Daewoo Doosan DD 80L Operation and Maintenance Manual 5022-7103E-R1 - PDF DOWNLOAD

DD 80L Operation and Maintenance Manual 5022-7103E-R1 Serial Number 0093 and Up July 1998

Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment.

This documentation may include attachments and optional equipment that is not available in your machine’s package. Please call your distributor for additional items that you may require.

Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item.

5022-7103E-R1 Operation and Maintenance Manual

TABLE OF CONTENTS Safety ......................................................................................... 1-1 To the Operator of a Daewoo Dozer................................................... 1-1 General Safety Essentials .................................................................. 1-2 Locations of Safety Labels ................................................................. 1-3 Unauthorized Modifications ................................................................1-6 Work-site Precautions ........................................................................ 1-6 Operation............................................................................................1-8 Equipment ........................................................................................ 1-12 Maintenance..................................................................................... 1-15 Shipping and Transportation ............................................................ 1-17

Operating Controls ................................................................... 2-1 Component Locations ........................................................................ 2-2 Operator’s Area ..................................................................................2-3 Instrument Panel ................................................................................ 2-7 Stereo...............................................................................................2-16 Calibration Switch............................................................................. 2-20 Limp Home Switches........................................................................ 2-20 Miscellaneous Electrical Devices .....................................................2-23 Fuel Transfer Pump (If Equipped).....................................................2-24 Seat Adjustment ............................................................................... 2-25 Seat Belt...........................................................................................2-26 Door Side Latch................................................................................2-27 Miscellaneous Access Covers and Doors ........................................ 2-28

Operation................................................................................... 3-1 To Handle a New Dozer ..................................................................... 3-1 Starting and Stopping the Engine ......................................................3-2 Travel ................................................................................................3-11 Operating Instructions ...................................................................... 3-15

5022-7103E-R1 Operation and Maintenance Manual

Table of Contents I

Operating Precautions...................................................................... 3-17 Parking Dozer................................................................................... 3-19 Towing Procedure............................................................................. 3-20

Inspection, Maintenance and Adjustment.............................. 4-1 Preliminary Work Machine Setup for Maintenance ............................ 4-2 Table of Recommended Lubricants.................................................... 4-3 Maintenance Intervals ........................................................................ 4-5 10 Hour / Daily Service ...................................................................... 4-7 50 Hour / Weekly Service................................................................. 4-13 150 Hour Service ............................................................................. 4-16 250 Hour / Monthly Service ..............................................................4-17 500 Hour / 3 Month Service .............................................................4-24 1000 Hour / 6 Month Service ........................................................... 4-27 1500 Hour Service ........................................................................... 4-30 2000 Hour / Yearly Service............................................................... 4-30 4000 Hour / Biennial Service............................................................ 4-31 Electrical System.............................................................................. 4-32 Blade ................................................................................................4-35 Calibration Procedure for Micro Controller ....................................... 4-36 Track Tension ................................................................................... 4-46 Bolt and Nut Inspection .................................................................... 4-48 Maintenance In Special Conditions .................................................. 4-49 Long Term Storage........................................................................... 4-50

Transportation........................................................................... 5-1 Loading and Unloading ...................................................................... 5-1 Lifting with Sling ................................................................................. 5-2

Troubleshooting........................................................................ 6-1 Engine ................................................................................................6-1 Hydraulic System ............................................................................... 6-2 Electrical System................................................................................ 6-3

Table of Contents II

5022-7103E-R1 Operation and Maintenance Manual

Travel System ..................................................................................... 6-4

Specification ............................................................................. 7-1 General Specifications ....................................................................... 7-1 Overall Dimensions ............................................................................ 7-4

Index .......................................................................................... 8-1

5022-7103E-R1 Operation and Maintenance Manual

Table of Contents III

1SAFETY TO THE OPERATOR OF A DAEWOO DOZER DANGER! Unsafe use of the dozer could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.

Please respect the importance of taking responsibility for your own safety, and that of other people who may be affected by your actions.

The safety information on the following pages is organized into the following sections: 1.

“General Safety Essentials” on page 1-2

2.

“Locations of Safety Labels” on page 1-3

3.

“Unauthorized Modifications” on page 1-6

4.

“Work-site Precautions” on page 1-6

5.

“Operation” on page 1-8

6.

“Equipment” on page 1-12

7.

“Maintenance” on page 1-15

8.

“Shipping and Transportation” on page 1-17

SAFETY ALERT SYMBOL Be Prepared - Get To Know All Operating and Safety Instructions.

This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.

LEARN THE SIGNAL WORDS USED WITH THE SAFETY ALERT SYMBOL The words "CAUTION", "WARNING", and "DANGER" used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears next to the "Exclamation Point" symbol.

5022-7103E-R1 Operation and Maintenance Manual

Safety 1-1

CAUTION! Indicates potential of a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice.

WARNING! Indicates potential of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against a highly unsafe practice.

DANGER! Indicates imminent hazard of a situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be used to alert against equipment that may explode or detonate if handled or treated carelessly.

GENERAL SAFETY ESSENTIALS ACCESSORY APPLICATIONS The dozer has been primarily designed for moving earth with a blade. DO NOT use the machine for activities for which it was not intended.

1-2 Safety

5022-7103E-R1 Operation and Maintenance Manual

LOCATIONS OF SAFETY LABELS

Figure 1 Always keep these labels clean. If they are lost or damaged, replace them with a new label. It is the responsibility of the equipment owner and crew to provide essential safety information in the immediate vicinity of hazards.

Safety labels may be available in languages other than English, or labels providing a warning for other hazards than those that follow may be available. Contact your Daewoo distributor to find out what labels are available.

5022-7103E-R1 Operation and Maintenance Manual

Safety 1-3

1.

WARNING FOR OPERATION, INSPECTION, MAINTENANCE (5190-2611).

CAUTION! •

Read manual and labels before operation and maintenance. Follow instructions and warnings in manual and on labels on the machine.

•

Never get in under the machine while it is being jacked up with blade.

•

Sound the horn to alert the people nearby before operating, and make sure all persons are clear of area.

•

Always make sure when leaving operator’s seat to:

1-4 Safety

HAOA010L

–

Lower blade or other working tools to the ground.

–

Place all levers in "NEUTRAL" position.

–

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

5022-7103E-R1 Operation and Maintenance Manual

2.

WARNING FOR BATTERIES MAINTENANCE (2190 - 2533).

WARNING! •

Battery fumes can explode. Keep sparks and flames away from batteries.

•

Always avoid storing metals like tools or inflammable materials around or on the batteries. Explosion or fire can be caused by short circuiting batteries.

•

Sulfuric acid in battery is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed in eyes.

•

If you spill acid on yourself: 1.

Flush your skin with water.

2.

Apply baking soda or lime to help neutralize the acid.

3.

Flush your eyes with water for 10-15 minutes.

Get medical attention immediately.

3.

WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (2190 - 2529)

.

WARNING! To prevent hot oil from spurting out: •

Turn engine off.

•

Allow oil to cool.

•

Slowly open cap to relieve pressure before removing cover.

5022-7103E-R1 Operation and Maintenance Manual

Safety 1-5

4.

WARNING FOR HIGH TEMPERATURE COOLANT (2190 - 2531)

.

WARNING! To prevent hot water from spurting out:

5.

•

Turn engine off.

•

Allow water to cool.

•

Slowly loosen cap to relieve pressure before removing.

WARNING TAG - USED WHEN PERFORMING INSPECTION OR MAINTENANCE (2190 - 2549).

Hang this tag on instrument panel when performing maintenance.

WARNING

HAOC920L

Figure 2

UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from Daewoo can create a safety hazard, for which the machine owner must be held responsible.

For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised.

WORK-SITE PRECAUTIONS ATTACHMENT PRECAUTIONS Options kits are available through your dealer. Because Daewoo cannot anticipate, identify or test all of the attachments that owners may wish to install on their machines, please contact Daewoo for authorization and approval of attachments, and their compatibility with options kits.

1-6 Safety

5022-7103E-R1 Operation and Maintenance Manual

BEFORE STARTING TO DIG, CONTACT AUTHORITIES Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know what’s underneath the work-site before starting to dig.

BE AWARE OF HEIGHT OBSTACLES Any type of object in the vicinity of the unit that could represent a potential hazard, or cause the operator to react suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines, work-site scaffolds, or other obstructions.

USE CARE ON LOOSE SUPPORT Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load conditions and possible tipover and injury. Travel without a load may also be hazardous.

If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground. Stay away from ditches, overhangs and all other weak support surfaces.

OVERHANGS ARE DANGEROUS Digging the workface under an overhang – the work area beneath a cliff or under the edge of a ditch – is dangerous. Know the height and limits of the DOZER and plan ahead while working. Working around deep pits or along high walls may require support blocks, especially after heavy rainfalls or during spring thaws.

Park the DOZER away from overhangs before work shutdown.

SLOPING TERRAIN REQUIRES CAUTION Dig evenly around the work-site whenever possible, trying to gradually level any existing slope. If it’s not possible to level the area or avoid working on a slope, reducing the size the workload is recommended.

On sloping surfaces, use caution when positioning the DOZER prior to starting work.

Stay alert for instability situations in order to avoid getting into them.

Figure 3

5022-7103E-R1 Operation and Maintenance Manual

Safety 1-7

STAY ALERT FOR PEOPLE MOVING THROUGH THE WORK AREA Slow down work and use slower travel speeds in congested or populated areas. Use a commonly understood signal so that other members of the work crew can warn the operator to slow or halt work in an impending hazard situation.

BE AWARE OF AND CONFORM TO LOCAL REGULATIONS Minimum levels of insurance coverage, work permits or certification, physical barriers around the work-site or restricted hours of operation may be mandated by governing authorities.

There may also be guidelines, standards or restrictions on equipment that may be used to perform certain kinds of work. Check and follow all local requirements, which may also be related to below ground hazards and power lines.

HAOA170L

Figure 4

OPERATION OPERATE WHILE SEATED AT THE OPERATOR’S STATION ONLY Never reach in through a window to work a control. Don’t try to operate the DOZER unless you’re in the command position stay alert and focused on your work at all times but DON’T twist out of the seat if job activity behind you (or to the side) requires your attention.

Use a spotter or signal person if you can’t see clearly and something is happening behind you.

Replace damaged safety labels and lost or damaged owner’s manuals.

HAOA151L

Figure 5

Do not let anyone operate the machine unless they’ve been fully and completely trained, in safety and in operation of the machine.

BEFORE STARTING THE ENGINE Do a "pre-start" safety check: •

Walk around your machine before getting in the operator’s cab. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard.

•

All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated.

1-8 Safety

5022-7103E-R1 Operation and Maintenance Manual

•

Look around the work-site area for potential hazards, or people or property that could be at risk while operation is in progress.

•

NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a warning tag is attached to controls in the cab.

•

A machine that has not been used recently, or is being operated in extremely cold temperatures, could require a warm-up or maintenance service prior to start-up.

•

Check gauges and monitor displays for normal operation prior to starting the engine. Listen for unusual noises and remain alert for other potentially hazardous conditions at the start of the work cycle.

NEVER USE ETHER STARTING AIDS An electric-grid type manifold heater is used for cold starting. The glowing heater element can cause ether or other starting fluid to detonate, causing injury.

Figure 6 MOUNTING AND DISMOUNTING NEVER get on or off a moving machine. Don’t jump on/off. The entry/egress path should be clear of mud, oil and spills and mounting hardware must be kept tight and secure.

Always use handholds, steps or track shoes and maintain at least 3-point contact of hands and feet. Never use controls as handholds.

NEVER get up from the operator’s seat or leave the operator’s station and dismount the machine if the engine is running.

Figure 7 OBSERVE GENERAL SAFETY RULES Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be allowed to operate or perform maintenance or service on the dozer.

All personnel at the work-site should be aware of assigned individual responsibilities and tasks.

Communication and hand signals used should be understood by everyone.

Terrain and soil conditions at the job site, approaching traffic, weather-related hazards and any above or below ground obstacles or hazards should be observed and monitored by all work crew members.

5022-7103E-R1 Operation and Maintenance Manual

Safety 1-9

,,,

,,,

ENGINE VENTILATION Engine exhaust gases can cause fatal accidents, as well as unconsciousness, loss of alertness, judgement and motor control and serious injury.

Make sure of adequate ventilation before starting the engine in any enclosed area.

You should also be aware of open windows, doors or ductwork into which exhaust may be carried, or blown by the wind, exposing others to danger.

HAOA070L

Figure 8 ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be HAZARDOUS to your health if it is inhaled.

If you handle materials containing asbestos fibers, follow these guidelines as given below: •

Never use compressed air for cleaning

•

Use water for cleaning to keep down the dust.

•

Work on the machine or component with the wind at your back whenever possible.

•

Use an approved respirator.

TAKE TIME TO PROVIDE GOOD VISIBILITY Halt work if visibility is poor. Strong rains, snow, fog and extremely dusty conditions can all obscure visibility so badly that it is best to wait for weather to change or dust to settle before continuing operation.

Night work in areas of limited visibility should be halted if installation of extra work lights on the machine (or work area) is necessary.

Keep dirt and dust off the lens surfaces of work lights. Stop working if lights or mirrors need cleaning or adjustment.

FUEL, OIL AND HYDRAULIC FLUID FIRE HAZARDS Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area. The machine must be parked with controls, lights and switches turned off. The engine must be off and any flames, glowing embers, auxiliary heating units or spark-causing equipment must be doused, turned off and/or kept well clear of the machine.

Static electricity can produce dangerous sparks at the fuel filling nozzle. In very cold, dry weather or other conditions that could produce static discharge, keep the tip of the fuel nozzle in constant contact with the neck of the fuel filling nozzle, to provide a ground.

1-10 Safety

HAOA120L

Figure 9

5022-7103E-R1 Operation and Maintenance Manual

Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured.

BOOST STARTING OR CHARGING ENGINE BATTERIES Turn off all electrical equipment before connecting leads to the battery. This includes electrical switches on the battery charger or boost starting equipment.

When boost-starting from another machine or vehicle do not allow the two machines to touch.

Wear safety glasses or goggles while required parallel battery connections – positive to positive and negative to negative – are made.

HAOA310L

24 volt battery units consisting of two seriesFigure 10 connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery. Booster or charger cable connections must be made between the non-series-connected positive terminals and between the negative terminal of the booster battery and the metal frame of the machine being boosted or charged. Refer to the procedure and illustration in this manual.

Connect positive cable first when installing cables and disconnect the negative cable first when removing them. The final cable connection, at the metal frame of the machine being charged or boost-started, should be as far away from the batteries as possible.

KEEP "PINCH POINT" AREAS CLEAR - USE CAUTION IN REVERSE Use a signal person in high traffic areas and whenever the operator’s view is not clear, such as when traveling in reverse.

Anyone standing near the track frames or working assemblies is at risk of being caught between moving parts of the machine.

Never allow anyone to ride on any part of the machine or attachment, including any part of the operator’s station.

HAOA170L

Figure 11 TRAVEL PRECAUTIONS Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope or obstacle that causes 10 degrees tilt, or more.

OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES In icy cold weather avoid sudden travel movements and stay away from even very slight slopes. The machine could skid off to one side very easily.

Snow accumulation could hide or obscure potential hazards. Use care while operating or while using the machine to clear snow.

Warming up the engine for a short period may be necessary, to avoid operating with sluggish or reduced working capacity. The jolting shocks and impact loads caused by bumping or bottoming the blade or

5022-7103E-R1 Operation and Maintenance Manual

Safety 1-11

attachment are more likely to cause severe stress in very cold temperatures. Reducing work cycle rate and work load may be necessary.

PARKING THE MACHINE Avoid making sudden stops, or parking the machine wherever it happens to be at the end of the work day.

Plan ahead so that the dozer will be on a firm, level surface away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable, block the crawler tracks to prevent movement. Lower the blade or other working attachment completely to the ground, or to an overnight support blocking. There should be no possibility of unintended or accidental movement.

EQUIPMENT ROUGH OPERATION MAY REQUIRE USE OF CERTIFIED SAFETY EQUIPMENT Work in mines, tunnels, deep pits or on loose or wet surfaces could produce danger of falling rock, roll over or hazardous flying objects.

Additional protection for the operator’s cab could be required in the form of a ROPS / Roll Over Protective Structure, FOPS / Falling Object Protective Structure and/or windows guards.

HAOA110L

Figure 12 Any reinforcement system that is installed on the machine must pass safety and certification standards and carry appropriate labeling and rating information. For example, the most often added type of reinforcement system, FOPS, must meet or exceed Society of Automotive Engineers standard SAE J1356, "Performance Criteria for Falling Object Guards for dozers."

Never attempt to alter or modify any type of protective structure reinforcement system, by drilling holes, welding or remounting or relocating fasteners. Any serious impact or damage to the system requires a complete integrity reevaluation.

Reinstallation, recertification and/or replacement of the system may be necessary.

HAOA100L

Figure 13

INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE When working with a forest or some other work applications, a front guard over the windshield may be required. The windshield guard may or may not be OPS/certified, depending upon the specific application and working situation.

1-12 Safety

5022-7103E-R1 Operation and Maintenance Manual

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

Contact your Daewoo distributor for available safety guards and/or recommendations if there is any danger of getting hit by objects that could strike the operator’s cab. Make sure that all other work-site crew members are kept well away from the DOZER and safe from potential hazards.

BACKUP ALARM The dozer is equipped with an audible backup alarm that must be tested on a daily basis. The audible alarm should sound as soon as the travel system is engaged into reverse.

SEAT BELTS SHOULD BE USED AT ALL TIMES Whenever the engine is running, the operator should be seated at the control station with the seat belt properly engaged.

Figure 14 KEEP A FIRE EXTINGUISHER AT HAND It is recommended that an appropriately sized (2.27 kg [5 lb.] or larger) multi-purpose "A/B/C" fire extinguisher be mounted in the cab. Check and service the fire extinguisher at regular intervals and make sure that all work-site crew members are adequately trained in its use.

MAINTAIN STANDARD SAFETY EQUIPMENT IN GOOD CONDITION Machinery guards and body panel covers must be in place at all times. Keep well clear of rotating parts. Pinch point hazards such as cooling fan and alternator drive belts could catch hair, jewelry or oversize or very loose clothing.

HAOA080L

Figure 15

Safety labels must be replaced if they are damaged or become unreadable. The information on labels gives work crew members an important safety reminder exactly where it will do the most good. Part numbers for each label and required mounting locations are shown in “Locations of Safety Labels” on page 1-3 of this section.

WINCH OPERATION When unit is equipped with a winch, the operator’s compartment must be guarded to protect operator from a breaking cable. A cable that breaks under tension can wipe and cause serious bodily injury or death.

Always use extreme care when handling loads with a winch.

5022-7103E-R1 Operation and Maintenance Manual

Safety 1-13

SAFETY-CRITICAL PARTS MUST BE REPLACED PERIODICALLY Replace the following fire-related components as soon as they begin to show any sign of wear, or at regular periodic intervals, whether or not deterioration is visible: •

Fuel system flexible hoses, the tank overflow drain hose and the fuel fill cap.

•

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

•

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

HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT Check cylinder drift rate at regular intervals. Maximum allowable rates are included in the Specification section in the DOZER Shop Manual. Overhaul seal kits are available through Daewoo.

HIGH PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY Exposed hydraulic hoses on the C-frame could react with explosive force if struck by a falling rock, overhead obstacle or other jobsite hazard. Extra safety guards may be required. NEVER allow hoses to be hit, bent or interfered with during operation.

THE OPERATOR’S CAB DECK SHOULD BE KEPT CLEAN Cleaning off accumulations of grease and dirt helps extend equipment service life. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result.

Keep the cab floor and consoles free of tools and personal items.

WEAR EYE PROTECTION AND SAFETY CLOTHING Full eye protection, a hard hat, safety shoes and gloves may be required at the job site.

While working on the machine, never use inadequate tools. They could break or slip, causing injury, or they may not adequately perform intended functions.

BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED Don’t forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries.

HAOA020L

Figure 16

NOTE:

The sound level in the closed operator’s cab is 75 dB(A). Additional information on the machine sound and vibration levels can be found in the Shop Manual.

1-14 Safety

5022-7103E-R1 Operation and Maintenance Manual

BATTERY ELECTROLYTE AND EXPLOSIVE GASES CAN BE LETHAL Flush eyes with water for 10-15 minutes if acid is splashed in the face. Anyone who swallows acid must have immediate medical aid. Call the Poison Control listing in the front cover of the telephone directory. Water, a popsicle or ice cream are likely better than old remedies that try to induce vomiting (which would expose tissue to damage twice).

Explosive battery gas can be set off by sparks from incidental contact or static discharge. Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.

HAOA440L

Figure 17

DISCONNECT BATTERIES FOR ELECTRICAL SERVICE BEFORE ELECTRICAL WELDING Remove cable to negative terminal first, when disconnecting cable. Connect positive terminal cables first when installing a battery.

Disconnect the micro controller prior to welding.

USE LOW HEAT PORTABLE LIGHTING Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.

MAINTENANCE USE WARNING TAG CONTROL LOCKOUT PROCEDURES DURING SERVICE Alert others that service or maintenance is being performed and tag operator’s cab controls – and other machine areas if required – with a warning notice.

WARNING

Warning tags for controls are available from Daewoo distributors.

DO NOT RUN THE ENGINE IF REPAIRS OR WORK IS BEING PERFORMED ALONE You should always have at least two people working together if the engine must be run during service. One person needs to remain in the operator’s seat, ready to work the controls or stop the machine and shut off the engine.

5022-7103E-R1 Operation and Maintenance Manual

HAOC920L

Figure 18

Safety 1-15

ALWAYS USE ADEQUATE EQUIPMENT SUPPORTS AND BLOCKING Do not allow weight or equipment loads to remain suspended. Lower everything to the ground before leaving the operator’s seat. Do not use hollow, cracked or unsteady, wobbling weight supports. Do not work under any equipment supported solely by a lift jack.

DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS Wait for the engine to cool off after normal operation. Park the dozer on a firm, level surface and lower all equipment before shutting down and switching off controls. When engine lube oil, gearbox lubricant or other fluids require change, wait for fluid temperatures to decrease to a moderate level before removing drain plugs.

NOTE:

Oil will drain more quickly and completely if it is warm. Do not drain fluids at 95°C (203°F) temperatures but don’t allow full cool-down.

COOL-DOWN IS REQUIRED PRIOR TO RADIATOR OR RESERVOIR CHECKS Stop the engine and allow heat to dissipate before performing service on the engine radiator or hydraulic fluid reservoir. Both assemblies have air vent levers at or near the fill cap for venting built-up air pressure. Release the levers before trying to take off fill caps and LOOSEN CAPS SLOWLY, prior to removal.

PRESSURIZED HYDRAULIC OIL FLUID LEAKS CAN BE DANGEROUS

HAOA060L

Figure 19

Fluid leaks from hydraulic hoses or pressurized components can be difficult to see but pressurized oil has enough force to pierce the skin and cause serious injury.

Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands or expose your fingers.

HAOA420L

Figure 20

1-16 Safety

5022-7103E-R1 Operation and Maintenance Manual

OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES THE SKIN.

WARNING! Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE Refer to the "General Maintenance" section of the Shop Manual for information on tightening torques and recommended assembly compounds and always use the correct part.

Poor or incorrect fastener connections can dangerously weaken assemblies.

DISPOSE OF ALL PETROLEUM-BASED OILS AND FLUIDS PROPERLY Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue.

Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. Never drain any petroleumbased product on the ground or dispose of old oil in municipal waste collection containers, or in metropolitan sewer systems or rural landfills.

Check state and local regulations for other requirements.

HAOA470L

Figure 21

TRACK TENSION ADJUSTMENTS REQUIRE CAUTION NEVER turn out the track tension grease fitting nut. To release pressure from the crawler frame track tension assembly, you should NEVER attempt to disassemble the track adjuster or attempt to remove the grease fitting or valve assembly.

Keep your face and body away from the valve. Refer to the track adjustment procedure in the Operation and Maintenance Manual or the Shop Manual.

SHIPPING AND TRANSPORTATION OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS Check state and local restrictions regarding weight, width and length of a load prior to making any other preparation for transport.

The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.

Partial disassembly or tear-down of the DOZER may be necessary to meet travel restrictions or particular conditions at the job site. See the Shop Manual for information on partial disassembly.

Refer to “Transportation” on page 5-1 of this manual for information on loading, unloading and towing.

5022-7103E-R1 Operation and Maintenance Manual

Safety 1-17

1-18 Safety

5022-7103E-R1 Operation and Maintenance Manual

2OPERATING CONTROLS The "Operating Controls" section presented here consists of the following groups: 1.

“Component Locations” on page 2-2

2.

“Operator’s Area” on page 2-3

3.

“Instrument Panel” on page 2-7

4.

“Stereo” on page 2-16

5.

“Calibration Switch” on page 2-20

6.

“Limp Home Switches” on page 2-20

7.

“Miscellaneous Electrical Devices” on page 2-23

8.

“Fuel Transfer Pump (If Equipped)” on page 2-24

9.

“Seat Adjustment” on page 2-25

10.

“Seat Belt” on page 2-26

11.

“Door Side Latch” on page 2-27

12.

“Miscellaneous Access Covers and Doors” on page 2-28

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

Indicator lights work in addition to the gauges on the instrument panel. The operator should monitor machine pressure on the instrument panel along with pilot lights. These lights will only give the operator an indication that there is a problem

WARNING! Warning lights. When any one or more of the warning lights located on the control console come "ON", immediately discontinue operation and shutdown unit. Investigate and correct the problem before proceeding with operation.

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-1

COMPONENT LOCATIONS

Figure 1

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

BACKUP ALARM REAR WORK LIGHTS FUEL TANK AIR CLEANER BATTERY BOX ENGINE TRAVEL MOTOR BLADE CYLINDER TRACK FRAME TRACK LINK, SHOE ANGLE CYLINDER FRAME

2-2 Operating Controls

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

BLADE BELL CRANK TILT CYLINDER RADIATOR HEADLIGHTS PRE-CLEANER MUFFLER WIPERS FRONT WORK LIGHTS HYDRAULIC OIL TANK CAB OPERATOR’S AREA (See page 2-3)

5022-7103E-R1 Operation and Maintenance Manual

OPERATOR’S AREA

Figure 2

1.

2.

3.

4.

5.

HORN FORWARD/REVERSE TRAVEL LEVER ENGINE SPEED CONTROL LEVER LEFT STEERING PEDAL BRAKE PEDAL

1.

HORN

6.

7.

8.

9.

10.

RIGHT STEERING PEDAL INSTRUMENT PANEL (See page 2-7) OPERATING LEVER (ANGLE) OPERATING LEVER (LIFT, TILT) SEAT

There are two horn buttons located in the operator’s cab.

Press horn button (located under rubber lever cover) to sound horn. See Figure 3

Figure 3

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-3

Press horn button (located on side of forward/reverse travel lever) to sound horn.

See Figure 4

Figure 4 2.

FORWARD/REVERSE TRAVEL LEVER This lever controls travel direction of unit.

Moving the lever farther in one direction increases travel speed of unit.

A.

In this position “NEUTRAL.”

B.

Push lever forward for “FORWARD” travel. Travel speed increases as lever is moved farther from “NEUTRAL.”

is

in

NOTE:

Depress button on top right of Figure 5 lever to allow lever to be moved out of “NEUTRAL” position.

When lever is returned to “NEUTRAL,” it will be latched automatically.

NOTE:

There is a second (small) button located on side of lever. This button is used for the horn.

C.

Pull lever back for “REVERSE” travel. Travel speed increases as lever is moved farther from “NEUTRAL.”

NOTE: 3.

lever

When reverse travel is selected a backup alarm will sound.

ENGINE SPEED CONTROL LEVER This lever controls engine RPM. A.

Pull lever back engine RPM.

B.

Push lever forward to “DECREASE” engine RPM.

NOTE:

to

“INCREASE”

The engine speed control lever is mechanically connected to the fuel inject pump. There is a potentiometer connected to this lever.

This potentiometer electronically monitors the position of the lever to help maintain engine RPM.

2-4 Operating Controls

Figure 6

5022-7103E-R1 Operation and Maintenance Manual

4.

LEFT STEERING PEDAL Left track travel speed decreases the farther the pedal is depressed. Speed control is accomplished by controlling the swash plate angle of the left hand travel pump and motor.

Fully depressing pedal reverses travel direction of track.

NOTE:

5.

There is a spring loaded plunger located beneath the pedal. When the pedal starts to depress this plunger, the track travel direction is reversed.

Figure 7

BRAKE PEDAL Travel speed decreases the farther the pedal is depressed.

Braking is accomplished by controlling the swash plate angle of both travel pumps and motors.

Fully depressing the brake pedal engages the hydraulic brake.

NOTE:

There is a spring loaded plunger located beneath the pedal. When the pedal starts to depress this plunger, the brake is applied.

Figure 8

When the pedal is fully depressed a parking brake latch can be engaged.

6.

RIGHT STEERING PEDAL Right track travel speed decreases the farther the pedal is depressed. Speed control is accomplished by controlling the swash plate angle of the right-hand travel pump and motor.

Fully depressing pedal reverses travel direction of track.

NOTE:

There is a spring loaded plunger located beneath the pedal. When the pedal starts to depress this plunger, the track travel direction is reversed.

5022-7103E-R1 Operation and Maintenance Manual

Figure 9

Operating Controls 2-5

7.

INSTRUMENT PANEL For explanation of gauges, indicator lights and switches see “Instrument Panel” on page 2-7

HAOL113L

Figure 10 8.

OPERATING LEVER (ANGLE) This lever controls blade angle.

A.

Push lever to angle blade to “LEFT.”

B.

Pull lever to angle blade to “RIGHT.”

Figure 11 9.

OPERATING LEVER (LIFT, TILT) This lever controls blade lift and tilt.

A.

Push lever to “LOWER” blade.

B.

Pull lever to “RAISE” blade.

C.

Push lever to left to “TILT” blade to left (rotate ccw). Left end of blade will go down.

D.

Push lever to right to “TILT” blade to right (rotate cw). Right end of blade will go down.

Figure 12

10.

SEAT See “Seat Adjustment” on page 2-25.

HAOB111L

Figure 13

2-6 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

INSTRUMENT PANEL 1

2

3

18

17

16

4

5

6

7

8

9

10

21 20 19

15 14 13 12

11 HAOL112L

Figure 14

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

ENGINE OVERHEAT WARNING LIGHT ENGINE OIL PRESSURE WARNING LIGHT CHARGE WARNING LIGHT TACHOMETER WORK MODE SELECTION SWITCH HEATER SWITCH FAN CONTROL SWITCH WINDSHIELD WASHER SWITCH WINDSHIELD WIPER SWITCH LIGHT SWITCH START SWITCH SYSTEM ERROR LIGHT

5022-7103E-R1 Operation and Maintenance Manual

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

LIMP HOME WARNING LIGHT EMPTY (NOT USED) PREHEAT COMPLETION LIGHT ENGINE OIL FILTER WARNING LIGHT AIR CLEANER ELEMENT CLOGGING WARNING LIGHT HYDRAULIC OIL FILTER CLOGGING WARNING LIGHT HOURMETER FUEL GAUGE ENGINE COOLANT WATER TEMPERATURE GAUGE STEREO (NOT SHOWN) (See page 2-16)

Operating Controls 2-7

1.

ENGINE OVERHEAT WARNING LIGHT This indicator light will turn “ON” when coolant temperature rises excessively.

When this light comes “ON,” immediately stop the work and keep the engine at idle and wait until coolant temperature drops.

If you stop the engine at this time, coolant temperature rises again. Therefore, do not stop the engine until coolant temperature drops.

HAOD350L

Figure 15 2.

ENGINE OIL PRESSURE WARNING LIGHT This indicator light will turn "ON" when the engine starter switch is turned "ON," and should go "OFF" after the engine starts.

For example, if the engine oil pressure becomes too low, the light will turn "ON" and a warning buzzer will sound. If this happens, shut the engine down immediately and determine the cause of the problem. If you continue to work when this light is "ON," it will result in serious engine damage.

3.

HAOA620L

Figure 16

CHARGE WARNING LIGHT This indicator light will turn "ON" when the engine starter switch is turned "ON," and should go "OFF" after the engine starts. If it does not turn "OFF" shut the engine down immediately and determine the cause of the problem.

HAOA610L

Figure 17

2-8 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

4.

TACHOMETER x100rpm

This meter displays engine speed in Revolutions Per Minute (RPM).

10

15

20 25

5 0

30 HAOJ891L

Figure 18 5.

6.

WORK MODE SELECTION SWITCH A.

“O” Position - When in this position the unit will travel at a slower speed.

The pumps and motors are automatically configured for higher torque with a slower rotational speed.

Greater tractive effort is applied for moving loads.

B.

“I” Position - When in this position the unit is able to travel faster. The pumps and motors are automatically configured for low torque with higher rotational speed.

I

O HAOA701L

Figure 19

HEATER SWITCH This is a three position switch used to control the heater and fan.

A.

“OFF” Position - Heater is turned “OFF.”

B.

“I” Position - Heater fan runs at “LOW” speed.

C.

“II” Position - Heater fan runs at “HIGH” speed.

II I

O HAOA732L

Figure 20

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-9

NOTE:

Two heater shut off valves are located by the thermostat housing on front of engine.

When heater is not in use these valves can be closed to prevent coolant from circulating through heater core. They can also be used to regulate amount of coolant that passes through core, thus regulating heat.

Figure 21 7.

FAN CONTROL SWITCH Use this control to activate the electric fan.

A.

“O” Position - Turns fan “OFF.”

B.

“I” Position - Turns fan “ON.”

I

O HAOK288L

Figure 22 8.

WINDSHIELD WASHER SWITCH While the windshield wipers are running, depress the washer switch to spray windshield washer fluid onto the windshield. Use only the proper windshield washer fluid in the system.

A.

"O" Position - “OFF” position.

B.

"I" Position - Sprays fluid. When released the switch returns to the "OFF" position.

O I

HAOA741L

NOTE:

Do not operate the windshield washer without any fluid. If you operate it in spite of running out of fluid, the washer motor may be damaged. Check level in washer tank, and add fluid as required.

NOTE:

If you use soapy water or synthetic detergent instead of window cleaning fluid, the wiper blade or painted surfaces may be damaged. Use standard window cleaning fluid: SSK703

2-10 Operating Controls

Figure 23

5022-7103E-R1 Operation and Maintenance Manual

9.

WINDSHIELD WIPER SWITCH A.

"O" Position – Windshield wipers are “OFF.”

B.

"I" Position - Windshield wipers run at “LOW” speed.

C.

"II" Position - Windshield wipers run at “HIGH” speed.

Operating wipers without washer fluid or when there are sand or dirt present will damage the window and/or wipers.

NOTE:

10.

II

I O HAOA733L

Figure 24

LIGHT SWITCH A.

"O" Position - All working lights are “OFF.”

B.

"I" Position - Instrument panel lights are turned “ON.”

C.

"II" Position - Working lights and instrument panel lights are turned “ON.”

II I

O HAOA721L

Figure 25 11.

START SWITCH To start or stop the engine for equipment operation.

There is a key slot cover (if equipped) which must be moved to one side before inserting key into switch.

NOTE:

A.

B.

C.

D

"I" Position (On) - Turning the switch to this position turns the engine electrical system on. The charge indicator light and the oil pressure indicator light should be on at this time.

B

A C

HAOC341L

Figure 26

"O" Position (Off) - Turning the switch to this position turns the engine "OFF" along with its electrical system. In this position the engine is "OFF" but the interior cab light and fuel tank transfer pump (if equipped) are functional. "

"

Position (Start) - If you turn the starter switch to this position, the engine will start. When released, the key will return to the "ON" position automatically. Do not operate the starter switch over 15 seconds at a time, this will help prevent damage to starter.

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-11

WARNING! DO NOT USE STARTING FLUIDS WHEN USING THE PREHEAT SYSTEM. The preheat system could cause the starting fluid to explode.

D.

12.

"

"

Position (Preheating) - Use this position to start in cold weather. When preheating is completed, the preheating completion light, located on the instrument panel will light up. Start the engine immediately after the light comes "ON."

SYSTEM ERROR LIGHT This indicator light will turn “ON” when there is an error in the drive control system. If the light comes “ON” the machine will stop operating. Check for error reading on micro controller.

NOTE:

Only authorized distributors should service.

ERROR

Daewoo perform

To move unit for repair there is a “Limp Home” control system. This system must be manually activated.

13.

SYSTEM

HAOA636L

Figure 27

LIMP HOME WARNING LIGHT This indicator light will turn “ON” when the “Limp Home” control system is activated.

LIMP HOME

HAOA637L

Figure 28 14.

EMPTY (NOT USED) This indicator light location on panel is empty.

HAOA638L

Figure 29

2-12 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

15.

PREHEAT COMPLETION LIGHT This indicator light will turn “ON” when the engine preheat function has been completed. Turn start switch to “START” position.

PREHEAT HAOA635L

Figure 30 16.

ENGINE OIL FILTER WARNING LIGHT This indicator light will turn “ON” when the engine oil filter needs to be changed.

Figure 31 17.

AIR CLEANER ELEMENT CLOGGING WARNING LIGHT This indicator light will turn “ON” if the air filter becomes clogged and reduces air flow to the engine. This indicates that the filter requires replacement.

HAOA660L

Figure 32 18.

HYDRAULIC OIL FILTER CLOGGING WARNING LIGHT This indicator light will turn “ON” when the hydraulic oil filter needs changing.

NOTE:

Under normal operating conditions this light should not turn “ON” between filter changes. If the light does come “ON” investigate cause.

NOTE:

In cold weather this light may turn “ON” until oil warms up.

Figure 33

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-13

19.

HOUR METER The hour meter shows the cumulative running time.

HOUR

It can show up to 99,999.9 hours.

When the engine begins cranking, the indicator starts to rotate, indicating that the engine is working.

HKB2011L

Figure 34 20.

FUEL GAUGE The fuel gauge shows the level of fuel remaining in the tank.

Fill the tank before gauge enters “E” range.

HAOD370L

Figure 35 21.

ENGINE COOLANT WATER TEMPERATURE GAUGE The engine coolant water temperature gauge shows engine coolant temperature.

WHITE RANGE: Indicates that engine has not reached normal operating temperature.

GREEN RANGE: Indicates normal engine operating temperature.

RED RANGE: Indicates that engine has overheated. Open engine hood with engine at idle to improve ventilation. After indicator drops, stop engine. Allow engine to cool down, then check for low coolant level, leaks, a plugged radiator core and check fan belt tension.

2-14 Operating Controls

HAOD360L

Figure 36

5022-7103E-R1 Operation and Maintenance Manual

22.

STEREO See “Stereo” on page 2-16.

HAOA951L

Figure 37

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-15

STEREO

Figure 38

1.

2.

3.

4.

5.

6.

ON-OFF / VOLUME CONTROL KNOB BALANCE / FADER CONTROL BASS/TREBLE CONTROL AM/FM BAND SELECTION AUTOMATIC MEMORY (AME) TAPE EJECT BUTTON

1.

ON-OFF / VOLUME CONTROL KNOB

7.

CASSETTE SLOT 8. & 9. PLAY DIRECTION BUTTON 10. AUTOMATIC SELECTION 11. DOLBY B SELECTION 12. METAL SELECTION 13. LED DISPLAY PANEL

When this button is pressed the stereo will be turned on.

When this button is pressed a second time the power turns off.

Increase volume by rotating the control clockwise.

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

2.

BALANCE / FADER CONTROL This control adjusts both the side to side balance of the stereo sound as well as front to back fading.

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

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

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

3.

BASS/TREBLE CONTROL This control adjust bass and treble tone levels.

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

2-16 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

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

4.

AM/FM BAND SELECTION This button sets the radio to either AM-1, AM-2, FM-1 or FM-2 frequency bands. Each of the frequency bands will enable the stereo to store 6 preset radio station frequencies. Each time the button is pressed the stereo will move to the next band.

5.

AUTOMATIC MEMORY (AME) This function automatically finds the six strongest radio signals in the frequency selected and stores them in memory.

Select the band (AM-1, AM-2, FM-1, FM-2). Press and hold the AME button for approximately two seconds and the stereo will search out the strongest stations in the area. These stations can then be recalled by pressing buttons (1 through 6, Figure 39).

NOTE:

6.

To manually store radio station settings, use the band selector to select the frequency band to be listened to. Then use the tuning control to select the desired station. Press and hold any of the preset keys for approximately 2 seconds; a beep will sound when station has been set.

HAOC990L

Figure 39

TAPE EJECT BUTTON Eject the tape from the cassette deck by pressing this button. The stereo returns to the tuner mode.

7.

CASSETTE SLOT Press the "ON/OFF" switch for power. Insert a tape with the exposed tape facing to the right. The tape will start to play. "TAPE" is displayed on the LED display.

8. & 9. PLAY DIRECTION BUTTON Pressing this control button to either the right or the left will fast forward or rewind the tape. The button will lock into this position. To stop the action, press the opposite side to the button and the tape will return to the normal play mode.

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

10.

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

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-17

11.

DOLBY B SELECTION If the tape being listened to has been recorded with Dolby B, press the preset selector button 1 to turn the Dolby B control on. The Dolby symbol will appear on the display. Press this control a second time to turn the Dolby B control off.

12.

METAL SELECTION If the tape being listened to is either a metal or chromium type of tape, press the preset selector button 2 to select the "MTL" setting. "MTL" will appear on the display. Press this control a second time to turn this setting off.

13.

LED DISPLAY PANEL A.

Tape Reverse Direction Indicator

B.

Tape Forward Direction Indicator

C.

Preset Radio Indicator

D.

Radio Station Frequency

E.

AM/FM Band Indicator

F.

Stereo Radio Signal

G.

Dolby Noise Reduction Indicator

H.

Metal Tape Indicator

Memory

Channel

H G F

A B C

E

D HAOA960L

Figure 40

CARE OF STEREO Do not use a tape which has a longer playing time than C-90 (90 minutes). Avoid use of C-120 tapes because the tapes are made of a thinner material that may break and get tangled inside the stereo.

Figure 41

2-18 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

Make sure tapes are wound tight3. If you use a loose tape, it may cause a problem in the deck.

If they are loose, use a pencil or similar device to wind up the slack.

Do not use poor quality tapes.

Figure 42

•

Direct sunlight.

•

Humid place.

•

Dusty place.

•

Around heater or heater vents which discharge heat.

•

Around speakers and other magnet devices that generates a strong magnetic field (solenoid valves).

2720

Do not store cassette tapes in the following places or under the following conditions.

Damage to the tape and stereo may result.

HAOK840L

Figure 43

Clean head and pinch roller periodically. They continuously contact the tape. If they are not kept clean the stereo and tapes may be damaged. Keep them clean for optimum performance.

Figure 44 If the head gets dirty, clean it with a soft cotton swap through the cassette slot.

It is recommendable t0 use a cassette deck cleaning tape for easy and efficient cleaning of head, capstan and pinch roller.

When you turn off power, be sure to take out the cassette tape by pressing the eject button When not using a cassette tape, keep it stored in a plastic case.

Figure 45

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-19

CALIBRATION SWITCH A calibration switch is located to left of operator’s seat under a clear plastic cover.

This switch is used to set operational parameters of various sensors. See “Calibration Procedure for Micro Controller” on page 4-36 for further information.

NOTE:

Under normal operating conditions this switch should not have to be used.

Figure 46

LIMP HOME SWITCHES In the event that the micro controller should have a “System Error” the unit is equipped with limp home switches. These switches are a means of over-riding the micro controller and controlling (driving) the dozer.

Figure 47

Figure 48

Limp home switches are located on back of panel shown in Figure 47 (with canopy) and Figure 48 (with cab). Remove two screws holding panel to underside of instrument panel.

WARNING! When using switches to drive unit, the unit may not travel in a straight line. Use extreme care when operating unit in this mode.

Once unit is repaired, limp home on/off switch must be turned “OFF,” and track switches must be returned to “NEUTRAL.”

2-20 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

The limp home panel (Figure 49) contains four switches; 1.

LEFT TRACK SWITCH

2.

LIMP HOME ON/OFF SWITCH

3.

LIMP HOME HIGH/LOW SWITCH

4.

RIGHT TRACK SWITCH

1.

LEFT TRACK SWITCH

Figure 49 A.

“FORWARD TRAVEL” Position Used to drive left track in forward direction.

B.

“NEUTRAL” Position - When in this position left track movement stops.

C.

“REVERSE TRAVEL” Position - Used to drive left track in reverse direction.

Figure 50 2.

LIMP HOME ON/OFF SWITCH A.

“ON” Position - Used to turn “ON” limp home system. Indicator light on instrument panel will turn “ON.”

B.

“OFF” Position - Turns limp home system “OFF.” Under normal operating conditions switch must be in this position.

Figure 51 3.

LIMP HOME HIGH/LOW SWITCH A.

“LO” Position - When in this position the unit will travel at a slower speed.

The pumps and motors are automatically configured for higher torque with a slower rotational speed.

Greater tractive effort is applied for climbing inclines.

B.

“HI” Position - When in this position the unit is able to travel faster. The pumps and motors are automatically configured for low torque with higher rotational speed.

5022-7103E-R1 Operation and Maintenance Manual

Figure 52

Operating Controls 2-21

4.

RIGHT TRACK SWITCH A.

“FORWARD TRAVEL” Position Used to drive right track in forward direction.

B.

“NEUTRAL” Position - When in this position right track movement stops.

C.

“REVERSE TRAVEL” Position - Used to drive right track in reverse direction.

Figure 53

2-22 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

MISCELLANEOUS ELECTRICAL DEVICES 1.

OPERATOR’S COMPARTMENT LIGHT (WITH CAB ONLY) A light is installed near the roof on each side of the operator’s compartment.

Press the push button to turn it "ON." Press the button again to turn it "OFF." The light will work regardless of starter switch position.

NOTE:

If light is left on for a long time while the engine is not running, the battery will be discharged.

Figure 54

3.

CIRCUIT BREAKER A main circuit breaker is located in the battery box compartment.

It will automatically cut off in the event of an electrical circuit short or overload. This will prevent the electric wiring and components from being burned or damaged.

If circuit breaker is cut off, check all related circuits, this means something is wrong in the electric circuit.

After maintenance, press the red button for normal operation of circuit breaker.

4.

Figure 55

FUSIBLE LINK A fusible link is located in the battery box compartment.

If engine does not crank, first check that the starter switch is turned "ON" and that no power is available (No indicator lights will light.). Check that the "A" portion (Figure 56) of the fusible link is not broken or burned through. Replace the fusible link if damage and investigate cause.

Figure 56

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-23

FUEL TRANSFER PUMP (IF EQUIPPED) The fuel transfer pump (1, Figure 57) is located inside the battery compartment. An “ON/OFF” switch is located on motor end of pump.

WARNING! Use extreme safety precautions while refueling to prevent explosions or fire.

Immediately clean up any spilt fuel.

To fuel unit use the following procedure;

Figure 57

1.

Clean pump refueling hose (2, Figure 57) and suction strainer (3) before inserting into fuel supply tank or drum.

2.

Remove fuel tank cap to help vent tank and allow for less back pressure on refueling pump.

3.

Insert refueling hose (2, Figure 57) into fuel supply.

4.

Turn “ON” refueling pump (1, Figure 57).

5.

Turn “OFF” pump (1, Figure 57) when fuel tank is full.

NOTE:

6.

Do not overfill the tank.

Securely tighten fuel cap after fueling.

NOTE:

If breather holes in cap are clogged, a vacuum may form in the tank preventing proper fuel flow to engine. Keep holes in fuel cap clean.

HAOC510L

Figure 58

2-24 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

SEAT ADJUSTMENT WARNING! Whenever the operator or operating condition has changed, check to see that the seating position is suitable for the condition at hand. Always fasten your seat belt while operating vehicle. Adjust the backrest so that the operator can fully reach and operate the pedals.

HAOB111L

Figure 59 1.

ADJUSTING THE SEAT FORWARD/ BACKWARD LEVER (FIGURE 60) Holding lever push it to the right, while pushing or pulling the seat to desired position. Release lever once desired position is reached. Adjustment range is 160 mm (6.3 in.)

2.

BACKREST ADJUSTMENT LEVER (FIGURE 60) Pulling up lever allows seat backrest to be moved forward or backward.

3.

3

2 1 HAOB112L

Figure 60

ANGLE ADJUSTMENT OF ARMREST Adjustment angle of left and right armrest is done by pushing in bottom on end of armrest. When you adjust the angle, manually raise the armrest before releasing button.

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-25

SEAT BELT WARNING! The seat belt is for the operator's safety and should be worn at all times. Before driving the machine, adjust the seat to the desired position for maximum comfort and machine control, then fasten the seat belt. Seat belts must be worn across the pelvic region and adjusted snugly to lessen the chance and severity of injury in the event of an accident. Never fasten a seat belt across the abdomen.

Under no circumstances should the operator be standing in the cab when operating the dozer.

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

Stop the machine, apply the parking brake, and then adjust the seat.

Always, check the condition of seat belt and belt bracket before fastening it. Do not use it with twists in it. Replace belt or bracket if damaged or worn.

SEAT BELT LOCKING AND UNLOCKING Insert belt end (1, Figure 61) into buckle (2). Pull belt to check that belt end is locked into buckle.

Adjust belt length so that it comfortably tight against operator’s pelvic region (hipbone).

HAOB140L

Figure 61 Press button (3, Figure 62) located in center of buckle (2) and pull out belt (1) to unlock.

HAOB150L

Figure 62

2-26 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

DOOR SIDE LATCH 1.

The door side latch (1, Figure 63) is used to secured the door to the side of the cab when it is opened.

NOTE:

Keep the door closed and locked when machine is not in use.

Figure 63 2.

To release door from side of cab, push the latch knob (Figure 64).

Figure 64

5022-7103E-R1 Operation and Maintenance Manual

Operating Controls 2-27

MISCELLANEOUS ACCESS COVERS AND DOORS BATTERY BOX DOOR Open door and pull prop rod (1, Figure 65) from stowing bracket (2). Insert end of rod in prop rod hole on door (3).

Figure 65 INSTRUMENT PANEL COVER (WITH CANOPY) If unit is equipped with a canopy, a vandalism cover is provided to protect instrument panel from weather and physical damage.

Figure 66

2-28 Operating Controls

5022-7103E-R1 Operation and Maintenance Manual

3OPERATION TO HANDLE A NEW DOZER All Daewoo dozers are inspected and adjusted prior to leaving the factory. However, it is required that the operator follow these steps during the initial break-in period. Failure to follow these steps may result in damage to the equipment or reduced performance.

HOUR

LOAD

For first 50 hours of operation.

Maintain about 80% load of full capacity (Engine RPM: 80% of rated RPM)

After first 50 hours of operation.

Full load

If machine is used at full load before it is broken in, it may affect the life cycle and safe running operations.

This could lead to problems later.

NOTE:

1.

Check daily for leakage of coolant, engine oil and hydraulic oil.

2.

Inspect all lubricants daily, add appropriate lubricants as required.

3.

During operation, monitor all instruments and gauges from time to time.

4.

Avoid a extreme engine load.

5.

Operate unit at 80% load until engine and all other components are at operating temperature.

6.

Check that work equipment is operating normally during operation.

7.

Check machine for loose parts or for damage that may have occurred during shipping.

8.

Check for loose wiring or terminals, check gauge operation and battery fluid level.

LUBRICATION AND FILTERS 1.

Change engine oil and replace oil filter element after first 50 hours of operation.

2.

Replace travel and reduction gear oil after first 250 hours of operation.

NOTE:

For the replenishment of oil or grease, refer to “Inspection, Maintenance and Adjustment” on page 4-1 of this manual.

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-1

STARTING AND STOPPING THE ENGINE INSPECTION BEFORE STARTING ENGINE

WARNING! If a flammable materials such as leaves, paper, etc. are allow to accumulate on high temperature components, such as the engine muffler and turbo, a fire may occur. Fuel, lubricant and hydraulic oil leaks, may cause a fire. If there is anything wrong, perform the appropriate corrective action.

Before starting engine, inspect the following items; 1.

Electric system - Check for damaged electric cables, and loose or missing connectors.

2.

Fuel system - Drain water and sediment from fuel tank.

3.

Hydraulic system - Check for hydraulic oil leaks, damaged tubing and hoses, and interference points of components.

4.

Lubrication - Perform all daily and periodic maintenance services. Perform services according to reading shown on hourmeter.

5.

Safety - Perform a machine walk-around. Make sure that no one is under the machine or performing any maintenance on it, before starting engine.

6.

After starting machine - Check that all operational controls and components, are in proper operating condition, and are functioning correctly. Stop operation and correct any malfunction before continuing work.

OPERATIONAL CHECKS BEFORE STARTING ENGINE

WARNING! When leaving operator's seat, set all control levers in ”NEUTRAL” position, if not a serious accident could occur by accidentally moving them.

1.

Fasten seat belt. Check for proper operation and condition

2.

Set all operation levers to "NEUTRAL." NOTE:

3-2 Operation

Be careful not to touch any switches when starting engine.

5022-7103E-R1 Operation and Maintenance Manual

3.

Rotate the starter switch to the "I" - (ON) position (Figure 67). Check all indicator lights. After 2 seconds, all lights except the following will turn off.

•

Engine coolant temperature gauge

•

Charging warning light

•

Fuel gauge

•

Engine oil pressure warning light

•

Engine RPM (0 RPM)

NOTE:

If all of the indicator lights do not come "ON" when the key is first turned, there is a problem.

HAOB320L

Figure 67

Check LED display (Figure 68) in micro controller for any fault codes. If any fault codes are displayed correct problem prior to operation.

The “System Error” light should come “ON” if any problems exist in the system.

NOTE:

LED display is located to left of operator’s under a clear plastic cover.

Figure 68

ENGINE START

WARNING! Start engine after sounding horn and making sure that there are no people or obstacles in area.

1.

Perform all steps in “Operational Checks Before Starting Engine” on page 3-2.

2.

Set engine speed control lever slightly above “LOW IDLE” (Figure 69).

3.

Sound horn.

Figure 69

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-3

4.

"

"

Turn starter switch to - "START" position (Figure 70). Engine should start in approximately 5 seconds.

WARNING! If engine does not start after approximately 15 seconds of cranking, release starter switch. Wait about 5 minutes and repeat above step.

5.

After engine has started, release key. Key will return to "I" - "ON" position (Figure 71).

6.

Follow procedures in “Hydraulic System Warm-up” on page 3-8.

HAOB35L

Figure 70

HAOB360L

Figure 71 7.

After warming unit, check all operating indicators to make sure that all engine systems (oil pressure, coolant, etc.) are in normal operating range. If any problems are noticed, stop engine. Normal indicators are:

HAOL113L

Figure 72 INSTRUMENT PANEL LIGHT OR GAUGE

INDICATOR READING

ENGINE COOLANT TEMPERATURE GAUGE

GREEN RANGE

FUEL GAUGE

GREEN RANGE

CHARGING WARNING LIGHT

OFF

ENGINE OIL PRESSURE WARNING LIGHT

OFF

ENGINE OVERHEAT WARNING LIGHT

OFF

3-4 Operation

5022-7103E-R1 Operation and Maintenance Manual

INSTRUMENT PANEL LIGHT OR GAUGE

INDICATOR READING

PREHEATING COMPLETION LIGHT

OFF

ENGINE OIL FILTER WARNING LIGHT

OFF

HYDRAULIC OIL FILTER WARNING LIGHT

OFF

AIR CLEANER ELEMENT WARNING LIGHT

OFF

8.

Check color of exhaust smoke.

•

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

•

Black - Incomplete combustion. Check cause.

•

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

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

NOTE:

If engine coolant temperature gauge shows red while running, take the following action; Discontinue work and allow engine to run at low idle. Open engine compartment cover for good ventilation. Once engine temperature gauge returns to the green zone, shutdown engine. After engine has cooled, check coolant level, look for leaks, clogged or dirty radiator fins (radiator core), and fan belt tension.

COLD WEATHER STARTING

WARNING! DO NOT USE STARTING FLUIDS WHEN USING THE PREHEAT SYSTEM. The preheat system could cause the starting fluid to explode. Starting fluids should never be used.

1.

Perform all steps in "Operational Checks Before Starting Engine."

2.

Set engine speed control lever slightly above “LOW IDLE” (Figure 73).

3.

Sound horn.

Figure 73

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-5

4.

"

"

Turn start switch to - "PREHEAT" position (Figure 74). Hold it there for 3.5 seconds.

When preheat cycle is completed, preheat light (Figure 75) will turn “ON.”.

HAOC020L

Figure 74

HAOL114L

Figure 75

3-6 Operation

5022-7103E-R1 Operation and Maintenance Manual

5.

After preheat light is “ON,” turn starter "

"

switch to - "START" position (Figure 70). Engine should start in approximately 5 seconds.

WARNING! If engine does not start after approximately 15 seconds of cranking, release starter switch. Wait about 5 minutes and repeat above step.

6.

After engine has started, release key. Key will return to "I" - "ON" position (Figure 77).

7.

After engine starts, check all operating indicators to make sure that all engine systems (oil pressure, coolant, etc.) are in normal operating range. If any problems are noticed, stop engine.

8.

Follow "Hydraulic System procedures in this section.

HAOB35L

Figure 76

Warm-up"

HAOB360L

Figure 77 STARTING ENGINE USING A BOOSTER BATTERY

WARNING! Wear safety glasses.

Never connect negative leads to positive terminals and vice versa.

DO NOT connect the auxiliary of booster battery ground terminal directly to the battery terminal. Locate and use a ground point on the main frame.

HAOA440L

Figure 78

Depleted batteries generate hydrogen gas.

Electrical sparks around or near the batteries can cause an explosion.

Jump start vehicles on dry ground or concrete. Do not jump start the machine on a steel floor, because the floor is always grounded.

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-7

IMPORTANT The electrical system is a 24V (-) negative ground type. Use the same capacity 24V booster batteries when jump starting engine.

If the batteries are drained during starting procedures, jump start engine using auxiliary or booster batteries according to the following procedure; 1.

Connect the positive jumper cable (1, Figure 79) from the auxiliary batteries (2) to the dozer’s depleted batteries (3).

2.

Connect negative jumper cable (4, Figure 79) from auxiliary batteries to a ground point on upper frame (5). DO NOT CONNECT DIRECTLY TO THE NEGATIVE BATTERY TERMINAL.

3.

Follow normal engine starting procedures.

4.

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

1

2 4

3 5

HAOB390L

Figure 79 HYDRAULIC SYSTEM WARM-UP

WARNING! If a problem or abnormal operation occurs, immediately stop engine. Allow dozer to reach normal operating temperature before starting work, especially in cold weather.

Correct operating temperature of hydraulic oil is 50° – 80°C (120° –175°F). Make sure to follow procedures listed below for hydraulic fluid warm-up.

1.

Run engine for approximately 5 minutes set at “MIDDLE” of speed range, without a load.

Figure 80

3-8 Operation

5022-7103E-R1 Operation and Maintenance Manual

2.

Slowly cycle all blade cylinders about five times without a load to circulate oil through system. Do this for 5 minutes.

3.

Travel forwards and backwards at a low speed for two revolutions of drive sprocket.

Figure 81 HYDRAULIC SYSTEM WARM-UP – COLD WEATHER 1.

Run engine at “LOW IDLE” (no load) for 5 minutes (Figure 82).

2.

Run engine for approximately 5 minutes set at “MIDDLE” of speed range, without a load (Figure 83).

Figure 82

Figure 83 3.

Slowly cycle blade cylinders about five times without a load to circulate oil through system. Do this for 5 minutes.

Figure 84

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-9

4.

Set engine speed control lever to “HIGH IDLE” (Figure 85).

5.

Repeat Step 3 for 5 minutes. If working speeds continue to be slow, continue to operate, but use extreme caution because the machine function may be erratic.

6.

Travel forwards and backwards at low speed for two revolutions of drive sprocket.

ENGINE SHUTDOWN NOTE:

Allow engine to idle for 3 - 5 minutes before shutting down the engine. If not allowed to idle, heat surge may develop which will damage the engine.

Allowing the engine to idle will dissipate heat.

Park dozer on level and firm ground

2.

Lower blade to ground and make sure all operating controls are in "NEUTRAL." 2720

1.

Figure 85

HAOK622L

Figure 86 3.

Set engine speed control lever to “LOW IDLE” (Figure 87). Allow engine to idle for 3 - 5 minutes.

Figure 87

3-10 Operation

5022-7103E-R1 Operation and Maintenance Manual

4.

Stop engine turning by turning key to "O" "OFF" position (Figure 88).

5.

Pull key out of starter switch.

CHECK AND CONFIRMATION AFTER STOPPING ENGINE 1.

Repair dozer, if there is any coolant or oil leaks.

2.

Inspect blade assembly and under carriage for abnormal appearances.

Correct any problems.

HAOC340L

Figure 88

3.

Fill fuel tank.

4.

Get rid of any accumulated ignitable material such as leaves and paper etc. in engine compartment.

5.

Clean all mud, etc. from undercarriage and tracks. Make sure that all steps and hand holds are clean, and that the operator’s compartment is clean.

TRAVEL WARNING! Before moving, make sure that there are no personnel in the way or on the machine. Sound horn to alert workers that you are about to move machine.

Be sure travel path is clear during travel.

Use extreme caution when reversing travel. Be sure there is a clear path behind machine.

Make sure to operate the travel control lever and pedals smoothly to avoid sudden starts or stops.

Before leaving operator's seat, make sure to lock out all control systems and shut down engine to avoid accidental activation.

AUTOMATIC TRAVEL SPEED CONTROL

WARNING! Do not change the travel mode while traveling. It is very dangerous to change to II-speed mode indicated "I" while going down a slope. Only change travel mode after coming to a complete stop.

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-11

Two travel speed ranges can be selected by using the automatic speed control switch on the control panel (Figure 89).

"O" Position - Low travel speed and a higher torque are selected when the control is set at the "O" position.

"I" Position - Setting the control at the "I" position enables the machine to automatically change to a different speed range. This change happens automatically depending on the engine speed and the hydraulic oil pressure in the travel circuit. When engine speed is about 1,350 RPM the travel speed is automatically set to low. An example is if the machine is traveling on a flat, solid surface, the higher speed range would be used. When a slope is encountered, the speed drops and the travel circuit hydraulic pressure rises, causing the control circuit to shift to the higher torque, lower speed range.

I

O HAOA701L

Figure 89

GENERAL TRAVEL INSTRUCTIONS 1.

Set engine speed control lever (Figure 90) on desired speed.

2.

Raise blade from 40 - 50 cm (15 - 19 in.) above ground. See “X” Figure 91.

2720

Figure 90

"X" HAOK630L

Figure 91

3-12 Operation

5022-7103E-R1 Operation and Maintenance Manual

3.

As much as possible, travel on firm level ground. Avoid sudden movements and sharp turns.

4.

When traveling on rough ground, travel at a slow speed [1.0 - 1.5 km/hr (0.62 - 0.93 m.p.h.)]. Reduced engine speed, to avoid shock loading the equipment. Be careful that an excessive force is not added to equipment by touching or climbing on rocks.

5.

On rough, frozen or uneven terrain, travel slowly.

Figure 92

WARNING! When traveling on slopes, keep blade from 200 - 300 mm (8 - 12 in.) above ground.

Do not travel backward on a slope.

Never turn or travel crosswise on a slope.

Choose a safe alternate route before climbing a slope.

If dozer starts to slip or becomes unstable, lower the blade immediately into the ground using it as a brake.

Do not travel on slopes over 30° due to turnover danger.

6.

Travel straight up or down slopes, never diagonally across the slope. If the engine stalls, lower the blade, make sure that all controls are in the neutral position and restart the engine.

NOTE:

Do not open or close operator’s door on a slope. Make sure door is latched.

If dirt or mud builds up in the track frame, rotate and clean that track.

8.

The dozer can travel in water that comes up to the top of the upper roller (1, Figure 93). Make sure that footing is solid so that the machine will not sink.

2720

7.

1 HAOB841L

Figure 93

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-13

TRAVEL CONTROL LEVER OPERATION 1.

To travel straight (Figure 94), push forward/ reverse travel lever forwards or backwards.

The farther the lever is moved, the faster the travel speed.

NOTE:

"X" is the sprocket end of the track.

"X" HAOB511L

Figure 94 2.

3.

Pivot turns (Figure 95) are made by depressing one of the steering pedals.

This will reduce the track speed on that side of the unit causing it to turn in that direction. The machine will pivot on the slower moving track.

NOTE:

Pressing steering pedal past detent will cause track to reverse direction, making the unit perform a spin turn.

NOTE:

"X" is the sprocket end of the track.

"X" HAOB521L

Figure 95

Spin turns (Figure 96) are made by rotating one track forward and one track backward. A steering pedal must be fully depressed to cause track to reverse direction of movement. The machine will spin around its centerpoint, thus counterrotating.

NOTE:

"X" is the sprocket end of the track.

"X" HAOB531L

Figure 96 4.

Stopping travel (Figure 97) - Returning forward/reverse travel lever to "NEUTRAL" position will automatically apply brakes and stop dozer.

NOTE:

"X" is the sprocket end of the track.

"X" HAOB541L

Figure 97

3-14 Operation

5022-7103E-R1 Operation and Maintenance Manual

OPERATING INSTRUCTIONS GENERAL BLADE OPERATION. Excavate dirt by lowering blade into soil. As machine moves forward blade depth may have to be adjusted to maintain a level cut.

Figure 98 Angling blade will windrow (pile) dirt to one side.

Control depth of cut so that material windrows to proper side without spilling off blade.

NOTE:

Do not try to move excessive amounts of dirt. Dirt that spills over top of blade or off end of blade other than the windrow side, will get under tracks which will lead to uneven cuts.

Figure 99 LEVELING Once an area has been roughed out additional leveling action may be accomplished by lowering blade to ground and placing it in “FLOAT,” while dragging it backwards.

Figure 100

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-15

HARD OR SIDE DOZING To change contour of ground (such as removing banks), use blade tilt.

Lower corner of blade into bank and then angle blade to carry dirt away from bank.

Subsequent passes may have to be made to move windrowed material away from bank.

WARNING! Do not operate both angle and tilt with the blade lifted to end of stroke. This can cause an interference between cylinder and radiator core.

3-16 Operation

Figure 101

5022-7103E-R1 Operation and Maintenance Manual

OPERATING PRECAUTIONS WARNING! DO NOT rest your feet on the travel pedals during normal machine operation. Unexpected machine travel may occur in this situation.

Before starting work, investigate terrain and soil condition. Level ground and drain area if necessary.

2.

Install window guards when working where there is a possibility of falling rocks or other objects.

2720

1.

HAOB803L

Figure 102 Check strength of supported structures in advance before working on them. If insufficient, reinforce it. If any doubt exists about structural strength, refuse to operate unit.

2720

3.

HAOB801L

4.

DO NOT continually "bottom out" the hydraulic cylinders. Machine damage may occur if the cylinders are fully extended or retracted, example: blade angle cylinder fully retracted will impacting dirt piles.

5.

When working on soft or muddy ground, make sure that the machine is not sinking.

2720

Figure 103

HAOB802L

Figure 104

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-17

6.

When working close to excavated edge make sure that the ground the machine is sitting on is solid. See Figure 105.

HAOF082L

Figure 105 If the work is in an underground location or in a building, make sure that there is adequate overhead clearance and that there is adequate ventilation. See Figure 106.

2720

7.

HAOE042L

Figure 106 8.

Do not operate travel lever quickly when traveling in high range.

A.

Avoid sudden starts.

B.

When traveling in one direction come to a complete stop before reversing directions. Do not rock dozer back and forth with lever or pedals.

C.

Avoid sudden stops. Return pedals to rest slowly with foot. Do not let them snap back on their own.

HAOB902L

Figure 107 WORKING IN WATER. When working in water, do not operate in water over center of upper roller (1, Figure 108).

2720

After working in water, purge old grease on blade cylinder and pivot points.

1 HAOB841L

Figure 108

3-18 Operation

5022-7103E-R1 Operation and Maintenance Manual

PARKING DOZER WARNING! 2720

Park dozer on firm level ground. Avoid parking on slopes. If dozer must be parked on a slope, block tracks and place blade in ground. See Figure 109.

HAOK621L

Figure 109 Park dozer on firm level ground. Lower blade to ground as shown in Figure 110.

2720

1.

HAOK622L

Figure 110 2.

Set engine speed control lever at "LOW IDLE."

Figure 111

5022-7103E-R1 Operation and Maintenance Manual

Operation 3-19

TOWING PROCEDURE WARNING! Never use a damaged wire rope or chain.

They could brake and cause a serious accident.

Always wear gloves when handling a chain or wire rope.

When towing dozer use a wire rope or chain capable of handling the load.

Attach chain or wire rope to frame as shown in Figure 112 1.

To prevent damage to travel drive motors and pumps while towing dozer, remove final drive cover from each side of unit.

2.

As cover is removed, drain oil into suitable container.

3.

Remove sun gear (1, Figure 113) from planetary gears (2) and brake shaft.

NOTE:

4.

Sun gear (1, Figure 113) is splined into brake shaft.

Install final drive cover without sun gear (1, Figure 113).

NOTE:

3-20 Operation

Figure 112

Figure 113

Keep sun gear (1, Figure 113) in safe place to prevent damage. Do not forget to install sun gear after repairs are made.

5022-7103E-R1 Operation and Maintenance Manual

4INSPECTION, MAINTENANCE AND ADJUSTMENT Routine maintenance and inspections are required to keep your machine in the correct operating condition.

The following pages list the inspection intervals, the system or component checks and location references.

NOTE:

The following pages list the service checks and their required intervals. The service cycles may need to be shortened depending on the working conditions. Extremely hot or dusty conditions will require more frequent service. Operational hours are determined by the amount of time accumulated on the engine hour meter located on the instrument panel in the cab.

SERIAL NUMBERS There are two serial number plates attached to the body of the dozer. The main serial number plate (Figure 1) is located on just below the L.H. cab door. The engine serial number is stamped in the middle of the left side of the engine block, above the oil pan. Additional engine information is described on an identification label (Figure 2) on rocker cover.

Please make note of these numbers and their locations. These will be required whenever warranty service work is requested.

Figure 1 SAFETY PRECAUTIONS 1.

Make sure to lock out the hydraulic controls and post a notice (Warning Tag) that the machine is being serviced to prevent any unauthorized operation.

2.

Make sure to clean up any fluid spills, especially around the engine.

3.

Inspect all fuel lines to make sure that fittings, lines, filters and O-rings, etc., are tight and are not showing signs of wear or damage.

4.

If the inspection or test procedure requires that the engine is running, make sure to keep all unauthorized personnel away from the machine, and that all industry standard safety precautions are followed.

5022-7103E-R1 Operation and Maintenance Manual

Figure 2

Inspection, Maintenance and Adjustment 4-1

PRELIMINARY WORK MACHINE SETUP FOR MAINTENANCE When performing maintenance specified in this manual, always park the dozer as follows.

NOTE:

Certain types of maintenance may require the machine to be positioned differently. Always return machine to this position.

Park on a firm and level ground.

2.

Lower blade and any other attachments to ground.

2720

1.

HAOK622L

Figure 3 3.

Allow engine to run at low idle for a minimum of 5 minutes to allow engine to cool. If this is not done, heat surge may occur.

4.

Shut engine down and remove key from the starter switch.

WARNING! If engine must be run while performing maintenance, use extreme care. Always have one person in the cab at all times. Never leave the cab with the engine running.

5.

HAOA340L

Figure 4

Before starting maintenance work, hang up a tag, "Do Not Touch When Performing Inspection or Maintenance" on cab door or work lever.

4-2 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

TABLE OF RECOMMENDED LUBRICANTS IMPORTANT Do not use lubricants other than those recommended, without prior written approval from Daewoo.

NOTE:

Refer to the Maintenance Intervals Table for application points.

LUBRICANT MANUFACTURER

HYDRAULIC OIL

CALTEX

CALTEX HD32

LUBRICANT GREASE

ENGINE OIL CALTEX RPM or

MULTIFAC EP

MULTI-PURPOSE EP90

EXXON XD-3 STRAIGHT WEIGHT or 15W40

RONEX MP #2 or

SPARTAN EP220 or

MOBIL

DELVAC 1300 or

DTE 13M (ALLTEMP) or

SUPER 15W40 or

MOBIL FAW #2 or

DELO 300 EXXON/ESSO

GEAR OIL

NUTO (ANTIWEAR) HD 32 (BELOW 0°C (32°F)) or

RONEX MP #1 (COLD TEMPS)

EXXON GX 80W90

HD 46 (ABOVE 0°C (32°F)) or TERESSTIC (ANTI-RUST) MOBIL

DTE 24 (SUMMER) SHELL

TELLUS 32

MOBILUBE HD 80W90

MOBIL FAW #1 (COLD TEMPS)

DELVAC 1 or STRAIGHT WEIGHT

ALVANIA EP #2

ROTELLA T15W40 or

SPIRAX HD 80W90 or DONAX TD (TRANSMISSION)

T30 (WINTER) or T40 (SUMMER) PENNZOIL

PENNZBELL

LONGLIFE

AW 32 (BELOW 0°C (32°F)) or

SAE30 or

AW 46 (ABOVE 0°C (32°F))

SAE40 or

PENNZOIL 705 EP #2

PENZOIL MULTI-PUPOSE 4092 or 80W90

SAE15W40

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-3

LUBRICANT MANUFACTURER

HYDRAULIC OIL

DRYDEN

PARADENE AW 32 (BELOW 0°C (32°F)) or

CHEVRON

ENGINE OIL DIESELALL PLUS or

LUBRICANT GREASE EP #2 (RED)

AP80W90

DELO GREASE EP-2

DELO GEAR OIL or

30W or

AW 46 (ABOVE 0°C (32°F))

40W or

AW MV 32 (BELOW 0°C (32°F)) or

DELO 400 15W40

15W40

RPM UNIV GEAR 80W90

AW MV 46 (ABOVE 0°C (32°F)) TEXACO

RANDO HD32 (BELOW 0°C (32°F)) or HD46 (ABOVE 0°C (32°F))

GEAR OIL

URSA SUPER PLUS 15W40 or URSA PREMIUM TDX 15W40

STAR PLEX 2 STAR PLEX PREMIUM

MULTI-GEAR EPSAE 80W90

IDEMITSU KOSAN

DAPHNE KOSAN 46WR

APOROIL MOTIRE S300

DAPHNE CORRONE #2

APOROIL GEAR HE 90

NIPPON SEIKIYU

SUPER HIGHLAND S26 or 32

HIGH D. S3 STRAIGHT WEIGHT

LIPANOC GREASE

NISEKI SP90 or EP90

TOTAL

TOTAL EQUIVIS ZS46

TOTAL

TOTAL MUTRIS EP #2

TOTAL DA80W90

IMPORTANT Do not mix oils from different manufacturers. Daewoo does not endorse specific brands but does suggest that owners select quality oils whose suppliers provide assurance that required standards will always be met or exceeded.

Fluctuating daily or weekly extremes of temperature, or operation in sub-zero freezing weather may make it impractical to use straight weight lubricants. Use good judgement in selecting lubricant types that are appropriate for climate conditions.

4-4 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

MAINTENANCE INTERVALS 10 HOUR / DAILY SERVICE • • • • • • • • • • • • •

Grease Blade cylinders and Crank frame Pins (See page 4-7) Check Engine Oil Level (See page 4-7) Check Level of Hydraulic Oil Tank (See page 4-7) Check for Leaks in Hydraulic System (See page 4-8) Check Fuel Level (See page 4-8) Drain Water and Sediment from Fuel Filter (See page 4-9) Drain Water and Sediment from Fuel Tank (See page 4-9) Check for Leaks in Fuel System (See page 4-9) Check Cooling System and Refill As Required (See page 4-10) Check for Leaks in Cooling System (See page 4-10) Check Level of Window Washer Liquid (See page 4-10) Inspect Blade Edge for Signs of Wear (See page 4-11) Clean Engine Air Intake Precleaner (See page 4-11)

•

•

• • • •

•

• •

Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours) (See page 4-11) Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers) (See page 4-11) Inspect Seat Belt for Proper Operation (See page 4-11) Inspect the Structure for Cracks and Faulty Welds (See page 4-11) Check the Operation of All Switches (See page 4-11) Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights (See page 4-12) Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds (See page 4-12) Check Operation of All Controls (See page 4-12) Inspect for Any Loose or Missing Nuts and Bolts (See page 4-12)

50 HOUR / WEEKLY SERVICE • • •

Perform All 10 Hour / Daily Service Checks (See page 4-13) Grease Blade Cylinders and Crank frame Pins (See page 4-13) Check Oil Level in Front Track Idler (One Each Side) (See page 4-15)

• • •

Change Engine Oil and Filter (After First 50 Hours) (See page 4-15) Replace Full Flow Hydraulic Oil Filter (After First 50 Hours) (See page 4-15) Change Fuel Filter (After First 50 Hours) (See page 4-15)

150 HOUR SERVICE •

Perform All 10 Hour / Daily and 50 Hour Service Checks (See page 4-16)

5022-7103E-R1 Operation and Maintenance Manual

•

Check Engine Fan Belt for Cracks, Wear and Correct Tension (See page 4-16)

Inspection, Maintenance and Adjustment 4-5

250 HOUR / MONTHLY SERVICE • • • • • • •

Perform All Daily, 50 and 150 Operating Hour Service Checks (See page 4-17) Grease Levers and Pedals (See page 4-17) Clean Outer Element of Two Stage Air Cleaner (See page 4-17) Change Fuel Filter (See page 4-19) Change Engine Oil and Filter (See page 4-20) Clean Radiator and Oil Cooler (See page 4-21) Replace Full Flow Hydraulic Oil Filter (See page 4-22)

•

•

• •

Change Oil in Travel Reduction device (First 250 Hours) (One on Each Side of Unit) (See page 4-22) Inspect Pins and Bushings of Blade Cylinders and Crank frame Pins for Signs of Wear (See page 4-23) Check Fluid Levels in Batteries and Battery Charge Levels (See page 4-23) Inspect Fuel System Hose Clamps (See page 4-23)

500 HOUR / 3 MONTH SERVICE •

•

Perform All Daily (10 Hour), 50, 150 and 250 Operating Hour Service Checks (See page 4-24) Change Oil in Travel Reduction device (One on Each Side of Unit) (See page 4-24)

• •

Change Charge Pump Filter (One on Each Travel Drive Pump (See page 4-24) Change Radiator Coolant (See page 4-25)

1000 HOUR / 6 MONTH SERVICE •

•

Perform All Daily (10 Hour), 50, 150, 250 and 500 Operating Hour Service Checks (See page 4-27) Hydraulic Oil Exchange and Suction Strainer Cleaning (See page 4-27)

• •

Clean Fuel Tank Suction Strainer (See page 4-28) Clean Fuel Injection Priming Pump Strainer (See page 4-29)

1500 HOUR SERVICE •

Perform All Daily (10 Hour), 50, 150, 250 and 500 Operating Hour Service Checks (See page 4-30)

• •

Replace Outer Air Cleaner Element (See page 4-30) Replace Inner Air Cleaner Element (See page 4-30)

2000 HOUR / YEARLY SERVICE •

• •

Perform All Daily, 50, 150, 250, 500 and 1,000 Operating Hour Service Checks (See page 4-30) Check Alternator and Starter** (See page 4-30) Check All Rubber Anti-vibration Shock Mounts (See page 4-30)

• •

• •

Perform and Record the Results of the Cycle Time Tests (See page 4-30) Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage (See page 4-30) Check, Adjust Valve Clearance (See page 4-30) Check Head Bolt Torques (See page 4-30)

4000 HOUR / BIENNIAL SERVICE •

Major Parts - Periodic Replacement (See page 4-31)

** These checks need to be completed by an authorized Daewoo dealer.

4-6 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

10 HOUR / DAILY SERVICE GREASE BLADE CYLINDERS AND CRANK FRAME PINS Grease every 10 hours for first 100 hours and every 50 hours thereafter. (See page 4-13) NOTE:

If the unit been working in water the crank frame pins should be greased on a 10 Hour / Daily basis.

CHECK ENGINE OIL LEVEL 1.

Shutdown engine and wait for 15 minutes.

This will allow all oil to drain back to oil pan.

2.

Check engine oil level using dipstick.

3.

Engine oil level must be between "HIGH" and "LOW" marks on dipstick.

Figure 5

NOTE:

4.

If oil is above "HIGH" mark on dipstick, some must be drained to return oil to proper level.

Add oil through engine oil fill cap, as required.

HAOC280L

Figure 6 CHECK LEVEL OF HYDRAULIC OIL TANK

WARNING! The hydraulic oil will be hot after normal machine operation. Allow the system to cool before attempting to service any of the hydraulic components.

The hydraulic tank is pressurized. Release pressurized air from hydraulic tank by slowly turning breather/fill cap. After the pressure has been released, it is safe to remove either the fill cap or service covers.

5022-7103E-R1 Operation and Maintenance Manual

HAOA060L

Figure 7

Inspection, Maintenance and Adjustment 4-7

Position machine on firm level ground.

Lower blade to ground as shown in Figure 8.

2.

Shutdown engine.

3.

Remove key from switch

4.

Relieve hydraulic pressure in circuit by fully stroking each blade control lever in each direction.

2720

1.

HAOK622L

Figure 8 5.

Check level gauge (Figure 9). Oil level must be between marks on sight gauge.

Add hydraulic oil as required.

IMPORTANT Do not fill above "H" mark on sight gauge. Overfilling can result in damage to equipment and oil leaking from hydraulic tank due to expansion.

Figure 9 CHECK FOR LEAKS IN HYDRAULIC SYSTEM 1.

Perform a daily walk-around inspection to make sure that the hoses, piping, fittings, cylinders and hydraulic motors are not showing any signs of leakage. If any is noted, determine the source of the leak and repair.

CHECK FUEL LEVEL

WARNING! Use extreme safety precautions while refueling to prevent explosions or fire.

Immediately clean up any spilt fuel.

1.

2.

3.

Make sure that the fuel fill hose is grounded to the dozer before fueling begins.

Figure 10 Check amount of fuel in tank by observing fuel tank sight gauge and fuel gauge in instrument panel. Fill tank using fill tube with the proper fuel for operating conditions. Fuel tank capacity is 230 liters (60.77 U.S. Gal.).

The dozer may be equipped with the optional battery operated fuel fill pump. The pump assembly is located in the battery box. Attach the suction hose to the pump and run this hose to the fuel resupply tank. The fuel will be pumped into the dozer fuel tank.

4-8 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

4.

Do not overfill the tank.

5.

Securely tighten fuel cap after fueling.

NOTE:

If breather holes in cap are clogged, a vacuum may form in the tank preventing proper fuel flow to engine. Keep holes in fuel cap clean.

HAOC510L

Figure 11 DRAIN WATER AND SEDIMENT FROM FUEL FILTER 1.

Drain water and sediment from bottom of fuel filter by removing plug (1, Figure 12) and O-ring (2) from bottom of fuel filter (3).

Figure 12 DRAIN WATER AND SEDIMENT FROM FUEL TANK 1.

Drain water and sediment from bottom of fuel tank.

CHECK FOR LEAKS IN FUEL SYSTEM 1.

Perform an inspection of the engine compartment to verify that the fuel system is not leaking. If any is noted, determine the source of the leak and repair.

Figure 13

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-9

CHECK COOLING SYSTEM AND REFILL AS REQUIRED

WARNING! Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to release any remaining pressure.

Radiator cleaning is performed while the engine is running. Take extreme caution when working on or near a running engine. Make sure to lock out and tag the controls notifying personnel that service work is being performed.

1.

When the engine is cold, remove the radiator cap and check the coolant level inside the radiator. Do not rely on the level of coolant in the reserve tank. Refill radiator as required. Refer to coolant concentration table. (See page 4-26)

2.

Check to make sure that coolant transfer line from reserve tank to radiator is free and clear of obstructions, or not pinched.

3.

Observe level of coolant in reserve tank.

The normal cold engine fluid level should be between "FULL" and "LOW" marks on tank.

4.

Figure 14

If coolant is below the "LOW" mark, add coolant to this tank.

CHECK FOR LEAKS IN COOLING SYSTEM 1.

Perform a daily walk-around inspection to make sure that hoses, fittings, and radiator are not showing any signs of leakage. If any is noted, determine the source of the leak and repair.

CHECK LEVEL OF WINDOW WASHER LIQUID 1.

Check fluid level in windshield washer tank.

2.

Open fill cap and add fluid.

NOTE:

Use a washer liquid that is rated for all seasons. This will prevent freezing during cold weather operation.

Figure 15

4-10 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

INSPECT BLADE EDGE FOR SIGNS OF WEAR 1.

On a daily basis, inspect the blade edge to make sure that excessive wear or breakage has not developed.

2.

Do not allow the replaceable blade edge to wear down to the point that the bottom edge of blade is exposed. See Figure 16.

NOTE:

These instructions are only for Daewoo OEM blades. If you are using other manufacturers’ blades, refer to their specific instructions.

Figure 16

CLEAN ENGINE AIR INTAKE PRECLEANER 1.

Remove wing nut and cover

2.

Clean inside of engine precleaner.

NOTE:

Do not allow dirt to collect above line on side of dust bowl.

Figure 17

CHECK ENGINE FAN BELT FOR CRACKS, WEAR AND CORRECT TENSION (AFTER FIRST 50 HOURS) 1.

Inspect after first 50 hours of operation and every 150 hours thereafter.

INSPECT THE TRACK ASSEMBLIES FOR PROPER TENSION AND LOOSE, WORN OR DAMAGED PARTS (LINKS, SHOES, ROLLERS, IDLERS) 1.

Do a daily walk-around inspection of all components including the track assemblies. Look for missing, damaged or excessively worn parts. See “Track Tension” on page 4-46.

INSPECT SEAT BELT FOR PROPER OPERATION INSPECT THE STRUCTURE FOR CRACKS AND FAULTY WELDS 1.

During the daily walk-around inspection and when greasing the machine, look for any visible damage to the machine. Repair or replace any damaged parts before operating the machine.

CHECK THE OPERATION OF ALL SWITCHES 1.

Verify the working condition of all switches before starting the engine.

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-11

CHECK THE OPERATION OF ALL EXTERIOR LIGHTS, HORN AND CONTROL CONSOLE INDICATOR AND MONITOR LIGHTS 1.

Turn engine starter switch to “ON” position and observe all of the indicator lights.

2.

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

3.

Sound horn. Repair or replace if required.

4.

Turn “ON” and inspect all exterior work lights. Replace any monitors, burned out bulbs or cracked or broken housings or lenses.

START ENGINE, CHECK STARTING ABILITY, AND OBSERVE EXHAUST COLOR AT START-UP AND AT NORMAL OPERATING TEMPERATURE. LISTEN FOR ANY ABNORMAL SOUNDS CHECK OPERATION OF ALL CONTROLS

IMPORTANT Cold weather operation requires that the operator fully warm up the hydraulic oil before beginning machine operation. Follow all warm up instructions listed in the Operating Instruction section of this manual. Make sure to cycle oil through all of the components, including all cylinders and both travel motors. Cold hydraulic oil in the lines and components needs to be warmed before beginning full operation. If this is not done, damage to the cylinders or hydraulic motors can occur.

1.

With engine at rated speed, operate all controls.

2.

Follow cold weather hydraulic system warm-up procedures.

3.

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

INSPECT FOR ANY LOOSE OR MISSING NUTS AND BOLTS

4-12 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

50 HOUR / WEEKLY SERVICE PERFORM ALL 10 HOUR / DAILY SERVICE CHECKS GREASE BLADE CYLINDERS AND CRANK FRAME PINS

NOTE:

•

2720

Grease every 10 hours for first 100 hours and every 50 hours thereafter.

If unit has been working in water, the front attachment should be greased on a 10 hour / daily basis.

Position machine as shown in Figure 18 and lower blade to ground and stop engine

•

Press the grease fitting and inject grease with the grease gun on the marked point

•

After injection, clean off the old grease that has been purged.

A.

BLADE CYLINDER - ROD END AND BASE END (R.H. & L.H. SIDE)

B.

BLADE ANGLE CYLINDER - ROD END AND BASE END (R.H. & L.H. SIDE)

HAOK622L

Figure 18

Figure 19

WARNING! Use extreme caution when greasing base end of blade angle cylinder.

Blade must be lowered and track raised off ground to gain excess to fitting.

Place blocking under track and shut off engine.

5022-7103E-R1 Operation and Maintenance Manual

Figure 20

Inspection, Maintenance and Adjustment 4-13

C.

BLADE TILT CYLINDER - ROD END AND BASE END (R.H. SIDE)

D.

BLADE TILT ROD (BOTH ENDS)

E.

BELL CRANK FRAME

Figure 21

Figure 22

Figure 23 IF

FRAME (R.H. & L.H. SIDES)

Figure 24

4-14 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

CHECK OIL LEVEL OF TRAVEL REDUCTION DEVICE ON BOTH SIDES OF UNIT (DRAIN AND REFILL AFTER FIRST 250 HOURS)

WARNING! The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before fully removing any motor case inspection port plug, etc., loosen the plug slightly to allow pressurized air to escape.

NOTE:

Figure 25

Drain and refill oil after first 250 hours of operation and every 500 hours thereafter.

1.

Make sure that the machine is on a solid, level work area.

2.

Rotate the track until ports (1 and 2, Figure 25) are in their proper positions as shown.

3.

Remove plug (1, Figure 25). Fill the travel reduction device case with fluid until the fluid level is at port. Install plug (1).

4.

Repeat this procedure on the other travel reduction device.

CHECK OIL LEVEL IN FRONT TRACK IDLER (ONE EACH SIDE)

Figure 26

CHANGE ENGINE OIL AND FILTER (AFTER FIRST 50 HOURS) 1.

Change engine oil and filter after first 50 hours of operation or rebuild, then every 250 thereafter. (See page 4-20)

REPLACE FULL FLOW HYDRAULIC OIL FILTER (AFTER FIRST 50 HOURS) 1.

Replace hydraulic oil filter after first 50 hours of operation or rebuild, then every 250 hours thereafter.

(See page 4-22)

CHANGE FUEL FILTER (AFTER FIRST 50 HOURS) 1.

Replace fuel filter after first 50 hours of operation, then every 250 hours thereafter. (See page 4-19)

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-15

150 HOUR SERVICE PERFORM ALL 10 HOUR / DAILY AND 50 HOUR SERVICE CHECKS CHECK ENGINE FAN BELT FOR CRACKS, WEAR AND CORRECT TENSION 10 ~ 15 mm (10 kg)

IMPORTANT A loose fan belt can cause engine overheating, poor charging, and/or premature belt wear. A belt that is too tight can cause damage to the water pump, alternator bearing or belt.

HAOM091L

1.

Inspect every 150 hours. (Inspect after first 50 hours of operation.)

2.

With engine shut off, check tension of fan belt by pressing downwards on belt, midway between fan pulley and alternator pulley. Belt should flex approximately 10 15 mm (0.500 - 0.600 in.). See Figure 27.

3.

Inspect all engine belts for worn, cracked or frayed edges. Replace any belts that show signs of wear.

Figure 27

Belt tension adjustment; NOTE:

Adjust belt if deflection is too great or after replacing belt.

1.

Loosen adjusting bolt (1, Figure 28) on sub-plate and alternator mounting bolt (not shown).

2.

Tilt alternator (2, Figure 28) to adjust belt tension.

3.

When tension is correct, tighten adjusting bolt (1, Figure 28) and secure alternator mounting bolt (not shown).

4.

Run engine at low speed, under no load for about 5 minutes and recheck belt tension.

4-16 Inspection, Maintenance and Adjustment

Figure 28

5022-7103E-R1 Operation and Maintenance Manual

250 HOUR / MONTHLY SERVICE PERFORM ALL DAILY, 50 AND 150 OPERATING HOUR SERVICE CHECKS GREASE LEVERS AND PEDALS •

Press the grease fitting and inject grease with the grease gun on the marked point

•

After injection, clean off the old grease that has been purged.

A.

PEDALS (3 POINTS)

Figure 29 B.

LEVERS (3 POINTS)

Figure 30 CLEAN OUTER ELEMENT OF TWO STAGE AIR CLEANER

WARNING! Never clean or attempt to remove the air cleaner element if the engine is running.

If you are using compressed air to clean the element, make sure that proper eye protection is worn.

HAOL115L

Figure 31

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-17

1.

Locate air filter assembly (Figure 32).

Remove access cover and remove outer element of air filter assembly.

NOTE:

If indicator light on instrument panel comes "ON" the air cleaner must be serviced.

NOTE:

Replace outer element every 500 hours / 3 months of service.

Figure 32 2.

Clean outer filter by blowing compressed air from the inside of filter towards outside.

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

3.

Clean inside of air filter housing and inside of air filter housing cover.

4.

Properly install air filter and cover. Tighten cover wing nut finger tight. Do not use any tools to tighten wing nut.

HAOC570L

Figure 33 Remove and clean rubber evacuator valve (Figure 32) from bottom of air cleaner housing.

Inspect seal lips for wear or damage. Replace valve if necessary.

Figure 34

4-18 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

CHANGE FUEL FILTER NOTE:

Replace fuel filter after first 50 hours of operation and 250 hours thereafter.

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

1.

Locate fuel compartment.

filter

inside

engine

2.

Position a small container under fuel filter assembly. Drain filter by removing plug (1, Figure 35) and O-ring (2) from center bolt (3).

3.

Remove center bolt (3, Figure 35), O-ring (4), housing (5), spring (6), spring seat (7), packing (8), element (9), packing (10), and packing (11) from cover (12).

4.

Discard old filter element (5, Figure 35).

5.

Position center bolt (3, Figure 35) with Oring (4) in housing (5).

6.

Slide spring (6, Figure 35), spring seat (7), packing (8), new element (9) and packing (10) on center bolt (3). make sure all parts are properly seated in housing (5).

Figure 35

7.

Coat packing (11, Figure 35) with clean fuel. Position packing and housing (5) against cover (12).

Screw center bolt (3) into cover.

8.

Install O-ring (2, Figure 35) and plug (1) in end of center bolt (3).

9.

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

If engine does not start, the fuel system may need priming. Prime fuel system using the following procedure; 1.

Loosen plug on top of fuel filter head.

2.

Unscrew and pump the hand operated primer pump located by the fuel injection pump. Pump primer until fuel is present at plug hole in fuel filter head.

3.

Tighten plug in fuel filter head.

4.

Continue to pump primer pump until a strong resistance is felt. Screw the primer pump knob back into housing.

5.

Start engine and look for signs of leaks.

6.

Repeat procedure if necessary.

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-19

CHANGE ENGINE OIL AND FILTER NOTE:

Change engine oil and filter after first 50 hours of operation or rebuild, then every 250 thereafter.

WARNING! DO NOT change oil on a hot engine. Allow the engine to cool down before attempting to change the engine oil and filter.

1.

Remove access cover (1, Figure 36) and rubber seal (2) from cover (3).

2.

Position a larger container under engine.

Remove drain plug (Figure 37) to allow all of the engine oil to drain from engine into container. Install drain plug.

Figure 36

Figure 37

4-20 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

3.

Replace engine oil filter. The engine oil filter is a spin-on type. See Figure 38.

Remove and discard filter.

4.

Install new filter. Apply a small amount of oil around filter gasket. Screw filter on head until gasket contacts head by hand, turn filter 1/2 turn more with filter wrench.

5.

Refill the engine with the correct oil through the oil fill port. Refer to the Lubrication Table of this manual for the recommended oil for the operating conditions.

6.

Start engine and check engine oil pressure light.

7.

Shutdown engine. Look for signs of leaks at filter. Recheck oil level.

Figure 38

CLEAN RADIATOR AND OIL COOLER

WARNING! Cleaning radiator requires use of high pressure steam or water. Make sure that all extra personnel are clear of work area.

Excessive pressure can damage radiator and oil cooler.

1.

Make sure to wear all appropriate safety apparel (safety glasses, safety shoes, etc.) during the cleaning process.

2.

Clean outside of radiator and oil cooler with high pressure steam or water. Wash from outside of engine compartment inwards. Repeat cleaning process from inside of engine compartment outwards to remove all dirt and debris.

Figure 39

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-21

REPLACE FULL FLOW HYDRAULIC OIL FILTER NOTE:

Replace hydraulic oil filter after first 50 hours of operation and 250 hours thereafter.

WARNING! The hydraulic oil will be hot after normal machine operation. Allow the system to cool before attempting to service any of the hydraulic components.

The hydraulic tank is pressurized. Loosen the hydraulic oil fill cap slightly to allow the pressurized air to vent. After the pressure has been released, it is safe to remove either the fill cap or service covers or drain water from the tank.

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

1.

Remove bolts (1, Figure 40) and service cover (2). Remove spring (3), valve (4) and O-ring (5) from filter element (6).

2.

Remove filter element (6, Figure 40) and properly discard.

3.

Install new filter element (6, Figure 40) and a new O-ring (5). Install valve (4) and spring (3).

4.

Install service cover plate (2, Figure 40) and bolts (1).

5.

Run engine for 10 minutes at low idle to purge air from circuit.

6.

Stop engine.

7.

Check level in hydraulic oil tank. Add oil if necessary

HAOC460P

Figure 40

CHANGE OIL IN TRAVEL REDUCTION DEVICE (FIRST 250 HOURS) (ONE ON EACH SIDE OF UNIT) NOTE:

Drain oil after first 250 hours of operation and every 500 hours thereafter. (See page 4-24)

4-22 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

INSPECT PINS AND BUSHINGS OF BLADE CYLINDERS AND CRANK FRAME PINS FOR SIGNS OF WEAR

CHECK FLUID LEVELS IN BATTERIES AND BATTERY CHARGE LEVELS

INSPECT FUEL SYSTEM HOSE CLAMPS

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-23

500 HOUR / 3 MONTH SERVICE PERFORM ALL DAILY (10 HOUR), 50, 150 AND 250 OPERATING HOUR SERVICE CHECKS CHANGE OIL IN TRAVEL REDUCTION DEVICE (ONE ON EACH SIDE OF UNIT)

WARNING! The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before fully removing any motor case, inspection port plug, etc., loosen the plug slightly to allow pressurized air to escape.

Figure 41 NOTE:

Drain oil after first 250 hours of operation and every 500 hours thereafter.

1.

Make sure that machine is on a solid, level work area.

2.

Rotate track until ports (1 and 2, Figure 41) are in their proper positions.

3.

Place a container under plug (2, Figure 41) and remove plug (1 and 2) to drain travel reduction device oil.

4.

Install plug (2, Figure 41). Refill travel reduction device case with oil through port (1) until oil level is present at port.

5.

Repeat this procedure on other travel reduction device.

CHANGE CHARGE PUMP FILTER (ONE ON EACH TRAVEL DRIVE PUMP 1.

Change charge pump filter located on side of each travel drive pump.

NOTE:

Change filter if indicator light turn “ON.”

Figure 42

4-24 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

CHANGE RADIATOR COOLANT

WARNING! 1.

Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to release any remaining pressure.

2.

Radiator cleaning is performed while the engine is running. Take extreme caution when working on or near a running engine. Make sure to lock out and tag the controls notifying personnel that service work is being performed.

3.

Figure 43

Do not remove the radiator cap unless it is required. Observe the coolant level in the reserve tank.

1.

Remove access cover (1, Figure 43) and rubber seal (2) from cover (3).

2.

Slowly open the radiator cap to allow any pressure to escape.

3.

Place a container under the radiator and open the drain valve (Figure 44).

4.

Remove coolant drain plug (Figure 45) from engine.

5.

Install drain plug and close drain valve after coolant has completely drained from system.

6.

Fill cooling system with a flushing solution.

7.

Run engine at low idle until the coolant temperature gauge reaches the "GREEN ZONE." Run engine for another 10 minutes.

8.

Alter allowing engine to cool.

9.

Drain flushing fluid and fill system with water.

10.

Run engine again to allow water to completely circulate.

Figure 44

5022-7103E-R1 Operation and Maintenance Manual

Figure 45

Inspection, Maintenance and Adjustment 4-25

11.

Drain water and fill system with proper anti-freeze mixture for ambient temperature. Refer to coolant concentration table (See page 4-26)

12.

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

13.

Drain and fill radiator reserve tank.

AMBIENT TEMPERATURE

COOLING WATER

ANTIFREEZE

-10°C (15°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-5°F)

67%

33%

-25°C (-15°F)

60%

40%

-30°C (-20°F)

56%

44%

-40°C (-30°F)

50%

50%

4-26 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

1000 HOUR / 6 MONTH SERVICE PERFORM ALL DAILY (10 HOUR), 50, 150, 250 AND 500 OPERATING HOUR SERVICE CHECKS HYDRAULIC OIL EXCHANGE AND SUCTION STRAINER CLEANING

WARNING! The hydraulic oil will be hot after normal machine operation. Allow the system to cool before attempting to service any of the hydraulic components.

The hydraulic tank is pressurized. Release pressurized air from hydraulic tank by slowly turning breather/fill cap. After the pressure has been released, it is safe to remove either the fill cap or service covers.

HAOA060L

Figure 46

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

Based on the type of work being completed, the working conditions (extremely hot or dusty) and attachments being used, the hydraulic fluid will need to be changed more frequently.

1.

Position machine on firm, level ground.

Lower blade to ground as shown in Figure 47.

2.

Release pressurized air from hydraulic tank by slowly turning breather/fill cap.

2720

NOTE:

HAOK622L

Figure 47

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-27

3.

Drain hydraulic oil from tank into a container capable of holding 150 liters (39.60 U.S. gal.). After draining tank install drain plug.

IMPORTANT Be careful of squirting oil when removing drain plug.

Figure 48 4.

Remove strainer (Figure 49) from inside hydraulic oil tank.

5.

Clean inside and outside of strainer.

Replace strainer if it is broken.

6.

Install cleaned strainer (Figure 49) in hydraulic oil tank.

7.

Remove full flow filter and O-ring assembly. Reassemble and install the filter assembly. See Figure 40. Make sure to use a new O-ring seal.

8.

Fill hydraulic oil tank. Check level using sight gauge located on side of tank.

9.

After replacing and cleaning the hydraulic oil, filter element and strainer vent the system. See “Electrical System” on page 4-32.

Figure 49

CLEAN FUEL TANK SUCTION STRAINER 1.

Completely drain the fuel tank and remove the access cover located on the bottom of the tank. See Figure 50.

Figure 50

4-28 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

2.

The suction strainer is attached to the fuel tank access cover. See Figure 51. Remove strainer and clean it in fresh fuel.

3.

Reattach the cover to the tank and securely tighten all of the bolts.

4.

Refill the tank and inspect the cover to make sure that it is not leaking.

Figure 51 CLEAN FUEL INJECTION PRIMING PUMP STRAINER 1.

Remove fitting, fuel line and strainer from priming pump.

2.

Clean strainer.

3.

Position strainer in priming pump and install fuel line and fitting.

Figure 52

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-29

1500 HOUR SERVICE PERFORM ALL DAILY (10 HOUR), 50, 150, 250 AND 500 OPERATING HOUR SERVICE CHECKS REPLACE OUTER AIR CLEANER ELEMENT NOTE:

Replace inner element whenever a new outer element is installed.

REPLACE INNER AIR CLEANER ELEMENT 1.

Replace inner element element is replaced.

2.

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

3.

Clean out inside of air cleaner housing.

DO NOT use compressed air to blow out housing.

4.

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

5.

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

6.

Install air cleaner cover.

NOTE:

when

outer

Figure 53

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

2000 HOUR / YEARLY SERVICE PERFORM ALL DAILY, 50, 150, 250, 500 AND 1,000 OPERATING HOUR SERVICE CHECKS CHECK ALTERNATOR AND STARTER** **These Checks Need To Be Completed By An Authorized Daewoo Dealer.

CHECK ALL RUBBER ANTI-VIBRATION SHOCK MOUNTS PERFORM AND RECORD THE RESULTS OF THE CYCLE TIME TESTS INSPECT MACHINE TO CHECK FOR CRACKED OR BROKEN WELDS OR OTHER STRUCTURAL DAMAGE CHECK, ADJUST VALVE CLEARANCE CHECK HEAD BOLT TORQUES

4-30 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

4000 HOUR / BIENNIAL SERVICE MAJOR PARTS - PERIODIC REPLACEMENT To ensure safe operation and work, perform periodical inspection. Also, to increase safety, replace the following parts. These parts are the ones most often subjected to abrasion, heat and fatigue. Exchange these parts with a new ones at the designated time intervals, even if the old parts look good.

Always replace all related parts such as gaskets and O-rings. Use only original equipment manufacturers parts.

MAJOR COMPONENT

PARTS NAME TO BE EXCHANGED PERIODICALLY

TIME TO EXCHANGE

ENGINE

Fuel hose (Tank to filter)

2 years or 4,000 hours

Fuel hose (Tank to fuel injection pump) Heater hose (Heater to engine) HYDRAULIC SYSTEM

BODY

Pump suction hose Pump discharge hose

WORK DEVICE Blade cylinder line hose Pilot hose

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-31

ELECTRICAL SYSTEM NOTE:

Never disassemble electrical or electronic parts. Consult with a DAEWOO distributor or sales agency before servicing.

BATTERY

WARNING! Before starting any battery service work, make sure to shut the engine off and turn the ignition key to the "OFF" position.

The batteries create hydrogen gas. An explosion hazard exists, particularly with a deeply discharged battery. Make sure that open flames, burning objects or sparks are kept away from the battery compartment.

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

The electrolyte can cause severe chemical burns. If any electrolyte gets on your clothing or skin, wash it off immediately with large quantities of water. If the electrolyte gets into your eyes, flush them immediately with a large quantity of water and contact a doctor at once.

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

When removing a battery, remove the Negative (-) or ground terminal first, and then the Positive (+) terminal. This will prevent sparks or arcing that could cause an explosion. When installing a battery, connect the Positive terminal first and then the Negative terminal. Make sure to fully tighten the terminal clamps.

1.

In colder weather a greater drain is placed on the batteries when they are used for the preheat cycle and when starting a cold engine. Battery performance decreases as the temperature gets lower.

2.

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

3.

Inspection of battery electrolyte level.

NOTE:

4.

The battery installed at the factory is a Maintenance Free (MF) type. Electrolyte under normal conditions should remain at its proper level.

Inspect the charge condition of battery by looking at the indicator light built into the battery.

•

GREEN: Normal

•

BLACK: Insufficient charging - check alternator.

•

TRANSPARENT: Insufficient battery fluid - replace with new battery.

HJB5002L

Figure 54

NOTE:

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

NOTE:

The batteries should always be replaced in pairs. Using an old battery with a new one will shorten the life span of the new battery.

4-32 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

FUSES 1.

The fuses located in the fuse box are used to protect the various electrical circuits and their components from damage. See Figure 55. The fuses used are standard automotive type fuses.

2.

The Fuse Table lists the circuits and the fuse amperage required for each circuit. If a fuse blows, determine the cause and repair any faults or failures.

3.

DO NOT insert a higher amperage fuse into a lower amperage slot. Serious damage to the electrical components or fire can result.

O

X

HAOC670L

Figure 55

FUSE BOX The fuse box is located in one of two places. The location is dependent upon whether unit is equipped with a canopy or cab.

The fuses prevent electrical devices from overloading or shorting.

A decal is attached to fuse box to identify fuses A spare fuse is located on inside of fuse box's cover.

Fuses are rated for the following amps; 10 AMP 15 AMP 20 AMP 30 AMP Canopy units - fuse box is located inside battery compartment.

Figure 56

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-33

Cab units - fuse box is locate under the instrument panel.

Figure 57

4-34 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

BLADE BLADE EDGE REPLACEMENT

WARNING! Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing cutting edges.

Rest blade assembly on blocking. Shut engine off and lock out the hydraulic controls before working on blade.

NOTE:

These instructions are only for Daewoo OEM blades. If you are using other manufacturers blades, refer to their specific instructions.

1.

On a routine basis, inspect the blade’s cutting edge to make sure that wear or breakage has not occurred that will expose the blade. See Figure 58.

2.

To replace a cutting edge (1, Figure 59), rest crank frame on blocking so that cutting edge just clears ground.

Figure 58

WARNING! Do not work on blade will it is raised.

Always support blade on blocking.

3.

Shutdown engine.

4.

Remove key from switch

5.

Fully stroke each blade control lever to relieve hydraulic pressure from cylinders and lines.

6.

Remove nuts and washers (2) from bolts (3).

NOTE:

Figure 59

Cutting edges can be inverted.

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-35

CALIBRATION PROCEDURE FOR MICRO CONTROLLER SYSTEM CONCEPT The propel system of the dozer is a hydrostatic transmission. This transmission is composed of two hydraulic pumps and motors in a closed loop circuit. A micro controller then controls the right and left transmission circuits independently.

Figure 60

4-36 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

MICRO CONTROLLER The micro controller is the computer processor that controls the vehicle travel performance in an optimum condition by controlling the displacement of both pumps and motors. It eventually generates a current (mA) to the EDC (Electric Displacement Control) that converts an electrical signal into a hydraulic pilot pressure to change the displacement of both pumps and motors. It receives as input signals the position of each control lever and pedal and also the speed of engine and left and right motors. It has a calibration function to initialize the working range of each sensor and a diagnostic function which displays the vehicle operating condition and the content of fault as well when system fault happens.

The following is a list of terminal connection to the micro controller (Figure 61).

1.

RS232

2.

ANALOG INPUTS (4)

3.

POWER, GROUND

4.

TIMING INPUTS (4) DC, (1) AC

5.

ON/OFF INPUTS (8)

6.

SENSOR POWER

7.

BIDERECTIONAL VALVE

8.

3A OUTPUTS (4)

9.

CAN NETWORK

Figure 61

SENSORS Two basic kinds of sensors are used: one is a rotary position sensor (1, Figure 62) that converts the angular position of each lever and pedal into an electric signal (Voltage), and the other is a magnetic pulse pickup (2 and 3) that converts the RPM of the engine, and left and right travel motors into an electric signal (Frequency).

5 position (1, Figure 62) signal and 3 speed (2 and 3) signal are connected to micro controller and used in internal calculation.

5022-7103E-R1 Operation and Maintenance Manual

Figure 62

Inspection, Maintenance and Adjustment 4-37

WORKING RANGE OF ROTARY POSITION SENSOR Each rotary sensor (1, Figure 62) contains a non-contacting hall effect sensor with an input shaft supported by a sleeve bearing. Due to manufacturing tolerances each sensor may respond differently when placed into operation. This is a normal condition which must be compensated for by mechanical adjustment and calibration of the micro controller.

There are five rotary sensors used on the dozer. There is one for each of the following controls; Throttle Lever Forward/Reverse Lever Right Steer Pedal Brake Pedal Left Steer Pedal The following illustrations show each mechanical adjustment dimension and range of lever movement. It also indicates the voltage that should be read at the end of each lever or pedal stop.

NOTE:

These adjustments should only be made by qualified service personnel. Attempting to make adjustments to these sensors will not improve machine performance (faster acceleration, increased horsepower, etc.). Remember that the micro controller controls the final output, and that these devices are for only input.

4-38 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

Throttle lever Sensor

Figure 63

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-39

Travel (FNR) Lever Sensor

HAOM600L

Figure 64

4-40 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

Left and Right Steering Pedal Sensors

Figure 65

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-41

Brake Pedal Sensor

Figure 66

CALIBRATION PROCEDURE General Notes: Calibration is required in the field or at a service center any time a sensor or component is replaced or adjusted.

NOTE:

Calibration should be done when the machine is warmed up

NOTE:

Calibration of EDC thresholds should be done on a smooth, level surface

NOTE:

Fault diagnostics are not performed during calibration

NOTE:

Pressing the calibrate button during normal operation does not have any effect.

NOTE:

If power is lost during calibration procedure, simply start over.

NOTE:

Move each lever or pedal through its full calibration range!

•

Steer and Brake: Depress pedals only to detent position. Do not go beyond this point.

•

Throttle and FNR: Move levers through entire range.

4-42 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

Procedure 1.

Start the machine while pressing and holding the calibrate button. Do not release the calibrate button until after the engine has started. The 4 character LED display (hereafter referred to as the display) will show “CAL.” until the calibrate button is released.

2.

The red STATUS LED (Figure 67) on the controller will turn on and the display will then show a scrolling list of characters representing the items to be calibrated.

The initial list is 3456789AC and is scrolled on the display at the rate of 2 shifts per second as illustrated below.

3456 4567 5678 6789

Figure 67

789A 89AC 9AC_ AC_3 C_34 _345 (List returns to first number shown below.)

3456 The characters shown correspond to the fault codes. For example, the 4 represents the neutral switch, the 7 represents the brake sensor, and the C represents engine RPM. The 9 and A represent the left and right EDC threshold calibrations (not as direct a correlation as the rest but the PPU’s are used to find the thresholds).

3.

Move each pedal and lever to be calibrated through its range of motion. Order is not important and not all items need to be calibrated each time. For example, if replacing a left steer sensor, only that sensor would need to be calibrated. While calibrating the FNR sensor, no other pedals or levers can be calibrated because the controller is finding the EDC thresholds. Some important considerations are listed below A.

Steer and Brake Pedals - Move each pedal from its full out position to its detent position and back out again.

B.

Throttle Lever - Moving this lever calibrates both the throttle sensor and the corresponding engine RPM. Move the lever slowly from low to high and back again.

WARNING! Machine may move during following procedure, but can be stopped by moving FNR Lever to “NEUTRAL,” or stepping “ON” brake pedal, or turning “OFF” the engine.

C.

FNR Lever - Moving this lever calibrates the neutral switch, the FNR sensor, and the EDC thresholds. Move the lever slowly forward out of neutral until the STATUS LED turns off indicating that you are out of neutral, then move the lever to the full forward position. Leave the lever in that position until the STATUS LED turns on again indicating that the thresholds have

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-43

been found. Then return the lever to neutral. Repeat the same procedure in the reverse direction 4.

As each item is calibrated, its corresponding character in the scrolling list is removed (the display will stop scrolling when there are four or fewer characters to display). When all sensors have been calibrated, the display will be blank.

5.

Press the calibrate button again. The STATUS LED will turn off and the display will show characters corresponding to any items that failed calibration. If all items calibrated properly, the display will be blank. The calibration procedure is now complete.

6.

Press the calibrate button once more and the controller will resume normal operation as if it had just been turned “ON.”

7.

If any item fails calibration, the controller will use the most recent valid calibration value for that item.

Calibration Point and Sensor Voltage Calibration is the operation that initializes the working range of each rotary position sensor including micro neutral switch and engine, and also reads the pump thresholds. This operation should be done in any case that initialization is necessary as when the sensor is first installed or replaced and when sensor settings deviate over tolerance from the calibration points.

The analog output of voltage that rotary position sensor produces is converted into digital value (A/D value) so that the micro controller can utilize in calculating.

A/D value = 186 x sensor output voltage The following figure describes the allowance of calibration point and the tolerance not to generate fault with used.

4-44 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

Figure 68 For example, if the FNR sensor output whose calibration point of FNR. FWD is 3.65V (679) exceeds 3.65 + 0.11 (tolerance) = 3.76 (699), system error takes place and the machine automatically and immediately stop running with "SYSTEM ERROR" lamp ON and with the controller displayed "F:3". In this case, if the maximum output of this sensor is set 3.85V as moving the FNR lever to maximum travel speed, the voltage is still within the calibration allowance 2.80~4.20V and consequently can be calibrated to revise the old value 3.65V.

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-45

TRACK TENSION WARNING! Safely measuring track tension requires two people. One person must be in the operator's seat, running the controls to keep one side frame in the air, while the other person makes dimensional checks. Take all necessary precautions to make sure the machine won’t move or shift position during service. Warm up the engine to prevent stalls, travel the dozer to an area that provides level, uniform ground support and/or use support blocks when necessary.

The track adjusting mechanism is under very high pressure. NEVER release pressure too suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from the fully snugged down position. Bleed off pressure slowly and keep your body away from the valve at all times.

1.

Track tension is checked by slowly running the dozer forwards and backwards on a smooth surface. Travel in one direction must be three times the length of the unit.

This will ensure that the track makes one full revolution.

2.

Bring unit to a stop without using brake.

2720

Track shoe link pins and bushings wear with normal usage, reducing track tension. Periodic adjustment is necessary to compensate for wear and it may also be required by working conditions.

HAOK624L

Figure 69 3.

Using a straight edge, measure slack in track on both front and rear ends of unit (Figure 70).

"F"

"R"

F = 23 - 33 mm (0.9 - 1.3 in.)

R = 25 - 35 mm (1.0 - 1.4 in.)

HAOK625L

Figure 70

4-46 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

4.

Adjust track tension.

WARNING! The track adjusting mechanism is under very high pressure. NEVER release pressure too suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from the fully snugged down position. Bleed off pressure slowly and keep your body away from the valve at all times.

A.

B.

Track tension adjustments are made through the grease fitting (1, Figure 71) in the middle of each side-frame.

Adding grease increases the length of an adjustment cylinder (2). The longer the adjustment cylinder, the greater the pressure on the tension spring pushing the track idler wheel outward.

If there isn’t enough slack or clearance in the tracks and the adjustment is too tight, the idler wheel and adjusting cylinder can be retracted by bleeding off grease thru hole in valve (3, Figure 71).

3

2

1 HAOC760L

Figure 71

5.

Run dozer forwards and backwards again as in Step 1. This will allow slack from track that is in contact with ground to be removed.

6.

Using a straight edge, measure slack in track on both ends of unit.

7.

Repeat Step 1 thru 6 until proper measurement is obtained.

NOTE:

If dimension “C” (Figure 72) is more than 120 mm (4.7 in.) do not adjust track. The track must be replaced.

Figure 72

5022-7103E-R1 Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-47

BOLT AND NUT INSPECTION Inspect ALL fasteners after the first 50 hours of operation and every 250 hours thereafter. If any are loose or are missing tighten them or install new hardware. Always use a calibrated torque wrench.

IMPORTANT Always clean fasteners before tightening. .

NO.

1

POINT TO BE INSPECTED

2

Fuel & hydraulic oil tank mounting bolt

3

High pressure hose (union)

High pressure hose (flange)

kg•m

N•m

lbf ft

4

24

21

205

152

M12 (H)

4

19

9

88

65

M16 (H)

16

24

21

205

152

PF 1/2

27

9.5

93

69

PF 1

41

21

205

152

7/16 UNC (T)

8.25

81

60

M12 (T)

11

108

79

32.36

31.5

308

227

High pressure hose (ORFS)

QTY.

M16 (H)

TORQUE

BOLT HEAD SIZE

Engine mounting bolt

BOLT DIA. MM

1 3/16 UNF

4

Pump mounting bolt

M14 (T)

4

22

16

157

115

5

Control valve mounting bolt

M8 (H)

3

13

2

20

14

6

Battery mounting bolt

M10 (H)

2

17

5

49

36

7

Battery frame mounting bolt

M16 (H)

18

24

21

205

152

8

Front beam mounting bolt

M24 (T)

16

36

95

930

686

9

Rear beam mounting bolt

M24 (T)

20

36

95

930

686

10

Final drive mounting bolt

M20 (T)

24

30

11

Travel motor mounting bolt

M12 (T)

8

11

108

79

12

Upper roller mounting bolt

M16 (T)

4

24

27

265

195

Upper roller bracket mounting bolt

M14 (H)

8

22

14

137

101

13

Lower roller mounting bolt

M12 (T)

48

19

11

108

79

14

Drive sprocket mounting bolt

M20 (T)

50

30

55

538

397

15

Drive sprocket mounting bolt

9/16 UNC

312

22

27

265

195

16

Blade mounting bolt

M24 (H)

2

36

70

685

505

4-48 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

MAINTENANCE IN SPECIAL CONDITIONS CONDITIONS

MAINTENANCE REQUIRED

Operating in mud, water or rain.

1.

Perform a walk around inspection to check for any loose fittings, obvious damage to the machine or any fluid leakage.

2.

After completing operations, clean mud, rocks or debris from the machine. Inspect for damage, cracked welds or loosened parts.

3.

Perform all daily lubrication and service.

4.

If the operations were in salt water or other corrosive materials, make sure to flush the affected equipment with fresh water.

1.

Clean the air intake filters on a more frequent basis.

2.

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

3.

Clean the fuel system intake strainer and fuel filter more frequently.

4.

Inspect and clean as required the starter and alternator.

1.

Check the undercarriage and track assemblies for damage or excessive wear.

2.

Inspect for loose or damaged fittings or bolts.

3.

Relax track tension.

4.

On a more frequent basis, inspect the front end attachments for damage or excessive wear.

5.

Install a top guard and front guard as required for protection against falling rock.

1.

Use the proper conditions.

2.

Using a hydrometer, check the antifreeze to make sure that it is providing the proper cold weather freeze protection.

3.

Verify the condition of the batteries. In extremely cold weather remove the batteries at night and store them in a warmer area.

4.

Remove mud build-up as soon as possible to prevent it from freezing to the undercarriage and causing damage.

Operating in an extremely dusty or hot environment.

Operating in rocky terrain.

Operating in extreme cold.

5022-7103E-R1 Operation and Maintenance Manual

fuel

for

the

temperature

Inspection, Maintenance and Adjustment 4-49

LONG TERM STORAGE Perform the following if storing the dozer for more than one month.

CONDITIONS

MAINTENANCE REQUIRED

1. Cleaning

1.

Pressure wash the undercarriage and track assemblies. Inspect for damage or loose or missing parts.

2. Lubrication

1.

Perform all daily lubrication procedures.

2.

Apply a coating of light oil to the exposed plated metal surfaces, such as hydraulic cylinder rods, etc.

3.

Apply a coating of light oil to all of the control linkages and control cylinders (control valve spools, etc.).

3. Battery

1.

Remove the battery from the dozer or remove the battery leads from the battery to fully charge and store.

4. Cooling System

1.

Inspect the coolant reserve tank to make sure that the antifreeze level in the system is at the correct level.

2.

Every 90 days or 750 hours on the hour meter, use a hydrometer to measure the protection level of the coolant. Refer to the antifreeze/coolant protection chart to determine the amount of protection the cooling system requires. Add coolant as required.

1.

Once a month, start the engine and follow the "Hydraulic Oil Warm-up" procedures listed in this manual.

5. Hydraulic System

4-50 Inspection, Maintenance and Adjustment

5022-7103E-R1 Operation and Maintenance Manual

5TRANSPORTATION Obey all local, state or federal regulations for the transportation of the excavator. If unsure of regulations check with local authorities.

Check the intended route for road width, overhead clearances, weight restrictions, and traffic control regulations. Special approval or permits may be required.

LOADING AND UNLOADING WARNING! When transporting the machine, know the width, height, length and weight.

Loading or unloading the machine can be a dangerous operation. Make sure to run the engine at the lowest speed setting, and travel at the slowest speed possible.

Make sure that the ramp being used is capable of handling the weight of the machine. If required, add blocking under the ramp for additional support.

Make sure that the ramp surface is free of grease or mud that could cause the machine to slip or slide.

Make sure that the trailer is parked on firm, level ground before attempting to load/unload the machine.

If it is required to turn the machine while it is on the trailer, make sure to do this at the slowest engine and travel speeds possible.

Make sure to secure the machine onto the trailer as required by local transportation laws.

1.

Make sure that the trailer is parked on a firm and level surface. See Figure 1.

2.

Make sure that ramps being used are designed to handle weight of machine. If required, add blocking under ramp to provide additional support.

3.

The ramp angle should be less than or not exceeding a 15° angle. Ramps steeper than this may cause a problem when loading or unloading.

4.

Set engine speed to "LOW IDLE."

5.

Fully raise blade and any attachment.

6.

Once unit is in position on trailer lower blade and attachment.

NOTE:

7.

Figure 1

Place blade control lever in float to ensure all pressure is off blade. Return blade lever to “normal centered position when done.

Stop engine and remove key from starter switch.

5022-7103E-R1 Operation and Maintenance Manual

Transportation 5-1

Make sure to secure the machine onto the trailer before transporting. Place blocking (Figure 2) in front of and behind each track. Use chains or cable tie-downs as required by local transportation laws.

9.

Refer to “Specification” on page 7-1 for overall machine height and width measurements.

2720

8.

HAOK626L

Figure 2

LIFTING WITH SLING WARNING! Improper lifting can allow load to shift and cause injury or damage.

1.

Refer to “Specification” on page 7-1 of this manual for information on weight and dimensions.

2.

Use properly rated cables and slings for lifting.

3.

Position machine for a level lift.

4.

Lifting cables should have a long enough length to prevent contact with the machine.

Spreader bars may be required.

NOTE:

If spreader bars are used, be sure that cables are properly secured to them and that the angle of the cables is factored into the lift strength.

HAOL090L

Figure 3

5-2 Transportation

5022-7103E-R1 Operation and Maintenance Manual

6TROUBLESHOOTING At any case, if you find out a malfunction, you must take a measures. Check the cause and prepare for a trouble in advance through maintenance and repair. Because a trouble sometimes may occur by several overlapped cause, you need to take a measure in systematic according to a principle. If a trouble occur, investigate a cause on following articles and take a measure such as adjustment and repair. And if you couldn't find out a cause clearly, consult with near DAEWOO service center on it. Especially, never perform an adjustment, disassembly and repair on hydraulic instrument and electric & electronic, and contact with a near service center.

ENGINE PROBLEM

CAUSE

REMEDY

Starter does not operate

Low battery power.

Charge battery.

Poor terminal contact.

Clean and tighten connections.

Starter switch failed.

Replace switch.

Starter relay failed.

Replace relay.

Starter control failed.

Replace controller.

Wiring harness faulty.

Replace harness.

Battery relay failed.

Replace relay.

Blown fuse.

Replace fuse.

Fuel gelled in cold weather.

Replace fuel.

Fuel filters plugged.

Replace filters.

Water or dirt in fuel system.

Clean system and add new fuel.

Air in fuel system.

Purge air from system.

Engine stop control failed.

Replace stop control.

Engine stop relay failed.

Replace relay.

Blown fuse.

Replace fuse.

Engine oil viscosity incorrect.

Change oil.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine stop motor cable out of adjustment.

Readjust.

Engine speed control cable out of adjustment.

Readjust.

Starter engages, engine does

Engine starts, runs only at low speed or shuts down.

5022-7103E-R1 Operation and Maintenance Manual

Troubleshooting 6-1

PROBLEM

CAUSE

REMEDY

Engine knocks, runs unevenly or surges.

Low engine oil.

Refill.

Plugged air intake system.

Clean system and replace filter.

Injection pump out of adjustment.

Contact your Daewoo dealer.

Plugged fuel filter.

Replace fuel filter.

Water or dirt in fuel system.

Clean system and add new fuel.

Clogged or dirty fuel injectors.

Clean injectors.

Plugged air intake system.

Clean system and replace filter.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine speed control cable out of adjustment.

Readjust.

Injection pump out of adjustment.

Contact your Daewoo dealer.

Valve backlash faulty.

Adjust backlash.

Low coolant level.

Add coolant.

Thermostat faulty.

Replace thermostat.

Radiator cap faulty.

Replace radiator cap.

Radiator core plugged.

Clean radiator.

Oil cooler core plugged.

Clean oil cooler.

Fan belt loose or damaged.

Tighten or replace as required.

Temperature sensor faulty.

Replace sensor.

Engine has poor power

Engine runs hot

HYDRAULIC SYSTEM PROBLEM

CAUSE

REMEDY

None of the controls function (loud noise from pumps)

Hydraulic pump failed.

Contact your Daewoo dealer.

Low hydraulic oil level.

Add hydraulic oil as required.

Suction line plugged or damaged.

Clean or replace as required.

Implement pump failure.

Contact your Daewoo dealer.

None of the controls function (no noise from pumps)

6-2 Troubleshooting

5022-7103E-R1 Operation and Maintenance Manual

PROBLEM

CAUSE

REMEDY

All actuators have low power

Low hydraulic oil level.

Add hydraulic oil as required.

Suction filter clogged.

Clean filter.

Hydraulic pumps faulty.

Contact your Daewoo dealer.

Main relief pressure too low.

Contact your Daewoo dealer.

Hydraulic pumps excavating.

Bleed air from hydraulic pumps.

Overload relief pressure too low.

Reset pressure.

Make-up check valve leaking.

Clean or replace as required.

Control valve spool faulty.

Replace valve spool.

Dirt in valve spool.

Clean or replace as required.

Actuator failed.

Repair or replace as required.

Cylinder seal failed.

Repair or replace as required.

Cylinder rod damaged.

Repair or replace as required.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

Oil cooler faulty.

Contact your Daewoo dealer.

Fan belt loose.

Tighten fan belting as required.

Only one or two actions have little or no power

Oil temperature too high

ELECTRICAL SYSTEM PROBLEM

CAUSE

REMEDY

Battery will not hold a charge

Low battery power.

Clean and retighten.

Alternator belt loose or bad.

Tighten or replace belt.

Loose or corroded terminals.

Tighten or replace as required.

Alternator faulty.

Repair or replace as required.

Internal battery short.

Replace battery.

Short circuit in wiring.

Repair as required.

Low battery power

5022-7103E-R1 Operation and Maintenance Manual

Troubleshooting 6-3

PROBLEM

CAUSE

REMEDY

Engine speed is not controllable

Speed control dial failed.

Replace control dial.

Throttle controller failed.

Replace controller.

Speed control motor failed.

Repair or replace as required.

Blown fuse.

Replace fuse.

Wiring harness damaged.

Repair or replace as required.

Connector failed.

Repair or replace as required.

Blown fuse.

Replace fuse.

Power mode selector switch failed.

Replace switch.

Connector failed.

Replace connector.

Wiring harness damaged.

Repair or replace as required.

Micro controller failed.

Repair or replace as required "Engine speed is not controllable."

Blown fuse.

Replace fuse.

Working mode selector switch.

Replace switch failed.

Connector failed.

Replace connector.

Wiring harness damaged.

Repair or replace as required.

Micro controller failed.

Repair or replace as required "Engine speed is not controllable."

Power mode selector does not work

Working mode selector does not work

TRAVEL SYSTEM GENERAL PROBLEM

CAUSE

REMEDY

Travel motion does not function

Parking brake will not release.

Repair parking brake.

Travel motor failed.

Repair or replace as required.

Wrong pilot line connection.

Reconnect pilot lines.

Track tension too high or too low.

Adjust tension.

Damaged rollers or idlers.

Repair or replace as required.

Track frame damaged.

Repair as required.

Parking brake will not release.

Repair parking brake.

Travel speed is too low

6-4 Troubleshooting

5022-7103E-R1 Operation and Maintenance Manual

MICRO CONTROLLER The following table lists and explains the diagnostics performed by the micro controller.

The DISPLAY column shows the 4 character LED display as it would appear on the micro controller display (Figure 1) for the given fault.

The FAULT column indicates what the fault is.

The SHUTDOWN column indicates whether or not the controller will shut down (i.e. ramp the machine to a stop and require operator to restart) or not (the fault is reported, but no action is taken).

Figure 1

The CRITERIA TO DIAGNOSE FAULT column explains the conditions the controller uses to determine If the fault has occurred.

The TIME ALLOWED column lists the amount of time that the criteria in the previous column must be true for the micro controller to diagnose the fault. For a fault that does not shut down the controller, this is also the time required to clear a fault once the fault criteria are not true.

In all cases except the last one (FNR not in neutral), the micro controller will turn “ON” the System Error lamp on the instrument panel upon diagnosing a fault. If several faults are diagnosed at the same time of if another fault occurs while one that has not caused a shutdown is present, the display will cycle through the displays for all faults present. In all cases a fault that causes a shutdown will take precedence and shut down the machine.

TIME ALLOWED

DISPLAY

FAULT

SHUTDOWN

CRITERIA TO DIAGNOSE

FAIL

Controller

Yes

Several different conditions can cause this fault. It is used to indicate a failure in the controller software or hardware. The number recorded on the Controller fault log (accessible using GPl) gives further information about the last fault. These numbers are useful to Sauer-Sundstrand in diagnosing the problem with the controller.

None

F:2

SV Sensor Power

Yes

Measured Sensor Power Voltage is not within 4.75V to 5.25V

0.3 seconds

F:3

FNR Sensor

Yes

FNR Sensor A/D reading is more than 20 counts (0.1V) outside the calibrated range

0.3 seconds

5022-7103E-R1 Operation and Maintenance Manual

Troubleshooting 6-5

DISPLAY

FAULT

SHUTDOWN

CRITERIA TO DIAGNOSE

TIME ALLOWED

F:4

Neutral Switch

Yes

FNR Sensor A/D Sensor A/D reading is more than "Neutral Deadband" counts inside FNR neutral top and bottom calibration points when FNR is in neutral (based on neutral switch) or FNR A/D reading is more than "Neutral Deadband" counts outside FNR neutral top and bottom calibration points when FNR is not in neutral.

0.3 seconds

F:5

Left Steer Sensor

Yes

Left Steer Sensor A/D reading is more than 20 counts (0.1V) beyond the calibrated pedal out position or more than 120 counts (0.6V)beyond the calibrated pedal detent position.

0.3 seconds

F:6

Right Steer Sensor

Yes

Right Steer Sensor A/D reading is more than 20 counts (0.1V) beyond the calibrated pedal out position or more than 120 counts (0.6V)beyond the calibrated pedal detent position.

0.3 seconds

F:7

Brake Sensor

Yes

Brake Sensor A/D reading is more than 20 counts (0.1V) beyond the calibrated pedal out position or more than 80 counts (0.4V) beyond the calibrated pedal in (detent) position.

0.3 seconds

F:8

Throttle Sensor

Yes

Throttle Sensor A/D reading is more than 20 counts (0.1V) outside the calibrated range.

0.3 seconds

F:9

Left Motor PPU

Yes

Measured Left Motor Speed is zero while the left EDC current drive is at its max. value and the left EDC has not been diagnosed shorted or open (fault E or F).

If Engine speed is zero (i.e. Engine not running), this fault is not diagnosed.

0.3 seconds

F:A

Right Motor PPU

Yes

Measured Right Motor Speed is zero while the right EDC current driver is al its max. value and the right EDC has not been diagnosed shorted or open (fault H or J). If Engine speed is zero (i.e. Engine not running), this fault is not diagnosed)

0.3 seconds

F:C

Engine PPU

Yes

Measure Engine RPM is zero but either left or right measured motor speed is not zero.

0.3 seconds

F:E

Shorted Coil on Left EDC

Yes

Left EDC Coil Resistance is less than 5 The check is not done when there is no current commanded

0.12 seconds

6-6 Troubleshooting

5022-7103E-R1 Operation and Maintenance Manual

TIME ALLOWED

DISPLAY

FAULT

SHUTDOWN

CRITERIA TO DIAGNOSE

F:F

Open Coil on Left EDC

Yes

Left EDC Coil Resistance is greater than 30. The check is not done when there is no current commanded

0.12 seconds

F: H

Shorted Coil on Right EDC

Yes

Right EDC Coil Resistance is than 5 The check is not done when there is no current commanded.

0.12 seconds

F:J

Open Coil on Right EDC

No

Right EDC Coil Resistance is greater than 30. The check is not done when there is no current commanded

0.12 seconds

F:L

System Error Lamp

No

The status bit of the high current drive used for the system Error Lamp indicates an open or short.

0.3 seconds

F:P

Battery Voltage

Yes

Measured Battery Voltage is not within 1 8V to 32V.

0.3 seconds

No, but FNR must be returned to Neutral to operate.

FNR lever is not in Neutral when controller is turned on. Both the Neutral Switch and the A/D reading of the FNR sensor are checked.

none

FNR!

FNR not in Neutral

The following table lifts explain the other messages that may be displayed on the 4 character LED and explains their meanings.

DISPLAY

DESCRIPTION

K139

During controller initialization, the display scrolls the software part number and revision level.

CYC3

When the controller has been put into a cycle mode the LED will display the current cycle mode. The sample shows cycle mode 3, but it could display CYC 1-6.

AUT

Displayed during normal operation when the controller is in the AUTO mode (closed loop).

MAN

Displayed during normal operation when the controller is in the MAN mode (open loop).

COM

This message will be displayed if the controller has not been programmed with application software and still contains the factory test software.

CAL

Displayed at start-up while the calibrate button is pressed. The following section explains other messages displayed during calibration.

5022-7103E-R1 Operation and Maintenance Manual

Troubleshooting 6-7

MICRO CONTROLLER TROUBLESHOOTING Normal Operation 1.

2.

3.

4.

5.

6.

7.

8.

9.

Micro controller does not power-up A.

Check connectors.

B.

Check fuse, battery voltage, etc.

FAlL = Controller A.

Check connectors.

B.

Check fuse, battery voltage, etc.

C.

Reinstall software in the controller.

D.

Replace controller.

F:2 = 5V Sensor Power A.

Check sensor wiring for short open or ground

B.

Check supply and ground voltages of sensors

C.

Replace controller

F;3 = FNR Sensor A.

Recapitulate FNR sensor

B.

Check FNR wiring for open short or ground

F:4 = Neutral Switch A.

Recapitulate FNR sensor

B.

Check neutral switch

C.

Check FNR wiring

F:5/F:6 = Left/Right Steer Sensor A.

Re calibrate Left/Right steer sensor

B.

Check Left/Right Steer Sensor wiring for open, short or ground

F:7/F:8 = Brake/Throttle Sensor A.

Recapitulate Brake/Throttle sensor.

B.

Check Brake/Throttle sensor wiring for open short or ground

F:9/F:A = Left/Right Motor PPU A.

If machine is moving when fault is indicated.

B.

Check PPU wiring.

C.

Check PPU clearance and orientation.

D.

Replace PPU.

E.

If engine is running but machine does NOT move.

F.

Check pump and motor components (charge pressure etc.).

F:C = Engine PPU A.

Check PPU wiring.

6-8 Troubleshooting

5022-7103E-R1 Operation and Maintenance Manual

10.

11.

12.

B.

Check PPU clearance and orientation

C.

Replace PPU

F:E,F,H,J = Left/Right EDC Coil, Short or Open A.

Check EDC wiring

B.

Check EDC resistance

C.

Replace EDC

F:L = System Error Lamp A.

Replace lamp

B.

Check wiring

COM A.

Program controller with proper software (install latest version of K13944 with FEPS)

Calibration 1.

2.

3.

4.

5.

Cannot get Into CAL.mode: A.

Is green power light ON?

B.

Is FNR in neutral and neutral switch closed?

C.

Check function of CAL switch

D.

Use GPI to check sensor A/D values and state of neutral switch

Rotary sensor will not calibrate: A.

Use GPI to verity A/D limits are within range

B.

Adjust fix mechanical linkage

C.

Verify output voltage with linkage disconnected.

D.

Replace sensor

Neutral switch will not calibrate: A.

Check switch and wiring

B.

Use GPI to verify A/D limits of FNR are within range when switch closes

EDC/Motor PPU will not calibrate: A.

Does it calibrate at full throttle, ITA, warm/cold. etc.

B.

Adjust EDC null.

Engine PPU will not calibrate: A.

Use GPI to verify PPU Is OK at low idle and high idle

B.

Use GPI to verify indicated speed at low and high idle is within limits

Cycle Modes 1.

Can not run in Cycle Mode A.

Check instructions

B.

Use GPI to verify command is changing.

5022-7103E-R1 Operation and Maintenance Manual

Troubleshooting 6-9

2.

Stops during Cycle Mode

Check Fail Log in GPI to determine cause of Fault.

6-10 Troubleshooting

5022-7103E-R1 Operation and Maintenance Manual

7SPECIFICATION GENERAL SPECIFICATIONS ITEM Equipment type

DESCRIPTION Dozer

Model

DD80L

Manufacturer

Daewoo Heavy Industries

Machine class

8 ton

Operating weight

DD80 17,526 lb (7,950 kg) DD80L 18,519 lb (8,400 kg)

Gradeability

35° (no load)

ENGINE Model

Daewoo DB58

Displacement

353 cu. in. (5.785 liter)

Bore and stroke

102 mm x 118 mm (4.02 in. x 4.65 in.)

Output

89 hp @ 1800 rpm (90 ps @ 1800 rpm)

Maximum torque

239 lb-ft @ 1600 rpm (33 kg m @ 1600 rpm)

Cycle

4

Cylinders

6

Cooling system

Water cooled

Fuel type

Diesel

Starting system

24V electric motor

Battery

(2) 12V @ 100AH

Automatic Horsepower Control: Engine performance and fuel efficiency has been maximized by incorporating an engine output controller which automatically adjusts the engine output based on the load throughout the speed range.

When the anti-stall system senses an overload, the controller adjusts the engine speed to the maximum torque level by monitoring the load to prevent the engine from stalling.

FINAL DRIVE Rotating housing, planetary type final drive.

Bolt-on type sprockets HYDROSTATIC TRANSMISSION (HST) Variable displacement hydraulic pump and motor are connected in closed circuit and permits smooth forward and reverse travel. Left and right track speeds are independently controllable and allows 360O turns within its own machine length for the most efficient operation. The forward and reverse direction is selected by the in-line pattern select lever.

Maximum speed (forward & reverse)

7.27 mph (11.7 km/hr)

5022-7103E-R1 Operation and Maintenance Manual

Specification 7-1

ITEM

DESCRIPTION

TRAVEL AND BRAKING Travel and braking are controlled by 2 travel pedals and 1brake pedal. The travel speed is reduced in proportion to the amount of pressure applied to the travel pedals. When one of the pedals are depressed to the detent position the dozer will make a pivot turn, when the brakes are applied while traveling, the swashplate angle will change and the hydraulic brakes will be activated. The mechanical brake are activated when the engine is shut off or the brake pedal is locked in the parking position.

Emergency travel (limp home) system: When malfunction is detected the warning lamp will become lit and the machine will automatically shut down. The limp-home system can be used to move the machine to a safe location for inspection or repair.

UNDERCARRIAGE SALT (Sealed and Lubricated Track) type link have been incorporated for increased durability. 2-piece Master Link system has been selected for increased serviceability and replacement. The hydraulic track adjust system for track tension adjustment allows for easy maintenance.

Suspension

Rigid type

Track and roller frame

Box section construction

Rollers and idlers

Lubricated idlers, carrier rollers are sealed with floating seals

Number of track rollers (each side)

6

Number of carrier rollers (each side)

1 DD80

Track shoes

DD80L

Only 18 in. single grouser shoe

STD: 30 in. single grouser shoe OPT: 18 in. single grouser shoe

Number of shoes (each side)

39

39

Width of standard shoe (Single Grouser)

18 in. (457 mm)

30 in. (762 mm)

Length ground

80.9 in. (2,055 mm)

80.9 in. (2,055 mm)

Ground contact area with standard shoe

2,911 sq. in. (1.88 m2)

4,854 sq. in. (3.13 m2)

Track gauge

59.8 in. (1,520 mm)

70.9 in. (1,800 mm)

Ground pressure

5.26 psi (0.37 kg/cm2)

3.41psi (0.24 kg/cm2)

of

track

on

OPERATING EQUIPMENT Blade type

6 way angle tilt

Max. tilt distance/angle

470 mm / 25°

Blade width

3100 mm

Blade height

866 mm

Blade capacity

2.3 cu. yd. (1.76 m3)

Max. drawbar pull

22,690 lb (10292 kg)

7-2 Specification

5022-7103E-R1 Operation and Maintenance Manual

ITEM

DESCRIPTION

TRACK Shoe type

single grouser

Shoe width

18 in. (457 mm) or 30 in. (762 mm)

Track width (from center to center)

71 in. (1803 mm)

Track height

827 mm

Ground pressure

5.26 psi (0.32 kg/cm2) or 3.41 psi (0.24 kg/cm2)

FLUID CAPACITIES Fuel tank

70 gal (265 liters)

Hydraulic oil

32 gal (121 liters)

Coolant

3.75 gal (14.2 liters)

Engine oil

3.2 gal (12.0 liters)

Final drive (one each side

1.2 gal (4.5 liters)

5022-7103E-R1 Operation and Maintenance Manual

Specification 7-3

457(1'6") 457(1'6") 762(2'6") 1520(4'11") /1800(5'10") 762(2'6") 2704 (8'10")

56(2")

868(2'10")

1070(3'6")

336 (1'1")

415(1'4")

2659.6(8'8")

2720 (8'11")

OVERALL DIMENSIONS

2055(6'9") 1042.5(3'5")

2840.6(9'4")

173.4(7")

4169(13'8")

HAOK850L

457(1'6") 457(1'6") 762(2'6") 1520(4'11") /1800(5'10") 762(2'6") 2704 (8'10")

56(2")

868(2'10")

1070(3'6")

336 (1'1")

415(1'4")

2659.6(8'8")

2729(8'12")

Figure 2

1042.5(3'5")

2055(6'9") 2840.6(9'4") 4169(13'8")

173.4(7")

HAOK860L

Figure 3

7-4 Specification

5022-7103E-R1 Operation and Maintenance Manual

8INDEX Engine Coolant Water Temperature Gauge 2-14 Engine Fan Belt 4-16 Engine Oil And Filter 4-15 Engine Oil Level 4-7 Engine Oil Pressure Warning Light 2-8 Engine Start 3-3 Engine Start and Stop 3-2

Numerics 10 Hour / Daily Service 4-7 1000 Hour / 6 Month Service 4-27 150 Hour Service 4-16 1500 Hour Service 4-30 2000 Hour / Yearly Service 4-30 250 Hour / Monthly Service 4-17 4000 Hour / Biennial Service 4-31 50 Hour / Weekly Service 4-13 500 Hour / 3 Month Service 4-24

F

A

Fuel Filter 4-9 Fuel gauge 2-14 Fuel Level 4-8 Fuel Tank Drain Valve 4-9 Fuel Tank Suction Strainer Fuse Box 4-33 Fuses 4-33 Fusible Link 2-23

Air Cleaner Element Warning Light 2-13 Air Intake Precleaner 4-11 Air Intake System Inner Air Cleaner Element 4-30 Outer Element Of Air Cleaner 4-17 Replace Outer Air Cleaner Element 4-30 Automatic Travel Speed Control 3-11

G

B

Gauges Engine Coolant Water Temperature Gauge

Battery 4-32 Battery Box Door 2-28 Blade Cylinder and Attachment Pins Bolt And Nut Inspection 4-48 Bucket 4-35 Tooth 4-35

2-14 Fuel gauge 2-14 Hour meter 2-14 Tachometer 2-9

4-13 H

C Charge Warning Light 2-8 Check and Confirmation After Stopping Engine

3-11 Circuit Breaker 2-23 Cold Weather Hydraulic System Warm-Up Cold Weather Starting 3-5 Component Locations 2-2 Cooling Systems Clean Radiator and Oil Cooler 4-21 Radiator Coolant 4-25 Refill Cooling System 4-10 Cracks and Faulty Welds 4-11

3-9

D Door Side Latch

2-27

E Electrical System Engine 6-1

4-28

4-32, 6-3

5022-7103E-R1 Operation and Maintenance Manual

Handling a New Excavator 3-1 Hour meter 2-14 Hydraulic Oil Exchange 4-27 Hydraulic Oil Filter 4-15, 4-22 Hydraulic Oil Tank 4-7 Hydraulic System Warm-up 3-8 Hydraulic Systems 6-2 Hydraulic Oil Exchange 4-27 Hydraulic Oil Filter 4-15, 4-22 Hydraulic Oil Tank 4-7 Leaks In the Hydraulic System

4-8, 4-10

I Indicator Lights Air Cleaner Clogging Warning Light 2-13 Charge Warning Light 2-8 Engine Oil Pressure Warning Light 2-8 Preheating Completion Light 2-13 Inner Air Cleaner Element 4-30 Inspecting Engine Before Starting 3-2 Inspection, Maintenance, and Adjustment 4-1

Index 8-1

Specification 7-1 Starter Switch 2-11 Starting Engine Using a Booster battery 3-7 Start-up Cold Weather Hydraulic System Warm-Up

L Leaks In the Cooling System 4-10 Leaks In the Fuel System 4-9 Leaks In the Hydraulic System 4-8 Levers Adjusting the Seat Forward 2-25 Angle Adjustment of Armrest 2-25 Light Switch 2-11 Loading and Unloading 5-1 Locations of Safety Labels 1-3 Long Term Storage 4-50

3-9 Cold Weather Starting 3-5 Engine Start 3-3 Hydraulic System Warm-up 3-8 Inspection Before Starting Engine 3-2 Starting Engine Using a Booster battery Stereo 2-15, 2-16 Am/Fm Band Selection 2-17 Automatic Memory (AME) 2-17 Automatic Selection 2-17 Balance / Fader Control 2-16 Bass/Treble Control 2-16 Care of Stereo 2-18 Cassette Slot 2-17 Dolby B Selection 2-18 LED Display Panel 2-18 Metal Selection 2-18 On-Off / Volume Control Knob 2-16 Play Direction Button 2-17 Tape Eject Button 2-17 Suction Strainer 4-27 Switches Automatic Travel Speed Control 3-11 Light Switch 2-11 Starter Switch 2-11 Washer Switch 2-10 Wiper Switch 2-11

M Maintenance In Special Conditions 4-49 Maintenance Intervals 4-5 Miscellaneous Access Doors 2-28 Miscellaneous Electrical Devices 2-23

O Oil Level of Travel Reducer 4-15 Operating Controls 2-1 Operating Instructions 3-15 Operating Precautions 3-17 Operation 3-1 Operational Controls and Panels 2-7 Operator’s Area 2-3 Operator’s Compartment Light 2-23 Outer Air Cleaner Element 4-30 Outer Element Of Air Cleaner 4-17

P Parking Excavator 3-19 Preheating Completion Light 2-13 Preliminary Work Machine Maintenance 4-2

T Setup

for

R Radiator Coolant 4-25 Refill Cooling System 4-10

S Safety 1-1 Safety Precautions 4-1 Seat Adjustment 2-25 Adjusting the Seat Forward 2-25 Angle Adjustment of Armres 2-25 Seat Belt 2-26 Serial Numbers 4-1 Shipping and Transportation 1-17 Shutdown Check and Confirmation After Stopping Engine 3-11 Parking Excavator 3-19

8-2 Index

3-7

Table of Recommended Lubricants Tachometer 2-9 Towing Procedure 3-20 Track Tension 4-46 Transportation 5-1 Travel 3-11 Travel Instructions 3-12 Travel Reducer 4-15, 4-22, 4-24 Travel System 6-4 Troubleshooting 6-1

4-3

U Unloading and Loading

5-1

V Venting And Priming Hydraulic System

4-32

W Washer Switch

2-10

5022-7103E-R1 Operation and Maintenance Manual

Window Washer Liquid

4-10

5022-7103E-R1 Operation and Maintenance Manual

Wiper Switch 2-11

Index 8-3