Doosan Solar 255LC-V. Operation and Maintenance Manual (2002)

DO NOT operate the breaker with the

boom or arm cylinders fully extended

(bottomed out). See Figure 72.

Leave over 100 mm (4 in) of clearance

between rod end of cylinder and cylinder

head. This will help prevent damage to

cylinders during breaker operation.

HAOB940L

Figure 72

DO NOT use the breaker if the hydraulic

hoses vibrate excessively. See Figure 73.

Check the breaker’s hydraulic accumulator

(1) for damage and repair as required. If

excavator is operated under this condition,

structural and hydraulic components can

be damaged.

HAOB950L

Figure 73

DO NOT allow the breaker body to go into

water if not equipped for underwater

operation. The breaker seal can be

damaged and allow rust, foreign material

or water to enter the hydraulic system and

cause damage. Only insert the breaker

tool into water. See Figure 74.

HAOB970L

Figure 74

DO NOT any lifting or towing with a

breaker. See Figure 75.

HAOB980L

Figure 75

022-00031E Operation and Maintenance Manual

Operation 3-33

Operate the breaker only to the front and

rear of the excavator. DO NOT use the

breaker to either side of the excavator. DO

NOT swing the breaker from side to side

when operating it. See Figure 76

WARNING!

Operating a breaker with the upper

body turned 90° to the tracks can

result in tipping over the machine or

HAOB990L

reduction in service life.

Figure 76

DO NOT curl the breaker tool tip into the

arm or boom when traveling or parking the

excavator. See Figure 77.

HAOB960L

Figure 77

TO ACTIVATE BREAKER;

Press the left side button on the top of the

right hand work lever (joystick) to activate

the hydraulic breaker.

Release the left side button on the top of

the right hand work lever

(joystick) to

deactivate the hydraulic breaker.

ARO0120L

Figure 78

3-34 Operation

022-00031E Operation and Maintenance Manual

HYDRAULIC OIL AND FILTER SERVICE INTERVALS

When using a hydraulic breaker, the viscosity breakdown and contamination of hydraulic oil is faster

because the work condition is more severe than during normal digging work. To prevent the hydraulic

components (especially pump) from having a shortened life-cycle, replace the hydraulic oil and main

hydraulic oil filter using the following schedule.

ATTACHMENT

OPERATION RATE

HYDRAULIC OIL

FILTER

250 HOURS (First Replacement)

BUCKET WORK

100%

2000 HOURS

500 HOURS (After First Replacement)

HYDRAULIC

100%

500 HOURS

100 HOURS

BREAKER WORK

100

105

551

106

110

614

112

130

692

FILTER

119

150

(First Replacement)

782

128

180

893

HYDRAULIC OIL

137

210

1028

FILTER

250

(After First Replacement)

1196

156

175

300

1400

206

370

1658

500

1000

1500

2000

MACHINE OPERATING HOURS

ARO0990L

Figure 79

NOTE: The replacement intervals of hydraulic oil and filter depend upon the amount of time the

hydraulic breaker is being used. These intervals should be followed as opposed to

regularly scheduled maintenance.

022-00031E Operation and Maintenance Manual

Operation 3-35

OPERATING TECHNIQUES

LIFTING

IMPORTANT

There may be local or government regulations, about the use of excavators for the lifting of

heavy loads. Always contact your local and government agencies in regards to these

regulations.

To prevent injury, do not exceed the rated load capacity of the machine. If the machine is not on level

ground, load capacities will vary.

Short slings will prevent excessive load swing.

Use the lifting eye on the bucket that is provided to lift objects.

Always try to maintain the lifting eye (Figure 80)

straight below the centerline of the arm and

bucket pin. In this manner the weight of the load

is being primarily held only by the pin, and not

by the bucket cylinder, link, and link pins.

When a lifting eye is used, the sling/lifting device

must be fastened to the eye in a manner that will

not allow it to come loose.

The most stable position is over the corner of

the machine.

For best stability, carry a load as close to the

HAAD3830

ground and machine as possible.

Figure 80

Lift capacity decreases as the distance from the

machine swing centerline is increased.

3-36 Operation

022-00031E Operation and Maintenance Manual

Lifting Unknown Weight

When loads are not accurately

known are to be lifted, the person

responsible for the job shall

ascertain that the weight of the

FRONT LIFT

load does not exceed the machine

ZONE

LOAD RATING CHART at the

radius at which it is to be lifted.

It is recommended that you feel

your way into any lift as a

precaution against tip-over. One

SIDE LIFT

method is to position the boom at

ZONE

90° over the side of the machine.

Slowly lift the load until it clears the

ground. A lift over the side is the

most unstable, and as the load is

swung into the front zone of the

excavator it will become more

stable. DO NOT INCREASE

REAR LIFT

SWING RADIUS AFTER THE

ZONE

LOAD IS LIFTED.

HAAD3842

Figure 81

DANGER!

If a load is picked up from the front zone and swung into the side zone, a tip-over could result

causing a deadly or fatal injury.

Lifting Known Weight

The load chart is the governing factor when lifting known weights. It is recommended that you feel your way

into any lift as a precaution against tip-over. When ever possible, lift and swing payloads between the front

idler area.

Pick and Carry

The machine has the ability to pick and carry payloads without added labor. We recommend when traveling

with a suspended payload, you evaluate the prevailing conditions and determine the safety precautions

required in each case. The following factors must be considered before attempting to pick and carry a load.

Align the boom with the forward direction of machine travel. Maintain this boom position when turning the

machine. Turn only when necessary, at the slowest speed, and at a wide turning radius.

Use the shortest lifting radius distance possible.

Keep the load as close to the ground as conditions will permit.

Provide tag lines to prevent load from pendulating. Pendulating can cause a change in radius. A

change in radius could exceed the load chart rating or cause a tip-over condition.

Govern travel speed to suit conditions.

Avoid sudden starts and stops.

022-00031E Operation and Maintenance Manual

Operation 3-37

OPERATION UNDER UNUSUAL CONDITIONS

NOTE: See “Maintenance in Special Conditions” on page 4-67 for other recommendations.

OPERATION IN EXTREME COLD

If machine is to be operated in extreme cold weather temperatures, certain precautions must be taken to

assure continued normal operation. The following paragraphs detail checks to be made to be certain the

machine is capable of operating at these temperatures.

Check the cooling system for correct antifreeze solution for lowest temperature expected. Carefully

inspect cooling system and correct or report any leaks.

Keep batteries fully charged to prevent freezing. If water is added to batteries, run engine at least one

hour to mix electrolyte solution.

Keep engine in best possible mechanical condition to assure easy starting and good performance

during adverse weather conditions.

Use engine oil of the proper specifications for the expected temperatures. Refer to the "Lubrication

Specifications" of the engine manual for details.

Keep fuel tank full at all times. Drain condensation from tank before and after operation. Drain and

service fuel filter. To eliminate clogging of fuel filters due to wax crystal formation in the fuel, be sure

that the fuel used has a cloud point specification below the lowest expected temperature.

Lubricate entire machine according to "Periodic Service Table and Chart" Section 4, in this manual or

lubrication chart on machine.

Start engine and allow it to reach normal operating temperature before applying load.

A. If mud and ice collects and freezes on any of the moving parts while machine is idle, apply heat

to thaw the frozen material before attempting to operate machine.

B. Operate hydraulic units with care until they have reached a temperature to enable them to

operate normally.

C. Check all machine controls and/or functions to be sure they are operating correctly.

An extra outer air filter element should be kept in the operator's cab to replace element that could

become iced and cause restricted air flow to engine.

If cold weather starting aid must be used, see "Engine Starting" COLD WEATHER START portion of

this manual.

10.

Clean off all mud, snow and ice to prevent freezing. Cover machine with tarpaulin if possible, keep

ends of tarpaulin from freezing to ground.

OPERATION IN EXTREME HEAT

Continuous operation of the machine in high temperatures may cause the machine to overheat. Monitor

engine and transmission temperatures and stop machine for a cooling-off period whenever necessary.

Make frequent inspections and services of the fan and radiator. Check coolant level in radiator. Check

grills and radiator fins for accumulation of dust, sand and insects which could block the cooling

passages.

A. Formation of scale and rust in cooling system occurs more rapidly in extremely high

temperatures. Change antifreeze each year to keep corrosion inhibitor at full strength.

B. If necessary, flush cooling system periodically to keep passage clear. Avoid use of water with a

high alkali content which increases scale and rust formation.

3-38 Operation

022-00031E Operation and Maintenance Manual

Check level of battery electrolyte daily. Keep electrolyte above plates preventing damage to batteries.

Use a slightly weaker electrolyte solution in hot climates. Dilute 1.280 specific gravity electrolyte as

issued to 1.200 to 1.240 specific gravity readings at full charge. Recharge batteries whenever they

reach a 1.160 specific gravity reading. Batteries self-discharge at a higher rate if left standing for long

periods at high temperatures. If machine is to stand for several days, remove batteries and store in a

cool place.

WARNING!

Do not store acid-type storage batteries near stacks of tires; the acid fumes have a harmful

affect on rubber.

Service fuel system as directed in "Engine Fuel System" Section 5, of this manual. Check for water

content before filling fuel tank. High temperatures and cooling off cause condensation in storage

drums.

Lubricate as specified in "Periodic Service Chart and Table" Section 4, in this manual or Lubrication

Decal on the machine.

Do not park machine in sun for long periods of time. When practical park machine under cover to

protect it from sun, dirt and dust.

A. Cover inactive machine with tarpaulin if no suitable shelter is available. Protect engine

compartment, transmission and hydraulics from entrance of dust.

B. In hot, damp, climates corrosive action will occur on all parts of the machine and will be

accelerated during the rainy season. Rust and paint blisters will appear on metal surfaces and

fungus growth on other surfaces.

C. Protect all unfinished, exposed surfaces with a film of preservative lubricating oil. Protect cables

and terminals with ignition insulation compound. Apply paint or suitable rust preventive to

damaged surfaces to protect them from rust and corrosion.

OPERATION IN DUSTY OR SANDY AREAS

Operation of the machine can cause dust in almost any area. However, when in predominantly dusty or

sandy areas, additional precautions must be taken.

Keep cooling system fins and cooling areas clean. Blow out with compressed air, if possible, as often

as necessary.

WARNING!

Wear goggles when using compressed air.

Use care when servicing fuel system to prevent dust and sand from entering the tank.

Service the air cleaner at frequent intervals, check air restriction indicator daily and keep dust cup

and dust valve clean. Prevent dust and sand from entering engine parts and compartments as much

as possible.

Lubricate and perform services outlined on current lubrication chart on machine and "Lubrication

Chart and Table" Section 4. Clean all lubrication fittings before applying lubricant. Sand mixed with

lubricant becomes very abrasive and speeds wear on parts.

022-00031E Operation and Maintenance Manual

Operation 3-39

Protect machine from dust and sand as much as possible. Park machine under cover or protect with

tarpaulin to keep dust and sand from damaging unit.

OPERATION IN RAINY OR HUMID CONDITIONS

Operation under rainy conditions is similar to that as in extreme heat procedures listed previously.

Keep all exposed surfaces coated with preservative lubricating oil. Pay particular attention to

damaged or unpainted surfaces. Cover all paint cracks and chip marks as soon as possible to prevent

corrosive effects.

OPERATION IN SALT WATER AREAS

The corrosive effect of salt water and salt water spray is very extensive. When operating in salt water

areas, observe the following precautions.

When exposed to salt water, dry machine thoroughly and rinse with fresh water as soon as possible.

Keep all exposed surfaces coated with preservative lubricating oil. Pay particular attention to

damaged paint surfaces.

Keep all painted surfaces in good repair.

Lubricate machine as prescribed on lubrication chart on machine or "Periodic Service Table and

Chart" Section 4, in this manual. Shorten lubricating intervals for parts subject to exposure to salt

water, if found to be necessary.

OPERATION AT HIGH ALTITUDES

Normally, operation of machine at high altitudes will be as outlined in extreme cold. Before operating at

high altitudes, engine fuel and air mixture may have to be adjusted according to appropriate engine

manual.

Check engine operating temperature for evidence of overheating. The pressure cap on radiator must

make a perfect seal to maintain coolant pressure in the system.

3-40 Operation

022-00031E Operation and Maintenance Manual

4INSPECTION, MAINTENANCE AND

ADJUSTMENT

Routine maintenance and inspections are

required to keep your machine in the correct

operating condition. The following pages list the

inspection intervals, the system or component

checks and location references.

NOTE: The following pages list the

service checks and their

required intervals. The service

cycles may need to be

shortened depending on the

working conditions. Extremely

hot or dusty conditions will

HAOA600L

require more frequent service.

Figure 1

Operational

hours

are

determined by the amount of

time accumulated on the

engine hour meter on the

control console in the cab.

NOTE: Besides the normal hour meter,

the multifunction gauge can be

used to keep track of the hours

on individual filters. See “Filter /

Oil Info” on page 2-28.

1.Fuel Filter

Hrs: 0232 Reset:

POWER

AUTO

DISPLAY

ESC

HAAD3781

Figure 2

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-1

SERIAL NUMBERS

There are two serial number plates attached to

the body of the excavator. The machine serial

number plate (Figure 3) is on the right side of

the cab on the outside. The engine serial

number is stamped on the rear left side of the

engine block, above the starter. Additional

engine information is described on a label

(Figure 4) on the rocker cover.

Please make note of these numbers and their

locations. These will be required whenever

warranty service work is requested.

Figure 3

SAFETY PRECAUTIONS

Make sure to lock out the hydraulic

controls and post a notice (Warning Tag)

that the machine is being serviced to

prevent any unauthorized operation.

Make sure to clean up any fluid spills,

especially around the engine.

Inspect all fuel lines to make sure that

fittings, lines, filters and O-rings, etc., are

tight and are not showing signs of wear or

damage.

Figure 4

If the inspection or test procedure requires

that the engine be running, make sure to

keep all unauthorized personnel away from

the machine, and that all industry standard

safety precautions are followed.

4-2 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

PRELIMINARY WORK MACHINE SETUP FOR

MAINTENANCE

When performing maintenance specified in this manual, always park the excavator as follows.

NOTE: Certain types of maintenance may require the machine to be positioned differently. Always

return machine to this position.

Park on firm, level ground.

Lower bucket to ground.

HAOB920L

Figure 5

Set safety lever on "LOCK" position.

HAOA390L

Figure 6

Allow engine to run at low idle for a

minimum of 5 minutes to allow engine to

cool. If this is not done, heat surge may

occur.

HAOB290L

Figure 7

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-3

TABLE OF RECOMMENDED LUBRICANTS

IMPORTANT

Do not use lubricants other than those recommended, without prior written approval from

Daewoo.

NOTE: Refer to the Maintenance Intervals Table for application points.

LUBRICANT

HYDRAULIC OIL*

ENGINE OIL**

GEAR OIL

MANUFACTURER

GREASE

CALTEX

CALTEX HD32

CALTEX RPM or

MULTIFAC EP

MULTIPURPOSE

EP90

DELO 300

EXXON/ESSO

NUTO (ANTI-

EXXON 15W40

RONEX MP #2 or

SPARTAN EP220

WEAR)

RONEX MP #1

HD 32 (BELOW

(COLD TEMPS)

EXXON GX

0°C (32°F)) or

80W90

HD 46 (ABOVE

0°C (32°F)) or

TERESSTIC

(ANTI-RUST)

MOBIL

DELVAC 1300 or

MOBIL FAW #2

MOBILUBE HD

80W90

DTE 13M (ALL-

SUPER 15W40

TEMP) or

MOBIL FAW #1

(COLD TEMPS)

DTE 24

(SUMMER)

SHELL

TELLUS 32

ROTELLA

ALVANIA EP #2

SPIRAX HD

80W90 or

T15W40

DONAX TD

(TRANSMISSION)

PENNZOIL

PENNZBELL

LONGLIFE

PENNZOIL 705

PENZOIL

EP #2

MULTIPUPOSE

AW 32 (BELOW

SAE15W40

4092 or

0°C (32°F)) or

80W90

AW 46 (ABOVE

0°C (32°F))

Hydraulic oil change interval is 2,000 hours, only when Daewoo Genuine Oil is used. If other

brands of oil is used, guaranteed change interval is 1,000 hours.

Engine oil must meet ACEA-E2, ACEA-E3 or API-CH-4 EQUIVALENT and be SAE 15W40 or

10W40.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-5

LUBRICANT

HYDRAULIC OIL*

ENGINE OIL**

GEAR OIL

MANUFACTURER

GREASE

DRYDEN

PARADENE

DIESELALL

EP #2 (RED)

AP80W90

PLUS 15W40

AW 32 (BELOW

0°C (32°F)) or

AW 46 (ABOVE

0°C (32°F))

CHEVRON

AW MV 32

DELO 400

DELO GREASE

DELOGEAR OIL

(BELOW 0°C

15W40

EP-2

(32°F)) or

RPM UNIV GEAR

AW MV 46

80W90

(ABOVE 0°C

(32°F))

TEXACO

RANDO

URSA SUPER

STAR PLEX 2

MULTIGEAR

PLUS 15W40 or

EPSAE 80W90

HD32 (BELOW

STAR PLEX

0°C (32°F)) or

URSA PREMIUM

PREMIUM

TDX 15W40

HD46 (ABOVE

0°C (32°F))

IDEMITSU

DAPHNE KOSAN

APOROIL

DAPHNE

APOROIL GEAR

KOSAN

46WR

MOTIRE S300

CORRONE #2

HE 90

NIPPON SEIKIYU

SUPER

LIPANOC

NISEKI SP90 or

HIGHLAND S26

GREASE

EP90

or 32

TOTAL

TOTAL EQUIVIS

TOTAL

TOTAL MUTRIS

TOTAL DA80W90

ZS46-III

EP #2

Hydraulic oil change interval is 2,000 hours, only when Daewoo Genuine Oil is used. If other

brands of oil is used, guaranteed change interval is 1,000 hours.

Engine oil must meet ACEA-E2, ACEA-E3 or API-CH-4 EQUIVALENT and be SAE 15W40 or

10W40.

IMPORTANT

Do not mix oils from different manufacturers. Daewoo does not endorse specific brands but

does suggest that owners select quality oils whose suppliers provide assurance that required

standards will always be met or exceeded.

Fluctuating daily or weekly extremes of temperature, or operation in sub-zero freezing weather

may make it impractical to use straight weight lubricants. Use good judgement in selecting

lubricant types that are appropriate for climate conditions.

4-6 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

FLUID CAPACITIES

Component

Capacity

Engine

Oil Pan with Filter

21 liters

(5.5 U.S. gal.)

Cooling System

36 liters

(9.5 U.S. gal.)

Fuel Tank

370 liters

(98 U.S. gal.)

Hydraulic Oil

Tank Level

155 liters

(41 U.S. gal.)

System

290 liters

(77 U.S. gal.)

Traveling Device (Each)

5 liters

(1.3 U.S. gal.)

Swing Device

11 liters

(2.9 U.S. gal.)

LUBRICATION AND SERVICE CHART

Lubrication and service chart is on the inside of battery box cover. The symbols shown here are used in the

lubrication and service chart on the next page.

Symbol

Description

Symbol

Description

Lubrication

Coolant

Gear Oil

(Swing Device, Travel

Air Cleaner Element

Device)

Fuel Filter

Engine Oil

Engine Oil Filter

Air-conditioner Filter

Hydraulic Oil

Drain Water

Hydraulic Oil Filter

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-7

SERVICE DATA

S255LC-V

Items To

No.

Service

Service Interval

Check

Qty.

150

250

500

1000

2000

Front Joint Pin

Grease

F100

W10

Swing Bearing

Grease

Swing Gear

Grease

and Pinion

Swing

Gear Oil

Reduction

11 L

(80W90)

Device

Travel

Gear Oil

Reduction

2X5 L

V, F

(80W90)

Device

Engine Oil

21 L

(15W40)

Hydraulic

Hydraulic Oil

Oil (Equivis

290 L

46)

Fuel Tank

Diesel

370 L

Coolant

Radiator

36 L

(Antifreeze)

Water

Separator

Hydraulic Full-

Element

flow Filter

Pilot filter

Element

Hydraulic Oil

Suction

Strainer

Engine Oil

Cartridge

Filter

Fuel Filter

Cartridge

Air Cleaner

Element

(Outer)

Air Cleaner

Element

(Inner)

Air Conditioner

Element

Filter

Coolant

Recovery Tank

(Antifreeze)

V: Maintenance & Refill.

C: Cleaning.

F: First Time Exchange Only.

F100: Every 10 Hours For First 100 Hours.

W10: Every 10 Hours If Operating In Water.

Gray Box: Replacement On Every Interval.

NOTE: For additional service items see list of “Maintenance Intervals” on page 4-10.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-9

MAINTENANCE INTERVALS

10 HOUR / DAILY SERVICE

•

Grease Boom, Arm and Front Attachment

•

Inspect the Bucket Teeth and Side Cutters

Pins (for first 100 hours) (See page 4-12)

for Signs of Wear (See page 4-19)

•

Check Engine Oil Level (See page 4-12)

•

Inspect Engine Fan Blade (See page 4-19)

•

Check Level of Hydraulic Oil Tank (See page

•

Check Air Intake System (See page 4-20)

4-13)

•

Inspect Seat Belt for Proper Operation (See

•

Check for Leaks in the Hydraulic System

page 4-20)

(See page 4-14)

•

Inspect the Structure for Cracks and Faulty

•

Check Fuel Level (See page 4-15)

Welds (See page 4-20)

•

Check for Leaks in the Fuel System (See

•

Check the Operation of All Switches (See

page 4-15)

page 4-20)

•

Check Water Separator and Drain Water As

•

Check the Operation of All Exterior Lights,

Required (See page 4-16)

Horn and Control Console Indicator and

•

Check Oil Level of Swing Reduction Device

Monitor Lights (See page 4-20)

(See page 4-17)

•

Start Engine, Check Starting Ability, and

•

Clean Dust Net in Front of Oil Cooler (See

Observe Exhaust Color at Start-up and at

page 4-18)

Normal Operating Temperature. Listen for

•

Check Cooling System and Refill As

Any Abnormal Sounds (See page 4-21)

Required (See page 4-18)

•

Check Operation of All Controls (See page

•

Check Level of Window Washer Liquid (See

4-21)

page 4-19)

50 HOUR / WEEKLY SERVICE

•

Perform All 10 Hour / Daily Service Checks

•

Check Engine Fan Belt for Cracks, Wear and

(See page 4-22)

Correct Tension (After First 50 Hours) (See

•

Grease Boom, Arm and Front Attachment

page 4-25)

Pins (See page 4-22)

•

Change Engine Oil and Filter (After First 50

•

Grease Swing Bearing (See page 4-24)

Hours) (See page 4-25)

•

Drain Water and Sediment from Fuel Filter

•

Inspect the Track Assemblies for Proper

(See page 4-25)

Tension and Loose, Worn or Damaged Parts

•

Drain Water and Sediment from Fuel Tank

(Links, Shoes, Rollers, Idlers) (See page

(See page 4-25)

4-25)

250 HOUR / MONTHLY SERVICE

•

Perform All 10 hour / daily and 50 Operating

•

Change Oil in Travel Reduction Device (One

Hour Service Checks (See page 4-26)

on Each Side of Unit) (After First 250 Hours)

•

Change Swing Reduction Device Oil (Drain

(See page 4-30)

and Refill After First 250 Hours) (See page

•

Replace Full Flow Hydraulic Oil Filter (After

4-26)

First 250 Hours) (See page 4-30)

•

Clean Outer Element of Two Stage Air

•

Change Pilot Filter (After First 250 Hours)

Cleaner (See page 4-26)

(See page 4-30)

•

Check Engine Fan Belt Tension (See page

•

Inspect Pins and Bushings of the Front End

4-27)

Attachments for Signs of Wear (See page

•

Check Engine Fan Belt Wear (See page

4-30)

4-28)

•

Check Fluid Levels in Batteries and Battery

•

Change Engine Oil and Filter (See page

Charge Levels (See page 4-30)

4-29)

•

Inspect for Any Loose or Missing Nuts and

•

Check Oil Level In Travel Reduction Device

Bolts (See page 4-30)

(One on Each Side of Unit) (See page 4-30)

•

Inspect Fuel System Hose Clamps (See

page 4-30)

4-10 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

500 HOUR / 3 MONTH SERVICE

•

Perform All Daily (10 Hour), 50, and 250

•

Clean Air Conditioning Filter (See page

Operating Hour Service Checks (See page

4-34)

4-31)

•

Clean Radiator, Oil Cooler, Intercooler and

•

Grease Swing Gear and Pinion (See page

Air Conditioner Condenser Core (See page

4-31)

4-35)

•

Replace Full Flow Hydraulic Oil Filter (See

•

Replace Outer and Inner Air Cleaner

page 4-32)

Elements (See page 4-36)

•

Change Pilot Filter (See page 4-33)

•

Change Fuel Filter (See page 4-37)

1000 HOUR / 6 MONTH SERVICE

•

Perform All Daily (10 Hour), 50, 250 and 500

•

Change Radiator Coolant (See page 4-41)

Operating Hour Service Checks (See page

•

Clean Fuel Injection Priming Pump Strainer

4-39)

(See page 4-43)

•

Change Swing Reduction Device Oil (See

•

Check Air Conditioner Refrigerant (See

page 4-39)

page 4-43)

•

Change Oil in Travel Reduction Device (One

•

Check and Adjust Engine ** (See page 4-44)

on Each Side of Unit) (See page 4-40)

2000 HOUR / YEARLY SERVICE

•

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

•

Inspect Machine to Check for Cracked or

Operating Hour Service Checks (See page

Broken Welds or other Structural Damage

4-45)

(See page 4-45)

•

Check Alternator and Starter** (See page

•

Check, Adjust Valve Clearance ** (See page

4-45)

•

Check All Rubber Anti-vibration Shock

•

Check Head Bolt Torques (See page 4-45)

Mounts (See page 4-45)

•

Hydraulic Oil Exchange and Suction Strainer

•

Perform and Record the Results of the Cycle

Cleaning (See page 4-45)

Time Tests (See page 4-45)

4000 HOUR / BIENNIAL SERVICE

•

Major Parts - Periodic Replacement (See

page 4-48)

12,000 HOUR / SIX YEAR SERVICE

•

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN) (See

page 4-49)

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

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-11

10 HOUR / DAILY SERVICE

GREASE BOOM, ARM AND FRONT ATTACHMENT PINS (FOR FIRST 100 HOURS)

Grease every 10 hours for first 100 hours and every 50 hours thereafter. (See page 4-22)

NOTE: If the unit has been running or working in water the front attachment should be greased on

a 10 hour / Daily basis.

CHECK ENGINE OIL LEVEL

WARNING!

Allow the engine to cool before checking

the oil level to avoid burns by touching hot

engine parts.

NOTE: When checking level using a

dipstick always remove and

wipe it clean before making

final level check.

Figure 11

Shut down engine and wait for 15 minutes.

This will allow all oil to drain back to oil

pan.

Remove dipstick (1, Figure 11) and wipe

the oil off with a clean cloth.

Insert dipstick fully in the oil gauge tube,

then take it out again.

Engine oil level must be between "HIGH"

and "LOW" marks on dipstick.

NOTE: If oil is above "HIGH" mark on

dipstick, some must be drained

to return oil to proper level.

Add oil through engine oil fill cap (2, Figure

11), if the oil level is below the "LOW"

mark.

Figure 12

4-12 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

CHECK LEVEL OF HYDRAULIC OIL TANK

WARNING!

The hydraulic oil will be hot after normal

machine operation. Allow the system to

cool before attempting to service any of

the hydraulic components.

The hydraulic tank is pressurized. Turn

the breather cap slowly to allow the

ARO1760L

pressurized air to vent. After the pressure

Figure 13

has been released, it is safe to remove

either the fill cap or service covers.

Position the machine on firm, level ground.

Lower boom and position bucket on

ground as shown in Figure 14.

Set engine speed to "LOW IDLE."

HAOC360L

Figure 14

Set safety lever to "LOCK" position.

Check level gauge by opening right access

door. Oil level must be between marks on

sight gauge.

Figure 15

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-13

If the level is below "L" mark add oil.

A. Shut down engine.

B. The hydraulic tank is pressurized.

Turn the breather cap slowly to allow

the pressurized air to vent.

C. Remove the upper cover of the

hydraulic tank and add oil.

IMPORTANT

Figure 16

Do not fill above "H" mark on sight

gauge. Overfilling can result in

damage to equipment and oil leaking

from hydraulic tank due to

expansion.

If oil level is above the "H" mark drain oil.

A. Shut down engine and wait for the

hydraulic oil to cool down.

B. Drain the excess oil from drain plug

(Figure 17) at the bottom of the tank

into a suitable container.

NOTE: Dispose of drained fluids

according to local regulation.

CHECK FOR LEAKS IN THE HYDRAULIC

SYSTEM

Figure 17

Perform a daily walk-around inspection to

make sure that the hoses, piping, fittings,

cylinders and hydraulic motors are not

showing any signs of leakage. If any is

noted, determine the source of the leak

and repair.

4-14 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

CHECK FUEL LEVEL

WARNING!

Use extreme safety precautions while

refueling to prevent explosions or fire.

Immediately clean up any spilt fuel.

At end of each work day, fill fuel tank. Add

fuel through fuel filler tube (1, Figure 18).

When working at a temperature of 0°C

Figure 18

(32°F) or higher, use ASTM No. 2-D or its

equivalent. At temperatures below

0°C

(32°F) use ASTM No. 1-D or its equivalent.

Make sure that the fuel fill hose is grounded to the excavator before fueling begins.

Check the amount of fuel in the tank by observing the fuel tank sight gauge (2, Figure 18).

NOTE: See “Fluid Capacities” on page 4-7. for capacity.

The excavator may be equipped with the optional battery operated fuel fill pump. The pump assembly

is in the hydraulic pump compartment. Put the suction hose of the pump into the fuel resupply tank.

Turn the switch in the battery box "ON," and the fuel will be pumped into the excavator fuel tank.

Do not overfill the tank.

Securely tighten cap after fueling.

NOTE: If breather holes in cap are

clogged, a vacuum may form in

the tank preventing proper fuel

flow to engine. Keep holes in

fuel cap clean.

CHECK FOR LEAKS IN THE FUEL SYSTEM

Perform an inspection of the engine

compartment to verify that the fuel system

is not leaking. If any is noted, determine

the source of the leak and repair.

HAOC510L

Figure 19

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-15

CHECK OIL LEVEL OF SWING REDUCTION DEVICE

WARNING!

The gear oil is very hot after the machine has been operating. Shut all systems down and allow

them to cool. Before fully removing any motor case inspection port plug, etc., loosen the plug

slightly to allow pressurized air to escape.

NOTE: When checking level using a dipstick always remove and wipe it clean before making final

level check.

Remove dipstick (1, Figure 21) and wipe

the oil from the dipstick with a cloth.

Insert dipstick (1, Figure 21) fully in the

guide.

Figure 21

When dipstick is pulled out, oil level must

be between "HIGH" and "LOW" marks on

dipstick.

NOTE: If oil is above "HIGH" mark on

dipstick, some must be drained

to proper level.

If the oil does not reach the "L" mark on

the dipstick, add oil through fill port

(2,

Figure 21).

Figure 22

If the oil level exceeds the "H" mark on the

dipstick, remove drain plug (Figure 23) and

drain the excess oil into a suitable

container.

NOTE: Dispose of drained fluids

according to local regulations.

Figure 23

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-17

CLEAN DUST NET IN FRONT OF OIL

COOLER

IMPORTANT

If running excavator in dusty area, check

dust net everyday and clean it if dirty.

WARNING!

Figure 24

If using compressed air or water to clean

the dust net, make sure that proper eye

protection is worn.

Loosen the wing nut(s) and remove dust

net.

Clean with compressed air or a water.

CHECK COOLING SYSTEM AND REFILL AS REQUIRED

WARNING!

Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to

release any remaining pressure.

Radiator cleaning is performed while the engine is running. Take extreme caution when working

on or near a running engine. Make sure to lock out and tag the controls notifying personnel that

service work is being performed.

Do not remove the radiator cap unless it is required. Observe the coolant level in the coolant

recovery tank.

When the engine is cold, remove the

radiator cap and check the coolant level

inside the radiator. Do not rely on the level

of coolant in the coolant recovery tank.

Refill radiator as required. Refer to coolant

concentration table. (See page 4-42)

Check to make sure that the coolant

transfer line from the coolant recovery tank

to the radiator is free and clear of

obstructions, or not pinched.

Observe the level of coolant in the coolant

recovery tank. The normal cold engine

Figure 25

fluid level should be between "FULL" and

"LOW" marks on tank.

If the coolant is below the "LOW" mark,

add coolant to this tank.

4-18 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

CHECK LEVEL OF WINDOW WASHER

LIQUID

Open left front door and check fluid level in

windshield washer tank.

Open fill cap and add fluid.

NOTE: Use a washer liquid that is rated

for all seasons. This will prevent

freezing during cold weather

operation.

Figure 26

INSPECT THE BUCKET TEETH AND SIDE

CUTTERS FOR SIGNS OF WEAR

On a daily basis, inspect the bucket teeth

to make sure that tooth wear or breakage

has not developed.

Do not allow the replaceable bucket teeth

to wear down to the point that the bucket

adapter is exposed. See Figure 27.

NOTE: These instructions are only for

Daewoo OEM buckets. If you

are using other manufacturers’

buckets, refer to their specific

Figure 27 1. POINT, 2. ADAPTER & 3. PIN

instructions.

INSPECT ENGINE FAN BLADE

WARNING!

Personal injury can result from a fan blade

failure. Never pull or pry on the fan. This

can damage the fan blade(s) and cause

fan failure.

NOTE: Manually rotate the crankshaft

by using a wrench on the

accessory drive pulley nut.

Figure 28

An inspection of the cooling fan is required

daily. Check for cracks, loose bolts, bent or

loose blades, and for contact between the

blade tips and the fan shroud. Check the

fan to make sure it is securely mounted.

Tighten the bolts if necessary. Replace

any fan that is damage.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-19

CHECK AIR INTAKE SYSTEM

CAUTION!

Hot engine components can cause burns.

Avoid contact with hot engine

components

Park the machine on a level surface, lower

the attachment to the ground, set safety

HAOA050L

lever to "LOCK" position, and shut down

Figure 29

engine.

Check the engine intake hose, and hose

bands for damage and tightness.

If damaged, wrinkled or loose, replace or

retighten or contact your nearest Daewoo

dealer.

IMPORTANT

Severe engine damage will result

from running with unfiltered air.

Do not operate engine if any leaks or

defects are found on air intake

Figure 30

system.

INSPECT SEAT BELT FOR PROPER OPERATION

INSPECT THE STRUCTURE FOR CRACKS AND FAULTY WELDS

During the daily walk-around inspection and when greasing the machine, look for any visible damage

to the machine. Repair or replace any damaged parts before operating the machine.

CHECK THE OPERATION OF ALL SWITCHES

Verify the working condition of all switches before starting the engine.

CHECK THE OPERATION OF ALL EXTERIOR LIGHTS, HORN AND CONTROL CONSOLE

INDICATOR AND MONITOR LIGHTS

Turn the engine starter switch to the ON position and observe all of the indicator lights.

Restore operation of any light bulbs that do not turn on at this point.

Sound the horn. Repair or replace if required.

Turn on and inspect all exterior work lights. Replace any monitors, burned out bulbs or cracked or

broken housings or lenses.

4-20 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

START ENGINE, CHECK STARTING ABILITY, AND OBSERVE EXHAUST COLOR AT START-UP

AND AT NORMAL OPERATING TEMPERATURE. LISTEN FOR ANY ABNORMAL SOUNDS

CHECK OPERATION OF ALL CONTROLS

IMPORTANT

Cold weather operation requires that the operator fully warm up the hydraulic oil before

beginning machine operation. Follow all warm up instructions listed in the Operating Instruction

section of this manual. Make sure to cycle oil through all of the components, including all

cylinders, both travel motors and the swing motor. Cold hydraulic oil in the lines and

components needs to be warmed before beginning full operation. If this is not done, damage to

the cylinders or hydraulic motors can occur.

With the engine at rated speed, operate all of the controls.

Follow cold weather hydraulic system warm-up procedures.

Note any slow operations or unusual movements. Determine the cause and repair the fault before

operating.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-21

50 HOUR / WEEKLY SERVICE

PERFORM ALL 10 HOUR / DAILY SERVICE CHECKS

GREASE BOOM, ARM AND FRONT ATTACHMENT PINS

Grease every 10 hours for first 100 hours and every 50 hours thereafter.

NOTE: If the unit has been running or working in water the front attachment should be greased on

a 10 hour / Daily basis.

•

Position machine as shown below and lower front attachment to ground and shut down engine.

•

Press the grease fitting and inject grease with the grease gun on the marked point.

•

After injection, clean off the old grease that has been purged.

HAOC150L

Figure 31

A. BOOM CYLINDER FOOT PIN (2 POINTS)

G. BUCKET CYLINDER FOOT PIN (1 POINT)

B. BOOM FOOT PIN (2 POINTS)

H. ARM LINK JOINT PIN (2 POINTS)

C. BOOM CYLINDER ROD PIN (2 POINTS)

LINK JOINT PIN (2 POINTS)

D. ARM CYLINDER FOOT PIN (1 POINT)

ARM BUCKET JOINT PIN (2 POINTS)

E. BOOM ARM JOINT PIN (2 POINTS)

BUCKET LINK JOINT PIN (1 POINT)

ARM CYLINDER ROD (1 POINT)

BUCKET CYLINDER ROD (1 POINT)

4-22 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

DRAIN WATER AND SEDIMENT FROM FUEL

FILTER

Open drain valve on bottom of fuel filter

and drain water and sediment into a

suitable container.

NOTE: Dispose of drained fluids

according to local regulation.

Figure 40

DRAIN WATER AND SEDIMENT FROM FUEL

TANK

Perform this procedure before operating

machine.

Drain water and sediment from bottom of

fuel tank into a suitable container.

NOTE: Dispose of drained fluid

according to local regulations.

NOTE: Always completely fill fuel tank

at end of each workday to

prevent condensation from

Figure 41

forming on the inside walls of

the tank.

CHECK ENGINE FAN BELT FOR CRACKS, WEAR AND CORRECT TENSION (AFTER FIRST 50

HOURS)

Inspect after first 50 hours of operation and every 250 hours thereafter. For details, See “Check

Engine Fan Belt Tension” on page 4-27.

CHANGE ENGINE OIL AND FILTER (AFTER FIRST 50 HOURS)

Change engine oil and filter after first 50 hours of operation or rebuild, then every 250 thereafter. For

details, See “Change Engine Oil and Filter” on page 4-29.

INSPECT THE TRACK ASSEMBLIES FOR PROPER TENSION AND LOOSE, WORN OR DAMAGED

PARTS (LINKS, SHOES, ROLLERS, IDLERS)

Do a daily walk-around inspection of all components including the track assemblies. Look for missing,

damaged or excessively worn parts. See “Track Tension” on page 4-64.

Jack up each track and perform the two speed travel motor test.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-25

250 HOUR / MONTHLY SERVICE

PERFORM ALL 10 HOUR / DAILY AND 50 OPERATING HOUR SERVICE CHECKS

CHANGE SWING REDUCTION DEVICE OIL (DRAIN AND REFILL AFTER FIRST 250 HOURS)

NOTE: Change swing reduction device oil after first 250 hours on a new machine and every 1000

hours thereafter (See page 4-39).

CLEAN OUTER ELEMENT OF TWO STAGE AIR

CLEANER

02/05

[MO] 11:30A

WARNING!

2059 RPM

Never clean or attempt to remove the air

cleaner element if the engine is running.

Air Cleaner

If using compressed air to clean the

CLOGGED!!

element, make sure that proper eye

protection is worn.

ARO0210L

Figure 42

Locate the air filter assembly. Remove the

access cover and remove the outer

element

(1, Figure

43) of the air filter

assembly.

NOTE: If indicator light (Figure 42) on

instrument panel comes "ON"

the air cleaner must be

serviced.

NOTE: Replace outer element every

500 hours

3 months of

service.

Remove and clean rubber evacuator valve

Figure 43

(2, Figure 43) from bottom of air cleaner

housing. Inspect seal lips for wear or

damage. Replace valve if necessary.

4-26 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

Clean the outer filter by blowing

compressed air from the inside of the filter

towards the outside. Do not use more than

205 kPa (30 psi) air pressure.

Clean the inside of the air filter housing

and the inside of the air filter housing

cover.

Properly reinstall the air filter and cover.

Tighten the cover wing nut finger tight. Do

not use any tools to tighten the wing nut.

HAOC570L

Figure 44

CHECK ENGINE FAN BELT TENSION

10mm /10kg

IMPORTANT

A loose fan belt can cause engine

overheating, poor charging, and/or

premature belt wear. A belt that is too tight

can cause damage to the water pump,

alternator bearing or belt.

HJB5001I

Inspect every 250 hours. (Inspect after first

50 hours of operation.)

Figure 45

With the engine shut off, check the tension

of the fan belt by pressing downwards on

the belt, midway between the fan pulley

and alternator pulley. The belt should flex

approximately

10 mm (0.500 in). See

Figure 45. To adjust the belt, loosen the

alternator adjustment plate bolts, adjust

the belt tension and retighten the bolts.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-27

CHECK ENGINE FAN BELT WEAR

WARNING!

Keep clear of engine fan and fan drive

belts when the engine is running. Rotating

fan and belt contact can cause injury.

WARNING!

Figure 46

When checking, adjusting or replacing

drive belts, care must be taken to prevent

accidental cranking of the engine. Be sure

the starter switch is in the "OFF" position

and the controls are tagged.

Replace badly worn, greasy or severely cracked belts immediately. These conditions prevent proper

belt function. Visually inspect the belt. Check the belt for intersecting cracks. Transverse (across the

belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with

transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces of material missing.

Before installing new belts, make sure all pulley grooves are clean and not worn. Replace pulley, if

damaged, or if the grooves are worn.

All pulley support bearings, shafts, and brackets must be in working order.

When replacing belts and pulleys, pulley alignment must be checked with belts tensioned and

brackets securely clamped. A misalignment that can be detected by the naked eye is detrimental to

belt performance.

Do not force the belts into the pulley grooves by prying with a screwdriver or pry bar. This will damage

the belt side cords which will cause the belts to turn and result in complete destruction of the belts in

operation.

Belts on new machines and replacement belts lose their tension as they seat into the pulley grooves.

Check the tension of new belts at 50 hour intervals until tension is stabilized and thereafter, every 250

hours. If the tension falls below the required minimum, the belt slips damaging the belts and pulley

grooves.

NOTE: When operating in abrasive conditions, check tension every 100 hours.

4-28 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

CHANGE ENGINE OIL AND FILTER

NOTE: Change engine oil and filter after first 50 hours of operation or rebuild, then every 250

thereafter.

WARNING!

DO NOT change oil on a hot engine. Allow the engine to cool down before attempting to change

the engine oil and filter to avoid burns by touching hot engine parts.

Position a larger container under the

engine. Remove cap (1, Figure 47) and

install hose

(2) to drain the engine oil.

Remove hose (2) and install cap (1).

NOTE: Dispose of drained fluids

according to local regulation.

Figure 47

Replace engine oil filter by using filter

wrench. The engine oil filter is a spin-on

type. See Figure 48. Remove and discard

filter.

Install new filter. Apply a small amount of

oil around filter gasket. Screw filter on

head until gasket contacts head, turn filter

1/2 turn more.

Figure 48

Refill the engine with the correct oil

through the oil fill port (Figure 49). Refer to

the Lubrication Table of this manual for the

recommended oil for the operating

conditions.

NOTE: See

“Fluid Capacities” on

page 4-7. for capacity.

Start engine and check engine oil pressure

light.

Shut down engine. Look for signs of leaks

at filter. Recheck oil level.

Figure 49

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-29

CHECK OIL LEVEL IN TRAVEL REDUCTION

DEVICE (ONE ON EACH SIDE OF UNIT)

WARNING!

The gear oil is very hot after the machine

has been operating. Shut all systems

down and allow them to cool. Before fully

removing any motor case inspection port

plug, etc., loosen the plug slightly to allow

pressurized air to escape.

Figure 50

Make sure that the machine is on a firm,

level work area.

Rotate the track until ports (1 and 2, Figure 50) are in their proper positions as shown.

Remove oil level plug (1, Figure 50).

Check oil level. The oil should be near the bottom of the level plug opening.

Add oil through the level plug opening, if necessary.

Clean and install oil level plug (1, Figure 50).

Repeat this procedure on the other travel reduction device.

CHANGE OIL IN TRAVEL REDUCTION DEVICE (ONE ON EACH SIDE OF UNIT) (AFTER FIRST 250

HOURS)

NOTE: Drain and refill oil after first 250 hours of operation and every 1000 hours thereafter (See

page 4-40).

REPLACE FULL FLOW HYDRAULIC OIL FILTER (AFTER FIRST 250 HOURS)

NOTE: Replace full flow hydraulic oil filter after first 250 hours of operation or rebuild, then every

500 hours thereafter (See page 4-32).

CHANGE PILOT FILTER (AFTER FIRST 250 HOURS)

NOTE: Change pilot filter after first 250 hours and every 500 hours thereafter (See page 4-33).

INSPECT PINS AND BUSHINGS OF THE FRONT END ATTACHMENTS FOR SIGNS OF WEAR

CHECK FLUID LEVELS IN BATTERIES AND BATTERY CHARGE LEVELS

INSPECT FOR ANY LOOSE OR MISSING NUTS AND BOLTS

INSPECT FUEL SYSTEM HOSE CLAMPS

4-30 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

500 HOUR / 3 MONTH SERVICE

PERFORM ALL DAILY (10 HOUR), 50, AND 250 OPERATING HOUR SERVICE CHECKS

GREASE SWING GEAR AND PINION

Remove inspection cover and inspect the

condition of the grease. Make sure that

water or other contaminants are not

noticeable.

NOTE: The upper structure must be

rotated a little at a time so that

the entire face of the swing gear

can be lubricated. Use extreme

caution when performing this

operation.

Figure 51

If water or other contaminations are found,

remove the lower access cover so that the

gear teeth can be thoroughly cleaned and

lubricated.

Install access covers after lubricating gear

teeth.

Figure 52

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-31

REPLACE FULL FLOW HYDRAULIC OIL FILTER

NOTE: Change full flow hydraulic oil filter after first 250 hours of operation and every 500 hours

thereafter.

WARNING!

The hydraulic oil will be hot after normal machine operation. Allow the system to cool before

attempting to service any of the hydraulic components.

The hydraulic tank is pressurized. Loosen the hydraulic air breather cap slightly to allow the

pressurized air to vent. After the pressure has been released, it is safe to remove either the fill

cap or service covers or drain water from the tank.

IMPORTANT

Make sure to clean any dirt or water from the top of the hydraulic tank, especially around the fill

port and filter ports.

Position the machine on firm, level ground.

Lower front attachment to ground and shut

down engine.

Loosen the air breather cap slightly to

release the internal pressure.

Remove bolts (1, Figure 53) and service

cover (2). Remove spring (3), valve (4) and

O-ring (5) from filter element (6).

Remove filter element and properly

discard.

Install new filter element and a new O-ring.

Install valve and spring. Install service

cover plate.

Run engine for 10 minutes at low idle to

purge air from circuit.

Shut down engine.

Check level in hydraulic oil tank. Add oil if

necessary

HAOC460P

Figure 53

4-32 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

CHANGE PILOT FILTER

NOTE: Change pilot filter after first 250

hours of operation and every

500 hours thereafter.

WARNING!

The hydraulic oil will be hot after normal

machine operation.

Allow the system to cool down before

changing pilot filter.

Figure 54

Position the machine on the firm, level

ground. Lower front attachment to ground

and shut down engine.

Loosen the air breather cap slightly to

release the internal pressure.

Locate pilot system filter assembly. See

Figure 54.

Unscrew canister

(5, Figure

55) and

remove O-ring (3) and filter cartridge (4).

NOTE: The canister will be filled with

oil. Use caution when removing

this assembly.

Insert a new filter cartridge and O-ring.

Apply a small amount of oil around the

entire O-ring and reinstall the canister

assembly onto the filter head (1, Figure

55).

After changing pilot filter, vent air from

HAOC480L

pump and check level of hydraulic oil tank.

Figure 55

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-33

CLEAN AIR CONDITIONING FILTER

The unit is equipped with an air filtration system which filters out dirt and dust particles from air being

circulated into operator’s cab. This filter should be cleaned out.

NOTE: In the event that the unit is being operated in a dusty environment, the cleaning and

replacement should be performed more frequently. If filter element is damaged, replace

damaged filter by a new one.

WARNING!

All service and inspection of air conditioning system should be performed with the starter

switch in the "O" (OFF) position.

WARNING!

If using compressed air to clean the element, make sure that proper eye protection is worn.

NOTE: All right and left call outs are based on the operator being seated in the operator’s seat

facing the front.

Turn the key cylinder (1, Figure 56) to open

cover

(2, Figure

56) behind operator’s

seat.

Disconnect speaker harness.

Remove cover (2, Figure 56) from the rear

box.

Remove filter cover (3, Figure 56) from air

conditioning unit.

HAAD3860

Figure 56

Remove filter element (1, Figure 57) and

inspect for any damage.

Use compressed air to clean filter element.

If filter element is very dirty use a mild

soap or detergent and water to clean it.

NOTE: If water was used to clean filter,

be certain it is completely dry

before installing.

NOTE: When assembling the filter

again, install so that the arrow

on top of filter is facing the

inside of the cab.

HAOO790L

Figure 57

4-34 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

CLEAN RADIATOR, OIL COOLER,

INTERCOOLER AND AIR

CONDITIONER CONDENSER CORE

WARNING!

If compressed air, steam or water hit your

body directly, there is danger of injury.

Always wear protective glasses, mask and

safety shoes. Make sure that all extra

personnel are clear of the work area.

Figure 58

Make sure to wear all appropriate safety

apparel

(mask safety glasses, safety

shoes, etc.) during the cleaning process.

Loosen the wing nut(s) and remove dust

net from in front of oil cooler.

Figure 59

Remove wing nuts and plate (Figure 60)

between radiator and oil cooler.

Clean the outside of the radiator and oil

cooler and intercooler with compressed

air, steam or water. Wash from the outside

of the engine compartment inwards.

Repeat the cleaning process from the

inside of the engine compartment

outwards to remove all dirt and debris.

NOTE: Clean dust net and install it

after cleaning radiator, oil cooler

and intercooler.

Figure 60

Clean air conditioner condenser core with

compressed air, steam or water.

IMPORTANT

To prevent damage to the cores,

apply compressed air from an

appropriated distance. Damaged

core may cause water leakage or

overheating. In a dusty site, check

the core daily, irrespective of the

maintenance interval.

Figure 61

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-35

REPLACE OUTER AND INNER AIR

CLEANER ELEMENTS

WARNING!

Never clean or attempt to remove the air

cleaner element if the engine is running.

NOTE: Replace

inner

element

whenever a new outer element

is installed.

Figure 62

Open the access door at the rear of the

cabin,

Remove the wing nut and air cleaner

cover.

Remove the wing nut and outer element

from the air cleaner housing.

Clean the air cleaner cover and the inside

of the air cleaner housing.

Remove wing nut and inner element.

Clean out inside of air cleaner housing.

DO NOT use compressed air to blow out

housing.

Install new inner element, and secure it

into position with wing nut. DO NOT clean

and re-use inner element.

Install new outer element, and secure it

into position with wing nut.

Install air cleaner cover.

NOTE: Make sure that all gaskets on

Figure 63

wing nuts and cover are

properly installed and seated.

4-36 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

CHANGE FUEL FILTER

WARNING!

Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke.

Locate fuel

filter

inside

engine

compartment.

Position a small container under fuel filter.

Drain fuel by opening drain valve on

bottom of filter.

NOTE: Dispose of drained fluids

according to local regulation.

Unscrew fuel filter from head assembly.

Discard fuel filter.

After cleaning filter head, install new fuel

filter. Screw filter on head until gasket

Figure 64

contacts head, turn filter

1/3

1/2 turn

more.

NOTE: Coat fuel filter gasket with fuel.

NOTE: Fill fuel filter with clean fuel.

This will help reduce fuel

system priming.

Start engine. After engine has run for a

couple of minutes, shut down engine and

look for leaks.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-37

Prime the Fuel System

If engine does not start, the fuel system may

need priming. Prime the fuel system using the

following procedure;

Loosen plug (Figure 65) on top of fuel filter

head.

Figure 65

Unscrew and pump the hand operated

primer pump

(Figure

66) by the fuel

injection pump. Pump primer until fuel is

present at plug hole in fuel filter head.

Tighten plug in fuel filter head.

Continue to pump primer pump until a

strong resistance is felt. Screw the primer

pump knob back into housing.

Start engine and look for signs of leaks.

Repeat procedure if necessary.

Figure 66

4-38 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

1000 HOUR / 6 MONTH SERVICE

PERFORM ALL DAILY (10 HOUR), 50, 250 AND 500 OPERATING HOUR SERVICE CHECKS

CHANGE SWING REDUCTION DEVICE OIL

NOTE: Change swing reduction device

oil after first 250 hours on a new

machine and every 1000 hours

thereafter.

WARNING!

The gear oil is very hot after the machine

has been operating. Shut all systems

down and allow them to cool.

Figure 67

Set a container under excavator.

Open drain plug (Figure 67).

NOTE: Dispose of drained fluids

according to local regulation.

After draining oil close drain plug.

Remove breather/fill cap (2, Figure 68) and

add oil to "H" mark on dipstick (1, Figure

68)

Figure 68

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-39

CHANGE OIL IN TRAVEL REDUCTION

DEVICE (ONE ON EACH SIDE OF UNIT)

WARNING!

The gear oil is very hot after the machine

has been operating. Shut all systems

down and allow them to cool. Before fully

removing any motor case, inspection port

plug, etc., loosen the plug slightly to allow

pressurized air to escape.

Figure 69

NOTE: Drain oil after first 250 hours of

operation and every 1000 hours

thereafter.

Make sure that the machine is on a firm,

level work area.

Rotate the track until ports (1 and 2, Figure

69) are in their proper positions as shown.

Place a container under drain plug

(2,

Figure 69) and remove plugs (1 and 2) to

drain the travel motor fluid.

NOTE: Dispose of drained fluids

according to local regulation.

Install drain plug (2, Figure 69). Refill the

travel motor case with fluid through level

port (1) until the fluid level is at port (1).

Install level plug (1).

NOTE: See

“Fluid Capacities” on

page 4-7. for capacity.

Repeat this procedure on the other travel

motor.

4-40 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

CHANGE RADIATOR COOLANT

WARNING!

Allow the engine to cool before

releasing the radiator cap. Make sure

to loosen the cap slowly to release

any remaining pressure.

Radiator cleaning is performed while

the engine is running. Take extreme

caution when working on or near a

Figure 70

running engine. Make sure to lock

out and tag the controls notifying

personnel that service work is being

performed.

Do not remove the radiator cap

unless it is required. Observe the

coolant level in the coolant recovery

tank.

Slowly open the radiator cap to allow any

pressure to escape.

Place a container under the radiator and

open the drain valve (Figure 70).

NOTE: Dispose of drained fluids

according to local regulation.

Open heater shut-off valves (Figure 71 and

Figure 72) to allow coolant to drain from

heater core.

Figure 71

Figure 72

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-41

Remove coolant drain plug (1, Figure 73)

from engine.

Install drain plug, and close drain valve

after coolant has completely drained from

system.

Fill cooling system with a flushing solution.

Run engine at low idle until the coolant

temperature gauge reaches the "GREEN

ZONE." Run engine for another

minutes.

After allowing engine to cool.

Figure 73

Drain flushing fluid and fill system with

water.

10.

Run engine again to allow water to

completely circulate.

11.

Drain water and fill system with proper

anti-freeze

mixture

for

ambient

temperature.

Refer

coolant

concentration table. (See page 4-42)

12.

Run engine without radiator cap installed,

so that all air will be purged from system.

Fill radiator to fill neck.

13.

Drain and fill radiator coolant recovery

tank.

AMBIENT TEMPERATURE

COOLING WATER

ANTIFREEZE

-10°C (15°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-5°F)

67%

33%

-25°C (-15°F)

60%

40%

-30°C (-20°F)

56%

44%

-40°C (-30°F)

50%

4-42 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

CLEAN FUEL INJECTION PRIMING PUMP

STRAINER

Remove fitting, fuel line and strainer from

side of priming pump.

Clean strainer.

Position strainer in priming pump and

install fuel line and fitting.

Figure 74

CHECK AIR CONDITIONER REFRIGERANT

WARNING!

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging air conditioning system.

Run engine about 1800 rpm. Operate for a

minimum of ten minutes to stabilize the

system.

Press the "HI" fan speed switch to set

maximum air flow.

Put the temperature control switch in

maximum cool position.

Press the "Internal Air Circulation" switch.

Compare the flow of bubbles in the sight

glass of receiver dryer with the drawings in

the following table.

Figure 75

CAUTION!

Overfilling refrigerant may cause dangerous high pressure and poor cooling action; and low

refrigerant level may cause compressor damage.

Always maintain refrigerant at normal level.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-43

2000 HOUR / YEARLY SERVICE

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

CHECK ALTERNATOR AND STARTER**

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

CHECK ALL RUBBER ANTI-VIBRATION SHOCK MOUNTS

PERFORM AND RECORD THE RESULTS OF THE CYCLE TIME TESTS

INSPECT MACHINE TO CHECK FOR CRACKED OR BROKEN WELDS OR OTHER STRUCTURAL

DAMAGE

CHECK, ADJUST VALVE CLEARANCE **

CHECK HEAD BOLT TORQUES

HYDRAULIC OIL EXCHANGE AND SUCTION

STRAINER CLEANING

WARNING!

The hydraulic oil will be hot after normal

machine operation. Allow the system to

cool before attempting to service any of

the hydraulic components.

The hydraulic tank is pressurized. Loosen

ARO1760L

the air breather cap to allow the

Figure 76

pressurized air to vent. After the pressure

has been released, it is safe to remove

either the fill cap or service covers.

IMPORTANT

Make sure to clean any dirt or water from the top of the hydraulic tank, especially around the fill

port and filter ports.

Hydraulic oil change interval is 2,000 hours, only when Daewoo Genuine Oil is used. If other

brands of oil is used, guaranteed change interval is 1,000 hours.

NOTE: Based on the type of excavating being completed, the working conditions (extremely hot or

dusty) and the extra front end attachments being used (hydraulic breaker, etc.), the

hydraulic fluid will need to be changed more frequently.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-45

Position the machine on firm, level ground.

Swing upper structure perpendicular (90°)

to tracks. Lower boom and position bucket

on ground as shown in Figure 77.

Set safety lever on "LOCK" position.

Shut down engine.

Release pressurized air from hydraulic

tank by rotating air-breather cap (1, Figure

80).

HAOC390L

Figure 77

Drain hydraulic oil from tank into a

container capable of holding 290 liters (77

U.S. gal.). After draining tank install drain

plug.

IMPORTANT

Be careful of squirting oil when

removing drain plug.

NOTE: Used filter and used oil should

always be disposed of

Figure 78

according to local regulations.

Carefully remove bolts and cover

(2,

Figure 80) from top of hydraulic oil tank.

There is a spring (3) under the cover that

will force the cover up.

Remove spring (3, Figure 80) and strainer

(5), by pulling on rod (4).

Clean inside and outside of strainer.

Replace strainer if it is broken.

Position strainer

(5, Figure

80) on boss

portion of suction pipe (6).

NOTE: Measurement "A" is 655 mm

(25.79 in).

HAOC411L

Figure 79

4-46 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

10. Fill the hydraulic oil tank. Check level using

sight gauge on side of tank.

11. Place spring (3, Figure 80) on rod (4) and

assemble cover (2).

12. After replacing and cleaning the hydraulic

oil, filter element and strainer, vent the

system. See

“Venting and Priming

Hydraulic System” on page 4-50.

IMPORTANT

When the hydraulic breaker is being

used, due to the higher heat

generated by this unit, use

replacement intervals recommended

under the “Hydraulic Oil and Filter

Service Intervals” on page 3-35.

13. Check level of hydraulic oil tank. (See page

4-13)

ARO1720L

Figure 80

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-47

4000 HOUR / BIENNIAL SERVICE

MAJOR PARTS - PERIODIC REPLACEMENT

To ensure safe operation and work, perform periodic inspections. Also, to increase safety, replace the

following parts. These parts are the ones most often subjected to abrasion, heat and fatigue. Exchange

these parts with new ones at the designated time intervals, even if the old parts look good.

Always replace all related parts such as gaskets and O-rings. Use only original equipment manufacturers

parts.

MAJOR COMPONENT

PARTS NAME TO BE EXCHANGED

TIME TO EXCHANGE

PERIODICALLY

ENGINE

Fuel hose (Tank to water separator)

2 years or 4,000 hours

Fuel hose (Water separator to fuel injection pump)

Fuel hose (Tank to fuel injection pump)

Heater hose (Heater to engine)

Heater hose (Heater to radiator)

Air-conditioner hose

HYDRAULIC

BODY

Pump suction hose

SYSTEM

Pump discharge hoses

Pump side branch hoses

Swing motor hoses

Travel motor hoses

WORK

Boom cylinder line hoses

DEVICE

Arm cylinder line hoses

Bucket cylinder line hoses

4-48 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

12,000 HOUR / SIX YEAR SERVICE

HOSE IN-SERVICE LIFETIME LIMIT (EUROPEAN STANDARD ISO 8331 AND EN982 CEN)

European regulations state that the in-service life of any hydraulic hose may not exceed six years. Daewoo

recommends the following;

•

Hoses at the customer premises can not be stored more than 2 years before being discarded or

installed on a machine.

•

In-service lifetime of hoses fitted on a machine can never exceed 6 years, but replace hoses

describe in “Major Parts - Periodic Replacement” on page 4-48, every 2 years. Always replace

hoses having exceeded the allowed in-service lifetime irrespective of the external appearance/

wear.

•

Always store hoses in a dark place at a maximum of 65% relative humidity, between 0°C (32°F)

and 35°C (95°F) but as close as possible to 15°C (59°F) and away from copper, manganese or

tube generating Ozone.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-49

VENTING AND PRIMING HYDRAULIC SYSTEM

MAIN SYSTEM PUMP

NOTE: If pump is run without sufficient

oil in the main hydraulic pump,

damage can occur. Always vent

pump of air after draining

hydraulic system.

With the engine stopped, remove vent plug

(Figure 81) to see if any oil is present.

If oil is not present, fill pump with oil

through port (Figure 81).

Install vent plug (Figure 81) first.

Figure 81

Start engine and run it for several minutes

at low idle engine speed. This will

pressurize the hydraulic oil tank and

system.

Slowly loosen vent plug (Figure 81) several

turns, until hydraulic oil flows out of plug.

This shows that air has been released.

Tighten the plug (Figure 81).

HYDRAULIC CYLINDERS

IMPORTANT

If cylinders are operated in high idle after the hydraulic system has been drained or the cylinder

has been rebuilt, damage to piston packing and seals may occur. Always vent air from cylinders

at low idle and at a slow speed.

Run engine at low idle. Extend and retract each cylinder to within 100 mm (4 in) of fully stroking it 4 -

5 times.

Operate fully extend and retract each cylinder 3- 4 times.

Repeat procedure until cylinders extend and retract smoothly.

4-50 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

SWING MOTOR

IMPORTANT

If the air is not vented from the system, it

will cause damage to the swing motor and

bearings.

NOTE: Perform this only when oil has

been drained from swing motor.

Shut down engine.

Figure 82

Disconnect drain hose and fill swing motor

case with hydraulic oil.

Connect the drain hose.

Start engine and set throttle at "LOW

IDLE" and swing upper structure slowly

two full revolutions to the left and right.

AIR RELEASE OF TRAVEL MOTOR

NOTE: Perform this only when oil is

drained from travel motor

Shut down engine.

Disconnect drain hose (Figure 83) and fill

motor case with hydraulic oil.

Connect drain hose.

Start engine and set engine speed control

dial to "LOW IDLE." Run the engine for

one minute and slowly drive excavator

forwards and backwards.

Figure 83

GENERAL VENTING

After venting air from all components, shut the engine down and check the hydraulic oil level. Fill

hydraulic oil tank to "H" mark on sight gauge.

Start engine and operate all controls again, run engine for 5 minutes to ensure all system have been

vent and purged of air. Shut down engine and check hydraulic oil level again. Add oil as necessary.

Check for oil leaks and clean all fill and venting locations.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-51

HANDLING OF ACCUMULATOR

WARNING!

Even though the engine is stopped, the hydraulic accumulators for the pilot system are still

charged. Do not disconnect any pilot system hoses until accumulator pressure has been

released from the circuit. To release pressure, turn the starter switch to “I” (ON) position and

operate all hydraulic control levers and forward/reverse travel levers. Even though the engine is

shut down, hydraulic actuated components may move while releasing pilot pressure. Keep all

personnel away from excavator while performing this operation.

•

Set safety lever on "LOCK" position after stopping engine.

•

DO NOT mishandle accumulator(s). They are very dangerous because they contain

high pressure nitrogen gas.

•

DO NOT punch a hole or apply heat or fire to an accumulator.

•

DO NOT weld on accumulator, or try attaching anything to it.

•

When replacing an accumulator, contact a DAEWOO distributor or sales agency so the

gas can be properly released.

•

Wear safety goggles and protective gloves when working on an accumulator.

Hydraulic oil under pressure can penetrate the skin and cause serious injuries.

Release pilot accumulator pressure using the

following procedure;

Lower front attachment

(bucket) on the

ground.

Shut down engine.

Set safety lever on "RELEASED" position.

Turn starter switch "ON."

Fully stroke work and travel levers in all

directions.

Set safety lever on "LOCK" position.

Figure 84

Turn key to "OFF" position and remove

from starter switch.

Remove accumulator by unscrewing it

slowly.

4-52 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

FUEL TRANSFER PUMP (OPTION)

WARNING!

Do not dry operate fuel pump for more than 15 seconds.

•

Cooling and lubrication of pump is achieved by fuel passing through pump. If pump is

dry operated, heat generated by moving parts will cause damage to pump rotors,

vanes and seals. To prevent unnecessary wear and/or damage to pump do not dry

operate fuel pump for more than 15 seconds.

Do not operate pump for more than 15 minutes at a time.

•

Continuous usage of pump over recommended time interval will cause overheating of

motor and will result in causing motor damage.

Do not use refueling pump for other types of fuel or fluids. (Use only for diesel fuel.)

•

Do not use refueling pump for other types of fuel which have a low flash point.

•

Do not use refueling pump for fuel contaminated with water or high humidity. Moisture

in pump mechanism can cause rust and can create pump failure.

Always operate pump using strainer installed on inlet hose. This will prevent any foreign

materials from being introduced into pump. Always maintain pump and all of its

components in a clean condition.

•

If dirt or other foreign materials enter pump, it can become lodged between the rotor

and/or vanes and generate heat which can cause pump damage.

•

Do not remove strainer or use a strainer with larger mesh to increase flow of fuel.

Be careful not to overfill or spill fuel.

Make sure direction of check valve is in line with flow direction of fuel.

If any pump parts or components become lost, damaged or inoperable, immediately

replace it with a new ones.

IMPORTANT

If there are any sign of leakage while operating transfer pump, inspect the following components

to prevent any fires or hazardous fuel spills.

•

Check all hoses leading to and from the transfer pump.

•

Check all hose clamps.

•

Check transfer pump inlet port.

The transfer pump is used to transfer fuel from a refueling source to the fuel tank. A check valve is installed

in the inlet hose to prevent fuel from flowing back from fuel tank to source. A strainer is installed in inlet

hose to prevent any foreign material from being introduced into transfer pump or fuel tank.

A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it

from damage.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-53

FUEL

FUEL TANK

HAOP551L

Figure 85

BODY

STRAINER CAP

CHECK VALVE

INLET HOSE

STRAINER

Remove strainer cap (4, Figure 85) from

strainer (3) on end of inlet hose (5).

NOTE: Keep strainer cap (4, Figure 85)

in a safe location to reseal

strainer

(3) after refueling is

complete.

Insert inlet hose

(5, Figure

85) into

refueling tank.

Turn fuel pump switch (Figure 86) inside of

battery box on front side to “ON” position.

NOTE: Transfer pump rate of flow is

Figure 86

approximately

35 liters/minute

(9.24 U.S. gpm). Use extra care

not to overfill fuel tank so that

fuel does not over flow.

Once fuel transfer is completed,

immediately turn switch to “OFF” position

to stop pump.

Lift inlet hose (5, Figure 85) from fueling

source and turn switch to “ON” position for

2 - 3 seconds to drain remaining fuel from

hose to fuel tank.

Install strainer cap (4, Figure 85) on inlet

strainer (3) and return hose (5) to storage

position.

4-54 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

ELECTRICAL SYSTEM

NOTE: Never disassemble electrical or electronic parts. Consult with a DAEWOO distributor or

sales agency before servicing.

BATTERY

WARNING!

Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing.

If you spill acid on yourself, immediately flush the area with water.

Battery acid could cause blindness if splashed into the eyes. If acid into the eyes, flush them

immediately with large quantities of water and see a doctor at once.

If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil.

Call a doctor or poison prevention center immediately.

When working with batteries, always wear safety glasses or goggles.

Battery generates hydrogen gas, so there is danger of explosion. Do not bring lighted cigarettes

near the battery, or do anything that will cause sparks.

Before working with batteries, shut down engine and turn the starter switch to the "OFF"

position.

Avoid short circuiting the battery terminals through accidental contact with metallic objects,

such as tool.

When removing or installing, check which is the positive (+) terminal and negative (-) terminal.

When removing the battery, first disconnect the negative (-) terminal. When installing the battery,

first connect the positive (+) terminal.

If the terminals are loose, there is danger that the defective contact may generate sparks that

will cause an explosion. When installing the terminals, install them tightly.

Batteries in Cold Weather

In colder weather a greater drain is placed on the batteries when they are used for the preheat cycle and

when starting a cold engine. Battery performance decreases as the temperature gets lower.

In extremely cold weather, remove the batteries at night and move them to a warm location. This will help

to keep them at a higher power level.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-55

Inspection of Battery Electrolyte Level

This machine has two maintenance free

batteries. They never require the addition to

water.

When the charge indicator becomes

transparency, it means low electrolyte state

because of the leakage or charging system

error. Determine the cause of problem and

replace the batteries immediately.

Check Charging State

HAOC660L

Figure 87

Check charging state through the charging

indicator.

•

GREEN: Sufficiently charged.

•

BLACK: Insufficient charged.

•

TRANSPARENT: Replace battery.

Check the Battery Terminals

Be certain that the battery is held securely in its

compartment. Clean the battery terminals and

the battery cable connectors. A solution of

baking soda and water will neutralize acid on the

battery

surface,

terminals,

and cable

connectors. Petroleum jelly or grease can be

applied to the connectors to help prevent

corrosion.

Battery Replacement

When the charging indicator indicates

Figure 88

transparency state, replace the battery. The

batteries should always be replaced in pairs.

Using an old battery with a new one will shorten

the life span of the new battery.

4-56 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

FUSES

The fuses in the fuse box are used to

protect the various electrical circuits and

their components from damage. See

Figure 89. The fuses used are standard

automotive type fuses.

The section on

“Fuse Identification” on

page 4-58, lists the circuits and the fuse

amperage required for each circuit. If a

fuse blows, determine the cause and

repair any faults or failures.

HAOC670L

DO NOT insert a higher amperage fuse

Figure 89

into a lower amperage slot. Serious

damage to the electrical components or

fire can result.

CAUTION!

Before replacing a fuse, be sure to

turn starter switch to "O"

(OFF)

position.

Fuse Boxes

There are two fuse boxes (1 and 2, Figure 90)

on the left side of the heater box. The fuses

prevent electrical devices from overloading or

shorting.

A decal attached to the inside of the fuse box's

cover indicates the function and amperage of

each fuse.

Spare fuses are mounted on the inside of fuse

box's cover.

Change a fuse if the element separates. If the

element of a new fuse separates, check the

circuit and repair the circuit.

CAUTION!

ARO0620L

Figure 90

Always replace fuses with the same type

and capacity fuse that was removed.

Otherwise, electrical damage could result.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-57

Fuse Identification

Fuse Box (1)

Fuse Box (2)

ARO1340L

Figure 91

Fuse Box One

Fuse Box Two

No.

Name

Capacity

Name

Capacity

Breaker,

Horn

10A

2-Way Valve (Option)

Instrument Panel,

10A

12V Power

10A

Pressure Sensor

Beacon Light (Option)

10A

Engine Speed Control

10A

Window Washer

10A

Travel Swing Alarm (Option)

10A

Wiper

10A

Spare

10A

Pilot Cut-off

10A

Spare

10A

Engine Stop

10A

Memory Backup

10A

Starter Switch

10A

Room Light, Hour Meter

10A

Air-conditioner, Heater

30A

Cabin Light (Option)

30A

e-EPOS, Booster,

20A

Work Light

20A

Travel Speed Change

Spare

15A

Headlight

15A

Spare

15A

Cigar Lighter

15A

Spare

15A

Spare

15A

Stereo

15A

Fuel Pump (Option)

15A

4-58 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

AIR CONDITIONING SYSTEM

NOTE: See “Clean Air Conditioning Filter” on page 4-34.

CHECK CONTROL PANEL

When a switch is turned "ON," the pilot LED of pressed switch should light up and buzzer should sound.

When the light switch is turned "ON," the LED display should light up.

CHECK AIR CONDITIONER HOSES

Check the hose for cracking and damage.

CAUTION!

When a leak occurs, dirt will accumulate in the area where the leak is. Consult a DAEWOO

distributor or sales agency.

CHECK CONDENSER

Inspect the condenser for dust and debris. Clean if necessary.

NOTE: See “Clean Radiator, Oil Cooler, Intercooler and Air Conditioner Condenser Core” on

page 4-35.

CHECK MAGNETIC CLUTCH

Check the magnet clutch for dirt and interference.

Turn the starter switch to "I" (ON) position and check the magnet clutch for operation. If a fan speed is not

selected, the magnet clutch will not operate.

CHECK BELT TENSION

NOTE: See “Check Engine Fan Belt Tension” on page 4-27.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-59

BUCKET

BUCKET TOOTH REPLACEMENT

WARNING!

Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and

eye protection when changing bucket teeth.

Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground.

Shut the engine off and lock out the hydraulic controls before working on the bucket.

NOTE: These instructions are only for Daewoo OEM buckets. If you are using other

manufacturers buckets, refer to their specific instructions.

HAOC680L

Figure 92

On a routine basis, inspect bucket teeth to

make sure that tooth wear or breakage has

not developed. Do not allow replaceable

bucket teeth to wear down to a point that

bucket adapter is exposed. See Figure 92.

To replace a tooth (1, Figure 93), use a

hammer and punch to drive locking pin (2)

and lock washer (3) out of tooth adapter

(4).

Once worn tooth has been removed, use a

putty knife to scrape adapter as clean as

possible.

Figure 93

Slide new tooth into position and insert

lock washer.

Insert locking pin into tooth and with a

hammer, drive pin in until lock washer

seats in locking groove.

4-60 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

BUCKET O-RING REPLACEMENT

WARNING!

Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye

protection when changing pins.

Inspect bucket O-rings on a routine basis.

If worn or damaged, replacement is

necessary.

HAOH640I

Figure 94

Roll old O-ring (1, Figure 95) onto boss (2)

around bucket pin (3). Remove bucket pin

and move arm or bucket link (4) out of way.

HAOC710L

Figure 95

Remove old O-ring and temporarily install

new O-ring (1, Figure 96) onto bucket boss

(2). Make sure that O-ring groove on both

bucket link

(4) and boss have been

cleaned.

Realign arm or link with bucket pin hole

and insert bucket pin (3, Figure 95).

HAOC701L

Figure 96

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-61

Doosan Solar 255LC-V. Operation and Maintenance Manual (2002) - page 3