Daewoo Doosan Solar 450-III Shop Manual 2023-7097E – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Solar 450-III Shop Manual 2023-7097E – PDF DOWNLOAD
Solar 450-111
Shop Manual
2023-7097E
Serial Number 0004 and Up
April 1997
Accessory Applications:
- The excavator has been primarily designed for moving earth with a bucket.
- For use as a grapple or for other object handling, contact Daewoo.
- Lifting work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no sideloading.
- DO NOT use the machine for activities for which it was not intended.
- DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration.
- Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.
- Refer to Page 1-1 o for additional information on Falling Object Protective Structures (F.O.P.S.) and other reinforcement systems.
Lifting Capacity Rating Configuration:
- Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration.
- Loads must be balanced and supported evenly.
- Use taglines to keep the load steady if wind conditions and large surface area are a problem.
- Work crew hand signals, individual tasks and safe procedures should all be universally understood before the lift is made.
NOTE:
- Before using the excavator to make lifts check for regulations that could apply.
- Regulations may require that all heavy lifting be done with single purpose equipment specifically designed for making lifts, or other local restrictions may apply.
- Making heavy lifts with a general purpose excavator that can be used for digging, loading, grading or other work may be expressly forbidden.
- Always follow all instructions, guidelines and restrictions for Safe Lifting in the Operation and Maintenance and Shop Manuals.
Locations of Safety Labels:
- Always keep these labels clean.
- If they are lost or damaged, replace them with a new label.
- It is the responsibility of the equipment owner and crew to provide essential safety information in the immediate vicinity of hazards.
- Safety labels may be available in languages other than English, or labels providing a warning for hazards other than those that follow may be available.
- Contact your Daewoo distributor to find out what labels are available.
TABLE OF CONTENTS:
Daewoo Doosan Solar 450-III Shop Manual 2023-7097E – PDF DOWNLOAD
SAFETY
To the Operator of a Daewoo Excavator …………………………………….. 1-1
General Safety Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Locations of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Summary of Safety Precautions for Lifting in Leveling Mode I . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Work-site Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 o
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Shipping and Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Excavator Rated Lift Capacity Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
SPECIFICATIONS
Excavator Machinery Plan ………………………………………………. 2-1
Excavator Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Excavator Engine Performance Curves ……………………………………… 2-4
Hydraulic System Component Specifications ………………………………….. 2-5
Hydraulic Pump Performance Characteristics …………………………………. 2-7
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
General Dimensions ………………………………………………….. 2-9
Working Range Diagram ……………………………………………….. 2-10
Reference Table – Approximate Weight of Workload Materials ………………………. 2-11
Performance Standards ………………………………………………… 2-13
Performance Tests …………………………………………………… 2-14
Excavator Rated Lift Capacity Tables ……………………………………….. 2-17
UPPER STRUCTURE
Operator’s Cab Removal Procedure ……………………………………….. 3-1
Falling Object Protective Structures (F.O.P.S.) …………………………………. 3-3
Front Attachment Pin Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Bucket Tooth Inspection and Replacement …………………………………… 3-5
Shimming Bucket Linkage ………………………………………………. 3-6
Bucket Attachment, Removal and Reversal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Removal and Installation of the Front Attachment ………………………………. 3-8
Engine Components and Accessories ………………………………………. 3-11
Fuel Tank Removal and Installation ………………………………………… 3-12
Engine Cooling System: Radiator/Oil Cooler ………………………………….. 3-13
Counterweight Removal and Installation …………………………………….. 3-16
Hydraulic System Description ……………………………………………. 3-18
Operation of Working Components ………………………………………… 3-21
Hydraulic System General Precautions ……………………………………… 3-24
Maintenance Service and Repair Procedures …………………………………. 3-25
Welding Precautions and Guidelines ……………………………………….. 3-26
Accumulator ……………………………………………………….. 3-27
Hydraulic Cylinder Operation …………………………………………….. 3-29
Hydraulic Attachment Cylinder, Components ………………………………….. 3-30
Hydraulic Cylinder Disassembly and Assembly ………………………………… 3-31
Swing Bearing Maintenance …………………………………………….. 3-37
450-111 Shop Manual
Swing Bearing Rebuild ………………………………………………… 3-38
Center Joint (Swivel) Overhaul/Repair ………………………………………. 3-40
Main Pump Assembly Description …………………………………………. 3-42
Pump Regulator Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Main Pump Parts List …………………………………………………. 3-51
Main Pump Disassembly and Reassembly …………………………………… 3-52
Reassembly of Main Pumps and Valve Block ………………………………….. 3-55
Pump Regulator Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Pump Regulator Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Swing Motor Basic Operation ……………………………………………. 3-64
Swing Motor Parts List ………………………………………………… 3-67
Swing Motor Disassembly ………………………………………………. 3-68
Swing Motor Reassembly ………………………………………………. 3-73
Swing Motor Gearbox Parts List ………………………………………….. 3-79
Swing Motor Gearbox Disassembly ………………………………………… 3-80
Swing Motor Gearbox Reassembly ………………………………………… 3-85
Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Remote Control Valve …………………………………………………. 3-108
Remote Control Valve Parts List ………………………………………….. 3-109
Remote Control Valve Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
Travel Control Valve Parts List ……………………………………………. 3-119
Travel Control Valve Disassembly and Reassembly ……………………………… 3-120
Hydraulic System Schematic …………………………………………….. 3-124
LOWER STRUCTURE
General Description ………………………………………………….. 4-1
Travel Motor Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Travel Motor Speed Reduction Gearbox Assembly and Parts List ……………………. 4-10
Travel Motor Speed Reduction Gearbox Disassembly ……………………………. 4-12
Travel Motor Speed Reduction Gearbox Reassembly …………………………….. 4-17
Front Idler Roller …………………………………………………….. 4-24
Lower Roller ……………………………………………………….. 4-27
Upper Roller ……………………………………………………….. 4-30
Track Spring and Track Adjusting Cylinder ……………………………………. 4-31
Track Tensioning …………………………………………………….. 4-32
Service Standards for Lower Travel Frame Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
ELECTRICAL SYSTEM
General Description ………………………………………………….. 5-1
24 Volt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Engine Start-up and Shutdown …………………………………………… 5-3
Cylinder Preheat – Intake Air Electrical Heater ………………………………… 5-4
Alternator Circuit …………………………………………………….. 5-5
Low Current Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Climate Control (Air Conditioning) Circuit …………………………………….. 5-9
Power Mode System Operating Components ………………………………….. 5-11
Instrument Panel …………………………………………………….. 5-12
Instrument Panel LED Displays and Input Terminal Connections …………………….. 5-14
Instrument Panel Connector Arrangement ……………………………………. 5-14
Instrument Panel Selector Switches ……………………………………….. 5-15
Instrument Panel Coolant Overheating Circuit …………………………………. 5-15
Instrument Panel Indicator Lights …………………………………………. 5-15
Instrument Panel Engine Oil Pressure Circuit …………………………………. 5-16
Start-up Electrical Test Circuit ……………………………………………. 5-16
Interior Lighting ……………………………………………………… 5-16
Hydraulic Pump Discharge Pressure Sensor ………………………………….. 5-16
Power Mode Circuit Instrument Panel Summary ……………………………….. 5-18
Power Mode System Basic Operation ………………………………………. 5-19
Power Mode Ill ……………………………………………………… 5-20
Power Mode 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Power Mode I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Swing Priority Circuit ………………………………………………….. 5-25
Swing and Arm Dump Combined Operation ………………………………….. 5-26
Swing Priority and Arm Crowd Recovery Function ………………………………. 5-27
Loading Work Mode ………………………………………………….. 5-28
Leveling Mode II …………………………………………………….. 5-29
Boom Up, Arm Crowd and Bucket Crowd Combined Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Leveling Mode I: Boom Up and Arm Crowd Combined Operation ……………………. 5-31
Forward Travel: Swing During Straight Travel ………………………………….. 5-32
Forward Travel: Arm Operation or Boom Operation While Traveling …………………… 5-33
Electrical Wiring Diagram ………………………………………………. 5-36
ENGINE
Wear Limits of Major Engine Components ……………………………………. 6-1
Engine Oil Pump Overhaul ……………………………………………… 6-10
Fuel Injection Pump Timing and Installation …………………………………… 6-13
Cylinder Head ………………………………………………………. 6-19
Engine Control System ………………………………………………… 6-23
Engine Throttle Controller ………………………………………………. 6-25
Engine Speed Sensor …………………………………………………. 6-27
INSPECTION, MAINTENANCE AND ADJUSTMENT
Periodic Inspection and Maintenance ………………………………………. 7-1
Maintenance Intervals …………………………………………………. 7-2
Table of Recommended Lubricants ………………………………………… 7-3
Inspection and Maintenance …………………………………………….. 7-4
Daily or Every 1 0 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Weekly or Every 50 Operating Hours ………………………………………. 7-8
150 Operating Hours ………………………………………………….. 7-11
Monthly or Every 250 Operating Hours ……………………………………… 7-12
Three Months or Every 500 Operating Hours …………………………………. 7-15
Six Months or Every 1,000 Operating Hours ………………………………….. 7-16
Annually or Every 2,000 Operating Hours ……………………………………. 7-19
General Maintenance Procedures …………………………………………. 7-19
Torque Specifications …………………………………………………. 7-20
Torque Wrench Extension Tools …………………………………………… 7-21
Flange and Thread Sealant Assembly Compounds ……………………………… 7-23
General Maintenance …………………………………………………. 7-25
Hydraulic System Cleanliness and Oil Leaks ………………………………….. 7-26
Engine Control Setting ………………………………………………… 7-27
Track Tensioning …………………………………………………….. 7-29
450-111 Shop Manual iii
TESTING, TROUBLESHOOTING AND ADJUSTING
Troubleshooting Recommendations ………………………………………… 8-1
Troubleshooting – Engine Problems ……………………………………….. 8-2
EPOS-III Self-diagnostic Codes …………………………………………… 8-6
Engine Throttle Controller ………………………………………………. 8-8
Troubleshooting Electrical System ……………………………………….. 8-10
Flow Meter and Flow Meter Kit Installation and Testing …………………………… 8-11
Pilot Pressure ………………………………………………………. 8-12
Power Mode Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Boom/Swing Priority ………………………………………………….. 8-14
Pressure Up Valve …………………………………………………… 8-15
Pump Input Power Control ……………………………………………… 8-16
Swing System Troubleshooting …………………………………………… 8-18
Troubleshooting Hydraulic Problems ………………………………………. 8-20
Troubleshooting – Control Valve ………………………………………….. 8-22
Troubleshooting – Travel Control Valve ………………………………………. 8-24
Troubleshooting – Joystick Control Valve …………………………………….. 8-25
Troubleshooting – Swing System ………………………………………….. 8-26
Troubleshooting – Swing Gearbox …………………………………………. 8-27
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PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
M.A