DAEWOO DOOSAN SOLAR 55V PLUS EXCAVATOR OPERATION AND MAINTENANCE MANUAL Serial Number 1001 and Up – PDF DOWNLOAD
DESCRIPTION:
DAEWOO DOOSAN SOLAR 55V PLUS EXCAVATOR OPERATION AND MAINTENANCE MANUAL Serial Number 1001 and Up – PDF DOWNLOAD
Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item
TO THE OPERATOR OF A DAEWOO EXCAVATOR
Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
Please respect the importance of taking responsibility for your own safety, and that of other people who may be affected by your actions.
The safety information on the following pages is organized into the following sections
1. “General Safety Essentials” on page 5
2. “Location of Safety Labels” on page 5
3. “Summary of Safety Precautions for Lifting” on page 5
4. “Work-site Precautions” on page 6
5. “Operation” on page 9
6. “Equipment” on page 14
7. “Maintenance” on page 17
8. “Shipping and Transportation” on page 20
TABLE OF CONTENTS:
DEAWOO DOOSAN SOLAR 55V PLUS EXCAVATOR OPERATION AND MAINTENANCE MANUAL Serial Number 1001 and Up – PDF DOWNLOAD
Safety.......................................................................................................... 7 To the Operator of a Daewoo Excavator....................................................................... 7 Learn the Signal Words Used with the Safety Alert Symbol................................................ 9 Location of Safety Labels................................................................................... 10 1. Warnings for Operation, Inspection and Maintenance (19000688, 19000092)............................ 11 2. Warnings When Opening a Front Window (19000808, 19000093).......................................... 11 3. Warnings for High Voltage (19000689, 19000096)..................................................... 12 4. Warnings for a Highpressure Cylinder (19000122).................................................... 12 5. Warnings When Adjusting Track Tension (21903386A, 19000521)........................................ 12 6. Warnings for Leaving Operator's Seat (19000693, 19000094).......................................... 13 7. Warnings for Batteries Maintenance (21902533A, 19000100)........................................... 13 8. Warnings for Hot Coolant (19000692, 19000097)...................................................... 14 9. Warnings for Rotating Parts (19000694, 19000095, 19000557)........................................ 14 10. Warning Tag Used When Inspection and Maintenance (19000695, 19000098)........................... 15 11. Keep Out of the Swing Area (21903380, 19000163)................................................... 15 12. Warnings for Front Attachments (19000772).......................................................... 16 13. Warning for a Hot Surface (19000161)............................................................... 16 Summary of Safety Precautions for Lifting in Digging Mode................................................... 17 Unauthorized Modifications.................................................................................. 18 General Hazard Information.................................................................................. 18 Safety Rules............................................................................................ 18 Safety Features......................................................................................... 18 Inside Operator's Compartment........................................................................... 19 Clothing and Personal Protective Items.................................................................. 19 Breathing Masks, Ear Protection May Be Required......................................................... 20 Vibration Information................................................................................... 20 Mounting and Dismounting................................................................................ 20 Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 21 Precautions When Handling Fluids at High Temperature.................................................... 22 Asbestos Dust Hazard Prevention......................................................................... 22 Injury from Work Equipment.............................................................................. 23 Fire Extinguisher and First Aid Kit..................................................................... 23 Protection from Falling or Flying Objects............................................................... 24 Attachment Precautions.................................................................................. 24 Accumulator............................................................................................. 25 Indoor Ventilation...................................................................................... 25 Emergency Exit.......................................................................................... 25 Before Starting Engine...................................................................................... 26 Work Site Precautions................................................................................... 26 Checks Before Starting Engine........................................................................... 27 Engine Starting......................................................................................... 28 Before Operating Machine................................................................................ 28 Machine Operation........................................................................................... 29 When Swinging or Changing Direction of Travel........................................................... 29 Travel Precautions...................................................................................... 30 Traveling on Slopes..................................................................................... 31 Prohibited Operations................................................................................... 32 Precautions for Operation............................................................................... 32 Avoid Highvoltage Cables............................................................................... 33 Operate Carefully on Snow, Ice and in Very Cold Temperatures............................................ 33 Operations on Slopes.................................................................................... 34 Parking Machine......................................................................................... 34 Never Let Anyone Ride on Attachment..................................................................... 34 Maintenance................................................................................................. 35 Warning Tag............................................................................................. 35 Clean Before Inspection or Maintenance.................................................................. 35 Proper Tools............................................................................................ 36 Use of Lighting......................................................................................... 36 Fire Prevention and Explosion Prevention................................................................ 36 Burn Prevention......................................................................................... 37 Welding Repairs......................................................................................... 38 Warning for Counterweight and Front Attachment Removal.................................................. 38 Precautions for Removal, Installation, and Storage of Attachments....................................... 39 Precautions when Working on Machine..................................................................... 39 Lock Inspection Covers.................................................................................. 39 Crushing Prevention and Cutting Prevention.............................................................. 40 Track Tension Adjustments Require Caution............................................................... 40 Supports and Blocking for Work Equipment................................................................ 40 Action When Abnormally Is Found During Inspection....................................................... 41 Precautions with Highpressure Line, Tubes and Hoses.................................................... 41 Waste Materials......................................................................................... 42 Battery..................................................................................................... 43 Battery Hazard Prevention............................................................................... 43 Starting Engine With a Booster Cable.................................................................... 44 Towing...................................................................................................... 46 Precautions When Towing................................................................................. 46 Shipping and Transportation................................................................................. 47 Obey State and Local OvertheRoad Regulations.......................................................... 47 Excavator Rated Lift Capacity Tables........................................................................ 48 Operating Controls.............................................................................................. 53 Component Locations......................................................................................... 54 Operator's Area............................................................................................. 56 1. Instrument Panel..................................................................................... 57 2. Heater and Air Conditioner Control Switches.......................................................... 57 3. Seat................................................................................................. 57 4. Travel Levers (Right and left)....................................................................... 57 5. Righthand Work Lever (Joystick) With Horn Button (S/N 1001 thru 1200, 31210 thru 32182)............. 58 5a. Righthand Work Lever (Joystick) With Breaker Operation Button (S/N 32183 and Up)................... 58 6. Switch Panel......................................................................................... 58 7. Engine Speed Control Lever........................................................................... 58 8. Digital Clock........................................................................................ 59 9. Electrical Box....................................................................................... 59 10. Ashtray............................................................................................. 60 11. Cup Holder.......................................................................................... 60 12. Blade Control Lever................................................................................. 60 13. Boom Swing Pedal.................................................................................... 60 14. Stereo.............................................................................................. 61 15. Fuse Box............................................................................................ 61 16. Lefthand Work Lever (Joystick) With Horn Button / Breaker Operation Button (S/N 1001 thru 12....... 62 16a. Lefthand Work Lever (Joystick) With Horn Button (S/N 32183 and Up)................................ 62 17. Safety Lever........................................................................................ 62 Instrument Panel............................................................................................ 63 Inspection of the controls for operation................................................................ 63 1 Engine Coolant Temperature Gauge...................................................................... 64 2. Fuel Gauge........................................................................................... 64 3. Hour Meter........................................................................................... 64 4. Engine Oil Pressure Warning Light.................................................................... 65 5. Battery Warning Light................................................................................ 65 6. Engine Coolant Temperature Warning Light............................................................. 65 7. Air Cleaner Clogged Warning Light.................................................................... 66 8. Fuel Level Warning Light (S/N 1001 thru 1200, 31201 thru 32266)...................................... 66 8A. Overload Warning Light (Optional) (S/N 32267 and Up)................................................ 66 9. Preheat Indicator Light.............................................................................. 67 Switch Panel................................................................................................ 68 1. Starter Switch....................................................................................... 69 2. Cigar Lighter........................................................................................ 70 3. light Switch......................................................................................... 70 4. Travel Speed Selector Switch......................................................................... 70 5. Wiper Switch......................................................................................... 71 6. Windshield Washer Switch............................................................................. 71 7. Breaker Selector Switch (Optional) (S/N 1001 thru 1200, 31201 thru 32266)............................ 72 7A. Overload Warning Switch (Optional) (S/N 32267 and Up)............................................... 72 8. Warning Light Switch (Optional)...................................................................... 73 9. Travel Alarm Switch (Optional)....................................................................... 73 Heating and Airconditioning System......................................................................... 74 Location of Vents....................................................................................... 74 control switches........................................................................................ 74 Additional Operating Instructions....................................................................... 76 Stereo...................................................................................................... 77 Security and Area Code Setting.......................................................................... 77 Order to Set Up Security and Area Code.................................................................. 77 Front Panel............................................................................................. 78 1. Power/Volume Control Knob............................................................................ 78 2. Sound Mode Selector Button........................................................................... 78 3. Band Selector Switch................................................................................. 79 4. Tuning Up/Down....................................................................................... 79 5 & 6. Auto Memory and Preset Scan Button / Preset Station Button....................................... 80 7. Tape Slot............................................................................................ 80 8. Tape Ejection Button................................................................................. 80 9. Cassette and Program Buttons......................................................................... 81 10. Security Warning LED................................................................................ 81 11. Scan................................................................................................ 81 12. LCD................................................................................................. 82 Care of Stereo.......................................................................................... 82 Miscellaneous Electrical Devices............................................................................ 84 1. Cab Light............................................................................................ 84 2. Circuit Breaker...................................................................................... 84 3. Fusible Link (1)..................................................................................... 85 Fusible Link (2)........................................................................................ 85 4. Pilot Cutoff Switch.................................................................................. 85 Fuse Boxes.................................................................................................. 86 Seat Adjustment............................................................................................. 87 1. Forward / Backward Adjustment (Figure 62)............................................................ 87 2. Adjusting the Seat's Tilt and Seat Height (Figure 62)................................................ 87 3. Weight Adjustment (Figure 62)........................................................................ 87 4. Adjusting Reclining (Figure 62)...................................................................... 87 5. Moving the Whole Seat Setting Forward/Backward (Figure 62)........................................... 88 6. Angle Adjustment of Armrest (Figure 63).............................................................. 88 7. Headrest (Figure 63)................................................................................. 88 Recommendations for Limiting Vibrations................................................................. 88 Seat Belt................................................................................................... 89 Seat Belt Locking and Unlocking......................................................................... 89 Front Windows............................................................................................... 90 Front Upper Window...................................................................................... 90 Front Bottom Window..................................................................................... 91 Door Side Latch............................................................................................. 91 Cab Storage Compartments.................................................................................... 92 Window Glass Breaking Tool.................................................................................. 93 Safety Lever................................................................................................ 94 Operation....................................................................................................... 95 To Handle a New Excavator................................................................................... 95 Lubrication and Filters................................................................................. 95 Starting and Stopping the Engine............................................................................ 96 Inspection Before Starting Engine....................................................................... 96 Operational Checks Before Starting Engine............................................................... 96 Engine Start............................................................................................ 97 Cold Weather Starting................................................................................... 99 Hydraulic System Warmup................................................................................100 Hydraulic System Warmup – Cold Weather.................................................................101 Engine Shutdown.........................................................................................102 Check and Confirmation After Stopping Engine............................................................103 Starting Engine With a Booster Cable....................................................................104 Travel......................................................................................................106 General Travel Instructions.............................................................................106 Travel Control Lever Operation..........................................................................109 Travel Speed Switch.....................................................................................111 Work Levers (Joysticks) (ISO Style).....................................................................111 Blade Control Lever.....................................................................................113 Operating Precautions.......................................................................................114 Working in Water........................................................................................118 Traveling on weak ground................................................................................119 Grading.................................................................................................119 Be careful of blade position............................................................................120 Precautions for blade use...............................................................................120 Use care when crowding (moving in) front attachment.....................................................120 Be careful not to hit obstacles with blade..............................................................121 Be careful of track shoes...............................................................................121 Handle rubber crawler tracks carefully..................................................................121 Parking Excavator...........................................................................................123 Towing Procedure............................................................................................125 Hydraulic Breaker...........................................................................................126 Selection of Hydraulic Breaker..........................................................................126 Hydraulic Hoses and Tubing for Breaker..................................................................126 Hydraulic Breaker Operation.............................................................................126 To activate breaker (S/N 1001 thru 1200, 31210 thru 32182)..............................................129 To activate breaker (S/N 32183 and Up)..................................................................129 Hydraulic Oil and Filter Service Intervals..............................................................130 Operating Techniques........................................................................................131 Lifting.................................................................................................131 Operation Under Unusual Conditions..........................................................................133 Operation In Extreme Cold...............................................................................133 Operation In Extreme Heat...............................................................................134 Operation In Dusty or Sandy Areas.......................................................................135 Operation In Rainy or Humid Conditions..................................................................135 Operation In Salt Water Areas...........................................................................135 Operation at High Altitudes.............................................................................135 Inspection, Maintenance and Adjustment..........................................................................137 Preventive Maintenance......................................................................................137 Serial Numbers..........................................................................................138 Safety Precautions......................................................................................138 Preliminary Work Machine Setup for Maintenance..............................................................139 Table of Recommended Lubricants.............................................................................141 Fluid Capacities............................................................................................143 Lubrication and Service Chart...............................................................................143 Maintenance Intervals.......................................................................................147 10 Hour / Daily Service.................................................................................147 50 Hour / Weekly Service................................................................................147 250 Hour / Monthly Service..............................................................................147 500 Hour / 3 Month Service..............................................................................148 1,000 Hour / 6 Month Service............................................................................148 2,000 Hour / Yearly Service.............................................................................148 4,000 Hour / Biennial Service...........................................................................148 12,000 Hour / Six Year Service..........................................................................148 10 Hour / Daily Service.....................................................................................149 Grease Dozer Blade Pins.................................................................................149 Grease Boom, Arm and Front Attachment Pins..............................................................149 Grease Boom Swing Cylinder Head and Rod Pins (Optional).................................................149 Check Engine Oil Level..................................................................................149 Check Level of Hydraulic Oil Tank.......................................................................150 Check for Leaks In Hydraulic System.....................................................................150 Check Fuel Level........................................................................................151 Check Fuel Water Separator..............................................................................152 Check for Leaks in Fuel System..........................................................................152 Check Oil Level of Swing Reduction Device...............................................................153 Check Cooling System and Refill As Required.............................................................154 Clean Dust Net in Front of Radiator.....................................................................155 Check Level of Window Washer Liquid.....................................................................155 Inspect Bucket Teeth and Side Cutters for Signs of Wear.................................................155 Check Engine Fan Belt for Cracks, Wear and Correct Tension..............................................156 Inspect Seat Belt for Proper Operation..................................................................156 Inspect the Structure for Cracks and Faulty Welds.......................................................156 Check the Operation of All Switches.....................................................................156 Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......157 Start Engine, Check Starting Ability, and Observe Exhaust Color at Startup and at Normal Operati.......157 Check Operation of All Controls.........................................................................157 Inspect for Any Loose or Missing Nuts and Bolts.........................................................157 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, R.......157 Clean Engine Air Intake Precleaner......................................................................158 50 Hour / Weekly Service....................................................................................159 Perform All Daily Service Checks........................................................................159 Grease Boom, Arm and Front Attachment Pins..............................................................159 Grease Swing Bearing....................................................................................163 Boom Swing Cylinder Head Pin............................................................................163 Fuel Tank Drain Valve...................................................................................164 Change Engine Oil and Filter (After First 50 Hours).....................................................164 Check Battery Electrolyte Level and Condition...........................................................164 Clean Fuel Tank Strainer................................................................................164 250 Hour / Monthly Service..................................................................................165 Perform All Daily and 50 Hour Service Checks............................................................165 Change Swing Reduction Device Oil (Drain and Relief after First 250 Hours)..............................165 Change Engine Oil and Filter............................................................................165 Clean Outer Element of Two Stage Air Cleaner............................................................166 Drain Water and Sediment from Hydraulic Oil Tank........................................................168 Check Oil Level of Travel Reduction device (One On Each Side of Unit)...................................169 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear................................169 Inspect Fuel System Hose Clamps.........................................................................169 Replace Flow Full Hydraulic Oil Filter (After First 250 Hours)..........................................169 500 Hour / 3 Month Service..................................................................................170 Perform All Daily, 50, 100 and 250 Hour Service Checks..................................................170 Grease Swing Gear Pinion Teeth (500 Hours)..............................................................170 Change Fuel Filter......................................................................................170 Replace Outer and Inner Air Cleaner Filters.............................................................171 Clean Radiator, Oil Cooler and Air Conditioner Condenser Coil...........................................172 Replace Full Flow Hydraulic Oil Filter..................................................................173 1,000 Hour / 6 Month Service................................................................................174 Perform All Daily, 50, 100, 250 and 500 Hour Service Checks.............................................174 Grease Swing Reduction Device Bearing...................................................................174 Change Swing Reduction Device Oil.......................................................................174 Change Oil in Travel Reduction Device (One On Each Side of Unit)........................................176 Change Radiator Coolant (Ethylene Glycol Standard Life Antifreeze)....................................176 Check Air Conditioner Refrigerant.......................................................................177 Check, Adjust Valve Clearance **........................................................................178 Check, Torque Head Bolts **.............................................................................178 Clean Fuel Injection Priming Pump Strainer..............................................................178 2,000 Hour / Yearly Service.................................................................................179 Perform All Daily, 50, 150, 250, 500 and 1,000 Hour Service Checks......................................179 Hydraulic Oil Exchange and Suction Strainer Cleaning....................................................179 Change Radiator Coolant (Propylene Glycol Extended Life Antifreeze)...................................181 Check Alternator and Starter**..........................................................................182 Check All Rubber Antivibration Shock Mounts............................................................182 Perform and Record the Results of the Cycle Time Tests..................................................182 Inspect Machine To Check for Cracked or Broken Welds or Other Structural Damage.........................182 4,000 Hour / Biennial Service...............................................................................183 Major Parts Periodic Replacement......................................................................183 12,000 Hour / Six Year Service..............................................................................184 Hose Inservice Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................184 Air Conditioning System.....................................................................................185 Bolt and Nut Inspection.....................................................................................186 Bucket......................................................................................................187 Bucket Tooth Replacement................................................................................187 Bucket Oring Replacement...............................................................................188 Bucket Shimming Procedures..................................................................................190 New Bucket Installation.................................................................................190 Shimming Procedures for Installed Bucket................................................................190 Engine Cooling System.......................................................................................191 General.................................................................................................191 Antifreeze Concentration Tables.........................................................................192 Electrical System...........................................................................................193 Battery.................................................................................................193 Fuse....................................................................................................195 Fuel Transfer Pump..........................................................................................196 Handling of Accumulator (If Equipped).......................................................................198 Long Term Storage...........................................................................................199 Maintenance in Special Conditions...........................................................................200 Track Tension...............................................................................................201 Venting and Priming Hydraulic System........................................................................204 Main System Pump........................................................................................204 Hydraulic Cylinders.....................................................................................204 Swing Motor.............................................................................................205 Air Release of Travel Motor.............................................................................205 General Venting.........................................................................................205 Transportation..................................................................................................207 Loading and Unloading.......................................................................................207 Warning for Counterweight and Front Attachment Removal..................................................207 Loading.................................................................................................208 Unloading...............................................................................................210 Lifting With Sling..........................................................................................210 Troubleshooting.................................................................................................211 Attachments.................................................................................................211 Center Joint................................................................................................211 Control Lever...............................................................................................211 Control Valve...............................................................................................212 Hydraulic Cylinder..........................................................................................212 Hydraulic Motor.............................................................................................213 Hydraulic Pump..............................................................................................213 Relief Valve................................................................................................214 Swing System................................................................................................214 Travel......................................................................................................215 Specification...................................................................................................217 General Specifications......................................................................................217 Dimensions..................................................................................................219 Working Range...............................................................................................220 Approximate Weight of Workload Materials....................................................................221 Index...........................................................................................................223
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- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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S.M