Daewoo Excavator Solar 55-V Plus Shop Manual 023-00045AE – PDF

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Daewoo Excavator Solar 55-V Plus Shop Manual 023-00045AE – PDF DOWNLOAD

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Daewoo Excavator Solar 55-V Plus Shop Manual 023-00045AE – PDF DOWNLOAD

Language : English
Pages : 460
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Daewoo Excavator Solar 55-V Plus Shop Manual 023-00045AE – PDF DOWNLOAD

Publication Request for Proposed Revision.....................................................................  0
Safety........................................................................................................  5
	Track Excavator Safety S0102035K..........................................................................  7
		To the Operator of a Daewoo Excavator................................................................. 11
			Learn the Signal Words Used with the Safety Alert Symbol.......................................... 13
		General Safety Essentials............................................................................. 14
			Accessory Applications............................................................................ 14
			Lifting Capacity Rating Configuration............................................................. 14
		Location of Safety Labels............................................................................. 14
		Summary of Safety Precautions for Lifting in Digging Mode............................................. 15
		Unauthorized Modifications............................................................................ 16
		General Hazard Information............................................................................ 16
			Safety Rules...................................................................................... 16
			Safety Features................................................................................... 16
			Inside Operator's Compartment..................................................................... 17
			Clothing and Personal Protective Items............................................................ 17
			Breathing Masks, Ear Protection May Be Required................................................... 18
			Vibration Level Information....................................................................... 18
			Mounting and Dismounting.......................................................................... 19
			Fuel, Oil and Hydraulic Fluid Fire Hazards........................................................ 20
			Precautions When Handling Fluids at High Temperature.............................................. 20
			Asbestos Dust Hazard Prevention................................................................... 21
			Injury from Work Equipment........................................................................ 21
			Fire Extinguisher and First Aid Kit............................................................... 22
			Protection from Falling or Flying Objects......................................................... 22
			Attachment Precautions............................................................................ 23
			Accumulator....................................................................................... 23
			Indoor Ventilation................................................................................ 24
			Emergency Exit.................................................................................... 24
		Before Starting Engine................................................................................ 25
			Work Site Precautions............................................................................. 25
			Checks Before Starting Engine..................................................................... 26
			Engine Starting................................................................................... 27
			Before Operating Machine.......................................................................... 27
		Machine Operation..................................................................................... 28
			When Swinging or Changing Direction of Travel..................................................... 28
			Travel Precautions................................................................................ 29
			Traveling on Slopes............................................................................... 30
			Prohibited Operations............................................................................. 30
			Precautions for Operation......................................................................... 31
			Avoid Highvoltage Cables......................................................................... 32
			Operate Carefully on Snow, Ice and in Very Cold Temperatures...................................... 32
			Operations on Slopes.............................................................................. 33
			Parking Machine................................................................................... 33
			Never Let Anyone Ride on Attachment............................................................... 33
		Maintenance........................................................................................... 34
			Warning Tag....................................................................................... 34
			Clean Before Inspection or Maintenance............................................................ 34
			Proper Tools...................................................................................... 35
			Use of Lighting................................................................................... 35
			Fire Prevention and Explosion Prevention.......................................................... 35
			Burn Prevention................................................................................... 36
			Welding Repairs................................................................................... 37
			Warning for Counterweight and Front Attachment Removal............................................ 37
			Precautions for Removal, Installation, and Storage of Attachments................................. 38
			Precautions when Working on Machine............................................................... 38
			Lock Inspection Covers............................................................................ 38
			Crushing Prevention and Cutting Prevention........................................................ 39
			Track Tension Adjustments Require Caution......................................................... 39
			Supports and Blocking for Work Equipment.......................................................... 39
			Action When Abnormally Is Found During Inspection................................................. 40
			Precautions with Highpressure Line, Tubes and Hoses.............................................. 40
			Waste Materials................................................................................... 41
		Battery............................................................................................... 42
			Battery Hazard Prevention......................................................................... 42
			Starting Engine With a Booster Cable.............................................................. 43
		Towing................................................................................................ 45
			Precautions When Towing........................................................................... 45
		Shipping and Transportation........................................................................... 46
			Obey State and Local OvertheRoad Regulations.................................................... 46
		Lifting With Sling.................................................................................... 46
Specifications................................................................................................ 47
	Specifications for Solar 55V PLUS S0202035K.............................................................. 49
		General Description................................................................................... 51
		Component Locations................................................................................... 52
		General Dimensions.................................................................................... 54
		Working Range......................................................................................... 56
		General Specifications................................................................................ 58
		Weight Table.......................................................................................... 60
		Machine Number........................................................................................ 61
		Working Attachments................................................................................... 62
			Pin and Bushing Wear Limits....................................................................... 62
			Crosssection of Pins............................................................................. 64
			Measuring Cylinder Drift.......................................................................... 67
			Measuring Speed................................................................................... 68
General Maintenance........................................................................................... 71
	General Maintenance Procedures S0302000................................................................... 73
		Welding Precautions and Guidelines.................................................................... 75
		Hydraulic System  General Precautions................................................................ 76
		Maintenance Service and Repair Procedure.............................................................. 77
			General Precautions............................................................................... 77
		Hydraulic System Cleanliness and Oil Leaks............................................................ 78
			Maintenance Precautions for Hydraulic System Service.............................................. 78
			Oil Leakage Precautions........................................................................... 78
		Cleaning and Inspection............................................................................... 79
			General Guidelines................................................................................ 79
			Bearing inspection................................................................................ 80
	Standard Torques S0309000................................................................................. 87
		Torque Values for Standard Metric Fasteners........................................................... 89
		Torque Values for Standard U.S. Fasteners............................................................. 90
		Type 8 Phosphate Coated Hardware...................................................................... 92
		Torque Values for Hose Clamps......................................................................... 93
		Torque Values for Split Flanges....................................................................... 94
		Torque Wrench Extension Tools......................................................................... 95
			Torque Multiplication............................................................................. 95
			Other Uses for Torque Wrench Extension Tools...................................................... 96
			Tightening Torque Specifications (Metric)......................................................... 96
Upper Structure............................................................................................... 99
Lower Structure and Chassis...................................................................................101
	Track Assembly S0505070...................................................................................103
		General Description...................................................................................105
		Track Tension.........................................................................................105
		Track Assembly........................................................................................108
			Parts List........................................................................................108
		Track Shoes and Links.................................................................................110
			Parts List........................................................................................110
			Track Removal.....................................................................................111
			Tra1ck Installation...............................................................................112
		Front Idler Roller....................................................................................113
			Parts List........................................................................................113
			Front Idler Roller Disassembly....................................................................114
			Front Idler Roller Reassembly.....................................................................116
		Lower Roller..........................................................................................117
			Parts List........................................................................................117
			Lower Roller Removal..............................................................................118
			Lower Roller Installation.........................................................................118
		Upper Roller..........................................................................................119
			Parts List........................................................................................119
			Upper Roller Removal..............................................................................120
			Upper Roller Disassembly..........................................................................120
			Upper Roller Reassembly...........................................................................120
		Track Spring and Track Adjusting Cylinder.............................................................121
			Parts List........................................................................................121
Engine and Drive Train........................................................................................123
	Air Conditioner S0605015..................................................................................125
		General Description...................................................................................127
		Refrigerant Circulation...............................................................................128
		Airconditioning System Circuit Diagram...............................................................130
		Troubleshooting.......................................................................................131
		Weight of R134a Gas Used In Machines..................................................................134
		Refrigerant System Repairs............................................................................136
			Refrigerant Safe Handling Procedures..............................................................136
			Repair and Replacement Procedure..................................................................137
			Refrigerant Recovery..............................................................................139
			Vacuuming Refrigerant System......................................................................139
			Leakage Check.....................................................................................140
			Refrigerant Charging..............................................................................141
			Inspecting System for Leakage.....................................................................143
Hydraulics....................................................................................................145
	Accumulator S0703010K.....................................................................................147
		General Description...................................................................................149
			Specifications....................................................................................150
	Center Joint (Swivel) S0704050............................................................................153
		General Description...................................................................................155
			Parts List........................................................................................156
		Troubleshooting, Testing and Adjustment...............................................................158
			Inspection........................................................................................158
			Testing...........................................................................................158
		Disassembly...........................................................................................159
		Reassembly............................................................................................160
	Cylinders S0705000........................................................................................161
		General Description...................................................................................163
			Theory of Operation...............................................................................163
			Parts List........................................................................................164
		Special Tools and Materials...........................................................................166
			Piston Nut........................................................................................166
			Piston Jig........................................................................................170
			Steel Bushing Jig.................................................................................174
			Dust Wiper Jig....................................................................................178
			Slipper Seal Jig..................................................................................184
			Slipper Seal Straightening Jig....................................................................188
		Disassembly...........................................................................................191
		Assembly..............................................................................................197
	Travel Motor S0707370 R1..................................................................................201
		General...............................................................................................204
			Configuration.....................................................................................204
			Features..........................................................................................204
			Structural Diagram of the Travelling System.......................................................205
			Structural Diagram of the Axial Piston Motor......................................................206
		Operating Principle...................................................................................207
			When Travelling...................................................................................207
			When Counterbalance Operates......................................................................208
			When Brake Functions..............................................................................209
			Operating Principle of Parking Brake..............................................................210
			2 Speed Limiting Function.........................................................................211
		Parts List............................................................................................214
			Hydraulic Motor...................................................................................214
			Reduction Gear....................................................................................216
		Special Tools and Materials...........................................................................218
			Standard Tools....................................................................................218
			Equipment and Materials...........................................................................219
			Measuring Devices.................................................................................219
			Manufacturing Tools...............................................................................220
			Tightening Torque.................................................................................224
			Weight Table......................................................................................225
		Travel Motor Troubleshooting..........................................................................225
			Travel Motor......................................................................................225
			Counterbalance Valve..............................................................................226
			Relief Valve......................................................................................226
			2Speed Change Over...............................................................................227
			Parking Brake.....................................................................................227
		Disassembly...........................................................................................228
			Preparations......................................................................................228
			General Suggestions When Working..................................................................228
			Disassembly Procedure.............................................................................229
		Service Preparations..................................................................................250
			Seals.............................................................................................250
			Service Standards for Parts Subject to Wear.......................................................250
		Assembly..............................................................................................252
			Preparation.......................................................................................252
			General Suggestions When Working..................................................................252
			Assembly Procedure................................................................................252
		Performance Confirmation Test.........................................................................272
		Clearance Adjustment Part Dimensions..................................................................273
	Swing Motor S0707380......................................................................................275
		Swing Motor...........................................................................................277
			Motor.............................................................................................277
			Valve Casing......................................................................................278
			Relief Valve......................................................................................278
		Troubleshooting.......................................................................................280
	Main Pump S0708370........................................................................................281
		General Description...................................................................................283
			Description of Ports..............................................................................284
		Operation Principle and Function of Components........................................................285
			Components of the Pump............................................................................285
			Operation Principle...............................................................................287
		Adjustment............................................................................................289
		Installation..........................................................................................290
		Driving...............................................................................................290
		Hydraulic Oil.........................................................................................290
		Procedures for Test Operation.........................................................................290
		Maintenance and Protection............................................................................292
		Checking Filters......................................................................................292
		Filter Replacement....................................................................................292
		Replacement of Hydraulic Oil..........................................................................293
		Hydraulic Fluid Leakage Check.........................................................................293
		Diagnosis of Troubles and Actions to be Taken.........................................................294
			Diagnosis of Troubles with the Pump...............................................................294
			Solenoid Valve and Relief Valve...................................................................295
		Disassembling and Reassembling hydraulic pump.........................................................296
			Necessary Tools and Jigs..........................................................................296
			Reminders for Disassembly and Assembly............................................................296
			Disassembling Procedure...........................................................................297
			Standard Values for Maintenance...................................................................308
			Reassembly Procedure..............................................................................310
	Main Control Valve S0709465K..............................................................................329
		Specifications........................................................................................332
		Internal Construction.................................................................................336
		Construction of Relief and makeup Valves..............................................................338
			Relief Valve......................................................................................338
			Makeup Valve......................................................................................339
			Overload Relief Valve.............................................................................339
		Operation.............................................................................................340
			Operation in Neutral Position.....................................................................340
			Operation for Travel..............................................................................342
			Boom Operation....................................................................................346
			Bucket Operation..................................................................................352
			Arm Operation.....................................................................................356
			Boom/Swing Operation..............................................................................360
			Swing Operation...................................................................................362
			Combined Operation (Actuation of Forward Travel Valve)............................................364
			Actuation of Relief Valve (MRV)...................................................................366
			Actuation of Overload Relief Valve (ORV)..........................................................367
			Function and Operation of Makeup Valve............................................................368
			Detail Views of Major Components..................................................................368
		Disassembly...........................................................................................379
			Valve Handling Guide..............................................................................379
			Disassembly of Relief Valve (MRV), Overload Relief Valve (ORV), and Anticavitation Valve (ACV)....380
			Check Valve Disassembly...........................................................................381
			Pressure Relief Load Check Valve Disassembly......................................................381
			Anticavitation Valve Disassembly..................................................................381
			Relief Valve Disassembly..........................................................................382
			Overload Relief Valve Disassembly.................................................................382
			Other Components Disassembly......................................................................382
			Joint Body Disassembly............................................................................382
			Disassembly Precautions...........................................................................383
		Assembly..............................................................................................384
			Assembly Precautions..............................................................................384
			Guide for Assembly of Each Part...................................................................384
		Criteria for Maintenance..............................................................................386
			Inspection of Spare Parts.........................................................................386
			Troubleshooting and Remedies......................................................................387
			Control Valve.....................................................................................387
			Relief Valve......................................................................................388
	Pilot Control Valve (Work Lever / Joystick) S0709470......................................................389
		General Description...................................................................................391
			Theory of Operation...............................................................................391
			Parts List........................................................................................392
			Specifications....................................................................................394
			Hydraulic Specifications..........................................................................394
		Special Tools.........................................................................................395
		Disassembly...........................................................................................396
		Reassembly............................................................................................401
	Hydraulic Schematic (Solar 55V PLUS) S0792095K...........................................................407
		General Description...................................................................................409
		Solar 55V PLUS (S/N 1001 thru 1200, 31201 thru 32135)................................................410
		Solar 55V PLUS (S/N 32136 and Up)....................................................................412
Electrical System.............................................................................................415
	Electrical System S0802085K...............................................................................417
		Overview..............................................................................................419
		Electric Supply System................................................................................420
		Engine Starting Circuit...............................................................................422
			Operation During Starting Process.................................................................422
			Operation After Start Process.....................................................................424
		Engine Preheating System..............................................................................426
		Engine Stop System....................................................................................428
		Charging System.......................................................................................429
		Instrument System.....................................................................................430
			Instrument Panel..................................................................................431
			Function Check....................................................................................431
			Operation.........................................................................................432
			Circuit Diagram of Instrument Panel...............................................................434
			Control Unit......................................................................................435
	Electrical Schematic (Solar 55V PLUS) S0892095K..........................................................437
		General Description...................................................................................439
		Solar 55V PLUS (S/N 1001 thru 1200, 31201 thru 32135)................................................440
		Solar 55V PLUS (S/N 32136 and Up)....................................................................442
Attachments...................................................................................................445
	Bucket S0904000...........................................................................................447
		Bucket Tooth Inspection and Replacement...............................................................449
			Type 1............................................................................................449
			Type 2............................................................................................450
			Type 3............................................................................................451
		Bucket Oring Replacement.............................................................................453
			Type 1............................................................................................453
			Type 2............................................................................................454
		Bucket Shimming Procedures............................................................................456
			New Bucket Installation...........................................................................456
			Type 1............................................................................................456
			Type 2............................................................................................457
		Bucket Attachment, Removal and Reversal...............................................................458
			Detaching the Bucket..............................................................................458
			Attaching the bucket..............................................................................458
			Reversing the Bucket..............................................................................459

S.S 06/24