Doosan 470LC-V Service Manual
Solar 470LC-V
Shop Manual
023-00047E
Serial Number 1001 and Up
May 2002
Daewoo reserves the righ t to improve our products in a continuing proc ess to provide the best possible
product to the mar ket place. These improvements can be implem ented at any time with no obligation t o
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.
023-00047E Shop Manual
Product Label
Instructions
Trim Out The Label Along
The Lines And Insert Into
Pocket On The Binder Spine
Pub.No. 023-00047E
Solar 470LC-V
Serial Number 1001 and Up
Pub. No. 023-00047E
1
TABLE OF CONTENTS
Safety
Track Excavator Safety................................................ .... ..... ..... ............S0102000
Specifications
Specifications for Solar 470LC-V........................................................S0202090K
General Maintenance
General Maintenance Procedures.........................................................S0302000
Standard Torques..................................................................................S0309000
Upper Structure
Cab.....................................................................................................S0402040K
Counterweight.....................................................................................S0403050K
Fuel Tank............................................................................................S0405120K
Fuel Transfer Pump...............................................................................S0405500
Swing Bearing........................................................................................S0407000
Swing Reduction Gearbox.....................................................................S0408060
Lower Structure and Chassis
Track Assembly............................................. .... ..... ..... ..........................S0505120
Engine and Drive Train
Air-Conditioner....................................................................................S0605060K
Drive Coupling (Main Pump)...............................................................S0609010K
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment.............S0702190K
Accumulator........................................................................................S0703010K
Center Joint (Swivel)...........................................................................S0704090K
Cylinders................................................................................................S0705000
Table of Contents
Page 1
Swing Motor...........................................................................................S0707260
Travel Motor (With Gearbox) (A6V160HD)......................................... ...S0707365
Main Pump (Rexroth)..........................................................................S0708325K
Control Valve (Kayaba Model KVMG-400-DA)...................................S0709402K
Pilot Control Valve (Work Lever / Joystick).........................................S0709452K
Travel Control Valve (With Damper)...................................................S0709820K
Hydraulic Schematic (S470LC-V).......................................................S0792170K
Electrical System
Electrical System................................................................................S0802220K
Electrical Schematic (S470LC-V).......................................................S0892170K
Attachments
Boom and Arm.......................................................................................S0902110
Bucket.................................................................................................S0904005K
Table of Contents
Page 2
1
SAFETY
S0102000
1
TRACK EXCAVATOR
SAFETY
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TRACK EXCAV ATOR SAFETYS0102000
R1
MODEL SERIAL NUMBER RANGE
Solar 130LC-V 0001 and Up
Solar 170LC-V 1001 and Up
Solar 220LC-V 0001 and Up
Solar 220N-V 1001 and Up
Solar 250LC-V 1001 and Up
Solar 290LC-V 0001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 1001 and Up
Solar 330LC-V 1001 and Up
Solar 340LC-V 1001 and Up
Solar 400LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up
Copyright 2002 Daewoo
May 2002
Track Excavator Safety
S0102000
Page 1
TABLE OF CONTENTS
To the Operator of a Daewoo Excavator.........................................................3
General Safety Essentials..............................................................................6
Location of Safety Labels...............................................................................6
Summary of Safety Precautions for Lifting in Digging Mode..........................7
Unauthorized Modifications............................................................................8
General Hazard Information...........................................................................8
Before Starting Engine.................................................................................16
Machine Operation.......................................................................................19
Maintenance.................................................................................................26
Battery..........................................................................................................34
Towing ..........................................................................................................36
Shipping and Transportation ........................ ..... ............................ ..... .... ......37
Lifting With Sling...........................................................................................37
S0102000
Page 2
Track Excavator Safety
TO THE OPERATOR OF A DAEWOO EXCAV ATOR
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 impor tance of taking respons ibility 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 6
2. “Location of Safety Labels” on page 6
3. “Summary of Safety Precautions for Lifting in Digging Mode” on page 7
4. “Unauthorized Modifications” on page 8
5. “General Hazard Information” on page 8
6. “Before Starting Engine” on page 16
7. “Machine Operation” on page 19
8. “Maintenance” on page 26
9. “Battery” on page 34
10. “Towing” on page 36
11. “Shipping and Transportation” on page 37
12. “Lifting With Sling” on page 37
Track Excavator Safety
S0102000
Page 3
WARNING!
Improper operation and maintenance of this machine can be hazardous and could result in
serious injury or death.
Operator and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in the storage compar tment to the rear of the operator’s seat, and have all
personnel in volved in working on the machine periodically read the manual.
Some actions involved in operation and maintenance of the machine can cause a serious
accident, if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the
machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for any others. In no event should you or others engage in prohibited uses
or actions as described in this manual.
Daewoo delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether
your product complies with the applicable standards and regulations of your country, consult
Daewoo or your Daewoo distributor before operating the machine.
S0102000
Page 4
Track Excavator Safety
SAFETY ALERT SYMBOL
Be Prepared - Get To Know All Operating and Safety Instructions.
This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the
machine you should be alert to the potential for personal injury or accidents. Always observe
safety precautions and follow recommended procedures.
LEARN THE SIGNAL WORDS USED WITH THE SAFETY ALERT SYMBOL
The words
machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety
is involved. Observe precautions indica ted whenever you see the Safety Alert "Triangle," no matter which
signal word appears next to the "Exclamation Point" symbol.
"CAUTION," "WARNING,"
"DANGER"
and
used throughout this manual and on decals on the
CAUTION!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not av oided, could result in minor or moderate injury. It may also be used to alert
against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and 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!
This word is used on safety messages and safety labels and indicates an 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 detonat e if handled or treate d carelessl y.
Safety precautions are described in SAFETY from page -6 on.
Daewoo cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or ac tions not specifi cally recommended or allowed in this
manual are used, you must be sure that you and others can do such proce dures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact a
DAEWOO distributor.
Track Excavator Safety
S0102000
Page 5
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 restri cted or prohibited by local reg ulations) are permi tted in approved lift configuration, to rate d
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 accessor y hydraulic hammer (breaker), wor k in rough terrain, demolit ion 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 prin ted at the end of this safety section are based on the machin e being
level, on a firm suppor tin g surface, with hooks and slings attac hed in ap proved configuration. Load s must
be balanced and supported evenly. Use taglines to keep the load steady if wind conditions and large
surface area are a problem. Work c rew hand signals, individua l tasks and safe procedur es should all b e
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 Manuals.
LOCATION OF SAFETY LABELS
Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and
Maintenance Manual, and parts manual for your unit.
Always replace damaged or faded decals.
S0102000
Page 6
Track Excavator Safety
SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING IN DIGGING MODE
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, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Tag lines on opp osite sides of the load ca n be ver y help ful in keeping a susp ended lo ad sec ure, if they are
anchored safely to control points on the ground.
WARNING!
NEVER wrap a tagline around your hands or body.
NEVER rely on taglines or make rated lifts when wind gusts are more than 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
work.
"Digging Mode"
control on the Instru ment Panel before using the excavator for lifting
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.
Track Excavator Safety
S0102000
Page 7
UNAUTHORIZED MODIFICATIONS
Any modification made without au thor izati on or wr itte n approval from Daewoo can create a s afety 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 correc t replacement par ts could lead to a
condition in which the safety of critical assemblies is dangerously compromised.
GENERAL HAZARD INFORMATION
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
Do not operate the machine if you are not feeling well, if you are taking medicati on that makes you feel
sleepy, if you have been drinking, or if you are suffering from emotional problems. These p roblems will
interfere with your sense of judgement in emergencies and may cause accidents.
When working with anothe r operator or with a person on work site traffic duty, be sure that all personnel
know the nature of the work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
SAFETY FEATURES
Be sure that all guards and c overs are installed i n their p roper pos ition. Have guards and covers repaire d
immediately if damaged.
Be sure that you understand the method of use of safety features such as safety lock lever and the seat
belt, and use them properly.
Never remove any safety features. Always keep them in good operating condition.
Failure to use safety f eatures according to the instructions in the Operation and Maintenance Manual could
result in seriou s bodily inj ury.
S0102000
Page 8
Track Excavator Safety
INSIDE OPERATOR'S COMPARTMENT
L
When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If
you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a
serious accident.
After using the ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to
close the ashtray. If the ashtray is left open, there is danger of fire.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not leave lighters laying around the operator's com partment. If the temperature inside the operator's
compartment becomes high, there is danger that the lighter may explode.
Do not use cellular telep hones insi de the operator's compar tm ent when dr iving o r operating the m achine.
There is danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or explosive items into the operator's cab.
To en su re safety, do not use the radio or music headphones when operat ing the mac hi ne. There is dan ger
that this may lead to a serious accident.
When operating the machine, do not put your hands or head out of the window.
When standing up from the operator's seat, always place safety lock lever securely in the "LOCK" position.
If you accidentally touch the wor k equipme nt levers when they are not locked, the machine may suddenly
move and cause serous injury or damage.
When leaving the machine, lower the work equipment completely to the ground, set safety lock lever to the
"LOCK" position and shu t down engi ne. Use th e key to lock all the equipme nt. A lways remove the key and
take it with you.
CLOTHING AND PERSONAL PROTECTIVE
ITEMS
Contain long hair, and avoid loose clothing and
jewelry. They can catch on controls or in
protruding parts and cause serious injury or
death.
Do not wear oily clothes. They are highly
flammable.
Full eye protection, a hard hat, safety shoes and
gloves may be required at the work site.
While working on the machine, never use
inadequate tools. They could break or slip,
causing injury, or they may not adequately
perform intended functions.
Do not forget that some risks to your health may
not be immediately apparent. Exhaust gases
and noise pollution may not be visible, but these
hazards can cause disabling or permanent
injuries.
HAOA020
Figure 1
Track Excavator Safety
S0102000
Page 9
MOUNTING AND DISMOUNTING
Before getting on or off the machine, if there i s any oil. grease, or mud on the handrails, steps, or track
shoes, wipe it off i mmediately. Always keep these par ts clean. Repair any damag e and tighte n any loose
bolts.
Never jump on or off the machine. In particular, never get on or off a moving machine. These action s may
lead to serious injury.
When getting on or off th e mach ine, always face the machine, and maintai n three-poi nt contact ( both feet
and one hand or one foot and both hands) with the han drails, steps, and track shoes to ensure t hat you
suppor t yourse lf secur el y.
Never hold any control levers when getting on or off the machine.
Apply the door lock securely. If you grip the handrail inside the door when moving on top of the track shoes,
and the door lock is not applied securely, the door may move and cause you to fall.
Use the points marked by arrows in the diagram when getting on or off the machine.
Figure 2
S0102000
Page 10
Track Excavator Safety
FUEL, OIL AND HYDRAULIC FLUID FIRE
L
L
HAZARDS
Fuel, oil and antifreeze will catch fire if it is
brought close to a flame. Fuel is particularly
flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the
machine only in a well-ventilated area. The
machine must be parked with controls, lights
and switches turned "OFF." The engine must be
"OFF" and any flames, glowing embers,
auxiliary heating units or spark-causing
equipment must be doused, turned off and/or
kept well clear of the machine.
Static electr icity can produce da ngerous spar ks
at the fuel filling nozzle. In very cold, dry
weather or other conditions that could produce a
static discharge, keep the tip of the fuel nozzle
in constant contact with the neck of the fuel
filling nozzle, to provide a ground.
Keep fuel and other fluid reservoir caps tight and
do not start the engine until caps have been
secured.
Figure 3
PRECAUTIONS WHEN HANDLING FLUIDS
AT HIGH TEMPERATURE
Immediately after operations are stopped, the
coolant, engine oil, and hydraulic oil are at high
temperature and the radiator and hydraulic tank
are still under pressure. Attempting to remove
the cap, drain the oil or coolant, or repl ace the
filters may lead to serious burns. Always wait for
the temperature to go down, and follow the
specified procedures when carrying out these
operations.
To prevent hot coolant from spurting out, stop
the engine, wait for the coolant to cool, then
loosen the cap slowly to relieve the pressure.
To prevent hot oil from spurting out, stop the
engine, wait for the oil to cool, then loosen the
cap slowly to relieve the pressure.
HAOA050
Figure 4
Track Excavator Safety
HAOA060
Figure 5
S0102000
Page 11
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:
• Use an approved respirator.
• 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.
• Always observe any rules and
regulations related to the work site
and working environment.
INJURY FROM WORK EQUIPMENT
Do not enter or put your hand, ar m or any other
part of your body between movable parts, such
as between the work equipm ent and cylinders,
or between the machine and work equipment.
ARO1770L
Figure 6
If the control levers are operated, the clearance
between the machine an d the work equipment
will change and this may lead to serious
damage or personal injury .
If going between movable parts is necessary,
always position and secure the work equipmen t
so that it cannot move.
HDO1010L
Figure 7
S0102000
Page 12
Track Excavator Safety
FIRE EXTINGUISHER AND FIRST AID KIT
L
As a precaution if any injury or fire should occur,
always do the following.
• Be sure that fire extinguishers have
been provided and rea d the lab els to
ensure that you know now to use
them. It is recommended that an
appropriately sized (2.27 k g [5 lb] or
larger) multipurpose "A/B/C" fire
extinguisher be mounted in the cab.
Check and service the fire
extinguisher at regular intervals and
make sure that all work site crew
Figure 8
HDO1009L
members are adequately trained in
its use.
• Provide a first aid ki t in the st orage com partment and keep a nother a t the work si te. Check the
kit periodically and ma ke any addition s if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance service, hospital and fire depar tment near
your telephone.
If the machine catches fire, it may lead to serious personal injury or death. If a fire occurs during operation,
escape from the machine as follows;
• Turn the starter switch "OFF" and stop the engine.
• If there is time, use the fire extinguisher to extinguish as much of the fire as possible.
• Use the handrails and steps to escape from the machine.
The above is the basic method for escaping from the machine, but changing the method may be necessary
according to the conditions, so carry out practice drills at the work site.
PROTECTION FROM FALLING OR FLYING OBJECTS
On work sites where there is danger that falling objects or flying objects may hit the operator's cab select a
guard to match the operating conditions to protect the operator.
Working in mines, tunnels, deep pits or on loose
or wet surfaces could produce danger of falling
rock or hazardous flying objects. Additional
protection for the operator's cab could be
required in the form of a FOPS (Falling Object
Protective Structure) or window guards.
HAOA110
Figure 9
Track Excavator Safety
S0102000
Page 13
Never attempt to alter or modify any type of
L
protective structure reinforcement system, by
drilling holes, weldi ng, remounting or relo cating
fasteners. Any serious impact or da mage to the
system requires a complete integrity
reevaluation. Reinstallation, recertification and/
or replacement of the system may be
necessary.
Contact your Daewoo distributor for available
safety guards and/or recomm endations if there
is any danger of getting hit by objects that co uld
strike the operator's cab. Make sure that all
other work site crew members are kept well
Figure 10
HAOA100
away from the excavator and safe from possible
hazards.
For breaker operation, install a front guard and apply a laminate d coatin g sheet to the front glas s. Contact
your DAEWOO distributor for recommendations.
When carrying out demolition or cutting operation, install a front guard and top guard, and apply a
laminated coating sheet to the front glass.
When working in m ines or quarries where there is dange r of falling rock, install FOPS (Falling Objects
Protective Structure) and apply a laminated coating sheet to the front glass.
If any glass on the machine is broken, replace it with new glass immediately.
ATTACHMENT PRECAUTIONS
Option kits are available through your dealer. Contact Daewoo for information on available one-way (singleacting) and two-way (double-acting) piping / valving / auxiliary control kits. Because Daewoo cannot
anticipate, identify or tes t all of the att achment s that owners may wish to instal l on their machines, pleas e
contact Daewoo for authorization and approval of attachments, and their compatibility with options kits.
ACCUMULATOR
The pilot control syste m is equipped with an accumula tor. For a brief period of tim e after the engine has
been shut down, the acc umulator will store a pressu re charge that may enable hydraulic controls to be
activated. Activation of any controls may enable the selected function to operate under force of gravity.
When performing maintenance on the pil ot control system, the hydraulic pressure in the system must be
released as describe in “Handling of Accumulator” in the Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas, so it is extremely dangerous if it is handled in
the wrong way. Always observe the following precautions;
• Do not drill or make any holes in the accumulator or expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching anything to it.
• When carr ying out disassembly or m aintenance of the acc umulator, or when disposing of the
accumulator, the charged gas must be properly released. Contact your Daewoo distributor.
• Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious injuries.
S0102000
Page 14
Track Excavator Safety
INDOOR VENTILATION
Engine exhaust gases can cause fatal
accidents, and unconsciousness, loss of
alertness, judgement and motor control and
serious injury.
Make sure there is 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.
EMERGENCY EXIT
This machine i s equipped with a glass breakin g
tool. It is behind the op erator seat in the upper
right cor ner of the cab. This tool can be used in
case of an emergency situation that requires the
breaking of glass to exit from the operator’s
cabin. Grip the han dle firm ly and use the shar p
point to break the glass.
ARO1770L
Figure 11
WARNING!
Protect your eyes when breaking the
glass.
Figure 12
Track Excavator Safety
S0102000
Page 15
BEFORE STARTING ENGINE
WORK SITE PRECAUTIONS
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work site, and determine the best and safest method of
operation.
Make the ground surface as hard and horizontal as possible before carrying out operations. If there is a lot
of dust and sand on the work site, spray water before starting operations.
If you need to operate on a street, protect
pedestrians and cars by designating a person
for work site traffic duty or by erecting fences
and posting "No Entry" signs around the work
site.
Erect fences, post "No Entry" signs, and take
other steps to prevent people from coming close
to or entering the work site. If people come
close to a moving machine, they may be hit or
caught by the machine, and this may lead to
serious personal injury or death.
Water lines, gas lines, phone lines and highvoltage electrical lines may be buried un der the
work site. Contact each utility and identify their
locations. Be careful not to damage or cut any of
these lines.
Figure 13
D
A
N
No Entry
G
E
R
ARO1250L
Check the condition of the river bed, and the
depth and flow of the water before operating in
water or crossing a river. NEVER be in water
that is in excess of the permissible water depth.
Any type of object in the vicinity of the boom
could represent a po tent ial ha za rd , or ca us e th e
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.
Figure 14
S0102000
Page 16
Track Excavator Safety
Minimum levels of insurance coverage, work
permits or cer t ification, physical barr iers around
the work site or restricted hours of operation
may be mandated by governing authorities.
There may also be regulations, guidelines,
standards or restr icti ons o n equi pment th at may
have to be followed for local requirements.
There may also be regulations related to
performing cer tain ki nds of work. If t here is any
question about whether your machine and work
site complies with the applic able standards and
regulations contact your local authorities and
agencies.
Avoid entering soft ground. It will be di fficult for
the machine to escape.
Avoid operating your machine to close to the edge o f c liffs, overhangs, and deep d itche s. The ground may
be weak in such areas. If the ground should collapse, the machine could fall or tip over and this could result
in serious injury or death.
Remember that the soil after heavy rain, blasting or after earthquakes, is weakened in these areas.
Earth laid on the gro und and the so il nea r ditche s is loose. It c an colla pse un der th e weight of vibrati on of
your machine and cause your machine to tip over.
Install the head guard (FOPS) if working in areas where there is danger of falling rocks.
Figure 15
CHECKS BEFORE STARTING ENGINE
Every day before starting the engine for the first time, carr y out the following checks. If these checks are
not carried out properly, there is danger of serious injury.
Completely remove all wood chips, leaves, grass , paper and other flammable materials accumulated in the
engine compar tment and ar ound the batter y. They could cause a fire. Remove any dir t from the window
glass, mirrors, handrails, and steps.
Do not leave tools or spare parts laying around in the operator's compartment. The vibration of the
machine when traveling or during operations may cause them to fall and damage or break the control
levers or switches. They ma y also get caught in the gap of the control levers and cause the work equipment
to malfunction or move dangerously. This may lead to unexpected accidents.
Check the coolant level, fuel level, and hydraulic tank oil level, and check for clogged air cleaner and
damage to the electrical wiring.
Adjust the operator's seat to a position where it is easy to operate the machine, and check the seat belt and
mounts for damage and wear.
Check the operation of the gauges and the angle of the mirrors, and check that the safety lever is in
"LOCKED" position .
If any abnormalities are found in the above checks, carry out repairs immediately.
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ENGINE STARTING
Walk around your machine before getting in the operator’s cab. Look for evidence of leaking fluid, lo ose
fasteners, misaligned assemblies or any other indications of possible equipment hazard.
All equipment covers and machiner y safety guards must be in place, to protect against injury whi le the
machine is being operated.
Look around the work site area for potential hazards, people or properly that could be at risk while
operation is in progress.
NEVER star t the engine if there is any indication tha t maintenance or ser vice work is in progress, or if a
warning tag is attached to controls in the cab.
A machine that ha s not been used recently, or is being operated in extremely cold te mperatures, could
require a warm-up or maintenance service before start-up.
Check gauges and monitor displ ays for normal operation before star ting the engine. Listen for unusual
noises and remain alert for other potentially hazardous conditions at the start of the work cycle.
Do not short circuit the starting motor to start the engine. This is not only dangerous, but may also damage
the machine.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
BEFORE OPERATING MACHINE
If checks are not carried out properly after starting the engine, it may result in a delay in discovering
abnormalities in the machine, and this may lead to personal injury or damage to the machine.
Carry out the checks in an open area where there are no obstructions. Do not let anyone near the machine
when carrying out the checks.
• Check the operating condition of th e equipment, and the actuation of th e bucket, arm, boom,
travel, and swing systems.
• Check the machine for any abnormal noise, vibration, heat, smell, or abnormality with the
gauges. Check also for leakage of air, oil, and fuel.
• If any abnormality is found, repair the problem immediately. If the machine is used without
repairing the problems, it may lead to unexpected injury or failure.
• Clear all personnel from directly around machine and from the area.
• Clear all obstacles from the machine's path. Beware of hazards.
• Be sure that all windows are clean. Secure the doors and the windows in the open position or in
the shut position.
• Adjust the rear view mirrors for best visibility close to the ma chi ne. Make sure that the horn, the
travel alarm (if equipped), and all other warning devices are working properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before operating machine.
• Before moving the machine, check the position of undercarr iage. The normal travel position is
with idler wheels to the front under the cab and the drive sprockets to the rear. When the
undercarriage is in the reversed position, the travel controls must be operated in opposite
directions.
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Track Excavator Safety
MACHINE OPERATION
L
WHEN SWINGING OR CHANGING
DIRECTION OF TRAVEL
Before operating the machine or the work
equipment, always observe the following
precautions to prevent serious injury or death.
• When changing the direction of travel
from forward to reverse or from
reverse to forward, reduce speed
early and stop the machine before
changing the direction of travel.
• Sound the horn to warn people in the
area.
• Check that there is no one in the area
around the machine. Th ere are blind
spots behind the machine, so if
necessary, swing the upper str ucture
to check that there is no one behind
the machine before traveling in
reverse.
• When operating in areas that may be
hazardous or have poor visibility,
designate a person to direct work site
traffic.
• Ensure that no unauthorized person
can come within the tur ning radiu s or
direction of travel.
Be sure to obser ve the above precautions even
if a travel alarm or mirrors are installed.
HAOA190
Figure 16
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TRAVEL PRECAUTIONS
Never turn the starting switch to the "O" (OF F) positio n when traveling. It is dangerous if the engine s tops
when the machine is traveling. It will be impossible to operate the steering.
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 40-
50 cm (16 - 20 in) above ground.
Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope or
obstacle that causes the machi ne to tilt 10 degrees or more to the ri ght or lef t, or 30 degrees or mor e from
front to rear.
Do not operate the stee ring s uddenly. The work equipment may hit the ground an d cause the machin e to
lose its balance, and this may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.
Always keep to the permissible water depth. Permissible water depth is to the centerline of the upper track
rollers.
When traveling over bridges or structures on private land, check first that the bridge or structure can
withstand the weight of the ma chine. When traveling on public roads, check with the local authorities and
follow their instructions.
TRAVEL POSTURE
Figure 17
INCORRECT
40 ~ 50 cm (16 ~ 20 in.)
ARO1280L
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Track Excavator Safety
TRAVELING ON SLOPES
L
L
Never jump onto a machine that is running away to stop it. There is danger of serious injury.
Traveling on slopes could result in the machine tipping over or slipping.
On hills, banks or slopes, c arr y the bucket approximately 20 - 30 c m (8 - 12 in) above the ground. In c ase
of an emergency, quickly lower the bucket to the ground to help stop the machine.
HAOB610
Figure 18
Do not travel on grass, fa llen leav es , or wet steel
plates. Even slight slopes may cause the
machine to slip to the side, so travel at low
speed and make sure that the machine is
always traveling directly up or down the slope.
Avoid changing the direction of travel on a slope.
This could result in tipping or side slipping of the
machine.
When possible, operate the mach ine up slopes
and down slopes. Avoid operating the machine
across the slope, when possible.
HAOB620
Figure 19
Figure 20
Track Excavator Safety
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PROHIBITED OPERATIO NS
Do not dig the work face under an overhand.
This may cause the overhand to collapse and
fall on top of the machine.
Do not carry ou t deep d igging under the front o f
the machine. The ground under the machine
may collapse and cause the machine to fall.
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 a balanced loa d
may also be hazardous.
Never relay on lift jacks or other inadequate
suppor ts when work is being done. Block tracks
fore and aft to prevent any movement.
When using the machine, to prevent accidents
caused by damage to the wor k equipment and
overturning because of an excessive load, do
not use the mach ine in excess of its ability (in
terms of the maximum load and stability
determined by the structure of the machine).
Figure 21
ARO0950L
Figure 22
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Track Excavator Safety
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