Daewoo Solar 300LC-V Manual

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Solar 300LC-V

Shop Manual

023-00043E

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.

023-00043E Shop Manual

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Summary of Contents for Daewoo Solar 300LC-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. 023-00043E...
Page 5 1TABLE OF CONTENTS Specifications Safety Track Excavator Safety................S0102000 Specifications for Solar 300LC-V............S0202080K General Maintenance General Maintenance Procedures ............S0302000 Standard Torques ..................S0309000 Upper Structure Cab ..................... S0402040K Counterweight..................S0403050K Fuel Tank.................... S0405110K Fuel Transfer Pump ................S0405500 Swing Bearing..................S0407000 Swing Reduction Gear................ S0408070K Lower Structure and Chassis Track Assembly ..................S0505000...
Page 6: Table Of Contents
Swing Motor (Toshiba MFC200)............S0707270K Travel Motor (with Gearbox) ............... S0707315K Main Pump (Kawasaki)............... S0708315K Main Control Valve (Kayaba).............. S0709401K Pilot Control Valve (Work Lever / Joystick)......... S0709451K Travel Control Valve (With Damper)........... S0709820K Hydraulic Schematic (S300LC-V) ............S0792160K Electrical System Electrical System ................
Page 7 1SAFETY...
Page 9 Solar 220LC-V 0001 and Up Solar 220N-V 1001 and Up Solar 250LC-V 1001 and Up 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...
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 300LC-VS0202080K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Specifications for Solar 300LC-V S0202080K 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 S0202080K Specifications for Solar 300LC-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 300LC-V S0202080K Page 3...
Page 52: Component Locations
COMPONENT LOCATIONS ARO0980L Figure 1 S0202080K Specifications for Solar 300LC-V Page 4...
Page 53: Swing Motor (Toshiba Mfc200)
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 300LC-V S0202080K Page 5...
Page 54 S0202080K Specifications for Solar 300LC-V Page 6...
Page 55: General Dimensions
3,930 mm (12’ 11") 2,960 mm (9’ 9") 1,500 mm (4’ 11") 1,460 mm (4’ 9") 2,600 mm (8’ 6") 3,200 mm (10’ 6") 600 mm (23.62 in) 500 mm (19.69 in) 3,065 mm (10’ 1") Specifications for Solar 300LC-V S0202080K 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. 2.5m (8.2 ft) ARM 3.1m (10.17 ft) ARM 3.75m (12.3 ft) ARM ARS1460L Figure 3 S0202080K Specifications for Solar 300LC-V Page 8...
Page 57 (9' 9") 575 mm 1,970 mm - 80 mm Min. Digging Reach (1' 11") (6' 6") (- 0' 9") 4,055 mm 4,107 mm 4,010 mm Min. Swing Radius (13' 4") (13' 6") (13' 2") Specifications for Solar 300LC-V S0202080K Page 9...
Page 58: General Specifications
Ground Pressure Ratings: Standard 600 mm (23.6") 0.57 kg/cm (8.1 psi) shoe - Optional 700 mm (28.0") 0.50 kg/cm (7.1 psi) shoe - Optional 800 mm (32.0") 0.44 kg/cm (6.2 psi) shoe - S0202080K Specifications for Solar 300LC-V Page 10...
Page 59 Track Shipping Length 4,930 mm (16’ 2") Transport Trailer Capacity 30 tons (33 short tons), minimum load capacity Transport Loading Ramp 15° angle CAUTION: Refer to Transport Maximum Procedure for Allowable Slope Safe Shipping Instructions. Specifications for Solar 300LC-V S0202080K Page 11...
Page 60: Engine Performance Curves (Per Din 6270 Standard)
ENGINE PERFORMANCE CURVES (PER DIN 6270 STANDARD) 1000 1500 2000 REVOLUTION (rpm) ARS1470L Figure 4 S0202080K Specifications for Solar 300LC-V Page 12...
Page 61 DIN 6270 200 ps @ 1,900 rpm Power (197 hp @ 1,900 rpm) 86 kg•m @ 1,300 rpm Max. Torque (620 ft lb @ 1,300 rpm) 165 g/ps•h Fuel Consumption (Rated) (5.82 oz/hp•h) Specifications for Solar 300LC-V S0202080K 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 S0202080K Specifications for Solar 300LC-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 300LC-V S0202080K 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 S0202080K Specifications for Solar 300LC-V Page 16...
Page 65: Performance Tests
Travel Speed 20 m High sec. 15.9 ±0.9 14.4 ±0.9 (65.62 ft) sec. 25.7 ±1.3 22.5 ±1.3 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 300LC-V S0202080K 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: S0202080K Specifications for Solar 300LC-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 300LC-V S0202080K 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 ARS4650L Number Figure 8 Start Swing 90° Swing Swing Force Swing Stop S0202080K Specifications for Solar 300LC-V Page 20...
Page 69: Cylinder Performance Tests
OPERATION STANDARD MODE POWER MODE High Speed 23.4 - 25.8 seconds 20.8 - 23.2 seconds Low Speed 38.3 - 42.1 seconds 33.1 - 36.9 seconds Specifications for Solar 300LC-V S0202080K Page 21...
Page 70 S0202080K Specifications for Solar 300LC-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 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. S0402040K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up...
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 Use lifting and hoisting equipment capable of safely handling load. 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...
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...
Page 115 NOTE: Tighten bolts (4, Figure 5) to ARS1650L values shown in following table. Figure 5 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).
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 S0405110K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 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 S0405110K 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 S0405110K Page 3...
Page 120: Parts List
PARTS LIST ARS1660L Figure 1 S0405110K Fuel Tank Page 4...
Page 121: Specifications
Reference Reference Description Description Number Number Fuel Tank Cap (=2188-9004) O-ring Plug; SP Cover Level Gauge Bolt (M10x1.5x25) O-ring Spring Washer (M10) O-ring Drain Valve Plug Bolt Spacer Shim Bolt Shim Clip Fuel Filter SPECIFICATIONS Fuel tank capacity is 450 liters (119 U.S. gal). Fuel Tank S0405110K Page 5...
Page 122: Removal
REMOVAL Look at fuel level display (Figure 2) on instrument panel in operator’s cab to see what it displays. The display is divided into GREEN separated segments, each representing 10 percent of total fuel supply. Also look at level gauge on side of tank to estimate volume of fuel left in tank.
Page 123 Lower front attachment (bucket) to the ground. Stop the engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while performing maintenance, Figure 4 extreme care. Always have one person in the cab at all times. Never leave the cab with the engine running.
Page 124 13. Place a large enough container under the tank to collect remaining fuel. Open drain valve (Figure 6) at bottom of tank and empty tank. NOTE: Fuel tank capacity is 450 liters (119 U.S. gal). Figure 6 14. Tag and disconnect fuel supply line (1, Figure 7) and fuel return line (2) from tank (3) and carefully drain remaining fuel from lines.
Page 125 19. Remove four bolts (1 and 2, Figure 10), clamp (6) and stay (3) from fuel tank and frame. Remove four bolts (4) and battery cover (5) from frame. ARS1750L Figure 10 20. Remove four bolts (1 and 2, Figure 11) and cover (3) from fuel tank and support.
Page 126: Installation
INSTALLATION Install two 12 mm eye bolts in threaded holes (1 and 2, Figure 13). Using a suitable lifting device, sling eye bolts. Set fuel tank (3, Figure 13) 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 Install six bolts (1, Figure 16) and cover (2) on fuel tank. ARS1670L Figure 16 Connect wires as tagged to fuel sensor (1, Figure 17) on side of fuel tank (2). If equipped, connect components to fuel filter pump port (3, Figure 17) on side of fuel tank (2).
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 20) on top of fuel filter head. Figure 20 Unscrew and pump the hand operated primer pump (Figure 21) 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 MODEL SERIAL NUMBER RANGE Solar 250LC-V 1001 and Up Solar 290LC-V 0001 and Up 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...
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 220LL 1001 and Up Solar 250LC-V 1001 and Up Solar 290LC-V 0001 and Up 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...
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 GEARS0408070K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Swing Reduction Gear S0408070K...
Page 142 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Parts List ....................4 Specifications ..................5 Special Tools and Materials................6 Special Tools ................... 6 Tool "A" .................... 6 Tool "B" .................... 6 Tool "C" .................... 7 Tool "D" .................... 7 Tool "E"...
Page 143: General Description
GENERAL DESCRIPTION THEORY OF OPERATION The swing motor final drive is a two-step planetary gearbox with two planet gears, two sun gears and two- step output reduction. The planetary gear engages with the ring gear. The pinion gear is connected with the output shaft and spline.
Page 144: Parts List
PARTS LIST ARS2590L Figure 1 S0408070K Swing Reduction Gear Page 4...
Page 145: Specifications
Reference Reference Description Description Number Number Motor No. 2 Planetary Gear Socket Bolt (M12x35) No. 2 Side Plate Level Gauge Gear Case Pipe Lock Ring Socket Bolt(M16x180) Pinion Gear Cover Plate Cover No.1 Sun Gear Hex Bolt (M16x40) No. 1 Carrier Assembly Collar Ring Gear Seal...
Page 146: Special Tools And Materials
SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS Tool "A" Dimension Measurement ∅190 mm (7.4803 in) ∅220 mm (8.6614 in) 350 mm (13.7795 in) ARS2600L Figure 2 Tool "B" Dimension Measurement ∅156 mm (6.1417 in) ∅130 mm (5.1181 in) +0.5 +0.3 (0.1299 - 0.1378 in) 128 mm (5.0394 in) ARS2610L...
Page 147: Tool "C
Tool "C" Dimension Measurement 70 mm (2.7559 in) 6 mm (0.2362 in) 6 mm (0.2362 in) 18 mm (0.7087 in) ARS2620L Figure 4 Tool "D" Dimension Measurement ∅60 mm (2.3622 in) ∅80 mm (3.1496 in) 150 mm (5.9055 in) ARS2630L Figure 5 Tool "E"...
Page 148: Tool "F
Tool "F" Dimension Measurement ∅128 mm (5.0394 in) ∅158 mm (6.2205 in) 150 mm (5.9055 in) ARS2650L Figure 7 S0408070K Swing Reduction Gear Page 8...
Page 149: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT Symptoms Possible Causes Remedies 1. No rotation and – a. Pressure at swing motor inlet Swing brake not releasing Check brake engagement increases and disengagement, check release pressure Internal damage to gearbox Replace broken gears, drive train drive train assemblies Overload Reduce load weight...
Page 150: 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 8 performing maintenance, extreme care. Always have one person in the cab at all times.
Page 151 11. Tag and disconnect hoses from swing motor (1, Figure 9). Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component. 12. Remove drain plug (3, Figure 9) from frame and drain oil from reduction gearbox (5, Figure 9).
Page 152: Disassembly
DISASSEMBLY Drain oil from port A. Using a pipe wrench, remove oil level gauge (3-1) and pipe (3-2) (PT1/4). TANK ARS2660L Figure 10 Using L-wrench, remove socket bolts (2) and motor (1). ARS2670L Figure 11 S0408070K Swing Reduction Gear Page 12...
Page 153 Using L-wrench, remove socket bolts (4) and cover (5). ARS2680L Figure 12 Remove sun gear No. 1 (6) and carrier assembly No. 1 (7). Remove thrust plate (10). IMPORTANT Do not remove carrier assembly No. 1 (7) in field because pin No. 1 and carrier No.
Page 154 Remove sun gear No. 2 (11). Remove carrier assembly No. 2 and disassemble it. ARS2700L Figure 14 Using special tool (C), drive spring pin (14) into shaft No. 2 (13). This will allow shaft to be pressed out of carrier No. 2. HAMMER ARS2710L Figure 15...
Page 155 Remove ring gear (8). Remove lock pin (9) and turn body over. ARS2730L Figure 17 10. Remove wire (28) and hex bolt (21) by using socket wrench. Remove cover (20) and pinion (19). ARS2740L Figure 18 11. Remove lock ring (18). Put jig (D) on shaft Hydraulic (26) and press shaft assembly (22, 24, 25 Press...
Page 156: Cleaning And Inspection (Wear Limits And Tolerances)
12. Put jig (A) on bearing (25) and press bearing (25), plate (24) and collar (22) Hydarulic Press from shaft (26). Pull spacer (29) out. ARS2760L Figure 20 HYDRAULIC PRESS 13. Remove bearing (27). Put jig (F) on seal (23) and using a rubber hammer, tap seal (23) out of gear case (17).
Page 157: Reassembly
REASSEMBLY Install spacer (29) on shaft (26). Position Hydarulic jig (A) on bearing (25) and press bearing Press (25) on shaft (26) until contact is obtained. ARS2780L Figure 22 HYDRAULIC PRESS Install plate (24) on shaft (26). Position Jig (A) on collar (22) and press collar (22) on shaft (26) until contact is obtained.
Page 158 Install pinion gear (19) on shaft assembly. Fasten cover (20) with hex bolts (21) and secure with lock wire (28) diagonally. NOTE: Apply Loctite #262 to bolt threads. NOTE: Tighten bolt to 2,700 kg•cm (195 ft lb). SHAFT ASS'Y ARS2800L Figure 24 Put jig (A) on pinion gear and press shaft assembly with pinion into case (17) until...
Page 159 Using jig (B), insert seal (23) into case (17). IMPORTANT When installing, tap with rubber hammer lightly not to damage seal. ARS2820L Figure 26 Place jig (F) on bearing (27) and press bearing (27) onto shaft assembly until contact is obtained. ARS2830L Figure 27 Insert lock pin (9) in case (17) and install...
Page 160 Install side plate No. 2 (16) on planetary gear No. 2 (15) and insert it into carrier No. 2 (12). Install shaft No. 2 (13) into carrier No. 2 (12) and planetary gear No. 2 (15). Using a hammer, tap pin (14) into carrier No.
Page 161 11. Secure cover plate (5) and ring gear (8) onto gear case (17) with socket bolt (4). NOTE: Coat mating faces of ring gear (8) and cover plate (5) with Loctite #609. NOTE: Apply Loctite #262 to bolt threads. NOTE: Tighten bolt to 2,700 kg•cm (195 ft lb).
Page 162: Installation
INSTALLATION Coat pinion gear with grease. Refer to operation manual for specifications. Make sure two alignment pins (6, Figure 34) are installed in flange of swing reduction gearbox (5). Using a suitable lifting device, sling swing motor (1, Figure 34) and position swing motor and reduction gearbox (5) as an assembly on unit.
Page 163: Start-Up Procedures
START-UP PROCEDURES IMPORTANT If the air is not vented from the system, it will cause damage to the swing motor and bearings. Disconnect drain hose and fill swing motor case with hydraulic oil. Connect the drain hose. Start engine and set throttle at "LOW Figure 35 IDLE"...
Page 164 S0408070K Swing Reduction Gear Page 24...
Page 165 1LOWER STRUCTURE AND CHASSIS...
Page 167 Use lifting and hoisting equipment capable of safely handling load. 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...
Page 168 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 169: 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 170 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) (13.0 - 14.17 in) Minimum "C"...
Page 171 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 172: Cleaning And Inspection (Wear Limits And Tolerances)
Reference (New) Limit for (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")
Page 173 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 174 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 175 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 176: 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 177 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 178: 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 179: 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 180 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 181: 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 182: 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 183: 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 184 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 185: Lower Roller Installation
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 186: 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 187 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 188 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 189: 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 190 Tighten plug (1, Figure 48). Figure 48 S0505000 Track Assembly Page 24...
Page 191: Track Spring And Track Adjusting Cylinder
TRACK SPRING AND TRACK ADJUSTING CYLINDER PARTS LIST Figure 49 Track Assembly S0505000 Page 25...
Page 192 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 193 1ENGINE AND DRIVE TRAIN...
Page 195 Use lifting and hoisting equipment capable of safely handling load. 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...
Page 196 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 197: 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 198 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 199: 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 200 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 201: 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 202: 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 203 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 204: 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 205 Face and Defroster ARS1300L Figure 12 Air-Conditioner S0605060K Page 11...
Page 206: 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 207 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 208: 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 209 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 210 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 211 1250 ±20 grams (44 ±0.7 oz.) Solar 290LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 290LL 850 ±20 grams (30 ±0.7 oz.) Solar 300LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 300LL 850 ±20 grams (30 ±0.7 oz.) Solar 330-III 1250 ±20 grams (44 ±0.7 oz.)
Page 212: 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 213: 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 214 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 215: 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 216: 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 217: 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 218 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 219: 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 220 S0605060K Air-Conditioner Page 26...
Page 221 Use lifting and hoisting equipment capable of safely handling load. 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...
Page 222 TABLE OF CONTENTS Drive Coupling....................3 Special Tools ....................4 Drive Coupling Installation................6 Installation Procedure ................8 S0609010K Drive Coupling (Main Pump) Page 2...
Page 223: 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 224: 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 225 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 226: 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 227 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 228: 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 229 1HYDRAULICS...
Page 231 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 S0702170K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Copyright 2002 Daewoo May 2002...
Page 232 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 233 Pump Input Power Control ................17 Pump Regulator Adjustment ..............17 Flow Meter and Flow Meter Kit Installation and Testing ....... 21 Swing System Troubleshooting ..............23 Precautions/Initial Checks..............23 Swing Relief Valve Checking and Adjustment........23 Troubleshooting – Swing Gearbox..............25 Troubleshooting –...
Page 234: Hydraulic System - General Notes
HYDRAULIC SYSTEM - GENERAL NOTES ARS1690L 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 235: Hydraulic Schematic (S300Lc-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 236: 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 237: 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 238: 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 239: 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 240: 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 241: 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 242: 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 243: 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 244: 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 245: 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 246 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. S0702170K Hydraulic System Troubleshooting, Testing and Page 16...
Page 247: 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 248 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 two different adjustments, along with the Negacon, negative control, adjustment screw (3, directly below 1 and 2). Each one of the adjustment procedures could affect the setting of the others.
Page 249 Start the engine and turn the engine speed dial maximum. When normal operating temperature is reached, loosen the largest diameter lock nut around the adjustment screw (2) for the outer regulator spring. Tightening the screw shifts the P/Q (Pressure/Flow) control curve to the right, and increases compensating control pressure.
Page 250 The adjusting screw (1, Figure 16) affects the delivery rate (Q) of the pump. Tightening the adjusting screw decreases the maximum cut flow (as shown in Figure 15) while backing out the screw increases cut flow delivery rate. Balance both pumps for equal output. HDA3008L Figure 15 Figure 16...
Page 251: 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 252 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 253: 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 254 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 255: 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 256: 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 257 Problem Possible Causes Remedies Sluggish performance of all Main pump(s) damaged or worn. Repair or replace. hydraulic functions – Main relief valve pressure off. Readjust pressure. attachment, swing and travel. Low oil level in hydraulic system. Refill. Hydraulic reservoir intake Clean.
Page 258: 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 259: 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 260: 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 261 Use lifting and hoisting equipment capable of safely handling load. 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...
Page 262 TABLE OF CONTENTS General Description..................3 Specifications ..................4 S0703010K Accumulator Page 2...
Page 263 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 264 Model Serial Number System Volume Pressure 320 cc S/N 1001 thru 1099 (19.53 in 10 kg/cm Solar 300LC-V Pilot / Travel (140 psi) 750 cc S/N 1100 and Up (45.77 in 750 cc 10 kg/cm Solar 300LL S/N 1100 and Up...
Page 265 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 266 S0703010K Accumulator Page 6...
Page 267 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. CENTER JOINT (SWIVEL)S0704080K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Copyright 2002 Daewoo May 2002...
Page 268 TABLE OF CONTENTS General Description..................3 Parts List ....................4 Troubleshooting, Testing and Adjustment............5 Inspection....................5 Testing..................... 5 Disassembly ....................6 Reassembly....................7 S0704080K Center Joint (Swivel) Page 2...
Page 269: 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 270: Parts List
PARTS LIST ARS1730L Figure 1 Reference Reference Description Description Number Number Body Cover Spindle Spring Washer Seal Bolt O-ring Plug Thrust Plate Shim Retaining Ring Shim O-ring S0704080K Center Joint (Swivel) Page 4...
Page 271: 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 272: 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 273: 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 stem and inner surface of the center swivel body. Apply slow, even-handed pressure, using both hands, to slowly push the stem into the body.
Page 274 S0704080K Center Joint (Swivel) Page 8...
Page 275 Solar 200W-V 0001 and Up Solar 220LC-V 0001 and Up Solar 250LC-V 1001 and Up 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...
Page 276 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 277: 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 278: 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 279 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 280: 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 281 Cylinders S0705000 Page 7...
Page 282 S0705000 Cylinders Page 8...
Page 283 Cylinders S0705000 Page 9...
Page 284: 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 285 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 286 MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER) P/S: Power Steering O/R: Out Rigger S0705000 Cylinders Page 12...
Page 287 Cylinders S0705000 Page 13...
Page 288: 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 289 -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 290 -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 291 Cylinders S0705000 Page 17...
Page 292: 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 293 -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 294 -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 295 -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 296: Slipper Seal Jig
SLIPPER SEAL JIG (B+40) ARS4770L Figure 10 S0705000 Cylinders Page 22...
Page 297 +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 298 +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 299 Cylinders S0705000 Page 25...
Page 300: Slipper Seal Straightening Jig
SLIPPER SEAL STRAIGHTENING JIG ∅ ARS4780L Figure 11 S0705000 Cylinders Page 26...
Page 301 +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 302 +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 303: 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 304 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 305 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 306 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 307 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 308 17. Force out pin bushing (1) from body of cylinder. Figure 28 S0705000 Cylinders Page 34...
Page 309: 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 310 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 311 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 312 S0705000 Cylinders Page 38...
Page 313 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. SWING MOTOR (TOSHIBA MFC200)S0707270K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Swing Motor (Toshiba MFC200)
Page 314 TABLE OF CONTENTS General Description..................4 Theory of Operation ................4 Hydraulic Motor................4 Make-up Valve Operation..............6 Super Shockless Relief Valve Operation (Relief Valve Section Drawing)............7 Bypass Valve Operation (Bypass Valve Section Drawing) ....8 Swing Brake Operation ..............9 Time Delay Valve (Time Delay Valve Section Drawing) ....
Page 315 Reassembly of Cylinder Assembly............27 Reassembly of Lining Plate And Plate ..........28 Reassembly of O-ring ................28 Reassembly of Brake Piston ..............28 Reassembly of Spring ................28 Reassembly of Balance Plate ............... 29 Reassembly of Inner Race..............29 Reassembly of O-ring ................
Page 316: General Description
GENERAL DESCRIPTION THEORY OF OPERATION The swing drive motor is an axial piston motor (MFC200). The motor also contains the following components; Mechanical brake Make-up valve Ultra shockless valve Time relay valve Bypass valve Hydraulic Motor The rotary group consist of a cylinder block (27) which is a single body design with an integral drive shaft. Nine piston assemblies (9) are housed in the cylinder block (27).
Page 317 3-2 Hydraulic Motor Operation Figure 1 Reference Reference Description Description Number Number Balance Plate Cylinder Block Shoe Piston Cam Plate The cross sectional view of the swing motor, Figure 1, show most of the main components of an axial- piston type hydraulic motor. Arrows indicating direction of flow and other graphic symbols provide a general guide for understanding basic operation.
Page 318: Make-Up Valve Operation
crowd dump speed is reduced. If trench mode is turned "OFF" - diminishing the size of the opening through the swing priority valve - arm speed increases as slew rate falls off. Connected through the e-EPOS controller, the switch of the trench mode changes the voltage of the electronic signal sent to the solenoid valve.
Page 319: Super Shockless Relief Valve Operation (Relief Valve Section Drawing)
Super Shockless Relief Valve Operation (Relief Valve Section Drawing) Figure 2 When starting When the control valve is first actuated, pressurized oil is supplied to port (A). Due to the large initial inertia of the upper structure the swing motion is slower than that of the oil amount of oil being supplied for normal movement.
Page 320: Bypass Valve Operation (Bypass Valve Section Drawing)
When piston (50) is moving like as mentioned above, spring (49) force is increased from low force to high force, cushion relief operation is actuated at low pressure first, then it is increased to the rated pressure after a few moments have passed. By this slowly increasing pressure, the shock loading of the motor decreases when starting or stopping.
Page 321: Swing Brake Operation
Swing Brake Operation The swing brake is normally held in the applied position - preventing the upper structure 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. Figure 4 IMPORTANT Along with the swing brake, a 2-position positive swing lock has also been provided.
Page 322 The swing brake is applied when the brake spring. (16, Figure 4) locks up the friction plate (11), split plate (12) and swing motor casing (301), preventing the motor drive shaft from turning. When hydraulic pressure is forced to the back side of the brake piston, the friction plate and swing motor casing are separated, releasing the brake.
Page 323: Time Delay Valve (Time Delay Valve Section Drawing)
Time Delay Valve (Time Delay Valve Section Drawing) Figure 5 Pressure over mechanical brake releasing pressure always exists in port (PG). Condition when drive shaft is locked by operation of mechanical brake In this condition, pressure in port (SH) does not exist, and spool (73) is pushed to the right side end by spring (77) and stops the flow of oil from port (PG) to port (PB).
Page 324: Parts List
PARTS LIST Figure 6 S0707270K Swing Motor (Toshiba MFC200) Page 12...
Page 325 Reference Reference Description Description Number Number Snap ring Balance Plate Inner Ring Needle Bearing Oil Seal Snap Ring Tapered Roller Bearing Cylinder Collar Housing Backing Spring Plug Cam Plate Bypass Valve Assembly Return Plate Back-up Ring Piston Assembly O-ring Lining Plate O-ring Plate O-ring...
Page 326: Specifications
SPECIFICATIONS Swing Motor Specification Theoretical Motor Displacement 186.70 cc (11.39 in Working Pressure 284.5 kg/cm (4,047 psi) Brake Torque 834.0 kg•m (6,030 ft lb) (At Back Pressure 0 kg/cm (0 psi)) PG Port Supplying Pressure 39.77 kg/cm² (565 psi) (100% Release Pressure) Allowable Pressure 49.97 kg/cm²...
Page 327: Special Tools
SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS Pressing Tool of Inner Ring (2) and Taper Roller Bearing (4) Inner Race Figure 7 Assembly Tool for Oil Seal (3) Figure 8 Assembly Tool for Brake Piston (13) Figure 9 Swing Motor (Toshiba MFC200) S0707270K Page 15...
Page 328: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT If abnormality is found when using motor, a way of handling to work is described when function is poor. As disassembling, inspection and reassembling is described in detain later also, use extreme care for handling absolutely not to damage the sliding surface of motor when working. Problem Possible Cause Remedy...
Page 329 Problem Possible Cause Remedy Torque is poor Sliding surface parts Open inlet and outlet port of motor, apply pilot Abnormal worn or damaged pressure of 3.9 - 4.9 Mpa to brake release port, and noise then check the turning of output shaft with torque of about 30 - 40 Nm over one revolution smoothly.
Page 330: Inspection Parts List
Inspection Parts List INSPECTION PARTS CORRECTION Wear of sliding part of balance plate(24) Repair or replace parts Damage of sliding part of cam plate(7) Repair parts or replace motor Damage of sliding part of piston assembly(9) Repair parts or replace motor Wear of piston circumference surface of piston Repair parts or replace motor assembly(9)
Page 331: Disassembly
DISASSEMBLY CAUTION! Read this manual before working on or performing disassembly, reassembly, inspection, repair etc. of this component. Disassembly of this component should be done after stopping machine and allowing surface temperature of this component to cool to 40°C or below. Working on this component when it is at higher temperatures can result in burns.
Page 332 Match mark cover (19) and housing (28) so that they can be properly oriented during reassembly. Figure 11 With motor output shaft pointing down, remove four socket head bolts (46) (hex hole size 17 mm) and cover (19) from housing. Figure 12 Remove snap ring (26), inner race of needle bearing (25) and balance plate...
Page 333 Remove O-ring (14) from cover (19). Figure 14 Remove bushing (16) attached in Teflon ring (17) and scrowave (18) from cover (19). Figure 15 Remove springs (15) from piston (13). NOTE: Match mark springs (15) with piston (13). Figure 16 Piston (13) will not come out of housing (28) due to sliding resistance of O-rings (12 and 14).
Page 334: Disassembly Of Lining Plates And Plates
DISASSEMBLY OF LINING PLATES AND PLATES Remove lining plate (10) and plates (11). Figure 18 DISASSEMBLY OF CYLINDER ASSEMBLY Holding cylinder (27) by the end part, remove cylinder assembly from housing (28). NOTE: Be careful not to drop cylinder (27) as it is slippery. The outer race of taper roller bearing (4) and oil seal (3) will remain in housing (28).
Page 335: Disassembly Of Cylinder Assembly
DISASSEMBLY OF CYLINDER ASSEMBLY Squeeze out snap ring (1). Remove outer taper roller bearing inner race (4) and inner ring (2) using bearing puller. Figure 21 Remove collar (5) from cylinder (27). Remove cam plate (7), return plate (8) and piston assembly (9) from cylinder (27).
Page 336: 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. REASSEMBLY GENERAL NOTE: When reassembling, first perform the following steps. Check each part for damage when disassembling. If it is damaged, repair it with fine grade oil stone or crocus cloth as necessary.
Page 337: Reassembly Of Cylinder Assembly
REASSEMBLY OF CYLINDER ASSEMBLY Apply hydraulic oil to round part (contact part of backing spring (6)) of cylinder (27) and insert backing spring (6). Figure 28 Insert piston assembly (9) into hole of return plate (8). Figure 29 Install piston assembly (9) and return plate (8) into cylinder (27).
Page 338: Reassembly Of Oil Seal
Press fit inner race of taper roller bearing (4) onto cylinder by using special tool and press. NOTE: When pressing, wrap surface of cylinder (27) with a lint free cloth or paper to protect it from being damage. Figure 32 After cleaning and drying, reassemble part of cylinder (27), by applying a thin coat of Loctite (515, 518 or equivalent) to it and...
Page 339: Reassembly Of Taper Roller Bearing Outer Race
REASSEMBLY OF TAPER ROLLER BEARING OUTER RACE Install taper roller bearing outer race (4) in housing (28). Figure 36 REASSEMBLY OF CYLINDER ASSEMBLY Apply a thin coat of grease on lip of oil seal (3). Hold end part of cylinder (27), and slowly install cylinder...
Page 340: Reassembly Of Lining Plate And Plate
REASSEMBLY OF LINING PLATE AND PLATE Install lining plates (10) and plates (11). NOTE: Apply hydraulic oil to both faces of each plate. Figure 38 REASSEMBLY OF O-RING Install O-ring (12) on housing (28) and O- ring (14) on piston (13). NOTE: Apply grease to O-rings (12 and 14).
Page 341: Reassembly Of Balance Plate
REASSEMBLY OF BALANCE PLATE Install scrowave (18) and bushing (16) with Teflon ring (17) into bushing hole of cover (19). Install balance plate (24), in which piston (23) is inserted, on cover (19). Figure 42 NOTE: Be careful of the reassembling direction, which was marked before disassembling,...
Page 342: Applying Liquid Packing
APPLYING LIQUID PACKING Clean and dry the mating surfaces of housing (28) and cover (19), and apply liquid packing (Three Bond kk "1211" white or equivalent) to it like right figure. Figure 46 REASSEMBLY OF COVER Clean and dry the mating surface of cover (19) against housing (28), lift cover (19) by hand, and install it to housing (28) slowly.
Page 343: Reassembly Of Relief Valve Assembly, Etc
REASSEMBLY OF RELIEF VALVE ASSEMBLY, ETC. Install relief valve assembly (45) (hex hole size 14 mm) to cover (19) with torque of 137 Nm. Install check (36) and spring (37) to cover (19) and tighten cap (38) (hex hole size) to cover (19) with torque of 137 Nm.
Page 344: Start-Up Procedures
START-UP PROCEDURES HYDRAULIC OIL Recommended hydraulic oil is listed in the Operation and Maintenance Manual. PRELIMINARY OPERATION Make sure that all hoses and pipes are flushed and free of contamination. Check all fittings and connections in the circuit to be sure that they are properly tighten and connected. Bleed air from motor case, when filling case with hydraulic oil.
Page 345 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. TRAVEL MOTOR (WITH GEARBOX)S0707315K MODEL SERIAL NUMBER RANGE Solar 290LC-V ------------------ Solar 300LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Travel Motor (with Gearbox) S0707315K Page 1...
Page 346 TABLE OF CONTENTS General Description..................4 Theory of Operation ................5 Hydraulic Motor................5 Reduction Gear................9 Parts List ....................12 Hydraulic Motor................12 Reduction Gear................14 Specifications ..................15 Special Tools and Materials................16 Special Tools ..................16 Reduction Gear Part ..............19 Hydraulic Motor Part ..............
Page 347 Changing Standard of Hydraulic Motor Part ......... 35 Parts Inspection and Inspection Standard of Reduction Gear ..37 Reassembly....................38 General Caution Matters ............... 38 Motor Part ..................... 38 Reassembling of Drive Shaft Subassembly ........38 Reassembling of Valve Casing Subassembly ........ 38 Reassembling of Cylinder Subassembly........
Page 348: General Description
GENERAL DESCRIPTION Travelling device consists of a hydraulic motor and reduction gear. Hydraulic motor is comprised of the following five items. • Rotary group - generating rotating force • Cross over relief valve • Negative brake • Counter balance valve •...
Page 349: 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 11 for indication numbers). The internal design allows the high pressure oil to flow to one side of the center line "Y-Y"...
Page 350 Operation of relief valve Relief valve performs the following two functions. When the hydraulic motor is operated, the relief valve maintains pressure and passes the surplus oil of motor inlet port to the outlet port in relationship to acceleration of inertial force. When inertial force has stopped, brake pressure can be generated to outlet port, so that equipment can be forced to stop.
Page 351 Counter balance valve Av port is connected to the hydraulic pump, and Bv port is connected to the hydraulic oil tank. Oil supplied from pump flows to Av, to Cv and to C', presses and opens poppet of check valve, flows to L and to Am, and is supplied to hydraulic motor.
Page 352 Operation of tilting part Capacity of travelling motor varies with the change of swash plate (201) tilting angle. The tilt angle is controlled by tilting valve. NOTE: The smaller the tilt angle is, the faster the motor will rotate, while creating less torque. NOTE: The larger the tilt angle is, the slower the motor will rotate, while creating more torque.
Page 353 External pilot pressure: Pi ≥ 20 kg/cm (284 psi) (Small tilt angle) If pilot pressure acts on tilting valve, the force acting to spool (531) is greater than the swash spring (533). This forces the swash spool (531) to move to the left. High pressure oil flows through port Sa and Sc of tilting valve and passages, and acts on swash piston (502) until swash piston (501) is stopped by stopper (514).
Page 354 • Planetary gear (P1, P2) revolves by turning of carrier (C). Torque is transmitted by turning gear R1 because gear P1 and P2 are coaxial and the gear ratios between P1 and R2, P1 and P2 are properly different. Input Shaft •...
Page 355 Travel Motor (with Gearbox) S0707315K Page 11...
Page 356 PARTS LIST Hydraulic Motor ARS3960L Figure 11 S0707315K Travel Motor (with Gearbox) Page 12...
Page 357 Reference Reference Description Description Number Number Shaft HP Plug Roller Bearing O-ring Needle Bearing O-ring Spacer - Bearing O-ring Stop Ring Oil Seal Stop Ring Swash Piston Cylinder Block Swash Piston Spring Cylinder Stopper (Left) Spacer O-ring Piston and Shoe Assembly Swash Rod Bush and Push Plate Assembly Lock Screw...
Page 358 Reduction Gear ARS3970L Figure 12 S0707315K Travel Motor (with Gearbox) Page 14...
Page 359 Reference Reference Description Description Number Number Housing Spacer Cover Thrust Needle Bearing Ring Gear No. 1 Angular Bearing Ring Gear No. 2 Floating Seal Coupling Gear Needle Roller Cluster Gear Snap Ring Sun Gear Hex. Socket Head Bolt Coupling Hex. Bolt Carrier Plug Thrust Bearing...
Page 360 SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS JIG 1 JIG 2 JIG 3 JIG 4 JIG 5 JIG 6 ARS3990L Figure 13 S0707315K Travel Motor (with Gearbox) Page 16...
Page 361 JIG 7 JIG 8 JIG 9 JIG 10 JIG 11 JIG 12 ARS4000L Figure 14 Travel Motor (with Gearbox) S0707315K Page 17...
Page 362 JIG 14 JIG 13 JIG 15 JIG 16 JIG 17 JIG 18 JIG 19 & 20 ARS4010L Figure 15 S0707315K Travel Motor (with Gearbox) Page 18...
Page 363 Tools Applicable Parts Tools Applicable Parts JIG 1 Angular Ball Bearing (18) JIG 11 Thrust Bearing (10), Shim (15) JIG 2 Shim (15) JIG 12 Cover (2), Ring Gear No.1 (3) JIG 3 JIG 13 Shim (15) JIG 4 Carrier Sub Assembly JIG 14 Floating Seal (19) JIG 5...
Page 364 Etc. Air pressure 6 kg/cm (85 psi) Oil bath Heating temperature: over 120°C Vacuum cleaner S0707315K Travel Motor (with Gearbox) Page 20...
Page 365 Hydraulic Motor Part Tool name B Dimension Applying part name Hex L- wrench 4 mm Plug (461), Orifice, Screw (545, 546) 8 mm Hex Socket Bolt (367), Plug (571) 10 mm Hex Socket Bolt (368) 14 mm Hex Socket Bolt (401, 402) Socket wrench spanner 19 mm Hp Plug (567)
Page 366 Tightening Torque Chart Tightening torque Section Name Standard kg•cm Relief valve 36 mm 1,700 - 1, 900 Plug NPTF 1/16 4 mm 70 - 110 HP Plug PF 1/2 27 mm 1,100 Plug PF 3/8 8 mm HP Plug PF 1/4 19 mm Hydraulic motor part...
Page 367: Inspection Method Of Abnormality Of Hydraulic Motor
TROUBLESHOOTING, TESTING AND ADJUSTMENT HYDRAULIC MOTOR General Caution Matters Before working, carefully judge the abnormal condition and be that there are not other causes besides the motor. As the causes of wear have lots of cases with mixing of foreign materials, when disassembling, be careful not to mix foreign materials.
Page 368 Problem Possible Cause Remedy Rated swing speed is not reached. Swing speed low Quantity of inflow oil low Check hydraulic circuit to motor. Oil temperature too high Lower oil temperature. Excessively large abnormal oil leaks Replace or repair abnormal parts. Each sliding surface worn or damaged Replace or repair abnormal parts.
Page 369 Problem Possible Cause Remedy Piston and shoe Excessive load swing of motor Check relief valve operation. Temperature increasing Check circuit. Shoe and swash plate Roughness of sliding surfaces poor Replace or repair abnormal parts. Piston and cylinder Hydraulic oil and lubricating poor Replace hydraulic oil.
Page 370: Disassembly
DISASSEMBLY GENERAL CAUTION MATTERS Select clean disassembling place. Place a rubber pad on the work bench to prevent parts from being damaged. Clean dirt and foreign materials from reduction gear and motor. Be careful not to damage the contact surface of O-ring, oil seal, and seal class and the contact or sliding surface of gear, pin, and bearing class.
Page 371 Remove carrier subassembly from housing (1) using jig (18) or eye bolt (M10x1.5) and rope, and put and align hole of jig (3) and shaft (11). Figure 19 Remove calking mark of carrier (9) and pull pin (12) using a pulling tap (M6x1). Tap and drop shaft (11) under jig (3) by using copper hammer.
Page 372 Using jig (12), remove ring gear No. 1 (3) from housing (1). 10. Remove socket head bolt (22) by using wrench (size B17). 11. Remove coupling gear subassembly from shaft casing using bolts M10x1.5x70) and pulling tap of coupling gear (5). Figure 23 12.
Page 373 15. Remove housing (1) from shaft casing, using eye bolts (3 ea. M10x1.5), rope and crane and place it with the mating surface of ring gear No. 1 (3) facing ground. Figure 27 16. Pull out floating seal (19) from housing by using drive and separate O-ring and seal.
Page 374 Remove hex socket bolts (401, 402) from shaft casing. Remove valve plate (131) from valve casing. Remove O-ring and orifice screw (545) and (546). (546, 2ea ∅ 1.5) (546, 1ea NOTE: ∅ 0.8) Figure 31 Remove brake spring (705). NOTE: (Spring, 10ea) (Hole, 11ea) Figure 32 Remove brake piston (702) from shaft...
Page 375: Disassembly Of Cylinder Subassembly
11. Remove swash assembly (201). Figure 35 12. Remove stopper (503) and swash piston (502). 13. Remove swash piston (501). 14. Using snap ring pliers remove lock ring (435). Figure 36 15. Remove drive shaft subassembly. NOTE: Lightly remove cylindrical roller and outer race of bearing (102) by using copper bar and plastic hammer.
Page 376: Disassembly Of Valve Casing
Remove friction plate (742) and separate plate (741) from cylinder. Figure 39 Remove cylinder spring (114), spacer (116) and spherical bush (122) from cylinder block (111). Figure 40 Disassembly of Valve Casing Remove drain HP plug (464) with O-ring (485). Remove O-ring (472) from valve casing.
Page 377: Disassembling Of Drive Shaft Subassembly
Remove spring (384), O-ring (485) and backup ring (383) from stopper (382). Remove plunger (381) from valve casing. Figure 43 Remove CB valve spool (361), damping check assembly (364) and spring (362). Remove left and right orifice screws (363) from CB valve spool (361). 10.
Page 378: 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 the following table. If parts have damages of external appearance, change without the following table. S0707315K Travel Motor (with Gearbox) Page 34...
Page 379: Changing Standard Of Hydraulic Motor Part
Changing Standard of Hydraulic Motor Part Recommend Standard Parts name and inspection item ed value of Remedy dimension replacement Clearance between piston and cylinder bore 0.035 0.06 Vertical direction vibration of piston and 0.05 Replace shoe Shoe thickness Height difference between spherical bush 13.5 Replace with set and pressure plate...
Page 380 Clearance between piston and cylinder bore: D-d Figure 46 Thickness of shoe: t Figure 47 Vibration of vertical direction of piston and shoe: δ Figure 48 Height difference of spherical bush and pressure plate: H-h Figure 49 S0707315K Travel Motor (with Gearbox) Page 36...
Page 381: Parts Inspection And Inspection Standard Of Reduction Gear
Parts Inspection and Inspection Standard of Reduction Gear This reduction gear has few parts and designing life of each part is about the same. And so a state of single part can be supplied, but when changing there are many parts to change simultaneously for structure and function.
Page 382: Reassembly
REASSEMBLY GENERAL CAUTION MATTERS After cleaning each part, blow dry with moisture free air. DO NOT clean friction plates with cleaning oil or solvent. When fastening each part, use the torque value. Surely use plastic hammer. MOTOR PART Reassembling of Drive Shaft Subassembly Install bearing spacer (106) on drive shaft (101).
Page 383 Install needle bearing (103). NOTE: Use plastic hammer and copper bar. Figure 52 Install seat (541), ball (543), stopper (542) and HP plug (567) with O-ring (568) according to the order. NOTE: Be careful of installing order direction seat stopper. NOTE: Tightening torque: 370 kg•cm (27 ft lb)
Page 384: Reassembling Of Cylinder Subassembly
Insert plunger (381) to valve casing and install spring (384), O-ring (485), stopper (382) with backup ring (383). NOTE: Be careful of order of O-ring and backup ring. Figure 55 Tighten cap R (366) and cap L (365) by means of hex socket bolts (367, 368). NOTE: When installing, cap R and L should not be changed.
Page 385: Reassembling Of Motor
Install friction plate (742) and separate plate (741) on cylinder. Figure 59 After inserting piston shoe (121) on pressure plate (122), install it on cylinder. Figure 60 Reassembling of Motor Tighten four plugs (461) to shaft casing (272) to proper torque. NOTE: After winding seal tape and applying Loctite to plug, install...
Page 386 Install oil seal (491). NOTE: Be careful not to damage lip when using assembling jig. Install lock ring (435). NOTE: Install snap ring (435) with rounded surface facing bearing side. Install swash piston (501). Figure 62 Install swash assembly (201). NOTE: Apply grease to sliding surface of swash plate.
Page 387 13. Install brake piston (702) on shaft casing (272). NOTE: Be careful of installing direction of brake piston. Figure 66 14. Install brake spring (705). NOTE: Quantity: Spring (10ea), Hole (11ea). NOTE: Do not install at highest top portion of brake piston. 15.
Page 388: Reassembling Of Angular Ball Bearing (18) Of Housing (1) Part
17. Tighten relief valve (350) to proper torque. Tightening torque: 1,800 ± 100 NOTE: kg•cm (130 ±7 ft lb) 18. Install stop ring (108) to shaft by using pliers. NOTE: Be careful of direction of stop ring. (Round direction bearing side.) Figure 69 REDUCTION GEAR Reassembling of Angular Ball Bearing (18) of Housing (1) Part...
Page 389 Selection Method of Shim (15) Thickness Depth micrometer Position coupling gear (5) on working stand like figure measure Jig2 dimension "A" by using jig (2) or jig (11). or Jig11 Calculate "T1." • T1= A - B Coupling gear ARS4360L Figure 71 Position housing on jig (13) like figure (3) Depth micrometer...
Page 390: Reassembling Of Floating Seal (19)
Reassembling of Floating Seal (19) Position shaft casing (25), of which mating part against housing (1) facing upward, on jig (16) by using two eye bolts and crane and fasten with two M20 bolts. O-ring Floating seal Apply grease lightly to O-ring of floating seal (19).
Page 391: Reassembling Of Coupling Gear Subassembly And Housing Subassembly
Reassembling of Coupling Gear (5) and Ring Gear No.2 (4) Snap ring Position ring gear No.2 (4) on working stand as shown in Figure 76. Install coupling gear (5) from upper side. Install snap ring (21) in groove of ring gear No.2 (4).
Page 392: Decision Of Cluster Gear (6) Phase
NOTE: Pay attention to the 25 needle roller bearing. After moving horizontally the whole except jig (4) in cluster subassembly to carrier (9), make jig (5) be inserted to hole of carrier (9). Place on thrust bearing subassembly cluster gear (6). Check alignment of pin (12) hole of shaft (11) and pin (12) hole of carrier (9).
Page 393: Selection Of Thrust Bearing (10) Thickness
Reassembly of Housing (1) and Ring Gear No.1 (3) Insert thrust bearing (10) T = 5.5 to shaft casing (25). Lightly apply grease to spline part of coupling (8). Insert coupling (8) on hydraulic motor shaft. Insert sun gear (7) on spline part of coupling (8). Take carrier subassembly down slowly by using M10 eye bolts and crane, making ring gear No.2 (4) align with tooth.
Page 394 NOTE: If the difference of (I) among four points over 0.3, reassembly carrier subassembly is wrong or there interference bottom Cover surface of carrier. Take out carrier subassembly and check whether there is interference. Calculate (T4). • T4 = I - G Calculate (T5).
Page 395: Installation
INSTALLATION CHECK Check the following items before installation and correct any defects. Checking Items Managing Matters Is there any damage from transporting? Report to Q/C Department. Are there any loose bolts? Tighten rated torque. (Refer to “Tightening Torque Chart” on page -22) Is gear oil filled with proper quantity? Refer to “Oil Filling”...
Page 396: Gear Oil
GEAR OIL Kinds of Oil Use GL-4 GRADE of service grouping API of SAE #90 equivalent. Do not mix oil of other types. Oil Drain Turn motor to position oil drain port to low side, then drain oil. (If level plug is loosened, the oil will drain faster.) Oil Filling Set LEVEL mark on cover horizontally, then fill 4.3 liters of oil.
Page 397 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MAIN PUMP (KAWASAKI)S0708315K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Main Pump (Kawasaki) S0708315K...
Page 398 TABLE OF CONTENTS Swash Plate Type K5V Series Axial Piston Pump.......... 4 Type Designation..................4 Specifications ..................5 Construction and Function ..............6 Construction..................6 Function ................... 6 Cautions for Operation ................8 Installation..................8 Cautions for Piping................8 Cautions for Filters ................9 Working Oil and Temperature Range..........
Page 399 Regulator for K5V, K3V Series of Kawasaki Swash Plate Type Axial Piston Pump............27 Type Description..................27 Construction of Regulator ..............28 Outline....................30 Horsepower Control ............... 30 Flow Control................... 31 Specifications ..................31 Functional Explanations ................ 32 Regulator Function Diagram ............32 Negative Flow Control..............
Page 400: Swash Plate Type K5V Series Axial Piston Pump
SWASH PLATE TYPE K5V SERIES AXIAL PISTON PUMP TYPE DESIGNATION K 5 V 1 4 0 D T - 1 C 9 R - 9 N 0 1 Regulator type: For more details, see the instruction manual for the regulator. Shaft rotation viewed from shaft end.
Page 401: Specifications
SPECIFICATIONS Item Specification Size Displacement 140 cm / rev Rated 34.3 MPa (350 kg/cm Pressure Max. 37.7 MPa (385 kg/cm Max. * 2,500 min Speed Max. for self-priming * 2,150 min Single Weight Double 130 kg Type Mineral working oil Oil temp range -20 ~ +95 °C Working Oil...
Page 402: Construction And Function
CONSTRUCTION AND FUNCTION Construction This pump assembly consists of two pumps connected by a splined coupling (114). The two pumps can be driven simultaneously as the rotation of the prime mover (engine) is transferred by the drive shaft (F) (111) on the front side.
Page 403 Valve Block Group The valve block group consists of valve block (312), valve plate (313) and valve plate pin (885). The valve plate has two melon-shaped ports, that are mated to the valve block. These feed and collect oil to and from the cylinder block.
Page 404: Cautions For Operation
CAUTIONS FOR OPERATION Installation Applied Item Caution Type Installed direction. Install pump with drive shaft horizontal in general. All types. External load to Apply neither radial nor thrust load externally to the pump shaft All types. shaft end. end. Removal of rust Since the shaft end splined section has been coated with rust All types.
Page 405: Cautions For Filters
Cautions for Filters The most important factor to prevent the pumps and other components from being damaged and to lengthen their life-spans is control of contamination in the hydraulic oil. A filter of 10µm must be provided in the circuit. Applied Item Caution...
Page 406: Working Oil And Temperature Range
Working Oil and Temperature Range Applied Item Caution Type Kind of oil. Use general-use working oil that has an antifoaming additive, All types. antioxidant, anticorrosive, sec. and has a high viscosity index. Optimum viscosity For the open circuit, the recommended working viscosity range All types.
Page 407: Oil Filling And Air Venting
Oil filling and Air Venting Applied Item Caution Type Oil filling. Fill the pump casing with oil. Inside the pump there are high- All types. speed sliding and moving parts, such as bearings, pistons/ shoes, retainer, etc. If not filled with oil, these parts may suffer some serious problems, such as seizures damage.
Page 408: Overload Of Prime Mover
Check the pump for abnormal noises and vibrations. If any, investigate if it is a noise in the regular frequency, such as hunting of the regulator or the relief valve of an accessory valve, or not. If it is an abnormal vibration or noise, it may be the result of cavitation or damage inside the pump.
Page 409: Abnormal Noises And Abnormal Vibrations
Abnormal Noises and Abnormal Vibrations Cause Countermeasure Remark Cavitation Prevention from cavitation. Check Low boost press. working oil for emulsion. Failure of the associated pump. Air leakage at the suction pipe. Increased suction resistance. Damage in the caulking suction Replace the piston shoe, plate, of the shoe.
Page 410: Construction Of Tandem Type Duplex Pump
CONSTRUCTION OF TANDEM TYPE DUPLEX PUMP Tightening Torque Flange Socket (4-M6x1.0) 6.9 Nm (70kgf.cm) Valve plate for c.clockwise rotation Valve plate for clockwise rotation Apply adhesive (No 1305N of Threebond make) 774 824 127 710 123 251 490 806 953 886 717 406 261 111 Apply (Sealup L101) to the all sealsurface circumferential...
Page 411 Reference Reference Description Description Number Number Gear Pump VP Plug Drive Shaft (F) VP Plug Drive Shaft (R) Tilting Pin Spline Coupling Servo Piston 1st Gear (for DTP) Stopper (L) Roller Bearing Stopper (S) Needle Bearing Feed Back Pin Bearing Spacer O-ring Cylinder Block O-ring...
Page 412: Tools
TOOLS The tools necessary to disassemble / reassemble the K3V pump are shown in the following list. The size of the bolts and plugs depend on the type of pump. Necessary Tool (Marked with O) Tool Name And Size Part Name Pump Type Hexagon Hexagon...
Page 413 Necessary Tool Tool Name and Size Part Name (Marked with O) Hexagon VP plug (PF Name K5V80 K5V140 Hexagon nut headed bolt thread) Double ring spanner, VP-1/4 Socket wrench, Double VP-3/8 (single) open spanner. VP-1/2 VP-3/4 VP-1 VP-1 VP-1 Adjustable angle Medium size, 1 set wrench...
Page 414: Axial Piston Pump Disassembling
AXIAL PISTON PUMP DISASSEMBLING For disassembling the pump, read this section thoroughly and disassemble it in the following sequence. The figures in parentheses after part names show the items in “Construction of Tandem Type Duplex Pump” on page 14. This maintenance manual describes the disassembling procedures for both a single pump and tandem type double-pump.
Page 415 Place pump horizontally on workbench with its regulator mounting surface facing down. Separate pump casing (271) from valve block (312). IMPORTANT Before laying this surface down, spread rubber mat on workbench to prevent this surface from being damaged. Figure 6 Pull cylinder (141) straight out of pump casing (271) over drive shaft (111).
Page 416 10. Lightly tap flange section of swash plate support (251) on the pump casing side. This will separate swash plate support from pump casing. Figure 9 11. Remove shoe plate (211) and swash plate (212) from pump casing (271). Figure 10 12.
Page 417 14. If necessary, remove stopper (L) (534), stopper (S) (535), servo piston (532) and tilting pin (531) from pump casing (271). Remove needle bearing (124) and splined coupling (114) from valve block (312). IMPORTANT When removing tilting pin, use a protector to prevent pin head from being damaged. Since Loctite is applied to mounting areas of tilting pin and servo piston, do not damage servo piston.
Page 418: Axial Piston Pump Reassembling
AXIAL PISTON PUMP REASSEMBLING For reassembling reverse the disassembling procedures, paying attention to the following items. • Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance. • Clean each part with cleaning oil and dry it with compressed air. •...
Page 419 On swash plate support (251), install drive shaft (111) with bearing (123), bearing spacer (!27) and snap ring (824). IMPORTANT Do not tap drive shaft with hammer. Assemble them into support, lightly tapping outer race of bearing with plastic hammer. Fully seat them, using steel bar.
Page 420 Install valve plate (313) on valve block (312), entering pin in to pin hole. IMPORTANT Do not mistake suction / delivery directions of valve plate. Figure 18 Install valve block (312) on pump casing (271) and tighten hexagon socket head bolts (401).
Page 421: Axial Pump Maintenance Criteria
AXIAL PUMP MAINTENANCE CRITERIA Worn Part Replacement Criteria When a part exceeds any of the following criteria, replace or readjust it. However, when a part is seriously damaged in appearance, replace it. Pump Type K3V63/K5V80 K5V140 Part Name and Inspection Item Countermeasures Standard Dimension / Recommended Replacement...
Page 422 TIGHTENING TORQUES Tightening Part Name Size Tool Name Torque Hexagon socket 70 kg•cm head bolt 120 kg•cm (Material: SCM 300 kg•cm 435) M 10 580 kg•cm M 12 1,000 kg•cm B=10 M 14 1,600 kg•cm B=12 M 16 2,400 kg•cm B=14 Allen wrench M 18...
Page 423: Regulator For K5V, K3V Series Of Kawasaki Swash Plate Type Axial Piston Pump
REGULATOR FOR K5V, K3V SERIES OF KAWASAKI SWASH PLATE TYPE AXIAL PISTON PUMP TYPE DESCRIPTION K R 3 G - 9 N 0 1 Regulator Design Series Number Kind of flow control O : Without flow control N : Negative flow control P : Positive flow control M : Manual flow control E : electric flow control...
Page 424: Construction Of Regulator
CONSTRUCTION OF REGULATOR Figure 22 S0708315K Main Pump (Kawasaki) Page 28...
Page 425 Reference Reference Description Description Number Number Hexagon Socket Head Screw Spool Hexagon Socket Head Screw Spring Seat Hexagon Socket Head Screw Return Spring Hexagon Socket Head Screw Set Spring Plug Block Cover Tilting Pin O-ring Feedback Pin O-ring Casing O-ring Feedback Lever O-ring Lever (1)
Page 426: Outline
OUTLINE The regulator for the K3V Series Kawasaki in-line type axial piston pump has various models to satisfy various kinds of specifications required. Therefore, the customer can select the appropriate model to its intended application. Horsepower Control Code Control Type Control Curve Function and Features According to the rise of delivery pressure...
Page 427: Flow Control
Flow Control Code Control Type Control Curve Function and Features With the manual control, the outlet flow Manual flow control can be freely controlled. Lever stroke Positive flow control can be carried out by Positive flow control using the pilot pressure. Pilot pressure Negative flow control can be carried out Negative flow control...
Page 428 FUNCTIONAL EXPLANATIONS The regulator for Kawasaki in-line axial piston pump K3V Series consists of the following control functions. Negative flow control Total cumulative horsepower control Variable horsepower control Regulator Function Diagram Figure 23 S0708315K Main Pump (Kawasaki) Page 32...
Page 429 Negative Flow Control By changing the pilot pressure Pi, the pump tilting angle (delivery flow) regulated arbitrarily, as shown in Figure 24. This regulator is a negative flow control in which the delivery flow Q decreases as the pilot pressure Pi rises. With this mechanism, when the pilot pressure corresponding to the flow required for the work is commanded, the pump discharges the required flow only, so it does not...
Page 430 Adjustment of flow control characteristic The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hexagon nut (801) and by tightening (or loosening) the hexagonal socket head screw (924). Tightening the screw shifts the control chart to the right as shown in the Figure NOTE: Adjusting values are shown in...
Page 431 the servo piston move to the right, reduces the pump delivery flow rate, and prevents the prime mover from being overloaded. The movement of the servo piston is transmitted to the feedback lever via point D. Then the feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The spool moves till the opening between the spool and sleeve (651) is closed.
Page 432: Variable Horsepower Control
Adjustment of inner spring Adjust it by loosening the hexagon nut (801) and by tightening (or loosening) the adjusting screw Cl (925). Tightening screw increases the flow and then the input horsepower as shown in the Figure Figure 28 Variable Horsepower Control The set horsepower valve is shifted by varying the command current level of the proportional pressure reducing valve attached to the pump.
Page 433: Adjustment Of Maximum And Minimum Flows
ADJUSTMENT OF MAXIMUM AND MINIMUM FLOWS The regulator can adjust the maximum and minimum flows with the adjusting screws. NOTE: Their respective adjustment values are shown in the attached Table. See “Summary of Regulator Adjustment Values” on page -38. Adjustment of Maximum Flow Adjust it by loosening the hexagon nut (809) and by tightening (or loosening) the set screw (954).
Page 434: Summary Of Regulator Adjustment Values
Summary of Regulator Adjustment Values Item Specification Speed 2200 min Adjustment of Maximum Flow Tightening amount of adjusting screw +1/4 Turn (954) Flow change amount -3.5 L/min Adjustment of Minimum Flow Tightening amount of adjusting screw +1/4 Turn (953) Flow change amount +3.5 L/min Adjustment of Input Adjustment of...
Page 435: Maximum Flow Is Not Available
Maximum Flow Is Not Available Check that the pilot pressure Pi is normal. The pilot piston (643) is stuck: • Disassemble and clean the regulator. The spool (652) is stuck: • Disassemble and clean the regulator. The piston QMC stopper (647) and piston (648) are stuck with each other: •...
Page 436: Preparation For Disassembly
PREPARATION FOR DISASSEMBLY Since the regulator consists of small precision-finished parts, disassembly and assembly are rather complicated. For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly.
Page 437: Regulator Disassembly
REGULATOR DISASSEMBLY Choose a place for disassembly. CAUTION! 1. Choose a clean place. 2. Spread rubber mat or cloth, on top of work-bench to prevent parts from being damaged. Remove dust, rust, etc. from surfaces of regulator with cleaning oil. Remove hexagon socket head screws (412,413) and regulator main body from pump main body.
Page 438 Remove hexagon socket head screws (436, 438) and pilot cover (641). After removing pilot cover, remove set spring (655) from pilot section. Figure 35 Remove snap ring (814), spring seat (653), return spring (654) and sleeve (651). IMPORTANT Sleeve (651) is attached with snap ring (836).
Page 439 Remove lever (2) (613). Do not draw out pin (875). IMPORTANT Work will be promoted by using pincers. Figure 39 10. Draw out pin (874) and remove feedback lever (611). Figure 40 IMPORTANT Push out pin (874) (4 mm in dia.) from above with slender steel bar so that it may not interfere with lever (1) (612).
Page 440: Regulator Reassembly
REGULATOR REASSEMBLY For assembly, reverse disassembly procedures, but pay attention to the following. • Always repair parts that were scored at disassembly. Get replacement parts ready beforehand. • Mixing of foreign material will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.
Page 441 Press fit pin in lever (2) (613) into groove of pilot piston. Then attach lever (2). Figure 44 Install fulcrum plug (614) so that pin pressed into fulcrum plug (614) can be inserted into pin hole of lever (2). Then attach locking ring (858).
Page 442 10. Install set spring (655) in spool hole. Slide compensating piston (621) and piston case (622) into compensating hole. 11. Install pilot cover (641) and secure it in place with hexagonal socket head screws (436 and 438). Figure 47 12. Insert spring seat (644), pilot spring (646) and adjusting ring (Q) (645) into pilot hole.
Page 443: Tightening Torque
TIGHTENING TORQUE Part Name Size Tightening Torque Tool Name Hexagon socket head 70 kg•cm B = 4 bolt (Material: SCM 120 kg•cm 435) 300 kg•cm M 10 580 kg•cm M 12 1,000 kg•cm M 14 1,600 kg•cm M 16 2,400 kg•cm Allen wrench M 18 3,400 kg•cm...
Page 444 S0708315K Main Pump (Kawasaki) Page 48...
Page 445 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...
Page 446 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 447 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 448 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 449: 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 450 Figure 1 S0709401K Main Control Valve (Kayaba) Page 6...
Page 451 Figure 2 Main Control Valve (Kayaba) S0709401K Page 7...
Page 452: 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 453 Main Control Valve (Kayaba) S0709401K Page 9...
Page 454: 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 455 Figure 4 Main Control Valve (Kayaba) S0709401K Page 11...
Page 456: 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 457 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 458: 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 459 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 460 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 461: 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 462 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 463 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 464: 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 465: 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 466: 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 467 Figure 16 Main Control Valve (Kayaba) S0709401K Page 23...
Page 468: 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 469: 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 470: Main Relief Valve
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 471: 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 472: 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 473: 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 474: Parts List
PARTS LIST 89,88 75 69 77,81 VIEW X ARS4580L Figure 32 S0709401K Main Control Valve (Kayaba) Page 30...
Page 475 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 476 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 477 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 478: Spool Assembly (2, Arm 2)
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 479: Spool Assembly (5, Travel)
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 480: Spool Assembly (15, Boom 2)
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 481 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 482: 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 483: 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 484: 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 485: 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 486: 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 487: 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 488: 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 489: 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 490: 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 491: 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 492: 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 493: 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 494: 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 495: 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 496: 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 497: Reassembly Procedure Of Control Valve Body
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 498: 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 499: 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 500 Figure 54 S0709401K Main Control Valve (Kayaba) Page 56...
Page 501: 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 502: 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 503 Use lifting and hoisting equipment capable of safely handling load. 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...
Page 504 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 505: 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 506: Parts List
PARTS LIST ARS2260L Figure 1 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 4...
Page 507: 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 508: 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 509 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 510 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 511: 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 512 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 513 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 514 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 515: 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 516: 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 517 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 518 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 519 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 520 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 521: 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 522: 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 523 Use lifting and hoisting equipment capable of safely handling load. 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...
Page 524 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 525: 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 526 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 527: 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 528: Parts List
PARTS LIST ARS1850L Figure 5 ARS1860L Figure 6 S0709820K Travel Control Valve (With Damper) Page 6...
Page 529: 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 530: 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 531: 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 532 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 533: 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 534 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 535 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 536 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 537 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 538 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 539: 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 540: 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 541 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 542 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 543 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 544 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 545: 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 546: 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 547 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. HYDRAULIC SCHEMATIC (S300LC-V)S0792160K MODEL SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Hydraulic Schematic (S300LC-V) S0792160K...
Page 548 TABLE OF CONTENTS General Description..................3 Solar 300LC-V....................4 S0792160K Hydraulic Schematic (S300LC-V) Page 2...
Page 549 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 (S300LC-V) S0792160K Page 3...
Page 550 SOLAR 300LC-V Pi1 of Pump Pi2 of Pump ARM2 ARM1 BOOM1 BOOM2 SWING TR(L) TR(R) VALVE(LEFT) VALVE(RIGHT) PH of Sol. v/v SWING MOTOR SH 500k 500k (FRONT) SENSOR SENSOR (REAR) 177u ENGINE SHUTTLE VALVE S1 Figure 2 S0792160K Hydraulic Schematic (S300LC-V)
Page 551 BUCKET BOOM L.TRAVEL R.TRAVEL LEFT RIGHT LEFT DUMP FORWARD FORWARD DUMP RIGHT CROWD BACKWARD BACKWARD DOWN CROWD pa6 pb1 (RH) To Front (LH) SOL. V/V P2 SHUTTLE VALVE S1 SOLAR 300LC-V Pi1 of pump Hydraulic Schematic (S300LC-V) S0792160K Page 5...
Page 552 S0792160K Hydraulic Schematic (S300LC-V) Page 6...
Page 553 1ELECTRICAL SYSTEM...
Page 555: Electrical System
Use lifting and hoisting equipment capable of safely handling load. 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...
Page 556 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 557 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 558: 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 559: 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 560: 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 561: 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 562 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 563: 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 564: 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 565 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 566 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 567: 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 568: 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 569: Instrument Panel
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 570: 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 571 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 572: Operation
OPERATION INSTRUMENTS Sensor Specification Function Display Input Input Specification Terminal 41°C (106°F) → 1,372 ohms GREEN 61°C (142°F) → 855 ohms Engine CN4-5 WHITE 102°C (216°F)→ 160 ohms 107°C Coolant CN4-6 105°C (221°F) → 147 Temperature 105°C ohms 107°C (225°F) → 128 61°C 41°C ohms...
Page 573 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 574 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 575 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 576: 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 577: 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 578: 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 579: 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 580: 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 581: 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 582: 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 583 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 584 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 585 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 586 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 587 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 588 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 589 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 590 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 591 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 592 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 593 • 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 594 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 595 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 596: 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 597 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 598: 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 599 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 600 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 601 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 602: 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 603 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 604: 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 605 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 606: 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 607: 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 608 S0802220K Electrical System Page 54...
Page 609: 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 610: 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 611 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 612: 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 613: 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 614: 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 615: 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 616: 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 617: 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 618: 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 619: 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 620 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 621 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 622: 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 623 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 624: 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 625: Wiper System
WIPER SYSTEM WIPER CIRCUIT ARS1200L Figure 67 Reference Reference Description Description Number Number Battery Washer Switch Battery Relay Wiper Timer Fuse Wiper Motor Wiper Switch Window Washer WIPER OPERATION Intermittent Operation (I - position) When the wiper switch (4) is turned "I" position, the current flows from the fuse (3) → "B" terminal of wiper motor (7) →...
Page 626: 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 627 Electrical System S0802220K Page 73...
Page 628: Lighting System
LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM (FR) (RR) (FML) (RL) (FMR) (FL) (FR) (FL) (RH) (LH) (RH) (LH) (RH) (LH) CN7-9 CN2-7 CN3-9 CN7-1 CN3-10 CN3-11 CN3-12 CN3-8 ARS1210L Figure 68 S0802220K Electrical System Page 74...
Page 629: 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 630: 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 631: Electrical Schematic (S300Lc-V)
Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. ELECTRICAL SCHEMATIC (S300LC-V)S0892160K MODEL SERIAL NUMBER RANGE Solar 300LC-V 0001 and Up Copyright 2002 Daewoo May 2002 Electrical Schematic (S300LC-V) S0892160K...
Page 632 TABLE OF CONTENTS General Description..................3 Solar 300LC-V....................4 S0892160K Electrical Schematic (S300LC-V) Page 2...
Page 633 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 (S300LC-V) S0892160K Page 3...
Page 634 SOLAR 300LC-V Figure 2 S0892160K Electrical Schematic (S300LC-V) Page 4...
Page 635 Model Solar 300LC-V Name ELECTRICAL DIAGRAM NO. 599-00035 DAEWOO HEAVY INDUSTRIES LTD. Electrical Schematic (S300LC-V) S0892160K Page 5...
Page 636 S0892160K Electrical Schematic (S300LC-V) Page 6...
Page 637 1ATTACHMENTS...
Page 639: 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 S0902000 MODEL SERIAL NUMBER RANGE Solar 290LC-V 0001 and Up Solar 300LC-V 1001 and Up Copyright 2002 Daewoo May 2002 Boom and Arm S0902000 Page 1...
Page 640 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 S0902000 Boom and Arm Page 2...
Page 641 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) 105 mm (4.134")
Page 642: 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 643 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 644: 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 645: 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 646 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. S0902000 Boom and Arm Page 8...
Page 647: Bucket
Use lifting and hoisting equipment capable of safely handling load. 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...
Page 648 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 649: 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 650 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 651 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 652: 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 653 Roll the new O-ring (1, Figure 9) into the O-ring groove. ARO1392L Figure 9 Bucket S0904005K Page 7...
Page 654: New Bucket Installation
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 655: 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 656: 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 657 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...

Daewoo Solar 300LC-V Manual

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