Daewoo doosan solar 400 lc v excavator operator and maintenance manual

2022-7168E Operation and Maintenance Manual Copyright 1998 Daewoo
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.
Operation and Maintenance Manual
2022-7168E
Serial Number 0001 and Up
October 1998
Solar 400LC-V

2022-7168E Operation and Maintenance Manual Table of Contents I
TABLE OF CONTENTS
Safety......................................................................................... 1-1
To the Operator of a Daewoo Excavator ............................................1-1
General Safety Essentials ..................................................................1-3
Location of Safety Labels ...................................................................1-4
Summary of Safety Precautions for Lifting in Digging Mode............1-10
Work-site Precautions ......................................................................1-11
Operation..........................................................................................1-13
Equipment ........................................................................................1-18
Maintenance.....................................................................................1-22
Shipping and Transportation ............................................................1-25
Excavator Rated Lift Capacity Tables...............................................1-26
Operating Controls ................................................................... 2-1
Component Locations ........................................................................2-2
Operator’s Area ..................................................................................2-4
Operational Controls and Panels........................................................2-5
Instrument Panel ..............................................................................2-11
Mode Selection Switches .................................................................2-16
Heater and Air Conditioning Control Panel ......................................2-17
Stereo...............................................................................................2-21
Miscellaneous Electrical Devices .....................................................2-25
Seat Adjustment...............................................................................2-26
Seat Belt...........................................................................................2-27
Ceiling Cover....................................................................................2-28
Front Windows..................................................................................2-29
Door Side Latch................................................................................2-32
Miscellaneous Access Covers and Doors ........................................2-33
Cab Storage Compartments ............................................................2-34
Ashtray .............................................................................................2-34
Emergency Glass Breaking Tool ......................................................2-35

II Table of Contents 2022-7168E Operation and Maintenance Manual
Operation................................................................................... 3-1
To Handle a New Excavator ...............................................................3-1
Starting and Stopping the Engine ......................................................3-2
Safety Lever .....................................................................................3-13
Travel................................................................................................3-14
Operating Instructions ......................................................................3-19
Operating Precautions......................................................................3-25
Parking Excavator ............................................................................3-30
Towing Procedure.............................................................................3-31
Hydraulic Breaker.............................................................................3-32
Inspection, Maintenance and Adjustment.............................. 4-1
Preliminary Work Machine Setup for Maintenance ............................4-2
Table of Recommended Lubricants....................................................4-4
Maintenance Intervals ........................................................................4-6
10 Hour / Daily Service ......................................................................4-8
50 Hour / Weekly Service.................................................................4-15
150 Hour Service .............................................................................4-19
250 Hour / Monthly Service..............................................................4-21
500 Hour / 3 Month Service .............................................................4-22
1000 Hour / 6 Month Service ...........................................................4-30
2000 Hour / Yearly Service...............................................................4-35
4000 Hour / Biennial Service............................................................4-36
Venting and Priming Hydraulic System ............................................4-37
Handling of Accumulator ..................................................................4-39
Fuel Transfer Pump ..........................................................................4-40
Electrical System..............................................................................4-42
Bucket ..............................................................................................4-46
Bucket Shimming Procedures ..........................................................4-48
Track Tension ...................................................................................4-49
Bolt and Nut Inspection ....................................................................4-52
Maintenance in Special Conditions ..................................................4-53
Long Term Storage...........................................................................4-54

2022-7168E Operation and Maintenance Manual Table of Contents III
Transportation........................................................................... 5-1
Loading and Unloading ......................................................................5-1
Troubleshooting........................................................................ 6-1
Engine ................................................................................................6-1
Hydraulic System ...............................................................................6-2
Swing System.....................................................................................6-3
Electrical System................................................................................6-4
Travel System.....................................................................................6-5
Specification ............................................................................. 7-1
Standard Specification .......................................................................7-1
Working Range...................................................................................7-3
Index .......................................................................................... 8-1

2022-7168E Operation and Maintenance Manual Safety 1-1
1SAFETY
TO THE OPERATOR OF A DAEWOO EXCAVATOR
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. “Work-site 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
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.
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.
SAFETY ALERT SYMBOL
Be Prepared - Get To Know All Operating and Safety Instructions.
This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the
machine you should be alert to the potential for personal injury or accidents. Always observe
safety precautions and follow recommended procedures.

1-2 Safety 2022-7168E Operation and Maintenance Manual
CAUTION!
Indicates potential of a hazardous situation that, if not avoided, could result in minor or
moderate injury. It may also be used to alert against a generally unsafe practice.
WARNING!
Indicates potential of a hazardous situation that, if not avoided, could result in serious injury or
death. It may also be used to alert against a highly unsafe practice.
DANGER!
Indicates imminent hazard of a situation that, if not avoided, is very likely to cause death or
extremely serious injury. It may also be used to alert against equipment that may explode or
detonate if handled or treated carelessly.

GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
The 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 lifting 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.

LOCATION OF SAFETY LABELS
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.
1
6
2
12
11
3
HAOE898L
4
5
9
10
8
7
Figure 1

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. WARNING FOR OPERATION, INSPECTION MAINTENANCE (2190 - 3312)
.
2. WARNINGS FOR HIGH VOLTAGE (2190 - 2532)
.
CAUTION!
• Read manual and labels before
operation and maintenance. Follow
instructions and warnings in manual
and on labels on the machine.
• Never get in under the machine
while it is being jacked up with
boom and arm.
• Turn Auto-Idle switch OFF, when
loading or unloading the machine.
• Sound the horn to alert the people
nearby before operating, and make
sure all persons are clear of area.
• Always make sure when leaving operator’s seat to:
– Lower bucket or other working tools to the ground.
– Pull SAFETY LOCK LEVER to LOCK position.
– Turn key switch OFF. Remove key from switch.
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.
HAOA010L
HAOA230L

3. WARNING WHEN OPENING FRONT WINDOW (2190 - 3388).
4. CAUTION FOR SAFETY LEVER LOCKING (2190 - 3383).
5. WARNING WHEN ADJUSTING TRACK TENSION (2190 - 3386).
WARNING!
When raising window, lock it in place with lock pins on both sides.
Falling window can cause injury.
CAUTION!
When putting down the side control stand, use the safety lever surely.
WARNING!
The track adjuster adjustment and handling:
• The spring in the track adjuster is loaded with great force and the pressure in the
cylinder is very high. For this reason there is a possibility of accident which may
involve injury to personnel. It is very dangerous to make mistakes in handling such an
adjustment or disassembly.
• Be sure to read the procedures described in the Operation and Maintenance Manual
carefully before adjusting the track tension.

6. WARNING FOR BATTERIES MAINTENANCE (2190 - 2533).
7. WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (2190 - 3318)
.
WARNING!
• Battery fumes can explode. Keep sparks and flames away from batteries.
• Always avoid storing metals like tools or inflammable materials around or on the
batteries. Explosion or fire can be caused by short circuiting batteries.
• Sulfuric acid in battery is poisonous. It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed in eyes.
• If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
WARNING!
To prevent hot oil from spurting out:
• Turn engine off.
• After oil to cooled.
• Push button on the breather to relieve pressure before removing cover.

8. WARNING FOR HIGH TEMPERATURE COOLANT (2190 - 3395)
.
9. WARNING FOR HANDLING ACCUMULATOR (2190 - 2528)
.
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.
WARNING!
To prevent hot water from spurting out:
• Turn engine off.
• Allow water to cool.
• Slowly loosen cap to relieve pressure before removing.
WARNING!
Explosion hazard
• Keep away from flame.
• Do not weld or drill.
WARNING!
Any raised attachment will lower to the ground if the accumulator holds a charge.
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.

10. WARNING FOR ENGINE FAN (2190 - 3315)
.
11. KEEP OUT OF THE SWING AREA (2190 - 3379).
12. WARNING TAG - USED WHEN
INSPECTING HYDRAULIC SYSTEM
(2190 - 2549).
WARNING!
Keep your hands away from the fan during
operation.
Entanglement in the fan can cause serious
injury.
DANGER!
KEEP OUT OF SWING AREA
HAOA411L
WARNING
HAOC920L
Figure 2

SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING
IN DIGGING MODE
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, lifting height and lifting radius
• Safe 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.
Always engage the "Digging Mode" control on the Instrument Panel before using the excavator for lifting
work.
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization or written approval from Daewoo can create a safety hazard,
for which the machine owner must be held responsible.
For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example,
not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a
condition in which the safety of critical assemblies is dangerously compromised.
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.
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.
WARNING!
If you need more information or have any questions or concerns about safe operating
procedures or working the excavator correctly in a particular application or in the specific
conditions of your individual operating environment, please consult your local Daewoo
representative.

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.
Use these minimum distances as a guideline only. Depending upon the voltage in the line and atmospheric
conditions, strong current shocks can occur with the boom or bucket as far away as 4 - 6 m (13 - 20 ft) from
the power line. Very high voltage and rainy weather could further decrease that safety margin.
NOTE: Before starting any type of operation near power lines (either above ground or buried
cable-type), you should always contact the power utility directly and work out a safety plan
with them.
BEFORE STARTING TO DIG, CONTACT AUTHORITIES
Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know
what’s underneath the work-site before starting to dig.
BE AWARE OF HEIGHT OBSTACLES
Any type of object in the vicinity of the boom could represent a potential hazard, or cause the operator to
react suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines,
work-site scaffolds, or other obstructions.
USE CARE ON LOOSE SUPPORT
Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load
conditions and possible tipover and injury. Travel without a load or balanced load may also be hazardous.
VOLTAGE MINIMUM SAFE
DISTANCE
6.6kV 3m
33.0kV 4m
66.0kV 5m
154.0kV 8m
275.0kV 10m
HAOA230L
Figure 3

If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen
ground. Stay away from ditches, overhangs and all other weak support surfaces. Halt work and install
support mats or blocking if work is required in an area of poor track support.
USE SOLID SUPPORT BLOCKING
Never rely on lift jacks or other inadequate supports when work is being done. Block tracks fore and aft to
prevent any movement.
OVERHANGS ARE DANGEROUS
Digging the 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 work-site whenever
possible, trying to gradually level any existing
slope. If it’s not possible to level the area or
avoid working on a slope, reducing the size and
cycling rate of the workload is recommended.
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 crawler tracks when parked
perpendicular to the slope. Slow all downhill
swing movements and avoid full extensions of
the bucket in a downhill direction. Lifting the
bucket too high, too close to the machine, while
the excavator is turned uphill can also be
hazardous.
HAOA210L
Figure 4

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STAY ALERT FOR PEOPLE MOVING
THROUGH THE WORK AREA
When loading a truck you should always know
where the driver is.
Avoid loading over the cab of a truck even if the
driver is in a safe spot. Someone else could
have gone inside, for any number of reasons.
Avoid working where unseen passersby might
be.
Slow down the work cycle and use slower travel
speeds in congested or populated areas. Use a
commonly understood signal so that other
members of the work crew can warn the
operator to slow or halt work in an impending
hazard situation.
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.
BEFORE STARTING THE ENGINE
Do a "pre-start" safety check:
HAOA170L
Figure 5
HAOA150L
Figure 6

• Walk around your machine before getting in the operator’s cab. Look for evidence of leaking
fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment
hazard.
• All equipment covers and machinery safety guards must be in place, to protect against injury
while the machine is being operated.
• Look around the work-site area for potential hazards, or people or property that could be at risk
while operation is in progress.
• NEVER start the engine if there is any indication that maintenance or service work is in
progress, or if a warning tag is attached to controls in the cab.
• A machine that has not been used recently, or is being operated in extremely cold temperatures,
could require a warm-up or maintenance service prior to start-up.
• Check gauges and monitor displays for normal operation prior to starting the engine. Listen for
unusual noises and remain alert for other potentially hazardous conditions at the start of the
work cycle.
NEVER USE ETHER STARTING AIDS
An electric-grid type manifold heater is used for
cold starting. The glowing heater element can
cause ether or other starting fluid to detonate,
causing injury.
MOUNTING AND DISMOUNTING
NEVER get on or off a moving machine. Do not
jump on/off. The entry/egress path should be
clear of mud, oil and spills and mounting
hardware must be kept tight and secure.
Always use handholds, steps or track shoes and
maintain at least 3-point contact of hands and
feet. Never use controls as handholds.
NEVER get up from the operator’s seat or leave
the operator’s station and dismount the machine
if the engine is running.
OBSERVE GENERAL SAFETY RULES
Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be
allowed to operate or perform maintenance or service on the excavator.
All personnel at the work-site should be aware of assigned individual responsibilities and tasks.
Communication and hand signals used should be understood by everyone.
Figure 7
Figure 8

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.
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your health if it is inhaled.
If you handle materials containing asbestos fibers, follow these guidelines as given below:
• Never use compressed air for cleaning
• Use water for cleaning to keep down the dust.
• Work on the machine or component with the wind at your back whenever possible.
• Use an approved respirator with proper filtration.
TAKE TIME TO PROVIDE GOOD VISIBILITY
Halt work if visibility is poor. Strong rains, snow, fog and extremely dusty conditions can all obscure visibility
so badly that it is best to wait for weather to change or dust to settle before continuing operation.
Night work in areas of limited visibility should be halted if installation of extra work lights on the machine (or
work area) is necessary.
Keep dirt and dust off of windows and off the lens surfaces of work lights. Stop working if lights, windows or
mirrors need cleaning or adjustment.
,,,
,,,

HAOA070L
Figure 9

Daewoo doosan solar 400 lc v excavator operator and maintenance manual

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