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

BUCKET SHIMMING PROCEDURES

NEW BUCKET INSTALLATION

If a new bucket is being installed on the excavator, measure the inside dimension between the bucket

ears and the outside dimension across the arm mounting boss.

Subtract the clearance on both sides from the difference of the two and shim accordingly, before

assembly.

WARNING!

To check end play (side-to-side) clearance at bucket attachment point, the bucket must be free to

move but at all other times lower it to the ground or use support blocks to immobilize this

assembly. Shut off engine and tag and lock out controls to prevent movement during this

procedure.

SHIMMING PROCEDURES FOR INSTALLED BUCKET

With bucket attached, curl bucket and arm outward and lower boom so that bucket teeth are pointing

away from excavator, just a few inches off ground. This position provides easy accessibility for

dimensional measurements.

Force bucket to one side and check for end

play (side-to-side) clearance under O-rings

at attachment point. Total clearance should

be 1 mm (0.04 in) between side face of

boss and inside edge of ear bushing (Y,

Figure 98). Too tight a fit (less than 1 mm

(0.04 in)) can cause excessive wear while

too much clearance may produce

excessive noise and potentially hazardous

slack control.

Recheck end play by forcing bucket

towards opposite side and repeating

clearance measurements.

If an adjustment is required, remove two

jam nuts (1, Figure 98) and bolt (2) from

(3). Add or remove shims

(4) as

required. Use equal amount of shims on

each side. Install bolt (2) and two jam nuts

(1). Jam nuts must clear boss by 1 - 2 mm

(0.04 - 0.08 in) at point (X).

Figure 98

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-63

TRACK TENSION

WARNING!

Safely measuring track tension requires two people. One person must be in the operator's seat,

running the controls to keep one side frame in the air, while the other person makes dimensional

checks. Take all necessary precautions to make sure the machine won’t move or shift position

during service. Warm up the engine to prevent stalls, travel the excavator to an area that

provides level, uniform ground support and/or use support blocks when necessary.

The track adjusting mechanism is under very high pressure. NEVER release pressure too

suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from

the fully tightened down position. Bleed off pressure slowly and keep your body away from the

valve at all times.

Track shoe link pins and bushings wear with normal usage, reducing track tension. Periodic adjustment is

necessary to compensate for wear and it may also be required by working conditions.

Track tension is checked by jacking up one

side of the excavator. See Figure 99. Place

blocking under frame while taking

measurement.

HAOC740L

Figure 99

Measuring the distance (A, Figure 100)

between the bottom of the side frame and

the top of the lowest crawler shoe.

Recommended tension for operation over

most types of terrain is

320 - 340 mm

(12.60 - 13.39 in)

NOTE: This measurement can be

thrown off if there is too much

mud or dirt or other material in

the track assembly. Clean off

the tracks before checking

clearance.

Figure 100

Too little sag in the crawler track (less than

320 mm (12.60 in) clearance) can cause

excessive

component wear. The

recommended adjustment can also be too

tight causing accelerated stress and wear

if ground conditions are wet, marshy or

muddy, or if the ground is hard and full of

rocks or gravel.

4-64 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

The increased clearance recommended for muddy ground conditions is between 340 - 380 mm

(13.39 - 15.0 in). The clearance should be approximately 380 mm (15.0 in) for operation over gravel,

rocky terrain, or over sand or snow.

WARNING!

The track adjusting mechanism is under very high pressure. NEVER release pressure too

suddenly. The grease cylinder valve should never be backed off more than 1 complete turn

from the fully tightened down position. Bleed off pressure slowly and keep your body away

from the valve at all times.

Track tension adjustments are made

through the grease fitting (1, Figure 101) in

the middle of each side-frame. Adding

grease increases the length of an

adjustment cylinder

(2). The longer the

adjustment cylinder, the greater the

pressure on the tension spring pushing the

track idler wheel outward.

If there is not enough slack or clearance in

the tracks and the adjustment is too tight,

the idler wheel and adjusting cylinder can

be retracted by bleeding off grease

HAOC760L

through hole in adjustment cylinder

(2,

Figure 101

Figure 101) by loosening valve slowly (3,

Figure 101).

WARNING!

Do not loosen or remove the grease fitting (1, Figure 101) until the pressure is entirely bleed

off by loosening valve (3, Figure 101) slowly.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-65

BOLT AND NUT INSPECTION

Inspect ALL fasteners after the first 50 hours of operation and every 250 hours thereafter. If any are loose

or are missing tighten them or install new hardware. Always use a calibrated torque wrench.

IMPORTANT

Always clean fasteners before tightening.

If counterweight is loose, contact a DAEWOO distributor or sales agent.

NO.

POINT TO BE INSPECTED

BOLT

QTY.

BOLT

TORQUE

DIA.

HEAD

kg•m

N•m

ft lb

SIZE

Joint bolt with engine

pump side

mounting bracket and

fan side

engine

Joint bolt & nut between

pump side

451

333

engine mounting

fan side

451

333

bracket and frame

Radiator mounting bolt

539

398

Tightening bolt for hydraulic oil tank

265

195

Tightening bolt for fuel tank

265

195

Tightening bolt for pump

431

318

Tightening bolt for control valve

265

195

Tightening bolt for swing reduction device

539

398

Tightening bolt for swing motor

333

246

Tightening bolt for battery

Joint bolt with cab mounting rubber and

6.7

frame

Joint bolt with cab mounting rubber and

206

152

cab

Joint bolt with swing bearing and upper

931

687

frame

Joint bolt with swing bearing and bottom

931

687

frame

Tightening bolt for travel device

539

398

Tightening bolt for sprocket

392

289

Tightening bolt for upper roller

205

152

Tightening bolt for bottom roller

265

195

4-66 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

NO.

POINT TO BE INSPECTED

BOLT

QTY.

BOLT

TORQUE

DIA.

HEAD

kg•m

N•m

ft lb

SIZE

Tightening bolt for track guard

265

195

Bolt for track shoes

408

765

564

205

152

Fixing bolt for front pin

392

289

MAINTENANCE IN SPECIAL CONDITIONS

NOTE: See “Operation Under Unusual Conditions” on page 3-38 for other recommendations.

CONDITIONS

MAINTENANCE REQUIRED

Operating in mud, water or rain.

Perform a walk around inspection to check for

any loose fittings, obvious damage to the

machine or any fluid leakage.

After completing operations, clean mud, rocks or

debris from the machine. Inspect for damage,

cracked welds or loosened parts.

Perform all daily lubrication and service.

If the operations were in salt water or other

corrosive materials, make sure to flush the

affected equipment with fresh water.

Operating in an extremely

dusty

hot

Clean the air intake filters on a more frequent

environment.

basis.

Clean the radiator and oil cooler fins to remove

embedded dirt and dust.

Clean the fuel system intake strainer and fuel

filter more frequently.

Inspect and clean as required the starter and

alternator.

Operating in rocky terrain.

Check the undercarriage and track assemblies

for damage or excessive wear.

Inspect for loose or damaged fittings or bolts.

Relax track tension.

On a more frequent basis, inspect the front end

attachments for damage or excessive wear.

Install a top guard and front guard as required for

protection against falling rock.

022-00031E Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-67

CONDITIONS

MAINTENANCE REQUIRED

Operating in extreme cold.

Use the proper fuel for the temperature

conditions.

Using a hydrometer, check the antifreeze to

make sure that it is providing the proper cold

weather freeze protection.

Verify the condition of the batteries. In extremely

cold weather remove the batteries at night and

store them in a warmer area.

Remove mud build-up as soon as possible to

prevent it from freezing to the undercarriage and

causing damage.

LONG TERM STORAGE

Perform the following if storing the excavator for more than one month.

CONDITIONS

MAINTENANCE REQUIRED

1. Cleaning

Pressure wash the undercarriage and track

assemblies. Inspect for damage or loose or missing

parts.

2. Lubrication

Perform all daily lubrication procedures.

Apply a coating of light oil to the exposed plated

metal surfaces, such as hydraulic cylinder rods, etc.

Apply a coating of light oil to all of the control

linkages and control cylinders (control valve spools,

etc.).

3. Battery

Remove the battery from the excavator or remove

the battery leads from the battery to fully charge

and store.

4. Cooling System

Inspect the coolant recovery tank to make sure that

the antifreeze level in the system is at the correct

level.

Every 90 days, use a hydrometer to measure the

protection level of the coolant. Refer to the

antifreeze/coolant protection chart to determine the

amount of protection the cooling system requires.

Add coolant as required.

5. Hydraulic System

Once a month, start the engine and follow the

"Hydraulic Oil Warm-up" procedures listed in this

manual.

4-68 Inspection, Maintenance and Adjustment

022-00031E Operation and Maintenance Manual

5TRANSPORTATION

Obey all local, state or federal regulations for the transportation of the excavator. If unsure of regulations

check with local authorities.

Check the intended route for road width, overhead clearances, weight restrictions, and traffic control

regulations. Special approval or permits may be required.

LOADING AND UNLOADING

DANGER!

Daewoo warns any user, that the removal of

the counterweight from the machine, front

attachment or any other part, may affect

the stability of the machine. This could

cause unexpected movement, resulting in

death or serious injuries. Daewoo is not

liable for any misuse.

Never remove the counterweight or front

attachment unless the upper structure is

in-line with the lower structure.

Never rotate the upper structure once the

counterweight or front attachment has

been removed.

HAAD4060

Figure 102

WARNING!

When transporting the machine, know the width, height, length and weight.

Loading or unloading the machine can be a dangerous operation. Make sure to run the engine at

the lowest speed setting, and travel at the slowest speed possible.

Make sure that the ramp being used can handle the weight of the machine. If required, add

blocking under the ramp for additional support.

Make sure that the ramp surface is free of grease or mud that could cause the machine to slip or

slide.

Make sure that the trailer is parked on firm, level ground before attempting to load/unload the

excavator.

If it is required to turn the machine while it is on the trailer, make sure to do this at the slowest

engine and travel speeds possible.

Make sure to secure the excavator onto the trailer as required by local transportation laws.

022-00031E Operation and Maintenance Manual

Transportation 5-1

TOTAL HEIGHT

TOTAL WIDTH

TOTAL LENGTH

WEIGHT

REMARKS

3,400 mm

3,200 mm

10,100 mm

24.65 metric tons

5.9 m Boom

(11' 2")

(10' 6")

(33' 2")

(27.61 tons)

3.0 m Arm

600 G Shoe

Make sure that the trailer is parked on a

firm and level surface. See Figure 1.

Make sure that the ramps that are being

used are designed to handle the weight of

the excavator. If required, add blocking

under the ramp to provide additional

support.

The ramp angle should be less than or not

exceeding a 15° angle. Ramps steeper

than this may cause a problem when

loading or unloading.

HAOC060L

Figure 1

The unit does not require disassembly for

normal over-the-road transportation. If the

boom and arm need to be removed, the

counterweight will place more weight on

the rear of the machine. Make sure to back

the excavator onto the trailer so that the

counterweight end of the excavator is

positioned on the ramp first. See Figure 2.

HAOC070L

Figure 2

Set the travel speed selection switch to "O"

(OFF) position. See Figure 3.

ARO0030L

Figure 3

5-2 Transportation

022-00031E Operation and Maintenance Manual

Turn "OFF" auto idle switch (1, Figure 4).

The indicator light (2) will not be lit.

Set engine speed to "LOW IDLE."

ARO0481L

Figure 4

Extend bucket and arm cylinders to

maximum length and then lower the boom

slowly.

HAOC080L

Figure 5

Set safety lever on "LOCK" position.

HAOA390L

Figure 6

10. Shut down engine by turning key to "O"

(OFF) position (Figure 7).

11. Remove key from starter switch.

HAOC340L

Figure 7

022-00031E Operation and Maintenance Manual

Transportation 5-3

12. Make sure to secure the excavator onto

the trailer before transporting. Place

blocking (1, Figure 8) in front of and behind

each track. Use chains or cable tie-downs

(2) as required by local transportation

laws.

13. Refer to the Dimensions for Transportation

table and drawing for overall machine

height and width measurements. Make

sure to position the excavator as shown. If

not transported in this position, the height

measurements may be different.

HAOC090L

Figure 8

LIFTING WITH SLING

WARNING!

Improper lifting can allow load to shift and

cause injury or damage.

Refer to “Specification” on page 7-1 of this

manual for information on weight and

dimensions.

Use properly rated cables and slings for

lifting.

Position machine for a level lift.

Lifting cables should have a long enough

length to prevent contact with the machine.

Spreader bars may be required.

Figure 9

NOTE: If spreader bars are used, be

sure that cables are properly

secured to them and that the

angle of the cables is factored

into the lift strength.

5-4 Transportation

022-00031E Operation and Maintenance Manual

6TROUBLESHOOTING

Anytime that a malfunction occurs, take immediate corrective action. Check for and investigate the cause

of the malfunction. A schedule maintenance program can prevent malfunctions from occurring by doing

preventative maintenance. A systematic approach should be taken to troubleshooting, since several

overlapping malfunctions may give the appearance of a problem that does not exist. If cause for the

malfunction cannot be determined, contact your Daewoo distributor. Never perform an adjustment of or

disassembly of, hydraulic components, electrical and electronic components, without first consulting a

Daewoo distributor.

ENGINE

PROBLEM

CAUSE

REMEDY

Starter does not operate.

Low battery power.

Charge battery.

Poor terminal contact.

Clean and tighten connections.

Starter switch failed.

Replace switch.

Starter relay failed.

Replace relay.

Starter controller failed.

Replace controller.

Wiring harness faulty.

Replace harness.

Battery relay failed.

Replace relay.

Blown fuse.

Replace fuse.

Starter engages, engine

Fuel gelled in cold weather.

Replace fuel.

does not start.

Fuel filters plugged.

Replace filters.

Water or dirt in fuel system.

Clean system and add new fuel.

Air in fuel system.

Purge air from system.

Engine stop control failed.

Replace stop control.

Engine stop relay failed.

Replace relay.

Blown fuse.

Replace fuse.

Engine starts, runs only at

Engine oil viscosity incorrect.

Change oil.

low speed or shuts down.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine stop motor cable out

Readjust.

adjustment.

Engine speed control cable out of

Readjust.

adjustment.

022-00031E Operation and Maintenance Manual

Troubleshooting 6-1

PROBLEM

CAUSE

REMEDY

Engine knocks, runs

Low engine oil.

Refill.

unevenly or surges.

Plugged air intake system.

Clean system and replace filter.

Injection pump out of adjustment.

Contact your Daewoo dealer.

Plugged fuel filter.

Replace fuel filter.

Water or dirt in fuel system.

Clean system and add new fuel.

Clogged or dirty fuel injectors.

Clean injectors.

Engine has poor power.

Plugged air intake system.

Clean system and replace filter.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine speed control cable out of

Readjust.

adjustment.

Injection pump out of adjustment.

Contact your Daewoo dealer.

Valve backlash faulty.

Adjust backlash.

Engine runs hot.

Low coolant level.

Add coolant.

Thermostat faulty.

Replace thermostat.

Radiator cap faulty.

Replace radiator cap.

Radiator core plugged.

Clean radiator.

Oil cooler core plugged.

Clean oil cooler.

Fan belt loose or damaged.

Tighten or replace as required.

Temperature sensor faulty.

Replace sensor.

HYDRAULIC SYSTEM

PROBLEM

CAUSE

REMEDY

None of the controls

Hydraulic pump failed.

Contact your Daewoo dealer.

function (loud noise from

Low hydraulic oil level.

Add hydraulic oil as required.

pumps).

Suction line plugged or damaged.

Clean or replace as required.

None of the controls

Pilot pump failure.

Contact your Daewoo dealer.

function (no noise from

Cut off solenoid valve failed.

Replace solenoid.

pumps).

Pilot cutoff switch is ON.

Adjust

pilot

cutoff

switch

clearance.

6-2 Troubleshooting

022-00031E Operation and Maintenance Manual

PROBLEM

CAUSE

REMEDY

All actuators have low

Low hydraulic oil level.

Add hydraulic oil as required.

power.

Suction filter clogged.

Clean filter.

Hydraulic pumps faulty.

Contact your Daewoo dealer.

Main relief pressure too low.

Contact your Daewoo dealer.

Hydraulic pumps excavating.

Bleed air from hydraulic pumps.

Only one or two actions

Overload relief pressure too low.

Reset pressure.

have little or no power.

Make-up check valve leaking.

Clean or replace as required.

Control valve spool faulty.

Replace valve spool.

Dirt in valve spool.

Clean or replace as required.

Actuator failed.

Repair or replace as required.

Cylinder seal failed.

Repair or replace as required.

Cylinder rod damaged.

Repair or replace as required.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

Oil temperature too high.

Oil cooler faulty.

Contact your Daewoo dealer.

Fan belt loose.

Tighten fan belting as required.

SWING SYSTEM

PROBLEM

CAUSE

REMEDY

No swinging motion.

Swing brake valve faulty.

Replace brake valve.

Hydraulic timer faulty.

Replace timer.

Low brake release pressure.

Adjust pressures.

Swing motor failed.

Replace swing motor.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

Swing motion jerky.

Swing gear worn.

Replace swing gear.

Swing bearing damaged.

Replace bearing.

Improper lubrication.

Add grease.

022-00031E Operation and Maintenance Manual

Troubleshooting 6-3

TRAVEL SYSTEM

PROBLEM

CAUSE

REMEDY

Travel motion does not

Center joint leaking.

Repair or replace as required.

function.

Parking brake will not release.

Repair parking brake.

Travel motor failed.

Repair or replace as required.

Remote control valve failed.

Repair or replace as required.

Wrong pilot line connection.

Reconnect pilot lines.

Travel speed is too low.

Track tension too high or too low.

Adjust tension.

Damaged rollers or idlers.

Repair or replace as required.

Track frame damaged.

Repair as required.

Parking brake will not release.

Repair parking brake.

ELECTRICAL SYSTEM

PROBLEM

CAUSE

REMEDY

Battery will not hold a

Low battery power.

Clean and retighten.

charge.

Alternator belt loose or bad.

Tighten or replace belt.

Loose or corroded terminals.

Tighten or replace as required.

Alternator faulty.

Repair or replace as required.

Low battery power.

Internal battery short.

Replace battery.

Short circuit in wiring.

Repair as required.

Engine speed is not

Speed control dial failed.

Replace control dial.

controllable.

Throttle controller failed.

Replace controller.

Speed control motor failed.

Repair or replace as required.

Blown fuse.

Replace fuse.

Wiring harness damaged.

Repair or replace as required.

Connector failed.

Repair or replace as required.

Power mode selector does

Blown fuse.

Replace fuse.

not work.

Instrument panel failed.

Replace panel.

Connector failed.

Replace connector.

Wiring harness damaged.

Repair or replace as required.

e-EPOS controller failed.

Repair or replace as required.

6-4 Troubleshooting

022-00031E Operation and Maintenance Manual

7SPECIFICATION

STANDARD SPECIFICATION

SPECIFICATION

COMPONENT

METRIC

ENGLISH

Bucket

SAE

1.1 m³

1.44 yd³

capacity

CECE

0.95 m³

1.24 yd³

Equipment weight

24.6 metric tons

27.1 tons

Engine

Model

DB58TIS

Type

Water cooled - 6 cylinders

Rated output

170 ps @2,000 rpm

168 hp @2,000 rpm

Maximum torque

70 kg•m @ 1,400 rpm

506 ft lb @ 1,400 rpm

Fuel tank capacity

370 liters

98 U.S. gal.

Hydraulic

Type

Axial piston

pump

Discharging pressure

5,000 psi

350 kg/cm²

Maximum discharge quantity

2 x 224 liters/min

2 x 59.14 U.S. gpm

Hydraulic oil

Tank Level

155 liters

41 U.S. gal.

capacity

System

290 liters

77 U.S. gal.

Performance

Digging

Bucket

15.2 metric tons

16.8 tons

capability

Arm

11.8 metric tons

13.0 tons

Swing speed

10.9 rpm

Travel speed

High speed

5.0 km/h

3.11 MPH

Low speed

3.5 km/h

2.17 MPH

Traction force

High speed

14.5 metric tons

15.98 tons

Low speed

21.1 metric tons

23.26 tons

Gradeability

35° (70% slope)

Ground pressure

7.1 psi

0.50 kg/cm²

Ground clearance

450 mm

17.2 in

Track shoe width

600 mm

23.6 in

Upper roller qty.

2 per side

Bottom roller qty.

10 per side

022-00031E Operation and Maintenance Manual

Specification 7-1

OVERALL DIMENSIONS

AYO0080L

Figure 1

DIMENSION

5.900 M (19' 4'') BOOM

3.0 M (9' 10'') ARM

2.5 M (8' 2'') ARM

3.5 M (11' 6'') ARM

10,110 mm (33’ 2")

10,140 mm (33’ 3")

10,120 mm (33’ 2")

3,035 mm (19’ 11")

7,075 mm (23’ 3")

7,105 mm (23’ 4")

7,085 mm (23’ 3")

3,830 mm (12’ 7")

4,635 mm (15’ 2")

1,110 mm (3’ 8")

3,250 mm (10’ 8")

3,470 mm (11’ 5")

3,200 mm (10’ 6")

1,350 mm (4’ 5")

1,360 mm (4’ 6")

2,600 mm (8’ 6")

3,200 mm (10’ 6")

600 mm (23.62 in)

450 mm (1’ 6")

3,000 mm (9’ 10")

7-2 Specification

022-00031E Operation and Maintenance Manual

WORKING RANGE

G.L

-1

-2

-3

-4

-5

-6

-7

AYO0090L

Figure 2

DIM.

5.900 M (19' 4'') BOOM

3.0 M (9' 10'') ARM

2.5 M (8' 2'') ARM

3.5 M (11' 6'') ARM

Max. digging radius

10,240 mm (33’ 7")

9,740 mm (31’ 11")

10,710 mm (35’ 2")

Max. digging depth

6,790 mm (22’ 3")

6,290 mm (20’ 8")

7,290 mm (23’ 11")

Max. digging height

9,500 mm (31’ 2")

9,180 mm (30’ 1")

9,720 mm (31’ 11")

Max. dump height

6,640 mm (21’ 9")

6,360 mm (20’ 10")

6,860 mm (22’ 6")

Min. swing radius

4,110 mm (13’ 6")

4,160 mm (13’ 8")

4,150 mm (13’ 7")

022-00031E Operation and Maintenance Manual

Specification 7-3

APPROXIMATE WEIGHT OF WORKLOAD MATERIALS

IMPORTANT

Weights are approximations of estimated average volume and mass. Exposure to rain, snow or

ground water; settling or compaction due to overhead weight and chemical or industrial

processing or changes due to thermal or chemical transformations could all increase value of

weights listed in table.

LOW WEIGHT OR

MEDIUM WEIGHT OR

HIGH WEIGHT OR

DENSITY

MATERIAL

1,100 KG/M³

1,600 KG/M³

2,000 KG/M³

(1,850 LB/YD³), OR

(2,700 LB/YD³), OR

(3,370 LB/YD³), OR LESS

LESS

Charcoal

401 kg/m³

---------------------

(695 lb/yd³)

Coke, blast furnace size

433 kg/m³

---------------------

(729 lb/yd³)

Coke, foundry size

449 kg/m³

---------------------

(756 lb/yd³)

Coal, bituminous slack,

801 kg/m³

---------------------

piled

(1,350 lb/yd³)

Coal, bituminous r. of m.,

881 kg/m³

---------------------

piled

(1,485 lb/yd³)

Coal, anthracite

897 kg/m³

---------------------

(1,512 lb/yd³)

Clay, DRY, in broken

1,009 kg/m³

---------------------

lumps

(1,701 lb/yd³)

Clay, DAMP, natural bed

1,746 kg/m³

---------------------

(2,943 lb/yd³)

Cement, Portland, DRY

1,506 kg/m³

---------------------

granular

(2,583 lb/yd³)

Cement, Portland, DRY

1,362 kg/m³

---------------------

clinkers

(2,295 lb/yd³)

Dolomite, crushed

1,522 kg/m³

---------------------

(2,565 lb/yd³)

Earth, loamy, DRY, loose

1,202 kg/m³

---------------------

(2,025 lb/yd³)

Earth, DRY, packed

1,522 kg/m³

---------------------

(2,565 lb/yd³)

7-4 Specification

022-00031E Operation and Maintenance Manual

LOW WEIGHT OR

MEDIUM WEIGHT OR

HIGH WEIGHT OR

DENSITY

MATERIAL

1,100 KG/M³

1,600 KG/M³

2,000 KG/M³

(1,850 LB/YD³), OR

(2,700 LB/YD³), OR

(3,370 LB/YD³), OR LESS

LESS

Earth, WET, muddy

1,762 kg/m³

---------------------

(2,970 lb/yd³)

Gypsum, calcined,

961 kg/m³

---------------------

(heated, powder)

(1,620 lb/yd³)

Gypsum, crushed to 3

1,522 kg/m³

---------------------

inch size

(2,565 lb/yd³)

Gravel, DRY, packed

1,810 kg/m³

---------------------

fragments

(3,051 lb/yd³)

Gravel, WET, packed

1,922 kg/m³

---------------------

fragments

(3,240 lb/yd³)

Limestone, graded above

1,282 kg/m³

---------------------

(2,160 lb/yd³)

Limestone, graded

1,362 kg/m³

---------------------

1-1/2 or 2

(2,295 lb/yd³)

Limestone, crushed

1,522 kg/m³

---------------------

(2,565 lb/yd³)

Limestone, fine

1,602 kg/m³

---------------------

(2,705 lb/yd³)

Phosphate, rock

1,282 kg/m³

---------------------

(2,160 lb/yd³)

Salt

929 kg/m³

---------------------

(1,566 lb/yd³)

Snow, light density

529 kg/m³

---------------------

(891 lb/yd³)

Sand, DRY, loose

1,522 kg/m³

---------------------

(2,565 lb/yd³)

Sand, WET, packed

1,922 kg/m³

---------------------

(3,240 lb/yd³)

Shale, broken

1,362 kg/m³

---------------------

(2,295 lb/yd³)

Sulphur, broken

529 kg/m³

---------------------

(1,620 lb/yd³)

022-00031E Operation and Maintenance Manual

Specification 7-5

1INDEX

Numerics

Cigar Lighter 2-11

10 Hour / Daily Service 4-12

Circuit Breaker 2-43

1000 Hour / 6 Month Service 4-39

Clock 2-27

12,000 Hour / Six Year Service 4-49

Cold Weather Hydraulic System Warm-Up 3-11

2000 Hour / Yearly Service 4-45

Cold Weather Starting 3-6

250 Hour / Monthly Service 4-26

Communication

4000 Hour / Biennial Service 4-48

Error Warning 2-20

50 Hour / Weekly Service 4-22

Indicator 2-19

500 Hour / 3 Month Service 4-31

Component Locations 2-2

Coolant Temperature Warning Light 2-17

Cooling System

Oil Cooler Dust Net 4-18

Adjust Valve Clearance 4-45

Radiator Coolant 4-41

Air Intake System 4-20

Refill Cooling System 4-18

Outer Element of Air Cleaner 4-26

Cooling Systems

Replace Outer Air Cleaner Element 4-36

Clean Radiator, Oil Cooler and Air

Alternator and Starter 4-45

Conditioner Condenser Coil 4-35

Anti-vibration Shock Mounts 4-45

Cracks and Faulty Welds 4-20

Ashtray 2-54

Cycle Time Tests 4-45

Auto Idle Mode 3-23

Auto Idle Selection Button 2-24

Description of Lubrication and Service Chart 4-8

Display Selection Button 2-25

Batteries 4-30

Door Side Latch 2-52

Battery 4-55

Box Door 2-53

Electrolyte Level 4-56

Terminals 4-56

Electrical System 4-55, 6-4

Voltage 2-20

Emergency Glass Breaking Tool 2-55

Bolt and Nut Inspection 4-66

Engine 6-1

Boom, Arm and Front Attachment Pins 4-22

Adjust Valve Clearance 4-45

Boost Mode 3-24

Check and Adjust Engine 4-44

Booster Cable 3-8

Coolant Temperature Gauge 2-15

Booster Switch 2-12

Cover 2-53

Breaker Switch 2-12

Fan Belt 4-27, 4-28

Bucket 4-60

Head Bolt Torques 4-45

Installation 4-63

Oil and Filter 4-25, 4-29

O-ring 4-61

Oil Level 4-12

Shimming Procedures 4-63

Oil Pressure Warning Light 2-17

Shimming Procedures for Installed Bucket

Shutdown 3-12

4-63

Speed 2-20

Teeth and Side Cutters 4-19

Speed Control Dial 2-6

Tooth 4-60

Start 3-4

Start and Stop 3-2

Excavator Rated Lift Capacity Tables 1-41

Cab Storage Compartments 2-54

Cab Work Light Switch 2-9

Ceiling Cover 2-48

Fan Belt 4-25

Charge Warning Light 2-17

Filter / Oil Info 2-28

Check and Confirmation After Stopping Engine

Filter State 2-22

3-13

Front End Attachments 4-30

022-00031E Operation and Maintenance Manual

Index 1-1

Front Hydraulic Pump Pressure 2-21

General Venting 4-51

Front Upper Windows 2-49

Hydraulic Breaker 3-32

Front Windows 2-49

Hydraulic Hoses and Tubing 3-32

Fuel

Oil and Filter 3-35

Filter 4-25, 4-37

Operation 3-32

Gauge 2-15

Selection 3-32

Injection Priming Pump Strainer 4-43

Hydraulic Cylinders 4-50

Level 4-15

Hydraulic Oil

System 4-38

Exchange 4-45

Transfer Pump 4-53

Filter 4-32

Tank Drain Valve 4-25

Tank 4-13

Transfer Pump 4-53

Leaks in the Hydraulic System 4-14

Fuse

Main System Pump 4-50

Box 4-57

Swing Motor 4-51

Boxes 2-42, 4-57

Travel Motor 4-51

Fuses 4-57

Warm-up 3-10

Fusible Link 2-44

Identification 4-58

Indicator

Communication Indicator 2-19

Gauges

Indicator Lights

Engine Coolant Temperature Gauge 2-15

Charge Warning Light 2-17

Fuel Gauge 2-15

Coolant Temperature Warning Light 2-17

Hour Meter 2-16

Engine Oil Pressure Warning Light 2-17

Multi-Function Gauge 2-16, 2-19

Overload Warning Light 2-18

General Venting 4-51

Preheating Completion Light 2-18

Work Light 2-18

Inspecting Engine Before Starting 3-2

Inspection, Maintenance and Adjustment 4-1

Handling a New Excavator 3-1

Instrument Panel 2-12, 2-14

Handling of Accumulator 4-52

Head Bolt Torques 4-45

Headlight Switch 2-7

Heater and Air Conditioner 2-30

Joystick -- Left Hand 2-12

Additional Operating Instruction 2-34

Blower Fan Switches 2-32

Control Panel 2-11

Language 2-27

Fan and Air-Conditioner Switch 2-31

Leaks in the Fuel System 4-15

Filter 4-34

Leaks in the Hydraulic System 4-14

Location of Controls and Vents 2-30

Left Hand Work Lever (Joystick) 2-12

Memory Function of Used Mode 2-34

Levers

Operation Panel 2-31

Adjusting the Seat Forward 2-45

Refrigerant 4-43

Adjusting the Seat's Angle 2-45

Selection Switch for Wind Direction 2-33

Angle Adjustment of Armrest 2-46

System 4-59

Moving the Total Seat Setting Forward 2-46

Temperature Control Switch 2-32

Safety Lever 2-13

Ventilation Selection Switch 2-34

Weight Adjustment Knob 2-45

Horn Switch 2-12

Lifting 3-36

Hose Clamps 4-30

Lifting With Sling 5-4

Hour Meter 2-16

Loading and Unloading 5-1

Hydraulic Oil

Locations of Safety Labels 1-4

Exchange 4-45

Long Term Storage 4-68

Filter 4-30, 4-32

Lubrication and filters 3-1

Tank 4-13

Lubrication and Service Chart 4-7

Hydraulic System 6-2

1-2 Index

022-00031E Operation and Maintenance Manual

Power Mode 3-22

Magnetic Clutch 4-59

Power Mode Selection Button 2-23

Main Menu 2-26

Power Socket 2-11

Maintenance in Special Conditions 4-67

Preliminary

Work Machine Setup for

Maintenance Intervals 4-10

Maintenance 4-3

Miscellaneous Access Doors 2-53

Pump Pressure

Mode Selection 3-22

Rear Pump 2-21

Mode Selection Buttons 2-23

Multi-Function

Display Selection Switch 2-16

Radiator Coolant 4-41

Gauge 2-16, 2-19

Rear Hydraulic Pump Pressure 2-21

Refill Cooling System 4-18

Nuts and Bolts 4-30

Safety 1-1

Safety Lever 2-13, 3-14

Oil Cooler Dust Net 4-18

Safety Precautions 4-2

Oil Level of Travel Reducer 4-30

Seat 2-45

Opening the Window 2-49

Seat Adjustment

Operating

Adjusting the Seat Forward 2-45

Controls 2-1

Adjusting the Seat's Angle 2-45

Instructions 3-20

Angle Adjustment of Armrest 2-46

Precautions 3-25

Headrest 2-46

Techniques 3-36

Moving the Total Seat Setting Forward 2-46

Operation 3-1

Weight Adjustment 2-45

Operation In

Seat Belt 2-47, 4-20

Extreme Cold 3-38

Serial Numbers 4-2

Extreme Heat 3-38

Setting Clock 2-27

High Altitudes 3-40

Shimming Procedures for Installed Bucket 4-63

Rainy or Humid Conditions 3-40

Shutdown

Salt Water Areas 3-40

Check and Confirmation After Stopping

Operation of All Switches 4-20

Engine 3-13

Operation Under Unusual Conditions 3-38

Engine Shutdown 3-12

Operational Checks Before Starting Engine 3-2

Parking Excavator 3-30

Operational Controls and Panels 2-5

Side Door 2-53

Operator’s Area 2-4

Specification 7-1

Operator’s Compartment Light 2-43

Standard Specification 7-1

Outer Air Cleaner Element 4-36

Starter Switch 2-6

Outer Element of Air Cleaner 4-26

Starting Engine Using a Booster Battery 3-8

Overall Dimensions 7-2

Start-up

Overload Warning

Cold Weather Hydraulic System Warm-Up

Light 2-18

3-11

Switch 2-10

Cold Weather Starting 3-6

Engine Start 3-4

Hydraulic System Warm-up 3-10

Inspection Before Starting Engine 3-2

Panels

Operational Checks Before Starting Engine

Air Conditioner Control Panel 2-11

3-2

Heater and Air Conditioner Operation Panel

Starting Engine Using a Booster Battery 3-8

2-31

Stereo 2-35

Instrument Panel 2-14

Care of Stereo 2-40

Parking Excavator 3-30

On/Off Switch 2-9

Pilot Cutoff Switch 2-43

Structural Damage 4-45

Pilot Filter 4-30, 4-33

Suction Strainer 4-45

Pins and Bushings 4-30

022-00031E Operation and Maintenance Manual

Index 1-3

Swing

Track Tension 4-64

Bearing 4-24

Transportation 5-1

Gear and Pinion 4-31

Travel 3-15

Motor 4-51

Control Lever Operation 3-18

Reduction Device 4-17, 4-26, 4-39

Instructions 3-16

System 6-3

Motor 4-51

Switches

Reduction Device 4-30, 4-40

Auto Idle Selection Button 2-24

Speed Selection Switch 2-8

Automatic Travel Speed Control 3-15

System 6-4

Blower Fan Switches 2-32

Travel/Swing Alarm Switch 2-10

Booster Switch 2-12

Troubleshooting 6-1

Breaker Switch 2-12

Cab Work Light Switch 2-9

Cigar Lighter 2-11

Unloading and Loading 5-1

Display Selection Button 2-25

Engine Speed Control 3-20

Engine Speed Control Dial 2-6

Venting and Priming Hydraulic System 4-50

Headlight Switch 2-7

General Venting 4-51

Heater and Air Conditioner Fan Switch 2-31

Hydraulic Cylinders 4-50

Heater and Air Conditioner Selection Switch

Main System Pump 4-50

for Wind Direction 2-33

Swing Motor 4-51

Heater and Air Conditioner Ventilation

Travel Motor 4-51

Selection Switch 2-34

Horn Switch 2-12

Multi-Function Display Selection Switch 2-16

Overload Warning Switch 2-10

Warning Light 2-9

Pilot Cutoff Switch 2-43

Washer Switch 2-8

Power Mode Selection Button 2-23

Water Separator 4-16

Power Socket 2-11

Weight of Workload Materials 7-4

Starter Switch 2-6

Window Washer Liquid 4-19

Stereo On/Off Switch 2-9

Windows

Travel Speed Selection Switch 2-8

Breaking Tool 2-55

Travel/Swing Alarm Switch 2-10

Front 2-49

Warning Light 2-9

Front Upper 2-49

Washer Switch 2-8

Opening 2-49

Wiper Switch 2-7

Work Levers (Joysticks) (ISO Style) 3-24

Work Mode 3-23

Work Mode Selection Button 2-24

Table of Recommended Lubricants 4-5

Working Range 7-3

Towing Procedure 3-31

Track Assemblies 4-25

1-4 Index

022-00031E Operation and Maintenance Manual

1PUBLICATION REQUEST FOR

PROPOSED REVISION

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Attention: Publications

Doosan Solar 255LC-V. Operation and Maintenance Manual (2002) - page 4