DOOSAN 015 PLUS EXCAVATOR OPERATION AND MAINTENANCE MANUAL 022 000 18CE - PDF DOWNLOAD

Solar 015 PLUS Operation and Maintenance Manual 022-00018CE Serial Number 1001 thru 1157 Serial Number 20001 thru 20065 Serial Number 20066 and 30000 May 2004

Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. 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.

022-00018CE Operation and Maintenance Manual

Copyright 2004 Daewoo

TABLE OF CONTENTS Safety ......................................................................................... 1-1 To the Operator of a Daewoo Excavator ............................................ 1-1 General Safety Essentials .................................................................. 1-3 Location of Safety Labels ................................................................... 1-4 Summary of Safety Precautions for Lifting ......................................... 1-8 Work Site Precautions........................................................................ 1-9 Operation.......................................................................................... 1-13 Equipment ........................................................................................ 1-19 Maintenance..................................................................................... 1-23 Shipping and Transportation ............................................................ 1-26 Excavator Rated Lift Capacity Tables............................................... 1-27

Operating Controls ................................................................... 2-1 Component Locations ........................................................................ 2-2 Operator's Area .................................................................................. 2-3 Instrument Panel .............................................................................. 2-11 Seat Adjustment ............................................................................... 2-15 Seat Belt........................................................................................... 2-15 Front Window ................................................................................... 2-16 Door Side Latch................................................................................ 2-17 Miscellaneous Electrical Devices ..................................................... 2-18 Ashtray ............................................................................................. 2-19 Window Glass Breaking Tool............................................................ 2-19

Operation................................................................................... 3-1 To Handle a New Excavator ............................................................... 3-1 Starting and Stopping The Engine ..................................................... 3-2 Safety Lever ..................................................................................... 3-14 Travel ................................................................................................3-15 Operating Precautions...................................................................... 3-24

022-00018CE Operation and Maintenance Manual

Table of Contents I

Parking Excavator ............................................................................ 3-33 Towing Procedure............................................................................. 3-35 Hydraulic Breaker............................................................................. 3-36 Operating Techniques ...................................................................... 3-41 Operation Under Unusual Conditions............................................... 3-43

Inspection, Maintenance and Adjustment.............................. 4-1 Preventive Maintenance ..................................................................... 4-1 Preliminary Work Machine Setup for Maintenance ............................4-3 Table of Recommended Lubricants.................................................... 4-5 Fluid Capacities.................................................................................. 4-7 Lubrication and Service Chart............................................................ 4-7 Maintenance Intervals ...................................................................... 4-10 10 Hour / Daily Service ....................................................................4-12 50 Hour / Weekly Service................................................................. 4-20 250 Hour / Monthly Service.............................................................. 4-25 500 Hour / 3 Month Service ............................................................. 4-32 1,000 Hour / 6 Month Service .......................................................... 4-36 2,000 Hour / Yearly Service.............................................................. 4-39 4,000 Hour / Biennial Service...........................................................4-42 12,000 Hour / Six Year Service ........................................................ 4-43 Bolt and Nut Inspection ....................................................................4-44 Bucket .............................................................................................. 4-45 Electrical System.............................................................................. 4-49 Engine Cooling System ....................................................................4-52 Long Term Storage........................................................................... 4-54 Maintenance in Special Conditions .................................................. 4-54 Track Tension ................................................................................... 4-56 Venting and Priming Hydraulic System ............................................ 4-58

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

II Table of Contents

022-00018CE Operation and Maintenance Manual

Troubleshooting........................................................................ 6-1 Attachments ....................................................................................... 6-1 Center Joint ........................................................................................ 6-1 Control Lever ...................................................................................... 6-1 Control Valve ...................................................................................... 6-2 Hydraulic Cylinder .............................................................................. 6-2 Hydraulic Motor .................................................................................. 6-3 Hydraulic Pump .................................................................................. 6-3 Relief Valve ........................................................................................ 6-4 Swing System..................................................................................... 6-4 Travel ..................................................................................................6-5

Specification ............................................................................. 7-1 General Specifications ....................................................................... 7-1 Working Range................................................................................... 7-8 Approximate Weight of Workload Materials ....................................... 7-9

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

022-00018CE Operation and Maintenance Manual

Table of Contents III

1SAFETY TO THE OPERATOR OF A DAEWOO EXCAVATOR DANGER! Unsafe use of the excavator 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 1-3

2.

"Location of Safety Labels" on page 1-4

3.

"Summary of Safety Precautions for Lifting" on page 1-8

4.

"Work Site Precautions" on page 1-9

5.

"Operation" on page 1-13

6.

"Equipment" on page 1-19

7.

"Maintenance" on page 1-23

8.

"Shipping and Transportation" on page 1-26

9.

"Excavator Rated Lift Capacity Tables" on page 1-27

022-00018CE Operation and Maintenance Manual

Safety 1-1

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.

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.

1-2 Safety

022-00018CE Operation and Maintenance Manual

GENERAL SAFETY ESSENTIALS ACCESSORY APPLICATIONS The excavator has been primarily designed for moving earth with a bucket.

Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.

NEVER USE MACHINE FOR LIFTING. The excavator is designed for excavating and loading only.

The excavator is not equipped for lifting and does not have safety devices for lifting.

HKA1013L

Figure 1

022-00018CE Operation and Maintenance Manual

Safety 1-3

LOCATION OF SAFETY LABELS 6

4

CABIN TYPE (OPTION)

5

3

1 2

AKO0680L

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.

1-4 Safety

022-00018CE Operation and Maintenance Manual

1.

WARNING FOR OPERATION, INSPECTION MAINTENANCE (2190-2627, 190-00092)

CAUTION! Read manual and labels before operation and maintenance.

Follow instructions and warnings in manual and on labels on machine.

For transporting the machine, the swing lock must be hung on.

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:

2.

ACO1360L

•

Lower bucket or other working tools to the ground.

•

Turn starter switch OFF. Remove key from switch.

•

If hydraulic components and units are ABNORMAL, consult nearest DAEWOO dealer or authorized service shop. Do not attempt to make an overhaul.

WARNING FOR ENGINE FAN (2190-3315, 190-00557)

WARNING! Keep your hands away from the fan during operation. Entanglement in the fan can cause serious injury.

AMO0390L

022-00018CE Operation and Maintenance Manual

Safety 1-5

3.

KEEP OFF OF THE SWING AREA (2190-2590, 190-00163)

DANGER! KEEP OFF OF SWING AREA

ACO1430L

4.

WARNING FOR HIGH TEMPERATURE WATER (2190-2531, 190-00097)

WARNING! To prevent hot water from spurting out: •

Turn engine off.

•

Allow water to cool.

•

Slowly loosen cap to pressure before removing.

relieve

ACO1410L

1-6 Safety

022-00018CE Operation and Maintenance Manual

5.

WARNING TAG (2190-2549, 190-00098)

WARNING! Do not touch when performing inspection or maintenance.

ACO1450L

6.

WARNING WHEN OPENING FRONT WINDOW (2190-2526, 190-00093) (IF EQUIPPED WITH CAB)

WARNING! When raising window, lock it in place with lock pins on both sides.

Falling window can cause injury.

ACO1360L

022-00018CE Operation and Maintenance Manual

Safety 1-7

SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING DANGER! Unsafe use of the excavator while making rated lifts could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property. Do not let anyone operate the machine unless they've been properly trained and understand the information in the Operation and Maintenance Manual.

To lift safely, the following items must be evaluated by the operator and the work site crew.

•

Condition of ground support.

•

Excavator configuration and attachments.

•

Weight, lifting height and lifting radius.

•

Safe rigging of the load.

•

Proper handling of the suspended load.

Tag lines on opposite sides of the load can be very helpful in keeping a suspended load secure, if they are anchored safely to control points on the ground.

WARNING! NEVER wrap a tag line around your hands or body.

NEVER rely on tag lines or make rated lifts when wind gusts are more than 48.3 km/h (30 MPH).

Be prepared for any type of wind gust when working with loads that have a large surface area.

WARNING! If you need more information or have any questions or concerns about safe operating procedures or working the excavator correctly in a particular application or in the specific conditions of your individual operating environment, please consult your local Daewoo representative.

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.

1-8 Safety

022-00018CE Operation and Maintenance Manual

WORK SITE PRECAUTIONS ATTACHMENT PRECAUTIONS Options kits are available through your dealer. Contact Daewoo for information on available one-way (single-acting) and two-way (double-acting) piping/valving/auxiliary control kits. 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.

AVOID HIGH VOLTAGE CABLES Serious injury or death can result from contact or proximity to high voltage electric lines. The bucket does not have to make physical contact with power lines for current to be transmitted.

A

Use a spotter and hand signals to stay away from power lines not clearly visible to the operator.

Voltage

Minimum Safe Distance

6.6 kV

3 m (9' 10")

33.0 kV

4 m (13' 1")

66.0 kV

5 m (16' 5")

154.0 kV

8 m (26' 3")

275.0 kV

10 m (32' 10")

HKB1012L

Figure 2

Use these minimum distances as a guideline only. Depending upon the voltage in the line and atmospheric conditions, strong current shocks can occur with the boom or bucket as far away as 4 - 6 m (13 - 20 ft) from the power line. Very high voltage and rainy weather could further decrease that safety margin.

NOTE:

Before starting any type of operation near power lines (either above ground or buried cable type), you should always contact the power utility directly and work out a safety plan with them.

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.

HKA1009L

Figure 3

022-00018CE Operation and Maintenance Manual

Safety 1-9

BE AWARE OF HEIGHT OBSTACLES Any type of object in the vicinity of the boom 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 or balanced load may also be hazardous.

HKA1010L

Figure 4

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. Halt work and install support mats or blocking if work is required in an area of poor track support.

USE SOLID SUPPORT BLOCKING Never rely on lift jacks or other inadequate supports when work is being done. Block tracks fore and aft to prevent any movement.

OVERHANGS ARE DANGEROUS Digging the work face under an overhang – the work area beneath a cliff or under the edge of a ditch – is dangerous. Know the height and reach limits of the excavator and plan ahead while working. Avoid creating dangerous situations by moving around the work site while making excavations. Go onto another digging area before steep overhangs are formed. Working around deep pits or along high walls or trenching may require support blocks, especially after heavy rainfalls or during spring thaws. Park the excavator away from overhangs before work shut down.

1-10 Safety

HKA1006L

Figure 5

022-00018CE Operation and Maintenance Manual

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 and cycling rate of the workload is recommended.

A

On sloping surfaces, use caution when positioning the excavator before starting a work cycle. Stay alert for unstable situations to avoid getting into them. For example, you should always avoid working the bucket over downhill crawler tracks when parked perpendicular to the slope. Slow all downhill swing movements and avoid full extensions of the bucket in a downhill direction. Lifting the bucket too high, too close to the machine, while the excavator is turned uphill can also be hazardous.

•

Raise bucket when encountering small obstacles.

•

Keep bucket 20 - 30 cm (8 - 12") off ground when driving on slopes.

•

If machine slips, lower bucket to ground and stop immediately.

•

When traveling on level ground, bring front attachment in and raise bucket 40 - 50 cm (15 - 20") with teeth facing up.

022-00018CE Operation and Maintenance Manual

A HKA1003L

Figure 6

Safety 1-11

STAY ALERT FOR PEOPLE MOVING THROUGH THE WORK AREA When loading a truck you should always know where the driver is.

Avoid loading over the cab of a truck even if the driver is in a safe spot. Someone else could have gone inside, for any number of reasons.

Avoid working where unseen passersby might be.

Slow down the work cycle 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.

HAOA170L

Figure 7

Check for hazards in the work area before starting and moving.

•

Use horn or other signal to warn others when you start and move the machine.

•

Use a signal man whenever the operator's vision is obstructed in any way. Make sure the signal man is in sight of the operator at all times.

•

Agree on signals before operation.

•

Keep bystanders and obstacles out of work area.

•

Keep work areas well lighted at night.

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.

1-12 Safety

022-00018CE Operation and Maintenance Manual

OPERATION OPERATE WHILE SEATED AT THE OPERATOR'S STATION ONLY Never reach in through a window to work a control. Do not try to operate the excavator unless you're in the command position stay alert and focused on your work at all times but Do not 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.

HAOA150L

Figure 8

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

ADJUST SEAT If the driver's seat is not adjusted correctly, the operator may become easily fatigued and injury and/or damage could result.

•

Be sure to adjust the driver's seat at the beginning of each work period.

•

Adjust driver's seat so that the operator can easily reach the pedals while his back is firmly against the lumbar support of the seat.

BEFORE STARTING THE ENGINE Do a "prestart" 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.

•

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 before start-up.

•

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

022-00018CE Operation and Maintenance Manual

Safety 1-13

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 9 MOUNTING AND DISMOUNTING NEVER get on or off a moving machine. Do not 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 10 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 excavator.

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 work 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.

ENGINE VENTILATION Engine exhaust gases can cause fatal accidents, and 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 11

1-14 Safety

022-00018CE Operation and Maintenance Manual

ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. Materials containing asbestos fiber can be present on work site.

Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage.

To prevent lung damage from asbestos fiber, observe following precautions; •

Use a respirator that is approved for use in an asbestos-laden atmosphere.

•

Never use cleaning.

compressed

air

for

•

Use water for cleaning to keep down the dust.

•

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

•

Always observe any rules and regulations related to the work site and working environment.

ARO1770L

Figure 12

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 of windows and off the lens surfaces of work lights. Stop working if lights, windows or mirrors need cleaning or adjustment.

NEVER CARRY PEOPLE IN OR ON THE MACHINE Never transport other persons in or on the machine.

Riders restrict visibility, reduce concentration and may cause and/or be subject to injury.

HKA1008L

Figure 13

022-00018CE Operation and Maintenance Manual

Safety 1-15

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.

HAOA120L

Figure 14

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 series Figure 15 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 nonseries 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 "Starting Engine With a Booster Cable" on page 3-8 of 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.

1-16 Safety

022-00018CE Operation and Maintenance Manual

TRAVEL CONTROLS MAY PRODUCE REVERSED OPERATIONS Before starting the machine you should always check to see which end of the track frame is under the operator's cab. In the normal travel configuration, track frame travel motors are at the rear of the machine, under the engine and counterweight. If the operator swings the cab 180°, travel motors will be underneath the operator's cab, toward the front of the track frame and operating travel will be reversed.

When traveling the excavator always keep lights on; make sure that you are in compliance with all state and local regulations concerning warning flags and signs and keep the operator's cab positioned over the idler end of the track frame. That will keep travel controls in their intended configuration and at the same time, maintain the proper orientation of lights on the machine and posted flags and signs.

KEEP "PINCH POINT" AREAS CLEAR - USE CAUTION IN REVERSE AND SWING Use a signal person in high traffic areas and whenever the operator's view is not clear, such as when traveling in reverse. Make sure that no one comes inside the swing radius of the machine.

Anyone standing near the track frames, or working assemblies of the attachment, 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 turntable or operator's cab.

HAOA190L

Figure 16

TRAVEL PRECAUTIONS Attachment control levers should not be operated while traveling.

Do not change selected travel mode (FAST/SLOW) while traveling.

Fold in work equipment so that the outer end of the boom is as close to the machine as possible, and is 203 mm – 304 mm (8" – 12") above ground.

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

022-00018CE Operation and Maintenance Manual

Safety 1-17

PARKING 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 excavator will be on firm, level ground 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 bucket or other working attachment completely to the ground, or to an overnight support saddle.

There should be no possibility of unintended or accidental movement.

SHUTDOWN CONTROL FUNCTIONS After the machine has been lowered to the overnight storage position and all switches and operating controls are in the "OFF" position, the control stand lock lever must be engaged.

Release the left console to disable all pilot circuit control functions.

HKA1004L

Figure 17

Insert the swing lock pin and engage all brakes and lock-down security equipment that may have been installed on the machine.

IMPORTANT When hydraulic system maintenance or service work must be performed, you should be aware that an accumulator in the system stores fluid under pressure after system lock down, even after the control stand is raised. Release this energy by working controls with the engine off, until pressure in the pilot circuit has been completely bled away.

1-18 Safety

022-00018CE Operation and Maintenance Manual

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 TOPS/Tip Over Protective Structure reinforcement system.

HAOA110L

Figure 18 Any reinforcement system that is installed on the machine must pass safety and certification standards and carry appropriate labeling and rating information.

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 19 INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE When working with a breaker or in some shear 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.

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 excavator and safe from potential hazards.

MOVEMENT ALARMS If the excavator is equipped with an audible travel movement alarm or visible swing movement alarm (strobe light), test the alarm on a daily basis. The audible alarm should sound as soon as the travel system is engaged. The strobe light should begin to flash as soon as the swing system is engaged.

022-00018CE Operation and Maintenance Manual

Safety 1-19

PROTECT YOURSELF FROM FLYING OR FALLING OBJECTS Wear safety glasses when operating in dusty or sandy conditions or when rock fragments could be thrown up by operation. Also wear protection when carrying out maintenance such as removing or installing the bucket pin, etc.

HFB1025L

Figure 20 WINDOW GLASS BREAKING TOOL This excavator is equipped with a glass breaking tool. It is behind the operator seat in the upper left corner of the cab. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the operator's cabin. Grip the handle firmly and use the sharp point to break the glass.

WARNING! Protect your eyes when breaking the glass.

Figure 21

KEEP A FIRE EXTINGUISHER AT HAND It is recommended that an appropriately sized (2.27 kg [5 lb.] or larger) multipurpose "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 22

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 "Location of Safety Labels" on page 1-4 of this section.

1-20 Safety

022-00018CE Operation and Maintenance Manual

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 Excavator 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 arm or boom could react with explosive force if struck by a falling rock, overhead obstacle or other work site hazard. Extra safety guards may be required. NEVER allow hoses to be hit, bent or interfered with during operation.

THE OPERATOR'S CAB AND TURNTABLE 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.

CLOTHING AND PERSONAL PROTECTIVE ITEMS Contain long hair, and avoid loose clothing and jewelry. They can catch on controls or in protruding parts and cause serious injury or death.

Do not wear oily clothes. They are highly flammable.

Full eye protection, a hard hat, safety shoes and gloves may be required at the work 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.

022-00018CE Operation and Maintenance Manual

HAOA020L

Figure 23

Safety 1-21

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

NOTE:

The equivalent continuous A-weighted sound pressure level at the workstation for this machine is 80 dB(A).

Measurement is obtained on a dynamic machine following the procedures and cab conditions as described in ISO 6396.

NOTE:

The guaranteed sound power level emitted by the machinery for this machine is 95 dB(A).

Measurement is obtained on a dynamic machine with the procedures as described in 2000/14/EC.

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 24

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.

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

1-22 Safety

022-00018CE Operation and Maintenance Manual

MAINTENANCE KEEP MACHINE CLEAN AT ALL TIMES Keep machine free of oil and grease at all times.

Water will damage the electrical system. Never use water or steam on the inside of the cab, in the engine compartment or in any location where it may reach sensors, connectors or other electrical components.

HFB1030L

Figure 25 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. OSHA mandated control lever lockout can be made with any OSHA certified lockout device and a length of chain or cable to keep the left-hand control console in the fully raised, nonactive position.

Warning tags for controls are available from Daewoo distributors.

WARNING

HAOC920L

Figure 26

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.

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.

90 ~ 100

HBOH810L

Figure 27

022-00018CE Operation and Maintenance Manual

Safety 1-23

WARNING FOR COUNTERWEIGHT AND FRONT ATTACHMENT REMOVAL

DANGER! Daewoo warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries. Daewoo is not liable for any misuse.

Never remove the counterweight or front attachment unless the upper structure is in-line with the lower structure.

X

X

Never rotate the upper structure once the counterweight or front attachment has been removed.

HAAD4060

Figure 28

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

NOTE:

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

COOL DOWN IS REQUIRED BEFORE RADIATOR OR RESERVOIR CHECKS Shut down 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, before removal.

HAOA060L

Figure 29

1-24 Safety

022-00018CE Operation and Maintenance Manual

PRECAUTIONS WITH HIGH-PRESSURE LINE, TUBES AND HOSES When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released from the circuit. Failure to release the pressure may lead to serious injury. Always do the following; •

Wear protective glasses and leather gloves.

•

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.

•

Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install lines, tubes or hoses that are bent or damaged.

•

Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration, rubbing against other parts, and excessive heat during operation.

–

If any of the following conditions are found, replace the part.

–

Damage or leakage from hose end.

–

Wear, damage, cutting of covering, or exposure of strengthening wire layer.

–

Cover portion is swollen in places.

–

There is twisting or crushing at movable parts of hose.

–

Foreign material is embedded in the covering.

–

Hose end is deformed.

Refer to "Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)" on page 4-43, for additional European regulations.

NOTE:

X

X

O

HAOA420L

Figure 30 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.

022-00018CE Operation and Maintenance Manual

Safety 1-25

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

X

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 petroleum based 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 31

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 before 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 excavator may be necessary to meet travel restrictions or particular conditions at the work site. See the Shop Manual for information on partial disassembly.

Refer to the Transportation and Shipping section of this Operation and Maintenance Manual for information on loading, unloading and towing.

1-26 Safety

022-00018CE Operation and Maintenance Manual

EXCAVATOR RATED LIFT CAPACITY TABLES WARNING! All rated lift capacities are based on the machine and the load both remaining level at all times.

DO NOT EXCEED THE RATED LIFT CAPACITY. Lifting loads greater than those shown in the rated capacity tables can cause catastrophic equipment failure and/or structural collapse of the machine.

To operate safely the excavator should be on a firm, level and uniformly supporting surface. The operator is expected to make due allowance for all specific work site and lift related conditions, and respond to changes in those conditions that could pose a hazard. The following could all cause hazardous conditions and accidents or injuries: •

Soft or uneven ground

•

Unlevel terrain

•

Side loads

•

Modifications or poor maintenance of the excavator

•

Failure to lift squarely over the end or over the side of the machine

When a load is in the air, the operator must remain alert.

•

Avoid side loads that may be caused by uneven slings, traveling with the load or swinging too quickly.

•

The load can become unbalanced if the hook line is twisted and starts to rotate. If the surface area of the load is large enough, wind gusts can create side loads.

•

Keep the bucket hook point directly over the load. Tag lines on opposite sides of the load can help maintain greater stability against side loads and wind gusts.

Avoid traveling with a suspended load. Before swinging (or if required, traveling), bring the load in to an arm position (radius and height) that has a safer weight capacity rating and adequate movement clearance.

The operator and all work site personnel should be thoroughly familiar with safety instructions and procedures within this Operation and Maintenance Manual.

WARNING! Lower the dozer blade to the ground to unload the chassis frame from weight of blade. By no way lift the chassis frame with the dozer blade which is not designed to increase the stability when performing a lifting task.

022-00018CE Operation and Maintenance Manual

Safety 1-27

Centerline of Rotation

Lifting radius

Lifting Point Height

Ground Line(Machine Supporting Surface) AXO0150L

Figure 32 The weight of slings and any auxiliary lifting device (and/or the weight difference of any attachment heavier than standard configuration) must be deducted from the rated lift capacity to determine allowable net lifting load. The lift point should be located on the back of the bucket, as shown in Figure 32.

1-28 Safety

022-00018CE Operation and Maintenance Manual

LIFTING CAPACITY (WITHOUT DOZER: 0.85M)

TRACK WIDTH BOOM ARM BUCKET SHOE

1.3 m (4' 3") STD TRACK 1.69 m (5' 5") 0.85 m (2' 8") CECE 0.24 m3 HEAPED 230 mm (9")

UNIT

RATING OVER FRONT RATING OVER SIDE OR 360 degree 1,000 kg (1,000 lb)

B

A

METRIC A(m)

2

2.5

MAX. REACH

3

A(m)

B(m) 2.5

* 0.28

* 0.28

2

* 0.28

* 0.28

* 0.29

* 0.29

1.5

* 0.36

* 0.36

* 0.31

* 0.31

1

* 0.47

0.45

0.34

0.32

0.26

0.25

0.5

0.48

0.44

0.33

0.32

0.25

0.24

0

0.47

0.44

0.33

0.32

-0.5

0.47

0.44

0.33

0.31

-1

0.48

0.44

-1.5

* 0.30

* 0.30

2.28

* 0.30

0.29

2.70

0.26

0.25

2.95

0.25

0.24

3.07

0.24

0.23

3.09

0.25

0.24

3.00

0.28

0.27

2.80

* 0.34

0.33

2.44

* 0.31

* 0.31

1.80

FEET 6'

A (ft)

8'

10'

MAX. REACH A (ft)

B (ft) 8' * 0.65

* 0.65

* 1.02 * 0.76

0.75

6' 4'

* 1.02

2'

1.21

1.12

0.77

0.73

0'

1.20

1.10

0.76

0.72

0.75

0.72

-2'

1.20

1.10

-4'

* 1.07

* 1.07

0.55

0.52

* 0.67

* 0.67

7.69

0.63

0.60

9.19

0.56

0.53

9.94

0.54

0.51

10.14

0.56

0.53

9.84

0.64

0.61

8.97

* 0.74

* 0.74

7.26

1. RATINGS ARE BASED ON SAE J1097 2. LOAD POINT IS THE HOOK ON THE BACK OF THE BUCKET. 3. * RATED LOADS ARE BASED ON HYDRAULIC CAPACITY. 4. RATED LOADS DO NOT EXCEED 87 % OF HYD. CAPACITY OR 75 % OF TIPPING CAPACITY. BQO0010L

Figure 33

022-00018CE Operation and Maintenance Manual

Safety 1-29

LIFTING CAPACITY (WITHOUT DOZER: 1.1M)

TRACK WIDTH BOOM ARM BUCKET SHOE

1.3 m (4' 3") STD TRACK 1.69 m (5' 5") 1.10 m (3' 7 ") CECE 0.24 m3 HEAPED 230 mm (9")

UNIT

RATING OVER FRONT RATING OVER SIDE OR 360 degree 1,000 kg (1,000 lb)

B

A

METRIC A(m)

2

2.5

MAX. REACH

3

A(m)

B(m) * 0.28

* 0.28

2.00

2.5

* 0.25

* 0.25

* 0.26

* 0.26

2.62

2

* 0.24

* 0.24

* 0.26

3

0.25

2.98

1.5

* 0.29

* 0.29

* 0.27

* 0.27

* 0.26

0.25

0.24

0.22

3.20

1

* 0.40

* 0.40

* 0.32

* 0.32

0.27

0.25

0.23

0.21

3.31

0.5

0.48

0.45

0.35

0.32

0.26

0.24

0.23

0.21

3.32

0

0.48

0.44

0.34

0.32

0.26

0.24

0.23

0.22

3.24

-0.5

0.47

0.43

0.34

0.31

0.26

0.24

0.25

0.23

3.06

-1

0.47

0.43

0.34

0.31

0.30

0.27

2.75

* 0.41

* 0.41

* 0.31

* 0.31

2.24

-1.5

FEET 6'

A (ft)

8'

10'

MAX. REACH A (ft)

B (ft) 8'

* 0.52

* 0.52

* 0.57

* 0.57

8.76

6'

* 0.54

* 0.54

* 0.57

0.53

0.57

0.53

10.06

* 0.83 * 0.67

* 0.67

4'

* 0.83

0.58

0.53

0.51

0.47

10.73

2'

1.23

1.13

0.80

0.74

0.57

0.53

0.50

0.46

10.92

0'

1.20

1.10

0.78

0.72

0.57

0.52

0.51

0.47

10.64

-2'

1.19

1.09

0.78

0.72

0.57

0.53

9.87

-4'

1.20

1.10

0.78

0.72

* 0.70

0.67

8.40

1. RATINGS ARE BASED ON SAE J1097 2. LOAD POINT IS THE HOOK ON THE BACK OF THE BUCKET. 3. * RATED LOADS ARE BASED ON HYDRAULIC CAPACITY. 4. RATED LOADS DO NOT EXCEED 87 % OF HYD. CAPACITY OR 75 % OF TIPPING CAPACITY. BQO0020L

Figure 34

1-30 Safety

022-00018CE 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 2-11

4.

"Seat Adjustment" on page 2-15

5.

"Front Window" on page 2-16

6.

"Door Side Latch" on page 2-17

7.

"Miscellaneous Electrical Devices" on page 2-18

8.

"Ashtray" on page 2-19

9.

"Window Glass Breaking Tool" on page 2-19

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 indicator 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 on the control console come "ON," immediately stop operation and shut down unit. Investigate and correct the problem before proceeding with operation.

022-00018CE Operation and Maintenance Manual

Operating Controls 2-1

COMPONENT LOCATIONS

1

2

3

4

23 22

5

6 21 7 20

8 18 17 19

9 10 12

11

13 16

14 15 AKO0011L

Figure 1

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

BOOM ARM CYLINDER T.O.P.S. WORK LEVERS (JOYSTICKS) SEAT ENGINE HOOD HOOD COUNTER WEIGHT MAIN FRAME TRAVEL MOTOR LOWER TRACK ROLLER RUBBER TRACK

2-2 Operating Controls

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

TRACK SPRING IDLER BLADE CYLINDER BLADE SWING BRACKET BOOM CYLINDER BUCKET DUMP LINKAGE BUCKET LINKAGE BUCKET CYLINDER ARM

022-00018CE Operation and Maintenance Manual

OPERATOR'S AREA

14

13

11

10

12

3

8

9 7

1

6 16 17

5

18

19

24V

2

4

15

BQO0040L

Figure 2

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

INSTRUMENT PANEL STARTER SWITCH HORN BUTTON FUSE BOX HEATER SWITCH (WITH CAB) WINDSHIELD WIPER SWITCH (WITH CAB) WORK LEVER (JOYSTICK), RIGHT-HAND WORK LEVER (JOYSTICK), LEFT-HAND BLADE CONTROL LEVER TRAKEL LEVER, RIGHT

022-00018CE Operation and Maintenance Manual

11.

12.

13.

14.

15.

16.

17.

18.

19.

TRAVEL LEVER, LEFT BREAKER PEDAL BOOM SWING PEDAL SAFETY LEVER SWING LOCK PIN WORK LIGHT SWITCH ROTATING BEACON LIGHT SWITCH (OPTION) CIGAR LIGHTER (WITH CAB) TRAVEL SPEED SELECTOR SWITCH

Operating Controls 2-3

1.

INSTRUMENT PANEL See "Instrument Panel"’ on page 2-11.

AKO0040L

Figure 3 2.

STARTER SWITCH Used to start or shut down engine for equipment operation.

A.

D

"ON" Position - Turning the switch to this position turns the engine electrical system on. The battery warning light and the engine oil pressure warning light should be "ON" at this time.

WARNING!

B

A C

HAOC341L

Figure 4

DO NOT USE STARTING FLUIDS. The preheat system could cause the starting fluid to explode. Starting fluids should never be used.

B.

"STOP" Position - 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 (if equipped) is functional.

C.

"START" Position - 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 for more than 10 seconds at a time. This will help prevent damage to starter.

D.

"PREHEATING" Position - Using this position to start in cold weather. When preheating is completed (about 6 second), the preheat indicator light, on the instrument panel will turn "ON." Start the engine immediately after the light turns "ON."

2-4 Operating Controls

022-00018CE Operation and Maintenance Manual

3.

HORN BUTTON (RIGHT-HAND WORK LEVER (JOYSTICK)) Pressing the button on top of right-hand work lever (joystick) causes the horn to sound.

AKO0050L

Figure 5 4.

FUSE BOX A fuse box is in front of the operators seat.

Refer to Figure 6.

Figure 6 5.

HEATER SWITCH (IF EQUIPPED WITH CAB) This is a three position switch used to control the heater and fan.

O.

Off

I.

Low speed

II.

High speed

AKO0070L

Figure 7 6.

WINDSHIELD WIPER AND WASHER SWITCH (IF EQUIPPED WITH CAB)

C

This switch is used both for operating the windshield wipers and ejecting washer fluid.

A.

Turns "ON" windshield wipers.

B.

Turns "ON" windshield wipers and sprays washer fluid while switch is held.

C.

Turns "OFF" wipers.

B

A

HAOD420L

Figure 8

022-00018CE Operation and Maintenance Manual

Operating Controls 2-5

WARNING! Actuating the wipers, when the windshield glass is dry or has sand or dirt on it, will damage the glass or wiper blades.

Actuating the washer switch, when glass cleaner is not available, will damage the washer motor. Check for glass cleaner level and add, as required.

Using soap and water or synthetic detergent instead of glass cleaner will damage the wiper blades or coating surface. Always use the specified glass cleaner.

7.

RIGHT-HAND WORK LEVER (JOYSTICK) WITH HORN BUTTON The work lever(s) can be configured for two different work patterns, ISO and John Deere.

ISO - This lever controls boom and bucket movements. For a more detailed explanation see "Work Levers (Joysticks) (ISO Style)" on page 3-20.

John Deere - This lever controls arm and bucket movements. For a more detailed explanation see "Work Levers (Joysticks) (John Deere)" on page 3-22.

Figure 9

Push button (under the rubber boot) of right-hand work lever (joystick) to sound horn.

8.

LEFT-HAND WORK LEVER (JOYSTICK) The work lever(s) can be configured for two different work patterns, ISO and USA Backhoe.

ISO - This lever controls swing and arm movements. For a more detailed explanation see "Work Levers (Joysticks) (ISO Style)" on page 3-20.

John Deere - This lever controls swing and boom movements. For a more detailed explanation see "Work Levers (Joysticks) (John Deere)" on page 3-22.

2-6 Operating Controls

Figure 10

022-00018CE Operation and Maintenance Manual

9

BLADE CONTROL LEVER The blade control lever, on right-hand side of driver's seat, controls operation of blade. When the lever is released, it goes to the "NEUTRAL" position and the blade stops immediately.

A.

Pushing lever forward lowers blade.

B.

Pulling lever back raises blade.

Figure 11 10 & 11.TRAVEL LEVERS (RIGHT AND LEFT) These levers are used to control forward and reverse travel of the unit. Each lever controls one track. See "Travel"’ on page 3-15.

Figure 12 12.

BREAKER PEDAL The breaker pedal is used to control optional attachments such as a hydraulic breaker.

A.

Pressing pedal activates attachment.

B.

Releasing attachment.

NOTE:

pedal

deactivates

In case of 2-way option piping, pressing pedal B also activates attachment.

Figure 13

022-00018CE Operation and Maintenance Manual

Operating Controls 2-7

13.

BOOM SWING PEDAL This pedal, near the operator's left foot swings the boom. The upper structure (cab, engine compartment, etc.) does not rotate. The pedal is used to dig along a gully wall or a retaining wall.

A.

Pressing the upper end of the pedal swings boom to the left.

B.

Pressing the lower end of the pedal swings the boom to the right.

Figure 14

Figure 15, shows the degrees from upper structure center line that the boom can be moved.

A.

75° to left of upper structure center line.

B.

50° to right of upper structure center line.

NOTE:

A

50

B

75

In case of roof type, A is 90° to left of upper structure center line.

HAOJ961L

Figure 15 14.

SAFETY LEVER This lever is used to lockout (disable) the hydraulic control levers. There is one on the left side of the operator's seat. See "Safety Lever"’ on page 3-14.

Figure 16 15.

SWING LOCK PIN This lever is used to prevent the upper structure from rotating during transportation of the excavator.

A.

Unlocked.

B.

Locked.

Figure 17

2-8 Operating Controls

022-00018CE Operation and Maintenance Manual

16.

WORK LIGHT SWITCH A.

"O" Position - Work light and instrument panel light are "OFF."

B.

"I" Position - Work light and instrument panel light are turned "ON."

O I HAOQ071L

Figure 18 17.

ROTATING BEACON LIGHT SWITCH (OPTION) If unit is equipped with a warning light, push this switch to activate it.

A.

"O" Position - "OFF" position.

B.

"I" Position - Lights turn "ON" and will start flashing.

O I HAOA750L

Figure 19 18.

CIGAR LIGHTER Push the lighter all the way into the socket and release your hand. After pushing it in, it will be ejected when it is heated. If it does not eject after a short time, pull it out and have it serviced.

12V

AIO0080L

Figure 20

022-00018CE Operation and Maintenance Manual

Operating Controls 2-9

19.

TRAVEL SPEED SELECTOR SWITCH This switch is used to select the travel speed.

A.

"O" Position - "LOW" travel speed is selected.

B.

"I" Position - "HIGH" travel speed is selected.

O I

WARNING! Do not change travel speed while traveling especially, changing speed to the high speed when descending slopes will create a very dangerous situation. Always stop the machine before changing the travel speed.

2-10 Operating Controls

HDO2022I

Figure 21

022-00018CE Operation and Maintenance Manual

INSTRUMENT PANEL 3

7

6

4

8

5

1 9

2

AKO0140L

Figure 22

1.

2.

3.

4.

ENGINE COOLANT TEMPERATURE GAUGE FUEL GAUGE HOUR METER ENGINE COOLANT TEMPERATURE WARNING LIGHT

022-00018CE Operation and Maintenance Manual

5.

6.

7.

8.

9.

ENGINE OIL PRESSURE WARNING LIGHT BATTERY WARNING LIGHT LOW FUEL WARNING LIGHT PREHEAT INDICATOR LIGHT AIR CLEANER CLOGGED WARNING LIGHT

Operating Controls 2-11

1.

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

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

GREEN RANGE: Indicates the normal engine operating temperature.

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

2.

AKO0150L

Figure 23

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

Fill the tank before gauge enters RED range.

NOTE:

As fuel reaches 2.4 liters (0.64 U.S. gal.) of fuel a low fuel warning light will turn "ON." AKO0160L

Figure 24 3.

HOUR METER The hour meter shows the cumulative running time.

It can show up to 99,999.9 hours.

This LCD hour meter can be viewed with the starter switch placed in the "ON" position. When the engine begins cranking, the indicator flashes at intervals of about 4 seconds, indicating that the engine is working.

AKO0170L

Figure 25

2-12 Operating Controls

022-00018CE Operation and Maintenance Manual

4.

ENGINE COOLANT TEMPERATURE WARNING LIGHT This light turns "ON" when temperature rises excessively.

coolant

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

If you shut down engine at this time, coolant temperature rises again.

Therefore, do not shut down engine until coolant temperature drops.

HAOD350L

Figure 26 5.

ENGINE OIL PRESSURE WARNING LIGHT This light turns "ON" when the starter switch is placed in the "ON" position. It goes out automatically when the engine is started.

If this light turns "ON" during operation, shut down engine immediately and check the lubrication system of the engine. Do not run the engine with this light "ON" as severe damage to it may occur.

HAOA620L

Figure 27 6.

BATTERY WARNING LIGHT This light turns "ON" in red when the starter switch is placed in the "ON" position. It goes out automatically when the engine is started.

If this light remains "ON" even if the engine has been started, it may indicate that the alternator is not charging the batteries.

Check the electrical system and repair, if necessary.

HAOA610L

Figure 28 7.

LOW FUEL WARNING LIGHT This light indicates when the fuel level in fuel tank reaches 2.4 liters (2.54 U.S. quarts). If light turns "ON," discontinue operation and fill fuel tank.

HKB2010L

Figure 29

022-00018CE Operation and Maintenance Manual

Operating Controls 2-13

8.

PREHEAT INDICATOR LIGHT This light turns "ON" When preheating is completed (about 6 second). Start the engine immediately after the light turns "ON." (0°C (32°F) approximately 1.5 seconds, -15°C (5°F) approximately 5 seconds.)

HAOA639L

Figure 30 9.

AIR CLEANER CLOGGED WARNING LIGHT This light turns "ON" when the air cleaner filter is clogged.

When it comes "ON," clean or replace the element as necessary. Then, if you place the starter switch in the "OFF" position and then "ON" position, this light goes out.

HAOA660L

Figure 31

2-14 Operating Controls

022-00018CE Operation and Maintenance Manual

SEAT ADJUSTMENT

3

FRONT/REAR ADJUSTMENT Moving the adjustment lever (1, Figure 32) moves the seat forward and backward over a range of 160 mm (6.30 in).

2

1

BACKREST ADJUSTMENT Lifting up the adjustment lever (2, Figure 32) on the left of the seat adjusts the seat back to obtain the desired backrest angle.

AKO0180L

Figure 32

ARMREST ADJUSTMENT Adjustment angle of left and right armrest is done by pushing in button (3, Figure 32) on end of armrest. When you adjust the angle, manually raise the armrest before releasing button.

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

Under no circumstances should operator be standing in cab when operating wheel loader.

Do not adjust seat position while vehicle is moving because a loss of control may result. Stop machine, apply parking brake, and then adjust seat.

Always, check 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 33) 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 33

022-00018CE Operation and Maintenance Manual

Operating Controls 2-15

Press button (3, Figure 34) in center of buckle (2) and pull out belt (1) to unlock.

HAOB150L

Figure 34

FRONT WINDOW Installing and removing windshield.

1.

Disconnect wiring connector (1, Figure 35) of windshield wiper motor.

Figure 35 2.

Release lock pins (1, Figure 36) in each corner of top of windshield.

3.

Using the two handles, raise windshield and stow it in the roof.

1 Figure 36 4.

Fasten the two rear lock pins (2, Figure 37) securely.

NOTE:

To install windshield, reverse the order of steps for removal.

2 Figure 37

2-16 Operating Controls

022-00018CE Operation and Maintenance Manual

DOOR SIDE LATCH 1.

The door side latch (1, Figure 38) 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.

HAOB240L

Figure 38 2.

Pull door lock release lever in the direction shown to release door latch lock.

WARNING! When operating the machine with the door open, make sure the door is secured to the door latch.

Figure 39

022-00018CE Operation and Maintenance Manual

Operating Controls 2-17

MISCELLANEOUS ELECTRICAL DEVICES 1.

CAB LIGHT A light is installed on the rear left 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 despite starter switch position.

NOTE:

1

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

HAOD520L

Figure 40 2.

PILOT CUTOFF SWITCH The pilot cutoff switch is by the hinge part of left-hand console. When the safety lever is raised, the switch operates which deactivates the joystick function. With the joysticks deactivated no digging/ operational work can be done.

HAOB080L

Figure 41 3.

CIRCUIT BREAKER A main circuit breaker is in the electrical box in the front right side of the frame. 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 the 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.

2-18 Operating Controls

HAOB090L

Figure 42

022-00018CE Operation and Maintenance Manual

ASHTRAY An ashtray (Figure 43) is to the right side of the operator's seat on the side of the cab. Always close ashtray after putting out a cigarette.

Figure 43

WINDOW GLASS BREAKING TOOL This excavator is equipped with a glass breaking tool. It is behind the operator seat in the upper left corner of the cab. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the operator's cabin. Grip the handle firmly and use the sharp point to break the glass.

WARNING!

Figure 44

Protect your eyes when breaking the glass.

022-00018CE Operation and Maintenance Manual

Operating Controls 2-19

3OPERATION TO HANDLE A NEW EXCAVATOR All Daewoo excavators are inspected and adjusted before 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 60% - 70% load of full capacity (Engine rpm: 60% - 70% 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, fuel, 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 an extreme engine load.

5.

Operate unit at 60% - 70% 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 electrolyte level.

LUBRICATION AND FILTERS 1.

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

2.

Change hydraulic oil filter after first 250 hours of operation.

3.

Replace travel 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.

022-00018CE Operation and Maintenance Manual

Operation 3-1

STARTING AND STOPPING THE ENGINE INSPECTION BEFORE STARTING ENGINE

WARNING! If flammable materials such as leaves, paper, etc. are allowed to accumulate on high temperature components, such as the engine muffler and intake manifold, 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 hour meter.

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 the safety lever to "LOCK" position, if not a serious accident could occur by accidentally moving the joysticks.

1.

2.

Set safety lever (Figure 1) to "LOCK" position.

Fasten seat belt. Check operation and condition.

3-2 Operation

for

Figure 1

proper

022-00018CE Operation and Maintenance Manual

3.

Make sure travel levers (1 and 2), boom swing pedal (4) and blade control lever (3) are in the "CENTER / AT REST" position.

NOTE:

Be careful not to touch any switches when starting engine.

Figure 2 4.

Rotate the starter switch to the "ON" position (Figure 3). 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.

NOTE:

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

GLOW

OFF ON START

AKO0350L

Figure 3

A warning buzzer will sound for about 2 seconds.

022-00018CE Operation and Maintenance Manual

Operation 3-3

ENGINE START

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

1.

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

2.

Set engine accelerator lever slightly above "LOW IDLE" (Figure 4).

3.

Sound horn.

4.

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

Figure 4

GLOW

OFF ON START

WARNING! If the engine does not start after approximately 10 seconds of cranking, release the starter switch.

Wait about 5 minutes and repeat above step.

AKO0360L

Figure 5 5.

6.

After engine has started, release key. Key will return to "ON" position (Figure 6).

GLOW

Follow "Hydraulic System Warm-up" on page 3-10.

OFF

ON START

AKO0400L

Figure 6

3-4 Operation

022-00018CE Operation and Maintenance Manual

7.

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

Normal indicators are shown in the following table.

AKO0040L

Figure 7

Instrument Panel Light or Gauge

8.

9.

Indicator Reading

Engine Coolant Temperature Gauge

GREEN RANGE

Fuel Gauge

GREEN RANGE

Charging Warning Light

OFF

Engine Oil Pressure Warning Light

OFF

Glow Plug Indicator Light

OFF

Engine Coolant Temperature Warning Light

OFF

Air Cleaner Clogged Warning Light

OFF

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, shut down engine. After engine has cooled, check coolant level, look for leaks, clogged or dirty radiator fins (radiator core), and fan belt tension.

022-00018CE Operation and Maintenance Manual

Operation 3-5

COLD WEATHER STARTING

WARNING! DO NOT USE STARTING FLUIDS. 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" on page 3-2.

2.

Set engine accelerator lever (Figure 8) slightly above "LOW IDLE."

3.

Sound horn.

4.

Turn starter switch to "GLOW" (preheat) position (Figure 9). Wait for a few seconds (about 6 seconds). When preheat cycle is completed, the preheat light (Figure 10) will turn "ON."

Figure 8

NOTE:

GLOW

OFF

ON START

Preheating time is adjusted automatically depending on engine coolant temperature.

[0°C (32°F) is approximately 1.5 seconds. -15°C (5°F) is approximately 5 seconds.]

AKO0410L

Figure 9

AKO0041L

Figure 10

3-6 Operation

022-00018CE Operation and Maintenance Manual

5.

After preheat light is "ON," turn starter switch to "START" position (Figure 11).

Engine should start in approximately 5 seconds.

GLOW

OFF ON START

WARNING! If the engine does not start after approximately 10 seconds of cranking, release the starter switch.

Wait about 5 minutes and repeat above step.

6.

7.

8.

AKO0360L

Figure 11

After engine has started, release key. Key will return to "ON" position (Figure 12).

•

Do not turn key to "START" while engine is running: the starter could be damaged.

•

If engine fails to start after repeating normal starting procedure, check fuel level and battery condition.

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

GLOW

OFF

ON START

AKO0400L

Figure 12

Follow "Hydraulic System Warm-up – Cold Weather" on page 3-11.

022-00018CE Operation and Maintenance Manual

Operation 3-7

STARTING ENGINE WITH A BOOSTER CABLE

WARNING! 1.

An explosive gas is produced while batteries are in use or being charged.

Keep flames or sparks away from the battery area.

2.

Charge batteries in a well ventilated area.

3.

Always wear eye protection when starting a machine with jumper cables.

4.

Improper jump starting procedures can cause an explosion resulting in personal injury.

5.

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

6.

When starting from another machine, make sure the machines do not touch.

7.

Always connect the auxiliary battery positive (+) terminal to depleted battery positive (+) terminal first.

Then connect auxiliary battery negative (-) terminal to the frame of the depleted battery machine second.

8.

Connect positive cable first when installing cables and disconnect the negative cable first when removing.

HAOA440L

Figure 13

IMPORTANT The machine has a 12V (-) negative ground electrical system. Use the same capacity 12V booster battery when jump starting engine.

If the battery is drained during starting procedures, jump start engine using auxiliary or booster battery according to the following procedure.

3-8 Operation

022-00018CE Operation and Maintenance Manual

Connecting the Booster Battery 1.

Shut down engine of the machine on which booster battery is mounted (c, Figure 14).

2.

Connect one end of red cable (a, Figure 14) to the positive (+) terminal of the machine battery, and the other end to the positive (+) terminal of the booster battery (c, Figure 14).

3.

4.

Connect one end of black cable (b, Figure 14) to the negative (-) terminal of the booster battery, and then make ground connection to the upper frame of the machine (e, Figure 14) to be started with the other end of black (-) cable (b, Figure 14). When making the last connection to upper frame, be sure to connect the cable end as far away from the machine battery as possible. DO NOT CONNECT DIRECTLY TO THE NEGATIVE BATTERY TERMINAL.

a

Red

d

c

Black

e

b AXO0510L

Figure 14

Start the engine

Disconnecting the Booster Battery 1.

Disconnect black negative (-) cable (b, Figure 14) from the machine frame first.

2.

Disconnect the other end of black negative (-) cable (b, Figure 14) from the booster battery.

3.

Disconnect red positive (+) cable (a, Figure 14) from the booster battery.

4.

Disconnect red positive (+) cable (a, Figure 14) from the machine battery.

022-00018CE Operation and Maintenance Manual

Operation 3-9

HYDRAULIC SYSTEM WARM-UP

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

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

1.

Run engine for approximately 5 - 10 minutes set at the middle of the speed range, without a load.

2.

Set safety lever (Figure 16) to "UNLOCK" position.

3.

Slowly cycle boom, arm and bucket cylinders about five times without a load to circulate the oil through the system. Do this for 5 minutes.

4.

Check for clearance and fully raise the front attachment. Swing clockwise 3 revolutions. Swing counterclockwise 3 revolutions.

5.

Swing perpendicular, raise track off the ground and activate that track's travel motor forward and reverse for 2 revolutions. Do this procedure for both the high range and low range. Repeat this procedure for the other track.

Figure 15

Figure 16

3-10 Operation

HAOB432L

Figure 17

022-00018CE Operation and Maintenance Manual

HYDRAULIC SYSTEM WARM-UP – COLD WEATHER 1.

Run engine at "LOW IDLE" (no load) for 5 minutes (Figure 18).

2.

Run engine for approximately 5 minutes set at the middle of the speed range, without a load (Figure 19).

3.

Set safety lever (Figure 20) to "UNLOCK" position.

4.

Slowly cycle boom, arm and bucket cylinders about five times without a load to circulate the oil through the system. Do this for 5 minutes.

Figure 18

Figure 19

Figure 20

NOTE:

Do not allow cylinders to pass hydraulic oil over relief valve for more than twenty seconds at a time.

HAOB432L

Figure 21

022-00018CE Operation and Maintenance Manual

Operation 3-11

5.

Set engine accelerator lever to "HIGH IDLE" (Figure 22).

6.

Repeat Step 4 for 5 minutes. If working speeds continue to be slow, continue to operate, but use extreme caution because the machine function may be erratic.

7.

Check for clearance and fully raise the front attachment. Slowly swing clockwise 3 revolutions. Slowly swing counterclockwise 3 revolutions.

8.

Swing perpendicular, raise track off the ground and activate that track's travel motor forward and reverse for 2 revolutions. Do this procedure for both the high range and low range. Repeat this procedure for the other track.

Figure 22

ENGINE SHUT DOWN 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.

1.

Park excavator on level and firm ground.

2.

Lower blade and front end attachment to ground and make sure all operating controls are in "NEUTRAL."

HKB3001L

Figure 23 3.

Set engine accelerator lever to "LOW IDLE" (Figure 24). Allow engine to idle for 3 - 5 minutes.

Figure 24

3-12 Operation

022-00018CE Operation and Maintenance Manual

4.

5.

Shut down engine by turning key to "OFF" position (Figure 25).

GLOW

OFF ON START

Remove key from starter switch.

AKO0520L

Figure 25 6.

Set safety lever to "LOCK" position by pulling it up (Figure 26).

Figure 26

CHECK AND CONFIRMATION AFTER STOPPING ENGINE 1.

Repair excavator, if there are any coolant or oil leaks.

2.

Inspect front attachment and under carriage for abnormal appearances. Correct any problems.

3.

Fill fuel tank.

4.

Get rid of any accumulated flammable materials 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.

022-00018CE Operation and Maintenance Manual

Operation 3-13

SAFETY LEVER WARNING! When stopping engine or leaving the operator's seat, "LOCK" the safety lever, otherwise, a serious accident may occur by accidental movement of work levers (joysticks).

Whenever leaving the operator's seat make sure the engine is shut down and the safety lever is "LOCKED." Be careful not to move the work levers (joysticks) when raising up or pushing down the safety lever.

The safety lever (Figure 27) is designed to lock the front working control levers so that even if the working control levers are moved unintentionally, they will not work. However, the safety lever does not control the travel levers, boom swing pedal or blade control lever.

1.

Pull safety lever (Figure 27) up to allow left-hand control console to raise into the "LOCKED" position. Make sure that the safety lever is "LOCKED" into the raised (up) position. When safety lever (Figure 27) is in the "LOCKED" position, front attachment movement will be disabled even though a lever is moved.

NOTE:

Lower bucket (front attachment) and blade to ground. Place all control levers in "NEUTRAL" and shut down engine.

Figure 27

2.

Set safety lever to "RELEASE/UNLOCK" position, by pushing it down before starting work.

NOTE:

When the engine is not running, but the safety lever is "RELEASED" and the starter key is tuned "ON," moving the joysticks may result in movement.

The charged accumulators in the system will provide pilot pressure for control valve spool movement.

NOTE:

If the front attachment moves when the safety lever is moved to the "RELEASE/UNLOCK" position and all levers and pedals are in "NEUTRAL," return the safety lever to "LOCK" position, shut down engine and contact your nearest Daewoo dealer. There is a malfunction with the system.

3-14 Operation

Figure 28

022-00018CE Operation and Maintenance Manual

TRAVEL WARNING! 1.

Before operating the travel levers, make sure that you know in which direction the machine is pointing. Look at the end of the track assemblies. If the drive motors are visible and the blade is at the rear while sitting in the operator's seat, you are looking at the back end of the track assembly (therefore, you are looking backwards). In this case, the response of the travel levers will be the reverse of normal operation.

2.

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

3.

Be sure the path is clear during travel.

4.

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

5.

Make sure to operate the travel control levers smoothly to avoid sudden starts or stops.

6.

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

GENERAL TRAVEL INSTRUCTIONS 1.

Set engine speed control lever (Figure 29) to desired speed.

Figure 29 2.

Set safety lever (Figure 30) to "UNLOCK" position.

Figure 30

022-00018CE Operation and Maintenance Manual

Operation 3-15

3.

Folding the front, raise it up 40 - 50 cm (15 - 19 in) above ground. See Figure 30.

4.

Make sure that blade is fully raised.

HKB2033L

Figure 31 5.

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

6.

When traveling on rough ground, travel at a slow speed [1.0 - 1.5 km/h (0.62 0.93 MPH)]. Reduce 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.

7.

On rough, frozen or uneven terrain, travel slowly.

3-16 Operation

Figure 32

022-00018CE Operation and Maintenance Manual

WARNING! When traveling, keep bucket 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 excavator starts to slip or becomes unstable, lower the bucket immediately into the ground using it as a brake.

HAOF062L

Figure 33

Avoid working on slopes, because there is a danger of overturning by coming unbalance while swinging and performing front attachment operations.

It is very dangerous to swing towards bottom of slope with a loaded bucket.

In unavoidable cases level the slope with fill soil, to make the vehicle as horizontal as possible. See Figure 33.

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

20~30cm

20~30cm

HAOD752L

Figure 34 8.

Travel straight up or down slopes, never diagonally across the slope. See Figure 34. Extend the arm and lower the boom to keep the bucket about 20 - 30 cm (8 - 12 in) off the ground. If the machine

022-00018CE Operation and Maintenance Manual

Operation 3-17

starts to slide or becomes unstable, lower the bucket to regain control. If the engine stalls, lower the bucket, make sure that all controls are in the neutral position and restart the engine.

9.

NOTE:

Even though engine stops on a slope, do not operate swing control. The hydraulic accumulators may cause the unit to swing.

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, raise each track and rotate and clean that track.

CAUTION! When using the boom and arm to lift any portion of the machine, roll the bucket until the round base is against the ground. The angle of the arm to the boom should be at 90°.

Figure 35 Make sure that the material build up has been cleared. See Figure 35 and Figure 36.

HBOH811L

Figure 36 TRAVEL CONTROL LEVER OPERATION 1.

To travel straight (Figure 37), push both travel control levers fully forward or backwards. The farther the levers/pedals are pressed, the faster the travel speed.

Figure 37

3-18 Operation

022-00018CE Operation and Maintenance Manual

2.

Pivot turns (Figure 38) are made by rotating only one track forward or backward. The machine will pivot on the nonmoving track.

HAOD680L

Figure 38 3.

Spin turns (Figure 39) are made by rotating one track forward and one track backward. The machine will spin around its center point, thus counterrotating.

4.

Stopping travel (Figure 40) - Returning travel levers to "NEUTRAL" position will automatically apply brakes and stop excavator.

Figure 39

Figure 40

022-00018CE Operation and Maintenance Manual

Operation 3-19

WORK LEVERS (JOYSTICKS) (ISO STYLE) NOTE:

When starting work, move joysticks slowly and check movement of swing and front attachment.

This equipment is manufactured using one of two lever configurations. The following description is for ISO standards. Do not change valving, hoses, etc. that would change this standard.

A plate on the right side of the driver's seat shows how to operate the work levers (joysticks). See Figure 41.

Figure 41 The boom, arm and bucket movements and swing direction of work levers (joysticks) are as follows:

1 4

5 3

2

7

8 6

HAOK010L

Figure 42 Left-hand work lever (joystick) (Figure 42 and Figure 43) 1.

Arm dump

2.

Arm crowd

3.

Right swing

4.

Left swing

3 4 1 2

HKB2041L

Figure 43

3-20 Operation

022-00018CE Operation and Maintenance Manual

NOTE:

The following is not a mechanical malfunction but a proper phenomenon of the excavator. When operating the arm, it may stop momentarily.

When the arm is operated, the weight of the arm may cause it to move faster than the amount of oil being supplied.

HAOB820L

Figure 44 Right-hand work lever (joystick) (Figure 42 and Figure 45) 5.

Boom down

6.

Boom up

7.

Bucket crowd

8.

Bucket dump

NOTE:

Even after stopping the engine, the front can be lowered to the ground by operating joystick.

Set safety lever to "UNLOCK" position and turn starter switch "ON."

022-00018CE Operation and Maintenance Manual

6 8 7

5

HKB2042L

Figure 45

Operation 3-21

WORK LEVERS (JOYSTICKS) (JOHN DEERE) NOTE:

When starting work, move joysticks slowly and check movement of swing and front attachment.

This equipment is manufactured using one of two lever configurations. The following description is for John Deere standards. Do not change valving, hoses, etc. that would change this standard.

A plate on the right side of the driver's seat shows how to operate the work levers (joysticks). See Figure 41.

Figure 46 The boom, arm and bucket movements and swing direction of work levers (joysticks) are as follows:

1 4

5 3

7

2

8 6

HAOK010L

Figure 47 Left-hand work lever (joystick) (Figure 47 and Figure 48) 1.

Boom down

2.

Boom up

3.

Right swing

4.

Left swing

3 4

2

1

HAOK540L

Figure 48

3-22 Operation

022-00018CE Operation and Maintenance Manual

Right-hand work lever (joystick) (Figure 47 and Figure 49) 5.

Arm out

6.

Arm in

7.

Bucket crowd

8.

Bucket dump

NOTE:

NOTE:

Even after stopping the engine, the front can be lowered to the ground by operating joystick.

Set safety lever to "UNLOCK" position and turn starter switch "ON."

5 8 7

6

HAOK550L

Figure 49

The following is not a mechanical malfunction but a proper phenomenon of the excavator. When operating the arm, it may stop momentarily.

When the arm is operated, the weight of the arm may cause it to move faster than the amount of oil being supplied.

HAOB820L

Figure 50

022-00018CE Operation and Maintenance Manual

Operation 3-23

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

1.

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.

3.

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.

4.

It is possible that the boom, arm or bucket may come into contact with the upper or lower structure of the machine. There are digging conditions which could allow this to happen.

5.

Do not continually "bottom out" the hydraulic cylinders. Machine damage may occur if the cylinders are fully extended or retracted, example: arm cylinder fully retracted and the bucket cylinder is extended to rotate the bucket into the ground.

Figure 51

Figure 52

HAOF071L

Figure 53

3-24 Operation

022-00018CE Operation and Maintenance Manual

6.

Do not use machine travel or swing when the bucket is in the ground to provide additional breakout force. See Figure 54.

HKB2055L

Figure 54 7.

Do not use machine weight to provide additional breakout force. See Figure 55.

8.

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

HKB2056L

Figure 55 9.

Make sure that the ground has enough bearing strength when operating on shoulders, near overhangs, etc. Use a signal man when operating in difficult terrain. Keep travel motor to the rear, blade in front, and tracks at right angles to the shoulder. See Figure 56.

HAOD911L

Figure 56 10.

Do not excavate underneath the machine.

See Figure 57.

HAOF081L

Figure 57

022-00018CE Operation and Maintenance Manual

Operation 3-25

11.

Make sure that there is adequate clearance from overhead electrical supply lines. See Figure 58.

Voltage

Minimum Safe Distance

6.6 kV

3 m (9' 10")

33.0 kV

4 m (13' 1")

66.0 kV

5 m (16' 5")

154.0 kV

8 m (26' 3")

275.0 kV 12.

10 m (32' 10")

A

HKB1012L

Figure 58

If the excavation 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 59.

HAOE041L

Figure 59 13.

Do not use the bucket as a hammer or ramming device. This is dangerous and causes damage to the front attachment.

See Figure 60.

HKB2057L

Figure 60

3-26 Operation

022-00018CE Operation and Maintenance Manual

14.

Do not dig with the excavator tracks raised.

This can result in structural and mechanical failures.

HAOF131L

Figure 61 15.

16.

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 excavator back and forth with levers.

C.

Avoid sudden stops. Return levers to neutral by hand. Do not let them snap back to "NEUTRAL" on there own.

If the optional long fronts or attachments or heavy duty front end attachments are used, the machine balance will be altered.

Follow these additional operating precautions.

HAOB901L

Figure 62

WARNING!

17.

•

Do not travel downhill with the front end attachments raised.

•

Do not travel across slopes; travel straight up or down slope.

•

Use extreme caution when swinging the upper frame when positioned on a slope.

•

Allow extra swing stopping room. The additional momentum generated by the longer or heavier front end equipment will increase the amount of time needed to stop the swing motion.

•

Make sure that all optional equipment has been authorized and installed properly.

Do not move dirt or objects by swinging the excavator into them. This can result in structural and mechanical failures.

022-00018CE Operation and Maintenance Manual

Operation 3-27

WORKING IN WATER

IMPORTANT When working in water, do not exceed a slope of more than 15°. If the slope is over 15°, the rear part of the upper structure will be immersed in water, resulting in radiator fan damage.

HAOF141L

Figure 63 1.

If a river bed is uneven or the current is swift, be especially careful. Do not travel in water deeper than the upper part of the shoes on the idler side. Be careful not to submerge the center joint, swivel bearing or pinion gear in water, mud or sand.

2.

On weak, unstable surfaces, the machine may sink: keep watching the tracks and checking the river bed surface.

NOTE:

3-28 Operation

If the machine is submerged to the point that water or mud gets into the swing bearing or center joint, stop machine operation.

Remove the machine from the submerged location to firm, dry ground. Do not operate until proper inspection and maintenance have been completed. Refer to the Shop Manual or contact your distributor.

HKB2037L

Figure 64

022-00018CE Operation and Maintenance Manual

TRAVELING ON WEAK GROUND 1.

Avoid traveling on weak surfaces whenever possible.

2.

Keep as much as possible of the track contact area on a solid surface. Do not allow tracks to dig down so far that you cannot be towed.

3.

If further travel becomes difficult, lower the bucket to the ground, and "winch" your way forward by moving the front attachment in.

WARNING! Be careful of slipping sideways when using the front attachment to jack up the machine.

4.

If the machine is stuck because of mud or gravel jammed into the tracks, use the front attachment to raise one track and turn the other track forward and backward to clear it.

5.

If the machine is stuck and there is a clear tow path, use a wire cable to tow the machine. See "Towing Procedure"’ on page 3-35.

HKB2035L

Figure 65

HKB2036L

Figure 66 GRADING

IMPORTANT Do not do extensive grading with the bucket or components may become overloaded and damage can result.

1.

Use the blade for back filling and grading.

2.

Using boom, combination.

arm

and

bucket

in

HKB2054L

Figure 67

A.

When leveling ground from the front to the back, move the arm gently while raising the boom. When the arm goes beyond vertical, lower the boom smoothly and let the bucket move horizontally.

B.

To level ground from the back to the front, reverse the operating sequence in Step 1.

C.

To finish grading the sides of a wall type earth structure, such as a dam, follow the general operating techniques described in Step 1 above.

022-00018CE Operation and Maintenance Manual

Operation 3-29

BE CAREFUL OF BLADE POSITION. 1.

When the blade is facing to the front, it can be hit by the boom cylinder or bucket. Be careful.

2.

When carrying out deep excavation, position blade to rear if possible and safe.

HKB2058L

Figure 68 PRECAUTIONS FOR BLADE USE 1.

Use the blade only for earth moving. Do not use the blade to dig: this can damage the blade or the track system.

2.

Do not apply a large or unbalanced, off-center load to the blade: this can damage the blade or the track system.

3.

Do not strike anything with the blade while traveling: this can damage the blade or track system.

4.

When using the blade to jack up the machine, make sure the ground is even and will give good support and that the blade contacts the ground evenly.

1

2 HAOD871L

Figure 69

USE CARE WHEN CROWDING (MOVING IN) FRONT ATTACHMENT 1.

When crowding (moving in) the front attachment, be careful not to strike the blade with the bucket.

HKB2059L

Figure 70

3-30 Operation

022-00018CE Operation and Maintenance Manual

BE CAREFUL NOT TO HIT OBSTACLES WITH BLADE 1.

Be careful not to hit obstacles with blade.

This can damage blade, cylinders or other parts of machine.

HKB2060L

Figure 71 BE CAREFUL OF TRACK SHOES 1.

During deep excavation, the boom cylinder can hit the tracks. Be careful to avoid this.

HKB2061L

Figure 72 HANDLE RUBBER CRAWLER TRACKS CAREFULLY

IMPORTANT As the rubber crawler is pliable on its section areas, it is inferior to steel crawler in stability. Especially, use care when you operate your machine sideways.

The tracks are designed to prevent damage to road surfaces. They can be damaged if the following precautions are not followed:

022-00018CE Operation and Maintenance Manual

Figure 73

Operation 3-31

1.

Do not travel or turn while crossing over sharp, raised objects that may crack or damage track.

2.

Never use rubber crawler tracks over rough stone material. This can cause damage to the tracks and to other parts of the track system such as track links, rollers, etc. Never use rubber crawler tracks to travel on sand. It will damage the track system.

3.

Excessive foreign material in the track will increase crawler tension and may cause damage.

4.

Avoid making sudden turns on surfaces that have high friction.

5.

Remove fuel or hydraulic oil from tracks immediately.

6.

Avoid salt water and salt air as much as possible. Salt corrodes the steel core of the tracks.

7.

When crawlers are not in use for an extended period of time, store them out of direct exposure to sunlight and rain.

8.

Avoid operating on road surfaces with a temperature higher than 60°C (140°F).

This may damage the tracks or the road surface.

9.

Avoid traveling on one crawler when the other crawler and the front are jacked up.

This can cause abrasion and damage.

10.

Traveling with loose crawlers can cause the track to come off or be damaged.

11.

Important:Rubber crawlers are pliable while steel crawlers are not. This requires extra care, especially when operating with the upper body at right angles to the track.

12.

Lower a jacked up machine very carefully.

Figure 74

Figure 75

HKB20631L

Figure 76

3-32 Operation

022-00018CE Operation and Maintenance Manual

13.

When rubber crawlers are scored or when internal steel wire belt is scored, contact your nearest Daewoo dealer for repair service.

"A" - Roller side "B" - Ground side (1) - Steel track frame (2) - Rubber track (3) - Steel wire belt Figure 77

PARKING EXCAVATOR WARNING! Park excavator on firm, level ground. Avoid parking on slopes. If excavator must be parked on a slope, block tracks and place bucket teeth in ground. See Figure 78

HKB2039L

Figure 78 1.

Park excavator on firm, level ground.

Lower bucket and blade to ground as shown in Figure 79.

HKB3001L

Figure 79

022-00018CE Operation and Maintenance Manual

Operation 3-33

2.

Set engine accelerator lever (Figure 80) to "LOW IDLE." Allow engine to idle for 3 - 5 minutes.

3.

Shut down engine by turning key to "OFF" position (Figure 81).

Figure 80

4.

GLOW

OFF ON START

Remove key from starter switch.

AKO0520L

Figure 81 5.

Set safety lever (Figure 82) to "LOCK" position by pulling it up.

Figure 82

3-34 Operation

022-00018CE Operation and Maintenance Manual

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 excavator use a wire rope or chain capable of handling the load.

Attach chain or wire rope to track frame as shown in Figure 83.

Do not use the light towing holes in the ends of the blade for towing the machine: damage will result.

Insert protective material such as pieces of wood between track frame and wire rope to prevent the wire rope from being damage.

If it is impossible for the machine to escape from the mud on its own tracks, connect a wire rope between the machine and another machine as illustrated. The wire rope should be connected to the machine frame. It is desirable to place wooden blocks in corners to prevent the machine and rope from being damaged.

Figure 83

022-00018CE Operation and Maintenance Manual

Operation 3-35

HYDRAULIC BREAKER IMPORTANT If a hydraulic breaker and piping is installed without DAEWOO's authorization, it may create a serious malfunction which will not be covered under the excavator warranty.

SELECTION OF HYDRAULIC BREAKER If a hydraulic breaker is installed, consider equipment's stability and suitability for such modification. Also consider hydraulic oil pressure and quantity. When selecting a hydraulic breaker consult with a DAEWOO distributor or sales agency.

HYDRAULIC HOSES AND TUBING FOR BREAKER 1.

When installing hydraulic breaker, assemble according to drawings provided with kit.

2.

If breaker is taken off excavator, be sure to plug and cap all hoses and tubing to prevent contamination from entering hydraulic system.

3.

Plug and cap all connectors and fittings on breaker to prevent contamination.

4.

Check all hydraulic connections for signs of leaks or loose components before starting operation.

HYDRAULIC BREAKER OPERATION NOTE:

Hydraulic pressure and flow settings may need to be changed. Refer to the Maintenance Section of this manual for further information.

1.

Make sure to read and understand the breaker user's manual.

2.

Inspect all mechanical and hydraulic connections.

3.

Do not use the breaker as a hammer. See Figure 84.

Do not drop breaker from extreme heights.

The breaker is relatively heavy and drops fast. Do not drop breaker from extreme heights or damage to upper structure may result.

HKB2065L

Figure 84

3-36 Operation

022-00018CE Operation and Maintenance Manual

4.

Do not operate the breaker with the boom or arm cylinders fully extended (bottomed out). See Figure 85.

Leave over 50 mm (2 in) of clearance between rod end of cylinder and cylinder head. This will help prevent damage to cylinders during breaker operation.

HKB2067L

Figure 85 5.

Do not use the breaker if the hydraulic hoses vibrate excessively. See Figure 86.

Check the breaker's hydraulic accumulator (1, Figure 86) for damage and repair as required. If excavator is operated under this condition, structural and hydraulic components can damaged.

1

HAOF151L

Figure 86 6.

Do not allow the breaker body to go into water if not equipped for underwater operation. The breaker seal can be damaged and allow rust, foreign material or water to enter the hydraulic system and cause damage. Only insert the breaker tool into water. See Figure 87.

HAOB970L

Figure 87 7.

Do not any lifting or towing with a breaker.

See Figure 88.

HKB2068L

Figure 88

022-00018CE Operation and Maintenance Manual

Operation 3-37

8.

Operate the breaker only to the front and rear of the excavator. Do not use the breaker to either side of the excavator. Do not swing the breaker from side to side when operating it. See Figure 89.

WARNING! Operating a breaker with the upper body turned 90° to the tracks can result in tipping over the machine or reduction in service life.

9.

HAOB990L

Figure 89

Do not curl the breaker tool tip into the arm or boom when traveling or parking the excavator. See Figure 90.

HKB2069L

Figure 90 10.

Do not move crushed material. Never move crushed material with the breaker or bucket. Especially avoid using swing force.

Damage to the boom, arm and breaker can result.

Figure 91

3-38 Operation

022-00018CE Operation and Maintenance Manual

TO ACTIVATE BREAKER 1.

To turn "ON" breaker depress PTO pedal in direction "A."

2.

To turn "OFF" breaker release PTO pedal and allow pedal to return to position "B." NOTE:

In case of 2-way option piping, pressing pedal B also activates breaker.

Figure 92

022-00018CE Operation and Maintenance Manual

Operation 3-39

HYDRAULIC OIL AND FILTER SERVICE INTERVALS When using a hydraulic breaker, the viscosity breakdown and contamination of hydraulic oil is faster because the work condition is more severe than during normal digging work. To prevent the hydraulic components (especially pump) from having a shortened life cycle, replace the hydraulic oil and main hydraulic oil filter using the following schedule.

Attachment

Operation Rate

Hydraulic Oil

Filter

Bucket Work

100%

2,000 Hours

250 Hours (First Replacement) 500 Hours (After First Replacement)

Hydraulic Breaker Work

100%

500 Hours

100 Hours

100 551

BREAKER OPTION RATE (%)

105 80

106 110

692

130

112 60

614

FILTER (First Replacement)

150

119

782

180

128

893 HYDRAULIC OIL

40

210

137 156 175

20

206

1028 FILTER (After First Replacement)

250

1196 1400

300 370

1658

0 0

500

1000

1500

2000

MACHINE OPERATING HOURS ARO0990L

Figure 93

NOTE:

3-40 Operation

The replacement intervals of hydraulic oil and filter depend upon the amount of time the hydraulic breaker is being used. These intervals should be followed as opposed to regularly scheduled maintenance.

022-00018CE Operation and Maintenance Manual

OPERATING TECHNIQUES LIFTING

IMPORTANT There may be local or government regulations, about the use of excavators for the lifting of heavy loads. Always contact your local and government agencies in regards to these regulations.

To prevent injury, do not exceed the rated load capacity of the machine. If the machine is not on level ground, load capacities will vary.

Short slings will prevent excessive load swing.

Use the lifting eye on the bucket that is provided to lift objects.

Always try to maintain the lifting eye (Figure 94) straight below the center line of the arm and bucket pin. In this manner the weight of the load is being primarily held only by the pin, and not by the bucket cylinder, link, and link pins.

When a lifting eye is used, the sling/lifting device must be fastened to the eye in a manner that will not allow it to come loose.

The most stable position is over the corner of the machine.

For best stability, carry a load as close to the ground and machine as possible.

HAAD3830

Figure 94

Lift capacity decreases as the distance from the machine swing center line is increased.

022-00018CE Operation and Maintenance Manual

Operation 3-41

Lifting Unknown Weight When loads are not accurately known are to be lifted, the person responsible for the job shall ascertain that the weight of the load does not exceed the machine LOAD RATING CHART at the radius at which it is to be lifted.

FRONT LIFT ZONE

It is recommended that you feel your way into any lift as a precaution against tip-over. One method is to position the boom at 90° over the side of the machine.

Slowly lift the load until it clears the ground. A lift over the side is the most unstable, and as the load is swung into the front zone of the excavator it will become more stable. DO NOT INCREASE SWING RADIUS AFTER THE LOAD IS LIFTED.

SIDE LIFT ZONE

SIDE LIFT ZONE

REAR LIFT ZONE HAAD3842

Figure 95

DANGER! If a load is picked up from the front zone and swung into the side zone, a tip-over could result causing a deadly or fatal injury.

Lifting Known Weight The load chart is the governing factor when lifting known weights. It is recommended that you feel your way into any lift as a precaution against tip-over. When ever possible, lift and swing payloads between the front idler area.

Pick and Carry The machine has the ability to pick and carry payloads without added labor. We recommend when traveling with a suspended payload, you evaluate the prevailing conditions and determine the safety precautions required in each case. The following factors must be considered before attempting to pick and carry a load.

Align the boom with the forward direction of machine travel. Maintain this boom position when turning the machine. Turn only when necessary, at the slowest speed, and at a wide turning radius.

1.

Use the shortest lifting radius distance possible.

2.

Keep the load as close to the ground as conditions will permit.

3.

Provide tag lines to prevent load from pendulating. Pendulating can cause a change in radius. A change in radius could exceed the load chart rating or cause a tip-over condition.

4.

Govern travel speed to suit conditions.

5.

Avoid sudden starts and stops.

3-42 Operation

022-00018CE Operation and Maintenance Manual

OPERATION UNDER UNUSUAL CONDITIONS NOTE:

See "Maintenance in Special Conditions" on page 4-54 for other recommendations.

OPERATION IN EXTREME COLD If machine is to be operated in extreme cold weather temperatures, certain precautions must be taken to assure continued normal operation. The following paragraphs detail checks to be made to be certain the machine is capable of operating at these temperatures.

1.

Check the cooling system for correct antifreeze solution for lowest temperature expected. Carefully inspect cooling system and correct or report any leaks.

2.

Keep batteries fully charged to prevent freezing. If water is added to batteries, run engine at least one hour to mix electrolyte solution.

3.

Keep engine in best possible mechanical condition to assure easy starting and good performance during adverse weather conditions.

4.

Use engine oil of the proper specifications for the expected temperatures. Refer to the "Lubrication Specifications" of the engine manual for details.

5.

Keep fuel tank full at all times. Drain condensation from tank before and after operation. Drain and service fuel filter. To eliminate clogging of fuel filters due to wax crystal formation in the fuel, be sure that the fuel used has a cloud point specification below the lowest expected temperature.

6.

Lubricate entire machine according to "Periodic Service Table and Chart" Section 4, in this manual or lubrication chart on machine.

7.

Start engine and allow it to reach normal operating temperature before applying load.

A.

If mud and ice collects and freezes on any of the moving parts while machine is idle, apply heat to thaw the frozen material before attempting to operate machine.

B.

Operate hydraulic units with care until they have reached a temperature to enable them to operate normally.

C.

Check all machine controls and/or functions to be sure they are operating correctly.

8.

An extra outer air filter should be kept in the operator's cab to replace element that could become iced and cause restricted air flow to engine.

9.

If cold weather starting aid must be used, see "Engine Starting" COLD WEATHER START portion of this manual.

10.

Clean off all mud, snow and ice to prevent freezing. Cover machine with tarpaulin if possible, keep ends of tarpaulin from freezing to ground.

022-00018CE Operation and Maintenance Manual

Operation 3-43

OPERATION IN EXTREME HEAT Continuous operation of the machine in high temperatures may cause the machine to overheat. Monitor engine and transmission temperatures and stop machine for a cooling-off period whenever necessary.

1.

2.

Make frequent inspections and services of the fan and radiator. Check coolant level in radiator. Check grills and radiator fins for accumulation of dust, sand and insects which could block the cooling passages.

A.

Formation of scale and rust in cooling system occurs more rapidly in extremely high temperatures. Change antifreeze each year to keep corrosion inhibitor at full strength.

B.

If necessary, flush cooling system periodically to keep passage clear. Avoid use of water with a high alkali content which increases scale and rust formation.

Check level of battery electrolyte daily. Keep electrolyte above plates preventing damage to batteries.

Use a slightly weaker electrolyte solution in hot climates. Dilute 1.28 specific gravity electrolyte as issued to 1.20 - 1.24 specific gravity readings at full charge. Recharge batteries whenever they reach a 1.16 specific gravity reading. Batteries self-discharge at a higher rate if left standing for long periods at high temperatures. If machine is to stand for several days, remove batteries and store in a cool place.

WARNING! Do not store acid type storage batteries near stacks of tires; the acid fumes have a harmful affect on rubber.

3.

Service fuel system as directed in "Engine Fuel System" Section 5, of this manual. Check for water content before filling fuel tank. High temperatures and cooling off cause condensation in storage drums.

4.

Lubricate as specified in "Periodic Service Chart and Table" Section 4, in this manual or Lubrication Decal on the machine.

5.

Do not park machine in sun for long periods of time. When practical park machine under cover to protect it from sun, dirt and dust.

A.

Cover inactive machine with tarpaulin if no suitable shelter is available. Protect engine compartment, transmission and hydraulics from entrance of dust.

B.

In hot, damp, climates corrosive action will occur on all parts of the machine and will be accelerated during the rainy season. Rust and paint blisters will appear on metal surfaces and fungus growth on other surfaces.

C.

Protect all unfinished, exposed surfaces with a film of preservative lubricating oil. Protect cables and terminals with ignition insulation compound. Apply paint or suitable rust preventive to damaged surfaces to protect them from rust and corrosion.

3-44 Operation

022-00018CE Operation and Maintenance Manual

OPERATION IN DUSTY OR SANDY AREAS Operation of the machine can cause dust in almost any area. However, when in predominantly dusty or sandy areas, additional precautions must be taken.

1.

Keep cooling system fins and cooling areas clean. Blow out with compressed air, if possible, as often as necessary.

WARNING! Wear goggles when using compressed air.

2.

Use care when servicing fuel system to prevent dust and sand from entering the tank.

3.

Service the air cleaner at frequent intervals, check air restriction indicator daily and keep dust cup and dust valve clean. Prevent dust and sand from entering engine parts and compartments as much as possible.

4.

Lubricate and perform services outlined on current lubrication chart on machine and "Lubrication Chart and Table" Section 4. Clean all lubrication fittings before applying lubricant. Sand mixed with lubricant becomes very abrasive and speeds wear on parts.

5.

Protect machine from dust and sand as much as possible. Park machine under cover or protect with tarpaulin to keep dust and sand from damaging unit.

OPERATION IN RAINY OR HUMID CONDITIONS Operation under rainy conditions is similar to that as in extreme heat procedures listed previously.

1.

Keep all exposed surfaces coated with preservative lubricating oil. Pay particular attention to damaged or unpainted surfaces. Cover all paint cracks and chip marks as soon as possible to prevent corrosive effects.

OPERATION IN SALT WATER AREAS The corrosive effect of salt water and salt water spray is very extensive. When operating in salt water areas, observe the following precautions.

1.

When exposed to salt water, dry machine thoroughly and rinse with fresh water as soon as possible.

2.

Keep all exposed surfaces coated with preservative lubricating oil. Pay particular attention to damaged paint surfaces.

3.

Keep all painted surfaces in good repair.

4.

Lubricate machine as prescribed on lubrication chart on machine or "Periodic Service Table and Chart" Section 4, in this manual. Shorten lubricating intervals for parts subject to exposure to salt water, if found to be necessary.

OPERATION AT HIGH ALTITUDES Normally, operation of machine at high altitudes will be as outlined in extreme cold. Before operating at high altitudes, engine fuel and air mixture may have to be adjusted according to appropriate engine manual.

1.

Check engine operating temperature for evidence of overheating. The pressure cap on radiator must make a perfect seal to maintain coolant pressure in the system.

022-00018CE Operation and Maintenance Manual

Operation 3-45

4INSPECTION, MAINTENANCE AND ADJUSTMENT PREVENTIVE MAINTENANCE 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 on the control console in the cab.

HAOA600L

Figure 1

SERIAL NUMBERS There are two serial number plates attached to the body of the excavator.

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

Machine Serial Number The machine serial number plate (Figure 2) is on the front of the operator's cab. A corresponding number is stamped into the left-hand side of the boom.

022-00018CE Operation and Maintenance Manual

Figure 2

Inspection, Maintenance and Adjustment 4-1

Engine Serial Number The engine serial number (Figure 3) is stamped on the left side of engine block, over the fuel injection pump.

AKO0230L

Figure 3 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 be running, make sure to keep all unauthorized personnel away from the machine, and that all industry standard safety precautions are followed.

4-2 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

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

NOTE:

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

1.

Park on firm and level ground.

2.

Lower bucket to ground.

HKB3001L

Figure 4 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.

GLOW

OFF

ON START

AKO0440L

Figure 5 4.

Shut engine down and remove key from the starter switch.

GLOW

OFF ON START

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

AKO0520L

Figure 6

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-3

5.

Set safety lever (Figure 7) to "LOCK" position.

6.

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

Figure 7

Figure 8

4-4 Inspection, Maintenance and Adjustment

022-00018CE 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

ENGINE OIL** CALTEX RPM or

LUBRICANT GREASE MULTIFAC EP

MULTIPURPOSE EP90

RONEX MP #2 or

SPARTAN EP220 or

RONEX MP #1 (COLD TEMPS)

EXXON GX 80W90

MOBILUBE HD 80W90

DELO 300 EXXON/ESSO

NUTO (ANTI-WEAR)

EXXON 15W40

HD 32 (BELOW 0°C (32°F)) or

GEAR OIL

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

MOBIL

DELVAC 1300 or

MOBIL FAW #2 or

DTE 13M (ALL-TEMP) or

SUPER 15W40

MOBIL FAW #1 (COLD TEMPS)

ROTELLA

ALVANIA EP #2

DTE 24 (SUMMER) SHELL

TELLUS 32

T15W40

SPIRAX HD 80W90 or DONAX TD (TRANSMISSION)

PENNZOIL

PENNZBELL

LONGLIFE

AW 32 (BELOW 0°C (32°F)) or

SAE 15W40

AW 46 (ABOVE 0°C (32°F))

PENNZOIL 705 EP #2

PENNZOIL MULTIPURPOSE 4092 or 80W90

*

Hydraulic oil change interval is 2,000 hours, only when Daewoo Genuine Oil is used. If other brands of oil is used, guaranteed change interval is 1,000 hours.

**

Engine oil must meet ACEA-E2, ACEA-E3 or API-CH-4 EQUIVALENT and be SAE 15W40 or 10W40.

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-5

LUBRICANT MANUFACTURER

HYDRAULIC OIL*

DRYDEN

PARADENE AW 32 (BELOW 0°C (32°F)) or

ENGINE OIL**

LUBRICANT GREASE

GEAR OIL

DIESELALL PLUS 15W40

EP #2 (RED)

AP80W90

DELO 400 15W40

DELO GREASE EP-2

DELO GEAR OIL or

AW 46 (ABOVE 0°C (32°F)) CHEVRON

AW MV 32 (BELOW 0°C (32°F)) or

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))

IDEMITSU KOSAN

DAPHNE KOSAN 46WR

NIPPON SEIKIYU

SUPER HIGHLAND S26 or 32

TOTAL

TOTAL EQUIVIS ZS46-III

STAR PLEX 2

URSA SUPER PLUS 15W40 or URSA PREMIUM TDX 15W40

APOROIL MOTIRE S300

TOTAL

STAR PLEX PREMIUM

MULTIGEAR EPSAE 80W90

DAPHNE CORRONE #2

APOROIL GEAR HE 90

LIPANOC GREASE

NISEKI SP90 or EP90

TOTAL MUTRIS EP #2

TOTAL DA80W90

*

Hydraulic oil change interval is 2,000 hours, only when Daewoo Genuine Oil is used. If other brands of oil is used, guaranteed change interval is 1,000 hours.

**

Engine oil must meet ACEA-E2, ACEA-E3 or API-CH-4 EQUIVALENT and be SAE 15W40 or 10W40.

Antifreeze Recommended Concentration

Manufacturers Meeting ASTM D3306 Dexcool ELC by Chevron Texaco

50% Antifreeze - 50% Distilled Water

Alugard G48 by BASF Others meeting or exceeding ASTM D3306

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.

4-6 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

FLUID CAPACITIES Component

Capacity

Oil Pan with Filter

3.6 liters (0.95 U.S. gal.)

Cooling System

1.8 liters (0.48 U.S. gal.)

Engine

19 liters (5 U.S. gal.)

Fuel Tank

26 liters (6.7 U.S. gal.)

Hydraulic Oil Tank

330 cc (11.2 oz)

Travel Reduction Device

LUBRICATION AND SERVICE CHART Lubrication and service chart is on the inside of battery box cover. The symbols shown here are used in the lubrication and service chart on the next page.

Symbol

Description

Symbol

Description

Lubrication

Coolant

Gear Oil (Swing Device, Travel Device)

Air Cleaner Element

Engine Oil

Fuel Filter

Engine Oil Filter

Air Conditioner Filter

Hydraulic Oil

Drain Water

Hydraulic Oil Filter

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-7

Description of Lubrication and Service Chart

7

4

5

2

1 13

2

8

2

11

2 2

10

9 10h 50h 250h 500h 1000h 2000h

16

14

12

15

2 BQO0051L

Figure 9

4-8 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

SERVICE DATA No.

Items To Check Radiator

1 2 3 4 5 6 7 8

9

Coolant Recovery Tank Front & Blade ----------------Swing Bearing Swing Gear Pinion Teeth ----------------Boom Swing Cylinder Travel Reduction Device Roller & Idler

10

Engine Oil

11

Hydraulic Oil

Service Coolant (Antifreeze) Coolant (Antifreeze) Grease

Qty. 1.8 L

V

PG

1

V

PG

20

F100

Grease

1

Grease

1

Grease

1

Gear Oil (80W90)

2X200 cc

SAE #30 Engine Oil (15W40) Hydraulic Oil (Equivis 46) Diesel

10

S015 PLUS Service Interval 50 250 500 1000

2000

W10

V, F

22 cc 40 cc 2.9 L

V

19 L

V

F

Fuel Tank 22 L V 12 Water ---------1 V Separator 13 Engine Oil Filter Cartridge 1 F 14 Fuel Filter Cartridge 1 F Full Flow 15 Hydraulic Oil Element 1 F Filter 16 Air Cleaner Element 1 C V: Maintenance & Refill.

C: Cleaning.

F: First Time Exchange Only.

F100: Every 10 Hours For First 100 Hours.

W10: Every 10 Hours If Operating In Water.

PG: Propylene Glycol - Extended Life Antifreeze (Drain and replace using this interval.) See "Engine Cooling System" on page 4-52, for further explanation.

Gray Box: Replacement On Every Interval.

For additional service items see list of "Maintenance Intervals" on page 4-10.

NOTE:

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-9

MAINTENANCE INTERVALS 10 HOUR / DAILY SERVICE •

• • • • • • • • • •

Grease Blade, Boom, Arm and Front Attachment Pins (For First 100 Hours) (See page 4-12) Check Engine Oil Level (See page 4-12) Check Level of Hydraulic Oil Tank (See page 4-13) Check for Leaks In Hydraulic System (See page 4-14) Check Fuel Level (See page 4-14) Check Fuel Water Separator (See page 4-15) Check for Leaks In Fuel System (See page 4-15) Check Cooling System and Refill As Required (See page 4-16) Check Level of Window Washer Liquid (If Equipped) (See page 4-16) Inspect the Bucket Teeth and Side Cutters for Signs of Wear (See page 4-17) Inspect Seat Belt for Proper Operation (See page 4-17)

• • •

•

• • •

•

Inspect the Structure for Cracks and Faulty Welds (See page 4-17) Check the Operation of All Switches (See page 4-17) Check the Operation of All Exterior Lights, Horn, Control Console Indicator and Monitor Lights (See page 4-17) Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds (See page 4-17) Check Operation of All Controls (See page 4-18) Inspect for Any Loose or Missing Nuts and Bolts (See page 4-18) Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers) (See page 4-18) Inspect Engine Fan Blade (See page 4-19)

50 HOUR / WEEKLY SERVICE • • •

Perform All Daily Service Checks (See page 4-20) Grease Blade, Boom, Arm and Front Attachment Pins (See page 4-20) Grease Swivel Bearing (See page 4-24)

• • •

Boom Swing Cylinder Head (See page 4-24) Change Engine Oil and Filter (After First 50 Hours) (See page 4-24) Check Battery Electrolyte Level and Condition (See page 4-24)

250 HOUR / MONTHLY SERVICE • • • • • •

*

Perform All Daily and 50 Hour Service Checks (See page 4-25) Check Travel Reduction Device Oil Level on Both Sides of Unit (See page 4-25) Change Engine Oil (See page 4-26) Change Fuel Filter (See page 4-26) Clean Air Cleaner Filter (See page 4-26) Drain Water and Sediment From Hydraulic Oil Tank (See page 4-28)

• •

• •

Replace Full Flow Hydraulic Oil Filter (See page 4-30) Inspect Pins and Bushings on the Front End Attachments for Signs of Wear (See page 4-31) Inspect Fuel System Hose Clamps (See page 4-31) Check Engine Fan Belt for Cracks, Wear and Correct Tension (See page 4-31)

Initial service interval during break-in.

4-10 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

500 HOUR / 3 MONTH SERVICE • • •

Perform All Daily, 50 and 250 Hour Service Checks (See page 4-32) Grease Swing Gear Pinion Teeth (See page 4-32) Change Engine Oil Filter (See page 4-32)

• • • •

Change Fuel Filter (See page 4-33) Replace Air Cleaner Filter (See page 4-34) Clean Radiator (See page 4-34) Replace Full Flow Hydraulic Oil Filter (See page 4-35)

1,000 HOUR / 6 MONTH SERVICE • •

Perform All Daily, 50, 250 and 500 Hour Service Checks (See page 4-36) Change Oil in Travel Reduction Device (One on Each Side of Unit) (See page 4-36)

•

• •

Change Radiator Coolant (Propylene Glycol - Extended Life Antifreeze) (See page 4-37) Check, Adjust Valve Clearance ** (See page 4-38) Check, Torque Head Bolts ** (See page 4-38)

2,000 HOUR / YEARLY SERVICE • • •

Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks (See page 4-39) Hydraulic Oil Exchange and Suction Strainer Cleaning (See page 4-39) Check Alternator and Starter** (See page 4-41)

• • •

Check All Rubber Antivibration Shock Mounts (See page 4-41) Perform and Record the Results of the Cycle Time Tests (See page 4-41) Inspect Machine to Check for Cracked or Broken Welds or Other Structural Damage (See page 4-41)

4,000 HOUR / BIENNIAL SERVICE •

Major Parts - Periodic Replacement (See page 4-42) 12,000 HOUR / SIX YEAR SERVICE

•

Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) (See page 4-43)

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

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-11

10 HOUR / DAILY SERVICE GREASE BLADE, BOOM, ARM AND FRONT ATTACHMENT PINS (FOR FIRST 100 HOURS) 1.

Grease every 10 hours for first 100 hours and every 50 hours thereafter (See page 4-20).

NOTE:

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

CHECK ENGINE OIL LEVEL NOTE:

When checking level using a dipstick always remove and wipe it clean before making final level check.

1.

Shut down engine and wait for 15 minutes.

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

2.

Check engine oil level using dipstick (1, Figure 11).

3.

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

4.

NOTE:

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

NOTE:

Dispose of drained fluids according to local regulations.

H L HAOE210L

Figure 10

Add oil through engine oil fill cap (2, Figure 11).

2

1

AKO0250L

Figure 11

4-12 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

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. Press button in center of breather 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.

1.

Position the machine on firm and level ground. Extend arm and lower bucket to ground as shown.

2.

Shut down engine.

HAOA060L

Figure 12

HKB3001L

Figure 13 3.

After stopping engine, set starter switch to "ON" position. Relieve hydraulic pressure in circuit by fully stroking each operating lever (Including travel lever) in each direction. Then remove key from switch.

4.

Check level gauge, 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. Drain excess oil using plug (Figure 14) on bottom of tank.

NOTE:

Figure 14

Dispose of drained fluids according to local regulations.

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-13

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.

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

2.

Check the amount of fuel in the tank by observing the fuel tank sight gauge. Fill the tank using the fill tube with the proper fuel for the operating conditions.

NOTE:

See "Fluid Capacities"’ page 4-7. for capacity.

3.

Do not overfill the tank.

4.

Securely tighten cap after fueling.

Figure 15

on

HAOC510L

Figure 16

4-14 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

5.

Check the fuel gauge (1, Figure 17) in the operator's compartment for proper operation.

NOTE:

NOTE:

NOTE:

2

A low fuel warning light (2, Figure 17) will turn "ON" when the fuel level reaches 2.4 liters (2.54 U.S. quarts) or less.

1

Always fill fuel tank at end of work day. This will help prevent condensation from forming inside tank.

See "Fluid Capacities"’ page 4-7. for capacity.

on

AKO0042L

Figure 17

CHECK FUEL WATER SEPARATOR 1.

Open engine cover and check water separator.

2.

When there is water in the cup, a red indicator will appear in the float window.

Figure 18 3.

Turn lever to "CLOSED" position to shut off fuel supply before draining water.

NOTE:

Lever should be pointing up.

4.

Remove ring nut (1, Figure 19), cup (2), separator (3) and seals (4) from head (5).

5.

Drain water and sediment from cup (2, Figure 19). Wipe inside of cup out and clean separator (3).

NOTE:

Dispose of drained fluids according to local regulations.

6.

Install seals (4, Figure 19), separator (3), cup (2) and ring nut (1) on head (5).

7.

Turn fuel lever to "OPEN" position.

NOTE:

Figure 19

Lever should be pointing down.

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.

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-15

CHECK COOLING SYSTEM AND REFILL AS REQUIRED NOTE:

Do not mix ethylene glycol and propylene glycol antifreeze together. If the two are mixed, the protection level will be reduced to the level of the ethylene glycol.

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.

Do not remove the radiator cap unless it is required. Observe the coolant level in the Recovery Tank.

1.

2.

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 recovery tank or the readout on the control console. Refill radiator as required. See "Antifreeze Concentration Tables"’ on page 4-53.

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

FULL

LOW HKB3009I

3.

Observe the level of coolant in the recovery tank. The normal cold engine fluid level should be between "FULL" and "LOW" marks on tank.

4.

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

Figure 20

CHECK LEVEL OF WINDOW WASHER LIQUID (IF EQUIPPED) 1.

Check fluid level in windshield washer tank, at the right side of the seat.

2.

Open fill cap and add fluid.

NOTE:

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

Figure 21

4-16 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

INSPECT THE BUCKET TEETH AND SIDE CUTTERS FOR SIGNS OF WEAR 1.

On a daily basis, inspect the bucket teeth to make sure that tooth wear or breakage has not developed.

2.

Do not allow the replaceable bucket teeth to wear down to the point that the bucket adapter is exposed. See Figure 22.

NOTE:

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

Figure 22

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.

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

Turn the 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 time.

3.

Sound the 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

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-17

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, both travel motors and the swing motor. 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 the engine at rated speed, operate all of the controls.

2.

Follow cold weather hydraulic system warm-up procedures.

3.

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

INSPECT FOR ANY LOOSE OR MISSING NUTS AND BOLTS 1.

See "Bolt page 4-44..

and

Nut

Inspection"’

on

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

2.

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 4-56..

Figure 23

Jack up each track and perform the two speed travel motor test.

4-18 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

INSPECT ENGINE FAN BLADE

WARNING! Personal injury can result from a fan blade failure. Never pull or pry on the fan. This can damage the fan blade(s) and cause fan failure.

NOTE:

1.

Manually rotate the crankshaft by using a wrench on the accessory drive pulley nut.

Figure 24

An inspection of the cooling fan is required daily. check for cracks, loose rivets, bent or loose blades, and for contact between the blade tips and the fan shroud. Check the fan to make sure it is securely mounted.

Tighten the bolts if necessary. Replace any fan that is damage.

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-19

50 HOUR / WEEKLY SERVICE PERFORM ALL DAILY SERVICE CHECKS GREASE BLADE, BOOM, ARM AND FRONT ATTACHMENT PINS 1.

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

NOTE:

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

•

Position machine as shown below and lower the front attachment to the ground and shut down 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.

1

2

3

4 5 6 7,8 9

13

12

10

11

AKO0240L

Figure 25

1.

2.

3.

4.

5.

6.

7.

8.

BOOM HINGE PIN (1 POINT) BOOM CYLINDER HEAD AND ROD PINS (2 POINTS) ARM CYLINDER HEAD PIN (1 POINT) ARM CYLINDER ROD PIN (1 POINT) BOOM AND ARM HINGE PIN (1 POINT) BUCKET CYLINDER HEAD PIN (1 POINT) BUCKET CYLINDER ROD PIN (1 POINT) LINK JOINT PIN (2 POINTS)

4-20 Inspection, Maintenance and Adjustment

9.

10.

11.

12.

13.

BUCKET PINS (2 POINTS) BUCKET LINK PIN (1 POINT) DOZER CYLINDER HEAD AND ROD PINS WITH PUSH ARM PIVOTS (4 POINTS) BOOM SWING HINGE PIN (2 POINTS) BOOM SWING CYLINDER ROD (1 POINT)

022-00018CE Operation and Maintenance Manual

1.

Boom hinge pin (1 point).

Figure 26 2.

Boom cylinder head and rod pins (2 points).

Figure 27

Figure 28 3.

Arm cylinder head pin (1 point).

Figure 29

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-21

4.

Arm cylinder rod pin (1 point).

Figure 30 5.

Boom and arm hinge pin (1 point).

Figure 31 6.

Bucket cylinder head pin (1 point).

Figure 32 7.

Bucket cylinder rod pin (1, 1 point).

8.

Link joint pin (2, 2 points).

9.

Bucket pins (3, 2 points).

10.

Bucket link pin (4, 1 point).

Figure 33

4-22 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

11.

Dozer cylinder head and rod pins with arm pivots (4 points).

Figure 34 12.

Boom swing hinge pin (2 points).

Figure 35 13.

Boom swing cylinder rod (1 point).

Figure 36

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-23

GREASE SWIVEL BEARING 1.

Inject two or three strokes of grease at grease fitting (2, Figure 37).

2.

Lift bucket about 20 cm (8 in) from ground.

Turn upper body 90° at a time for two full turns, greasing the swivel bearing at each stop.

NOTE:

Fittings (2 and 3, Figure 37) are greased every 50 hours. Fitting (1) is greased every 500 hours.

BOOM SWING CYLINDER HEAD 1.

Figure 37

Inject grease through the grease fitting (3, Figure 37) using a grease gun.

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

Change engine oil after first 50 hours of operation or rebuild, and every 250 hours thereafter (See page 4-26).

2.

Change engine oil filter after first 50 hours of operation or rebuild, and every 500 hours thereafter (See page 4-32).

CHECK BATTERY ELECTROLYTE LEVEL AND CONDITION 1.

Check condition of battery. See "Battery"’ on page 4-49..

4-24 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

250 HOUR / MONTHLY SERVICE PERFORM ALL DAILY AND 50 HOUR SERVICE CHECKS CHECK TRAVEL REDUCTION DEVICE OIL LEVEL ON BOTH SIDES 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 38 NOTE:

Change oil after first 250 hours of operation or rebuild, and every 1,000 hours thereafter.

(See page 4-36)

NOTE:

See "Fluid Capacities"’ page 4-7. for capacity.

on

1.

Park machine on firm, level ground.

2.

Rotate the track until ports (1 and 2, Figure 38) are in their proper positions as shown.

3.

Remove plug (1, Figure 38). 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.

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-25

CHANGE ENGINE OIL NOTE:

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

NOTE:

Change engine oil filter after first 50 hours of operation or rebuild, and every 500 hours thereafter (See page 4-32).

WARNING! Do not change oil on a hot engine. Allow the engine to cool down before attempting to change the engine oil and filter to avoid buns by touching hot engine parts.

1.

Position a larger container under the engine oil pan (1, Figure 39). Remove drain plug (2, Figure 39) to allow all of the engine oil to drain from engine oil pan into container. Install drain plug.

NOTE:

2.

Dispose of drained fluids according to local regulations.

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.

3.

Start engine and check engine oil pressure warning light.

4.

Shut down engine. Look for signs of leaks at drain plug. Recheck oil level.

1

2

AKO0251L

Figure 39

CHANGE FUEL FILTER 1.

Replace fuel filter after first 250 hours of operation on a new machine and every 500 hours thereafter (See page 4-33).

CLEAN AIR CLEANER FILTER

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

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

AKO0043L

Figure 40

4-26 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

1.

Locate air filter assembly. Remove access cover (1, Figure 41) and remove filter (2, Figure 42) from air cleaner assembly.

NOTE:

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

NOTE:

Replace filter every 500 hours / 3 months of service.

Figure 41

Figure 42 2.

Clean filter by blowing compressed air from the inside of the filter towards the outside. Do not use more than 205 kPa (30 psi) air pressure.

3.

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

4.

Properly reinstall the air filter and cover.

Tighten the cover wing nut finger tight,. Do not use any tools to tighten the wing nut.

HAOC570L

Figure 43

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-27

DRAIN WATER AND SEDIMENT FROM 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. 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, service covers or drain water from the tank.

IMPORTANT Make sure to clean any dirt or water from the bottom of the hydraulic tank, especially around the drain plug.

1.

Position the machine on firm, level ground.

Extend arm and lower bucket to ground as shown.

2.

Shut down engine.

HKB3001L

Figure 44 3.

Remove bolts from access cover under seat and open it (Figure 45).

Figure 45

4-28 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

4.

Pull out prop rod (1, Figure 46) from housed position and insert it into hole (2, Figure 46) to secure access cover.

5.

Release pressurized air from hydraulic tank by slowly loosening breather cap (3, Figure 46) on top of tank.

6.

Slowly loosen (do not remove) drain plug on bottom of tank to drain water and sediment. Tighten drain plug when done.

Figure 46

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-29

REPLACE FULL FLOW HYDRAULIC OIL FILTER NOTE:

Change full flow hydraulic oil filter after first 250 hours of operation or rebuild, and every 500 hours thereafter (See page 4-35).

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 and access cover under left-hand console (Figure 47).

2.

Replace hydraulic oil filter after first 250 hours of operation or rebuild, and every 500 hours thereafter (See page 4-35).

Figure 47

Figure 48

4-30 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

INSPECT PINS AND BUSHINGS ON THE FRONT END ATTACHMENTS FOR SIGNS OF WEAR INSPECT FUEL SYSTEM HOSE CLAMPS CHECK ENGINE FAN BELT FOR CRACKS, WEAR AND CORRECT TENSION

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.

1.

Inspect every 10 hours.

2.

With engine shut off, check fan belt tension by pressing downwards on belt, midway between fan pulley and alternator pulley.

Depressing belt with a force of 98 N [10 kg (22 lb)] should deflect belt about 8 - 12 mm (0.3 - 0.5 in). See Figure 49. Adjust belt if necessary.

3.

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

Figure 49

Belt tension adjustment; NOTE:

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

1.

Loosen adjusting bolt (1, Figure 50) on subplate and alternator mounting bolt (2).

2.

Tilt alternator (3, Figure 50) to adjust belt tension.

3.

When tension is correct, tighten adjusting bolt (1, Figure 50) and secure alternator mounting bolt (2).

4.

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

022-00018CE Operation and Maintenance Manual

Figure 50

Inspection, Maintenance and Adjustment 4-31

500 HOUR / 3 MONTH SERVICE PERFORM ALL DAILY, 50 AND 250 HOUR SERVICE CHECKS GREASE SWING GEAR PINION TEETH 1.

Inject grease at grease fitting (1, Figure 51).

2.

Lift bucket about 20cm (8 in) from ground.

Turn upper body 90° at a time for one full turn, greasing the gear teeth at each stop.

NOTE:

Fittings (2 and 3, Figure 51) are greased every 50 hours. Fitting (1) is greased every 500 hours.

Figure 51

CHANGE ENGINE OIL FILTER NOTE:

Change engine oil after first 50 hours of operation or rebuild, and every 250 hours thereafter (See page 4-26).

NOTE:

Change engine oil filter after first 50 hours of operation or rebuild, and every 500 hours 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 to avoid buns by touching hot engine parts.

1.

Position a larger container under the engine oil pan (1, Figure 39). Remove drain plug (2, Figure 39) to allow all of the engine oil to drain from engine oil pan into container. Install drain plug.

NOTE:

Dispose of drained fluids according to local regulations.

1

2

AKO0251L

Figure 52

4-32 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

2.

Replace engine oil filter. The engine oil filter is a spin-on type. See Figure 53.

Remove and discard filter.

3.

Install new filter. Apply a small amount of oil around filter gasket. Screw filter on head until gasket contacts head, turn filter 3/4 turn more.

4.

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.

5.

Start engine and check engine oil pressure warning light.

6.

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

AKO0252L

Figure 53

CHANGE FUEL FILTER

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

NOTE:

Replace fuel filter after first 250 hours of operation or rebuild, and every 500 hours thereafter.

Figure 54

1.

Locate fuel filter (1, Figure 54) inside engine compartment.

2.

Position a small container under fuel filter assembly.

NOTE:

Dispose of drained fluids according to local regulations.

3.

Remove and discard the cartridge type filter as an assembly.

4.

Install new fuel filter.

NOTE:

5.

Fill fuel filter with clean fuel. This will help reduce fuel system priming.

Start engine. After engine has run for a couple of minutes, shut down 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 plugs (2, Figure 54) on top of fuel filter head.

2.

Crank engine until all air is expelled from fuel filter and there are no air bubbles in fuel.

3.

Tighten plugs (2, Figure 54).

4.

Start engine and look for signs of leaks.

5.

Repeat procedure if necessary.

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-33

REPLACE AIR CLEANER FILTER

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

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

Figure 55 1.

Locate air filter assembly. Remove access cover (1, Figure 55) and remove filter (2, Figure 56) from air cleaner assembly.

2.

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

3.

Install air cleaner cover.

Figure 56

CLEAN RADIATOR

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

Excessive pressure can radiator and oil cooler.

damage

the Figure 57

1.

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

2.

Clean the outside of radiator 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.

NOTE:

Be sure to cover air inlet on air cleaner assembly to prevent water and other contaminants from entering the engine.

4-34 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

REPLACE FULL FLOW HYDRAULIC OIL FILTER NOTE:

Change full flow hydraulic oil filter after first 250 hours of operation or rebuild, and every 500 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 and access cover under left-hand console (Figure 58).

2.

Remove hydraulic oil filter (Figure 59).

Properly discard filter.

3.

Coat gasket on new filter (Figure 59) with clean hydraulic oil. Screw filter on head until gasket contacts head. Turn filter 3/4 of a turn more.

4.

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

5.

Shut down engine. Look for signs of leaks at filter.

6.

Check level in hydraulic oil tank. Add oil if necessary.

Figure 58

022-00018CE Operation and Maintenance Manual

Figure 59

Inspection, Maintenance and Adjustment 4-35

1,000 HOUR / 6 MONTH SERVICE PERFORM ALL DAILY, 50, 250 AND 500 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 60 NOTE:

Change oil after first 250 hours of operation or rebuild, and every 1,000 hours thereafter.

1.

Make sure that machine is on a firm, level ground.

2.

Rotate track until ports (1 and 2, Figure 60) are in their proper positions.

3.

Place a container under plug (2, Figure 60) and remove plug (1, Figure 60) to drain travel reduction device oil.

NOTE:

See "Fluid Capacities"’ on page 4-7. for capacity.

NOTE:

Dispose of drained fluids according to local regulations.

4.

Install plug (2, Figure 60). Refill travel reduction device case with oil through port (1, Figure 60) until oil level is present at port.

5.

Repeat this procedure on other travel reduction device.

4-36 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

CHANGE RADIATOR COOLANT (PROPYLENE GLYCOL - EXTENDED LIFE ANTIFREEZE) NOTE:

Do not mix ethylene glycol and propylene glycol antifreeze together. If the two are mixed, the protection level will be reduced to the level of the ethylene glycol. See "Engine Cooling System" on page 4-52, for further details.

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.

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

1.

Slowly open the radiator cap (1, Figure 61) to allow any pressure to escape.

2.

Place a container under the radiator and open the drain valve (2, Figure 61).

NOTE:

Dispose of drained fluids according to local regulations.

Figure 61 3.

Remove coolant drain plug (Figure 62) from engine.

Figure 62

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-37

4.

Open heater shutoff valve (Figure 63) to allow coolant to drain from heater core.

5.

Install drain plug and close drain valve (2, Figure 61) after coolant has completely drained from system.

6.

Fill cooling system with a flushing solution.

7.

Run engine at low idle until the engine 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.

11.

Drain water and fill system with proper antifreeze mixture for ambient temperature.

Refer to "Antifreeze Concentration Tables" on page 4-53.

12.

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

Fill radiator to 50 mm (2 in) below fill neck.

13.

Drain and fill radiator coolant recovery tank.

Figure 63

CHECK, ADJUST VALVE CLEARANCE ** CHECK, TORQUE HEAD BOLTS ** **These checks need to be completed by an authorized Daewoo dealer.

4-38 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

2,000 HOUR / YEARLY SERVICE PERFORM ALL DAILY, 50, 250, 500 AND 1,000 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. 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.

HAOA060L

Figure 64

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

NOTE:

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

1.

Position the machine on firm, level ground.

Extend arm and lower bucket to ground as shown.

2.

Shut down engine after setting safety lever to "LOCK" position.

HKB3001L

Figure 65

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-39

3.

Remove bolts from access cover under seat and open it (Figure 66).

Figure 66 4.

Pull out prop rod (1, Figure 67) from housed position and insert it into hole (2, Figure 67) to secure access cover.

5.

Release pressurized air from hydraulic tank by slowly loosening breather cap (3, Figure 67) on top of tank.

6.

Remove drain plug from below hydraulic oil tank and drain hydraulic oil from tank into a container.

7.

NOTE:

See "Fluid Capacities"’ page 4-7. for capacity.

on

NOTE:

Dispose of drained fluids according to local regulations.

Figure 67

After draining tank install drain plug.

IMPORTANT Be careful of squirting oil when removing drain plug.

8.

Remove bolts (1, Figure 68) and cover (2, Figure 68) from top of hydraulic oil tank.

Figure 68

4-40 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

9.

Remove oil suction strainer (1, Figure 69).

10.

Clean inside and outside of strainer.

Replace strainer if it is broken.

11.

Install strainer (1, Figure 69) on boss portion of suction pipe.

12.

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

Figure 69

CHECK ALTERNATOR AND STARTER** **These checks need to be completed by an authorized Daewoo dealer.

CHECK ALL RUBBER ANTIVIBRATION 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

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-41

4,000 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

Fuel hose (Tank - Fuel injection pump)

Engine

Heater hose (Heater - Engine; If equipped) Pump suction hose Body

Pump discharge hose Boom swing hose

Hydraulic System

Boom cylinder line hose Work Device

2 years or 4,000 hours

Arm cylinder line hose Bucket cylinder line hose Pilot hose

4-42 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

12,000 HOUR / SIX YEAR SERVICE HOSE IN-SERVICE LIFETIME LIMIT (EUROPEAN STANDARD ISO 8331 AND EN982 CEN) European regulations state that the in-service life of any hydraulic hose may not exceed six years. Daewoo recommends the following; •

Hoses at the customer premises can not be stored more than 2 years before being discarded or installed on a machine.

•

In-service lifetime of hoses fitted on a machine can never exceed 6 years, but replace hoses described in "Major Parts - Periodic Replacement" on page 4-42, every 2 years. Always replace hoses having exceeded the allowed in-service lifetime irrespective of the external appearance/ wear.

•

Always store hoses in a dark place at a maximum of 65% relative humidity, between 0°C (32°F) and 35°C (95°F) but as close as possible to 15°C (59°F) and away from copper, manganese or tube generating Ozone.

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-43

BOLT AND NUT INSPECTION Inspect ALL fasteners after the first 50 hours of operation or rebuild, 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.

If counterweight is loose, contact a DAEWOO distributor or sales agent.

NOTE:

At installation, remove rust, sand, dirt and dust.

At installation, lubricate to reduce abrasion.

Apply Loctite to lower roller mounting bolts.

No.

Bolt Dia. mm

Qty.

Bolt Head Size

Nm

ft lb

Front

10

2

17

20 - 25

15 - 18

Rear

12

2

19

45 - 50

33 - 37

10

7

17

49

36

PF1/4

-----

-----

27 - 29

20 - 22

PF3/8

-----

-----

46 - 51

34 - 38

PF1/2

-----

-----

56 - 62

41 - 43

Point To Be Inspected

1

Engine Vibration dampening mount bolts

2

Hydraulic, Fuel Tank Mounting Bolts

3

Hydraulic Hose and Pipe Joint

Torque

4

Pump Mounting Bolt

10

2

17

64

47

5

Control Valve Mounting Bolt

8

3

13

22

16

6

Control Valve Base Mounting Valve

8

4

13

22

16

7

Swing Assembly Mounting Bolt

12

12

19

88

65

8

Cabin Mounting Bolt

12

4

19

108

80

Swing Body

12

18

19

108

80

9

Swing Bearing Mounting Bolt

Track

12

18

19

108

80

10

Undercarriage Mounting Bolt

10

16

-----

64

47

11

Sprocket Mounting Bolts

10

18

-----

64

47

12

Lower Roller Mounting Bolt

16

6

24

206

152

13

Cover Mounting Bolt

8

-----

13

22

16

10

-----

17

42

31

14

Counter Weight mounting Bolt

14

4

22

176

130

4-44 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

BUCKET BUCKET TOOTH REPLACEMENT

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

Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground.

Shut the engine off and lock out the hydraulic controls before working on the bucket.

NOTE:

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

Figure 70

1.

On a routine basis, inspect the bucket teeth to make sure that tooth wear or breakage has not developed. Do not allow the replaceable bucket teeth to wear down to the point that the bucket is exposed.

See Figure 70.

2.

To replace a tooth, remove bolts, lock washers and plain washers from seat.

Remove tooth and shim(s) from bucket.

See Figure 71.

3.

Once the worn tooth has been removed, use a putty knife to scrape bucket as clean as possible.

022-00018CE Operation and Maintenance Manual

Figure 71

Inspection, Maintenance and Adjustment 4-45

4.

Slide the new tooth into position and insert shims. Shim tooth until gap is less than "X" [0.5 mm (0.02 in)]. See Figure 72.

5.

Secure tooth and shim into position with seat, plain washers, lock washers and bolts.

Figure 72

BUCKET O-RING REPLACEMENT

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

1.

Inspect the bucket O-rings on a routine basis. If worn or damaged, replacement is necessary.

HAOE360L

Figure 73 2.

Roll the old O-ring (1, Figure 74) onto the bushing (2) around the bucket pin (3).

Remove the bucket pin and move the arm or bucket link (4) out of the way.

1

4 2

3

HAOC710L

Figure 74

4-46 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

3.

4.

Remove the old O-ring and temporarily install the new O-ring (1, Figure 75) onto the bucket bushing (2). Make sure that the O-ring groove on both the bucket link (3) and bushing have been cleaned.

1

2

3

Realign the arm or link with the bucket pin hole and insert the bucket pin (3, Figure 74).

HAOC700L

Figure 75 5.

Roll the new O-ring (1, Figure 76) into the O-ring groove.

1

HAOC720L

Figure 76

BUCKET SHIMMING PROCEDURES New Bucket Installation 1.

If a new bucket is being installed on the excavator, measure the inside dimension between the bucket ears and the outside dimension across the arm mounting boss.

2.

Subtract the clearance on both sides from the difference of the two and shim accordingly, before assembly.

WARNING! To check end play (side-to-side) clearance at bucket attachment point, the bucket must be free to move but at all other times lower it to the ground or use support blocks to immobilize this assembly. Shut off engine and tag and lock out controls to prevent movement during this procedure.

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-47

Shimming Procedures for Installed Bucket 1.

With bucket attached, curl bucket and arm outward and lower boom so that bucket teeth are pointing away from excavator, just a few inches off ground. This position provides easy accessibility for dimensional measurements.

2.

Force bucket to one side and check for end play (side-to-side) clearance under O-rings at attachment point. Clearance should be between 0.2 - 0.7 mm (0.0078 - 0.0275 in) on each end of arm boss, between side face of boss and inside edge of ear bushing. Too tight a fit can cause excessive wear while too much clearance may produce excessive noise and potentially hazardous slack control.

3.

Recheck end play by forcing bucket towards opposite side and repeating clearance measurements.

4.

HAOE361L

Figure 77

If an adjustment is required, remove bolt (Figure 77) and pin. Add or remove shims as required. Install pin and bolt. Torque bolts to 42 Nm / 4.3 kg•m (31 ft lb).

4-48 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

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 starter switch to the "OFF" position.

The batteries create hydrogen gas. An explosion hazard exists, particularly with a deeply discharged battery. Make sure that open flames, burning objects or sparks 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 (1, Figure 78) by looking at the indicator light (2) built into the battery.

•

GREEN: Normal.

•

BLACK (DARK EYE): Insufficient charging - check alternator.

•

WHITE: Insufficient battery electrolyte - replace with new battery.

NOTE:

HAOC660L

Figure 78

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

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-49

FUSES 1.

The fuses in the fuse panel are used to protect the various electrical circuits and their components from being damaged.

See Figure 79. 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 79

FUSE BOX The fuse box is by the front of the seat. Fuses prevent electrical devices from overloading or shorting.

A decal attached to the inside of the fuse box's cover indicates the function and amperage of each fuse.

Spare fuses are mounted on the inside of fuse box cover (10A - Qty. 1, 15A - Qty. 1, 20A - Qty. 1).

Fuses are rated for the following amps; 10 AMP

Figure 80

15 AMP 20 AMP

4-50 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

The following is a listing of fuse identification:

HAOB050L

Figure 81

No.

Name

Capacity

No.

Name

Capacity

1

Spare

10 AMP

8

Spare

10 AMP

2

Instrument Panel

10 AMP

9

10 AMP

Preheat Timer, Heater (Option)

15 AMP

3

Wiper, Washer (Option)

10

Cigar Lighter (Option)

15 AMP

4

Cut Off Work

10 AMP

11

Horn

15 AMP

5

Rotating Beacon Light (Option)

10 AMP

12

Work Light

15 AMP

13

Spare

20 AMP

6

Alternator

10 AMP

14

Spare

20 AMP

7

Room Light (Option)

10 AMP

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-51

ENGINE COOLING SYSTEM GENERAL Keeping an engine's cooling system in peak operating condition, can have many benefits to keeping a machine in good operating condition. A properly functioning cooling system will; improve fuel efficiency, reduce engine wear, and extend component life.

Always use distilled water in the radiator. Contaminants in tap water neutralize the corrosion inhibitor components. If tap water must be used, it should not exceed 300 ppm hardness, or contain more than 100 ppm of either chloride or sulfate. Water that has been treated with a water softener also contains salt that will cause corrosion of components. Water from creeks and stagnant pools usually contains dirt, minerals and/or organic material that are deposited in the cooling system and impair cooling efficiency. Distilled water is the best.

Engine overheating is often caused by bent or clogged radiator fins. The spaces between the fins can be cleaned by use of air or water under pressure. When straightening bent fins, use care not to damage the tubes or break the bond between the fins and the tubes.

WARNING! Pressure at air nozzle must not exceed 2.1 kg/cm2 (30 psi). Always wear goggles when using compressed air.

Do not pour cold water into radiator when engine is very hot and water level is below the top of the tubes. Such action could result in damage to engine cylinder heads.

Heavy duty diesel engines require a balanced mixture of water and antifreeze. Drain and replace the mixture every year or 1,000 hours of operation, which ever comes first. This will eliminate buildup of harmful chemicals.

Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant's freezing point and by raising its boiling point. Do not use more than 50% antifreeze in the mixture unless additional freeze protection is required. Never use more than 68% antifreeze under any condition.

Types of Antifreeze There are two main classifications of antifreeze available on the market today.

1.

Ethylene Glycol - Standard Life Antifreeze

2.

Propylene Glycol - Extended Life Antifreeze

Ethylene glycol (standard life antifreeze) has been on the market for many years. Its chemical properties do not provide the improved corrosion resistance that propylene glycol (extended life antifreeze) does.

Ethylene glycol is also very hazardous to the environment, people and animals. Daewoo recommends that ethylene glycol be replaced with propylene glycol.

The newer propylene glycol antifreeze comes in many different colors. Some of the colors are pink, red, orange and yellow. There are even some that come in a blue-green color. The blue-green color makes it very difficult to tell the difference of what type of antifreeze is in a cooling system. The colors are only a dye added to the clear antifreeze. Do not rely on color. Keep careful machine records of what brand and type of antifreeze is used in the unit. If you are unsure of what type of antifreeze is in the system, drain and flush the system.

4-52 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

NOTE:

Do not mix ethylene glycol and propylene glycol antifreeze together. If the two are mixed, the protection level will be reduced to the level of the ethylene glycol.

ANTIFREEZE CONCENTRATION TABLES Ethylene Glycol - Standard Life Antifreeze Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-4°F)

67%

33%

-25°C (-13°F)

60%

40%

-30°C (-22°F)

56%

44%

-40°C (-40°F)

50%

50%

Propylene Glycol - Extended Life Antifreeze Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

78%

22%

-15°C (5°F)

71%

29%

-20°C (-4°F)

65%

35%

-25°C (-13°F)

59%

41%

-30°C (-22°F)

55%

45%

-40°C (-40°F)

48%

52%

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-53

LONG TERM STORAGE Perform the following if storing the excavator 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 excavator or remove the battery leads from the battery to fully charge and store.

4. Cooling System

1.

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

2.

Every 90 days, 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 procedures in "Hydraulic System Warm-up" on page 3-10.

5. Hydraulic System

MAINTENANCE IN SPECIAL CONDITIONS Conditions Operating in mud, water or rain.

4-54 Inspection, Maintenance and Adjustment

Maintenance Required 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.

022-00018CE Operation and Maintenance Manual

Conditions Operating in an extremely dusty or hot environment.

Operating in rocky terrain.

Operating in extreme cold.

022-00018CE Operation and Maintenance Manual

Maintenance Required 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 fuel for the temperature 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.

Inspection, Maintenance and Adjustment 4-55

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 excavator 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 tightened down position. Bleed off pressure slowly and keep your body away from the valve at all times.

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.

1.

Track tension is checked by jacking up one side of the excavator. See Figure 82. Place blocking under frame while taking measurement.

HBOH811L

Figure 82 2.

Measure clearance between track roller and track contact surfaces. Clearance should be approximately 10 - 15 mm (0.39 - 0.59 in).

NOTE:

This measurement can be thrown off if there is too much mud or dirt or other material in the track assembly. Clean off the tracks before checking clearance.

Figure 83

4-56 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

3.

Rubber tracks (Figure 84) have a 10 15 mm (0.39 - 0.59 in) clearance.

Figure 84

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 tightened down position. Bleed off pressure slowly and keep your body away from the valve at all times.

4.

Track tension adjustments are made through the grease fitting (1, Figure 86) in the middle of each side frame. Adding grease increases the length of an adjustment cylinder (2, Figure 86). The longer the adjustment cylinder, the greater the pressure on the tension spring pushing the track idler sprocket outward.

5.

If there isn't enough slack or clearance in the tracks and the adjustment is too tight, the idler sprocket and adjusting cylinder can be retracted by bleeding off grease thru hole in valve (3, Figure 86).

Figure 85

NOTE:

Tighten valve to 59 - 88 Nm / 6 9 kg•m (43 - 65 ft lb).

Figure 86

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-57

VENTING AND PRIMING HYDRAULIC SYSTEM MAIN SYSTEM PUMP NOTE:

If pump is run without sufficient oil in the main hydraulic pump, damage can occur. Always vent pump of air after draining hydraulic system.

1.

Tag and disconnect hoses and remove fittings (Figure 87) and fill pump through ports.

2.

Install fittings and connect hoses (Figure 87).

3.

Start engine and run it for several minutes.

4.

Shut down engine and inspection ports for signs of leaks.

Figure 87

HYDRAULIC CYLINDERS

IMPORTANT If cylinders are operated in high idle after the hydraulic system has been drained or the cylinder has been rebuilt, damage to piston packing and seals may occur. Always vent air from cylinders at low idle and at a slow speed.

1.

Run engine at low idle. Extend and retract each cylinder to within 100 mm (4 in) of fully stroking it 4 5 times.

2.

Operate fully extend and retract each cylinder 3 - 4 times.

3.

Repeat procedure until cylinders extend and retract smoothly.

SWING MOTOR

IMPORTANT If the air is not vented from the system, it will cause damage to the swing motor and bearings.

NOTE:

Perform this only when oil has been drained from swing motor.

4-58 Inspection, Maintenance and Adjustment

022-00018CE Operation and Maintenance Manual

1.

Shut down engine.

2.

Remove floor mat and access cover from cab floor (Figure 88).

3.

Disconnect drain hose (Figure 88) and fill swing motor case with hydraulic oil.

4.

Connect the drain hose.

5.

Start engine and set throttle at "LOW IDLE" and swing upper structure slowly two full revolutions to the left and right.

Figure 88

Figure 89 AIR RELEASE OF TRAVEL MOTOR NOTE:

Perform this only when oil is drained from travel motor.

1.

Shut down engine.

2.

Disconnect drain hose (Figure 90) and fill motor case with hydraulic oil.

3.

Connect drain hose.

4.

Start engine and set engine speed control dial to "LOW IDLE." Run the engine for one minute and slowly drive excavator forwards and backwards.

Figure 90

GENERAL VENTING 1.

After venting air from all components, shut the engine down and check the hydraulic oil level. Fill hydraulic oil tank to "H" mark on sight gauge.

2.

Start engine and operate all controls again, run engine for 5 minutes to ensure all system have been vent and purged of air. Shut down engine and check hydraulic oil level again. Add oil as necessary.

3.

Check for oil leaks and clean all fill and venting locations.

022-00018CE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-59

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 DANGER! Daewoo warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries. Daewoo is not liable for any misuse.

Never remove the counterweight or front attachment unless the upper structure is in-line with the lower structure.

X

X

Never rotate the upper structure once the counterweight or front attachment has been removed.

HAAD4060

Figure 91

022-00018CE Operation and Maintenance Manual

Transportation 5-1

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 can handle 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 excavator.

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 that the swing lock pin is inserted before transporting to prevent the machine from accidental swinging.

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

LOADING 1.

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

2.

Chock truck wheels so that truck cannot move during loading or unloading.

3.

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

4.

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.

5.

Load machine at slowest possible travel speed and engine rpm.

6.

When loading or unloading, be careful not to hit blade. Fully raise blade and position it to rear. Use bucket to prevent tracks from tipping suddenly as machine moves onto bed of transport vehicle.

5-2 Transportation

90 ~110

HKB2071L

Figure 1

022-00018CE Operation and Maintenance Manual

7.

When machine is in position for transport, raise bucket slightly from bed, turn upper body 180° slowly with arm retracted.

8.

Set engine speed to "LOW IDLE."

9.

Place blocking under bucket.

10.

Fully lower blade.

HKB2072L

Figure 2 11.

Set safety lever (Figure 3) to "LOCK" position.

12.

Shut down engine and remove key from starter switch.

13.

Before transporting the excavator, make sure that the swing lock has been engaged in the "B" position (See Figure 4). This will prevent the excavator from accidentally rotating during transportation.

Figure 3

Figure 4

022-00018CE Operation and Maintenance Manual

Transportation 5-3

14.

Make sure to secure the excavator onto the trailer before transporting. Place blocking in front of and behind each track.

Use chains or cable tie-downs as required by local transportation laws.

NOTE:

15.

Do not use wire cable on tracks of steel crawler. Secure machine by passing cable of the track frame as shown in Figure 5.

Refer to the Dimensions for Transportation table and drawing for overall machine height and width measurements. Make sure to position the excavator as shown. If not transported in this position, the height measurements may be different.

Figure 5

UNLOADING

WARNING! 90 ~110

When unloading machine, be careful of the point where the back end of the truck bed meets the loading ramp: the machine will tilt as it crosses this point.

1.

When moving on transport vehicle bed, keep arm at an angle of 90° - 110° to boom and move slowly. (Keeping arm retracted could cause damage to machine.)

2.

Go down loading ramp until bucket contacts ground.

3.

Until machine is completely off loading ramp, move machine slowly while lifting front attachment.

HKB2074L

Figure 6

HKB2075L

Figure 7

5-4 Transportation

022-00018CE Operation and Maintenance Manual

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.

HAOK330S

Figure 8

022-00018CE Operation and Maintenance Manual

Transportation 5-5

6TROUBLESHOOTING It is important to respond quickly to problems uncovered in troubleshooting. For adjustment or overhaul of hydraulic or electrical systems, see your nearest Daewoo dealer.

ATTACHMENTS Problem Lack of power.

Poor overall performance.

Lack of power.

Unusual sound from attachment connections.

Cause

Remedy

Lack of engine power.

Tune engine.

Poor performance due to worn hydraulic pump.

Replace hydraulic pump.

Bad main relief valve.

Adjust pressure or replace.

Low level of hydraulic oil.

Add oil.

Wrong viscosity hydraulic oil.

Replace with correct viscosity.

Suction filter restricted.

Replace filter.

Hydraulic pump failure.

Replace hydraulic pump.

Hydraulic oil level low.

Add oil.

Main or port relief valve pressure set too low.

Adjust pressure.

Damaged hydraulic cylinder seal.

Replace seal.

Hydraulic cylinder piston or rod damaged.

Replace piston or rod.

Lack of grease.

Add grease.

Coupling pin worn.

Replace bushing or pin.

CENTER JOINT Problem Lack of power.

Cause

Remedy

Bad center joint seal.

Replace.

Damaged center joint rotor.

Replace.

Bad seal.

Replace seal.

CONTROL LEVER Problem Lever feels "heavy" when operated.

Cause

Remedy

Foreign material in control valve spool.

Clean control valve.

Valve spool sticking.

Replace valve housing assembly.

Lack of linkage lubrication.

Lubricate.

022-00018CE Operation and Maintenance Manual

Troubleshooting 6-1

CONTROL VALVE Problem Fails to bear load.

Load drops when control is moved from neutral to UP.

Spool sticking.

Leaky oil seal.

Spool does not move.

Cause

Remedy

Leaky spool.

Replace valve housing assembly.

Leaky port relief valve.

Disassemble, clean or replace port relief valve.

Foreign material in load check valve.

Disassemble and clean load check valve.

Damaged poppet or seal in load check valve.

Replace poppet or lap poppet and seal.

Hydraulic oil excessively hot due to blockage.

Remove blockage.

Hydraulic oil fouled.

Change oil and clean oil passages.

Valve housing deformed due to overtightened fittings on hydraulic oil line.

Replace valve housing.

Foreign material in spool.

Clean or replace valve housing assembly.

Pressure too high.

Check with pressure gauge and adjust.

Lever or linkage bent.

Remove and check linkage.

Return spring damaged.

Replace.

Valve temperature uneven.

Warm up entire system.

Foreign material in seal.

Clean seal.

High back pressure in valve return line.

Increase size of return line.

Foreign material in seal.

Clean seal.

Damaged spool.

Replace valve housing assembly.

Seal cracked or damaged.

Replace.

Foreign material in valve.

Clean valve.

Spool cap fouled with oil.

Replace cap shaft seal.

Leaky spool.

Replace valve housing assembly.

HYDRAULIC CYLINDER Problem Lack of cylinder power.

6-2 Troubleshooting

Cause

Remedy

Relief valve pressure set too low.

Adjust pressure.

Oil leak from inside cylinder.

Replace cylinder seals.

Cylinder piston or rod damaged.

Replace piston or rod.

Oil leak from inside control valve.

Replace valve housing assembly.

022-00018CE Operation and Maintenance Manual

Problem

Cause

Remedy

Oil leak from outside cylinder.

Bad hydraulic cylinder seals.

Replace seals.

Damaged cylinder rod.

Replace rod.

Unsmooth piston movement.

Hydraulic oil temperature high.

Lower temperature.

Air in system.

Retighten fittings on oil fill and suction sides.

HYDRAULIC MOTOR Problem Hydraulic motor does not rotate.

Hydraulic motor will not allow turning to one side.

RPM low.

Unusual sound from hydraulic motor.

Cause

Remedy

Hydraulic oil low.

Add oil.

Hydraulic pump bad.

Replace pump.

Oil leak from inside hydraulic motor.

Replace motor.

Overload applied to output shaft.

Locate and remove cause of overload.

Low viscosity hydraulic oil.

Change to oil with correct viscosity.

Bad control valve relief valve.

Clean or replace relief valve.

Counterbalance valve spool sticking.

Replace counterbalance valve.

Hydraulic oil level low.

Add oil.

Oil leak due to excessive high temperature.

Reduce oil temperature.

Air in system.

Bleed.

Oil leak from inside motor.

Replace motor.

Hydraulic oil level low.

Add oil.

Air in motor.

Retighten fittings on suction side.

Wear and damage inside hydraulic motor.

Replace motor.

Shaft installed properly.

Readjust shaft.

HYDRAULIC PUMP Problem Poor oil delivery.

Pressure does not rise.

Cause

Remedy

Hydraulic oil level low.

Add oil.

Suction filter restricted.

Clean and replace filter.

Oil leak from inside pump.

Replace pump.

Air in pump.

Add oil or check suction side hose.

Main relief valve pressure set too low.

Adjust pressure.

022-00018CE Operation and Maintenance Manual

Troubleshooting 6-3

Problem

Cause

Unusual sound from hydraulic pump.

Oil leak from outside pump.

Remedy

Cavitation from bent suction side hose or clogged suction filter.

Replace hose and filter.

Cavitation from suction side fittings and air in system due to low oil level.

Tighten fittings and add oil.

Cavitation due to high viscosity oil.

Replace oil.

Pump and engine not aligned.

Readjust shaft.

Air in hydraulic oil.

Bleed.

Bad hydraulic pump seal.

Replace seal or pump.

RELIEF VALVE Problem

Cause

Remedy

Pressure does not rise.

Poppet sticking open.

Disassemble and clean.

Pressure unstable.

Damaged pilot poppet seal.

Replace damaged parts.

Main poppet of pilot piston sticking.

Disassemble, clean and remove surface pitting.

Wear, due to foreign material.

Replace worn parts.

Lock nut and adjusting spring loose.

Adjust pressure.

Seals leaking, O-ring worn.

Replace worn or damaged parts.

Parts sticking, due to foreign material.

Disassemble, check for damage and clean.

Abrupt rise and fall in pressure.

Oil leaks.

SWING SYSTEM Problem Swing power weak.

Braking power weak.

Swing motion drags while stopping.

Unusual sound.

6-4 Troubleshooting

Cause

Remedy

Hydraulic motor performs poorly.

Replace hydraulic motor.

Swing bearing seized.

Grease or replace swivel bearing.

Brake valve pressure set low.

Adjust pressure.

Foreign material in port relief or brake valves.

Clean valves.

Port relief or brake valve pressure set low.

Adjust pressure.

Foreign material in port relief or brake valves.

Clean valves.

Air in system.

Add oil.

Swing bearing needs grease.

Grease.

022-00018CE Operation and Maintenance Manual

TRAVEL Problem Lack of power when traveling.

Travel not smooth.

Machine wanders, does not travel straight.

Cause

Remedy

Main relief valve pressure set too low.

Adjust pressure.

Counterbalance valve bad.

Replace counterbalance valve.

Hydraulic motor performs poorly.

Replace hydraulic motor.

Damaged center joint seal.

Replace seal.

Hydraulic pump bad.

Replace hydraulic pump.

Oil leak from inside control valve.

Replace valve housing assembly.

Tracks tension low.

Adjust tension.

Stone(s) jammed in track.

Remove.

Counterbalance valve bad.

Replace valve.

Hydraulic motor performs poorly.

Replace hydraulic motor.

Air in hydraulic motor.

Add oil.

Tracks have different tension.

Adjust so that tracks have equal tension.

Hydraulic pump performs poorly.

Replace hydraulic pump.

Hydraulic motor performs poorly.

Replace hydraulic motor.

Oil leak from inside control valve.

Replace valve housing assembly.

Damaged center joint seal.

Replace seal.

Lever linkage loose.

Readjust linkage.

022-00018CE Operation and Maintenance Manual

Troubleshooting 6-5

7SPECIFICATION GENERAL SPECIFICATIONS SOLAR 015 PLUS (S/N 1001 thru 1157, 20001 thru 20065) Item

Specification

Equipment Weight (Canopy / Cabin)

1,550 kg (3,420 lb) / 1570 kg (3,460 lb)

Bucket Capacity

0.04 m3 (0.05 yd3)

Bucket Width

450 mm (17.72 in)

Engine

Speeds

Manufacturer & Model

MITSUBISHI L3E

Piston Displacement

0.952 liters

Rated Output

17.2 ps (17.0 hp) @ 2,300 rpm

Torque

5.5 kg•m (39.78 ft lb) @ 2,100 rpm

Travel Speed

Low Range

Swing Speed

Overall Dimensions

Track Assembly

11 rpm

Max. Grade

25°

Max. Digging Power

1,270 kg (2,800 lb)

Total Length

3,755 mm (12' 4")

Total Width (Canopy / Cabin)

1,300 mm (4' 3") / 1,000 mm (3' 3")

Total Height (Canopy / Cabin)

2,345 mm (7' 8") / 2,290 mm (7' 6")

Dozer Blade

Width & Height (Canopy / Cabin)

1,300 mm x 235 mm / 1,000 mm x 235 mm (51.18 in x 9.25 in / 39.37 in x 9.25 in)

Max Ground Clearance

155 mm (6.10 in)

Ground Pressure (Canopy / Cabin)

0.25 kg/cm2 (3.56 psi) / 0.26 kg/cm2 (3.7 psi)

Travel Motor Type

Orbitrol

Shoe

Hydraulic

Material

Rubber

Operating Control Type

Grease Cylinder Type

Pump Type

Gear Pump 2

Main Pressure kg/cm (psi)

Output/Discharge Capacity - liters/ min. (DBMS) Hydraulic Oil Tank Capacity Miscellaneous Fluid Capacities

2.2 km/h (1.37 MPH)

P1

P2

P3

210 (2,987)

210 (2,987)

165 (2,346)

11.7 (3.09)

11.7 (3.09)

10.7 (2.82)

26 liters (7 U.S. gal.)

Engine Oil Capacity

4.1 liters (1.08 U.S. gal.)

Fuel Tank Capacity

19 liters (5 U.S. gal.)

Coolant Capacity

1.8 liters (0.48 U.S. gal.)

022-00018CE Operation and Maintenance Manual

Specification 7-1

SOLAR 015 PLUS (S/N 20066 thru 30000) Item

Specification

Equipment Weight (Canopy / Cabin)

1,550 kg (3,420 lb) / 1,570 kg (3,461 lb)

Bucket Capacity

0.04 m3 (0.05 yd3)

Bucket Width

450 mm (17.72 in)

Engine

Speeds

Overall Dimensions

Manufacturer & Model Piston Displacement

0.952 liters

Rated Output

17.2 ps (17.0 hp) @ 2,300 rpm

Torque

5.5 kg•m (39.78 ft lb) @ 2,100 rpm

Travel Speed

11.1 rpm 25°

Max. Digging Power

1,270 kg (2,800 lb)

Total Length

3,760 mm (12' 4")

Total Width

1,000 mm (3' 3")

Total Height

2,390 mm (7' 10") Width & Height

1,000 mm x 235 mm (39.37 in x 9.25 in)

Max Ground Clearance

155 mm (6.10 in)

Ground Pressure (Canopy / Cabin)

0.25 kg/cm2 (3.56 psi) / 0.26 kg/cm2 (3.7 psi)

Travel Motor Type

Piston Material

Rubber

Operating Control Type

Grease Cylinder Type

Pump Type

Piston Pump 2

Main Pressure kg/cm (psi)

Output/Discharge Capacity - liters/ min. (DBMS) Miscellaneous Fluid Capacities

7-2 Specification

2.2 km/h (1.37 MPH) / 3.8 km/h (2.36 MPH)

Max. Grade

Shoe

Hydraulic

Low / High

Swing Speed

Dozer Blade

Track Assembly

MITSUBISHI L3E

Gear Pump

P1

P2

P3

P4

210 (2,987)

210 (2,987)

165 (2,346)

40 (569)

16.3

16.3

10.4

11.7

Hydraulic Oil Tank Capacity

26 liters (7 U.S. gal.)

Engine Oil Capacity

4.1 liters (1.08 U.S. gal.)

Fuel Tank Capacity

19 liters (5 U.S. gal.)

Coolant Capacity

1.8 liters (0.48 U.S. gal.)

022-00018CE Operation and Maintenance Manual

022-00018CE Operation and Maintenance Manual

Specification 7-3

C

A

B

D

E

G

F

Canopy Machine (Standard)

S

T

J

K

I

L

H

M U

N P

O R

V W AKS2190L

Figure 1

7-4 Specification

022-00018CE Operation and Maintenance Manual

DIMENSION

MEASUREMENT

A

315 mm (12.40 in)

B

450 mm (17.72 in)

C

50 mm (1.97 in)

D

452 mm (17.80 in)

E

175 mm (6.89 in)

F

1,190 mm (3' 11")

G

50°

H

75°

I

1,200 mm (3' 11")

J

235 mm (9.25 in)

K

425 mm (16.73 in)

L

2,345 mm (7' 8")

M

1,224 mm (4' 0")

N

920 mm (3' 0")

O

2,570 mm (8' 5")

P

1,190 mm (3' 11")

R

3,760 mm (12' 4")

S

370 mm (14.57 in)

T

155 mm (6.10 in)

U

1,070 mm (3' 6")

V

230 mm (9.06 in)

W

1,300 mm (51.18 in)

022-00018CE Operation and Maintenance Manual

Specification 7-5

C

A

D

B

E

G

F

Cab Machine (Option)

T

S

J

K

I

L

H

M V

N O

P R

U W AKS2200L

Figure 2

7-6 Specification

022-00018CE Operation and Maintenance Manual

DIMENSION

MEASUREMENT

A

315 mm (12.40 in)

B

450 mm (17.72 in)

C

50 mm (1.97 in)

D

452 mm (17.80 in)

E

175 mm (6.89 in)

F

1,190 mm (3' 11")

G

50°

H

75°

I

1,200 mm (3' 11")

J

235 mm (9.25 in)

K

425 mm (16.73 in)

L

2,290 mm (7' 6")

M

1,224 mm (4' 0")

N

920 mm (3' 0")

O

2,570 mm (8' 5")

P

1,190 mm (3' 11")

R

3,760 mm (12' 4")

S

370 mm (14.57 in)

T

155 mm (6.10 in)

U

770 mm (2' 6")

V

230 mm (9.06 in)

W

1,000 mm (39.37 in)

022-00018CE Operation and Maintenance Manual

Specification 7-7

WORKING RANGE F

D

B

G

H

C

A

E

I

J K L AKO0470L

Figure 3

DIMENSION

1.69 M (5' 7") BOOM WITH 0.85 M (2' 9") ARM (STANDARD)

1.69 M (5' 7") BOOM WITH 1.1 M (3' 7") ARM (OPTION)

A

3,400 mm (11' 2")

3,561 mm (11' 8")

7-8 Specification

B

2,140 mm (7' 0")

2,382 mm (7' 10")

C

2,245 mm (7' 4")

2,418 mm (7' 11")

D

1,630 mm (5' 4")

1,843 mm (6' 1")

E

1,470 mm (4' 10")

1,470 mm (4' 10")

F

1,190 mm (3' 11")

1,190 mm (3' 11")

G

425 mm (16.73 in)

434 mm (17.09 in)

H

2,345 mm (7' 8")

2,388 mm (7' 10")

I

1,224 mm (4' 0")

1,224 mm (4' 0")

J

2,646 mm (8' 8")

2,746 mm (9' 0")

K

3,608 mm (11' 10")

3,850 mm (12' 8")

L

3,700 mm (12' 2")

3,918 mm (12' 10")

022-00018CE Operation and Maintenance Manual

APPROXIMATE WEIGHT OF WORKLOAD MATERIALS IMPORTANT Weights are approximations of estimated average volume and mass. Exposure to rain, snow or ground water; settling or compaction due to overhead weight and chemical or industrial processing or changes due to thermal or chemical transformations could all increase value of weights listed in table.

LOW WEIGHT OR DENSITY 1,100 KG/M3 (1,850 LB/YD3), OR LESS

MEDIUM WEIGHT OR DENSITY 1,600 KG/M3 (2,700 LB/YD3), OR LESS

HIGH WEIGHT OR DENSITY 2,000 KG/M3 (3,370 LB/YD3), OR LESS

Charcoal

401 kg/m3 (695 lb/yd3)

---------------------

---------------------

Coke, blast furnace size

433 kg/m3 (729 lb/yd3)

---------------------

---------------------

Coke, foundry size

449 kg/m3 (756 lb/yd3)

---------------------

---------------------

Coal, bituminous slack, piled

801 kg/m3 (1,350 lb/yd3)

---------------------

---------------------

Coal, bituminous r. of m., piled

881 kg/m3 (1,485 lb/yd3)

---------------------

---------------------

Coal, anthracite

897 kg/m3 (1,512 lb/yd3)

---------------------

---------------------

Clay, DRY, in broken lumps

1,009 kg/m3 (1,701 lb/yd3)

---------------------

---------------------

Clay, DAMP, natural bed

---------------------

1,746 kg/m3 (2,943 lb/yd3)

---------------------

Cement, Portland, DRY granular

---------------------

1,506 kg/m3 (2,583 lb/yd3)

---------------------

Cement, Portland, DRY clinkers

---------------------

1,362 kg/m3 (2,295 lb/yd3)

---------------------

Dolomite, crushed

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

Earth, loamy, DRY, loose

---------------------

1,202 kg/m3 (2,025 lb/yd3)

---------------------

Earth, DRY, packed

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

MATERIAL

022-00018CE Operation and Maintenance Manual

Specification 7-9

LOW WEIGHT OR DENSITY 1,100 KG/M3 (1,850 LB/YD3), OR LESS

MEDIUM WEIGHT OR DENSITY 1,600 KG/M3 (2,700 LB/YD3), OR LESS

HIGH WEIGHT OR DENSITY 2,000 KG/M3 (3,370 LB/YD3), OR LESS

Earth, WET, muddy

---------------------

---------------------

1,762 kg/m3 (2,970 lb/yd3)

Gypsum, calcined, (heated, powder)

961 kg/m3 (1,620 lb/yd3)

---------------------

---------------------

Gypsum, crushed to 3 inch size

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

Gravel, DRY, packed fragments

---------------------

---------------------

1,810 kg/m3 (3,051 lb/yd3)

Gravel, WET, packed fragments

---------------------

---------------------

1,922 kg/m3 (3,240 lb/yd3)

Limestone, graded above 2

---------------------

1,282 kg/m3 (2,160 lb/yd3)

---------------------

Limestone, graded 1-1/2 or 2

---------------------

1,362 kg/m3 (2,295 lb/yd3)

---------------------

Limestone, crushed

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

Limestone, fine

---------------------

---------------------

1,602 kg/m3 (2,705 lb/yd3)

Phosphate, rock

---------------------

1,282 kg/m3 (2,160 lb/yd3)

---------------------

929 kg/m3 (1,566 lb/yd3)

---------------------

---------------------

Snow, light density

529 kg/m3 (891 lb/yd3)

---------------------

---------------------

Sand, DRY, loose

---------------------

1,522 kg/m3 (2,565 lb/yd3)

---------------------

Sand, WET, packed

---------------------

---------------------

1,922 kg/m3 (3,240 lb/yd3)

Shale, broken

---------------------

1,362 kg/m3 (2,295 lb/yd3)

---------------------

529 kg/m3 (1,620 lb/yd3)

---------------------

---------------------

MATERIAL

Salt

Sulphur, broken

7-10 Specification

022-00018CE Operation and Maintenance Manual

8INDEX Clean Radiator 4-34 Engine Coolant Temperature Gauge 2-12 Engine Coolant Temperature Warning Light

Numerics 1,000 Hour / 6 Month Service 4-36 10 Hour / Daily Service 4-12 12,000 Hour / Six Year Service 4-43 2,000 Hour / Yearly Service 4-39 250 Hour / Monthly Service 4-25 4,000 Hour / Biennial Service 4-42 50 Hour / Weekly Service 4-20 500 Hour / 3 Month Service 4-32

Radiator Coolant 4-37 Refill Cooling System 4-16 Cracks and Faulty Welds 4-17

A

Dimensions 7-4 Directional Control Lever 2-7 Door Side Latch 2-17 Dozer Blade Pins 4-23

Air Cleaner Clogged Warning Light 2-14 Air Intake System Air Cleaner Filter Replacement 4-34 Clean Air Cleaner Filter 4-26 Ashtray 2-19 Attachments 6-1

B Battery 4-49 Warning Light 2-13 Blade Control Lever 2-7 Bolt and Nut Inspection 4-44 Boom Swing Cylinder Head 4-24 Boom Swing Pedal 2-8 Boom, Arm and Front Attachment Pins 4-20 Booster Cable 3-8 Breaker Pedal 2-7 Bucket 4-45 Installation 4-47 O-rings 4-46 Shimming Procedures 4-47 Shimming Procedures for Installed Bucket 4-

48 Teeth 4-45 Teeth and Side Cutters 4-17

C Cab Light 2-18 Center Joint 6-1 Cigar Lighter 2-9 Circuit Breaker 2-18 Cold Weather Hydraulic System Warm-up Cold Weather Starting 3-6 Component Locations 2-2 Control Lever 6-1 Control Valve 6-2 Cooling System

3-11

022-00018CE Operation and Maintenance Manual

2-13

D

E Electrical System 4-49 Engine Coolant Temperature Gauge 2-12 Coolant Temperature Warning Light 2-13 Fan Belt 4-31 Fan Blade 4-19 Oil and Filter Change 4-24 Oil Level Check 4-12 Oil Pressure Warning Light 2-13 Serial Number 4-2 Shutdown 3-12 Start 3-4 Start and Stop 3-2 Excavator Rated Lift Capacity Tables 1-28

F Front Attachment Pins 4-12, Front Windows 2-16 Fuel System Filter 4-26, 4-33 Gauge 2-12 Leaks 4-15 Level 4-14 Water Separator 4-15 Fuse Box 2-5, 4-50

4-20

G Gauges Engine Coolant Temperature Fuel 2-12 Hour Meter 2-12 Glass Breaking Tool 1-20

2-12

Index 8-1

H

Lubrication and Service Chart

Handling a New Excavator 3-1 Heater Switch 2-5 Horn Button 2-6 Hour Meter 2-12 Hydraulic Breaker 3-36 Hydraulic Oil System Breaker 3-36 Breaker Hoses and Tubing 3-36 Breaker Oil and Filter 3-40 Breaker Operation 3-36 Breaker Selection 3-36 Cylinder 4-58, 6-2 Full Flow Filter Replacement 4-28,

M Machine Serial Number 4-1 Main System Pump 4-58 Maintenance In Special Conditions 4-54 Intervals 4-7 Miscellaneous Electrical Devices

2-18

O 4-30, 4-

35 General Venting 4-59 Hydraulic Cylinders 4-58 Hydraulic Oil Exchange 4-39 Hydraulic Oil Tank 4-13 Leaks 4-14 Main System Pump 4-58 Motor 6-3 Pump 6-3 Suction Strainer 4-39 Swing Motor 4-58 Travel Motor 4-59 Warm-up 3-10

Inspecting Engine Before Starting 3-2 Inspection, Maintenance and Adjustment Instrument Panel 2-11

Operating Controls 2-1 Operating Precautions 3-24 Operation 3-1 Operation In Dusty Or Sandy Areas 3-45 Extreme Cold 3-43 Extreme Heat 3-44 High Altitudes 3-45 Rainy or Humid Conditions 3-45 Salt Water Areas 3-45 Operation Under Unusual Conditions 3-43 Operational Checks Before Starting Engine Operator’s Area 2-3

3-2

P

I 4-1

J

Setup

for

Radiator Coolant 4-37 Relief Valve 6-4 Right-hand Work Lever 2-6 Right-hand Work Lever (Joystick) 2-6 Rotating Beacon Light Switch 2-9

L Leaks In Hydraulic System 4-14 Lift Capacity Tables 1-27 Lifting 3-41 Lifting With Sling 5-5 Lights Air Cleaner Clogged Warning 2-14 Battery Warning 2-13 Engine Coolant Temperature Warning Engine Oil Pressure Warning 2-13 Low Fuel Warning 2-13 Preheat Indicator 2-14 Loading and Unloading 5-1 Locations of Safety Labels 1-4 Long Term Storage 4-54 Low Fuel Warning Light 2-13

Parking Excavator 3-33 Pilot Cutoff Switch 2-18 Preheat Indicator Light 2-14 Preliminary Work Machine Maintenance 4-3 Preventive Maintenance 4-1

R

Joystick Left-hand Work Lever 2-6 Right-hand Work Lever 2-6

8-2 Index

4-7, 4-8

S

2-13

Safety 1-1 Lever 3-14 Precautions 4-2 Seat Adjustment Armrest Adjustment 2-15 Backrest Adjustment 2-15 Front/Rear Adjustment 2-15 Seat Belt 2-15, 4-17 Serial Numbers 4-1 Shimming Procedures for Installed Bucket Shipping and Transportation 1-26 Shutdown

4-48

022-00018CE Operation and Maintenance Manual

Check and Confirmation After Stopping Engine 3-13 Engine Shut Down 3-12 Parking Excavator 3-33 Specification 7-1 Starter Switch 2-4 Starting Engine Using a Booster Battery 3-8 Start-up Cold Weather Hydraulic System Warm-up 3-

11 Cold Weather Starting 3-6 Engine Start 3-4 Hydraulic System Warm-up 3-10 Inspection Before Starting Engine 3-2 Operational Checks Before Starting Engine

3-2 Starting Engine Using a Booster Battery Swing Gear 4-32 Motor 4-58 System 6-4 Switches Heater 2-5 Horn Button 2-6 Pilot Cutoff 2-18 Rotating Beacon Light 2-9 Starter 2-4 Travel Speed Selector Switch 2-10 Windshield Wiper 2-5 Work Light 2-9 Swivel Bearing 4-24

3-8

T Table of Recommended Lubricants

Towing Procedure 3-35 Tracks Tension 4-56 Transportation 5-1 Travel 3-15, 6-5 Instructions 3-15 Motor 4-59 Reduction Device Oil Level Check Travel Speed Selector Switch 2-10 Troubleshooting 6-1

4-25

U Unloading and Loading

5-1

V Venting and Priming Hydraulic Oil System General Venting 4-59 Hydraulic Cylinders 4-58 Main System Pump 4-58 Swing Motor 4-58 Travel Motor 4-59 Venting Hydraulic System 4-59

W Weight of Workload Materials 7-9 Windows Front 2-16 Glass Breaking Tool 1-20, 2-19 Washer Liquid 4-16 Wiper Switch 2-5 Work Light Switch 2-9 Working Range 7-8

4-5

022-00018CE Operation and Maintenance Manual

Index 8-3

1PUBLICATION REQUEST FOR PROPOSED REVISION In Daewoo’s continuing effort to provide the best customer satisfaction, we invite you to help us improve the manuals that you work with on a daily basis. This form is provided to give you a means of feedback to the publication department.

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