Solar 200W-' Operation and Maintenance Manual 2022-71645 Serial Number 0001 and Up June 1999 Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of ‘equipment, and may vary from the actual item. 2022-7164 Operation and Maintenance ManualTABLE OF CONTENTS Safety .. 1-1 To the Operator of a Daewoo Excavator .. 1 General Safety Essentials.... 13 Location of Safety Labels... 14 Summary of Safety Precautions for Lifting in Digging Mode .. 1-10 Work-site Precautions... At Operation... 1-13 Equipment... 118 Maintenance... 1-22 Shipping and Transportation .. -25 Excavator Rated Lift Capacity Tables Operating Controls... Component Locations Operator's Areé Operational Controls and Panels. Instrument Panel... Steering Console... Mode Selection Switches Heater and Air Conditioning Control Panel Stereo.... Miscellaneous Electrical Devices .. Seat Adjustment..... Seat Bett. Ceiling Cover Front Windows. Door Side Latch... Miscellaneous Access Covers and Doors. Swing Lock Pin and Mechanism Wheel Chocks 2022-7164 Operation and Maintenance Manual Table of Contents |Cab Storage Compartments Ashtray Emergency Glass Breaking Tool... Operation. To Handle a New Excavator Starting and Stopping the Engine . Safety Lever .... Travel. Operating Instructions Operating Precaution: Parking Excavator . Towing Procedure... Hydraulic Breaker... Inspection, Maintenance and Adjustment Preliminary Work Machine Setup for Maintenance .. Table of Recommended Lubricants... Maintenance Intervals 10 Hour / Daily Service .... 50 Hour / Weekly Service.. 150 Hour Service ... 250 Hour / Monthly Service. 500 Hour / 3 Month Service 750 Hour Service 1000 Hour / 6 Month Service .. 2000 Hour / Yearly Service. 4000 Hour / Biennial Service... Venting and Priming Hydraulic System Handling of Accumulator .. Fuel Transfer Pump.... Electrical System... Bucket .. II Table of Contents 2022-7164 Operation and Maintenance ManualBucket Shimming Procedures Tire Changing Procedure Bolt and Nut Inspection... Maintenance in Special Conditions... Long Term Storage... Transportation... Short Distance Self-powered Travel . Trailer Loading/Unloading Procedures Troubleshooting... Engine . Hydraulic System...... Swing System. Electrical System, Travel System. Steering Brakes... Specification .. Standard Specification . General Dimensions. Working Range. Index 2022-7164 Operation and Maintenance Manual Table of Contents IllSAFETY TO THE OPERATOR OF A DAEWOO EXCAVATOR A 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 in Digging Mode” on page 1-10 4, ‘Worksite Precautions’ on page 1-11 5. “Operation” on page 1-13 6. “Equipment” on page 1-18 7. “Maintenance” on page 1-22 8. “Shipping and Transportation” on page 1-25 9, “Excavator Rated Lift Capacity Tables” on page 1-26 2022-7164 Operation and Maintenance Manual Safety 1-1A SAFETY ALERT SYMBOL £4 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. A CAUTION! Indicates potential of a hazardous situation that, if not avolded, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice. A 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. Ay 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 2022-7164 Operation and Maintenance ManualGENERAL SAFETY ESSENTIALS ACCESSORY APPLICATIONS ‘The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for ‘other object handling, contact Daewoo for proper installation and application. Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading. DO NOT use the machine for activities for which it was not intended. DO NOT use the bucket for ting work, unless lift slings are used in the approved configuration. 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. LIFTING CAPACITY RATING CONFIGURATION Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration. Loads must be balanced and supported evenly. Use taglines to keep the load steady if wind conditions and large surface area are a problem. Work crew hand signals, individual tasks and safe procedures should all be Universally understood before the lift is made. IMPORTANT Before using the excavator to make lifts check municipal and regional regulations or statutes that could apply. Governing ordinances may require that all heavy lifting be done with single purpose equipment specifically designed for making lifts, or other local restrictions may apply. Making heavy lifts with a general purpose excavator that can be used for digging, loading, grading or other work may be expressly forbidden by a regional injunction or other legal prohibition. Always follow all of the other instructions, guidelines and restrictions for Safe Lifting in the Operation and Maintenance and Shop Manuals. 2022-7164 Operation and Maintenance Manual Safety 1-3LOCATION OF SAFETY LABELS Figure 1 ‘Always keep these labels clean. If they are lost or damaged, replace them with a new label. It is the responsibility of the equipment owner and crew to provide essential safety information in the immediate vicinity of hazards. Safety labels may be available in languages other than English, or labels providing a warning for other hazards than those that follow may be available. Contact your Daewoo distributor to find out what labels are available. 1-4 Safety 2022-7164 Operation and Maintenance Manual1. WARNING FOR OPERATION, INSPECTION MAINTENANCE (2190 - 3434) A CAUTION! . Read manual and labels before operation and maintenance. Follow inetructions and warnings in manual | \ = and on labels on the machine. * Never get in under the machine while it is being jacked up with boom and arm. * When transporting the machine the swing lock must be installed. + Tum Autos suitch OFF, when = Tooingo unloacng the machine HAoAO101| * Sound the horn to alert the people nearby before operating, and make sure all persons are clear of area. * Always make sure when leaving operator's seat — Lower bucket or other working tools to the ground. Pull SAFETY LOCK LEVER to LOCK position. = Turn key switch OFF. Remove key from switch. 2. WARNING FOR HIGH VOLTAGE (2190 - 2532) A DANGER! Serious injury or death can occur if machine or attachments contact with electric lines. Never move any part of unit or load closer to electric lines than 3 m (10') plus twice the line insulator length. HBOKE61L 2022-7164 Operation and Maintenance Manual Safety 1-53. WARNING WHEN OPENING FRONT WINDOW (2190 - 3388). A WaRNING! When raising window, lock it in place with lock pins on both sides. Falling window can cause injury. 4. CAUTION FOR SAFETY LEVER LOCKING (2190 - 3383). A CAUTION! When locking down the left side control stand, be certain the safety lever is securely locked. 5. WARNING FOR BATTERIES MAINTENANCE (2190 - 2533), A WARNING! ‘+ Battery fumes can explode. Keep sparks and flames away from batteries. * Always avoid storing metals like tools or inflammable materials around or on the batteries. Explosion or fire can be caused by short circuiting batterie: ‘+ Sulfuric acid in battery is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed in eyes. * Ifyou spill acid on yoursel 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10-15 minutes. Get medical attention immediately. HAOASIOP 1-6 Safety 2022-7164 Operation and Maintenance Manual6. WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (2190 - 3318) A WaRNING! To prevent hot oil from spurting out: + Tum engine off. * After oil to cooled. ‘+ Push button on the breather to relieve pressure before removing cover. 7. WARNING FOR HIGH TEMPERATURE COOLANT (2190 - 3395) A WaRNING! To prevent hot water from spurting out: + Turn engine off. + Allow water to cool. * Slowly loosen cap to relieve pressure before removing. 8. WARNING FOR HANDLING ACCUMULATOR (2190 - 2528) A WaRNING! Explosion hazard ‘+ Keep away from flame. * Do not weld or drill. MAoASIIP ACCUMULATOR ‘The pilot control system is equipped with an accumulator. The accumulator will store a pressure charge that may enable the hydraulic controls to be activated for a brief period of time after the engine has been shut down. Activation of any of the controls may enable the selected function to operate under the force of gravity, ‘When shutting the machine down, lower the front attachment to the ground. After the engine has been shut down, move the joystick controls to release the pressure in the accumulator. 2022-7164 Operation and Maintenance Manual Safety 1-7A Warnine! ‘Any raised attachment will lower to the ground if the accumulator holds a charge. A WARNING! Refer to the Shop Manual for service procedures. Do not release any of the pilot lines until the pressure within the accumulator has been released. 9, WARNING FOR ENGINE FAN (2190 - 3315) A WARNING! Keep your hands away from the fan during operation. Entanglement in the fan can cause serious Injury. HaoaAt | 10. KEEP OUT OF THE SWING AREA (2190 - 3379). A DANGER! KEEP OUT OF SWING AREA 1-8 Safety 2022-7164 Operation and Maintenance Manual11. WARNING TAG - USED WHEN INSPECTING HYDRAULIC SYSTEM (2190 - 2549). ‘A\WARNING ow rou wn PERFORMING INSPECTION (OR MANTENANCE Haocaza, Figure 2 2022-7164 Operation and Maintenance Manual Safety 1-9SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING IN DIGGING MODE A DANGER! Unsafe use of the excavator while making rated lifts could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property. Do not let anyone operate the machine unless they've been properly trained and understand the information in the Operation and Maintenance Manual To lift safely while in Digging Mode, the following items must be evaluated by the operator and the work-site crew. + Condition of ground support ‘+ Excavator configuration and attachments + Weight, ling height and lifting radius + Sale rigging of the load ‘+ Proper handling of the suspended load ‘Taglines 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. A WaRNING! NEVER wrap a tagline around your hands or body. NEVER rely on taglines or make rated lifts when wind gusts are in excess of 48.3 km/hr (30 mi/h). Be prepared for any type of wind gust when working with loads that have a large surface area. ‘Always engage the "Digging Mode" control on the Instrument Panel before using the excavator for lifting work. A WARNING! It you need more information or have any questions or concerns about safe operating procedures or working the excavator correctly in a particular application or in the specific conditions of your individual operating environment, please consult your local Daewoo representative. UNAUTHORIZED MODIFICATIONS. ‘Any modification made without authorization or written approval from Daewoo can create a safety hazard, for which the machine owner must be held responsible. For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example, rot 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. 1-10 Safety 2022-7164 Operation and Maintenance ManualWORK-SITE PRECAUTIONS ATTACHMENT PRECAUTIONS Options kits are available through your dealer. Contact Daewoo for information on available one-way (single-acting) and two-way (double-acting) piping/valving/auxiliary control kits. Because Daewoo cannot anticipate, identify or test all of the attachments that owners may wish to install on their machines, please contact Daewoo for authorization and approval of attachments, and their compatibility with options kits. AVOID HIGH-VOLTAGE CABLES Serious injury or death can result from contact or proximity to high-voltage electric lines. The bucket does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to stay away from power lines not clearly visible to the operator. VOLTAGE MINIMUM SAFE DISTANCE KV 3.0m (9'- 10") Figure 3 33.0KV 40m (139-1) 6.0K 5.0 m (16-5) 154.0KV 18.0 m (26-3) 275.0KV. 10.0 m (82'- 10") 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 utlty directly and work out a safety plan with them, BEFORE STARTING TO DIG, CONTACT AUTHORITIES Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know what's underneath the work-site before starting to dig. 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. 2022-7164 Operation and Maintenance Manual Safety 1-11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. lf 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 tire support. USE SOLID SUPPORT BLOCKING Never rely on lift jacks or other inadequate supports when work is being done. Block tires fore and aft to prevent any movement. OVERHANGS ARE DANGEROUS: Digging the workface under an overhang ~ the work area beneath a cliff or under the edge of a ditch — is dangerous. Know the height and reach limits of the excavator and plan ahead while working. Avoid creating dangerous situations by moving around the work-site while making excavations. Go on to 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 shutdown. ‘SLOPING TERRAIN REQUIRES CAUTION Dig evenly around the worksite whenever possible, trying to gradually level any existing slope. If it's not possible to level the area or ‘avoid working on a slope, reducing the size and cycling rate of the workload is recommended. ‘On sloping surfaces, use caution when positioning the excavator prior to starting a work cycle. Stay alert for instability situations in order to avoid getting into them. For example, you should always avoid working the bucket over downhill tres when parked perpendicular to the slope. Slow all downhill swing movements and void full extensions of the bucket in a downhill direction. Lifting the bucket t00 high, too close to 7 the machine, while the excavator is turned uphill HAoMTaNL can also be hazardous. Figure@ 112 Safety 2022-7164 Operation and Maintenance Manual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 @ 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. HB10131| Figure 5 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. OPERATION OPERATE WHILE SEATED AT THE OPERATOR'S STATION ONLY Never reach in through a window to work a control. Do not operate the excavator unless you're in the command position, stay alert and focused on your work at all times but DO NOT twist out of the seat if job activity behind you (or to the side) requires your attention. Use a spotter or signal person if you can't see clearly and something is happening behind you. Replace damaged safety labels and lost or damaged owner's manuals. Do not let anyone operate the machine unless they've been fully and completely trained, in ‘safety and in the operation of the machine. 2022-7164 Operation and Maintenance Manual HAOAtsoL| Figure 6 Safety 1-13BEFORE STARTING THE ENGINE Do a “pre-star safety check: Walk around your machine before getting in the operator's cab. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated. Look around the worksite 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. ‘Amachine that has not been used recently, or is being operated in extremely cold temperatures, could require a warm-up or maintenance service prior to startup. ‘Check gauges and monitor displays for normal operation prior to starting the engine. Listen for unusual noises and remain alert for other potentially hazardous conditions at the start of the work cycle. NEVER USE ETHER STARTING AIDS ‘An electric-grid type manifold heater is used for cold starting. The glowing heater element can cause ether or other starting fluid to detonate, causing injury. MOUNTING AND DISMOUNTING NEVER get on or off a moving machine. Do not jump onioff. The entry/egress path should be clear of mud, oil and spills and mounting hardware must be kept tight and secure, ‘Always use handholds and steps, while maintaining at least 3-point contact of hands and feet. Never use controls as handholds. NEVER get up from the operator's seat or leave the operator's station and dismount the machine if the engine is running, 1-14 Safety HAQASTIP Figure 7 (4 f HAOLOtOS| Figure 8 2022-7164 Operation and Maintenance Manual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 worksite should be aware of assigned individual responsibilities and tasks. ‘Communication and hand signals used should be understood by everyone. Terrain and soil conditions at the job site, approaching traffic, weather-related hazards and any above or below ground obstacles or hazards should be observed and monitored by all work crew members. ENGINE VENTILATION Engine exhaust gases can cause fatal accidents, as well as unconsciousness, loss of alertness, judgement and motor control and serious injury. Make sure of adequate ventilation before starting the engine in any enclosed area, You should also be aware of open windows, doors or ductwork into which exhaust may be carried, or blown by the wind, exposing others to danger. Haoao7ol| Figure 9 ASBESTOS DUST HAZARD PREVENTION ‘Asbestos dust can be HAZARDOUS to your health i itis inhaled. Ifyou handle materials containing asbestos fibers, follow these guidelines as given below: + Never use compressed air for cleaning ‘+ Use water for cleaning to keep down the dust. + Work on the machine or component with the wind at your back whenever possible. + Use an approved respirator, with proper filtration cartridges. ‘TAKE TIME TO PROVIDE GOOD VISIBILITY Halt work if visibility is poor. Strong rains, snow, fog and extremely dusty conditions can all obscure visibility ‘s0 badly that it is best to walt 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 ights, windows or mirrors need cleaning or adjustment. 2022-7164 Operation and Maintenance Manual Safety 1-15FUEL, OIL AND HYDRAULIC FLUID FIRE HAZARDS ‘Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area. The machine must be parked with controls, lights and switches tured 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 fat the fuel fling 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 filing nozzle, to provide a ground. 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. 24 volt battery units consisting of two series- connected twelve volt batteries have a cable connecting one positive terminal on one of the Si Haoar20u| igure 10 Haoasto4| Figure 17 12 volt batteries to a negative terminal on the other battery. Booster or charger cable connections must be made between the non-series-connected positive terminals and between the negative terminal of the booster battery and the metal frame of the machine being boosted or charged. Refer to the procedure and illustration in “Starting Engine Using A Booster Battery” 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 2022-7164 Operation and Maintenance Manual‘TRAVEL CONTROLS MAY PRODUCE REVERSED OPERATIONS. Before starting the machine you should always check to see which end of the lower structure is under the ‘operator's cab. In the normal travel configuration, the steering axle is at the front of the machine, and the rigid axle is under the engine and counterweight. If the operator swings the cab 180°, the rigid axle will be underneath the operator's cab, and steering will be reversed, When traveling the excavator always keep lights on; make sure that you are in compliance with all state and local regulations concerning warning flags and signs and keep the operator's cab positioned over the front end of lower structure. That will keep travel controls in thelr 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 & SWING Use a signal person in high traffic areas and (a) whenever the operator's view is not clear, such ‘as when traveling in reverse. Make sure that no fone comes inside the swing radius of the machine. Anyone standing near the lower structure, or working assemblies of the attachment, is at risk ‘of being caught between moving parts of the machine. Never allow anyone to ride on any part of the machine or attachment, including any part of the turntable or operator's cab. Host0144 Figure 12 ‘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 tit 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. 2022-7164 Operation and Maintenance Manual Safety 1-17PARKING THE MACHINE, ‘Avoid making sudden stops, or parking the machine wherever it happens to be at the end of the work day. Plan ahead so that the excavator will be on a firm, level surface away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable, block the tires 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. 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. EQUIPMENT ROUGH OPERATION MAY REQUIRE USE OF CERTIFIED SAFETY EQUIPMENT a e Working in mines, tunnels, deep pits or on loose or wet surfaces could produce danger of falling fock oF hazardous thing objects, Aaona / protean for ie operators eab could be 7 feauvedn te form ofa FOG | Faling Object Gard ox windows quads a Haoat 101] Figure 13 1-18 Safety 2022-7164 Operation and Maintenance ManualAny reinforcement system that is installed on the machine must pass safety and certification standards and carry appropriate labeling and rating information. For example, the most often added type of reinforcement system, FOG, must meet or exceed International Standard 18010262, Laboratory Tests and Performance Requirements Earth-Moving Machinery. Never attempt to alter or modify any type of protective structure reinforcement system, by drilling holes, welding, remounting or relocating fasteners. Any serious impact or damage to the HAOAto04| system requires a complete integrity Figure 14 reevaluation. Reinstallation, recertification andi or replacement of the system may be necessary. 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 OPSicertified, depending upon the specific application and working situation. Laminate glass protection for the front, side or rear windows may also be recommended depending upon particular site conditions. Contact your Daewoo distributor for available safety guards and/or recommendations if there is any danger of getting hit by objects that could strike the operator's cab. Make sure that all other work:site crew members are kept well away from the excavator and safe from potential hazards. MOVEMENT ALARMS If the excavator is equipped with an audible travel movement alarm or visible swing movement alarm (strobe light), test the alarm on a daily basis. The audible alarm should sound as soon as the travel system is engaged. The strobe light should begin to flash as soon as the swing system is engaged. ‘SEAT BELTS SHOULD BE USED AT ALL TIMES Whenever the engine is running, the operator should be seated at the control station with the seat belt properly engaged. Haono0e| Figure 15 2022-7164 Operation and Maintenance Manual Safety 1-19WINDOW GLASS BREAKING TOOL ‘This excavator is equipped with a glass breaking tool. It is located behind the operator seat in the Upper right corner of the cab. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the ‘operator's cabin. Grip the handle firmly and use the sharp point to break the glass. Figure 16 KEEP A FIRE EXTINGUISHER AT HAND It is recommended that an appropriately sized (2.27 kg [S lb] or larger) multi-purpose "A/B/C" fire extinguisher be mounted in the cab. Check ‘and service the fire extinguisher at regular intervals and make sure that all work-site crew members are adequately trained in its use. HaoAoeoL| igure 17 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, 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. ‘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 overfiow 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. 1-20 Safety 2022-7164 Operation and Maintenance Manual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 jobsite hazard. Extra safety guards may be required. NEVER allow hoses to be hit, bent or interfered with during operation. Always replace with same or greater bursting pressure for protection, ‘THE OPERATOR'S CAB AND TURNTABLE DECK SHOULD BE KEPT CLEAN Cleaning off accumulations of grease and dirt helps extend equipment service life. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result Keep the cab floor and consoles free of tools and personal items. WEAR EYE PROTECTION AND SAFETY CLOTHING & D Full eye protection, a hard hat, safety shoes and = gloves may be required at the job site. inadequate tools. They could break or slip, causing injury, or they may not adequately perform intended functions =B BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED (Pots Don't forget that some risks to your health may ie not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injures. 2022-7164 Operation and Maintenance Manual Safety 1-21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. Cail 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. HAOASAOL Figure 19 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. MAINTENANCE USE WARNING TAG CONTROL LOCKOUT PROCEDURES DURING SERVICE Alert others that service or maintenance is being performed and tag operator's cab controls = and other machine areas if required ~ with a warning notice. 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, non-active position. Warming tags for controls are available from Daewoo distributors. 1-22 Safety “A. WARNING ow ToucH WHEN PERFORMING INSPECTION (8 MAINTENANCE HaocazaL, Figure 20 2022-7164 Operation and Maintenance ManualDO NOT RUN THE ENGINE IF REPAIRS OR WORK IS BEING PERFORMED ALONE. ‘You should always have at least two people working together if the engine must be run during service. One Person needs to remain in the operator's seat, ready to work the controls or stop the machine and ‘SHUT OFF" the engine. ALWAYS USE ADEQUATE EQUIPMENT SUPPORTS AND BLOCKING Do not allow weight or equipment loads to remain suspended. Lower everything to the ground before leaving the operator's seat. Do not use hollow, cracked or unsteady, wobbling weight supports. Do not work Under any equipment supported solely by a lft jack, DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS. \Wait for the engine to cool off after normal operation. Park the excavator on a firm, level surface and lower all equipment before shutting down and switching *OFF* controls. When engine lube oil, gearbox lubricant or other fluids require change, wait for fluid temperatures to decrease to a moderate level before removing drain plugs. NOTE: — Oil will drain more quickly and completely if is warm. Do not drain fluids at 95°C (20°F) temperatures but don't allow full cool-down. COOL-DOWN IS REQUIRED PRIOR TO RADIATOR OR RESERVOIR CHECKS Stop the engine and allow heat to dissipate before performing service on the engine radiator or hydraulic fluid reservoir. Both assemblies have air vent levers at or near the fill cap for venting built-up air pressure. Release the levers before trying to take off fill caps and LOOSEN CAPS SLOWLY, prior to removal. HAOAO6OL Figure 21 2022-7164 Operation and Maintenance Manual Safety 1-23PRESSURIZED HYDRAULIC OIL FLUID LEAKS CAN BE DANGEROUS 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. oP eZ HAOM20U) Figure 22 OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES THE SKIN. A WARNING! Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue. USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE Refer to the "General Maintenance" section of the Shop Manual for information on tightening torques and recommended assembly compounds and always use the correct part, Poor or incorrect fastener connections can dangerously weaken assemblies. DISPOSE OF ALL PETROLEUM-BASED OILS AND FLUIDS PROPERLY Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. Never drain any petroloum- based product on the ground or dispose of old oil in municipal waste collection containers, or in metropolitan sewer systems or rural landfills. et Check state and local regulations for other Figure 23 requirements, 1-24 Safety 2022-7164 Operation and Maintenance ManualSHIPPING AND TRANSPORTATION OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS Check state and local restrictions regarding weight, width and length of a load prior to making any other preparation for transport. ‘The hauling vehicle, traler 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 job 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. 2022-7164 Operation and Maintenance Manual Safety 1-25EXCAVATOR RATED LIFT CAPACITY TABLES A 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 + Offlevel 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 hookline 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. Taglines 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. The following weight loads are in compliance with SAE (J1097) and ISO applicable, recommended standards for hydraulic excavators performing lifting operation on a firm supporting surface. An asterisk (*) Next to the lift rating indicates rated load does not exceed 87% of hydraulic capacity. All other ratings have been determined not to exceed 75% of tipping capacity. DO NOT attempt to lift or hold any load that exceeds rated load capacity at the specified distances (from the machine's rotation centerline and height - see “iit radius” and “lift height’ in the reference drawing, Figure 24). 1-26 Safety 2022-7164 Operation and Maintenance Manual‘Centarine iting Radius (of Rotation | Luing Point Height ™ Ground Line (Machine Supporting Surfaco) HAQUTAOL Figure 24 ‘The weight of slings and any auxiliary iting device (and/or the weight difference of any attachment heavier than standard configuration) must be deducted from the rated lift capacity to determine allowable net lifting load. The lift point should be located on the back of the bucket, as shown in Figure 24, IMPORTANT! Select the digging mode switch on the instrument panel before using the excavator for lifting work. Engine and hydraulic oll should both be fully warmed up to operating temperature before starting a lift. 2022-7164 Operation and Maintenance Manual Safety 1-27Toeznosh eo | os [mer | os | ou ws | mea | os | mea] wos =S_|_ me ovesia FET PRO Taoeeo ng 9) Woz WY 8 (2-24) Wes WOOK 2022-7164 Operation and Maintenance Manual 1-28 SafetyeznoaH elelrfelol+lols|-lelon rs wwe aE Sa THR 2022-7164 Operation and Maintenance Manual 1-34 Safetyorznoa com Coeuezun Wve (eet) 008 Safety 1-95 2022-7164 Operation and Maintenance ManualOPERATING CONTROLS ‘The “Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-2 “Operator's Area’ on page 2-4 “Operational Controls and Panels’ on page 2-5 “instrument Panef" on page 2-11 1 2 3, 4. 5. “Steering Console” on page 2-17 6. “Mode Selection Switches” on page 2-23 7. “Heater and Air Conditioning Control Panef” on page 2-24 8. “Stereo” on page 2-28 9. “Miscellaneous Electrical Devices” on page 2-32 10. “Seat Adjustment" on page 2-33 11, “Seat Belt” on page 2-35 12. “Ceiling Cover” on page 2-36 13. “Front Windows" on page 2-37 14, “Door Side Latch’ on page 2-40 15. “Miscellaneous Access Covers and Doors" on page 2-41 16. “Cab Storage Compartments” on page 2-43, 17. “Swing Lock Pin and Mechanism” on page 2-42 18, “Wheel Chocks” on page 2-42 19. “Ashtray” on page 2-43 20, “Emergency Glass Breaking Too!” on page 2-44 Each group is explained with a point location drawing or photo and a brief description of each control, ‘switch, gauge or valve. Indicator lights work in addition to the gauges on the instrument panel. The operator should monitor machine pressure on the instrument panel along with pilot lights. These lights will only give the operator an indication that there is a problem A WARNING! Warning lights. When any one or more of the warning lights located on the control console come "on", immediately discontinue operation and shutdown unit. Investigate and correct the problem before proceeding with operation. 2022-7164 Operation and Maintenance Manual Operating Controls 2-1COMPONENT LOCATIONS HBOKONIL Figure 1 2-2 Operating Controls 2022-7164E Operation and Maintenance Manual1. RADIATOR & OIL COOLER 19. ARM 2. AIR CLEANER 20. BUCKET CYLINDER 3. CAB 21. LINK 4, BATTERY COMPARTMENT 22. BUCKET 5. FUEL TANK FILL CAP 23, SIDE CUTTER 6. FUEL TANK 24, BUCKET TOOTH 7. HYD. OIL TANK 25. FENDER 8 PUMPS. 26. RAM CYLINDER 9, COUNTERWEIGHT 27. FRONT AXLE 10. ENGINE 28. STEP 11. MUFFLER 29. TRANSMISSION 12. CONTROL VALVE 30. TRAVEL MOTOR 13, SWING MOTOR 31. DRIVE SHAFT 14, CENTER JOINT 32. REAR AXLE 15. SWING BEARING 33. BLADE CYLINDER 16. BOOM CYLINDER 34, DOZER BLADE 17. BOOM 35. FENDER 18. ARM CYLINDER 2022-7164 Operation and Maintenance Manual Operating Controls 2-3OPERATOR’S AREA Figure 2 ASHTRAY (See page 2-43) INSTRUMENT PANEL (See page 2-11) ‘SEAT (See page 2-33) ‘CAB STORAGE COMPARTMENT (See page 2-43) ‘STEREO (See page 2-28) ed o 2-4 Operating Controls agoeNe a3 FUSE BOX (See page 4-49) ‘SAFETY LEVER (See page 3-13) ‘STEERING WHEEL (See page 3-20) BRAKE PEDAL (See page 3-20) ‘ACCELERATOR PEDAL (See page 3-20) ‘STEERING CONSOLE (See page 2-17) 2022-7164E Operation and Maintenance ManualOPERATIONAL CONTROLS AND PANELS Figure 3 STEERING CONSOLE INSTRUMENT PANEL 3. RIGHT HAND WORK LEVER (JOYSTICK) WITH BOOSTER / BREAKER OPERATION SWITCH 4, ENGINE SPEED CONTROL DIAL 5. HEATER AND AIR CONDITIONER CONTROL PANEL, 6. START SWITCH 7. CIGAR LIGHTER 2022-7164 Operation and Maintenance Manual 12, 13, 14, SWING ALARM SWITCH (OPTIONAL) HAZARD WARNING LIGHT SWITCH WORK LIGHT SWITCH BOOSTER / BREAKER SELECTION SWITCH DOZER BLADE CONTROL LEVER WITH OUTRIGGER SELECTOR SWITCH WARNING LIGHT SWITCH (OPTIONAL) LEFT HAND WORK LEVER (JOYSTICK) WITH HORN SWITCH Operating Controls 2-5‘STEERING CONSOLE This console contains various warning lights and switches. (See “Steering Console" on page 2-17.) Hace Figure 4 INSTRUMENT PANEL This instrument panel contains the various waring lights and selector switches for the work and engine speed modes. (See “instrument Panef” on page 2-11.) HAOASOIL, Figure § 3. RIGHT HAND WORK LEVER (JOYSTICK) WITH BOOSTER/BREAKER OPERATION SWITCH This lever controls boom and bucket movements. For a more detailed ‘explanation see "Work Lever (Joysticks) (ISO Style)’ on page 3-25. The button at top of right-hand joystick (located under the rubber boo!) allows the ‘operator to control one of two functions. Refer to "Booster/Breaker Selection Switch" for an explanation of the switch. uacore) Depending on position of selector switch, the operator can increase breakout force by about 10% or operate a hydraulic breaker by pressing on this button. When the button is released, breakout force returns to normal pressure settings or the breaker stops. Figure 6 2-6 Operating Controls 2022-7164E Operation and Maintenance Manual4, ENGINE SPEED CONTROL DIAL The engine speed is controlled by the dial Rotating it clockwise increases. engine speed (RPM) and counterclockwise decreases engine speed. ‘A. “LOW IDLE” (Lowest engine speed) B. “HIGH IDLE" (Highest engine speed) 5. HEATER AND AIR CONDITIONING CONTROL PANEL Used to control air-conditioner and heater in operators compartment. Refer to “Heater and Air Conditioner” for more details. (See page 2-24) 6. START SWITCH To start or stop the engine for equipment operation. ‘A. “I” Position (On) - Turning the switch to this position turns the engine electrical system “ON." The charge indicator light and the oil pressure tor light should be "ON" at this B. *0" Position (Off) - Turning the switch to this position turns the engine “OFF” along with its electrical system. In this position the engine is “OFF” but the interior cab light and fuel tank transfer pump (if equipped) are functional. HaoAeoot| Figure 7 HAOATTL| Haocs4it. Figure 9 c. © Position Star - it you turn the starter switch to this positon, the engine will start. When released, the key will return to the “ON” position automatically. Do not operate the starter switch ‘over 15 seconds at atime, this will help prevent damage to starter. 2022-7164 Operation and Maintenance Manual Operating Controls 2-7A Warnine! DO NOT USE STARTING FLUIDS WHEN USING THE PREHEAT SYSTEM. The preheat system could cause the starting fluid to explode. D. ® Position (Preheating) - Use this position to start in cold weather. When preheating is completed, the preheating completion light, located on the instrument panel wil ight up. Start the engine immediatly aftr the light comes “ON. 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 NOTE: — This cigar lighter is for 24V only. Never connect a 12V electrical device to the lighter. Haoareot| Figure 10 ‘SWING ALARM SWITCH (OPTIONAL) If unit is equipped with an alarm buzzer for ‘swing alarm, push this switch to activate the alarm, A. “0° Position B. ‘I’ Position - Turns alarm "ON." “OFF* position. HAOATEIL Figure 11 2-8 Operating Controls 2022-7164E Operation and Maintenance Manual9, HAZARD WARNING LIGHT SWITCH This light is used when the equipment is stopped due to a matfunction or when an ‘emergency occurs. When this switch is pressed the directional indicator lights in front and back of the machine light up and flash, warning others in the area. At the ‘same time the directional indicator lights fon the instrument panel will light up to warn the operator. The hazard warning lights operate independent of the start switch, HoB20131 A. *O" Position - "OFF* position, caoae B. “I" Position - Turns lights “ON.” NOTE: Hazard warning lights will funetion with start switch in “OFF* position. 10. WORK LIGHT SWITCH Operates the work lights mounted on the boom, NOTE: Be certain that the working lights are turned *OFF* when traveling on the streets. ‘A. *O" Position - "OFF* position, B. Position - Turns alarm "ON." HG820120 Figure 13 11. BOOSTER/BREAKER SELECTION ‘SWITCH This switch controls the push button located at the top of the right-hand joystick. ‘A. *0” Pressure-up Position - Pressing button on joystick increases breakout force by 10%. B. “I” Breaker Position - Button allows the operator to activate an optional hydraulic breaker if so equipped. Do Not leave switch in this position if not Haoariot| ‘equipped with a breaker. igure 14 2022-7164 Operation and Maintenance Manual Operating Controls 2-912 13. 14. DOZER BLADE CONTROL LEVER WITH OUTRIGGER SELECTOR SWITCH This lever controls movement of dozer blade. For a more detailed explanation sea “Dozer Blade Control Lever (Figure 43 and Figure 44)" on page 3-26. When switch located on the upper section of the dozer control lever is pressed it will ‘select the front outrigger. WARNING LIGHT SWITCH (OPTIONAL) If unit is equipped with a warning light, push this switch to activate it. ‘A. “0” Position - *OFF* position, B. “I" Position - Lights turn “ON" and will start flashing, LEFT HAND WORK LEVER (JOYSTICK) WITH HORN SWITCH This lever controls arm and swing movements. For a more detailed ‘explanation see “Work Lever (Joysticks) (ISO Styley" on page 3-26. Push button (located under the rubber boot) in left hand joystick to sound horn, 2-10 Operating Controls Hos2016. Figure 15 HAOA7SOL Haou200| Figure 17 2022-7164E Operation and Maintenance ManualINSTRUMENT PANEL @ © aouso0L Figure 18 1, RETURN FILTER CLOGGED WARNING LIGHT 2, PILOT FILTER CLOGGED WARNING LIGHT 3. CHARGE WARNING LIGHT 4, _ ENGINE OIL PRESSURE WARNING LIGHT 5, PREHEATING COMPLETION LIGHT 6 AIR CLEANER FILTER CLOGGED WARNING LIGHT 7. FUEL GAUGE 8. POWER MODE INDICATOR LIGHTS FUNCTIONAL CHECK 9. 10. 1. 12 13, 14 15. 16. WORK MODE INDICATOR LIGHTS MULTI-FUNCTION GAUGE DISPLAY SELECTION SWITCH AUTO IDLE SWITCH WORK MODE SELECTION SWITCH POWER MODE SELECTION SWITCH ENGINE COOLANT TEMPERATURE GAUGE MULTI-FUNCTION GAUGE DISPLAY PANEL HOURMETER ‘When the engine start switch is tured to the “ON" position, all indicator lights will tum "ON" and the alarm buzzer will sound for about 2 seconds. Any light that does not come “ON’ at this time may require replace- ment. 2022-7164 Operation and Maintenance Manual Operating Controls 2-11RETURN FILTER CLOGGED WARNING LIGHT. This light indicates that the filter for the return hydraulic oil has become clogged and requires replacement. 2. PILOT FILTER CLOGGED WARNING LIGHT Hf the hydraulic filter for the pilot control system becomes clogged, this light will come “ON,” indicating that the filter requires replacement. (CHARGE WARNING LIGHT This indicator light will turn “ON* when the ‘engine starter switch is turned “ON,” and should go "OFF" after the engine starts. If it does not turn “OFF” shut the engine down immediately and determine the ‘cause of the problem, 4, _ ENGINE OIL PRESSURE WARNING LIGHT This indicator light will turn “ON* when the ‘engine starter switch is turned “ON,” and should go “OFF” after the engine starts. For example, if the engine oil pressure becomes too low, the light will turn *ON" and a warning buzzer will sound. If this happens, shut the engine down immediately and determine the cause of the problem. If you continue to work when this light is “ON,” it will result in serious ‘engine damage. 212 Operating Controls “al h--4 1w0Aes01| Figure 19 “lo F--4 Haoasso1| Figure 20 HAOABIOL Figure 21 HAOAS201 Figure 22 2022-7164E Operation and Maintenance ManualPREHEATING COMPLETION LIGHT This light indicates that the engine preheat function has been completed. HAQAEOOL Figure 23 6. AIR CLEANER FILTER CLOGGED WARNING LIGHT This light will come “ON if the air fiter becomes clogged and reduces air flow to the engine. This indicates that the fiter requires replacement. -=— = =| HaoA660| Figure 24 FUEL GAUGE It shows remaining fuel quantity in tank. GREEN ZONE - Indicates a normal fuel E F quantity SS] RED ZONE - Indicates that the fuel level is low, The fed indeator ighis wil start to GUID flash. The unit should be refueled. Haoasert| Figure 25 2022-7164 Operation and Maintenance Manual Operating Controls 2-139. 10. POWER MODE INDICATOR LIGHTS (SEE “MODE SELECTION SWITCHES” ON PAGE 2-23.) WORK MODE INDICATOR LIGHTS (SEE “MODE SELECTION SWITCHES” ON PAGE 2-23.) MULTI-FUNCTION GAUGE DISPLAY ‘SELECTION SWITCH Used to change LED display modes on the ‘multi-function display panel. 1) ENGINE RPM - This readout provides an exact digital reading of the engine speed, 2) BATTERY VOLTAGE - When the starter is engaged or the preheat ‘system is being used, the voltage will drop below 24V temporarily. With the engine running, the reading should be between 26V and 29V, 2-14 Operating Controls DISPLAY a 0) een — VOLT lo vos 2022-7164E Operation and Maintenance Manual3) FRONT HYDRAULIC PUMP PRESSURE - This reading monitors ‘hydraulic pressure port in the front hydraulic pump. (Closest to engine F- PUMP flywheel housing.) It displays the reading in BARS BAR HAOAS7OU Figure 29 4) REAR HYDRAULIC PUMP PRESSURE - This reading monitors ‘a hydraulic pressure port in the rear hydraulic pump. (Farthest from ‘engine flywheel housing.) It displays the reading in BARS. R- PUMP BAR HAOASEOL Figure 30 11. AUTO IDLE SWITCH (SEE “MODE SELECTION SWITCHES" ON PAGE 2-23.) 12. WORK MODE SELECTION SWITCH (SEE “MODE SELECTION SWITCHES” ON PAGE 2-23.) 13. POWER MODE SELECTION SWITCH (SEE “MODE SELECTION SWITCHES” ON PAGE 2-23.) 2022-7164 Operation and Maintenance Manual Operating Controls 2-1514, ENGINE COOLANT TEMPERATURE GAUGE The colored bands indicate the temperature of the engine coolant and if any corrective action needs to be taken, WHITE ZONE - Indicates temperature is lower than the normal operating temperature, GREEN ZONE - Indicates temperature is within the normal operating range. RED ZONE - Indicates temperature is too high. When the temperature reaches the red zone the engine speed is automatically reduced to idle and a warning buzzer ‘sounds. The red indicator lights will start to flash. Allow the engine to run at ‘LOW IDLE" until temperature gauge registers in “GREEN ZONE.” When green zone is reached, shut engine down and look for probable causes, such as low coolant, loose fan belt, etc. When the temperature reaches a normal range, the engine speed will recover automatically 15. MULTI-FUNCTION GAUGE DISPLAY PANEL, ‘The Multi-function Display is a combination of gauge readouts. By pressing the “Display Switch” on the control panel, you can change the readout to observe a digital readout of engine RPM, battery voltage, and front and rear hydraulic pump pressures. Each time you press the Display switch, the readout function monitored will change. 16. HOURMETER ‘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 is functioning properly. NOTE: All regularly scheduled service intervals should be performed based on the hours displayed (on the hourmeter. 2-16 Operating Controls c H 0 eee oe ©] QHD HaoAs104] Figure 31 F-PUMP R-PUMP RPM VOLT lo BAR HAOASSOL Figure 32 HaoAsoo1| igure 33, 2022-7164E Operation and Maintenance ManualSTEERING CONSOLE 2) 1” 10) HAOKO6IL. Figure 34 ABNORMAL ENGINE SPEED WARNING. LIGHT LEFT DIRECTIONAL / HAZARD INDICATOR LIGHT ‘TRAVEL INDICATOR LIGHT HIGH BEAM INDICATOR LIGHT BRAKE FLUID PRESSURE WARNING LIGHT PARKING BRAKE INDICATOR LIGHT ABNORMAL ENGINE SPEED WARNING LIGHT When the engine speed rises above the Normal limit while in work mode, this warning light will turn "ON" and a buzzer will sound. If this light turns "ON* during operation, manually select a lower engine speed and examine the engine speed adjusting ‘system for the cause of the malfunction. 2022-7164 Operation and Maintenance Manual 7. RIGHT DIRECTIONAL / HAZARD INDICATOR LIGHT 8, BRAKE FILTER CLOGGED WARNING Light 9, RIGHT SIDE COMBINATION SWITCH 10. HEADLIGHT SWITCH 11. TRAVELWORK/PARK SELECT SWITCH 12. RAM SWITCH 13, LEFT SIDE COMBINATION SWITCH vmin HaB2007. Figure 35 Operating Controls 2-17DIRECTIONAL / HAZARD INDICATOR LIGHT - LEFT SIDE This light turns “ON” and “FLASHES” when the left turn signal switch is selected land when the hazard light switch is turned “ON” When one of the directional indicator lights is malfunctioning the indicator will flash abnormally fast. Inspect the lights and replace the blown light. 3. TRAVEL INDICATOR LIGHT When the “travel/work/park’ selector switch is in the “travel” position, this light turns "ON". HIGH BEAM INDICATOR LIGHT This light turns "ON" when the high beams are turned “ON.” 5. BRAKE FLUID PRESSURE WARNING LIGHT Lights up when the start switch isin the “I position and is automatically turned *OFF* when the engine is started. If the light turns “ON" and the warning buzzer sounds during operation, stop the tengine immediately and inspect the brake system. 2-18 Operating Controls Ha0G1016| Figure 36 HBOKO20L, Figure 37 HoB20081, Figure 38 HB20004 Figure 39 2022-7164E Operation and Maintenance ManualPARKING BRAKE INDICATOR LIGHT This light turns “ON” when the “travel/work/ park’ selector lever is placed in the “PARK” position and indicates that the parking brake is set and the equipment can not be operated. If this light turns "ON" during operation a warning buzzer will sound and the equipment will automatically stop. When this happens inspect the equipment immediately for the cause of malfunction. eee Figure 40 7. DIRECTIONAL / HAZARD INDICATOR LIGHT - RIGHT SIDE This light turns “ON” and “FLASHES” \ / switch when the right turn signal is selected and when the hazard light switch is turned “ON.” ihn en oe drotona nati Srornahnetonng bo er wi ah SSrermaly tan nape eis ad fone ew I HaoasP| Figure 41 BRAKE FILTER CLOGGED WARNING LIGHT This light turns “ON' when the brake system fluid fiteris clogged. Replace the fiter element when it is “ON.” HaB2O10L, Figure 42 2022-7164 Operation and Maintenance Manual Operating Controls 2-19RIGHT SIDE COMBINATION SWITCH ‘A. Forward Travel - Pushing the lever towards the front selects the forward travel gear. B. Neutral - Central position puts the ‘gear in the "NEUTRAL" position. C. Reverse Travel - Pull the lever to the rear to select the reverse gear. D. Cruise Control Switch - When this ‘switch is pressed while travelling, the travel speed is maintained without Using the foot pedal. While in this mode the engine speed can be adjusted by turning the engine speed control dial Figure 43 If the brakes are applied or if the travel select lever is moved to the “NEUTRAL position the cruise control is turned “OFF.” ‘When the auto idle mode is selected, the engine speed is lowered approximately 4 seconds after the cruise control is turned "OFF" The cruise control is not operable in the reverse travel mode. E. Travel Speed Select Switch - Selects one of two travel speeds in forward and reverse. “1” Position: Low speed “2° Position: High speed 10. HEADLIGHT SWITCH ‘A. *O" Position - Turns *OFF* all lights. B. “Position - Turns ‘ON" the clearance lights, tail lights and instrument lights. ©. “ll” Position - Turns *ON' the clearance lights, tall _ lights, instrument lights and headlights. aso. Figure 44 2-20 Operating Controls 2022-7164E Operation and Maintenance Manual11. TRAVELIWORK/PARK, SELECT swiTcH This toggle switch is used to select travel, _ a work or park modes. @. A. TRAVEL MODE: Select this mode for street travel. B. WORK MODE: Select this mode for normal operation. ©. PARK MODE: Select this mode to park the equipment. Also activates the parking brakes. 8 S 8@ Ha0K081L| Acaution: 1. When the toggle switch is in the park or travel position the operation levers are not functional 2. Although it is possible to travel with the toggle switch in the work position, extreme caution should be exercised since the front attachment can be moved by accidentally touching the work levers. In the above condition the engine speed will not increase even though the foot pedal Is press to the maximum position, this is not a malfunction. 12. RAM SWITCH Selects the operation mode of the ram cylinder i.e., "LOCK" and "UNLOCK". ‘A, UNLOCK: When placed in this mode ® the ram cylinder is unlocked and Ww lowe shows aheron and more ag & comtorabe travel 8. LOCK: While in travel or park mode, 8 locking the ram cyngor cuts of th ram lock valve and secures the ‘equipment. 2022-7164 Operation and Maintenance Manual Operating Controls 2-2113. LEFT SIDE COMBINATION SWITCH ‘A. Right side directional switch - Pushing the lever forward, activates the right outside directional lights as well as the directional indicator light on the instrument panel, B. Left side directional switch - Pulling the lever back, activates the left outside directional lights as well as the directional indicator light on the instrument panel. NoTE: azo When the turn is completed the Figure 47 lever automatically returns to the "NEUTRAL" _ position. ‘Should it not, itcan be manually returned by hand. NOTE: Turn signals will function with start switch in ‘OFF* position. ©. Window washer switch - When the outside area of the lever is pressed, it activates the washer pump and sprays fluid to the windshield. (Only while being pressed.) NOTE: 1. _ The washer pump can be damaged if its activated while there is no fluid in the tank. The fluid level should be regularly checked and refilled as necessary. 2. _ Using soap or other solvents instead of the recommended washer may damage the wiper blades and the paint finish. Only use the recommended washer fluid or equivalent. Horn button - The center button of the lever activates the horn. (Only while being pressed.) E. Wiper Switch - Activates the wipers when the outside area of the lever is rotated. 4J: Intermittent Mode - wipes every 5 seconds. 0: Stop (Off) |: Normal speed mode II: Normal speed mode F. Push down - Locks into position and lights up the high beams. G. Neutral Position - Normal low beams. H. Pull up - Momentarily turns *ON* both the low beams and high beams. (Returns to ‘NEUTRAL" position when released.) High and low beams will only function with the headlight switch in the "II" position. Figure 48 2-22 Operating Controls 2022-7164E Operation and Maintenance ManualMODE SELECTION SWITCHES @ ® ® 3) 6) ® ® 8 © WM a a oe Figure 49 POWER WODE WORKWODE SwiTeH —}7, POWER NODE 3, WORK NODE SATO DLE SWiTOH SELECTION SWITCH (1, |" SELECTIONSWITOH(®, | (1, Figure 40 on page Figure s8onpageS21)" | Figure soenpage 16)" | S19) 2 POWER MODE = WORK WODE &-MULTEFUNGTION ‘SELECTION SWITCH (2, ‘SELECTION SWITCH (2, GAUGE DISPLAY Figure 88onpage®-2) | Figure 49 on page 8.20)"| SELECTION SWITCH INOIGATOR |7, POWER NODE-I | 70. LEVELING NODE | 78 AUTO LE INoIGATOR INOWATOR INOATOR & POWER MODE | 17. Diggin WORK WODE INOIOATOR INDIOATOR 3. POWER MODE I | 7 TRENCHING WORK Inigaron ODE INDIGATOR + Regarding tho usage of power made and work mode selection swith See ‘Mode Selection’ on page 2h + Regarding the usage of multi-function gauge display switch (See page 2-16). ‘+ Regarding the usage of auto idle switch. See “Mode Selection” on page 3-21 2022-7164 Operation and Maintenance Manual Operating Controls 2-23HEATER AND AIR CONDITIONING CONTROL PANEL LOCATION OF CONTROLS AND VENTS Hacuaca. Figure 50 ‘The heater and air-conditioner are combined into one unit located in the rear cover of operator's seat. If necessary, the operator can control inner temperature using the operation panel installed in the right control stand. 2-24 Operating Controls 2022-7164E Operation and Maintenance ManualOPERATING PANEL ers 2 3 HaoAao1t| Figure 51 FAN AND AIR-CONDITIONER SWITCH 4, SELECTION SWITCH FOR WIND BLOWER FAN SWITCHES DIRECTION ‘TEMPERATURE CONTROL SWITCH 5, VENTILATION SELECTION SWITCH When a switch is selected, the LED located above that switch will light up as well as give an activation ‘sound. When the light switch is turned "ON," the panel LED's will light up. FAN AND AIR-CONDITIONER SWITCH A. ‘OFF" Switch - Turns "OFF" the heater and air conditioner unit. B. "AIC" Switch - Turns "ON" the air conditioner when one of the blower A/c switches is activated. Haoca90| Figure 52 2022-7164 Operation and Maintenance Manual Operating Controls 2-252. BLOWER FAN SWITCHES ‘These switches are used to control the speed of the blower fan. ‘A. *LO* Switch - Used for low blower speed B. "MID" Switch - Used for intermediate blower speed ©. "HI" Switch - Used for high blower speed : If you do not select a blower HAOCAOL speed the heater and air Figure 53 conditioner will not work. Nott 3. TEMPERATURE CONTROL SWITCH ‘The temperature control consists of 24 stages. An LED is lit up for every 3 stages. Whenever pushing it, it changes step by step. Pushing it continuously, it changes continuously. A. *COOL" Switch - Lowers the temperature, B. "WARM" Switch - Raises the temperature, LED COLOR STATUS Green LED - Air conditioner. Full green, maximum operation of air-conditioner. Red LED - Heater. Full red, maximum operation of heater. Figure 54 4, SELECTION SWITCH FOR WIND DIRECTION A. Used to direct air flow to upper portion of operator's cab. Figure 55 2-26 Operating Controls 2022-7164E Operation and Maintenance ManualB. Used to direct air flow to lower portion of operator's cab ©. Used to direct air flow for defrosting front window of operator's cab. VENTILATION SELECT SWITCH Switch - Draws fresh air into operator's compartment. B. "B" Switch - Recirculates air within the operator's compartment. Used to rapidly reduce condensation on windows. MEMORY FUNCTION OF USED MODE ‘The air conditioner panel has a memory function. When the starter switch is turned “OFF” the settings for the pane! will be stored. When the excavator is started, the last setting will be used. HAoCaBIL, Figure 68 ADDITIONAL OPERATING INSTRUCTION ‘proper indoor temperature in summer is 5 - 6°C less than the outdoor temperature. Operate the air conditioner from 20 - 30 minutes a week to circulate the refrigerant in the system. NOTE: The blower switch should be on ‘LO" speed. If operating the air conditioner or heater for a long time, operate the ventilation switch, and when smoking, vent the air to the outside to prevent iritation to eyes. 2022-7164 Operation and Maintenance Manual Operating Controls 2-27STEREO 0 n oR 8 Figure 59 ‘ON-OFF / VOLUME CONTROL KNOB BALANCE / FADER CONTROL BASS/TREBLE CONTROL AM/FM BAND SELECTION ‘AUTOMATIC MEMORY (AME) TAPE EJECT BUTTON oehens 1. ON-OFF/VOLUME CONTROL KNOB 7. CASSETTE SLOT 8, & 9, PLAY DIRECTION BUTTON 10. AUTOMATIC SELECTION 11. DOLBY B SELECTION 12. METAL SELECTION 13. LED DISPLAY PANEL, ‘When this button is pressed the stereo will be turned “ON.” When this button is pressed a second time the power turns "OFF" Increase volume by rotating the control clockwise. When the stereo is turned "ON" the LED display will indicate radio stations and/or tape functions. 2. BALANCE/FADER CONTROL This control adjusts both the side to side balance of the stereo sound as well as front to back fading, Rotating the contro! counterclockwise will increase the volume to the left speakers, clockwise increases the volume to the right speakers. Press on the control and it will pop out; you can now adjust the fader (front/rear) balance. Rotating the control counterclockwise increases volume to the rear speakers, clockwise increases the volume to the front speakers. 2-28 Operating Controls 2022-7164E Operation and Maintenance ManualBASS/TREBLE CONTROL, This control adjust bass and treble tone levels. ‘To adjust the treble tone level rotate the control counterclockwise to decrease treble and clockwise to increase treble. To adjust the bass tone level press on the control and it will pop out. Rotate the control counterclockwise to decrease bass and clockwise to increase bass. 4, AM/FM BAND SELECTION This button sets the radio to either AM-1, AM-2, FM-1 or FM-2 frequency bands. Each of the frequency bands will enable the stereo to store 6 preset radio station frequencies. Each time the button is pressed the stereo will move to the next band. AUTOMATIC MEMORY (AME) This function automatically finds the six strongest radio signals in the frequency selected and stores them in memory. Select the band (AM-1, AM-2, FM-1, FM.2). Press and hold the AME button for approximately two seconds and the stereo will search out the strongest stations in the area. These stations can then be recalled by pressing buttons (1 through 6, Figure 60). NOTE: To manually store radio station settings, use the band selector to select the frequency band to be listened to. Then use the tuning control to select the desired station. Press and hold any of the preset keys for approximately 2 seconds; a beep will sound when station has been set. HA0C990L Figure 60 . TAPE EJECT BUTTON Eject the tape from the cassette deck by pressing this button. The stereo returns to the tuner mode. CASSETTE SLOT Press the "ON/OFF" switch for power. Insert a tape with the exposed tape facing to the right. The tape wil start to play. "TAPE" is displayed on the LED display. . & 9, PLAY DIRECTION BUTTON Pressing this control button to either the right or the left will fast forward or rewind the tape. The button will lock into this position. To stop the action, press the opposite side to the button and the tape will return to the normal play mode. Pressing both control buttons at the same time will reverse the direction of the tape. 2022-7164 Operation and Maintenance Manual Operating Controls 2-2910. AUTOMATIC SELECTION Press this control to change channels manually to either higher or lower frequencies. 11. DOLBY B SELECTION If the tape being listened to has been recorded with Dolby B, press the preset selector button 1 to turn the Dolby B control on. The Dolby symbol will appear on the display. Press this control a second time to tum the Dolby B control "OFF." 12. METAL SELECTION If the tape being listened to is either a metal or chromium type of tape, press the preset selector button 2 to select to tum this setting "OFF" 13. LED DISPLAY PANEL ‘A. Tape Reverse Direction indicator B. Tape Forward Direction Indicator ©. Preset Radio Memory Channel Indicator Radio Station Frequency ‘AMIFM Band Indicator Stereo Radio Signal Dolby Noise Reduction Indicator zpommo Metal Tape Indicator CARE OF STEREO Do not use @ tape which has a longer playing time than C-90 (90 minutes). Avoid use of C-120 tapes because the tapes are made of a thinner material that may break and get tangled inside the stereo, 2-80 Operating Controls 19 "MTL" setting. "MTL" will appear on the display. Press this control a second time HAOA96OL | Figure 61 C60 90 le jf a Haoao7oP| Figure 62 2022-7164E Operation and Maintenance ManualMake sure tapes are wound tight. If you use a loose tape, it may cause a problem in the deck. If they are loose, use a pencil or similar device to wind up the slack. Do not use poor quality tapes. Do not store cassette tapes in the following places or under the following conditions. Damage to the tape and stereo may result. + Direct sunlight. + Humid place. + Dusty place. ‘+ Around heater or heater vents which discharge heat. + Around speakers and other magnet devices that generates a strong magnetic field (solenoid valves). Clean head and pinch roller periodically. They continuously contact the tape. If they are not kept clean the stereo and tapes may be damaged. Keep them clean for optimum performance. If the head gets dirty, clean it with a soft cotton ‘swap through the cassette slot. It is recommendable to use a cassette deck cleaning tape for easy and efficient cleaning of head, capstan and pinch roller. When you turn "OFF" power, be sure to take out the cassette tape by pressing the eject button When not using a cassette tape, keep it stored in aplastic case. 2022-7164 Operation and Maintenance Manual Figure 63 HAOKSIOL, Figure 65 ac010P| Figure 66 Operating Controls 2-31MISCELLANEOUS ELECTRICAL DEVICES 1. OPERATOR'S COMPARTMENT LIGHT AA light is installed on the rear right of the ‘operator's compartment. Press the push button to turn it "ON." Press the button again to turn it"OFF." The light will work regardless of starter switch position. NOTE: If light is left on for a long time while the engine is not running, the battery will be discharged. HAoBO6OL. Figure 67 2. PILOT CUTOFF SWITCH The pilot cutoff switch is located by the hinge part of left hand console. When the safety lever is raised, the switch operates Ly which deactivates the joystick function. SN With the joysticks deactivated no digging’ ‘operational work can be done. aoaoeo. | Figure 68 3. CIRCUIT BREAKER ‘A main circuit breaker is located in the battery box. 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 HAO BOSOL, normal operation of circuit breaker. Figure 69 2-82 Operating Controls 2022-7164E Operation and Maintenance Manual4, FUSIBLE LINK A tusible link is located in the battery box. If the engine does not crank, first check that the starter switch is turned “ON” and that no power is available (No indicator lights will light.). Check that the “A” portion (Figure 70) of the fusible link is not broken or burned through. Replace the fusible link if damage and investigate cause. SEAT ADJUSTMENT A Warnine! Whenever the operator or operating condition has changed, check to see that the seating position Is suitable for the condition at hand. Always fasten your seat belt while operating vehicle. Adjust the backrest so that the operator can fully reach and operate the pedals. When setting the safety lever to the "LOCK" Position, first make sure the left arm rest Is completely raised to the upright position. 1. ADJUSTING THE SEAT FORWARD/ BACKWARD LEVER (FIGURE 72) Holding lever and raise it up, while pushing or pulling the seat to desired position. Release lever once desired position is reached. Adjustment range is 160 mm (6.3, in) ADJUSTING THE SEATS ANGLE AND HEIGHT LEVER (FIGURE 72) Pulling left lover up allows rear part of seat to be moved up or down, Pushing it down allows front part of seat to be moved up or down. Adjust the seat according to operator's size and work conditions. Adjustment range is 60 mm (2.36 in.) for both front and rear. 2022-7164 Operation and Maintenance Manual HAOBIOOL, Figure 70 HaoB1101| Figure 71 Figure 72 Operating Controls 2-333. WEIGHT ADJUSTMENT KNOB (FIGURE 72) Turning knob to right makes the suspension harder. Turning knob to left makes the suspension softer. Adjust according to operator's weight by checking the weight indicator dial. Adjustment range is from 50 - 120 kg (110 - 265 Ibs.) 4, BACKREST ADJUSTMENT LEVER (FIGURE 72) Pulling up the right lever allows the seat backrest to be moved forward or backward. 5, MOVING THE TOTAL SEAT SETTING FORWARD/BACKWARD (FIGURE 72) Pushing lever to left allows the whole seat (Seat, Operation lever, safety lever, monitor) to be moved forward and backward. Adjustment range is 140 mm (5.51 in.). 6. ANGLE ADJUSTMENT OF ARMREST Adjustment angle of left and right armrest is done by turning a dial located in bottom of armrest. When you adjust the angle, manually raise the armrest before turning the dial 7. HEADREST ‘The headrest can be adjusted forward/ backward and up/down. Move it by holding both sides. aos 01) Figure 73 2-34 Operating Controls 2022-7164E Operation and Maintenance ManualSEAT BELT A WaRNING! The seat belt is for the operator's safety and should be worn at all times. Before driving the machine, adjust the seat to the desired position for maximum comfort and machine control, then fasten the seat belt. Seat belts must be worn across the pelvic region and adjusted snugly to essen the chance and severity of injury in the event of an accident. Never fasten a seat belt across the abdomen. Under no circumstances should the operator be standing in the cab when operating the excavator. Do not adjust the seat position while the vehicle is moving because a loss of control may result. ‘Stop the machine, apply the parking brake, and then adjust the seat. ‘Always, check the condition of seat belt and belt bracket before fastening it. Do not use it with twists in it. Replace belt or bracket if damaged or worn. ‘SEAT BELT LOCKING AND UNLOCKING Insert belt end (1, Figure 73) into the buckle (2) Pull the belt to check that belt end is locked into buckle, Adjust belt length so that it comfortably tight ‘against the operator's pelvic region (hipbone). Figure 74 Press the button (3, Figure 75) located in the center of buckle (2) and pull out belt (1) to unlock. Figure 75 2022-7164 Operation and Maintenance Manual Operating Controls 2-35CEILING COVER A Warnine! When leaving operator's seat, set the safety lever to "LOCK" position, if not a serious accident could occur by accidentally moving the joysticks. OPENING THE CEILING COVER 1. Park machine on even ground and stop ‘engine. Set safety lever (Figure 76) on “LOCK.” 8. Pull the lock (1, Figure 77) in front center of ceiling cover and push it up with handle (2). CLOSING THE CEILING COVER 1. Park machine on even ground and stop ‘engine. Set safety lever (Figure 76) on “LOCK.” 3. Pull down cover with the handle (2, Figure 7) 80 that the lock (1) can be locked in the bracket located in the ceiling frame. 2-36 Operating Controls Figure 76 aoa 60 | Figure 77 2022-7164E Operation and Maintenance ManualFRONT WINDOWS A Warnine! When leaving operator's seat, set the safety lever to “LOCK” (Figure 78) Position, if not a serious accident could ‘occur by accidentally moving the joysticks. FRONT UPPER WINDOW This can be opened and locked open in the cab's celling Opening the Window A Warnine! When stowing front window in the cab roof, secure left and right lock pins (1, Figure 79) so they do not fall out. 1. Park machine on even ground and stop engine. Set safety lever (Figure 78) on “LOCK.” 3. Unplug wiper connector (1, Figure 80) located on right front side of cab. 2022-7164 Operation and Maintenance Manual Figure 78 Ha081701| Figure 79 Haos1601| Figure 80 Operating Controls 2-374, Pull lock pin (1, Figure 81) to inside, one is located on left and right upper side of front window. This will allow front window to move. 5. Holding window handles (one located at top and the other at bottom of window) pull window up and then push it back. Make sure window is secured with latch (1, Figure 82). 6. Push lock pins (1, Figure 83) back into position, 2-38 Operating Controls HAOB90U, HA052001| Ha081701) Figure 83 2022-7164E Operation and Maintenance ManualClosing the Window A warnine! Be careful that your hands are not caught in window frame. 1. Park machine on even ground and stop engine. Set safety lever (Figure 78) on “LOCK.” 3. Unlock window by pulling the lock pin (1, Figure 84) out. 4, Holding upper handle of front window with right hand, push release lever (1, Figure 85) (in direction of arrow) to unlock catch Q. 5, _ Slowly lower front window into position, 6. Lock loft and right lock pins (1, Figure 86) to secure front window. 7. Plug in wiper connector (1, Figure 80) located on right front side of cab. 2022-7164 Operation and Maintenance Manual Haoe2101| Figure 84 Haoa22o| HAOB 904, Figure 86 Operating Controls 2-39FRONT BOTTOM WINDOW ‘The front bottom window can be removed and installed by using the left and right lock pins 1. After stowing the front upper window in the ‘cab roof, unlock the left and right lock pins (1, Figure 87) for front bottom window. Remove window from cab and separate the front window. 2. Set bottom window in rubber holders (1, Figure 88) located in back of operator's seat. Secure window to cab with left and right lock pins (2). DOOR SIDE LATCH 1. The door side latch (1, Figure 89) is used to secured the door to the side of the cab when itis opened. NoTE: Keep the door closed and locked when machine is not in use. 2. To release door from side of cab, push the latch lever (Figure 90) down. The latch lever is located to the left of the operator's seat. 2-40 Operating Controls rene ‘ i W 2022-7164E Operation and Maintenance ManualMISCELLANEOUS ACCESS COVERS AND DOORS ‘SIDE DOOR Pull out prop rod (1, Figure 91) from housed position and insert it hole (2) to secure side access door. BATTERY BOX DOOR Open door and slide prop rod (1, Figure 92) in slot (2) until it locks in notch at end of slot. ENGINE COVER ‘Open the cover and the latch pin (1, Figure 98) will lock to support the cover in the open position, 2022-7164 Operation and Maintenance Manual Figure 92 Figure 93 Operating Controls 2-41SWING LOCK PIN AND MECHANISM This wheel excavator is equipped with a swing lock device, which should be used when transporting or travelling on streets. The device consists of a pin and two holes which must be aligned and through which the pin is placed. This serves to keep the swing device from accidentally moving and causing damage to ‘other vehicles or people in its path. ‘The swing lock pin is stored in the front left section of battery compartment. (Figure 94) Make sure the upper section is facing forward. ‘Align upper structure of machine with lower frame and make sure holes are in alignment. Insert lock pin into hole (Figure 95) located in the upper frame, slightly left of the right boom. cylinder. WHEEL CHOCKS ‘A pair of wheel chocks are supplied with the machine and are stored on the lower frame directly below the battery compartment when the upper structure is facing the front of the machine. These wheel chocks should be used at all times when it is necessary to secure the machine for repairs or for transport. 2-42 Operating Controls Figure 95 2022-7164E Operation and Maintenance ManualCAB STORAGE COMPARTMENTS ‘Two storage compartments are located behind the operators seat. The large compartment (1, Figure 97) has a cover. Keep the operation and maintenance manual in it so it can be referred to when operating the machine or _ performing maintenance. Keep small objects such as cassette tapes, ote. in the small personal box (2, Figure 97). There is a separate case (1, Figure 98) which is located on right side of operator's seat. ASHTRAY An ashtray (1, Figure 99) Is located to the right side of the operator's seat on the side of the cab. Pressing end of ashtray will revolve it open. Always close ashtray after putting out a cigarette. 2022-7164 Operation and Maintenance Manual Hao82701| Figure 97 HAOB270L HaoB2eiL. Figure 99 Operating Controls 2-43EMERGENCY GLASS BREAKING TOOL ‘This excavator is equipped with a glass breaking tool. It is located behind the operator seat in the Upper right corner of the cab. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the ‘operator's cabin. Grip the handle firmly and use the sharp point to break the glass. 2-44 Operating Controls Figure 100 2022-7164E Operation and Maintenance ManualOPERATION TO HANDLE A NEW EXCAVATOR All Daewoo excavators are inspected and adjusted prior to leaving the factory. However, itis 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 Maintain about 80% load of full capacity (Engine RPM: 80% of rated operation. RPM) ‘After first 50 hours of Full load operation. lf machine is used at full load before itis broken in, it may affect the life cycle and safe running operations. This could lead to problems later. NOTE: 1. Check daily for leakage of coolant, engine oil and hydraulic oil 2. Inspect all lubricants daily, add appropriate lubricants as required. 3. During operation, monitor all instruments and gauges from time to time. 4. Avoid a extreme engine load. 5. Operate unit at 80% load until engine and all other components are at operating temperature. 6 Check that work equipment is operating normally during operation. (Check machine for loose parts or for damage that may have occurred during shipping. 8 Check for loose wiring or terminals, check gauge operation and battery fluid level. LUBRICATION AND FILTERS 1. Change engine oil and replace oil fiter element after first 50 hours of operation. 2. Change swing reduction device oil after first 250 hours of operation. NOTE: — For the replenishment of oll or grease, refer to “Inspection, Maintenance and Adjustment” (on page 4-1 of this manual. 2022-7164 Operation and Maintenance Manual Operation 3-1STARTING AND STOPPING THE ENGINE INSPECTION BEFORE STARTING ENGINE A WarRNING! ta flammable materials such as leaves, paper, etc. are allow to accumulate on high temperature components, such as the engine muffler and turbo, a fire may occur. Fuel, lubricant and hydraulic oil leaks, may cause a fire. If there is anything wrong, perform the appropriate corrective action. Before starting engine, inspect the following items; 1. Electric system - Check for damaged electric cables, and loose or missing connectors. 2. Fuel system - Drain water and sediment from fuel tank. 3. Hydraulic system - Check for hydraulic oil leaks, damaged tubing and hoses, and interference points of components. 4, Lubrication - Perform all daily and periodic maintenance services. Perform services according to reading shown on hourmeter. 5. Safety - Perform a machine walk-around. Make sure that no one is under the machine or performing any maintenance on it, before starting engine. 6. Alter 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 A 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. Sot safety lever on LOCK” (Figure 1). 2, Fasten seat belt. Check for proper ‘operation and condition HAOAgOIL Figure 1 3-2 Operation 2022-7164 Operation and Maintenance Manual3. Be certain to set the operation levers and forward / reverse select lever to “NEUTRAL.” Nott : Be careful not to touch any switches when starting engine. 4, Be certain to set the travellwork/park select toggle switch is set to the “park (C) position, 5. Rotate the starter switch to the “I” - "ON" position (Figure 4). Check all indicator lights. After 2 seconds, all lights except the following will turn "OF + Engine coolant temperature gauge = Charging warning light + Fuel gauge + Engine oil pressure warning light + Engine RPM (0 RPM) NOTE: If all of the indicator lights do not come “ON* when the key is first turned, there is a problem. ‘A warning buzzer will sound for about 2 seconds, ‘The sound of the engine contro! motor may be heard while it rotates to the correct starting position. 2022-7164 Operation and Maintenance Manual esso02 Figure 2 HBOKOTIL Figure 3 HAoBs20L| Figure 4 Operation 3-3,ENGINE START A WaRNING! Start the engine after sounding horn and making sure that there are no people or obstacles in the are 1. Perform all steps in “Operational Checks Before Starting Engine” on page 3-2. 2. Set engine speed control dial slightly above “LOW IDLE” (Figure 5). 8, Sound horn HAOBS¢L Figure 5 4. Tum starter switch to © - “stant position (Figure 6). Engine should startin approximately 5 seconds. A WaRNING! If the engine does not start after approximately 15 seconds of cranking, release the starter control. Wait about 5 minutes and repeat above step. Figure 6 HAOBS601| 5. After engine has started, release key. Key will return to I" - “ON” position (Figure 7). 6. Follow procedures in “Hydraulic System Warm-up" on page 3-9. HAOBOOL Figure 7 3-4 Operation 2022-7164 Operation and Maintenance Manual7. After warming unit, check all operating indicators to make sure that all engine systems (oll pressure, coolant, etc.) are in the normal operating range. If any problems are noticed, stop the engine. Normal indicators are’ poees Figures TNoIeATOR INSTRUMENT PANEL LIGHT OF GAUGE NDIGATOR ENGINE COOLANT TEMPERATURE GAUGE GREEN RANGE FUEL GAUGE GREEN RANGE CHARGING WARRING LIGHT OFF ENGINE OL PRESSURE WARNING LIGHT OFF PREHEATING COMPLETION LIGHT OFF PILOT FETER CLOGGING WARNING LIGHT OFF RETURN FTER CLOGGING WARWING LIGHT OF AIR CLEANER FCTER CLOGGING WARNING LGHT OFF 8 Check color of exhaust smoke. + No.color or light blue - Engine is running in good condition. + Black - Incomplete combustion. Check cause. + White or dark blue - Engine is burning engine oll Check cause. ‘Check for usual engine vibration and noises. If any are heard or felt, investigate cause, NOTE: If engine coolant temperature gauge shows red while running, take the following action; Discontinue work and allow engine to run at LOW IDLE." Open engine compartment cover for good ventilation. Once engine temperature gauge returns to the green zone, shutdown engine. After engine has cooled, check coolant level, look for leaks, clogged or dirty radiator fins (radiator core), and fan belt tension. 2022-7164 Operation and Maintenance Manual Operation 3-5