear near to
it, being careful not to drop the key into gear
case.
15. Remove the extractor.

Injection Nozzle(KCA Type) Removal
Remove the injection nozzle in the following order :
Structural View
Fig 4-28
1. Fuel injection pipe
2. Fuel leak pipe lock nut
3. Fuel leak pipe
4. Injection nozzle
5. Washer
Inspection and Adjustment

Checking Injection starting pressure
Fig 4-27
(1) Nozzle holder body. (2) Pressure Pin. (3) Pressure Spring.
Fig 4-29
(4) Retaining Nut. (5) Distance Piece. (6) Shim. (7) Washer.
(8) Nut. (9) Nozzle.
1. Set the nozzle on the nozzle tester.
2. Bleed the air by pumping the nozzle tester handle

several times.
3. Slowly lower the nozzle tester handle, and check

the value shown on the pressure gauge when
injection is started.
Injection starting pressure :

135 ~ 140 kgcm2 (1920 ~ 1991 lbin2)

Checking Atomizing Condition
Fig 4-30
4. If the injection starting pressure is not within the Fig 4-32

specified range, adjust the starting pressure with
the shim. The shim has 20 different thicknesses 1. Set the injection nozzle on a nozzle tester.
for every 0.05mm (0.0020in.) to 1.95mm
(0.0768in.). As 0.05mm (0.0020in.) is added, 2. Bleed the air by operating the nozzle tester handle
approx. 5kgcm2 (71.12 lbin2) of injection pressure several times.
increases.
3. Keeping the pressure gauge of the nozzle tester in
the non-functioning condition, quickly lower the
Checking Tightness of Valve Seat handle several times (lower the handle as quickly
as possible so that a pulsation whistling sound can
be heard) and check the atomizing condition.
(1) Fuel is atomized uniformly and properly.
(2) The injection angle and direction are normal. If

the atomizing condition is incorrect, it is
necessary to disassemble, wash and recheck
the injection nozzle, or to replace it.
Checking Nozzle Valve and Needle Valve

Fig 4-31
Apply a pressure of 115kgcm2 (1635.3 lbin2), and

check for fuel leaks from the nozzle injection hole. If
fuel leaks, it is necessary to disassemble, clean and
recheck the injection nozzle or replace it.
Fig 4-33
1. Check and ensure that the valve seat of the

needle valve and other parts are not damaged.
2. Make sure that the nozzle body is not damaged.

Hold the nozzle body upright and insert
approximately two thirds of the needle valve and
see if the needle valve drops to the valve seat by
its own weight.

Assembly
Pay attention to the following matters when
assembling injection nozzle.
Fig 4-34
CAUTIONS :
a) After assembling the injection nozzle, check the
injection starting pressure and atomizing condition.
b) Tighten the nozzle body on the nozzle holder to
the specified torque.
Nozzle tightening torque:

8 ~ 10 mkg (58 ~ 72 ftlb)
Installation
Install in reverse order of removal.
Fig 4-35
CAUTIONS :
a) The gasket and corrugated gasket and not be
reused.
b) Tighten the injection nozzle on the cylinder head
to the specified torque.
Nozzle tightening torque :

6 ~ 7 mkg (43 ~ 52 ftlb)

Engine Electrical System
Specifications
Item Specification
Voltage 12V, Negative Ground
Type Alternating
Alternator Output 12V-60A
Regulator Type Transistorized(built-in IC regulator)
Starter Type Electromagnetic push-in-type
Output 12V-2.5kW
Type Sheathed type
Glow plug Voltage 11V
Amperage 52A
Starter does not Battery and related parts
turn at all, or its Poor contact of battery terminals Clean and tighten
turning speed is Poor grounding of negative cable Clean and repair
too slow to start Voltage drop caused by discharged battery Recharge
the engine. Insufficient voltage caused by battery malfunction Replace
Magnetic switch and related parts
Loose wiring and / or connectors Repair
Burnt magnetic switch contact plate or improper contact Replace
Broken wire in magnetic switch contact plate or improper contact Replace
plate or improper contact
Broken wire magnetic switch holding coil Replace
Starter and related parts
Poor contact of brushes Adjust contact or replace
Fatigued brush spring Replace
Poor grounding of field coil Replace
Poor soldering of field coil Repair
Commutator malfunction Repair
Grounded armature Replace
Worn parts Replace
Starting problem Insufficient battery capacity Recharge
Starter turns but Tip of overrunning pinion is worn Replace
pinion gear does Fatigued overrunning clutch drive spring Replace
not mesh with Overrunning clutch races Replace
ring gear Improper sliding of spline Adjust contact and repair
Worn bushing Replace
Worn ring gear Replace
Starter turns Sticking contact place of magnetic switch Replace
continuously Layer shorting of coil magnetic switch Replace
(does not stop)
Diesel Engine D427 58 Engine Electrical System

Misfiring of motor Malfunction of wiring, or poor wiring contact Replace
Discharging of Loose drive belt Adjust
battery Grounded or broken stator coil Replace
Broken rotor coil Replace
Poor contact of brush and slip ring Clean or replace
Malfunction or rectifier Replace
Malfunction of IC regulator Replace
Insufficient or unsuitable battery electrolyte Adjust
Malfunction of battery electrode(internal short-circuit) Replace
Poor contact of battery terminals Clean and tighten
Excessive electric load Check power consumption
Overcharging IC regulator malfunction Replace
of battery Operating in extremely high temperature Repair

Starter Removal
1. Disconnect the battery (-) and (+) terminals.
On-Vehicle Inspection
2. Disconnect the wiring from the starter.
3. Remove the fixing bolts and remove the starter.
Installation
Install the start in the reverse order of removal, taking
care of the following.
1. Tighten terminals B and M to the specified torque.
Fig 5-5 Tightening torque :

8.0 ~ 10.0 mkg (57.9 ~ 72.3 ftlb)
1. Turn off the ignition switch and place the gear shift
lever to neutral position before inspection.
2. Directly connect the battery terminal B and starter

Free Running Test
terminal M.
3. The starter is functioning properly if it turns

smoothly, without abnormal noise.
WARNING
Be specially careful, when the starter is operated,

the engine may start.
Fig 5-7
Measure the current when the start begins to run

constantly connecting the battery, starter and
ammeter as shown in the figure.
Current : 200 A or less

Voltage : 11 V
Fig 5-6
4. If starting is slow, if the starter doesnt turn, or if

abnormal noise is heard, remove the starter and
check it, but be sure to check the following matters
before removing it.
A. Charging condition of battery
B. Looseness or corrosion of battery terminal
C. Condition of ignition switch
E. Locked engine.

Disassembly
Fig 5-8

Inspection
Checking the Armature
Fig 5-11
5. Measure the shrinkage of the mold between

segments. If the value is 0.2mm (0.008 in) or less,
Fig 5-9 undercut by 0.5 to 0.8mm (0.02 ~ 0.03 in).
1. Check insulation between all segments and core

Field Coil
of the armature coil.
2. It is normal if there is no continuity.
3. Check for continuity between all segments. It is

normal if there is continuity.
Fig 5-12
1. Check for continuity between the yoke and the

field terminal by using a circuit tester. It is normal if
there is continuity.
Fig 5-10
2. Check for continuity between leads by using a
circuit tester. It is normal if there is continuity.
4. Check for short circuit with a glower tester. The
armature is shorted if an iron piece, when placed
on the core while the armature is rotated, is
attracted or vibrates. In that case, replace the
core.

Checking the Brush Holder Replacement the Brush
Fig 5-13 Fig 5-15
Check for continuity between brush holder (+) line

and brush holder frame with a circuit tester. It is
normal if there is no continuity.
Checking for Brush Wear
Fig 5-16
1. Pull out the brush and brush lead wire from the
brush holder.
2. Remove the brush from the brush lead wire by

crushing the brush.
Fig 5-14
3. Replace a new brush in the brush lead wire. Clean
the brush lead wire. Fix the brush lead by inserting
Check the brush for any damage or wear. the lead through the small tapered hole on the
Wear limit : 14 mm (5.51 in) brush.
4. Solder the brush brush lead wire together. Use a

soldering iron of more than 200W.

Checking the Magnetic Switch Return Test
Attraction Test
Fig 5-19
Fig 5-17
1. Disconnect the lead wire between the terminal and
the starter.
1. Disconnect the lead wire between terminal M and
starter terminal. 2. Connect battery power to terminal M of magnetic
switch and its body.
2. It is normal if the plunger is pulled in and the
pinion jumps out when power is supplied to the 3. Pull and release the pinion. It is normal if the
magnetic switch S and the terminal M. pinion returns quickly to its original position ; but, if
it does not return, replace the magnetic switch.
CAUTION : Do not supply power for more than 10
seconds.
Pinion Jumping-out Condition
Attraction-holding Test
Fig 5-20
Fig 5-18
1. Disconnect the wire from the terminal M.
1. Disconnect the lead wire between the terminal M 2. The pinion jumps out when battery power is
and starter. supplied to terminal S and to starer body. Measure
the clearance between the pinion and stopper.
2. Supply battery power to S terminal of magnetic
switch and switch body, and then pull the pinion by Standard Pinion clearance :
hand. 0 ~ 2.0mm (0 ~ 0.078 in)
3. It is normal if the pinion does not return to its CAUTION : Do not supply power to starter for
original position when the pulled-out pinion is more than 20 seconds.
released.

Alternator On-Vehicle Inspection
Circuit Diagram Inspection of Charging System
Fig 5-21 Fig 5-23
1. Make current and voltage connections as shown in

Charging System Cautions the figure.
1. Be sure battery connections are not reversed, 2. Turn the ignition switch OFF.
because this will damage the rectifier.
3. Read the voltage between the L terminal and
2. Do not use high-voltage testers, such as a ground. The alternator is bad if the reading is not 0
Megger, because they will damage the rectifier. V.
3. Remember that battery voltage is always applied 4. Turn the ignition switch ON and read the voltmeter.
to the alternators B terminal. If the reading is 0 V, there is a malfunction of the
alternator or wiring.
4. Do not ground the L terminal while the engine is
running.
5. Do not start the engine while the coupler is

disconnected from the L and R terminals.

Checking No-Load Adjustment Checking Output
Voltage
Fig 5-25
Fig 5-24
1. Disconnect the negative battery cable.
1. Check to be sure that the battery is fully charged.
2. Connect an ammeter and a voltmeter as shown in
the figure.
2. Connect an ammeter and a voltmeter as shown in
the figure. Be sure that the voltmeter reading is 0 V. 3. Connect the negative battery cable.
3. Turn the ignition key to ON, and then check to be 4. Start the engine.
sure that the voltmeter reading is significantly
lower than the battery voltage(1 ~ 3V). If the 5. Apply a increase the engine speed. and read the
voltmeter reading is the same as the battery output current. If the voltage is higher than the
voltage, there may be a malfunction in the battery voltage and there is an output current,
alternator. there is no problem.
4. Short circuit the terminals of the ammeter, and

then start the engine. After starting, discontinue Removal
the short circuiting.
NOTE : Be careful, when starting the motor, that the

current of the starter doesnt flow to the ammeter.
5. Under no-load conditions, increase the alternator

speed to 5,000 rpm (engine speed of 2,000 ~
2,500 rpm).
6. Read the indication shown by the voltmeter and

the ammeter.
Ammeter : 5A or less Fig 5-26

Vlotemter (adjustment voltage) :
14.7 L 0.3 V (at 20C (68F))
1. Lift the seat cushion and fasten is with the strap.
2. Remove the drivers seat cushion.
3. Disconnect the negative battery cable.
4. Remove the drive belt.
5. Disconnect the wire from the B terminal of the

alternator and coupler from the L and R terminals,
and disconnect the wire harness from the clip.
6. Disconnect the vacuum hose and oil hose.

Installation Fornt Bracket and Rotor
Installation is the reverse order of removal. Note the

following points.
Fig 5-30
Fit a flat-tipped - screwdriver between the front

Fig 5-27
bracket and the stator core, and than separate the
stator and rotor by tapping the screwdriver with a
1. Install the drive belt so that the V fits into the nylon hammer.
grooves of each pulley.
CAUTION : Be careful not to force the screwdriver
2. Adjust the drive belt tension. too far in, because the coil may become scratched.
LOCK NUT
Disassemble in numbered order shown in the figure.
Assembly is the reverse order of disassembly.
Fig 5-31
Fig 5-32
Fig 5-28 Secure the rotor in a vise, and loosen the pulley nut.
(1) Front bracket. (2) Fan and pulley. (3) Rotor.

(4) Rear bracket. (5) Stator coil. (6) Brush holder.
(7) Rectifier.

Stator Brushes
Fig 5-33 Fig 5-35
Use a soldering iron to disconnect the stator lead

wiring.
CAUTION : Do the disconnecting quickly, using the

soldering iron no more than about 5 seconds,
because the rectifier may become damaged if the
inside is overheated.
Brush Holder and ic Regulator Assembly

Fig 5-36
When the rotor is to be attached to the rear bracket,

insert a wire through the hole in the rear bracket so
that the brushes are at the specified position
Seal Washers
Fig 5-34
Use a soldering iron to disconnect the brush holder

and IC regulator assembly from the rectifier.
Fig 5-37
Insert a seal washer at each end of the front bracket.

Inspection Rotor
Fig 5-38 Fig 5-40
Inspect the following parts, and repair or replace if a 1. Use a circuit tester to check for continuity between
problem is found. the core and each slip ring.
No-continuity is the normal condition.
Stator
1. Use a circuit tester to check for continuity between

the core and each lead wire. No continuity is the
normal condition.
Fig 5-41
2. Use an ohmmeter to check the resistance between

each slip ring. Resistnace : 3 ~ 4
Fig 5-39
2. Use a circuit tester to check for continuity between

lead wires. Continuity is normal condition.

Rectifiers Bearings
Fig 5-42 Fig 5-44
Use a continuity tester to check the continuity of each Check the front and rear bearings for improper
rectifier. There should be high resistance in one rotation and/or abnormal noise. Replace if an
direction and low resistance in the other direction. abnormal condition is discovered.
There is a short-circuit if the resistance is low in both
directions, and there is a broken wire if the resistance
is high in both directions. In either instance, replace
the rectifier. Glow Plugs
Checking Open Circuit of Glow
Brushes and Spring Plugs
Fig 5-43 Fig 5-45
1. Check the force of the brush spring. Measure the Check the continuity between the positive terminal of
force of the brush spring by using a spring the glow plug and cylinder head block with a circuit
pressure gauge, and push the brush into the brush tester. If there is no continuity, replace the glow plug.
holder until the tip projects 2mm (0.079 in).
Limit : Less than 210 g (7.4 oz)
2. Check for burnt or worn brushes.
Limit : 6.5 mm (0.256 in)

Fig 5-46
Remove in the following order :
1. Glow plug connector attaching nut. Use a suitable

wrench.
2. Glow plug connector
3. Glow plug
NOTE : Turn the glow plug counterclockwise and

remove it.
To install the glow plug, reverse order of removing.

Technical Data
Engine
Item
Type Diesel, four-cycle
Number and arrangement of cylinders Four cylinders, in-line
Type of combustion chamber Swirl floor type
Bore and Stroke mm B mm(in*in) 92.0 B 101.6 (3.62 B 4.00)
Total piston displacement cc 2701
Valve system Over head valve(0HV)
Valve timing
Intake valve Open(BTDC) 14
Closes(ABDC) 44
Exhaust valve Open(BBDC) 48
Closes(ATDC) 10
Firing order 1-3-4-2
Idling speed 1075 ~ 1125
Cylinder head
Valve clearance(cold) mm(in) Intake 0.30(0.012)
Exhaust 0.30(0.012)
Cylinder head distortion limit mm(in) 0.10(0.0040)
Valve seat
Seat sinking mm(in) Intake standard 48.05(1.892)
(Length L) Limit 49.05(1.931)
Exhaust Standard 48.05(1.892)
Limit 49.05(1.931)
Seat angle Intake 45
Exhaust 30
Seat contact width mm(in) Intake 2.0(0.079)
Exhaust 20(0.079)
Valve stem mm(in) Intake Standard 8.995 ~ 8.989(0.3526 ~ 0.3535)
Limit 8.904(0.3506)
Exhaust Standard 0.038 ~ 0.085(0.0015 ~ 0.0033)
Limit 0.127(0.0050)
Valve stem to guide Intake Standard 0.038 ~ 0.085(0.0015 ~ 0.0033)
clearance mm(in) Limit 0.127(0.0050)
Exhaust Standard 0.058 ~ 0.105(0.0023 ~ 0.0041)
Limit 0.127(0.0050)
Diesel Engine D427 72 Technical Data

Tappet
Standard outer diameter mm(in) 14.218 ~ 14.223(0.5598 ~ 0.5600)
Standard tappet hole diameter mm(in) 14.288 ~ 14.319(0.5625 ~ 0.5637)
Clearance between tappet Standard 0.055 ~ 0.101(0.0022 ~0.0040)
mm(in)
hole and outer Limit 0.10(0.0040)
Camshaft
Cam height mm(in) Intake Standard 42.580(1.6764)
Wear limit 42.478(1.6724)
Exhaust Standard 42.580(1.6764)
Wear limit 42.478(1.6724)
Journal mm(in) Elliptical limit 0.008(0.0003)
Diameter 1 51.910 ~ 51.940(2.044 ~ 2.045)
2 51.660 ~ 51.690(2.034 ~ 2.035)
3 51.410 ~ 51.440(2.024 ~ 2.025)
4 51.160 ~ 51.190(2.014 ~ 2.015)
Camshaft deflection limit mm(in) 0.8(0.00079 ~ 0.000709)
Camshaft end play mm(in) Standard 0.02 ~ 0.18(0.00079 ~ 0.000709)
Limit 0.3(0.0118)
Connecting rod and connecting rod bearing

Piston pin to small and bushing Standard 0.014 ~ 0.44(0.0006 ~ 0.0017)
Connecting rod side Standard 0.239 ~ 0.330(0.0094 ~ 0.00130)
Undersize connecting rod bearing mm(in) 0.254(0.010), 0.508(0.020), 0.762(0.030)
Crankshaft and main bearing

Crankshaft deflection limit mm(in) 0.05(0.002)
Crank pin diameter mm(in) Standard 57.112 ~ 57.125(2.2485 ~ 2.2490)
Limit 0.05(0.0020)
Grinding limit 56.35 (2.2185)
Standard 65.812~69.825(2.7485~2.7490)
Main journal diameter mm (in) Limit 0.008(0.0003)
Grinding limit 69.14(2.7220)
Main journal bearing mm(in) Standard 0.059 ~ 0.090(0.0023 ~ 0.00035)
oil clearance Limit 0.12(0.0047)
Undersize bearings mm(in) 0.254(0.010), 0.508(0.020), 0.762(0.030)
Crankshaft end play mm(in) Standard 0.14 ~ 0.39(0.0055 ~ 0.0154)
Limit 0.4(0.0157)

Cylinder block, piston and piston ring
Distortion limit 0.10(0.0040)

Cylinder liner inner diameter mm(in) A : 92.025 ~ 92.037(3.6230 ~ 3.6235)
B : 92.037 ~ 92.050(3.6235 ~ 3.6240)
Cylinder to cylinder liner clearance limit mm(in) 0.021 ~ 0.078(0.0008 ~ 0.0031)
Cylinder liner wear limit mm(in) 0.20(0.0079)
Piston standard outer diameter
(Diameter measured at 90 to pin bore mm(in) A : 91.967 ~ 91.980(3.6207 ~ 3.6213)
axis and 19 mm(0.75 in) below the oil B: 91.980 ~ 91.993(3.6213 ~ 3.6218)
ring groove)
Ring groove width mm(in) Top 2.433 ~ 2.453(0.0958 ~ 0.0966)
Second 2.423 ~ 2.443(0.0954 ~ 0.0962)
Oil 4.793 ~ 4.813(0.1887 ~ 0.1895)
Piston ring thickness mm(in) Top 2.363 ~ 2.383(0.0930 ~ 0.0938)
Second 2.363 ~ 2.383(0.0930 ~ 0.0938)
Oil 3.97 ~ 3.99(0.1563 ~ 0.1571)
Clearance between piston mm(in) Top 0.05 ~ 0.09(0.0020 ~ 0.0035)
ring and ring groove Second 0.04 ~ 0.08(0.0016 ~ 0.0032)
Oil 0.830 ~ 1.043(0.0316 ~ 0.0411)
Wear limit 0.3(0.0118)
Piston ring end gap Top 0.35 ~ 0.55(0.0138 ~ 0.0217)
mm(in) Second 0.35~ 0.55(0.0138 ~ 0.0217)
Oil O.35 ~ 0.55(0.0138 ~ 0.0217)
Wear limit 0.3(0.0118)
Piston pin diameter mm(in) 31.744 ~ 31.749(1.2498 ~ 1.2500)
Tightening torque m kg(ft-lb)

Cylinder head(cold engine) 11.0 ~ 11.7(80 ~ 85)
Manifold Intake 1.6 ~ 2.4(12 ~ 17)
Exhaust 2.7 ~ 3.3(20 ~ 24)
Crankshaft pulley 3.5 ~ 4.0(25 ~ 29)
Camshaft thrust plate 1.6 ~ 2.4(12 ~ 17)
Connecting rod bearing caps 7.6 ~ 8.3(55 ~22)
Cooling fan 1.6 ~ 2.4(12 ~ 17)
Injection pipe 2.5 ~ 3.0(18 ~ 22)
Oil pan 1.6 ~ 2.3(12 ~ 17)
Main bearing cap 11.0 ~ 11.7(80 ~ 85)
Idle gear 2.3 ~ 3.2(17 ~ 23)
Rear oil seal 1.5 ~ 2.0(11 ~ 14)
Water pump 1.6 ~ 2.3(12 ~ 17)
Camshaft gear 6.2 ~ 7.0 (45 ~ 51)
lnjection pump gear 4.0 ~ 7.0(29 ~ 51)

Lubrication System
Item Specification
Lubricating method Force-fed type
Oil Pump
Type Trochoid type
Oil pressure kg/cm2(lb/in2) 3.8(54) or more
Outer rotor and body mm(in) Standard 0.14 ~ 0.25(0.0055 ~ 0.0098)
clearance Limit 0.3(0.0118)
Pump shaft and body mm(in) Standard 0.06 ~ 0.15(0.0024 ~ 0.0059)
clearance Limit 0.1(0.0039)
Tightening torque mkg (ft-lb)

Oil filter By hand + 1/2 turn
Oil pan 1.6 ~ 2.3(12 ~ 17)
Oil pipe 0.8 ~ 1.2(6 ~ 9)
Oil pressure switch 1.2 ~ 1.8 (9 ~ 13)
Cooling System
Item Specification
Fan belt tension New belt 10 ~ 12(0.39 ~ 0.47)
(10kg force mm(in) Used belt 13 ~ 16(0.51 ~ 0.63)
Fan Type Blower
Number of blades 6
Outer diameter mm(in) 430(16.93)
Item Specification
Thermostat Opening temp C(F) 82 L 1.5(179.6 L 34.7)
Full-open temp C(F) 95(203)
Full-open lift mm(in) 8.0(0.31)
Water pump Type Centrifugal, timing belt driven
Radiator Type Corrugated
Cap valve opening 1.0 L 0.15(14.2 L 2.1)
Pressure kg/cm2(lb/in2)

Fuel System
Item Specification
Idle speed rpm 1100 L 25
Injection timing ATDC 2
2 2
Injection pressure kg/cm (lb/in ) 135 ~ 140(1920 ~ 1991)

Injection pump gear 4.0 ~ 7.0(29 ~ 51)
Injection nozzle holder 6.0 ~ 8.0(43 ~ 58)
Injection pipe 2.5 ~ 3.0(18 ~ 22)
Engine electrical system
Item Specification
Charging system
Alternator Type Alternating

Voltage capacity V-A 12 - 60
Regulated voltage V 14.4 L 0.3
Starting system
Starting motor Type Electromagnetic push-in type

Voltage V 12
Output kW 2.5
Free running test Voltage V 11
Current A 200 or less
Speed rpm 3000 or more

Starting motor 8.9 ~ 12.0(64 ~ 87)
Alternator 1.8 ~ 2.7(13 ~ 20)

Flywheel Housing 3.3 ~ 4.8(23 ~ 34)
Flywheel 13.1 ~ 13.8(94 ~ 99)

SB4035E00
Jul. 2000
Engine
D430 Diesel Engine
1760XL(DSL802)
2060XL(DSL902)
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as
shown below.
WARNING
The meaning of this safety alert symbol is as follows :
Attention! Become Alert! Your Safety is Involved.
The Message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
publication.
others. You should also ensure that the product will not be damaged or made unsafe by the operation, Iubrication,
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DAEWOO dealers have the most
current information available.
Vehicle Systems 1 Specifications

Index
Engine Fuel System

Engine Disassembly..................................................5 Fuel Flow System....................................................38
Inspection and Repair .............................................10 Fuel Filter ................................................................38
Cylinder Head Inspection...................................10 Fuel Injection Pump.................................................38
Replacing Combustion Chamber Insert .............10 Magnet Valve...........................................................44
Valve Spring Inspection .....................................10 Fuel Injection Nozzles .............................................45
Valve Inspection .................................................11
Valve Stem and Guide Inspection ......................11
Replacing Valve Guide .......................................11
Valve Seat Inspection and Refacing .................12 Electrical System
Checking Contact between Valve and Valve Seat ...12
Rocker Arm and Shaft Inspection ......................12 Summary .................................................................48
Cylinder Block Inspection...................................13 Trouble Shooting .....................................................49
Liner Inspection..................................................13 Alternator .................................................................50
Checking Piston Clearance................................14 Starting Motor..........................................................53
Piston and Piston Ring Inspection .....................14 Glow Plug ................................................................58
Checking Piston Pin and Bush ..........................14 Glow Plug Relay......................................................58
Checking Connecting Rod Alignment ................15 Technical Data.........................................................59
Crankshaft and Bearing Inspection....................15
Camshaft Inspection ..........................................16
Checking Idlegear and Spindle ..........................17 Technical Data ..............................................59
Checking Tappet and Guide Clearance .............17
Checking Push Rod ...........................................17
Cylinder Liner Repalcement .............................18
Engine Assembly ....................................................19
Engine Installation ..................................................27
Checking Compression Pressure ...........................27
Lubrication System
Lubricating Circuit ..................................................28
Oil Pump ................................................................29
Oil Pressure Relief Valve .......................................31
Oil Pressure Switch ................................................31
Checking Oil Pressure ...........................................31
Oil Filter ..................................................................32
Cooling System
Cooling Circuit .........................................................33
Antifreeze Solution ..................................................34
Radiator Inspection .................................................34
Thermostat ..............................................................34
Water Pump.............................................................35
V Belt and Tension Adjustment .............................37
D430 Diseel Engine 3 Index

Engine
Engine Disassembly
Disassemble the engine following the order numbered in Figs. 1-4, 1-5, 1-6 and 1-7.
Fig.1-4
(1) Exhaust manifold. (2) Alternator/bracket. (3) Injection pipe/nozzle holder/fuel leak pipe. (4) Oil filter.
(5) Fuel filter/separate mount on frame. (6) Intake manifold. (7) Cooling fan/belt/pulley assembly. (8) Water pump assembly
(9) Oil cooler assembly. (10) Thermostat housing assembly
D430 Diesel Engine 5 Engine

Fig.1-5
(12) Hose band. (13) Bleeder hose. (14) Bolt/seal washer. (15) Rocker arm cover/gasket. (16) Cylinder head bolt/washer.
(17) Rocker arm assembly. (18) Push rod. (19) Cylinder head bolt/washer. (20) Cylinder head. (21) Head gasket. (22) Cotter.
(23) Valve spring upper seat. (24) Oil deflector. (25) Valve spring outer. (26) Valve spring inner. (27) Valve spring lower seat.
(28) IN./EX. Valve. (29) Valve Cap.
NOTE : Identify parts as they are removed to ensure

reinstallation in original position.

Fig.1-6
(29) Crank pulley lock bolt. (30) Crank pulley. (31) Timing gear cover. (32) Oil deflector. (34) Crank shaft gear. (35) Nut. (36) Nut.
(37) Idle gear thrust plate. (38) Idle gear. (39) Injection pump drive gear. (40) Idle gear spindle. (44) Bolt. (45) Washer.
(46) Flywheel. (47) Bolt/washer. (48) Flywheel housing. (49) Bolt/washer. (50) Seal. (51) Oil pan. (52) Gasket.

Fig.1-7
(54) Bolt/washer. (55) Rear oil seal assembly. (56) Gasket. (57) Bolt/washer. (58) Oil pump lock screw/nut. (59) Oil pump assembly.
(60) Bolt/washer. (61) Cam shaft/gear assembly. (62) Bolt/washer. (63) Timing gear case. (64) Gasket. (65) Tappet.
(66) Connecting rod cap/bearing/bolt/nut. (67) Piston/connecting rod assembly. (68) Main bearing cap bolt. (69) Main bearing cap.
(70) Main bearing/thrust bearing. (71) Crank shaft. (72) Main bearing/thrust bearing.

Fig.1-8 Fig.1-11
Remove the injection pump gear, using the gear Remove the piston pin by using the piston pin
puller installer
Fig.1-9
Remove the crank shaft pulley, pressure plate and

flywheel by using the ring gear brake
Fig.1-10
Loosen the lock screw of oil pump and remove the oil
pump.
Remove the camshaft and gear.

Inspection and Repair
Cylinder Head Inspection
Fig.1-14
2. Locate new insert on the cylinder head as shown in Fig. 1-

Fig.1-12 14 with the welch washer which fits in a recess provided.
Check for cylinder head distortion.

If the distortion exceeds limit replace the head.
Max. permissible distortion

A, B .................................................0.1 mm (0.004 in)
C,D,E,F .........................................0.25 mm (0.010 in)
Replacing Combustion Chamber

Insert Fig.1-15
3. Secure the insert by means of expansion the

welch washer.
Valve Spring Inspection
Fig.1-13
1. Press out the insert with a suitable mandrel.
Fig.1-16
Examine the springs for corrosion or acid etching.

If it is severe, replace with new ones.
Check the springs and replace with new ones if the

free length is decreased more than the following
dimension.

Inner Spring Outer Spring Valve Stem and Guide Inspection
Limit 42.0mm (1.653in) 43.6mm (1.715 in)
Standard Dimension 44.1mm (1.736in) 45.9mm (1.807 in)
Fig.1-19
Fig.1-17
Check the clearance with a suitably mounted dial
indicator, or feel the clearance by moving the valve
Out of squareness should be less than 3 mm. per
stem back and forth.
100 mm (0.03 in per 1.00 in).
Standard:
IN. 0.046 ~ 0.096 mm (0.0018 ~ 0.0038 in)
Valve Inspection EX. 0.059~ 0.109 mm (0.0023 ~ 0.0043 in)
Limit; 0.127 mm (0.0050 in)
Replacing Valve Guide
Fig.1-18
Inspect all valves for warpage, cracks or excessive

burning and replace if any of these conditions is
found. Fig.1-20
Replace any worn, pitted or corroded valves that
cannot be cleaned or refaced.
1. Press out the guide with the valve guide remover.
Measure the stem diameter. If the wear exceeds
2. Press fit a new guide to the cylinder head, using
limit, replace the valve.
the valve guide remover and adaptor until the
adaptor comes in contact with the cylinder head.
Standard:
IN. 7.925 ~ 7.950 mm (0.3120 ~ 0.3130 in)
EX. 7.912 ~ 7.937 mm (0.3115 ~ 0.3125 in)
Limit:
IN. 7.880 mm (0.3102 in)
EX. 7.867 mm (0.3097 in)

Checking Contact between Valve
and Valve Seat
Fig 1-21
If the adaptor is not available, take care the distance

shown in Fig. 1-21 to be 16.5 mm (0.65 in).
Fig 1-23
An even transfer indicates accurate valve and valve

Valve Seat Inspection and Refacing seat refacing. If uneven, the valve must be lapped
into the valve seat using a suitable lapping
compound. Next, check its width with a seat width
scale or a steel scale placed across the face of the
valve seat.
Rocker Arm and Shaft Inspection

Make sure that the oil passage of the rocker arm
shaft is open.
Fig.1-22
Inspect the valve seats for cracks, burns, ridges of

improper angle and width.
When necessary to reface the valve seat, use a
valve seat grinder or a valve seat cutter and grind to
the specified angle as shown in Fig. 1-23.
NOTE: If the valve guides are to be replaced, this

must be done before refacing the valve seat.
Fig.1-24
1. Check the clearance between the rocker arm bore

and shaft. If it is more than specification, replace
the rocker arm bush or shaft.
Standard:
0.016 ~ 0.061 mm (0.0006 ~ 0.0024 in)
Limit:
0.070 mm (0.0028 in)

Liner Inspection
Fig.1-25
2. To replace the rocker arm bush, proceed as Fig.1-27

follows:
Check the cylinder liner bores for wear, scratching
1) Press out the old bush with a suitable mandrel.
and waveness. Measure the diameter of the cylinder
2) Press fit the new bush, being sure to align the
liner bore by using a cylinder gauge as shown in Fig.
oil holes of the bush and rocker arm.
1-27.
3) Finish the bush with a reamer or pin hole
grinder to the correct fit.
Cylinder Block Inspection
Fig.1-28
This measurement should be taken in the X-X

direction and the Y-Y direction at each of the 3
Fig.1-26
places, upper, middle and lower, of one cylinder liner,
as shown in Fig. 1-28. The difference between the
Examine the cylinder block for crack and any minimum and maximum values out of the 6
damage. Examine all machined surfaces of the block measured values is regarded as the amount of wear.
for burrs and scores. If the wear of cylinder liner bore is 0.20 mm (0.008
in) or more, it should be replaced.
Check for cylinder block distortion in the same way
as instructed in Cylinder head inspection. NOTE: Honing and reboring cannot be made on this
cylinder liner.

Checking Piston Clearance
Fig.1-31
Fig.1-29 3. Place the piston in the cylinder bore below the ring
travel, using a piston head to push the ring in
sequarely.
Check the clearance between each piston and
Check the piston ring end gap.
cylinder by measuring the diameter of the piston and
If it exceeds limit, the piston ring must be replaced.
cylinder bore. Refer to Liner Inspection for the bore
measurement procedure. Measure the piston
Limit: 1.5 mm (0.06 in)
diameter at 90 degrees to the pin bore axis and 58.4
mm (2.299 in) below the piston top.
If it is excessive the piston or liner must be replaced.
Checking Piston Pin and Bush
Standard:
0.187 ~ 0.212 mm (0.0074 ~ 0.0084 in)
Piston and Piston Ring Inspection
Fig.1-32
1. Check to see that the fir of the bush and piston pin
is 0.014~0.044 mm (0.001~0.002 in).
If it exceeds limit, the bush or piston pin must be
Fig.1-30 replaced.
Limit: 0.05 mm (0.0020 in)

1. Carefully inspect the piston and replace if it is
severely scored, scrached burned.
2. Check the side clearance of the piston rings at

several places. If it exceeds limit, replace the
piston ring or piston.
Standard:
0.050 ~ 0.096 mm (0.0020 ~ 0.0038 in)
Limit:
0.3 mm (0.012 in)

Crank Shaft and Bearing Inspection
Bearing Man journal Bearing Bearing

housing color clearance
mark Color Diameter
75.812~75.819mm 0.061~0.087mm
Green (2.9847~2.9850in) Green (0.0024~0.0034in)
A
Mark 75.819~75.825mm 0.065~0.090mm
White Yellow
(2.9850~2.9852in) (0.0026~0.0035in)
75.812~75.819mm 0.060~0.086mm
Green Brown
No (2.9847~2.9850in) (0.0024~0.0034in)
mark 75.819~75.825mm 0.065~0.090mm
White Green
(2.9850~2.9852in) (0.0025~0.0035in)
Fig.1-33
75.812~75.819mm 0.059~0.085mm
Green Black
2. To replace the bush, proceed as follows: C (2.9847~2.9850in) (0.0023~0.0033in)
Mark 75.819~75.825mm 0.063~0.087mm
White Brown
1) Press out the old bush with a suitable mandrel. (2.9850~2.9852in) (0.0025~0.0034in)
2) Press fit the new bush, being sure to align the
holes of the bush and connecting rod.
3) Finish the bush with a reamer or a pin hole 1. Inspect the bearings carefully and replace if they
grinder to the correct fit. are worn, scored or flacked.
The standard main bearing, main journal and

bearing housing are classified into several groups.
Checking Connecting Rod
To obtain the accurate main bearing clearance, the
Alignment combination of those related parts should be made
properly, referring to the table.
Fig.1-34
Fig.1-35
Check the connecting rod alignment by using a feeler
gauge and an aligner. The standard deflection is less 2. Measure the diameter of each crankpin and main
than 0.05 mm per 100 mm (0.0020 in per 4 in). If journal. If the wear exceeds limit, the crankshaft
realignment is necessary, correct by using a press should be ground to the under size of 0.254 mm
and applying a gradual pressure to the rod. (0.01 in) or replaced.
NOTE: The undersize connecting rod and main

journal bearings are 0.254 mm (0.01 in) only.
Crankpin Main journal Wear

diameter (STD) diameter (STD) Limit
61.112~61.225 mm 75.812~75.825 mm 0.05 mm
(2.4060~2.4065 in) (2.9847~2.9852 in) (0.002 in)

Fig.1-36 Fig.1-38
3. Check the crankshaft run-out. 2. Measure the diameters of the camshaft journals.
If it is not within the specification, correct with a
press or replace. The permissible diameters of the journals are in
the following table.
Max. allowable run-out 0.05 mm (0.002 in)
Permissible Diameter
Front No. 1 51.902 mm (2.0434 in)
No. 2 51.652 mm (2.0336 in)
Camshaft Inspection No. 3 51.402 mm (2.0237 in)
Rear No. 4 51.152 mm (2.0139 in)
Standard clearance:
0.06~0.12 mm (0.0024~0.0047 in)
Fig.1-37
1. Measure the cam height and replace the camshaft

if the wear exceeds limit.
Fig.1-39
Inlet and Exhaustt
Standard Limit 3. Check the camshaft run-out with a dial-indicator.
42.587 mm 42.485 mm
Camheight (1.6767 in) (1.6728 in)
If it is not within specification, correct with a press
or replace.
Max. allowable run-out 0.08 mm (0.0031 in)

Checking Tappet and Guide
Clearance
Fig.1-40
4. Check the end play with a feeler gauge.

Fig.1-42
The permissible limit of end play is 0.3 mm (0.012
in).
The standard tappet and guide clearance is
0.039~0.095 mm (0.0015~0.0037 in).
Checking Idle Gear and Spindle Replace if the contact surface of the tappet with the
cam is worn abnormally.
Checking Push Rod
Fig.1-41
Check for chipped, worn or broken teeth.
Check the clearance between the spindle.

Fig.1-43
If it exceeds limit, replace the spindle or gear.
Standard: To check the push rod for bend, place the push rod
0.034~0.084 mm (0.0013~0.0033 in) on the surface plate and determine the clearance
Limit: between the push rod and surface plate with a feeler
0.15 mm (0.006 in) gauge. If it exceeds 0.19 mm (0.007 in), repair or
replace with a new one.

Cylinder Liner Replacement
Removal:
Press
Fig.1-44
1. Use the liner remover and press out the liner.
2. Check the cylinder block bore for any scratches.
NOTE: Remove the scratches by oil soaked fine

emery paper for proper installation liner.
Installation:
Press
Fig.1-45
1. Press fit liner straight with the same tool, taking

special care so as not to distort the liner.
NOTE:
1) New liner supplied as spare parts should be
installed with lighter pressure than the removing.
2) There is no necessary to hone the cylinder liner
bore after installation.

Engine Assembly
Assemble the engine following the order numbered in Figs. 1-46, 1-47, 1-48 and 1-49.
Fig.1-46
(1) Piston pin. (2) Clip. (3) Piston ring. (4) Piston/connecting rod assembly. (5) Connecting rod bearing. (6) Tappet.
(7) Main bearing/thrust bearing. (8) Crank shaft. (9) Main bearing cap. (11) Cap bolt. (12) Connecting rod bearing/cap/bolt/nut.
(13) Idle gear spindle. (14) Gasket. (15) Timing gear case. (16) Bolt/washer. (17) Camshaft/gear assembly. (18) Bolt/washer.
(19) Gasket. (20) Rear oil seal assembly. (21) Bolt/washer. (22) Gasket. (23) Oil pump assembly. (24) Bolt/washer.
(25) Lock bolt/nut.

Fig.1-47
(26) Crank shaft gear. (27) Injection pump drive gear. (28) Idle gear. (29) Idle gear thrust plate. (30) Nut. (31) Nut.
(32) Oil deflector. (33) Gasket. (34) Timing gear cover. (35) Gasket. (36) Oil pan gasket. (37) Oil pan. (39) Bolt/washer.
(40) End plate. (41) Bolt/washer. (42) Flywheel. (43) washer. (44) Bolt. (49) Crank pulley. (50) Bolt.

Fig.1-48
(51) Valve/spring assembly. (52) Head gasket. (53) Cylinder head. (54) Push rod. (55) Rocker arm assembly.
(56) Cylinder head bolt/washer. (57) Cylinder head bolt/washer. (58) Rocker arm cover/gasket. (59) Bolt/seal washer.
(60) Bleeder hose. (61) Hose band.

Fig.1-49
(62) Water pump assembly. (63) Thermostat casing assembly. (64) Oil cooler assembly. (65) Intake manifold.
(66) Fuel filter assembly. (67) Oil filter/oil pipe. (68) Injection pipe/nozzle holder/fuel leak pipe. (69) Cooling fan/V belt/fan pulley.
(70) Alternator/bracket. (72) Exhaust manifold.

Fig.1-50
Assemble the piston and connecting rod.

Align the direction, piston and connecting rod as
shown in Fig. 1-50. Fig.1-53
Place the piston rings at about 90 apart as shown in

Fig. 1-53.
Fig.1-51
Insert the piston pin with the installer .

Fig.1-54
Preheat the piston, if tightly.
Install the piston and connecting rod assembly by

using the suitable piston guide.
NOTE: F mark of piston top should be faced front.
Fig.1-52
Install the piston rings with the inscription mark

upward.
Fig.1-55
Install the main bearing and thrust washer.
NOTE: Fit the thrust washer with a oil groove facing

outward.
Install the crankshaft and bearing cap.

Fig.1-56 Fig.1-58
Checking main bearing oil clearance. Install the caps to the connecting rods, ensuring that
the identification numbers are matched.
1) Place the plastigauge on the main journal in the
axial direction. NOTE: After tightening the nut turn the crankshaft
2) Tighten the cap bolts to 11.0~11.7 kgm (80~85 and make sure that the rotation is light and smooth.
lbft).
NOTE: Do not turn the crankshaft.
Compare the flattened width of Plastigauge with

measuring scale to determine the oil clearance.
Oil clearance:
New ...........0.059~0.090 mm (0.0023~0.0035 in)
Limit.....................................0.12 mm (0.0047 in)
Fig.1-59
Check the connecting rod oil clearance in the same

manner for the main bearing.
Tightening torque of bearing caps

......................................7.6~8.3 kgm (55~60 lbft)
Oil clearance
New ..........0.036~0.076 mm (0.0014~0.0030 in)
Fig.1-57
Limit ....................................0.10 mm (0.0039 in)
Check the crankshaft end play.
Check the end play with a dial indicator or a feeler

gauge. If it exceeds limit, use oversized thrust
washer.
Standard:
0.14~0.39 mm (0.006~0.015 in)
Limit:
0.4 mm (0.016 in)
Oversized thrust washer:
0.178 mm (0.007 in)

Fig.1-60 Fig.1-62
Check the connecting rod side play with a dial- Install the idle gear spindle, aligning the oil hole.
indicator or feeler gauge.
Standard:
0.239~0.330 mm (0.009~0.013 in)
Limit:
0.4 mm (0.016 in)
Fig.1-63
Install the timing gears, aligning the timing marks as

shown in Fig. 1-63.
Fig.1-61
Check the piston height.
When the piston has been replaced with new one,

the distance between the cylinder block face and
piston crown should be checked to ensure the limit of
-0.05~-0.15 mm (-0.002~-0.006 in), has been
maintained when that piston is at top dead center.
Fig.1-54
Check the timing gears.
Check the backlash with a dial-indicator or a feeler

gauge.
If it exceeds limit, replace with new one.
Standard:
0.1~0.2 mm (0.004~0.008 in)
Limit:
0.3 mm (0.012 in)

Fig.1-65 Fig.1-67
Check the idle gear end play with a feeler gauge. Cut off the excess gaskets along the mounting
surfaces of the oil pan.
Standard:
0.15~0.30 mm (0.006~0.012 in) Before installing the oil pan, make a final internal
inspection.
Apply a thin coat of gasket past on the oil pan.
Install a new gasket and the oil pan.
Fig.1-66
Install the timing gear cover.

Before tightening the nuts and bolts, install the timing
Fig.1-68
gear cover centering tool (49 0636 245) in the timing
gear cover oil seal as shown in Fig. 1-66.
Check the rocker arm offset both of the exhaust and
NOTE: It is important that centering tool be used to inlet side rocker arms 1 mm (0.04 in) from the valve
align the timing gear cover so that crankshaft pulley stem center.
installation will not damage and to prevent oil seal
leak.
Fig.1-69
Face the flat surface on the ball on each of the

rocker arms downward.

Engine Installation
Carry out the removing operations in the reverse
order.
Checking Compression
Pressure
Fig.1-70
Tighten the cylinder head bolts to 11.0~11.7 kgm

(80~85 lbft) in the order shown in Fig. 1-70.
Tighten the nut of the two stud bolts locating the

rocker arm shaft.
Adjust the valve clearance to 0.3 mm (0.012 in) for

both inlet and exhaust.
NOTE: Whenever the engine is overhauld, warm up Fig.1-71

the engine and readjust the valve clearance after
tightening the cylinder head bolts to the specified
1. Before measuring the compression pressure,
torque.
inspect the valve clearance and the functions of
the battery and the starting motor.
2. Run the engine until it obtains normal operating

temperature.
3. Disconnect the air hose from the inlet manifold.
4. Remove all injection nozzles.
5. Install the adaptor in the nozzle hole.
6. Set the fuel stop lever at stop position.
7. Connect the compression tester on the adaptor,

one after the other, and turn the engine over with
starting motor until the pressure reaches a
maximum value.
Compression pressure:
Standard Limit
30.0 kg/cm2 (427 lb/in2) 27.0 kg/cm2 (384 lb/in2)
at 200rpm at 200 rpm
Special Tools :
Adaptor, Compression gauge Pivot, Valve spring lifter

Puller, Injection pump gear Replacer, Valve guide
Installer, Piston pin Oil seal replacer, Timing cover
Lifter, Valve spring Centering tool, Timing cover

Lubrication System
Lubricating Circuit
Fig.2-1
1. Oil that has been filtered through the oil filter is

forced to the oil cooler and to the main oil gallery
and to the main bearings and others through the
passages.
2. The cylinder walls, piston pins and bushes are

lubricated by splash and oil mist.
3. Oil from the No. 3 main bearing lubricates the oil

pump drive shaft and pump driven gear.
4. Oil from the No. 1 camshaft bearing is directed up

to the No. 1 rocker arm support through a
passage, then passes through inside of the
rockers shaft and lubricates rocker arm bush and
shaft. Also, oil lubricates the valve stem, and other
valve train surface.
D430 Diesel Engine 28 Lubrication System

Oil Pump
Disassembling Oil Pump
Fig.2-2
(1) Bolt/washer. (2) Oil pipe. (3) Gasket. (4) Bolt/washer. (5) Oil strainer. (6) Gasket. (7) Bolt/washer.
(8) Cover. (9) Drive gear. (10) Rotor/shaft assembly. (11) Outer rotor. (12) Pin. (13) Inner rotor.
(14) Drive shaft. (15) Relief valve assembly.
Disassemble the parts in the order numbered above.

Checking Oil Pump
Fig.2-5
Fig.2-3 3. Check the end float of the rotors. Place a straight

edge across the pump body and measure the
clearance between the rotor and straight edge with
1. Check the clearance between the lobes of the
a feeler gauge.
rotors with a feeler gauge.
If the clearance exceeds limit, replace both rotors.
Then, place a straight edge across the pump cover
and measure the clearance between the straight
Limit ............................................0.3 mm (0.012 in)
edge and the cover.
Fig.2-4
Fig.2-6
2. Check the clearance between the outer rotor and

If the end float exceeds limit, correct the pump cover
pump body with a feeler gauge.
by grinding.
If the clearance exceeds limit, replace the rotor or
pump body.
Limit .........................................0.15 mm (0.006 in)
Limit ............................................0.3 mm (0.012 in)

Assembling Oil Pump Oil Pressure Switch
Carry out the disassembling operations in the revers
order.
Oil Pressure Relief Valve
Fig.2-8
Safe minimum pressure is 0.4 kg/cm2 (6 lb/in2) at

idle. If the oil pressure drops below 0.4 kg/cm2 (6
lb/in2), the oil pressure warning lamp lights up to
indicate some troubles in the lubricating system.
Checking Oil Pressure

Fig.2-7
When the engine revolution becomes high and

excessive oil pressure develops in the system, the
relief valve opens to relieve the pressure and to
return the excess oil to the oil pan.
Thus, the oil pressure maintains within the maximum
pressure of 4.0 kg/cm2 (57 lb/in2).
Fig.2-9
Warm up the engine to the normal operating

temperature. Remove the oil pressure switch and
connect the oil pressure gauge (49 0187 280)
instead.
The following table shows the normal oil pressure.
Oil pressure: ..........................4.0 kg/cm2 (57 lb/in2)

at 3,600 rpm. of engine

Oil Filter
Fig.2-10
The filter cartridge should be replaced at intervals,

following the maintenance schedule.
To replace, proceed as follows:
1. Remove the oil filter cartridge with the suitable

wrench.
2. Apply oil onto the oil seal on a new filter cartridge.
3. Position the filter and turn clockwise until the

gasket surface contacts sealing surface.
Then, give the filter an additional 5/6 turn by hand.
4. Start the engine and check that the joints are not
leaking. Top up with oil if necessary.

Cooling System
Cooling Circuit
Fig.3-1
When the engine gets warm, the coolant flows to the

water pump from the outlet in the lower left side of
the radiator. After passing through the pump, the
coolant is forced to the cylinder block. After cooling
off the cylinder block, the coolant circulates in the
cylinder head. Then the coolant flows through the
thermostat and back into the radiator.
Antifreeze Solution
To prevent freezing, add anti-freeze solution to the
water which lowers the freezing point of the coolant.
Before adding anti-freeze, inspect the cooling system
to be sure it is clean and leaktight.
D430 Diesel Engine 33 Cooling System

Radiator Inspection Thermostat
Removing Thermostat
3
2
1
Fig.3-3
1. Check the pressure cap function. To check, first Fig.3-5

wet the cap rubber gasket to insure an air tight
seal and then attach a tester to the cap. (1) Cover. (2) Gasket. (3) Thermostat
Valve opening pressure 1.0 kg/cm2 (14.2 lb/in2)
After draining until the coolant level is below the
2. Inspect the cooling system for leaks. thermostat housing, remove the thermostat following
the orders numberd in Fig.3-5.
1) Attach a tester in place of radiator pressure cap.
2) Run the engine until it reaches normal operating
temperature.
3) With the engine running and tester installed, Checking Thermostat
pump up the system to approx. 1.0 kg/cm2
(14.2 lb/in2) and observe the gauge.
If pressure drops rapidly, visually inspect all

external parts for leaks. If no external leaks appear
and pressure continues to drop, inspect the engine
oil to determine whether or not coolant is leaking
into the crankcase due to a cracked cylinder block
or leaking head gasket.
Fig.3-6
To test the thermostat, place it in water with a

thermometer and heat up the water gradually and
check the temperature when the thermostat starts to
open and when it opens fully. And also measure the
lift height when the thermostat is fully opened.
If the reading shows a large difference from the
specifications, replace with a new thermostat.

Water Pump
Checking Water Pump
Fig.3-8
Check the water pump for leaks and excessive play

or looseness of the shaft and bearings. If there is
evidence of excessive play when the fan blades are
manually moved up and down, it shows that the
bearings are rough.
Fig.3-7 If water leaks from the hole located on the pump
body, it indicates defective seal necessitating
overhaul of the pump.
Starts to open 82 L 1.5C (180 L 2.7F)
Fully opens at 95C (203F)
Lift 8 mm (0.315 in) or more
Removing Water Pump
Installing Thermostat
Follow the removal procedure in the reverse order.
Fill the cooling system. Operate the engine and
check for leaks.
Fig.3-9
(1) Bolt/washer. (2) Cooling fan. (3) Vbelt. (4) Pulley

(5) Nut/washer. (6) Water pump. (7) Gasket.
After draining cooling system, remove the water

pump following the order numbered in Fig. 3-9.

Disassembling Water Pump
Use puller to remove
Fig.3-10
(1) Nut/washer. (2) Bearing housing. (3) Gasket. (4) Pulley boss. (5) Snap ring. (6) Shaft, spacer/bearing assembly. (7) Impeller.
(8) Seal assembly. (9) Bearing. (10) Spacer. (11) Bearing. (12) Baffle plate. (13) Dust seal.
(14) Snap ring.

Assembling Water Pump V Belt and Tension Adjustment
Press down here with

10kg(22lb) force
Fig.3-12
1. If the belt is broken, glazed, or worn, replace the

belt with a new one. If the belt is stretched so that
it cannot be tightened sufficiently, install a new
Fig.3-11
belt.
2. If the belt is noisy, check the tension of the belt.

Assemble the water pump in the reverse order of
Also, check for misaligned pulleys.
disassembling, take care the cautions in Fig. 3-11.
3. When the belt is pressed down with 10 kg (22 lb)
force, the belt should deflect the specified amount.
Installing Water Pump
For new belt 10~13 mm (0.4~0.5 in)
Install the water pump in the reverse order of For used belt 13~16 mm (0.5~0.6 in)
removing.
NOTE:
1) Adjust the belt tension, as discribed in V Belt and
tension adjustment.
b) Fill the cooling system. Operate the engine and
check for leaks.

1. Remove the fuel filter cartridge with the suitable
Fuel System wrench.
2. Apply fuel onto the oil seal on a new filter

Fuel Flow System cartridge.
3. Position the filter and turn clockwise until the

gasket surface contacts sealing surface.
Then, give the filter an additional 2/3 turn .
4. After replacing the filter element, make sure that

the air is bled from the system. Push the priming
pump on top of the fuel filter adapter against the
spring to allow air mixed with fuel to escape
throught the bleeder screw.
Ensure that excess fuel is collected in a container
or rag to prevent fuel from getting onto engine
parts.
Repeat the pumping action until no bubbles are
visible in the flowing fuel.
Tighten the bleeder screw.
5. Start the engine and check that joints are not

Fig.4-1
leaking.
The fuel flow system, as shown in Fig. 4-1.
Fuel Injection Pump

Fuel filter
Important Service Points
Fuel Filter If the inside of the injection pump is disassembled for
maintenance, be sure to properly use the checking
The element of the filter is sealed in the container as device such as pump tester, and carefully inspect
a unit. each component parts.
The element should be replaced at intervals, Disassembly and maintenance should be made at a
following the maintenance schedule. clean place and the parts should be thoroughly
cleaned.
For the disassembling/reassembling, checking and

adjusting procedures for the injection pump itself, see
the service manual, Repair Service and
Maintenance, prepared by manufacturer of injection
pump.
Fig.4-2
(1) Adapter. (2) Filter catridge. (3) Bleeder screw
To replace proceed as follows:
D430 Diesel Engine 38 Fuel System

Construction of VE Injection Pump
Fig.4-5

Checking Idle Speed Adjusting Idle Speed
Sultable reflecting tape
Fig.4-8
Fig.4-10
4
3
Fig.4-9
1. Warm up the engine.

Fig.4-11
2. Remove any specks on the crankshaft pulley with
a waste cloth and place a piece of suitable 1. Inspect the deflection of accelerator cable.
reflecting tape on the pulley to facilitate use of a
photo-electric type tachometer. NOTE:To lengthen the play of the accelerator wire,
loosen the lock nut 1 of the wire bracket and tighten
3. Start and idle the engine. the adjust nut 2
4. Aim the light of the tachometer onto the reflecting 2. Loosen the lock nut 3 of the idle adjust bolt and
tape to confirm the engine speed. adjust the play by turning the idle adjust bolt 4.
5. Adjust the idle speed if the engine speed is not NOTE: Idle speed will increase when the adjust bolt
within the specified value. is turned clockwise and decrease when turned
counter clockwise.
Standard idling speed:
1100 L 25 rpm 3. After the adjustment, race the engine two or three
times to inspect the returning of the accelerator
wire.

Checking Injection Timing
Bolt
Fig.4-14
Fig.4-12 4. Set the flywheel ring gear to approximately 30of

BTDC and find the position in which the needle of
1. Disconnect the fuel injection pipes from the the dial gauge does not deflect even when the
injection pump. flywheel is turned.
2. Remove the bolt and gasket installed on the 5. When it is confirmed that the dial gauge needle
distributor head of the injection pump. does not deflect, set the needle to O on the
scale.
Fig.4-13
Fig.4-15
3. Set the measuring device on the injection pump.
Make sure that the tip of the feeler needle of the 6. Turn the flywheel in the normal direction until TDC
measuring device is in contact with plunger end at is indicated.
this time. The injection timing is normal when the dial gauge
needle of advanced 1.00 mm ahead of the value
set in the above 5.
Beginning of matic injection:

Cam lift 1.00 mm (0.0394 in.).
If the advance is more than 1.00 mm, adjust the

injection timing.

Adjusting Injection Pump Removal
Fig.4-16 Fig.4-17
1. If the injection timing is faulty, turn the injection

pump to a position in which the dial gauge needle
indicates 1.00 mm.
When the cam lift is larger than 1.00 mm, turn the
injection pump all the way in the engine revolving
direction once, and then turn it in the reverse
direction once, adjusting the cam lift to the 1.00 mm
point.
If the cam lift is smaller than 1.00 mm, adjust the lift Key groove
by turning the pump in the direction inverse to the
engine revolving direction. Fig.4-18
2. After the adjustment, install the head bolt and

gasket. 1. Disconnect both positive and negative terminals of
the battery.
3. Use a new head bolt and gasket.
2. Remove the upper fan shroud and cooling fan.
3. Remove the air hose.
4. Remove the fuel pipe and fuel injection pipes.
5. Disconnect the accelerator cable from the injection

pump.
6. Disconnect the wiring of the magnet valve (for fuel

cut).
7. Remove the injection pump cover.
8. Remove the lock nut.
9. Remove the plain washer.

Remove the plain washer with a wire, etc., taking
care not to drop it in the gear case.
10. While checking the injection pump shaft key by

using a mirror, turn the flywheel through the
clutch cover timing hole until the key comes to
the top position.

Installation
Install in the reverse order of removal and pay
attention to the following matters.
NOTE:
Support bracke Before installing the key on the drive shaft of the
injection pump, lightly tap the key groove of the
shaft with a hammer to assure that the key is tightly
inserted in the key groove.
After installing the injection pump, evacuate air.
Fig.4-19
Drive gear tightening torque:
4.0 - 7.0 kgm (29 - 51 lbft).
Air-Bleeding Fuel System

Whenever the fuel filter is replaced or the sedimentor
is cleaned, the filter must be air-bled in the following
manner:
Fig.4-20
11. Remove the auxiliary bracket tightening bolts

used for fixing the lower side of the injection
pump.
12. Remove the injection pump mounting nuts.

Fig.4-21
13. Separate the pump shaft and gear.

1. Loosen the air bleeder screw of fuel filter.
Set the extractor (Be sure to use the side with M
mark at all times). 2. Loosen the fuel pump priming plunger by turning
Separate the shaft and gear by tightening the counter-clockwise. Then pump the plunger in Up
extractor bolts. and Down motions.
14. Remove the injection pump. 3. Continue to pump until fuel flows from the air
Gradually remove the injection pump by pressing bleeder screw hole free of air bubbles.
the pump gear against the injection pump side,
ensuring not to drop the key into the gear case. 4. Depress the fuel pump priming plunger and close
the fuel filter air bleeder screw. Secure the priming
15. Remove the extractor. plunger by turning clockwise.

Magnet Valve
Air bleeder screw A
Checking
Fuel out magnet valve
Fig.4-22
If the engine should run out of fuel during operation

and air enters the injection system or whenever the
injection pump is removed, the system must be
airbled in the following manner: Fig.4-24
1. Air-bleed the fuel filter.
2. Loosen the air bleeder screw A and operate the

fuel pump priming plunger with hand until fuel
flows from the air bleeder screw hole free of air
bubbles.
Magnet valve
3. Close the air bleeder screw A with the priming
plunger depressed. O-ring
Spring
4. Loosen the injection pipe nipples on the nozzle
holders and crank the engine until fuel flows from Armature
the pipes free of air bubbles, and tighten the
nipples.
Fig.4-25
The magnet valve is in normal condition;

The engine runs smoothly when the engine switch is
Loosen
turned on, but the engine running is stopped when
the engine switch is turned off.
If the engine does not stop, check the wiring

connection or disconnect the wiring of the magnet
valve and check the flow of electric current.
If the electric current is flowing through the coupler

Fig.4-23
when the engine switch is on and is shut off when
the switch is off, the engine switch and wiring are in
5. Disconnect the injection nozzle side of the normal condition and the magnet valve is faulty.
injection pipe. When the magnet valve is faulty, replace the part
shown in Fig. 4-28 as a complete set.
6. Turn the engine switch to the start position, crank
the engine and make sure that the fuel flows out of
the injection pipe.

Fuel Injection Nozzles Disassembling Nozzle Holder
Disassembling nozzle holder following order
numbered in Fig. 4-38.
Fig.4-26
(1) Joint bolt & Gasket. (2) Fuel Leak pipe. (3) Injection pipe.
(4) Nut. (5) Nozzle holder. (6) Gasket & Dust seal. Fig.4-27
(1) Nozzle nut. (2) Nozzle. (3) Body. (4) Cap nut. (5) Gasket.
As the function of the injection nozzles greatly (6) Spring adjust screw. (7) Nozzle spring seat.
influences the engine performances, all the injection (8) Nozzle spring. (9) Push rod.
nozzles must be checked at every 3,000 km (2,000
miles) according to the following method. NOTE:
1) Greatest possible care should be taken in handling
the nozzles as they are the parts with high
precision.
Removing Nozzle Holder 2) As the nozzle and the needle valve are in pairs,
mixing up of the original combinations must be
Remove the nozzle holder following order numbered
prevented by disassembling and washing one
in Fig. 4-37.
nozzle assembly after another separately.
3) Carbon deposit on the nozzle body must be
removed with a piece of hard wood. However, it
would be advisable not to clean the surrounding
area of the nozzle orifice to avoid possible
damage to the orifice.
After cleaning, wash the nozzle body in clean
gasoline in a container.
CAUTION: Never assemble the nozzle needle valve

and the nozzle body and slide them on each other in
gasoline.

Checking Injection Nozzle Testing Injection Nozzle
Test the nozzles using light oil under temperature of
about 20C (68F).
Fig.4-28
Make sure to needle valve comes down until the

valve seat by its weight when it is pushed in the Fig.4-29
nozzle body about 18 mm (0.70 in).
If any defect is found, always replace the needle 1) Checking Oiltightness of Sliding Portion of Nozzle
valve and the nozzle body as a unit. Needle Valve:
Set the adjusting screw and operate the hand
lever to raise the pressure up to 250 kg/cm2 (3600
lb/in2) and see how soon the pressure drops from
Assembling Injection Nozzle the level to 200 kg/cm2 (2800 lb/in2).
If it takes longer than 3 seconds, the oiltightness
Assemble the injection nozzle in the reverse order of will be satisfactory. A remarkably quick drop of
disassemble. pressure indicates an excessive clearance at the
sliding portion between the needle valve and the
nozzle body due to wear, so in such a case
replace both needle valve and nozzle body.
Fig.4-30
2) Checking Injection Starting Pressure:

Operate the hand lever at 60 st/min to check for
the pressure under which injection is started.
Adjust the pressure to the prescribed value of 135
kg/cm2 (1,920 lb/in2) by turning the adjusting
screw, and then tighten the cap nut with torque of
3.5 kgm (25 lbft).

Installing Injection Nozzles
Fig.4-33
Fig.4-31
Install the injection nozzle holder in the reverse order

3) Checking Oiltightness of Needle Valve Seat:
of removing.
Operate the hand lever to raise the pressure up to
115 kg/cm2 (1635 lb/in2), which is 20 kg/cm2 (280
NOTE: When installing the nozzle holder, use the
lb/in2) lower than the injection starting pressure. If
new gasket, and tighten the nuts to 1.6 ~ 2.4 kgm
fuel does not drip from the nozzle orifice under the
(12 ~ 17 lbft).
pressure, oiltightness is satisfactory. Dripping of
fuel, on the other hand, is indicative of damage on
Fit the fuel pipe to the nozzle holder.
the needle valve or the valve body, or mal-contact
between both.
In that event, both needle valve and valve body
must be replaced.
Checking Fuel Injection:
Fig.4-32
Operate the hand lever quickly and verify that fuel is

injected correctly from the nozzle orifice in the
direction of the nozzle axis.
At fuel injection check, inspect for fuel staying at the
nozzle orifice after several times of injection. A large
amount of fuel staying there or dripping of fuel
therefrom are due to mal-contact between the needle
valve and the valve seat. In such a case, renew both
nozzle needle valve and nozzle body.

Electrical System
Summary
Structural View
Fig.5-1
(1) Alternator. (2) Glow plug. (3) External resistor. (4) Glow cord. (5) Battery. (6) Starting motor. (7) Oil pressure switch.
(8) Magnet valve (Fuel cut solenoid). (9) Water temperature gauge unit.
D430 Diesel Engine 48 Electrical System

Specification
Starting motor Nominal output 12V 12V - 2.5kW

Alternator Nominal output 12V 12V, 60A
Type Sheathed type
Glow plug
Voltage, amperage 12V 10.5V, 16.5A
Troubleshooting
Trouble Possible Cause Action to be Taken
Starting motor does Battery and related parts
not turn, or turns too Faulty contact of battery terminals Clean and tighten
slowly to start the Faulty grounding of negative cable Clean and repair
engine Voltage drop caused by discharging Charge
Insufficient voltage caused by faulty battery Charge
Engine switch (ignition switch)
Faulty contact on engine switch Replace
Loose engine switch wiring and connectors Repair
Broken wire between engine switch and magnetic switch Repair or replace
Magnetic switch and related parts
Loose wiring and connectors Repair
Faulty contact of magnetic switch contact plate Replace
Broken wire of magnetic switch pull-in coil Replace
Broken wire of magnetic switch holding coil Replace
Starting motor and related parts
Faulty contact of brushes Repair replace
Fatigued brush spring Replace
Faulty grounding of field coil Replace
Faulty soldering of field coil Repair
Faulty commutator Repair
Faulty grounding of armature Replace
Wear on parts Replace
Starting motor turns, Insufficient battery capacity Charge
but the engine does Quick start system and related parts
not start Faulty glow plug relay control unit Replace
Faulty glow plug relay Replace
Faulty glow plug Replace
Starting motor turns, Tip of overrunning clutch pinion is worn Replace
but pinion gear does Raced overrunning clutch Replace
not mesh with ring Faculty sliding surface of spline Repair or replace
gear Worn bushing Replace
Worn ring gear Replace
Starting motor turns Sticking contact plate of magnetic switch Replace
continuously and Layer short of magnetic switch coil Replace
does not stop Engine (ignition) switch does not return properly Replace
Battery discharge Loose V-belt Adjust

Grounded or broken stator coil Replace
Broken rotor coil Replace
Faulty contact between brush and slip ring Clean or replace
Faulty rectifier Replace
Faulty IC regulator Replace
Insufficient or unsuitable battery electrolyte Adjust
Faulty battery electrode (internal shortcircuit) Replace
Faulty contact of battery terminal Clean, tighten
Excessive electric load Check power consumption
Overcharged battery Faulty IC regulator Replace

Alternator
Disassembling Alternator
Fig.5-5
(1) Brush/holder assembly. (4) Rotor/vane. (5) Through bolt. (6) Rear housing assembly. (7) Front housing assembly.
(8) Nut/washer. (9) Pully/fan. (10) Spacer. (11) Front housing. (12) Rotor/bearing. (13) Rear housing. (14) Stator/heat sink.

Fig.5-7 Fig.5-9
Separate the rear housing assembly. To check for ground, connect one prod to the core
and the other to each lead wire.
Remove the heat sink attaching screws and remove If a ground is present, the current will flow and the
the heat sink from the rear housing. stator coil must be repaired or replaced.
Alternator Inspection
Fig.5-10
b. Checking rotor
To check for open circuit place both prods of an
Fig.5-8
ohmmeter on the slip rings. If the reading is 5~6
ohms, there is no trouble in the rotor.
a. Checking stator coil
Check the stator coil. To check for open, connect To check for ground, connect one prod to the slip
the prods to each of the two leads. If there is no ring and other prod to the core.
flow of current, the coil is open circuit and must be If the current flows, the rotor must be repaired or
repaired or replaced. replaced.

Assembling Alternator
Assemble the alternator in the reverse order of
disassembling.
NOTE: The soldering of the diode leads should be

performed in less than twenty seconds as the
excessive heat may damage the diode.
Fig.5-11
c. Checking diodes
To check diode, read the resistance between the
lead wire and case with a tester.
Then reverse the tester lead and note the reading.

If both readings are very low or high, the diode is
defective.
A good diode will give one low reading and one
high reading.
NOTE: The diodes and heat sink are serviced as an

assembly.
Fig.5-12
d. Checking brushes and springs

The brushes should be replaced when one - third
of the original length is worm away.
Standard tension
350 L 52.5 gr (0.8 L 0.12 lb)
If the tension is too low or if excessive corrosion

exists, the spring must be replaced.

Starting Motor
Checking Starting Circuit
Fig.5-17
(1) Weak battery. (2) Corroded or loose battery terminal. (3) Loose starting motor terminal.
(4) Broken or loose wires of the starting circuit. (5) Faulty ignition switch.
When the starting motor fails to operated or does not

satisfactorily operate, check the above points before
removing the starting motor.

Disassembling Starting Motor
Fig.5-18
(1) Field strap. (2) Screw. (3) Magnet switch/plunger. (4) Through bolt. (5) Rear cover. (6) Insulator/washer. (7) Yoke assembly.
(8) Rubber ring/spring/driving lever. (9) Center bracket. (10) Armature assembly. (11) Stop ring. (12) Piston stop coller.
(13) Over running clutch/pinion. (14) Screw/pole core. (15) Brush spring/brush.

Short-circuit test:
Fig.5-19
Drive the pinion stop collar toward the armature, and Fig.5-21
remove the stop ring.
Then, slide the stop collar and over-running clutch off Place a armature against the core of the growler
the armature shaft. tester, and hold a steel strip on the armature. Then,
rotate the armature slowly by hand. If the armature
coil is shorted, the steel strip will become magnetized
and vibrate. Replace the armature if a short is found.
Inspecting Starting Motor
b. Checking commutator
a. Checking armature
Ground test:
Fig.5-20 Fig.5-22
Touch one prod of an ohmmeter to each segment If the commutator is dirty, discolored or worn, clean it
and the other prod to the core or shaft. with emery paper and wash with clean solvent. After
An infinite reading should be obtained for each cleaning. undercut the mica between the segment to
segment. the depth of 05 ~ 0.8 mm (0.020 ~ 0.031 in) shown in
If the meter reading is not infinite, the armature Fig. 5-20.
windings are shorted to the core and shaft, and the
armature must be replaced.

c. Checking field coil Magnetic Switch Test
a. Pull-in coil test
Fig.5-23
Fig.5-25
To test the field coil for ground with a tester, place
one prod on the yoke or pole core and the other prod
to the field terminal. (for each prod) Apply the specified voltage (12V) between the S
If it is grounded, the current will no flow, and the field terminal and M terminal. If the magnetic switch is
coil must be repaired or replaced. forcefully attached, the pull-in coil is in good
condition.
d. Checking brushes and brush springs
b. Holding coil test
Fig.5-26
Fig.5-24
Ground the (M) terminal to the magnetic switch body
The brushes should be replaced when one - third of with lead and impose the specified voltage (12V)
the original length is worn away. upon the S terminal to pull in the plunger. If the
plunger remains attracted after disconnecting the
Standard length lead at the (M) terminal, there is no trouble with the
19 mm (0.748 in) holding coil.
Standard tension
2.0 L 0.3 Kg (4.4 L 0.661 lb)

c. Return test Testing Starting Motor
a. Free running test:
Fig.5-27
Push in the plunger with hand and apply the

specified voltage between the (M) terminal and the
magnetic switch body. If the plunger is not attracted,
there is no trouble.
Assembling Starting Motor Fig.5-29
To assemble the starting motor, reverse the

1. Connect an ammeter as illustrated.
procedure of Par. 5-D-3.
2. Apply the battery voltage adjusted to 11 volts to
the starting motor.
3. Operate the starting motor and take a reading.
Specified current
200A or less at 3,000 rpm. or more
b. Lock registance test:
Test the lock registance, following the instructions of

0.5~2.0mm
(0.020~0.079in)
the test equipment of manufacturer.
Fig.5-28
Voltage 3.0V
NOTE: When the magnetic switch is engaged, the Current 1200A or less
clearance between the pinion and stop collar should Torque 3.5 kgm
be 0.5~2.0 mm (0.020~0.079 in).
This clearance can be adjusted by inserting the
adjusting washer between the magnetic switch body
and the driving housing.

Glow Plug Glow Plug Relay
Checking Open Circuit of Glow Plug Checking Glow Plug Relay
Engine switch
Glow plug relay

Fig.5-30
Glow plug
Battery
Check the continuity between the positive terminal of
the glow plug and cylinder head with a circuit tester.
If there is no continuity, replace the glow plug.
Fig.5-33
Check continuity between B terminal and C

Removal terminal of glow plug relay when engine switch is
OFF position.
Remove in the following order.
If the continuity does not exist, the glow plug relay
is correct.
If the continuity exists, replace the glow plug relay.
Check continuity between B terminal and C

terminal of glow plug relay when engine switch is
turned to NO position or START Position.
If the continuity exists, the glow plug relay is

correct.
If the continuity does not exist, replace the glow

plug relay.
Fig.5-31
1. Glow plug connector attaching nut.

Use a suitable driver.
2. Resistor
3. Glow plug connector
4. Glow plug
NOTE: Turn the glow plug counter-clockwise and

remove it.
5. To install the glow plug, reverse order of removal.

Technical Data
1. ENGINE
Type Four cylinder four stroke engine in

line, water cooled, overhead valve
Bore
95 mm (3.74 in)
Stroke
105 mm (4.13 in)
Piston displacement
2977 cc (181.7 cu-in)

Compression pressure
(at 200 rpm)
Standard 30.0 Kg/cm2 (427 lbin2)
Limit 27.0 Kg/cm2 (384 lbin2)
Valve clearance
(Warm engine)
Inlet 0.30 mm (0.012 in)
Exhaust 0.30 mm (0.012 in)
Cylinder head
Permissible distortion of cylinder 0.10 mm (0.004 in)
head surface
+0.1
Cylinder head height 82.5 -0
mm (3.2481 +0.0039
-0
in)
Valve seat
Valve seat angle
Inlet 45
Exhaust 30
Valve seat width
Inlet 2.0 mm (0.079 in)
Exhaust 2.0 mm (0.079 in)
Valve guide
Protrusion from cylinder head 16.5 mm (0.6496)
Inner diameter 7.988~8.014mm (0.3145~0.3155in)
Stem to guide clearance limit 0.127 mm (0.005 in)
Valve-Inlet
Overall length 114.5 mm (4.5079 in)
Head diameter 40 L 0.1 mm (1.5748 L 0.0039 in)
Face angle 45
Stem diameter
Standard 7.925~7.950mm (0.3120~0.3130in)
Limit 7.880 mm (0.3102 in)
Valve margin
Limit 1.35 mm (0.0532 in)
Valve-Exhaust
Overall length 114.6 mm (4.5118 in)
Head diameter 36 L 0.13 mm (1.4173 L 0.0051 in)
Face angle 30
Stem diameter
Standard 7.912~7.937mm (0.3115~0.3125in)
Limit 7.867 mm (0.3097 in)
Valve margin
Limit 1.35 mm (0.0532 in)
Valve spring-Outer
Wire diameter 4.5 mm (0.177 in)
Outer coil diameter 38.0 mm (1.496 in)
Free length
Standard 45.9 mm (1.807 in)
Limit 43.6 mm (1.717 in)
Fitting length 40.3 mm (1.587 in)
Fitting load
Standard 18.0 L 0.9 Kg (39.7 L 2.0 lb)
Limit 14.5 Kg (32.0 lb)
D430 Diesel Engine 59 Technical Data

1. ENGINE
Valve spring-Inner
Wire diameter 3.5 mm (0.138 in)
Outer coil diameter 27.5 mm (1.083 in)
Free length
Limit 42.8 mm (1.685 in)
Fitting length 37.8 mm (1.486 in)
Fitting load
Standard 12.7 L 0.6 Kg (28.0 L 1.3 lb)
Limit 10.3 Kg (22.7 lb)
Rocker arm
Bore in rocker arm 18.258~18.278 mm
(0.7188~0.7196 in)
Rocker arm bushing
Inner diameter 15.876~15.896 mm
(0.6250~0.6258 in)
Outer diameter 18.288~18.309 mm
(0.7200~0.7208 in)
Rocker arm shaft
(0.6234~0.6244 in)
Clearance in rocker arm
Standard 0.016~0.061 mm
(0.0006~0.0024 in)
Limit 0.07 mm (0.003 in)
Tappet
Outer diameter
14.244~14.249 mm
(0.5600~0.5610 in)
Bore in cylinder block 14.288~14.319 mm
(0.5625~0.5637 in)
Clearance in cylinder block bore
(0.0015~0.0037 in)
Limit 0.10 mm (0.004 in)
Camshaft
Journal diameter (Standard)
No.1 (Front) 51.910~51,940 mm
(2.0437~2.0449 in)
No.2 (Center) 51.660~51.690 mm
(2.0339~2.0351 in)
No.3 (Rear) 51.410~51.440 mm
(2.0240~2.0252 in)
No.4 51.160~51.190 mm
(2.0142~2.0154 in)
Wear limit of journal 0.008 mm (0.0003 in)
Cam elevation
Inlet
Limit 42.485 mm (1.6728 in)
Exhaust
Limit 42.485 mm (1.6728 in)
Camshaft end play
(0.001~0.007 in)
Limit 0.30 mm (0.012 in)
Camshaft run-out
Limit 0.080 mm (0.0031 in)

1. ENGINE
Camshaft support bore
Bore in cylinder block
No.1 (Front) 52.000~52.030 mm
(2.0473~2.0485 in)
No.2 (Center) 51.750~51.780 mm
(2.0374~2.0386 in)
No. 3 (Rear) 51.500~51.530 mm
(2.0276~2.0288 in)
No.4 51.250~51.280 mm
(2.0177~2.0189 in)
Camshaft to bore clearance
New 0.060~0.120 mm
(0.0024~0.0047 in)
Limit 0.145 mm
(0.0057 in)
Backlash between gears
(0.004~0.008 in)
Limit 0.30 mm (0.012 in)
Idle gear
Bore in idle gear boss 48.000~48.025 mm
(1.8898~1.8908 in)
End play 0.15~0.30 mm
(0.006~0.012 in)
Idle gear bushing
(1.7327~1.7336 in)
(1.8915~1.8925 in)
Idle gear spindle
Length 28.95~29.05 mm
(1.1398~1.1437 in)
(1.729~1.731 in)
Spindle and bushing clearance
(0.0013~0.0033 in)
Limit 0.15 mm (0.006 in)
Valve timing
Inlet valve opens 14 BTDC
Inlet valve closes 44 ABDC
Exhaust valve opens 48 BBDC
Exhaust valve closes 10 ATDC
Connecting rod
Permissible bend or twist 0.05 mm per 100 mm
(0.0020 in per 3.937 in)
Side clearance
standard 0.239~0.330 m
(0.0094~0.0130 in)
Limit 0.4 mm (0.0157 in)
Small end bushing
(1.2505~1.2515 in)
(1.3785~1.3800 in)
Bore in connecting rod 34.919~34.955 mm
(1.3748~1.3762 in)
Piston pin and small end bushing
clearance
(0.0006~0.0017 in)
Limit 0.05 mm (0.0020 in)

1. ENGINE
Connecting rod bearing
Bearing clearance
(0.0014~0.0030 in)
Limit 0.1 mm (0.004 in)
Available undersize bearing 0.254 mm (0.010 in)
0.508 mm (0.020 in)
0.762 mm (0.030 in)
Piston
Diameter
94.825~94.851 mm
(3.7333~3.7344 in)
Measure at 90 to the piston pin
bore axis and 58.4 mm (2.299 in) below
the piston top.
Piston pin hole bore
31.737~31.750 mm
(1.2495~1.2500 in)
Ring groove width
Top 2.433~2.459 mm
(0.0958~0.0968 in)
Second 2.433~2.459 mm
(0.0958~0.0968 in)
Oil 4.813~4.839 mm
(0.1895~0.1905 in)
Piston and cylinder clearance 0.817~0.212 mm
(0.0074~0.0084 in)
Piston ring
Width
Top
3.7~3.9 mm
(0.1457~0.1535 in)
Second
3.7~3.9 mm
(0.1457~0.1535 in)
Oil
2.75~3.15 mm
(0.1083~0.1240 in)
Expander oil ring outer diameter 2.55~2.65 mm
(0.1004~0.1043 in)
Thickness
Top 2.363~2.383 mm
(0.0930~0.0938 in)
Second
2.363~2.383 mm
(0.0930~0.0938 in)
Oil
4.743~4.763 mm
(0.1867~0.1875 in)
Side clearance
Top
0.050~0.096 mm
(0.0020~0.0038 in)
Second
0.050~0.096 mm
(0.0020~0.0038 in)
Oil
0.050~0.096 mm
(0.0020~0.0038 in)
Side clearance limit 0.3 mm(0.0118 in)

1. ENGINE
End gap
Top
0.4~0.6 mm
(0.0157~0.0236 in)
Second
0.4~0.6 mm
(0.0157~0.0236 in)
Oil
0.4~0.53 mm
(0.0157~0.0209 in)
End gap limit 1.5 mm (0.0591 in)

Ring tension
Top 1.85 L 0.3 Kg (4.08 L 0.66 lb)
Second 1.85 L 0.3 Kg (4.08 L 0.66 lb)
Oil 4.47 L 0.45 Kg (9.85 L 0.99 lb)
Expander oil ring 4.5 L 0.45 Kg (9.92 L 0.99 lb)
Piston pin
Diameter 31.744~31.749 mm
(1.2498~1.2500 in)
Clearance between piston and pin -0.012~0.006 mm
(-0.0005~0.0002 in)
Crankshaft
Main journal diameter
Standard
75.812~75.825 mm
(2.9848~2.9853 in)
Wear limit 0.05 mm (0.0020 in)

Crankpin diameter
Standard
61.112~61.125 mm
(2.4060~2.4065 in)
Wear limit 0.05 mm (0.0020 in)

Crankshaft end play
(0.0055~0.0154 in)
Limit 0.40 mm (0.0157 in)
Crankshaft run-out
Limit 0.05 mm (0.0020 in)
Main bearing
Bearing clearance
(0.0023~0.0035 in)
Limit 0.12 mm (0.0047 in)
Available undersize bearing
Undersize bearing 0.254 mm (0.010 in)
0.508 mm (0.020 in)
0.762 mm (0.030 in)
Main journal processing
diameter 0.762 mm (0.030 in)
Cylinder block
Bore
98.500~98.526 mm
(3.8780~3.8790 in)

1. ENGINE
Wear limit of bore 0.20 mm (0.0079 in)
Warpage limit 0.10 mm (0.0039 in)
Liner protrusion above cylinder 0.659~0.790 mm
block (0.0259~0.0311 in)
Cylinder liner
Length
191.092~191.350 mm
(7.5234~7.5336 in)
Inner diameter
95.025~95.050 mm
(3.7412~3.7422 in)
Outer diameter
98.551~98.576 mm
(3.8800~3.8810 in)
Flywheel
Run-out
Limit 0.20 mm (0.0079 in)
2. LUBRICATING SYSTEM
Oil pressure 3.6 Kg/cm2(51 lb/in2) and more
at 3600rpm
Safe minimum pressure at idle 0.3 L 0.1 Kg/cm2
(4.3 L 1.4 lb/in2)
Oil pump
Outer rotor and body clearance
(0.006~0.008 in)
Limit 0.30 mm (0.012 in)
Clearance between rotor lobes
(0.002~0.008 in)
Limit 0.30 mm (0.012 in)
Rotor end float
(0.002~0.004 in)
Limit 0.15 mm (0.006 in)
Clearance between pump shaft and
body 0.10 mm (0.004 in)
3. COOLING SYSTEM
Fan belt tension (Slack)
New belt 10~13 mm (0.39~0.51 in)
Used belt 13~16 mm (0.51~0.63 in)
Fan
Fan diameter 430 L 2 mm (16.93 L 0.08 in)
Number of blades
6
Ratio of crankshaft and fan
Thermostat 1 : 1.25
Type Wax pellet
Starts to open 82 L 1.5C (180 L 2.7F)
Fully opens at 95C (203F)
Lift 8 mm (0.315 in) or more

4. FUEL SYSTEM
Idle speed
1100 L 25
Fuel injection pump
Type Distributor type
Plunger diameter 10.0 mm (0.393 in)
Cm lift 2.2 mm (0.08 in)
Governor Mechanical type, All speed
Injection timing 0 TDC
Injection nozzle Type
Throttle type
Number of nozzle and diameter 1-0.8 mm (0.031 in)
Injection pressure 135+5
-0
Kg/cm2 (1920+71
-0
lb/in2)
Glow plug
Type Sheathed type
Preheating method Pre-combustion chamber preheating
5. ELECTRICAL SYSTEM
Alternator
Ground polarity Negative
No load test
Voltage 14 volt
Current 0 amp.
Revolution 950 rpm or less
Load test
Voltage 13.5 volt
Current 56 amp.
Revolution 5000 rpm or less
Starting motor
Lock test
Voltage 3.0 volt
Current 1200 amp. or less
Torque 3.5 kgm
Free running test

Voltage 11 volt
Current 200 amp. or less
Speed 3000 rpm or more

SB4036E00
Jul. 2000
Vehicle Systems
1550XL(DSL702)
1760XL(DSL802)
2060XL(DSL902)
WARNING
in injury or death.
publication.
available.
1
Index
Specifications
Dimensional & Performance Specifications ..............5
Service Schedule ....................................................12
Special Torque.........................................................13
Disassembly & Assembly

Quick-Tach...............................................................16
Bucket Cylinder .......................................................19
Boom Lock & Boom Cylinder ..................................22
Boom Assembly & Boom Stopper ...........................22
Canopy ....................................................................24
Drive Control System ..............................................26
Hydraulic Control System........................................27
Parking Brake System.............................................28
Throttle Control........................................................30
Chain Drive System.................................................31
Hydrostatic Pump ....................................................35
Control Valve ...........................................................36
Oil Filter ...................................................................36
Muffer ......................................................................37
Radiator & Oil Cooler ..............................................37
Flexible Coupling Assembly ....................................39
Wheel & Tire............................................................40
Vehicle Systems 3 Index

Specifications
Dimensional & Performance Specifications
Dimensional Specifications
R S
Q
Q R
T G F S T G
F
O O
K K
M
A M
A
B B
L L C
C
I
I N
J U
N J U H
P
P H E
E D
D
1550XL(DSL702), 2060XL(DSL902) 1760XL(DSL802)
IGAT001I
Spec. Spec.
Item Unit 1550XL 1760XL 2060XL Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902) (DSL702) (DSL802) (DSL902)
Overall Height Dumping
A. Fully Raised in(mm) 145.8(3704) 152.8(3880) 156.2(3967) K. Dump Angle deg 45 40 44
B. To Hinge Pin in(mm) 114.8(2915) 119.1(3026) 122(3100) L. Dump Height in(mm) 87.6(2224) 91.5(2323) 93.6(2378)
C. To Canopy in(mm) 76.9(1954) 79.3(2015) 80.1(2035) Reach
Overall Length M.Fully Raised in(mm) 25.4(645) 22.5(572) 27.3(694)
D. With Bucket in(mm) 126.3(3208) 125.1(3177) 126.0(3200) Rollback
E. Less Bucket in(mm) 99.3(2521) 987(2508) <
------- N. Max. at Ground deg 25 26 <
-------
Overall Width O. Max. Fully Raised deg 94 98 94
F. With Bucket in(mm) 63.4(1611) 67.5(1714) 70(1778) Digging
G. Less Bucket in(mm) 58.5(1486) 65.4(1662) <
------- P. Digging Depth in(mm) 0.6(16) 0.4(10) <
-------
Others Clearance (Circle)
H. Wheel Base in(mm) 42.3(1074.8) 41.8(1061) <
------- Q. Front, Less Bucket in(mm) 51.3(1304) 45.1(1146) <
-------
I. Height of S.I.P. in(mm) 35.8(908.5) 40.9(1040) <
------- R. Front, With Bucket in(mm) 74.8(1901) 74.1(1883) 76.3(1939)
J. Ground Clearance in(mm) 7.5(190) 8.4(218) <
------- S. Rear in(mm) 63.3(1607) 62.7(1593) 61.8(1570)
T. Tread in(mm) 48.1(1222) 53.1(1350) <
-------
U. Departure Angle deg 26 28 <
-------

Definitions : (Daewoo Skid Steer Loader) Maximum Rollback (O) - Fully Raised - The angle
in degrees from the bucket cutting edge level position
Refer to sketches on previous page. to the maximum rollback position.
Overall Operating Height (A) - Fully Raised - The Digging Depth (P) - The vertical distance in inches
vertical distance in inches (millimeters) from the (millimeters) from the ground to the bottom of the
ground to the highest point attainable. bucket cutting edge at the lowest position with the
bucket cutting edge horizontal.
Height to Hinge Pin (B) - Fully Raised - The
vertical distance in inches (millimeters) from the Loader Clearance Circle (Q) - Front No
ground to the centerline of the bucket hinge pin. Attachment - The smallest diameter measured in
inches (millimeters) that the outermost front point on
Overall Height (C) - The vertical distance in inches
the machine will describe measured from a point
(millimeters) from the ground to the highest point on
located at 1/2 the wheelbase (H) and 1/2 the overall
the unit with the bucket on the ground.
width (G) of the machine.
Overall Length (D) - The horizontal distance in
Loader Clearance Circle (R) - Front with Standard
inches (millimeters) with the bucket on the ground
Attachment - The smallest diameter measured in
and level, measured from the foremost point of the
inches (millimeters) that the outermost front point on
bucket cutting edge to the rear most point of the
the machine will describe measured from a point
machine.
located at 1/2 the wheelbase (H) and 1/2 the overall
Overall Length (E) - Without Bucket - The width (G) of the machine.
horizontal distance in inches (millimeters) from the
Loader Clearance Circle (S) - Rear - The smallest
furthest rearward to the furthest point forward.
diameter measured in inches (millimeters) that the
Bucket Width (F) - The maximum outside width in outermost rear point on the machine will describe
inches (millimeters) of the bucket specified. measured from a point located at 1/2 the wheelbase
Overall Width (G) - The maximum outside width in (H) and 1/2 the overall width (G) of the machine.
inches (millimeters) of the machine specified exclusive Tread or Track Gauge (T) - The transverse distance
of bucket. in inches (millimeters) between the centerlines of the
Wheelbase (H) - The vertical distance in inches tires or sprockets. If the front and rear are different,
(millimeters) from the center of the front wheel or both must be specified.
idler to the center of the rear wheel or sprocket. Angle of Departure (U) - The angle in degrees
Height to S.I.P. (I) - The vertical distance in inches taken from a line drawn from the lowest and rear
(millimeters) from the ground to the Seat Index Point. most portion of the rear overhang to the rear bottom
face of the rear tire to the ground.
Ground Clearance (J) - The minimum vertical
distance in inches (millimeters) from the ground to
the lowest point on the machine between the tires or
tracks with the lift arm raised.
Dump Angle (K) - The maximum angle in degrees
that the longest flat section of the inside bottom of
the bucket will rotate below horizontal with the bucket
hinge pin at maximum height.
Dump Height (L) - The vertical distance in inches
(millimeters) from the ground to the lowest point of
the cutting edge with the bucket hinge pin at
maximum height and the bucket at a 45 dump
angle. The angle is less than 45, specify angle.
Reach (M) at Maximum Height - The horizontal
distance in inches (millimeters) from the foremost
point on the machine (including tires, tracks, or
loader frame) to the front most point on the bucket
cutting edge at a 45 angle with the bucket hinge pin
at maximum height. Specify angles less than 45.
Maximum Rollback (N) - at Ground - Maximum
rollback angle in degrees without movement of the lift
arm.

Operational Specification (Per SAE J732 Feb 80)
Performance
Spec.
Item Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Rated Capacity lb(kg) 1500 (680) 1700(771) 2000 (907)
Bucket Capacity ft3(m3) 11.9 (0.34) 13.5(0.38) 14.1 (0.40)
Operating Weight lb(kg) 5849 (2653) 6594(2991) 6777 (3074)
Tipping Load lb(kg) 3946 (1790) 3593(1630) 4647 (2108)
Hydraulic Lifting Capacity lb(kg) 4465 (2025) 5732(2600) 4718 (2140)
Break Out Force - Bucket lb(kg) 2910 (1320) 3770(1710) 3770 (1710)
- Boom lb(kg) 3285 (1490) 3467(2480) 5194 (2356)
Raising Time - W/O Load sec 5.1 3.7 4.6
- W/ Load sec 5.3 3.8 4.7
Lower Time - W/O Load sec 4.4 3.5 5.1
- W/ Load sec 3.8 3.1 4.3
Boom Dump Time - W/O Load sec 3.3 2.3 2.3
- W/ Load sec 2.3 2.2 2.1
Rollback Time - W/O Load sec 1.9 1.8 1.8
- W/ Load sec 2.0 2.2 2.3
Drawbar Pull - W/O Load lb(kg) 4923 (2233) 5291(2400) 5282 (2396)
- W/ Load lb(kg) 5908 (2680) 6305(2860) 6499 (2948)
Forward mph(km/h) 6.7 (10.8) 6.8(11.0) 6.77 (10.9)
Travel Speed
Reverse mph(km/h) 6.7 (10.8) 6.8(11.0) 6.77 (10.9)
Power Unit
Spec.
(DSL702) (DSL802) (DSL902)
Make - DAEWOO <
------- <
-------
Model - D427 D430 <
-------
Type of Fuel - Diesel <
------- <
-------
Cooling Medium - Water <
------- <
-------
No. of Cylinders ea 4 <
------- <
-------
Displacement in3(cc) 164.8 (2701) 181.7 (2977) <
-------
Bore Size in(mm) 3.62 (92.0) 3.74 (95) <
-------
Stroke in(mm) 4.0 (101.6) 4.13 (105) <
-------
Horsepower Net hp(ps)/rpm 50.2 (51.0)/2400 62.6 (63.5)/2500 <
-------
High Idle rpm 2600 50 265050 <
-------
Low Idle rpm 1100 25 <
------- <
-------
Torque ft.lb(kg.m)/rpm 115.8 (16.0) 130.2 (18.0) <
-------
2000 1800 <
-------
Torque Rise % 3.0 8.6 <
-------
Lubrication - Full Flow <
------- <
-------

Final Drive Components
Spec.
(DSL702) (DSL802) (DSL902)
Chain - 2 Chain with 2 Chain with
Super80HT & RS 100HT & <
-------
Super80HT RS 100HT
No. of Teeth
Drive Sprocket (Motor) ea 12 10 <
-------
Drive Sprocket (Axle) ea 32 28 <
-------
Ratio 2.67 2.8 <
-------
Tire
Type - Flotation- <
------- <
-------
Tubeless
Size - 10-16.5, 8PR 12-16.5, 8PR <
-------
2
Pressure psi(kg/cm ) 57 (4.0) 40(2.8) <
-------
Wheel
Size - 8.25 X 16.5 9.75 X 16.5 <
-------
Hole x Pitch Circle Diameter - 8 X 8 <
------- <
-------
Hydrostatic Transmission Pump
Spec.
(DSL702) (DSL802) (DSL902)
Type - Piston, Variable
Displacement <
------- <
-------
(Manual)
Max. Displacement in3(cc)/rev 2.68 (44) <
------- <
-------
Relief Setting Pressure bar (psi) 250 (3555) 280(4061) <
-------
Internal Charge Pump - None <
------- <
-------
Rotation - clockwise <
------- <
-------
Swash Plate Operating Angle deg 16 <
------- <
-------
Mounting - SAE 2 Bolt B Mount <
------- <
-------
ANSI B92.1-1970
Shaft - Class No.5 <
------- <
-------
30X15X16/32
Standard Pump
Flow (Max) LPM(GPM) 60 (16) 77.7(20.5) <
-------
Relief Pressure (max) psi 300035 <
------- <
-------
at charge pump (2072.4bar) <
------- <
-------
High Flow Option Pump
Flow (max) LPM(GPM) 101(26.7) 131.5(34.8) <
-------
Relief Pressure (max) psi 300035 <
------- <
-------
at charge pump (2072.4bar) <
------- <
-------

Hydraulic System
Spec.
(DSL702) (DSL802) (DSL902)
Motor
Type - Orbit, Fixed <
------- <
-------
Displacement
Bi-rotational
Displacement in3(cc)/rev 32.04 (523.6) <
------- <
-------
Mounting - SAE 4 Bolt B Mount <
------- <
-------
Spline Shaft
Pump
Type - Gear <
------- <
-------
Capacity in3(cc)/rev 1.47 (23.0) *1.92(31.5) <
-------
Max. Pressure bar(psi) 230 (3,335) <
------- <
-------
Max. Speed rpm 3,000 <
------- <
-------
Mounting - SAE 2 Bolt A Mount <
------- <
-------
Shaft SAE Spline Shaft <
------- <
-------
Rotation - Clockwise <
------- <
-------
Control Valve
No. of Spool - 3 <
------- <
-------
Relief Setting Pressure psi 2840 (+70) <
------- <
-------
(set by valve supplier) (195 (+5) bar)
Circuit - Series on Lift Float <
------- <
-------
Function with Detent
Series on Tilt
Series on Auxiliary
With Electric
Detent (thumb control)
* European Truck (CE Area) : 1.77 (29.0) in3 (cc)/rev
Spec.
(DSL702) (DSL802) (DSL902)
Boom Cylinder
Type - Single Rod, <
------- <
-------
Double Acting
Number ea. 2 <
------- <
-------
Cylinder Bore in(mm) 2.17 (55) 2.36(60) <
-------
Cylinder Rod in(mm) 1.58 (40) 1.50(38) 1.57(40)
Stroke in(mm) 39.2 (996) 33.5(850) 42.0(1065)
Mounting - Single Crest Crevice <
------- <
-------
Plating on Rod - Hard Chrome w/15-50 <
------- <
-------
Micron Thickness
Bucket Cylinder
Type - Single Rod, Double Acting <
------- <
-------
Number ea. 2 <
------- <
-------
Cylinder Bore in(mm) 2.36 (60) <
------- <
-------
Cylinder Rod in(mm) 1.10 (28) 1.50(38) 1.57(40)
Stroke in(mm) 14.45 (367) 20.0(507) <
-------
Mounting - Single Crest Crevice <
------- <
-------
Plating on Rod - Hard Chrome w/15-50 <
------- <
-------
Micron Thickness
HRC 52-60 Hardness

Spec.
(DSL702) (DSL802) (DSL902)
Hydraulic Filter
Type - Full Flow Spin-On <
------- <
-------
Filter Rating - 13 Micron Beta Rating <
------- <
-------
of 20
Rated Flow I(gal)/min 132.5 (35) <
------- <
-------
By-Pass Valve Closing PR50 PSID <
------- <
-------
( Normally Open Type )
Hydraulic Lines and Fittings

Type - O-Ring Face Seal <
------- <
-------
Fitting ( SAEJ1453 )
Thread - Unified Thread is <
------- <
-------
Standard
Medium Pressure Line - SAE 100R1 Hose <
------- <
-------
( SAE J517 )
Hydraulic High SAE 100R2 Hose <
------- <
-------
Pressure Line - ( SAEJ517 )
HST High SAE 100R12 Hose <
------- <
-------
Pressure Line - ( SAE J517 )
Electrical Components
Spec.
(DSL702) (DSL802) (DSL902)
Alternator - 12V - 60A <
------- <
-------
Battery - 12V-100AH, 700CCA <
------- <
-------
Starter - 12V - 2.5KW <
------- <
-------
Lighting -
Head Lamps each 2 <
------- <
-------
Rear Lamps each 1 <
------- <
-------

Instrument Features Seat
Item Unit Spec Item Unit Spec

Instrument Panel (A) Standard Cover Material - Vinyl, Black
-Buzzer alarm - Cushion Material - Urethane Foam
-Stop (Red) Warning Fore/Aft Adjustment in(mm) 3 (76)
(Yellow) Warning -
-Engine Oil Pressure
-Engine Water
Temperature each
-Battery Voltage each
-HST Charge Pressure
-HST Oil Temperature
-HST Filter
Instrument Panel (B) Standard
-Fuel Meter
-Hour Meter
-Park Brake Monitor
-Pre-Heater Monitor
Key Switch
Light Switch
Fuses
Fluid Capacities & Specifications
Spec.
Item Specifications Unit 1550XL 1760XL 2060XL
(DSL702) (DSL802) (DSL902)
Fuel Tank, Max #2 Diesel recommended for Ambient gal(liter) 14.3(54) 21.1(80) 18.2(69)
Temp above 40 deg. F
#1 Diesel recommended for Ambient
Temp below 40 deg. F
Hydraulic Max Oil Tank SAE 10W20CD; Taxaco TDH; Mobil gal(liter) 8.0 (30) 9.2(35) 11.9(45)
Hydraulic System Capacity Fluid 423; Chevron Tractor Hydraulic gal(liter) 11.1 (42) 12.7(48) <
-------
Fluid; G Automatic Fluids meeting
Caterpillar TO-2 or Allison C3 standards
Chain Case Oil API CC or CD SAE 10W30 gal(liter) 5.9 (22.5) 6.3(24) <
-------
Cooling Fluid Recommended mixture is 50/50 gal(liter) 1.8 (6.9) <
------- <
-------
ethylene glycol and water
Engine Lubrication - w/filter API CC or CD SAE 10W30 for gal(liter) 2.1 (8) <
------- <
-------
w/o filter Ambient Temp above -4 deg. F gal(liter) 2.0 (7.6) <
------- <
-------
API CC or CD SAE 5W30 for
Ambient Temp below -4 deg. F

Service Schedule
This maintenance schedule was designed for you to can lead to premature wear and component failure.
receive optimum performance and reliability from your Adverse conditions (e.g., excessive dust or corrosive
SKID STEER LOADER under typical working conditions. vapors, etc.) may require more frequent service.
Failure to follow a scheduled maintenance program
SERVICE SCHEDULE HOURS
ITEM every every every every every every

SERVICE REQUIRED day 50 100 250 500 1000
Check the oil level and fill oil as needed.
Engine Oil Replace the oil. (First time)
Replace the oil filter. (First time)
Clean and replace fuel filter element.
Fuel System
Drain water from the water separator (First time)
Engine Check cooling level and add as needed.
Cooling Check for leaks (First time)
System Check and adjust the tension of fan belt

Check the indicator.
(Clean or replace the outer element when the red ring shows.)
Clean the dust cover.
Air Cleaner
Replace the outer element.
(Replace the inner element every third time the outer
element is replaced).
Tires Check air pressure and for damage to tires.
Wheel Nuts Tighten to correct torque if loose.
Seat Belt Check the condition of seat belt.
Seat Bar Check the seat bar for correct operation.
Safety Signs Check for damaged signs and replace if needed.
Pivots Grease pivots as needed.
Check the water level and battery cables for corrosion.
Battery Check whether battery cables are tightly clamped.
Check covers.
Check the oil level and add as needed.
Hydraulic Fluid (First time)
Replace the fluid
Hydraulic Check for damage and leaks and replace as needed.
Tubes and Hoses
Chain Case Oil Replace the oil.
(First time)
Hydraulic Filter Replace the filter.
Hydraulic Replace the hydraulic oil.
Oil Tank
Spark Arrestor Clean the spark chamber
for Muffler
(First time)
Suction filter in tank Inspect and clean or change
Air breather cap Inspect and clean or change

Special Torque
Mounting gp-E/G & HST Pump
Fill MOS2 Grease on Hub-Spline
105 20 N.m
240 40 N.m
55 10 N.m
28 7 N.m 55 10 N.m
USE EXISTING HARDWARD
SUPPLIED WITH ENGINE
USE EXSISTING HARDWARD
SUPPLIED WITH ENGINE
100 30 N.m
& APPLY LOCTITE (NO.271)
55 1 N.m
2 EACH, SIDE
AS REQ'D

Canopy gp
54 ~ 68 N.m
Mount gp-Covers
15-25N.m 15-25N.m
Loctite #592
15-25N.m
Loctite #592
Apply sealant on all gaskets

Chain Drive Group
Initial Torque 200 20 N.m, and loosen bolt,

then retorgue 50 5 N.m(Loctite #271)
125 15N.m
(Loctite #243)
Initial Torque 200 20 N.m, and loosen bolt, Loctite #2C(gasket sealant)
then retorgue 50 5 N.m(Loctite #271) on the frange of Motor
Loctite #2C(gasket sealant) Loctite #243

on the frange of Housing

Disassembly & Assembly Disassembly & Assemble Quick-Tach
Start By :
Quick - Tach a. Remove the bucket.
Remove & Install Quick-Tach b. Remove the Quick-Tach.

1760XL(DSL802), 2060XL(DSL902)
Start By : 1 2
a. Remove the bucket.
3
IGAT007P
4
6 5
5 2 3
IGAT005P
1. Position the Quick-Tach (1) so that unexpected

movement does not occur when disassembling.
2. Remove the bolts and washers (2) and boom pin

assemblies (3).
4
3. Support Quick-Tach (1) with a hoist and remove IGAT008P
the bolts and washers (4), pin assemblies (5).
1. Remove cotter pins (1), nuts (2) and washers (3),

levers (4).
2. Remove bolts (5) and covers (6).
IGAT006P
4. Hoist the Quick-Tach and remove it.
NOTE : Install the Quick-Tach in reverse order of

removal.
End By :
a. Install the bucket.
Vehicle Systems 16 Disassembly & Assembly

Remove the Quick-Tach
1550XL(DSL702)
8 WARNING
Read the Operators Manual and decals on the

7 machine before operating or servicing the
machine. Follow all warnings and instructions
when making repairs, adjustments, or servicing.
Check for correct function after repairs,
IGAT009P
adjustments, or servicing. Failure to follow
instructions can cause injury or death.
3. Remove pins (7) and snap-ring (8).
4. Remove whole parts.

WARNING
NOTE : Assembly is the reverse order of
disassembly. Position the Quick-Tach so that unexpected
movement does not occur.
NOTE : When tightening bolts (5), apply Loctite
No.272.
End By :
a. Install the Quick-Tach.
b. Install the bucket.
1. Tilt the Quick-Tach forward in order to access the

bucket hinge pin mounting bolts and boom pin
mounting bolts.
2. Remove the boom pin mounting bolts and pins

from the Quick-Tach.
3. Rotate the Quick-Tach forward until the top of the

Quick-Tach reaches the ground. Remove the
bucket cylinder pin mounting bolts and hinge pins
from the boom. The Quick-Tach can now be
removed.

Disassemble the lever assembly.
4 12,13
19
6,17
5 7
8,14,15 3 20
1
18
2
9,10,11
21
16
1 WELDMENT 1. Remove the cotter pin, washer, and clevis pin at the
2 ROD AS lever assembly end.
3 WASHER 2. Remove the cotter pin, washer, and clevis pin from the
4 WASHER rod end.
5 NUT ; LOCK 3. Remove the spring pin and separate the wedge, spring,
6 PIN ; COTTER and rod.
7 WASHER
8 PIN
9 PIN ; GUIDE
10 PIN ; SPLIT
11 WASHER ; HARD
12 HANDLE-L.H.
13 HANDLE-R.H.
14 WASHER ; PLAIN
15 PIN ; SPLIT
16 WEDGE
17 NUT
18 SPRING
19 BUSHING
20 WASHER ; HARD
21 NIPPLE ; GREASE

Reassemble and install the Quick-Tach. Bucket Cylinder
1. Install the upper and lower pads on the weldment
assembly. Remove & Install Bucket Cylinder
2. Assemble the lever assembly: wedge, spring, and Start By :
rod held in place by the spring pin; clevis pin,
washer, and cotter pin at both the rod end and a. Remove the bucket.
lever assembly end.
b. Remove the Quick-Tach.
3. Assemble and install the handle assemblies:
washers and bushings, castle nut and cotter pin.
Mount the plates with 4 bolts, each side. Install the
bucket cylinder hinge pins and pin mounting bolts.
Install the boom pins and pin mounting bolts.
Adjust the Quick-Tach lever spring washers.
IGAT010P
1. Hoist the boom (1) so that bucket cylinder hidden

end can be easily accessed from behind of the
boom.
1. Remove the cotter pin.
2. Adjust the castle nut in or out against the spring 2

washers as necessary to obtain proper tension.
Torque specification: 2 - 2.7 Nm. You should be
able to move the handle with reasonable force, but
it should be tight enough to prevent loosening
under operation.
IGAT011P
3. Reinstall the cotter pin.

2. Hoist the bucket cylinder (2) or hold the bucket
cylinder (2) by another person for the bucket
cylinder not to be dropped freely.

3
4
7
IGAT012P IGAT015P
3. Remove the bolts and cover (4).
8
5
IGAT016P
IGAT013P
5. Disassemble the hose-RH (7) and the hose-LH
(8). Remove the bucket cylinder (2).
6 NOTE : The following steps are for installation of the

bucket cylinder.
4. Remove bolts and washer (5), pin assembly (6).

IGAT010P
6. Hoist the boom (1) so that bucket cylinder hidden

end can be easily accessed from behind of the
boom.

6
IGAT011P IGAT013P
7. Hoist the bucket cylinder (2) and put the bucket 9. Install the pin assembly (6) and bolt and washer
cylinder (2) in position on inside of the boom. (5).
IGAT015P IGAT012P
10. Install cover (4) and bolts (3).
End By :
8 a. Install the Quick-Tach.
b. Install the bucket.
IGAT016P
8. Assemble the hose-RH (7) and the hose-LH (8).

Boom Lock & Boom Cylinder Boom Assembly & Boom
Stopper
4 3
Remove & Install Boom Assembly

Start By :
a. Remove the bucket.
1 b. Remove the quick-Tach.

2
c. Remove the bucket cylinders.
IGAT017P
d. Remove the boom cylinders.
1. Remove the bolt and washer (1), pin assembly (2).
2. Remove knob (3) and lock assembly (4) (L.H.

only).
5
1
IGAT010P
1. Hoist the boom assembly.

6
IGAT018P 8 3
3. Remove the hoses (5). 2
4. Remove bolt and washer (6), pin assembly (7).
5. Remove boom cylinder (8) with a hoist.
NOTE : Install is the reverse order of removal. IGAT019P

1760XL(DSL802)
2 3
1550XL(DSL702), 2060XL(DSL902)
2. Remove the bolts and washers (2), boom hinge

pin assemblies (3) at both sides.

Adjustment of Boom Stopper
4
Spacer (2.3t)
Plate-stopper (6t)
IGAT020P Boom
Rubber
1760XL(DSL802)
Contacting surface of Frame
IGAT022I
1. Put each 1 plate-stopper (1) with rubber (3) on

both sides when boom is raised.
1550XL(DSL702), 2060XL(DSL902)
2. Pull down the boom fully.
3. Remove the related line hoses (RH.LH).
DANGER : When working on a machine with the
boom up, always engage the boom lock.
3. Check the gap between the plate - stopper (1) and

contacting surface of frame
4. Raise the boom.
5. Put spacer (2) as required on the side of occuring

the gap in order to have even contacting surface
of frame in both sides (L.H., R.H.) when boom is
down fully.
1550XL(DSL702), 2060XL(DSL902)
End By :
4. Remove the boom assembly with a hoist.
a. Install the boom cylinders.
NOTE : Install is the reverse order of removal.
b. Install the bucket cylinders.
c. Install the Quick-Tach.
d. Install the bucket.
IGAT021P
NOTE : If needed, add or remove shims (5), to adjust

boom seating balance as following procedure.

Canopy
IGAT023P 4. Disconnect the wiring connector at the rear canopy

(R.H.).
1. Loosen both mounting bolts at the front corners of
the canopy. 2 3
1
5
4
IGAT027P
IGAT024P 5. Remove ring - retaining (2) and link (3), nuts (4),
then dis connect parking cable assembly (5).
2. Remove the stopper-plastic (1) from the canopy
hinge mtg. bracket (RH, LH).
IGAT025P
3. Suspend the canopy from a hoist with a sling and

then lift slowly all the way up until canopy is
stopped.

9 10 8
6. Remove the cotter pin (8) and pin, then loosen the
nut (9) and disconnect the cable assembly (10).
IGAT032I
NOTE : Install is the reverse order of the removal.

9. Adjust the Canopy Stops
The canopy tilt should be adjusted at the stops so

that the maximum lifting angle is approximately 65.
13 This can be measured with a protractor held along
the bottom surface of the canopy when it is tilted
back against the adjusted stops. Adjust the stop on
each side as follows :
11 12
IGAT030P
7. Remove the cotter pin (11) and pin (12) from the
gas spring (13) where it attaches to the frame.
IGAT033P
1) Loosen the jam nut.
2) Turn the stop in or out until the it measures 62-

64mm from the surface of the cross member.
14
3) Tighten the jam nut.
IGAT031P
4) Check the canopy lock. It should hold the canopy
8. Remove the bolt (14) and nut from the rear hinges. with out excessive play.
The canopy can be removed with the hoist.

Drive Control System
2
3
18-22 ft.lb
IGAT034I
Neutral Adjusting of Linkage
1) Set drive lever (1) should have a perpendicular on

the upper plate with the related assemble parts.
2) Adjust rod assy (4) to reach the neutral locations

of HST control shaft.
3) To get the straight travel, adjust the length of bolts

(2) as to contact with the uppler plate (3).

Hydraulic Control System
1
4
2 3
VIEW A-A
A A
2
IGAT035I
Adjustment Procedure
1) Raise the seatbar (1).
2) Adjust cable (2) location by nuts (3) in order to get

the pedals should be locked.
3) Assemble the cable (3) on the seat bar (1) using

the yoke (4).
4) Check whether pedals can be movable when the

seatbar is down.

Parking brake system
Removal
The parking brake system includes the brake lever
assembly, 2 brake assemblies (1 on each side), 2
cable assemblies (1 set of 2 on each side), and
associated linkages, springs, and fasteners.
Remove the cable assemblies
SPRING
DISC
BELL CRANK(C)
02-8
1) Remove the chain case covers to access the Remove the parking brake
parking brake assemblies.
2) Place the parking brake lever in the release
assemblies (each side).
position.
1) Remove the 2 springs at bellcrank assembly (C).
3) Remove the spring (A) to release tension.
2) Remove the bolts and washers that mount the
4) Remove the cotter pin and clevis pin from the
parking brake assembly to the frame and lift out
clevis at the brake lever.
the brake assembly.
5) Loosen the bolts and clamp that hold the cable
assem-blies to the frame bracket and slide the
cables out of the bracket.
6) Remove the cotter pin and clevis pin from the
clevis at the end of the cable assembly where it
attaches to the seat bar.
7) Unscrew the clevis from the end of the cable.
8) Disconnect the cable where it attaches to the
frame at (B).
9) Remove the remaining fasteners from the cable
and remove the cable assembly from the frame.

Installation and adjustment
m
76m
SPRING
DISC
BELL CRANK(C)
10) Move the brake lever to the engaged position.

WARNING 11) Adjust cable (E) until the brake is fully engaged.
12) Raise the seat bar. Move the brake lever to the
Function and adjustment of the parking brake should engaged position and verify that it is engaged.
be checked on a routine basis to maintain proper Then move the lever to the disengaged position.
operation at all times. Verify that the brake is still engaged.
13) Lower the seat bar. Engage the brake and verify
Install and adjust the parking brake cables, brake that it is engaged. Disengage the brake and
assembly and disk. verify that it is disengaged.
14) Adjust plate by nuts until the dimension between
1) With the forward chain case covers removed, feed plate and cable mtg.plate to 76mm for keeping
the cable assembly into the frame and install the the tension of cable.
fasteners. 15) Set the parking lever to the unlock position.
2) Screw the clevis onto the end of the cable at the 16) Adjust S/W location until S/W lever should
seat bar. contact with the plate.
3) Attach the clevis to the seat bar with the clevis pin 17) Tighten all nuts.
and cotter pin. 18) Seal the chain case covers with sealant and
4) Clamp the cable assembly to the frame. install the covers.
5) Attach the clevis to the parking brake lever.
6) Place the lever in the engaged position. Adjust the IMPORTANT : When replacing the chain case/parking
rod so that the top arm at the bellcrank is brake area covers, seal the covers with sealant.
approximately 133 from horizontal.
7) Place brake lever in the disengaged position.
8) Lower the canopy. Raise the seat bar. Adjust the
slack out of cable (E) and tighten the jam nuts.
9) Lower the seat bar. Adjust the cable assembly yoke so
that the brake disengages and there is a 10mm
clearance between the brake assembly lock and the disc.

Throttle Control
Adjustment of Throttle lever
E/G Support Bracket

Cable
Pin
Wire
Position "B"
Position "A" Nut
Stopper Bracket
Upper-Plate
1) Mount cable to E/G support bracket and upper-

plate.
2) Install pin to cable end and adjust to align with

throttle lever hole in full off position (position B).
When the throttle-plate of E/G is normal
position(low idle).
3) Adjust throttle lever to achieve full throttle (position

A) with the stopper bracket.
4) Insert wire into lever bole and tighten lever screw
5) Tighten nut on the lever to get proper lever force.

Chain Drive System
Before Removing any power train system
components (except when removing only wheels and
tires), drain the oil from the chain case. See the
Periodic Maintenance section of this manual for the Upper Cover Axle Cover
correct procedure.
The following procedures are presented in the order TOP VIEW

required to disassemble the entire power train
system.
Power train disassembly

Remove wheels and tires.
Retangular Cover
WARNING
Be sure the skid steer loader is on a level surface

before removing wheels and tires. 1) Raise and securely lock the canopy.
1) Lift the frame and support it with jack stands so 2) Remove the upper covers and gaskets on chain
that the tires are off the ground. case.
2) Support the tire and remove the hub nuts. 3) Remove the rectangular covers and gaskets on
the outside frame, 4 Axle covers on the in side
3) Lift the wheel and tire by the rim and pull it free of frame
the wheel studs.
Remove the parking brake components.
Remove the chain case covers.
Follow the procedures under Parking Brake System
Removal.
WARNING
Be sure the canopy lock is securely latched

whenever the canopy is in the raised position.
Failure to lock the canopy securely may result in
injury or death.

Remove the chain and motor sprocket
1) Turn the axle shaft until the chain connecting link

4 Bolts
is accessible from the outside chain case opening.
2) Pull out the cotter pins, remove the connecting

link, and remove the chain from the case.
3) Remove the motor sprocket
Remove the hydrostatic motor
3) Remove the 4 bolts that attach the motor flange to

WARNING the frame. Remove the motor.
4) Remove the hoses from the motor.

Do not attempt to disconnect hydraulic lines and
hoses when they are hot. Allow the system to
IMPORTANT : When repairing hydrostatic and
cool before disconnecting lines and hoses.
hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always use
caps and plugs on hoses, tube lines and ports to
1) Remove the uppler and floor plate. keep dirt out. Dirt can quickly damage the system.
2) Disconnect the motor lines and hoses from the

hydrostatic pump.

Remove the axle shaft.
1) Remove the bolt, washer and driven sprocket. CAUTION : Be sure to install the spacer between the
bearing cone and the sprocket.
2) Remove the axle. Bearing cones are removed
from inside the chain case. CAUTION : Check the direction of sprocket
installation. Install the front and rear drive sprockets
CAUTION : Check for damage to the oil seal when according to the marks you made on their faces at
you pull out the axle. disassembly.
3) Install the inside bearing cone, spacer, drive

sprocket, disc and washer. (Disc shall be installed
Power train installation on front axle)
For installation, refer to the photos and illustrations 4) Initially, tighten the bolt to 200 L 20 Nm (147 L
with the removal steps, above. 15 ftlbs.).
5) Rotate the axle 1-2 times to be sure there is no

Install the axle shaft binding.
1) Check the oil seal and the inside and outside 6) Back off the bolt until it will turn by hand.
bearing cups before installing the axle shaft.
Replace any of these components if damaged. 7) Retighten the bolt to 50 L 5 Nm (38 L 4 ftlbs.)
with Loctite#271.
2) Install the axle shaft with outside bearing cone in
place.
Take care not to damage the oil seal in the axle
housing.

Install the Hydrostatic Motor Install the chain case covers and
gaskets
1) Install the motor flange with Loctite #2C(gasket
sealant) to the frame with 4 bolts with 125 L 15 Install the gular rectan covers opposite the hydraulic
Nm torque, Loctite # 243. motor.
Tighten the bolts to 20 L 5 Nm (15 L 4 ftlb)
2) Install the lines and hoses to the hydraulic motor. Install the upper covers and Axle covers with
gaskets. Tighten the bolts to 20 L 5 Nm (15 L
3) Fit the motor sprocket over the motor shaft 4ftlb).
IMPORTANT : When replacing the chain

case/parking brake area covers, seal the covers with
Install the Chain sealant.
1) Through the chain case opening, fit the chain over

the sprockets. Install the Wheels and Tires
2) Install the connecting link, link plate, and cotter 1) Install the tire and wheel onto the axle.
pins.
2) Place a wedge under the tire to stabilize it and
fasten the hub nuts.
Chain Slack
3) Tighten the nuts to 146 L 20 Nm (108 L 15flbs).
4) Check tire inflation.

C D
1550XL 1760XL(DSL802)
(DSL702) 2060XL(DSL902)
2
4.0 kg/cm 2.8 kg/cm2
(57 psi) (40 psi)
A B
S
1760XL(DSL802)
1550XL(DSL702)
2060XL(DSL902)
A-B 17 ~ 26 18 ~ 27
S(mm)
C-D 26 ~ 39 24 ~ 36

Hydrostatic Pump
Remove & Install Hydrostatic Pump
2
Start By:
a. Raise and securely lock the canopy
b. Remove floor plate GP. 1
c. Remove bottom plate.

IGAT046P
2. Fasten hydrostatic pump (1) to the hoist and

maintain tension on the hoist to protect hydrostatic
pump from free dropping.
3. Remove two bolts and washers (2)from the

housing of E/G.
4. Pull the hydrostatic pump (1) out to the front

carefully.
5. Remove hydrostatic pump.
NOTE : The following steps are for installation of the

1. Disconnect all linkges and hose assy connected
hydrostatic pump.
to hydrostatic pump.
1. Fasten hydrostatic pump to the hoist
IGAT046P
9. Push hydrostatic pump (1) for the shaft of pump to

be put into the internal spline of the coupling with
MOS2 grease.
10. Install the bolts (2) and washer.
11. Apply Loctite 271 on the threads and torque the

bolts (2) to 105 L 20 Nm (77 L 15 lbft).

Oil Filter
Remove & Install Oil Filter
5. Install the support bracket and all related parts to

hydrostaic pump
End By : 1550XL(DSL702)
a. Connect all the linkage connected to hydrostatic

pump.
b. Install the bottom plate.
c. Install the floor plate GP.
d. Unlock and lower the canopy.
Control Valve
1760XL(DSL802), 2060XL(DSL902)
Remove & Install Hydraulic Control Valve
1. Disconnect hoses and wire.
2. Remove pressure switch.
3. Remove 2 mounting bolts and oil filter assembly.
1. Disconnect all tubes and hoses from control valve.
2. Remove three bolts (1).
3. Remove control valve (2).

Muffler Radiator & Oil Cooler
Remove & Install Muffler Remove And Install Radiator & Oil Cooler
1. Drain oil and cooling water.
1 1
IGAT058P
1. Remove 4 bolts and washers (1) from frame.
1760XL(DSL802)
2 3
1
1550XL(DSL702), 2060XL(DSL902)
2. Remove nuts (2) and bolts (3). 2. Remove bolts and nuts, washers (1) at both sides.
4
5
3
2
6
IGAT059P
1760XL(DSL802)
3. Remove nuts and clamp (4), tail tube (5). 3. Remove nuts (2) and washers, shims and rubbers
(3) at both sides.
4. Remove muffler (6).

4
5
IGAT060P IGAT061P
1760XL(DSL802) 1760XL(DSL802)
1550XL(DSL702), 2060XL(DSL902) 1550XL(DSL702), 2060XL(DSL902)
4. Disconnect oil and cooling lines (4). 5. Pull out radiator and oil cooler assembly (5) by two
persons, disconnect radiator-out hose(6).
6. Completely pull out radiator and oil cooler

assembly (5) by two persons.
"A" "A"
IGAT062I
Shim spacer to adjust the even clearence between

the fan and shroud.
1550XL 1760XL 2060XL

(DSL702) (DSL802) (DSL902)
A(mm) 11 L 2 9.6 L 2 13 L 2

Flexible Coupling Assembly
Assembly Procedure
Torque to
206~225 N.m
(Socket Bolt)
(Element as - Insert R)
Clean Assembly
Face of Flywheel
(Element as-Insert A)
(Spring Pin)
(Hub-Spline)
Element As-Element)
Torque to
196~225 N.m
4.0 M AX
IGAT063I
STEP 1 : Make each items and assembling face of STEP 5 : Assemble hub and rubber element on fly
fly wheel clear. wheel with 3 hex socket bolt (tightening w/specified
torque).
STEP 2 : Assemble the spring pins(6ea) on the hub-
spline. (projection height of spring pin : MAX.4mm). *ATTENTION : Hex socket bolt assembly
STEP 3 : Assembling the hub into the rubber 1) Apply very little grease on bolt seat face(never let
element, make sure the spline direction correct, and the thread contaminanted with grease. erf. fig.1).
tighten 3 hex socket bolt with specified torque
aligning spring pin locations. 2) Loctite is coated on hex socket bolt(colored blue)
for anti-loosening.
STEP 4 : Assemble spring pins(3EA) on fly wheel The loctite can be workable within 3 times of
(projection height of spring pin : MAX. 4mm). assemble and disassemble.

Wheel & Tire
Remove And Install Wheel & Tire
WARNING
Be sure the skid steer loader is on a level surface

before removing wheel and tire.
1. Put a hydraulic jack in position under the frame.
IGAT064P
2. Loosen the nuts (1) that hold the wheel and tire in
place.
3. Lift frame until the tire is clear of the ground.

Remove nuts (1). Remove the wheel and tire.
NOTE : The following steps are for installation of the

wheel and tire.
4. Put the wheel and tire in position on the axle hub.
5. Install nuts (1) that hold the wheel and tire in

place.
Tighten the nuts to a torque of 146 L 20 Nm
(108 L 15 lbft).
6. Lower the frame and remove the hydraulic jack.

SB4037E00
Jul. 2000
Hydraulic & Hydrostatic

Systems
1550XL(DSL702)
1760XL(DSL802)
2060XL(DSL902)
WARNING
in injury or death.
publication.
available.
Hydraulic & Hydrostatic Systems 1 Systems Operation

Index
Systems Operation
Hydraulic System.......................................................5
HST System...............................................................6
Hydraulic Control Valve .............................................8
Optional Bucket Self-Leveling System ....................13
HST Pump ...............................................................19
HST Motor ...............................................................20
Specifications
Hydrostatic Systems ................................................22
Hydraulic Systems ...................................................23
Testing & Adjusting

Troubleshooting .......................................................26
Hydraulic Systems ...................................................34
Hydrostatic Systems ................................................35

HST Pump ...............................................................37
HST Motor ...............................................................40
Hydraulic Control Valve ...........................................44
Boom Cylinder .........................................................47
Bucket Cylinder........................................................49
Hydraulic Schematic .............................................51
Hydraulic & Hydrostatic Systems 3 Index

Systems Operation
Hydraulic System
8
To Valve Block
2
1 14
13
IGAT065I
(1) HST Pump. (2) Hydraulic Pump. (4) Control Valve. (5) Boom Cylinder. (6) Bucket Cylinder. (7) Quick Coupling. (8) Quick Coupling.
(13) Suction Strainer. (14) Hydraulic Tank.
The hydraulic pump (2) is driven by a shaft through pressure reaches the setting pressure of relief valve
the hydrostatic (HST) pump (1). The fluid flows from (3000psi), it will open and let the fluid by-pass the
the hydraulic tank to the hydraulic pump (2), then hydraulic circuit internally and go to the valve block.
goes from the hydraulic pump to control valve (4). When the spool goes back to neutral position, there
The pump draws hydraulic oil from the tank and is fluid available for the other sections of the control
charges the hydraulic system with hydraulic power valve (4). Two sections of the control valve can be
converted from engine power. used at the same time as long as the main relief
valve is not open.
When all three spools (boom, bucket, attach) of the
control valve are in neutral position, the fluid goes
through the control valve (4) and the valve block. If
one of the spools is activated by pedal (boom,
bucket) or electric rocker switch (attach), the fluid
goes out respective port and to either the base end
or the rod end of cylinders (5, 6), or attachment is
operated. As the fluid goes into one end of the
cylinders (5, 6), the fluid from the other side of
cylinder flows back into the control valve. The control
valve (4) has an adjustable relief valve. When the
cylinders (5, 6) reach the end of the stroke, the fluid

HST System
11 12
From Control Valve
3
9
2
10 14
IGAT066I
Schematic for 1760XL(DSL802) and 2060XL(DSL902)
(1) HST Pump. (2) Hydraulic Pump. (3) HST Motors. (9) Valve Block. (10) Drain Relief Valve. (11) Oil Cooler. (12) Hydraulic Filter.
(14) Hydraulic Tank.
11 12
From Control Valve
3
9
2
10 14
IGAT066I
Schematic for 1550XL(DSL702)
(1) HST Pump. (2) Hydraulic Pump. (3) HST Motors. (9) Valve Block. (10) Drain Relief Valve. (11) Oil Cooler. (12) Hydraulic Filter.
(14) Hydraulic Tank.

Return oil from actuating devices is sent to the valve The fluid is called drive pressure fluid. Drive
block (9) for distribution to HST pump. pressure is much higher than charge pressure
causing the replenishing valves (check valves) of
HST pump supplies the oil to the left and right HST hydrostatic pump to close, allowing the flow of fluid to
motors. HST pump drives the motor forward or go the hydrostatic motors. There are four
reverse direction according to the control lever. The replenishing valves (check valves), two for each parts
oil from the control valve flows to the HST pump of hydrostatic pump (1). One is for forward travel and
through the valve block (9), oil cooler (11) and the other is for reverse travel.
hydraulic filter (12).
When the loader is driven with bucket into a pile of
Various hydraulic lines carry hydraulic oil among the material, there is resistance causing high pressure in
control valve, valve block, oil cooler, and filter. drive loop.
There is relief valve built into the high relief
The fluid flows from the oil cooler (11) through the valve/replenishing valve (for forward travel). This
filter to the center section of the hydrostatic pump (1). relief valve opens at the relief setting pressure (Refer
The fluid is called charge supply fluid. In the center to Specifications), the extra fluid goes from the drive
section of hydrostatic pump, the fluid works against loop to the charge loop to be used again.
two high relief/ replenishing (check) valves,
replenishing valve (3-position) of motors (3) and The hydrostatic motors (3) are roller-geroler type. In
charging relief valve (160psi). The replenishing valve each hydrostatic motor there are two kinds of fluid ;
of hydrostatic pump and the replenishing valve of case drain fluid which is generated in housing of
motor open and let fluid go into the hydrostatic pump each hydrostatic motor and flushing fluid which is
for replenishing, lubrication and cooling. The controlled by the orifice and the replenishing valve
hydrostatic pump does not need the full volume of (3-position) of each hydrostatic motor. These fluids
the fluid flow, so there is extra fluid. The extra fluid go through drain relief valve (10) and back to the
goes to the charge relief valve (160psi). tank.
There are two parts of hydrostatic pump (1) and two The filter (12) has a by-pass valve (50psi, check
hydrostatic motors (3). One part of hydrostatic pump valve and 40 psi pressure switch) to allow fluid flow
and one of hydrostatic motors work together as a pair when the fluid will not go through the filter element
to drive one side of the loader. The other part of (plugged).
pump and the other motor work as a pair to drive the
opposite side of the loader. The valve block (9) works as a cooler-by-pass valve
and surge valve (for 1760XL/DSL802 and
When the driving levers are in neutral, hydrostatic 2060XL/DSL902). The by-pass valve (20 psi, check
pump (1) and the hydrostatic motors (3) are not valve) of valve block will open when the boom arms
working, but have charge pressure. When the driving are lowered quickly with heavy load in the bucket.
levers are moved, the swashplates in the hydrostatic For 1760XL/DSL802 and 2060XL/DSL902, when the
pump are angled and the fluid is forced out of the pressure which works against the oil cooler is higher
pressure side of hydrostatic pump and goes to than 220 psi at the same condition, the relief valve
hydrostatic motors. (220 psi) of valve block will open to protect the oil
cooler (11) and filter (12). The by-pass valve (20 psi)
of oil cooler (11) will also open when the fluid is cold
and is thick to go through the cooler and filter.

Hydraulic Control Valve
Configuration
INE
N K L ort
TA p
T
6
5
4 8
orts
P
A
ts
P or
B
RE
2
E SSU ort Monoblock Valve Body
PR P p

IGAT067I
Configuration of Hydraulic Control Valve

(1) Spool. (2) Dust Cover Plate. (3) Main Relief Valve. (4) Float Detent Spool Control. (5) Spring Centering Spool Control.
(6) Check Valves. (7) Internal Pilot Electro-Hydraulic Spool Control. (8) Back-Pressure Valve.

Schematic
P1 A1 B1 A2 B2 A3 B3 T
SC1
SC3
MV SC2
CV1 CV2 CV2
210 bar 10 bar
3000 psi 145 psi
P
BPV
S1 S2 S3
SLP1 SLP2 SLP3
IGAT068I
1760XL(DSL802)
P1 A1 B1 A2 B2 A3 B3 T
SC1
SC3
MV
SC2
CV1 CV2 CV2
210 bar 10 bar
3000 psi 145 psi
P
BPV
S1 S2 S3
SLP1 SLP2 SLP3
IGAT068I 1550XL(DSL702) and 2060XL(DSL902)
Legend MV = Main relief valve

P = Inlet line S1,S2,S3 = Spools
P1 = 2nd inlet line (plugged) SC1 = Float detent spool control kit
A1-B1 = 1st section ports SC2 = Spring centering spool control kit
A2-B2 = 2nd section ports SC3 = Internal pilot electro-hydraulic
A3-B3 = 3rd section ports spool control kit
T = Outlet line SLP1,SLP2,SLP3 = Spool dust cover kit
BPV = Back-pressure valve
CV1,CV2,CV3 = Load check valves

Operations Neutral
Spool push-in Load

Check
A B
Valve Working Ports
Pressure
Line 0
A B Spool
1 0
Tank Passage
Free Line
3 1 0 2
To Next Section
Oil return from work port A B or to Tank
3 1 0 2
To Next Section
A B or to Tank
P T
P T
IGAT070I
IGAT069I Oil discharged from the pump returns to the valve

block and HST pump through the free passage. A
and B ports are blocked.
When the free line passage is closed, the oil
discharged from the pump flows to port B.
The return oil from port A is returned to the other
section (series) or go through the free passage. The
spool is returned to neutral by the return spring when
released.

Spool pull-out Spool pull-out in float position
A B
A B
0 2
0 3
Oil return from work port
3 1 0 2
3 1 0 2
A B A B
P T
P T
IGAT071I IGAT072I
When the free line passage is closed, the oil Oil discharged from the pump returns to the valve
discharged from the pump flows to port A. block through the tank line. A and B are connected.
The return oil from port B is returned to the other
section (series) or goes through the free passage.
The spool is retuned to neutral by the return spring
when released.

Electrical Connections
A1 A2 A3
IN
P OUT
ON OFF ON
B1 B2 B3
Knob with 3 Positions

Push-Button
12 VDC Battery
IGAT073I
Configuration of Electrical Connections.

Optional Bucket Self- Loader control valve metering and timing are
important in maintaining good boom and bucket
Leveling System control in both conventional and self-leveling circuits.
Cavitation of the boom cylinder is possible, in the
boom lower mode, if inlet to workport metering lags
Operation
behind workport to return metering. If this is allowed
to happen, the bucket will hesitate during the next
raise cycle while the rod end of the boom cylinder
A fills with oil. This may be unacceptable to the
operator.
B The following schematics and their accompanying

explanations explain the operation of the Self-Level
valve. Five different operating modes are described :
Self-Leveling, Bucket Cylinder Extended, Retracting
Boom Cylinder, Extending Bucket Cylinder, and
Retracting Bucket Cylinder.
C D
IGAT074I
Hydraulic Circuit of Self-Leveling
The boom and bucket section of the control valve

work together to position the bucket as the boom
arms of the loader are being raised. When the boom
spool of the control valve is engaged to raise the
boom arms, the fluid from the rod end of the boom
cylinders is directed through the self-leveling valve.
The self-leveling valve has a flow divider of 2-
position, which directs some of the returning fluid
directly back to the boom section of control valve.
The remaining fluid goes through a check poppet
valve (between 2-position valve and 3-position valve
in self-leveling valve) and to the base end of bucket
cylinder. This forces the bucket cylinder rod out and
adjusts the position of bucket as the boom arms are
raised. Since the fluid is trapped in the base end of
bucket cylinder(bucket pedal in neutral), the pressure
will increase and push the flow return spool of 3-
position open and allow fluid from the rod end of the
bucket cylinder to return to boom section of the
control valve along with the remaining of the
returning fluid from the rod end of boom cylinders.
When the bucket cylinders are fully extended and
boom arms are still raising, fluid goes over the relief
valve and back to the boom section of control valve.

Self-Leveling
Boom Cylinder
Port A
Adjustable Orifice
Boom
Pump Input
Port B Spool
Flow Divider Spool Out
Control Valve
with Fixed Orifice Bucket
Spool
Return
Neutral
Unloading
Spool
Port C Port D
Bucket Cylinder
IGAT075I
With the bucket spool in Neutral and the boom

spool pulled Out, flow from the control valve enters
the head port of the boom cylinder. As the boom
cylinder extends, flow from the rod port is directed to
port A on the self-level valve. Flow entering port A
is able to pass through the adjustable orifice and
fixed orifice in the flow divider spool. The proportion
of the flow split is determined by size of the
adjustable orifice. The remainder of the flow passes
through the fixed orifice, out port B back to the
control valve. The flow that passes through the
adjustable orifice flows out port D and goes to the
head port of the bucket cylinder. The resistance on
the movement of the bucket cylinder creates a
pressure high enough to open the unloading spool in
the self-level valve. As the bucket cylinder extends
the flow from the rod port of the bucket cylinder
enters port C past the open unloading spool,
around the flow divider spool and out port B back to
the control valve. The purpose of the unloading spool
is to prevent the bucket cylinder from dumping during
the self-level cycle.

Bucket Cylinder Extended
Boom Cylinder
Port A
Pump Input Boom

Port B Spool
Out
Control Valve
Bucket
Spool
Return
Neutral
Unloading
Spool
Port D
Port C
Bucket Cylinder
Stroked Out
IGAT076I
In case the bucket cylinder strokes out first during

the self-level cycle, or the operator moves the bucket
spool to dump the bucket, the boom cylinder will
continue to raise.
The unloading spool will shift to the left and unload
the flow going to the bucket cylinder head port.
The oil flow goes back to control valve, thus
preventing the boom cylinder from stopping during
the Raise function.

Retracting Boom Cylinder
Boom Cylinder
Port A
Lift Check
Boom
Pump Input Spool
Port B In
Control Valve
Bucket
Return Spool
Neutral
Port C Port D
Bucket Cylinder
IGAT077I
Moving boom spool In, the oil flow is directed to

port B on the self-level valve. Flow enters self-level
valve, opens lift check and flows out port A to the
rod port on the boom cylinder. Flow from head port is
directed back to the control valve.

Extending Bucket Cylinder
Boom Cylinder
Port A
Boom
Pump Input Spool
Port B
Neutral
Control Valve
Bucket
Spool
Return
Out
Lift Check
Unloading
Spool
Port D
Port C
Bucket Cylinder
IGAT078I
With the bucket spool shifted Out oil flow is directed

from the control valve to the head port of the bucket
cylinder. The flow also enters port D on the self-
level valve but is blocked by the lift check. Return
flow also enters port C on the self-level valve and is
blocked by the unloading spool.
Flow from the rod port is directed back to the control
valve.

Retracting Bucket Cylinder
Boom Cylinder
Port A
Boom
Pump Input Spool
Port B Neutral
Control Valve
Bucket
Return Spool
In
Lift Check
Unloading
Spool
Port D
Port C
Bucket Cylinder
IGAT079I
With the bucket spool shifted In, oil flow is directed

to the rod port of the bucket cylinder. Flow also
enters port C on the self-level valve through a tee
connection but is blocked by the unloading spool. Oil
returning from the head port is directed back to the
control valve. Oil flow from the head port enters port
D on the self-level valve through a tee connection
but is blocked by the lift check.

HST Pump Basic Closed Circuit
General Description
HST Pump and motors provide an infinitely variable

speed range between zero and maximum, in both
forward and reverse modes of operation.
This variable displacement pump is a compact OUTPUT

INPUT PUMP MOTOR
design, using the parallel axial piston/slipper design
in conjunction with a tillable swashplate to vary the
pumps displacement. Reversing the direction of tilt of
the swashplate reverses the flow of oil from the pump
and thus reverses the direction of the motor output CASE
FLOW (BI-DIRECTIONAL) DRAIN
rotation.
LINE
A direct displacement control system is used on this
HST tandem pump. The swashplate control shaft is TANK
connected directly to the swashplate. Movement of
IGAT080I
the control shaft causes a proportional swashplate
movement and change in pump flow. This control is
located on either side of the unit.
The main ports of the pump are connected by
hydraulic lines to the main ports of the motors. Fluid
A charge relief valve and charge check valves are
flows, in either direction, from the pump to the motor
included in the pump end cap to control the makeup
then back to the pump in this closed circuit. Either of
and cooling oil flow for the system. The charge check
the hydraulic lines can be under high pressure. The
valves also incorporate the bypass valve function and
direction and speed of fluid flow (and the motor
high pressure relief valve function into their design.
output shaft rotation) depends on the position of the
pump swashplate. The system pressure is
determined by the machine load.
Case Drain
The pump and motor require case drain lines to

remove hot fluid from the system. The pump case
should be drained from its drain port to insure the
case remains full of fluid. The motor housing drain
port is connected to the tank.
Charge System and Filter
The charge pump supplies cool fluid to the system

and keeps the closed loop charged to prevent
cavitation. The charge pump draws its fluid from the
tank. A filter is required to insure that only clean fluid
enters the system.

Since either of the main hydraulic lines can be high HST Motor
pressure, four charge check valves are used to direct
the charge supply into the low pressure line. These The outer ring of the gear wheel set of HST motor is
check valves (located in the pump end cap) also stationary part of the motor housing. This ring has
incorporate the high pressure relief valve function. internal teeth which mesh with teeth on a gear wheel
Any charge flow not being used for the closed circuit or rotor which rolls inside the ring.
is discharged over a direct operating charge relief
valve, through the pump and motor housings, and The motion of the rotor is transmitted to the output
back to the tank. shaft through a drive. The drive consists of a
movable shaft extension with crowned involute
splines at either end. These splines match the
High Pressure Relief Valves corresponding tooth system of the output shaft and
rotor, resulting in a toothed coupling between rotor
Four combination check /high pressure relief valves and drive and between drive and shaft respectively.
are provided in the pump end cap for overload As it rotates, the rotor causes continuous opening
protection. These cartridge type relief valves are and closing of tooth spaces. Four of these spaces
factory set, and are not field adjustable. are subjected to fluid pressure, and the opposed four
are connected to return line.
Direct Displacement Control

Outer ring
The direct displacement control (DDC) is located on
either side of the pump, and provides a simple
method of control. Movement of the swashplate Rotor
control shaft produces a proportional swashplate
movement and change in pump flow and/or motor
shaft speed and direction.
The vehicle control system should be designed to
return the swashplate to its neutral position.
Zero Position
Bypass Valve
In some applications it is desirable to bypass fluid

around the pump allowing, for example, a vehicle to
be moved short distance at low speed without
running the engine. This is accomplished by
manually operated bypass valves incorporated into
the charge check/high pressure relief valves in the
pump. When open (unscrewed 4 turns maximum),
these valves connect both sides of the pump/motor 1/18 Shaft Rotation
closed circuit, allowing the motor to turn. Both valves
must be opened for bypass operation and must be
fully closed for normal operation. The engine should
be shut down when opening or closing the bypass
valves.
1/9 Shaft Rotation
IGAT081P
Above pictures show three positions of the rotor, the
corresponding rotor center movements, and the
locations of pressure and return chambers
respectively.

As can be seen, the circular movement of the rotor Above illustrations show the typical example which
center will cause the shaft to move in the opposite has one shaft revolution against 6 rotor center
direction at eight times smaller angular velocity. revolution with displacement of 42 chambers.
Hence 1/9 shaft revolution corresponds to 8/9 rotor A simple rotary channel plate guides the fluid so that
center revolution causing the oil from 8 fluid pressure and suction chambers rotate synchronously
chambers to be displaced, i.e. that one shaft with the rotor, thus causing continuous rotation.
revolution gives 8 revolutions of the rotor centre with
displacement of 72 chambers.
When used in this way, the gear wheel set thus

constitutes a hydraulic motor with a power which is
approximately 8 times greater per revolution,
compared with hydraulic motors of conventional
design. The torque which is approximately 8 times
greater is obtained at a speed which is 8 times lower
without using a reductions gear.
Furthermore, the displacement of 72 fluid chambers

per shaft revolution offers the special advantage of
steady operation due to the smoothing effect of the
increased number of chambers.
Outer Ring
IGAT083P
Above illustrations show the shaft rotation according

to flow directions of two main ports of HST motor.
Disc Valve
Zero Position Channel Plate
Rotor
Revolution of Rotor
Center
1/14 Shaft Rotation
1/7 Shaft Rotation

High Pressure Low Pressure
IGAT082I

Specifications
Hydrostatic Systems
Hydrostatic Transmission Pump
Charging Pump Hydrostatic Pump
IGAT084I
Item Unit Specification

Type Piston, Variable Displacement
Maximum Displacement in (cc)/rev
3
2.68 (44)
Relief Setting Pressure psi (bar) 1550XL/DSL702 : 3555(250),
1760XL/DSL802 & 2060XL/DSL902 : 4061(280)
Internal Charge Pump None
Rotation Clockwise
Swash Plate Operating Angle Deg L 16
Mounting SAE 2 Bolt B Mount
Shaft ANSI B92.1-1970
Class No.5 30 B 15 B 16/32
Hydraulic & Hydrostatic Systems 22 Specifications

Hydraulic Motor

Type - Geroler
Displacement in (cc)/rev
3
32.04(523.6)
Mounting - SAE 4 Bolt B Mount
Shaft - Spline Shaft
Hydraulic Systems
Hydraulic Pump

Type - Gear
Capacity in (cc)/rev
3
1550XL/DSL702 : 1.47(23.0)
1760XL/DSL802 and 2060XL/DSL902 : 1.92(31.5)*
Maximum Pressure psi (bar) 3335 (230)
Maximum Speed rpm 3000
Mounting - SAE 2 Bolt A Mount
Shaft - SAE Spline Shaft
Rotation - Clockwise
*European Truck (CE Area) for 1760XL/DSL802 and 2060XL/DSL902 : 1.77(29.0)
Control Valve

Number of spool Ea 3
Relief Setting Pressure psi 2840 (+70)
(set by valve supplier) (195(+5) bar)
Circuit - - Series on Lift Float Function with Detent
- Series on Tift
- Series on Auxiliary with Electric Detent (thumb control)
Pressure and Flow of Standard Skid Steer Loader

Flow (maximum) LPM (GPM) 1550XL/DSL702 : 60.0(16.0)
1760XL/DSL802 & 2060XL/DSL902 : 77.7(20.5)
Maximum System Pressure at psi 3000 L 35 (207 L 2.4 bar)
charging pump

Pressure and Flow of High Flow Skid Steer Loader

Flow (maximum) LPM(GPM) 1550XL/DSL702 : 101(26.7)
1760XL/DSL802 & 2060XL/DSL902 : 131.5(34.8)
Maximum System Pressure psi 3000 L 35
at charging pump (207 L 2.4 bar)
Boom Cylinder

Type - Single Rod, Double Acting
Number Ea 2
Cylinder Bore in (mm) 1550XL/DSL702 : 2.17(55)
1760XL/DSL802 & 2060XL/DSL902 : 2.36(60)
Cylinder Rod in (mm) 1550XL/DSL702 & 1760XL/DSL802 : 1.50(38)
2060XL/DSL902 : 1.57(40)
Stroke in (mm) 1550XL/DSL702 : 39.2(996.0)
1760XL/DSL802 : 33.5 (850.0)
2060XL/DSL902 : 42.0(1065)
Mounting - Single Crest Crevice
Plating on Rod - Hard chrome w/15-50 Micron Thickness
Bucket Cylinder

Type - Single Rod, Double Acting
Number Ea 2
Cylinder Bore in (mm) 2.36 (60.0)
Cylinder Rod in (mm) 1550XL/DSL702 : 1.18(28)
1760XL/DSL802 : 1.5 (38)
2060XL/DSL902 : 1.57(40)
Stroke in (mm) 1550XL/DSL702 : 13.99 (355.3)
1760XL/DSL802 & 2060XL/DSL902 : 20.0(507)
Mounting - Single Crest Crevice
Plating on Rod - Hard chrome w/15-50
Micron Thickness HRC 52-60 Hardness

Hydraulic Filter

Type - Full Flow Spin-On
Filter Rating - 13 Micron Beta Rating of 20
Rated Flow LPM (GPM) 132.5 (35)
By-Pass Valve Closing PR50 PSID (Normally Open Type)

Type - O-ring Face Seal Fitting (SAE J1453)
Thread - Unified Thread is Standard
Medium Pressure Line - SAE 100R1 Hose (SAE J517)
Hydraulic High Pressure Line - SAE 100R2 Hose (SAE J517)
ST High Pressure Line - SAE 100R12 Hose (SAE J517)
Fluid Capacity
Specification
Item Unit
1550XL(DSL702) 1760XL(DSL802) 2060XL(DSL902)
Fuel Tank (Maximum) gal (liter) 14.3(54) 21.1 (80) 18.2(69)
Hydraulic Maximum Oil Tank gal (liter) 8.0(30) 9.2 (35) 11.9(45)
Hydraulic System Capacity gal (liter) 11.1(42) 12.7 (48) 12.7(48)
Chain Case Oil gal (liter) 5.9(22.5) 6.3(24) 6.3(24)
Cooling Fluid gal (liter) 1.8(6.9) 1.8 (6.9) 1.8(6.9)
Engine Lubrication - with filter gal (liter) 2.1(8.0) 2.1 (8.0) 2.1(8.0)
Without filter gal (liter) 2.0(7.6) 2.0 (7.6) 2.0(7.6)
Oil Type

Chain Case - SAE 10W-20: Texaco TDH
API CC or CD SAE 10W30
Hydraulic Oil - SAE10W-20 : Texaco TDH

Testing & Adjusting Visual Checks
A visual inspection of the hydraulic and hydrostatic
system and its components is the first step when a
Troubleshooting diagnosis of a problem is made. Lower the bucket to
the ground and follow these inspections;
Troubleshooting of hydraulic system can be difficult.
A list of possible problems and remedies are on the
1. Measure the oil level. Look for air bubbles in the
pages that follow.
oil tank.
This list of problems and remedies will only give an
2. Remove the filter element and look for particles
indication of where a problem can be and what
removed from the oil by the filter element. A
repairs are needed. Normally, more or other repair
magnet will separate ferrous particles from
work is needed beyond the recommendations on the
nonferrous particles (piston rings, O-ring seals,
list. Remember that a problem is not necessarily
etc.).
caused only by one part, but by the relation of one
part with other parts. This list can not give all
3. Check all oil lines and connections for damage or
possible problems and remedies. The serviceman
leaks.
must find the problem and its source, then make the
necessary repairs.
The pressure Gauge Kit and fittings can be used to

make the pressure tests of the hydraulic system.
Before any test is made, visually inspect the
complete hydraulic system for leakage of oil and for
parts that have damage.
WARNING
To prevent personal injury when testing and

adjusting the hydraulic system, move the machine
to a smooth horizontal location. Move away from
machines and personnel that are at work. There
must be only one operator. Keep all other
personnel away from the machine or where the
operator can see the other personnel.
Hydraulic & Hydrostatic Systems 26 Testing & Adjusting

Hydraulic System
Symptom Possible Cause Remedy

No hydraulic cylinder action. Hydraulic oil level is low or empty. Check level in tank. Add oil if
necessary. Check for leaks.
Pedals are disconnected. Check linkage. Repair as needed.
Contaminated/Damaged relief valve. Clean/Replace the relief valve.
Damaged hydraulic pump. Check pump. Replace if needed.
Hydraulic oil is too thick. Let machine warm up before
operating.
Rough hydraulic cylinder action. Hydraulic oil level is low. Check level in tank. Add oil if
necessary. Check for leaks.
Slow hydraulic cylinder action. Pedal is hitting floor, or there is Check adjustment. Remove dirt.
dirt under pedal.
Internal cylinder leakage. Check condition of cylinders and
repair as needed.
Damaged hydraulic pump. Check pump. Replace if needed.
Damaged control valve. Check valve. Replace if needed.
Hydraulic oil is too thick. Let machine warm up before
operating.
Hydraulic cylinders leak oil. Damaged cylinder rods or seals. Repair cylinders.
Boom and Bucket Cylinders
There is leakage of oil inside the The piston seals are worn and Replace seals. Or replace cylinder
cylinder or loss of boom or let oil go through. assembly.
bucket power. Cylinder has damage. Replace cylinder assembly.
Foreign material behind the The wiper rings show wear and do Replace wiper rings.
wiper rings which causes not remove dirt and foreign material.
scratches on the cylinder rod.
Too much drift. Defective boom cylinder seals. Inspect and replace seals.
Defective control valve. Replace spool. Or replace control
valve assmbly (with changing oil).

Control Valve
The boom or bucket cylinders do The valve neutral spring is week Replace the neutral return spring.
not hold their position with the or broken.
valve control spools in neutral Valve spool worn out. Replace spool.
position. Load check valve in the control Replace load check valve.
valve is defective.
Dirt or foreign particles between Clean or replace load check valve.
check poppet and its seat.
The control valve spools do not The oil is too thick at low temperature. Warm the oil by running of engine.
move freely. There is foreign material in the Replace the hydraulic oil and
hydraulic oil. control valve.
Bent spool. Replace spool.
Damage to return springs of the Replace return springs.
spools.
Control valve spools have There is foreign material under seal. Clean.
leakage around the seals. The valve spools worn. Replace spool.
The seal plates are loose. Tighten seal plates.
The seals have damage or are Replace seals.
badly worn.
The bucket lowers when the There is foreign material in the Clean.
boom spool is moved from check valve area.
neutral position to the boom-up The load check valve poppet and Replace load check valve.
position. seat show wear.
Damage to the relief valve which Replace relief valve.
causes low oil pressure.
Spools do not return to neutral. The spring broken. Replace spring.
The spool is bent. Replace spool.
The system or valve has foreign Clean and change oil.
particles in it.
The fastening bolts of valve have Tighten with specified torque.
too much torque.
No motion or slow, then too The relief valve is not correctly set, The relief valve is correctly set.
sudden action of the hydraulic or will not move in base and or is Or replace the relief valve.
system. worn.
There is air in the system. Remove the air.
Dirt or foreign particles between Clean.
relief valve control poppet and its
seat.
Valve body has a crack inside. Replace relief valve.
Spool not moved to a full stroke. Inspect spool and spring. Change
them if needed.
Auxiliary function doesnt move. No electric power. Check electric circuit.
On/off pressure reducing valve blocked. Remove the rod pressure regulator,
clean it carefully and reassemble.
Or replace it.
High spool friction. Remove the spool, clean it carefully
and reassemble.
Too much back pressure in tank line. Check hydraulic circuit and reduce
back pressure lower than 20bar.
No enough back pressure on free line. Remove the back pressure valve,
clean it and reassemble.

Hydrostatic Pump
Symptom : Difficult or Impossible to find neutral position of HST pump
Possible cause and remedy
OK
Check Control Input Check System Pressure
(Linkage, Pressure, Differential
Current)
More Than
Defective
50 PSI
Repair or Adjust
Replace Swashplate Neutral
OK
Replace
Pump

Symptom : System Operating Hot
Check Oil Level Inspect Check Check

OK OK OK
in Tank Heat Exchanger Charge System
Pressure Pressure
(No Load and
Low Defective
Under Load)
OK High
Low
Fill to Proper Repair or
Level Replace
Reduce
Transmission
Inspect Load
Inspect OK OK Inspect
Charge Relief
Charge Pump Inlet Filter
Valve
Defective Defective Clogged

OK
Replace
Repair or Repair or
Replace
Replace Replace
Transmission
(Pump & Motor)
Symptom : Transmission Operates in one Direction Only
Inspect System
Replace
Check Control OK Check/Relief OK
Transmission
Linkage Valves or Charge
(Pump and Motor)
Check Valves
Defective Defective
Repair or Repair or
Replace Replace

Symptom : System Response is Sluggish
Check Inspect Inspect

OK OK OK
Charge Control Pump Inspect Orifice Control
Pressure Valve By-Pass Valve
Defective Defective Defective
Low in Repair or Repair or Repair or

Neutral Replace Replace Replace
OK
Low in Neutral & Forward
or Reverse
Inspect Inspect Inspect Inspect Replace

Charge Relief Charge Relief OK Inlet OK Charge OK Transmission
Valve at Pump Valve at Pump Filter Pump (Pump & Motor)
Defective Defective Defective Defective
Repair or Repair or Repair or

Replace
Replace Replace Replace

Symptom : Loss of power or transmission will not operate in either direction
Check Oil Level OK Inspect Heat OK Check Charge OK Check System

Pressure High
In Reservoir Exchanger Pressure
(No Load and
Under Load)
Reduce
Low Defective Transmission
Low Low Load
Fill to Proper Repair or

Level Replace
Inspect Check/Relief Valves or
Charge Check Valves
Inspect Defective
Inspect OK OK Inspect
Charge Relief
Charge Pump Inlet Filter
Valve
OK
Repair or
Defective Defective Clogged Replace
OK
Repair or Repair or
Replace
Replace Replace
Replace
Transmission
(Pump & Motor)

Hydrostatic Motor

Motor shaft does not rotate. Pump does not run or runs in the Start pump in the correct direction
wrong direction. of rotation.
Motor spool has seized in housing. Replace complete shaft and housing.
Cardan shaft or spool broken Replace cardan shaft or complete
(shaft and communicate valve in two). shaft and housing. Eliminate
external force which caused the
fracture.
Sand, steel chips or similar Clean the motor and flush system
impurities in motor. thoroughly. Renew defective parts.
Change the filter.
The seals which are incorporated Inspect and replace them.
into balance plate are damaged.
Motor shaft rotates in wrong Oil lines are wrongly connected Change the connections.
direction. to motor ports.
Gear-wheel and rotary valve Adjust setting.
incorrectly fitted.
Leakage at motor shaft. Shaft seal worn out or cut. Replace shaft seal.
Leak between motor spigot Spigot is loose. Tighten screws with specified torque.
and housing. O-ring defective. Replace O-ring.
Leaks between housing, Screws are loose. Tighten screws with specified torque.
spacer plate , gear wheel set O-ring defective. Replace O-ring.
and end cover, respectively. Steel washer defective. Replace steel washer.

Hydraulic System a. With the engine off, locate the adjustment screw
on the control valve.
b. Loosen the lock nut and turn the adjustment screw

WARNING approximately 1/8 turn. The adjustment screw is
very sensitive, do not rotate it over 1/4 turn at a
Hydraulic oil under pressure can remain in the time. To increase the relief pressure tighten the
system after the engine has been stopped. adjustment screw clockwise, to decrease the relief
Personal injury can be caused if this pressure is pressure loosen it.
not released from the system before any work is
started. c. Retighten the lock nut and check the relief
To be sure that the system is not pressurized, pressure with above procedure. If the relief
lower the boom to the ground with the engine off pressure still does not fall in the specific range,
move the control pedals back and forth several shut off the engine and adjust again. Repeat until
times. This will release any pressure left in the the relief pressure falls into the specific range.
system after shutting off the engine. The
procedure must be done before any fitting, hose,
or component is loosened.
Perform adjustments on level ground away traffic.
When making adjustments or taking measurements
with the engine running, make sure that all Adjustment Screw
personals clear of the machine.
Lock nut
Check & Adjusting Procedure of Relief Pressure
of Control Valve
A1 A2 A3
1. If attachment is installed on the truck, take it out
from truck. OUT
IN
2. Check the engine speed. It should be 2640 L 50
rpm (1550XL/DSL702) or 2730 L 50rpm
(1760XL/DSL802 and 2060XL/DSL902), if it is not
adjusted. B1 B2 B3
3. Warm the hydraulic oil to the temperature 100-

120F (50 L 5C).
4. With the engine off, install 5000psi (350bar) rated

pressure gage into the female coupler of the IGAT085I
auxiliary hydraulic line(down side) on the boom.
5. Start the engine and at high idle push the

auxiliary. With keeping depressing the left side of
thumb button on right driving control lever after
pushing on switch of attachment on control
panel, read the pressure gage.
6. The pressure gage should read between 3000 L

35 psi (210 L 2.5 bar)
7. If the relief pressure does not fall into the above

range, do the steps that follow.

Hydrostatic System WARNING
Do not start prime mover unless pump is neutral

Start-Up Procedure of Hydrostatic
position (0 swashplate angle). Take precautions to
System prevent machine movement in case pump is
actuated during initial start up.
The following start-up procedure should always be
followed when starting up a new installation or when
restarting an installation in which either the
hydrostatic pump or hydrostatic motor had been Once charge pressure has been established,
removed from the system. increase speed to normal operation speed.
Charge pressure should be 160psi minimum. If
charge pressure is incorrect, shut down and
determine cause for improper pressure.
WARNING
With motor output shaft disconnected or drive wheels
The following procedure may require the vehicle raised off the ground, run system as full input and
to be disabled (wheels raised off the ground, work output speeds in both directions. Operate system for
function disconnected, etc.) while performing the at least 15 minutes.
procedure in order to prevent injury to the
technician and by-standers. Shut down prime mover, remove gauge, and plug
ports. Check the tank level and add fluid if necessary.
The transmission in now ready for operation.
Prior to installing the hydrostatic pump and/or motor,
inspect the units for damage incurred during shipping
and handling. Make sure that all system components
(tank, hoses, valves, fittings, oil cooler, etc) are clean
prior to filling with fluid.
Fill the tank with recommended hydraulic fluid which

should be passed through 10 micron filter prior to
entering tank.
The inlet line leading from tank to pump must be

filled prior to start up. Check inlet line for properly
tightened fittings and make sure it is free of
restrictions and air leaks.
Be certain to fill the hydrostatic pump and/or motor

housing with clean hydraulic fluid prior to start up. Fill
the housing by pouring filtered oil into the upper case
drain port.
Install a 500psi (35 bar) pressure gauge in the

charge pressure gauge port to monitor the charge
pressure during start-up.
With the pump swashplate in its neutral (0 angle)

position, jog or slowly rotate prime mover until
charge pressure starts to rise. Start the prime mover
and run at the lowest possible RPM until charge
pressure has been established. Excess air may be
bled from the high pressure lines through the high
pressure gages ports.

Hydrostatic pump Gauge Information
A System Pressure 10000 psi (690Bar) gauge
Gage Installation
Port A 9/16-18 O-ring fitting
It will be necessary to install a high pressure gauge B System Pressure 10000 psi (690Bar) gauge
into the system pressure port (or tee into the high Port B 9/16-18 O-ring fitting
pressure line) to check the setting of the system
C Charge Pressure 500 psi (35Bar) gauge
pressure relief valves.
Measuring the charging pump inlet vacuum will help 7/8-14 O-ring fitting
locate restrictions in the inlet lines, filter etc. D Case Pressure 500 psi (35Bar) gauge
Case pressure readings can help locate restrictions 1-1/16-12 O-ring fitting
in the return lines, oil cooler, and return filter.
Direct Displacement Control
Inspect the connection of the control linkage to the

swashplate control shaft to insure that the linkage is
A Front B Rear C (With properly attached. Neutral position of the swashplate
Charge is determined by the vehicle control linkage.
Pump)
D D Check High Pressure Relief Valves
When a problem occurs in one direction, interchange

C (Less the charge check or check/relief valves to see if the
Charge problem changes to the other direction. If so, one
Pump) valve is malfunctioning or the check/relief valve
B Front A Rear cartridge does not have the proper setting pressure.
CAUTION : The relief valves are factory set and

should not be tampered with except for replacing the
IGAT086I entire cartridge. Disassembly may change the setting
and cause erratic unit operation or premature failure.
Gauge Connections (Top View)
Pump Charge Relief Valve
If charge pressure is low, the charge relief valve

should be inspected. Inspect for foreign material
holding the poppet open, and for scoring or wear on
B Rear the poppet and seat in the housing.
(Opposite Side)
Adjustment of the charge pressure is accomplished
by changing the shim thickness behind the spring.
Bypass Valve
The bypass function is accomplished by manually

B Front opening the charge check/high pressure relief valves.
If the system is operating hot, check that the valves
are fully seated by turning the special plugs
clockwise with a 5/16 internal hex wrench. Torque
the plugs to 30 to 50 ftlb (41 to 68 Nm).
IGAT087I
Gauge Connections (Side View)

HST Pump
NOTE : Only trained personnel should disassemble.
When making repairs on hydrostatic systems, clean
the work area before disassembly and keep all parts
clean. Mark the match points on housing.
5
IGAT090P
1
3. Remove four check and relief valves (5). The valve

may be removed from the special plug by pulling
straight out.
2 3
IGAT088P
1. Remove the screws (1) and hydraulic pump (2)

from the HST pump (3).
4 16
IGAT091P
4. Remove the charge relief valve (6) from end cap

(16).
1
7 8 9 10
11
IGAT089P
2. Remove the coupling (4) from the hydraulic pump.
IGAT092P
5. Remove plug (7), O-ring (8), shim (9), spring (10)

and valve poppet (11) from the charge relief valve.
NOTE : Protect all exposed sealing surfaces and

open cavities from damage and foreign material.
It is recommended that all gaskets and O-rings be
replaced.
Hydraulic & Hydrostatic Systems 37 Disassembly & Assembly

17
12
IGAT093P IGAT096P
6. Remove screws (12) from the pump. 9. Remove the valve plate (17) from the end cap
Separate the front and rear sections of pump. (16).
(Front pump is engine side and rear pump is
hydraulic pump side).
19
Followings are disassembly procedure of front

pump.
14
13 18
IGAT097P
10. Remove the cylinder block (18) from the housing

(19).
IGAT094P
24
7. Remove coupling (13) and O-ring (14) from the 22
front pump.
21 23
15
IGAT098P 20
16 11. Remove the slipper retainer and piston assembly

(20) from the cylinder block (21). Remove the
slipper retainer guide (24), pins (22) and slipper
IGAT095P
hold down retainer (23) from the cylinder block.
8. Remove screws (15) and the end cap (16) with the
valve plate from the front pump.

26
19
25
31
30
IGAT099P IGAT102P
12. Remove the retaining ring (25) from the housing 16. Remove the screws (30) and the trunnion covers
(19) using plier. (31) (mark the position of cover for re-assembly).
13. Remove support washer (26) and lip seal.
27
28
32
IGAT103P
IGAT100P
17. Remove both bearings (32).
14. Remove retaining ring (27) and front shaft (28)

with bearing from the housing.
28 33
34
29
IGAT104P
18. Remove thrust plate (33).

IGAT101P
19. Do step 14 through 18 to disassemble rear pump.

15. Remove the retaining ring (29) and press the
shaft (28) out of the bearing (34). NOTE : There is no lip seal in the rear pump.
Remove the retaining ring first. Then the shaft and
bearing may be removed.

20. Assemble HST pump in the reverse order of HST Motor
disassembly. Refer to following torques when
installing.
CAUTION : Cleanliness is extremely important when
End cap onto the housing..........................47~61 Nm repairing a hydraulic motor. Work in a clean area.
(35~45 lbft) Before disconnecting the lines, clean the port area of
the motor thoroughly. Before starting the disassembly
Assembly of front and rear pump ..............47~61 Nm procedures, drain the oil from inside the motor.
(35~45 lbft)
1
Charge relief valve ..................................54~125 Nm
(40~100 lbft)
Check and relief valve ...............................41~68 Nm

(31~50 lbft)
IGAT105P
1. Place the motor in a vise with the output shaft

down. Clamp across the mounting flange of the
motor not the housing. Excessive clamping
pressure will cause distortion.
2. Remove four bolts (1) from motor with socket

spanner.
IGAT106P
3. Lift the valve housing (2) straight up.

3
4 7
IGAT107P IGAT110P
4. Remove O-ring (3) and channel plate (4) from the 7. Remove valve drive (7).
valve housing (2).
IGAT111P
IGAT108P
8. Remove gear wheel set (8) from bearing housing

5. Remove disc valve (5) from the valve housing (2). (9).
6
10
IGAT109P IGAT112P
6. Remove balance plate (6) from the valve housing. 9. Remove O-ring (10) from gear wheel set (8).
Apply some clean oil for removal, if needed.

11
16
IGAT113P IGAT116P
10. Remove cardan shaft (11) from bearing housing 14. Remove shaft and bearing assembly (16) from
(9). bearing housing.
11. Separate bearing housing from the vise. Followings are procedures for assembly of HST
motor.
12
16
13
IGAT114P
IGAT116P
12. Remove six screws (12) and front cover (13) from
bearing housing. 15. Install shaft and bearing assembly (16) to bearing
housing (9).
14
14
15
15
13
13
IGAT115P
IGAT115P
13. Remove shaft seal (14) and O-ring (15) from front
cover (13). 16. Install shaft seal (14) and O-ring (15) to front
cover (13).

12
13 8
IGAT119P IGAT111P
17. Install front cover (13) to bearing housing (9) and 20. Install gear wheel set (8) to bearing housing (9).
tighten six screws (12) with torque of 24 L 2 Nm
(210 L 17 lbin).
7
8
10
IGAT110P
IGAT112P
21. Install valve drive (7) to gear wheel set (8).
18. Install O-ring (10) to gear wheel set (8).

4
11
IGAT124P
IGAT113P
22. Install channel plate (4) with O-ring to gear wheel
set.
19. Install cardan shaft (11) to bearing housing (9).

5
1
4
IGAT125P IGAT105P
23. Install disc valve (5) to channel plate (4). 26. Tighten four bolts with the torque of 140 L 5 Nm
(100 L 4 lbft).
16 Hydraulic Control Valve
1
2
IGAT109P
2
24. Install balance plate (6) to valve housing (2).

3
IGAT129P
2
1. Remove four screws (1) and electro-hydraulic kit

(2) from the control valve assembly (3).
IGAT106P
25. Install valve housing (2) including balance plate

to motor. 2
IGAT130P
2. Remove spool assembly (4) from the electro-

hydraulic kit (2).

20
24
6
23 19
5 22
21
IGAT131P IGAT134P
3. Remove boot (5) and coil (6). 7. Remove joint (19), piston (21), flange (22), O-ring
(23), spool control kit (20) and end cap (24).
11 9 16
28
27
25
26
15 14 13 12 10 8 7
IGAT132P
IGAT135P
4. Remove tube (7), O-ring (16), pin (8), open ring

(9), ring (10), spring (11), ring (12), rod (13), 8. Remove two screws (25), cover flange (26), ring
bushing (14) and spring (15). (27) and O-ring (28) from the control valve.
5. Do steps 3 and 4 to disassemble the other coil

assembly. 27 25
26
18 28
IGAT136P
17 9. Remove plug (25), spring (26) and piston (27) from

IGAT133P
back-pressure valve body (28).
6. Remove flange (17) and O-ring (18). 10. Remove back-pressure valve body from the
control valve.

31
30
29
43
IGAT137P IGAT139P
11. Remove main relief valve (29) from the control 15. Remove load check valve (43) from the control
valve. valve.
12. Remove four screws (30) and float detent spool 16. Assemble control valve in the reverse order of
control kit (31). disassembly. Refer to following torques when
installing.
34
38 Main relief valve.........................42 Nm (31 lbft).
Back-pressure valve ..................42 Nm (31 lbft).
33 39 Load check valve .......................24 Nm (18 lbft).
35 40
41
36
32
42
37
IGAT138P
13. Remove boom spool assembly (32) from control

valve.
14. Remove cover (33), O-ring (34), spring (35),

thrust ring (36), bushing (37), cover (38), pin (39),
bushing (40), spring (41) and bushing (42).

Boom Cylinder of 1760XL(DSL802)
IGAT140I
1. Place the boom cylinder in a vice and remove the 6. Remove the bushing (17) from the knuckle and
rod cover (3). head cover.
2. Remove rod assembly (2) from the cylinder 7. Assemble the boom cylinder in the reverse order
assembly. of disassembly.
3. Remove spring pin (16), hex nut (15), piston (10)

and rod cover (3) from the rod assembly.
4. Remove O-ring (11), dust ring (14), slipper seal

(12) and wear ring (13) from the piston.
5. Remove dust wiper (4), back up ring (6),

U-packing (5), DU-bush (7), O-ring (8) and back
up ring (9) from the rod cover.

Boom Cylinder of 1550XL(DSL702) & 2060XL(DSL902)
IGAT140I
1. Place the boom cylinder in a vice and remove the 6. Remove the bushing (17) from the knuckle and
2. Remove rod assembly (2) from the cylinder 7. Assemble the boom cylinder in the reverse order
3. Remove socket bolt (16), hard washer (15), piston

(10) and rod cover (3) from the rod assembly.
4. Remove O-ring (11), wear ring (13), slipper seal


U-packing (5), DU-bush (7), O-ring (8) and back
up ring (9) from the rod cover.

Bucket Cylinder of 1760XL(DSL802)
IGAT141I
1. Place the bucket cylinder in a vice and remove the 6. Remove the bushing (19) from the knuckle and
2. Remove rod assembly (2) from the cylinder 7. Assemble the bucket cylinder in the reverse order
3. Remove spring pin (18), hex nut (17), piston (12)

and rod cover (3) from the rod assembly.
4. Remove cushion ring (11), O-ring (13), dust ring

(14), slipper seal (15) and wear ring (16) from the
piston.

U-packing (5), washer (10), DU bush (7), back up
ring (9) and O-ring (8) from the rod cover.

Bucket Cylinder of 1550XL(DSL702) & 2060XL(DSL902)
IGAT141I
1. Place the bucket cylinder in a vice and remove the 6. Remove the bushing (18) from the knuckle and
2. Remove rod assembly (2) from the cylinder 7. Assemble the bucket cylinder in the reverse order
3. Remove socket bolt (17), hard washer (16), piston

(11) and rod cover (3) from the rod assembly.
4. Remove O-ring (15), wear ring (14), slipper seal


U-packing (6), washer (10), DU bush (5), back up
ring (9) and O-ring (8) from the rod cover.

Hydraulic Schematic for 1550XL(DSL702)
8
7
11 6
9
14
5 OPTIONAL SELF LEVELING

B2
A2
4 BUCKET
CYL.
12
BOOM
B1 CYL.
A1
1
3 3
2
ITEM COMPONENTS
1 HST PUMP
2 HYDRAULIC PUMP
3 HST MOTOR
4 CONTROL VALVE
5 BOOM CYLINDER
6 BUCKET CYLINDER
7 QUICK COUPLING
8 QUICK COUPLING
9 VALVE BLOCK
10 DRAIN RELIEF VALVE
10
15 11 OIL COOLER
12 HYDRAULIC FILTER
13 13 SUCTION STRAINER
14 ONE DIRECTIONAL RESTRICTOR
15 CONNECTOR WITH SCREEN FILTER
51
Hydraulic Schematic for 1760XL(DSL802) 8
7
6
11
12 14
5
OPTIONAL SELF LEVELING
B2
A2
BUCKET
CYL.
4
BOOM
B1 CYL.
A1
3 1
2 ITEM COMPONENTS
1 HST PUMP
2 HYDRAULIC PUMP
3 HST MOTOR
4 CONTROL VALVE
5 BOOM CYLINDER
3 6 BUCKET CYLINDER
7 QUICK COUPLING
8 QUICK COUPLING
9 VALVE BLOCK
15
10 11 OIL COOLER
12 HYDRAULIC FILTER
13 SUCTION STRAINER
13 14 ONE DIRECTIONAL RESTRICTOR
52
Hydraulic Schematic for 2060XL(DSL902) 8
7
6
11 9
14
12
5
OPTIONAL SELF LEVELING
B2
A2
4 BUCKET
CYL.
BOOM
B1 CYL.
A1
1
3
2
ITEM COMPONENTS
1 HST PUMP
2 HYDRAULIC PUMP
3 HST MOTOR
4 CONTROL VALVE
5 BOOM CYLINDER
6 BUCKET CYLINDER
7 QUICK COUPLING
8 QUICK COUPLING
3
9 VALVE BLOCK
15
10
11 OIL COOLER
13 12 HYDRAULIC FILTER
13 SUCTION STRAINER
14 ONE DIRECTIONAL RESTRICTOR
53
SB4038E00
Jul. 2000
Electric Systems
1550XL(DSL702)
1760XL(DSL802-D430)
2060XL(DSL902)
WARNING
in injury or death.
publication.
available.
Electric Systems 1 E/G Starting & Stop System

Electric Systems
1. E/G Starting & Stop System (1550XL(DSL702), 1760XL(DSL802-D430), 2060XL(DSL902))
3
E/G Starting & Stop System
12Volts, 100AH battery with 750 Cold-Cranking Amps.

The start motor is rated 2.5 kW.
Electric Systems
2. Preheating & Charging System (1760XL(DSL802-D430))
4
Preheating & Charging System
The Preheat Controller controls the operation of the Glow Plugs to give better starts to a cold engine.
The controller will turn ON the Preheat Lamp for 5 seconds and also activate the Preheat Relay for 7 seconds.
According to the temperature which is sensed by Thermal Sender, the time of After Heating will be set after starting.
Electric Systems
3. Preheating & Charging System (1550XL(DSL702), 2060XL(DSL902))
5
Preheating & Charging System
The Preheat Controller controls the operation of the Glow Plugs to give better starts to a cold engine.
The controller will turn ON the Preheat Lamp for 5 seconds and also activate the Preheat Relay for 7 seconds.
According to the temperature which is sensed by Thermal Sender, the time of After Heating will be set after starting.
4. Instrument Panel Layout (1760XL(DSL802-D430))
9 10 8 11 14 13 12 15
2 3 4 5 6 7 1 16 17 18 19
A C B D E
1) Key Switch A) On switch

2) Water temperature warning light B) OFF switch
3) Engine oil pressure warning light C) Green indicator light
4) Charge warning light D) detent switch ON
5) HST oil temperature warning light E) Detent switch OFF
6) HST pressure warning light
7) Oil filter warning light NOTE : The left-hand instrument panel is a sealed
8) Warning light unit. Warning lamps cannot be replaced individually.
9) Stop light In the right-hand unit, the pre-heat light (12) and
10) Buzzer parking brake light (13) can be replaced from the
11) Light switch back.
12) Pre-heat light
13) Parking brake light NOTE : Refer to 5.4.1 MONITORING SYSTEM.
14) Fuel gage
15) Hour meter
16) Fuse-lamp
17) Fuse-instrument panel
18) Fuse-start
19) Fuse-horn
Electric Systems 6 Instrument Panel Layout

5. Instrument Panel Layout (1550XL(DSL702), 2060XL(DSL902))
15 3 4 2 5 14 11 E D
B
12 10 8 6 9 7 13 A C
Instrument Panel-LH Instrument Panel-RH
1) Key Switch A) On switch

2) Water temperature warning light B) OFF switch
3) Engine oil pressure warning light C) Green indicator light
4) Charge warning light D) detent switch ON
5) HST oil temperature warning light E) Detent switch OFF
6) HST pressure warning light
7) Oil filter warning light NOTE : Reter to MONITORING SYSTEM
8) Warning light(Yellow)
9) Stop light(Red)
10) Sediment
11) Light switch
12) Pre-heat light
13) Parking brake light
14) Fuel gage
15) Hour meter
Electric Systems 7 Instrument Panel Layout

Electric Systems
6. Monitoring System (1760XL(DSL802-D430))
8
Monitoring System
Electric Systems
7. Monitoring System (1550XL(DSL702), 2060XL(DSL902))
9
Monitoring System
Electric Systems
- Relay, solenoid valve, spool motion of control valve and direction of pump flow to attachment quick coupler port
8. Operation of the related parts in momentary control & detent control

Operation Relay Attachment Attachment Flow out of
(1760XL(DSL802-D430), 1550XL(DSL702), 2060XL(DSL902))

mode Operation by operator operation spool spool motion attachment
solenoid of hydraulic line port on
activation control valve boom(left side)
Button(A,C)on Detent rocker Thumb button
forward control switch(D,E) on on right control
panel forward control lever
panel
Momentary Pushing button(A) Pushing switch(E) Neutral ON relay - - -
control
Pushing switch(E) Keep depressing ON relay FWD solenoid Spool-out Down side
left hand side F1 relay
of button F2 relay
Pushing switch(E) Keep kepressing ON relay REV solenoid Spool-in Upper side
right hand side R1 relay
of button R2 relay
10
Pushing button(C) Either way Either way - - - -

Detent Pushing button(A) Pushing switch(D) Neutral ON relay - - -
control D1 relay
Operation of the related parts in momentary
D2 relay
Pushing switch(D) -Keep depressing ON relay FWD solenoid Spool-out Down side
left handside F1 relay
of button, F2 relay
-After that D1 relay
releasing button D2 relay
control & detent control
Pushing switch(D) -Keep depressing ON relay REV solenoid Spool-in Upper side
right hand side R1 relay
of button, R2 relay
-After that D1 relay
releasing button D2 relay
Pushing button(C) Pushing switch(E) Either way - - - -
NOTE : Refer to Schematic-Elec for Thumb Control.

Electric Systems
9. Thumb Control (1760XL(DSL802-D430))
11
Thumb Control
Electric Systems
10. Thumb Control (1550XL(DSL702), 2060XL(DSL902))
12
Thumb Control
11. Lights and Options
Dual front and single rear area flood lights for

standard.
Available Options
Strobe light
Horn
Back up buzzer
Heater
Cigar lighter
NOTE : Refer to WIRING SCHEMATIC - ELEC.
Electric Systems 13 LIGHTS and OPTIONS

12. Item Descriptions and Functions 4) Charge warning Light
(1550XL(DSL702), 2060XL(DSL902))
1) Key Switch
The light turns on when trouble occurs in the

charging system.
2) Water Temperature Warning Light 5) HST Oil temperature Warning Light
The light turns on when the temperature of the The light turns on when the temperaturre of the
engine cooling water exceeds 110C (230 F). hydraulic oil to drive HST goes up to 100C (212 F).
3) Engine Oil Pressure Warning Light 6) HST Pressure Warning Light
The light turns on when the engine oil pressure is The light turns on when the pressure of the HST
below 0.5 kg/cm2(15 psi). pump oil falls below 6.0 kg/cm2 (85 psi).
Electric Systems 14 Item Descriptions and Functions

7) Oil filter warning Light 10) Buzzer
If the oil filter becomes clogged, the light turns on. The light turns ON when the water exceeds 100cc
in the fuel filter.
8) Warning Light 11) Light Switch
The light turns on simultaneously with Charge HST Step 1 : Two front lights turn on.
oil temperature, HST pressure and oil filter warning Step 2 : Two front lights and one rear light turn on
lights. simultaneously.
9) Stop Light 12) Pre-heat Light
The light turns on simultaneously with water When the key is turned to the IGN position, the
temperature and engine oil pressure warning lights. glowplug relay turns on this light.

13) Parking Brake Light Buzzer
Raising the hand lever, the parking brake is The buzzer is activated simultaneously with water
engaged and the light turns on. temperature and engine oil pressurre warning lights.
14) Fuel Gage
Fuel gage shows the amount of fuel in the fuel tank.
15) Hour meter
Hour meter indicates the total hours of vehicle

operating.

13. Trouble Shooting 13.2. Trouble Shooting Guide
13.1. Test Equipment NOTE 1 : The DSL has no electrical shutdowns, only
visual and auditory indicators.
The following items should be sufficient to allow you
to perform most electrical troubleshooting operations NOTE 2 : The lighting, instrument panel, and start
on the electrical system. (key switch) fuses (and horn fuse-optional, if
equipped) located in the right-side instrument panel
Volt/ohmmeter (Multimeter) are all 15-amp tube-type fuses.
Jumper wires (variety of lengths) with alligator clip
ends The following troubleshooting guide presents
Needle tips possible causes and actions in a logial order from
External 12-volt source simplest/most likely to more complex/less likely
Wiring diagrams (more drastic). For any symptom, if a given action
does not identify the problem, proceed to the next
action.
Symptom Possible Cause Action

Discharged battery Loose/damaged alternator belt. Tighten/replace belt.
Loose/dirty connections. Adjust/clean clamps, posts.
Battery faulty. Replace battery.
Alternator faulty. Check or replace.
Engine does not crank Battery may be discharged. Check battery condition.
Start fuse may be blown. Check fuse in instrument panel.
Problem in neutrl safety Wiggle drive levers while trying to
mechanisms. start. If engine starts, adjust neutral
switches and/or centering control(s).
Neutral switch(es) may be faulty. Jumper neutral switch(es) one at a
time. If engine starts, replace neutral
switch(es).
Start relay may be faulty. Jumper start relay. If engine starts,
replace start relay.
Engine cranks but does not start Loader is out of fuel. Check fuel tank.
Engine has starting problem not Check engine. See section
related to electrical system. Engine in this manual.
Alternator may be faulty. Check alternator.
Glow plug does not work Wiring problem. Check glow plug wiring.
Glow plug relay may be faulty. Check wiring to relay. Jumper relay.
If glowplug works, replace relay.
Glow plug elements(s) may be Check elements. If problems found,
faulty. replace glow plug.
Instrument panel indicator lights do Fuse may be blown Check/replace fuse in instrument
not come on or give faulty panel.
indications. Control unit may be faulty Replace control unit.
Individual panel lights do not Bulbs may be faulty. Check/replace bulbs.
come on. Wiring to light may be faulty. Check individual wiring.
Repair faulty connections or replace
wires.
Electric Systems 17 Trouble shooting

Symptom Possible Cause Action
Fuel gage does not work or gigves Sender wiring may be faulty. Check wiring between meter and
faulty indication (other instrument instrument panel. Check sender
panel functions are OK) ground.
Gage may be faulty. Replace gage.
Hour meter does not register hours Meter wiring may be faulty. Check meter wiring.
(other instrument panel functions
are OK). Meter may be faulty. Replace meter.
Rear or front flood lights do not Fuse may be blown in instrument Check/replace fuse in instrument
turn on. panel. panel.
Bulb(s) may be burned out. Check/replace bulbs.
Wiring may be faulty. Check connections and wires.
Check connections in cab wiring
connector.
Electric Systems 18 Trouble shooting

1
WIRING SCHEMATIC-ELECTRIC
MODEL : 1760XL(DSL802)
(FOR D430 E/G)
2
WIRING SCHEMATIC-ELEC
MODEL : 1550XL(DSL702), 2060XL(DSL902)
WARNING
Do not start, operate or service this machine unless you have read and understood these instructions
and received proper training.
Unsafe or improper use of the machine may cause serious injury or death.
Operators and maintenance personnel must read this manual and receive training before operating or
maintaining the machine.
This manual should be kept with the machine for reference and periodically reviewed by the machine
operator and by all personnel who will come into contact with it.
The following warning is povided pursuant to California Health & Safety Code Sections 25247.5 et, seq,
WARNING
California Proposition 65
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
S-1
FOREWORD
This manual explains the safety rules, lubrication, testing and controls to operate and maintain the DAEWOO Skid
Steer Loader for safe and optimal performance.
The operator should be familiar with all of the contents of this manual before starting the vehicle to insure maxi-
mum performance, safety and economy.
Descriptions explain the testing, starting, operation, and stop procedures in detail.
To maintain the vehicle in top condition, the operator should periodically check the vehicle in accordance with the
service schedule.
The periodic maintenance intervals in this manual are based on the service hour meter.
Environment Management
Note that DAEWOO INDUSTRIAL VEHICLE DIVISION is ISO 14001 certified which is harmonized with ISO 9001
Periodic ENVIRONMENTAL AUDITS & ENVIRONMENTAL PERFORMANCE EVALUATIONS have been made by
internal and external inspection entities. LIFE - CYCLE ANALYSIS has also been made through out the total prod-
uct life. ENVIRONMENT MANAGEMENT SYSTEM includes DESIGN FOR ENVIRONMENT from the initial stage
of the design.
ENVIRONMENT MANAGEMENT SYSTEM considers environmental laws & regulations, reduction or elimination of
resource consumption as well as environmental emission or pollution from industrial activities, energy saving, envi-
ronment - friendly product design(lower noise, vibration, emission, smoke, heavy metal free, ozone depleting sub-
stance free, etc.), recycling, material cost reduction, and even environmentally oriented education for the employee.
S-2
SAFETY INFORMATION
This is the safety-alert symbol.

When you see this symbol on your machine
or in this manual, be alert to the
potential for personal injury.
Follow recommended precautions and
safe operating practices
HA0OA00I
S-3
SIGNAL WORDS
A signal word - DANGER, WARNING, or CAUTION - is

used with the safety-alert symbol.
DANGER : Indicates an imminently hazardous situation

which, if not avoided, will result in DEATH or SERIOUS
INJURY.
DANGER
WARNING : Indicates a potentially hazardous situation
which, if not avoided, COULD result in DEATH or SERI- WARNING
OUS INJURY.
CAUTION : Indicates a potentially hazardous situation CAUTION

which, if not avoided, MAY result in INJURY.
ATTENTION : Indicates potential machine damage if a ATTENTION

certain procedure is not followed.
IMPORTANT : Indicates information an operator should

IMPORTANT
know to prevent minor machine damage if a certain proce-
dure is not followed. IACOA00I
S-4
WARNING SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual and all safety labels
on your machine. Keep safety labels in good condition. Replace missing or CAU
TIO
N
NING
damaged safety labels. Be sure new equipment components and WAR
repair parts include the current safety labels. Learn how to operate the
machine and how to use controls properly. Do not let anyone operate
the machine without instruction. Keep your machine in proper working
condition. Unauthorized modifications to the machine may impair operator
safety and well being and/or machine life and function.
HA0OA01I
DANGER SAFETY RULES
ONLY trained and authorized personnel should operate and maintain the machine.
Use common sense and follow all safety rules, precautions and instructions when operating or perform-
ing maintenance on the machine.
When working with another person, be sure all hand signals to be used are understood.
Certain operating conditions may require reference to applicable OSHA, ANSI, ISO, EEC or other local
and national regulations. Consult your supervisor or safety coordinator to be sure all applicable stan-
dards are being followed, and for special operating conditions.
Never operate equipment under the influence of drugs or alcohol. Certain prescription and over-the-
counter medications can affect alertness and coordination. Follow instructions on labels and/or consult
your physician. Notify your supervisor or consult your physician for clarification.
S-5
CONTENTS
1.0. OWNER/OPERATOR SAFETY OVERVIEW

1.1. Safety Message for Owners and Operators ..........................................................................................1
1.1.1. Owner/Employer Responsibility ................................................................................................1
1.1.2. Operator Responsibility ..............................................................................................................2
1.2. Maintaining a Safe Workplace ................................................................................................................3
1.3. Matching the Machine to the Job ..........................................................................................................4
1.3.1. Warning Signal Options..............................................................................................................4
1.3.2. Modifications ..............................................................................................................................4
1.4. Maintenance Practices ..........................................................................................................................5
1.5. Operator Safety Training ........................................................................................................................5
1.5.1. Formal Training ..........................................................................................................................5
1.5.2. Inspection Training ....................................................................................................................6
1.5.3. Training Program Development ................................................................................................6
1.5.4. Practical Training........................................................................................................................7
1.5.5. Recognition ................................................................................................................................7
1.6. Information Resources for Operation, Maintenance, and Safety ..........................................................7
2.0. SAFETY INFORMATION

2.1. Safe Operating Practices........................................................................................................................9
2.2. Rated Operating Load Plate ................................................................................................................11
2.3. Safety Warning Label Locations and Descriptions ..............................................................................12
2.3.1. Label Locations ........................................................................................................................12
2.3.2. Label Descriptions....................................................................................................................13
2.4. General Safety and Hazard Information ..............................................................................................17
S-7
cont. 2.0 SAFETY INFORMATION
2.4.1. Unauthorized Modification ......................................................................................................17

2.4.2. Clothing and Personal Protective Items..................................................................................17
2.4.3. Mounting and Dismounting ......................................................................................................18
2.4.4. Fire Prevention and Hazardous Fluids and Vapors ................................................................19
2.5. Operating Safety ..................................................................................................................................20
2.5.1. Work Site Safety ......................................................................................................................20
2.5.2. Operators Cab ........................................................................................................................21
2.5.3. Safe Operating Practices ........................................................................................................21
2.5.4. Ventilation for Enclosed Areas ................................................................................................22
2.5.5. Flammable and Explosive Atmospheres ..................................................................................22
2.5.6. Precautions for Mirrors, Windows, and Lights ........................................................................23
2.5.7. Ensuring Visibility ....................................................................................................................23
2.5.8. Traveling in Reverse, Safe Working Zone ..............................................................................24
2.5.9. Avoiding High-Voltage Cables..................................................................................................24
2.5.10. Operating on Snow ..................................................................................................................25
2.5.11. Working on Loose Ground or Uneven Surfaces ......................................................................25
2.5.12. Preventing Crushing or Cutting ................................................................................................26
2.5.13. Parking ....................................................................................................................................26
2.5.14. Precautions for Attachments ....................................................................................................27
2.5.15. Precautions for Loading and Emptying the Bucket ..................................................................27
2.6. Maintenance Safety ..............................................................................................................................28
2.6.1. Periodic Maintenance ..............................................................................................................28
2.6.2. Precautions for High Temperature Operations ........................................................................29
2.6.3. Maintaining and Inspecting Hydraulic Equipment ....................................................................30
2.6.4. Precautions for High Pressure Oil............................................................................................31
S-8
2.6.5. Battery Hazard Precautions ....................................................................................................32

2.6.6. Waste Material Precautions ....................................................................................................33
2.6.7. Rotating Fans and Belts ..........................................................................................................33
2.6.8. Tire Maintenance......................................................................................................................34
3.0. SERIAL NUMBER LOCATIONS

3.1. Vehicle Serial Number ..........................................................................................................................35
3.2. Engine Serial Number ..........................................................................................................................35
4.0. MACHINE COMPONENTS

4.1. Identification of Machine Parts ............................................................................................................36
5.0. CONTROLS AND INSTRUMENTS

5.1. Instrument Panel ..................................................................................................................................38
5.2. Controls ..............................................................................................................................................42
5.2.1. Drive Control Lever ................................................................................................................42
5.2.2. Pedals ....................................................................................................................................43
5.2.3. Boom Pedal ............................................................................................................................43
5.2.4. Attachment Pedal ....................................................................................................................44
5.2.5. Bucket Pedal ..........................................................................................................................44
5.2.6. Engine Control & Auxiliary hydraulic attachment bleed off ....................................................45
5.2.7. Seat Bar ..................................................................................................................................46
6.0. OPERATING INSTRUCTIONS

6.1. Inspection Before Boarding ................................................................................................................47
S-9
cont. 6.0. OPERATING INSTRUCTIONS
6.2. Boarding the Loader ............................................................................................................................47

6.3. Starting..................................................................................................................................................48
6.4. Traveling and Steering ........................................................................................................................50
6.5. Operation ............................................................................................................................................51
6.6. Traveling on a Slope, Parking ............................................................................................................54
6.7. Towing Procedures ..............................................................................................................................55
6.8. Lifting ..................................................................................................................................................56
6.9. Transportation ......................................................................................................................................57
6.10. Bucket and Attachments ......................................................................................................................58
6.11. Boom Lock Operation.......................................................................................................................... 61
7.0. PERIODIC MAINTENANCE

7.1. Safety Warnings....................................................................................................................................63
7.2. Access to Items Requiring Service ......................................................................................................64
7.2.1. Rear door and engine hood ....................................................................................................64
7.2.2. Canopy Tilting ..........................................................................................................................65
7.3. Daily Pre/Post Start Checks ................................................................................................................66
7.3.1. Pre-Start Checks ......................................................................................................................66
7.3.2. After Starting-Before Operation................................................................................................67
7.4. Service Schedule ................................................................................................................................68
7.5. Lubrication Points ................................................................................................................................70
7.6. Operator Restraint Lubrication and Maintenance ................................................................................74
7.6.1. Lubrication ..............................................................................................................................75
7.6.2. Function ..................................................................................................................................75
7.7. Engine Lubrication ..............................................................................................................................75
S-10
cont. 7.0 PERIODIC MAINTENANCE
7.7.1. General ....................................................................................................................................76

7.7.2. Draining Engine Oil ..................................................................................................................76
7.7.3. Remove/Replace Engine Oil Filter ..........................................................................................76
7.8. Engine Cooling System ........................................................................................................................77
7.9. Fan Belt ................................................................................................................................................78
7.9.1. Belt Tension ..............................................................................................................................78
7.9.2. Adjustment................................................................................................................................78
7.10. Two Stage Air Filter ..............................................................................................................................79
7.10.1. Removal-Primary Element ......................................................................................................79
7.10.2. Removal-Secondary Element ..................................................................................................80
7.10.3. Installation ................................................................................................................................80
7.11. Spark Arrestor ......................................................................................................................................80
7.11.1. General ....................................................................................................................................80
7.11.2. Maintenance ............................................................................................................................81
7.12. Battery ..................................................................................................................................................81
7.12.1. Remove and Install ..................................................................................................................81
7.12.2. Jump Starting the Loader ........................................................................................................82
7.13. Priming the Fuel System ......................................................................................................................83
7.13.1. Remove/Installation-Fuel Filter ................................................................................................83
7.13.2. Fuel Tank Drain ........................................................................................................................84
7.14. Injection Pump Priming ........................................................................................................................84
7.15. Hydraulic System Maintenance ............................................................................................................85
7.15.1. Oil Level Indicator ....................................................................................................................85
7.15.2. Filter Replacement ..................................................................................................................86
7.15.3. Hydraulic Fluid Replacement ..................................................................................................87
S-11
7.16. Chain Case Drain and Refill ................................................................................................................88

7.17. Parking Brake Adjustment ....................................................................................................................89
7.18. Tire Maintenance ..................................................................................................................................90
7.18.1. General Information..................................................................................................................90
7.18.2. Inflation Pressures....................................................................................................................90
7.18.3. Installation and Removal ..........................................................................................................90
8.0. DIMENSIONAL & PERFORMANCE SPECIFICATION

8.1. Dimensional Specifications ..................................................................................................................91
8.2. Operational Specification (Per SAE J732 Feb 80) ..............................................................................95
8.2.1. Performance ............................................................................................................................95
8.2.2. Power Unit................................................................................................................................95
8.2.3. Final Drive Components ..........................................................................................................96
8.2.4. Hydrostatic Transmission Pump ..............................................................................................96
8.2.5. Hydraulic System ....................................................................................................................97
8.2.6. Electrical Components ............................................................................................................98
8.2.7. Instrument Features ................................................................................................................99
8.2.8. Seat ..........................................................................................................................................99
8.2.9. Fluid Capacities & Specifications ..........................................................................................100
ENVIRONMENT PROTECTION SECTION

WORLDWIDE NETWORK
S-12
1. OWNER/OPERATOR SAFETY also includes establishing daily inspections
OVERVIEW and scheduled maintenance practices to
ensure the equipments ongoing safe operat-
1.1. Safety Message for Owners and ing condition.
Operators
The manual you are reading now is intended
Your DAEWOO equipment has been designed to help you meet your responsibilities. It iden-
with the safety of the persons who will operate tifies warning labels on the equipment and
and service it in mind. However, our care in explains what they mean. It describes some
designing this equipment does not guarantee of the general and specific hazards to be
that it will be used in a safe manner. Safe aware of when operating the equipment. It
operating practice is where your responsibility also offers some suggestions for establishing
and the responsible actions of the persons workplace rules and operator training pro-
who operate this equipment take over. grams.
1.1.1. Owner/Employer Responsibility As the owner/employer, you also have the

Both the Occupational Safety and Health Act responsibility to be certain that the equipment
(OSHA) and the American National Stan- you have placed into service is capable of
dards Institute (ANSI) make you, the employ- doing its intended job. This includes match-
er, responsible for providing formal training ing equipment design to working conditions,
and a safe workplace environment for the capacity to the size of loads it will be han-
use of this equipment. Your responsibility dling, and selecting suitable attachments and
-1-
options. This section of the manual discuss- Recognize and avoid potential hazards in
es these issues as well. your workplace.
At the end of this overview, we list specific Understand and abide by the Warning labels
OSHA, ANSI, and other published resources attached to the equipment.
you can consult for ways to help you comply Inspect the equipment for its serviceability at
with safety requirements for the use of this the beginning of each shift.
equipment in your workplace. Report immediately any service problems you
notice before you use the equipment or that
1.1.2. Operator Responsibility develop while you are using it.
Report immediately any unsafe workplace
If your job includes operating this equipment,
conditions that threaten your safety or the
you should first get formal training in how to
safety of others.
operate it properly and safely. Furthermore,
Avoid horseplay or other reckless actions that
you should ensure that your workplace is
you know endanger yourself or others.
maintained to assure your continued safety
and the safety of others around whom you
In short, every operator of this equipment has
work.
the responsibility to use common sense at all
times and to make safety his or her number
In addition, you, the operator, have the
one job priority.
responsibility to:
Follow the safety practices in which you are

trained - every day.
-2-
1.2. Maintaining a Safe Workplace
As we said, operators should recognize and When the equipment is driven onto trailers, use
avoid hazards in the workplace. Although some wheel chocks and jack supports if necessary to
injuries occur because of unsafe operating prevent creeping and possible collapse.
practices, many result from unnecessary work- Develop - and enforce - workplace safety rules
place hazards. To maintain a safe workplace for all employees.
environment for this equipment, do the follow- Post these rules conspicuously in the areas
ing: where they apply.
Remove physical hazards where the equipment Many appropriate workplace rules are published
will be operated, in either the plant or the yard. by OSHA, ANSI, and the National Safety
Separate pedestrian and equipment traffic Council. (See the list below under Information
wherever possible. Resources for Operation, Maintenance, and
Place convex mirrors at blind intersections. Safety.) We recommend that you consult
Require the use of horns at intersections or these publications as you develop and update
when approaching pedestrian areas. the safety rules for your workplace.
Establish equipment speed limits.
Install and maintain backup alarms and flashing
caution lights on equipment.
Use edge guards, levelers and trailer locks on
docks.
-3-
1.3. Matching the Machine to the Job

Every employer and operator should ensure effective warning signal devices to meet the
that equipment is properly suited to the job it conditions of your application.
must perform. It should be selected with condi-
tions and capacity well in mind, otherwise oper- 1.3.2. Modifications
ators and other workers may face hazards
Many times the addition of a special attach-
resulting directly from wrong equipment selec-
ment can affect the ability of equipment to
tion. Furthermore, equipment suited for one
operate at the capacity originally intended.
job or environment may not be suitable at all
When modifications potentially change equip-
when moved to a different work area.
ment safety, OSHA and ANSI require you to
obtain written approval from the manufactur-
Equipment should be used for its intended pur-
er. If a modification changes a machines
pose only. For example, lift truck forks and
capacity, the machines capacity plate must
skid steer loader buckets should never serve
also be changed. Consult your DAEWOO
as man-lifts or mobile work platforms.
dealer before making modifications to your
equipment.
1.3.1. Warning Signal Options
ANSI requires audible or visual alarms in
high noise or low lighting environments, or in
areas where pedestrians and equipment
intermix. Your DAEWOO dealer can provide
-4-
1.4. Maintenance Practices 1.5. Operator Safety Training
Well maintained equipment is safer equipment. Although this manual contains much informa-
A regular program of scheduled maintenance tion about safety practices, it is not meant to be
should be part of your facilitys ongoing safety a training manual for new operators. An
program. Daily inspections or inspections at employers responsibility extends beyond hand-
the start of every shift are required by OSHA. ing an employee this or any other document
Your DAEWOO dealer can help you train your and saying read this to learn how to operate
operators for this task and provide you with this equipment.
genuine replacement parts and service equip-
ment when scheduled (or unscheduled) main- 1.5.1. Formal Training
tenance and repairs are needed.
OSHA and ANSI require formal training for
new operators and refresher training for ex-
Although operators have a daily responsibility
perienced operators, along with appropriate
to inspect and report service problems, OSHA
on-the-job supervision. Furthermore, training
and ANSI standards require that equipment
must be tailored to the specific conditions of
maintenance and repair be performed by au-
your workplace and the workplace rules you
thorized mechanics only. Understand what is
have developed to protect your employees.
reasonable to expect in this area, and leave the
Whenever work conditions change in ways
serious maintenance and repair tasks to pro-
that affect operator safety, training for the new
fessional mechanics and technicians.
conditions must be provided. Of course,
before any employee can be selected to
-5-
operate industrial or construction type equip- In what areas of our workplace does operating
ment, the employee must meet the employ- the equipment pose hazards to pedestrians?
ers specific visual, auditory, physical and What hazards must operators be trained to
mental ability standards. deal with?
Does our workplace have any one-way aisles,
1.5.2. Inspection Training speed zones, high noise, low light, or fire haz-
ard areas?
OSHA furthermore requires that operators be
What are the specific features of our loading
trained to conduct daily equipment safety
docks, ramps, or railcar loading facilities?
inspections. The goal of these inspections is
What specialized attachments are used on our
to prevent any piece of equipment in need of
equipment?
repairs from being placed into service and
What personal protective equipment or special
thereby endangering personnel. Your DAE-
clothing is necessary to operate the equipment
WOO dealer can help you develop training to
in our work environment? (hard hats, seat
comply to this and to other OSHA/ANSI re-
restraints, respirators, protective shoes or
quirements.
gloves, etc.)
Are operators conducting daily inspections
1.5.3. Training Program Development
prior to shift start?
As noted above, OSHA/ANSI requires your Does our equipment require any special refu-
training to be designed around the conditions eling procedures?
present in your operation. To ensure this, ask
yourself specific questions: One additional recommendation: ask those
-6-
employees who work around (but do not op- 1.6. Information Resources for
erate) the equipment for suggestions about Operation, Maintenance, and
what the operators should be taught. Safety
1.5.4. Practical Training The following publications contain information, in-

structions, and standards for various operation,
The questions above and others like them maintenance, and safety issues related to your
can help you design an appropriate training DAEWOO equipment.
course for your operators. But above all, be
sure that your training incorporates a signifi- General Industry Standards, OSHA 2206:
cant portion of practical experience. OSHA Safety and Health Standards (29 CFR
1910), Subpart N - Materials Handling and
1.5.5. Recognition
Storage; 29 CFR 1910.178 powered industrial
A key part of any training program is recogni- trucks; 1910.177 - Servicing Multi-Piece and
tion. Think of ways you can recognize the Single Rim Wheels. Available from: Superin-
achievement of those who successfully com- tendent of Documents, U.S. Government
plete this important training. Certificates, Printing Office, Washington, DC 20402.
licenses, patches, authorization cards and the
like set these individuals apart and help cre- National Fire Protection (NFPA) 505, Powered
ate a lasting attitude of commitment to the Industrial Trucks, Type Designation, Areas of Use,
job. Maintenance, and Operation. Available from: Su-
perintendent of Documents, U.S. Government
Printing Office, Washington, DC 20402.
-7-
ANSI/ASME B56.1-1988: Safety Standard for Pedestrian. Available from: National Safety
Low Lift and High Lift Trucks (Safety Code of Council, 444 North Michigan Avenue, Chicago,
Powered Industrial Trucks). Available from: IL 60611.
Society of Mechanical Engineers, United
Accident Prevention Manual for Industrial Opera-
Engineering Center, 345 E. 47Th Street, New
York, NY 10017. tions: Two volumes: Administration and
EN474-1: Earth - moving Machinery - Safety - Programs and Engineering and Technology.
General Requirements , Available from: National Safety Council, 444
EN474-3 : Earth - moving Machinery - Safety - North Michigan Avenue, Chicago, IL 60611.
Requirements for Loaders . Publications Concerning Safe Handling and
Available from: European Committee for Storage of LP Gas: Available from: National LP
Standardization, rue de Stassart, 36 B - 105C Gas Association, 1301 West 22nd Street,
Brussels.
Oakbrook, IL 60521
NFPA 58: Storage and Handling of Liquified
Other OSHA regulations which may be applica-
Petroleum Gases. Available from: National Fire
ble to the place of use.
Protection Association, Inc., Batterymarch Park,
Quincy, MA 02269. You can receive help in applying information
Skid-Steer Loader Safety Manual. Available from from these sources to your workplace by con-
the Equipment Manufacturers Institute, 10 S tacting OSHA or your Workers Compensation
Riverside Plaza, Chicago, Illinois 60606-3710. Insurance Company.
National Safety Council Data Sheets: 1-664 -
Writing and Publishing Employee Safety
Regulations; 479 - Liquified Petroleum Gases
for Industrial Trucks; 195.71 - The In-Plant
-8-
2. SAFETY INFORMATION
The following section of this manual discusses rules or take obvious precautions. Often you can
some of the general and specific safety issues avoid an accident by recognizing situations that
for your equipment. It gives you basic safety pre- might be hazardous. Furthermore, anyone who
cautions. It also shows you where to find warn- operates, maintains, or repairs this equipment
ing labels used on this equipment. The warnings should have the necessary training, skills, and
themselves are reproduced here for you to read. tools.
Before you operate or perform any maintenance Improper operation, maintenance, or repair of
on this equipment, read this Safety Information this equipment can be dangerous and could
section carefully. Also carefully read the opera- result in injury or death.
tion and other sections of this manual and heed
all of the safety information they contain. Also Do not operate or perform any lubrication, main-
locate, read, and understand the warning decals tenance, or repair on this equipment until you
on the equipment itself. have read and understood the operation, main-
tenance, and repair information in this manual.
2.1. Safe Operating Practices

You will find safety precautions and warnings
Always use common sense and be alert for pos- both in this manual and on the equipment itself.
sible hazards. Most accidents happen because If you ignore these warnings, bodily injury or
someone failed to follow basic safety death could occur to you or to others.
-9-
Hazards are identified by the exclamation point every possible circumstance that might involve a
(!) Safety Alert Symbol followed by words such hazard. You must ensure that your operating
as DANGER, WARNING, or CAUTION. techniques, tools, and work procedures are safe
for you and others. You should also make sure
that the equipment will not be damaged or made
unsafe by your chosen operation, maintenance,
DANGER or repair procedures.
WARNING The information in this manual was current at

the time the manual was written. However, spec-
CAUTION ifications, torques, pressures, measurements,
IA0OA01I adjustments, and illustrations can change at any
Pay attention to safety alert symbols. They time. These changes can affect
mean your safety and/or the safety of others equipment service. Before starting any job,
is involved. obtain the most current and complete informa-
tion. Consult your DAEWOO dealer for the most
Hazard messages appear with the safety alert current information.
symbol. They explain the hazard, either in words
or by internationally recognized pictures. The safety rules and regulations in this section
represent some, but not all rules and regulations
The dangers, warnings, and cautions in this of the Occupational Safety and Health Act
manual and on the equipment cannot cover (OSHA). They are paraphrased without repre-
- 10 -
sentation that the OSHA rules and regulations 2.2. Rated Operating Load Plate
have been reproduced verbatim.
DO NOT exceed machine rated operating load
as described on the rated operating load plate
The best method for preventing serious injury or
attached to your machine.
death is for the operator to be familiar with the
proper operation of the equipment. Be alert and
avoid actions or conditions that can result in an
accident.
DAEWOO HEAVY INDUSTRIES LTD.
MADE IN KOREA
MACHINE TYPE SKID-STEER LOADER
MACHINE NAME
SERIAL NUMBER
ENGINE POWER kW rpm
OPERATING WEIGHT LBS. kg
OPERATING LOAD LBS. kg
IA0OA02I
- 11 -
2.3. Safety Warning Label Locations and Descriptions

2.3.1. Label Locations
CAUTION
Always keep safety and information labels clean. If they are lost or damaged, attach them again or
replace them with a new label. Safety labels are available in languages other than ENGLISH. Please
contact your dealer or DAEWOO if you need non-English labels.
E E
D
2
3 4 5 6 D
1 DAEWOO HEAVY INDUSTRIES LTD. CO.
THIS STRUCTURE (CANOPY WELDMENT : DSL601-D415200.
1760XL/DSL802-D416447) HAS BEEN TESTED
AND MEETS THE FOLLOWING STANDARDS :
ROPS - ROLLOVER PROTECTIVE STRUCTURE
ISO 3471 FEB '94 AND SAE J1040 MAY '94
FOPS - 3471 FALLING OBJECT PROTECTIVE STRUCTURE
ISO 3449 MAY '92 AND SAE J1043 SEP '87
WARNING CERTIFIED FOR THE FOLLOWING LOADERS :

601 SERIES DAEWOO SKID LOADERS :
BE SURE CANOPY LOCK IS SECURELY LATCHED

W 1760XL DSL802 SERIES DAEWOO SKID LOADERS
D416849
ANYTIME THE CANOPY IS IN THE RAISED POSION.

A
USE MECHANICAL LOCK WHEN LEAVING LIFT
R WARNING
ARMS IN RAISED POSITION FOR SERVICE. N
DAILURE TO HEED MAY RESURT IN DEATH I HOT EXHUAUST AND MUFFLER
OR SEROUS INJURY. N D415546
D415547
G
C
B
C B
A
7
A
IA4O2001
- 12 -
2.3.2. Label Descriptions
1 Danger warning for Boom lock 3 Warning for canopy latch
REMOVING HOSES OR COMPONENT FAILURE WARNING

D CAN CAUSE LIFT ARMS TO DROP.
A USE MECHANICAL LOCK WHEN LEAVING LIFT BE SURE CANOPY LOCK IS SECURELY LATCHED
N ANYTIME THE CANOPY IS IN THE RAISED POSION
ARMS IN RAISED POSITION FOR SERVICE.
G FAILURE TO LOCK CANOPY IN SECURE POSITION
E FAILURE TO HEED MAY RESULT IN DEATH MAY RESULT IN INJURY OR DEATH AFTER
R OR SERIOUS INJURY. LOWERING CANOPY MAKE SURE THAT LOCKING
D415530 BOLTS ARE IN PLACE AND TIGHT
D415547
IA0OA11I
IA0OA10I
2 Boom Lock Operation
TO ENGAGE BOOM LOCK TO DISENGAGE BOOM LOCK

THE RELEASE LEVER SHOULD REMAIN LOCK POSITION THE RELEASE LEVER SHOULD BE IN THE RELEASE POSITION
IN LOCKED POSITION WITH BOOM RELEASE POSITION ONLY WHEN RELEASING
IN UP AND LOCKED POSITION THE BOOM LOCK
HOLD LOCK ARM REMOVE KNOB ROTATE LEVER CLOCKWISE TO RELEASE POSITION
LOWER LOCK ARM ONTO CYLINDER RAISE BOOM TO HIGHEST POSITION
ENSURE RELEASE LEVER IS IN LOCKED POSITION LOWER BOOM SLOWLY TO LOWEST POSITION
RAISE BOOM UNTIL LOCK ARM RESTS LIFT BOOM LOCK ARM, ROTATE LEVER COUNTER-CLOCKWISE
ON THE CYLINDER ROD MOUNT LOCK ARM IN ORIGINAL POSITION USING KNOB
LOWER BOOM SLOWLY UNTIL THE LOCK ENGAGES
AGAINST TOP CYLINDER D415332
IA0OA12I
- 13 -
4 Warning for engine fan 6 ROPS/FOPS
DAEWOO HEAVY INDUSTRIES LTD. CO.

THIS STRUCTURE HAS BEEN TESTED AND
MEETS THE FOLLOWING STANDARDS :
ROPS - ROLLOVER PROTECTIVE STRUCTURE
W ISO 3471 FEB '94 AND SAE J1040 MAY '94
FOPS - FALLING OBJECT PROTECTIVE STRUCTURE
A ISO 3449 MAY '92 AND SAE J1043 SEP '87

CERTIFIED FOR THE FOLLOWING LOADERS :
R 600kg SERIES DAEWOO SKID LOADERS

800kg SERIES DAEWOO SKID LOADERS
N D422635
I IA0OA07I
N 7 Warning for Universal Attachment System

G D415545 (Quick-tach)
IA0OA08I
UNLATCHED WARNING LATCHED
5 Warning for high temperature muffler ALWAYS ASSURE

THAT LATCHED ARE
FULLY ENGAGED.
D415534
WARNING View A- A IA0OA05I
HOT EXHUAUST AND MUFFLER

D415546
IA0OA09I
- 14 -
WARNING DANGER
ALWAYS WEAR SEAT BELT. BEFORE LEAVING SEAT :

ALWAYS OPERATE WITH SEAT LOWER BOOM OR ATTACHMENTS
BAR IN DOWN POSITIONL TO THE GROUND.
AVOID SUDDEN AND ABRUPT STOP ENGINE.
MACHINE OPERATION.
SET PARKING BRAKE.
NEVER CARRY RIDERS. RAISE THE SEAT BAR.
NEVER USE LOADER AS TO EXIT WHILE THE BOOM IS IN A
MANLIFT OR WORK
PLATFORM.
D415532 D415535
8
9 10
3
VIEW "B-B" View "C-C"

(Inside of Canopy RH) (Inside of Canopy. LH)
IA4O2002 IA0OA17I
8 Warning for general safety rules. 9 Warning for fastening seat belt and seat bar.
WARNING
WARNING
AVOID DEATH OR SERIOUS INJURY
READ AND UNDERSTAND THE OPERATOR'S MANUAL PRIOR ALWAYS WEAR SEAT BELT.
TO OPERATING THIS MACHINE FAILURE TO FOLLOW THESE ALWAYS OPERATE WITH SEAT
PRECAUTIONS CAN CAUSE INJURY OR DEATH.
CARRY LOAD LOW.
BAR IN DOWN POSITION.
AVOID STEEP SLOPES AND HIGH SPEED TURNS. AVOID SUDDEN AND ABRUPT
TRAVEL SLOWLY OVER ROUGH TERRAIN. MACHINE OPERATION.
NEVER CARRY MORE THAN RATED OPERATING LOAD.
NEVER PLACE ANY PART OF YOUR BODY UNDER BOOM NEVER CARRY RIDERS.
OR ATTACHMENTS.
KEEP BOTH FEET ON PEDALS AND BOTH HANDS ON
NEVER USE LOADER AS
CONTROLS WHILE OPERATING MACHINE. MANLIFT OR WORK
D416620
PLATFORM.
D415532
IA0OA15I IA0OA13I
- 15 -
10 Danger warning for maintenance. 12 Anti-Skid surface
DANGER FRAME
BEFORE LEAVING SEAT :

LOWER BOOM OR ATTACHMENTS BOOM
TO THE GROUND.
STOP ENGINE.
SET PARKING BRAKE.
RAISE THE SEAT BAR. D422441 D416315
BE SURE PEDALS ARE LOCKED.
TO EXIT WHILE THE BOOM IS IN A
RAISED POSITION, THE BOOM
LOCK MUST BE ENGAGED. (SEE
INSTRUCTIONS ON OUTSDE OF D422440
BOOM LOCK OR OPERATION
MANUAL.)
D415535
IA0OA14I
11 Service Shedule label
View "E-E" IA0OA18P
View D-D IA4O2004
- 16 -
2.4. General Safety and Hazard Information
2.4.1. Unauthorized Modification
WARNING UNAUTHORIZED MODIFICATION
Any modification made without authorization from DAEWOO can create hazards.
Before making a modification, consult your DAEWOO dealer.
Improper modification could result in injury or death.
Improper use of safety features could result in serious bodily harm or death.
2.4.2. Clothing and Personal Protective Items
WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS
Do not operate or perform system maintenance with loose clothing,

jewelry, and loose long hair. They can catch on controls or in mov-
ing parts and cause serious injury or death. Also, do not wear oily
clothes or wear or have other flammable substances around the
equipment.
Always wear personal protective equipment appropriate for your
working conditions, such as a hard hat, safety shoes, hearing pro-
tection, mask and gloves. HA0OA02I
- 17 -
2.4.3. Mounting and Dismounting
CAUTION MOUNTING AND DISMOUNTING
NEVER jump on or off the machine. NEVER get on or off a moving machine.
When mounting or dismounting, always face the machine and use the handrails.
Do not grasp or come in contact with any control levers when getting on or off the machine.
Ensure safety by always maintaining at least three-point contact of hands and feet with the
handrails and steps.
Always remove any oil or mud from the handrails, steps and shoes.
NEVER mount or dismount the machine with engine running.
HA0OA03I
- 18 -
2.4.4. Fire Prevention and Hazardous Fluids and Vapors
DANGER FIRE PREVENTION AND HAZARDOUS FLUIDS AND VAPORS
Fuel, oil, antifreeze, and other flammable fluids and combustibles can be ignited by a flame or hot sur-
faces. Vapors can be particularly FLAMMABLE and can be HAZARDOUS.
Keep open flame and hot surfaces away from flammable fluids and combustibles.
Stop the engine and do not smoke when refueling.
Tighten all fuel and oil caps securely.
Refueling and oiling should be done in well ventilated areas.
Keep oil and fuel in a designated area and do not allow unauthorized persons to enter.
Thoroughly remove wood chips, leaves, paper and other flammable items accumulated in the engine
compartment .
Check fuel and hydraulic systems for leaks prior to starting or using vehicle.
Have any leaks repaired before operating the machine.
Wipe up any excess oil, fuel or other flammable fluids.
Be sure a fire extinguisher is present and working and that personnel are properly trained in extin-
guisher operation.
Never use ether or other starting aids on any engine with glow plugs or other engine preheating devices.
See OSHA Class 1910.178.
Avoid skin contact, injestion and excessive breathing of vapors from fuel, oil, antifreeze, and other fluids.
See California Proposition 65 in the front of this book.
HA0OA04I
- 19 -
2.5. Operating Safety

2.5.1. Work Site Safety
WARNING SAFETY AT WORK SITE
Before starting the engine, thoroughly check the area for any
unusual conditions that could pose a hazard.
Before starting the engine, examine the terrain and soil condi-
tions of the work site. Determine the best and safest method
of operation.
If you need to operate on a street, protect pedestrians and

cars by designating a person for work site traffic duty and/or
by installing fences around the work site.
Water lines, gas lines, and high-voltage electrical lines (or

other objects) may be buried under the work site. Contact
each utility and identify their locations. Be careful not to sever
or cut any of these lines.
IA0OA16S
DAEWOO does not recommend operation of loader in moving
water. User should consult a supervisor or safety coordinator
anytime water is encountered for any special operating proce-
dures.
- 20 -
2.5.2. Operators Cab
WARNING IN OPERATORS CAB
Do not leave tools or spare parts lying around in the operators compartment. They may damage,
break, or interfere with the control levers or switches.
Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
Always check the seat belt, seat bar, and hardware for damage or wear. Replace any worn or dam-
aged parts. Always use seat belts and seat bar when operating your machine.
2.5.3. Safe Operating Practices
WARNING SAFE OPERATING PRACTICES
Never use vehicle as a personnel lift.

Never carry riders, vehicle is designed for single operator only.
Keep bystanders out of work area.
Always keep bucket or attachments as low to the ground as possible during all machine operations.
Loading, unloading, and turning should be performed on flat, level surfaces.
Never exceed machines rated capacity.
- 21 -
2.5.4. Ventilation for Enclosed Areas
DANGER
,,,
VENTILATION FOR ENCLOSED AREAS
If it is necessary to start or run the engine within an enclosed area, provide
,,,
adequate ventilation. Exhaust fumes from the engine can KILL.
HA0OA07I
2.5.5. Flammable and Explosive Atmospheres
DANGER FLAMMABLE AND EXPLOSIVE ATMOSPHERES
NEVER OPERATE A LOADER IN AN AREA WITH A FLAMMABLE/EXPLOSIVE ATMOSPHERE!
A standard loader or a loader equipped with a spark arrestor/spark arresting muffler cannot be
operated in these areas. Use of these machines in flammable/explosive atmospheres can result in
fires and/or explosions which could cause serious injury or death.
See Code of Federal Regulations (OSHA) 29CFR Part 1910.178, to determine where machines
which are approved and labeled as G, GS, D, DS, DY, LP, LPS, G/LP, or GS/LPS are permitted to
operate.
- 22 -
2.5.6. Precautions for Mirrors, Windows, and Lights
CAUTION PRECAUTIONS FOR MIRRORS, WINDOWS AND LIGHTS
Always remove all dirt from the surface of the windows and lights to ensure that you can see well.
Check that the head lamps and working lamps are installed to match the operating conditions.
Check also that they light up properly.
2.5.7. Ensuring visibility
CAUTION ENSURE GOOD VISIBILITY
When working in dark places, install working lamps and head lamps, and set up lighting in the
work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or other cause, and wait for con-
ditions to improve to a level that allows the operation to be carried out safely.
- 23 -
2.5.8. Traveling in Reverse, Sate Working Zone
DANGER CHECK THAT NO ONE IS NEAR THE MACHINE BEFORE MOVING, TURNING,
TRAVELING IN REVERSE OR OPERATING ANY ATTACHMENTS
Always use a signalman in dangerous places or places where the view

is not clear.
Make sure that no one comes inside the turning radius or direction of travel.
Before starting to move any part of the machine, give a signal to
bystanders to remain clear of the machine. IA0OA20I
2.5.9. Avoiding High-Voltage Cables
DANGER AVOID HIGH-VOLTAGE CABLES
Serious injury or death can result from contact with or close

proximity to electric lines.
Keep all parts of the machine or load far away from all
electric lines.
IA0OA22S
- 24 -
2.5.10. Operating on Snow
CAUTION OPERATE CAREFULLY ON SNOW, ICE, OR WET SURFACES
When working on snow or icy or wet roads, even a slight slope may cause the machine to slip to
the side, so always travel at low speed and avoid sudden starting, stopping, or turning.
When there has been heavy snow, the road and objects placed beside the road are buried in the
snow and cannot be seen, so always carry out snow-clearing operations carefully.
2.5.11. Working on Loose Ground
DANGER WORKING ON LOOSE GROUND OR UNEVEN SURFACES
Avoid operating your machine too close to the edge of cliffs, overhangs, loading docks, deep
ditches, and other uneven surfaces or drop-offs. If these areas collapse or you get too close to
the edge, your machine could fall or tip over and result in serious injury or death. Remember that
the soil after heavy rain or blasting is weakened in these areas.
Earth laid on the ground and the soil near ditches are loose. It can collapse under the weight or
vibration of your machine.
- 25 -
2.5.12. Preventing Crushing or Cutting
DANGER CRUSHING OR CUTTING PREVENTION
Never enter, or put your hand or arm or any other part of your body between movable parts such
as between the work equipment and cylinders, or between the machine and work equipment. If the
machine or work equipment is operated or moved, the clearance will change and this may lead to
serious damage or personal injury.
ALWAYS keep both feet on pedals and both hands on controls when operating loader.
The cab structure of the 1340XL/ DSL602 complies with the following ROPS (Rollover Protective
Structure) and FOPS (Falling Object Protective Structure) criteria. -ROPS per ISO 3471 -FOPS per
ISO 3449 Level I
Never operate without a ROPS/ FOPS approved cab.
2.5.13. Parking
DANGER PARKING MACHINE
Avoid stopping suddenly. Give yourself ample room when stopping.

When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoid-
ably necessary to park the machine on a slope, insert blocks between tires and ground. As a safe-
ty measure, thrust the bucket into the ground.
If the control lever is touched by accident, the work equipment or the machine may move suddenly,
and this may lead to a serious accident.
Before leaving the operators compartment, always fully engage the park brake.
Lower the bucket horizontally until the bottom touches the ground.
NEVER exit machine with engine running.
NEVER leave lift arms raised without boom safety locks being fully engaged.
- 26 -
2.5.14. Precautions for Attachments
WARNING PRECAUTIONS FOR ATTACHMENTS
When installing/using an optional attachment, read the instruction manual for the attachment and
the information related to attachments in the manual.
Never use attachments that are not authorized by DAEWOO or your DAEWOO dealer. Use of
unauthorized attachments could create a safety problem and adversely affect the proper operation
and useful life of the machine.
NEVER attempt to engage or disengage the Universal Attachment System (Quik-tach) levers with
the engine running.
2.5.15. Precautions for Loading and Emptying the Bucket
WARNING
Load, unload and turn on flat level ground. Do not exceed machine rated operating load shown
on the rated operating load name plate attached to your machine. Failure to obey warnings can
cause the machine to tip or roll over and cause injury or death.
WARNING
Never dump over an obstruction that can enter the operator cab. The machine could tip forward
and cause injury or death.
- 27 -
2.6. Maintenance Safety

2.6.1. Periodic Maintenance
WARNING
1. Never attempt to service a machine unless you are authorized and qualified to do so.
2. Before attempting any service on this machine, familiarize yourself with all instructions and warn-
ings in the operators manual and all machine decals.
3. Do not attempt to service machine unless you have the necessary skill, information, safety gear,
and tools and equipment to perform the procedure correctly.
4. While service is being performed ensure a warning tag is installed on or near the ignition key switch
and clearly visible to prevent inadvertent starting of the machine during service.
5. If a service procedure necessitates running the engine, the control levers must remain in the neu-
tral position and the emergency brake must be fully engaged. Failure to do so can result in injury
or death.
6. After completing service check for: proper operation of all controls, correct torque on all fasteners
and fittings, any fluid leaks (prior to and after starting engine), all tools and equipment must be
removed from the machine.
7. Ensure all hoisting and supporting equipment is in good repair and of adequate capacity to support
loader.
8. Failure to follow safety precautions and proper service procedures can lead to machine malfunction
or damage, injury to operator or bystanders, or death.
- 28 -
2.6.2. Precautions for High Temperature Operations
WARNING PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES
Immediately after operations are stopped, the engine coolant, engine

oil, and hydraulic oil are at high temperatures, and are still under
pressure. Attempting to remove the cap, drain the oil or water, or
replace the filters may lead to serious burns. Always wait for the tem-
perature to go down, and follow the specified procedures when car-
rying out those operations.
To prevent hot water and oil from spurting out:

1. Turn engine off.
2. Allow water and oil to cool.
3. Slowly loosen cap to relieve pressure before removing.
HA0OA05I
- 29 -
2.6.3. Maintaining and Inspecting Hydraulic Equipment
CAUTION MAINTAINING AND INSPECTING HYDRAULIC EQUIPMENT

1. Be sure that the machine is parked on level, solid ground when servicing hydraulic equipment.
2. Lower the bucket to the ground and stop the engine.
3. Begin servicing hydraulic equipment only after components, hydraulic oil and lubricant are com-
pletely cooled, as they will remain hot and pressurized for a period of time after operation. While
servicing heated and pressurized hydraulic equipment, oil may flow off or escape suddenly with a
potential of serious injury.
4. Before servicing hydraulic equipment, bleed air from the hydraulic oil tank to release internal pressure.
5. Even after bleeding the air from the hydraulic oil tank, pressure can remain in the various circuits
of the hydraulic system. Be sure to operate each control lever a few times to release residual
pressure from the system.
6. Avoid inspecting and servicing the travel circuits on slopes, as they are pressurized by gravity
even after bleeding the hydraulic oil tank.
7. When connecting hydraulic hoses and tubes, take special care to keep seal surfaces free from dirt
and to avoid damaging them.
8. When adding hydraulic oil, always use a recommended manufacturers oil. Do not mix oil viscosi-
ties. See section 8.2.9, Fluid Capacities & Specifications in the back of this manual.
9. Do not run the engine without oil in the hydraulic oil tank.
During operation the hydraulic system parts become very hot.
Allow the machine to cool down before beginning inspection or maintenance.
Keep body and face away from plugs or screws when removing them as they may be pressur-
ized even when cooled.
The hydraulic oil tank is pressurized. Remove tank cap to release pressure.
10. Whenever possible, all maintenance and lubrication should be done on the machine with the
boom lowered to the ground and the engine stopped. Secure boom locks if maintenance is per-
formed with boom raised.
11. Before disconnecting any hydraulic lines, be sure to attach proper labels to the lines to prevent
incorrect connections. Always check the machine for proper function after the repair.
- 30 -
2.6.4. Precautions for High Pressure Oil
WARNING PRECAUTIONS WITH HIGH PRESSURE OIL
Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked
piping, tubes or hoses. They may burst during use.
Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
Be aware that the machine hydraulic circuits are always under pressure.
Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the
internal pressure.
If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil
hits your skin or enters your eyes. It also can be extremely hot. Always wear safety glasses and
appropriate gloves, and use a piece of cardboard or a sheet of wood to check for oil leakage. The
stream of oil may not be visible.
If your skin is punctured by a jet of high-pressure oil, seek a doctor immediately for medical atten-
tion.
IA0OA26I
- 31 -
2.6.5. Preventing Battery Hazards
WARNING BATTERY HAZARD PRECAUTIONS
Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If
you spill acid on yourself, immediately flush the area with water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into eyes, flush them
immediately with large quantities of water and see a doctor immediately.
If you accidentally swallow battery acid, drink a large quantity of water or milk, beaten egg or veg-
etable oil. Call a doctor or poison prevention immediately.
When working with batteries, ALWAYS wear safety glasses, goggles, or face shield.
Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a
small spark or flame.
Before working with batteries, stop the engine and turn the starting switch to the OFF position.
Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as
tools, across the terminals or between the hot (+) post and frame or other grounding surface.
Keep the battery terminals tightened securely. Loose terminals can generate sparks and lead to an
explosion.
When repairing the electrical system or when carrying out electrical welding, remove the negative
(-) terminal of the battery to stop the flow of current.
NEVER attempt to charge or jump start a frozen battery. An explosion may occur.
IA0OA27I
- 32 -
2.6.6. Waste Material Precautions
CAUTION WASTE MATERIALS
Never dump waste oil in a sewer system, rivers, etc.
Always put oil drained from your machine in containers. Never drain
oil directly on the ground.
Obey appropriate state, local, and federal laws and regulations when
disposing of harmful liquids, objects, or wastes such as oil, fuel,
coolant, solvent, acids, filters, batteries and others.
HA0O1043I
2.6.7. Rotating Fans and Belts
DANGER ROTATING FAN AND BELT
Keep away from all moving or rotating parts and be careful not to let
anything get caught in them.
Never touch any rotating parts. If your body or tools touch the fan
blades or fan belt, they may be cut off or sent flying or it may pull you
into the equipment.
IA0OA28I
- 33 -
2.6.8. Tire Maintenance

Tires should be checked regularly for wear, premature wear and damage to drive train
damage, and proper inflation. When replacing components. If tires are replaced in pairs,
tires, ensure that the size matches those they should be mounted on the same side of
already on the vehicle. Mismatched tire sizes the vehicle to minimize stress on the drive
can change vehicle performance and cause train.
DANGER
Tires should only be mounted/dismounted from rims or repaired by trained and authorized personnel
using the proper equipment and procedures. Death or serious injury could result. See OSHA
1910.177.
- 34 -
3. SERIAL NUMBER LOCATIONS
3.1. Vehicle Serial Number 3.2. Engine Serial Number
MODEL
OUTPUT PS
DAEWOO HEAVY INDUSTRIES LTD. RPM
MADE IN KOREA
DISPLACEMENT
MACHINE TYPE SKID-STEER LOADER ENGINE NO
MACHINE NAME YANMAR DIESEL ENGINE
SERIAL NUMBER
ENGINE POWER kW rpm

YANMAR
YANMAR DIESEL ENGINE CO. LTD
MADE IN JAPAN
IA4O3001
IA0OA02I
The engine serial number tag is riveted to the
top of engine valve cover.
The vehicle serial number plate is riveted on
the inner side of left-hand mast. If you need parts, service or information for
your engine, you must give the complete
engine number to your Yanmar distributor.
- 35 -
4. MACHINE COMPONENTS
4.1. Identification of Machine Parts
Seat bar Canopy (ROPS & FOPS) Rear lamp

Head lamps
Hoist points
Canopy lock
Drive levers
Seat belts
Engine
Rear door
hood
handle
Bucket
cylinder Rear door
Anti-skid
Bucket
Draw/Tiedown eyes
IA4O4001
- 36 -
Head lamps
Grab handles Seat bar Boom lock
Seat belt
Boom cylinder Seat belt Throttle Anti-skid Drive lever Brake lever Boom
cylinder
IA4O4002
- 37 -
5. CONTROLS AND INSTRUMENTS
5.1. Instrument Panel
(9) (10) (8) (11) (14) (13) (15)
STOP
FUEL
(2) (3) (4) (5) (6) (7) (1) (16) (17) (12) (18) (19)
IA0OA32I IA0OA33I
INSTRUMENT PANEL-LH INSTRUMENT PANEL-RH
(1) Key Switch (12) Pre-heat light

(2) Water temperature warning light (13) Parking brake light
(3) Engine oil pressure warning light (14) Fuel gage
(4) Charge warning light (15) Hour meter
(5) HST oil temperature warning light (16) Fuse-lamp
(6) HST pressure warning light (17) Fuse-instrument panel
(7) Oil filter warning light (18) Fuse-start
(8) Warning light (19) Fuse-horn
(9) Stop light
(10) Buzzer
(11) Light switch
- 38 -
(1) Key switch (3) Engine oil pressure warning light

When the key is turned to The light turns on when
the PREHEAT posi- the engine oil pressure is
tion, the light turns on and below 0.5kg/cm2 (15 psi).
preheat of air heater
begins. The light goes off
automatically after 30 sec-
onds.
When the key is turned to the IGN position, all the (4) Charge warning light
warning lights on the instrument panel come on. The light turns on when
When the key is turned to the ST position, trouble occurs in the
the engine is started. charging system.
When the key is released, it will return to the
IGN position automatically.
(2) Water Temperature warning light

(5) HST oil temperature warning light
The light turns on when
the temperature of the The light turns on when
engine cooling water the temperature of the hy-
exceeds 110C (230 F). draulic oil to drive HST
goes up to 100C (212F).
- 39 -
(6) HST pressure warning light (9) Stop light
The light turns on when The light turns on simulta-
the pressure of the HST neously with water tem-
pump oil falls down below STOP perature and engine oil
3.51 kg/cm2 (50psi). pressure warning lights.
(10) Buzzer
(7) Oil filter warning light
The buzzer is activated
If the oil filter becomes
simultaneously with water
clogged, the light turns on.
temperature and engine oil
pressure warning lights.
(11) Light Switch

(8) Warning light
Step 1 : Two front lights
The light turns on simulta-
turn on.
neously with Charge, HST
oil temperature, HST pres-
and on rear light turn on
sure and oil filter warning
simultaneously.
lights.
- 40 -
(12) Pre-heat light (14) Fuel Gage

When the key is turned to Fuel gage shows the
the PREHEAT position, amount of fuel in the fuel
the light turns on and pre- tank.
heating of air begins. FUEL
Light turns off automatical-

ly after 30 seconds.
(13) Parking brake light (15) Hour Meter
Raising the hand lever, the Hour meter indicates the

parking brake is engaged total hours of vehicle
and the light turns on. operating
- 41 -
5.2. Controls 5.2.1. Drive control lever( 1 2 )
(2) (3) (4) (5) (6) (1) (9)

(2) (1)
(8)
(7)
FASTEN SEAT BELT FASTEN SEAT BELT
IA4O5001 IA4O5002
(1) Drive Control Lever(RH) (6) Seat Bar The steering levers are on the left and right sides in
(2) Drive Control Lever(LH) (7) Parking Brake front of the seat. The levers are independent of each
(3) Boom Pedal (Released Position) other.
(4) Attachment Pedal (8) Throttle Lever FORWARD MOVE : Push both levers forward.
(5) Bucket Pedal (9) Horn Button(Option) BACKWARD MOVE : Pull both levers back-
ward.
STOP : Hold both levers at neutral position.
- 42 -
The distance of lever movement is proportional

5.2.3. Boom Pedal ( 3 )
to travel speed.
Boom pedal controls the lifting and lowering of
NOTE : For safety purposes, the operator can the boom. The speed is controlled by the
start the engine only when both drive levers are degree of the pedal.
in the neutral position.
5.2.2. Pedals ( 3 4 5 )
Boom up
Neutral
Boom down
(3) (4) (5) Floating
position
FASTEN SEAT BELT IA0OA37L
NOTE: Press the front part of the pedal fully to

the bottom, then the pedal will be locked to
floating position, which makes the boom move
IA4O5003 freely. That is a comfortable function to level
the ground. To release the boom from the
- 43 -
floating status, press the rear part of the pedal.
5.2.5. Attachment Pedal( 4 )
Float position should only be used with vehi-
cle in reverse. This pedal is used to operate the auxiliary
hydraulics(attachments) instead of the stan-
5.2.4. Bucket Pedal ( 5 ) dard bucket.
This is the pedal to tilt the bucket forward or Note: Press the right part of the pedal fully to
backward. The speed is controlled both for for- the bottom, then the pedal will be locked
ward and backward tilting by the degree of the to detent position, which makes the
pedal pressing. attachment operate in succession.
To release the attachment from detent posi-
tion, press the left part of pedal.
Neutral Neutral
Backward Forward
tilting
Forward tilting
Forward
tilting Reverse
Backward tilting
Detent position
IA4O5006
IA0OA38I
- 44 -
5.2.7. Seat Bar

CAUTION The seat bar is installed to help protect the op-
When using an attachment other than the stan- erator.
dard bucket, follow the instructions for each
separate attachment.
5.2.6. Engine Control
IA4O5005
Raised Position
NOTE: The pedals are locked if the seat bar is

in the raised position. Lower the seat bar to
IA4O5004 operate the pedals.
Throttle lever (A) controls the engine speed.

Push the throttle lever forward to increase the
engine rpm and pull backward to decrease the
engine rpm.
- 45 -
Operating Position
NOTE : 1340XL is equipped with a seat bar

safety interlock that sets the park brake with
the seat bar raised. The seat bar must be
lowered for travel.
- 46 -
6. OPERATING INSTRUCTIONS
6.1. Inspection Before Boarding

Refer to Section 7.3 Pre/Post Start Checks
6.2. Boarding the Loader
IA0OA42P
(2) Adjust the seat position with the seat adjusting

lever.
IA4O6001
(1) Use the bucket steps and grip handles to get on

and off the loader.
IA4O6002
- 47 -
(3) Fasten the seat belt and adjust it snugly across (1) Be sure all controls (the foot pedals and drive
the hips. control levers) are in neutral position.
(2) Set the throttle lever at half-throttle position.
(3) When the key is turned to the PREHEAT
position, the light turns on and preheating of air
begins. The light goes off automatically after 30
seconds. Then start the engine by turning the
key to the start position.
IA0OA18P
(4) Lower the seat bar all the way.
6.3. Starting
IA4O6003
CAUTION
Refer to section 7.3 for pre-start maintenance
checks.
- 48 -
DANGER Cold Temperature Starting and Operation
Before any Daewoo skid steer loader is operated in cold ambient temperatures (below 45 F), the
hydrostatic system needs to be properly warmed up to assure precise drive operation. This is espe-
cially crucial due to the fact it has a servo controlled hydrostatic drive system.
To properly warm up the hydraulic system you should: 1. Disconnect any attachment lines from the
auxiliary hydraulic couplings. 2. Following all proper procedures as outlined in this manual, start the
engine and run at high idle (full throttle position). 3. Set the auxiliary hydraulic pedal in the full oper-
ational position. 4. Depending on ambient temperature proper warm up time will vary from 3 to 15
minutes. This procedure should be continued until both A) The outside of the hydraulic tank is warm
to the touch and B) Using short slow movements the drive controls react normally to inputs. Caution
should be taken during the initial control movements as warm oil may be delayed in reaching the
control servos.
- 49 -
6.4. Traveling and Steering

(1) Push the throttle lever forward to raise the (1) Steering procedure is illustrated as follows:
engine speed. Gradual Turning
(2) Operate the boom and bucket pedals to raise the Push one lever farther forward than the other.
bucket to 15-20 cm (6-8 in) above the ground.
(3) Push left and right drive control levers simulta-
neously forward (or pull them backward) to make
the vehicle travel forward (or backward).
(4) To stop the vehicle, make the left and right drive
control levers return to the neutral position slow-
ly. DAEWOO skid steer loader is designed with
drive control levers which return to neutral posi-
tions automatically, when the levers are released.
Left Turn Right Turn
IA0OA46I
CAUTION
When traveling or steering, always lower the
boom to the carry position.
Forward Backward
IA0OA45I
- 50 -
Sharp Turning 6.5 Operation
Push one lever forward and pull another leverback-
ward.
CAUTION
For safe and economical handling with the
DAEWOO skid steer loader, the operator must
have a thorough knowledge of safety instruc-
tions and a good grasp of the construction and
performance features of the vehicle. Then he
must choose the operating approach best
matched to the actual conditions.
IA0OA47I
(1) Bucket filling
CAUTION
Be alert for tail swing.
IA4O6004
- 51 -
(3) Bucket dumping

CAUTION Keep the bucket load level while raising the boom
to prevent the load from falling down over the back
When traveling forward into the material, make
of the bucket. Raise the bucket high enough and
the bucket parallel to ground. .
tilt the bucket forward to dump a bucketful of ma-
terial. When loading a truck, be careful not to con-
tact the bucket or frame with the truck.
(2) Bucket scooping
IA4O6005 IA4O6006
Move the vehicle forward slowly with the bucket IMPORTANT Do not shake the buck-
held parallel to the ground or tilted down slightly. et unnecessarily to dislodge sticky material. Vibra-
When the bucket is sufficiently full, roll back and tions put excess stress on the bucket cylinder and
raise the bucket simultaneously. stopper, which in turn will reduce machine life.
- 52 -
(4) Leveling the ground Also, leveling jobs can be performed by using
Drive forward or backward with the bucket tilted the floating position for the boom according to
and raised slightly off the ground to perform lev- operating conditions. Make the bucket parallel to
eling. the ground as much as possible.
IA4O6007
CAUTION
Do not drive forward with the boom in float po-
sition.
- 53 -
6.6. Traveling on a Slope, Parking
(With Full Bucket - forward up and backward

CAUTION down)
Operate your DAEWOO skid-steer loader on

level ground as much as possible.
Use caution when operating on slopes.
Keep load as low as possible for maximum
stability.
(1) Traveling on a slope

Drive the loader on slopes as illustrated below.
IA4O6009
(With Empty Bucket - forward down and back-

ward up)
(2) Parking
Stop the loader on level ground.
Lower the boom and put the bucket cutting edge
IA4O6008 on the ground.
- 54-
Pull the throttle lever all the way back. 6.7. Towing Procedures
Engage the parking brake.
Turn the key to the OFF position.
Make sure that all controls in operator cabin are WARNING
in stop position.
Raise the seat bar all the way up to the roof. Towing loaders without following the procedures
listed below can result in damage to machine
Disconnect the seat belt.
and injury to personnel
Remove the key from the switch.
(1) Open canopy and secure with safety latches.

DANGER (2) Locate bypass/relief valves on each side of HST
pumps (refer to illustrations)
Front Rear
DANGER
NEVER exit machine with boom arms raised
unless secured by safety locks.
IA0OA52I
- 55 -
(3) Loosen valves by turning counterclockwise two 6.8. Lifting

revolutions.
WARNING
Opening of bypass valves will result in a loss of
hydrostatic braking capacity. Take precautions
to prevent machine movement when opening
the valves, and after valves are opened.
(4) Tow loader using the two draw eyes located at IA0OA53S
lower rear portion of frame.
(5) After towing, tighten valves to 9.5-14 Nm (7-10
ft/lbs.)
Damage to units may result from over-torquing WARNING
valves.
Lifting may shift the load and could result in
(6) DAEWOO Skid Steer Loader can draw another death or serious injury.
machine using the 2 drawing eyes on rear frame.
Specified draw bar forces are as follows:
1340 XL : 2,110Kg(w/load) 1,800Kg (w/o load)
- 56 -
1. Use proper rated cables and slings for lifting. 6.9. Transportation
(min. durable force of cable/sling = 1,400Kgf)
2. Lifting cables should have sufficient length to
prevent contact with the machine.
3. Use the 4 holes for lifting i.e. 2 holes in front up-
per frame and 2 holes in rear inner mast with U-
clamp or strap. 15 or less
IA0OA55I
U-Clamp
or Strap
Use secure, stable, sufficient strength ramps to

load (or unload) the machine onto (or from) a
transport vehicle and keep the steel ramps
Mast
inclined 15 or less.
Follow instructions of the traveling on slopes,
while moving on the ramp.
IA4O6010
Lower the bucket to the floor and stop the engine
after loading the machine onto a transport vehi-
cle.
- 57 -
Fix the skid loader tightly to the transport truck 6.10. Bucket and Attachments
bed with an approved securing device. The ma-
The loader is equipped with a Universal
chine has 3 fixing points, i.e. 1 holes in front up-
Attachment System (Quick-tach) in front of the
per frame and 2 holes in lower rear frame.
vehicle for rapid replacement of bucket or var-
Use wheel blocks to prevent vehicle from moving
ious attachments.
during transportation.
(1) Installation
Wire Rope
Wire Rope
IA4O6012
IA4O6011 <Figure 1>
(1) Pull up both handles assembled on the

upper area of Quick-tach.
(2) Tilt the Quick-tach forward slightly and
drive forward to the bucket until the upper
- 58 -
edge of the Quick-tach is completely insert- backward until the back of bucket becomes
ed to the flange of the bucket. (Figure 1) perpendicular to ground. (Figure 2)
IA4O6013 IA4O6014
<Figure 2> <Figure 3>
(4) Lock the bucket and Quick-tach by pushing
CAUTION down both handles. (Figure 3)
Do not hit the Quick-tach handles when

engaging the bucket.
(3) Make sure that the top edge of the Quick-

tach is inserted and tilt the Quick-tach
- 59 -
IA4O6015 IA4O6016
(3) Remove the bucket from the machine by

(5) Make sure that both wedges are inserted
driving backward with the Quick-tach tilting
firmly through the holes on the bucket (or
down. (Figure 6)
attachments). (Figure 4)
(2) Removal
(1) Lower the boom thoroughly and tilt the
bucket down until the bucket cutting edge
touches to ground.
(2) Pull out both handles and disengage the
locking pin. (Figure 5)
IA4O6012
<Figure 6>
- 60 -
6.11. Boom Lock Operation
DANGER
When working on a machine with the boom up,
always engage the boom lock.
IA0OA24P
<Figure 2>
IA0OA23P
<Figure 1>
IA0OA25P
<Figure 3>
- 61 -
(1) To engage boom lock shown in illustration. (Figure 3)

Make sure the release lever is secured in the Lower boom slowly to lowest position
lock position with knob when the boom lock is Lift boom lock arm, rotate lever counter-
in use. clockwise
Mount lock arm in original position using knob
With boom fully lowered, hold lock arm and
remove knob
Lower lock arm onto cylinder IMPORTANT Do not attempt to
Ensure release lever is in lock position and lower boom once lock is engaged or cylinder dam-
secured with knob age will result.
Raise boom until lock arm rests on the cylinder
rod.
Lower boom slowly until the lock arm contacts
top of cylinder. (Figure 1)
(2) To disengage boom lock

The release lever shold be in the release posi-
tion only when releasing the boom lock.
Rotate lever clockwise to release position

(Figure 2)
Raise boom until lever reaches position as
- 62 -
7. PERIODIC MAINTENANCE
7.1. Safety Warnings
WARNING
4. While service is being performed ensure a warning tag is installed on or near the ignition key
switch and clearly visible to prevent inadvertent starting of the machine during service.
or death.
loader.
- 63 -
7.2. Access to Items Requiring Service NOTE: The rear door can by locked by placing
a pad lock on the hasp provided on the handle.
IMPORTANT Daily maintenance

checks can be carried out by opening the rear
door and engine hood of DAEWOO skid steer
CAUTION
loader. ALWAYS keep rear door closed except for ser-
vice. Confirm that the rear door is closed and
the door latch is firmly engaged before operat-
7.2.1. Rear Door and Engine Hood ing the loader.
Pull the door handle backward to open the rear
door.
IA4O7001
IA0OA62P
More service space can be obtained if opera-
Push the door handle forward to close the rear tor opens up the engine hood after opening the
door. rear door.
- 64 -
7.2.2. Canopy Tilting
IA0OA65P
IA0OA64P Remove attaching hardware
Stop the loader on level ground and lower the

boom all the way.
Turn off skid loader
Set park brake
Loosen both mounting bolts at the front cor-
ners of the canopy.
IA4O7004
Hold the grip handles on canopy and then lift-

slowly all the way up.
- 65 -
7.3. Daily Pre/Post Start Checks

7.3.1. Pre-Start Checks
1. Check engine oil level. Refill if necessary.
2. Check hydraulic oil level. Refill if necessary.
3. Check coolant level. Refill if necessary.
4. Check the engine fan/alternator belt.
IA4O7005 5. Check the battery and battery cables.
(Canopy Lock) 6. Check the fuel system for leaks.
7. Check the hydraulic system.
Hook the rectangular canopy lock to the hook 8. Grease all fittings.
attached on left rear side of the canopy. 9. Inspect for any loose or missing nuts and bolts
To lower, reverse the above procedure. 10. Inspect structural members and welds for
cracks or deformation.
11. Check the loader tires for proper inflation and
CAUTION unusual wear

12. Check the fuel level.
Never operate without canopy lowered and 13. Check the condition and security of the opera-
properly secured. tor seat belt and seat bar.
- 66 -
service manual for proper adjustment pro-
WARNING cedure.
b. Check for proper operation of boom, buck-
If any of the following pre/post start checks
et, and accessories (if attached).
indicate that service may be required, have
such service performed before using the c. Insure that the boom, bucket, attachment
machine. pedals are locked with the seat bar raised.
7.3.2. After Starting-Before Operation

1. Start the engine and observe the intial exhaust
color at start and at normal operating temper-
atures.
Excessively black, blue, or white exhaust is an
indication of a problem. Listen for any abnor-
mal sounds.
2. Check the operation of all exterior lights,
instrument panel indicator lights and installed
optional equipment.
3. Check the operation of all switches.
4. Check the operation of all controls.
a. Check loader for movement with controls in
neutral. Should movement occur refer to
- 67 -
7.4. Service Schedule

This maintenance schedule was designed for scheduled maintenance program can lead to prema-
you to receive optimum performance and relia- ture wear and component failure. Adverse conditions
bility from your SKID STEER LOADER under (e.g., excessive dust or corrosive vapors, etc.) may
typical working conditions. Failure to follow a require more frequent service.

Fuel System Clean and replace fuel filter element. (Replace (Clean) (Replace)
First time)
Cooling Check for leaks
System
Check and adjust the tension of fan belt
Air
Clean the dust cover.
Cleaner
(Clean) (Replace)
- 68 -
ITEM SERVICE REQUIRED every every every every every every
day 50 100 250 500 1000
Check covers.
Replace the fluid
Tubes and Hoses
(First time)
Oil Tank
for Muffler
(First time)
- 69 -
7.5. Lubrication Points
4 5
IA4O7006
- 70 -
1. Bucket cylinder pivot 3. Upper bucket cylinder pivot
IA4O7007 IA4O7009
2. Lower bucket/boom pivot 4. Front mast cylinder pivot
IA4O7008 IA4O7010
- 71 -
5. Rear mast cylinder pivot
IA4O7011
6. Upper mast pivot
IA4O7012
- 72 -
(8) (7) (8)
FASTEN SEAT BELT
IA4O7013
- 73 -
7. Pedal assembly grease fittings 7.6. Operator Restraint Lubrication and

Maintenance
1. Seat bar mounting points
IA4O7031
8. Drive control lever fitting

NOTE: Cab must be opened to access.
IA4O7031
IA0OA77P
- 74 -
7.6.1. Lubrication 7.7. Engine Lubrication
All seat bar mounting points (right shown-left
in mirror position) should be checked for secu-
rity, cleaned of any dirt and debris, and lubri-
cated daily. Use either a spray lubricant or a
light machine oil at the points marked on the
illustration. Lubrication for the pedal lock link-
age is covered in the previous section (7.5).
7.6.2. Function
Drain Plug Cap Bottom Cover
Sit in seat and fasten seat belt. Check the seat
IA4O7015
belt for security at mounting points. With the
seat bar up, check for full engagement of the
pedal locks (right and left) into the correspond-
ing slots under the pedal assembly. Lower the
seat bar. Pedal lock assemblies should fully
disengage from pedals.
Oil Filter
IA4O7016
- 75 -
7.7.1. General 7.7.2. Draining Engine Oil

Engine oil level should be checked daily. After Remove the four bolts from the access plate locat-
draining oil and changing filter approximate refill ed on the left bottom corner of the chassis.
amounts is 1.5 gallon for the 1340XL/DSL602. Remove the drain plug by either reaching through
Run loader briefly and check oil level on dipstick the opening between the radiator and the chassis
before returning the loader to service. or through the access plate. Drain oil into an
See section 8.2.9 for fluid recommendations. approved waste oil receptacle. Inspect drain plug
gasket and if serviceable, replace drain plug. If
gasket is deformed or torn, replace gasket and re-
install drain plug. Discard oil in accordance with
local environmental rules and regulations.
Dip Stick
7.7.3. Remove/Replace Engine Oil Filter
Raise and secure operators cab. Filter is located
on left side of engine block. Using a strap type or
IA0OA81P other style filter wrench, remove the engine oil
filter. Before installing new filter, coat the rubber
gasket on the filter with clean oil. Install filter BY
HAND and tighten until gasket fully contacts the
mounting surface. Once this tighten another 2/3
turn to fully seat the gasket.
- 76 -
7.8. Engine Cooling System tubing to the nipple on the petcock to allow fluid
to drain outside of the chassis. Collect the fluid
NOTE: Check the cooling water level while the
and discard it in accordance with local/federal
engine is cold.
environmental rules and regulations.
Accurate coolant level check is not guaranteed
when engine is hot, because a hot radiator can
flow coolant to sub-tank.
Check the coolant level on the sub-tank. Re-
move the top cap of the sub-tank and fill to the
FULL mark if coolant level is below LOW
mark on sub-tank.
IA4O7018
FULL
Fuel Tank
CAUTION
LOW
(1) Steam or hot liquid may spurt out if the
radiator cap is removed soon after the
engine is stopped.
(2) When removing the radiator cap, turn your
IA0OA82I face away from cap and cover the cap with
a cloth. Turn the cap slowly to release the
NOTE: The radiator drain petcock is located on
pressure inside the radiator.
the right radiator tank. Attach a section of 5/16
- 77 -
7.9. Fan Belt 7.9.2. Adjustment
7.9.1. Belt Tension Belt tension can be adjusted by loosening the

upper and lower pivot bolts on the alternator.
Properly adjusted, the belt should have
Use a small pry bar to move the alternator to
approximately 3/8 to 9/16(10-15 mm) of free
achieve proper tension and retighten pivot
play when checked by pressing firmly on the
bolts.
belt between the fan and alternator pulleys.
IA0OA85S
IA0OA84S
- 78 -
7.10. Two Stage Air Filter
Primary Element
Indiccator
IA4O7021
IA4O7019 7.10.1. Removal-Primary Element

Every 50 operating hours or when the red
ring shows on the air cleaner indicator, the
primary air cleaner element should be
Secondary Element removed and cleaned. Access to the air
cleaner assembly is gained through the rear
service door. Loosen the canister cover wing
nut and remove the cover and gasket.
Remove the primary element wing nut and
remove the primary element. This element
can be cleaned up to six times using com-
IA4O7020 pressed air and should be replaced every
250 operating hours.
- 79 -
7.10.2. Removal-Secondary Element 7.11. Spark Arrestor

Unlike the primary element, the secondary
element is designed for replacement only
and is not to be cleaned. The secondary ele-
ment is nested inside the primary element
and can be removed easily once the primary
element is out of the vehicle. The secondary Clean out plug
element should be replaced at least with
every third change of the primary element.
IA4O7022
7.10.3. Installation
Installation is simply the reverse of the above 7.11.1. General
procedures. Ensure that the element and
This vehicle is equipped with a U.S.D.A.
gasket are not damaged during replacement.
Forestry Service approved spark arrestor
The air cleaner will not function properly if the
muffler. To keep it in working condition, the
gaskets do not seat completely.
spark chamber must be emptied every 100
hours of operation.
IMPORTANT Extreme operating

conditions may greatly accelerate the need to
clean or replace these elements.
- 80 -
7.11.2. Maintenance 7.12. Battery
The engine must be completely cool before
attempting to clean the spark chamber.
NEVER attempt to empty the spark chamber
on a hot engine. Raise and support the
loader and open and secure the operators
cab. Remove the clean out plug from the
spark chamber. Ensure that the individuals
performing this operation are wearing safety
glasses with side shields. Start the engine IA4O7023
and run for approximately 10 seconds while
the second individual wearing protective
7.12.1. Remove and Install
gloves holds a piece of wood over the
exhaust outlet. Re-install plug and lower and Removal: The battery is located in the right
secure cab. rear corner of the chassis. Access to battery
is gained through the rear service door.
Disconnect the negative (-) battery cable
first, then disconnect the positive (+) cable.
Remove the wing nuts from the battery hold
down clamp, and remove the clamp assem-
bly. Remove the battery from the loader.
Installation: Installation procedure is the
- 81 -
reverse of the removal procedure. Before jumper battery to the negative (-) terminal on
beginning installation, clean the battery ter- the loader frame. Once loader has started,
minals and cable ends with a wire brush. Be remove the ground cable from the frame first.
sure to connect the negative (-) cable last to
minimize the potential for sparking. Coat the NOTE: Ensure the jumper battery being used
terminals and cable ends with grease to pre- is a 12 volt battery or electrical system dam-
vent corrosion. age will result.
7.12.2. Jump Starting the Loader

(See caution pg. 37-frozen battery)
Never attempt to jump start a loader by your-

self. There must be one person in the oper-
ators seat and one person to connect and
disconnect the jumper cables. Before begin-
ning to connect jumper cables, ensure that
the ignition switch is in the off position, con-
trols are in neutral and parking brake in fully
engaged. Connect from the positive (+) ter-
minal from the jumper battery to the positive
(+) terminal on the loader battery. Next, con-
nect from the negative (-) terminal on the
- 82 -
7.13. Fuel System/Filters 7.13.1. Removal/Installation-Fuel Filter
1. Fuel filter Open and secure the operators cab. Facing
the loader, the fuel filter is located above the
right corner of the engine. Use a spanner
wrench to remove the retaining ring from the
filter head and remove the filter bowl. Follow
the service schedule for replacement/cleaning
intervals. Clean the filter using a light grade
machine oil and compressed air. NEVER use
gasoline to clean filter. Align the filter bowl and
IA4O7024 tighten the retaining ring by hand until snug.
Finish tightening using the spanner wrench.
2. Water Separator When complete, refer to section 7.14 for fuel
system priming.
WATER SEPARATOR: The water separator

is located inside the rear door on the left hand
side. Removal, cleaning and installation are
identical to the procedure for the fuel filter.
IA4O7025
- 83 -
7.13.2. Fuel Tank Drain 7.14. Injection Pump Priming
IA0OA93P IA4O7026
The fuel tank drain plug is located directly

behind the left rear tire on the chassis. Fuel
drained should be disposed of into an
approved waste oil container. Discard the
fuel in accordance with local/federal environ-
mental rules and regulations.
IA4O7027
Should you run the loader dry of fuel, it will be

necessary to prime the fuel system. This is
- 84 -
accomplished by loosening the vent joint (A) 7.15. Hydraulic System Maintenance
and pumping the priming lever (B) until air is
bled from the system. Tighten vent joint (A) 7.15.1. Oil Level Indicator
when complete. The hydraulic oil level indicator and filler neck
are located on the right hand side of the loader
inside the rear service door. To daily check the
fluid level, the loader should be on level ground
with the boom completely lowered and the
Quick-tach assembly tilted back. The fluid level
as indicated on the sight gauge should read
between the two red lines. Refer to specifica-
tions section 8.2.9 for complete information on
fluid capacities and requirements.
IA4O7032
OIL LEVEL INDICATOR
- 85 -
7.15.2. Filter Replacement

Replace the filter accordiy to service sched-
ule(7.4)
The filter should be changed whenever the
fluid is changed or whenever the filter indica-
tor shows that it is necessary to change the
filter(a red warning lamp on the instrument
IA4O7033 pannel is lit)
HYDRAULIC FLUID FILLER NECK REMOVAL

Access to the Hydraulic filter is through the
rear service door. Remove the filter by turn-
ing counterclockwise. Drain the hydraulic oil
into an approved waste oil container. While
draining, check fluid and filter base for signs
of particle contaminants.
INSTALLATION
Before installation you must coat the rubber
IA4O7028
seal on the new filter with a light coat of
Hydraulic filter hydraulic oil. Spin on filter by hand turning
clockwise until the rubber filter seal makes
complete contact with the filter head assembly.
- 86 -
At this point, turn the filter an additional 3/4 sis. Before draining, the loader should be on
turn to fully tighten. When complete, run the level ground with the boom completely low-
loader and check the hydraulic oil level indi- ered and the Quick-tach tilted back. Once the
cator. Add fluid as needed. Discard the used loader is drained, oil should be disposed of
filter in accordance with local/federal environ- into an approved waste oil container in accor-
mental rules and regulations. dance with local/federal rules and regula-
tions.
7.15.3. Hydraulic fluid replacement

INTERVAL OF REPLACEMENT
Replace the fluid according to service sched-
ule(7.4)
It may be nessary to change more frequently
then the normal interual if the fluid becomes
with foreign material(dirt, water, grease, etc)
or if the fluid has beer subjected to tempera-
ture levels greater than the maximum
recommeded.
IA0OA99P
TO REPLACE THE FLUID

The hydraulic tank drain plug is located
directly behind the right rear tire on the chas-
- 87 -
7.16. Chain Case Drain and Refill

1. Chain case drain plugs TO DRAIN CHAIN CASE:
1) Remove drain plugs and drain case oil into
an approved waste oil container.
TO REFILL CHAIN CASE:

1) Re-install and tighten case drain plugs.
2) Remove chain case covers.
NOTE: Recommended fluid is API CC or CD
SAE 10W30
IA4O7029 3) Refill is 2.6 gal/side for 1340XL/ DSL 602.
4) Replace chain case covers.
2. Chain case cover
IA4O7030
- 88 -
7.17. Parking Brake Adjustment
and re-connect spring when completed with the

adjustment procedure. Inability to achieve proper
adjustment using this procedure is indicative of more
serious problem and should be referred to your DAE-
A WOO dealer.
C
IA0OB02P
Should adjustment be required begin by opening the

cab and securing with safety latches. Locate the park
brake handle linkage and return spring. Remove the
spring (A) to release tension from the parking brake
linkage. Loosen the jam nut (B), remove bolt (C), and
rotate the clevis on the linkage to adjust the cable ten-
sion until parking brake engages fully and interlock
functions properly. Re-attach clevis, re-tighten jam nut
- 89 -
7.18. Tire Maintenance 7.18.2. Inflation Pressures

1340XL-45 psi (3.2 kg/cm2)
7.18.1. General Information
Tires should be checked regularly for wear, 1
damage, and proper inflation. When replacing 3 6
tires, ensure that the size matches those
already on the vehicle. Mismatched tire sizes 5 8
can change vehicle performance and cause
premature wear and damage to drive train 7 4
components. If tires are replaced in pairs, they 2
IA0OB03I
should be mounted on the same side of the
vehicle to minimize stress on the drive train.
7.18.3. Installation and Removal
REMOVAL: Support the frame so that the tire(s) to
be removed are off the ground. Insert a wedge
DANGER under the tire to prevent rotation while the lug nuts
are being removed. Remove tire and rim assembly.
Tires should only be mounted/dismounted from
INSTALLATION: Install the tire and rim
rims or repaired by trained and authorized per-
sonnel using the proper equipment and proce- assembly on the axle. Tighten lug nuts to seat
dures. Death or serious injury could result. rim against axle assembly. Insert a wedge
See OSHA 1910.177. under the tire to prevent rotation while torquing
lug nuts. Torque lug nuts to 102-112 ft/lbs (138-
152Nm) in the pattern illustrated above.
Recheck torque after 10 hours of operation.
- 90 -
8. DIMENSIONAL & PERFORMANCE SPECIFICATIONS
8.1. Dimensional Specifications
Q
R
Item Unit Spec.
F S T G
Overall Height
A. Fully Raised in(mm) 142.4 (3617)
B. To Hinge Pin in(mm) 112.0 (2845)
C. To Canopy in(mm) 76.1 (1934) O
Overall Length
D. With Bucket in(mm) 115.5 (2924) K
E. Less Bucket in(mm) 90.4 (2296)
Overall Width A M
F. With Bucket in(mm) 61.5 (1562)
B
G. Less Bucket in(mm) 58.5 (1486) L C
Others
I
H. Wheel Base in(mm) 37.9 (962) N
I. Height of S.I.P. in(mm) 37.8 (959) J U
P H
J. Ground Clearance in(mm) 7.5 (190) E
T. Tread in(mm) 48.1 (1222) D
U. Departure Angle deg 27 IA0OB04I
- 91 -
Q
R
Item Unit Spec.
F S T G
Dumping
K. Dump Angle deg 55
L. To Hinge Pin in(mm) 86.3 (2192)
Reach O
M. Fully Raised in(mm) 20.4 (518)
Rollback K
N. Max. at Ground deg 25
O. Max. Fully Raised deg 94 A M
Digging
B
P. Digging Depth in(mm) 0.5 (13) L C
Clearance (Circle)
I
Q. Front, Less Bucket in(mm) 46.6 (1183) N
R. Front, With Bucket in(mm) 71.0 (1804) J U
P H
S. Rear in(mm) 57.7 (1465)
E
D
IA0OB04I
- 92 -
Definitions: (Daewoo Skid Steer Loader)
Refer to sketches on pages 88 or 90 of this section.
Overall Operating Height (A) - Fully Raised - The vertical distance in inches (millimeters) from the ground to
the highest point attainable.
Height to Hinge Pin (B) - Fully Raised - The vertical distance in inches (millimeters) from the ground to the
centerline of the bucket hinge pin.
Overall Height (C) - The vertical distance in inches (millimeters) from the ground to the highest point on the unit
with the bucket on the ground.
Overall Length (D) - The horizontal distance in inches (millimeters) with the bucket on the ground and level,
measured from the foremost point of the bucket cutting edge to the rear most point of the machine.
Overall Length (E) - Without Bucket - The horizontal distance in inches (millimeters) from the furthest rearward
to the furthest point forward.
Bucket Width (F) - The maximum outside width in inches (millimeters) of the bucket specified.
Overall Width (G) - The maximum outside width in inches (millimeters) of the machine specified exclusive of bucket.
Wheelbase (H) - The vertical distance in inches (millimeters) from the center of the front wheel or idler to the
center of the rear wheel or sprocket.
Height to S.I.P. (I) - The vertical distance in inches (millimeters) from the ground to the Seat Index Point.
Ground Clearance (J) - The minimum vertical distance in inches (millimeters) from the ground to the lowest
point on the machine between the tires or tracks with the lift arm raised.
Dump Angle (K) - The maximum angle in degrees that the longest flat section of the inside bottom of the bucket
will rotate below horizontal with the bucket hinge pin at maximum height.
Dump Height (L) - The vertical distance in inches (millimeters) from the ground to the lowest point of the cutting
- 93 -
edge with the bucket hinge pin at maximum height and the bucket at a 45 dump angle. The angle is less than
45, specify angle.
Reach (M) at Maximum Height - The horizontal distance in inches (millimeters) from the foremost point on the
machine (including tires, tracks, or loader frame) to the front most point on the bucket cutting edge at a 45 angle
with the bucket hinge pin at maximum height. Specify angles less than 45.
Maximum Rollback (N) - at Ground - Maximum rollback angle in degrees without movement of the lift arm.
Maximum Rollback (O) - Fully Raised - The angle in degrees from the bucket cutting edge level position to the
maximum rollback position.
Digging Depth (P) - The vertical distance in inches (millimeters) from the ground to the bottom of the bucket cut-
ting edge at the lowest position with the bucket cutting edge horizontal.
Loader Clearance Circle (Q) - Front No Attachment - The smallest diameter measured in inches (millimeters)
that the outermost front point on the machine will describe measured from a point located at 1/2 the wheelbase
(H) and 1/2 the overall width (G) of the machine.
Loader Clearance Circle (R) - Front with Standard Attachment - The smallest diameter measured in inches
(millimeters) that the outermost front point on the machine will describe measured from a point located at 1/2 the
wheelbase (H) and 1/2 the overall width (G) of the machine.
Loader Clearance Circle (S) - Rear - The smallest diameter measured in inches (millimeters) that the outermost
rear point on the machine will describe measured from a point located at 1/2 the wheelbase (H) and 1/2 the over-
all width (G) of the machine.
Tread or Track Gauge (T) - The transverse distance in inches (millimeters) between the centerlines of the tires
or sprockets. If the front and rear are different, both must be specified.
Angle of Departure (U) - The angle in degrees taken from a line drawn from the lowest and rear most portion of
the rear overhang to the rear bottom face of the rear tire to the ground.
- 94 -
8.2. Operational Specification (Per SAE J732 Feb 80)
8.2.1. Performance 8.2.2. Power Unit
Item Unit Spec. Item Unit Spec.

Rated Capacity lb(kg) 1300 (590) Make - Yanmar
3 3
Bucket Capacity (Dirt-60) ft (m ) 10.5 (0.30) Model - 4TNE84
Operating Weight lb(kg) 4907 (2226) - Diesel
Type of Fuel
Tipping Load lb(kg) 2602 (1180)
Cooling Method - Water
Hydraulic Lifting Capacity lb(kg) 3373 (1530)
Break Out Force -Bucket lb(kg) 3031 (1375) No. of Cylinders each 4
-Boom lb(kg) 3064 (1390) Displacement in3(cc) 121.7 (1995)
Bore Size in(mm) 3.31 (84)
Raising Time -W/O Load sec 4.2
Stroke in(mm) 3.54 (90)
-W/ Load sec -
Lower Time -W/O Load sec 2.1 Horsepower Net hp(ps)/rpm 41.1 (41.7)/2800
-W/ Load sec - High Idle rpm 2920 50
Boom Dump Time -W/O Load sec 2.4 Low Idle rpm 900 25
-W/ Load sec - Torque ft.lb(kg.m)/rpm >
_ 89.0 (12.3)
Rollback Time -W/O Load sec 1.7
1500-1700
-W/ Load sec -
Torque Rise % >
_ 19.0
Drawbar Pull -W/O Load lb(kg) 4350 (1973)
-W/ Load lb(kg) 4949 (2245) Lubrication - Full Flow
Travel Speed Forward mph(km.h) 6.6 (10.7)

Reverse mph(km/h) 6.6 (10.7)
- 95 -
8.2.3. Final Drive Components 8.2.4. Hydrostatic Transmission Pump

Chain - 2 Chain with Type - Piston, Variable
Super #80 & #80 Displacement (Manual)
Max. Displacement in3(cc)/rev 2.14(35)
No. of Teeth Relief Setting Pressure psi 3270
Drive Sprocket each 11 Charge Pump - None
Rotation - clockwise
(Motor) Swash Plate Operating Angle deg 16
Drive Sprocket each 32 Mounting - SAE 2 Bolt B Mount
(Axle) Shaft - ANSI B92.1-1970
Class No.5
Ratio 2.91 30 15 16 32
Tire Standard Pump

Pressure and Flow
Type - Floatation-Tubeless Flow (Max)
Size - 10-16.5, 6PR Max. System Pressure LPM(GPM) 44.9 (11.9)
Pressure psi (kg/cm2) 45(3.2) at charge pump psi- 254035
bar (1752.4bar)
Wheel High Flow Option Pump

Pressure and Flow
Size - 8.25 x 16.5
Flow LPM(GPM) 101 (26.7)
Hole x Pitch Circle - 8 x 8 Max. System Pressure psi- 254035
Diameter at charge pump bar (1752.4bar)
- 96 -
8.2.5. Hydraulic System

Motor Boom Cylinder
Type - Orbit, Fixed Type - Single Rod, Double
Displacement Acting
Bi-rotational
Number each 2
Displacement in3(cc)/rev 28.11 (460.8)
Mounting - SAE 4 Bolt B Mount Cylinder Bore in(mm) 1.97 (50)
Spline Shaft Cylinder Rod in(mm) 1.38 (35)
Pump Stroke in(mm) 31.0 (788)
Type - Gear Mounting - Single Crest Crevice
Capacity in3(cc)/rev 0.98(16.0) Plating on Rod - Hard Chrome w/15-50
Max. Pressure psi 3000 Micron Thickness
Max. Speed rpm 3000
Mounting -
Bucket Cylinder
Shaft SAE 2 Bolt A Mount
SAE Spline Shaft Type - Single Rod, Double
Rotation -
Clockwise Acting
Control Valve Number each 2
No. of Spool - 3 Cylinder Bore in(mm) 2.36 (60)
Relief Setting Pressure psi 2392 (+70) Cylinder Rod in(mm) 1.18 (30)
(set by valve supplier) (165(+5) bar) Stoke in(mm) 14.45 (367)
Circuit - Series on Lift Float Mounting - Single Crest Crevice
Function with Detent
Plating on Rod - Hard Chrome w/15-50
Series on Tilt
Micron Thickness
Series on Auxiliary
With Detent HRC 52-60 Hardness
- 97 -
8.2.6. Electrical Components

Item Unit Spec.
Hydraulic Filter
Item Unit Spec.
Filter Rating - 10 Micron Beta Rating Alternator - 12V - 40A
of 20 Battery - 12V-100AH, 625CCA
Rated Flow I(gal)/min 132.5 (35) Starter - 12V - 2.5kW
By-Pass Valve Closing PR13-17
(Normally Open Type) Lighting
Head Lamps each 2
Hydraulic Lines and
Rear Lamps each 1
Fittings
Type - O-Ring Face Seal
Fitting (SAEJ1453)
Thread - Unified Thread is
Standard
Medium Pressure Line - SAE 100R1 Hose
(SAE J517)
Hydraulic High - SAE 100R2 Hose
Pressure Line (SAEJ517)
HST High - SAE 100R2 Hose
Pressure Line (Parker 381-10)
- 98 -
8.2.7. Instrument Features 8.2.8. Seat

Instrument Panel (A) - Standard Cover Material - Vinyl, Black
(Yellow) Warning - Density
-Engine Oil Pressure -Cushion lb/ft3(kg/m3) 833 (52)
-Engine Water Temperature each
-Backrest lb/ft3(kg/m3) 609 (38)
-HST Filter
-Fuel Meter
-Hour Meter
-Park Brake Monitor
-Pre-Heater Monitor
Key Switch
Light Switch
Fuses
- 99 -
8.2.9. Fluid Capacities & Specifications
Item Specifications Unit Qty
Engine Lubrication API CC or CD SAE 10W30 for

-W/ Filter Ambient Temp above -4 deg. F gal(liter) 1.5 (5.7)
-W/ O Filter Ambient Temp below -4 deg. F 1.4 (5.3)
Hydraulic Tank SAE 10W20CD; Taxaco TDH; Mobil gal(liter) 6.1 (23.1)
Hydraulic System Fluid 423; Chevron Tractor Hydraulic gal(liter) 7.8 (29.5)
Chain Case API CC or CD SAE 10W30 gal(liter) 2.6 (10)
Fuel Tank #2 Diesel recommended for Ambient gal(liter) 13.8 (52.2)
Cooling Fluid Recommended mixture is 50/50 gal(liter) 1.6 (6.1)
Grease Recommended is a mineral based grease
with a lithium thickener and
rust, corrosion and extreme pressure addi-
tives. Viscosity conforms to
NOGI grade 2.
- 100 -
WARNING
Do not start, operate or service this machine unless you have read and understand these instruc-
tions and received proper training.
Operators and maintenance personnel must read this manual and receive training before operat-
ing or maintaining the machine.
This manual should be kept with the machine for reference and periodically reviewed by the
machine operator and by all personnel who will come into contact with it.
- 101 -
When servicing this lift truck, use an authorized servicing area and an approved container to collect coolant, oil,
fuel, grease, electrolyte and any other potential environmental pollutant before any lines, fittings or related items
are disconnected or removed. After servicing, dispose of those materials in an authorized place and container.
When cleaning the lift truck, be sure to use an authorized area.
- 102 -
WARNING
Do not start, operate or service this machine unless you have read and understand these instructions
Operators and maintenance personnel must read this manual and receive training before operating or
maintaining the machine.
The following warning is provided pursuant to California Health & Safety Code Sections 25247.5
et, seq,
WARNING
Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals
known to the State of California to cause cancer birth defects of other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known
to the State of California to cause cancer and birth defects or other reproductive harm.
WASH HANDS AFTER HANDLING.
FOREWORD
service schedule.
of the design.
S-1
SAFETY INFORMATION

HA0OA00I
S-2
SIGNALWORDS
A signal word - DANGER, WARNING, OR CAUTION - is

DANGER: Indicates an imminently hazardous situation

INJURY.
DANGER
WARNING: Indicates a potentially hazardous situation
OUS INJURY.
CAUTION: Indicates a potentially hazardous situation CAUTION

ATTENTION: Indicates potential machine damage if a ATTENTION

IMPORTANT: Indicates information an operator should

IMPORTANT
S-3
TIO
N
NING
HA0OA01I
DANGER SAFETY RULES
S-4
CONTENTS

1.3.2. Modifications ..............................................................................................................................4
1.5.1. Formal Training ..........................................................................................................................5
1.5.5. Recognition ................................................................................................................................7

2.3.1. Label Locations ........................................................................................................................12
S-5

2.5.1. Work Site Safety ......................................................................................................................21
2.5.2. Operators Cab ........................................................................................................................22
2.5.11. Working on Loose Ground ......................................................................................................26
2.5.13. Parking ....................................................................................................................................27
2.5.16. Precautions for Stopping the engine ........................................................................................29
S-6
2.6.5. Preventing Battery Hazards ....................................................................................................34




5.2. Controls ..............................................................................................................................................44
5.2.2. Pedals ....................................................................................................................................45
5.2.3. Boom Pedal ............................................................................................................................45
5.2.4. Bucket Pedal ..........................................................................................................................46
5.2.5. Auxiliary Hydraulics Thumb Control ........................................................................................46
5.2.6. Engine Control ........................................................................................................................47
5.2.7. Seat Bar ..................................................................................................................................48

S-7
cont. 6.0. OPERATING INSTRUCTIONS

6.3. Starting..................................................................................................................................................50
6.5. Operation ............................................................................................................................................53
6.8. Lifting ..................................................................................................................................................58
6.9. Transportation ......................................................................................................................................59

7.1. Safety Warnings....................................................................................................................................65
7.2.1. Rear Door and Engine Hood ..................................................................................................66
7.2.2. Canopy Tilting ..........................................................................................................................67
7.3.1. Pre-Start Checks ......................................................................................................................68
7.6.1. Lubrication ..............................................................................................................................78
7.6.2. Function ..................................................................................................................................78
S-8
7.7.1. General ....................................................................................................................................79

7.9. Fan Belt ................................................................................................................................................82
7.9.1. Belt Tension ..............................................................................................................................82
7.9.2. Adjustment................................................................................................................................82
7.10.3. Installation ................................................................................................................................84
7.11. Spark Arrestor ......................................................................................................................................84
7.11.1 General ....................................................................................................................................84
7.11.2 Maintenance ............................................................................................................................85
7.12. Battery ..................................................................................................................................................85
7.12.2 Jump Starting the Loader ........................................................................................................86
7.13. Fuel System/Filters ..............................................................................................................................87
7.13.1. Removal/Installation-Fuel Filter,Water Separater ....................................................................88
7.13.2. Fuel Tank Drain ........................................................................................................................89
7.14. Injection Pump Priming ........................................................................................................................91
S-9


8.2. Operational Specification (Per SAE J732 Feb 80) ............................................................................102
8.2.1. Performance ..........................................................................................................................102
8.2.2. Power Unit..............................................................................................................................103
8.2.3. Final Drive Components ........................................................................................................104
8.2.4. Hydrostatic Transmission Pump ............................................................................................105
8.2.5. Hydraulic System ..................................................................................................................106
8.2.6. Electrical Components ..........................................................................................................109
8.2.7. Instrument Features................................................................................................................110
8.2.8. Seat ........................................................................................................................................110
8.2.9. Fluid Capacities & Specifications ............................................ .......................................111
ENVIRONMENT PROTECTION SECTION ...........................................................................................112

WORLDWIDE NETWORK
S-10
1. OWNER / OPERATOR SAFETY OVERVIEW
1.1. Safety Message for Owners and Your responsibility also includes establishing
Operators daily inspections and scheduled maintenance
practices to ensure the equipments ongoing
Your DAEWOO equipment has been designed safe operating condition.
with the safety of the persons who will operate
and service it in mind. However, our care in The manual you are reading now is intended
designing this equipment does not guarantee to help you meet your responsibilities.
that it will be used in a safe manner. It identifies warning labels on the equipment
Safe operating practice is where your responsi- and explains what they mean.
bility and the responsible actions of the per- It describes some of the general and specific
sons who operate this equipment take over. hazards to be aware of when operating the
equipment.It also offers some suggestions for
1.1.1. Owner/Employer Responsibility establishing workplace rules and operator
training programs.
Both the Occupational Safety and Health Act
(OSHA) and the American National Stan- As the owner/employer, you also have the
dards Institute (ANSI) make you, the employ- responsibility to be certain that the equipment
er, responsible for providing formal training you have placed into service is capable of
and a safe workplace environment for the doing its intended job.
use of this equipment.
-1-
This includes matching equipment design to In addition, you, the operator, have the responsi-
working conditions, capacity to the size of bility to :
loads it will be handling, and selecting suit- Follow the safety practices in which you are
able attachments and options. This section trained - every day.
of the manual discusses these issues as well. Recognize and avoid potential hazards in
At the end of this overview, we list specific your workplace.
OSHA, ANSI, and other published resources Understand and abide by the Warning labels
you can consult for ways to help you comply attached to the equipment.
with safety requirements for the use of this Inspect the equipment for its serviceability at
equipment in your workplace. the beginning of each shift.
Report immediately any service problems you
1.1.2. Operator Responsibility notice before you use the equipment or that
develop while you are using it.
safety of others.
work.
times and to make safety his or her number one
job priority.
-2-
As we said, operators should recognize and When the equipment is driven onto trailers,
avoid hazards in the workplace. Although some use wheel chocks and jack supports if nec-
injuries occur because of unsafe operating essary to prevent creeping and possible col-
practices, many result from unnecessary work- lapse.
place hazards. To maintain a safe workplace Develop - and enforce - workplace safety
environment for this equipment, do the follow- rules for all employees.
ing: Post these rules conspicuously in the areas
where they apply.
Remove physical hazards where the equip-
ment will be operated, in either the plant or Many appropriate workplace rules are published
the yard. by OSHA, ANSI, and the National Safety
Install and maintain backup alarms and
flashing caution lights on equipment.
Use edge guards, levelers and trailer locks
on docks.
-3-

Every employer and operator should ensure 1.3.1. Warning Signal Options
that equipment is properly suited to the job it
tions and capacity well in mind, otherwise oper-
effective warning signal devices to meet the
conditions of your application.
1.3.2. Modifications
Equipment should be used for its intended pur- Many times the addition of a special attach-
pose only. For example, lift truck forks and ment can affect the ability of equipment to
skid steer loader buckets should never serve operate at the capacity originally intended.
as man-lifts or mobile work platforms. When modifications potentially change equip-
equipment.
-4-
conditions must be provided.
-5-
Of course, before any employee can be To ensure this, ask yourself specific questions:
selected to operate industrial or construction In what areas of our workplace does operating
type equipment, the employee must meet the the equipment pose hazards to pedestrians?
employers specific visual, auditory, physical What hazards must operators be trained to
and mental ability standards. deal with?
ard areas?
equipment?
quirements.
gloves, etc.)
15.3. Training Program Development Are operators conducting daily inspections
present in your operation.
-6-
1.6. Information Resources for
One additional recommendation: ask those Operation, Maintenance, and
employees who work around (but do not op- Safety
erate) the equipment for suggestions about
The following publications contain information,
what the operators should be taught.
instructions, and standards for various operation,
1.5.4. Practical Training maintenance, and safety issues related to your
DAEWOO equipment.
The questions above and others like them
can help you design an appropriate training General Industry Standards, OSHA 2206: OSHA
course for your operators. But above all, be Safety and Health Standards (29 CFR 1910),
sure that your training incorporates a signifi- Subpart N - Materials Handling and Storage; 29
cant portion of practical experience. CFR 1910.178 powered industrial trucks;
1910.177 - Servicing Multi-Piece and Single Rim
1.5.5. Recognition
Wheels. Available from: Superintendent of
A key part of any training program is recogni- Documents, U.S. Government Printing Office,
tion. Think of ways you can recognize the Washington, DC 20402.
achievement of those who successfully com-
plete this important training. Certificates, National Fire Protection (NFPA) 505, Powered In-
licenses, patches, authorization cards and the dustrial Trucks, Type Designation, Areas of Use,
like set these individuals apart and help cre- Maintenance, and Operation. Available from: Su-
ate a lasting attitude of commitment to the perintendent of Documents, U.S. Government
job. Printing Office, Washington, DC 20402.
-7-
ANSI/ASME B56.1-1988: Safety Standard for Accident Prevention Manual for Industrial Opera-
Low Lift and High Lift Trucks (Safety Code of tions: Two volumes: Administration and
Powered Industrial Trucks). Available from: Programs and Engineering and Technology.
Society of Mechanical Engineers, United Available from: National Safety Council, 444
Engineering Center, 345 E. 47Th Street, New North Michigan Avenue, Chicago, IL 60611.
York, NY 10017.
Publications Concerning Safe Handling and
NFPA 58: Storage and Handling of Liquified Storage of LP Gas: Available from: National LP
Petroleum Gases. Available from: National Fire Gas Association, 1301 West 22nd Street,
Protection Association, Inc., Batterymarch Park, Oakbrook, IL 60521
Quincy, MA 02269.
Skid-Steer Loader Safety Manual. Available from ble to the place of use.
the Equipment Manufacturers Institute, 10 S
Riverside Plaza, Chicago, Illinois 60606-3710. You can receive help in applying information
from these sources to your workplace by con-
National Safety Council Data Sheets: 1-664 - tacting OSHA or your Workers Compensation
Writing and Publishing Employee Safety Insurance Company.
Regulations; 479 - Liquified Petroleum Gases
for Industrial Trucks; 195.71 - The In-Plant
Pedestrian. Available from: National Safety
Council, 444 North Michigan Avenue, Chicago,
IL 60611.
-8-

-9-

manual and on the equipment cannot cover (OSHA).
- 10 -
They are paraphrased without representation 2.2. Rated Operating Load Plate
that the OSHA rules and regulations have been
reproduced verbatim.
as described on the rated operating load plate
attached to your machine.
accident. DAEWOO HEAVY INDUSTRIES LTD.
MADE IN KOREA
MACHINE NAME
SERIAL NUMBER
ENGINE POWER kW rpm
IA0OA02I
- 11 -

CAUTION
replace them with a new label. Safety labels are available in languages other than ENGLISH.
Please contact your dealer or DAEWOO if you need non-English labels.
2
1
14 5
D D 15 15
4 6
C B
C B
A
A
IC0O001I
- 12 -

D415547
IA0OA11I
IA0OA10I

IA0OA12I
- 13 -
W
A
R
N
I IC0O047I
N 7 Warning for Universal Attachment System

G D415545
IA0OA08I UNLATCHED WARNING LATCHED
ALWAYS ASSURE
5 THAT LATCHED ARE
Warning for high temperature muffler FULLY ENGAGED.
D415534
WARNING View "A-A"

(Quick Tach)
IC0O002I
HOT EXHUAUST AND MUFFLER

D415546
IA0OA09I
- 14 -
WARNING DANGER
10
MACHINE OPERATION.
SET PARKING BRAKE.
MANLIFT OR WORK
PLATFORM.
D415532 D415535
8 9
3 11
View "B-B"
(Inside of Canopy RH)
IA0OA04I View "C-C"
(Inside of Canopy. LH) IA0OA17I
WARNING
WARNING
CARRY LOAD LOW.
OR ATTACHMENTS.
NEVER USE LOADER AS
D416620
PLATFORM.
D415532
IA0OA15I IA0OA13I
- 15 -
10 Danger warning for maintenance.

CHAIN CASE HYDRAULIC
TANK
DANGER GREASE
BEFORE LEAVING SEAT : COOLANT

CHAIN CASE
LOWER BOOM OR ATTACHMENTS GREASE
TO THE GROUND. GREASE
STOP ENGINE.
SET PARKING BRAKE.
RAISE THE SEAT BAR.
INSTRUCTIONS ON OUTSDE OF
MANUAL.)
D415535
D423402
IA0OA14I IC0O050I
11 Service Shedule label 2060XL/DSL902
CHAIN CASE
COOLANT
12 Anti-Skid surface
GREASE
CHAIN CASE
HYDRAULIC TANK
GREASE
GREASE
ANTI SKID - STEP ANTI SKID - BOOM

P/N D422440 P/N D422441
D423400
IC0O049I View
View D-D
"E-E"
1550XL/DSL702 IC0O003P
- 16 -
13 Extinguisher
IC0O059P
Right Side
IA0OA76I
15 Warning for Boom
14 Warning for pinch point
IC0O058P
Left Side IC0O060P
- 17 -


equipment.
- 18 -
HA0OA03I
- 19 -
compartment .
guisher operation.
HA0OA04I
- 20 -
of operation.


IA0OA16S
dures.
- 21 -

- 22 -
DANGER
,,,
,,,
HA0OA07I
operate.
- 23 -
- 24 -

is not clear.

electric lines.
IA0OA22S
- 25 -
- 26 -
as between the work equipment and cylinders, or between the machine and work equipment.
If the machine or work equipment is operated or moved, the clearance will change and this may
lead to serious damage or personal injury.
The cab structure of the 1550XL, 2060XL complies with the following ROPS (Rollover Protective
Structure) and FOPS (Falling Object Protective Structure) criteria. -ROPS per ISO 3471 -FOPS per
ISO 3449 Level I
Never operate without a ROPS/FOPS approved cab.
2.5.13. Parking

ably necessary to park the machine on a slope, insert blocks between tires and ground.
As a safety measure, thrust the bucket into the ground.
- 27 -
NEVER attempt to engage or disengage the Universal Attachment System (Quick-tach) levers with
the engine running.
WARNING
WARNING
- 28 -
2.5.16. Precautions for Stopping the engine.
CAUTION
When the engine stops and the seat bar (pedal locking device/parking) is secured in place (lowered).
if the pedal is depressed, then the boom or the bucket descends.
CAUTION
When the pedal is kept depressing, then even though the seat bar (pedal locking device/parking) is
raised, the boom or the bucket keeps moving regardless of engines running or not.
- 29 -

WARNING
or death.
loader.
- 30 -


1. Turn engine off.
HA0OA05I
- 31 -

- 32 -
internal pressure.
tion.
IA0OA26I
- 33 -
explosion.
IA0OA27I
- 34 -
HA0O1043I
into the equipment.
IA0OA28I
- 35 -

DANGER
1910.177.
- 36 -

MADE IN KOREA
MACHINE NAME
SERIAL NUMBER
ENGINE POWER kW rpm

IC0O061P
IA0OA02I
The engine number is stamped on a plate on
the right side of the cylinder block.
engine number to your Daewoo distributor.
- 37 -
Canopy
Head lamps ( ROPS & FOPS ) Rear lamp Strobe light (CE Option)
Seat bar
Canopy lock
Rear door
Drive levers handle
Seat belts
Bucket Engine hood

cylinder
Rear door
Rear door
latch
Draw / Tiedown eyes

Bucket Anti - skid IC0O004P
- 38 -
Head lamp
Grab Handles
Seat bar
Drive levers
Boom cylinder
Anti - skid
Boom cylinder
IC0O005P
- 39 -
1 2 3 4 5 6 14 15
7 8 9 10 11 12 13
IC0O006I IC0O007I
(1) Hour meter (9) Warning light

(2) Engine oil pressure warning light (10) HST pressure warning light
(3) Alternator indicator light (11) Stop light
(4) Water temperature warning light (12) Oil filter warning light
(5) HST oil temperature warning light (13) Parking brake light
(6) Fuel gage (14) Key Switch
(7) Pre-heat light (15) Light switch
(8) Diesel engine water in fuel filter indicator light
- 40 -
(1) Hour Meter (4) Water Temperature warning light

Hour meter indicates the The light turns on when
total hours of vehicle the temperature of the
operating engine cooling water
exceeds 110C (230 F)
(2) Engine oil pressure warning light (5) HST oil temperature warning light
The light turns on when The light turns on when
the engine oil pressure is the temperature of the hy-
below 0.5kg/cm2 (15 psi). draulic oil to drive HST
(3) Alternator indicator light (6) Fuel Gauge

indicates if the battery Fuel gauge shows the
charging system is opera- amount of fuel in the fuel
tional. The light will come tank.
on when the ignition switch
is turned to the ON posi-
tion.
- 41 -
(7) Pre-heat light (10) HST pressure warning light
the PREHEAT position, the pressure of the HST
the light turns on and pre- pump oil falls down below
heating of air begins. 5.97 kg/cm2 ( 85 psi )
ly after 30 seconds. (11) Stop light
(8) Diesel engine water in fuel filter indicator
neously with water tem-
light
perature and engine oil
Indicates when the engine
is running, there is water in
the fuel filter exceeds
100cc.
(9) Warning light
neously with charge, HST
lights.
- 42 -
(13) Parking brake light (15) Light Switch

Raising the hand lever, the Step 1 : Two front lights
parking brake is engaged turn on.
and the light turns on. Step 2 : Two front lights
and on rear light
turn on simul-
taneously.
(14) Key switch
When the key is turned to
the PREHEAT posi-
tion, the light turns on and
onds.
When the key is turned to the IGN position, all the
warning lights on the instrument panel come on.
When the key is turned to the ST position,
the engine is started.
- 43 -
5.2. Controls 5.2.1. Drive control lever( 1 2 )
(2) (3) (6) (4) (1) (8) (9) (2) (1)

(7)
(5)
(10)
IA0OA34I IA0OA35I
(1) Drive control lever(RH) (7) Parking Brake The steering levers are on the left and right sides in
(2) Drive control lever(LH) (Released Position) front of the seat. The levers are independent of each
(3) Boom pedal (8) Auxiliary Hydraulic other.
(4) Bucket pedal Thumb Control FORWARD MOVE : Push both levers forward.
(5) Throttle Lever (9) Horn Button BACKWARD MOVE : Pull both levers backward.
(6) Seat Bar (10) Pressure Relief STOP : Hold both levers at neutral position.
- 44 -
The distance of lever movement is proportional

5.2.3. Boom Pedal ( 3 )
to travel speed.
NOTE : For safety purposes, the operator can the boom. The speed is controlled by the
start the engine only when both drive levers are degree of the pedal.
5.2.2. Pedals ( 3 4 ) Boom up

Neutral
(3) (4) Boom down

Floating
position
FASTEN SEAT BELT
IA0OA37I

IA0OA36I freely. That is a comfortable function to level
- 45 -
floating status, press the rear part of the pedal. 5.2.5. Auxiliary Hydraulics Thumb Control (6)
cle in reverse. (4) (5)
5.2.4. Bucket Pedal ( 4 )

This is the pedal to tilt the bucket forward or
backward. The speed is controlled both for for-
ward and backward tilting by the degree of the
pedal pressing. (6)
(1) (2) (3)
Neutral
Backward
tilting IA0OA39I
Forward tilting
CAUTION
Forward When using an attachment other than the stan-
tilting
Backward tilting separate attachment.
IA0OA38I
- 46 -
The Auxiliary Hydraulics Thumb Control 5.2.6. Engine Control

system is activated by pushing the on button
(1) on the forward control panel. The green
light (2) on the panel will illuminate when the
system is active. This system can be operat-
ed in two modes by utilizing the rocker switch
(4) (5) on control panel.
Momentary control: This system is activated
with the rocker switch (5) in the down position.
The auxiliary hydraulics will only operate when A
the thumb button (6) on the drive control han-
IC0O008P
dle is depressed.
Detent control: This system is activated with
the rocker switch (4) in the down position. The Throttle lever (A) controls the engine speed.
thumb button (6) controls the direction of flow Push the throttle lever forward to increase the
in this mode but it cannot stop or pause flow engine rpm and pull backward to decrease the
once the system is activated. Auxiliary engine rpm.
hydraulics will remain active until the off but-
ton (3) on the panel is pushed or the key
switch is turned to off.
- 47 -
5.2.7. Seat Bar
The seat bar is installed to help protect the op-
erator.
IA0OA17P IA0OA18P
Raised Position Raised Position
NOTE: The pedals are locked if the seat bar is NOTE: 1550XL, 2060XL are equipped with a
in the raised position. Lower the seat bar to seat bar safety interlock that sets the park
operate the pedals. brake with the seat bar raised. The seat bar
must be lowered for travel.
- 48 -

IA0OA42P

lever.
IA0OA41P

and off the loader.
IA0OA43P
- 49 -
IA0OA18P
6.3. Starting
A
IC0O008P
CAUTION
checks.
- 50 -
control servos.
- 51 -

IA0OA46I
CAUTION
Forward Backward
IA0OA45I
- 52 -
ward.
CAUTION
IA0OA47I
(1) Bucket filling
CAUTION
IC0O011I
- 53 -
(3) Bucket dumping

(2) Bucket scooping
IC0O012I IC0O013I
Move the vehicle forward slowly with the bucket IMPORTANT Do not shake the buck-
held parallel to the ground or tilted down slightly. et unnecessarily to dislodge sticky material. Vibra-
When the bucket is sufficiently full, roll back and tions put excess stress on the bucket cylinder and
raise the bucket simultaneously. stopper, which in turn will reduce machine life.
- 54 -
IC0O014I
CAUTION
sition.
- 55 -

CAUTION down)

stability.

IC0O062P

ward up)
(2) Parking
IC0O063P on the ground.
- 56 -
in stop position.

Front Rear
DANGER
IA0OA52I
- 57 -

revolutions.
WARNING
(4) Tow loader using the two draw eyes located at

(5) After towing, tighten valves to 9.5-14 Nm (7-10 IA0OA53S
ft/lbs.)
Damage to units may result from over-torquing
valves.
WARNING
(6) DAEWOO Skid Steer Loader can draw another Lifting may shift the load and could result in
machine using the 2 drawing eyes on rear frame. death or serious injury.
1550XL (DSL 702) : 2,680Kg (w/ load)
2,233Kg (w/o load)
2060XL (DSL 902) : 2,948Kg (w/ load)
2,494Kg (w/o load)
- 58 -
3. Use the 4 holes for lifting i.e. 2 holes in front side
frame and 2 holes in inside mast with U-clamp or
strap. 15 or less
U - Clamp or Strap
IA0OA55I
BOOM

Inside Mast inclined 15 or less.
IC0O051I
cle.
- 59 -
Attachment System (Quick-Tach) in front of the
ious attachments.
(1) Installation
Wire Rope
Wire Rope
IA0OA57P
IC0O046I <Figure 1>
(1) Pull up both handles.

(2) Tilt the Quick-Tach forward slightly and
drive forward to the bucket until the upper
- 60 -
edge of the Quick-tach is completely insert- backward until the back of bucket becomes
ed to the flange of the bucket.(Figure 1) perpendicular to ground.(Figure 2)
IA0OA58P IA0OA59P
(4) Lock the bucket and Quick-tach by pushing
CAUTION down both handles.(Figure 3)
Do not hit the Quick-tach handles when

(3) Make sure that the top edge of the Quick-

tach is inserted and tilt the Quick-tach
- 61 -
IA0OA60P IA0OA61P

driving backward with the Quick-tach tilting
down.(Figure 6)
attachments).(Figure 4)
(2) Removal
touches to ground.
IA0OA57P
<Figure 6>
- 62 -
DANGER
IA0OA24P
<Figure 2>
IA0OA23P
<Figure 1>
IA0OA25P
<Figure 3>
- 63 -
(1) To engage boom lock (2) To disengage boom lock

Make sure the release lever is secured in the The release lever shold be in the release posi-
lock position with knob when the boom lock is tion only when releasing the boom lock.
in use.
With boom fully lowered, hold lock arm and (Figure 2)
remove knob Raise boom until lever reaches position as
Lower lock arm onto cylinder shown in illustration. (Figure 3)
Ensure release lever is in lock position and Lower boom slowly to lowest position
secured with knob Lift boom lock arm, rotate lever counter-
Raise boom until lock arm rests on the cylinder clockwise
rod. Mount lock arm in original position using knob
IMPORTANT Do not attempt to
lower boom once lock is engaged or cylinder dam-
age will result.
- 64 -
WARNING
or death.
loader.
- 65 -
7.2. Access to Items Requiring Service NOTE: The rear door can be locked by placing
a pad lock on the hasp provided on the rear
IMPORTANT Daily maintenance door.

door and engine hood of DAEWOO skid steer CAUTION
loader.
ALWAYS keep rear door closed except for ser-
7.2.1. Rear Door and Engine Hood the door latch is firmly engaged before operat-
ing the loader.
After pulling the door latch, pull the door han-
dle backward to open the rear door.
IC0O016P
IC0O015P
door. rear door.
- 66 -
IA0OA64P IA0OA65P
Remove attaching hardware
boom all the way.
Set park brake
ners of the canopy.
IA0OA66P

- 67 -

IC0O017P 5. Check the battery and battery cables.
Canopy Lock 6. Check the fuel system for leaks.
7. Check the hydraulic system.
Hook the rectangular canopy lock to the hook 8. Grease all fittings.
attached on right rear side of the canopy. 9. Inspect for any loose or missing nuts and bolts
To lower, reverse the above procedure. 10. Inspect structural members and welds for
11. Check the loader tires for proper inflation and
CAUTION unusual wear

12. Check the fuel level.
Never operate without canopy lowered and 13. Check the condition and security of the opera-
properly secured. tor seat belt and seat bar.
- 68 -
WARNING 1. Start the engine and observe the intial exhaust
If any of the following pre/post start checks color at start and at normal operating temper-
indicate that service may be required, have atures. Excessively black, blue, or white
such service performed before using the
exhaust is an indication of a problem. Listen
machine.
for any abnormal sounds.
optional equipment.
Check loader for movement with controls in
neutral. Should movement occur refer to
service manual for proper adjustment
procedure.
a. Check for proper operation of boom, buck-
et, and accessories ( if attached ).
b. Insure that the boom and bucket pedals are
locked with the seat bar raised.
- 69 -


Fuel System


Air Clean the dust cover.
Cleaner
- 70 -
day 50 100 250 500 1000
Check covers.
Replace the fluid
Tubes and Hoses
(First time)
Oil Tank
for Muffler
(First time)
- 71 -
7 8 9
4
3
1
2
5
IC0O018I
- 72 -
IC0O019P IC0O021P
IC0O020P IC0O022P
- 73 -
5. Rear mast cylinder pivot 7. Rear mast pivot
IC0O052P IC0O025P
6. Front mast pivot 8. Front boom pivot
IC0O024P IC0O026P
1550XL/DSL702
- 74 -
9. Rear boom pivot
IC0O027P
2060XL/DSL902 IC0O028P
1550XL/DSL702
IC0O029P
2060XL/DSL902
- 75 -
8 7 8
FASTEN SEAT BELT
IA0OA75I
- 76 -
7. Pedal assembly grease fittings 7.6. Operator Restraint Lubrication and
Maintenance
IA0OA76P
8. Drive control lever fitting

NOTE: Cab must be opened to access.
IA0OA78P
IA0OA77P
- 77 -

IC0O030I
7.6.2. Function
IC0O031P
E/G Oil filter
- 78 -
7.7.1. General
Engine oil level should be checked daily.
After draining oil and changing filter approximate refill amounts is 2.1gallon(8 liter) for the 1550XL,
2060XL. Run loader briefly and check oil level on dipstick before returning the loader to service.
See section 8.2.9 (page 111) for fluid recommendations.
IC0O032P IC0O032P
1550XL/DSL702 - Dipstick 2060XL/DSL902 - Dipstick
- 79 -
7.7.2. Draining Engine Oil 7.7.3. Remove/ Replace Engine Oil Filter
Remove the four bolts from the access plate locat- Raise and secure operators cab.
ed on the left bottom corner of the chassis. Filter is located on left side of engine block.
Remove the drain plug by either reaching through Using a strap type or other style filter wrench,
the opening between the radiator and the chassis remove the engine oil filter. Before installing new
or through the access plate. Drain oil into an filter, coat the rubber gasket on the filter with
approved waste oil receptacle. Inspect drain plug clean oil.
gasket and if serviceable, replace drain plug. Install filter BY HAND and tighten until gasket
If gasket is deformed or torn, replace gasket and fully contacts the mounting surface.
re-install drain plug. Discard oil in accordance with Tighten 1/2 to 3/4 of a turn, by hand only.
- 80 -
NOTE: Check the cooling water level while the to drain outside of the chassis. Collect the fluid
engine is cold. and discard it in accordance with local/federal
Accurate coolant level check is not guaranteed environmental rules and regulations.
HOT mark if coolant level is below COLD
mark on sub-tank.
IC0O033P
Fuel Tank
Hot
CAUTION
Cold (1) Steam or hot liquid may spurt out if the
engine is stopped.
IA0OA82I (2) When removing the radiator cap, turn your
face away from cap and cover the cap with
- 81 -
7.9. Fan Belt

7.9.1. Belt Tension 7.9.2. Adjustment
Properly adjusted, the belt should have Belt tension can be adjusted by loosening the
approximately 3/8 (10 mm) of free play when upper and lower pivot bolts on the alternator.
checked by pressing (thumb pressure 45N) Use a small pry bar to move the alternator to
firmly on the belt between the fan and alterna- achieve proper tension and retighten pivot
tor pulleys. bolts.
IA0OA84S IA0OA85S
- 82 -
IA0OA87P
IC0O034P 7.10.1. Removal-Primary Element

Every day or when the red ring shows on the
air cleaner indicator, the primary air cleaner
element should be removed and cleaned.
Access to the air cleaner assembly is gained
through the rear service door. Loosen the can-
ister cover wing nut and remove the cover and
gasket. Loosen the cover latches and remove
the cover. Rotate the element slightly to sepa-
rate it from its base and remove it from the air
cleaner housing. This element can be cleaned
IA0OA86P
up to six times using compressed air and
should be replaced every 500 operating hours.
- 83 -

element is out of the vehicle. The secondary
IA0OA89P
hours of operation.

- 84 -
glasses with side shields. Start the engine IC0O035P

exhaust outlet. Re-install plug and lower and Removal: The battery is located in the left
secure cab. center side of the chassis. Access to battery
is gained through the opened canopy.
- 85 -
Installation: Installation procedure is the Next, connect from the negative (-) terminal
reverse of the removal procedure. Before on the jumper battery to the negative (-) ter-
beginning installation, clean the battery terminal on the loader frame. Once loader has
minals and cable ends with a wire brush. Be started, remove the ground cable from the
sure to connect the negative (-) cable last to frame first.
minimize the potential for sparking. Coat the
terminals and cable ends with grease to pre- NOTE: Ensure the jumper battery being used
vent corrosion. is a 12 volt battery or electrical system dam-
age will result.
(See caution pg. 34-frozen battery)

(+) terminal on the loader battery.
- 86 -
7.13. Fuel System/Filters
1. Fuel filter & Water Separator
IC0O053P IC0O054P
1550XL/DSL702 2060XL/DSL902
- 87 -
7.13.1. Removal/Installation-Fuel Filter,

Water separater
FUEL FILTER : Access to the 1550XL WATER SEPARATOR: The water separator
( 2060XL ) fuel filter is through the rear service is located inside the rear door on the right
door. The filter is located inside the rear door ( left ) hand side for the 1550XL ( 2060XL ).
on the right ( left ) hand side for the 1550XL The water separator acts as a water trap to
( 2060XL ). The filter can be removed with a separate the water from the diesel fuel. If the
standard filter wrench. This filter cannot be engine fails to start or there is a loss of power,
cleaned or reused. Before installation, coat it may have to be drained. Remove plug at
the rubber gasket on the filter with baseline or the bottom of the separator bowl and allow
light machine oil. Tighten filter until point of the water to drain.
complete gasket contact, then tighten another NEVER use gasoline to clean filter. Align the
1/2 to 3/4 turn to completely seal. The filter bowl and tighten the retaining ring by
1550XL, 2060XL are self-priming, no proce- hand until snug. Finish tightening using the
dure is necessary. spanner wrench. When complete, refer to
section 7.14 for fuel system priming.
- 88 -
7.13.2. Fuel Tank Drain
The fuel tank drain plug is located directly behind the 1550XL ( right ), 2060XL ( left ) rear tire on the
chassis. Fuel drained should be disposed of into an approved waste oil container. Discard the fuel in
accordance with local/federal environmental rules and regulations.
IC0O038P IC0O039P
1550XL/DSL702 2060XL/DSL902
- 89 -
FUEL FILLER
IC0O040P IC0O041P
1550XL/DSL702 2060XL/DSL902
- 90 -
7.14. Injection Pump Priming
If air enters the fuel system, it must be elimi- 1. Loosen the vent plug (A1) on the side of
nated before the engine can be started. the fuel injection pump.
2. Operate the priming lever (A2) of the fuel
Air can enter the system if: lift pump until fuel, free from air, comes
The fuel tank is drained during normal operation. from the vent point. Tighten the vent plug.
The low-pressure fuel pipes are disconnected. 3. Turn the start key on the ON position.
A part of the low-pressure fuel system leaks 4. Operate the starter motor for intervals of
during engine operation. 15 seconds until the engine starts. If the
engine runs correctly for a short time and
In order to eliminate air from the fuel system,
then stops or runs roughly, check for air in
proceed as follows:
the fuel system. If there is air in the fuel
system, there is probably a leakage in the
low pressure system. Stop the engine and
turn the start key to the OFF position.
IA0OA94S
- 91 -
7.15. Hydraulic System Maintenance

7.15.1. Oil Level Indicator HYDRAULIC FILTER
The hydraulic oil level indicator and filler neck are

located on the 1550XL ( left ), 2060XL ( right ) hand
side of the loader inside the rear service door. To
daily check the fluid level, the loader should be on
level ground with the boom completely lowered
and the Quick-tach assembly tilted back. The fluid
level as indicated on the sight gauge should read
between the two red lines. Refer to specifications IC0O055P
section 8.2.9 ( page 111 ) for complete information
1550XL/DSL702
on fluid capacities and requirements.
IA0OA95P IC0O056P
OIL LEVEL INDICATOR 2060XL/DSL902

- 92 -
7.15.2. Filter Replacement
Replace the filter accordiy to service schedule(7.4)

The filter should be changed whenever the fluid is changed or whenever the filter indicator shows
that it is necessary to change the filter(a red warning lamp on the instrument pannel is lit)
REMOVAL INSTALLATION
Access to the 1550XL, 2060XL filter are Before installation you must coat the rubber
through the rear service door. Remove the fil- seal on the new filter with a light coat of
ter by turning counterclockwise. Drain the hydraulic oil. Spin on filter by hand turning
hydraulic oil into an approved waste oil con- clockwise until the rubber filter seal makes
tainer. While draining, check fluid and filter complete contact with the filter head assem-
base for signs of particle contaminants. bly. At this point, turn the filter an additional
3/4 turn to fully tighten. When complete, run
the loader and check the hydraulic oil level
indicator. Add fluid as needed. Discard the
used filter in accordance with local/federal
- 93 -
7.15.3. Hydraulic Fluid Replacement
TO REPLACE THE FLUID

directly behind the 1550XL ( left ), 2060XL
( right ) rear tire on the chassis. Before drain-
ing, the loader should be on level ground with
the boom completely lowered and the Quick-
tach tilted back. Once the loader is drained,
oil should be disposed of into an approved IC0O042P
waste oil container in accordance with 1550XL/DSL702
local/federal rules and regulations.
ule(7.4)
with foreigu material(dirt, water, grease, etc)
ture levels greater than the maximum IC0O043P
recommeded. 2060XL/DSL902
- 94 -
7.16. Chain Case Drain and Refill
1. Chain case drain plugs
TO DRAIN CHAIN CASE:

1) Re-install and tighten case drain plugs.
2) Open cab and secure with safety latches.
3) Remove covers
IA0OB00P ( left side shown-right in mirror position )
4) Locate chain case filter necks.
2. Fill cover NOTE: Recommended fluid is API CC or CD
SAE 10W30
5) Refill is 1550XL : 2.95 gal/side, 2060XL : 3.15
gal/side or until level is within 1/2 of inspec-
tion cover plug.
6) Replace and tighten inspection cover.
7) Close and secure cab.
IC0O057P
- 95 -

brake handle linkage and return spring.
Remove the spring (A) to release tension from the

parking brake linkage.
Loosen the jam nut (B), remove bolt (C), and rotate
the clevis on the linkage to adjust the cable tension
until parking brake engages fully and interlock func-
IA0OB02P
tions properly.
Re-attach clevis, re-tighten jam nut and re-connect

spring when completed with the adjustment proce-
dure. Inability to achieve proper adjustment using this
procedure is indicative of more serious problem and
should be referred to your DAEWOO
- 96 -
7.18. Tire Maintenance 7.18.2. Inflation Pressures
1550XL/DSL702 - 57 psi ( 4.0 kg/cm2 )
7.18.1. General Information
2060XL/DSL902 - 50 psi ( 3.5 kg/cm2 )
Tires should be checked regularly for wear,
damage, and proper inflation. When replacing 1
tires, ensure that the size matches those 3 6
already on the vehicle. Mismatched tire sizes

5 8
premature wear and damage to drive train
7 4
components. If tires are replaced in pairs, they
2
IA0OB03I
7.18.3. Installation and Removal
DANGER under the tire to prevent rotation while the lug nuts
Tires should only be mounted/dismounted from are being removed. Remove tire and rim assembly.
rims or repaired by trained and authorized per- INSTALLATION: Install the tire and rim
sonnel using the proper equipment and proce- assembly on the axle. Tighten lug nuts to seat
dures. Death or serious injury could result. rim against axle assembly. Insert a wedge
See OSHA 1910.177. under the tire to prevent rotation while torquing
lug nuts. Torque lug nuts to 102-112 ft/lbs (138-
152Nm) in the pattern illustrated above.
- 97 -
Spec.
Item Unit 1550XL 2060XL
R S
DSL702 DSL902 Q
Overall Height
F
A. Fully Raised in(mm) 145.8 (3704) 156.2 (3967)
B. To Hinge Pin in(mm) 114.8 (2915) 122 (3100)
C. To Canopy in(mm) 76.9 (1954) 80.1 (2035)
Overall Length
D. With Bucket in(mm) 126.3 (3208) 126.0 (3200) O
E. Less Bucket in(mm) 99.3 (2521) 98.7 (2508)
Overall Width K
F. With Bucket in(mm) 63.4 (1611) 70 (1778) M

G. Less Bucket in(mm) 58.5 (1486) 65.4 (1662) A
B
Others L
H. Wheel Base in(mm) 42.3 (1074.8) 42.0 (1066.5) C
I. Height of S.I.P. in(mm) 35.8 (908.5) 40.9 (1040) I

J. Ground Clearance in(mm) 7.5 (190) 8.6 (218) N J U
P H
T. Tread in(mm) 48.1 (1222) 53.1 (1350) E
U. Departure Angle deg 26 D
28
IC0O045I
- 98 -
Spec.
R S
Item Unit 1550XL 2060XL Q
DSL702 DSL902
F
Dumping
K. Dump Angle deg 45 44
L. Dump Height in(mm) 87.6 (2224) 93.6 (2378)
Reach
M. Fully Raised in(mm) 25.4 (645) 27.3 (694) O
Rollback
N. Max. at Ground deg 25 26 K
O. Max. Fully Raised deg 94 94

M
Digging A
B
P. Digging Depth in(mm) 0.6 (16) 0.4 (10) L
Clearance (Circle) C
Q. Front, Less Bucket in(mm) 51.3 (1304) 45.1 (1146) I

R. Front, With Bucket in(mm) 74.8 (1901) 76.3 (1939) N J U
H
S. Rear in(mm) 63.3 (1607) 61.8 (1570) P
E
D
IC0O045I
- 99 -
- 100 -
edge with the bucket hinge pin at maximum height and the bucket at a 45 dump angle. The angle is less than
45, specify angle.
Digging Depth (P) - The vertical distance in inches (millimeters) from the ground to the bottom of the bucket cut-
ting edge at the lowest position with the bucket cutting edge horizontal.
rear point on the machine will describe measured from a point located at 1/2 the wheelbase (H) and 1/2 the over-
all width (G) of the machine.
- 101 -
8.2.1. Performance
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Rated Capacity lb(kg) 1500 (680) 2000 (907)
Bucket Capacity ft3(m3) 11.9 (0.34) 14.1 (0.40)
Operating Weight lb(kg) 5849 (2653) 6777 (3074)
Tipping Load lb(kg) 3946 (1790) 4647 (2108)
Hydraulic Lifting Capacity lb(kg) 4465 (2025) 4718 (2140)
Break Out Force - Bucket lb(kg) 2910 (1320) 3770 (1710)
- Boom lb(kg) 3285 (1490) 5194 (2356)
Raising Time - W/O Load sec 5.1 4.6

- W/ Load sec 5.3 4.7
Lower Time - W/O Load sec 4.4 5.1
- W/ Load sec 3.8 4.3
Boom Dump Time - W/O Load sec 3.3 2.3
- W/ Load sec 2.3 2.1
Rollback Time - W/O Load sec 1.9 1.8
- W/ Load sec 2.0 2.3
Drawbar Pull - W/O Load lb(kg) 4923 (2233) 5282 (2396)
- W/ Load lb(kg) 5908 (2680) 6499 (2948)
Forward mph(km/h) 6.7 (10.8) 6.77 (10.9)

Travel Speed
Reverse mph(km/h) 6.7 (10.8) 6.77 (10.9)
- 102 -
8.2.2. Power Unit
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Make - DAEWOO DAEWOO
Model - D427 D430
Type of Fuel - Diesel Diesel
Cooling Medium - Water Water
No. of Cylinders ea 4 4
3
Displacement in (cc) 164.8 (2701) 181.7 (2977)
Bore Size in(mm) 3.62 (92.0) 3.74 (95)
Stroke in(mm) 4.0 (101.6) 4.13 (105)
Horsepower Net hp(ps)/rpm 50.2 (51.0)/2400 62.6 (63.5)/2500
High Idle rpm 260050 265050
Low Idle rpm 90025 90025
Torque ft.lb(kg.m)/rpm 115.8 (16.0) 130.2 (18.0)
2000 1800
Torque Rise % 3.0 8.6
Lubrication - Full Flow Full Flow
- 103 -
8.2.3. Final Drive Components
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Chain - 2 Chain with 2 Chain with
Super80HT & Super100HT &
Super80HT Super100HT
No. of Teeth
Drive Sprocket (Motor) ea 12 10
Counter Sprocket ea
Drive Sprocket (Axle) ea 32 28
Ratio 2.67 2.8
Tire
Type - Flotation- Flotation-
Tubeless Tubeless
Size - 10-16.5, 8PR 12-16.5, 8PR
Pressure psi (kg/cm2) 57 (4.0) 50 (3.5)
Wheel
Size - 8.25 X 16.5 9.75 X 16.5
Hole x Pitch Circle Diameter - 8 X 8 8 X 8
- 104 -
8.2.4. Hydrostatic Transmission Pump
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Type - Piston, Variable Piston, Variable
Displacement Displacement
3
(Manual) (Manual)
Max. Displacement in (cc)/rev 2.68 (44) 2.68 (44)
Relief Setting Pressure bar (psi) 250 (3555) 250 (3555)
Internal Charge Pump - None None
Rotation - clockwise clockwise
Swash Plate Operating Angle deg 16 16
Mounting - SAE 2 Bolt B SAE 2 Bolt B
- Mount Mount
Shaft ANSI B92.1-1970 ANSI B92.1-1970
Class No.5 Class No.5
30X15X16/32 30X15X16/32
Standard Pump
Flow (Max) LPM(GPM) 60 (16) 77.7 (20.5)
Relief Pressure (max) psi- 300035 300035
at charge pump (2072.4bar) (2072.4bar)
High Flow Option Pump
Flow (max) LPM(GPM) 101(26.7) 131.5(34.8)
Relief Pressure (max) psi 300035 300035
at charge pump (2072.4bar) (2072.4bar)
- 105 -
Spec.
Item Unit
1550XL/DSL702 2060XL/DSL902
Motor
Type - Orbit, Fixed Orbit, Fixed
Displacement Displacement
Bi-rotational Bi-rotational
Displacement in3(cc)/rev 32.04 (523.6) 32.04 (523.6)
Mounting - SAE 4 Bolt B Mount SAE 4 Bolt B Mount
Spline Shaft Spline Shaft
Pump
Type - Gear Gear
3
Capacity in (cc)/rev 1.47 (23.0) *1.92 (31.5)
Max. Pressure bar(psi) 230 (3,335) 230 (3,335)
Max. Speed rpm 3,000 3,000
Mounting - SAE 2 Bolt A Mount SAE 2 Bolt A Mount
Shaft SAE Spline Shaft SAE Spline Shaft
Rotation - Clockwise Clockwise
Control Valve
No. of Spool - 3 3
Relief Setting Pressure psi 2840 (+70) 2840 (+70)
(set by valve supplier) (195 (+5) bar) (195 (+5) bar)
Circuit - Series on Lift Float Series on Lift Float
Function with Detent Function with Detent
Series on Tilt Series on Tilt
Series on Auxiliary Series on Auxiliary
With Electric Detent With Electric Detent
(thumb control) (thumb control)
3
* European Truck (CE Area) : 1.77 (29.0) in (cc)/rev
- 106 -
Models
Item Unit
1550XL/DSL702 2060XL/DSL902
Boom Cylinder
Type - Single Rod, Double Acting Single Rod, Double Acting
Number ea. 2 2
Cylinder Bore in(mm) 2.17 (55) 2.36 (60)
Cylinder Rod in(mm) 1.58 (40) 1.57 (40)
Stroke in(mm) 39.2 (996.0) 42.0 (1065)
Mounting - Single Crest Crevice Single Crest Crevice
Plating on Rod - Hard Chrome w/15-50 Hard Chrome w/15-50
Micron Thickness Micron Thickness
Bucket Cylinder
-
Type Single Rod, Double Acting Single Rod, Double Acting
Number ea. 2 2
Cylinder Bore in(mm) 2.36 (60) 2.36 (60.0)
Cylinder Rod in(mm) 1.10 (28) 1.57 (40)
Stroke in(mm) 14.45 (367) 20.0 (507)
Mounting - Single Crest Crevice Single Crest Crevice
Plating on Rod - Hard Chrome w/15-50 Hard Chrome w/15-50
Micron Thickness Micron Thickness
HRC 52-60 Hardness HRC 52-60 Hardness
- 107 -
Models
Item Unit
1550XL/DSL702 2060XL/DSL902
Hydraulic Filter
Type - Full Flow Spin-On Full Flow Spin-On
Filter Rating - 13 Micron Beta Rating 13 Micron Beta Rating
of 20 of 20
Rated Flow I(gal)/min 132.5 (35) 132.5 (35)
By-Pass Valve Closing PR50 PSID Closing PR50 PSID
( Normally Open Type ) ( Normally Open Type )

Type O-Ring Face Seal O-Ring Face Seal
- Fitting ( SAEJ1453 ) Fitting ( SAEJ1453 )
Thread Unified Thread is Unified Thread is
- Standard Standard
Medium Pressure Line SAE 100R1 Hose SAE 100R1 Hose
- ( SAE J517 ) ( SAE J517 )
Hydraulic High SAE 100R2 Hose SAE 100R2 Hose
Pressure Line - ( SAEJ517 ) ( SAEJ517 )
HST High SAE 100R12 Hose SAE 100R12 Hose
Pressure Line - ( SAE J517 ) ( SAE J517 )
- 108 -
Spec
Item Unit
1550XL/DSL702 2060XL/DSL902
Alternator - 12V - 60A 12V - 60A
Battery - 12V-100AH, 700CCA 12V-100AH, 700CCA
Starter 12V - 2.5KW 12V - 2.5KW
Lighting -
Head Lamps each 2 2
Rear Lamps each 1 1
- 109 -

-Engine Oil Pressure -Cushion
3 3
lb/ft (kg/m ) 833 (52)
-Engine Water Temperature each 3
-Backrest lb/ft (kg/m3) 609 (38)
-HST Filter
-Fuel Meter
-Hour Meter
-Park Brake Monitor
-Pre-Heater Monitor
Key Switch
Light Switch
Fuses
- 110 -
Models
Item Specifications Unit
1550XL/DSL702 2060XL/DSL902
Fuel Tank, Max #2 Diesel recommended for Ambient gal (liter) 14.3 (54) 18.2 (69)
Hydraulic Max Oil Tank SAE 10W20CD; Taxaco TDH; Mobil gal (liter) 8.0 (30) 11.9 (45)
Hydraulic System Capacity Fluid 423; Chevron Tractor Hydraulic gal (liter) 11.1 (42) 12.7 (48)
Chain Case Oil API CC or CD SAE 10W30 gal (liter) 5.9 (22.5) 6.3 (24)
Cooling Fluid Recommended mixture is 50/50 gal (liter) 1.8 (6.9) 1.8 (6.9)
Engine Lubrication - w/filter API CC or CD SAE 10W30 for gal (liter) 2.1 (8) 2.1 (8)
w/o filter Ambient Temp above -4 deg. F gal (liter) 2.0 (7.6) 2.0 (7.6)
- 111 -
- 112 -
WARNING
Do not start, operate or service this machine unless you have read and understand these instructions
Operators and maintenance personnel must read this manual and receive and receive training before
operating or maintaining the machine.
The following warning is povided pursuant to California Health & Safety Code Sections 25247.5 et, seq,
WARNING
WARNING
Engine Exhaust, some of its consituents, and certain vehicle components contain or emit chemi-
cals known to the State of California to cause cancer and birth defects or other reproductive
harm.
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and birth defects or other reproductive harm.
WASH HANDS AFTER HANDLING.
S-1
FOREWORD
service schedule.
of the design.
S-2
SAFETY INFORMATION

HA0OA00I
S-3
SIGNAL WORDS
A signal word - DANGER, WARNING, or CAUTION - is

DANGER : Indicates an imminently hazardous situation

INJURY.
DANGER
WARNING : Indicates a potentially hazardous situation
OUS INJURY.
CAUTION : Indicates a potentially hazardous situation CAUTION

ATTENTION : Indicates potential machine damage if a ATTENTION

IMPORTANT : Indicates information an operator should

IMPORTANT
S-4
TIO
N
NING
HA0OA01I
DANGER SAFETY RULES
S-5
CONTENTS

1.3.2. Modifications ..............................................................................................................................4
1.5.1. Formal Training ..........................................................................................................................5
1.5.5. Recognition ................................................................................................................................7

2.3.1. Label Locations ........................................................................................................................12
S-7

2.5.1. Work Site Safety ......................................................................................................................20
2.5.2. Operators Cab ........................................................................................................................21
2.5.11. Working on Loose Ground or Uneven Surfaces ......................................................................25
2.5.13. Parking ....................................................................................................................................26
2.5.16. Precautions for Stopping the engine ........................................................................................28
S-8

2.6.5. Battery Hazard Precautions ....................................................................................................33



5.2. Controls ..............................................................................................................................................41
5.2.2. Pedals ....................................................................................................................................44
5.2.3. Boom Pedal ............................................................................................................................44
5.2.4. Attachment Pedal ....................................................................................................................45
5.2.5. Bucket Pedal ..........................................................................................................................45
5.2.6. Engine Control & Auxiliary hydraulic attachment bleed off ....................................................46
5.2.7. Seat Bar ..................................................................................................................................47
S-9
6.3. Starting..................................................................................................................................................49
6.5. Operation ............................................................................................................................................52
6.8. Lifting ..................................................................................................................................................57
6.9. Transportation ......................................................................................................................................58

7.1. Safety Warnings....................................................................................................................................64
7.2.1. Rear door and engine hood ....................................................................................................65
7.2.2. Canopy Tilting ..........................................................................................................................66
7.3.1. Pre-Start Checks ......................................................................................................................67
7.6.1. Lubrication ..............................................................................................................................76
7.6.2. Function ..................................................................................................................................76
S-10

7.7.1. General ....................................................................................................................................77
7.9. Fan Belt ................................................................................................................................................79
7.9.1. Belt Tension ..............................................................................................................................79
7.9.2. Adjustment................................................................................................................................79
7.10.3. Installation ................................................................................................................................81
7.11. Spark Arrestor ......................................................................................................................................81
7.11.1. General ....................................................................................................................................81
7.11.2. Maintenance ............................................................................................................................82
7.12. Battery ..................................................................................................................................................82
7.12.2. Jump Starting the Loader ........................................................................................................83
7.13. Priming The Fuel System ....................................................................................................................84
7.13.1. Bleeding the Fuel System ........................................................................................................84
7.13.2. Draining the Water From the Fuel Fillter ..................................................................................85
7.13.3. Fuel Tank Drain ........................................................................................................................85
S-11


8.2. Operational Specification (Per SAE J732 Feb 80) ..............................................................................94
8.2.1. Performance ............................................................................................................................94
8.2.2. Power Unit................................................................................................................................94
8.2.3. Final Drive Components ..........................................................................................................95
8.2.4. Hydrostatic Transmission Pump ..............................................................................................95
8.2.5. Hydraulic System ....................................................................................................................96
8.2.6. Electrical Components ............................................................................................................97
8.2.7. Instrument Features ................................................................................................................98
8.2.8. Seat ..........................................................................................................................................98
8.2.9. Fluid Capacities & Specifications ............................................................................................99
ENVIRONMENT PROTECTION SECTION ..................................................................................................102
WORLDWIDE NETWORK
S-12
1. OWNER/OPERATOR SAFETY also includes establishing daily inspections
OVERVIEW and scheduled maintenance practices to
ensure the equipments ongoing safe operat-
1.1. Safety Message for Owners and ing condition.
Operators
The manual you are reading now is intended
Your DAEWOO equipment has been designed to help you meet your responsibilities. It iden-
with the safety of the persons who will operate tifies warning labels on the equipment and
and service it in mind. However, our care in explains what they mean. It describes some
designing this equipment does not guarantee of the general and specific hazards to be
that it will be used in a safe manner. Safe aware of when operating the equipment. It
operating practice is where your responsibility also offers some suggestions for establishing
and the responsible actions of the persons workplace rules and operator training pro-
who operate this equipment take over. grams.
1.1.1. Owner/Employer Responsibility As the owner/employer, you also have the

Both the Occupational Safety and Health Act responsibility to be certain that the equipment
(OSHA) and the American National Stan- you have placed into service is capable of
dards Institute (ANSI) make you, the employ- doing its intended job. This includes match-
er, responsible for providing formal training ing equipment design to working conditions,
and a safe workplace environment for the capacity to the size of loads it will be han-
use of this equipment. Your responsibility dling, and selecting suitable attachments and
-1-
options. This section of the manual discuss- Recognize and avoid potential hazards in
es these issues as well. your workplace.
At the end of this overview, we list specific Understand and abide by the Warning labels
OSHA, ANSI, and other published resources attached to the equipment.
you can consult for ways to help you comply Inspect the equipment for its serviceability at
with safety requirements for the use of this the beginning of each shift.
equipment in your workplace. Report immediately any service problems you
notice before you use the equipment or that
1.1.2. Operator Responsibility develop while you are using it.
safety of others.
work.
times and to make safety his or her number
In addition, you, the operator, have the
one job priority.
responsibility to:
Follow the safety practices in which you are

trained - every day.
-2-
As we said, operators should recognize and When the equipment is driven onto trailers, use
avoid hazards in the workplace. Although some wheel chocks and jack supports if necessary to
injuries occur because of unsafe operating prevent creeping and possible collapse.
practices, many result from unnecessary work- Develop - and enforce - workplace safety rules
place hazards. To maintain a safe workplace for all employees.
environment for this equipment, do the follow- Post these rules conspicuously in the areas
ing: where they apply.
Remove physical hazards where the equipment Many appropriate workplace rules are published
will be operated, in either the plant or the yard. by OSHA, ANSI, and the National Safety
Install and maintain backup alarms and flashing
caution lights on equipment.
Use edge guards, levelers and trailer locks on
docks.
-3-

Every employer and operator should ensure effective warning signal devices to meet the
that equipment is properly suited to the job it conditions of your application.
tions and capacity well in mind, otherwise oper- 1.3.2. Modifications
Many times the addition of a special attach-
ment can affect the ability of equipment to
operate at the capacity originally intended.
When modifications potentially change equip-
Equipment should be used for its intended pur-
pose only. For example, lift truck forks and
skid steer loader buckets should never serve
as man-lifts or mobile work platforms.
equipment.
1.3.1. Warning Signal Options
-4-
conditions must be provided. Of course,
before any employee can be selected to
-5-
operate industrial or construction type equip- In what areas of our workplace does operating
ment, the employee must meet the employ- the equipment pose hazards to pedestrians?
ers specific visual, auditory, physical and What hazards must operators be trained to
mental ability standards. deal with?
ard areas?
equipment?
quirements.
gloves, etc.)
Are operators conducting daily inspections
1.5.3. Training Program Development
present in your operation. To ensure this, ask
yourself specific questions: One additional recommendation: ask those
-6-
employees who work around (but do not op- 1.6. Information Resources for
erate) the equipment for suggestions about Operation, Maintenance, and
what the operators should be taught. Safety
1.5.4. Practical Training The following publications contain information,

instructions, and standards for various operation,
The questions above and others like them maintenance, and safety issues related to your
can help you design an appropriate training DAEWOO equipment.
course for your operators. But above all, be
sure that your training incorporates a signifi- General Industry Standards, OSHA 2206:
cant portion of practical experience. OSHA Safety and Health Standards (29 CFR
1910), Subpart N - Materials Handling and
1.5.5. Recognition
Storage; 29 CFR 1910.178 powered industrial
A key part of any training program is recogni- trucks; 1910.177 - Servicing Multi-Piece and
tion. Think of ways you can recognize the Single Rim Wheels. Available from: Superin-
achievement of those who successfully com- tendent of Documents, U.S. Government
plete this important training. Certificates, Printing Office, Washington, DC 20402.
licenses, patches, authorization cards and the
like set these individuals apart and help cre- National Fire Protection (NFPA) 505, Powered
ate a lasting attitude of commitment to the Industrial Trucks, Type Designation, Areas of Use,
job. Maintenance, and Operation. Available from: Su-
perintendent of Documents, U.S. Government
Printing Office, Washington, DC 20402.
-7-
ANSI/ASME B56. 1 : Safety Standard for Low NFPA 58: Storage and Handling of Liquified
Lift and High Lift Trucks (Safety Code of Petroleum Gases. Available from: National Fire
Powered Industrial Trucks). Available from: Protection Association, Inc., Batterymarch Park,
Society of Mechanical Engineers, United Quincy, MA 02269.
Engineering Center, 345 E. 47Th Street, New
National Safety Council Data Sheets: 1-664 -
York, NY 10017.
Writing and Publishing Employee Safety
EN474 - 1 : Earth - moving Machinery - Safety Regulations; 479 - Liquified Petroleum Gases
-General Requirements , for Industrial Trucks; 195.71 - The In-Plant
EN474 - 3 : Earth - moving Machinery - Safety Pedestrian. Available from: National Safety
-Requirements for Loaders. Council, 444 North Michigan Avenue, Chicago,
Available from : European Committee for IL 60611.
Standardization, rue de Stassart, 36 B - 1050
Publications Concerning Safe Handling and
Brussels.
Storage of LP Gas: Available from: National LP
Skid - Steer Loader Safety Manual. Available Gas Association, 1301 West 22nd Street,
from the Equipment Manufacturers Institute, 10 S Oakbrook, IL 60521
Riverside Plaza, Chicago, Illinois 60606-3710.
Accident Prevention Manual for Industrial Opera- ble to the place of use.
tions : Two volumes: Administration and
You can receive help in applying information
Programs and Engineering and Technology.
from these sources to your workplace by con-
Available from : National Safety Council, 444
tacting OSHA or your Workers Compensation
North Michigan Avenue, Chicago, IL 60611.
Insurance Company.
-8-

-9-

manual and on the equipment cannot cover (OSHA). They are paraphrased without repre-
- 10 -
sentation that the OSHA rules and regulations 2.2. Rated Operating Load Plate
have been reproduced verbatim.
(marked ) as described on the rated operat-
ing load plate attached to your machine.
accident.
MADE IN KOREA
MACHINE NAME
SERIAL NUMBER
ENGINE POWER kW rpm
IA0OA02I
- 11 -

CAUTION
replace them with a new label. Safety labels are available in languages other than ENGLISH. Please
contact your dealer or DAEWOO if you need non-English labels.
2 D
F D
1 5 3
6
F 4 C
B
E E C B
A A
IA0OA03I
- 12 -

D415547
IA0OA11I
IA0OA10I

IA0OA12I
- 13 -
W
A
R
N View
View F-F
I (Inside
(Inside of
"F-F"
of Canopy
Canopy LH)
LH)
N IA0OA07I
G D415545
IA0OA08I 7 Warning for Universal Attachment System

(Quick-tach)
5 Warning for high temperature muffler
UNLATCHED WARNING LATCHED
ALWAYS ASSURE
WARNING THAT LATCHED ARE

FULLY ENGAGED.
D415534
View
View A-A
"A-A"
HOT EXHUAUST AND MUFFLER IA0OA05I
D415546
IA0OA09I
- 14 -
WARNING DANGER

MACHINE OPERATION.
SET PARKING BRAKE.
MANLIFT OR WORK
PLATFORM.
D415532 D415535
8
9 10
3
View "B-B" View "C-C"
(Inside of Canopy RH) (Inside of Canopy. LH)
IA0OA04I IA0OA17I
WARNING
WARNING
CARRY LOAD LOW.
OR ATTACHMENTS.
NEVER USE LOADER AS
D416620
PLATFORM.
D415532
IA0OA15I IA0OA13I
- 15 -
10 Danger warning for maintenance. 12 Anti-Skid surface
DANGER
BEFORE LEAVING SEAT :
LOWER BOOM OR ATTACHMENTS
TO THE GROUND. Pedal
STOP ENGINE.
SET PARKING BRAKE.
RAISE THE SEAT BAR.
INSTRUCTIONS ON OUTSDE OF
MANUAL.)
D415535
IA0OA14I View "E-E" IA0OA100

11 Service Shedule label
13 Extinguisher
Every
Every Every Every Every Every
ITEM SERVICE REQUIRED Day CHAIN CASE
50 100 250 500 1000
Check the oil level and fill oil os needed. HYDRAULIC
TANK
Engine Oil Replace the oil.
Replace the oil filter.
Fuel System Clean and replace fuel filter element.
Engine Check coolent level and add os needed.

GREASE
Cooling Check for leaks.
System Check and adjust the tention of fan belt.
Check the indicater.
(Clean or replace the outer element when the red COOLANT
ring shows.) Clean the dust cover. CHAIN CASE
Air
Cleaner GREASE
Replace the indicator.
(Every third replacement of the outer element,
GREASE
replace the inner element also.)
Spark Arres-
Clean the spork chamber.
tor Muffler
Tires Check air pressure and damage to tires.
Seat Bar Check the seat bor for correct operation.
Safety Signs Check for damaged signs and replace damaged signs.
Check the water level and battery cables for

Battery corrosion. Check that the battery cables are
fight. Check covers.
Check the oil level and add as needed. Lubricate all pivot points with
Hydraulic Oil
the specified grease using
Hydraulic appropriate grease gun.
Check for damage and leaks and
Tubes and
replace as needed.
Hoses Chean each grease fitting
before and after lubricating
Chain Case oil Replace the chain cose oil
the pivot points.
Hydraulic
Replace the hydraulic filter.
Filter

Oil Tank
D416685
View D-D IA0OA06I IA0OA76I
- 16 -

equipment.
- 17 -
HA0OA03I
- 18 -
compartment .
guisher operation.
HA0OA04I
- 19 -

of operation.


IA0OA16S
dures.
- 20 -

- 21 -
DANGER
,,,
,,,
HA0OA07I
operate.
- 22 -
- 23 -

is not clear.

electric lines.
IA0OA22S
- 24 -
- 25 -
as between the work equipment and cylinders, or between the machine and work equipment. If the
machine or work equipment is operated or moved, the clearance will change and this may lead to
serious damage or personal injury.
The cab structure of the 1760XL complies with the following ROPS (Rollover Protective Structure) and
FOPS (Falling Object Protective Structure) criteria. -ROPS per ISO 3471 -FOPS per ISO 3449 Level I
Never operate without a ROPS/FOPS approved cab.
2.5.13. Parking

ably necessary to park the machine on a slope, insert blocks between tires and ground. As a safe-
ty measure, thrust the bucket into the ground.
- 26 -
NEVER attempt to engage or disengage the Universal Attachment System (Quik-tach) levers with
the engine running.
WARNING
WARNING
- 27 -
2.5.16. Precautions for Stopping the engine.
CAUTION
When the engine stops and the seat bar (pedal locking device/parking) is secured in place (lowered).
if the pedal is depressed, then the boom or the bucket descends.
CAUTION
When the pedal is kept depressing, then even though the seat bar (pedal locking device/parking) is
raised, the boom or the bucket keeps moving regardless of engines running or not.
- 28 -
WARNING
or death.
loader.
- 29 -


1. Turn engine off.
HA0OA05I
- 30 -

- 31 -
internal pressure.
tion.
IA0OA26I
- 32 -
explosion.
IA0OA27I
- 33 -
HA0O1043I
into the equipment.
IA0OA28I
- 34 -
DANGER
1910.177.
- 35 -

MADE IN KOREA
MACHINE NAME
SERIAL NUMBER
ENGINE POWER kW rpm

IA0OC01P
IA0OA02I
The engine number is stamped on a plate on
the right side of the cylinder block.
engine number to your DHI distributor.
- 36 -
IA0OA30P
- 37 -
IA0OA31P
- 38 -
(9) (10) (8) (11) (15) (13) (16)
STOP
(2) (3) (4) (5) (6) (7) (1) (17) (18) (12) (14) (19) (20)
IA0OC02I IA0OC03I
(1) Key Switch (12) Pre-heat light

(2) Water temperature warning light (13) Parking brake light
(3) Engine oil pressure warning light (14) Water separator light
(4) Charge warning light (15) Fuel gage
(5) HST oil temperature warning light (16) Hour meter
(6) HST pressure warning light (17) Fuse-lamp
(7) Oil filter warning light (18) Fuse-instrument panel
(8) Warning light (19) Fuse-start
(9) Stop light (20) Fuse-horn
(10) Buzzer
(11) Light switch
- 39 -
(1) Key switch (3) Engine oil pressure warning light

the PREHEAT posi- the engine oil pressure is
tion, the light turns on and below 0.5kg/cm2 (15 psi).
onds.
When the key is turned to the IGN position, all the (4) Charge warning light
warning lights on the instrument panel come on. The light turns on when
When the key is turned to the ST position, trouble occurs in the
the engine is started. charging system.
(2) Water Temperature warning light

(5) HST oil temperature warning light
The light turns on when
the temperature of the The light turns on when
engine cooling water the temperature of the hy-
exceeds 110C (230 F). draulic oil to drive HST
- 40 -
(6) HST pressure warning light (9) Stop light
The light turns on when The light turns on simulta-
the pressure of the HST neously with water tem-
pump oil falls down below STOP perature and engine oil
5.97 kg/cm2 (85psi). pressure warning lights.
(10) Buzzer
The buzzer is activated
simultaneously with water
temperature and engine oil
(11) Light Switch

(8) Warning light
turn on.
neously with Charge, HST
and on rear light turn on
simultaneously.
lights.
- 41 -
(12) Pre-heat light (15) Fuel Gage

When the key is turned to Fuel gage shows the
the PREHEAT position, amount of fuel in the fuel
the light turns on and pre- tank.
FUEL
heating of air begins.
ly after 30 seconds.
(13) Parking brake light (16) Hour Meter

Raising the hand lever, the Hour meter indicates the
parking brake is engaged total hours of vehicle
and the light turns on. operating.
(14) Water separator light

If the light turns on with the
engine running. Drain some
fuel (and any water) until
clean fuel flows from the
filter which approximately
IA0OC04I takes 5 to 6 seconds.
- 42 -
5.2. Controls 5.2.1. Drive control lever (1) (2)
(2) (3) (6) (4) (1) (8) (9) (2) (1)

(7)
(5)
(10)
IA0OC05I IA0OC06I
The steering levers are on the left and right sides in

(1) Drive control lever(RH) (7) Parking Brake front of the seat. The levers are independent of each
(2) Drive control lever(LH) (Released Position) other.
(3) Boom pedal (8) Auxiliary Hydraulic FORWARD MOVE : Push both levers forward.
(4) Bucket pedal Thumb Control BACKWARD MOVE : Pull both levers back-
(5) Throttle Lever (9) Horn Button ward.
(6) Seat Bar (10) Pressure Relief STOP : Hold both levers at neutral position.
- 43 -
The distance of lever movement is proportional 5.2.3. Boom Pedal (3)

to travel speed.
the boom. The speed is controlled by the
NOTE : For safety purposes, the operator can
degree of the pedal.
start the engine only when both drive levers are
5.2.2. Pedals (3) (4) Boom up

Neutral
(3) (4) Boom down

Floating
position
FASTEN SEAT BELT
IA0OC08I

IA0OC07I freely. That is a comfortable function to level
- 44 -
floating status, press the rear part of the pedal. 5.2.5. Auxiliary Hydraulics Thumb Control (6)
cle in reverse.
5.2.4. Bucket Pedal (4)

This is the pedal to tilt the bucket forward or AUX ON AUX OFF DETENT ON/OFF
backward. The speed is controlled both for for-

ward and backward tilting by the degree of the
pedal pressing. (1) (2) (3) (4) (5) (6)
RH Dir. Cont.
IA0OA39I
Neutral
Backward
tilting
CAUTION
Forward tilting
When using an attachment other than the stan-
Forward separate attachment.
tilting
Backward tilting
IA0OC09I
- 45 -
The Auxiliary Hydraulics Thumb Control 5.2.6. Engine Control & Auxiliary Hydraulic
system is activated by pushing the on button Attachment Bleed Off
(1) on the forward control panel. The green
light (2) on the panel will illuminate when the
A
system is active. This system can be operat-
ed in two modes by utilizing the rocker switch
(4) (5) on control panel. B
Momentary control: This system is activated
with the rocker switch (5) in the down position.
The auxiliary hydraulics will only operate when
the thumb button (6) on the drive control han-
dle is depressed. IA0OC10P
Detent control: This system is activated with
the rocker switch (4) in the down position. The
Throttle lever (A) controls the engine speed.
thumb button (6) controls the direction of flow
Push the throttle lever forward to increase the
in this mode but it cannot stop or pause flow
engine rpm and pull backward to decrease the
once the system is activated. Auxiliary
engine rpm.
hydraulics will remain active until the off but-
When auxiliary hydraulic attachment has
ton (3) on the panel is pushed or the key
residual pressure, so you cannot remove
switch is turned to off.
attachment from machine, you must recipro-
cate the knob(B) up and down to bleed off the
attachment.
- 46 -
5.2.7. Seat Bar
The seat bar is installed to help protect the op-
erator.
IA0OA17P IA0OA18P
Raised Position Raised Position
NOTE: The pedals are locked if the seat bar is NOTE: 1760XL/ DSL802 is equipped with a
in the raised position. Lower the seat bar to seat bar safety interlock that sets the park
operate the pedals. brake with the seat bar raised. The seat bar
must be lowered for travel.
- 47 -

IA0OA42P

lever.
IA0OA41P

and off the loader.
IA0OA43P
- 48 -
IA0OA18P
6.3. Starting
IA0OC11P
CAUTION
checks.
- 49 -
control servos.
- 50 -

IA0OA46I
CAUTION
Forward Backward
IA0OA45I
- 51 -
ward.
CAUTION
IA0OA47I
(1) Bucket filling
CAUTION
IA0OA48I
- 52 -
(3) Bucket dumping

(2) Bucket scooping
IA0OA49I IA0OA50I
Move the vehicle forward slowly with the bucket IMPORTANT Do not shake the
held parallel to the ground or tilted down slightly. bucket unnecessarily to dislodge sticky material.
When the bucket is sufficiently full, roll back and Vibrations put excess stress on the bucket cylinder
raise the bucket simultaneously. and stopper, which in turn will reduce machine life.
- 53 -
IA0OA51I
CAUTION
sition.
- 54 -

CAUTION down)

stability.

IA0OA21P

ward up)
(2) Parking
IA0OA20P on the ground.
- 55-
in stop position.

Front Rear
DANGER
IA0OA52I
- 56 -

revolutions.
WARNING
(4) Tow loader using the two draw eyes located at IA0OA53S
(5) After towing, tighten valves to 9.5-14 Nm (7-10
ft/lbs.)
Damage to units may result from over-torquing WARNING
valves.
Lifting may shift the load and could result in
(6) DAEWOO Skid Steer Loader can draw another death or serious injury.
machine using the 2 drawing eyes on rear frame.
1760XL/ DSL802 : 2,644 Kg ( w/load )
2,066 Kg ( w/o load )
- 57 -
3. Use the 4 holes for lifting i.e. 2 holes in front up-
per frame and 2 holes in rear inner mast with U-
clamp or strap. 15 or less
IA0OA55I
U-Clamp
or Strap

Mast
inclined 15 or less.
IA0OA54I
cle.
- 58 -
Attachment System (Quik-tach) in front of the
ious attachments.
(1) Installation
Wire Rope
Wire Rope
IA0OA57P
IA0OA56I <Figure 1>
(1) Pull up both handles.

(2) Tilt the Quik-tach forward slightly and drive
forward to the bucket until the upper edge
- 59 -
of the Quik-tach is completely inserted to ward until the back of bucket becomes per-
the flange of the bucket.(Figure 1) pendicular to ground.(Figure 2)
IA0OA58P IA0OA59P
(4) Lock the bucket and Quik-tach by pushing
CAUTION down both handles.(Figure 3)
Do not hit the Quik-tach handles when

(3) Make sure that the top edge of the Quik-

tach is inserted and tilt the Quik-tach back-
- 60 -
IA0OA60P IA0OA61P

driving backward with the Quik-tach tilting
down.(Figure 6)
attachments).(Figure 4)
(2) Removal
touches to ground.
IA0OA57P
<Figure 6>
- 61 -
DANGER
IA0OA24P
<Figure 2>
IA0OA23P
<Figure 1>
IA0OA25P
<Figure 3>
- 62 -
(1) To engage boom lock shown in illustration. (Figure 3)

Make sure the release lever is secured in the Lower boom slowly to lowest position
lock position with knob when the boom lock is Lift boom lock arm, rotate lever counter-
in use. clockwise
Mount lock arm in original position using knob
With boom fully lowered, hold lock arm and
remove knob
Lower lock arm onto cylinder IMPORTANT Do not attempt to
Ensure release lever is in lock position and lower boom once lock is engaged or cylinder dam-
secured with knob age will result.
Raise boom until lock arm rests on the cylinder
rod.
(2) To disengage boom lock

The release lever shold be in the release posi-
tion only when releasing the boom lock.

(Figure 2)
Raise boom until lever reaches position as
- 63 -
WARNING
or death.
loader.
- 64 -
7.2. Access to Items Requiring Service NOTE: The rear door can by locked by placing
a pad lock on the hasp provided on the handle.
IMPORTANT Daily maintenance

door and engine hood of DAEWOO skid steer
CAUTION
loader. ALWAYS keep rear door closed except for ser-
the door latch is firmly engaged before operat-
7.2.1. Rear Door and Engine Hood ing the loader.
Pull the door handle backward to open the rear
door.
IA0OC12P
IA0OA62P
door. rear door.
- 65 -
IA0OA65P
IA0OA64P Remove attaching hardware

boom all the way.
Set park brake
ners of the canopy.
IA0OA66P

- 66 -

IA0OC13P 5. Check the battery and battery cables.
Canopy Lock 6. Check the fuel system for leaks.
Hook the rectangular canopy lock to the hook 7. Check the hydraulic system.
attached on left rear side of the canopy. 8. Grease all fittings.
To lower, reverse the above procedure. 9. Inspect for any loose or missing nuts and bolts
10. Inspect structural members and welds for
CAUTION 11. Check the loader tires for proper inflation and
unusual wear
Never operate without canopy lowered and 12. Check the fuel level.
properly secured. 13. Check the condition and security of the opera-
tor seat belt and seat bar.
- 67 -
WARNING 1. Start the engine and observe the intial exhaust
If any of the following pre/post start checks color at start and at normal operating temper-
indicate that service may be required, have atures. Excessively black, blue, or white
such service performed before using the
exhaust is an indication of a problem. Listen
machine.
for any abnormal sounds.
optional equipment.
a. Check for proper function of the motion
interlock system. With the loader running,
lift the seat-bar to the raised position.
Move the control levers in either direction.
The engine should shut off with less than
1 inch of movement in either direction.
Adjust as necessary.
b. Check for proper operation of boom,
bucket, and accessories ( if attached ).
c. Insure that the boom and bucket pedals are
locked with the seat bar raised.
- 68 -


Fuel System


Air Clean the dust cover.
Cleaner
- 69 -
day 50 100 250 500 1000
Check covers.
Replace the fluid
Tubes and Hoses
(First time)
Oil Tank
for Muffler
(First time)
- 70 -
5
3
IA0OA68I
- 71 -
IA0OA69P IA0OA71P
IA0OA70P IA0OA72P
- 72 -
5. Rear mast cylinder pivot 6. Upper mast pivot
IA0OA73P IA0OA74P
- 73 -
8 7 8
FASTEN SEAT BELT
IA0OC14I
- 74 -
7. Drive control lever fitting 7.6. Operator Restraint Lubrication and

NOTE: Cab must be opened to access. Maintenance
IA0OA77P
IA0OA78P
- 75 -
IA0OA101
7.6.2. Function
IA0OC16P
- 76 -
7.7.1. General 7.7.2. Draining Engine Oil

Engine oil level should be checked daily. After Remove the four bolts from the access plate locat-
draining oil and changing filter approximate ed on the left bottom corner of the chassis.
refill amounts is 2.1 gallon (8 liter) for the Remove the drain plug by either reaching through
1760XL/ DSL802. the opening between the radiator and the chassis
Run loader briefly and check oil level on dipstick or through the access plate. Drain oil into an
before returning the loader to service. approved waste oil receptacle. Inspect drain plug
See section 8.2.9 (page.99) for fluid recom- gasket and if serviceable, replace drain plug. If
mendations. gasket is deformed or torn, replace gasket and re-
install drain plug. Discard oil in accordance with
7.7.3. Remove/Replace Engine Oil Filter

Raise and secure operators cab. Filter is located
on left side of engine block. Using a strap type or
other style filter wrench, remove the engine oil
IA0OC17P filter. Before installing new filter, coat the rubber
gasket on the filter with clean oil. Install filter BY
HAND and tighten until gasket fully contacts the
mounting surface. Tighten 1/2 to 3/4 of a turn, by
hand only.
- 77 -
NOTE: Check the cooling water level while the to drain outside of the chassis. Collect the fluid
engine is cold. and discard it in accordance with local/federal
Accurate coolant level check is not guaranteed environmental rules and regulations.
HOT mark if coolant level is below COLD
mark on sub-tank.
IA0OA83P
Fuel Tank
Hot
CAUTION
Cold (1) Steam or hot liquid may spurt out if the
engine is stopped.
IA0OA82I (2) When removing the radiator cap, turn your
face away from cap and cover the cap with
- 78 -
7.9. Fan Belt 7.9.2. Adjustment
7.9.1. Belt Tension Belt tension can be adjusted by loosening the

upper and lower pivot bolts on the alternator.
Properly adjusted, the belt should have
Use a small pry bar to move the alternator to
approximately 3/8 (10 mm) of free play when
achieve proper tension and retighten pivot
checked by pressing (thumb pressure 45N)
bolts.
firmly on the belt between the fan and alterna-
tor pulleys.
IA0OC19P
Free play IA0OC18P
- 79 -
IA0OC22P
IA0OC20P 7.10.1. Removal-Primary Element

Every day or when the red ring shows on the
air cleaner indicator, the primary air cleaner
element should be removed and cleaned.
Access to the air cleaner assembly is gained
through the rear service door. Loosen the can-
ister cover wing nut and remove the cover and
gasket. Loosen the cover latches and remove
the cover. Rotate the element slightly to sepa-
rate it from its base and remove it from the air
cleaner housing. This element can be cleaned
IA0OC21P
up to six times using compressed air and
should be replaced every 500 operating hours.
- 80 -

element is out of the vehicle. The secondary
IA0OA89P
hours of operation.

- 81 -
glasses with side shields. Start the engine IA0OA90P
exhaust outlet. Re-install plug and lower and Removal: The battery is located in the right
secure cab. rear corner of the chassis. Access to battery
is gained through the rear service door.
Installation: Installation procedure is the
- 82 -
reverse of the removal procedure. Before jumper battery to the negative (-) terminal on
beginning installation, clean the battery ter- the loader frame. Once loader has started,
minals and cable ends with a wire brush. Be remove the ground cable from the frame first.
sure to connect the negative (-) cable last to
minimize the potential for sparking. Coat the NOTE: Ensure the jumper battery being used
terminals and cable ends with grease to pre- is a 12 volt battery or electrical system dam-
vent corrosion. age will result.

(See caution pg. 33- frozen battery)

(+) terminal on the loader battery. Next, con-
nect from the negative (-) terminal on the
- 83 -
7.13. Priming the Fuel System
7.13.1. Bleeding the Fuel System
After changing the fuel filter cartridge assem-
bly, or after having serviced any part of the
fuel system, make sure that the air is bled
from the system.
IA0OC24P
2. Push the priming pump on top of the fuel

filter housing against the spring to allow
air mixed with fuel to escape through the
bleeding screw.
Ensure that excess fuel is collected in a
1
container of rag to prevent fuel from
IA0OC23P getting onto engine parts.
3. Repeat the pumping action until no
1. Loosen one of four bleeding screws(1) on bubbles are visible in the flowing fuel.
overflow pipes to injection nozzles. 4. Tighten the bleed screw.
5. Start the engine and check fuel system
for leaks.
- 84 -
7.13.2. Draining the Water From the Fuel Filter 7.13.3. Fuel Tank Drain
IA0OC25P IA0OA93P
1. Turn the wing nut counter clockwise to The fuel tank drain plug is located directly
open the drain valve on the bottom of the behind the left rear tire on the chassis. fuel
fuel filter. drained should be disposed of into an
2. Drain some fuel (and any water) until approved waste oil container. Discard the
clean fuel flows from the filter. fuel in accordance with local/federal environ-
mental rules and regulations.
- 85 -
7.14. Hydraulic System Maintenance
7.14.1. Oil Level Indicator
The hydraulic oil level indicator and filler neck
are located on the right hand side of the loader
inside the rear service door. To daily check the
fluid level, the loader should be on level ground
with the boom completely lowered and the
IA0OC26P
Quik-tach assembly tilted back. The fluid level
HYDRAULIC FLUID FILTER NECK
as indicated on the sight gauge should read
between the two red lines. Refer to specifica-
tions section 8.2.9 (pg. 93) for complete infor-
mation on fluid capacities and requirements. 7.14.2. Filter Replacement
Replace the filter accordiy to service sched-
ule(7.4)
The filter should be changed whenever the
fluid is changed or whenever the filter indica-
tor shows that it is necessary to change the
filter(a red warning lamp on the instrument
pannel is lit)
IA0OA95P
OIL LEVEL INDICATOR
- 86 -
REMOVAL
Access to the 1760XL(H) / DSL802(H) filter is
through the rear service door. Remove the fil-
ter by turning counterclockwise. Drain the
hydraulic oil into an approved waste oil con-
tainer. While draining, check fluid and filter
base for signs of particle contaminants.
IA0OC27P
INSTALLATION
HYDRAULIC OIL FILTER
Before installation you must coat the rubber
seal on the new filter with a light coat of
7.14.3. Hydraulic fluid replacement
hydraulic oil. Spin on filter by hand turning
clockwise until the rubber filter seal makes
complete contact with the filter head assem-
bly. At this point, turn the filter an additional
3/4 turn to fully tighten. When complete, run
the loader and check the hydraulic oil level
indicator. Add fluid as needed. Discard the
used filter in accordance with local/federal
IA0OA99P
- 87 -
TO REPLACE THE FLUID 7.15. Chain Case Drain and Refill
1. Chain case drain plugs
directly behind the right rear tire on the chas-
sis. Before draining, the loader should be on
level ground with the boom completely low-
ered and the Quik-tach tilted back. Once the
loader is drained, oil should be disposed of
into an approved waste oil container in accor-
dance with local/federal rules and regula-
tions.
IA0OB00P
ule(7.4) 2. Fill plug
with foreigu material(dirt, water, grease, etc)
ture levels greater than the maximum
recommeded.
IA0OB01P
- 88 -

TO DRAIN CHAIN CASE:
A

1) Re-install and tighten case drain plugs. C B
2) Remove fill plugs (left side shown-right in mir-
ror position)
3) Open cab and secure with safety latches.
4) Locate chain case filter necks.
NOTE: Recommended fluid is API CC or CD IA0OC28P
SAE 10W30
5) Refill is 3.95 gal/side or until level is within
1/2 of inspection cover plug.
6) Replace and tighten inspection cover plug
brake handle linkage and return spring. Remove the
7) Close and secure cab.
spring (A) to release tension from the parking brake
linkage. Loosen the jam nut (B), remove bolt (C), and
rotate the clevis on the linkage to adjust the cable ten-
sion until parking brake engages fully and interlock
functions properly. Re-attach clevis, re-tighten jam nut
- 89 -
7.17. Tire Maintenance
and re-connect spring when completed with the 7.17.1. General Information
adjustment procedure. Inability to achieve proper Tires should be checked regularly for wear,
adjustment using this procedure is indicative of more damage, and proper inflation. When replacing
serious problem and should be referred to your DAE- tires, ensure that the size matches those
WOO dealer. already on the vehicle. Mismatched tire sizes
premature wear and damage to drive train
components. If tires are replaced in pairs, they
DANGER
Tires should only be mounted/dismounted from
rims or repaired by trained and authorized per-
sonnel using the proper equipment and proce-
dures. Death or serious injury could result.
See OSHA 1910.177.
- 90 -
7.17.2. Inflation Pressures 7.17.3. Installation and Removal

40 psi (2.8 kg/cm )2
under the tire to prevent rotation while the lug nuts
1
3 6
are being removed. Remove tire and rim assembly.
INSTALLATION: Install the tire and rim
assembly on the axle. Tighten lug nuts to seat
5 8
rim against axle assembly. Insert a wedge
under the tire to prevent rotation while torquing
7 4
2 lug nuts. Torque lug nuts to 102-112 ft/lbs (138-
IA0OB03I 152Nm) in the pattern illustrated above.
- 91 -
Q
R
Item Unit Spec.
F S T G
Overall Height
A. Fully Raised in(mm) 152.8 (3880)
B. To Hinge Pin in(mm) 119.1 (3026)
C. To Canopy in(mm) 79.3 (2015) O
Overall Length
D. With Bucket in(mm) 125.1 (3177) K
E. Less Bucket in(mm) 98.7 (2508)
Overall Width A M
F. With Bucket in(mm) 67.5 (1714)
B
G. Less Bucket in(mm) 65.4 (1662) L C
Others
H. Wheel Base in(mm) 41.5 (1057) I
N
I. Height of S.I.P. in(mm) 40.9 (1040) J U
P H
J. Ground Clearance in(mm) 8.6 (218)
E
T. Tread in(mm) 53.1 (1350) D
U. Departure Angle deg 28 IA0OB04I
- 92 -
Q
R
Item Unit Spec.
F S T G
Dumping
K. Dump Angle deg 40
L. To Hinge Pin in(mm) 91.5 (2323)
Reach O
M. Fully Raised in(mm) 22.5 (572)

Rollback K
N. Max. at Ground deg 26
O. Max. Fully Raised deg 98 A M
Digging
B
P. Digging Depth in(mm) 0.4 (10) L C
Clearance (Circle)
I
Q. Front, Less Bucket in(mm) 45.1 (1146) N
R. Front, With Bucket in(mm) 74.1 (1883) J U
P H
S. Rear in(mm) 62.7 (1593) E
D
IA0OB04I
- 93 -
8.2.1. Performance 8.2.2. Power Unit

Rated Capacity lb(kg) 1700 (771) Make - kia
3 3
Bucket Capacity (Dirt-60) ft (m ) 13.0 (0.37) Model - D430
Operating Weight lb(kg) 6594 (2991) - Diesel
Type of Fuel
Tipping Load lb(kg) 3593 (1630)
Cooling Method - Water
Hydraulic Lifting Capacity lb(kg) 5732 (2600)
Break Out Force -Bucket lb(kg) 3770 (1710) No. of Cylinders each 4
-Boom lb(kg) 3467 (2480) Displacement in3(cc) 181.7 (2977)
Bore Size in(mm) 3.74 (95)
Raising Time -W/O Load sec 3.7
Stroke in(mm) 4.13 (105)
-W/ Load sec 3.6
Lower Time -W/O Load sec 4.0 Horsepower Net hp(ps)/rpm 60.2 (61)/2500
-W/ Load sec 3.0 High Idle rpm 2700 50
Boom Dump Time -W/O Load sec 2.3 Low Idle rpm 950 25
-W/ Load sec 2.14 Torque ft.lb(kg.m)/rpm 133.8 (18.5)/
Rollback Time -W/O Load sec 1.3
1800
-W/ Load sec 1.4
Drawbar Pull -W/O Load lb(kg) 5291 (2400) Torque Rise % 8.6
-W/ Load lb(kg) 6305 (2860) Lubrication - Full Flow
Travel Speed Forward mph(km.h) 6.8 (11.0)

Reverse mph(km/h) 6.8 (11.0)
- 94 -
8.2.3. Final Drive Components 8.2.4. Hydrostatic Transmission Pump

Chain - 2 Chain with Type - Piston, Variable
R.S 100HT Displacement
Max. Displacement in3(cc)/rev 2.68 (44)
No. of Teeth Relief Setting Pressure psi 4061
Drive Sprocket each 10 Charge Pump - None
Rotation - clockwise
(Motor) Swash Plate Operating Angle deg 16
Drive Sprocket each 28 Mounting - SAE 2 Bolt B Mount
(Axle) Shaft - ANSI B92.1-1970
Class No.5
Ratio 2.8 30 15 16/32
Tire Standard Pump

Pressure and Flow
Type - Floatation-Tubeless Flow (Max)
Size - 12-16.5, 8PR Max. System Pressure LPM(GPM) 77.7 (20.5)
Pressure psi (kg/cm2) 40(2.8) at charge pump psi- 300035
bar (2072.4bar)
Wheel High Flow Option Pump

Pressure and Flow
Size - 9.75 x 16.5
Flow LPM(GPM) 131.5(34.8)
Hole x Pitch Circle - 8 x 8 Max. System Pressure psi- 300035
Diameter at charge pump bar (2072.4bar)
- 95 -

Motor Boom Cylinder
Type - Orbit, Fixed Type - Single Rod, Double
Displacement
Acting
Bi-rotational
Displacement in3(cc)/rev 32.04 (523.6) Number each 2
Mounting - SAE 4 Bolt B Mount Cylinder Bore in(mm) 2.36 (60)
Spline Shaft Cylinder Rod in(mm) 1.50 (38)
Pump Stroke in(mm) 33.5 (850)
Type - Gear Mounting - Single Crest Crevice
Capacity in3(cc)/rev 1.92(31.5) Plating on Rod - Hard Chrome w/15-50
Max. Pressure psi 3335
Micron Thickness
Max. Speed rpm 3000
Mounting -
Shaft SAE 2 Bolt A Mount Bucket Cylinder
Rotation - SAE Spline Shaft Type - Single Rod, Double
Clockwise Acting
Control Valve Number each 2
No. of Spool - 3
Cylinder Bore in(mm) 2.36 (60.0)
Relief Setting Pressure psi 2840 (+70)
(set by valve supplier) (195(+5) bar) Cylinder Rod in(mm) 1.5 (38.0)
Circuit - Series on Lift Float Stoke in(mm) 20.0 (507)
Function with Detent Mounting - Single Crest Crevice
Series on Tilt Plating on Rod - Hard Chrome w/15-50
Series on Auxiliary With
Micron Thickness
Electric Detent
(thumb control)
- 96 -

Item Unit Spec.
Hydraulic Filter
Item Unit Spec.
Filter Rating - 13 Micron Beta Rating Alternator - 12V - 60A
of 20 Battery - 12V-100AH, 700CCA
Rated Flow I(gal)/min 132.5 (35) 12.5 X 6.75 X 8.0
By-Pass Valve Closing PR50 PSID Starter - 12V - 2.5kW
(Normally Open Type)
Lighting
Hydraulic Lines and
Head Lamps each 2
Fittings
Rear Lamps each 1
Type - O-Ring Face Seal
Fitting (SAEJ1453)
Thread - Unified Thread is
Standard
Medium Pressure Line - SAE 100R1 Hose
(SAE J517)
Hydraulic High - SAE 100R2 Hose
Pressure Line (SAEJ517)
HST High - SAE 100R12 Hose
Pressure Line (SAE J517)
- 97 -

-Engine Oil Pressure -Cushion lb/ft3(kg/m3) 833 (52)
-Engine Water Temperature each lb/ft3(kg/m3) 609 (38)
-Backrest
-HST Filter
-Fuel Meter
-Hour Meter
-Park Brake Monitor
-Pre-Heater Monitor
Key Switch
Light Switch
Fuses
- 98 -
Item Specifications Unit Qty
Engine Lubrication API CC or CD SAE 10W30 for

-W/ Filter Ambient Temp above -4 deg. F gal(liter) 2.1 (8)
Hydraulic Tank SAE 10W20CD; Taxaco TDH; Mobil gal(liter) 9.2 (35)
Hydraulic System Fluid 423; Chevron Tractor Hydraulic gal(liter) 12.7 (48)
Chain Case API CC or CD SAE 10W30 gal(liter) 6.3 (24)
Fuel Tank #2 Diesel recommended for Ambient gal(liter) 21.1 (80)
Cooling Fluid Recommended mixture is 50/50 gal(liter) 1.8 (6.9)
Grease Recommended is a mineral based grease
with a lithium thickener and
rust, corrosion and extreme pressure addi-
tives. Viscosity conforms to
NOGI grade 2.
- 99 -
- 100 -
edge with the bucket hinge pin at maximum height and the bucket at a 45 dump angle.
The angle is less than 45, specify angle.
Digging Depth (P) - The vertical distance in inches (millimeters) from the ground to the bottom of the bucket
cutting edge at the lowest position with the bucket cutting edge horizontal.
rear point on the machine will describe measured from a point located at 1/2 the wheelbase (H) and 1/2 the
overall width (G) of the machine.
- 101 -
- 102 -

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SERVICE MANUAL CONTENTS

TITLE FORM NUMBER

Service Manual Contents SB4032E00

Safety & Foreword SB4033E00

D427 Diesel Engine (1550XL(DSL702)) SB4034E00

Vehicle Systems SB4036E00

HYDRAULIC & HYDROSTATIC

Hydraulic & Hydrostatic Systems SB4037E00

Electric Systems SB4038E00

OPERATION & MAINTENANCE

Operation & Maintenance Manual SB2313E00

Models ; 1550XL(DSL702), 1760XL(DSL802), 2060XL(DSL902)

Satety & Foreword

15. Do not damage wiring during removal operations.

16. Be sure all protective devices including guards

17. Loose or damaged fuel, lubricant and hydraulic

18. Tighten connections to the correct torque. Make

19. Relieve all pressure in air, oil or water systems

Precautions For Disassembly

Foreword 5 How to Use This Manual

Keep each set of shims or washers stored in an 1) Cleaning

Cover washed parts in storage to keep them free

Keep the area where the machine is to be

Foreword 6 General Precautions For Disassembly

Foreword 7 General Precautions For Assembly

(7) Handling of bearings

a. Leave the bearings in their original package until

Pressure Handling of Common Parts

(1) Handling of packings and O-ring

Inner Race Replace all packings, gaskets O-rings, and copper

Foreword 8 General Precautions For Assembly

(3) Handling of oil seals

Be careful to see that the oil seal lips face the

Main Lip Main LipDust Sealing Lip

a. In case of a single-lip type oil seal:

b. In case of a double-lip type oil seal :

Foreword 9 General Precautions For Assembly

Engine 1 2.1. General Information

Engine Cooling System

Diesel Engine D427 3 Index

Technical Data ..............................................72

Diesel Engine D427 4 Index

Engine model D427

Diesel Engine D427 5 Engine

Problem Possible Cause Remedy

Diesel Engine D427 6 Engine

Diesel Engine D427 7 Engine

Adjustment of Cylinder Head

Fig 1-2 1. Remove the cylinder head cover.

2. With the No. 1 cylinder piston at TDC, check and

2. Remove the head bolts. Intake side : No.1, No.2

4. Assemble the cylinder head cover.

Diesel Engine D427 8 Engine

2. Run the engine at idle.

Standard ldling speed : 1100 L 25

1. Remove the lock nut of the idling adjusting bolt.

2. Turn the idling adjusting bolt until the idling speed

3. Tighten the lock nut.

4. Run the engine for about 2-3 minutes and check if

4. With the flywheel ring gear in proximity to BTDC

Inspection 5. When it is confirmed that the needle of dial guage