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Daewoo Solar 470LC-V Shop Manual

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Solar 470LC-V

Shop Manual

023-00047E

Serial Number 1001 and Up

May 2002

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.

023-00047E Shop Manual

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Summary of Contents for Daewoo Solar 470LC-V

Page 1 Serial Number 1001 and Up May 2002 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.
Page 3 Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Pub. No. 023-00047E...
Page 5 1TABLE OF CONTENTS Safety Track Excavator Safety................S0102000 Specifications Specifications for Solar 470LC-V............S0202090K General Maintenance General Maintenance Procedures ............S0302000 Standard Torques ..................S0309000 Upper Structure Cab ..................... S0402040K Counterweight..................S0403050K Fuel Tank.................... S0405120K Fuel Transfer Pump ................S0405500 Swing Bearing..................S0407000 Swing Reduction Gearbox ..............S0408060 Lower Structure and Chassis Track Assembly ..................S0505120...
Page 6 Swing Motor...................S0707260 Travel Motor (With Gearbox) (A6V160HD)..........S0707365 Main Pump (Rexroth)................S0708325K Control Valve (Kayaba Model KVMG-400-DA)........S0709402K Pilot Control Valve (Work Lever / Joystick)......... S0709452K Travel Control Valve (With Damper)........... S0709820K Hydraulic Schematic (S470LC-V) ............S0792170K Electrical System Electrical System ................S0802220K Electrical Schematic (S470LC-V) ............
Page 7 1SAFETY...
Page 9 Solar 330LC-V 1001 and Up Solar 340LC-V 1001 and Up Solar 400LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Track Excavator Safety S0102000 Page 1...
Page 10: Table Of Contents
TABLE OF CONTENTS To the Operator of a Daewoo Excavator............3 General Safety Essentials ................6 Location of Safety Labels ................6 Summary of Safety Precautions for Lifting in Digging Mode ......7 Unauthorized Modifications ................8 General Hazard Information ................8 Before Starting Engine .................
Page 11: To The Operator Of A Daewoo Excavator
TO THE OPERATOR OF A DAEWOO EXCAVATOR DANGER! 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.
Page 12 In no event should you or others engage in prohibited uses or actions as described in this manual. Daewoo delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
Page 13 Safety precautions are described in SAFETY from page -6 on. Daewoo cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.
Page 14: General Safety Essentials
The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for other object handling, contact Daewoo for proper installation and application. Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading.
Page 15: Summary Of Safety Precautions For Lifting In Digging Mode
If you need more information or have any questions or concerns about safe operating procedures or working the excavator correctly in a particular application or in the specific conditions of your individual operating environment, please consult your local Daewoo representative.
Page 16: Unauthorized Modifications
For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised.
Page 17 INSIDE OPERATOR'S COMPARTMENT When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
Page 18 MOUNTING AND DISMOUNTING Before getting on or off the machine, if there is any oil. grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.
Page 19 FUEL, OIL AND HYDRAULIC FLUID FIRE HAZARDS Fuel, oil and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well-ventilated area.
Page 20 ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. If you handle materials containing asbestos fibers, follow these guidelines as given below: • Use an approved respirator. • Never compressed cleaning. • Use water for cleaning to keep down the dust.
Page 21 FIRE EXTINGUISHER AND FIRST AID KIT As a precaution if any injury or fire should occur, always do the following. • Be sure that fire extinguishers have been provided and read the labels to ensure that you know now to use them.
Page 22 If any glass on the machine is broken, replace it with new glass immediately. ATTACHMENT PRECAUTIONS Option kits are available through your dealer. Contact Daewoo for information on available one-way (single- acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because Daewoo cannot anticipate, identify or test all of the attachments that owners may wish to install on their machines, please contact Daewoo for authorization and approval of attachments, and their compatibility with options kits.
Page 23 INDOOR VENTILATION Engine exhaust gases cause fatal accidents, unconsciousness, loss alertness, judgement and motor control and serious injury. Make sure there is adequate ventilation before starting the engine in any enclosed area. You should also be aware of open windows, doors or ductwork into which exhaust may be carried, or blown by the wind, exposing others to danger.
Page 24: Before Starting Engine
BEFORE STARTING ENGINE WORK SITE PRECAUTIONS Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation.
Page 25 Minimum levels of insurance coverage, work permits or certification, physical barriers around the work site or restricted hours of operation may be mandated by governing authorities. There may also be regulations, guidelines, standards or restrictions on equipment that may have to be followed for local requirements. There may also be regulations related to performing certain kinds of work.
Page 26 ENGINE STARTING Walk around your machine before getting in the operator’s cab. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated.
Page 27: Machine Operation
MACHINE OPERATION WHEN SWINGING OR CHANGING DIRECTION OF TRAVEL Before operating the machine or the work equipment, always observe following precautions to prevent serious injury or death. • When changing the direction of travel from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing the direction of travel.
Page 28 TRAVEL PRECAUTIONS Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops when the machine is traveling. It will be impossible to operate the steering. Attachment control levers should not be operated while traveling. Do not change selected travel mode (FAST/SLOW) while traveling.
Page 29 TRAVELING ON SLOPES Never jump onto a machine that is running away to stop it. There is danger of serious injury. Traveling on slopes could result in the machine tipping over or slipping. On hills, banks or slopes, carry the bucket approximately 20 - 30 cm (8 - 12 in) above the ground. In case of an emergency, quickly lower the bucket to the ground to help stop the machine.
Page 30 PROHIBITED OPERATIONS Do not dig the work face under an overhand. This may cause the overhand to collapse and fall on top of the machine. Figure 21 Do not carry out deep digging under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
Page 31 PRECAUTIONS FOR OPERATION Be careful not to go close to the edge of a cliff by mistake. Use the machine only for its main purpose. Using it for other purposes will cause failures. To ensure an ample view, do as follows: •...
Page 32 AVOID HIGH-VOLTAGE CABLES Serious injury or death can result from contact or proximity to high-voltage electric lines. The bucket does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to stay away from power lines not clearly visible to the operator.
Page 33 OPERATIONS ON SLOPES When working on slopes. there is danger that the machine may lose its balance and turn over, when swinging, or when work equipment is operated. Always carry out these operations carefully. Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded.
Page 34: Maintenance
Warning tags, for controls are available from 190-00695 Daewoo distributors. ARO1320L Figure 27 CLEAN BEFORE INSPECTION OR MAINTENANCE Clean the machine before carrying out inspection and maintenance. This prevents dirt from getting into the machine and also ensures safety during maintenance.
Page 35 PROPER TOOLS Use only tools suited to the task. Using damaged, low qualify, faulty, or makeshift tools could cause personal injury. There is danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness.
Page 36 BURN PREVENTION When checking the radiator coolant level, stop the engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
Page 37 Remove all flammable objects and provide a fire extinguisher. WARNING FOR COUNTERWEIGHT AND FRONT ATTACHMENT REMOVAL 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.
Page 38 PRECAUTIONS FOR REMOVAL, INSTALLATION, AND STORAGE OF ATTACHMENTS Before starting removal and installation of attachments, decide the team leader. Do not allow anyone except the authorized workers close to the machine or attachment. Place attachments that have been removed from the machine in a safe place so that they do not fall.
Page 39 CRUSHING PREVENTION AND CUTTING PREVENTION You should always have at least two people working together if the engine must be run during service. One person needs to remain in the operator’s seat, ready to work the controls or stop the machine and shut off the engine.
Page 40 If necessary depending on the type of failure, please contact your Daewoo distributor for repairs. PRECAUTIONS WITH HIGH PRESSURE LINE, TUBES AND HOSES When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released form the circuit.
Page 41 WASTE MATERIALS Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities.
Page 42: Battery
BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following; • Do not smoke or bring any flame near the battery. •...
Page 43 BOOST STARTING OR CHARGING ENGINE BATTERIES If any mistake is made in the method of connecting the booster cables, it may cause an explosion or fire. Always do the following; • Turn off all electrical equipment before connecting leads battery. This includes electrical...
Page 44: Towing
• If the engine on the problem machine will not start or there is a failure in the brake system. always contact your HAOC910L Daewoo distributor. Figure 41 • Never between towing machine and the towed machine during the towing operation.
Page 45: Shipping And Transportation
SHIPPING AND TRANSPORTATION OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.
Page 46 S0102000 Track Excavator Safety Page 38...
Page 47 1SPECIFICATIONS...
Page 49 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. SPECIFICATIONS FOR SOLAR 470LC-VS0202090K MODEL SERIAL NUMBER RANGE Solar 470LC-V 1001 and UP Copyright 2002 Daewoo May 2002 Specifications for Solar 470LC-V S0202090K Page 1...
Page 50 Performance Tests..................17 Excavator Performance Standards............... 18 Test Conditions..................18 Travel Speed and Travel Motor Balance (Steering Deviation) Tests ..18 Swing Speed and Deceleration Force Test ........... 20 Cylinder Performance Tests ..............21 S0202090K Specifications for Solar 470LC-V Page 2...
Page 51: General Description
The excavator has three main component sections: • The Upper Turntable • The Lower Undercarriage and Track Frames • The Excavator Front-end Attachment The following illustration identifies main components and their locations. (See Figure 1 on page -4.) Specifications for Solar 470LC-V S0202090K Page 3...
Page 52: Component Locations
COMPONENT LOCATIONS 18 19 ASO0010L Figure 1 S0202090K Specifications for Solar 470LC-V Page 4...
Page 53 12. ARM CYLINDER 30. SIDE CUTTER 13. BOOM 31. BUCKET 14. BOOM CYLINDER 32. PUSH LINK 15. CAB 33. GUIDE LINK 16. SEAT 34. BUCKET CYLINDER 17. CENTER JOINT 35. ARM 18. SWING MOTOR Specifications for Solar 470LC-V S0202090K Page 5...
Page 54 S0202090K Specifications for Solar 470LC-V Page 6...
Page 55: General Dimensions
3,300 mm (10' 10'') Extended (Working) / 2,740 mm (8' 12'') Retracted (Transport) 3,900 mm (12' 10'') Extended (Working) / 3,340 mm (10' 11'') Retracted (Transport) 600 mm (2' 0") 761 mm (2' 6") 3,350 mm (10' 11") Specifications for Solar 470LC-V S0202090K Page 7...
Page 56: Working Range
Digging too far underneath the excavator if soil conditions are wet, loose or unstable can collapse ground support, which could cause injury and/or equipment damage. 2.9M(9'6") ARM 3.35M(11') ARM 4.0M(13'5"") ARM ASS1170L Figure 3 S0202090K Specifications for Solar 470LC-V Page 8...
Page 57 (12' 11") (12' 11") 2,095 mm 925 mm 120 mm Min. Digging Reach (6' 11") (3' 0") (0' 5") 5,195 mm 5,170 mm 5,135 mm Min. Swing Radius (17' 1") (16' 12") (16' 10") Specifications for Solar 470LC-V S0202090K Page 9...
Page 58: General Specifications
(11.5 psi) shoe - Optional 750 mm (30") 0.66 kg/cm (9.4 psi) shoe - Optional 800 mm (32") 0.62 kg/cm (8.8 psi) shoe - Optional 900 mm (35") 0.56 kg/cm (7.9 psi) shoe - S0202090K Specifications for Solar 470LC-V Page 10...
Page 59 Track Shipping Length 5,465 mm (17’ 11") Transport Trailer Capacity 47 tons, minimum load capacity Transport Loading Ramp 15° angle CAUTION: Refer to Transport Maximum Procedure for Allowable Slope Safe Shipping Instructions. Specifications for Solar 470LC-V S0202090K Page 11...
Page 60: Engine Performance Curves (Per Din 6270 Standard)
ENGINE PERFORMANCE CURVES (PER DIN 6270 STANDARD) 1000 1500 2000 REVOLUTION(rpm) ASS1190L Figure 4 S0202090K Specifications for Solar 470LC-V Page 12...
Page 61 DIN 6270 316 ps @ 2,000 rpm Power (312 hp @ 2,000 rpm) 133 kg•m @ 1,400 rpm Max. Torque (962 ft lb @ 1,400 rpm) 165 g/ps•h Fuel Consumption (Min. Rated) (5.82 oz/hp•h) Specifications for Solar 470LC-V S0202090K Page 13...
Page 62: Approximate Weight Of Workload Materials
--------------------- --------------------- granular (2,583 lb/yd Cement, Portland, DRY 1,362 kg/m --------------------- --------------------- clinkers (2,295 lb/yd Dolomite, crushed 1,522 kg/m --------------------- --------------------- (2,565 lb/yd Earth, loamy, DRY, 1,202 kg/m --------------------- --------------------- loose (2,025 lb/yd S0202090K Specifications for Solar 470LC-V Page 14...
Page 63 929 kg/m --------------------- --------------------- (1,566 lb/yd Snow, light density 529 kg/m --------------------- --------------------- (891 lb/yd Sand, DRY, loose 1,522 kg/m --------------------- --------------------- (2,565 lb/yd Sand, WET, packed 1,922 kg/m --------------------- --------------------- (3,240 lb/yd Specifications for Solar 470LC-V S0202090K Page 15...
Page 64 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Shale, broken 1,362 kg/m --------------------- --------------------- (2,295 lb/yd Sulphur, broken 529 kg/m --------------------- --------------------- (1,620 lb/yd S0202090K Specifications for Solar 470LC-V Page 16...
Page 65: Performance Tests
Travel Speed 20 m High sec. 15.7 ±1.0 14.5 ±1.0 (65.62 ft) sec. 24.2 ±1.5 23.5 ±1.5 Travel Deviation 20 m High mm (in) 150 (5.91) 150 (5.91) (65.62 ft) mm (in) 150 (5.91) 150 (5.91) Specifications for Solar 470LC-V S0202090K Page 17...
Page 66: Excavator Performance Standards
Operate both travel levers at the fully engaged position and measure the time it takes to cross 20 m (65' 7- 1/2"). Compare measured results against the standard for new machines: S0202090K Specifications for Solar 470LC-V Page 18...
Page 67 (Figure A greater amount of deviation is allowed with the travel control set for high speed. RATE OF TRAVEL MAX. DISTANCE High Speed 150 mm (6 in) Low Speed 150 mm (6 in) Specifications for Solar 470LC-V S0202090K Page 19...
Page 68: Swing Speed And Deceleration Force Test
Maximum distance should be less than 1200 mm (47-1/4"), in both Power Mode and Standard Mode. Reference Description HJA7007L Number Figure 8 Start Swing 90° Swing Swing Force Swing Stop S0202090K Specifications for Solar 470LC-V Page 20...
Page 69: Cylinder Performance Tests
OPERATION STANDARD MODE POWER MODE High Speed 23.4 - 26.4 seconds 22.0 - 25.0 seconds Low Speed 38.7 - 42.7 seconds 36.0 - 40.0 seconds Specifications for Solar 470LC-V S0202090K Page 21...
Page 70 S0202090K Specifications for Solar 470LC-V Page 22...
Page 71 1GENERAL MAINTENANCE...
Page 73 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. GENERAL MAINTENANCE PROCEDURESS0302000 MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES Copyright 2002 Daewoo May 2002 General Maintenance Procedures S0302000 Page 1...
Page 74 Return to Master Table of Contents TABLE OF CONTENTS Welding Precautions and Guidelines ............. 3 Hydraulic System - General Precautions ............4 Maintenance Service and Repair Procedure ..........5 General Precautions ................5 Hydraulic System Cleanliness and Oil Leaks..........6 Maintenance Precautions for Hydraulic System Service ......
Page 75: Welding Precautions And Guidelines
(that is not always readily visible) could be caused. Always consult Daewoo After Sales Service before welding on integral components (loader arm, frames, car body, track frames, turntable, attachment, etc.) of the machine. It is possible that some types of structurally critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make sure there are no hidden cracks or damage, before the machine can be returned to service.
Page 76: Hydraulic System - General Precautions
Return to Master Table of Contents CAUTION! Observe the following safety precautions: Use extra caution and adequate safety shielding when welding near fuel and oil tanks, batteries, hydraulic piping lines or other fire hazards. Never weld when the engine is running. Battery cables must be disconnected before the welding procedure is started.
Page 77: Maintenance Service And Repair Procedure
Return to Master Table of Contents IMPORTANT Hydraulic system operating conditions (repetitive cycling, heavy work loads, fluid circulating under high pressure) make it extremely critical that dust, grit or any other type of contamination be kept out of the system. Observe fluid and filter change maintenance interval recommendations and always pre-clean any exterior surface of the system before it is exposed to air.
Page 78: Hydraulic System Cleanliness And Oil Leaks
Return to Master Table of Contents HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS MAINTENANCE PRECAUTIONS FOR HYDRAULIC SYSTEM SERVICE Whenever maintenance, repairs or any other type of troubleshooting or service is being performed, it’s important to remember that the hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating fluid - must be protected from contamination.
Page 79: Cleaning And Inspection
Return to Master Table of Contents NOTE: Grease seals before assembly. Figure 1 CLEANING AND INSPECTION GENERAL GUIDELINES All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as thrust bearing, matched parts, etc.
Page 80: Bearing Inspection
Return to Master Table of Contents scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on lips of oil seals.
Page 81 Return to Master Table of Contents Normal Bearing Smooth even surfaces with no discoloration or marks. Figure 2 Bent Cage Cage damage due to improper handling or tool usage. Replace bearing. Figure 3 Figure 4 Galling Metal smears on roller ends due to overheat, lubricant failure or overload.
Page 82 Return to Master Table of Contents Abrasive Step Wear Pattern on roller ends caused by fine abrasives. Clean all parts and housings, check all parts and housings, check seals and bearings and replace if leaking, rough or noisy. Figure 6 Etching Bearing surfaces appear gray or grayish black in color with related etching away of material...
Page 83 Return to Master Table of Contents Fatigue Spalling Flaking of surface metal resulting from fatigue. Replace bearing - clean all related parts. Figure 10 Brinelling Surface indentations in raceway caused by rollers either under impact loading or vibration while the bearing is not rotating. Replace bearing if rough or noisy.
Page 84 Return to Master Table of Contents Cracked Inner Race Race cracked due to improper fit, cocking or poor bearing seat. Replace all parts and housings, check seals and bearings and replace if leaking. Figure 14 Smears Smearing of metal due to slippage caused by poor fitting, lubrication, overheating, overloads or handling damage.
Page 85 Return to Master Table of Contents Heat Discoloration Heat discoloration can range from faint yellow to dark blue resulting from overload or incorrect lubrication. Excessive heat can cause softening of races or rollers. To check for loss of temper on races or rollers, a simple file test may be made.
Page 86 Return to Master Table of Contents S0302000 General Maintenance Procedures Page 14...
Page 87 Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. STANDARD TORQUESS0309000 MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES Copyright 2002 Daewoo May 2002 Standard Torques S0309000 Page 1...
Page 88 TABLE OF CONTENTS Torque Values for Standard Metric Fasteners ..........3 Torque Values for Standard U.S. Fasteners............ 4 Type 8 Phosphate Coated Hardware ............. 6 Torque Values for Hose Clamps ..............7 Torque Values for Split Flanges ..............8 Torque Wrench Extension Tools ..............9 Torque Multiplication ................
Page 89: Torque Values For Standard Metric Fasteners
TORQUE VALUES FOR STANDARD METRIC FASTENERS NOTE: The units for the torque values are kg•m (ft lb). Grade Dia. x Pitch (mm) 10.9 12.9 (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48...
Page 90: Torque Values For Standard U.s. Fasteners
TORQUE VALUES FOR STANDARD U.S. FASTENERS S.A.E. BOLT HEAD TYPE DESCRIPTION GRADE MARKING WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD. 1 OR 2 Low or Medium Carbon Steel Not Heat Treated. WILL HAVE THREE RADIAL LINES. Quenched and Tempered Medium Carbon Steel. WILL HAVE 6 RADIAL LINES.
Page 91 The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are not given NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED (WET) THREADS; VALUES SHOULD BE INCREASED 1/3 FOR NON-LUBRICATED (DRY) THREADS. HEAT TREATED MATERIAL GRADE 5 AND GRADE 8 GRADE 5 GRADE 8 THREAD SIZE...
Page 92: Type 8 Phosphate Coated Hardware
TYPE 8 PHOSPHATE COATED HARDWARE This chart provides tightening torque for general purpose applications using original equipment standard hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases, original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru hardened flat washers (Rockwell "C"...
Page 93: Torque Values For Hose Clamps
TORQUE VALUES FOR HOSE CLAMPS The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator, air cleaner, operating lever boots, hydraulic system, etc.). TORQUE RADIATOR, AIR CLEANER, HYDRAULIC SYSTEM BOOTS, ETC. CLAMP TYPE AND SIZE KILOGRAM KILOGRAM INCH POUNDS...
Page 94: Torque Values For Split Flanges
TORQUE VALUES FOR SPLIT FLANGES The following chart provides the tightening torques for split flange connections used in hydraulic systems. Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly. NOTE: Over torquing bolts will damage the flanges and/or bolts, which may cause leakage. BOLT TORQUE FLANGE BOLT...
Page 95: Torque Wrench Extension Tools
TORQUE WRENCH EXTENSION TOOLS Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force to achieve recommended tightening torque values. Common problems that could occur as a result are: • Recommended torque exceeds the measuring capacity of the torque wrench. •...
Page 96: Other Uses For Torque Wrench Extension Tools
Use the information on this page as a general guide in selecting specific formulas that will meet the particular requirements of individual assembly installations. Daewoo does not specifically endorse a specific manufacturer or brand name but the following table of "Loctite" applications is included for which cross-references to other makers’...
Page 97 I. "Loctite" Fastener Adhesives Break-away Cure Strength Product Application Color Removal (in lb) of Sealer Alone Low strength for 6 mm (1/4") or Purple Hand tools smaller fasteners. Medium strength for 6 mm (1/4") and Blue Hand tools larger fasteners. Heat/260°C (500°F) High strength...
Page 98 IV. "Loctite" retaining compounds Product Application Color Notes For bushings, sleeves, press-fit bearings, Use Locquic "N" primer for splines and collars. For gaps to 0.0002 mm Green increased bond strength and all (0.005"), temperatures to 121°C (250°F). cold temperature applications. For high temperatures to 232°C (450°F).
Page 99 1UPPER STRUCTURE...
Page 101 Remember, that ultimately safety is your own personal responsibility. S0402040K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 S0402040K Page 1...
Page 102 TABLE OF CONTENTS Removal ......................3 Installation ...................... 6 S0402040K Page 2...
Page 103 REMOVAL CAUTION! Avoid disassembling cab if there are strong wind gusts, which could catch large surface area of cab shell and push it sideways during lift. Park on firm and level ground. Lower front attachment (bucket) to the ground. Stop the engine. Set safety lever on "RELEASED"...
Page 104 12. Remove floor mat. 13. Remove operator’s seat (1, Figure 2). NOTE: Be careful not to damage seat covering. 14. Remove duct covers (2, 3 and 4, Figure 2). When removing cover (2) disconnect hour meter connector cigar lighter connector. Disconnect main harness...
Page 105 21. Remove three bolts (2, Figure 5) after disconnect speaker wire and antenna wire. Remove stereo assembly. 22. Disconnect cab lamp wiring connector. 23. Disconnect cabin ground cable (7, Figure ARS1540L Figure 5 24. Remove four mounting nuts from four corners of cabin floor (2, Figure 6).
Page 106 INSTALLATION Using a suitable lifting device, attach slings to four lift points on top of cab (Figure 7). NOTE: Cab weighs approximately 290 kg (639 lb). Lower cab into position on cab floor Figure 8 Install four mounting nuts on four corners of cabin floor (2, Figure 9).
Page 107 Install stereo assembly with bolts (2, Figure 10) after connect speaker wire and antenna wire. ARS1540L Figure 10 10. Install right side dash cover (4, Figure 11) with bolts (1, Figure 10). 11. Install left side dash cover (3, Figure 11) with bolts (1, Figure 10).
Page 108 15. Install side panel (6, Figure 13) and pocket (5). 16. Install cover (4, Figure 13) and connect main harness. Install cover (3). Connect hour meter connector and cigar lighter connect of cover (2). 17. Install cover (2, Figure 13). 18.
Page 109 COUNTERWEIGHT S0403050K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Counterweight S0403050K Page 1...
Page 110 Return to Master Table of Contents TABLE OF CONTENTS General......................3 Removal ......................5 Installation ...................... 7 S0403050K Counterweight Page 2...
Page 111 Return to Master Table of Contents GENERAL 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.
Page 112 Return to Master Table of Contents WARNING! If the turntable deck has been unbalanced by removal of weight from one end only, traveling the excavator, swinging the turntable, movement over bumps or sloping and uneven surfaces could cause loss of control and possible accidents or injuries. To maintain stability the counterweight should be removed whenever the front attachment is taken off the machine.
Page 113 Return to Master Table of Contents REMOVAL Park on firm and level ground. Lower front attachment (bucket) to the ground. Stop the engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while Figure 3 performing maintenance, extreme care.
Page 114 13. Install two lifting eyes in lifting holes (3, Figure 4). Model Lifting Eye Size Solar 300LC-V Solar 300LL Solar 340LC-V M48x5.0 Solar 420LC-V Solar 470LC-V 14. Using a suitable lifting device capable of handling load, partially support counterweight Figure before beginning to loosen four bolts (4).
Page 115 250 kg•m Solar 340LC-V (1,807 ft lb) Solar 420LC-V Solar 470LC-V Remove lifting device and lifting eyes from counterweight lifting holes (3, Figure 5). Install two caps (1, Figure 5) in lifting holes (3). Connect negative (-) battery cable to battery.
Page 116 Return to Master Table of Contents S0403050K Counterweight Page 8...
Page 117 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. FUEL TANK S0405120K MODEL SERIAL NUMBER RANGE Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Fuel Tank S0405120K Page 1...
Page 118 TABLE OF CONTENTS General Description..................3 Parts List ....................4 Specifications ..................5 Removal ......................6 Installation ....................10 Start-up Procedures ..................12 S0405120K Fuel Tank Page 2...
Page 119: General Description
GENERAL DESCRIPTION WARNING! Engine fuel is highly flammable and potentially explosive. To prevent possible injury and/or damage to equipment, extinguish or move to a safe distance all potential fire hazards. Fuel Tank S0405120K Page 3...
Page 120: Parts List
PARTS LIST ASS1180L Figure 1 S0405120K Fuel Tank Page 4...
Page 121: Specifications
Reference Reference Description Description Number Number Fuel Tank O-ring Plug Cover Level Gauge Bolt (M10x1.5x25) O-ring Spring Washer O-ring Drain Cock Plug Bolt (M16x2.6x60) Spacer Shim Bolt (M12x1.75x16) Shim Bolt (M8x1.25x12) Fuel Filter Clip SPECIFICATIONS Fuel tank capacity is 620 liters (164 U.S. gal). Fuel Tank S0405120K Page 5...
Page 122: Removal
REMOVAL Look at fuel level display (Figure 2) on instrument panel in operator’s cab to see what it displays. The display is divided into GREEN separated segments, each representing 10 percent of total fuel supply. Also look at level gauge on side of tank to estimate volume of fuel left in tank.
Page 123 Lower front attachment (bucket) to the ground. Stop the engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while performing maintenance, Figure 4 extreme care. Always have one person in the cab at all times. Never leave the cab with the engine running.
Page 124 13. Place a large enough container under fuel tank to collect remaining fuel. Open drain valve (Figure 6) at bottom of tank and drain. NOTE: Fuel tank capacity is 620 liters (164 U.S. gal). Figure 6 14. Tag and disconnect fuel supply line (1, Figure 7) and fuel return line (2) from Fuel tank (3) and carefully drain remaining fuel from lines.
Page 125 18. Remove four bolts (1 and 2, Figure 9), clamp (6) and stay (3) from fuel tank and frame. Remove four bolts (4) and cover (5) from fuel tank. ASS1220L Figure 9 19. Install two 12 mm eye bolts in threaded holes (1 and 2, Figure 10).
Page 126: Installation
INSTALLATION Install two 12 mm eye bolts in threaded holes (1 and 2, Figure 11). Using a suitable lifting device, sling eye bolts. Set fuel tank (3, Figure 11) into position. Install six bolts and washers (4) finger tight, to secure tank to frame. NOTE: The clear level gauge on the side of the tank is easily...
Page 127 Connect wires as tagged to fuel sensor (1, Figure 13) on side of fuel tank (2). If equipped, connect components to the fuel filter pump port (3, Figure 13) on side of fuel tank (2). ASS1210L Figure 13 Connect as tagged, fuel supply line (1, Figure 14) and fuel return line (2) to fuel tank (3).
Page 128: Start-Up Procedures
START-UP PROCEDURES If engine does not start, the fuel system may need priming. Prime the fuel system using the following procedure; Loosen plug (Figure 16) on top of fuel filter head. Figure 16 Unscrew and pump hand operated primer pump (Figure 17) by fuel injection pump. Pump primer until fuel is present at plug hole in fuel filter head.
Page 129 1001 and Up Solar 200W-V 0001 and Up Solar 220LC-V 0001 and Up Solar 220LL 1001 and Up Solar 220N-V 1001 and Up Models continued on back of cover. Copyright 2002 Daewoo June 2002 Fuel Transfer Pump S0405500 Page 1...
Page 130 Solar 400LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Troubleshooting ....................4 Replacement of Rotor and Vane ..............4 Replacement of Rear Cover ................
Page 131: General Description
GENERAL DESCRIPTION THEORY OF OPERATION Figure 1 Reference Reference Description Description Number Number Motor Inlet Hose Pump Outlet Hose Pump Cover Check Valve Rotor and Vane Strainer Cap Fuel pump consists of motor, pump, switch and hose assembly. Figure 2 Fuel Transfer Pump S0405500 Page 3...
Page 132: Troubleshooting
TROUBLESHOOTING On some pumps the ON-OFF switch is installed separately at a remote location. A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it from damage. NOTE: OPEN TEMP: 150 ±5°C (302 ±41°F). After circuit is automatically shut off due to overheating the pump will stop running.
Page 133: Replacement Of Rear Cover
Insert vane, with the circled edge of vane facing in the counterclockwise direction. (Detail A) Insert O-ring again at reassembly of pump cover. Figure 6 REPLACEMENT OF REAR COVER Brush assembly and a thermal limiter are installed in the rear cover. If you find any damage, replace them with new ones.
Page 134: Replacement Of Armature
REPLACEMENT OF ARMATURE You can replace only the armature in case motor was damaged by a short circuit. Remove the switch cover and rear cover, than remove the armature from the housing. Remove the pump cover and remove the rotor and vane.
Page 135 Solar 330LC-V 1001 and Up Solar 340LC-V 1001 and Up Solar 400LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Swing Bearing S0407000 Page 1...
Page 136 TABLE OF CONTENTS Swing Bearing Maintenance ................3 Operating Recommendation ..............3 Measuring Swing Bearing Axial Play ............3 Measuring Bearing Lateral Play .............. 3 Swing Bearing Basic Operation .............. 4 Rebuilding Swing Bearing ............... 4 S0407000 Swing Bearing Page 2...
Page 137: Swing Bearing Maintenance
SWING BEARING MAINTENANCE OPERATING RECOMMENDATION The service life of the swing bearing may be extended if a conscious, daily effort is made to equalize usage over both ends of the excavator. If the excavator is used in the same operating configuration day in and day out (for example, with the travel motors always under the counterweight, or with the attachment over one side of the machine more than the other), the bearing’s service life could be reduced.
Page 138: Swing Bearing Basic Operation
SWING BEARING BASIC OPERATION The swing bearing, which connects the upper structure with the lower structure, consists of a inner ring, outer ring and ball bearings. During swing movement, power from the swing motor is transferred to the pinion by planetary gears connected to gears on the inner ring, which is fixed in the undercarriage.
Page 139 Lift outer ring and check that inner ring can move freely. See Figure 5, if not, replace seal (3, Figure 4) and/or seal (4, Figure 4). Figure 5 Turn inner ring and use magnet bar (1, Figure 6) to remove steel balls (2). Figure 6 Turn inner ring and use wire (1, Figure 7) to remove retainers (2).
Page 140 S0407000 Swing Bearing Page 6...
Page 141 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. SWING REDUCTION GEARBOXS0408060 MODEL SERIAL NUMBER RANGE Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Swing Reduction Gearbox S0408060 Page 1...
Page 142 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Parts List ....................4 Specifications ..................5 Special Tools and Materials................6 Special Tools ................... 6 Troubleshooting, Testing and Adjustment............8 Removal ......................9 Disassembly ....................11 Cleaning and Inspection (Wear Limits and Tolerances) ....... 14 Reassembly....................
Page 143: General Description
GENERAL DESCRIPTION THEORY OF OPERATION The swing motor final drive is a two-step planetary gearbox with two planet gears, two sun gears and two- step output reduction. The planetary gear engages with the ring gear. The pinion gear is connected with the output shaft and spline.
Page 144: Parts List
PARTS LIST HAAA4260 Figure 1 S0408060 Swing Reduction Gearbox Page 4...
Page 145: Specifications
Reference Reference Description Description Number Number Casing ------------- Drive Shaft No. 1 Planet Gear Plate No. 1 Pin Assembly Roller Bearing Socket Bolt Cover Plate No. 1 Sun Gear Thrust Washer No. 1 Spacer Oil Seal Plug Roller Bearing Plug No.
Page 146: Special Tools And Materials
SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS Drive Shaft Front Bearing Jig Dimension Measurement 130.0 mm (5.1181 in) Dia. 100.0 mm (3.9370 in) Dia, 83.0 mm (3.2677 in) HAAC8850 Figure 2 Oil Seal Insert Jig Dimension Measurement 10.0 mm (0.3937 in) 20.0 mm (0.7874 in) 99.0 mm (3.8976 in) Dia.
Page 147 Swage Jig Dimension Measurement 18.0 mm (0.7087 in) Dia. 26.0 mm (1.0236 in) Dia. 40.0 mm (1.5748 in) Dia. 10.0 mm (0.3937 in) 1.0 mm (0.0394 in) Radius 2.0 mm (0.0787 in) Radius HAAC8880 Figure 5 Roller Bearing insert Jig Dimension Measurement 90.10 - 90.20 mm...
Page 148: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT Symptoms Possible Causes Remedies 1. No rotation and – a. Pressure at swing motor inlet Swing brake not releasing Check brake engagement increases and disengagement, check release pressure Internal damage to gearbox Replace broken gears, drive train drive train assemblies Overload Reduce load weight...
Page 149: Removal
REMOVAL Park on firm and level ground. Lower front attachment (bucket) to the ground. Stop the engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while Figure 7 performing maintenance, extreme care. Always have one person in the cab at all times.
Page 150 (1, Figure 8). Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component. 12. Disconnect tube (2, Figure 8) from reduction gear box (5). (Solar 470LC-V) -or- Disconnect tube from drain cock (not shown). (Solar 450LC-V) 13.
Page 151: Disassembly
Remove breather (5, Figure 9) from breather pipe replacement necessary. Remove adapters (6 and 7, Figure 9) from gearbox (8). (Solar 470LC-V) -or- Remove drain cock and reducer (not shown) to drain gear oil from gearbox (8). (Solar 450LC-V) IMPORTANT Use a clean, dry container (with at least 11 liters, or 2.9 gallons capacity)
Page 152 HAAA4261 Figure 10 S0408060 Swing Reduction Gearbox Page 12...
Page 153 Snap ring (1, Figure 10) will remain on swing motor shaft. Remove snap ring only if replacement is necessary. Remove No. 1 sun gear (25, Figure 10) from No. 1 carrier (20) and from end of No. 2 sun gear (18). 10.
Page 154: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Inspect all components in the assembly. Pay particular attention to oil seals, lock and spring pins and fastener bolts. Using new replacement parts for these components is recommended whenever there is any doubt at all about the condition or serviceability of original parts.
Page 155 Swing Reduction Gearbox S0408060 Page 15...
Page 156: Reassembly
REASSEMBLY HAAA4261 Figure 11 S0408060 Swing Reduction Gearbox Page 16...
Page 157 Install two plugs (27, Figure 11) and plug (28) in front casing (1), if replacement was necessary. NOTE: Use Loctite #592 Pipe Sealant on plugs. Press oil seal (7, Figure 11) into casing (1). NOTE: Use Loctite #277 on O.D. of seal. Be careful not to get sealant on lips of seal. Press roller bearing (8, Figure 11) into casing (1).
Page 158 HAAA4261 Figure 13 S0408060 Swing Reduction Gearbox Page 18...
Page 159 As shown in Figure 14, use a punch to stake spring pins (15, Figure 13) (inserted in the previous step) into place. Repeat procedure remaining planetary gear assemblies. 10. Position No. 2 carrier (10, Figure 13) on drive shaft (2). 11.
Page 160 Tighten bolts to 27 kg•m (195 ft lb). AZS0090L 21. Use lock wire (9, Figure 15) to secure Figure 15 SOLAR 470LC-V drilled head bolts (10) into position. 22. Install adapters (6 and 7, Figure 15) in gearbox (8). (Solar 470LC-V)
Page 161: Installation
Figure 16) to secure swing reduction gearbox (5) to frame. NOTE: Apply Loctite #262 to bolt threads. Connect tube (2, Figure 16) to reduction gear box (5). (Solar 470LC-V) -or- AZS0080L Connect tube to drain cock (not shown). Figure 16 SOLAR 470LC-V (Solar 450LC-V) Connect grease lubrication line (3, Figure 16) from reduction gearbox (5).
Page 162: Start-Up Procedure
START-UP PROCEDURE IMPORTANT If air is not vented from hydraulic system, it will cause damage to swing motor and bearings. Disconnect drain hose and fill swing motor case with hydraulic oil. Connect drain hose. Start engine and set throttle at "LOW Figure 17 IDLE"...
Page 163 1LOWER STRUCTURE AND CHASSIS...
Page 165 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. TRACK ASSEMBLY S0505120 MODEL SERIAL NUMBER RANGE Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Track Assembly S0505120 Page 1...
Page 166 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Track Tension....................3 Cleaning and Inspection (Wear Limits and Tolerances) ......... 5 Track Shoes and Links ................... 9 Parts List ....................9 Track Removal..................10 Track Installation..................11 Front Idler Roller...................
Page 167 Return to Master Table of Contents GENERAL DESCRIPTION The track assembly is composed of the following major components: Track Front Idler Roller Upper Roller Lower Roller Track Spring and Track Adjustment Cylinder 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.
Page 168 Return to Master Table of Contents Measuring the distance (A, Figure 2) 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 380 - 430 mm (14.93 - 16.90 in) NOTE: This...
Page 169: Cleaning And Inspection (Wear Limits And Tolerances)
Return to Master Table of Contents CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) CAUTION! Refer to the "Welding Precautions and Guidelines" information in "General Maintenance Procedures" section for general recommendations and specific safety precautions, before starting any lower travel frame component rebuilding procedure. The tables that follow provide factory-specified dimensional limits (as-new condition, recommended service and replacement limit) for lower travel frame components.
Page 170 Return to Master Table of Contents Normal Recommended Limit for Use Component / Reference Dimensions Reference (New) Limit for (Repair - P or Dimension Maintenance Replace - R) Track link, master pin bushing, 71 mm 68 mm 66 mm [R] master bushing (2.80 in) (2.68 in)
Page 171 Return to Master Table of Contents Normal Recommended Limit for Use Component / Reference Dimensions Reference (New) Limit for (Repair - P or Dimension Maintenance Replace - R) Figure 9 60 mm 59.5 mm 59.2 mm [R] Upper roller, axle (2.36 in) (2.34 in) (2.33 in)
Page 172 Return to Master Table of Contents Normal Recommended Limit for Use Component / Reference Dimensions Reference (New) Limit for (Repair - P or Dimension Maintenance Replace - R) HDA7018L Figure 11 Front idler, axle 85 mm 84.5 mm 84.2 mm [R] (3.35 in) (3.33 in) (3.31 in)
Page 173: Track Shoes And Links
Return to Master Table of Contents TRACK SHOES AND LINKS PARTS LIST Figure 13 Reference Reference Description Description Number Number Track Link Assembly Pin; Lock Link; Track (R.H.) Bushing Link; Track (L.H.) Bushing; Master Link; Master (R.H.) Pin; Master Link; Master (L.H.) Shoe 600 mm (24 in) Bolt Spacer...
Page 174: Track Removal
Return to Master Table of Contents TRACK REMOVAL Position machine on a smooth level surface with adequate room for forward and reverse travel. Relieve track tension. Refer to "Track Tension" in this section for procedure. Move machine until master link (1) is positioned at approximately 10 o’clock from top position on travel reduction gearbox.
Page 175: Track Installation
Return to Master Table of Contents TRACK INSTALLATION Lay rebuilt or new track into position under track frame. End of track should be positioned under front idler roller. With upper structure at 90° to track frame. Use bucket and boom to raise track frame off blocking.
Page 176: Front Idler Roller
Return to Master Table of Contents FRONT IDLER ROLLER PARTS LIST Figure 19 Part No. Part Quantity Part No. Part Quantity Bearing Axle Plug Group Seal Idler O-ring Bushing S0505120 Track Assembly Page 12...
Page 177: Front Idler Roller Disassembly
Return to Master Table of Contents FRONT IDLER ROLLER DISASSEMBLY Remove plug (2, Figure 20) and drain oil from idler (7, Figure 20). Figure 20 Separate the pin (3, Figure 21) from the bearing (1). Figure 21 Use a press to remove the bearing from the axle.
Page 178 Return to Master Table of Contents Detach the group seal (6, Figure 23) from the idler (7) and bearing (1). Figure 23 Use a press to separate the axle (5, Figure 24), O-ring (4) and bearing (1). Figure 24 Remove bushing (8, Figure 25) with the press and special tool (ST-1909).
Page 179: Front Idler Roller Reassembly
Return to Master Table of Contents FRONT IDLER ROLLER REASSEMBLY Degrease, clean and dry all parts before reassembly. Insert bushing (8, Figure 26) into the idler (7). Grease O-ring (4, Figure 26) and insert it into the axle. Align the bearing (1, Figure 26) and axle (5) holes and pin (3) them together.
Page 180: Lower Roller
Return to Master Table of Contents LOWER ROLLER Heat treatment of the lower rollers provides improved wear resistance and hardness. High quality bushings and seals will ensure long service life if lubricant is replaced at recommended intervals. NOTE: An exploded view of the lower roller is shown in Figure 29. Figure 29 Reference Reference...
Page 181: Lower Roller Removal
Return to Master Table of Contents LOWER ROLLER REMOVAL Relieve track tension. Refer to "Track Tension" in this section for procedure. Swing upper structure at 90° to frame. Using bucket raise track off ground and place blocking under frame. Remove four bolts and lower roller assembly from track frame.
Page 182: Lower Roller Reassembly
Return to Master Table of Contents Detach O-rings (2, Figure 33) from the axle. Separate group seals (6, Figure 33) from the collar and roller (5). Detach collar (3, Figure 33) and O-rings (2) from the axle, using a press. Figure 33 LOWER ROLLER REASSEMBLY Degrease, clean and dry all parts before...
Page 183 Return to Master Table of Contents Insert group seals (6, Figure 36) into the roller (5) and collar (3). NOTE: Apply clean engine oil to the joint side of the group seal. Apply grease to the group seal O-ring. Slide the axle inside the roller. Figure 36 Install the collar (3, Figure 37), O-ring (2), and pin (1) on the remaining side.
Page 184: Upper Roller
Return to Master Table of Contents UPPER ROLLER NOTE: An exploded view of the upper roller is shown in Figure 39. PARTS LIST Figure 39 S0505120 Track Assembly Page 20...
Page 185: Upper Roller Removal
Return to Master Table of Contents Part No. Part Quantity Part No. Part Quantity Washer Plug Cover Bushing Bolt Floating Seal Spring Washer O-ring O-ring Thrust Ring Body Spacer Bushing Shaft UPPER ROLLER REMOVAL Relieve track tension. See This will allow track to be raised so that links clear top of roller.
Page 186 Return to Master Table of Contents Separate the roller (6, Figure 43) from the axle (7). Figure 43 Separate the group seal (8, Figure 44) from the roller and bracket (9). Figure 44 Separate the bushing (10, Figure 45) from the roller with a press and special tool (ST- 1919).
Page 187: Upper Roller Reassembly
Return to Master Table of Contents UPPER ROLLER REASSEMBLY Degrease, clean and dry all parts before reassembly. Insert bushing (10, Figure 46) into the roller (6). Figure 46 Insert group seal (8, Figure 47) into the roller (6) and bushing. NOTE: Apply clean engine oil to the joint side of the group seal.
Page 188 Return to Master Table of Contents Tighten plug (1, Figure 49). Figure 49 S0505120 Track Assembly Page 24...
Page 189: Track Spring And Track Adjusting Cylinder
Return to Master Table of Contents TRACK SPRING AND TRACK ADJUSTING CYLINDER PARTS LIST 3A,3B A Z S 0 0 6 0 L Figure 50 Reference Reference Description Description Number Number Body Rod Packing Bracket Back Up Ring Dust Seal Rod Plate Plate Spring...
Page 190 Return to Master Table of Contents S0505120 Track Assembly Page 26...
Page 191 1ENGINE AND DRIVE TRAIN...
Page 193 AIR-CONDITIONER S0605060K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Air-Conditioner S0605060K Page 1...
Page 194 TABLE OF CONTENTS General Description..................3 Refrigerant Circulation..................5 Control Panel....................7 Control Specifications..................8 Temperature Level Control and Display............9 Air Discharge According to Path Selection........... 10 Air-conditioning System Circuit Diagram............12 Troubleshooting .................... 14 Weight of R134a Gas Used In Machines ............. 17 Refrigerant System Repairs .................
Page 195: General Description
GENERAL DESCRIPTION ARO0550L Figure 1 The heater and air-conditioner are combined into one unit in the rear cover behind the operator's seat. If necessary, the operator can control inner temperature using the operation panel installed in the right-hand control stand. The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator’s cab.
Page 196 WARNING! If using compressed air to clean the element, make sure that proper eye protection is worn. NOTE: All right and left call outs are based on the operator being seated in the operator’s seat facing the front. Turn the key cylinder (1, Figure 2) to open cover (2, Figure 2) behind operator’s seat.
Page 197: Refrigerant Circulation
REFRIGERANT CIRCULATION HDA6046L Figure 4 Reference Reference Description Description Number Number Evaporator Compressor Expansion Valve Blower Fan Condenser Receiver Dryer Condenser Fan Air-Conditioner S0605060K Page 5...
Page 198 Shading Temperature Refrigerant State High High Pressure Gas High High Pressure Liquid Low Pressure Liquid High High Pressure Gas/Liquid Low Pressure Gas • Refrigerant (R134a) is compressed to approximately 15.0 kg/cm (213 psi) within the compressor. • The compressed refrigerant flows into the condenser at high temperature (approximately 80°C (176°F)).
Page 199: Control Panel
CONTROL PANEL ARO0501L Figure 5 INPUT OUTPUT CONTROL PANEL DISPLAY TEMPERATURE SENSOR LOW SPEED RELAY BLOWER OFF SW MID SPEED RELAY MOTOR A / C SW VENT SW HIGH SPEED RELAY DEF. SW TEMP. CONTROL HEAT SW MIX DOOR ACTUATOR CONTROL FRE SW PANEL...
Page 200: Control Specifications
CONTROL SPECIFICATIONS Control Item Control Switch Control Specifications Temperature ‘COOL’ Switch MAX COOL Control ‘WARM’ Switch 100% MAX HOT HDA6049L Figure 7 Temperature control switch consists of a 24 step variable selector. The display uses 7, Green / Red two- color LEDs to display the selected temperature.
Page 201 TEMPERATURE LEVEL CONTROL AND DISPLAY Position Step LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Sensor Remark Voltage Green Green Green Green Green Green Green 4.50 V ± 0.2 MAX. COOL Green Green Green Green Green Green...
Page 202: Air Discharge According To Path Selection
AIR DISCHARGE ACCORDING TO PATH SELECTION Face, Rear, and Defroster ARS1280L Figure 10 Foot ARS1290L Figure 11 S0605060K Air-Conditioner Page 10...
Page 203 Face and Defroster ARS1300L Figure 12 Air-Conditioner S0605060K Page 11...
Page 204: Air-Conditioning System Circuit Diagram
AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM 15-1 15-2 15-3 15-4 15-5 LED 1~12 HIGH 15-6 MODE SELECT VENT AIR MODE 15-7 RECIRCLE/FRESH FOOT BLOWER SPEED TEMP. CONTROL (WARM) (COOL) 15-8 15-9 FOOT HRS 26P AMP MIC 13P + 250 4P HRS NO.GT7A-26PD-DS 26P AMP MIC 13P 12 11 25 24...
Page 205 Reference Reference Description Description Number Number Battery Compressor Battery Relay A/C Control Panel Fusible Link A/C Unit Circuit Breaker 15-1 Blower Motor Fuse 15-2 Resister Lamp Switch 15-3 High Speed Relay Condenser Fan Relay 15-4 Mid Speed Relay Condenser Fan Motor 15-5 Low Speed Relay Compressor Relay...
Page 206: Troubleshooting
TROUBLESHOOTING Refrigerant Pressure Check HDA6074L Figure 14 Open all doors and windows. Install manifold gauge set. Start engine and maintain engine speed at 1,800 - 2,000 RPM. Check high / low pressure of refrigerant. High Pressure: 8.0 - 10.0 kg/cm (114 - 142 psi) Low Pressure: Approximately 1.0 kg/cm (14 psi)
Page 207 High Pressure: Approximately 20 - 25 kg/cm (285 - 356 psi) Low Pressure: Approximately 2.5 - 3.5 kg/cm (36 - 50 psi) Possible Cause: Air in system. Recover any remaining refrigerant. Vacuum out system. Recharge system. NOTE: If the system has been exposed to the air for a long period of time, replace the receiver dryer.
Page 208 High Pressure: Over 7.0 - 11.0 kg/cm (100 - 156 psi) Low Pressure: 4.0 - 6.0 kg/cm (57 - 85 psi) Possible Cause: Low refrigerant pressure due to poor compressor compression Inspect and replace compressor if necessary. S0605060K Air-Conditioner Page 16...
Page 209: Weight Of R134A Gas Used In Machines
850 ±20 grams (30 ±0.7 oz.) Solar 450LC-III 1250 ±20 grams (44 ±0.7 oz.) Solar 450LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 470LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 70-III 800 ±20 grams (28 ±0.7 oz.) Air-Conditioner S0605060K...
Page 210: Refrigerant System Repairs
REFRIGERANT SYSTEM REPAIRS WARNING! Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately flush with clean, running water and consult a physician. Select a clean and well ventilated area to work. The refrigerant container is under high pressure and should be stored below 40°C (104°F).
Page 211: Repair And Replacement Procedure
The new refrigerant oil (PAG type) has a high moisture absorption characteristic. When the refrigerant system vacuum seal has been broken, immediately plug up all openings to prevent moisture from entering into the system. When joining unions which use O-ring seals, lightly coat O-rings with refrigerant oil. Be careful not to drip oil on the threads of the nut.
Page 212 INSTALL REPAIR TOOL RECOVER REFRIGERANT REPAIR / REPLACE DEFECTIVE PARTS VACUUM SYSTEM (OVER 5 MINUTES) CHECK SYSTEM FOR AIR LEAKAGE REPAIR VACUUM SYSTEM (OVER 20 MINUTES) CHARGE SYSTEM (APPROXIMATELY 100 g) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL (Standard Capacity less Initial Charge) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL...
Page 213: Refrigerant Recovery
REFRIGERANT RECOVERY Reference Description Number To Compressor Low Pressure Side High Pressure Side From Receiver Refrigerant Recovery Tank Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. HDA6067L Figure 17 NOTE: Be careful not to switch the connections for the low and high pressure valves.
Page 214: Leakage Check
Check system for vacuum leak. Allow system to sit for 10 minutes and check whether the system is holding the pressure. If the pressure has dropped, it must be repaired before proceeding to the next step. Vacuuming Procedure If the system is holding the pressure and it has not changed for 10 minutes, vacuum out the system for an additional 20 minutes.
Page 215: Refrigerant Charging
Using a refrigerant leak detector or soapy water check each joint for leakage. Reference Description Number Refrigerant Leak Detection Device If a leak is detected, check for O-ring damage or correct tightening torque and replace or repair as necessary. If no leaks are detected, proceed with the HDA6071L charging process.
Page 216 Engine Speed: 1,300 - 1,500 RPM WARNING! When charging refrigerant system with the engine running; • Always keep refrigerant supply container in the upright position. • Never open the high side pressure valve. Open the manifold gauge low side valve and charge system to standard capacity. Gauge Dial Standard Reading 13 - 20 kg/cm...
Page 217: Inspecting System For Leakage
INSPECTING SYSTEM FOR LEAKAGE After completing charging procedures, clean all joints and connections with a clean dry cloth. Using a refrigerant leak detecting device or soapy water, inspect system for leaks starting from the high pressure side. NOTE: When the refrigerant circulation has been stopped the high pressure will start to decrease and the low pressure will start...
Page 218 S0605060K Air-Conditioner Page 26...
Page 219 SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Drive Coupling (Main Pump) S0609010K Page 1...
Page 220 TABLE OF CONTENTS Drive Coupling....................3 Special Tools ....................4 Drive Coupling Installation................6 Installation Procedure ................8 S0609010K Drive Coupling (Main Pump) Page 2...
Page 221: Drive Coupling
DRIVE COUPLING When installing the main pump on the engine, it is very important to properly adjust clearance between the face of the coupling hub and end of pump drive shaft ("Measurement H" shown in the following procedure) to a specific value. Figure 1 thru Figure 2, show typical drive coupling installations.
Page 222: Special Tools
SPECIAL TOOLS This tool is used to control the distance between the end of the pump drive shaft and the front face of the drive coupling hub (Figure 3 and Figure 5). This distance will be referred to as "Measurement H" in the installation instructions that follow.
Page 223 Dimensional Details for Figure 4 Dimension Measurement Models 6 ±0.1 mm S300LC-V, S300LL (0.2362 ±0.0039 in) 7 ±0.1 mm S340LC-V, S420LC-V, S470LC-V (0.2756 ±0.0039 in) 20.0 mm (0.787 in) 7.0 mm (0.275 in) 18.0 mm (0.708 in) Radius 22.0 mm (0.866 in) Radius 30.0 mm (1.181 in) Radius 1.0 mm (0.039 in) x 45°...
Page 224: Drive Coupling Installation
DRIVE COUPLING INSTALLATION Whenever the drive coupling for main pump is installed, the following mounting dimensions and installation procedures must be observed. NOTE: If these procedures are not followed, noise will occur and/or the service life of drive coupling or main pump will be reduced. Figure 5 DRIVE COUPLING INSTALLATION S0609010K Drive Coupling (Main Pump)
Page 225 Table 1 Parts Information and Torque for Figure 5 Reference Description Qty. Torque Number (See Table 2) Spring Pin Insert Bolt Flywheel Spring Pin Insert Bolt Pump shaft Clamping screw Element Specification for "Measurement H," from front hub face to pump shaft end, and TIGHTENING TORQUE of bolts and screws written in the "Table 2"...
Page 226: Installation Procedure
INSTALLATION PROCEDURE NOTE: Refer to Figure 5 while using following procedure. Install spring pin (1) and attach insert (2) with bolt (3) to engine flywheel (4). NOTE: Tighten bolts to value "Ta" in the tables. Install two spring pins (5) and attach insert (6) to hub (7) bolts (8).
Page 227 1HYDRAULICS...
Page 229 Remember, that ultimately safety is your own personal responsibility. HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENT S0702190K MODEL SERIAL NUMBER RANGE Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Hydraulic System Troubleshooting, Testing and S0702190K Adjustment...
Page 230 TABLE OF CONTENTS Hydraulic System - General Notes ..............4 Hydraulic Schematic..................5 General Notes ..................5 Operation of Working Components ..............6 Boom Operating Circuit................6 Boom Up Circuit ..................6 Boom Down Circuit ................. 6 Arm Operating Circuit ................7 Arm Crowd Circuit ...................
Page 231 Pump Input Power Control ................17 Pump Regulator Adjustment ..............17 Flow Meter and Flow Meter Kit Installation and Testing ....... 20 Swing System Troubleshooting ..............22 Precautions/Initial Checks..............22 Swing Relief Valve Checking and Adjustment........22 Troubleshooting - Swing Gearbox ..............24 Troubleshooting - Hydraulic Problems............
Page 232: Hydraulic System - General Notes
HYDRAULIC SYSTEM - GENERAL NOTES HAOF420L Figure 1 Pattern of Drawing (Solar 470LC-V) The hydraulic system has several improvements over conventional hydraulic systems - including cross- sensing total horsepower control - to maximize output efficiency. The system features an electronically controlled output optimization system, which allows the operator to choose between two, distinctly different power modes: high-output/rapid cycling maximum-speed power mode, and a standard power mode for most types of general operation.
Page 233: Hydraulic Schematic
HYDRAULIC SCHEMATIC The hydraulic schematic(s) is available in the "Hydraulic and Electrical Schematic Shop Manual." This manual is a collection of diagrams and schematics for a number of models. GENERAL NOTES When referring to the schematic, refer to the following items: •...
Page 234: Operation Of Working Components
OPERATION OF WORKING COMPONENTS BOOM OPERATING CIRCUIT The boom operating circuit includes the right and left main hydraulic pumps (both halves of the main pump assembly), both sides of the control valve and the boom cylinder. The circuit operates in boom down mode through the first shift position and through the second shift position in boom up mode.
Page 235: Arm Operating Circuit
ARM OPERATING CIRCUIT The arm operating circuit includes both the right and left hydraulic main pumps, the right and left halves of the control valve, arm regeneration valve, and the arm cylinder. The circuit can be operated in the two- stage speed control mode which works through both halves of the control valve and doubles the volume of oil flowing to the cylinder.
Page 236: Bucket Operating Circuit
BUCKET OPERATING CIRCUIT The bucket operating circuit includes the right and left main pumps, the both sides of the control valve and the bucket cylinder. 360 kg/cm (5,112 psi) overload relief valves located at crowd and dump cylinder ports on BUCKET of the control valve protect the circuit and its components from damage. BUCKET CROWD CIRCUIT When the bucket control lever is placed in the crowd position, the right side pilot valve...
Page 237: Right Swing Operating Circuit
RIGHT SWING OPERATING CIRCUIT SWING MOTOR When the swing control lever is pushed to the right swing position, pilot pressure from the left side pilot valve is directed to SWING spool of the control valve. Output flow from PUMP(R) is goes to the swing motor.
Page 238: Forward Travel Circuit
FORWARD TRAVEL CIRCUIT TRAVEL TRAVEL MOTOR(R) When the right and left travel control levers are MOTOR(L) pushed forward, output from both of the main pumps is directed through the TRAVEL (R) and TRAVEL (L) spools on the control valve, through CENTER JOINT the upper works center joint, to the travel motors on each side of the machine.
Page 239: Procedural Troubleshooting Baseline Recommendations
PROCEDURAL TROUBLESHOOTING BASELINE RECOMMENDATIONS INITIAL CHECKS AND TESTS TO ESTABLISH OPERATING CONDITION OF THE EXCAVATOR Triage Summary An excavator that fails to deliver designed performance should be checked for the following: • Hydraulic flow, first, and • Hydraulic pressure, afterwards, in a specified order of priority through different points of the system.
Page 240: Pilot Pressure
PILOT PRESSURE ADJUSTMENT AND TESTING WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made. Vent hydraulic pressure from the reservoir before breaking the seal on fittings to install two in-line "t-style" adapters and test gauges (60 bar/1,000 psi) at the gear pump outlet port, and at the joystick control valve pilot line.
Page 241: Power Mode Valve
The jumper harness (which is available through Daewoo After Sales Service, or could be spliced together from commonly available, purchased parts) has extra leads so that a VOM meter can be connected to the circuit.
Page 242: Boom/Front Priority Valve
BOOM/FRONT PRIORITY VALVE CONTROL VALVE PRESSURE AND CURRENT ADJUSTMENTS WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made. The front priority control valves are located inside the compartment behind the cabin.
Page 243: Pressure Up Valve
PRESSURE UP VALVE CHECKS AND ADJUSTMENTS WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made. Vent hydraulic pressure from the reservoir to install an in-line "t-style" adapter and test gauge (60 bar/1,000 psi) at the pilot pump signal port relief valve outlet.
Page 244 NOTE: The electrical pressure up (power boost) solenoid valve located alongside the swing priority solenoid and arm speed control solenoid, in compartment rear of the operator’s cab, must be operating correctly, or pressure tests and further adjustments cannot be made. S0702190K Hydraulic System Troubleshooting, Testing and Page 16...
Page 245: Pump Input Power Control
PUMP INPUT POWER CONTROL PUMP REGULATOR ADJUSTMENT WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made. To perform these adjustments accurately the use of a flow meter is strongly recommended, as is consulting the factory (before starting work) to validate the need for making regulator adjustments.
Page 246 ASS0320L Figure 12 Refer to the illustration of the pump regulator control valve (Figure 12) for the location of adjustment screws (1, 2 and 3). There are three different adjustments, Qmax, Pi-Q Pd-Q, adjustment screws (1, 2 and 3). Each one of the adjustment procedures could affect the setting of the others. Check and record the arm dump speed performance test before and after input power adjustment, whether or not a flow meter is used.
Page 247 Start the engine and turn the engine speed dial maximum. When normal operating temperature reached, adjust screw clockwise to shift the Pi-Q control valve curve decrease compensating control pressure. A 1/2 turn on the adjusting screw is equal to approximately -0.7 kg/cm of Pi.
Page 248: Flow Meter And Flow Meter Kit Installation And Testing
The After Sales Service department of the nearest local Daewoo dealer can assist you with these tests or, if you prefer carrying out your own testing, they should be able to help in putting together a hose and fitting kit (or the required dimensions and specifications for hoses and fittings) to allow you to install a flow meter downstream from the main pump assembly.
Page 249 Engine RPM Pressure Flow 100 kg/cm (1,422 psi) 135 kg/cm (1,930 psi) 180 kg/cm (2,560 psi) 240 kg/cm (3,413 psi) 320 kg/cm (4,550 psi)* *See Note, below Compare recorded values with output shown in the P-Q curve in the specifications section of this book. If test results do not measure up to specified values, pump output tests can be repeated using different control levers.
Page 250: Swing System Troubleshooting
SWING SYSTEM TROUBLESHOOTING PRECAUTIONS/INITIAL CHECKS Stop work. Release all weight or any type of load safely before proceeding. Avoid risking injury or adding to damage. Turn off engine and disengage control functions until initial tests are ready to be made. WARNING Prevent possible injury and/or loss of operating control.
Page 251 Connect a 10 bar (145 psi) gauge at the motor makeup valve. Pressure should stay consistently above 2.5 bar (36 psi). If pressure falls below the recommended minimum level, forceful acceleration of the swing motor could lead to cavitation of the circuit and stalling, slowed rotation, noise and possible damage. If main inlet and outlet pressures were off in the preceding tests in Step 1, adjust swing relief valve pressure.
Page 252: Troubleshooting - Swing Gearbox
TROUBLESHOOTING - SWING GEARBOX Problem Possible Causes Remedies Swing motor fails to operate and: Three pressure tests at motor, Swing relief valve defective Adjust pressure brake or makeup valve show low Brake release valve defective recommended range in affected reading(s). Motor makeup valve defective.
Page 253: Troubleshooting - Hydraulic Problems
Problem Possible Causes Remedies Swing movement is in one If pilot pressure is unequal, Check to see that pilot pressure direction only. clean or repair piping or repair/ is the same right and left. replace valve. Swing control valve spool may Repair/Replace swing be stuck.
Page 254 Problem Possible Causes Remedies Sluggish performance of Main pump(s) damaged or worn. Repair or replace. hydraulic functions - attachment, Main relief valve pressure off. Readjust pressure. swing and travel. Low oil level in hydraulic system. Refill. Hydraulic reservoir intake Clean. strainer clogged.
Page 255: Troubleshooting - Control Valve
Problem Possible Causes Remedies Swing motor operates unevenly. Swing gear, bearing or mounting Repair or replace loose or worn. Lubricant worn away, Grease inadequate. Repair/Replace the swing relief Swing relief valve may be faulty. valve. TROUBLESHOOTING - CONTROL VALVE Check control valve problems only after other hydraulic circuit operational tests have been made. Refer to the "Troubleshooting Baseline Recommendations"...
Page 256: Troubleshooting - Travel Control Valve
Problem Possible Causes Remedies Swing priority not operating Sticking spool. Clean/replace. correctly. Solenoid valve faulty. Replace. Boom and arm cylinders do not Priority valve faulty or spool Check pilot pressure. perform normally in combined sticking. operation. Broken or deformed spring. Replace.
Page 257: Troubleshooting - Joystick Control Valve
TROUBLESHOOTING - JOYSTICK CONTROL VALVE Problem Possible Causes Remedies Secondary pressure does not Low primary pressure. Check primary pressure. increase. Broken spring. Replace spring. Spool sticking. Clean, repair or replace. Excess spool casing Replace spool casing. clearance. Worn loose handle Repair replace handle...
Page 258 S0702190K Hydraulic System Troubleshooting, Testing and Page 30 Adjustment...
Page 259 ACCUMULATOR S0703010K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Accumulator S0703010K Page 1...
Page 260 TABLE OF CONTENTS General Description..................3 Specifications ..................4 S0703010K Accumulator Page 2...
Page 261 GENERAL DESCRIPTION The accumulator is a gas-charged storage device designed to hold a reserve quantity of hydraulic fluid under pressure. Accumulators are used in hydraulic circuits in much the same way that condensers (or capacitors) are used to collect, store and maintain electrical charge in a circuit.
Page 262 NOTE: Pre-charge pressure is referred to as the "P1" pressure. The accumulator manufacturer’s "P1" rated pressure should be stamped or marked on the accumulator’s rating plate. Annual checks of actual pre-charge pressure should be made by tapping a hydraulic pressure gauge (and 3-way adapter coupling) into the valve on the bottom of the accumulator.
Page 263 Charge Model Serial Number System Volume Pressure 320 cc S/N 1001 thru 1049 (19.53 in 10 kg/cm Solar 470LC-V Pilot / Travel (140 psi) 750 cc S/N 1050 and Up (45.77 in Accumulator S0703010K Page 5...
Page 264 S0703010K Accumulator Page 6...
Page 265 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. CENTER JOINT (SWIVEL)S0704090K MODEL SERIAL NUMBER RANGE Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Center Joint (Swivel) S0704090K...
Page 266 TABLE OF CONTENTS General Description..................3 Parts List ....................4 Troubleshooting, Testing and Adjustment............5 Inspection....................5 Testing..................... 5 Disassembly ....................6 Reassembly....................7 S0704090K Center Joint (Swivel) Page 2...
Page 267: General Description
GENERAL DESCRIPTION The center joint (swivel) is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure. It is capable of allowing continuous 360° rotation of the upper structure in relationship to the lower structure.
Page 268: Parts List
PARTS LIST Figure 1 Reference Reference Description Description Number Number Center Joint Body Hex Bolt Spindle Spring Washer O-ring Plug Slipper Seal Plug O-ring Spring Washer Cover Bolt S0704090K Center Joint (Swivel) Page 4...
Page 269: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT INSPECTION The center joint should be checked for evidence of external oil leakage every 2,000 hour of operation. Leaking or defective O-rings are an indication that dirt and other contaminants could be getting inside the assembly, which will promote accelerated, abnormal wear and may cause early failure of the assembly. If internal seals or other sliding surface components are worn and there is internal fluid leakage, complete overhaul and repair or replacement of the center joint may be required.
Page 270: Disassembly
DISASSEMBLY Refer to the assembly drawing of the swivel joint for component references (Figure 1). IMPORTANT Do not unbolt the center joint from the lower car body until an adequate number of piping block- off plates are available, for disconnected piping lines. Be sure that system pressure has been vented - including the hydraulic accumulator and tank reserve pressure - before disassembly is started.
Page 271: Reassembly
REASSEMBLY Pre-lubricate O-rings with hydraulic oil, white grease or petroleum jelly. CAUTION! Apply a very light film of white grease or petroleum jelly to the lower rim of the spindle and inner surface of the center swivel body. Apply slow, even-handed pressure, using both hands, to slowly push the spindle into the body.
Page 272 S0704090K Center Joint (Swivel) Page 8...
Page 273 1001 and Up Solar 330LC-V 1001 and Up Solar 340LC-V 1001 and Up Solar 400LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Cylinders S0705000 Page 1...
Page 274 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Parts List ....................4 Special Tools and Materials................6 Piston Nut....................6 Piston Jig....................10 Steel bush Jig..................14 Dust Wiper Jig..................18 Slipper Seal Jig ..................22 Slipper Seal Straightening Jig ............... 26 Disassembly ....................
Page 275: General Description
GENERAL DESCRIPTION Two essentially similar types of hydraulic cylinders are used on the excavator. The cylinder that is used to operate the excavator boom or bucket is equipped with a rod stopper, which acts as a cushion only when the cylinder rod is fully retracted (and the bucket is pulled close to the arm). This type of cylinder is shown in the lower drawing.
Page 276: Parts List
Because the volume of oil needed to lengthen the cylinder rod (Q1) is greater than the volume of oil required to retract the cylinder rod, it takes more time to decrease cylinder stroke length than it does to lengthen it. = S x π(B Figure 3 = S x π(B...
Page 277 Reference Reference Description Description Number Number Bushing Piston Dust Wiper Slide Ring Retaining Ring Wear Ring U-Packing Slipper Seal Buffer Seal O-ring Rod Bushing Backup Ring Bolt Piston Nut Retaining Ring Set Screw Rod Cover Cushion Plunger O-ring Bushing O-ring Check Valve Backup Ring Spring Support...
Page 278: Special Tools And Materials
SPECIAL TOOLS AND MATERIALS PISTON NUT -0.1 -0.2 (C3~C5) ∅ Through Hole R(R15 ~ R20) ARS4730L Figure 6 Material SM45C (AISI 1045) Rockwell Harden from 22 - 27 Oil Quench S0705000 Cylinders Page 6...
Page 279 Cylinders S0705000 Page 7...
Page 280 S0705000 Cylinders Page 8...
Page 281 Cylinders S0705000 Page 9...
Page 282: Piston Jig
PISTON JIG 2-∅"B" ∅ Through Hole R(R15~20) ARS4740L Figure 7 Material SM45C (AISI 1045) Rockwell Harden from 22 - 27 Oil Quench S0705000 Cylinders Page 10...
Page 283 MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER) 80.0 mm 11.0 mm 45.0 mm 100.0 mm S55-V (BOOM (OP)) BOOM (3.15 in) (0.43 in) (1.77 in) (3.94 in) S55W-V (BOOM) S55-V 58.0 mm 11.0 mm 38.0 mm 80.0 mm SWING MEGA 300 (P/S) (2.28 in)
Page 284 MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER) P/S: Power Steering O/R: Out Rigger S0705000 Cylinders Page 12...
Page 285 Cylinders S0705000 Page 13...
Page 286: Steel Bush Jig
STEEL BUSH JIG (∅20) ARS4750L Figure 8 Material: SM45C which is done thermal refining <QT> Hrc 22 - 28 Undefined Chamfer C/R = 0.5 Max. Place: Finally work to used DNMG Tip <Nose R0.4> S0705000 Cylinders Page 14...
Page 287 -0.05 +0.05 MODEL CYLINDER øA øB (±0.1) Part MODEL (CYLINDER) -0.15 50.0 mm 65.0 mm 30.0 mm BOOM S55W-V (BOOM) (1.97 in) (2.56 in) (1.18 in) 40.0 mm 50.0 mm 20.0 mm S55-V SWING (1.58 in) (1.97 in) (0.79 in) 65.0 mm 70.0 mm 30.0 mm...
Page 288 -0.05 +0.05 MODEL CYLINDER øA øB (±0.1) Part MODEL (CYLINDER) -0.15 S330LC-V (ARM, BOOM, BUCKET) S340LC-V (ARM, BOOM, 7.5 mm BUCKET) BUCKET 100 mm 115 mm 45 mm S330LC-V (0.30 S370LC-V (ARM, BOOM, (OP) (3.94 in) (4.53 in) (1.77 in) BUCKET) MEGA 300-V (BUCKET) MEGA 400-V (BUCKET)
Page 289 Cylinders S0705000 Page 17...
Page 290: Dust Wiper Jig
DUST WIPER JIG ARS4760L Figure 9 Material: SM45C which is done thermal refining <QT> Hrc 22 - 28 Undefined Chamfer C/R = 0.5 Max. Place: Finally work to used DNMG Tip <Nose R0.4> S0705000 Cylinders Page 18...
Page 291 -0.2 -0.2 MODEL CYLINDER øA øB MODEL (CYLINDER) -0.3 -0.3 -0.1 35.0 mm 47.0 mm 6.0 mm TILT (1.38 in) (1.85 in) (0.24 in) 45.0 mm 57.0 mm 0.5 mm 6.0 mm DD80L DOZER DD80L (ANGLE) (1.77 in) (2.24 in) (0.02 in) (0.24 in) 45.0 mm...
Page 292 -0.2 -0.2 MODEL CYLINDER øA øB MODEL (CYLINDER) -0.3 -0.3 -0.1 S340LC-V (ARM) S420LC-V (BOOM) S470LC-V (BOOM, BUCKET) 115.0 mm 131.0 mm 6.0 mm 7.0 mm ARM (STICK) S370LC-V (ARM) (4.53 in) (5.16 in) (0.24 in) (2.28 in) S360LC-V (ARM) S400LC-V (BOOM) S220LL S450LC-V (BOOM, BUCKET)
Page 293 -0.2 -0.2 MODEL CYLINDER øA øB MODEL (CYLINDER) -0.3 -0.3 -0.1 120.0 mm 136.0 mm 9.0 mm 7.0 mm S420LC-V (ARM) (4.72 in) (5.35 in) (0.35 in) (2.28 in) S290LL (ARM (STICK)) 115.0 mm 131.0 mm 6.0 mm 7.0 mm S400LC-V BOOM (4.53 in)
Page 294: Slipper Seal Jig
SLIPPER SEAL JIG (B+40) ARS4770L Figure 10 S0705000 Cylinders Page 22...
Page 295 +0.2 +0.2 MODEL CYLINDER øA MODEL (CYLINDER) +0.1 +0.1 85.0 mm 32.0 mm S55W-V (ARM) (3.35 in) (1.26 in) 110.0 mm 21.5 mm S55-V (BOOM (OP)) BOOM (4.33 in) (0.85 in) S55W-V (BOOM) S55-V 80.0 mm 30.0 mm S55W-V (BUCKET, SWING) SWING (3.15 in) (1.18 in)
Page 296 +0.2 +0.2 MODEL CYLINDER øA MODEL (CYLINDER) +0.1 +0.1 135.0 mm 28.5 mm S220LC-V (ARM) S200W-V BOOM (5.32 in) (1.12 in) S220N-V (ARM (OP)) P/S: Power Steering S0705000 Cylinders Page 24...
Page 297 Cylinders S0705000 Page 25...
Page 298: Slipper Seal Straightening Jig
SLIPPER SEAL STRAIGHTENING JIG ∅ ARS4780L Figure 11 S0705000 Cylinders Page 26...
Page 299 +0.2 CYLINDER øA MODEL (CYLINDER) +0.1 85.0 mm S55W-V (ARM) (3.35 in) 110.0 mm S55-V (BOOM (OP)) BOOM (4.33 in) S55W-V (BOOM) S55-V 80.0 mm S55W-V (BUCKET, SWING) SWING (3.15 in) MEGA 300-III P/S 100.0 mm DOZER S55W-V (DOZER) (3.94 in) S55-V (ARM) 85.0 mm S70-III...
Page 300 +0.2 CYLINDER øA MODEL (CYLINDER) +0.1 135.0 mm S220LC-V (ARM) S200W-V BOOM (5.32 in) S220N-V (ARM (OP)) P/S: Power Steering S0705000 Cylinders Page 28...
Page 301: Disassembly
DISASSEMBLY CAUTION! Vent air from the hydraulic system before disconnecting cylinder piping connections. Use the lever on the reservoir, while the engine is running. Discharge the hydraulic accumulator and vent residual tank pressure after the engine is shut off. Pour clean replacement fluid back into the system if excessive fluid is lost.
Page 302 Tap two bolts into cover of cylinder head, 180° apart. Tighten them in a staggered, even sequence, to back off piston rod end cover from edge of cylinder wall. Look for adequate clearance between cover and end of cylinder wall before using a plastic or other soft-faced hammer for final disassembly.
Page 303 Figure 19 Fabricate or purchase a piston nut removal wrench. (Dimensions are called off at beginning of this procedure. This tool may also be ordered through your local Daewoo Parts distributor). Remove nut from end of piston. Figure 20 Cylinders S0705000...
Page 304 10. Use second piston tool described at beginning of this procedure to separate piston. Detach cushion ring (15), taking care not to damage cushion ring. Figure 21 11. Use a plastic hammer to evenly pull off rod cover (9) from end of piston rod. Be careful not to damage rod bushing (6) and dust wiper, U-packing and other seals.
Page 305 14. Pull off O-ring (20) and backup ring (21) from cylinder head. HAOF38OS Figure 25 15. During disassembly of cylinder head, be careful not to damage buffer seal (5) and U-packing (4). HAOF39OL Figure 26 16. Disassemble retaining ring (3) and dust wiper (2).
Page 306 17. Force out pin bushing (1) from body of cylinder. Figure 28 S0705000 Cylinders Page 34...
Page 307: Reassembly
REASSEMBLY IMPORTANT Replace any part that shows evidence of damage or excessive wear. Replacement of all O-rings and flexible seals is strongly recommended. Before starting the cylinder reassembly procedure, all parts should be thoroughly cleaned and dried, and/or prelubricated with clean hydraulic fluid. Prepare the work area beforehand to maintain cleanliness during the reassembly procedure.
Page 308 Pre-lubricate O-rings and seals before reassembly (Figure 31). Figure 31 Before starting to rebuild piston assembly, heat slipper seal for 5 minutes in an oil bath warmed to 150° - 180°C (302° - 356°F). Use special slipper seal jig (third item in list of specialized tools at the beginning of this procedure) to attach seal.
Page 309 Use specially fabricate or factory-sourced tool to tighten piston nut (22). Figure 35 Assemble wear ring (18), slide ring (17) and set screw (23) to piston assembly. Reference Description Number Set Screw Figure 36 Immobilize body cylinder before reassembly. Figure 37 10.
Page 310 S0705000 Cylinders Page 38...
Page 311 Remember, that ultimately safety is your own personal responsibility. SWING MOTOR S0707260 MODEL SERIAL NUMBER RANGE Solar 170LC-V 1001 and Up Solar 170W-V 1001 and Up Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Swing Motor S0707260 Page 1...
Page 312 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Swing Motor Anti-cavitation Make-up Valve ..........4 Relief Valve ..................... 5 Swing Brake Operation ................6 Parts List ....................8 Specifications ..................10 Special Tools ....................11 Disassembly ....................12 Cleaning and Inspection (Wear Limits and Tolerances) .......
Page 313: General Description
GENERAL DESCRIPTION THEORY OF OPERATION Figure 1 Reference Reference Description Description Number Number Valve Plate Cylinder Block Shoe Piston Swash Plate The cross sectional views of the swing motor, show most of the main components of an axial-piston type hydraulic motor. Arrows indicating direction of flow and other graphic symbols provide a general guide for understanding basic operation (Figure 1).
Page 314: Swing Motor Anti-Cavitation Make-Up Valve
If oil flow to the motor is directed to the opposite port (so that the supply side becomes the exhaust side and vice versa), the rotation of the motor is reversed. Trench mode allows the operator to "prioritize" hydraulic oil flow between swing function and boom and arm function.
Page 315: Relief Valve
RELIEF VALVE The relief valve is one in a set of two, and is Item "51" of the swing motor assembly. Return line pressure (the normal pressurization of the hydraulic reservoir, also referred to as "tank pressure") pushes the valve piston to open ports "R"...
Page 316: Swing Brake Operation
SWING BRAKE OPERATION The swing brake is normally held in the applied position - preventing the upper deck revolving superstructure from rotating - whenever the hydraulic system is not operated (pressurized). The brake system is automatically released whenever the swing controls are engaged to swing in one direction or the other.
Page 317 Swing Motor S0707260 Page 7...
Page 318: Parts List
PARTS LIST HAAA4340 Figure 4 S0707260 Swing Motor Page 8...
Page 319 Reference Reference Description Description Number Number Brake Valve Socket Bolt 31-1 O-ring Snap Ring 31-2 O-ring Snap Ring Relief Valve Snap Ring 51-1 O-ring Snap Ring 51-2 Backup Ring Roller Bearing Reactionless Swing Valve Roller Bearing 52-1 O-ring Spring Pin Drive Shaft VP Plug Spacer...
Page 320: Specifications
SPECIFICATIONS Specification Solar 170W-V Item Solar 450LC-V Solar 220LC-V Solar 170LC-V Solar 470LC-V Solar 220LL Type Axial Piston 121.6 cc/rev 128.0 cc/rev 2 x 128.0 cc/rev Displacement (18.85 in /rev.) (7.81 in /rev.) (2 x 7.81 in /rev.) Crossover Relief...
Page 321: Special Tools
SPECIAL TOOLS Figure 5 Swing Motor S0707260 Page 11...
Page 322: Disassembly
DISASSEMBLY The area where the motor is going to be rebuilt should be well lighted, clean and protected from dust and/or wind gusts that could carry grit or dust. Use a rubber mat or other protective covering on the workbench area to prevent damage or scratching of any precision machined components. IMPORTANT Clean all of the exterior surfaces of the motor before disassembly.
Page 323 Make two permanent marks on exterior of motor to indicate assembly position of motor casing (301) and upper valve casing (303). Figure 8 Disassemble brake valve (31) from side of casing. Figure 9 Remove relief valve assemblies (51) from upper valve casing (303). Figure 10 Remove RO plug (469) from upper valve casing (303).
Page 324 Remove all four socket head bolts (401) and separate upper valve casing (303) from lower casing (301). NOTE: Valve plate (131) inside upper valve casing (303) must be separated from assembly but take extra care to make sure that it is not scratched or damaged by an accidental fall, after cover is removed.
Page 325 11. Reposition motor so that end of drive shaft faces out to one side. Pull out cylinder block (111) and disassemble pistons (121), retainer plate (123), spherical bushing (113), front spacer (117) and shoe plate (124). Be careful not to make any scratches or leave nicks on reciprocating parts.
Page 326 14. Separate casing and drive shaft (101). Tap upper end of drive shaft with a soft-faced, plastic hammer. To avoid damaging drive shaft, do not use excessive force. Figure 18 15. Tap bearing race out of casing. Figure 19 16. Disassembly of motor has now been completed, unless there is any reason to suppose that drive shaft bearing has become excessively worn.
Page 327 NOTE: Final disassembly of individual components may also require: Disassemble oil seal from the front cover if they were not separated during removal. Apply force (2, Figure 21) and use a plug (1) to hammer through drive shaft opening in cover. Reference Description Number...
Page 328 Relief valves can be replaced in sets by ordering one part number through your authorized Daewoo dealer/parts distributor. To disassemble relief valves, pull out plug (201, Figure 4), disassemble bushing (343), spring (322) and spring seat (331) from rod (303). Position valve housing facing...
Page 329: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) Inspect all components and precision surfaces, to confirm that they haven’t been worn beyond service limits. Refer to table below for dimensional specifications. All parts should be cleaned, air-dried and re-lubricated with clean, approved-type hydraulic fluid, before final reassembly or as the final step after the unit has been put back together.
Page 330 Service Standards for Replacing Worn Parts NOTE: When parts exceed the standard, replace them. When there is conspicuous surface damage, it is always safer to replace parts, whether standards are exceeded or not. Standard Value Replacement Item Remedy mm (In) Limit mm (In) Clearance between cylinder 0.028 mm...
Page 331: Reassembly
REASSEMBLY Reassembly of the motor is basically accomplished by reversing disassembly steps. Use a torque wrench to make sure that assembly fasteners are tightened to specified values. Always begin a bolt tightening sequence from the innermost part of the assembly, working outward toward the ends in careful, even rotation.
Page 332 Reassemble drive shaft (101, Figure 4), roller bearing (443) and lower casing (301). Pay attention to bearing alignment inside bore of case. Make sure it is fully seated. Figure 29 There is a "right side" and "wrong side" on oil seal. Be careful that you install seal inside cover with correct side facing in.
Page 333 Use snap-ring pliers to replace lock ring (437) into lower casing (301). Figure 33 Turn motor sideways and assemble shoe plate (124), placing it in motor housing in same position it was in before removal. Using grease on assembled side can help keep individual components in place.
Page 334 11. Put cylinder block (111) and retainer plate (123) back in motor. Spherical bushing and grooves of cylinder block splines should fit together without undue difficulty. (Do not try to force or pound parts together.) Figure 37 12. Turn motor so that front cover side (304) is down.
Page 335 15. Reinstall brake springs, making sure that each gets fully seated on piston. Figure 41 16. Tap roller bearing (444) race back into upper valve casing (303), using hammer and copper rod specified in tool list. Figure 42 17. Assemble valve plate (131), O-ring and upper valve casing...
Page 336 19. Put plungers (351), springs (355), O-rings (488), and RO plugs (469) back in casing. Make sure that both plungers are free to move back and forth. Figure 45 20. Reassemble relief valves (51) by putting rod, spring, stop and piston back together, then turning plunger side of valve up to reassemble valve...
Page 337 22. Replace the VP plugs (464, 468) and O- rings (485, 487) on each of the three plugs. Reinstall the brake cutoff valve (31). Figure 49 Swing Motor S0707260 Page 27...
Page 338 S0707260 Swing Motor Page 28...
Page 339 Remember, that ultimately safety is your own personal responsibility. TRAVEL MOTOR (WITH GEARBOX) (A6V160HD)S0707365 MODEL SERIAL NUMBER RANGE Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 1...
Page 340 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Hydraulic Motor Operation ..............4 Reduction Gearbox Operation .............. 11 Parts List ....................12 Specifications ..................20 Tightening Torques................21 Travel Motor Disassembly................23 Sectional View..................23 Seal Kits and Component Groups............24 Sealing Drive Shaft ................
Page 341: General Description
GENERAL DESCRIPTION THEORY OF OPERATION Refer to the assembly cross-section at the end. Travel motor consists of the hydraulic motor and reduction gearbox. Hydraulic motor consists of the rotary part, cross relief valve, negative brake, counter balance valve and tilting parts. The reduction gearbox consists of a 3-speed planetary gearbox. The next figure shows the motor as a symbol.
Page 342: Hydraulic Motor Operation
HYDRAULIC MOTOR OPERATION Hydraulic Motor operation. Figure 2 The high pressure oil from the hydraulic pump goes to the cylinder block (104) through the rear flange (101) of the motor and the brake valve device and the timing plate (109). This high pressure oil acts only on the single side of the line Y1-Y2 which connects the bottom dead center and the top dead center of the piston (105) stroke.
Page 343 Brake Valve During Travel. Figure 3 If the pressure oil is supplied from port A, this oil opens the valve (130), flows into the inlet port C of the hydraulic motor, and turns the hydraulic motor. At the same time, the oil, which flows from a small hole of the spool (126) to the chamber b through passage a, exerts pressure on the spool section, and moves the spool to the left over spring (128) force.
Page 344 When Stopping by Deceleration. Figure 4 If the pressure oil supplied by the port A is cut off during drive. there will be no hydraulic force. Then, the spool (126) returns to the right (neutral position) through the stopper (125) by the spring (128).
Page 345 Parking Brake During Travel. If the pressure oil is supplied by the brake valve, the brake valve spool of the hydraulic motor part is operated, and the passage into the parking brake is opened. So the pressure oil flows into the cylinder a which consists of a spindle and a piston.
Page 346 During Braking. If the pressure of the cylinder drops below kg/cm because pressure oil of the brake valve is blocked, the piston (112) returns by the spring (113) force. If the piston (112) is pushed by the spring force, the separator plate (116) and the friction plate (115) are pushed to the spindle of the reduction device.
Page 347 4. High and Low Speed Switching Device At low speed (If the pilot pressure is lower than 10 kg/cm Figure 7 If pilot pressure is not applied from port A (If the pressure is lower than 10 kg/cm ), the valve (163) is pushed to the left by the spring (I66) force, the pressure oil from the supply port B is blocked, and the oil of the chamber C flows through the valve (l63) into the motor case.
Page 348 At high speed (If the pilot pressure is higher than 20 kg/cm Figure 8 If pilot pressure is supplied from port A (If the pressure is higher than 20 kg/cm ), the valve (163) is pushed to the right bv the spring (166) force, the pressure oil from the supply port B goes through valve (163) into the chamber C.
Page 349: Reduction Gearbox Operation
REDUCTION GEARBOX OPERATION This reduction gear is a combined system of planetary gear and differential gear, It reduces rotational speed, while increasing output torque of the hydraulic motor, and rotates the gear case. Planetary gear If the sun gear (S) connected to the input shaft rotates, the planetary gear (P) turns (P1) (P2)
Page 350: Parts List
PARTS LIST Travel Motor HTS6331 Figure 12 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 12...
Page 351 Reference Reference Description Qty. Description Qty. Number Number 6315-- Travel Motor Backup Plate Rotary Group O-ring Control Rocking Screw Housing Threaded Pin Retaining Ring Seal Lock Nut Shaft Seal Ring S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 13...
Page 352 Travel Motor - Rotary Group HTS6321 Figure 13 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 14...
Page 353 Reference Reference Description Qty. Description Qty. Number Number 6325-- Rotary Group Retaining Plate Rotary Screw Cylinder Drive Shaft Control Lens Shim Center Pin Backup Plate Piston Retaining Ring Steel Sealing Ring Tapered Roller Bearing Adjustment Shim Tapered Roller Pressure Spring Bearing Travel Motor (With Gearbox) (A6V160HD) S0707365...
Page 354 Travel Motor - Control HTS6331 Figure 14 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 16...
Page 355 Reference Reference Description Qty. Description Qty. Number Number 6335-- Control Bush Brake Valve Socket - Head Screw Throttle Pin Socket - Head Valve Screw Pressure Control Socket - Head Valve Screw Pressure Relief Cylinder Pin Valve Rocking Screw Port Plate Rocking Screw Positioning Piston O-ring...
Page 356 Travel Motor Speed Reduction Gearbox Assembly 3033 Figure 15 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 18...
Page 357 Reference Description Qty. Reference Description Qty. Number Number Washer Spacer Breather Plug Brake Shaft Screw O-ring Cover Set Disc O-ring Ring, Steel Ring, Backup Sun Gear O-ring 1st Red Assembly O-ring Sun Gear Ring, Spiral 2nd Red Gear Piston Assembly Spring Screw, Uni 5931 Spacer...
Page 358: Specifications
SPECIFICATIONS Name Plate Identification A6VE 160 HZ3 / 63W - V Z L - 220B - S Reference Description Number Unit With CBV, Brake Release Valve and Relief Valves Incorporated Beginning of Regulation At Max Displacement 2 hole Flange Drive Shaft 45 mm Diameter Vitron Seals Alternating Direction of Rotation Series...
Page 359: Tightening Torques
Component specifications are shown in following table. Item Unit Specification Rated Torque kg•m 81.5 Max Rotation Rate 3680@99 cc/rev Max Output/rev cc/rev Operating Rotation 2900 Max Output Pressure kg/cm 2 Speed Switching Pressure Auto. Switching kg/cm Parking Brake Torque kg•m 11.140 kg•m Parking Brake Releasing Pressure kg/cm...
Page 360 Tightening Torques For Locking Screws Vsti (Metric ISO Fine Thread) Thread Size Designation Tightening Torques Tightening Torques (Ib.ft) (Nm) M 8 x 1 VSTI 8x1 -ED/SA M 10 x 1 VSTI 10x1 M 12 x 1,5 VSTI 12x1,5 M 14 x 1,5 VSTI 14x1,5 M 16 x 1,5 VSTI 16x1,5...
Page 361: Travel Motor Disassembly
TRAVEL MOTOR DISASSEMBLY SECTIONAL VIEW HTS063S Figure 16 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 23...
Page 362: Seal Kits And Component Groups
SEAL KITS AND COMPONENT GROUPS NOTE: Observe the following notices when carrying out repair work at hydraulic aggregates! HTS001S Figure 17 Close points hydraulic aggregates. HTS002S Figure 18 Replace all seals. NOTE: Use only original spare parts. HTS003S Figure 19 Check all seal and sliding surfaces for w ear.
Page 363 Full up hydraulic aggregates with hydraulic oil before start-up. HTS005S Figure 21 Seal kit for drive shaft. HTS006S Figure 22 External seal kit. HTS007S Figure 23 Housing. HTS008S Figure 24 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 25...
Page 364 Complete rotary group. HTS009S Figure 25 Port plate with control piston and counter- balance valve. HTS010S Figure 26 10. Relief valve / Make up check valve. HTS011S Figure 27 11. Replace seal nut. NOTE: First measure record setting height. HTS012S Figure 28 S0707365 Travel Motor (With Gearbox) (A6V160HD)
Page 365: Sealing Drive Shaft
12. When tightening, counter hold setting screw, then check setting height. HTS013S Figure 29 SEALING DRIVE SHAFT HTS014S Figure 30 Protecting the drive shaft. Remove retaining ring and shim. HTS015S Figure 31 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 27...
Page 366: Sealing Control Parts
Screw in sheet metal screw into the holes fitted with rubber. Pull out seal with pliers. HTS016S Figure 32 Press in shaft seal and shim with bush to stop. NOTE: Pay attention to pressing depth! * Mark for pressing depth. Assemble retaining ring.
Page 367: Disassembly Port Plate
Inspect O-ring. HTS021S Figure 36 DISASSEMBLY PORT PLATE Note dimension X. Remove Q -screw. HTS023S Figure 37 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 29...
Page 368 For disassembly of the port plate, swivel always rotary group to zero position. Piston rings to hang out the cylinder boring. Swivel rotary group to zero position with screw Q max. HTS024S Figure 38 Port plate. Mark position. Loosen screws. Remove.
Page 369 Braking valve. HTS027S Figure 41 Throttle pin. HTS028S Figure 42 Valve. HTS029S Figure 43 10. Pressure control valve. HTS030S Figure 44 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 31...
Page 370 11. Pressure relief valve. HTS031S Figure 45 12. Positioning piston. HTS032S Figure 46 13. H-Z- control. HTS033S Figure 47 14. Check valve. HTS034S Figure 48 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 32...
Page 371 HTS035S Figure 49 HTS036S Figure 50 15. Screw in threaded pin into center pin. 16. Fix the cylinder with disc and locknut. HTS037S Figure 51 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 33...
Page 372: Exchanging Rotary Group
17. Press out rotary group. NOTE: If the bearings are used again do not hit on the drive shaft. HTS038S Figure 52 EXCHANGING ROTARY GROUP Complete rotary group. NOTE: Setting hydraulic part necessary. HTS039S Figure 53 Rotary group. • Mechanical part; Adjust drive shaft with bearing.
Page 373 Disassemble retaining plate. NOTE: screws are glued. Use Torx- tools. HTS042S Figure 56 Free of corrosion, erosion or fretting; No damage to splines or keyways. HTS043S Figure 57 Pistons; No scoring and no pitting. HTS044S Figure 58 Center pin; No scoring and no pitting. HTS045S Figure 59 Travel Motor (With Gearbox) (A6V160HD)
Page 374 Retaining plate; No scoring and no evidence of wear. HTS046S Figure 60 10. Cylinder block / control lens; Bores free of scoring, no evidence of wear. Faces smooth and even, free of cracks and scoring. HTS047S Figure 61 11. Control housing; Sliding surface and side guides free of scoring and no wear.
Page 375: Travel Motor Speed Reduction Gearbox Disassembly
TRAVEL MOTOR SPEED REDUCTION GEARBOX DISASSEMBLY Drain gear oil and remove travel motor and O-ring. Remove motor flange (8 socket bolts, M16 x 35). Figure 64. 3034 Figure 64 Remove O-ring from motor flange. Figure 3035 Figure 65 Remove O-ring from hub groove. Figure 66. 3036 Figure 66 Travel Motor (With Gearbox) (A6V160HD)
Page 376 Attach disc (B, Figure 67) to spring retainer; fasten pusher (A) to hub and install screw rod (C). 3037 Figure 67 Remove retaining ring from hub groove using pliers. Figure 68. 3038 Figure 68 Remove jig and retaining ring. Figure 69. 3039 Figure 69 S0707365...
Page 377 Remove spring retainer. Figure 70. 3040 Figure 70 Pull spring from groove. Figure 71. 3041 Figure 71 10. Blow air into brake port hole and remove brake piston using pliers. Figure 72. 3042 Figure 72 11. Remove brake shaft. Figure 73. 3043 Figure 73 Travel Motor (With Gearbox) (A6V160HD)
Page 378 12. Remove disc. Figure 74. 3044 Figure 74 13. Remove O-ring and backup ring. Figure 75. 3045 Figure 75 14. Turn reduction gear assembly over and remove 2 plugs (M22 x 1.5). Figure 76. 3046 Figure 76 15. Remove 16 socket bolts (M14 x 40). Figure 3047 Figure 77 S0707365...
Page 379 16. Remove end cover, using puller. Figure 78. 3048 Figure 78 17. Remove O-ring from end cover groove. Figure 79. 3049 Figure 79 18. Remove first sun gear. Figure 80. 3050 Figure 80 19. Remove first planetary gear assembly. Figure 81. 3051 Figure 81 Travel Motor (With Gearbox) (A6V160HD)
Page 380 20. Remove second sun gear. Figure 82. 3052 Figure 82 21. Remove second planetary gear assembly. Figure 83. 3053 Figure 83 22. Remove third sun gear. Figure 84. 3054 Figure 84 23. Remove bolts (4, M 30 x 150) from third planetary gear assembly.
Page 381 24. Remove bolts. Figure 86. 3056 Figure 86 25. Separate hub from reduction gear housing, using press and stopper. Figure 87. NOTE: remove main ball bearing. 3057 Figure 87 26. Remove third shift assembly from hub. Figure 88. 3058 Figure 88 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 43...
Page 382 27. Remove bushing from hub using a jig. Figure 89. 3059 Figure 89 28. Remove bearing inner race and spacer from hub, using puller. Figure 90. 3060 Figure 90 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 44...
Page 383 29. Remove gasket. Figure 91. 3061 Figure 91 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 45...
Page 384: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Gearbox Inspection If a gear is damaged, replace the damaged gear and the interlocking gear next to it. If one planetary gear is damaged, replace the entire planetary gear assembly.
Page 385: Travel Motor Speed Reduction Gearbox Reassembly
TRAVEL MOTOR SPEED REDUCTION GEARBOX REASSEMBLY Install seal to jig. Figure 92. HTS3062S 3062 Figure 92 Install jig to housing. Figure 93. 3063 Figure 93 Clean seal surface. Figure 94. 3064 Figure 94 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 47...
Page 386 Install seal to hub using jig used in Step 1. Figure 95. 3065 Figure 95 Apply lubricant to seal surface. Figure 96. 3066 Figure 96 Support ball bearing housing with spacers (1 and 2, Figure 97) and install bearing into housing.
Page 387 Install hub to housing. Figure 99. 3069 Figure 99 Press hub into housing using a press and a stopper. Figure 100. 3070 Figure 100 10. Install four bushings using a press. Figure 101. 3071 Figure 101 11. Assemble planetary gear assembly. Figure 102.
Page 388 12. Install four planetary gear assemblies, using press. Figure 103. 3073 Figure 103 13. Tighten gear planetary gear assembly to 150 Nm (110.7 ft lb). Figure 104. 3074 Figure 104 14. Assemble third shift sun gear. Figure 105. 3075 Figure 105 15.
Page 389 16. Place planetary gear carrier on hub. Figure 107. 3077 Figure 107 17. Press planetary gear carrier into hub. Figure 108. 3078 Figure 108 18. Apply loctite to planetary gear carrier fastening bolts. 19. Install and tighten bolts. Figure 109. NOTE: In next step, the O-ring and backup rings are different.
Page 390 21. Install end cover to housing. NOTE: Apply Loctite 243 to bolts and torque to 10 Nm (7.38 ft lb). Figure 111 3081 Figure 111 22. Tighten plugs to 6 - 8 Nm (4.42 - 5.90 ft lb). Figure 112. 3082 Figure 112 23.
Page 391 25. Install first shift sun gear. Figure 115. 3085 Figure 115 26. Install O-ring (1, Figure 116) and backup ring (2) into hub groove. NOTE: The O-ring and backup rings are different. Be careful not to switch them. 3086 Figure 116 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 53...
Page 392 27. Install brake shaft while turning the reduction gear assembly. Figure 117. 3087 Figure 117 28. Install brake disc assembly, starting with a copper disc (seven pieces) and alternating with steel discs (six pieces). Figure 118 and Figure 119. 3088 Figure 118 3089 Figure 119...
Page 393 30. Install retaining ring using retaining ring pliers. Figure 121. 3091 Figure 121 31. Install O-ring to hub groove. Figure 122. 3092 Figure 122 32. Place brake piston inside hub being careful not to damage seal. Figure 123. 3093 Figure 123 33.
Page 394 34. Install retainer disc. Figure 125. 3095 Figure 125 35. Install O-ring to motor flange groove. Figure 126. 3096 Figure 126 36. Tighten motor flange to hub. Figure 127. 3097 Figure 127 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 56...
Page 395: Travel Motor Reassembly
TRAVEL MOTOR REASSEMBLY ROTARY GROUP ASSEMBLY Rotary group completely assembled ready for assembly. Figure 128 Place assembly sleeve. HTS051S Figure 129 Warm up housing to 80°C (176°F). HTS052S Figure 130 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 57...
Page 396: Rotary Group Adjustment (See Serve Information)
Insert rotary group into housing to seat position. HTS053S Figure 131 Fix zero position of cylinder with Q screw. Disassemble cylinder fixing screw. Insert O-ring. HTS054S Figure 132 ROTARY GROUP ADJUSTMENT (SEE SERVE INFORMATION) Determine cylinder swivel range to max. angle with screw.
Page 397 Disc. HTS056S Figure 134 Place centering disc. HTS057S Figure 135 Mount measuring device. HTS058S Figure 136 Check dimension X. HTS059S Figure 137 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 59...
Page 398: Assembly Of Port Plate
ASSEMBLY OF PORT PLATE Stick control lens in sliding surface with grease. Assemble in reversal order. Mount port plate. HTS060S Figure 138 Assemble port plate. NOTE: Take care of assembly design! Tighten fixing screws with torque. Set Q crew to dimension (*). Assemble plug.
Page 399 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MAIN PUMP (REXROTH)S0708325K MODEL SERIAL NUMBER RANGE Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Main Pump (Rexroth) S0708325K Page 1...
Page 400 TABLE OF CONTENTS Sectional View....................4 A8VO200LA1KH1/63 ................4 General Repair Guidelines ................6 Seal Kits and Sub-assemblies................ 8 Sealing the Drive Shaft................. 12 Gear Pump Sealing ..................14 Remove the Control Housing ............... 16 Control Module ..................... 20 Control Module LR ................20 Control Module H ..................
Page 401 Main Pump (Rexroth) S0708325K Page 3...
Page 402: Sectional View
SECTIONAL VIEW A8VO200LA1KH1/63 ASS0010L Figure 1 S0708325K Main Pump (Rexroth) Page 4...
Page 403 ASS0020L Figure 2 Main Pump (Rexroth) S0708325K Page 5...
Page 404: General Repair Guidelines
GENERAL REPAIR GUIDELINES NOTE: Observe the following cautions when carrying out repairs on hydraulic units. ASS1140L Figure 3 Close off all openings of hydraulic unit. ASS0030L Figure 4 Replace all seals. Use only original spare parts. ASS0040L Figure 5 S0708325K Main Pump (Rexroth) Page 6...
Page 405 Check all sealing and sliding surfaces for wear. NOTE: Rework sliding surfaces using crocus cloth or other similar materials, can damage the surface. ASS0050L Figure 6 Fill hydraulic unit with hydraulic oil before putting into operation. ASS0060L Figure 7 Main Pump (Rexroth) S0708325K Page 7...
Page 406: Seal Kits And Sub-Assemblies
SEAL KITS AND SUB-ASSEMBLIES Seal kit for drive shaft. ASS0070L Figure 8 Peripheral seal kit. ASS0080L Figure 9 Rotary group 1, ready to install. ASS0090L Figure 10 S0708325K Main Pump (Rexroth) Page 8...
Page 407 Rotary group 2, ready to install. ASS0100L Figure 11 Rotary group, hydraulic component (order rotary groups 1 and 2 separately). NOTE: Adjustment is necessary. Pay attention to direction of rotation. ASS0110L Figure 12 Rotary group 1, mechanical section, ready to install. ASS0120L Figure 13 Rotary group 2, mechanical section, ready...
Page 408 Control, pre-adjusted. ASS0140L Figure 15 Gear pump, complete. ASS0150L Figure 16 10. Intermediate gear. ASS0160L Figure 17 S0708325K Main Pump (Rexroth) Page 10...
Page 409 11. Auxiliary drive. ASS0170L Figure 18 12. Valve plate with valves. ASS0180L Figure 19 13. Pipe, complete with fittings. ASS0190L Figure 20 Main Pump (Rexroth) S0708325K Page 11...
Page 410: Sealing The Drive Shaft
SEALING THE DRIVE SHAFT ASS0200L Figure 21 Protect drive shaft. (e.g. with tape). ASS0210L Figure 22 Remove retaining ring and shim. ASS0220L Figure 23 S0708325K Main Pump (Rexroth) Page 12...
Page 411 Screw sheet metal screw(s) into holes fitted with rubber. Pull out seal with pliers. ASS0230L Figure 24 Press in shaft seal ring and shim with bushing to stop. NOTE: Take note of press-in depth. Install mark for press-in depth of safety ring. ASS0240L Figure 25 Main Pump (Rexroth)
Page 412: Gear Pump Sealing
GEAR PUMP SEALING ASS0250L Figure 26 Remove gear pump. Visually check: O-ring (1, Figure 27). ASS0260L Figure 27 S0708325K Main Pump (Rexroth) Page 14...
Page 413 Sealing surface of housing (2, Figure 27). ASS0270L Figure 28 Main Pump (Rexroth) S0708325K Page 15...
Page 414: Remove The Control Housing
REMOVE THE CONTROL HOUSING ASS0280L Figure 29 S0708325K Main Pump (Rexroth) Page 16...
Page 415 Place pump into a disassembly / assembly device with a crane and secure it into position. ASS0290L Figure 30 Remove screws holding port plate. Using a suitable lifting device, remove port plate. NOTE: Mark installation position. NOTE: Be careful, control lenses can fall out.
Page 416 Remove paper seal, and clean sealing surface. ASS0310L Figure 32 ASS0320L Figure 33 Number Description Setting Screw: Q Setting Screw: Hydraulic Stroke Limitation Setting Screw: Power Characteristic (Begin of Regulation) S0708325K Main Pump (Rexroth) Page 18...
Page 417 NOTE: Before carrying out setting or disassembly regulator, measure distance "X" adjustment screw and record value. ASS0330L Figure 34 Main Pump (Rexroth) S0708325K Page 19...
Page 418: Control Module Lr
CONTROL MODULE CONTROL MODULE LR ASS0340L Figure 35 Remove and disassemble control module LR. ASS0350L Figure 36 S0708325K Main Pump (Rexroth) Page 20...
Page 419: Control Module H
CONTROL MODULE H ASS0360L Figure 37 Remove and disassemble control module H. ASS0370L Figure 38 Main Pump (Rexroth) S0708325K Page 21...
Page 420: Removing The Controller
REMOVING THE CONTROLLER ASS0380L Figure 39 Remove cover. NOTE: Do not change the setting of adjustment screw (1, Figure 39). ASS0390L Figure 40 S0708325K Main Pump (Rexroth) Page 22...
Page 421 Remove screws. NOTE: Install control lens - torque support. ASS0400L Figure 41 Remove locking screw and replace with a new one. NOTE: Loosen adhesive with a "gentle" flame (approximately 120 ° C). ASS0410L Figure 42 ASS0420L Figure 43 Remove swivel pin. ASS0430L Figure 44 Main Pump (Rexroth)
Page 422: Valve Plate With Valves
VALVE PLATE WITH VALVES ASS0440L Figure 45 Pressure relief valve. Electro- proportional pressure reducing valve (EPPR). S0708325K Main Pump (Rexroth) Page 24...
Page 423: Remove The Rotary Groups
REMOVE THE ROTARY GROUPS ASS0450L Figure 46 Keep cylinder with device (Remove it completely along with drive shaft). ASS0460L Figure 47 Remove cylinder (Take out the drive shaft without cylinder). ASS0470L Figure 48 Main Pump (Rexroth) S0708325K Page 25...
Page 424 Remove cup springs 1 and spring cup 2. ASS0480L Figure 49 Note disassembly position: (1, 2 and 3, Figure 50). Rotary Group 2 Rotary Group 1 ASS0490L Figure 50 Press out rotary group with an appropriate device. 2 2 2 2 2 1 1 1 1 1 ASS0500L Figure 51...
Page 425 Fixing screws are glued Adjustment of measurement D * * * * * 1. Holding device Drive shaft 2 Drive shaft 1 1. Holding device * * * * * Adjustment of measurement D Fixing screws are glued ASS0510L Figure 52 NOTE: 1) Position (*) drive shafts with bearing set are the smallest assembly group.
Page 426: Remove The Intermediate Wheel
REMOVE THE INTERMEDIATE WHEEL Press bolt (*, Figure 53) into gear wheel. (Fixed pressing fit). NOTE: Can only be disassembled with a hydraulic press. * * * * * * * * * * ASS0520L Figure 53 Install sleeve. NOTE: Press out bolt with a hydraulic press.
Page 427 Remove gear wheel through side drive opening. ASS0540L Figure 55 Remove bearing with extraction device. ASS0550L Figure 56 Main Pump (Rexroth) S0708325K Page 29...
Page 428: Remove Auxiliary Drive
REMOVE AUXILIARY DRIVE ASS0560L Figure 57 Remove screws and auxiliary drive. ASS0570L Figure 58 Press off bearing cap. ASS0580L Figure 59 S0708325K Main Pump (Rexroth) Page 30...
Page 429 In the event of oil leakage, visually check O-ring, housing and groove. ASS0590L Figure 60 Install extractor device. ASS0600L Figure 61 Pull out output pinion. ASS0610L Figure 62 Install bearing extractor device. ASS0620L Figure 63 Main Pump (Rexroth) S0708325K Page 31...
Page 430 Completely mount device and pull out bearing. ASS0630L Figure 64 Pull out pinion bearing. ASS0640L Figure 65 S0708325K Main Pump (Rexroth) Page 32...
Page 431: Inspection
INSPECTION Check to see that bearing bore is free of scores and that there is no evidence of wear. ASS0650L Figure 66 Visually check: To ensure that bearing seats are free of scores. ASS0660L Figure 67 Visually check: Check to see that bearing bores are free of scores and that there is no evidence of wear.
Page 432 Axial piston play: Checked with retaining plate installed. ASS0680L Figure 69 Drive shafts: Check to ensure that cups are free of scores and that there is no pitting (1. Figure 70). Check to see that there is no evidence of corrosion and wear steps (2, Figure 70).
Page 433 Retaining plate: Check to ensure that it is free of scores and that there is no evidence of wear. ASS0720L Figure 73 Check cylinder block / control lens. Bores (1, Figure 74) are free of scores, no evidence of wear. Faces (2, Figure 74) are even, that there are no cracks, no scores.
Page 434 12. Complete rotary group. NOTE: Adjustment of the hydraulic component is necessary. Mechanical component: drive shaft is adjusted with the bearing (1, Figure 77). Hydraulic component (2, Figure 77): Adjustment is necessary (*, Figure 77). ASS0760L Figure 77 S0708325K Main Pump (Rexroth) Page 36...
Page 435 13. Rotary group: All of the components. * Adjustment (Figure 78). For adjustment values and torque values, see service information. ASS0770L Figure 78 Main Pump (Rexroth) S0708325K Page 37...
Page 436: Re-Fitting The Rotary Group
RE-FITTING THE ROTARY GROUP Threads must be free of oil, grease, dust or any other contaminants which may impair locking of screws. ASS0780L Figure 79 Assemble retaining plate with pistons and center pin in position. Use screws that have a Precoat coating. NOTE: For tightening torques, see service information.
Page 437 Ensure that all parts are assembled in correct order and orientation. ASS0810L Figure 82 Insert pistons into cylinder. Using a soft surface as a support to prevent sliding surfaces from being damaged. Pre- assemble both rotary groups in this manor. ASS0820L Figure 83 Main Pump (Rexroth)
Page 438: Pump Assembly
PUMP ASSEMBLY Warm up housing to approximately 80°C. ASS0830L Figure 84 Insert pre-assembled rotary group 2, being sure to align gear tooth marks. ASS0840L Figure 85 Insert rotary group 1. Align the marked gear teeth. ASS0850L Figure 86 S0708325K Main Pump (Rexroth) Page 40...
Page 439 Gear tooth marks must align with each other. ASS0860L Figure 87 Main Pump (Rexroth) S0708325K Page 41...
Page 440 Adjustment of measurement D. NOTE: Hydraulic control portion. Stop Stop ASS0870L Figure 88 NOTE: Drive shafts with bearing set. The assembly group is adjusted to dimension (A). The tapered roller bearings are adjusted to the stipulated breakaway torque. Assembly Guideline Retaining force: After rotary group has been installed into housing, it has to be pressed in until the end stop is reached.
Page 441 Adjustment of the Hydraulic Component of the Rotary Group The adjustment of dimension "D" is carried out using spring plates of differing thickness, so that the correct clearance is achieved between the rotary group which is installed in housing and center pin, and spring plates.
Page 442: Mounting Position
MOUNTING POSITION NOTE: sure that correct mounting position is used. The numbers on the top of the measuring device (*, Figure 89) refer to the piston diameter. ASS0900L Figure 90 Size Mounting Position ASS0890L Figure 91 Install intermediate ring or plates onto the housing.
Page 443: Measuring Procedure
Only Size 140 - 200 (Figure 93). ASS0920L Figure 93 Zero adjustment - measuring device. Turn using the hand wheel until the stop is reached. Set dial gauge to zero. Size 80 - 107 (Figure 94). Figure 94 Size 140 - 200 (Figure 95). Figure 95 MEASURING PROCEDURE Turn down by 4 turns on the dial gauge.
Page 444 Size 140 - 200 (Figure 97). ASS0960L Figure 97 Turn down, using the hand wheel, until resistance is met. Read the measured value. NOTE: Do not use excessive force. Size 82 - 107 (Figure 98). Figure 98 Size 140 - 200 (Figure 99). Figure 99 S0708325K Main Pump (Rexroth)
Page 445: Installation Of Control Housing
INSTALLATION OF CONTROL HOUSING ASS0990L Figure 100 Install swivel pin into correct position and orientation. Take hardening time and tightening torque into account. NOTE: Tightening Torques (*): M6 = 8.5 Nm (0.87 kg•m (6.27 ft lb)) M8 = 14 Nm (1.43 kg•m (10.33 ft lb)) M10 = 35 Nm (3.57 kg•m (25.81 ft lb))
Page 446 Push on piston ring by hand. Fix adjustment piston. Take the tightening torques into account. ASS1010L Figure 102 Install control housing. ASS1020L Figure 103 Install control lens in their correct position using grease to hold them in place. Direction of rotation Direction of rotation clockwise counterclockwise...
Page 447 ASS1040L Figure 105 Install seal and controller. ASS1050L Figure 106 Main Pump (Rexroth) S0708325K Page 49...
Page 448: Assembly Of Intermediate Wheel
ASSEMBLY OF INTERMEDIATE WHEEL Press bearing (1, Figure 107) into housing. Install and align intermediate wheel (2, Figure 107) through side drive opening. New Assembly Position Cool down bolt (3, Figure 107) with nitrogen and install it. Press in bearing (4, Figure 107). ASS1060L Figure 107 Press bearing into housing.
Page 449: Installation Of Gear Pump
INSTALLATION OF GEAR PUMP ASS1080L Figure 109 Assemble shaft seal, disc and safety ring. Press-in with assemble sleeve. NOTE: Take care of press-in depth! ASS1090L Figure 110 Main Pump (Rexroth) S0708325K Page 51...
Page 450: Installation Of Cover / Auxiliary Drive
INSTALLATION OF COVER / AUXILIARY DRIVE ASS1100L Figure 111 S0708325K Main Pump (Rexroth) Page 52...
Page 451: Assembly Guidelines For Tightening Torques
ASSEMBLY GUIDELINES FOR TIGHTENING TORQUES BOLTS (TO N 08.001) Values stated are valid for bolts with metric ISO threads to DIN 13 part 13, as well as head areas to DIN 912 socked head cap screws, DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up to the head.
Page 452: Plugs With Internal Hexagon And Profile Seal Ring (To N 02.009)
PLUGS WITH INTERNAL HEXAGON AND PROFILE SEAL RING (TO N 02.009). Seal ASS1120L Figure 113 Tightening Torque M In Nm Tightening Torque M In Nm Thread Thread M8 x 1 G 1/8 A M10 x 1 G 1/4 A M12 x 1.5 G 3/8 A M14 x 1.5 G 1/2 A...
Page 453: Seal-Lock - Sealing Nuts (To N 02.100)
SEAL-LOCK - SEALING NUTS (TO N 02.100) Tightening Torque M Thread M6 x 0.5 M8 x 1 M10 x 1 ASS1130L Figure 114 M12 x 1.5 M14 x 1.5 M16 x 1.5 Main Pump (Rexroth) S0708325K Page 55...
Page 454 S0708325K Main Pump (Rexroth) Page 56...
Page 455 Remember, that ultimately safety is your own personal responsibility. CONTROL VALVE (KAYABA MODEL KVMG-400-DA)S0709402K MODEL SERIAL NUMBER RANGE Solar 420LC-V 1001 and Up Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 1...
Page 456 TABLE OF CONTENTS General Description..................6 When All Spools are in Neutral ............... 6 Neutral Passage (Figure 1 and Figure 2)......... 6 Signal Passage (Figure 2) ............... 8 Single Operation ................... 10 Travel Spool Shifting (Figure 3 and Figure 4)......... 10 Swing Spool Shifting (Figure 4) .............
Page 457 Spool Assembly (3, Arm 2) ............35 Spool Assembly (20, Arm Regeneration Release Valve ....36 Spool Assembly (24)..............36 Poppet Assembly (36)..............36 Plug Assembly (51)................ 37 Plug Assembly (58)................ 37 Relief Valve Assembly (48) ............38 Relief Valve Assembly (49) ............39 Relief Valve Assembly (50) ............
Page 458 Cleaning ....................49 Inspection....................49 Reassembly....................50 Subassembly..................50 Main Spool (3) - (11) ..............50 Subspool (20)................. 50 Subspool (24)................. 50 Boom, Arm Anti Drift Valve ............51 Swing Load Check ................. 51 Reassembly of Control Valve ..............51 Reassembly of Load Check Valve ..........
Page 459 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 5...
Page 460: General Description
GENERAL DESCRIPTION WHEN ALL SPOOLS ARE IN NEUTRAL Neutral Passage (Figure 1 and Figure 2) Oil supplied to port (P1) flows through neutral passage (L1) to low pressure relief valve throttle (Lc1), to tank passage (Ta), and returns to ports (T1 and T3). Oil supplied to port (P2) flows through neutral passage (R1), to low pressure relief valve throttle (Rc1), to tank passage (Ta), and returns to ports (T1 and T3).
Page 461 Figure 1 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 7...
Page 462: Signal Passage (Figure 2)
Signal Passage (Figure 2) Oil supplied to port (PP , Figure 2), after passing through orifice (Lc3), is divided into two flows. One flow is sent to port (PT), and the other flows through land (Lc4) and passage (5) to land (Rc3) and into tank passage (Ta).
Page 463 Figure 2 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 9...
Page 464: Single Operation
SINGLE OPERATION Travel Spool Shifting (Figure 3 and Figure 4) When shifting travel spool by increasing pressure of travel (section 1) pilot port (Pb1 (Pa1)), oil supplied to port (P1) flows through neutral passage (L1), to spool, and flows to port (B1 (A1)). Return oil flows through port (A1 (B1)) to spool and returns to tank passage (Ta).
Page 465 Figure 3 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 11...
Page 466: Swing Spool Shifting (Figure 4)
Swing Spool Shifting (Figure 4) When shifting swing spool by increasing pressure of swing (section 2) pilot port (Pb2 (Pa2)), neutral port (L1) is closed. Oil supplied to port (P1) flows through, parallel passage (L3), load check valve (S2-1), and spool to port (B2 (A2)). Return oil flows through port (A2 (B2)), to spool, and returns to tank passage (Ta).
Page 467: Boom Spool Shifting
Boom Spool Shifting Neutral (Figure 5) This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder. When in neutral, poppet (AD1) is closed by pressure from port (A7), that is sent through passage (AD2), spool (AD3), and passage (AD4) to poppet (AD1).
Page 468 Boom up (2 speed junction) (Figure 6) When boom spool 1 (section 7) is shifted by increasing pressure of boom 1 pilot port (Pa7), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3), and load check valve (S7-1), to spool and flows into port (A7).
Page 469 Boom down (regeneration) (Figure 7) When boom spool 1 (section 7) is shifted by increasing pressure of boom 1 pilot port (Pb7), neutral passage (R1) is closed. Oil supplied to port (P2), flows through parallel passage (R3), and load check valve (S7-1), to spool, and flows into port (B7).
Page 470: Spare Spool Shifting (Figure 8)
Spare Spool Shifting (Figure 8) When spare spool is shifted by increasing pressure of spare (section 4) pilot port (Pb4 (Pa4)), neutral passage (L1) is closed. Oil supplied to port (P1) flows through, parallel passage (L3), load check valve (S4-1), passage (S4-2), and spool, into port (B4 (A4)). When neutral-cut spool (R) is shifted by increasing pressure of port (pa10) (Figure 1) also, oil supplied from port (P2) flows through passage (11), and poppet (S4-3), it then joins with passage (S4-2).
Page 471: Arm Spool Shifting
Arm Spool Shifting Arm dump (2 speed junction) (Figure 9) When arm spool 1 is shifted by increasing pressure of arm 1 (section 5) pilot port (Pb5), oil supplied from port (P1) flows through, neutral passage (L1), load check valve (S5-1), passage (S5-2), and spool, into port (B5).
Page 472 Arm crowd (2 speed junction) When arm spool 1 is shifted by increasing pressure of arm 1 (section 5) pilot port (Pa5), oil supplied from port (P1) flows through, neutral passage (L1), load check valve (S5-1), passage (S5-2), and spool, into port (A5). When arm 2 spool is shifted by increasing pressure of arm 2 (section 9) pilot port (pa9) also, oil supplied from port (P2) flows through neutral passage (R1), load check valve (S9- 1), passage (S9-2), spool and passage (9), it then joins with port (A5).
Page 473: Neutral-Cut Spool Shifting (Figure 11)
Neutral-cut Spool Shifting (Figure 11) This valve has a neutral-cut spool that is installed in lowest flow side (the upper flow side of low pressure relief valve). When spool (L (R)) is shifted by increasing pressure of port (pa10 (pa11)), neutral passage (L1 (R1)) is closed.
Page 474: Relief Valve
Relief Valve Main relief valve (Figure 12) Oil supplied to port (P1) flows through poppet (LP), oil supplied from port (P2), flows through poppet (RP), and passage (3) also, it then joins with the main relief valve. The highest pressure of pump (P1) and (P2) is controlled by actuating of main relief valve.
Page 475 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 21...
Page 476: Combined Operation
COMBINED OPERATION Travel Combined Operation (Figure 13) When applying simultaneously the operation except travel while travel left and right simultaneous operating (while forward traveling, backward traveling, or pivot turning) or when applying travel left and right simultaneous operating while applying the operation except travel, oil supplied from port (PP) is disconnected with the tank passage (Ta) at the signal land part of section of exception of travel shifted with the land (Lc4) (Lc7) (Rc3) (Rc5), and the pressure of signal passage increases up to the relief setting pressure of pressure source for signal.
Page 477 Figure 13 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 23...
Page 478: Swing Combined Operation (Figure 14)
Swing Combined Operation (Figure 14) When applying the combined operation with the swing and another implement, poppet (S2-1) is fixed by increasing port (pc6) pressure, poppet (S2-3) is opened, and pressure supplied to port (L3) is increased through throttle (S2-4). Accordingly, even in the case that the swing load pressure is low, the simultaneous operation character with the other implement can be secured.
Page 479: Anti Drift Valve
ANTI DRIFT VALVE The anti drift valve is installed in the cylinder port of arm rod (boom bottom) side to prevent the arm (boom) cylinder from natural lowering. In neutral condition (Figure 15), cylinder port pressure is sent through passage (AD2), spool (AD3), and passage (AD4) to spring chamber (AD5).
Page 480: Main Relief Valve
MAIN RELIEF VALVE The main relief valve is located between neutral oil passage (HP , Figure 18) and low pressure oil passage (LP). Pressurized oil flows into neutral oil passage (HP) through orifice in the main poppet (C) to fill internal cavity (D).
Page 481: Overload Relief Valve
OVERLOAD RELIEF VALVE The overload relief valve is located between cylinder port (HP) and low pressure oil passage (LP). Pressurized oil at cylinder port (HP), flows through an orifice in piston (C), to fill internal cavity (G). Due to the difference in area between (A) and (B) on which the hydraulic pressure acts, main poppet (D) seats on sleeve (K).
Page 482: Low Pressure Relief Valve
Sucking operation An anti void unit is installed in cylinder port (HP) to prevent the development of cavitation. If pressure at cylinder port (HP) becomes lower than that of oil passage (LP), sleeve (K) moves so that oil is supplied from the low pressure oil passage (LP) to cylinder port (HP) to eliminate cavitation.
Page 483: Parts List
PARTS LIST Figure 30 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 29...
Page 484 Figure 31 S0709402K Control Valve (Kayaba Model KVMG-400-DA) Page 30...
Page 485 Figure 32 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 31...
Page 486: Spool Assembly (4, Bucket)
Reference Reference Description Description Number Number Valve Housing O-ring Valve Housing Backup Ring Spool Assembly (Arm-2) Body Spool Assembly (Bucket) Piston Spool Assembly (Boom 1) Flange Spool Assembly (Travel) O-ring Spool Assembly (Straight Poppet Travel) Body Assembly Spool Assembly (Arm-1) Relief Valve Assembly Spool Assembly (Service) Relief Valve Assembly...
Page 487 Spool Assembly (4, Bucket) Reference Description Number Spool Spring Seat Spring Spring Spool End Figure 33 Spool Assembly (5, Boom) Reference Description Number Spool Spring Seat Spring Spring Spool End Poppet Spring Figure 34 Plug O-ring Backup Ring Spool Assembly (6, Travel) Reference Description Number...
Page 488 Spool Assembly (7, Straight Travel) Reference Description Number Spool Spring Seat Spring Spring Spool End Figure 36 Spool Assembly (8, Arm1) Reference Description Number Spool Spring Seat Spring Spring Spool End Poppet Spring Figure 37 Plug O-ring Backup Ring Spool Assembly (9, Service) Reference Description Number...
Page 489 Spool Assembly (10, Boom 2) Reference Description Number Spool Spring Seat Spring Spring Spool End Figure 39 Spool Assembly (11, Swing) Reference Description Number Spool Spring Seat Spring Spring Spool End Figure 40 Spool Assembly (3, Arm 2) Reference Description Number Spool Spring Seat...
Page 490: Spool Assembly (7, Straight Travel)
Spool Assembly (20, Arm Regeneration Release Valve Reference Description Number Spool Sleeve Sleeve Piston O-ring Backup Ring Figure 42 O-ring Backup Ring Spool Assembly (24) Reference Description Number Spool Spool End Figure 43 Poppet Assembly (36) Reference Description Number Poppet Poppet Spring Plug...
Page 491: Plug Assembly (51)
Plug Assembly (51) Reference Description Number Plug O-ring O-ring O-ring Figure 45 Plug Assembly (58) Reference Description Number Plug O-ring O-ring Backup Ring Figure 46 Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 37...
Page 492: Relief Valve Assembly (48)
Relief Valve Assembly (48) Figure 47 S/N 1001 thru 1050 Figure 48 S/N 1051 and Up Item Specification Serial No. 1001 thru 1050 1051 and Up Hi: 34.3 ± 0.5 MPa Hi: 34.3 ± 0.5 MPa Relief Valve Pressure Low: 31.4 ± 0.5 MPa Low: 31.4 ±...
Page 493: Relief Valve Assembly (49)
Relief Valve Assembly (49) Reference Description Number O-ring O-ring O-ring Backup Ring O-ring Backup Ring O-ring Figure 49 Item Specification Relief Valve 35.3 ± 0.5 MPa Pressure Flow 20 liter/min. Relief Valve Assembly (50) Reference Description Number Plug Spring Poppet Sleeve O-ring O-ring...
Page 494: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT GENERAL Problem Possible Cause Remedy Spool does not stroke. Hydraulic oil excessively hot. Remove blockage in oil piping. Hydraulic oil contaminated. Change oil and clean oil passages. Overtightened piping port fittings. Check torque. Valve housing deformed when Remove assembling bolts and assembling.
Page 495: Relief Valve
RELIEF VALVE Problem Possible Cause Remedy Pressure does not rise. Pressure does not rise. Replace relief valve. Pressure unstable Pressure unstable Relief pressure is incorrect. Seat parts worn due to dirt. Lock nut and adjuster deformed. Reset pressure and tighten lock nut in rated torque.
Page 496: Over Load Relief Valve
Loosen lock nut (3) and turn adjusting plug (4) clockwise to raise relief pressure at the condition of step A. Turn adjusting plug (4) counterclockwise to lower relief pressure. One turn varies pressure by approximately 25.7 MPa. Tighten lock nut (3) after pressure has been adjusted. Low pressure adjustment Loosen lock nut (5) and turn adjusting plug (6) counterclockwise to lower relief pressure at step 4.
Page 497: Disassembly
DISASSEMBLY GENERAL INSTRUCTIONS FOR DISASSEMBLY Stop engine at low actuator pressure. It is dangerous to disassemble control valve while it is under pressure. High pressure oil can squirt out or components can spring out. When partially disassembling control valve that is on machine, be careful to follow the following caution.
Page 498: Disassembly Of Subspool (24)
Disassembly of spool IMPORTANT Work with spool gripped in vise with wood (see Figure 51) not to scratch outside diameter of spool. Because Loctite applied threaded portion of spool end, heat outside surface spool with industrial drier to release Loctite. Figure 51 Heat spool until spool end is easily loosened, and remove immediately...
Page 499: Disassembly Of Swing Load Check
Remove plug assembly (47-7, width across flats: 6 mm) and O-ring. IMPORTANT The filter in plug assembly (47-7) is pressed into place and can not be removed. If filter replacement is necessary, replace it with a new plug assembly. Remove plug (47-8, width across flats: 8 mm) and O-ring. Remove plug (47-9, width across flats: 5 mm) and O-ring.
Page 500: Disassembly Of Flange
Remove semi parallel check valve from arm two. Remove plug (61, width across flats: 10 mm) and O- ring. Remove spring (29) and poppet (30). DISASSEMBLY OF FLANGE Remove flange from spare port. Remove socket head bolt (77, width across flats: 10 mm) and flange (76) and O-ring (78).
Page 501: Disassembly Of Main Relief Valve
DISASSEMBLY OF MAIN RELIEF VALVE This relief valve should be replaced as an assembly. When replacing it, loosen cap (8, width across flats: 41) and O-ring (1, Figure 52). If oil leaks from nut (3), remove nut (3) and plug (4) and replace O-ring and backup ring.
Page 502: Disassembly Of Overload Relief Valve
DISASSEMBLY OF OVERLOAD RELIEF VALVE This relief valve should be replaced as an assembly. When replacing it, loosen cap (1, width across flats: 31.75 mm) and O-ring (2). If oil leaks from nut (3), remove adjusting kit and replace O-ring (4). NOTE: When disassembling adjusting kit, be careful not to allow components to spring out by force of spring or to lose the poppet.
Page 503: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) CLEANING Clean all parts thoroughly using a suitable cleaning fluid and dry them with moisture free compressed air. Put them on a clean paper or a vinyl surface for inspection. INSPECTION Inspect all parts for scratches, notches and the other defects. Inspect load check seat surface of valve housing for scratches, scores, dirt, notches and corrosion.
Page 504: Reassembly
REASSEMBLY NOTE: Before reassembling, confirm number of components, reassembling position, tools and etc. SUBASSEMBLY Before reassembling valve housing, subassemble parts as needed. Main Spool (3) - (11) Apply Loctite to threads of spools (3, 4, 6, 7, 9, 10 and 11). Assemble spring seat (above parts numbers - 2), spring (above parts numbers - 3, 4) and spool end (above parts numbers - 5), and assemble spool end in spool that is gripped in vise with wood.
Page 505: Boom, Arm Anti Drift Valve
Boom, Arm Anti Drift Valve Grip body in vise, taking care not to scratch O-ring (35 and 70) surface of body (47-1). Insert spring seat (47-3) in spool (47-2), and insert spool in body (47-1) hole. Assemble spring (47-4). Tighten plug (47-5) with O-ring (47-10) in body (47-1). Torque is 2.86 - 3.06 kg•m (21 - 22 ft lb). Tighten plug (47-9) with O-ring to body (47-1).
Page 506: Reassembly Of Other Check Valve
Fasten flange (44) and body (42) with socket head bolt (68). Torque is 10.81 - 11.52 kg•m (78 - 83 ft lb). Reassembly of Other Check Valve Assemble two common check valves of main relief valve. Install poppet (15) and spring (16). Insert spacer (17) with O-ring (18) and backup ring (19).
Page 507: Reassembly Of Subspool (20)
IMPORTANT Insert spool in hole perpendicularly. Make sure that spool is in correct position. If it is not in correct position, a malfunction can occur. Reassembly of Subspool (20) Install spool assembly in valve hole it was removed from during disassembly. Install spring seat (21) and spring (22).
Page 508: Reassembly Of Main Relief Valve
Reassembly of Main Relief Valve Check whether there is dirt or paint chips around plug (2 and 4, Figure 56) and nut (3). Reassemble with new O-rings. Clean the installation portion of relief valve and install it. Tighten cap (8: Width across flats 41).
Page 509 Figure 57 S/N 1051 and Up Control Valve (Kayaba Model KVMG-400-DA) S0709402K Page 55...
Page 510: Reassembly Of Overload Relief Valve
Reassembly of Overload Relief Valve Check whether there is dirt or paint chips around cap (1, width across flats: 31.75 mm) and reassemble with a new O-ring. Clean the installing part of relief valve and install it. Tighten cap (1). Torque is 7.95 - 8.97 kg•m (58 - 65 ft lb).
Page 511: Installation
INSTALLATION Be careful not to work other foreign strength to control valve by pipe laying. Tighten the assembling bolts alternately and evenly to the specified torque. If welding procedures are being performed near the control valve, the valve could damaged by weld spatter and heat.
Page 512 S0709402K Control Valve (Kayaba Model KVMG-400-DA) Page 58...
Page 513 Remember, that ultimately safety is your own personal responsibility. PILOT CONTROL VALVE (WORK LEVER / JOYSTICK)S0709452K MODEL SERIAL NUMBER RANGE Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Pilot Control Valve (Work Lever / Joystick) S0709452K...
Page 514 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Structure ..................3 Function ................... 3 Parts List ....................4 Specifications ..................5 Torques .................... 5 Performance..................6 Removal ......................7 Disassembly ....................9 Cleaning and Inspection (Wear Limits and Tolerances) ....... 13 Reassembly....................
Page 515: General Description
GENERAL DESCRIPTION THEORY OF OPERATION Structure The remote control valve contains four push rods, spring holders, spools and return springs, which are located in the valve casing. The valve works as a pressure reduction valve. The housing has six ports, which include input port P , tank port T, and four secondary pressure ports. The electric horn switch is installed in the valve handle.
Page 516: Parts List
PARTS LIST ASS1240L Figure 1 S0709452K Pilot Control Valve (Work Lever / Joystick) Page 4...
Page 517: Specifications
Reference Reference Description Description Number Number Case Plate Plug Boot Plug Joint Assembly O-ring Swash Plate O-ring Hex Nut Spool Handle Bar Shim Spring Boot Spring Seat Spring Pin Spring Handle Assembly Stopper Bushing Plug Terminal O-ring Seal Wire Rod Seal Housing Push Rod Rear Holder...
Page 518: Performance
Performance (31.1) 28±1.5 25.8±4 (22) Operating Torque 18.4±3 9.6±2.5 6.8±2 5±1 SECONDARY PRESSURE 1.1±0.3 6.5±0.5 PUSH-ROD STROKE(mm) ASS1250L Figure 2 S0709452K Pilot Control Valve (Work Lever / Joystick) Page 6...
Page 519: Removal
REMOVAL Park on firm and level ground. Lower front attachment (bucket) to the ground. Stop the engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while Figure 3 performing maintenance, extreme care. Always have one person in the cab at all times.
Page 520 15. Tag and disconnect hoses from joystick valve (1, Figure 5). 16. Remove six fittings (3, Figure 5) and O- rings (2, Figure 5). ATS0890L Figure 5 S0709452K Pilot Control Valve (Work Lever / Joystick) Page 8...
Page 521: Disassembly
DISASSEMBLY Lift up boot (23) and pull switch cord through hole in case (1). Figure 6 Loosen nut (22) from hex nut (20) and remove handle assembly (25). Figure 7 Remove hex nut (20) and swash plate (19). Figure 8 Pilot Control Valve (Work Lever / Joystick) S0709452K Page 9...
Page 522 Remove boot (17). Figure 9 Remove joint assembly (18) from case (1). Figure 10 Remove plate (16). Figure 11 Press spring (10) and remove plug (12). Figure 12 S0709452K Pilot Control Valve (Work Lever / Joystick) Page 10...
Page 523 Remove pressure reduction valve (6, 7, 8, 9, 11) and spring (10). IMPORTANT Mark valve disassembling position (port). Figure 13 Remove plug (3). Figure 14 10. Remove stopper (11) from pressure reduction valve (6, 7, 8, 9, 11). Figure 15 11.
Page 524 12. Remove push rod (15) and plug (12). Figure 17 13. Remove O-ring (13) from plug (12). Figure 18 14. Remove seal (14) from plug (12). Figure 19 S0709452K Pilot Control Valve (Work Lever / Joystick) Page 12...
Page 525: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Clean all parts and dry them with compressed air. Keep all parts free from dust. Lubricate all moving parts. Pilot Control Valve (Work Lever / Joystick) S0709452K Page 13...
Page 526: Reassembly
REASSEMBLY Tighten plug (3) slowly. NOTE: Torque: 350 kg•cm (25 ft lb). Figure 20 Install shim (7), spring (8), spring seat (9), and spool (6). Figure 21 Press spring (10) and install stopper (11). Figure 22 S0709452K Pilot Control Valve (Work Lever / Joystick) Page 14...
Page 527 Install spring (10) in case (1) and pressure reducing valve assembly (6, 7, 8, 9, 11). Figure 23 Install seal (14) on plug (12). Figure 24 Install O-ring (13) on plug (12). Figure 25 Install push rod (15) on plug (12). Figure 26 Pilot Control Valve (Work Lever / Joystick) S0709452K...
Page 528 Install plug (12) in case (1). Figure 27 Install plate (16). Figure 28 10. Tighten joint assembly (18). Figure 29 11. Install swash plate (19) on joint (18). Figure 30 S0709452K Pilot Control Valve (Work Lever / Joystick) Page 16...
Page 529 12. Install hex nut (20) and tighten swash plate (19). Figure 31 13. Grease joint (18), swash plate (19) and push rod (15). Figure 32 14. Install boot (17). NOTE: Apply grease onto fitting surface swash plate and push rod. Figure 33 15.
Page 530 16. Push switch cord through hole in case (1). Figure 35 17. Install boot (23). Figure 36 S0709452K Pilot Control Valve (Work Lever / Joystick) Page 18...
Page 531: Installation
INSTALLATION Install six fittings (3, Figure 37) and O- rings (2, Figure 37). Connect hoses to joystick valve (1, Figure 37). ATS0890L Figure 37 Install plate and four socket bolts top secure joystick (5, Figure 38) valve to control stand bracket. Install left and right control stand case (1 and 2, Figure 38).
Page 532 Slowly cycle boom, arm, bucket cylinders and swing motor about five times without a load to vent air from pilot lines. Do this for 5 minutes. ARO0470L Figure 40 S0709452K Pilot Control Valve (Work Lever / Joystick) Page 20...
Page 533 SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Travel Control Valve (With Damper) S0709820K Page 1...
Page 534 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Pressure Reducing Valve..............3 Operating Theory of Damper Mechanism........5 Parts List ....................6 Specification.................... 7 Torque ..................... 7 Troubleshooting, Testing and Adjustment............8 Removal ......................9 Disassembly ....................11 Cleaning and Inspection (Wear Limits and Tolerances) .......
Page 535: General Description
GENERAL DESCRIPTION THEORY OF OPERATION The damper valve is divided into two areas of operation. There is the pressure reducing valve (a) and the damper mechanism (b). The following hydraulic circuit is an example of a remotely located control valve. ARS1810L Figure 1 Reference...
Page 536 primary pressure is transmitted to operating port as secondary pressure equivalent to control spring force compressed by spool. Full Operating Condition If pedal is moved to a maximum, bottom part of push rod presses spool seat to a maximum, and compresses control spring to a maximum.
Page 537: Operating Theory Of Damper Mechanism
Operating Theory of Damper Mechanism Operation When Operating Lever When pushing pedal, pushing force pushing push rod and spool presses cylinder, return spring and hydraulic oil in cylinder is compressed, piston coming down with push rod compresses vibration prevention chamber of lower part, oil of vibration prevention chamber of lower part is flowed through orifice to oil pressure vibration prevention chamber of upper part...
Page 538: Parts List
PARTS LIST ARS1850L Figure 5 ARS1860L Figure 6 S0709820K Travel Control Valve (With Damper) Page 6...
Page 539: Specification
Reference Reference Description Description Number Number Body (1) Snap Ring Body (2) Plug Plug O-ring Plug Rod Seal Spring Seat Dust Deal Spring Cover Spring Seat Wrench Bolt Spool Stopper Bushing Spring Camshaft Rod Guide Set Screw O-ring Set Screw Snap Ring Hex Nut Push Rod...
Page 540: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT At times pinpointing the source of the problem may be difficult. The following table lists some possible problems, causes and remedies. Refer to this table for possible causes and remedies to help in correcting problems. The table only lists general problems, causes and remedies. Often the problem is not caused by the failure of a single part but, may be the result of a combination of problems from related parts and their components.
Page 541: Removal
REMOVAL Park on firm and level ground. Lower front attachment (bucket) to the ground. Stop the engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while Figure 7 performing maintenance, extreme care. Always have one person in the cab at all times.
Page 542 13. Remove rubber boots (1, Figure 9). 14. Remove four bolts and washers (2, Figure 9), pedal brackets (3) with levers. ARS2951L Figure 9 15. Remove four bolts and washers (2, Figure 10), and pedal valve (1). ARS2940L Figure 10 S0709820K Travel Control Valve (With Damper) Page 10...
Page 543: Disassembly
DISASSEMBLY IMPORTANT Prepare a clean, well lit, stable work bench where disassembly can be performed. Prepare the necessary tools, materials and a container in which disassembled parts can be stored. All precision parts must be handled with great care and all parts must be reassembled to their original position.
Page 544 Remove cam shaft (29) and bushing (28) from cam (27). Figure 13 Figure 14 Remove cam (27) from cover (25). Figure 15 Remove wrench bolt (26) by using tool. Figure 16 S0709820K Travel Control Valve (With Damper) Page 12...
Page 545 Remove cover (25) from body (1 and 2). Figure 17 Remove plug assembly (21 - 24) with push rod assembly (14 - 20). Figure 18 Remove snap ring (13). IMPORTANT Be careful not to spring rod guide (11). Figure 19 Remove rod guide (11).
Page 546 10. Remove spool assembly (5 - 9). Figure 21 11. Remove spring (10). Figure 22 12. Remove stopper (9), spring (6) and spring seat (7) from spool assembly (5 - 9). Figure 23 Figure 24 S0709820K Travel Control Valve (With Damper) Page 14...
Page 547 13. Remove plug assembly (21 - 24) from push rod assembly (14 - 20). Figure 25 14. Remove seal (23 and 24) from plug (21). Figure 26 15. Remove O-ring (22) from plug (21). Figure 27 16. Remove seal (16) from push rod (14). Figure 28 Travel Control Valve (With Damper) S0709820K...
Page 548 17. Remove snap ring (20) from push rod (14). Figure 29 18. Remove plate (19) from push rod (14). Figure 30 19. Remove spring (18) from push rod (14). Figure 31 20. Remove steel ball (17) from push rod (14). Figure 32 S0709820K Travel Control Valve (With Damper)
Page 549: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) Cleaning disassembled parts. Place parts in a container with cleaning solvent. • Allow all parts to soak in solvent until grease and other foreign substances have dissolved and become loose, before cleaning. • Contaminated cleaning solvent may cause damage to parts and may cause poor equipment performance.
Page 550: Reassembly
REASSEMBLY IMPORTANT Prepare a clean, well lit, stable work bench where assembly can be performed. Prepare the tools and materials necessary for reassembly process. Inspect all parts, making sure that all parts are free from dirt and damage. If minor surface scratches are visible, use a very fine crocus cloth to clean it off.
Page 551 Clean plug (21) with thinner, inspect burrs and install rod seal (23) and dust seal (24) on both sides of plug by using tool. Figure 34 Install O-ring (22) on outside diameter of plug (21) and check plug whether it is abnormal.
Page 552 Install steel ball (17), spring (18), plate (19) and spring pin (15) on push rod (14). Figure 38 Install snap ring (20) on push rod assembly (14 - 19). Figure 39 Install seal (16) on push rod (14). Figure 40 10.
Page 553 11. Install plug assembly (21 - 24) with push rod assembly (14 - 20) on body (1 and 2). Figure 42 12. Install cover (25) on the upside of body (1 and 2). Figure 43 13. Tighten wrench bolt (26). NOTE: Tightening torque: 88 kg•cm (6.37 ft lb).
Page 554 15. Tighten set screw (30) on center of cam (27) not to loose cam (27) and cam shaft (29) by using wrench. NOTE: Tightening torque: 88 kg•cm (6.37 ft lb). Figure 46 16. One side holds L wrench and the other side holds spanner and tighten set screw (31) and hex nut (32) attached to cam (27) not to loose.
Page 555: Installation
INSTALLATION Position pedal valve (1, Figure 49) on cabin floor plate and install four bolts and washers (2). ARS2940L Figure 49 Install pedal brackets (3) and levers (4, Figure 50) on pedal valve and install four bolts and washers (2). Install rubber boots (1, Figure 50).
Page 556: Start-Up Procedures
START-UP PROCEDURES Start engine and set throttle at "LOW IDLE." Set safety lever on "UNLOCK" position. HAOB290L Figure 52 Slowly push and pull both travel lever about five times without a load to vent air from pilot lines. HAOB903L Figure 53 S0709820K Travel Control Valve (With Damper) Page 24...
Page 557 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. HYDRAULIC SCHEMATIC (S470LC-V)S0792170K MODEL SERIAL NUMBER RANGE Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Hydraulic Schematic (S470LC-V) S0792170K...
Page 558 TABLE OF CONTENTS General Description..................3 Solar 470LC-V....................4 S0792170K Hydraulic Schematic (S470LC-V) Page 2...
Page 559 GENERAL DESCRIPTION Schematic(s) presented in this section are laid out on facing pages. An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together to make a complete schematic. Figure 1 Hydraulic Schematic (S470LC-V) S0792170K Page 3...
Page 560 SOLAR 470LC-V Figure 2 S0792170K Hydraulic Schematic (S470LC-V) Page 4...
Page 561 Hydraulic Schematic (S470LC-V) S0792170K Page 5...
Page 562 S0792170K Hydraulic Schematic (S470LC-V) Page 6...
Page 563 1ELECTRICAL SYSTEM...
Page 565 ELECTRICAL SYSTEMS0802220K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Electrical System S0802220K Page 1...
Page 566 TABLE OF CONTENTS Troubleshooting - Electrical System ............... 4 Overview ......................5 Electric Supply System .................. 6 Engine Starting Circuit ................... 7 Operation During Start Process .............. 7 Operation After Start Process ..............8 Engine Preheating System................9 Engine Stop System..................10 Charging System..................
Page 567 Operation ....................45 Power Mode Control - Circuit Diagram ............48 Trenching Mode Control ................50 Operation ....................51 Trenching Mode Control - Circuit Diagram ........... 52 Engine Control System................. 53 Engine Control Motor ................... 55 Engine Control Dial ..................56 Engine Control Circuit Diagram..............
Page 568: Troubleshooting - Electrical System
TROUBLESHOOTING - ELECTRICAL SYSTEM Problem Possible Causes Remedies Battery will not stay Internal battery short. Replace battery. charged. Short in other part of circuit. Repair wiring or replace component. Battery does not Battery worn out or defective. Replace battery. charge. Defective alternator or belt.
Page 569: Overview
OVERVIEW The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24 volts with the exception of the car stereo and the air-conditioning control actuator. The system contains two 12 volt batteries connected in series and a three phase AC generator with a rectifier. The electric wiring used in the system is easily identifiable by the insulator color.
Page 570: Electric Supply System
ELECTRIC SUPPLY SYSTEM The electric power circuit supplies electric current to each electric component. It consists of a battery, battery relay, starter switch, circuit breaker, fusible link and fuse box. The negative terminal of the battery is grounded to the vehicle body. Even when the starter switch (5) is in the "OFF"...
Page 571: Engine Starting Circuit
ENGINE STARTING CIRCUIT OPERATION DURING START PROCESS When the starter switch is turned to the start position, the "S" and "E" terminals of the starter controller (7) are connected. At this time the contacts in the starter relay (8) are closed by the current flow from the battery (1, Figure 2) →...
Page 572: Operation After Start Process
OPERATION AFTER START PROCESS Once the engine has been started, the belt driven alternator (10) generates a current. The output generated by the alternator (10) is a square wave pulse voltage through the "P" terminal and the frequency of the pulse voltage is proportional to the rotation of the alternator. The starter controller (7) monitors the frequency of the output current.
Page 573: Engine Preheating System
ENGINE PREHEATING SYSTEM An air heater (8) device is installed in the intake manifold of the engine. When the starter switch (5) is turned to the "Preheat" position, the current flows from the battery (1) → fusible link (3) → "B" terminal of starter switch (5) → "R1" terminal of starter switch (5) → "C" terminal of preheat relay (7) →...
Page 574: Engine Stop System
ENGINE STOP SYSTEM The engine stop circuit consists of a starter switch (5), engine stop motor (9) and engine stop relay (8). There are two modes of operation - engine running and engine stop. The worm gear built into the motor reduces the engine stop motor’s speed and changes motor’s revolution to reciprocation.
Page 575 Operation In Engine Running Mode When the starter switch (3) is turned to the "ON" position, the contact points "30" and "87" of the engine stop relay (5) are closed due to current flowing from the battery (1) → fusible link (2) → "B" terminal of starter switch (3) →...
Page 576 Operation In Engine Stop Mode When the starter switch (3) is in the "OFF" position, the electric current flow to the coil of the engine stop relay (5) is shut off. As a result, the "30" and "87a" contact point of the engine stop relay are connected and current is supplied to the engine stop motor from the battery (1) →...
Page 577: Charging System
CHARGING SYSTEM When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this condition the alternator (7) starts charging.
Page 578: Monitoring System
MONITORING SYSTEM ARS0090L Figure 9 Reference Reference Description Description Number Number Instrument Panel Pump Discharge Pressure Sensor Battery Engine Coolant Engine Speed Sensor Temperature Sensor Return Filter Switch Fuel Sensor Pilot Filter Switch Air Cleaner Indicator e-EPOS Controller Engine Oil Pressure Switch Alternator Light Switch Warning Buzzer...
Page 579 INSTRUMENT PANEL ARO0100L Figure 10 Gauges Warning Lights Mode Select Switches Engine Coolant Temp. Charge Warning Light 12. Power Mode Select Switch Gauge (Up Arrow Button) Engine Pressure Fuel Gauge Warning Light 13. Trenching Mode Select Switch (Down Arrow Multi-function Gauge and Coolant Temp.
Page 580: Monitoring System Schematic
MONITORING SYSTEM SCHEMATIC R1 B ILLUMINATION CN4-1 CN4-2 CN4-3 CN4-4 WARNING LAMP L1 : BATTERY CHARGE L2 : ENG. OIL PRESS CN4-5 L3 : WATER TEMP. CN4-6 L4 : PREHEAT L5 : WORK LAMP L6 : OVER LOAD CN4-7 CN4-8 LCD DISPLAY PANEL WATER TEMPERATURE FUEL LEVEL...
Page 581 Reference Reference Description Description Number Number Instrument Panel Engine Oil Pressure Switch Pilot Buzzer Air Cleaner Indicator Light Switch Return Filter Switch Start Switch Pilot Filter Switch Front Pump Pressure Alternator Sensor e-EPOS Controller Rear Pump Pressure Battery Sensor Battery Relay Engine Coolant Circuit Breaker Temperature Sensor...
Page 582: Operation
OPERATION INSTRUMENTS Sensor Specification Function Display Input Input Specification Terminal 41°C (106°F) → 1,372 ohms GREEN 61°C (142°F) → 855 ohms Engine CN4-5 WHITE 102°C (216°F)→ 160 ohms 107°C Coolant CN4-6 105°C (221°F) → 147 Temperature 105°C ohms 107°C (225°F) → 128 61°C 41°C ohms...
Page 583 Sensor Specification Function Display Input Input Specification Terminal 02/05 [MO] 11:30A Main pump CN4-1 FRONT PUMP discharge pressure CN4-2 (front pump) V = 0.00816 x P + 1.0 V: Sensor output voltage ARO0190L P: Displayed pressure (Bar) 02/05 [MO] 11:30A Main pump discharge CN4-3...
Page 584: Operation
WARNING AND INDICATOR LIGHTS Input Description Symbol Operation Remarks Terminal Lights up when not charging [R(I) Lights up before terminal output engine start up and Charge CN2 - 1 drops below 12±1V] shut off once engine and over charging is running. [R(I) terminal output increase over 33 V].
Page 585 Input Description Symbol Operation Remarks Terminal Warning buzzer will Lights up when sound. lifting load exceeds limit. (When the 2.80 V (S300LC-V) over load warning CN1 - 3 Overload 2.80 V (S300LL) switch is turned (Optional) CN1 - 4 "ON," output 2.80 V (S340LC-V) voltage increases 2.88 V (S420LC-V)
Page 586: Initial Operation
INITIAL OPERATION Item Input (Terminal) Output (Operation and initial setting mode) Initial When battery voltage is input • All LCD, LED and warning lights are turned on Operation to CN7 - 9 (starter switch is and turned off after about 2 seconds. turned from "OFF"...
Page 587: Mode Select Switch
MODE SELECT SWITCH Power Mode / Trenching Mode Switch e-EPOS Output Output Check Pump Discharge (Operation Operation Mode Volume Control Swing Priority 7-Segment mode display Valve Current Solenoid Valve Display LED) (mA) Power Power Mode Variable Output Mode Standard Mode Work Mode Trenching Mode Digging Mode...
Page 588: Graphic Information Area Display
GRAPHIC INFORMATION AREA DISPLAY OVERVIEW Many kinds of condition of machine are displayed on the letter information display department. The information display department is divided into two menus. One is main menu for user and the other is special menu for specialist. These menus can be moved from normal display mode by the combination of select buttons.
Page 589: Main Menus For The Graphic Display Area
MAIN MENUS FOR THE GRAPHIC DISPLAY AREA Main menu: Language setting, Time setting, Filter/Oil information Special menu: Information of machine status, failure information, Information of machine operation. MENU SELECTION BUTTONS Up Arrow Button ( , 1 on Figure 12): Move the cursor to up, left and previous screen. Down Arrow Button ( , 2 on Figure 12): Move the cursor to down, right and next screen.
Page 590: Main Menu
MAIN MENU When the "ESC" button is pressed for more than 3 seconds, the main menu screen is displayed. Main menu offers three sub-menus (language M A I N M E N U setting, time setting, or filter/oil information) to the operator.
Page 591: Filter/Oil Information
FILTER/OIL INFORMATION This mode displays total operating hours of filters and oils. After changing the filter and oil, reset the operating hour and then the operating hours until the next service interval can be easily 1.Fuel Filter checked. Hrs: 0232 Reset: ARO0400L Figure 16 Menu Display Order and Icon Explanation...
Page 592: Special Menu
SPECIAL MENU In this menu, many types of operating conditions and functions can be accessed and disp[layed, including the e-EPOS controller. This menu is mainly used for machine testing and failure diagnostics. The special menu offers three sub-menus; Machine status. Failure information.
Page 593: Special Menu Selections
Special Menu Screen NOTE: Displayed language on the special menu screen consists SPECIAL MENU of Korean and English. achine Info If any language except for Korean selected during Failure Info language selection mode of main menu, only English will be Operating Hrs displayed special...
Page 594 Contents of Machine Status Display Item of Machine State Information Display Remarks 1. EPPR Current "mA" EPPR valve current 2. Dial Voltage "mV" Dial voltage 3. TPS Voltage "mV" TPS voltage 1. Alternator 8. Pressure (Px) Input status delivered from 2.
Page 595 Display Example: Machine Status Information EPPR Valve Current EPPR CURRENT ARS0870L Figure 24 Dial Voltage DIAL VOLTAGE 2089 ARS0880L Figure 25 TPS Voltage Output voltage of potentiometer built into engine control motor. TPS VOLTAGE 2095 ARS0890L Figure 26 Electrical System S0802220K Page 31...
Page 596 Input Status "YES" or "NO" for alternator’s generation (Generation: "ON"/ Non-generation: M AC H I N E I N F O "OFF"), selection status of select switch (Selection: "ON"/ Non-selection: "OFF") Input State and the other statuses of on/off type sensors.
Page 597 Output Status: Output status of solenoid valves and spare valves are displayed. (Output: "ON"/ Non- output: "OFF") Relief Pess Up Spare Out 1 : OFF : OFF High Speed Spare Out 2 : ON : ON Swing Priority : OFF ARS0920L Figure 29 Hydraulic Oil Temperature...
Page 598 Boom Pressure (Optional) On machine with OWD (Overload Warning Device), detected pressure from boom BOOM PRESSURE cylinder is displayed with numeric values (Unit: Bar). The relative equation between the, output voltage of pressure sensor, and the pressure of boom cylinder, is as follows. •...
Page 599 Current failure information Current status of failure is displayed (Failure code, failure contents). REALTIME FAIL When a number of failures are produced, failure information can be C O D E : 1 2 checked by using "PRV" ( , 1 on Press up s/v open Figure 18) or "NXT"...
Page 600 Failure record deletion This mode is used to delete the memorized record of past failure. If FA I L U R E L O G this mode is selected, all records will be deleted. A l l F a i l L o g When "YES"...
Page 601 Display Contents of Failure Information Code Reset Code Contents Cause Operation Procedure Communication error Automatic reset between e-EPOS Communication Err!! * Note when problem is controller and instrument corrected panel After correcting EPPR v/v short Short Circuit problem, turn Press Up s/v short Short Circuit Cut off output start...
Page 602 Reset Code Contents Cause Operation Procedure EPPR v/v open Open Circuit Press Up s/v open Open Circuit Swing pri. s/v open Open Circuit Output voltage Over Dial Voltage Err (H) 4.6±0.2 V Output voltage Over Dial Voltage Err (L) 0.4±0.2 V Output voltage Over...
Page 603 • Work mode: Digging mode • Auto idle: "ON" (Selection state) The above mentioned two statuses are applicable to normal condition of an e-EPOS controller. Under the abnormal condition of an e-EPOS controller, communication cable or instrument panel failure, "Failure code: 82" can be generated. Information of Machine Operation Accumulated operation hour of each mode and status is displayed.
Page 604 Information contents of operation hour Item Information Contents Detection Method Power mode switch (Instrument panel) - Operation hours used power mode Power Mode "ON" status and Alternator signal (CN2- are displayed. Trenching mode switch (Instrument Trenching Operation hours used trenching panel) - "ON"...
Page 605 Menu Selection of Operation Hour Information 1. Power : 0345 Hr 4. Travel Speed 2. Trenching : 0190 Hr High : 0012 Hr 3. Auto Idle : 0227 Hr Low : 0059 Hr 5. Hyd. Oil Temp (°C) 6. Coolant Temp (°C) 30 ↓...
Page 606: Electronic Hydraulic Control System (E-Epos)
ELECTRONIC HYDRAULIC CONTROL SYSTEM -EPOS) CONTROL SYSTEM SCHEMATIC (Wheel) (Pump control signal) (Engine speed sensor signal) (Switch signal) (Throttle signal) (Engine throttle control signal) (Throttle command) (Coolant water temp. signal) (Mode select signal) (Auto idle signal) (Machine information) Figure 43 S0802220K Electrical System Page 42...
Page 607 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Pressure Engine Control Motor Solenoid Valve (Swing Engine Priority) Main Hydraulic Pump Solenoid Valve (High Control Pump Speed) Control Valve Travel Motor Pressure Switch Engine Throttle Control Pump Pressure Sensor Engine Control Dial Engine Speed Sensor e-EPOS Controller...
Page 608: Power Mode Control
POWER MODE CONTROL (Wheel type) (Pump control signal) (Engine speed sensor signal) (Throttle Position signal) (Engine throttle control signal) (Throttle signal) (Power mode switch signal) ARS1040L Figure 44 Reference Reference Description Description Number Number Instrument Panel (Power Engine Speed Sensor Mode Selection Switch) E.P .P.R.
Page 609 The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by the operator. The pump output in each mode is determined by the mode selection and is listed in the following table Mode Standard Mode Power Mode...
Page 610 HDA6020L Figure 46 Reference Reference Description Description Number Number Engine Horsepower (hp) Pump Discharge Pressure Engine Speed (rpm) (kg/cm Pump Discharge Volume (lpm) Standard Mode Standard Mode is used for general work. When this mode is selected it will reduce noise and fuel consumption in comparison with Power Mode.
Page 611 Reference Reference Description Description Number Number Engine Horsepower (hp) Pump Discharge Pressure (kg/cm Engine Speed (rpm) Pump Discharge Volume (lpm) Electrical System S0802220K Page 47...
Page 612: Power Mode Control - Circuit Diagram
POWER MODE CONTROL - CIRCUIT DIAGRAM CN1-1 CN1-2 CN1-8 CN1-9 CN4-16 CN4-17 CN3-9 CN3-10 RS-422 CN3-11 CN3-12 CN3-8 P/V(A) CN1-10 CN1-19 S-MODE CN1-5 A/I MODE CN1-7 CN4-10 CN4-11 RETRACT (+) (+) (-) (-) HIGH CN4-12 CN4-13 TERMINAL NO 10 9 8 16 15 13 12 (CN4)
Page 613 Reference Reference Description Description Number Number Battery Engine Speed Sensor Battery Relay Engine Throttle Controller Fuse Engine Control Motor e-EPOS Controller Engine Control Dial Instrument Panel Electrical System S0802220K Page 49...
Page 614: Trenching Mode Control
TRENCHING MODE CONTROL Main Relief v/v (Wheel) (Engine throttle control signal) (Throttle signal) (Trenching mode switch signal) ARS1070L Figure 49 Reference Reference Description Description Number Number Instrument Panel (Trenching Control Valve Mode Select Switch) Solenoid Valve Engine Control Motor Engine Throttle Control Engine Engine Control Dial Main Hydraulic Pump...
Page 615: Operation
OPERATION Digging Mode This mode is used for general digging work, loading work and ground leveling work requiring quick stops. The current to the solenoid valve for swing priority is shut off. Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles.
Page 616: Trenching Mode Control - Circuit Diagram
TRENCHING MODE CONTROL - CIRCUIT DIAGRAM CN1-1 CN1-2 CN1-8 CN1-9 CN3-9 CN1-14 CN3-10 RS-422 CN3-11 CN3-12 CN3-8 TERMINAL NO 6 5 4 18 17 (CN4) (CN3) (CN7) (CN1) (CN2) ARS1080L Figure 51 Reference Reference Description Description Number Number Battery e-EPOS Controller Battery Relay Instrument Panel Fuse...
Page 617: Engine Control System
ENGINE CONTROL SYSTEM (Feedback Signal) (Drive Signal) (Command Signal) BATT. RELAY AUTO IDLE COMMAND e-EPOS CONTROLLER OVER HEAT BATTERY RETRACT ARS1090L Figure 52 Reference Reference Description Description Number Number Engine Control Motor Engine Throttle Controller Engine Engine Control Dial When the engine control dial is moved the output voltage changes according to the dial position. This signal is input to the engine throttle controller.
Page 618 S0802220K Electrical System Page 54...
Page 619: Engine Control Motor
ENGINE CONTROL MOTOR CIRCUIT DIAGRAM (GREEN) P1(Gr) P2(P) P3(L) (YELLOW) (RETRACT) (GRAY) ACCEL (PINK) P4(G) P5(Y) (5.0V) (BLUE) DECEL (EXTEND) ARS1100L Figure 53 Reference Description Number Motor Assembly Cable Spring Assembly The engine control motor uses a D.C. motor with a built in potentiometer to sense the position of the control cable.
Page 620: Engine Control Dial
ENGINE CONTROL DIAL 7th STEP 13th STEP 1st STEP ( 10 ) ( 10 ) MECHANICAL MECHANICAL STOP STOP 4.0V 2.5V 1.0V SETUP 1ST 2nd 12th 13th STOP STOP VIEW ( POTENTIOMETER BOTTOM) HDA6033L Figure 54 Reference Description Number Knob Potentiometer (Variable Resistor) S0802220K...
Page 621 The engine control dial has a built in potentiometer. When the control knob is moved the output voltage (through terminals 2 and 3) will vary from the 5 V supplied from the throttle controller as shown in the graph. Electrical System S0802220K Page 57...
Page 622: Engine Control Circuit Diagram
ENGINE CONTROL CIRCUIT DIAGRAM ARS1110L Figure 55 Reference Reference Description Description Number Number Battery Engine Throttle Controller Battery Relay Engine Control Motor Fuse Engine Control Dial e-EPOS Controller Pressure Switch (Py Port) Instrument Panel Pressure Switch (Px Port) Engine Speed Sensor S0802220K Electrical System Page 58...
Page 623: Automatic Deceleration Control (Auto Idle Control)
AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL) (Feedback Signal) (Drive Signal) (Command Signal) Auto deceleration Switch Signal ARS1120L Figure 56 Reference Reference Description Description Number Number Instrument Panel Engine Throttle Controller Engine Control Motor Engine Control Dial Engine e-EPOS Controller Pressure Switch If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed is automatically lowered.
Page 624: Engine Overheat Protection System
ENGINE OVERHEAT PROTECTION SYSTEM (Pump control signal) Engine overheat signal Engine overheat signal ARS1130L Figure 57 Reference Reference Description Description Number Number Instrument Panel E.P .P.R. Valve Engine Control Motor Engine Throttle Controller Engine e-EPOS Controller Main Pump Warning Buzzer Control Pump When the engine coolant temperature increases to over 107°C (225°F), the sensor mounted in the coolant line will send a signal to the instrument panel.
Page 625: Power Boost Mode
POWER BOOST MODE OPERATION Main Relief v/v (Button Signal) ARS1140L Figure 58 Reference Reference Description Description Number Number Engine Solenoid Valve Main Pump e-EPOS Controller Control Pump Power Boost Switch (Top of Right Work Lever) Control Valve The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation ability.
Page 626: Power Boost Control - Circuit Diagram
POWER BOOST CONTROL - CIRCUIT DIAGRAM CN1-1 CN1-2 CN1-8 CN1-9 CN3-9 CN1-13 CN3-10 RS-422 CN3-11 CN3-12 CN3-8 CN2-3 TERMINAL NO 18 17 14 13 (CN4) (CN3) (CN7) 16 15 (CN1) (CN2) ARS1150L Figure 59 Reference Reference Description Description Number Number Battery Instrument Panel Battery Relay...
Page 627: Automatic Travel Speed Control
AUTOMATIC TRAVEL SPEED CONTROL ARS1160L Figure 60 Reference Reference Description Description Number Number Engine Solenoid Valve (High speed) Main Pump Travel Motor Control Valve Engine Control Dial Pressure Switch (Py) e-EPOS Controller Pump Pressure Sensor Selection Switch For Automatic Travel If the automatic travel speed control switch is set to the "OFF"...
Page 628: Automatic Travel Speed Control - Circuit Diagram
AUTOMATIC TRAVEL SPEED CONTROL - CIRCUIT DIAGRAM CN1-1 CN4-1 CN1-2 CN4-2 CN4-3 CN1-8 CN4-4 CN1-9 CN1-12 CN4-10 CN4-11 HIGH CN2-5 (MANUAL) CN2-6 (AUTO) TERMINAL NO 10 9 (CN4) (CN3) 11 10 15 14 13 (CN1) (CN2) ARS1170L Figure 61 Reference Reference Description Description...
Page 629: Engine Control Device - Adjustment
ENGINE CONTROL DEVICE - ADJUSTMENT Engine speed adjustment should be made by following the procedures listed below. (Under no load conditions) Adjusting The High Idle Speed Turn the starter switch to the "ON" position. Select Power Mode from the instrument panel. Turn the engine speed control dial to the "HIGH IDLE"...
Page 630 Variable Mode Dial Position and Mode Setting Engine Speed Setting Resistor Automatic Refer to throttle controller Deceleration name plate (3, Figure 64). (Auto Idle) ENGINE SPEED ARS1180L Standard Refer to throttle controller Mode name plate (3, Figure 64). ENGINE SPEED ARS1181L ARS1441L Figure 64...
Page 631 Figure 65 Reference Reference Description Description Number Number Engine - Fuel Control Lever Engine Speed Control Cable Area To Engine Control Motor Control Motor Cable Bracket Electrical System S0802220K Page 67...
Page 632: Self-Diagnostic Function
SELF-DIAGNOSTIC FUNCTION E-EPOS CONTROLLER The system operation status and malfunction codes can be checked through the display on top of the e- EPOS controller box in the drawer under the operator’s seat. ARS1190L Figure 66 Reference Reference Description Description Number Number Upper Digit Power Monitor (Stays On...
Page 633 Normal Operation Display Readout Display Readout Mode Selection Operation Status Upper Digit Lower Digit Normal Operation Power Mode Power Mode HAOH340L Power Mode Normal Operation Standard Mode Standard Mode HAOH350L Normal Operation Digging Digging Mode HAOH370L Work Mode Normal Operation Trenching Trenching Mode HAOH380L...
Page 634: Engine Throttle Controller
ENGINE THROTTLE CONTROLLER Under the rubber cap on the surface of the engine controller, there are three LEDs. Based on the equipment status the following LEDs will turn "ON." LED Status Voltage At Throttle Controller Status Control Motor Input Signal Green Yellow Terminal...
Page 635: Wiper System
WIPER SYSTEM WIPER CIRCUIT ARS1200L Figure 67 Reference Reference Description Description Number Number Battery Washer Switch Battery Relay Wiper Timer Fuse Wiper Motor Wiper Switch Window Washer WIPER OPERATION Intermittent Operation (I - position) When the wiper switch (4) is turned "I" position, the current flows from the fuse (3) → "B" terminal of wiper motor (7) →...
Page 636: Window Washer Operation
When the wiper switch (4) is turned "OFF," the current flows from the fuse (3) → "B" terminal of wiper motor (7) → "L" terminal of wiper motor (7) → No. 5 terminal of wiper timer (6) → No. 4 terminal of wiper timer (6) →...
Page 637 Electrical System S0802220K Page 73...
Page 638: Lighting System
LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM (FR) (RR) (FML) (RL) (FMR) (FL) (FR) (FL) (RH) (LH) (RH) (LH) (RH) (LH) CN7-9 CN2-7 CN3-9 CN7-1 CN3-10 CN3-11 CN3-12 CN3-8 ARS1210L Figure 68 S0802220K Electrical System Page 74...
Page 639: Kind Of Light
Reference Reference Description Description Number Number Battery Rear Cabin Light Relay Battery Relay Instrument Panel Fuse Box e-EPOS Controller Light Switch Rotating Warning Light Warning Light Switch Headlight (2 ea.) Cabin Light Switch Work Light (2 ea.) Headlight Relay (Work Light Additional Work Light (2 ea.) Indicate Light) Front Cabin Light (2 ea.)
Page 640: Overload Warning Device
OVERLOAD WARNING DEVICE OVERLOAD WARNING DEVICE CIRCUIT DIAGRAM ARS1260L Figure 69 Reference Reference Description Description Number Number Battery e-EPOS Controller Battery Relay OWD Select Switch Fuse Box Pressure Sensor S0802220K Electrical System Page 76...
Page 641 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. ELECTRICAL SCHEMATIC (S470LC-V)S0892170K MODEL SERIAL NUMBER RANGE Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Electrical Schematic (S470LC-V) S0892170K...
Page 642 TABLE OF CONTENTS General Description..................3 Solar 470LC-V....................4 S0892170K Electrical Schematic (S470LC-V) Page 2...
Page 643 GENERAL DESCRIPTION Schematic(s) presented in this section are laid out on facing pages. An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together to make a complete schematic. Figure 1 Electrical Schematic (S470LC-V) S0892170K Page 3...
Page 644 SOLAR 470LC-V Figure 2 S0892170K Electrical Schematic (S470LC-V) Page 4...
Page 645 Model Solar 470LC-V Name ELECTRICAL DIAGRAM NO. 599 - 00039 DAEWOO HEAVY INDUSTRIES LTD. Electrical Schematic (S470LC-V) S0892170K Page 5...
Page 646 S0892170K Electrical Schematic (S470LC-V) Page 6...
Page 647 1ATTACHMENTS...
Page 649 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. BOOM AND ARM S0902110 MODEL SERIAL NUMBER RANGE Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Boom and Arm S0902110 Page 1...
Page 650 TABLE OF CONTENTS Front Attachment Pin Specifications............... 3 Front Attachment - Removal and Installation ..........4 Arm Removal Procedure................. 4 Boom Removal Procedure ..............6 Installation ...................... 7 Arm Installation Procedure..............7 Boom Installation Procedure ..............7 Start-up Procedures ..................8 S0902110 Boom and Arm Page 2...
Page 651: Front Attachment Pin Specifications
NOTE: Some mounting pins must be drilled and tapped for lubrication fittings and piping, or may have other required specifications. Consult Daewoo After Sales Service for information on wear tolerances and replacement limits for mounting pins. Mounting Pin Diameter, mm (Inches) Length, mm (Inches) 125.0 mm (4.92 in)
Page 652: Front Attachment - Removal And Installation
NOT proceed with attachment disassembly unless you are completely sure of what you are doing. Please call your local Daewoo distributor or Daewoo After Sales Service for assistance. DO NOT allow personnel to stand underneath a weakened or only partially supported attachment section.
Page 653 Park the excavator away from obstructions and all traffic on clear, flat, level ground. Extend the arm cylinder and crowd the arm into the boom. Partially retract the boom cylinder so that the boom is stretched out in front of the excavator, as low to the ground as possible, with the arm crowded under the boom. The tip of the arm point should be lowered to secure blocking that will safely support the weight of the arm.
Page 654: Boom Removal Procedure
BOOM REMOVAL PROCEDURE NOTE: Boom removal may be simplified if the shell of the operator’s cab is taken off the turntable deck first. Refer to the Operator’s Cab Removal procedure before continuing, if both components are to be removed from the excavator. After the bucket, arm and arm cylinder have been removed, lower the end of the boom to a stable, secure blocking support.
Page 655: Installation
Refer to the General Safety Pages, Lift Ratings, Working Range Diagrams and Weights of Materials sections in the Operation and Maintenance Manual. Consult your dealer or Daewoo After Sales Service for more information if you have any questions or require more information.
Page 656: Start-Up Procedures
START-UP PROCEDURES Once the boom has been serviced, it should be lubricated as outlined in the initial start-up procedures of the operation manual. Refer to the appropriate operation and maintenance manual for unit. S0902110 Boom and Arm Page 8...
Page 657 BUCKET S0904005K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Bucket S0904005K Page 1...
Page 658 TABLE OF CONTENTS Bucket Tooth Inspection and Replacement ............ 3 Type 1...................... 3 Type 2...................... 4 Bucket O-ring Replacement ................6 Bucket Shimming Procedures ................ 8 New Bucket Installation ................8 Bucket Attachment, Removal and Reversal ........... 9 Detaching the Bucket ................9 Attaching The bucket................
Page 659 BUCKET TOOTH INSPECTION AND REPLACEMENT There are several different types of attachment methods for replaceable bucket teeth. Some of the most common types are shown in the following drawings. Bucket teeth are usually replaced in sets but it may sometimes be necessary to replace individual teeth. TYPE 1 Look for the following indications of wear or damage: •...
Page 660 TYPE 2 WARNING! Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing bucket teeth. Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground. Place wooden blocks under front of bucket.
Page 661 On a routine basis, inspect bucket teeth to make sure that tooth wear or breakage has not developed. Do not allow replaceable bucket teeth to wear down to a point that bucket adapter is exposed. See Figure 4. To replace a tooth, use a hammer (1, Figure 5) and punch (2) to drive locking pin assembly out of tooth and tooth adapter.
Page 662 BUCKET O-RING REPLACEMENT WARNING! Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins. Inspect the bucket O-rings on a routine basis. If worn or damaged, replacement is necessary. ARO1350L Figure 6 Roll the old O-ring (1, Figure 7) onto the boss (2) around the bucket pin (3).
Page 663 Roll the new O-ring (1, Figure 9) into the O-ring groove. ARO1392L Figure 9 Bucket S0904005K Page 7...
Page 664 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, prior to assembly.
Page 665 BUCKET ATTACHMENT, REMOVAL AND REVERSAL DETACHING THE BUCKET Park the excavator away from obstructions on clear, flat, level ground. Lower the bucket carefully to pre- assembled blocking on the ground. Brace the bucket so that there is no load weight on the pin connecting the bucket and arm.
Page 666 When the link pin has been installed, withdraw the temporary support rod from the bucket pin holes, lower and raise the arm and boom and install the bucket pin. WARNING! When making linkage alignments, never insert fingers into holes. attachment or bucket could shift position and cause a severe injury.
Page 667 HAS THIS BEEN DISCUSSED WITH A DAEWOO SERVICE REPRESENTATIVE: IF YES - WHO: (It is advised to discuss this with a Daewoo service representative to ensure that the above correction is appropriate and valid.) Mail to: Daewoo Heavy Industries America Corporation...