Download Print this page

Daewoo Solar 340LC-V Shop Manual

Table of Contents

Advertisement

Quick Links

Solar 340LC-V

Shop Manual

023-00051E

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.

023-00051E Shop Manual

Table of Contents

Advertisement

Chapters

Table of Contents

Troubleshooting

Need help?

Need help?

Do you have a question about the Solar 340LC-V and is the answer not in the manual?

Questions and answers

Summary of Contents for Daewoo Solar 340LC-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. 023-00051E...
Page 5 1TABLE OF CONTENTS Safety Track Excavator Safety................S0102000 Specifications Specifications for Solar 340LC-V............S0202110K General Maintenance General Maintenance Procedures ............S0302000 Standard Torques ..................S0309000 Upper Structure Cab ..................... S0402040K Counterweight..................S0403050K Fuel Tank.................... S0405130K Fuel Transfer Pump ................S0405500 Swing Bearing..................S0407000 Swing Reduction Gearbox ..............S0408030 Lower Structure and Chassis Track Assembly ..................S0505000...
Page 6: Table Of Contents
Swing Motor...................S0707280 Travel Motor (with Gearbox) ............... S0707345K Main Pump (Rexroth)................S0708355K Main Control Valve (Kayaba).............. S0709401K Pilot Control Valve (Work Lever / Joystick)......... S0709451K Travel Control Valve (With Damper)........... S0709820K Hydraulic Schematic (S340LC-V) ............S0792190K Electrical System Electrical System ................S0802220K Electrical Schematic (S340LC-V) ............
Page 7 1SAFETY...
Page 9 Solar 290LC-V 0001 and Up Solar 300LC-V 1001 and Up Solar 300LL 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...
Page 10 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 340LC-VS0202110K MODEL SERIAL NUMBER RANGE Solar 340LC-V 1001 and UP Copyright 2002 Daewoo May 2002 Specifications for Solar 340LC-V S0202110K 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 S0202110K Specifications for Solar 340LC-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 340LC-V S0202110K Page 3...
Page 52: Component Locations
COMPONENT LOCATIONS Figure 1 S0202110K Specifications for Solar 340LC-V Page 4...
Page 53: 18. Swing Motor
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 340LC-V S0202110K Page 5...
Page 54 S0202110K Specifications for Solar 340LC-V Page 6...
Page 55: General Dimensions
4,040 mm (13’ 3") 2,990 mm (9’ 10") 1,500 mm (4’ 11") 1,490 mm (4’ 11") 2,680 mm (8’ 10") 3,280 mm (10’ 9") 600 mm (23.62 in) 506 mm (19.92 in) 3,080 mm (10’ 1") Specifications for Solar 340LC-V S0202110K 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. 2.6m (8.5 ft) ARM 3.2m (10.5 ft) ARM 4.0m (13.1 ft) ARM AUS0520L Figure 3 S0202110K Specifications for Solar 340LC-V Page 8...
Page 57 (10' 9") (10' 10") 2310 mm 1,100 mm -326 mm Min. Digging Reach (7' 7") (3' 7") (-1' 1") 4,510 mm 4,490 mm 4,510 mm Min. Swing Radius (14' 10") (14' 9") (14' 10") Specifications for Solar 340LC-V S0202110K Page 9...
Page 58: General Specifications
- Optional 700 mm (28.0") 0.56 kg/cm (7.96 psi) shoe - Optional 800 mm (32.0") 0.50 kg/cm (7.11 psi) shoe - Optional 850 mm (34.0") 0.47 kg/cm (6.68 psi) shoe - Transport Dimensions S0202110K Specifications for Solar 340LC-V Page 10...
Page 59 Track Shipping Length 4,960 mm (16’ 3") Transport Trailer Capacity 35 tons, minimum load capacity Transport Loading Ramp 15° angle CAUTION: Refer to Transport Maximum Procedure for Allowable Slope Safe Shipping Instructions. Specifications for Solar 340LC-V S0202110K Page 11...
Page 60: Engine Performance Curves (Per Ks-R1004 Standard)
ENGINE PERFORMANCE CURVES (PER KS-R1004 STANDARD) 1000 1500 2000 REVOLUTION (rpm) AUS0510L Figure 4 S0202110K Specifications for Solar 340LC-V Page 12...
Page 61 KS-R1004 250 ps @ 1,900 rpm Power (246.58 hp @ 1,900 rpm) 108 kg•m @ 1,400 rpm Max. Torque (780 ft lb @ 1,400 rpm) 160.0 g/ps•h Fuel Consumption (Min. Rated) (5.64 oz/hp•h) Specifications for Solar 340LC-V S0202110K 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 S0202110K Specifications for Solar 340LC-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 340LC-V S0202110K 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 S0202110K Specifications for Solar 340LC-V Page 16...
Page 65: Performance Tests
High sec. 15.8 ±1.0 15.8 ±1.0 (65.62 ft) sec. 23.8 ±1.5 23.8 ±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 340LC-V S0202110K 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: S0202110K Specifications for Solar 340LC-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 340LC-V S0202110K 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 S0202110K Specifications for Solar 340LC-V Page 20...
Page 69: Cylinder Performance Tests
OPERATION STANDARD MODE POWER MODE High Speed 22.3 - 25.3 seconds 22.3 - 25.3 seconds Low Speed 33.7 - 37.7 seconds 33.7 - 37.7 seconds Specifications for Solar 340LC-V S0202110K Page 21...
Page 70 S0202110K Specifications for Solar 340LC-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...
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 Remember, that ultimately safety is your own personal responsibility. 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...
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 12. Remove two caps (1, Figure 4) from counterweight (2). 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...
Page 115 Model Bolt Torque Solar 300LC-V Solar 300LL 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).
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 S0405130K MODEL SERIAL NUMBER RANGE Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Copyright 2002 Daewoo May 2002...
Page 118 TABLE OF CONTENTS General Description..................3 Parts List ....................4 Specifications ..................5 Removal ......................6 Installation ....................10 Start-up Procedures ..................12 S0405130K 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 S0405130K Page 3...
Page 120: Parts List
PARTS LIST ATS0700L Figure 1 S0405130K Fuel Tank Page 4...
Page 121: Specifications
Reference Reference Description Description Number Number Fuel Tank Cap (=2188-9004) O-ring SP Plug Cover Level Gauge Bolt (M10x1.5x25) O-ring Spring Washer (M10) O-ring Drain Valve Plug Bolt Spacer Shim Bolt Shim Bolt Fuel Filter Clip SPECIFICATIONS Model Fuel Tank Capacity S340LC-V 550 liters (145 U.S.
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: See "Specifications" section of this section fuel tank capacity. 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 battery cover (5) from frame. ARS1750L 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 fuel FUEL TANK filler pump port (3, Figure 13) on side of fuel tank (2). OIL TANK ATS0711L 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 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 the hand operated primer pump (Figure 17) by the fuel injection pump.
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 290LL 1001 and Up Solar 300LC-V 1001 and Up Solar 300LL 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...
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 290LL 1001 and Up Solar 300LC-V 1001 and Up Solar 300LL 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...
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 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 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 GEARBOXS0408030 MODEL SERIAL NUMBER RANGE Solar 330LC-V 1001 and Up Solar 340LC-V 1001 and Up Solar 400LC-V 1001 and Up Solar 420LC-V 1001 and Up Copyright 2002 Daewoo...
Page 142 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Parts List ....................4 Special Tools ................... 6 Specifications ..................7 Troubleshooting, Testing and Adjustment............8 Removal ......................9 Disassembly ....................10 Reassembly....................13 Installation ....................
Page 143: General Description
Return to Master Table of Contents GENERAL DESCRIPTION THEORY OF OPERATION The swing reduction gearbox is a two-step planetary gearbox with three planet gears, one sun gear and 2- 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
Return to Master Table of Contents PARTS LIST Figure 1 S0408030 Swing Reduction Gearbox Page 4...
Page 145 Return to Master Table of Contents Reference Reference Description Description Number Number Shaft Lock Pin Gear Case Spacer Carrier #2 Collar Sun Gear #2 Plate Planetary Gear #2 Lock Ring Side Plate #2 Roller Bearing Shaft For Pin #2 Roller Bearing Bushing #2 Oil Seal Carrier #1...
Page 146: Special Tools
Return to Master Table of Contents SPECIAL TOOLS The special tools shown in Figure 2 can be fabricated to assist in gearbox assembly. Figure 2 S0408030 Swing Reduction Gearbox Page 6...
Page 147: Specifications
Return to Master Table of Contents SPECIFICATIONS Swing Reduction Specification Gearbox Solar 330LC-V Solar 340LC-V Solar 400LC-V Solar 420LC-V Drive Type Two Stage Two Stage Two Stage Two Stage Planetary Gear Planetary Gear Planetary Gear Planetary Gear Reduction Ratio 19.560 19.560...
Page 148: Troubleshooting, Testing And Adjustment
Return to Master Table of Contents 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...
Page 149: Removal
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 150 Return to Master Table of Contents 11. Tag and disconnect hoses from swing motor (1, Figure 4). Plug and cap hoses and port to prevent contamination from entering hydraulic system or component. 12. Disconnect tube (2) from drain cock (3) and hose fitting (7) from fill hole.
Page 151: Disassembly
Return to Master Table of Contents DISASSEMBLY NOTE: Clean all exterior surfaces of the gearbox before beginning disassembly. Remove the drain plugs and allow all oil to drain from the gearbox. IMPORTANT Use a clean, dry container (with at least 11 liters, or 2.9 gallons capacity) to catch gear oil. A clean container allows an evaluation to be made of the used oil.
Page 152 Return to Master Table of Contents Use a flat tipped punch to drive the spring pin back into the shaft, so that the shaft can be pulled out of the gear housing. Drive back the spring pins on the other two shafts.
Page 153 Return to Master Table of Contents 11. Insert the gear case into a hydraulic press. Position the gear case so that the input end of the shaft is facing up. Insert a metal spacer into the bore of the shaft. Press down on the shaft until the shaft, with the spacer, plate, and roller bearing attached, is pressed out of the gear case.
Page 154: Reassembly
Return to Master Table of Contents REASSEMBLY Slide the bearing spacer into its position on the shaft. Lubricate the part of the shaft that the bearing will rest on. Heat the bearing to 50°C (122°F). Set the bearing on the shaft. Invert the shaft on the pipe that has a 145 mm inside diameter.
Page 155 Return to Master Table of Contents Use the Seal Protector shown in Figure 2 to cover the spline on the input end of the shaft. This will prevent damage to the seal lips when the shaft assembly is installed into the gear case. Position the gear case so that the output end is facing upward.
Page 156 Return to Master Table of Contents Set the ring gear down into the gear case. Figure 22 Use gear oil to lubricate the inside of the three 2nd level planetary gears and the outside of the three planetary shafts. Insert a planetary gear and thrust plate into the gear housing.
Page 157 Return to Master Table of Contents 12. Install eye bolts into the shafts. Loop lifting slings through the eye bolts. Lift up the gear housing assembly and set it down into the ring gear. To get the housing to slide completely down into the ring gear, it may be necessary to slightly rotate the gear housing to align the planetary gears with the splines on the shaft.
Page 158: Installation
Return to Master Table of Contents INSTALLATION Coat pinion gear with grease. Refer to operation manual for specifications. Make sure two alignment pins (6) are installed in flange of swing reduction gearbox (5). Using a suitable lifting device, sling swing motor (1, Figure 4) and position swing motor and reduction gearbox (5) as an assembly on unit.
Page 159 1LOWER STRUCTURE AND CHASSIS...
Page 161 Remember, that ultimately safety is your own personal responsibility. TRACK ASSEMBLY S0505000 MODEL SERIAL NUMBER RANGE Solar 290LC-V 0001 and Up Solar 300LC-V 1001 and Up Solar 340LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Track Assembly S0505000 Page 1...
Page 162 TABLE OF CONTENTS General Description..................3 Track Tension....................3 Cleaning and Inspection (Wear Limits and Tolerances) ......... 6 Track Shoes and Links ................. 10 Track Removal..................10 Track Installation..................11 Front Idler Roller................... 12 Parts List ....................12 Front Idler Roller Disassembly .............. 13 Front Idler Roller Reassembly...............
Page 163: General Description
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 164 The clearance should be approximately distance "E" on below table for operation over gravel, rocky terrain, or over sand or snow. Distance "A" Terrain Type Solar 290LC-V Solar 340LC-V Solar 300LC-V Normal "B" 320 - 340 mm 330 - 360 mm (12.60 - 13.39 in)
Page 165 Track tension adjustments are made through the grease fitting (1, Figure 3) in the middle of each side-frame. Adding grease increases length adjustment cylinder (2). The longer the adjustment cylinder, greater pressure on the tension spring pushing the track idler wheel outward. If there is not enough slack or clearance in the tracks and the adjustment is too tight, the idler wheel and adjusting cylinder can...
Page 166: Cleaning And Inspection (Wear Limits And Tolerances)
(Repair - P or Dimension Maintenance Replace - R) Standard 600 mm Shoe Solar 290LC-V 24 mm Solar 300LC-V (0.945") 26 mm Solar 340LC-V (1.024") 18 mm (0.709") Solar 290LC-V 26 mm 20 mm 16 mm [P] Solar 300LC-V (1.024") (0.787")
Page 167 Normal Recommended Limit for Use Component / Reference Dimensions Reference (New) Limit for (Repair - P or Dimension Maintenance Replace - R) Track link, master pin bushing, 66.65 mm 62.5 mm 59.0 mm [R] master bushing (2.624") (2.461") (2.323") 44.8 mm 47.0 mm 49.0 mm [R] (1.764")
Page 168 Normal Recommended Limit for Use Component / Reference Dimensions Reference (New) Limit for (Repair - P or Dimension Maintenance Replace - R) Figure 9 55 mm 54.5 mm 54.2 mm [R] Upper roller, axle (2.165") (2.146") (2.134") 55.5 mm 56 mm [R] Upper roller, bushing (2.185") (2.205")
Page 169 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 90 mm 89.5 mm 89.2 mm [R] (3.543") (3.524") (3.512") 90.5 mm 91 mm [R] Front idler, bushing (3.563")
Page 170: Track Shoes And Links
TRACK SHOES AND LINKS 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, Figure 13) is positioned at approximately 10 o’clock from...
Page 171 Rotate upper structure to 90° from track. Use bucket and boom to raise track frame off track. Position blocking under frame. HAOC741L Figure 15 TRACK INSTALLATION Lay rebuilt or new track into position under track frame. End of track should be positioned under front idler roller.
Page 172: Front Idler Roller
FRONT IDLER ROLLER PARTS LIST Figure 18 Reference Reference Description Description Number Number Bearing Axle Plug Group Seal Idler O-ring Bushing S0505000 Track Assembly Page 12...
Page 173: Front Idler Roller Disassembly
FRONT IDLER ROLLER DISASSEMBLY Remove plug (2, Figure 19) and drain oil from roller assembly (1). Figure 19 Separate the pin (3, Figure 20) from the bearing (1). Figure 20 Use a press to remove the bearing from the axle. Separate the O-ring (4, Figure 21) from the axle and insert it into the bearing.
Page 174 Detach the group seal (6, Figure 22) from the idler (7) and bearing (1). Figure 22 Use a press to separate the axle (5, Figure 23), O-ring (4) and bearing (1). Figure 23 Remove bushing (8, Figure 24) with the press and special tool (ST-1909).
Page 175: Front Idler Roller Reassembly
FRONT IDLER ROLLER REASSEMBLY Degrease, clean and dry all parts before reassembly. Insert bushing (8, Figure 25) into the idler (7). Grease O-ring (4, Figure 25) and insert it into the axle. Align the bearing (1, Figure 25) and axle (5) holes and pin (3) them together.
Page 176: Lower Roller
LOWER ROLLER PARTS LIST Figure 28 Reference Reference Description Description Number Number Roller O-ring Group Seal Collar Bushing Axle Plug S0505000 Track Assembly Page 16...
Page 177: Lower Roller Removal
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. There is an alignment pin on each end of lower roller assembly.
Page 178: Lower Roller Reassembly
Detach O-rings (2, Figure 32) from the axle. Separate group seals (6, Figure 32) from the collar and roller (5). Detach collar (3, Figure 32) and O-rings (2) from the axle, using a press. Figure 32 LOWER ROLLER REASSEMBLY Degrease, clean and dry all parts before reassembly.
Page 179 Insert group seals (6, Figure 35) 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 35 Install the collar (3, Figure 36), O-ring (2), and pin (1) on the remaining side.
Page 180: Upper Roller
UPPER ROLLER PARTS LIST Figure 38 Reference Reference Description Description Number Number Plug Axle Bolt Group Seal Cover Bracket Bolt Bushing Washer O-ring Roller Lock Washer S0505000 Track Assembly Page 20...
Page 181: Upper Roller Removal
UPPER ROLLER REMOVAL Relieve track tension. See This will allow track to be raised so that links clear top of roller. Position a bottle jack on top of track frame and apply pressure to track shoe. Remove mounting hardware holding upper roller assembly to track frame.
Page 182 Separate the group seal (8, Figure 43) from the roller and bracket (9). Figure 43 Separate the bushing (10, Figure 44) from the roller with a press and special tool (ST- 1919). Figure 44 S0505000 Track Assembly Page 22...
Page 183: Upper Roller Reassembly
UPPER ROLLER REASSEMBLY Degrease, clean and dry all parts before reassembly. Insert bushing (10, Figure 45) into the roller (6). Figure 45 Insert group seal (8, Figure 46) into the roller (6) and bushing. NOTE: Apply clean engine oil to the joint side of the group seal.
Page 184 Tighten plug (1, Figure 48). Figure 48 S0505000 Track Assembly Page 24...
Page 185: Track Spring And Track Adjusting Cylinder
TRACK SPRING AND TRACK ADJUSTING CYLINDER PARTS LIST Figure 49 Track Assembly S0505000 Page 25...
Page 186 Reference Reference Description Description Number Number Piston Rod Flange Piston Ring Backup Ring Valve Packing Bolt Retaining Ring Plate Yoke O-ring Socket Bolt Cylinder Flange Spring O-ring Spacer S0505000 Track Assembly Page 26...
Page 187 1ENGINE AND DRIVE TRAIN...
Page 189 Remember, that ultimately safety is your own personal responsibility. 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...
Page 190 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 191: 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 192 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 193: 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 194 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 195: 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 196: 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 197 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 198: 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 199 Face and Defroster ARS1300L Figure 12 Air-Conditioner S0605060K Page 11...
Page 200: 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 201 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 202: 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 203 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 204 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 205: Weight Of R134A Gas Used In Machines
850 ±20 grams (30 ±0.7 oz.) Solar 330-III 1250 ±20 grams (44 ±0.7 oz.) Solar 330LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 340LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 400LC-III 1250 ±20 grams (44 ±0.7 oz.) Solar 400LC-V 850 ±20 grams (30 ±0.7 oz.)
Page 206: 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 207: 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 208 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 209: 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 210: 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 211: 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 212 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 213: 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 214 S0605060K Air-Conditioner Page 26...
Page 215 Remember, that ultimately safety is your own personal responsibility. DRIVE COUPLING (MAIN PUMP)S0609010K 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...
Page 216 TABLE OF CONTENTS Drive Coupling....................3 Special Tools ....................4 Drive Coupling Installation................6 Installation Procedure ................8 S0609010K Drive Coupling (Main Pump) Page 2...
Page 217: 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 218: 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 219 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 220: 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 221 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 222: 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 223 1HYDRAULICS...
Page 225 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENT S0702180K MODEL SERIAL NUMBER RANGE Solar 340LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Hydraulic System Troubleshooting, Testing and S0702180K...
Page 226 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 227 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 –...
Page 228: Hydraulic System - General Notes
HYDRAULIC SYSTEM - GENERAL NOTES Figure 1 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 229: Hydraulic Schematic (S340Lc-V)
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 230: 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 231: 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, a slow return orifice, 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 232: Bucket Operating Circuit
BUCKET OPERATING CIRCUIT The bucket operating circuit includes the left main pump, the left half of the control valve and the bucket cylinder. 360 kg/cm (5,112 psi) overload relief valves located at BKT and BKTD 1 ports of the control valve protect the circuit and its components from damage.
Page 233: Right Swing Operating Circuit
RIGHT SWING OPERATING CIRCUIT When the swing control lever is pushed to the right swing position, pilot pressure from the left side pilot valve is directed to the right side pump CONTROL regulator and right half of the control valve. VALVE(L) Output flow from the right pump is then directed through the PR and SWR ports of the control...
Page 234: Forward Travel Circuit
FORWARD TRAVEL CIRCUIT When the right and left travel control levers are TRAVEL TRAVEL pushed forward, output from both of the main MOTOR(L) MOTOR(R) pumps is directed through the PR, PL, TRRF and TRLF ports on the control valve, through CENTER JOINT the upper works center joint, to the travel motors on each side of the machine.
Page 235: 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 236: 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 237: 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 238: Swing Priority Valve
SWING 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 swing priority control valve is located inside the compartment behind the cabin.
Page 239: 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 240 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. S0702180K Hydraulic System Troubleshooting, Testing and Page 16...
Page 241: 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 242 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, Pd-Q, adjustment screws (1, 2 and 3). Each one of the adjustment procedures could affect the setting of the others.
Page 243 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. 1/2 turn on the adjusting screw is equal to approximately -0.7 kg/cm of Pi.
Page 244: 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 245 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. Recheck front pump operation while stroking the bucket cylinder out lever, and the rear pump by actuating the swing control lever.
Page 246: 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 247 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 248: 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 to brake or makeup valve show low Brake release valve defective recommended range in affected reading (s).
Page 249: Troubleshooting - Hydraulic Problems
Problem Possible Causes Remedies No rotation and: Pressure at swing motor inlet Swing brake not releasing. Check brake engagement and increases. disengagement; check release pressure. Internal damage to gearbox Replace broken gears and drive drive train. train assemblies. Overload. Reduce load weight. Pressure at swing motor inlet Swing motor drive shaft Replace swing motor.
Page 250 Problem Possible Causes Remedies Sluggish performance of all Main pump (s) damaged or Repair or replace. hydraulic functions – worn. attachment, swing and travel. Main relief valve pressure off. Readjust pressure. Low oil level in hydraulic system. Refill. Hydraulic reservoir intake Clean.
Page 251: 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. Swing relief valve may be faulty. Repair/Replace the swing relief 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 252: 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 253: 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 to casing Replace spool casing. clearance. Worn or loose handle Repair or replace handle subassembly.
Page 254 S0702180K Hydraulic System Troubleshooting, Testing and Page 30 Adjustment...
Page 255 Remember, that ultimately safety is your own personal responsibility. 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...
Page 256 TABLE OF CONTENTS General Description..................3 Specifications ..................4 S0703010K Accumulator Page 2...
Page 257 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 258 S/N 1100 and Up Pilot / Travel (140 psi) (45.77 in 320 cc S/N 1001 thru 1059 (19.53 in 10 kg/cm Solar 340LC-V Pilot / Travel (140 psi) 750 cc S/N 1060 and Up (45.77 in 320 cc S/N 1001 thru 1029 (19.53 in...
Page 259 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 260 S0703010K Accumulator Page 6...
Page 261 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. CENTER JOINT (SWIVEL)S0704030 MODEL SERIAL NUMBER RANGE 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...
Page 262 TABLE OF CONTENTS General Description..................3 Parts List ....................4 Troubleshooting, Testing and Adjustment............5 Inspection....................5 Testing..................... 5 Disassembly ....................6 Reassembly....................7 S0704030 Center Joint (Swivel) Page 2...
Page 263: 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 264: 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 S0704030 Center Joint (Swivel) Page 4...
Page 265: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT INSPECTION The center joint should be checked for evidence of external oil leakage every 2,000 operating hours. 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 266: 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 267: 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 268 S0704030 Center Joint (Swivel) Page 8...
Page 269 Solar 290LC-V 0001 and Up Solar 300LC-V 1001 and Up Solar 300LL 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...
Page 270 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 271: 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 272: 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 273 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 274: 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 275 Cylinders S0705000 Page 7...
Page 276 S0705000 Cylinders Page 8...
Page 277 Cylinders S0705000 Page 9...
Page 278: 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 279 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 280 MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER) P/S: Power Steering O/R: Out Rigger S0705000 Cylinders Page 12...
Page 281 Cylinders S0705000 Page 13...
Page 282: 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 283 -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 284 -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 285 Cylinders S0705000 Page 17...
Page 286: 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 287 -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 288 -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 289 -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 290: Slipper Seal Jig
SLIPPER SEAL JIG (B+40) ARS4770L Figure 10 S0705000 Cylinders Page 22...
Page 291 +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 292 +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 293 Cylinders S0705000 Page 25...
Page 294: Slipper Seal Straightening Jig
SLIPPER SEAL STRAIGHTENING JIG ∅ ARS4780L Figure 11 S0705000 Cylinders Page 26...
Page 295 +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 296 +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 297: 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 298 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 299 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 300 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 301 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 302 17. Force out pin bushing (1) from body of cylinder. Figure 28 S0705000 Cylinders Page 34...
Page 303: 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 304 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 305 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 306 S0705000 Cylinders Page 38...
Page 307 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. SWING MOTOR S0707280 MODEL SERIAL NUMBER RANGE Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Copyright 2002 Daewoo May 2002...
Page 308 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Swing Motor Anti-cavitation Make-up Valve ..........4 Relief Valve ..................... 5 Swing Brake Operation ................5 Parts List ....................7 Specifications ..................8 Special Tools ....................
Page 309 Return to Master Table of Contents 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.
Page 310 Return to Master Table of Contents 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 311 Return to Master Table of Contents 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 312 Return to Master Table of Contents 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 313 Return to Master Table of Contents PARTS LIST NOTE: The item numbers used to identify the swing motor parts refer to Figure 4. Figure 4 Reference Reference Description Description Number Number Body Oil Seal Needle Bearing Roll Bearing Rear Cover Snap Ring Wrench Bolt Shaft...
Page 314 Return to Master Table of Contents SPECIFICATIONS Swing Motor Specification Type Axial Piston Displacement 250.0 cc (15.26 cu. in.) Crossover Relief Valve Setting 270.0 kg/cm (3,840.30 psi) Maximum Supply Flow Rate @ 1,950 280 liter/min. (73.97 gpm) Motor Shaft Speed 1,120 rpm Motor Shaft Torque 107.40 kg•m (776.83 ft lb)
Page 315 Return to Master Table of Contents SPECIAL TOOLS AND MATERIALS The special tools shown in Figure 5 can be fabricated for use in Swing Motor assembly. TOOLS Reference Number Tool Dimension 24, 25 12 mm L-Wrench 17 mm L-Wrench 46 mm Spanner M36 x 1.5P 5 mm L-Wrench M6 x 75...
Page 316 Return to Master Table of Contents Figure 6 S0707280 Swing Motor Page 10...
Page 317 Return to Master Table of Contents DISASSEMBLY After thoroughly cleaning motor assembly using a suitable cleaning fluid, dry it using moisture-free compressed air. Drain oil from drain port of body (1). Figure 1 Position motor with its shaft facing down. Match mark the mating part of body (1) and rear cover (23).
Page 318 Return to Master Table of Contents Figure 4 Remove wrench bolt (32) (using M6 wrench) and time delay valve assembly (31). NOTE: Be careful of the remaining oil still on the inside. Figure 5 Figure 6 Remove wrench bolt (24, 25), rear cover (23) and valve plate (20).
Page 319 Return to Master Table of Contents Figure 8 Figure 9 Pull out spring (19) from brake piston (17). Figure 10 Remove brake piston (17, Figure 12) using special tool. Figure 11 Swing Motor S0707280 Page 13...
Page 320 Return to Master Table of Contents Figure 12 10. After setting motor assembly horizontally, grasp cylinder block (9) and pull out the interior kit. NOTE: Cylinder block (9), spring (10), ball guide seat (11), ball guide (12), set plate (13), piston assembly (14), friction plate (15), plate (16), and shoe plate Figure 13...
Page 321 Return to Master Table of Contents 12. Grasp shaft (5), tap the opposite end of it and remove. NOTE: Be careful not to damage the machined surface. Figure 16 Figure 17 13. Remove oil seal (2) using special tool. NOTE: Be careful not to damage the oil seal and the machined surface.
Page 322 Return to Master Table of Contents 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, prior to final reassembly or as the final step after the unit has been put back together.
Page 323 Return to Master Table of Contents Figure 19 Reference Description Number Clearance Between Piston and Cylinder Bore Spring Free Length Piston Ball – Shoe Socket Clearance Thickness of Shoe Height Between Round Bushing and Push Plate NOTE: Spherical bushing and push plate must always be replaced as a set. If either one requires replacement, replace the other Swing Motor S0707280...
Page 324 Return to Master Table of Contents REASSEMBLY • If any damage occurred during disassembling, it should be repaired and/or parts replaced. • Before reassembling, clean dismantled parts using a suitable cleaning fluid and dry them using moisture-free compressed air. • Apply clean hydraulic oil to sliding parts and reassemble them.
Page 325 Return to Master Table of Contents Install spring (10), ball guide seat (11), ball guide (12), set plate (13) and piston assembly (14) on cylinder block (9) in order to prepare cylinder block assembly (#3). Figure 23 Figure 24 Install shaft subassembly (#2) into body subassembly (#1) and install snap ring (4).
Page 326 Return to Master Table of Contents Figure 27 Figure 28 Install brake piston (17) with O-ring (18) on body (1) and install springs (19). NOTE: Be careful not to damage O- ring (18). Figure 29 Figure 30 S0707280 Swing Motor Page 20...
Page 327 Return to Master Table of Contents Install valve plate (20) on body (1). Install O-ring (18) on rear cover (23) and install them on body (1) using wrench bolt (24, 25). NOTE: Be careful not to damage O- ring (18). Figure 31 Figure 32 Install time delay valve assembly (31) on...
Page 328 Return to Master Table of Contents 10. Install relief valve assembly (30) in body (1). 11. Install O-ring (29) on plug (28). Install poppet (26), spring (27) and plug (28). NOTE: Be careful not to damage O- ring (18). Figure 35 Figure 36 NOTE: After assembling, cover port parts using clean caps, plugs or tapes to protect motor...
Page 329 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. TRAVEL MOTOR (WITH GEARBOX)S0707345K MODEL SERIAL NUMBER RANGE Solar 340LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Travel Motor (with Gearbox)
Page 330 TABLE OF CONTENTS General Description..................3 Theory of Operation ................4 Parts List ....................12 Specifications ..................15 Special Tools and Materials................16 Hydraulic Motor Part ................16 Reduction Gear Part ................17 Tightening Torque Chart ............... 18 Troubleshooting, Testing and Adjustment............. 19 General Precautions ................
Page 331: General Description
GENERAL DESCRIPTION This motor is comprised of a motor section and reduction gear section. Hydraulic motor consists of the following five items. • Rotary part generating rotating force • Relief valve • Brake part • Counterbalance valve part • Swash tilting part The reduction gear section contains a 3-level planetary gear and differential gear.
Page 332: Theory Of Operation
THEORY OF OPERATION Hydraulic Motor Generation of rotational force. Cylinder Piston Drive Shaft High pressure Low pressure ARS4530L Figure 2 High pressure oil supplied from the hydraulic pump flows through valve casing (303) and valve plate (131) into cylinder block (111). (Refer to Figure 9 for indication numbers). The internal design allows the high pressure oil to flow to one side of the center line "Y-Y"...
Page 333 Operation of relief valve The relief valve operates as follows: The relief valve maintains constant starting pressure of hydraulic motor and, in response to accelerated speed of inertial object, bypasses excess oil flow at motor's input port to return circuit. If inertial object stops its movement, relief valve brakes delivery section to forcibly stop inertial object.
Page 334 Brake operation Pressurized oil opens counterbalance spool (022) in valve casing (303). Oil entering through counter balance spool (022) in valve casing (303), forces brake piston (702) to release the brake. When hydraulic oil pressure, is not present, the brake is spring applied by springs. Braking force is generated by separator plate (741) and shaft casing (272), which are assembled to shaft casing (272), and friction plate (742), which is connected between brake piston (702) and periphery of cylinder block (111) by splines.
Page 335 • How to release brake Release Operation Tool Remove two plugs (564) from valve casing (303). Insert a bolt Socket wrench (M10X135L) to tighten it to thread of brake piston, and brake will be released. This state becomes same as brake release pressure is applied. If you release brake without applying brake release pressure, follow instructions below: CAUTION! If hydraulic motor does not rotate even after brake is released, pump or other part is...
Page 336 Operation of Counterbalance Valve Port BV is connected to hydraulic pump, while port AV is connected to tank. Pressurized oil from hydraulic pump passes through BV to CV, from CV to C', opening check valve poppet and flowing through passage K, out port BM to hydraulic motor. Also, if hydraulic pressure delivered from pump is increased, pressurized oil flowing from gallery G passes spring chamber "E,"...
Page 337 Operation of tilting part This is a supporting device for swash plate (201) on which shoe slides. It has a hemispherical pivot ball (504) arranged along its both ends which bears load against swash stopper. Changing in tilting angle of this swash plate changes capacity. This device has tilting pistons (502) arranged along swash stopper section and uses tilting control valve to control inflow/outflow of working oil from / to piston chamber, and thus it can determine tilting angle (large or small) of swash plate.
Page 338 Operation of Reduction Gear The reduction gear comprises 3-level planetary gear and differential gear as shown in Figure 8. It has floating type sun gear, and therefore tooth profile error and carrier pin hole pitch variation may affect life of gear. Input (Output of hydraulic motor) Input rotation of hydraulic motor is transmitted to No.
Page 339 Travel Motor (with Gearbox) S0707345K Page 11...
Page 340: Parts List
PARTS LIST Hydraulic Motor Figure 9 S0707345K Travel Motor (with Gearbox) Page 12...
Page 341 Reference Reference Description Description Number Number C.B Spool Assembly O-ring Shaft O-ring Roller Bearing Oil Seal Needle Bearing Piston Snap Ring Shoe Cylinder Pivot Ball Spherical Bushing O-ring Spring Cylinder Tilting Spool Piston Tilting Spring Shoe Seat2A Set Plate Stopper Valve Plate Steel Ball Swash Plate...
Page 342 Reduction Gear Figure 10 S0707345K Travel Motor (with Gearbox) Page 14...
Page 343: Specifications
Reference Reference Description Description Number Number Ring Gear Thrust Ring 60 Housing Thrust Ring 90 Side Cover Socket Bolt Carrier No. 1 Socket Bolt 0096 Carrier No. 2 P/F 1/2 Plug Sun Gear No. 1 Angular Bearing Sun Gear No. 2 Floating Seal Sun Gear No.
Page 344: Hydraulic Motor Part
SPECIAL TOOLS AND MATERIALS HYDRAULIC MOTOR PART Tool name B Dimension Applying part name Hex L-wrench 2 mm Orifice (703) 2.5 mm Orifice (704) 4 mm Plug (461), Orifice (545, 546) 6 mm PT Plug (564), PF Plug (569) 8 mm PF Plug (571) 10 mm Socket Bolt (366)
Page 345: Reduction Gear Part
REDUCTION GEAR PART Tool name B Dimension Applying part name Hex L-wrench 4 mm Socket Screw (054) 84 mm Socket Bolt (030) 10 mm Plug (032) 14 mm Socket Bolt (029) Pliers (For shaft) Snap Ring (044, 037) Eye Bolt (M8) Ring Gear (001) Eye Bolt (M10) No.
Page 346: Tightening Torque Chart
TIGHTENING TORQUE CHART Tightening torque Section Name Size (mm) kg•cm Socket Bolt M12x45 1,000 Socket Bolt NPTF 1/16 4,400 Socket Bolt M20x100 4,400 Plug NPTF 1/16 VP Plug PF 1/4 1,100 Orifice NPTF 1/16 Hydraulic motor Orifice NPTF 1/16 part Plug PF 1/4 VP Plug...
Page 347: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT GENERAL PRECAUTIONS If a defect is identified, check to see if same problem has ever occurred before. When taking corrective action, handle each part carefully. Use care not to cause possible damage or rust to/on sliding parts, gear surfaces, bearings, and pins. Travel Motor (with Gearbox) S0707345K Page 19...
Page 348: Troubleshooting
TROUBLESHOOTING Refer to following tables. AUS0640L S0707345K Travel Motor (with Gearbox) Page 20...
Page 349 AUS0640L Travel Motor (with Gearbox) S0707345K Page 21...
Page 350 AUS0660L S0707345K Travel Motor (with Gearbox) Page 22...
Page 351: Disassembly
DISASSEMBLY GENERAL CAUTION MATTERS Use care so that contact surface of seals such as O-ring and oil seals, gears, pins, bearings, and sliding surface may not be damaged. If disassembling this motor with it mounted on machine, use care that dust or foreign materials may not enter it.
Page 352 Remove No. 1 carrier (005) with No. 1 planetary gear (012) and No. 2 sun gear (010) assembled. Figure 14 Disassemble No. 1 carrier subassembly. Remove snap ring (044), disassemble side plate (018), No. 1 planetary gear (012), and needle cage (021).
Page 353 Disassemble No. 2 carrier (006), No. 2 planetary gear (013) and No. 3 sun gear (011). NOTE: Attach two M10 eyebolts and lift No. 1 carrier with a crane. Figure 18 Disassembly of No. 2 carrier subassembly. Remove spring (036), remove No.
Page 354 Remove snap ring (046), and No. 2 carrier (006) from No. 3 sun gear (011). Figure 21 10. Remove socket bolt (029), attach two M8 eyebolts, then use a crane to disassemble ring gear (001). Remove O-ring (082) from housing (002). NOTE: Use a hex wrench and pipe to disassemble it.
Page 355 12. Remove side plate (020), No. 3 planetary gear (014), needle cage (023), and floating bush (025) from shaft casing (272). Figure 25 13. Remove set screw (054) from nut ring (047). Remove nut ring (047) from shaft casing (272). Figure 26 NOTE: After disconnecting nut ring...
Page 356 15. Remove floating seal (034) from housing (002). Do not damage it. NOTE: Be careful not to damage O- ring surface and seat. Figure 29 16. Remove floating seal (034) from shaft casing (272). Do not damage it. NOTE: Be careful not to damage O- ring surface and seat.
Page 357: Hydraulic Motor Part
HYDRAULIC MOTOR PART Disassembly of Main Body of Motor Section Place output side of hydraulic motor facing down and fix it. Figure 32 Remove relief valve (35), decompression valve (351), and adjustment cover (352) from valve casing (303). Remove plug. Figure 33 Figure 34 Travel Motor (with Gearbox)
Page 358 After removing plug (564) from valve casing (303), insert M10x135 bolts into holes (2) for releasing brake restraint and tighten them to subassemble valve casing and brake piston. Figure 35 Remove socket bolts (401, 402) tightened with valve casing (303). Figure 36 Remove socket bolts, and valve plate (131) together with valve casing subassembly.
Page 359 Remove cylinder block piston assembly NOTE: Be sure to place motor in level position. Figure 39 Remove swash plate (201). Figure 40 Remove pivot ball (504) and tilting piston assembly. Figure 41 Figure 42 Travel Motor (with Gearbox) S0707345K Page 31...
Page 360 10. Remove snap ring (435). Tap front side of drive shaft (101) with plastic hammer to remove it from shaft casing (272). NOTE: disassemble roller bearing (102), if it does not need to be replaced. Figure 43 11. Remove oil seal (491) from shaft casing (272).
Page 361 Remove socket bolt (366). Remove cover (364) and counterbalance valve assembly. NOTE: If counterbalance spool and counterbalance spring have been damaged, replace them with new ones. Figure 47 Remove plug (569) and high pressure select valve assembly. NOTE: disassemble tilting switching system if it functions properly.
Page 362: 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. MAINTENANCE STANDARD Change parts with standard of following table. If parts have damages of external appearance, change without following table. S0707345K Travel Motor (with Gearbox) Page 34...
Page 363 Changing Standard of Hydraulic Motor Part Recommend Standard Parts name and inspection item ed value of Remedy dimension replacement Clearance (D-d) between piston and 0.52 mm 0.077 mm cylinder bore Replace Clearance between piston and shoe (δ) 0.1 mm 0.3 mm Shoe thickness 5.5 mm 5.3 mm...
Page 364 Thickness of shoe: t Figure 52 Vibration of vertical direction of piston and shoe: δ Figure 53 Height difference of spherical bushing and pressure plate: H-h Figure 54 S0707345K Travel Motor (with Gearbox) Page 36...
Page 365 Parts Inspection and Inspection Standard of Reduction Gear Inspection item Standard Standard of Remark replacement Pitting and crack on gear teeth Pitting area Replace if pitted or ratio: 10% cracked Drive shaft and spline of motor Overpin 43.91 (∅4.5) 43.31 mm Z=14 Spline in No.
Page 366: Reassembly
REASSEMBLY GENERAL CAUTION MATTERS Clean each part with clean oil and then dry it with compressed air. Do not use an oil cloth, but if it is necessary to use one, be sure to use a clean one and use care that dust or dirt does not collect on it. Use a torque wrench when tightening each bolt and plug.
Page 367 Install pin (451). Figure 57 Install needle bearing (103) (if assembling it newly) if removed during disassembly. Figure 58 Assembly of Valve Casing Subassembly Assemble seat (541), steel ball (543), stopper (542), and plug (569). NOTE: Be careful of assembly direction of seat and stopper.
Page 368 Attach cover (364) with socket bolt (366). NOTE: Tightening torque for socket bolt (366): 1000 kgf•cm Figure 61 Install tilting spool (531), tilting spring (533), and plug (571). NOTE: Tightening torque plug (571): 750kgf•cm Figure 62 Install orifice (703) into brake piston. NOTE: Tightening torque: 35kgf•cm Figure 63...
Page 369 Assembly of Cylinder Subassembly Assemble cylinder spring (114) spherical bushing (113) onto cylinder block (111). NOTE: Align cylinder with spline of spherical bushing. Figure 65 Insert piston (121) and shoe (122) assembly into plate (123) and assemble it on cylinder block. Figure 66 Assemble plug (461) and orifices (545 and 546) on shaft casing (272) to specified...
Page 370 Figure 68 Use assembly jig for oil seal(491) to assemble oil seal (491) to shaft casing (272). Figure 69 Fit drive shaft subassembly and assemble snap ring (435). NOTE: Use key for outer race of roller bearing (102) and gently tap it with a hammer to assemble it.
Page 371 Assemble tilting piston subassembly and pivot ball (504). Figure 72 Figure 73 Coat rear side of swash plate (201) with and then assemble it to shaft casing (272). NOTE: Check swash plate for smooth movement. Figure 74 Turn shaft casing (272) so it is in a horizontal position and then assemble cylinder block subassembly.
Page 372 Turn shaft casing (272) so it is in a vertical position. Figure 76 10. Assemble mating plate (741) and friction plate 742) onto shaft casing (272) and cylinder (111), respectively. Figure 77 11. Assemble O-rings (707, 708) into shaft casing (272). NOTE: When reassembling, replace O- ring with a new one.
Page 373 NOTE: Coat rear side of valve plate with grease, so that valve plate does not become disconnected. NOTE: Use guide bolt. NOTE: Coat needle bearing roller with grease, so that it can be easily assembled onto shaft. NOTE: Use a crane when assembling valve casing to shaft casing.
Page 374 Reduction Gear Part Assemble angular bearing (033) housing (002). NOTE: hammer assemble angular bearings apiece time before pressing. NOTE: When reusing housing, use M16 tap to completely remove adhesive such as Teflon from M16 thread. Figure 84 Assemble O-ring of floating seal (034) to seat and then to housing (002).
Page 375 Lift housing subassembly with floating seal facing down, and then insert inner diameter of angular bearing into outside of shaft casing. NOTE: Do not damage sliding surface of floating seal. Figure 87 Position shim (035) on nut ring (047). NOTE: Coat surfaces with...
Page 376 Figure 91 Install thrust ring (027) on shaft casing (272). NOTE: Use care to assembly direction for thrust ring (Guide groove should face up.). Figure 92 Install needle cage (023) inside No. 3 planetary gear (014) and assemble side plate (020) on both sides, then insert gear assembly into shaft casing.
Page 377 Figure 95 11. Install O-ring (082) on housing (002), and lift ring gear (001) with a crane and position it on outer race of No. 3 planetary gear (014), then assemble housing (002). NOTE: Lightly coat O-ring with grease. When reassembling, use a new O-ring.
Page 378 Install needle cage (022) inside No. 2 planetary gear (013). Place a side plate (019) on each side, then insert gear assembly into No. 2 carrier. Figure 99 NOTE: Align carrier pin with center of planetary gear. Figure 100 Insert spring pin (036) into pin hole of No.
Page 379 15. Assembly of No. 1 carrier subassembly Fit inner race (024) in No. 1 carrier (005). NOTE: Heat inner race ease installation. Figure 103 Install No. 1 carrier (005) in No. 2 sun gear (010) and secure into position with clip (045). Figure 104 Position thrust ring (026) on No.
Page 380 16. Carefully install No. 1 carrier subassembly and ring gear (001). Figure 107 17. Position No. 1 sun gear (009) on motor shaft splines and engage No. 1 planetary gears. Figure 108 18. Using ring gear (001) as a measuring surface, measure distance from it to top side of No.
Page 381 • The dimension: B (the value after subtracting thickness of jig) 20. Select a thickness of washer r(053) according to following formula: • 1.5 ~ 2.0 = (B + A) - (thickness of thrust + thickness of washer) NOTE: Maintain a clearance of 1.5 ~ 2.0 mm in shaft direction for No.
Page 382: Checkup After Assembly
CHECKUP AFTER ASSEMBLY Air Test for Reduction Gear Remove one plug (032) from reduction gear section and apply compressed air (0.3 kgf/cm ) through threaded hole for 2 minutes under water. No air bubbles should be generated. NOTE: Gear oil volume: 5.5 liter (equivalent to SAE #90, GL-4 grade or higher by API classification) Air Test for Motor Seal tightly all ports, except one location, of piping port of motor and apply compressed air (3 kgf/cm...
Page 383 Operation test for 2-speed section If applying 30 kgf/cm or more of pressurized oil to 2-speed switching pilot port ("D" port) when carrying out no-load test in test operation as shown in (A) and (B) above, check to see that 2-speed section shifts from low gear to high gear.
Page 384: Installation
INSTALLATION CHECK Check each item before assembling and take proper action if there is anything to be corrected. Checking Items Managing Matters Is there any damage from transporting? Report to Q/C Department. Is there any loose bolts? Tighten rated torque. (Refer to “Tightening Torque Chart”...
Page 385: Oil Filling
Oil Drain Remove motor while turning it with drain port (PF 1/2) facing down. OIL FILLING Position check port (PF 1/2) vertically (See external dimension diagram.) and add oil until oil it is present at level port. (approximately 5.5 liter) GENERAL CAUTION MATTERS Check whether there are loose bolts or oil leaks.
Page 386 S0707345K Travel Motor (with Gearbox) Page 58...
Page 387 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MAIN PUMP (REXROTH)S0708355K MODEL SERIAL NUMBER RANGE Solar 340LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Main Pump (Rexroth) S0708355K...
Page 388 TABLE OF CONTENTS Sectional View....................3 A8VO140LA1KH1/63 ................3 General Repair Guidelines ................5 Seal Kits and Sub-assemblies................ 7 Sealing the Drive Shaft................. 11 Gear Pump Sealing ..................14 Remove the Control Housing ............... 16 Control Module ..................... 19 Control Module LR ................19 Removing the Controller................
Page 389: Sectional View
SECTIONAL VIEW A8VO140LA1KH1/63 AUS0010L Figure 1 Main Pump (Rexroth) S0708355K Page 3...
Page 390 AUS0020L Figure 2 S0708355K Main Pump (Rexroth) Page 4...
Page 391: 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 Main Pump (Rexroth) S0708355K Page 5...
Page 392 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 S0708355K Main Pump (Rexroth) Page 6...
Page 393: 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 Main Pump (Rexroth) S0708355K Page 7...
Page 394 Rotary group 2, ready to install. ASS0100L Figure 11 Rotary group, hydraulic component (order rotary groups 1 and 2 separately). NOTE: Adjustment is necessary. NOTE: Pay attention to direction of rotation. ASS0110L Figure 12 Rotary group 1, mechanical section, ready to install.
Page 395 Control, pre-adjusted. AUS0440L Figure 15 Gear pump, complete. AUS0450L Figure 16 10. Intermediate gear. AUS0460L Figure 17 Main Pump (Rexroth) S0708355K Page 9...
Page 396 11. Auxiliary drive. AUS0470L Figure 18 12. Valve plate with valves. ASS0180L Figure 19 13. Pipe, complete with fittings. AUS0480L Figure 20 S0708355K Main Pump (Rexroth) Page 10...
Page 397: Sealing The Drive Shaft
SEALING THE DRIVE SHAFT Protect drive shaft. (e.g. with tape). ASS0210L Figure 21 Remove retaining ring. AUS0030L Figure 22 Press off cover ring. AUS0040L Figure 23 Main Pump (Rexroth) S0708355K Page 11...
Page 398 Visually check: Shaft seal (1), cover ring (2), drive shaft (3), housing (4), O-ring (5) and shim (6). AUS0050L Figure 24 Remove old shaft seal. AUS0060L Figure 25 Press in shaft seal. AUS0070L Figure 26 If the shaft is deeply scored, insert the shim provided in front of the shaft seal.
Page 399 Install new O-ring, ensure that it is seated correctly. Grease O-ring as well as the seal and dust lips of the drive shaft. AUS0090L Figure 28 Install cover ring. AUS0100L Figure 29 10. Install retaining ring, tapping home until it springs into place, carry out visually check to ensure that the retaining ring is correctly seated.
Page 400: Gear Pump Sealing
GEAR PUMP SEALING AUS0120L Figure 31 Remove gear pump. Visually check: O-ring. AUS0130L Figure 32 S0708355K Main Pump (Rexroth) Page 14...
Page 401 Sealing surface of the housing. AUS0140L Figure 33 Main Pump (Rexroth) S0708355K Page 15...
Page 402: Remove The Control Housing
REMOVE THE CONTROL HOUSING AUS0150L Figure 34 Place pump into a disassembly / assembly device with a crane and secure it into position. AUS0160L Figure 35 S0708355K Main Pump (Rexroth) Page 16...
Page 403 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. AUS0170L Figure 36 Remove paper seal, clean sealing surface. ASS0310L Figure 37 Main Pump (Rexroth) S0708355K Page 17...
Page 404 AUS0180L Figure 38 Number Description Setting Screw: Q Setting Screw: Hydraulic Stroke Limitation Setting Screw: Power Characteristic (Begin of Regulation) NOTE: Before carrying out setting or disassembly regulator, measure distance "X" adjustment screw and record value. ASS0330L Figure 39 S0708355K Main Pump (Rexroth) Page 18...
Page 405: Control Module Lr
CONTROL MODULE CONTROL MODULE LR AUS0190L Figure 40 Remove and disassemble control module LR. ASS0350L Figure 41 Main Pump (Rexroth) S0708355K Page 19...
Page 406 AUS0200L Figure 42 Remove and disassemble control module. AUS0210L Figure 43 S0708355K Main Pump (Rexroth) Page 20...
Page 407: Removing The Controller
REMOVING THE CONTROLLER AUS0220L Figure 44 Remove cover. NOTE: Do not change the setting of adjustment screw (1, Figure 44). ASS0390L Figure 45 Main Pump (Rexroth) S0708355K Page 21...
Page 408 Remove screws. NOTE: Install control lens - torque support. ASS0400L Figure 46 Remove locking screw and replace with a new one. NOTE: Loosen adhesive with a "gentle" flame (approximately 120 ° C). ASS0410L Figure 47 ASS0420L Figure 48 Remove swivel pin. ASS0430L Figure 49 S0708355K...
Page 409: Valve Plate With Valves
VALVE PLATE WITH VALVES ASS0440L Figure 50 Pressure relief valve. Electro- proportional pressure reducing valve (EPPR). Main Pump (Rexroth) S0708355K Page 23...
Page 410: Remove The Rotary Groups
REMOVE THE ROTARY GROUPS AUS0230L Figure 51 Remove cylinder (Take out the drive shaft without cylinder). ASS0470L Figure 52 Remove cup springs 1 and spring cup 2. ASS0480L Figure 53 S0708355K Main Pump (Rexroth) Page 24...
Page 411 Note disassembly position: (1, 2 and 3, Figure 54). Rotary Group 2 Rotary Group 1 AUS0240L Figure 54 Press out rotary group with an appropriate device. 2 2 2 2 2 1 1 1 1 1 AUS0250L Figure 55 Main Pump (Rexroth) S0708355K Page 25...
Page 412 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 AUS0260L Figure 56 NOTE: 1) Position (*) drive shafts with bearing set are the smallest assembly group. 2) The assembly group is adjusted to measurement A.
Page 413: Remove The Intermediate Wheel
REMOVE THE INTERMEDIATE WHEEL Press bolt (*, Figure 57) into gear wheel. (Fixed pressing fit). NOTE: Can only be disassembled with a hydraulic press. * * * * * * * * * * AUS0270L Figure 57 Remove bearing. AUS0280L Figure 58 Main Pump (Rexroth) S0708355K...
Page 414 Install sleeve. NOTE: Press out bolt with a hydraulic press. AUS0290L Figure 59 Remove gear wheel through side drive opening. ASS0540L Figure 60 S0708355K Main Pump (Rexroth) Page 28...
Page 415 Remove bearing with extraction device. ASS0550L Figure 61 Main Pump (Rexroth) S0708355K Page 29...
Page 416: Remove Auxiliary Drive
REMOVE AUXILIARY DRIVE AUS0300L Figure 62 Remove screws and auxiliary drive. ASS0570L Figure 63 Press off bearing cap. ASS0580L Figure 64 S0708355K Main Pump (Rexroth) Page 30...
Page 417 In the event of oil leakage, visually check O-ring, housing and groove. ASS0590L Figure 65 Install extractor device. Pull out output pinion. ASS0610L Figure 66 Install bearing extractor device. ASS0620L Figure 67 Completely mount device and pull out bearing. ASS0630L Figure 68 Main Pump (Rexroth) S0708355K...
Page 418 Pull out pinion bearing. ASS0640L Figure 69 S0708355K Main Pump (Rexroth) Page 32...
Page 419: Inspection
INSPECTION Check to see that bearing bore is free of scores and that there is no evidence of wear. AUS0310L Figure 70 ASS0650L Figure 71 Visually check: To ensure that bearing seats are free of scores. ASS0660L Figure 72 Main Pump (Rexroth) S0708355K Page 33...
Page 420 Visually check: Check to see that bearing bores are free of scores and that there is no evidence of wear. ASS0670L Figure 73 Axial piston play. Checked with retaining plate installed. ASS0680L Figure 74 Drive shafts: Check to ensure that cups are free of scores and that there is no pitting (1.
Page 421 Central pin: Check to ensure that it is free of scores and that there is no pitting. ASS071L Figure 77 Retaining plate: Check to ensure that it is free of scores and that there is no evidence of wear. ASS0720L Figure 78 Check cylinder block / control lens: Bores (1, Figure 79) are free of scores, no...
Page 422 11. Check: That sliding surfaces (1, Figure 81) are free of scores. Seal (2, Figure 81). ASS0750L Figure 81 12. Complete rotary group. NOTE: Adjustment of the hydraulic component is necessary. Mechanical component: drive shaft is adjusted with the bearing (1, Figure 82). Hydraulic component (2, Figure 82): Adjustment is necessary (*, Figure 82).
Page 423 13. Rotary group: All of the components. * Adjustment (Figure 83). For adjustment values and torque values, see service information. AUS0320L Figure 83 Main Pump (Rexroth) S0708355K Page 37...
Page 424: 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 84 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 425 Ensure that all parts are assembled in correct order and orientation. ASS0810L Figure 87 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. ASS0821L Figure 88 Main Pump (Rexroth)
Page 426: Pump Assembly
PUMP ASSEMBLY Warm up housing to approximately 80°C. ASS0830L Figure 89 Insert the pre-assembled rotary group 1, taking into account gear tooth marks. ASS0840L Figure 90 Insert pre-assembled rotary group 2, being sure to align gear tooth marks. ASS0850L Figure 91 S0708355K Main Pump (Rexroth) Page 40...
Page 427 Gear tooth marks must align with each other. ASS0860L Figure 92 Main Pump (Rexroth) S0708355K Page 41...
Page 428 Adjustment of measurement D. NOTE: Hydraulic control portion. Stop Stop AUS0330L Figure 93 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 429 HYDRAULIC COMPONENT - MEASUREMENT "D" MEASURING DEVICE - HYDRAULIC COMPONENT 452 269 Size 140 - 200 Size 80-107 ASS0880L Figure 94 Measuring Centering Intermediate Intermediate Size Shim (5) S.H.C.S (6) Device (*) Device (1) Ring (4) Plate (7) 9452269 9452019 9452014 9083277 9083105...
Page 430: Mounting Position
MOUNTING POSITION NOTE: sure that correct mounting position is used. The numbers on the top of the measuring device (*, Figure 94) refer to the piston diameter. ASS0900L Figure 95 Size Mounting Position ASS0890L Figure 96 Install intermediate ring or plates onto the housing.
Page 431: Measuring Procedure
Only Size 140 - 200 (Figure 98). ASS0920L Figure 98 Zero adjustment - measuring device: Turn using the hand wheel until the stop is reached. Set dial gauge to zero. Size 80 - 107 (Figure 99) Figure 99 Size 140 - 200 (Figure 100) Figure 100 MEASURING PROCEDURE Turn down by 4 turns on the dial gauge.
Page 432 Size 140 - 200 (Figure 102). ASS0960L Figure 102 Turn down, using the hand wheel, until resistance is met. Read the measured value. NOTE: Do not use excessive force. Size 80 - 107 (Figure 103). Figure 103 Size 140 - 200 (Figure 104). Figure 104 S0708355K Main Pump (Rexroth)
Page 433: Installation Of Control Housing
INSTALLATION OF CONTROL HOUSING AUS0340L Figure 105 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 434 Push on piston ring by hand. Fix adjustment piston. Take the tightening torques into account. AUS0360L Figure 107 Install control housing. AUS0370L Figure 108 Install control lens in their correct position using grease to hold them in place. Direction of rotation Direction of rotation counterclockwise clockwise...
Page 435 AUS0380L Figure 110 Install seal and controller. AUS0390L Figure 111 Main Pump (Rexroth) S0708355K Page 49...
Page 436 ASSEMBLY OF INTERMEDIATE WHEEL Press bearing (1, Figure 112) into housing. Install and align intermediate wheel (2, Figure 112) through side drive opening. New Assembly Position Cool down bolt (3, Figure 112) with nitrogen and install it. Press in bearing (4, Figure 112). AUS0400L Figure 112 Press bearing into housing.
Page 437: Installation Of Gear Pump
INSTALLATION OF GEAR PUMP AUS0410L Figure 114 Install front cover. AUS0420L Figure 115 Main Pump (Rexroth) S0708355K Page 51...
Page 438: Installation Of Cover / Auxiliary Drive
INSTALLATION OF COVER / AUXILIARY DRIVE AUS0430L Figure 116 S0708355K Main Pump (Rexroth) Page 52...
Page 439: 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 440 PLUGS WITH INTERNAL HEXAGON AND PROFILE SEAL RING (TO N 02.009). Seal ASS1120L Figure 118 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 441 SEAL-LOCK - SEALING NUTS (TO N 02.100) Tightening Torque M Thread M6 x 0.5 M8 x 1 M10 x 1 ASS1130L Figure 119 M12 x 1.5 M14 x 1.5 M16 x 1.5 Main Pump (Rexroth) S0708355K Page 55...
Page 442 S0708355K Main Pump (Rexroth) Page 56...
Page 443 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MAIN CONTROL VALVE (KAYABA)S0709401K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 340LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Main Control Valve (Kayaba) S0709401K Page 1...
Page 444 TABLE OF CONTENTS General Description..................5 When All Spools are in Neutral ............... 5 Neutral Passage................5 Signal Passage ................8 Single Operation ................... 10 Travel Spool Shifting ..............10 Spare Spool Shifting ..............10 Swing Spool Shifting ..............12 Bucket Spool Shifting ..............
Page 445 Spool Assembly (17, Option) ............36 Spool Assembly (20, Arm Regeneration Release Valve ....36 Spacer Assembly (40)..............37 Plug Assembly (60)................ 37 Anti-draft Valve Assembly (67)............38 Relief Valve Assembly (70) ............39 Plug Assembly (90)................ 39 Specifications ..................39 Troubleshooting, Testing and Adjustment.............
Page 446 Instructions for Reassembly ..............50 Handling Instructions of O-ring ............50 Handling Instructions for Spool ............50 Application Method of Loctite............51 Procedure of Subassembly ..............51 Reassembly of Spool Assembly (Main Spool) ....... 51 Reassembly of Arm 1 Para Turn Spool Assembly ......52 Reassembly of Antidrift Valve Assembly........
Page 447: General Description
GENERAL DESCRIPTION WHEN ALL SPOOLS ARE IN NEUTRAL Neutral Passage Oil supplied to port (P1, Figure 1 and Figure 2) flows through neutral passage (L1) to low pressure relief valve orifice (Lc1), to tank passage (Ta) and returns to ports (T1, T2, and T3). Oil supplied to port (P1) flows through neutral passage (R1), to low pressure relief valve orifice (Rc1), then to tank passage (Ta), and returns to ports (T1, T2, and T3).
Page 448 Figure 1 S0709401K Main Control Valve (Kayaba) Page 6...
Page 449 Figure 2 Main Control Valve (Kayaba) S0709401K Page 7...
Page 450: Signal Passage
Signal Passage Oil supplied to port (PP , Figure 2 and Figure 3) flows through orifice (Lc3) to port (PT) and simultaneously flows through land (Lc4), passage (5), and land (Rc3) into tank passage (Ta). The same oil supplied to port (PP), then flows through orifice (Lc5) into port (PA), and it also flows through passages (L4)(7) and (R4) to bucket spool land (Rc4) and then flows into drain passage (DR).
Page 451 Main Control Valve (Kayaba) S0709401K Page 9...
Page 452: Single Operation
SINGLE OPERATION Travel Spool Shifting When shifting travel spool by increasing pressure of travel (section 1, Figure 4) 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 453 Figure 4 Main Control Valve (Kayaba) S0709401K Page 11...
Page 454: Swing Spool Shifting
Swing Spool Shifting When shifting swing spool by increasing pressure of swing (section 3, Figure 5) pilot port (Pb3 (Pa3)), neutral port (L1) is closed. Oil supplied to port (P1) flows through parallel passage (L3), load check valve (S3-2), passage (S3-1) and spool, it then flows to port (B3 (A3)). Return oil flows through port (A3 (B3)) to spool and is returned to tank passage (Ta).
Page 455 Crowd When bucket spool is shifted by increasing pressure of bucket (section 7, Figure 6) pilot port (Pb7), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3), load check valve (S7-2), passage (S7-1), spool and into port (A7). Oil flows through port (B7) and one portion of the oil returns through spool to tank passage (Ta), and the other portion of oil flows through inside of spool, and pushes up load check, and then is combined at port (A7).
Page 456: Boom Spool Shifting
Boom Spool Shifting Neutral This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder. When in neutral, poppet (AD1, Figure 7) is closed by port (A8) pressure that is sent through passage (AD2), spool (AD3) to spring chamber (AD4).
Page 457 Boom Up (2 Speed Junction) When boom 1 spool is shifted by increasing pressure of boom 1 (section 8, Figure 8) pilot port (Pa8), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3) and load check valve (S8-2) to spool and flows into port (A8).
Page 458 Boom Down (Regeneration) When boom 1 (section 8, Figure 9) spool is shifted by increasing pressure of boom 1 pilot port (Pb8), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3) and load check valve (S8-2) to spool and flows into port (B8). When spool (AD3) of antidrift valve is shifted by increasing pressure of port (P2), poppet (AD1) is opened by decreasing of pressure of spring chamber (AD4), and return oil from port (A8) flows to tank passage.
Page 459: Arm Spool Shifting
Arm Spool Shifting Neutral This valve also works with an anti drift valve that is installed on rod side of the arm cylinder. When in neutral, poppet (AD1, Figure 10) is closed by port (A5) pressure that is sent through passage (AD2), spool (AD3) and to spring chamber (AD4).
Page 460 Arm Crowd (2 Speed Junction) When arm 1 spool is shifted by increasing pressure of arm 1 (section 5, Figure 11) pilot port (Pb5), oil supplied to port (P1) flows through neutral passage (L1), load check valve (S5-2), passage (S5-1) and spool into port (B5).
Page 461 Arm Crowd (Variable Regeneration) When crowding arm, after return oil from port (A5, Figure 12) flows through notch (a), one portion of the oil returns through fixed orifice (d), passage (e) and variable orifice (f) and to tank passage (Ta). The other portion of the oil flows through fixed orifice (b), regeneration check (c), and fixed orifice (i) in arm 1 spool, and joins in bridge passage (S5-1).
Page 462: Parallel Orifice For Arm
Arm Dump (2 Speed Junction) When arm 1 spool is shifted by increasing pressure of arm 1 (section 5, Figure 13) pilot port (Pa5), oil supplied to port (P1) flows through neutral passage (L1), load check valve (S5-2), passage (S5-1) and spool and into port (A5).
Page 463: Relief Valve
Relief Valve Main Relief Valve Oil supplied to port (P1, Figure 15) flows through poppet (LP). Oil supplied to port (P2) flows through poppet (RP) and passage (3). They join at the main relief valve. The highest pressure of pump (P1) and (P2) is controlled by reaction of main relief valve.
Page 464: Combined Operation
COMBINED OPERATION When the unit is in operation the control valve spools will function differently, depending upon the type of operation and work being done. The following spools are use for straight travel Section 6: Travel Section 1: Travel Section ST: Straight Travel When only travelling straight and no other functions are activated the following will occur: Straight travel Pump 1: 100% (Section 1: Travel)
Page 465 Figure 16 Main Control Valve (Kayaba) S0709401K Page 23...
Page 466: Bucket Combined Operation
Bucket Combined Operation A priority control valve is installed in bucket section 7, Figure 17). This valve controls oil flow entering into bucket when operating during a combined operation with travel, boom 1, and arm 2 sections, on P2 side. If pressure at port (Pi) is increased when operating bucket, piston (S7-6), piston (S7-5) and plug (S7-4) are pressed, and poppet assembly (S7-2) is seated on valve housing.
Page 467: Antidrift Valve
ANTIDRIFT VALVE The antidrift valve is installed in cylinder port of arm rod (boom bottom) side to prevent arm (boom) cylinder from natural lowering. (As a representative arm side (A5) is shown.) Neutral condition (A5, Figure 18 port keeping condition) The holding pressure of A5 port is sent through passage (a, b, and c), and into spring chamber (d) of poppet (1).
Page 468 MAIN RELIEF VALVE The main relief valve is located between neutral oil passage (HP , Figure 21) 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 469: Overload Relief Valve (69, Total: Six Places)
OVERLOAD RELIEF VALVE (69, TOTAL: SIX PLACES) 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).
Page 470: Low Pressure Relief Valve (70, Total: Two Places)
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 471: Relief Operation
Relief Operation If excessive oil flows into passage (L2 (R2)), pressure generated at passage (L2 (R2)) by orifice (Lc1 (Rc1)) goes to back chamber of poppet, and poppet operates by the difference of pressurized area between passage and back chamber. By operation of this poppet, oil flows from passage through plug and drill hole to tank passage (Ta).
Page 472: Parts List
PARTS LIST 89,88 75 69 77,81 VIEW X ARS4580L Figure 32 S0709401K Main Control Valve (Kayaba) Page 30...
Page 473 SECTION A1-A1 X - 41 SECTION A-A Y - 42 SECTION L-L 61 62 SECTION B-B X - 41 Y - 42 SECTION K-K ARS4570L Figure 33 Main Control Valve (Kayaba) S0709401K Page 31...
Page 474 38 39 40 22 2 SECTION C-C SECTION D-D SECTION E-E SECTION G-G SECTION F-F SECTION H-H DETAIL F1 53 55 SECTION J-J SECTION I-I ARS4590L Figure 34 S0709401K Main Control Valve (Kayaba) Page 32...
Page 475: Spool Assembly (2, Arm 2)
Reference Reference Description Description Number Number Valve Housing O-ring Spool Assembly (Arm2) Spring Spool Assembly (Boom1) Poppet Spool Assembly (Bucket) Steel Ball Spool Assembly (Travel) Poppet Spool Assembly Flange (Straight Travel) Spacer O-ring O-ring Backup Ring Spacer Valve Housing Plug Assembly Spool Assembly (Arm1) Plug Spool Assembly (Boom2)
Page 476 Spool Assembly (2, Arm 2) Reference Description Number Spool Spring Seat Spring Spool End Figure 35 Spool Assembly (3, Boom1) Reference Description Number Spool Spring Seat Spring Spool End Plug Poppet Spring Figure 36 O-ring Backup Ring Spool Assembly (4, Bucket) Reference Description Number...
Page 477 Spool Assembly (5, Travel) Reference Description Number Spool Spring Seat Spring Spool End Figure 38 Spool Assembly (6, Straight Travel) Reference Description Number Spool Spring Seat Spring Spool End Figure 39 Spool Assembly (14, Arm1) Reference Description Number Spool Spring Seat Spring Spool End Plug...
Page 478: Spool Assembly
Spool Assembly (15, Boom 2) Reference Description Number Spool Spring Seat Spring Spool End Figure 41 Spool Assembly (16, Swing) Reference Description Number Spool Spring Seat Spring Spool End Figure 42 Spool Assembly (17, Option) Reference Description Number Spool Spring Seat Spring Spool End Figure 43...
Page 479 Spacer Assembly (40) Reference Description Number Spacer O-ring Backup Ring O-ring Figure 45 Plug Assembly (60) Reference Description Number Plug O-ring O-ring O-ring Figure 46 Main Control Valve (Kayaba) S0709401K Page 37...
Page 480: Plug Assembly (60)
Anti-draft Valve Assembly (67) Figure 47 Reference Reference Description Description Number Number Body O-ring Poppet Backup Ring Plug Backup Ring Piston O-ring Spool Plug Assembly Sleeve Plug Assembly Spring Spring Seat Spring Steel Ball O-ring S0709401K Main Control Valve (Kayaba) Page 38...
Page 481: Relief Valve Assembly (70)
Relief Valve Assembly (70) Reference Description Number Plug Spring Poppet Sleeve O-ring O-ring Figure 48 Plug Assembly (90) Reference Description Number Plug O-ring O-ring Backup Ring Figure 49 SPECIFICATIONS Control Valve Specification Rated Flow 270 liter/min. 50 liter.min at Neutral Max.
Page 482: 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 clean passages. Over tightened piping port fittings. Check torque. Valve housing deformed when Remove assembling bolts and assembling.
Page 483: Relief Valve
RELIEF VALVE Problem Possible Cause Remedy Pressure does not rise. Stuck main poppet, sleeve or pilot Replace relief valve. poppet opened or dirt in seat part. Relief pressure unstable Seat parts of pilot poppet damaged. Piston or main poppet stuck. Relief pressure Seat parts worn due to dust.
Page 484: Over Load Relief Valve
Loosen lock nut (4) and turn adjusting plug (6) clockwise to raise relief pressure of preceding step. Turn adjusting plug (6) counterclockwise to lower relief pressure. One turn varies pressure by approximately 28.4 MPa. Tighten lock nut (4) after pressure has been adjusted. Low pressure adjustment (second stage) Loosen lock nut (7) and turn adjusting plug (8) counterclockwise to lower relief pressure at state of 4.
Page 485: Disassembly
DISASSEMBLY GENERAL INSTRUCTIONS FOR DISASSEMBLY Stop engine when pressure of actuator is not indicated. 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 486: Disassembly Of Arm 1 Para Spool Turn
Disassembly of spool IMPORTANT Work with spool gripped in vise with wood (see Figure 50) 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 50 Heat spool until spool end is easily loosened, and remove immediately...
Page 487: Disassembly Of Arm Regeneration Release Valve Part
Disassembly of Arm Regeneration Release Valve Part Small parts in assembly are indicated to (parental number - son number). CAUTION! When removing a plug, when pressure is not fully released, or bucket is not lowered to ground, is very dangerous. A part in the valve may spring out and drop the bucket at the same time. Always lower bucket to ground and fully release pressure before disassembling.
Page 488: Disassembly Of Antidrift Valve
14. Remove spring (48) and poppet (49) from valve housing. 15. Remove socket head bolt (101, four places, width across flats: 8 mm) from body (96, one places). 16. Remove body (96) from valve housing. Remove sleeve (99), piston (97), spring (98), poppet assembly (100), backup ring (103), and O-ring (104).
Page 489: Disassembly Of Relief Valve
Disassembly of Relief Valve CAUTION! Removing relief valve, when pressure is not fully released, or bucket is not lowered to ground, is very dangerous. A part in the valve may spring out and drop the bucket at the same time. Always lower bucket to ground and fully release pressure before disassembling.
Page 490: Disassembly Of Main Relief Valve
Disassembly of Main Relief Valve This relief valve should be replaced as an assembly. When replacing it, remove plug (1, width across flats: 32 mm), and O-ring (2). If oil is leaking from nut (4), remove nut (4) and plug (1), and replace O-ring (3). If oil is leaking from nut (7), remove nut (7) and plug (8), and replace O-ring (3).
Page 491: Disassembly Of Low Pressure Relief Valve
This relief valve should be replaced as an assembly. When replacing it, Remove cap (1, width across flats: 31.75 mm) and O-ring (2). If oil is leaking from adjusting kit (3), remove adjusting kit (3), and replace O-ring (4). IMPORTANT When disassembling adjuster kit, be careful not to let parts spring out or lose poppet because of spring force.
Page 492: 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 for inspection. INSPECTION Inspect all parts for scratches, notches and other defects. Inspect load check seat surface of valve housing for scratches, scores, dirt, notches and corrosion.
Page 493: Application Method Of Loctite
Application Method of Loctite Male and female screw threads of parts which need to adhere. CAUTION! When working with Loctite, work in a place that is well ventilated. Cleaning (removal of grease) Remove grease with steam, acetate, etc. or clean with an alkali cleanser. Dry Loctite surface with moisture free air or naturally.
Page 494: Reassembly Of Arm 1 Para Turn Spool Assembly
Reassembly of Arm 1 Para Turn Spool Assembly Apply Loctite to threaded portion of spool (19) and install spring seat (20), spring (21) and spool end (22). After gripping spool in vise with wood (that is used when disassembling it), tighten spool end. Tightening torque: 1.94 - 2.24 kg•m (14 - 16 ft lb).
Page 495: Reassembly Of Relief Valve
REASSEMBLY PROCEDURE OF CONTROL VALVE BODY Reassembly of Relief Valve CAUTION! When reassembling safety valve, securely tighten plug that is installed in body. Do not loosen adjusting plug for pressure setting or lock nut. Adjusting plug for pressure setting is dangerous because pressure setting will be changed which may result in a dangerous situation.
Page 496: Reassembly Of Antidrift Valve
Install O-ring (36) in valve housing and fasten body by means of socket head bolt (101). Tightening torque: 5.91 - 6.53 kg•m (43 - 47 ft lb) Insert poppet (32) and spring (33) in arm 1 para turn part (section C-C). Install plug assembly (72) with O-ring.
Page 497: Reassembly Of Main Spool
Reassembly of Main Spool Install O-ring on mating surface of valve housing cap. Install spool of subassembly condition (2-6, 14-17) in same positions that they were remove from during disassembly IMPORTANT Align spool with hole and insert it slowly. After inserting spool, check to see if it slides easily. If spool is inserted when it is in a poor operating condition with a scratch, it can cause a malfunction of the spool.
Page 498 Figure 54 S0709401K Main Control Valve (Kayaba) Page 56...
Page 499: Reassembly Of Overload Relief Valve
Reassembly of Overload Relief Valve Check if there is dirt and paint chips around cap (1). Replace O-ring with new one. Clean installation portion of relief valve and valve housing. Install relief valve and tighten cap (1). Torque: 78-88N*M If relief valve was disassembled, adjust pressure by referring to “Over Load Relief Valve” on page 42. NOTE: The torque values are based on use of lubricated threads.
Page 500: Installation
INSTALLATION Be careful not to apply stress on control valve when attaching piping and hoses. Unnecessary stress may cause spools to bind and the control valve from functioning properly. 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 501 Remember, that ultimately safety is your own personal responsibility. PILOT CONTROL VALVE (WORK LEVER / JOYSTICK)S0709451K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 340LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Pilot Control Valve (Work Lever / Joystick) S0709451K...
Page 502 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Structure ..................3 Function ................... 3 Parts List ....................4 Specifications ..................5 Torques .................... 5 Performance..................6 Removal ......................6 Disassembly ....................9 Cleaning and Inspection (Wear Limits and Tolerances) ....... 13 Reassembly....................
Page 503: 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 504: Parts List
PARTS LIST ARS2260L Figure 1 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 4...
Page 505: Specifications
Reference Reference Description Description Number Number Case O-ring Plug Rod Seal Plug Plate O-ring Boot O-ring Joint Assembly Spool Swash Plate Shim Hex Nut Spring Handle Bar Spring Seat Spring Boot Stopper Spring Pin Stopper Handle Assembly Spring Bushing Push Rod Terminal Spring Seal Wire...
Page 506: Performance
Performance ARS2270L Figure 2 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 507 11. Remove four bolts and washers (2, Figure 4) and cover (1). 12. Pull cap (5, Figure 4) out and remove two screws, two bolts and washers (6) and cover (3). 13. Remove three screws, one bolt and washers (7, Figure 4) and cover (4). ARS2910L Figure 4 14.
Page 508 19. Remove four bolts (3, Figure 7) and cover (2), and pull remote control valve RH (1) out. 20. Tag and disconnect hoses from remote control valve RH (1, Figure 7). Plug and hoses ports prevent contamination from entering hydraulic system or component.
Page 509: Disassembly
DISASSEMBLY Lift up the boot (28) and pull the switch cord through the hole in the case (1). Figure 8 Figure 9 Loosen nut (27) from hex nut (25) and remove handle assembly (30). Figure 10 Pilot Control Valve (Work Lever / Joystick) S0709451K Page 9...
Page 510 Remove hex nut (25) and swash plate (24). Figure 11 Remove joint (23) from case (1). Figure 12 Remove plate (21). Figure 13 Press spring (10) and remove plug (18). Figure 14 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 10...
Page 511 Remove pressure reduction valve (6, 7, 8, 9, 11) and spring (10). IMPORTANT Mark valve disassembling position (port). Figure 15 Remove plug (3) and four plugs (2). Figure 16 Remove stopper (11) from pressure reduction valve (6, 7, 8, 9, 11). Figure 17 10.
Page 512 11. Remove push rod (14) and plug (18). Figure 19 12. Remove O-ring (19) from plug (18). Figure 20 13. Remove seal (20) from plug (18). Figure 21 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 12...
Page 513: 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) S0709451K Page 13...
Page 514: Reassembly
REASSEMBLY Tighten plug (3) slowly. NOTE: Tightening torque: 350 kg•cm (25.3 ft lb). Tighten four plugs (2). NOTE: Use Loctite #592 pipe sealant on plugs. NOTE: Tightening torque 150 kg•cm (10.9 ft lb). Figure 22 Install shim (7), spring (8), spring seat (9), and spool (6).
Page 515 Install spring (10) in case (1) and pressure reducing valve assembly (6, 7, 8, 9, 11). Figure 25 Install seal (20) on plug (18). Figure 26 Install O-ring (19) on plug (18). Figure 27 Install push rod (14) on plug (18). Figure 28 Pilot Control Valve (Work Lever / Joystick) S0709451K...
Page 516 Install spring (13) on stopper (12). Figure 29 Position stopper (12) and spring (13) on pressure reducing valve. Figure 30 10. Install plug (18) in case (1). Figure 31 11. Install plate (21) and tighten joint (23). Figure 32 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 16...
Page 517 12. Install swash plate (24) on joint (23). Figure 33 13. Install hex nut (25) and tighten swash plate (24). NOTE: Tightening torque 1,240 kg•cm (89.7 ft lb). Figure 34 14. Pull cord and tube out through hole of hex nut (25).
Page 518 16. Grease joint (23), swash plate (24) and push rod (14). Figure 37 17. Install boot (28). Figure 38 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 18...
Page 519: Installation
INSTALLATION Connect hoses as tagged during removal to remote control valve RH (1, Figure 39). Position remote control valve RH (1, Figure 39) on control stand and install four bolts and washers (3) and cover (2). ARS2920L Figure 39 Install two screws, two bolts and washers (7 and 8, Figure 40) and cover (4).
Page 520: Start-Up Procedures
Install three screws, one bolts and washers (7, Figure 42), and cover (4). Install two screws, two bolts and washers (6, Figure 42), and cover (3). Push cap (5) into cover (3). 10. Install four bolts and washers (2, Figure 42), and cover (1).
Page 521 Remember, that ultimately safety is your own personal responsibility. TRAVEL CONTROL VALVE (WITH DAMPER)S0709820K 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...
Page 522 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 523: 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 524 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 525: 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 526: Parts List
PARTS LIST ARS1850L Figure 5 ARS1860L Figure 6 S0709820K Travel Control Valve (With Damper) Page 6...
Page 527: 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 528: 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 529: 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 530 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 531: 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 532 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 533 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 534 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 535 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 536 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 537: 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 538: 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 539 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 540 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 541 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 542 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 543: 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 544: 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 545 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. HYDRAULIC SCHEMATIC (S340LC-V)S0792190K MODEL SERIAL NUMBER RANGE Solar 340LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Hydraulic Schematic (S340LC-V) S0792190K...
Page 546 TABLE OF CONTENTS General Description..................3 Solar 340LC-V....................4 S0792190K Hydraulic Schematic (S340LC-V) Page 2...
Page 547 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 (S340LC-V) S0792190K Page 3...
Page 548 SOLAR 340LC-V Figure 2 S0792190K Hydraulic Schematic (S340LC-V) Page 4...
Page 549 Hydraulic Schematic (S340LC-V) S0792190K Page 5...
Page 550 S0792190K Hydraulic Schematic (S340LC-V) Page 6...
Page 551 1ELECTRICAL SYSTEM...
Page 553: Electrical System
Remember, that ultimately safety is your own personal responsibility. 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...
Page 554 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 555 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 556: 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 557: 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 558: 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 559: 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 560: 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 561: 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 562: 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 563 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 564 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 565: 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 566: 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 567 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 568: 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 569 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 570 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 571 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 572: 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 573 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 574: 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 575: 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 576: 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 577: 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 578: 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 579: 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 580: 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 581: 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 582 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 583 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 584 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 585 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 586 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 587 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 588 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 589 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 590 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 591 • 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 592 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 593 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 594: 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 595 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 596: 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 597: Operation
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 598 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 599 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 600: 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 601 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 602: 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 603: 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 604: 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 605: 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 606 S0802220K Electrical System Page 54...
Page 607: 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 608: 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 609 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 610: 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 611: 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 612: 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 613: 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 614: 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 615: 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 616: 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 617: 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 618 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 619 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 620: 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 621 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 622: 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 623 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 624: 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 625 Electrical System S0802220K Page 73...
Page 626: Lighting System Circuit Diagram
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 627: 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 628: 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 629: Electrical Schematic (S340Lc-V)
Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. ELECTRICAL SCHEMATIC (S340LC-V)S0892190K MODEL SERIAL NUMBER RANGE Solar 340LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Electrical Schematic (S340LC-V) S0892190K...
Page 630 TABLE OF CONTENTS General Description..................3 Solar 340LC-V....................4 S0892190K Electrical Schematic (S340LC-V) Page 2...
Page 631 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 (S340LC-V) S0892190K Page 3...
Page 632 SOLAR 340LC-V Figure 2 S0892190K Electrical Schematic (S340LC-V) Page 4...
Page 633 Model Solar 340/370LC-V Name ELECTRICAL DIAGRAM 599-00042 DAEWOO HEAVY INDUSTRIES LTD. Electrical Schematic (S340LC-V) S0892190K Page 5...
Page 634 S0892190K Electrical Schematic (S340LC-V) Page 6...
Page 635 1ATTACHMENTS...
Page 637: Boom And Arm
Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. BOOM AND ARM S0902040 MODEL SERIAL NUMBER RANGE Solar 330LC-V 1001 and Up Solar 340LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Boom and Arm S0902040 Page 1...
Page 638 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 S0902040 Boom and Arm Page 2...
Page 639: 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) 110.0 mm (4.33 in)
Page 640: 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 641 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 642: 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 643: 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 644: 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. S0902040 Boom and Arm Page 8...
Page 645: Bucket
Remember, that ultimately safety is your own personal responsibility. 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...
Page 646 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 647: Bucket Tooth Inspection And Replacement
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 648 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 649 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 650: Bucket O-Ring Replacement
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 651 Roll the new O-ring (1, Figure 9) into the O-ring groove. ARO1392L Figure 9 Bucket S0904005K Page 7...
Page 652: Bucket Shimming Procedures
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 653: Bucket Attachment, Removal And Reversal
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 654: Reversing The Bucket
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 655 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...

Save PDF