Daewoo doosan solar s220 lc v excavator operator and maintenance manual

Operation and Maintenance Manual
2022-7145E
Serial Number 0001 and Up
April 1998
Solar S220LC-V

2022-7145E 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..........................................................................................1-14
Equipment ........................................................................................1-19
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

II Table of Contents 2022-7145E 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.................................................................4-14
150 Hour Service .............................................................................4-18
250 Hour / Monthly Service..............................................................4-21
500 Hour / 3 Month Service .............................................................4-24
750 Hour Service .............................................................................4-26
1000 Hour / 6 Month Service ...........................................................4-27
2000 Hour / Yearly Service...............................................................4-33
4000 Hour / Biennial Service............................................................4-34
Venting and Priming Hydraulic System ............................................4-35
Handling of Accumulator ..................................................................4-37
Electrical System..............................................................................4-38
Bucket ..............................................................................................4-41
Bucket Shimming Procedures ..........................................................4-43
Track Tension ...................................................................................4-44
Bolt and Nut Inspection ....................................................................4-47
Maintenance in Special Conditions ..................................................4-48
Long Term Storage...........................................................................4-49

2022-7145E Operation and Maintenance Manual Table of Contents III
Transportation........................................................................... 5-1
Loading and Unloading ......................................................................5-1
Lifting With Sling.................................................................................5-3
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

2022-7145E 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 s afety, and t hat 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 1-14
6. “Equipment” on page 1-19
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 SIGNAL WORDS USED WITH SAFETY ALERT SYMBOL
Words "CAUTION", "WARNING", and "DANGER" used throughout this m anual an d on dec als on t he
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 "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 potential for personal injury or accidents. Always observe safety
precautions and follow recommended procedures.

1-2 Safety 2022-7145E 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 ear th with a bucket. For use as a gr apple or for
other obj ect ha ndling, contact Daew oo for p roper i nstallation and application. Lifting-work appl ications
(unless restricted or prohi bited 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 approved configuration.
Use of an ac cessory hydraulic hammer (breaker), work in rough terrain, demolition applications or ot her
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 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 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 other instructions, guidelines and restrictions for Safe Lifting in
Operation and Maintenance and Shop Manuals.

LOCATION OF SAFETY LABELS
Always keep these l abels c lean. If t hey are lost or da maged, replace them with a n ew l abel. I t is t he
responsibility equipment owner and crew to provide essential safety information in the immediate vicinity of
hazards.
1
6
2
12
11
8
10
3
13
9
7
HAOE891L
4
5
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 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 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 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 side control stand, use the safety lever surely.
WARNING!
Track adjuster adjustment and handling:
• The spring in track adjuster is loaded with great force and 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 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
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 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 breather to relieve pressure before removing cover.

8. WARNING FOR HIGH TEMPERATURE COOLANT (2190 - 2531)
.
9. WARNING FOR HANDLING ACCUMULATOR (2190 - 2528)
.
ACCUMULATOR
The pilot control system is equipped with an accum ulator. The accumulator will store a pressure charge
that may enable hydraulic controls to be activated for a b rief period of time after engine has been shut
down. Activation of any controls may enable selected function to operate under force of gravity.
When shutting machine down, lower front attachment to ground. After engine has been shut down, move
joystick controls to release pressure in 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 accumulator holds a charge.
WARNING!
Refer to Shop Manual for service procedures. Do not release any pilot lines until pressure within
accumulator has been released.

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

13. WARNING FOR HOT ENGINE SURFACE (2190-3314)
SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING
IN DIGGING MODE
To lift safely while in Digging Mode, following items must be evaluated by operator and work-site crew.
• Condition of ground support
• Excavator configuration and attachments
• Weight, lifting height and lifting radius
• Safe rigging of load
• Proper handling of suspended load
Taglines on opposite sides of load can be very helpful in keeping a suspended load secure, if they are
anchored safely to control points on ground.
CAUTION!
Hot surfaces. Do not touch.
DANGER!
Unsafe use of 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 machine unless
they’ve been properly trained and understand the information in 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.
HAOA050L

Always engage "Digging Mode" control on Instrument Panel before using 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.
WORK-SITE PRECAUTIONS
ATTACHMENT PRECAUTIONS
Options kits a re a vailable through y our deal er. Co ntact Daew oo f or information on av ailable on e-way
(single-acting) and two-way (double-acting) piping/valving/auxiliary control kits. Because Daewoo cannot
anticipate, identify or test all 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 pro ximity to h igh-voltage electric l ines. T he
bucket does not have to make physical contact
with power lines for current to be transmitted.
Use a s potter and hand s ignals t o stay aw ay
from pow er lines no t c learly v isible t o t he
operator.
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.
VOLTAGE MINIMUM SAFE
DISTANCE
6.6kV 3m
33.0kV 4m
66.0kV 5m
154.0kV 8m
275.0kV 10m
HAOA230L
Figure 3

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 s tarting any type of operation near po wer l ines (ei ther abov e 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 u neven, broken terrain can cause dangerous side load
conditions and possible tipover and injury. Travel without a load or balanced load may also be hazardous.
If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen
ground. Stay away from ditches, overhangs and al l other weak support surfaces. Halt wor k an d i nstall
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. K now t he hei ght and reac h l imits of t he e xcavator and pl an ahead while wor king. A void
creating dangerous situations by moving around the work-site while making excavations. Go on to another
digging area bef ore s teep ov erhangs are formed. W orking arou nd de ep pi ts or a long high walls or
trenching m ay requ ire s upport blocks, especially af ter heavy rai nfalls or during s pring thaws. Park t he
excavator away from overhangs before work shutdown.

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SLOPING TERRAIN REQUIRES CAUTION
Dig evenly aroun d t he wor k-site whenever
possible, t rying t o g radually l evel any e xisting
slope. I f i t’s not possible t o l evel t he area or
avoid working on a slope, reducing the size and
cycling rate of the workload is recommended.
On s loping s urfaces, us e c aution whe n
positioning the excavator prior to starting a work
cycle. Stay alert for instability situations in order
to avoid g etting i nto t hem. F or e xample, y ou
should a lways a void w orking t he buc ket ov er
downhill c rawler t racks when parked
perpendicular t o the s lope. S low al l downhi ll
swing m ovements an d a void f ull e xtensions of
the b ucket in a downhi ll di rection. L ifting t he
bucket too high, too close to the machine, while
the e xcavator is turned u phill can also b e
hazardous.
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 i s i n a s afe s pot. S omeone el se could
have gone i nside, f or any number of reas ons.
Avoid work ing where uns een pa ssersby m ight
be.
Slow down the work cycle and use slower travel
speeds in congested or populated areas. Use a
commonly u nderstood s ignal s o t hat ot her
members of the w ork crew c an w arn t he
operator t o s low or hal t w ork i n an i mpending
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 equ ipment that m ay be used to pe rform certain kinds of wor k. Check a nd
follow all local requirements, which may also be related to below ground hazards and power lines.
HAOA210L
Figure 4
HAOA170L
Figure 5

OPERATION
OPERATE WHILE SEATED AT THE
OPERATOR’S STATION ONLY
Never reach in t hrough a wi ndow t o w ork a
control. D on’t t ry to o perate t he e xcavator
unless you’re in the command position stay alert
and focused on your work at all times but DON’T
twist out of the seat if job activity behind you (or
to the side) requires your attention.
Use a s potter or s ignal person if you can’t see
clearly and something is happening behind you.
Replace dam aged s afety l abels an d l ost or
damaged owner’s manuals.
Do not let anyone operate the m achine unless
they’ve been f ully and c ompletely t rained, in
safety and in operation of the machine.
BEFORE STARTING THE ENGINE
Do a "pre-start" safety check:
• Walk around your m achine before getting in the operator’s cab. Look for evidence of leaking
fluid, l oose fasteners, m isaligned as semblies or any ot her i ndications of p ossible e quipment
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 s tart the engi ne if t here is any i ndication t hat m aintenance or service work i s 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 rem ain alert for other potentially hazardous conditions at the start of the
work cycle.
HAOA150L
Figure 6

NEVER USE ETHER STARTING AIDS
An electric-grid type manifold heater is used for
cold s tarting. T he gl owing heat er el ement c an
cause ether or ot her s tarting f luid t o det onate,
causing injury.
MOUNTING AND DISMOUNTING
NEVER get on or off a moving machine. Don’t
jump o n/off. T he entry/egress pat h s hould b e
clear o f mu d, o il a nd s pills a nd mo unting
hardware must be kept tight and secure.
Always use handholds, steps or track shoes and
maintain at l east 3-poi nt c ontact of hand s an d
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 t he w ork-site should be aware of as signed i ndividual r esponsibilities and t asks.
Communication and hand signals used should be understood by everyone.
Terrain and s oil 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 c an c ause f atal
accidents, as well as unconsciousness, loss of
alertness, judgement an d m otor control an d
serious injury.
Make s ure of ad equate v entilation bef ore
starting the engine in any enclosed area.
You s hould al so be a ware of open wi ndows,
doors or ductwork into whi ch e xhaust may b e
carried, or blown by the wind, exposing others to
danger.
Figure 7
Figure 8
,,,
,,,

HAOA070L
Figure 9

Daewoo doosan solar s220 lc v excavator operator and maintenance manual

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