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Solar 015 PLUS


Solar 018-VT
Operation and Maintenance Manual
022-00075E
S/N 3001 and Up
March 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
machines 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.

022-00075E Operation and Maintenance Manual

Copyright 2004 Daewoo

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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
Operators Area .................................................................................. 2-4
Instrument Panel .............................................................................. 2-13
Seat Adjustment ............................................................................... 2-17
Seat Belt........................................................................................... 2-17
Front Window ................................................................................... 2-18
Door Side Latch................................................................................ 2-19
Miscellaneous Electrical Devices ..................................................... 2-20
Cup Holder .......................................................................................2-21
Window Glass Breaking Tool............................................................ 2-21

Operation................................................................................... 3-1
To Handle a New Excavator ............................................................... 3-1
Starting and Stopping The Engine ..................................................... 3-2
Safety Lever ..................................................................................... 3-14
Travel ................................................................................................3-15
Control Track Width .......................................................................... 3-22

022-00075E Operation and Maintenance Manual

Table of Contents I

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Operating Precautions...................................................................... 3-24


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 .......................................................... 4-35
2,000 Hour / Yearly Service.............................................................. 4-36
4,000 Hour / Biennial Service...........................................................4-40
12,000 Hour / Six Year Service ........................................................ 4-41
Bolt and Nut Inspection ....................................................................4-42
Bucket .............................................................................................. 4-43
Electrical System.............................................................................. 4-47
Engine Cooling System ....................................................................4-50
Long Term Storage........................................................................... 4-52
Maintenance in Special Conditions .................................................. 4-52
Track Tension ................................................................................... 4-54
Venting and Priming Hydraulic System ............................................ 4-56

Transportation........................................................................... 5-1
Loading and Unloading ......................................................................5-1

II Table of Contents

022-00075E Operation and Maintenance Manual

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Lifting with Sling ................................................................................. 5-5

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
Overall Dimensions ............................................................................ 7-2
Working Range................................................................................... 7-6
Approximate Weight of Workload Materials ....................................... 7-8

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

022-00075E Operation and Maintenance Manual

Table of Contents III

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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

022-00075E Operation and Maintenance Manual

Safety 1-1

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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

022-00075E Operation and Maintenance Manual

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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

022-00075E Operation and Maintenance Manual

Safety 1-3

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LOCATION OF SAFETY LABELS


4

CABIN TYPE (OPTION)

2
BTO0010L

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

022-00075E Operation and Maintenance Manual

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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 operators
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

022-00075E Operation and Maintenance Manual

Safety 1-5

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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

022-00075E Operation and Maintenance Manual

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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

022-00075E Operation and Maintenance Manual

Safety 1-7

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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 theyve 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 safetys 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

022-00075E Operation and Maintenance Manual

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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.

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 whats underneath the work
site before starting to dig.

HKA1009L

Figure 3

022-00075E Operation and Maintenance Manual

Safety 1-9

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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

022-00075E Operation and Maintenance Manual

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SLOPING TERRAIN REQUIRES CAUTION
Dig evenly around the work site whenever
possible, trying to gradually level any existing
slope. If its not possible to level the area or
avoid working on a slope, reducing the size and
cycling rate of the workload is recommended.

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.

022-00075E Operation and Maintenance Manual

A
Figure 6

HKA1003L

Safety 1-11

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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


operators 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

022-00075E Operation and Maintenance Manual

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OPERATION
OPERATE WHILE SEATED AT THE
OPERATORS STATION ONLY
Never reach in through a window to work a
control. Do not try to operate the excavator
unless youre 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 cant see
clearly and something is happening behind you.
Replace damaged safety labels and lost or
damaged owners manuals.

HAOA150L

Figure 8

Do not let anyone operate the machine unless


theyve been fully and completely trained, in
safety and in operation of the machine.
ADJUST SEAT
If the drivers seat is not adjusted correctly, the operator may become easily fatigued and injury and/or
damage could result.

Be sure to adjust the drivers seat at the beginning of each work period.

Adjust drivers 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 operators 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.

022-00075E Operation and Maintenance Manual

Safety 1-13

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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 operators seat or leave
the operators 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

022-00075E Operation and Maintenance Manual

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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

022-00075E Operation and Maintenance Manual

Safety 1-15

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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

022-00075E Operation and Maintenance Manual

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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
operators 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 operators 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 operators 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 operators 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 operators 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.

022-00075E Operation and Maintenance Manual

Safety 1-17

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

HKA1004L

Figure 17

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.

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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 operators 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 operators 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.

022-00075E Operation and Maintenance Manual

Safety 1-19

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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 operators
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.

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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 OPERATORS 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.

022-00075E Operation and Maintenance Manual

HAOA020L

Figure 23

Safety 1-21

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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 79 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.

VIBRATION LEVEL INFORMATION


Hands/Arms: The weighted root mean square acceleration to which the hands/arms are subjected, is less
than 2.5 m/s2.
whole body: The weighted root mean square acceleration to which the whole body is subjected, is less
than 0.5 m/s2.
Measurements are obtained on a representative machine, using measuring procedures as described in the
following standard: ISO 2631/1. ISO 5349, and SAE J1166.
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.

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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 operators 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 operators 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 operators 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

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Safety 1-23

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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.

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 95C (203F)
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

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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.

NOTE:

Refer to Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)
on page 4-41, for additional European regulations.

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.

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USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE
Refer to the "General Maintenance" section of the Shop Manual for information on tightening torques and
recommended assembly compounds and always use the correct part.
Poor or incorrect fastener connections can dangerously weaken assemblies.
DISPOSE OF ALL PETROLEUM BASED OILS
AND FLUIDS PROPERLY

Physical contact with used motor oil may pose a


health risk. Wipe oil from your hands promptly
and wash off any remaining residue.
Used motor oil is an environmental contaminant
and may only be disposed of at approved
collection facilities. Never drain any 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.

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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.

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Lifting radius

Center line
of Rotation

Lifting
Point
Height

BTO0020L

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 pin point of the bucket, as shown in Figure 32.

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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 0.04 m3 HEAPED (SAE 0.042 m3)
230 mm (9")

UNIT

RATING OVER FRONT


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

METRIC
A(m)

2.5

MAX. REACH

A(m)

B(m)
2.5

* 0.28

* 0.28

* 0.30

* 0.30

2.28

* 0.28

* 0.28

* 0.29

* 0.29

* 0.30

* 0.30

2.70

1.5

* 0.36

* 0.36

* 0.31

* 0.31

* 0.30

* 0.30

2.95

* 0.47

* 0.31
* 0.31

3.07

0.29

3.09

* 0.60

0.54

* 0.40
* 0.43

* 0.36 * 0.31
0.40 * 0.32

0.30

0.5

* 0.47
* 0.56

0.39

* 0.32

0.30

3.00

-0.5

* 0.58

0.54

* 0.41

0.39

* 0.34

0.33

2.80

-1

* 0.49

* 0.49

* 0.34

* 0.34

2.44

* 0.31

* 0.31

1.80

0.54

0.36

0.31
0.30

-1.5

FEET
6'

A (ft)

8'

10'

MAX. REACH

B (ft)

A (ft)
* 0.67

* 0.67

7.69

* 0.65

* 0.65

* 0.65

* 0.65

9.19

* 0.67

0.67

9.94

* 0.69

0.64

10.14

8'
6'

1.
2.
3.
4.

4'

* 1.02

* 1.02 * 0.76

* 0.76

2'

* 1.40

1.37 * 0.90

* 0.90

0'

1.47

-2'

* 1.42

-4'

* 1.07

* 0.70

0.66

0.96

0.90

* 0.72

0.67

9.84

1.35 * 0.93

0.89

* 0.74

* 0.74

8.97

* 0.74

* 0.74

7.26

1.35

* 1.07

RATINGS ARE BASED ON SAE J1097


LOAD POINT IS THE HOOK ON THE BACK OF THE BUCKET.
* RATED LOADS ARE BASED ON HYDRAULIC CAPACITY.
RATED LOADS DO NOT EXCEED 87 % OF HYD. CAPACITY OR 75 % OF TIPPING CAPACITY.
BTO0030L

Figure 33

022-00075E Operation and Maintenance Manual

Safety 1-29

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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 0.04 m3 HEAPED (SAE 0.042 m3)
230 mm (9")

UNIT

RATING OVER FRONT


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

METRIC
A(m)

2.5

MAX. REACH

A(m)

B(m)
* 0.28

* 0.28

2.00

2.5

* 0.25

* 0.25

* 0.26

* 0.26

2.62

* 0.24

* 0.24

* 0.26

0.26

2.98

0.26

0.26

0.26

3.20

1.5

* 0.29

* 0.29

* 0.27

* 0.27

* 0.40

* 0.40

* 0.32

* 0.32

0.28

0.28

0.27

0.27

3.31

0.5

0.52

0.52

0.38

0.38

0.31

0.31

0.28

0.26

3.32

0.58

0.54

0.42

0.39

0.33

0.30

0.29

0.27

3.24

-0.5

0.58

0.54

0.42

0.39

0.32

0.30

0.30

0.29

3.06

-1

0.55

0.54

0.39

0.39

0.31

0.31

2.75

* 0.41

* 0.41

* 0.31

* 0.31

2.24

-1.5

* 0.26

FEET
6'

A (ft)

8'

10'

MAX. REACH

B (ft)

1.
2.
3.
4.

A (ft)

8'

* 0.52

* 0.52

6'

* 0.54

* 0.54

* 0.57

* 0.83 * 0.67

* 0.67

0.60

* 0.57

* 0.57

8.76

0.57

0.57

0.57

10.06

0.60

0.59

0.59

10.73

4'

* 0.83

2'

1.27

1.27

0.83

0.83

0.66

0.66

0.61

0.58

10.92

0'

1.47

1.36

0.95

0.90

0.70

0.65

0.64

0.60

10.64

-2'

1.46

1.35

0.96

0.89

0.67

0.66

9.87

-4'

1.26

1.26

0.79

0.79

* 0.70

0.70

8.40

RATINGS ARE BASED ON SAE J1097


LOAD POINT IS THE HOOK ON THE BACK OF THE BUCKET.
* RATED LOADS ARE BASED ON HYDRAULIC CAPACITY.
RATED LOADS DO NOT EXCEED 87 % OF HYD. CAPACITY OR 75 % OF TIPPING CAPACITY.
BTO0040L

Figure 34

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

Component Locations on page 2-2

2.

Operators Area on page 2-4

3.

Instrument Panel on page 2-13

4.

Seat Adjustment on page 2-17

5.

Front Window on page 2-18

6.

Door Side Latch on page 2-19

7.

Miscellaneous Electrical Devices on page 2-20

8.

Cup Holder on page 2-21

9.

Window Glass Breaking Tool on page 2-21

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.

022-00075E Operation and Maintenance Manual

Operating Controls 2-1

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COMPONENT LOCATIONS

23
22

21

6
7

20

8
18
19

17
9

30
27

12
16

14

11

10

13

15

28
26
24

29
25

27

16
BTO0530L

Figure 1

2-2 Operating Controls

022-00075E Operation and Maintenance Manual

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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

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
TRACK SPRING
IDLER
BLADE CYLINDER

022-00075E Operation and Maintenance Manual

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

BLADE
SWING BRACKET
BOOM CYLINDER
BUCKET
DUMP LINKAGE
BUCKET LINKAGE
BUCKET CYLINDER
ARM
EXTENSION CYLINDER (ONLY S018-VT)
ADDITIONAL DOZER (LH)
ADDITIONAL DOZER (RH)
SLIDING BRACKET
FRAME CENTER
SIDE FRAME (LH)
SIDE FRAME (RH)

Operating Controls 2-3

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OPERATORS AREA

10

11
5
3

9
1

18

14

16
4

19
21

12

13

20

17

BTO0460L

Figure 2

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

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 (OR VARIABLE
TRACK CONTROL FOR S018-VT)
DIRECTION CONTROL LEVER, RIGHT
DIRECTION CONTROL LEVER, LEFT

2-4 Operating Controls

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

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
PILOT CUTOFF SWITCH
VARIABLE TRACK & DOZER SELECTOR
SWITCH

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1.

INSTRUMENT PANEL
See Instrument Panel on page 2-13.
1
10

BPO0230L

2.

STARTER SWITCH

Figure 3

Used to start or shut down engine for


equipment operation.
A.

"ON" Position - Turning the switch to


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

WARNING!

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."

022-00075E Operation and Maintenance Manual

Operating Controls 2-5

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3.

HORN BUTTON (LEFT-HAND WORK


LEVER (JOYSTICK))
Pressing button on top of left-hand work
lever (joystick) will sound horn.

AKO0051L

Figure 5
4.

FUSE BOX
A fuse box is in front of the operators seat.
Refer to Figure 6.

BTO0190L

Figure 6
5.

WINDSHIELD WIPER AND WASHER


SWITCH
This switch is used both for operating the
windshield wipers and spraying washer
fluid.
A.

Turns "ON" windshield wipers.

B.

Turns "ON" windshield wipers and


sprays washer fluid while switch is
held.

C.

Turns "OFF" wipers.

C
B

Figure 7

HAOD420L

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.

2-6 Operating Controls

022-00075E Operation and Maintenance Manual

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6.

HEATER SWITCH
This switch is used to control the speed of
the heater blower fan.
O.

Off

I.

Low speed

II.

High speed

BPO0310L

Figure 8
7.

RIGHT-HAND WORK LEVER


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.

Figure 9

8.

LEFT-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 swing and arm
movements. For a more detailed
explanation see Work Levers
(Joysticks)
(ISO
Style)
on
page 3-20.
Pressing button on top of left-hand work
lever (joystick) will sound horn.

022-00075E Operation and Maintenance Manual

Figure 10

Operating Controls 2-7

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9.

BLADE CONTROL LEVER (S015 PLUS)

The blade control lever, on right-hand side


of drivers seat, controls operation of blade.
When the lever is released, it returns to the
"NEUTRAL" position and the blade stops
immediately.
A.

Pushing lever forward lowers blade.

B.

Pulling lever back raises blade.

BTO0220L

Figure 11
9. A BLADE OR EXTENSION CONTROL
LEVER (S018 -VT ONLY)
The blade or extension control lever, on
right-hand side of drivers seat, controls
operation of blade or variable track.

Check the switch of selector track


extension or blade on left-hand side.

For operating blade


Set switch to position I

BTO0060L

Figure 12
A.

Pushing lever forward lowers blade.

B.

Pulling lever back raises blade.

BTO0220L

Figure 13

2-8 Operating Controls

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For operating variable track.
Set switch to position O

O
I
BTO0070L

Figure 14
A.

Pushing lever forward wider track.

B.

Pulling lever back narrow track.

BTO0220L

10 & 11.TRAVEL LEVERS (RIGHT AND LEFT)

Figure 15

These levers are used to control forward


and reverse travel of the unit. Each lever
controls one track. See Travel on
page 3-15.

BTO0490L

12.

Figure 16

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.

BTO0200L

Figure 17

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Operating Controls 2-9

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13.

BOOM SWING PEDAL


This pedal, near the operators 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.
B.

Pressing the upper end of the pedal


swings boom to the left.

Pressing the lower end of the pedal


swings the boom to the right.
BTO0210L

Figure 18
Figure 19, 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:

50

75

In case of roof type, A is 90 to


left of upper structure center
line.
HAOJ961L

Figure 19
14.

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

BTO0430L

Figure 20
15.

SWING LOCK PIN

This lever is used to prevent the upper


structure
from
rotating
during
transportation of the excavator.
A.

Unlocked.

B.

Locked.

BTO0230L

Figure 21

2-10 Operating Controls

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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 22
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 23
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 24

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Operating Controls 2-11

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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.
20.

HDO2022I

Figure 25

PILOT CUTOFF SWITCH


If the pilot cutoff switch is pressed to I
position when the safety lever is in
RELEASE/UNLOCK
position,
the
operator can fully control the movement of
the work levers (joysticks). (Returns to O
position when released.)

BPO0490L

21.

VARIABLE TRACK & DOZER


SELECTOR SWITCH (FOR VARIABLE
TRACK)

Figure 26

When dozer lever operates this switch


selects variable track or dozer.
A.

O Position - Variable track selected.

B.

I Position - Dozer selected.

O
I
BTO0060L

Figure 27

2-12 Operating Controls

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INSTRUMENT PANEL

1
10

5
1

6
7
8

2
9

BPO0010L

Figure 28

1.
2.
3.
4.
5.

ENGINE COOLANT TEMPERATURE


GAUGE
FUEL GAUGE
HOUR METER
ENGINE OIL PRESSURE WARNING
LIGHT
BATTERY WARNING LIGHT

022-00075E Operation and Maintenance Manual

6.
7.
8.
9.

ENGINE COOLANT TEMPERATURE


WARNING LIGHT
AIR CLEANER CLOGGED WARNING
LIGHT
FUEL LEVEL WARNING LIGHT
GLOW PLUG INDICATOR LIGHT

Operating Controls 2-13

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1.

COOLANT TEMPERATURE GAUGE

White

The coolant temperature gauge indicates


the temperature of engine coolant.

Red

WHITE RANGE: Indicates temperature is


within normal operating range.
RED RANGE: Indicates temperature is too
high.
When the needle indicates this range,
allow the engine to run at low idle until the
temperature registers in white range.
When the white range is reached, shut
down engine.

AXO0280L

Figure 29

Check the coolant level, a loose fan belt, debris around radiator and so on.
2.

FUEL GAUGE

Red

Shows remaining fuel quantity in tank.

White

WHITE RANGE: Indicates a normal fuel


quantity.
RED RANGE: Indicates that fuel level is
low.
NOTE:

3.

When the needle indicates this


range, add fuel immediately.
Check the fuel level on smooth
level ground.

HOUR METER

BNO0590L

Figure 30

The hour meter is used to count the total


number of running hours on the engine.
The meter will be visible only when the
engine is running and will flash every 4
seconds to indicate that it if functioning
properly.
NOTE:

1
10

All regularly scheduled service


intervals should be performed
based on the hours displayed
on the hour meter.

HA0O2012

Figure 31

2-14 Operating Controls

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4.

ENGINE OIL PRESSURE WARNING


LIGHT
This light turns "ON" when engine oil
pressure is below the specified level.
Immediately shut down engine, check
engine oil level and check filter and
lubrication system for leaks.

HAOA620L

5.

BATTER CHARGE WARNING LIGHT

Figure 32

This light turns "ON" when the battery


charging system is an abnormal condition.
Check fan belt tension, and charging
system components such as alternator
and battery.

HAOA610L

6.

ENGINE COOLANT TEMPERATURE


WARNING LIGHT
This light turns ON when
temperature rises excessively.

Figure 33

coolant

When the light turns ON during


operation, 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 34

When coolant temperature of the engine


becomes low, shut down engine.
Check the coolant level, a loose fan belt,
debris around radiator and so on.

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Operating Controls 2-15

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7.

AIR CLEANER CLOGGED WARNING


LIGHT
This light turns "ON" when the air cleaner
element is clogged. Clean or replace
element.

HAOA660L

8.

FUEL LEVEL WARNING LIGHT

Figure 35

The fuel level warning light turns "ON"


when there is 2.4 liters (2.5 U.S quarts) in
the tank with the machine on level ground.
Fill tank immediately.

AXO0300L

9.

GLOW PLUG INDICATOR LIGHT

Figure 36

This light turns ON when preheating is


completed (about 6 second). Start the
engine immediately after the light turns
ON. (0C (32F)) approximately 1.5
seconds, -15C (5F) approximately 5
seconds.)

HAOA639L

Figure 37

2-16 Operating Controls

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SEAT ADJUSTMENT
FRONT/REAR ADJUSTMENT
Pulling up the adjustment lever (1, Figure 38)
allows the seat to be moved forward and
backward over a range of 210 mm (8.27 in).
BACKREST ADJUSTMENT
Lifting up the adjustment lever (2, Figure 38)
under the front of the seat adjusts the seat back
to obtain the desired backrest angle.

SUSPENSION ADJUSTMENT
The seat is adjusted for the drivers weight with
the seat empty. The adjustment is made by
pulling out the actuator lever (3, Figure 38). To
read off the current seating pull the actuator
leave out until there is a slight resistance, pulling
the actuator lever out of the end stop will return
the setting to 50 kg.

BTO0080L

Figure 38

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.

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Operating Controls 2-17

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SEAT BELT LOCKING AND UNLOCKING
Insert belt end (1, Figure 39) into buckle (2). Pull
belt to check that belt end is locked into buckle.
Adjust belt length so that it comfortably tight
against operators pelvic region (hipbone).

HAOB140L

Figure 39
Press button (3, Figure 40) in center of buckle
(2) and pull out belt (1) to unlock.

HAOB150L

FRONT WINDOW

Figure 40

Installing and removing windshield.


1.

Disconnect wiring connector (1, Figure 41)


of windshield wiper motor.

2.

Release lock pins (1, Figure 42) in each


corner of top of windshield.

3.

Using the two handles, raise windshield


and stow it in the roof.

Figure 41

1
Figure 42

2-18 Operating Controls

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4.

Fasten the two rear lock pins (2, Figure 43)


securely.
NOTE:

To install windshield, reverse


the order of steps for removal.

DOOR SIDE LATCH


1.

Figure 43

The door side latch (1, Figure 44) 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.

1
BTO0090L

Figure 44
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 45

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Operating Controls 2-19

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MISCELLANEOUS ELECTRICAL DEVICES


1.

CAB LIGHT
A light is installed on the rear left of the
operators 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:

If light is left on for a long time


while the engine is not running,
the battery will be discharged.

HAOD520L

Figure 46
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.

BTO0100L

Figure 47
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.

2-20 Operating Controls

HAOB090L

Figure 48

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CUP HOLDER
An cup holder (Figure 49) is to the right side of
the operators seat on the side of the cab.
Always close cup holder when a cup is not used.

WINDOW GLASS
BREAKING TOOL

Figure 49

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 operators
cabin. Grip the handle firmly and use the sharp
point to break the glass.

WARNING!

Figure 50

Protect your eyes when breaking the


glass.

022-00075E Operation and Maintenance Manual

Operating Controls 2-21

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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.

022-00075E Operation and Maintenance Manual

Operation 3-1

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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.

Set safety lever (Figure 1) to "LOCK"


position.

2.

Fasten seat belt. Check


operation and condition.

3-2 Operation

for

BTO0430L

Figure 1

proper

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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.

4
BTO0400L

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.

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Operation 3-3

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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.

BTO0240L

Figure 4
4.

Turn starter switch to "START" position


(Figure 5). 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.

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

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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.

1
10

Normal indicators are shown in the


following table.
E

BPO0230L

Figure 7

Instrument Panel Light or Gauge

8.

9.

Indicator
Reading

Engine Coolant Temperature Gauge

WHITE RANGE

Fuel Gauge

WHITE 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.

022-00075E Operation and Maintenance Manual

Operation 3-5

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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.

BTO0240L

Figure 8
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."
NOTE:

GLOW

OFF

ON
START

Preheating time is adjusted


automatically depending on
engine coolant temperature.
[0C (32F) is approximately
1.5 seconds. -15C (5F) is
approximately 5 seconds.]
AKO0410L

Figure 9

1
10

BTO0250L

Figure 10

3-6 Operation

022-00075E Operation and Maintenance Manual

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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.

022-00075E Operation and Maintenance Manual

Operation 3-7

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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

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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.

Red

Black

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.

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Operation 3-9

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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 - 80C (120 - 175F). 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.

BTO0240L

Figure 15
2.

Set safety lever (Figure 16) to "UNLOCK"


position.

BTO0450L

Figure 16
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 tracks 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.

3-10 Operation

HAOB432L

Figure 17

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HYDRAULIC SYSTEM WARM-UP COLD
WEATHER
1.

Run engine at "LOW IDLE" (no load) for 5


minutes (Figure 18).

BTO0270L

Figure 18
2.

Run engine for approximately 5 minutes


set at the middle of the speed range,
without a load (Figure 19).

BTO0240L

Figure 19
3.

Set safety lever (Figure 20) to "UNLOCK"


position.

BTO0450L

Figure 20
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.
NOTE:

Do not allow cylinders to pass


hydraulic oil over relief valve for
more than twenty seconds at a
time.

HAOB432L

Figure 21

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Operation 3-11

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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 tracks 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.

BTO0280L

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.

BTO0270L

Figure 24

3-12 Operation

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4.
5.

Shut down engine by turning key to "OFF"


position (Figure 25).

GLOW

Remove key from starter switch.

OFF ON
START

AKO0520L

Figure 25
6.

Set safety lever to "LOCK" position by


pulling it up (Figure 26).

BTO0430L

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 operators compartment is clean.

022-00075E Operation and Maintenance Manual

Operation 3-13

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SAFETY LEVER
WARNING!
When stopping engine or leaving the operator's seat, first, the left arm rest on the seat fully pull
up, "LOCK" the safety lever, otherwise, a serious accident may occur by accidental movement of
work levers (joysticks).
Whenever leaving the operators 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 and boom swing pedal.
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.

BTO0430L

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.

BTO0450L

NOTE:

Figure 28
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, stop engine and contact your nearest Daewoo dealer.
There is a malfunction with the system.

NOTE:

If the pilot cutoff switch mounted on switch panel is not pressed to I position when the
safety lever is in RELEASE/UNLOCK position, the operator can not operate the work
levers (joysticks).

3-14 Operation

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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.

BTO0240L

Set safety lever (Figure 30) to "UNLOCK"


position.

BTO0450L

Figure 30

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Operation 3-15

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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

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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

022-00075E Operation and Maintenance Manual

Operation 3-17

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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 operators 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

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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

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Operation 3-19

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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 drivers 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

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

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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."

022-00075E Operation and Maintenance Manual

6
8
7

HKB2042L

Figure 45

Operation 3-21

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CONTROL TRACK WIDTH


WARNING!
Use the machine with the tracks extended to the 1,200 mm position for normal operation. The
extended/wide track position provides a more stable operating condition when; traveling,
digging, leveling dirt with dozer, or performing breaker operations.
Only change width of tracks on level ground. Do not change width of tracks while on a slope.
Only use the retracted, 980 mm position, when operating in tight areas, where overall track width
is a concern. Be aware that the stability is lessened, when working over the side of the tracks.
BLADE OR EXTENSION CONTROL LEVER WITH VARIABLE TRACK

WARNING!
There is obstacle, change the wide of track after cleaning obstacle, it is impossible that obstacle
be cleaned, move the machine to level ground and then change the wide of track.
It is impossible to change the track wide after moving machine to level ground jack machine up
by front and dozer and change the wide of track clean the soil on sliding plate.
Find switch for selecting, track extension or blade control on left-hand side.
Set switch to position O

O
I
BTO0290L

Figure 46

3-22 Operation

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A.

Pushing lever forward wider track.

B.

Pulling lever back narrow track.

BTO0220L

Figure 47
CONTROL A WIDE OF BLADE
1

Take off pin (1) and then change wide or


narrow after putting the additional blade,
insert the pin (1).
A.

Wide Blade

B.

Narrow Blade

BTO0300L

Figure 48

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Operation 3-23

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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.

BTO0550L

Figure 49
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.
BTO0560L

Figure 50
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.

HAOF071L

Figure 51

3-24 Operation

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6.

Do not use machine travel or swing when


the bucket is in the ground to provide
additional breakout force. See Figure 52.

HKB2055L

Figure 52
7.

Do not use machine weight to provide


additional breakout force. See Figure 53.

8.

When working on soft or muddy ground,


make sure that the machine is not sinking.

HKB2056L

Figure 53
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 54.

HAOD911L

Figure 54
10.

Do not excavate underneath the machine.


See Figure 55.

HAOF081L

Figure 55

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Operation 3-25

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11.

12.

Make sure that there is adequate


clearance from overhead electrical supply
lines. See Figure 56.
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 56

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 57.

HAOE041L

Figure 57
13.

Do not use the bucket as a hammer or


ramming device. This is dangerous and
causes damage to the front attachment.
See Figure 58.

HKB2057L

Figure 58

3-26 Operation

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14.

Do not dig with the excavator tracks raised.


This can result in structural and
mechanical failures.

HAOF131L

Figure 59
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 60

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.

022-00075E Operation and Maintenance Manual

Operation 3-27

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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 61
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 62

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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 63

HKB2036L

Figure 64

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 65

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.

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Operation 3-29

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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

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.

Figure 66

2
HAOD871L

Figure 67

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 68

3-30 Operation

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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

BE CAREFUL OF TRACK SHOES


1.

Figure 69

During deep excavation, the boom cylinder


can hit the tracks. Be careful to avoid this.

HKB2061L

Figure 70
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:

022-00075E Operation and Maintenance Manual

Figure 71

Operation 3-31

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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 60C (140F).
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 72

Figure 73

HKB20631L

Figure 74

3-32 Operation

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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 75

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 76

HKB2039L

Figure 76
1.

Park excavator on firm, level ground.


Lower bucket and blade to ground as
shown in Figure 77.

HKB3001L

Figure 77

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2.

Set engine accelerator lever (Figure 78) to


"LOW IDLE." Allow engine to idle for 3 - 5
minutes.

BTO0270L

Figure 78
3.
4.

Shut down engine by turning key to "OFF"


position (Figure 79).

GLOW

Remove key from starter switch.

OFF ON
START

AKO0520L

Figure 79
5.

Set safety lever (Figure 80) to "LOCK"


position by pulling it up.

BTO0430L

Figure 80

3-34 Operation

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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 81.
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 81

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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 equipments 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 users manual.

2.

Inspect all mechanical and hydraulic connections.

3.

Do not use the breaker as a hammer. See


Figure 82.
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 82

3-36 Operation

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4.

Do not operate the breaker with the boom


or arm cylinders fully extended (bottomed
out). See Figure 83.
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 83
5.

Do not use the breaker if the hydraulic


hoses vibrate excessively. See Figure 84.
Check the breakers hydraulic accumulator
(1, Figure 84) for damage and repair as
required. If excavator is operated under
this condition, structural and hydraulic
components can damaged.

HAOF151L

Figure 84
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 85.

HAOB970L

Figure 85
7.

Do not any lifting or towing with a breaker.


See Figure 86.

HKB2068L

Figure 86

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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 87.

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 87

Do not curl the breaker tool tip into the arm


or boom when traveling or parking the
excavator. See Figure 88.

HKB2069L

Figure 88
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 89

3-38 Operation

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TO ACTIVATE BREAKER
1.

To activate breaker, check the position of


valve (Figure 90).

BTO0110L

Figure 90
2.

Position the breaker tool as needed and


press and hold the upper end of the control
pedal (Figure 91).
Release the pedal when the breaker action
has been completed.

BTO0330L

Figure 91
TO ACTIVATE THE ACTUATOR OF TWO
WAY
1.

To activate the actuator of two way type,


check the position of valve (Figure 92).

BTO0130L

Figure 92
2.

Position the actuator tool as needed and


press and hold the upper or lower end of
the control pedal (Figure 93).
Release the pedal when the actuator
action has been completed.

BTO0320L

Figure 93

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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

782

180

893
HYDRAULIC OIL

210

137
156
175

20

FILTER
(First Replacement)

150

119
128

40

692

130

112
60

614

206

FILTER
(After First Replacement)

250

1028
1196
1400

300
370

1658

0
0

500

1000

1500

MACHINE OPERATING HOURS

2000

ARO0990L

Figure 94

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.

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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 95)
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 95

Lift capacity decreases as the distance from the


machine swing center line is increased.

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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 96

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

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OPERATION UNDER UNUSUAL CONDITIONS


NOTE:

See Maintenance in Special Conditions on page 4-52 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 operators 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.

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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 1.280 specific gravity electrolyte as
issued to 1.200 to 1.240 specific gravity readings at full charge. Recharge batteries whenever they
reach a 1.160 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

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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.

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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 operators cab. A
corresponding number is stamped into the
left-hand side of the boom.

022-00075E Operation and Maintenance Manual

Figure 2

Inspection, Maintenance and Adjustment 4-1

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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

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

022-00075E Operation and Maintenance Manual

AKO0520L

Figure 6

Inspection, Maintenance and Adjustment 4-3

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5.

Set safety lever (Figure 7) to "LOCK"


position.

BTO0430L

Figure 7
6.

Before starting maintenance work, hang


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

BTO0540L

Figure 8

4-4 Inspection, Maintenance and Adjustment

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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
0C (32F)) or

GEAR OIL

HD 46 (ABOVE
0C (32F)) 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
0C (32F)) or

SAE15W40

AW 46 (ABOVE
0C (32F))

PENNZOIL 705
EP #2

PENNZOIL
MULTIPUPOSE
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.

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Inspection, Maintenance and Adjustment 4-5

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LUBRICANT
MANUFACTURER

HYDRAULIC OIL*

DRYDEN

PARADENE
AW 32 (BELOW
0C (32F)) or

LUBRICANT
GREASE

ENGINE OIL**

GEAR OIL

DIESELALL PLUS
15W40

EP #2 (RED)

AP80W90

DELO 400 15W40

DELO GREASE
EP-2

DELO GEAR OIL


or

AW 46 (ABOVE
0C (32F))
CHEVRON

AW MV 32
(BELOW 0C
(32F)) or

RPM UNIV GEAR


80W90

AW MV 46
(ABOVE 0C
(32F))
TEXACO

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

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

STAR PLEX
PREMIUM

URSA PREMIUM
TDX 15W40

APOROIL
MOTIRE S300

TOTAL

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

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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

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Inspection, Maintenance and Adjustment 4-7

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Description of Lubrication and Service Chart

1
13

11

2
2

10

9
3
10h
50h
250h
500h
1000h
2000h

16

14

12

15

2
BTO0520L

Figure 9

4-8 Inspection, Maintenance and Adjustment

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SERVICE DATA
No.

Items To
Check
Radiator

1
2
3
4
5
6
7
8
9

Coolant
Recovery Tank
Front & Blade
Variable
Cylinder
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.

PG

PG

20

F100

Grease

Grease

Grease

Gear Oil
(80W90)

2X330
cc

Engine Oil
(15W40)
Hydraulic Oil
(Equivis 46)
Diesel

2000

1.8 L

Grease

SAE #30

10

S015 PLUS / S018-VT


Service Interval
50
250
500
1000

W10

V, F

22 cc
40 cc
4.1 L

26 L

Fuel Tank
19 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 4-50, for further explanation.
Gray Box: Replacement On Every Interval.
For additional service items see list of Maintenance Intervals on page 4-10.
NOTE:

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-9

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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 Variable Cylinder (See page 4-23)
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 and Filter (See page
4-26)
Change Fuel Filter (See page 4-26)
Clean Air Cleaner Filter (See page 4-27)
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

022-00075E Operation and Maintenance Manual

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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 Fuel Filter (See page 4-32)

Replace Air Cleaner Filter (See page 4-33)


Clean Radiator (See page 4-33)
Replace Full Flow Hydraulic Oil Filter (See
page 4-34)

1,000 HOUR / 6 MONTH SERVICE

Perform All Daily, 50, 250 and 500 Hour


Service Checks (See page 4-35)
Change Oil in Travel Reduction Device
(One on Each Side of Unit) (See page
4-35)

Check, Adjust Valve Clearance ** (See


page 4-35)
Check, Torque Head Bolts ** (See page
4-35)

2,000 HOUR / YEARLY SERVICE

Perform All Daily, 50, 250, 500 and 1,000


Operating Hour Service Checks (See page
4-36)
Change Radiator Coolant (Propylene
Glycol - Extended Life Antifreeze) (See
page 4-36)
Hydraulic Oil Exchange and Suction
Strainer Cleaning (See page 4-37)

Check Alternator and Starter** (See page


4-39)
Check All Rubber Antivibration Shock
Mounts (See page 4-39)
Perform and Record the Results of the
Cycle Time Tests (See page 4-39)
Inspect Machine to Check for Cracked or
Broken Welds or Other Structural Damage
(See page 4-39)

4,000 HOUR / BIENNIAL SERVICE

Major Parts - Periodic Replacement (See


page 4-40)
12,000 HOUR / SIX YEAR SERVICE

Hose In-service Lifetime Limit (European


Standard ISO 8331 and EN982 CEN) (See
page 4-41)

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

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-11

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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).

AKO0250L

Figure 11

4-12 Inspection, Maintenance and Adjustment

022-00075E Operation and Maintenance Manual

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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:

BTO0350L

Figure 14

Dispose of drained fluids


according to local regulations.

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-13

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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 split fuel.
1.

2.

Make sure that the fuel fill hose is


grounded to the excavator before fueling
begins.

BTO0340L

Figure 15

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.

on

HAOC510L

Figure 16

4-14 Inspection, Maintenance and Adjustment

022-00075E Operation and Maintenance Manual

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5.

Check the fuel gauge (1, Figure 17) in the


operators
compartment
for
proper
operation.
1
10

NOTE:

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.

NOTE:

Always fill fuel tank at end of


work day. This will help prevent
condensation from forming
inside tank.

NOTE:

See Fluid Capacities


page 4-7 for capacity.

on

BTO0360L

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.

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-15

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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 4-51
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.

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.

FULL

LOW
HKB3009I

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

022-00075E Operation and Maintenance Manual

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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

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-17

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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 4-42.

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 4-54.

Figure 23

Jack up each track and perform the two


speed travel motor test.

4-18 Inspection, Maintenance and Adjustment

022-00075E Operation and Maintenance Manual

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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.

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-19

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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.

5
6
7,8
9

13

12

10

11

BTO0480L

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)

022-00075E Operation and Maintenance Manual

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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

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-21

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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

022-00075E Operation and Maintenance Manual

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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
GREASE VARIABLE CYLINDER
1.

Lower the front attachment to the ground.

2.

There are two grease fittings for the


variable cylinder. Do not over lubricate.
Purge old grease with new. Remove all
purged grease.

BTO0470L

Figure 37

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-23

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GREASE SWIVEL BEARING
1.

Inject two or three strokes of grease at


grease fitting (2, Figure 38).

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 38) are


greased every 50 hours. Fitting
(1) is greased every 500 hours.

BOOM SWING CYLINDER HEAD


1.

Figure 38

Inject grease through the grease fitting (3,


Figure 38) using a grease gun.

CHANGE ENGINE OIL AND FILTER (AFTER


FIRST 50 HOURS)
1.

Change engine oil and filter after first 50


hours of operation or rebuild, and every
250 hours thereafter. For details, See
Change Engine Oil and Filter on
page 4-26.

CHECK BATTERY ELECTROLYTE LEVEL


AND CONDITION
1.

Check condition of battery. See Battery


on page 4-47.

4-24 Inspection, Maintenance and Adjustment

022-00075E Operation and Maintenance Manual

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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 39
NOTE:

Change oil after first 250 hours


of operation or rebuild, and
every 1,000 hours thereafter.
(See page 4-35)

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


39) are in their proper positions as shown.

3.

Remove plug (1, Figure 39). 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.

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-25

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CHANGE ENGINE OIL AND FILTER
NOTE:

Change engine oil and filter after first 50 hours of operation or rebuild, and every 250
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 40). Remove
drain plug (2, Figure 40) 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.

AKO0251L

Figure 40
2.

Replace engine oil filter. The engine oil


filter is a spin-on type. See Figure 41.
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 41

CHANGE FUEL FILTER


1.

Replace fuel filter after first 250 hours of


operation on a new machine and every
500 hours thereafter (See page 4-32).

4-26 Inspection, Maintenance and Adjustment

022-00075E Operation and Maintenance Manual

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CLEAN AIR CLEANER FILTER

WARNING!

1
10

Never clean or attempt to remove the air


cleaner filter if the engine is running.
E

If you are using compressed air to clean


the element, make sure that proper eye
protection is worn.

BTO0370L

Figure 42
1.

Locate air filter assembly. Remove access


cover (1, Figure 43) and remove filter (2,
Figure 44) 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 43

Figure 44
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 45

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-27

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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.

Figure 46
3.

HKB3001L

Remove bolts from access cover under


seat and open it (Figure 47).

BTO0380L

Figure 47

4-28 Inspection, Maintenance and Adjustment

022-00075E Operation and Maintenance Manual

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4.

Pull out prop rod (1, Figure 48) from


housed position and insert it into hole (2,
Figure 48) to secure access cover.

5.

Release pressurized air from hydraulic


tank by slowly loosening breather cap (3,
Figure 48) 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 48

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-29

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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 4-34).

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 49).

BTO0510L

Figure 49
2.

Replace hydraulic oil filter after first 250


hours of operation or rebuild, and every
500 hours thereafter (See page 4-34).

Figure 50

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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 51. Adjust belt if
necessary.

3.

Inspect all engine belts for worn, cracked


or frayed edges. Replace any belts that
show signs of wear.

Figure 51

Belt tension adjustment;


NOTE:

Adjust belt if deflection is too


great or after replacing belt.

1.

Loosen adjusting bolt (1, Figure 52) on


subplate and alternator mounting bolt (2).

2.

Tilt alternator (3, Figure 52) to adjust belt


tension.

3.

When tension is correct, tighten adjusting


bolt (1, Figure 52) and secure alternator
mounting bolt (2).

4.

Run engine at low speed, under no load


for about 5 minutes and recheck belt
tension.

022-00075E Operation and Maintenance Manual

Figure 52

Inspection, Maintenance and Adjustment 4-31

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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


53).

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 53) are


greased every 50 hours. Fitting
(1) is greased every 500 hours.

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.

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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.

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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).

BTO0510L

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.

4-34 Inspection, Maintenance and Adjustment

Figure 59

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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.

CHECK, ADJUST VALVE CLEARANCE **


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

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2,000 HOUR / YEARLY SERVICE


PERFORM ALL DAILY, 50, 250, 500 AND 1,000 OPERATING HOUR SERVICE CHECKS
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 4-50, 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

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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 4-51.

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

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.

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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
3.

Remove bolts from access cover under


seat and open it (Figure 66).

BTO0380L

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.

NOTE:

Dispose of drained fluids


according to local regulations.

on
Figure 67

After draining tank install drain plug.

IMPORTANT
Be careful of squirting oil when
removing drain plug.

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8.

Remove bolts (1, Figure 68) and cover (2,


Figure 68) from top of hydraulic oil tank.

Figure 68
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

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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

Hydraulic
System

Pump discharge hose


Boom swing hose
Boom cylinder line hose

Work
Device

2 years or 4,000
hours

Arm cylinder line hose


Bucket cylinder line hose
Pilot hose

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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
describe in Major Parts - Periodic Replacement on page 4-40, 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 0C (32F)
and 35C (95F) but as close as possible to 15C (59F) and away from copper, manganese or
tube generating Ozone.

022-00075E Operation and Maintenance Manual

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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

17

20 - 25

15 - 18

Rear

12

19

45 - 50

33 - 37

10

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

Engine Vibration
dampening mount
bolts

Hydraulic, Fuel Tank Mounting


Bolts

Hydraulic Hose and Pipe Joint

Torque

Pump Mounting Bolt

10

17

64

47

Control Valve Mounting Bolt

13

22

16

Control Valve Base Mounting Valve

13

22

16

Swing Assembly Mounting Bolt

12

12

19

88

65

Cabin Mounting Bolt

12

19

108

80

Swing Body

12

18

19

108

80

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

24

206

152

13

Cover Mounting Bolt

-----

13

22

16

10

-----

17

42

31

14

Counter Weight mounting Bolt

14

22

176

130

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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.

022-00075E Operation and Maintenance Manual

Figure 71

Inspection, Maintenance and Adjustment 4-43

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4.

Slide the new tooth into position and insert


shims. Shim tooth until gap is less than "X"
[0.5 mm (0.020 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.

HAOC710L

Figure 74

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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.

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.

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.

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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 kgm (31 ft lb).

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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.

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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.

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 boxs
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

BTO0340L

Figure 80

15 AMP
20 AMP

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The following is a listing of fuse identification:

HAOB050L

Figure 81

No.

Name

Capacity

No.

Name

Capacity

Spare

10 AMP

Spare

10 AMP

Instrument Panel

10 AMP

10 AMP

Preheat Timer,
Heater (Option)

15 AMP

Wiper, Washer
(Option)

10

Cigar Lighter (Option)

15 AMP

Cut Off Work

10 AMP

11

Horn

15 AMP

Rotating Beacon
Light (Option)

10 AMP

12

Work Light

15 AMP

13

Spare

20 AMP

Alternator

10 AMP

14

Spare

20 AMP

Room Light (Option)

10 AMP

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ENGINE COOLING SYSTEM


GENERAL
Keeping an engines 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 30 PSI (2.1 kg/cm2). 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 2,000 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
coolants 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.

4-50 Inspection, Maintenance and Adjustment

022-00075E Operation and Maintenance Manual

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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

-10C (14F)

80%

20%

-15C (5F)

73%

27%

-20C (-4F)

67%

33%

-25C (-13F)

60%

40%

-30C (-22F)

56%

44%

-40C (-40F)

50%

50%

Propylene Glycol - Extended Life Antifreeze


Ambient Temperature

Cooling Water

Antifreeze

-10C (14F)

78%

22%

-15C (5F)

71%

29%

-20C (-4F)

65%

35%

-25C (-13F)

59%

41%

-30C (-22F)

55%

45%

-40C (-40F)

48%

52%

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-51

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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.

4-52 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.

022-00075E Operation and Maintenance Manual

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Conditions
Operating in an extremely dusty or hot
environment.

Operating in rocky terrain.

Operating in extreme cold.

022-00075E 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 4-53

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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 wont 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

4-54 Inspection, Maintenance and Adjustment

022-00075E Operation and Maintenance Manual

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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 isnt 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 kgm (43 - 65 ft lb).

Figure 86

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-55

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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.

4-56 Inspection, Maintenance and Adjustment

022-00075E Operation and Maintenance Manual

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1.

Shut down engine.

2.

Remove floor mat and access cover from


cab floor (Figure 88).

BTO0390L

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 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.

022-00075E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-57

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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.

Never rotate the upper structure once the


counterweight or front attachment has
been removed.
HAAD4060

Figure 91

022-00075E Operation and Maintenance Manual

Transportation 5-1

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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

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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.

BTO0430L

Figure 3
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.

A
B

BTO0230L

Figure 4

022-00075E Operation and Maintenance Manual

Transportation 5-3

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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

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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

022-00075E Operation and Maintenance Manual

Transportation 5-5

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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.

022-00075E Operation and Maintenance Manual

Troubleshooting 6-1

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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.

022-00075E Operation and Maintenance Manual

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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.

022-00075E Operation and Maintenance Manual

Troubleshooting 6-3

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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.

022-00075E Operation and Maintenance Manual

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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.

022-00075E Operation and Maintenance Manual

Troubleshooting 6-5

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7SPECIFICATION
GENERAL SPECIFICATIONS
SOLAR 015 PLUS / SOLAR 018-VT (S/N 30001 and Up)
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

MITSUBISHI L3E

Piston Displacement

0.952 liters

Rated Output

17.2 ps (16.97 hp) @ 2,300 rpm

Torque

5.5 kgm (39.78 ft lb) @ 2,100 rpm

Travel Speed

Low / High

Swing Speed

11.1 rpm

Max. Grade

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
Dozer Blade

Track
Assembly

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

Shoe

Hydraulic

Material

Rubber

Operating Control
Type

Grease Cylinder Type

Pump Type

Piston 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) / 3.8 km/h (2.36 MPH)

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

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.)

022-00075E Operation and Maintenance Manual

Specification 7-1

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OVERALL DIMENSIONS
CANOPY MACHINE (STANDARD)

M
P

R
J

H
I

L
Q
BTO0570L

Figure 1

7-2 Specification

022-00075E Operation and Maintenance Manual

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Dimension

Description

Canopy Model
Solar 015 PLUS

Boom Type (One Piece)


Arm Type

Solar 018-VT

1,690 mm (66.53 in)


850 mm
(33.46 in)

1,100 mm
(43.30 in)

850 mm
(33.46 in)

Bucket Type (SAE)

0.04 m3

Boom Offset

400 mm (15.75 in)

Boom Offset

360 mm (14.17 in)

Bucket Wide

452 mm (17.81 in)

Boom Swing Angle

75

Boom Swing Angle

50

Tail Swing Radius

1,190 mm (46.85 in)

Shipping Length

Tumbler Distance

1,224 mm (48.19 in)

Track Length

1,585 mm (62.40 in)

Track Length (Dozer)

1,765 mm (69.46 in)

Track Height

370 mm (14.57 in)

360 mm (14.17 in)

Track Gauge

770 mm (30.31 in)

750 mm (29.53 in)~


970 mm (38.19 in)

Track Width

1,000 mm (39.37 in)

980 mm (38.58 in)~


1,200 mm (47.24 in)

Shoe Width

Car Body Clearance

Body Width

Shipping Width

1,000 mm (39.37 in)

980 mm (38.58 in)

Dozer Width

1,000 mm (39.37 in)

980 mm (38.58 in)~


1,200 mm (47.24 in)

Dozer Height

Shipping Height

Shipping Height (Boom)

022-00075E Operation and Maintenance Manual

3,755 mm (147.83 in)

1,100 mm
(43.30 in)

3,750 mm (147.64 in)

1,915 mm (75.39 in)

230 mm (9.06 in)


155 mm (6.10 in)

165 mm (6.50 in)

980 mm (38.58 in)

235 mm (9.25 in)


2,325 mm (91.53 in)
1,120 mm
(44.09 in)

1,250 mm
(49.21 in)

2,390 mm (94.09 in)


1,135 mm
(44.69 in)

1,265 mm
(49.80 in)

Specification 7-3

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CAB MACHINE (OPTION)

M
P

R
J

H
I

L
Q
BTO0580L

Figure 2

7-4 Specification

022-00075E Operation and Maintenance Manual

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Dimension

Description

Cabin Model
Solar 015 PLUS

Boom Type (One Piece)


Arm Type

Solar 018-VT

1,690 mm (66.53 in)


850 mm
(33.46 in)

1,100 mm
(43.30 in)

Bucket Type (SAE)

850 mm
(33.46 in)

1,100 mm
(43.30 in)

0.04 m3

Boom Offset

400 mm (15.75 in)

Boom Offset

360 mm (14.17 in)

Bucket Wide

452 mm (17.81 in)

Boom Swing Angle

75

Boom Swing Angle

50

Tail Swing Radius

1,190 mm (46.85 in)

Shipping Length

Tumbler Distance

3,755 mm (147.83 in)

3,750 mm (147.64 in)

1,224 mm (48.19 in)

Track Length

Track Length (Dozer)

1,765 mm (69.46 in)

1,915 mm (75.39 in)

Track Height

370 mm (14.57 in)

360 mm (14.17 in)

Track Gauge

770 mm (30.31 in)

750 mm (29.53 in)~


970 mm (38.19 in)

Track Width

1,000 mm (39.37 in)

980 mm (38.58 in)~


1,200 mm (47.24 in)

Shoe Width

Car Body Clearance

Body Width

Shipping Width

1,000 mm (39.37 in)

980 mm (38.58 in)

Dozer Width

1,000 mm (39.37 in)

980 mm (38.58 in)~


1,200 mm (47.24 in)

Dozer Height

Shipping Height

Shipping Height (Boom)

022-00075E Operation and Maintenance Manual

1,585 mm (62.40 in)

230 mm (9.06 in)


155 mm (6.10 in)

165 mm (6.50 in)

980 mm (38.58 in)

235 mm (9.25 in)


2,280 mm (89.76 in)
1,120 mm
(44.09 in)

1,250 mm
(49.21 in)

2,345 mm (92.32 in)


1,135 mm
(44.69 in)

1,265 mm
(49.80 in)

Specification 7-5

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WORKING RANGE
I

d
B
A
BTO0590L

Figure 3

7-6 Specification

022-00075E Operation and Maintenance Manual

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MACHINE TYPE
Boom Type (One Piece)
Arm Type

S015P

S018-VT

1,690 mm (5 6.5")

1,690 mm (5 6.5")

850 mm
(2 9.5")

1,100 mm
(3 7.2")

850 mm
(2 9.5")

1,100 mm
(3 7.2")

Max. Digging Reach

3,700 mm
(12 1.7")

3,920 mm
(12 10.3")

3,700 mm
(12 1.7")

3,920 mm
(12 10.3")

Max. Digging Reach


(Ground)

3,605 mm
(11 10")

3,850 mm
(12 7.6")

3,565 mm
(11 8.4")

3,595 mm
(11 9.5")

Max. Digging Depth

2,140 mm
(7 2.4")

2,385 mm
(7 9.8")

2,075 mm
(6 9.7")

2,325 mm
(7 7.6")

Max. Loading Height

2,245 mm
(7 4.4")

2,420 mm
(7 11.3")

2,310 mm
(7 7.0")

2,485 mm
(8 1.83")

Min. Loading Height

1,225 mm
(4 0.2")

1,085 mm
(3 6.7")

1,285 mm
(4 2.6")

1,500 mm
(4 11")

Max. Digging Height

3,400 mm
(11 1.8")

3,560 mm
(11 8.2")

3,465 mm
(11 4.4")

3,625 mm
(11 10.7")

Max. Bucket Pin Height

2,830 mm
(9 3.4")

3,005 mm
(9 10.3")

2,870 mm
(9 5")

3,045 mm
(9 11.9")

Max. Vertical Wall Depth

1,630 mm
(5 4.2")

1,845 mm
(6 0.6")

1,565 mm
(5 1.6")

1,780 mm
(5 10.1")

Min. Swing Radius

1,500 mm
(4 11")

1,670 mm
(5 5.8")

1,500 mm
(4 11")

1,670 mm
(5 5.8")

Bucket Angle

159

159

159

159

022-00075E Operation and Maintenance Manual

Specification 7-7

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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

7-8 Specification

022-00075E Operation and Maintenance Manual

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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

022-00075E Operation and Maintenance Manual

Specification 7-9

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1INDEX
Numerics

Cracks and Faulty Welds

1,000 Hour / 6 Month Service 4-35


10 Hour / Daily Service 4-12
12,000 Hour / Six Year Service 4-41
2,000 Hour / Yearly Service 4-36
250 Hour / Monthly Service 4-25
4,000 Hour / Biennial Service 4-40
50 Hour / Weekly Service 4-20
500 Hour / 3 Month Service 4-32

A
Air Intake System
Air Cleaner Filter Replacement
Clean Air Cleaner Filter 4-27
Ashtray 2-21
Attachments 6-1

4-33

Battery 4-47
Blade Control Lever 2-8
Bolt and Nut Inspection 4-42
Boom Swing Cylinder Head 4-24
Boom Swing Pedal 2-10
Boom, Arm and Front Attachment Pins 4-20
Booster Cable 3-8
Breaker Pedal 2-9
Bucket 4-43
Installation 4-45
O-rings 4-44
Shimming Procedures 4-45
Shimming Procedures for Installed Bucket 4-

46

Teeth 4-43
Teeth and Side Cutters 4-17

Cab Light 2-20


Center Joint 6-1
Cigar Lighter 2-11
Circuit Breaker 2-20
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
Clean Radiator 4-33
Radiator Coolant 4-36
Refill Cooling System 4-16

4-17

Dimensions 7-2
Directional Control Lever 2-9
Door Side Latch 2-19
Dozer Blade Pins 4-23

Electrical System 4-47


Engine
Fan Belt 4-31
Fan Blade 4-19
Oil and Filter Change 4-24
Oil Level Check 4-12
Serial Number 4-2
Shutdown 3-12
Start 3-4
Start and Stop 3-2
Excavator Rated Lift Capacity Tables

Front Attachment Pins 4-12,


Front Windows 2-18
Fuel System
Filter 4-26, 4-32
Leaks 4-15
Level 4-14
Water Separator 4-15
Fuse
Box 2-6, 4-48

G
Glass Breaking Tool

1-28

4-20

1-20

3-11

022-00075E Operation and Maintenance Manual

Handling a New Excavator 3-1


Heater Switch 2-7
Horn Button 2-7
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 4-56, 6-2
Full Flow Filter Replacement 4-28,

34

4-30, 4-

Index 8-1

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General Venting 4-57
Hydraulic Cylinders 4-56
Hydraulic Oil Exchange 4-37
Hydraulic Oil Tank 4-13
Leaks 4-14
Main System Pump 4-56
Motor 6-3
Pump 6-3
Suction Strainer 4-37
Swing Motor 4-56
Travel Motor 4-57
Warm-up 3-10

Operational Checks Before Starting Engine


Operators Area 2-4

Parking Excavator 3-33


Pilot Cutoff Switch 2-20
Preliminary
Work
Machine
Maintenance 4-3
Preventive Maintenance 4-1

Inspecting Engine Before Starting 3-2


Inspection, Maintenance and Adjustment
Instrument Panel 2-13

4-1

for

Radiator Coolant 4-36


Relief Valve 6-4
Right-hand Work Lever 2-7
Right-hand Work Lever (Joystick) 2-7
Rotating Beacon Light Switch 2-11

J
Joystick
Left-hand Work Lever 2-7
Right-hand Work Lever 2-7

Leaks In Hydraulic System 4-14


Lift Capacity Tables 1-27
Lifting 3-41
Lifting With Sling 5-5
Loading and Unloading 5-1
Locations of Safety Labels 1-4
Long Term Storage 4-52
Lubrication and Service Chart 4-7,

4-8

2-20

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

8-2 Index

Setup

Machine Serial Number 4-1


Main System Pump 4-56
Maintenance
In Special Conditions 4-52
Intervals 4-7
Miscellaneous Electrical Devices

3-2

Safety 1-1
Lever 3-14
Precautions 4-2
Seat Adjustment
Armrest Adjustment 2-17
Backrest Adjustment 2-17
Front/Rear Adjustment 2-17
Seat Belt 2-17, 4-17
Serial Numbers 4-1
Shimming Procedures for Installed Bucket 4-46
Shipping and Transportation 1-26
Shutdown
Check and Confirmation After Stopping
Engine 3-13
Engine Shut Down 3-12
Parking Excavator 3-33
Specification 7-1
Starter Switch 2-5
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

3-43

Starting Engine Using a Booster Battery


Swing
Gear 4-32
Motor 4-56
System 6-4
Switches
Heater 2-7
Horn Button 2-7

3-8

022-00075E Operation and Maintenance Manual

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Pilot Cutoff 2-20
Rotating Beacon Light 2-11
Starter 2-5
Travel Speed Selector Switch 2-12
Windshield Wiper 2-6
Work Light 2-11
Swivel Bearing 4-24

Table of Recommended Lubricants 4-5


Towing Procedure 3-35
Tracks
Tension 4-54
Transportation 5-1
Travel 3-15, 6-5
Instructions 3-15
Motor 4-57
Reduction Device Oil Level Check 4-25
Travel Speed Selector Switch 2-12
Troubleshooting 6-1

022-00075E Operation and Maintenance Manual

U
Unloading and Loading

5-1

V
Venting and Priming Hydraulic Oil System
General Venting 4-57
Hydraulic Cylinders 4-56
Main System Pump 4-56
Swing Motor 4-56
Travel Motor 4-57
Venting Hydraulic System 4-57

Weight of Workload Materials 7-8


Windows
Front 2-18
Glass Breaking Tool 1-20, 2-21
Washer Liquid 4-16
Wiper Switch 2-6
Work Light Switch 2-11
Working Range 7-6

Index 8-3

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1PUBLICATION REQUEST FOR


PROPOSED REVISION
In Daewoos 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.
COMPANY NAME:

DATE:

STREET ADDRESS:

TELEPHONE:

CITY:

FAX:

STATE / PROVINCE:
COUNTRY:
NAME:
MACHINE MODEL:
SERIAL NUMBER:
MANUAL NUMBER:
SHOP MANUAL SECTION NUMBER:
PROPOSED DESCRIPTION OF CORRECTION AND/OR SUGGESTION:

Use additional paper if needed. Please include copy of current manual pages for reference. Attach any photos or
illustrations. If digital photos are available, e-mail them to Bill.Bernhardt@dhiac.com (If possible, use 1024 x 768
resolution.).

HAS THIS BEEN DISCUSSED WITH A DAEWOO SERVICE REPRESENTATIVE:

YES

NO

IF YES - WHO:
(It is advised to discuss this with a Daewoo service representative to ensure that the above correction is appropriate
and valid.)

Mail to:
Daewoo Heavy Industries America Corporation
2905 Shawnee Industrial Way
Suwanee, GA 30024
Attention: Publications

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