Daewoo Excavadora Varios

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1SAFETY
S0102000 R1
1TRACK EXCAVATOR SAFETY

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. 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.
TRACK EXCAVATOR SAFETYS0102000

MODEL Solar 130LC-V Solar 170LC-V Solar 220LC-V Solar 220N-V Solar 250LC-V Solar 290LC-V Solar 300LC-V Solar 300LL Solar 330LC-V Solar 340LC-V Solar 400LC-V Solar 420LC-V Solar 450LC-V Solar 470LC-V SERIAL NUMBER RANGE 0001 and Up 1001 and Up 0001 and Up 1001 and Up 1001 and Up 0001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up
Copyright 2001 Daewoo December 2001 Track Excavator Safety S0102000 Page 1
TABLE OF CONTENTS
To the Operator of a Daewoo Excavator ........................................................ 3 General Safety Essentials .............................................................................. 5 Location of Safety Labels ............................................................................... 5 Summary of Safety Precautions for Lifting in Digging Mode .......................... 6 Work-site Precautions .................................................................................... 7 Operation........................................................................................................ 9 Equipment .................................................................................................... 14 Maintenance................................................................................................. 18 Shipping and Transportation......................................................................... 21 Lifting With Sling........................................................................................... 21
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Track Excavator Safety
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. Please respect the importance of taking responsibility for your own safety, and that of other people who may be affected by your actions. The safety information on the following pages is organized into the following sections: 1. 2. 3. 4. 5. 6. 7. 8. General Safety Essentials on page 5 Location of Safety Labels on page 5 Summary of Safety Precautions for Lifting in Digging Mode on page 6 Work Site Precautions on page 7 Operation on page 9 Equipment on page 14 Maintenance on page 18 Shipping and Transportation on page 21
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SAFETY ALERT SYMBOL

Be Prepared - Get To Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures. LEARN THE SIGNAL WORDS USED WITH THE SAFETY ALERT SYMBOL The words "CAUTION," "WARNING" and "DANGER" used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears next to the "Exclamation Point" symbol.
CAUTION!
Indicates potential of a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice.
WARNING!
Indicates potential of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against a highly unsafe practice.
DANGER!
Indicates imminent hazard of a situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be used to alert against equipment that may explode or detonate if handled or treated carelessly.
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GENERAL SAFETY ESSENTIALS

ACCESSORY APPLICATIONS 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 conguration, to rated capacity only, with no side-loading. DO NOT use the machine for activities for which it was not intended. DO NOT use the bucket for lifting work, unless lift slings are used in the approved conguration. Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator. LIFTING CAPACITY RATING CONFIGURATION Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a rm supporting surface, with hooks and slings attached in approved conguration. Loads must be balanced and supported evenly. Use taglines to keep the load steady if wind conditions and large surface area are a problem. Work crew hand signals, individual tasks and safe procedures should all be universally understood before the lift is made.
IMPORTANT
Before using the excavator to make lifts check municipal and regional regulations or statutes that could apply. Governing ordinances may require that all heavy lifting be done with single purpose equipment specically designed for making lifts, or other local restrictions may apply. Making heavy lifts with a general purpose excavator that can be used for digging, loading, grading or other work may be expressly forbidden by a regional injunction or other legal prohibition. Always follow all of the other instructions, guidelines and restrictions for Safe Lifting in the Operation and Maintenance Manuals.
LOCATION OF SAFETY LABELS

Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and Maintenance Manual, and parts manual for your unit. Always replace damaged or faded decals.
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SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING IN DIGGING MODE DANGER!

Unsafe use of the excavator while making rated lifts could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property. Do not let anyone operate the machine unless theyve been properly trained and understand the information in the Operation and Maintenance Manual. To lift safely while in Digging Mode, the following items must be evaluated by the operator and the work site crew. Condition of ground support. Excavator conguration and attachments. Weight, lifting height and lifting radius. Safe rigging of the load. Proper handling of the suspended load.
Taglines on opposite sides of the load can be very helpful in keeping a suspended load secure, if they are anchored safely to control points on the ground.
WARNING!
NEVER wrap a tagline around your hands or body. NEVER rely on taglines or make rated lifts when wind gusts are more than 48.3 km/hr (30 mi/h). Be prepared for any type of wind gust when working with loads that have a large surface area. Always engage the "Digging Mode" control on the Instrument Panel before using the excavator for lifting work.
WARNING!
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 specic conditions of your individual operating environment, please consult your local Daewoo representative. UNAUTHORIZED MODIFICATIONS Any modication made without authorization or written approval from Daewoo can create a safety hazard, for which the machine owner must be held responsible. For safetys 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.
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WORK SITE PRECAUTIONS

ATTACHMENT PRECAUTIONS Options 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. 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. VOLTAGE 6.6 kV 33.0 kV 66.0 kV 154.0 kV 275.0 kV MINIMUM SAFE DISTANCE 3.0 m (9 10") 4.0 m (13 1") 5.0 m (16 5") 8.0 m (26 3") 10.0 m (32 10")
HAOA230L
Figure 1
Use these minimum distances as a guideline only. Depending upon the voltage in the line and atmospheric conditions, strong current shocks can occur with the boom or bucket as far away as 4 - 6 m (13 - 20 ft) from the power line. Very high voltage and rainy weather could further decrease that safety margin. NOTE:
Before starting any type of operation near power lines (either above ground or buried cable-type), you should always contact the power utility directly and work out a safety plan with them.
BEFORE STARTING TO DIG, CONTACT AUTHORITIES Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know whats underneath the work site before starting to dig. BE AWARE OF HEIGHT OBSTACLES Any type of object in the vicinity of the boom could represent a potential hazard, or cause the operator to react suddenly and cause an accident. Use a spotter or signal person working near bridges, phone lines, work site scaffolds, or other obstructions.
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Return to Master Table of Contents USE CARE ON LOOSE SUPPORT Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load conditions and possible tipover and injury. Travel without a load or balanced load may also be hazardous. If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground. Stay away from ditches, overhangs and all other weak support surfaces. Halt work and install support mats or blocking if work is required in an area of poor track support. USE SOLID SUPPORT BLOCKING Never rely on lift jacks or other inadequate supports when work is being done. Block tracks fore and aft to prevent any movement. OVERHANGS ARE DANGEROUS Digging the workface under an overhang - the work area beneath a cliff or under the edge of a ditch - is dangerous. Know the height and reach limits of the excavator and plan ahead while working. Avoid creating dangerous situations by moving around the work site while making excavations. Go onto another digging area before steep overhangs are formed. Working around deep pits or along high walls or trenching may require support blocks, especially after heavy rainfalls or during spring thaws. Park the excavator away from overhangs before work shut down. SLOPING TERRAIN REQUIRES CAUTION Dig evenly around the work site whenever possible, trying to gradually level any existing slope. If its not possible to level the area or avoid working on a slope, reducing the size and cycling rate of the workload is recommended. On sloping surfaces, use caution when positioning the excavator before starting a work cycle. Stay alert for instability situations to avoid getting into them. For example, you should always avoid working the bucket over downhill crawler tracks when parked perpendicular to the slope. Slow all downhill swing movements and avoid full extensions of the bucket in a downhill direction. Lifting the bucket too high, too close to the machine, while the excavator is turned uphill can also be hazardous.
HAOA210L
Figure 2
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Return to Master Table of Contents STAY ALERT FOR PEOPLE MOVING THROUGH THE WORK AREA When loading a truck you should always know where the driver is. Avoid loading over the cab of a truck even if the driver is in a safe spot. Someone else could have gone inside, for any number of reasons. Avoid working where unseen passersby might be. Slow down the work cycle and use slower travel speeds in congested or populated areas. Use a commonly understood signal so that other members of the work crew can warn the operator to slow or halt work in an impending hazard situation. BE AWARE OF AND CONFORM TO LOCAL REGULATIONS Minimum levels of insurance coverage, work permits or certication, physical barriers around the work site or restricted hours of operation may be mandated by governing authorities. There may also be guidelines, standards or restrictions on equipment that may be used to perform certain kinds of work. Check and follow all local requirements, which may also be related to below ground hazards and power lines.
HAOA170L
Figure 3
OPERATION
OPERATE WHILE SEATED AT THE OPERATORS STATION ONLY Never reach in through a window to work a control. Do not operate the excavator unless youre in the command position stay alert and focused on your work at all times but DO NOT twist out of the seat if job activity behind you (or to the side) requires your attention. Use a spotter or signal person if you cannot see clearly and something is happening behind you. Replace damaged safety labels and lost or damaged owners manuals. Do not let anyone operate the machine unless theyve been fully and completely trained, in safety and in the operation of the machine.
HAOA150L
Figure 4
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Return to Master Table of Contents BEFORE STARTING THE ENGINE Do a "pre-start" safety check: Walk around your machine before getting in the operators cab. Look for evidence of leaking uid, 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. Look around the work site area for potential hazards, or people or property that could be at risk while operation is in progress. NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a warning tag is attached to controls in the cab. A machine that has not been used recently, or is being operated in extremely cold temperatures, could require a warm-up or maintenance service before start-up. Check gauges and monitor displays for normal operation before starting the engine. Listen for unusual noises and remain alert for other potentially hazardous conditions at the start of the work cycle.
NEVER USE ETHER STARTING AIDS An electric-grid type manifold heater is used for cold starting. The glowing heater element can cause ether or other starting uid to detonate, causing injury.
Figure 5 MOUNTING AND DISMOUNTING NEVER get on or off a moving machine. Do not jump on/off. The entry/egress path should be clear of mud, oil and spills and mounting hardware must be kept tight and secure. Always use handholds, steps or track shoes and maintain at least 3-point contact of hands and feet. Never use controls as handholds. NEVER get up from the operators seat or leave the operators station and dismount the machine if the engine is running. Figure 6
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Return to Master Table of Contents OBSERVE GENERAL SAFETY RULES Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be allowed to operate or perform maintenance or service on the excavator. All personnel at the work site should be aware of assigned individual responsibilities and tasks. Communication and hand signals used should be understood by everyone.
Terrain and soil conditions at the work site, approaching trafc, weather-related hazards and any above or below ground obstacles or hazards should be observed and monitored by all work crew members. ENGINE VENTILATION Engine exhaust gases can cause fatal accidents, and unconsciousness, loss of alertness, judgement and motor control and serious injury. Make sure of 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. ASBESTOS DUST HAZARD PREVENTION
Figure 7
Asbestos dust can be HAZARDOUS to your health if it is inhaled.
,,, ,,,
HAOA070L
If you handle materials containing asbestos bers, follow these guidelines as given below: Never use compressed air for cleaning. Use water for cleaning to keep down the dust. Work on the machine or component with the wind at your back whenever possible. Use an approved respirator with proper ltration.
TAKE TIME TO PROVIDE GOOD VISIBILITY Halt work if visibility is poor. Strong rains, snow, fog and extremely dusty conditions can all obscure visibility so badly that it is best to wait for weather to change or dust to settle before continuing operation. Night work in areas of limited visibility should be halted if installation of extra work lights on the machine (or work area) is necessary. Keep dirt and dust off of windows and off the lens surfaces of work lights. Stop working if lights, windows or mirrors need cleaning or adjustment.
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Return to Master Table of Contents FUEL, OIL AND HYDRAULIC FLUID FIRE HAZARDS Add fuel, oil, antifreeze and hydraulic uid to the machine only in a well-ventilated area. The machine must be parked with controls, lights and switches turned off. The engine must be off and any ames, glowing embers, auxiliary heating units or spark-causing equipment must be doused, turned off and/or kept well clear of the machine. Static electricity can produce dangerous sparks at the fuel lling nozzle. In very cold, dry weather or other conditions that could produce static discharge, keep the tip of the fuel nozzle in constant contact with the neck of the fuel lling nozzle, to provide a ground. Keep fuel and other uid reservoir caps tight and do not start the engine until caps have been secured. BOOST STARTING OR CHARGING ENGINE BATTERIES Turn off all electrical equipment before connecting leads to the battery. This includes electrical switches on the battery charger or boost starting equipment. When boost-starting from another machine or vehicle do not allow the two machines to touch. Wear safety glasses or goggles while required parallel battery connections - positive to positive and negative to negative - are made.
HAOA120L
Figure 8
HAOA310L
24 volt battery units consisting of two seriesFigure 9 connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery. Booster or charger cable connections must be made between the non-series-connected positive terminals and between the negative terminal of the booster battery and the metal frame of the machine being boosted or charged. Refer to the procedure and illustration in Operation and Maintenance Manual. Connect positive cable rst when installing cables and disconnect the negative cable rst when removing them. The nal cable connection, at the metal frame of the machine being charged or boost-started, should be as far away from the batteries as possible. TRAVEL CONTROLS MAY PRODUCE REVERSED OPERATIONS Before starting the machine you should always check to see which end of the track frame is under the operators cab. In the normal travel conguration, track frame travel motors are at the rear of the machine, under the engine and counterweight. If the operator swings the cab 180, travel motors will be underneath the operators cab, toward the front of the track frame and operating travel will be reversed. When traveling the excavator always keep lights on; make sure that you are in compliance with all state and local regulations concerning warning ags and signs and keep the operators cab positioned over the
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Return to Master Table of Contents idler end of the track frame. That will keep travel controls in their intended conguration and at the same time, maintain the proper orientation of lights on the machine and posted ags and signs. KEEP "PINCH POINT" AREAS CLEAR - USE CAUTION IN REVERSE AND SWING Use a signal person in high trafc areas and whenever the operators view is not clear, such as when traveling in reverse. Make sure that no one comes inside the swing radius of the machine. Anyone standing near the track frames, or working assemblies of the attachment, is at risk of being caught between moving parts of the machine. Never allow anyone to ride on any part of the machine or attachment, including any part of the turntable or operators cab. TRAVEL PRECAUTIONS Attachment control levers should not be operated while traveling. Do not change selected travel mode (FAST/SLOW) while traveling. Fold in work equipment so that the outer end of the boom is as close to the machine as possible, and is 200 mm - 300 mm (8" - 12") above ground. Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope or obstacle that causes 10 degrees tilt, or more. OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES In icy cold weather avoid sudden travel movements and stay away from even very slight slopes. The machine could skid off to one side very easily. Snow accumulation could hide or obscure potential hazards. Use care while operating or while using the machine to clear snow. Warming up the engine for a short period may be necessary, to avoid operating with sluggish or reduced working capacity. The jolting shocks and impact loads caused by bumping or bottoming the boom or attachment are more likely to cause severe stress in very cold temperatures. Reducing work cycle rate and work load may be necessary. PARKING THE MACHINE Avoid making sudden stops, or parking the machine wherever it happens to be at the end of the work day. Plan ahead so that the excavator will be on a rm, level surface away from trafc and away from high walls, cliff edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable, block the crawler tracks to prevent movement. Lower the bucket or other working attachment completely to the ground, or to an overnight support saddle. There should be no possibility of unintended or accidental movement. Figure 10
HAOA190L
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Return to Master Table of Contents SHUTDOWN CONTROL FUNCTIONS After the machine has been lowered to the overnight storage position and all switches and operating controls are in the "OFF" position, the control stand lock lever must be engaged. Release the left console to disable all pilot circuit control functions. Insert the swing lock pin and engage all brakes and lock-down security equipment that may have been installed on the machine.
IMPORTANT
When hydraulic system maintenance or service work must be performed, you should be aware that an accumulator in the system stores uid under pressure after system lock down, even after the control stand is raised. Release this energy by working controls with the engine off, until pressure in the pilot circuit has been completely bled away.
EQUIPMENT
ROUGH OPERATION MAY REQUIRE USE OF CERTIFIED SAFETY EQUIPMENT Working in mines, tunnels, deep pits or on loose or wet surfaces could produce danger of falling rock or hazardous ying objects. Additional protection for the operators cab could be required in the form of a FOG / Falling Object Guard or windows guards.
HAOA110L
Figure 11 Any reinforcement system that is installed on the machine must pass safety and certication standards and carry appropriate labeling and rating information. For example, the most often added type of reinforcement system, FOG, must meet or exceed International Standard ISO10262, Laboratory Tests and Performance Requirements Earth-Moving Machinery. Never attempt to alter or modify any type of protective structure reinforcement system, by drilling holes, welding, remounting or relocating fasteners. Any serious impact or damage to the system requires a complete integrity reevaluation. Reinstallation, recertication and/ or replacement of the system may be necessary.
HAOA100L
Figure 12
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Return to Master Table of Contents INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE When working with a breaker or in some shear work applications, a front guard over the windshield may be required. The windshield guard may or may not be OPS/certied, depending upon the specic application and working situation. Laminate glass protection for the front, side or rear windows may also be recommended depending upon particular site conditions. Contact your Daewoo distributor for available safety guards and/or recommendations if there is any danger of getting hit by objects that could strike the operators cab. Make sure that all other work site crew members are kept well away from the excavator and safe from potential hazards. MOVEMENT ALARMS If the excavator is equipped with an audible travel movement alarm or visible swing movement alarm (strobe light), test the alarm on a daily basis. The audible alarm should sound as soon as the travel system is engaged. The strobe light should begin to ash as soon as the swing system is engaged. SEAT BELTS SHOULD BE USED AT ALL TIMES Whenever the engine is running, the operator should be seated at the control station with the seat belt properly engaged.
Figure 13 WINDOW GLASS BREAKING TOOL This excavator is equipped with a glass breaking tool. It is behind the operator seat in the upper right corner of the cab. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the operators cabin. Grip the handle rmly and use the sharp point to break the glass.
WARNING!
Figure 14 Protect your eyes when breaking the glass.
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Return to Master Table of Contents KEEP A FIRE EXTINGUISHER AT HAND It is recommended that an appropriately sized (2.27 kg [5 lb] or larger) multipurpose "A/B/C" re extinguisher be mounted in the cab. Check and service the re extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use. MAINTAIN STANDARD SAFETY EQUIPMENT IN GOOD CONDITION Machinery guards and body panel covers must be in place at all times. Keep well clear of rotating parts. Pinch point hazards such as cooling fan and alternator drive belts could catch hair, jewelry or oversize or very loose clothing.
HAOA080L
Figure 15
Safety labels must be replaced if they are damaged or become unreadable. The information on labels gives work crew members an important safety reminder exactly where it will do the most good. Part numbers for each label and required mounting locations are shown in Operation and Maintenance Manual. SAFETY-CRITICAL PARTS MUST BE REPLACED PERIODICALLY Replace the following re-related components as soon as they begin to show any sign of wear, or at regular periodic intervals, whether or not deterioration is visible: Fuel system exible hoses, the tank overow drain hose and the fuel ll cap. Hydraulic system hoses, especially the pump outlet lines and front and rear pump branch hoses. Keep mounting brackets and hose and cable routing straps tight. Hose routing should have gradual bends.
HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT Check cylinder drift rate at regular intervals. Maximum allowable rates are included in the in this manual. Overhaul seal kits are available through Daewoo. HIGH PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY Exposed hydraulic hoses on the arm or boom could react with explosive force if struck by a falling rock, overhead obstacle or other work site hazard. Extra safety guards may be required. NEVER allow hoses to be hit, bent or interfered with during operation. THE OPERATORS CAB AND TURNTABLE DECK SHOULD BE KEPT CLEAN Cleaning off accumulations of grease and dirt helps extend equipment service life. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result. Keep the cab oor and consoles free of tools and personal items.
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Return to Master Table of Contents WEAR EYE PROTECTION AND SAFETY CLOTHING Full eye protection, a hard hat, safety shoes and gloves may be required at the work site. While working on the machine, never use inadequate tools. They could break or slip, causing injury, or they may not adequately perform intended functions. BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED Dont forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries. BATTERY ELECTROLYTE AND EXPLOSIVE GASES CAN BE LETHAL Flush eyes with water for 10-15 minutes if acid is splashed in the face. Anyone who swallows acid must have immediate medical aid. Call the Poison Control listing in the front cover of the telephone directory. Water, a popsicle or ice cream are likely better than old remedies that try to induce vomiting (which would expose tissue to damage twice). Explosive battery gas can be set off by sparks from incidental contact or static discharge. Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.
HAOA440L
HAOA020L
Figure 16
Figure 17
DISCONNECT BATTERIES FOR ELECTRICAL SERVICE BEFORE ELECTRICAL WELDING Remove cable to negative terminal rst, when disconnecting cable. Connect positive terminal cables rst when installing a battery. USE LOW HEAT PORTABLE LIGHTING Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.
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MAINTENANCE
USE WARNING TAG CONTROL LOCKOUT PROCEDURES DURING SERVICE Alert others that service or maintenance is being performed and tag operators cab controls - and other machine areas if required - with a warning notice. OSHA-mandated control lever lockout can be made with any OSHA certied lockout device and a length of chain or cable to keep the left-hand control console in the fully raised, nonactive position. Warning tags for controls are available from Daewoo distributors. DO NOT RUN THE ENGINE IF REPAIRS OR WORK IS BEING PERFORMED ALONE 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 operators seat, ready to work the controls or stop the machine and shut off the engine. ALWAYS USE ADEQUATE EQUIPMENT SUPPORTS AND BLOCKING Do not allow weight or equipment loads to remain suspended. Lower everything to the ground before leaving the operators seat. Do not use hollow, cracked or unsteady, wobbling weight supports. Do not work under any equipment supported solely by a lift jack. DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS Wait for the engine to cool off after normal operation. Park the excavator on a rm, level surface and lower all equipment before shutting down and switching off controls. When engine lube oil, gearbox lubricant or other uids require change, wait for uid temperatures to decrease to a moderate level before removing drain plugs. NOTE:
WARNING
HAOC920L
Figure 18
Oil will drain more quickly and completely if it is warm. Do not drain uids at 95C (203F) temperatures but dont allow full cool-down.
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Return to Master Table of Contents COOL-DOWN IS REQUIRED PRIOR TO RADIATOR OR RESERVOIR CHECKS Stop the engine and allow heat to dissipate before performing service on the engine radiator or hydraulic uid reservoir. Both assemblies have air vent levers at or near the ll cap for venting built-up air pressure. Release the levers before trying to take off ll caps and LOOSEN CAPS SLOWLY, before removal. PRESSURIZED HYDRAULIC OIL FLUID LEAKS CAN BE DANGEROUS Fluid leaks from hydraulic hoses or pressurized components can be difcult to see but pressurized oil has enough force to pierce the skin and cause serious injury. Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands or expose your ngers.
HAOA060L
Figure 19
HAOA420L
Figure 20
OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES THE SKIN
WARNING!
Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue. USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE Refer to the "General Maintenance" section of this manual for information on tightening torques and recommended assembly compounds and always use the correct part. Poor or incorrect fastener connections can dangerously weaken assemblies.
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Return to Master Table of Contents DISPOSE OF ALL PETROLEUM-BASED OILS AND FLUIDS PROPERLY 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. Never drain any petroleumbased product on the ground or dispose of old oil in municipal waste collection containers, or in metropolitan sewer systems or rural landlls. Check state and local regulations for other requirements. Figure 21
HAOA470L
TRACK TENSION ADJUSTMENTS REQUIRE CAUTION NEVER turn out the track tension grease tting nut. To release pressure from the crawler frame track tension assembly, you should NEVER attempt to disassemble the track adjuster or attempt to remove the grease tting or valve assembly. Keep your face and body away from the valve. Refer to the track adjustment procedure in the Operation and Maintenance Manual or this manual.
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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. Partial disassembly or tear-down of the excavator may be necessary to meet travel restrictions or particular conditions at the work site. See this manual for information on partial disassembly. Refer to the Transportation and Shipping section of the Operation and Maintenance Manual for information on loading, unloading and towing.
LIFTING WITH SLING WARNING!

Improper lifting can allow load to shift and cause injury or damage. 1. Refer to Specication section of Operation and Maintenance Manual for information on weight and dimensions. Use properly rated cables and slings for lifting. Position machine for a level lift. Lifting cables should have a long enough length to prevent contact with the machine. Spreader bars may be required. NOTE:
2. 3. 4.
Figure 22
If spreader bars are used, be sure that cables are properly secured to them and that the angle of the cables is factored into the lift strength.
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1SPECIFICATIONS
S0202080K
1SPECIFICATIONS FOR SOLAR 300LC-V

CAUTION!
SPECIFICATIONS FOR SOLAR 300LC-V

MODEL Solar 300LC-V SERIAL NUMBER RANGE 1001 and Up
Copyright 2001 Daewoo November 2001 Specifications for Solar 300LC-V S0202080K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Component Locations .................................................................................... 4 General Dimensions....................................................................................... 6 Working Range............................................................................................... 8 General Specications ................................................................................. 10 Engine Performance Curves (Per Ks-r1004 Standard) ................................ 12 Approximate Weight Of Workload Materials................................................. 14 Performance Tests........................................................................................ 17 Excavator Performance Standards............................................................... 18 Test Conditions...................................................................................... 18 Travel Speed and Travel Motor Balance (Steering Deviation) Tests ...... 18 Cylinder Performance Tests .................................................................. 21
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Specifications for Solar 300LC-V
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 identies main components and their locations. (See Figure 1 on page -4.)
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COMPONENT LOCATIONS
35 12
11
10
13 34 29 33 30 15 16 17 32 31 28 27 18 19 14
26
25
24
23
22
21
20
ARO0980L
Figure 1
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
BATTERY FUEL TANK FILL CAP FUEL TANK HYDRAULIC OIL TANK PUMPS MUFFLER COUNTERWEIGHT ENGINE RADIATOR AND OIL COOLER AIR CLEANER CONTROL VALVES ARM CYLINDER BOOM BOOM CYLINDER CAB SEAT CENTER JOINT SWING MOTOR
19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
PRECLEANER TRAVEL MOTOR LOWER ROLLER UPPER ROLLER TRACK GUIDE TRACK ADJUSTER IDLER TRACK LINK AND SHOE TRAVEL LEVER WORK LEVER (JOYSTICK) CONTROLS TOOTH POINT SIDE CUTTER BUCKET PUSH LINK GUIDE LINK BUCKET CYLINDER ARM
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GENERAL DIMENSIONS
H I J B A C
O N M K L D E F
ARO1740L
Figure 2 DIMENSION 3.1 M (10.17 FT) ARM A B C D E F G H I J K L M N O 3,365 mm (11 0'') 7,420 mm (24 4'') 10,620 mm (34 10'') 6.245 M (20.5 FT) BOOM 2.5 M (8.2 FT) ARM 10,705 mm (35 1'') 3,200 mm (10 6'') 7,505 mm (24 7'') 4,010 mm (13 2'') 4,930 mm (16 2'') 1,175 mm (3 10'') 3,515 mm (11 6'') 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'') 3,930 mm (12 11'') 7,500 mm (24 7'') 3.75 M (12.3 FT) ARM 10,700 mm (35 1'')
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WORKING RANGE WARNING!

The actual value for dimension "L" Digging Reach, depends on the stability and support provided by ground conditions. 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.
L H J
2.5m (8.2 ft) ARM 3.1m (10.17 ft) ARM 3.75m (12.3 ft) ARM
G K I B A 8'
ARS1460L
Figure 3
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Boom Type Dim. Arm Type Bucket Type (PCSA) A B C D F G H I J K L M Max. Digging Reach Max. Digging Reach (Ground) Max. Digging Depth Max. Loading Height Max. Digging Height Max. Bucket Pin Height Max. Vertical Wall Max. Radius Vertical Max. Depth to 8 ft Line Min. Radius 8 ft Line Min. Digging Reach Min. Swing Radius 3.1 m (10.17 ft) 1.27 m3 (1.66 yd3) 10,735 mm (35' 3'') 10,540 mm (37' 7'') 7,330 mm (24' 1'') 7,286 mm (23' 11'') 10,345 mm (33' 11'') 8,890 mm (29' 2'') 6,145 mm (20' 2'') 6,820 mm (22' 5'') 7,150 mm (23' 5'') 3,005 mm (9' 10'') 575 mm (1' 11'') 4,055 mm (13' 4'')
One Piece 6.245 m (20.5 ft) 2.5 m (8.2 ft) 1.50 m3 (1.96 yd3) 10,155 mm (33' 4'') 9,950 mm (32' 8'') 6,725 mm (22' 1'') 6,960 mm (22' 10'') 9,985 mm (32' 9'') 8,565 mm (28' 1'') 5,370 mm (17' 7'') 6,865 mm (22' 6'') 6,505 mm (21' 4'') 2,965 mm (9' 9'') 1,970 mm (6' 6'') 4,107 mm (13' 6'')
3.75 m (12.3 ft) 1.75 m3 (2.29 yd3) 11,290 mm (37' 0'') 11,105 mm (36' 5'') 7,980 mm (26' 2'') 7,475 mm (24' 6'') 10,520 mm (34' 6'') 9,080 mm (29' 9'') 6,745 mm (22' 2'') 6,950 mm (22' 10'') 7,810 mm (25' 7'') 2,970 mm (9' 9'') - 80 mm (- 0' 9'') 4,010 mm (13' 2'')
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GENERAL SPECIFICATIONS
Shipping Weight 29.3 metric tons (64,600 lb), includes 10% fuel, boom, 3,100 mm (10 2") arm, 1,334 mm (4 5") backhoe bucket and standard shoes Add weight of full fuel tank and operator. Add 600 kg (1,320 lb) for 700 mm (28") shoes Add 1,000 kg (2,204 lb) for 800 mm (32") shoes Add 1,200 kg (4,408 lb) for 850 mm (34") shoes Standard Boom 2,330 kg (5,137 lb) 2,500 mm (8 2") Arm 900 kg (1,984 lb) 3,100 mm (10 2") Arm 1,050 kg (2,315 lb) 3,750 mm (12 4") Arm 1,060 kg (2,337 lb) Boom Cylinders 260 kg (573 lb) each Arm Cylinder 340 kg (750 lb) Bucket Cylinder 220 kg (485 lb) Counterweight 4,900 kg (10,800 lb) Upper Turntable 7,700 kg (16,975 lb) Lower - below Swing Bearing 11,050 kg (24,360 lb) 177 KN or 18,100 kg (39,900 lb) - (with either 3,100 mm [10 2"] or 2,500 mm [8 2"] arm) 131 KN or 13,400 kg (29,500 lb) with 3,100 mm (10 2") standard arm 450 liters (119 U.S. gal) 290 liters (77 U.S. gal) 160 liters (42 U.S. gal) PCSA 0.90 - 1.5 m3 (1.18 - 1.96 yd3) IMPORTANT: Refer to the Load Weight, Bucket and Arm Length Compatibility Table for information on which bucket sizes may be used safely with which arm length, for load material weights. Triple Grouser 600 mm (23.5") - standard 700 mm (28") - optional 800 mm (32") - optional 850 mm (34") - optional 910 mm (36") - special option (triangular) 0.57 kg/cm2 (8.1 psi) 0.50 kg/cm2 (7.1 psi) 0.44 kg/cm2 (6.2 psi)
Operating Weight Shipping Weights With Optional Track Shoes Major Component Weights
Digging Forces: Bucket Cylinder Arm Cylinder Fuel Tank Capacity Hydraulic System Capacity Hydraulic Reservoir Capacity Bucket Heaped Capacity Range
Shoe Type Shoe Width and Optional Sizes
Ground Pressure Ratings: Standard 600 mm (23.6") shoe Optional 700 mm (28.0") shoe Optional 800 mm (32.0") shoe -
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Optional 850 mm (34.0") shoe Optional 910 mm (36.0") shoe Transport Dimensions Overall Shipping Length (standard boom and arm) Overall Shipping Width (standard shoes) Overall Shipping Height (to top of cylinder hose) Track Shipping Length Transport Trailer Capacity Transport Loading Ramp Allowable Slope
0.42 kg/cm2 (6.0 psi) 0.39 kg/cm2 (5.5 psi)
10,620 mm (34 10'') 3,200 mm (10 6") 3,365 mm (11) 4,930 mm (16 2") 30 tons (33 short tons), minimum load capacity 15 angle CAUTION: Refer to Transport Maximum Procedure for Safe Shipping Instructions.
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ENGINE PERFORMANCE CURVES (PER KS-R1004 STANDARD)
90 70 TORQUE (kg.m)
ARS1470L
80
POWER OUTPUT (ps)
200
1 50
100 170 160 150 1000 1500 REVOLUTION (rpm) 2000
Figure 4
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FUEL CONSUMPTION (g/ps.h)
Condition Engine Model Barometic Pressure Cooling Fan Alternator Air Cleaner Mufer Performance Standard Power Max. Torque Fuel Consumption (Min. Rated)
Specication DE08TIS 760 mmHg (20C) 711 mm, SUCKER 24V x 50A Installed Installed KS-R1004 200 ps @ 1,900 rpm 86 kgm @ 1,300 rpm (620 ft lb @ 1,300 rpm) 165.0 g/psh (5.82 oz/hph)
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APPROXIMATE WEIGHT OF WORKLOAD MATERIALS IMPORTANT

Weights are approximations of estimated average volume and mass. Exposure to rain, snow or ground water; settling or compaction due to overhead weight, chemical or industrial processing or changes due to thermal or chemical transformations could all increase the value of weights listed in the table. LOW WEIGHT OR DENSITY 1,100 KG/M3 (1,850 LB/YD3), OR LESS 401 kg/m3 (695 lb/yd3) 433 kg/m3 (729 lb/yd3) 449 kg/m3 (756 lb/yd3) 801 kg/m3 (1,350 lb/yd3) 881 kg/m3 (1,485 lb/yd3) 897 kg/m3 (1,512 lb/yd3) 1,009 kg/m3 (1,701 lb/yd3) --------------------MEDIUM WEIGHT OR DENSITY 1,600 KG/M3 (2,700 LB/YD3), OR LESS --------------------HIGH WEIGHT OR DENSITY 2,000 KG/M3 (3,370 LB/YD3), OR LESS ---------------------
MATERIAL
Charcoal
Coke, blast furnace size Coke, foundry size
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---------------------
Coal, bituminous slack, piled Coal, bituminous r. of m., piled Coal, anthracite
---------------------
---------------------
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---------------------
---------------------
Clay, DRY, in broken lumps Clay, DAMP, natural bed Cement, Portland, DRY granular Cement, Portland, DRY clinkers Dolomite, crushed
--------------------1,746 kg/m3 (2,943 lb/yd3) 1,506 kg/m3 (2,583 lb/yd3) 1,362 kg/m3 (2,295 lb/yd3) 1,522 kg/m3 (2,565 lb/yd3) 1,202 kg/m3 (2,025 lb/yd3)
---------------------
---------------------
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---------------------
---------------------
---------------------
---------------------
Earth, loamy, DRY, loose
---------------------
---------------------
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MATERIAL
LOW WEIGHT OR DENSITY 1,100 KG/M3 (1,850 LB/YD3), OR LESS ---------------------
MEDIUM WEIGHT OR DENSITY 1,600 KG/M3 (2,700 LB/YD3), OR LESS 1,522 kg/m3 (2,565 lb/yd3) ---------------------
HIGH WEIGHT OR DENSITY 2,000 KG/M3 (3,370 LB/YD3), OR LESS --------------------1,762 kg/m3 (2,970 lb/yd3) ---------------------
Earth, DRY, packed
Earth, WET, muddy
--------------------961 kg/m3 (1,620 lb/yd3) ---------------------
Gypsum, calcined, (heated, powder) Gypsum, crushed to 3 inch size Gravel, DRY, packed fragments Gravel, WET, packed fragments Limestone, graded above 2 Limestone, graded 1-1/2 or 2 Limestone, crushed
--------------------1,522 kg/m3 (2,565 lb/yd3) ---------------------
--------------------1,810 kg/m3 (3,051 lb/yd3) 1,922 kg/m3 (3,240 lb/yd3) ---------------------
---------------------
---------------------
--------------------1,282 kg/m3 (2,160 lb/yd3) 1,362 kg/m3 (2,295 lb/yd3) 1,522 kg/m3 (2,565 lb/yd3) --------------------1,282 kg/m3 (2,160 lb/yd3) ---------------------
---------------------
---------------------
---------------------
---------------------
--------------------1,602 kg/m3 (2,705 lb/yd3) ---------------------
Limestone, ne
---------------------
Phosphate, rock
--------------------929 kg/m3 (1,566 lb/yd3) 529 kg/m3 (891 lb/yd3) ---------------------
Salt
---------------------
Snow, light density
--------------------1,522 kg/m3 (2,565 lb/yd3) ---------------------
---------------------
Sand, DRY, loose
--------------------1,922 kg/m3 (3,240 lb/yd3)
Sand, WET, packed
---------------------
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MATERIAL
LOW WEIGHT OR DENSITY 1,100 KG/M3 (1,850 LB/YD3), OR LESS --------------------529 kg/m3 (1,620 lb/yd3)
MEDIUM WEIGHT OR DENSITY 1,600 KG/M3 (2,700 LB/YD3), OR LESS 1,362 kg/m3 (2,295 lb/yd3) ---------------------
HIGH WEIGHT OR DENSITY 2,000 KG/M3 (3,370 LB/YD3), OR LESS ---------------------
Shale, broken
Sulphur, broken
---------------------
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PERFORMANCE TESTS
1. Main Relief Pressure normal operation: with "Pressure Up": 2. Actuator Speeds Operation Boom Arm Bucket Swing (3 Revolutions) Jack-Up Speed (3 Turns) Travel Speed 20 m (65.62 ft) Travel Deviation 20 m (65.62 ft) Up Down Dump Crowd Dump Crowd High Low High Low High Low Unit sec. sec. sec. sec. sec. sec. sec. sec. sec. sec. sec. mm (in) mm (in) Power Mode II 3.8 0.4 2.8 0.4 2.9 0.4 4.1 0.4 2.7 0.4 3.6 0.4 16.5 1.0 22.0 1.2 35.0 1.9 14.4 0.9 23.5 1.3 150 (5.91) 150 (5.91) Power Mode III 3.5 0.4 2.7 0.4 2.8 0.4 3.8 0.4 2.6 0.4 3.5 0.4 16.5 1.0 22.0 1.2 35.0 1.9 14.4 0.9 22.5 1.3 150 (5.91) 150 (5.91) 330 kg/cm3 (4,689 psi) 350 kg/cm3 (4,970 psi)
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EXCAVATOR PERFORMANCE STANDARDS

Evaluation of equipment performance and operating condition can be made by running the excavator through a series of different tests, and recording results with a stop watch and tape measure. Compare results of performance tests against the specications and standards that follow, which are for equipment in new or renewed condition. TEST CONDITIONS 1. 2. 3. 4. 5. All tests should be performed on a at, level, rmly supporting ground surface. All recommended, applicable maintenance and adjustment service should be completed prior to testing. Hydraulic uid and engine oil should be of appropriate viscosity for ambient weather conditions. Warm up hydraulic oil to standard operating temperature, between 45 - 55C (112 - 135F). Run all tests with the engine speed control set to maximum RPM. Repeat tests with Power Mode engine control settings at both Power Mode II (standard work mode) and Power Mode III (high speed mode). Travel speed tests should also be repeated at both high and low speed.
TRAVEL SPEED AND TRAVEL MOTOR BALANCE (STEERING DEVIATION) TESTS Speed Test Prepare the excavator for travel speed tests by extending all hydraulic cylinders - boom, arm and bucket to the fully extended position, shown in Figure 5.
0.3 M - 0.5 M (1' - 2')

ARS1480L
Figure 5 The lowest part of the bucket linkage should be 0.3 - 0.5 m (1' - 2') off the ground. Mark off a 20 m (65' 7-1/2") test distance, with a 3 - 5 m (10' - 15') run-up area, and a 3 - 5 m (10' - 15', or longer) speed run-off distance. Travel the excavator back and forth to be sure steering is centered and side frames are perfectly parallel with the test course. Operate both travel levers at the fully engaged position and measure the time it takes to cross 20 m (65' 71/2"). Compare measured results against the standard for new machines:
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RATE OF TRAVEL High Speed Low Speed
TIME MODE II 14.4 0.9 seconds 23.5 1.3 seconds MODE III 14.4 0.9 seconds 22.5 1.3 seconds
Rotate the turntable 180. Both tests should be repeated three times. Average all results to obtain a nal value.
3M - 5M (10' - 15')
20 M (65' 7-1/2")
3M - 5M (10' - 15') ARS1500L
Figure 6
Travel Deviation To check steering deviation (travel motor balance), use a long tape or rope, or the edge of an undeviating straight road curb or other marker to verify side-to-side travel motor uniformity. Deviation distance should always be measured at the 20 m (65' 7-1/2") "nish line." Repeat the test in reverse to measure in both directions, with starting point becoming the nish line, and vice versa. (Figure 6) A greater amount of deviation is allowed with the travel control set for high speed. RATE OF TRAVEL High Speed Low Speed MAX. DISTANCE 150 mm (6 in) 150 mm (6 in)
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Swing Speed Test
1.5 m ARS1490L
Figure 7 Extend the bucket cylinder completely and retract the arm cylinder, as shown in Figure 7, to test swing speed. The lowest point of the bucket will be approximately 1.5 m (3') off the ground. Use paint marks at the same point on the turntable and undercarriage, or select alternate measuring locations and use a stopwatch to time 3 full 360 rotations. The time required for 3 revolutions should be between 15.5 and 17.5 seconds in Power Mode II, 15.5 and 17.5 seconds in Power Mode III. Swing Force Test With the boom, arm and bucket in the same position as for the swing speed test, rotate the turntable so that the boom is evenly centered between the side frames, pointing straight ahead. Locate the 90 reference point, perpendicular to the boom. Mark the turntable and undercarriage with paint at the 90 point. Make several attempts to rotate the turntable exactly 90, starting from the boom straight ahead position. Engage the swing lever and brake at the 90 point, shown as "swing stop" in Figure 8. Record how far the turntable drifts past the stop point, measuring the distance between paint marks. Maximum distance should be less than 1200 mm (47-1/4"), in both Power Mode III and Power Mode II. Reference Number 1 2 3 4 Description Start Swing 90 Swing Swing Force Swing Stop Figure 8
HJA7007L
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CYLINDER PERFORMANCE TESTS NOTE:
All tests are performed with standard boom, arm and bucket conguration. The bucket should be empty.
Boom Cylinders Test The starting points for the test are with the boom and arm extended away from the excavator, and the bucket curled inward. The arm cylinder should be fully retracted; boom and bucket cylinders must be extended. Test movement in both directions, several times, and average results for both Power Mode II and Power Mode III. Arm Cylinder Test Start with the boom up and the arm cylinder fully retracted. Test movement in both directions several times, between the "crowd" and "dump" positions, and average the results of both tests, in both standard and extra-duty power modes. Bucket Cylinder Test Start with the boom up and the teeth of the bucket hanging vertically, 500 mm (1-1/2 - 2) above the ground. Dump and crowd the bucket several times, and average results, for both standard and extra-duty power modes. OPERATION Boom Up Boom Down Arm Dump Arm Crowd Bucket Dump Bucket Crowd Hydraulic Cylinder Natural Drop Test To check boom and arm cylinder tightness against the specied performance standard for new cylinders, put a full load of dirt in the bucket and move the attachment cylinders so that the arm cylinder is extended 20 - 50 mm (1" - 2") and boom cylinders are retracted the same amount, 20 - 50 mm (1" - 2"). The top of the bucket should be approximately 2 m (6' - 7') off the ground. Turn off the engine and measure cylinder drop after 5 minutes. Bucket cylinder should not show more than 40 mm (1.57") change, while the arm and boom cylinders should not fall more than 10 mm (0.39"). Travel Motor Jack-up Test Test travel motor operation on each side by painting or chalking a mark on one crawler shoe, with a corresponding mark on the travel frame. Use the attachment to jack up one side of the machine and operate the raised travel motor. Record the number of seconds it takes the crawler shoe to make 3 full rotations, during both high speed and low speed operation. OPERATION High Speed Low Speed MODE II 20.8 - 23.2 seconds 33.1 - 36.9 seconds MODE III 20.8 - 23.2 seconds 33.1 - 36.9 seconds MODE II 3.4 - 4.2 seconds 2.4 - 3.2 seconds 2.5 - 3.3 seconds 3.7 - 4.5 seconds 2.3 - 3.1 seconds 3.2 - 4.0 seconds MODE III 3.1 - 3.9 seconds 2.3 - 3.1 seconds 2.4 - 3.2 seconds 3.4 - 4.2 seconds 2.2 - 3.0 seconds 3.1 - 3.9 seconds
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1GENERAL MAINTENANCE
S0302000 R1
1GENERAL MAINTENANCE PROCEDURES

CAUTION!
GENERAL MAINTENANCE PROCEDURESS0302000

MODEL ALL MODELS ALL RANGES SERIAL NUMBER RANGE
Copyright 2000 Daewoo December 2000 General Maintenance Procedures S0302000 Page 1
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 ........................ 6 Oil Leakage Precautions ......................................................................... 6 Cleaning and Inspection................................................................................. 7 General Guidelines ................................................................................. 7 Bearing inspection .................................................................................. 8
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General Maintenance Procedures
WELDING PRECAUTIONS AND GUIDELINES IMPORTANT

To avoid accidents, personal injury and the possibility of causing damage to the machine or to components, welding must only be performed by properly trained and qualied personnel, who possess the correct certication (when required) for the specic welding fabrication or specialized repair being performed.
WARNING!
Structural elements of the machine may be built from a variety of steels. These could contain unique alloys or may have been heat treated to obtain particular strength characteristics. It is extremely important that welding repairs on these types of steel are performed with the proper procedures and equipment. If repairs are performed incorrectly, structural weakening or other damage to the machine (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.
CAUTION!
Always perform welding procedures with the proper safety equipment on hand. Adequate ventilation and a dry work area are absolutely essential. Keep a re extinguisher nearby and always wear protective clothing and the recommended type of eye protection.
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CAUTION!
Observe the following safety precautions: 1. 2. 3. 4. Use extra caution and adequate safety shielding when welding near fuel and oil tanks, batteries, hydraulic piping lines or other re hazards. Never weld when the engine is running. Battery cables must be disconnected before the welding procedure is started. Never weld on a wet or damp surface. The presence of moisture causes hydrogen embrittlement and structural weakening of the weld. If welding procedures are being performed near cylinder rods, operators cab window areas or any other assemblies that could be damaged by weld spatters, use adequate shielding protection in front of the assembly. During equipment setup, always attach ground cables directly to the area or component being welded to prevent arcing through bearings, bushings, or spacers. Always use correct welding rods for the type of weld being performed and observe recommended precautions and time constraints. AWS Class E7018 welding rods for low alloy to medium carbon steel must be used within two hours after removal from a freshly opened container. Class E11018G welding rods for T-1 and other higher strength steel must be used within 1/2 hour.
5. 6.
HYDRAULIC SYSTEM - GENERAL PRECAUTIONS

Always maintain oil level in the system at recommended levels. Assemblies that operate under heavy loads, at high speed, with extremely precise dimensional tolerances between moving parts - pistons and cylinders, or shoes and swash plates, for example - can be severely damaged if oil supply runs dry. Assemblies can be run dry and damaged severely in a very short time when piping or hoses are disconnected to repair leaks and/or replace damaged components. Hoses that are inadvertently switched during disassembly (inlet for outlet and vice versa), air introduced into the system or assemblies that are low on oil due to neglect or careless maintenance, could all produce sufcient uid loss to cause damage. When starting the engine (particularly after long layoff or storage intervals), make sure that all hydraulic controls and operating circuits are in neutral, or "OFF." That will prevent pumps or other components that may be temporarily oil-starved from being run under a load. Replacement of any hydraulic system component could require thorough cleaning, ushing, and some amount of pre-lling with fresh, clean oil if the protective seal on replacement parts has obviously been broken or if seal integrity may have been compromised. When protective seals are removed before installation and reassembly, inspect all replacement parts carefully, before they are installed. If the replacement part is bone dry (with no trace of factory pre-lube) or has been contaminated by dirt or by questionable oils, ushing and pre-lling with clean hydraulic uid is recommended. Vibration, irregular or difcult movement or unusual noise from any part of the hydraulic system could be an indication of air in the system (and many other types of problems). As a general precaution (and to help minimize the risk of potential long-term damage), allow the engine to run at no-load idle speed immediately after initial start-up. Hydraulic uid will circulate, releasing any air that may have been trapped in the system before load demands are imposed. A daily walk-around pre-start equipment safety inspection, including a quick visual scan for any exterior evidence of leaking hydraulic uid, can help extend the service life of system components.
S0302000 Page 4
IMPORTANT
Hydraulic system operating conditions (repetitive cycling, heavy work loads, uid circulating under high pressure) make it extremely critical that dust, grit or any other type of contamination be kept out of the system. Observe uid and lter change maintenance interval recommendations and always pre-clean any exterior surface of the system before it is exposed to air. For example, the reservoir ller cap and neck area, hoses that have to be disassembled, and the covers and external surfaces of lter canisters should all be cleaned before disassembly.
MAINTENANCE SERVICE AND REPAIR PROCEDURE

GENERAL PRECAUTIONS Fluid level and condition should always be checked whenever any other type of maintenance service or repair is being performed. NOTE:
If the unit is being used in an extreme temperature environment (in sub-freezing climates or in high temperature, high humidity tropical conditions), frequent purging of moisture condensation from the hydraulic reservoir drain tap should be a regular and frequent part of the operating routine. In more moderate, temperate climates, draining reservoir sediment and moisture may not be required more than once or twice every few months.
Inspect drained oil and used lters for signs of abnormal coloring or visible uid contamination at every oil change. Abrasive grit or dust particles will cause discoloration and darkening of the uid. Visible accumulations of dirt or grit could be an indication that lter elements are overloaded (and will require more frequent replacement) or that disintegrating bearings or other component failures in the hydraulic circuit may be imminent or have already occurred. Open the drain plugs on the main pump casings and check and compare drain oil in the pumps. Look for evidence of grit or metallic particles. Vibration or unusual noise during operation could be an indication of air leaking into the circuit (Refer to the appropriate Troubleshooting section for component or unit for procedures.), or it may be evidence of a defective pump. The gear-type pilot pump could be defective, causing low pilot pressure, or a main pump broken shoe or piston could be responsible. NOTE:
If equipped, indicated operating pressure, as shown on the multidisplay digital gauge on the Instrument Panel ("F-Pump" and "R-Pump") will be reduced as a result of a mechanical problem inside the pump. However, pressure loss could also be due to cavitation or air leakage, or other faults in the hydraulic system.
Check the exterior case drain oil in the main pumps. If no metallic particles are found, make sure there is no air in the system. Unbolt and remove the tank return drain line from the top part of the swing motor, both travel motors and each main pump. If there is air in any one of the drain lines, carefully pre-ll the assembly before bolting together the drain line piping connections. Run the system at low rpm.
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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, its important to remember that the hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating uid - must be protected from contamination. Dust and other foreign contaminants are major contributors to premature wear in hydraulic circuits. The narrow tolerances, rapidly moving parts and high operating pressures of the system require that uid be kept as clean as possible. The performance and dependability of the machine (and the service lift of individual components) can be noticeably reduced if proper precautions are not observed: Use a safe, non-combustible, evaporative-type, low-residue solvent and thoroughly clean exterior surfaces of assemblies before any part of the circuit is opened up or disassembled.
NOTE:
Its just as important to clean the cap and reservoir top before routine uid changes or quick checks as it is before major repairs. (Accumulated dirt attracts moisture, oil and other uids - and more dirt.)
Keep dismantled parts covered during disassembly. Use clean caps, plugs or tape to protect the disconnected openings of anges, manifolds and piping. Do not allow cleaning solvents or other uids to mix with the oil in the system. Use clean oil to ush any traces of solvent or other residue before reassembly. If metal or rubber fragments are found in the system, ush and replace all uid in the system and troubleshoot the circuit to identify the source of contamination.
IMPORTANT
Make sure that cleaning solvents will be compatible with rubber materials used in the hydraulic system. Many petroleum based compounds can cause swelling, softening, or other deterioration of system sealing elements, such as O-rings, caps and other seals. OIL LEAKAGE PRECAUTIONS Oil that is visibly seeping from joints or seals should always serve as a "red ag" alarm. Leaks must alert the machine operator and maintenance crew that air, water and dirt have an open, free passageway through which to enter the circuit. Harsh, corrosive salt air, freezing and thawing condensation cycles and working environments that are full of ne dust are especially hazardous. Clogging of valve spools or external piping (especially pilot circuit piping) can gradually diminish or very suddenly put a complete stop to normal hydraulic function. You can prevent having to make these types of repairs by following recommended assembly procedures: 1. 2. 3. Use new O-rings and oil seals whenever hydraulic assemblies are rebuilt. Prepare joint surfaces before assembly by checking alignment and atness. Clean and repair corrosion or any other damage. Follow bolt torque recommendations and all other assembly requirements.
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Return to Master Table of Contents NOTE:
Grease lip assembly.
seals
before
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 tting parts such as thrust bearing, matched parts, etc.
WARNING!
Care should be exercised to avoid inhalation of vapors, exposure to skin and creating re hazards when using solvent type cleaners. 1. Clean all metal parts thoroughly using a suitable cleaning uid. It is recommended that parts be immersed in cleaning uid and moved up and down slowly until all oils, lubricants, and/or foreign materials are dissolved and parts are thoroughly clean. For bearings that can be removed, soak them in a suitable cleaning uid for a minute or two, then remove bearings from cleaning uid and strike at against a block of wood to dislodge solidied particles of lubricant. Immerse again in cleaning uid to ush out particles. Repeat above operation until bearings are thoroughly clean. To dry bearings, use moisture-free compressed air. Be careful to direct air stream across bearing to avoid spinning bearings that are not lubricated. DO NOT SPIN BEARINGS WHEN DRYING; bearings may be rotated slowly by hand to facilitate drying process. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine condition. Do not replace a bearing cone or cup individually without replacing mating cup or cone at the same time. After inspection, dip bearings in light weight oil and wrap in clean lintless cloth or paper to protect them until installation. For those bearings that are to be inspected in place; inspect bearings for roughness of rotation, scoring, pitting, cracked or chipped races. If any of these defects are found, replace bearings. Also inspect defective bearing housing and/or shaft for grooved, galled or burred conditions that indicate bearing has been turning in its housing or on its shaft. 4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for replacement items. Be extremely careful when installing sealing members, to avoid cutting or
2.
3.
S0302000 Page 7
Return to Master Table of Contents scratching. Curling under of any seal lip will seriously impair its efciency. Apply a thin coat of Loctite #120 to outer diameter, of metal casing, on oil seals to assure an oil tight t into retainer. Use extreme care not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle and allow leakage. When replacing lip type seals, make sure spring loaded side is towards oil to be sealed. 5. If available, use magna-ux or similar process for checking for cracks that are not visible to the eye. Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all gears showing cracks or spots where case hardening has worn through. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they have not been sprung, bent, or splines twisted, and that shafts are true. NOTE:
Spline wear is not considered detrimental except where it affects tightness of splined parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or worn. 6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves and dirt. Remove any scratches and burrs with crocus cloth. Remove foreign matter. Replace any parts that are deeply grooved or scratched which would affect their operation.
BEARING INSPECTION The conditions of the bearing are vital to the smooth and efcient operation of the machinery. When any component containing bearings is disassembled, always carefully examine the condition of the bearings and all of its components for wear and damage. Once the bearing is removed, clean all parts thoroughly using a suitable cleaning solution. If the bearing is excessively dirty soak the bearing assembly in a light solution and move the bearing around until all lubricants and or foreign materials are dissolved and the parts are thoroughly clean. When drying bearings, moisture free compressed air can be used. Be careful not to direct the air in a direction which will force the bearing to dry spin while not being properly lubricated. After the bearings have been cleaned and dried, carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks. If the bearing cannot be removed and is to be inspected in place, check foe roughness of rotation, scoring, pitting, cracked or chipped races. If any of these defects are found replace the whole bearing assembly. NEVER replace the bearing alone without replacing the mating cup or the cone at the same time. After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper and protect them from moisture and other foreign materials until installation. It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that indicate that the bearing has been turning in its housing or on its shaft. If available, use magna-ux or similar process for checking for cracks that are not visible to the naked eye. The following illustrations will aid in identifying and diagnosing some of the bearing related problems. NOTE:
The illustrations will only show tapered roller bearings, but the principles of identifying, diagnosing and remedying the defects are common to all styles and types of bearings.
S0302000 Page 8
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. Replace bearing - check seals and check for proper lubrication.
Figure 5
S0302000 Page 9
Return to Master Table of Contents Abrasive Step Wear Pattern on roller ends caused by ne 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 usually at roller spacing. Replace bearings - check seals and check for proper lubrication.
Figure 7 Misalignment Outer race misalignment due to foreign object. Clean related parts and replace bearing. Make sure races are properly seated.
Figure 8 Indentations Surface depressions on race and rollers caused by hard particles of foreign materials. Clean all parts and housings, check seals and replace bearings if rough or noisy.
Figure 9
S0302000 Page 10
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.
Figure 11 Cage Wear Wear around outside diameter of cage and roller pockets caused by abrasive material and inefcient lubrication. Replace bearings - check seals.
Figure 12 Abrasive Roller Wear Pattern on races and rollers caused by ne abrasives. Clean all parts and housings, check seals and bearings and replace if leaking, rough or noisy.
Figure 13
S0302000 Page 11
Return to Master Table of Contents Cracked Inner Race Race cracked due to improper t, 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 tting, lubrication, overheating, overloads or handling damage. Replace bearings, clean related parts and check for proper t and lubrication. Replace shaft if damaged.
Figure 15 Frettage Corrosion set up by small relative movement of parts with no lubrication. Replace bearing. Clean all related parts. Check seals and check for proper lubrication.
Figure 16
S0302000 Page 12
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 le test may be made. A le drawn over a tempered part will grab and cut metal, whereas a le drawn over a hard part will glide readily with no metal cutting. Replace bearing if over heating damage is indicated. Check seals and other related parts for damage. Stain Discoloration Discoloration can range from light brown to black caused by incorrect lubrication or moisture. if the stain can be removed by light polishing or if no evidence of overheating is visible, the bearing can be reused. Check seals and other related parts for damage. Figure 17
Figure 18
S0302000 Page 13
S0302000 Page 14
S0309000
1STANDARD TORQUES
CAUTION!
STANDARD TORQUESS0309000
MODEL ALL MODELS ALL RANGES SERIAL NUMBER RANGE
Copyright 2000 Daewoo December 2000 Standard Torques S0309000 Page 1
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 ............................................................................... 9 Other Uses for Torque Wrench Extension Tools.................................... 10 Tightening Torque Specications (Metric) ............................................. 10
S0309000 Page 2
Standard Torques
TORQUE VALUES FOR STANDARD METRIC FASTENERS

NOTE:
The units for the torque values are kgm (ft lb).
Grade
Dia. x Pitch (mm)
3.6 (4A) 0.15 (1.08) 0.28 (2.02) 0.43 (3.11) 0.70 (5.06) 0.73 (5.28) 1.35 (9.76) 1.50 (10.84) 2.40 (17.35) 2.55 (18.44) 3.70 (26.76) 4.10 (29.65) 5.60 (40.50) 6.20 (44.84) 7.80 (56.41) 9.10 (65.82) 11.50 (83.17) 12.80 (92.58) 15.50 (112.11) 17.00 (122.96) 20.50 (148.27) 23.00 (166.35)
4.6 (4D) 0.16 (1.15) 0.30 (2.16) 0.46 (3.32) 0.75 (5.42) 0.80 (5.78) 1.40 (10.12) 1.60 (11.57) 2.50 (18.08) 2.70 (19.52) 3.90 (28.20) 4.30 (31.10) 6.00 (43.39) 6.50 (47.01) 8.30 (60.03) 9.50 (68.71) 12.00 (86.79) 13.50 (97.64) 16.00 (115.72) 18.50 (133.81) 21.50 (155.50) 35.00 (253.15)
4.8 (4S) 0.25 (1.80) 0.45 (3.25) 0.70 (5.06) 1.10 (7.95) 1.20 (8.67) 2.20 (15.91) 2.50 (18.08) 3.70 (26.76) 4.00 (28.93) 6.00 (13.23) 6.60 (47.73) 9.00 (65.09) 9.70 (70.16) 12.50 (90.41) 14.40 (104.15) 18.00 (130.19) 20.50 (148.27) 24.50 (177.20) 28.00 (202.52) 33.00 (238.68) 37.00 (267.62)
5.6 (5D) 0.22 (1.59) 0.40 (2.89) 0.63 (4.55) 1.00 (7.23) 1.00 (7.23) 1.90 (13.74) 2.10 (15.18) 3.30 (23.86) 3.50 (25.31) 5.20 (37.61) 5.70 (41.22) 8.00 (57.86) 8.60 (62.20) 11.00 (79.56) 12.50 (90.41) 16.00 (115.72) 18.00 (130.19) 21.00 (151.89) 24.00 (173.59) 27.00 (195.29) 31.00 (224.22)
5.8 (5S) 0.31 (2.24) 0.55 (3.97) 0.83 (6.00) 1.40 (10.12) 1.50 (10.84) 2.70 (19.52) 3.10 (22.42) 4.70 (33.99) 5.00 (36.16) 7.50 (54.24) 8.30 (60.03) 11.50 (83.17) 12.50 (90.41) 16.00 (115.72) 18.50 (133.81) 22.00 (159.12) 25.00 (180.82) 30.00 (216.99) 34.00 (245.92) 40.00 (289.32) 45.00 (325.48)
6.6 (6D) 0.28 (2.02) 0.47 (3.39) 0.78 (5.64) 1.25 (9.04) 1.35 (9.76) 2.35 (19.99) 2.80 (20.25) 4.20 (30.37) 4.50 (32.54) 7.00 (50.63) 7.50 (54.24) 10.50 (75.94) 11.30 (81.73) 14.50 (104.87) 16.70 (120.79) 19.00 (137.42) 22.50 (162.74) 26.00 (188.05) 29.00 (209.75) 34.00 (245.92) 38.00 (202.52)
6.8 (6S) 0.43 (3.11) 0.77 (5.56) 1.20 (8.67) 1.90 (13.74) 2.10 (15.18) 3.70 (26.76) 4.30 (31.10) 6.30 (45.56) 6.80 (49.18) 10.00 (72.33) 11.10 (80.28) 15.50 (112.11) 17.00 (122.96) 21.00 (151.89) 24.50 (177.20) 31.50 (227.83) 35.00 (253.15) 42.00 (303.78) 47.00 (339.95) 55.00 (397.81) 61.00 (441.21)
6.9 (6G) 0.48 (3.47) 0.85 (6.14) 1.30 (9.40) 2.10 (15.18) 2.30 (16.63) 4.20 (30.37) 4.90 (35.44) 7.20 (52.07) 7.70 (55.69) 11.50 (83.17) 12.50 (90.41) 17.90 (129.47) 19.50 (141.04) 27.50 (198.90) 27.50 (198.90) 35.00 (253.15) 39.50 (285.70) 46.00 (332.71) 52.00 (44.76) 58.00 (419.51) 67.00 (484.61)
8.8 (8G) 0.50 (3.61) 0.90 (6.50) 1.40 (10.12) 2.20 (15.91) 2.40 (17.35) 4.40 (31.18) 5.00 (36.16) 7.50 (54.24) 8.00 (57.86) 12.00 (86.79) 13.00 (94.02) 18.50 (133.81) 20.00 (144.66) 28.50 (206.14) 28.50 (206.14) 36.00 (260.38) 41.00 (296.55) 49.00 (354.41) 56.00 (405.04) 63.00 (455.67) 74.00 (535.24)
10.9 (10K) 0.75 (5.42) 1.25 (9.04) 1.95 (14.10) 3.10 (22.42) 3.35 (24.23) 6.20 (44.84) 7.00 (50.63) 10.50 (75.94) 11.20 (81.00) 17.00 (122.96) 18.50 (11.26) 26.00 (188.05) 28.00 (202.52) 41.00 (296.55) 41.00 (296.55) 51.00 (368.88) 58.00 (419.51) 67.00 (484.61) 75.00 (542.47) 82.00 (593.10) 93.00 (672.66)
12.9 (12K) 0.90 (6.50) 1.50 (10.84) 2.35 (16.99) 3.80 (27.48) 4.10 (29.65) 7.20 (52.07) 8.40 (60.75) 12.50 (90.41) 13.40 (96.92) 20.00 (144.66) 22.00 (158.12) 31.00 (224.22) 35.50 (256.77) 43.00 (311.01) 49.00 (354.41) 60.00 (433.98) 68.00 (491.84) 75.00 (542.47) 85.00 (614.80) 92.00 (655.43) 103.00 (744.99)
M5 x Std. M6 x Std. M7 x Std. M8 x Std. M8 x 1 M10 x Std. M10 x 1 M12 x Std. M12 x 1.5 M14 x Std. M14 x 1.5 M16 x Std. M16 x 1.5 M18 x Std. M18 x 1.5 M20 x Std. M20 x 1.5 M22 x Std. M22 x 1.5 M24 x Std. M24 x 1.5
Standard Torques
S0309000 Page 3
TORQUE VALUES FOR STANDARD U.S. FASTENERS

TYPE S.A.E. GRADE DESCRIPTION WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD. Low or Medium Carbon Steel Not Heat Treated. BOLT HEAD MARKING
1 OR 2
WILL HAVE THREE RADIAL LINES. 5 5 Quenched and Tempered Medium Carbon Steel.
WILL HAVE 6 RADIAL LINES. 8 8 Quenched and Tempered Special Carbon or Alloy Steel.
Recommended torque, in foot pounds, for all Standard Application Nuts and Bolts, provided: 1. 2. 3. All thread surfaces are clean and lubricated with SAE-30 engine oil. (See Note.) Joints are rigid, that is, no gaskets or compressible materials are used. When reusing nuts or bolts, use minimum torque values. NOTE:
Multiply the standard torque by: 0.65 0.70 0.75 0.85 0.90 when nished jam nuts are used. when Molykote, white lead or similar mixtures are used as lubricants. when parkerized bolts or nuts are used. when cadmium plated bolts or nuts and zinc bolts w/waxed zinc nuts are used. when hardened surfaces are used under the nut or bolt head.
NOTE:
When reusing bolts and nuts in service, use minimum torque values.
S0309000 Page 4
Standard Torques
Return to Master Table of Contents 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 THREAD SIZE GRADE 5 (3 RADIAL DASHES ON HEAD) NEWTON FOOT POUNDS METER (ft lb) (Nm) 6 8 7 9 13 18 15 20 24 33 27 37 38 52 42 57 58 79 65 88 84 114 93 126 115 156 130 176 205 278 240 312 305 414 334 454 455 617 510 691 610 827 685 929 860 1166 955 1295 1130 1532 1290 1749 1400 2034 1690 2291 2370 3213 3550 4813 GRADE 8 (6 RADIAL DASHES ON HEAD) FOOT POUNDS (ft lb) 9 11 18 21 34 38 54 60 82 90 120 132 165 185 290 320 455 515 695 785 990 1110 1400 1550 1830 2085 2430 2730 3810 5760 NEWTON METER (Nm) 12 15 24 28 46 52 73 81 111 122 163 179 224 251 393 434 617 698 942 1064 1342 1505 1898 2102 2481 2827 3295 3701 5166 7810
1/4" - 20 1/4" - 28 5/16" - 18 5/16" - 24 3/8" - 16 3/8" - 24 7/16" - 14 7/16" - 20 1/2" - 13 1/2" - 20 9/16" - 12 9/16" - 18 5/8" - 11 5/8" - 18 3/4" - 10 3/4" - 16 7/8" - 9 7/8" - 14 1" - 8 1" - 14 1 1/8" - 7 1 1/8" - 12 1 1/4" - 7 1 1/4" - 12 1 3/8" - 6 1 3/8" - 12 1 1/2" - 6 1 1/2" - 12 1 3/4" - 5 2" - 4 1/2 NOTE:
If any bolts and nuts are found loose or at values less than what the chart states, it is recommended that the loose bolt and/or nut be replaced with a new one.
Standard Torques
S0309000 Page 5
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 dened as Type 8, coarse thread bolts and nuts and thru hardened at washers (Rockwell "C" 38 - 45), all phosphate coated and assembled without supplemental lubrication (as received) condition. The torques shown below also apply to the following: 1. 2. 3. Phosphate coated bolts used in tapped holes in steel or gray iron. Phosphate coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted threads or plastic inserts). Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required torque.
STANDARD TORQUE 10% NOMINAL THREAD DIAMETER KILOGRAM METER (kgm) 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1" 1 - 1/8" 1 - 1/4" 1 - 3/8" 1 - 1/2" 1 - 3/4" 2 1.1 2.2 3.9 6.2 9.7 13.8 19.4 33.2 53.9 80.2 113.4 160.4 210.2 279.4 347.1 522.8 FOOT POUNDS (ft lb) 8 16 28 45 70 100 140 240 390 580 820 1160 1520 2020 2510 3780
S0309000 Page 6
Standard Torques
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 5 in lb (0.1 kgm) RADIATOR, AIR CLEANER, BOOTS, ETC. KILOGRAM METER (kgm) "T" Bolt (Any Diameter) Worm Drive - 1-3/4 in Open Diameter and Under Worm Drive - Over 1-3/4 in Open Diameter Worm Drive - All "UltraTite" 0.6 - 0.7 0.2 - 0.3
HYDRAULIC SYSTEM
CLAMP TYPE AND SIZE
INCH POUNDS (in lb) 55 - 65 20 - 30
KILOGRAM METER (kgm) ------0.5 - 0.6
INCH POUNDS (in lb) -----40 - 50
0.5 - 0.6
40 - 50
-------
------
1.1 - 1.2
95 - 105
0.5 - 0.6
40 - 50
Standard Torques
S0309000 Page 7
TORQUE VALUES FOR SPLIT FLANGES

The following chart provides the tightening torques for split ange connections used in hydraulic systems. Split anges and tting shoulders should t squarely. Install all bolts, nger tight and then torque evenly. NOTE:
Over torquing bolts will damage the anges and/or bolts, which may cause leakage.
BOLT TORQUE FLANGE SIZE (*) BOLT SIZE KILOGRAM METER (kgm) 2.1 - 2.5 3.0 - 3.7 3.7 - 4.8 4.8 - 6.2 6.4 - 8.0 7.6 - 9.0 10.9 - 12.6 19.1 - 20.7 16.2 - 18.4 FOOT POUNDS (ft lb) 15 - 18 22 - 27 27 - 35 35 - 45 46 - 58 55 - 65 79 - 91 138 - 150 117 - 133
1/2" 3/4" 1" 1 - 1/4" 1 - 1/2" 2" 2 - 1/2" 3" 3 - 1/2"
5/16" 3/8" 3/8" 7/16" 1/2" 1/2" 1/2" 5/8" 5/8"
(*) - Inside diameter of ange on end of hydraulic tube or hose tting. NOTE:
Values stated in chart are for Standard Pressure Series (Code 61) Split Flanges.
S0309000 Page 8
Standard Torques
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. Specialized sockets do not t the adapter on the front end (nose) of the torque wrench. Generating adequate force on the back end (handle) of the wrench is difcult or impossible. Restricted access or an obstruction may make use of the torque wrench impossible. A unique application requires fabrication of an adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one of the proceeding needs or situations, if the right extension tool is used or fabricated. TORQUE MULTIPLICATION A wrench extension tool can be used to increase the tightening force on a high capacity nut or bolt. For example, doubling the distance between the bolt and the back (handle) end of the torque wrench doubles the tightening force on the bolt. It also halves the indicated reading on the scale or dial of the torque wrench. To accurately adjust or convert indicated scale or dial readings, use the following formula: I = A x T / A + B where: I = Indicated force shown on the torque wrench scale or dial. Figure 1
T = Tightening force applied to the nut or bolt (actual Torque). A = Length of the torque wrench (between the center of the nut or bolt and the center of the handle). B = Length of the extension. As an example, if a 12" extension is added to a 12" torque wrench, and the indicated torque on the dial reads "150 ft lb," the real force applied to the bolt is 300 ft lb:
I= NOTE:
AxT A+B
12 x 300 12 + 12
3600 24
= 150
The formula assumes that there is no added deection or "give" in the joint between the extension and torque wrench. Readings may also be inaccurate:
If the extension itself absorbs some of the tightening force and starts to bend or bow out. If an extension has to be fabricated that is not perfectly straight (for example, an extension made to go around an obstruction, to allow access to a difcult to tighten fastener), the materials and methods used must be solid enough to transmit full tightening torque.
Standard Torques
S0309000 Page 9
Return to Master Table of Contents OTHER USES FOR TORQUE WRENCH EXTENSION TOOLS Torque wrench extensions are sometimes made up for reasons other than increasing leverage on a fastener. For example, a torque wrench and extension can be used to measure adjustment "tightness" of a linkage or assembly. Specially fabricated extensions can be used to make very precise checks of the force required to engage or disengage a clutch mechanism, release a spring-applied brake assembly, or "take up" free play in most any movable linkage. Once the value of the adjustment force is established, repeated checks at regular intervals can help to monitor and maintain peak operating efciency. These types of adjustment checks are especially useful if physical measurements of linkage travel are difcult to make or will not provide the needed degree of precision and accuracy. To allow the assembly or mechanism to accept a torque wrench, welding a nut or other adapter on the end of a linkage shaft or other leverage point will allow turning the shaft or assembly manually. TIGHTENING TORQUE SPECIFICATIONS (METRIC) (For coated threads, prelubricated assemblies.)
CAUTION!
Disassembly, overhaul and replacement of components on the machine, installation of new or replacement parts and/or other service-related maintenance may require the use of thread or ange sealing assembly compound. Use the information on this page as a general guide in selecting specic formulas that will meet the particular requirements of individual assembly installations. Daewoo does not specically endorse a specic manufacturer or brand name but the following table of "Loctite" applications is included for which cross-references to other makers products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of fastener adhesives, with Thread locker sealers 222, 242/243, 262, 271, 272, or 277.
S0309000 Page 10
Standard Torques
Return to Master Table of Contents I. "Loctite" Fastener Adhesives Break-away Cure Strength (in lb) Of Sealer Alone 45 80
Product
Application Low strength for 6 mm (1/4") or smaller fasteners. Medium strength for 6 mm (1/4") and larger fasteners. High strength for high grade fasteners subject to shock, stress and vibration. Extra high strength for ne thread fasteners up to 25 mm (1") diameter. High temperature/high strength for hostile environments to 232C (450F). Extra high strength for coarse thread fasteners 25 mm (1") diameter and larger.
Color
Removal
222 242 243 262 or
Purple Blue
Hand tools Hand tools Heat/260C (500F) Remove HOT (NO solvent) Heat/260C (500F) Remove HOT Heat/316C (600F) Remove HOT Heat/260C (500F) Remove HOT
Red
160
271 272
Red Red
160 180
277
Red
210
II. "Loctite" Pipe Thread Sealant Product 545 Application "No-ller/non-clog" formula for highpressure hydraulic systems. Overapplication will not restrict or foul system components. Solvent-resistant, higher viscosity tapered thread sealer. Color Purple Removal Hand tools Required Setup 4 Hours (or 1/2 hour with Locquic "T" Primer) 4 Hours (or 1/2 hour with Locquic "T" Primer)
656
White
Hand tools
III. "Loctite" gasket/ange sealer Product 518 Application Gasket eliminator specically made for aluminum anges/surfaces. For hydraulic systems to 34,475 kPa (5,000 psi). Low pressure/wide-gap gasket eliminator compound. Fills gaps to 0.0012 mm (0.030"), cures to rigid seal. General purpose, fast setup, exible-cure gasket eliminator. For non-rigid assemblies subject to shock, vibration or deection. Color Red Notes Use Locquic "N" primer for fast (1/2 - 4 hours) setup. Unprimed setup 4 - 24 hours. Use Locquic "N" primer for faster (1/2 - 4 hours) setup. Unprimed setup 4 - 24 hours. Use Locquic "N" primer for faster (1/4 - 2 hours) setup. Unprimed setup 1 - 12 hours.
504
Orange
515
Purple
Standard Torques
S0309000 Page 11
Return to Master Table of Contents IV. "Loctite" retaining compounds Product 609 620 680 Application For bushings, sleeves, press-t bearings, splines and collars. For gaps to 0.0002 mm (0.005"), temperatures to 121C (250F). For high temperatures to 232C (450F). For high strength bonds and tight clearance gaps, to 0.00008 mm (0.002"). Color Green Green Green Notes Use Locquic "N" primer for increased bond strength and all cold temperature applications. Same as 609, above. Same as 609, above.
V. "Loctite" Adhesives Product 380 454 480 Application Black Max instant adhesive for shock and vibration-resistant bonds. Adhesive for porous surfaces. Increased strength (+50%), shock and vibration-resistant. Color Black Clear Black Notes May take 120 hours to reach full cure strength. Full strength in 24 hours. Full strength in 24 hours.
S0309000 Page 12
Standard Torques
1UPPER STRUCTURE
S0402040K
1CAB
CAUTION!
CAB
MODEL Solar 300LC-V Solar 300LL Solar 340LC-V Solar 420LC-V Solar 470LC-V SERIAL NUMBER RANGE 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up
Copyright 2001 Daewoo December 2001 Cab S0402040K Page 1
TABLE OF CONTENTS
Removal ......................................................................................................... 3 Installation ...................................................................................................... 6
S0402040K Page 2
Cab
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. 1. 2. 3. Park on rm and level ground. Lower bucket to ground. Shut engine down and remove key from starter switch.
WARNING!
If engine must be run while performing maintenance, use extreme care. Always have one person in the cab at all times. Never leave the cab with the engine running. 4. 5. 6. 7. Set safety lever on "LOCK" position. Hang maintenance controls. warning tag on
Figure 1
Disconnect negative (-) battery cable leading to frame from battery. Prepare cab shell for removal by disconnecting wiring connectors for: A. B. C. D. Cab interior lighting. External light wiring. Radio antenna and connections. Wiper/washer connections.
NOTE: NOTE:
Control console wiring harnesses and hydraulic piping lines that pass through the oor of the cab do not need to be disassembled. If unit is equipped with a cab protective structure (for forestry, or hazardous working conditions), it must be removed.
Cab
S0402040K Page 3
8. 9.
Remove oor mat. Remove operators seat (1, Figure 2). NOTE:
1 4 6 5
Be careful not to damage seat covering.
10.
Remove duct covers (2, 3 and 4, Figure 2). When removing cover (2) disconnect hour meter connector and cigar lighter connector. Disconnect main harness connector before removing cover (4). Removing pocket (5, Figure 2) before removing side panel (6, Figure 2).
2
11.
3 ARS1510L
Figure 2 12. Remove air duct (1, 2 and 3, Figure 2) located at right side of cab. Disconnect duct wiring connector before removing duct (2). Disconnect washer hose located at oor plate bottom.
13.
2 ARS1520L
Figure 3 14. Remove cover (5, Figure 4) on left side dash cover (3) and bolts (1, Figure 5). NOTE: 15.
When removing cover disconnect speaker wire.
2 3
Remove two rubber stops (2, Figure 4) used in storing the front lower glass. Remove bolts (1) from the rear left and right dash covers. Remove left side cover (3). Lift right side dash cover (4, Figure 4) and disconnect speaker wire. Remove cover.
16.
ARS1530L
Figure 4
S0402040K Page 4
Cab
17.
Remove three bolts (2, Figure 5) after disconnect speaker wire and antenna wire. Remove stereo assembly. Disconnect cab lamp wiring connector. Disconnect cabin ground cable (7, Figure 2).
2
18. 19.
ARS1540L
Figure 5 20. 21. 22. Remove four mounting nuts from four corners of cabin oor (2, Figure 6). Remove four hex bolts (3, Figure 6) from door side of cabin oor. Remove two hex bolts (1, Figure 6) from right side of cabin oor and one bolt (4) under front window of cab oor. Quantity 4 4 3 Description 16 mm hex nuts at each corner of the cab 10 mm x 1.5 hex bolts at the door side of the cab 10 mm x 1.5 mm hex head bolts, 2 on the right side of the cab and 1 under the front window.
2 4
3
HAOF270L
Figure 6
23.
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).
24.
Lift cab from 25 - 50 mm (1" - 2") above deck height. Check that all electrical connections have been disconnected and all other items unbolted. Continue lifting with the assist crane to remove the cab shell. Lower the shell to a pre-prepared safe blocking support. Figure 7
25.
Cab
S0402040K Page 5
INSTALLATION
1. Using a suitable lifting device, attach slings to four lift points on top of cab (Figure 7). NOTE: 2.
Cab weighs approximately 290 kg (639 lb).
Lower cab into position on cab oor
Figure 8 3. Install four mounting nuts on four corners of cabin oor (2, Figure 9). NOTE: 4. 5.
Mounting nut torque 20.2 kgm (146 ft lb)
Install four hex bolts (3, Figure 9) in door side of cabin oor. Install two hex bolts (1, Figure 9) in right side of cabin oor and one bolt (4) under front window of cab oor. Quantity 4 4 3 Description 16 mm hex nuts at each corner of the cab 10 mm x 1.5 hex bolts at the door side of the cab 10 mm x 1.5 mm hex head bolts, 2 on the right side of the cab and 1 under the front window.
2 4
3
HAOF270L
Figure 9
6. 7. 8.
Once cab is mounted to oor, unhook lifting device Connect cabin ground cable (7, Figure 2). Connect cab light wiring connector.
S0402040K Page 6
Cab
9.
Install stereo assembly with bolts (2, Figure 10) after connect speaker wire and antenna wire.
2
ARS1540L
Figure 10 10. Lift right side dash cover (4, Figure 11) with bolts (1, Figure 10). Install two rubbers (2, Figure 11). Install left side dash cover (3, Figure 11) with bolts (1, Figure 10). Install two rubbers (2, Figure 11). Install cover (5, Figure 11) on left side dash cover (3). NOTE: 13. 14.
4 2 1 2 3 5
11.
12.
Connect speaker wire before installing cover.

ARS1530L
Connect washer hose located at oor plate bottom. Install air duct (3, 2 and 1, Figure 12) located at right side of cab. NOTE:
Figure 11
Connect wire connector of duct (2).
15.
Install side panel (6, Figure 12) and pocket (5).
2 ARS1520L
Figure 12
Cab
S0402040K Page 7
16.
Install cover (4, Figure 13) and connect main harness. Install cover (3, Figure 13). Connect hour meter connector and cigar lighter connect of cover (2, Figure 13). Install cover (2). Install operators seat (1, Figure 13). NOTE:
6 4
1 5
17. 18.
Be careful not to damage seat covering.
19. 20.
Install oor mat. Disconnect negative (-) battery cable leading to frame from battery.
2 7
3 ARS1510L
Figure 13
S0402040K Page 8
Cab
S0403050K
1COUNTERWEIGHT
CAUTION!
COUNTERWEIGHT
Copyright 2001 Daewoo December 2001 Counterweight S0403050K Page 1
TABLE OF CONTENTS
General........................................................................................................... 3 Removal ......................................................................................................... 5 Installation ...................................................................................................... 6
S0403050K Page 2
Counterweight
GENERAL
Before any attempt is made to begin removal or installation of the counterweight, the excavator must be parked on a rm and level supporting surface, with no sloping surfaces or soft or muddy ground in the area where the assist lift crane will be working. Position all accessories in the overnight storage position.
WARNING!
The weight of counterweight is given in the following table. Use only rated and approved slings and hardware when removal or installation lifts are being made. Lifting slings, shackles and all other hardware must be rigged safely. An assist crane that is rated above weight capacity is required. MODEL Solar 300LC-V Solar 300LL Solar 340LC-V Solar 420LC-V Solar 470LC-V WEIGHT OF COUNTERWEIGHT 4,900 kg (10,803 lb) 6,300 kg (13,890 lb) 6,500 kg (14,330 lb) 8,200 kg (18,078 lb) 8,500 kg (18,740 lb)
Responsibility should be assigned to one person to be in charge of the lifting crew, and to verify that required safe lifting precautions have been taken before each part of the procedure has been started. All members of the working crew should know and understand the signals that will be used between the lifting leader, the assist crane operator and the remainder of the work crew.
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. 90 ~ 110
15
HDO4002I
Figure 1
Counterweight
S0403050K Page 3
When loading an excavator (either track or wheeled type) on a trailer for transport after the front attachment has been removed, secure the swing lock (if equipped) to hold the deck in place and always go backwards up the loading ramp. The counterweight end of the deck has to get on the trailer rst, while the cab is still going up the ramp (Figure 1). 15
HDO4003I
Figure 2
S0403050K Page 4
Counterweight
REMOVAL
1. 2. 3. Park on rm and level ground. Lower bucket to ground. Shut engine down and remove key from starter switch.
WARNING!
If engine must be run while performing maintenance, use extreme care. Always have one person in the cab at all times. Never leave the cab with the engine running. 4. 5. 6. 7. 8. 9. Set safety lever on "LOCK" position. Hang maintenance controls. warning tag on
Figure 3
Disconnect negative (-) battery cable leading to frame from battery. Raise engine compartment cover. Remove two caps (1, Figure 4) from counterweight (2). Install two lifting eyes in lifting holes (3, Figure 4). Model Solar 300LC-V Solar 300LL Solar 340LC-V Solar 420LC-V Solar 470LC-V Lifting Eye Size
3 2 3
M48x5.0
10.
Using a suitable lifting device capable of handling load, partially support counterweight (2, Figure 4) before beginning to loosen four bolts (4). Stop lifting with assist crane as soon as lifting slings are taut. Remove four bolts (4, Figure 4) and washers (5) from counterweight (2). NOTE:
6 5 4
ARS1650L
11.
Heat bolts if necessary, to free them.
12.
When bolts (4, Figure 4) and washers (5) have been removed, lift counterweight (2)
Figure 4
Counterweight
S0403050K Page 5
a very short distance above support frame (6) and stop. Check slings and make sure counterweight is being supported evenly.
INSTALLATION
1. 2. Raise engine compartment cover. Using suitable lifting device capable of handling load, raise counterweight (2, Figure 5) into position just above support frame (6) leaving counterweight suspended. Verify that counterweight is level and even. NOTE:
3 1
3 2
Leave counterweight (2, Figure 5) suspended 3 mm (0.125") above support frame (6) until all four mounting bolts (4) are started in counterweight mounting holes.
3.
Slide washers (5, Figure 5) onto bolts (4). Apply Loctite #242 to mounting bolt threads. Install four bolts (4, Figure 5) with washers (5) into counterweight until washers contact support frame. Fully lower counterweight onto support frame and nish tightening bolts. NOTE:
6 5 4
ARS1650L
4.
Tighten bolts (4, Figure 5) to values shown in following table.
Figure 5 Bolt Torque 250 kgm (1,807 ft lb)
Model Solar 300LC-V Solar 300LL Solar 340LC-V Solar 420LC-V Solar 470LC-V 5. 6. 7.
Remove lifting device and lifting eyes from counterweight lifting holes (3, Figure 5). Install two caps (1, Figure 5) in lifting holes (3). Connect negative (-) battery cable to battery.
S0403050K Page 6
Counterweight
S0405110K
1FUEL TANK
CAUTION!
FUEL TANK
MODEL Solar 300LC-V Solar 300LL SERIAL NUMBER RANGE 1001 and Up 1001 and Up
Copyright 2001 Daewoo December 2001 Fuel Tank S0405110K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Parts List ................................................................................................. 4 Specications .......................................................................................... 5 Removal ......................................................................................................... 6 Installation .................................................................................................... 10 Start-up Procedures ..................................................................................... 12
S0405110K Page 2
Fuel Tank
GENERAL DESCRIPTION WARNING!

Engine fuel is highly ammable and potentially explosive. To prevent possible injury and/or damage to equipment, extinguish or move to a safe distance all potential re hazards.
Fuel Tank
S0405110K Page 3
PARTS LIST
12 11
13 16
34 33 14 19 20
10 9 23 8 3
4 6 5 7 ARS1660L
Figure 1
S0405110K Page 4
Fuel Tank
Reference Number 1 3 4 5 6 7 8 9 10 11
Description Fuel Tank O-ring Cover Bolt (M10x1.5x25) Spring Washer (M10) Drain Valve Bolt Shim Shim Fuel Filter
Reference Number 12 13 14 16 19 20 23 33 34
Description Cap (=2188-9004) Plug; SP Level Gauge O-ring O-ring Plug Spacer Bolt Clip
SPECIFICATIONS Fuel tank capacity is 450 liters (119 U.S. gal).
Fuel Tank
S0405110K Page 5
REMOVAL
1. Look at fuel level display (Figure 2) on instrument panel in operators cab to see when it shows. The display is divided into ten 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. NOTE: GREEN RED
If possible, work excavator until available fuel supply in tank has been run down as far as possible.
Figure 2
E
ARO0150L
2.
Park on rm and level ground and swing turntable to approximately a 90 with respect to tracks. See Figure 3.
ARS1550L
Figure 3 3. 4. Lower bucket to ground. Shut engine down and remove key from starter switch.
WARNING!
If engine must be run while performing maintenance, use extreme care. Always have one person in the cab at all times. Never leave the cab with the engine running. 5. 6. 7. Set safety lever on "LOCK" position. Hang maintenance controls. warning tag on
Figure 4
Disconnect negative (-) battery cable leading to frame from battery.
S0405110K Page 6
Fuel Tank
8.
Clean area around fuel tank ll cap (1, Figure 5). Open fuel cap.
Figure 5 9. 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 10. Tag and disconnect fuel supply line (1, Figure 7) and fuel return line (2) from tank (3) and carefully drain remaining fuel from lines. Remove clamp (4, Figure 7) holding fuel return line (2) to tank (3).
4
11.
ARS1740L
Figure 7 12. Tag and disconnect wires leading to fuel sensor (1, Figure 8) on side of fuel tank (2). If equipped, remove components from fuel ller pump port (3, Figure 8) on side of fuel tank (2).
13.
3 2 1
ARS1680L
Figure 8
Fuel Tank
S0405110K Page 7
14.
Remove six bolts (1, Figure 9) and cover (2) from fuel tank.
1
ARS1670L
Figure 9 15. 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.
2 4 6
ON T
FR
1 5
ARS1750L
Figure 10 16. Remove four bolts (1 and 2, Figure 11) and cover (3) from fuel tank and support.
3 2
ARS1670L
Figure 11
S0405110K Page 8
Fuel Tank
17.
Install two 12 mm eye bolts in threaded holes (1 and 2, Figure 12). Using a suitable lifting device, sling eye bolts. Remove six bolts and washers (4, Figure 12) holding tank (3) to frame. Lift tank 25 mm (1") and make sure it is balanced. Make sure that there are no other electrical wires or hoses connected to tank. Completely remove tank after inspection. NOTE:
2 1
18.
5 4
ARS1700L
The clear level gauge on the side of the tank is easily damaged. Be careful of obstacles and wind gusts.
Figure 12
19.
Remove shims (5, Figure 12). NOTE:
If tank is to be reused note position and amount of shims used for each mounting bolt location.
Fuel Tank
S0405110K Page 9
INSTALLATION
1. 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) nger tight, to secure tank to frame. NOTE:
2 1
2.
The clear level gauge on the side of the tank is easily damaged. Be careful of obstacles and wind gusts.
5 4
ARS1700L
3.
Install shims (5, Figure 13) as needed to prevent tank (3) from rocking or stress from mounting bolts (4). Tighten mounting bolts (4, Figure 13) after shims are installed. NOTE:
Figure 13
4.
Bolt torque is 27 kg.m

2 3
5.
Install four bolts (1and 2, Figure 14) and cover (3) on fuel tank and support.
ARS1670L
Figure 14 6. Install four bolts (4, Figure 15) and battery cover (5) on frame.
FR ON T
Install four bolts (1 and 2), clamp (6) and stay (3) on fuel tank and frame.
2 4 6
1 5
ARS1750L
Figure 15
S0405110K Page 10
Fuel Tank
7.
Install six bolts (1, Figure 16) and cover (2) on fuel tank.
1
ARS1670L
Figure 16 8. 9. Connect wires as tagged to fuel sensor (1, Figure 17) on side of fuel tank (2). If equipped, connect components to fuel lter pump port (3, Figure 17) on side of fuel tank (2).
3 2 1
ARS1680L
Figure 17 10. Connect as tagged, fuel supply line (1, Figure 18) and fuel return line (2) to fuel tank (3). Install clamp (4, Figure 18) to hold fuel return line (2) to tank (3).
2 4
11.
ARS1740L
Figure 18 12. 13. 14. Make sure fuel tank drain valve (Figure 19) on bottom of tank is closed. Fill fuel tank and check for signs of leaks. Correct any problems found. Connect negative (-) battery cable to battery.
Figure 19
Fuel Tank
S0405110K Page 11
START-UP PROCEDURES
If engine does not start, the fuel system may need priming. Prime the fuel system using the following procedure; 1. Loosen plug (Figure 20) on top of fuel lter head.
Figure 20 2. Unscrew and pump the hand operated primer pump (Figure 21) by the fuel injection pump. Pump primer until fuel is present at plug hole in fuel lter head. Tighten plug in fuel lter head. Continue to pump primer pump until a strong resistance is felt. Screw the primer pump knob back into housing. Start engine and look for signs of leaks. Repeat procedure if necessary. Figure 21
3. 4.
5. 6.
S0405110K Page 12
Fuel Tank
S0405500
1FUEL TRANSFER PUMP
CAUTION!
FUEL TRANSFER PUMPS0405500

MODEL Mega 130 Mega 160 Mega 200-III Mega 200-V Mega 250-III Mega 250-V Mega 300-V Mega 400-III PLUS Mega 400-V Mega 500-V Solar 130LC-V Solar 130W-V Solar 170LC-V Solar 170W-V Solar 200W-V Solar 220LC-V Solar 220LL Solar 220N-V Solar 250LC-V Models continued on back of cover. 0001 and Up 0001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 thru 2000 0001 and Up 0001 and Up 1001 and Up 1001 and Up 0001 and Up 0001 and Up 1001 and Up 1001 and Up 1001 and Up SERIAL NUMBER RANGE
Copyright 2001 Daewoo December 2001 Fuel Transfer Pump S0405500 Page 1
Return to Master Table of Contents MODEL Solar 290LC-V Solar 290LL Solar 300LC-V Solar 300LC-V Solar 300LL Solar 340LC-V Solar 400LC-V Solar 420LC-V Solar 450LC-V Solar 470LC-V SERIAL NUMBER RANGE 0001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up
TABLE OF CONTENTS
General Description ....................................................................................... 3 Theory of Operation ................................................................................ 3 Troubleshooting .............................................................................................. 4 Replacement of Rotor and Vane .................................................................... 4 Replacement of Rear Cover........................................................................... 5 Replacement of Armature .............................................................................. 6
S0405500 Page 2
Fuel Transfer Pump
GENERAL DESCRIPTION
THEORY OF OPERATION
Figure 1 Reference Number 1 2 2-1 2-2 Description Motor Pump Pump Cover Rotor and Vane Reference Number 3 4 5 6 Description Inlet Hose Outlet Hose Check Valve Strainer Cap
Fuel pump consists of motor, pump, switch and hose assembly.
Figure 2
Fuel Transfer Pump
S0405500 Page 3
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 5C (302 41F). After circuit is automatically shut off due to overheating the pump will stop running. When temperature drops below 143C (289F) the circuit will reactivate allowing the pump to restart.
Figure 3 WITH TOGGLE SWITCH
Figure 4 WITHOUT TOGGLE SWITCH
Check resistance at connectors "A." If reading is zero, or very close to zero, the motor is bad and must be replaced. On units equipped with a toggle switch, check the resistance through the toggle switch, while the switch is in the "ON" position. If continuity is not present, the switch is bad. Be sure to check resistance through the motor.
REPLACEMENT OF ROTOR AND VANE

If dirt or other foreign materials enter pump during operation, it can become lodged between the rotor and/or vanes and generate heat which can cause pump damage. Remove the pump cover and check the rotor and vane. If any pump parts or components become lost, damaged or inoperable, immediately replace them with a new ones.
Figure 5 WITHOUT TOGGLE SWITCH
S0405500 Page 4
Fuel Transfer Pump
Return to Master Table of Contents 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 nd any damage, replace them with new ones. Loosen the switch cover and screw (M5 x L95) from the rear cover. Remove cover. At reassembly of rear cover, widen the space of brush and insert it to the armature. Then t the hole of screw in the housing. Be careful when installing screw. The cover screw may be attracted by the motor magnet. Figure 7
Fuel Transfer Pump
S0405500 Page 5
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. Loosen the pump cover and remove the rotor and vane. Insert a new armature into the housing. Refer to Replacement of Rear Cover on page 5, for installation of rear cover. Fit the rotor in the shaft ute of armature. Insert vane to the rotor being careful for the direction. Refer to Replacement of Rotor and Vane on page 4. Figure 8
S0405500 Page 6
Fuel Transfer Pump
S0407000 R1
1SWING BEARING
CAUTION!
SWING BEARING
MODEL Solar 130LC-V Solar 170LC-V Solar 220LC-V Solar 220LL Solar 250LC-V Solar 290LC-V Solar 290LL Solar 300LC-V Solar 300LL Solar 330LC-V Solar 340LC-V Solar 400LC-V Solar 420LC-V Solar 450LC-V Solar 470LC-V
S0407000
SERIAL NUMBER RANGE 0001 and Up 1001 and Up 0001 and Up 1001 and Up 1001 and Up 0001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up
Copyright 2001 Daewoo December 2001 Swing Bearing S0407000 Page 1
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 Page 2
Swing Bearing
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 conguration 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 bearings service life could be reduced. Taking a few minutes in the middle of each work shift to reposition the excavator, to work the opposite end of the bearing, will provide a payoff in terms of more even, gradual rate of wear and extended service life. MEASURING SWING BEARING AXIAL PLAY Periodic, regular checks of bearing displacement should be made at least twice a year. Use a dial indicator. Push the attachment against the ground to lift the excavator off the ground and take measurements at 4 points, 90 apart, around the circumference of the bearing (Figure 1). Record and keep all measurements. Play in the bearing should increase minimally from one inspection to the next. Eventually, however, as the bearing begins to approach the limit of its service life, clearance increases become much more pronounced and the actual measured play in the bearing could exceed twice the value that was measured when the machine was new. MEASURING BEARING LATERAL PLAY When vertical checks are made, the side-to-side play in the bearing can be checked by fully retracting the arm and bucket cylinders and extending the tip of the bucket as far forward as it will go. With the excavator parked on a at, level surface and the bucket tip just off the ground, push against the bucket sideways to take up all of the lateral clearance in the bearing. (Less than 100 lb of force should be required to move the bucket over all the way.) Check lateral play in both directions and record the values. When the bearing is beginning to approach the end of its service life, measured lateral clearance should start to show larger and larger increases.
Figure 1
Swing Bearing
S0407000 Page 3
Return to Master Table of Contents 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 xed in the undercarriage. Ball bearings turn the outer ring. Reference Number 1 2 3 4 5 6 7 8 9 Description Ball Seal A Seal B Retainer Retainer Outer Ring Inner Ring Tapered Pin Plug
Figure 2 REBUILDING SWING BEARING 1. Remove tip of tapered pin (1, Figure 3) using grinder and tap lightly to remove debris.
Figure 3 2. Remove plug (1, Figure 4) using a M10 x 1.25 bolt (2).
Figure 4
S0407000 Page 4
Swing Bearing
Return to Master Table of Contents 3. 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 4. Turn inner ring and use magnet bar (1, Figure 6) to remove steel balls (2).
Figure 6 5. Turn inner ring and use wire (1, Figure 7) to remove retainers (2).
Figure 7 6. Assemble in reverse order of disassembly and then adjust the gap between the steel balls and retainers using the following guidelines: Assemble steel ball, retainer (A) and retainer (B) to bearing; if gap is too wide, adjust by moving steel balls or by replacing one of the retainers.
Figure 8
Swing Bearing
S0407000 Page 5
S0407000 Page 6
Swing Bearing
S0408070K
1SWING REDUCTION GEAR (M105)

CAUTION!
SWING REDUCTION GEAR (M105)S0408070K

MODEL Solar 300LC-V Solar 340LC-V Solar 420LC-V SERIAL NUMBER RANGE 1001 and Up 1001 and Up 1001 and Up
Copyright 2001 Daewoo December 2001 Swing Reduction Gear (M105) S0408070K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Theory of Operation ................................................................................ 3 Parts List ................................................................................................. 4 Specications .......................................................................................... 5 Special Tools and Materials............................................................................ 6 Special Tools ........................................................................................... 6 Tool "A" ............................................................................................ 6 Tool "B" ............................................................................................ 6 Tool "C" ............................................................................................ 7 Tool "D" ............................................................................................ 7 Tool "E" ............................................................................................ 7 Tool "F"............................................................................................. 8 Troubleshooting, Testing and Adjustment....................................................... 9 Removal ....................................................................................................... 10 Disassembly ................................................................................................. 11 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 15 Reassembly.................................................................................................. 16 Installation .................................................................................................... 21 Start-up Procedures ..................................................................................... 22
S0408070K Page 2
Swing Reduction Gear (M105)
GENERAL DESCRIPTION
THEORY OF OPERATION The swing motor nal drive is a two-step planetary gearbox with two planet gears, two sun gears and twostep output reduction. The planetary gear engages with the ring gear. The pinion gear is connected with the output shaft and spline. The nal drive reduces swing motor RPM in order to increase swing motor output torque. The available maximum swing speed provides a fast turning rate for efcient, rapid work cycling with more than adequate power for good acceleration.
S0408070K Page 3
PARTS LIST
2 4
1 2
5
8 9 1
14 10 11 12 27 2 29 25 24 22 2 18 19 20 17 15 1
21 28
2590
Figure 1
S0408070K Page 4
Reference Number 1 2 3-1 3-2 4 5 6 7 8 9 10 11 12 13 14
Description Motor Socket Bolt (M12x35) Level Gauge Pipe Socket Bolt(M16x180) Cover Plate No.1 Sun Gear No. 1 Carrier Assembly Ring Gear Lock Pin Thrust Plate No. 2 Sun Gear No. 2 Carrier No. 2 Shaft For Pin Spring Pin
Reference Number 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Description No. 2 Planetary Gear No. 2 Side Plate Gear Case Lock Ring Pinion Gear Cover Hex Bolt (M16x40) Collar Seal Plate Bearing Shaft Bearing Lock Wire Spacer
SPECIFICATIONS Swing Reduction Gearbox Drive Type Reduction Ratio Maximum Output Speed Maximum Output Torque Weight Pinion Gear Type Gear P.C.D No. of Teeth Module Specication 2-Stage Planetary Gear 21.968 63 rpm 1,860 kgm (1,345 ft lb) 320 kg (706 lb) Specication Spur Gear 190 mm (7.48 in.) 14 14
S0408070K Page 5
SPECIAL TOOLS AND MATERIALS

SPECIAL TOOLS Tool "A" Dimension A B C Measurement 190 mm (7.4803 in) 220 mm (8.6614 in) 350 mm (13.7795 in)
A B
ARS2600L
Figure 2 Tool "B" Dimension A B C D E F G H I Measurement 156 mm (6.1417 in) 130 mm (5.1181 in) 3 +0.3 mm (0.1299 - 0.1378 in) 128 mm (5.0394 in) 20 mm (0.7874 in) 120 mm (4.7244 in) 268 mm (10.5512 in) 60 mm (2.3622 in) 168 mm (6.6142 in)
+0.5
C D E G F
ARS2610L
Figure 3
S0408070K Page 6
H I
Tool "C" Dimension A B C D Measurement 70 mm (2.7559 in) 6 mm (0.2362 in) 6 mm (0.2362 in) 18 mm (0.7087 in)
A B C D ARS2620L A B ARS2630L C A B ARS2640L C
Figure 4 Tool "D" Dimension A B C Measurement 60 mm (2.3622 in) 80 mm (3.1496 in) 150 mm (5.9055 in)
Figure 5 Tool "E" Dimension A B C Measurement 108 mm (4.2520 in) 138 mm (5.4331 in) 150 mm (5.9055 in)
Figure 6
S0408070K Page 7
Tool "F" Dimension A B C Measurement 128 mm (5.0394 in) 158 mm (6.2205 in) 150 mm (5.9055 in)
A B ARS2650L
Figure 7
S0408070K Page 8
TROUBLESHOOTING, TESTING AND ADJUSTMENT

Symptoms 1. No rotation and a. Pressure at swing motor inlet increases Swing brake not releasing Check brake engagement and disengagement, check release pressure Replace broken gears, drive train assemblies Reduce load weight Replace swing motor Repair/replace broken or faulty assemblies Troubleshoot hydraulic system Possible Causes Remedies
Internal damage to gearbox drive train Overload b. Pressure at swing motor inlet shows no increase, and the swing motor is making irregular noises c. Pressure at swing motor inlet shows no increase, but without irregular noises from the swing motor 2. Oil leakage a. From drive shaft b. From bolted connections or other assembled surfaces Oil seal damaged Assembly compound (joint sealer) old and not sealing, bolt not tight or flange warped Swing motor drive shaft damage Internal damage to gearbox drive train Hydraulic pump or valve broken
Replace oil seal Disassemble and check mating surfaces. Reapply Loctite, torque bolts to specifications
3. Excess heat Gearbox casing becomes excessively hot, with or without irregular noise(s) during operation Low oil level Replace oil, refill to specified level Repair or replace gearbox
HAOE960L
Bearings or gear worn but not completely inoperative
S0408070K Page 9
REMOVAL
1. 2. Lower bucket to ground. Shut engine down and remove key from starter switch.
WARNING!
If engine must be run while performing maintenance, use extreme care. Always have one person in the cab at all times. Never leave the cab with the engine running. 3. Fully stroke work levers (joysticks) in all directions to relieve pressure from accumulators. Set safety lever on "LOCK" position. Hang maintenance controls. warning tag on
Figure 8
4. 5. 6. 7.
Disconnect negative (-) battery cable leading to frame from battery. 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. Remove drain plug (3, Figure 9) from frame and drain oil from reduction gearbox (5, Figure 9). Disconnect and grease lubrication line (7, Figure 9) from reduction gearbox (5). Remove twelve bolts and washers (4, Figure 9) holding swing reduction gearbox (5) to frame. Using a suitable lifting device, sling swing motor (1, Figure 9) and remove swing motor and reduction gearbox (5) as an assembly from unit. NOTE:
6 5
1 4
8.
9. 10.
11.
There are two alignment pins (6, Figure 9), located on reduction gearbox ange.
Figure 9
3
ARS2900L
S0408070K Page 10
DISASSEMBLY
1. 2. Drain oil from port A. Using a pipe wrench, remove oil level gauge (3-1) and pipe (3-2) (PT1/4).
1 3-1 3-2
TANK ARS2660L
Figure 10 3. Using L-wrench, remove socket bolts (2) and motor (1).
1 2
Figure 11
S0408070K Page 11
4.
Using L-wrench, remove socket bolts (4) and cover (5).
Figure 12 5. 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 eld because pin No. 1 and carrier No. 1 are caulked.
93.5994
Figure 13
S0408070K Page 12
6.
Remove sun gear No. 2 (11). Remove carrier assembly No. 2 and disassemble it.
11
Figure 14 7. 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
AR
Figure 15 8. Remove shaft No. 2 (13) from carrier No. 2 (12). Remove spring pin (14) from shaft No. 2 (13). Remove planetary gear No. 2 (15) and side plate (16) from carrier No. 2 (12).
1 1 1 1
16
Figure 16
S0408070K Page 13
9.
Remove ring gear (8). Remove lock pin (9) and turn body over.
9
Figure 17 10. Remove wire (28) and hex bolt (21) by using socket wrench. Remove cover (20) and pinion (19).
2 21 2
Figure 18 11. Remove lock ring (18). Put jig (D) on shaft (26) and press shaft assembly (22, 24, 25 and 26) out.
Hydraulic Press
25 24 22 26 18
ARS2750L
Figure 19 HYDRAULIC PRESS
S0408070K Page 14
12.
Put jig (A) on bearing (25) and press bearing (25), plate (24) and collar (22) from shaft (26). Pull spacer (29) out.
24
22
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).
17
77
Figure 21
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES)

For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Inspect all components in the assembly. Pay particular attention to oil seals, lock and spring pins and fastener bolts. Using new replacement parts for these components is recommended whenever there is any doubt at all about the condition or serviceability of original parts.
S0408070K Page 15
REASSEMBLY
1. Install spacer (29) on shaft (26). Poisition jig (A) on bearing (25) and press bearing (25) on shaft (26) until contact is obtained.
Figure 22 HYDRAULIC PRESS 2. Install plate (24) on shaft (26). Position Jig (A) on collar (22) and press collar (22) on shaft (26) until contact is obtained.
Hydarulic Press
Figure 23 HYDRAULIC PRESS
S0408070K Page 16
3.
Install pinion gear (19) on shaft assembly. Fasten cover (20) with hex bolts (21) and secure with lock wire (28) diagonally. NOTE: NOTE:
2 21 2
Apply Loctite #262 to bolt threads. Tighten bolt to 2,700 kgcm (195 ft lb).
1
Figure 24 4. Put jig (A) on pinion gear and press shaft assembly with pinion into case (17) until contact is obtained. Install lock ring (18) and turn case over.
PRESS
RS
Figure 25
S0408070K Page 17
5.
Using jig (B), insert seal (23) into case (17).
IMPORTANT
When installing, tap with rubber hammer lightly not to damage seal.
23
22
Figure 26 6. Place jig (F) on bearing (27) and press bearing (27) onto shaft assembly until contact is obtained.
F
27
Figure 27 7. Insert lock pin (9) in case (17) and install ring gear (8) on case (17). NOTE:
Coat mating faces of case (17) and ring gear (8) with Loctite #609.
Figure 28
S0408070K Page 18
8.
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. 2 (12) and shaft No. 2 (13).
1 1 1 1
16
Figure 29 9. Install carrier assembly No. 2 onto ring gear (8) and shaft assembly and install sun gear No. 2 (11) in carrier assembly No. 2.
11
Figure 30 10. Insert thrust plate (10) in sun gear No. 2 (11). Install carrier assembly No. 1 (7) onto ring gear (8) and sun gear No. 2 (11). Install sun gear No. 1 (6) onto carrier assembly No. 1 (7).
1 11
Figure 31
S0408070K Page 19
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. Apply Loctite #262 to bolt threads. Tighten bolt to 2,700 kgcm (195 ft lb).
NOTE: NOTE:
Figure 32 12. Secure motor (1) onto cover plate (5) with socket bolt (2). Install pipe (3-2) onto cover plate (5). Insert oil level gauge (3-1) into pipe. NOTE:
3-1
2
Coat mating faces of cover plate (5) and motor (1) with Loctite #609. Apply Loctite #262 to bolt threads. Tighten bolt to 1,100 kgcm (875 ft lb).
3-2
NOTE: NOTE:
IMPORTANT
After reassembling, turn gear pinion by hand and check if it is turned smoothly.
2
1
Figure 33
S0408070K Page 20
INSTALLATION
1. 2. Coat pinion gear with grease. Refer to operation manual for specications. Make sure two alignment pins (6, Figure 34) are installed in ange 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. Install twelve bolts and washers (4, Figure 34) to secure swing reduction gearbox (5) to frame. NOTE: NOTE: 5. 6. 7. 8.
4 1
3.
6 5
4.
Apply Loctite #262 to bolt threads. Tighten bolt to 95 kgm (6.87 ft lb).
7
Install drain plug (3) to frame. Connect and grease lubrication line (7, Figure 34) to reduction gearbox (5). Connect hoses as tagged during removal to swing motor (1, Figure 34). Fill swing reduction gearbox with oil. Refer to operation manual for specications. Figure 34
3
ARS2900L
S0408070K Page 21
START-UP PROCEDURES IMPORTANT

If the air is not vented from the system, it will cause damage to the swing motor and bearings. 1. 2. 3. Disconnect drain hose and ll swing motor case with hydraulic oil. Connect the drain hose. Start engine and set throttle at "LOW IDLE" and swing upper structure slowly two full revolutions to the left and right. Figure 35
4. 5.
Shut the engine down and check the hydraulic oil level. Fill hydraulic oil tank to "H" mark on sight gauge. Check for oil leaks and clean all ll and venting locations.
S0408070K Page 22
1LOWER STRUCTURE AND CHASSIS
S0505000 R1
1TRACK ASSEMBLY
CAUTION!
TRACK ASSEMBLY S0505000

MODEL Solar 290LC-V Solar 300LC-V SERIAL NUMBER RANGE 0001 and Up 1001 and Up
Copyright 2001 Daewoo December 2001 Track Assembly S0505000 Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Track Tension.................................................................................................. 3 Cleaning and Inspection (Wear Limits and Tolerances) ................................. 5 Track Shoes and Links ................................................................................... 9 Track Removal......................................................................................... 9 Track Installation ................................................................................... 10 Front Idler Roller........................................................................................... 11 Parts List ............................................................................................... 11 Front Idler Roller Disassembly .............................................................. 12 Front Idler Roller Reassembly............................................................... 14 Lower Roller ................................................................................................. 15 Parts List ............................................................................................... 15 Lower Roller Removal ........................................................................... 16 Lower Roller Disassembly..................................................................... 16 Lower Roller Reassembly ..................................................................... 17 Lower Roller Installation........................................................................ 18 Upper Roller ................................................................................................. 19 Parts List ............................................................................................... 19 Upper Roller Removal ........................................................................... 20 Upper Roller Disassembly..................................................................... 20 Upper Roller Reassembly ..................................................................... 22 Track Spring and Track Adjusting Cylinder ................................................... 24 Parts List ............................................................................................... 24
S0505000 Page 2
Track Assembly
GENERAL DESCRIPTION
The track assembly is composed of the following major components: 1. 2. 3. 4. 5. 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. Take all necessary precautions to make sure the machine wont move or shift position during service. Warm up the engine to prevent stalls, travel the excavator to an area that provides level, uniform ground support and/or use support blocks when necessary. The track adjusting mechanism is under very high pressure. NEVER release pressure too suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from the fully snugged down position. Bleed off pressure slowly and keep your body away from the valve at all times. Track shoe link pins and bushings wear with normal usage, reducing track tension. Periodic adjustment is necessary to compensate for wear and it may also be required by working conditions. 1. Track tension is checked by jacking up one side of the excavator. See Figure 1. Place blocking under frame while taking measurement.
HAOC740L
Figure 1
Track Assembly
S0505000 Page 3
Return to Master Table of Contents 2. Measuring the distance (A, Figure 2) between the bottom of the side frame and the top of the lowest crawler shoe. Recommended tension for operation over most types of terrain is 340 - 370 mm (13.39 - 14.57 in) NOTE:
This measurement can be thrown off if there is too much mud or dirt or other material in the track assembly. Clean off the tracks before checking clearance.
3.
Figure 2 Too little sag in the crawler track (less than 340 mm (13.39 in) clearance) can cause excessive component wear. The recommended adjustment can also be too tight causing accelerated stress and wear if ground conditions are wet, marshy or muddy, or if the ground is hard and full of rocks or gravel. The increased clearance recommended for muddy ground conditions is between 370 - 410 mm (14.57 - 16.14 in). The clearance should be approximately 410 mm (16.14 in) for operation over gravel, rocky terrain, or over sand or snow. Terrain Type Normal Muddy Gravel, Rocky, Sand or Snow Distance "A" 340 - 370 mm (13.39 - 14.57 in) 370 - 410 mm (14.57 - 16.14 in) 410 mm (16.14 in)
4.
WARNING!
The track adjusting mechanism is under very high pressure. NEVER release pressure too suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from the fully snugged down position. Bleed off pressure slowly and keep your body away from the valve at all times. 5. Track tension adjustments are made through the grease tting (1, Figure 3) in the middle of each side-frame. Adding grease increases the length of an adjustment cylinder (2). The longer the adjustment cylinder, the greater the 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 be retracted by bleeding off grease thru hole in adjustment cylinder (2, Figure 3).
6.
1
HAOC760L
Figure 3
S0505000 Page 4
Track Assembly
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) CAUTION!

Refer to the "Welding Precautions and Guidelines" information in "General Maintenance Procedures" section for general recommendations and specic safety precautions, before starting any lower travel frame component rebuilding procedure. The tables that follow provide factory-specied dimensional limits (as-new condition, recommended service and replacement limit) for lower travel frame components. Recommended maintenance to renew most listed components requires welding on additional material and grinding off excess. Some components must be replaced before the service limit is exceeded. No maintenance or renewal is possible. Compare the values in the tables with dimensions and proles shown in the adjacent gures.
Component / Reference Dimensions Reference Normal (New) Dimension Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
Standard 600 mm Shoe

D A B C
A B C
E HDA7012L
D E
Figure 4
26 mm (1.024") 26 mm (1.024") 37 mm (1.457") 232.5 mm (9.154") 110 mm (4.331") 116.4 mm (4.583") 50 mm (1.969") 203.2 mm (8.0")
20 mm (0.787") 20 mm (0.787") 30 mm (1.181")
13 mm [P] (0.512") 13 mm [P] (0.512") 23 mm [P] (0.906")
Track link, master link
A B
A
108 mm (4.252") 45 mm (1.772") 206 mm (8.110")
B C
C*
HDA7013L
103 mm [P] (4.055") 40 mm [P] (1.575") 208 mm [R] (8.189")
Figure 5
*Check and record the pitch of at least 5 links. Use average of all measurements to assess required service or action. Master links must be replaced, they cannot be renewed or rebuilt.
Track Assembly
S0505000 Page 5

Normal (New) Dimension Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
Component / Reference Dimensions
Reference
Track link, master pin bushing, master bushing
A B
C
D
C
D* * Master pin
66.45 mm (2.616") 45.0 mm (1.772") 44.5 mm (1.752") 42.9 mm (1.689")
62.5 mm (2.461") 47.0 mm (1.850") 42.5 mm (1.673") 40.5 mm (1.594")
59.0 mm [R] (2.323") 49.0 mm [R] (1.929") 41.5 mm [R] (1.634") 39.0 mm [R] (1.535")
HDA7014L
Figure 6
HDA7015L
Figure 7 Lower roller, axle Lower roller, bushing Axle-bushing, clearance Lower roller, axle Lower roller, bushing B B 10 mm (0.394") 9.0 mm (0.354") 246 mm (9.685") 12.35 mm (0.486") 190 mm (7.480") 226 mm (8.898") 252 mm (9.921") 9.0 mm (0.354") 280 mm (11.024") 210 mm (8.268") 8.5 mm (0.335") A A 70 mm (2.756") 69.5 mm (2.736") 70.5 mm (2.776") 1.0 mm (0.039") 69.2 mm [R] (2.724") 71 mm [R] (2.796") 1.8 mm (0.071")
Lower roller dimensions

A B
A B C D
D C
257 mm [R] (10.118") 6.0 mm [P] (0.236") 175 mm [P] (6.890") 205 mm [P] (8.071")
HDA7016L
Figure 8
S0505000 Page 6
Track Assembly

Reference
Lower roller, side collar

C
A B
9.75
B D A
70 mm (2.756") 145 mm (5.709") 64.75 mm (2.550")
70.5 mm (2.776") 138 mm (5.433") 63.5 mm (2.50")
70.7 mm [R] (2.783") 135 mm [R] (5.315") 62.5 mm [R] (2.461")
HDA7017L
Figure 9
Figure 10 Upper roller, axle Upper roller, bushing Axle-bushing, clearance Upper roller, axle Upper roller, bushing B B 6.5 mm (0.256") 5.5 mm (0.217") 78 mm (3.071") 14 mm (0.551") 142 mm (5.591") 169 mm (6.654") 73 mm (2.874") 11 mm (0.433") 135 mm (5.315") 160 mm (6.299") 5.0 mm (0.197") 70 mm [P] (2.756") 8 mm [P] (0.315") 130 mm [P] (5.118") 155 mm [P] (6.102") A A 55 mm (2.165") 54.5 mm (2.146") 55.5 mm (2.185") 1.0 mm (0.039") 54.22 mm [R] (2.134") 56 mm [R] (2.205") 1.8 mm (0.071")
Upper idler
A B C D
Figure 11
Track Assembly
S0505000 Page 7

Reference
Front idler, axle
90 mm (3.543")
89.5 mm (3.524")
89.2 mm [R] (3.512")
HDA7018L
Figure 12 Front idler, bushing Axle-bushing, clearance Front idler, axle Front idler, bushing B B 8 mm (0.315") 7.0 mm (0.276") 200 mm (7.874") 99 mm (3.898") 600 mm (23.622") 25 mm (0.984") 192 mm (7.559") 95 mm (3.740") 590 mm (23.228") 30 mm (1.181") 6.5 mm (0.256") 188 mm [P] (7.401") 93 mm [P] (3.661") 585 mm [P] (23.031") 32.5 mm [P] (1.280") A 90.5 mm (3.563") 1.0 mm (0.039") 91 mm [R] (3.583") 1.8 mm (0.071")
Front idler
A B
B A
C
C D
D
HDA7021L
Figure 13
Front idler, bearing

A B 10
A B C
C E
74 mm (2.913") 32.5 mm (1.280") 120 mm (4.724") 90 mm (3.543")
70 mm (2.756") 30 mm (1.181") 117 mm (4.606") 90.5 mm (3.563")
66 mm [P] (2.598") 28 mm [P] (1.102") 114 mm [P] (4.488") 90.7 mm [P] (3.571")
HDA7022L
Figure 14
S0505000 Page 8
Track Assembly
TRACK SHOES AND LINKS

TRACK REMOVAL 1. 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 15) is positioned at approximately 10 oclock from top position on travel reduction gearbox. Remove four nuts and bolts (2, Figure 15) holding shoe to link. Remove enough shoes to make access to lock pin easier. NOTE:
2. 3.
4.
Figure 15
Support track shoes with blocking so that when master pin (4, Figure 15) is removed tack will not fall.
5.
Straighten lock pin (3, Figure 15) and remove it from master pin (4). Discard lock pin. Remove master pin from master links. Move unit forward until entire track is laying on ground. NOTE:
6. 7.
Do not drive unit off track.
HAOV100L
Figure 16
Track Assembly
S0505000 Page 9
Return to Master Table of Contents 8. Rotate upper structure to 90 from track. Use bucket and boom to raise track frame off track. Position blocking under frame.
9.
HAOC741L
Figure 17 TRACK INSTALLATION 1. Lay rebuilt or new track into position under track frame. End of track should be positioned under front idler roller. With upper structure at 90 to track frame. Use bucket and boom to raise track frame off blocking. With blocking removed, lower track frame onto track. Make sure all rollers are properly positioned on track.
HAOC741L
2.
3.
Figure 18 4. Move unit backwards while feeding track up over front idler roller. Continue to pull track back until it engages drive sprocket. Align master links and install master pin. Insert new lock pin in master pin. Bend end of pin over so it is pointing in opposite direction of other end as shown. Apply track tension. Refer to "Track Tension" in this section for procedure.
HAOV101L
5. 6.
7.
Figure 19
S0505000 Page 10
Track Assembly
FRONT IDLER ROLLER

PARTS LIST
Figure 20 Reference Number 1 2 3 4 Reference Number 5 6 7 8
Description Bearing Plug Pin O-ring
Description Axle Group Seal Idler Bushing
Track Assembly
S0505000 Page 11
Return to Master Table of Contents FRONT IDLER ROLLER DISASSEMBLY 1. Remove plug (2, Figure 21) and drain oil from roller assembly (1).
Figure 21 2. Separate the pin (3, Figure 22) from the bearing (1).
Figure 22 3. Use a press to remove the bearing from the axle. Separate the O-ring (4, Figure 23) from the axle and insert it into the bearing.
Figure 23
S0505000 Page 12
Track Assembly
Return to Master Table of Contents 4. Detach the group seal (6, Figure 24) from the idler (7) and bearing (1).
Figure 24 5. Use a press to separate the axle (5, Figure 25), O-ring (4) and bearing (1).
Figure 25 6. Remove bushing (8, Figure 26) with the press and special tool (ST-1909).
Figure 26
Track Assembly
S0505000 Page 13
Return to Master Table of Contents FRONT IDLER ROLLER REASSEMBLY 1. Degrease, clean and dry all parts before reassembly. Insert bushing (8, Figure 27) into the idler (7). Grease O-ring (4, Figure 27) and insert it into the axle. Align the bearing (1, Figure 27) and axle (5) holes and pin (3) them together.
2. 3.
Figure 27 4. Install group seal (6, Figure 28) inside the idler (7) and bearing (1). NOTE:
Apply clean engine oil to the joint side of the group seal. Apply grease to the group seal O-ring.
Figure 28 5. 6. Install idler (7, Figure 29) on the axle. Install bearing (1, Figure 29) and pin (3) to the axle. NOTE:
Fill the idler assembly with new engine oil with approximately 260 cc (1/2 pint).
Figure 29
S0505000 Page 14
Track Assembly
LOWER ROLLER
PARTS LIST
Figure 30 Reference Number 1 2 3 4 Reference Number 5 6 7 8
Description Pin O-ring Collar Axle
Description Roller Group Seal Bushing Plug
Track Assembly
S0505000 Page 15
Return to Master Table of Contents LOWER ROLLER REMOVAL 1. 2. 3. 4. 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. NOTE:
HAOC740L
To gain access to some rollers the link guard may have to be removed. Remove four spring washers and bolts to remove guard. If additional track clearance is required, remove upper rollers before raising track.
Figure 31
NOTE:
LOWER ROLLER DISASSEMBLY 1. 2. Remove plug from the collar and drain oil. Pull the pin (1, Figure 32) from the collar.
Figure 32 3. Separate the collar (3, Figure 33) from the axle, using a press.
Figure 33
S0505000 Page 16
Track Assembly
Return to Master Table of Contents 4. 5. 6. Detach O-rings (2, Figure 34) from the axle. Separate group seals (6, Figure 34) from the collar and roller (5). Detach collar (3, Figure 34) and O-rings (2) from the axle, using a press.
Figure 34 LOWER ROLLER REASSEMBLY 1. Degrease, clean and dry all parts before reassembly. Insert bushing (7, Figure 35) into roller. Apply grease to the O-rings (2, Figure 35) and insert into axle.
2.
Figure 35 3. Align collar (3, Figure 36) and axle (4) pin holes and pin (1) the collar.
Figure 36
Track Assembly
S0505000 Page 17
Return to Master Table of Contents 4. Insert group seals (6, Figure 37) into the roller (5) and collar (3). NOTE:
5.
Slide the axle inside the roller.
Figure 37 6. 7. Install the collar (3, Figure 38), O-ring (2), and pin (1) on the remaining side. Fill with clean engine oil approximately 350 cc (3/4 pint). with
Figure 38 LOWER ROLLER INSTALLATION 1. Install four bolts to hold lower roller assembly to track frame. NOTE:
To gain access to some rollers a link guard may have to be removed. Remove four spring washers and bolts to remove guard.
HAOC740L
Figure 39
S0505000 Page 18
Track Assembly
UPPER ROLLER
PARTS LIST
Figure 40 Reference Number 1 2 3 4 5 6 Reference Number 7 8 9 10 11 12
Description Plug Bolt Cover Bolt Washer Roller
Description Axle Group Seal Bracket Bushing O-ring Lock Washer
Track Assembly
S0505000 Page 19
Return to Master Table of Contents UPPER ROLLER REMOVAL 1. 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.
2. 3.
Figure 41 UPPER ROLLER DISASSEMBLY 1. Remove the plug (1, Figure 42) from the cover and drain oil.
Figure 42 2. Remove the bolts and cover (3, Figure 43). Detach bolts (4) and washer (5).
Figure 43 3. Separate the roller (6, Figure 44) from the axle (7).
Figure 44
S0505000 Page 20
Track Assembly
Return to Master Table of Contents 4. Separate the group seal (8, Figure 45) from the roller and bracket (9).
Figure 45 5. Separate the bushing (10, Figure 46) from the roller with a press and special tool (ST1919).
Figure 46
Track Assembly
S0505000 Page 21
Return to Master Table of Contents UPPER ROLLER REASSEMBLY 1. Degrease, clean and dry all parts before reassembly. Insert bushing (10, Figure 47) into the roller (6).
Figure 47 2. Insert group seal (8, Figure 48) into the roller (6) and bushing. NOTE:
Figure 48 3. 4. 5. Install the axle, washer (5, Figure 49) and bolt (4). Attach group seal (8, Figure 40) to the roller (6, Figure 49) and cover (3). Insert the O-ring (11, Figure 49) to the cover. Attach cover (3) and bolt (2) to the roller. Fill with engine oil.
6.
Figure 49
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Track Assembly
Return to Master Table of Contents 7. Tighten plug (1, Figure 50).
Figure 50
Track Assembly
S0505000 Page 23
TRACK SPRING AND TRACK ADJUSTING CYLINDER

PARTS LIST
Figure 51
S0505000 Page 24
Track Assembly
Return to Master Table of Contents Reference Number 1 2 3 4 5 6 7 8 9 10 Description Piston Rod Piston Ring Backup Ring Packing Retaining Ring Rod O-ring Cylinder Spring Spacer Reference Number 11 12 13 14 15 16 17 18 19 Description Flange Nut Valve Bolt Plate Yoke Socket Bolt Flange O-ring
Track Assembly
S0505000 Page 25
S0505000 Page 26
Track Assembly
1ENGINE AND DRIVE TRAIN
S0605060K
1AIR-CONDITIONER
CAUTION!
AIR-CONDITIONER
MODEL Solar 300LC-V Solar 300LL Solar 340LC-V Solar 420LC-V Solar 470LC-V 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up SERIAL NUMBER RANGE
Copyright 2001 Daewoo October 2001 Air-Conditioner S0605060K Page 1
TABLE OF CONTENTS
Refrigerant Circulation ................................................................................... 3 Control Panel.................................................................................................. 5 Control Specications..................................................................................... 6 Temperature Level Control and Display ......................................................... 7 Air Discharge According to Path Selection..................................................... 8 Air-conditioning System Circuit Diagram...................................................... 10 Troubleshooting ............................................................................................ 12 Refrigerant System Repairs ......................................................................... 15 Refrigerant Safe Handling Procedures ................................................. 15 Repair and Replacement Procedure..................................................... 16 Refrigerant Recovery ............................................................................ 18 Vacuuming Refrigerant System............................................................. 18 Leakage Check ..................................................................................... 19 Refrigerant Charging............................................................................. 20 Inspecting System For Leakage............................................................ 22
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Air-Conditioner
REFRIGERANT CIRCULATION
1
5 4
3
Figure 1 Reference Number 1 2 3 4 Description Evaporator Expansion Valve Condenser Condenser Fan Reference Number 5 6 7
HDA6046L
Description Compressor Blower Fan Receiver Dryer
Air-Conditioner
S0605060K Page 3
Shading
Temperature High High Low High Low
Refrigerant State High Pressure Gas High Pressure Liquid Low Pressure Liquid High Pressure Gas/Liquid Low Pressure Gas
Refrigerant (R134a) is compressed to approximately 15.0 kg/sq cm (213 psi) within the compressor. The compressed refrigerant ows into the condenser at high temperature (approximately 80C (176F)). The refrigerant in the condenser is cooled to approximately 60 by the condenser fan. At this time the refrigerant changes from the gas to the liquid state, even though the temperature has only been reduced 20C (68F). (From 80 - 60C (176 - 140F)). The refrigerant in its liquid form is injected into the evaporator through the expansion valve. At this time the pressure is reduced by approximately 2.0 kg/sq cm (28 psi) and the temperature is also reduced. As a result, the refrigerant absorbs the heat from the air surrounding the evaporator creating a cooling effect and changes from the gas to the liquid state. The refrigerant once again ows into the compressor in the gaseous state and the process is repeated.
WARNING!
Refrigerant gas is pressurized and sealed in the air conditioning system. Special precautions are required for the proper recharging or release of refrigerant. Release of refrigerant into the atmosphere is strictly regulated by law. Make sure that you are in compliance with all mandated federal, state and municipality requirements, before starting any service or repair of the air conditioner. Refrigerant gas used in the system must meet or exceed specications for R134a refrigerant, or any subsequently issued environmentallymandated standard.
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Air-Conditioner
CONTROL PANEL
ARO0501L
Figure 2
INPUT
CONTROL PANEL
OUTPUT
DISPLAY TEMPERATURE SENSOR

OFF SW A / C SW VENT SW DEF. SW HEAT SW FRE SW REC SW LOW SW MID SW HI SW COOL SW WARM SW
LOW SPEED RELAY MID SPEED RELAY HIGH SPEED RELAY BLOWER MOTOR
A/C CONTROL PANEL
TEMP. CONTROL ACTUATOR VENT ACTUATOR DEF. ACTUATOR INTAKE ACTUATOR COMP. RELAY CONDENSER FAN RELAY
MIX DOOR VENT CONTROL FOOT / DEF. RECYCLE/FRESH AIR CONTROL COMPRESSOR CONDENSER FAN
TEMPERATURE CONTROL ACTUATOR
HDA6048L
Figure 3
Air-Conditioner
S0605060K Page 5
CONTROL SPECIFICATIONS
Control Item Temperature Control Control Switch COOL Switch WARM Switch
100%
Control Specications
MAX COOL
50%
MAX HOT 0%
HDA6049L
Figure 4 Temperature control switch consists of a 24 step variable selector. The display uses 7, Green / Red twocolor LEDs to display the selected temperature. Blower Fan Speed Control OFF Switch LOW Switch MID Switch HI Switch
HI RELAY MID RELAY LOW RELAY
OFF
LOW
MID
HI
HDA6050L
Figure 5 Compressor Control Temperature Sensor

COMP ON
COMP OFF 1.5 C 4.0 C

HDA6051L
Figure 6
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Air-Conditioner
TEMPERATURE LEVEL CONTROL AND DISPLAY

Step 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 LED 1 Green Green Green Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red LED 2 Green Green Green Green Green Green Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red LED 3 Green Green Green Green Green Green Green Green Green Red Red Red Red Red Red Red Red Red Red Red Red Red Red Red LED 4 Green Green Green Green Green Green Green Green Green Green Green Green Red Red Red Red Red Red Red Red Red Red Red Red LED 5 Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Red Red Red Red Red Red Red Red Red LED 6 Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Red Red Red Red Red Red LED 7 Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Green Red Red Red Position Sensor Voltage 4.50 V 0.2 4.33 V 0.2 4.15 V 0.2 3.98 V 0.2 3.80 V 0.2 3.63 V 0.2 3.46 V 0.2 3.28 V 0.2 3.11 V 0.2 2.93 V 0.2 2.76 V 0.2 2.59 V 0.2 2.41 V 0.2 2.24 V 0.2 2.07 V 0.2 1.89 V 0.2 1.72 V 0.2 1.54 V 0.2 1.37 V 0.2 1.20 V 0.2 1.02 V 0.2 0.85 V 0.2 0.67 V 0.2 0.50 V 0.2 Remark MAX. COOL
MAX. HOT
Air-Conditioner
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AIR DISCHARGE ACCORDING TO PATH SELECTION

Face, Rear, and Defroster
ARS1280L
Figure 7
Foot
ARS1290L
Figure 8
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Air-Conditioner
Face and Defroster
ARS1300L
Figure 9
Air-Conditioner
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AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM
5
10A 20A 30A
3
B
2
A BR E
4 6
0 6 3 10 I II 9 15 14 2
1 15-2
-
15-1
+ M
22 11 13
15-3
15-4
15-5
8
+ M
7
87a 30 87 85 86 3 5 8 18 19 10 MODE SELECT 23 AIR MODE RECIRCLE/FRESH 30 87 85 86 BLOWER SPEED TEMP. CONTROL 14 15 2 9 16 4 DEF 2 3 7 6 26 CN 6 HRS 26P 16 1 3 2 4 5 1 6 (COOL) M M 21 20 7 17 8 VENT DEF FOOT 11 12 13 9 10 HIGH MID LOW REC FRE M
15-6 15-7 15-8
9
87a
10
M FOOT
15-9
CN5 AMP MIC 13P + 250 4P
11 12
14
HR
15
3P
13
(CN6) (C N 5)
ARS1310L
Figure 10
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Air-Conditioner
Reference Number 1 2 3 4 5 6 7 8 9 10 11 12
Description Battery Battery Relay Fusible Link Circuit Breaker Fuse Lamp Switch Condenser Fan Relay Condenser Fan Motor Compressor Relay Foot / Defrost Control Actuator Receiver Dryer (Low / High Pressure Cut Off Switch) Diode
Reference Number 13 14 15 15-1 15-2 15-3 15-4 15-5 15-6 15-7 15-8 15-9
Description Compressor A/C Control Panel A/C Unit Blower Motor Resister High Speed Relay Mid Speed Relay Low Speed Relay Recirculate / Fresh Air Control Actuator Vent Actuator Temperature Control Actuator Temperature Sensor (Evaporator)
Air-Conditioner
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TROUBLESHOOTING
Refrigerant Pressure Check
LO
HI
HDA6074L
Figure 11 1. 2. 3. 4. 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. 1 High Pressure: 8.0 - 10.0 kg/cm2 (114 - 142 psi)
Low Pressure: Approximately 1.0 kg/cm2 (14 psi) Possible Cause: Low Refrigerant Level Step Inspection Item 1 Check for traces of refrigerant oil. Using a leak detection device or soapy water check for refrigerant leakage at all major components and joints. High Pressure: Over 23 kg/cm2 (327 psi) Yes No 2 Yes No
Remedy Reassemble using tightening torque. Go to next step.
correct
Repair leaking component. Recharge system to correct pressure.
Low Pressure: Approximately 2.5 - 3.0 kg/cm2 (36 - 43 psi) Remedy Clean, repair or replace condenser. Refrigerant overcharge.
Possible Cause: Overcharge, Frost on condenser Step Inspection Item 1 Check for condenser contamination. pin damage or Yes No
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Air-Conditioner
Low Pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi) Possible Cause: Air in system. 1. Recover any remaining refrigerant. 2. 3. Vacuum out system. Recharge system. NOTE:
High Pressure: Approximately 20 - 25 kg/cm2 (285 - 356 psi)
If the system has been exposed to the air for a long period of time, replace the receiver dryer.
High Pressure: Over 6 kg/cm2 (85 psi)
Low Pressure: Approximately 760 mmHg (Negative Pressure) Possible Cause: Refrigerant does not circulate Step Inspection Item Remedy 1. 2. 3. 4. 1 5. Connect manifold gauge and start engine. Turn on air-conditioner. Set blower switch to HIGH position. Turn air-conditioner OFF and wait 10 minutes. Recheck high / low pressure readings. No Contaminated system, expansion valve. (Replace assembly.) evaporator replace core Yes Moisture in receiver dryer. system, replace
High Pressure: 13.0 - 19.0 kg/cm2 (185 - 270 psi) Low Pressure: 1.5 - 3.3 kg/cm2 (21.3 - 46.9 psi)
High Pressure: Over 6 - 18 kg/cm2 (85 - 256 psi)
Low Pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable. Possible Cause: Moisture in system has iced up the expansion valve. NOTE: 1. 2. 3.
When the absorbed moisture freezes the pressure readings may look normal. Careful readings should be made to determine whether pressure is in normal range. 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.
Low Pressure: 2.5 kg/cm2 (36 psi) Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor. Step Inspection Item Remedy 1 Inspect whether the temperature sensor is installed properly. Yes No Replace expansion valve. Exchange duct sensor.
High Pressure: Over 22.0 - 23 kg/cm2 (313 - 327 psi)
Air-Conditioner
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Low Pressure: 4.0 - 6.0 kg/cm2 (57 - 85 psi) Possible Cause: Low refrigerant pressure due to poor compressor compression Inspect and replace compressor if necessary.
High Pressure: Over 7.0 - 11.0 kg/cm2 (100 - 156 psi)
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Air-Conditioner
REFRIGERANT SYSTEM REPAIRS WARNING!

Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately ush 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 40C (104F). Be careful not to drop the container from a high location The contents are under high pressure and should not be used with compressed air or near an open ame. REFRIGERANT SAFE HANDLING PROCEDURES
UNION
NUT
TORQUE WRENCH
CORRECT WRONG WRONG CORRECT
WRONG
O - RING POSITION
CAP & PLUG

Figure 12
CORRECT
WRONG
WRONG
HDA6066L
The following procedures should be observed for safe handling of refrigerant during vacuum and charging process. 1. 2. 3. 4. Use an approved recovery / charging device which can safely perform vacuum and charge work simultaneously. The new refrigerant has improved cooling characteristics than the old type and care should be used not to overcharge the system. Do not over tighten connections when working on refrigerant system. The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to use equipment use in servicing the old refrigerant system.
Air-Conditioner
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5.
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. Be certain the O-rings are seated properly on the refrigerant line lip. Always use new O-rings when reassembling parts. Do not reuse old O-rings. Use a vacuum pump to evacuate refrigerant system of air. When charging the refrigerant system with the engine running, do not open the high pressure valve on the manifold gauge as the reverse ow of high pressure refrigerant will rupture the hose. When releasing the high pressure hose after completing the charging process, quickly disconnect the hose to minimize refrigerant released to the air.
6. 7. 8. 9. 10.
REPAIR AND REPLACEMENT PROCEDURE 1. Work Procedure A. 2. Before repairing or replacing any refrigerant components rst, return all refrigerant oil to the compressor and perform recovery procedures.
Operating Condition A. B. C. Run engine at maximum engine speed. Select HI blower fan speed and select A/C switch to ON. Set the temperature control switch for maximum cooling and leave running for approximately 20 minutes.
NOTE:
The manifold gauge dial pointer can vary depending on the outdoor temperatures.
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Air-Conditioner
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
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS
HDA6067L Figure 13
Air-Conditioner
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REFRIGERANT RECOVERY Reference Number 1 2 3 4 5 1. Description To Compressor Low Pressure Side High Pressure Side From Receiver Refrigerant Recovery Tank 1 2 3 4
Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. NOTE:
5
HDA6067L
Be careful not to switch the connections for the low and high pressure valves.
Figure 14
2.
Open the high pressure valve slowly to release the refrigerant to the recovery unit. NOTE:
Open the valve slowly, while checking to see that refrigerant is not leaking out.
3. 4.
When the manifold gauge dial falls below 3.5 kg/cm2 (50 psi), slowly open the low pressure valve. Open both the high and low pressure valves slowly until the manifold gauge dials indicates 0 kg/cm2 (0 psi).
VACUUMING REFRIGERANT SYSTEM Reference Number 1 2 3 4 5 1. 2 Description To Compressor Low Pressure Side High Pressure Side From Receiver Vacuum Pump 5
HDA6068L
3 4
Vacuuming Procedure NOTE:
When the A/C system has been exposed to the air, it must be vacuumed out. Perform vacuum process for 30 minutes for complete moisture and air evacuation.
Figure 15
A. B. C.
Attach the manifold gauges and vacuum pump to the refrigerant system as shown. Turn on the vacuum pump and open both valves. When the low pressure gauge shows approximately 710 mmHg, close both valves and turn off vacuum pump.
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Air-Conditioner
2.
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.
3.
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. A. B. C. Turn on the vacuum pump and slowly open both valves. Figure 16
HDA6069L
Allow vacuum pump to run for additional 20 minutes until the low pressure gauge dial reads approximately 750 mmHg. Close both valves and stop the vacuum pump.
4.
Installation Of Refrigerant Container Reference Number 1 2 3 A. Description Handle Hose Connection Mounting Disk 3 2 1
Before mounting valve on the container, make sure the handle is in the counter clockwise most position, with the puncture pin retracted and the mounting disk is in the raised position. Attach the manifold gauge center hose to the valve assembly.
HDA6070L
Figure 17
B. C. D. E.
Turn the disc in the clockwise direction and securely mount valve onto refrigerant container. Turn the valve handle in the clockwise direction and puncture the container seal with the pin. Once the can has been punctured, turn the handle in the counter clockwise direction so the refrigerant can ow into the manifold gauge center hose. At this time, do not open the low and high pressure valves of the manifold gauge. Press the manifold gauge low side valve to eliminate the trapped air in the hose.
F.
LEAKAGE CHECK NOTE: 1. 2.
Perform the leakage check after completing vacuuming process.
After attaching the manifold gauge, open the high side valve. Charge system until the low side gauge dial indicates a pressure of 1 kg/cm2 (14 psi) and close the high side valve.
Air-Conditioner
S0605060K Page 19
3.
Using a refrigerant leak detector or soapy water check each joint for leakage. Reference Number 1 Description Refrigerant Leak Detection Device
4.
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 charging process.
HDA6071L
5.
Figure 18
WARNING!
For accurate refrigerant leak detection, perform leak detection procedure in a well ventilated area. REFRIGERANT CHARGING 1. Perform the vacuuming procedure, vacuum holding and leaking tests as described in the proceeding headings. NOTE:
First charge the refrigerant system with 100g (3.5 ounces) of refrigerant with the engine off. Then using the manifold gauges as a guide fully charge the system with the engine running. When exchanging refrigerant containers, press the manifold gauge low side valve to eliminate air from the charging hose.
Reference Number 1 2 3 4 5
Description To Compressor Low Pressure Side High Pressure Side From Receiver Refrigerant Supply Container 1
3 4
2.
Charge the system by opening the manifold gauge low side valve. Initial charge amount: 100 g (3.5 ounces). Figure 19
5
HDA6072L
3.
If refrigerant does not ow freely into system, try starting engine rst before operating air-conditioner. Temperature control switch setting: Maximum Cooling Blower Speed Setting: Hi (3 step)
S0605060K Page 20
Air-Conditioner
Engine Speed: 1,300 - 1,500 RPM
WARNING!
When charging refrigerant system with the engine running; 4. 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 High Side Gauge Low Side Gauge NOTE: Standard Reading 13 - 20 kg/cm2 (185 - 285 psi) 1.5 - 3.5 kg/cm2 (22 - 50 psi)
These standards are for outside temperatures between 30 - 35C (86 - 95F). The gauge readings may vary for extreme temperature conditions.
WARNING!
When outside temperature is low, warm the refrigerant supply container with warm water not exceeding 40C (104F). Do not allow water to come in contact with the charging adapter valve handle. When outside temperature is high, cool off refrigerant supply container and condenser to aid the refrigerant charging process.
5. 6.
Close low pressure side valve. Shut off engine and close refrigerant supply container adapter valve. Disconnect manifold gauge hoses from vehicle.
Air-Conditioner
S0605060K Page 21
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:
2 1
When the refrigerant circulation has been stopped the high pressure will start to decrease and the low pressure will start to increase until they are equalized. Starting the inspection from the high side will result in a accurate test.
Description Pressure High Pressure Low Pressure Compressor Stop
3 4 Figure 20
HDA6073L
Reference Number 1 2 3 4 Inspection Procedure 1.
High Pressure Side Compressor outlet condenser inlet receiver dryer inlet air-conditioner unit inlet
2.
Low pressure side Compressor inlet air-conditioner unit outlet
3.
Compressor Compressor shaft area, bolt hole area and magnetic clutch area.
4.
Receiver dryer Pressure switch and plug area.
5.
Connection valve area Inspect all valve areas. Verify all valves are capped to prevent leaking. Check for foreign matter inside of valve cap.
6.
Interior of air-conditioning unit. After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds minimum.) NOTE:
When inspecting leakage from the air-conditioning unit, perform the inspection in a well ventilated area.
S0605060K Page 22
Air-Conditioner
S0609010K
DRIVE COUPLING (MAIN PUMP)

CAUTION!
DRIVE COUPLING (MAIN PUMP)

Copyright 2001 Daewoo December 2001 Drive Coupling (Main Pump) S0609010K Page 1
TABLE OF CONTENTS
Drive Coupling................................................................................................ 3 Special Tools .................................................................................................. 4 Drive Coupling Installation.............................................................................. 6 Installation Procedure ............................................................................. 9
S0609010K Page 2
Drive Coupling (Main Pump)
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 specic value. Figure 1 thru Figure 2, show typical drive coupling installations.
ARS1710L
Figure 1 KAWASAKI
ARS1720L
Figure 2 REXROTH
S0609010K Page 3
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. NOTE:
In manufacturing drawings (Figure 4), dimension "A" and "B" equal the "Measurement H." The two tools shown are designed to be used on various models of equipment. Only one end of the tool is used for a specic model of equipment.
Figure 3
B D E F G
RELIEF
H RELIEF KNURL
HAAA8350
Figure 4
S0609010K Page 4
Dimension A B C D E F G H
Dimensional Details for Figure 4 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 Chamfer
S0609010K Page 5
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 Page 6
Table 1 Parts Information and Torque for Figure 5 Reference Description Qty. Number 1 Spring Pin 4 2 Insert 4 3 Bolt 4 4 Flywheel 1 5 Spring Pin 8 6 Insert 4 7 Hub 1 8 Bolt 4 9 Pump shaft 1 10 Clamping screw 2 11 Element 1
Torque (See Table 2)
Ta
Ta Tb
S0609010K Page 7
Specication for "Measurement H," from front hub face to pump shaft end, and TIGHTENING TORQUE of bolts and screws written in the "Table 2" must be observed.
Table 2 Specication for "Measurement H" and Torque (Refer to Figure 5) Coupling Part Torque Value for Model "Measurement H" Number "Ta" S300LC-V 5.5 - 6.5 mm 44 - 49 kgm 414-00040 (0.216 - 0.256 in.) (318 - 354 ft lb) S300LL S340LC-V S420LC-V S470LC-V 414-00041 6.5 - 7.5 mm (0.256 - 0.295 in.) 44 - 49 kgm (318 - 354 ft lb)
Torque Value for "Tb" 20 - 22 kgm (145 - 159 ft lb) 20 - 22 kgm (145 - 159 ft lb)
S0609010K Page 8
INSTALLATION PROCEDURE NOTE: 1.
Refer to Figure 5 while using following procedure.
Install spring pin (1) and attach insert (2) with bolt (3) to engine ywheel (4). NOTE:
Tighten bolts to value "Ta" in the tables.
2.
Install two spring pins (5) and attach insert (6) to hub (7) bolts (8). NOTE:
Tighten bolts to value "Ta" in the tables.
3. 4.
Attach ywheel cover to the main pump with bolts. (S300LC-V, S340LC-V only.) Slide hub (7) into place on pump shaft (9) as specied in the "Table 2" for "Measurement H" and secure it in position with clamping screws (10). NOTE: NOTE:
Tighten clamping screws to value "Tb" in the tables. Coat clamping screws (10) with Loctite #262.
Figure 6 DRIVE COUPLING INSTALLATION
5. 6. 7.
Install element (11) between inserts (2) on engine ywheel (4) Install main pump and hub (7) by pushing it softly into element (11). Attach ywheel cover / pump housing to ywheel housing with bolts
CAUTION!
1. 2. 3. 4. Bolts (3 and 8) are coated against loosening with a bonding compound. Do not use any additional bonding compounds, oils or cleaning solvents on them. Element (11) is non-resistant to bonding compounds, oil or grease. Be careful not to expose it to them. Remove oil or dirt from ywheel cover and pump shaft before assembly. Misalignment between pump and engine should be controlled to less than 0.6 mm (0.023 in.).
S0609010K Page 9
S0609010K Page 10
1HYDRAULICS
S0702170K
1HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENT

CAUTION!
HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENT

Copyright 2001 Daewoo November 2001 Hydraulic System Troubleshooting, Testing and Adjustment S0702170K Page 1
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 ................................................................................... 7 Arm Dump Circuit.................................................................................... 7 Bucket Operating Circuit ......................................................................... 8 Bucket Crowd Circuit............................................................................... 8 Bucket Dump Circuit ............................................................................... 8 Swing Operating Circuit .......................................................................... 8 Right Swing Operating Circuit ................................................................. 9 Left Swing Operating Circuit ................................................................... 9 Swing Relief Valve and Make-up Valve ................................................... 9 Travel Operating Circuit........................................................................... 9 Forward Travel Circuit............................................................................ 10 Reverse Travel Circuit............................................................................ 10 Procedural Troubleshooting Baseline Recommendations ............................ 10 Initial Checks and Tests to Establish Operating Condition of the Excavator .............................................................................................. 10 Pilot Pressure ............................................................................................... 11 Adjustment and Testing ......................................................................... 11 Power Mode Valve ........................................................................................ 12 Current Signal and Hydraulic Pressure Adjustments ............................ 12 Swing Priority Valve...................................................................................... 13 Control Valve Pressure and Current Adjustments................................. 13 Pressure Up Valve........................................................................................ 14 Checks and Adjustments ...................................................................... 14
S0702170K Page 2
Hydraulic System Troubleshooting, Testing and Adjustment
Pump Input Power Control ........................................................................... 15 Pump Regulator Adjustment ................................................................. 15 Flow Meter and Flow Meter Kit Installation and Testing ............................... 17 Swing System Troubleshooting .................................................................... 18 Precautions/Initial Checks..................................................................... 18 Swing Relief Valve Checking and Adjustment....................................... 19 Troubleshooting Swing Gearbox................................................................ 20 Troubleshooting Hydraulic Problems ......................................................... 21 Troubleshooting Control Valve ................................................................... 23 Troubleshooting Travel Control Valve......................................................... 24 Troubleshooting Joystick Control Valve ..................................................... 25
S0702170K Page 3
HYDRAULIC SYSTEM - GENERAL NOTES

3
ARS1690L
Figure 1 The hydraulic system has several improvements over conventional hydraulic systems - including crosssensing total horsepower control - to maximize output efciency. The system features an electronically controlled output optimization system, which allows the operator to choose between three, distinctly different power modes: high-output/rapid cycling maximum-speed power mode, low fuel consumption/low-noise light duty power mode, and a standard power mode for most types of general operation offering some of the advantages of each of the other two power modes. Electronic management of hydraulic control valves assists in optimizing the application speed and overall operator control of hydraulic actuators and functions.
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HYDRAULIC SCHEMATIC
The hydraulic schematic(s) is available in the "Hydraulic and Electrcial Schematic Shop Manual." This manual is a collection of diagrams and schematics for a number of models. GENERAL NOTES When refering to the schematic, refer to the following items: As shown in the schematic, the main pump assembly is driven by the engine. Mechanical energy is converted to hydraulic power, generating the required hydraulic ow which drives the system. Two main pumps (a right side pump and a left side pump) make up the main pump assembly. Hydraulic output from the right side pump is transmitted to the right side of the control valve. Output from the left side pump is transmitted to the valve spools on the left side of the control valve. Hydraulic output from the pilot pump is used to control the pump and to operate pilot and solenoid valves. The right half of the hydraulic control valve, supplied by the right pump in the pump assembly, operates valve spools for right travel, swing, boom up and arm functions. The amount of oil ow to the actuators at the output end of each of those circuits is regulated through the movement of each individual valve spool. The left half of the hydraulic control valve, fed by the left pump in the pump assembly, has control spools for left travel, bucket, boom and arm operation. Two-stage operation is a feature of boom and arm function. All of these circuits can be operated using the output of only one half of the hydraulic pump assembly (one pump or the other), or since both halves of the control valve have a spool and available circuit for these functions the output of both pumps can be combined, allowing higher speed operation. Boom up, arm crowd and dumping functions can operate in any one of the two available power modes the standard or general duty mode, the high speed/rapid cycling mode. Whenever the right travel or left travel control spools are shifted, output from the main pump assembly passes through the center joint to one or both of the axial piston motors driving the side frame crawler tracks. A pilot valve connected to the swash plate of each travel motor changes motor capacity (and output) in direct proportion to the position of the travel switch selected by the operator. The hydraulic reservoir return line and the pilot circuit both have 10 micron full ow lters. The disposable elements in these two canister-type lters trap and remove impurities from the oil in the system. An 80 mesh, 177 micron reservoir intake strainer also helps maintain system cleanliness and should be cleaned each time hydraulic uid is drained and replaced. An oil cooler in the hydraulic system helps maintain the operating temperature of the system at approximately 50C (122F). The arm cylinder operating circuit includes anti-vacuum valves which protect the hydraulic system from vacuum that could result from external shocks or other unusual conditions. Boom, Arm, and Bucket cylinder circuit are also protected by overload relief valves. Whenever high pressure is generated as a result of a shock or overload, excess pressure is dumped to the reservoir return circuit through the relief valve.
A selection valve in the travel circuit can be used to provide constant high torque/low speed travel, or variable speed/variable torque output for travel. To prevent sliding during simultaneous travel and boom/ arm/bucket operation, select the high torque/low speed travel position.
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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 rst shift position and through the second shift position in boom up mode. Overload relief valves set at 360 kg/cm sq. (5,112 psi) protect the hydraulic system from damage as a result of overloads or shocks to the boom. BOOM UP CIRCUIT When you pull the boom control lever backward, the right side pilot valve generates secondary boom up pilot pressure that is transmitted to the right and left sides of the control valve simultaneously. When secondary pilot pressure reaches 4 - 6 kg/cm sq. (57 - 85 psi), boom control valve spools open and oil from both pumps goes to the boom cylinder.
BOOM CYLINDER
BMD TL
BM1 PL
PILOT VALVE
BM2 PR CONTROL VALVE(R)
CONTROL VALVE(L)
PUMP(L)
PUMP(R)
ARS1560L
Figure 2 BOOM DOWN CIRCUIT When the boom control lever is pushed forward, the right side pilot valve generates secondary boom down pilot pressure that is transmitted only to the left side of the control valve. When secondary pilot pressure reaches 4 - 6 kg/cm sq. (57 - 85 psi), the valve spool on the left side of the control valve opens so that oil from only one half of the pump assembly goes to the boom cylinder for boom lowering.
BOOM CYLINDER
PILOT VALVE
BM1 PL
BMD TL
CONTROL VALVE(L)
PUMP(L)
ARS1570L
Figure 3
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Return to Master Table of Contents 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 orice, 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 owing to the cylinder. Overload relief valves set at 360 kg/cm sq.(5,112 psi) have been installed at the AM 1 and AMD 1 ports on the right side of the control valve to protect the circuit and system components from possible damage caused by shocks and/or overload pressure. Additional protection - to prevent cavitation of the cylinder - is provided by a make-up valve and reservoir return circuit, which ensures that the volume of oil going to the cylinder will not exceed the volume of oil coming out. ARM CROWD CIRCUIT When the arm control lever is put in the crowd mode, the left side pilot valve generates secondary pressure that is transmitted to the right and left sides of the control valve simultaneously. When secondary pilot pressure reaches 4 - 6 kg/cm sq. (57 - 85 psi), the arm control valve spool on the right and left sides of the control valve opens. Output ow from both halves of the pump assembly is directed to the arm cylinder.
AM2
ARM CYLINDER REGENERATION VALVE
PILOT VALVE
AMD1
AM1
PL
TL
PR
CONTROL VALVE(L)
CONTROL VALVE(R)
When working in the arm crowd mode, under certain conditions, oil in the cylinder could PUMP(L) suddenly be forced out by the weight of the arm and bucket itself. Insufcient oil ow to the Figure 4 cylinder could lead to cavitation in the cylinder and/or surging or irregular movement. This is prevented by a regeneration valve attached to the control valve which maintains the balance between oil owing into the cylinder and oil owing out. ARM DUMP CIRCUIT When the arm control lever is put in "dump" mode, the left side pilot valve generates secondary pilot pressure that goes to both halves of the control valve simultaneously. When pilot pressure reaches 4 - 6 kg/cm sq. (57 - 85 psi), the control spools open on both sides allowing oil from the right and left pumps to ow to the arm cylinder.
AM2 PL AMD2 TL
PUMP(R)
ARS1580L
ARM CYLINDER
PILOT VALVE
AMD1
AM1 PR
CONTROL VALVE(L)
CONTROL VALVE(R)
PUMP(L)
PUMP(R)
ARS1590L
Figure 5
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Return to Master Table of Contents 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 sq. (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. BUCKET CROWD CIRCUIT When the bucket control lever is placed in the crowd position, the bucket control valve spool on the left side of the control valve opens and oil from left main pumps ows to the bucket cylinder.
BKTD TL BKT PL
BUCKET CYLINDER
PILOT VALVE
CONTROL VALVE(L)
PUMP(L)
ARS1600L
Figure 6 BUCKET DUMP CIRCUIT When the bucket control lever is put in the dump mode, the bucket control valve spool in the left half of the control valve opens to supply oil from the left main pump to the cylinder.
BKTD TL BKT PL
BUCKET CYLINDER
PILOT VALVE
CONTROL VALVE(L)
PU M P( L )
ARS1770L
Figure 7 SWING OPERATING CIRCUIT The swing operating circuit consists of the right main pump in the pump assembly, the right half of the control valve and the swing motor. To keep the upper works from coasting when the swing control is in neutral, an electrical sensor in the control circuit activates a valve to automatically engage a mechanical brake.
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Return to Master Table of Contents 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 regulator and right half of the control valve. Output ow from the right pump is then directed through the PR and SWR ports of the control valve to the swing motor.
CONTROL VALVE(L)
PILOT VALVE
SWD
SW
TL
PR
CONTROL VALVE(R)
PUMP(R)
ARS1620L
Figure 8 LEFT SWING OPERATING CIRCUIT When the swing control lever is pushed to the left swing position, the control valve spool at the right side of the control valve moves in the opposite direction and output ow from the right pump is directed through the PR and SWL ports of the control valve to the swing motor.
CONTROL VALVE(L)
SWD
SW
PILOT VALVE
TL
PR
CONTROL VALVE(R)
PUMP(R)
ARS1610L
Figure 9
SWING RELIEF VALVE AND MAKE-UP VALVE Whenever the spool is shifted to the neutral mode during swing operation, the possibility exists that surge pressure in the circuit - caused by inertial momentum of the upper works and correspondingly reduced pressure at the opposite motor port - could produce cavitation in the circuit. To keep that from happening, a 285 kg/cm sq. (4,052 psi) relief valve is installed in the swing motor and a large-capacity make-up valve is connected to the entrance port of the hydraulic reservoir, helping maintain acceptable pressures on both sides of the circuit. TRAVEL OPERATING CIRCUIT Output ow from both halves of the pump assembly is directed to the right and left travel motors through the right and left sides of the control valve, and the upper works center joint.
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Return to Master Table of Contents FORWARD TRAVEL CIRCUIT When the right and left travel control levers are pushed forward, output from both of the main pumps is directed through the PR, PL, TRRF and TRLF ports on the control valve, through the upper works center joint, to the travel motors on each side of the machine.
TRAVEL MOTOR(L) TRAVEL MOTOR(R)
CENTER JOINT
TRL
TRLD TL
PILOT VALVE
TRRD
TRR PR
PL
CONTROL VALVE(L)
CONTROL VALVE(R)
PUMP(L)
PUMP(R)
ARS1630L
Figure 10 REVERSE TRAVEL CIRCUIT When the right and left travel control levers are pushed backward, output from both main pumps is directed through the PR, PL, TRRR and TRLR ports on the control valve, through the upper works center joint, to the travel motors.
TRAVEL MOTOR(L) TRAVEL MOTOR(R)
CENTER JOINT
TRL PL
TRLD TL
PILOT VALVE
TRRD
TRR PR
CONTROL VALVE(L)
CONTROL VALVE(R)
PUMP(L)
PUMP(R)
ARS1640L
Figure 11
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 ow, rst, and Hydraulic pressure, afterwards, in a specied order of priority through different points of the system.
To verify adequate available hydraulic ow, before any other tests are performed through the circuit: Check engine operation at 1,950 RPM with no load
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Return to Master Table of Contents at 1,950 RPM stall load
If engine RPM drops excessively with a load or fails to surpass rated speed (1,900 RPM), performance problems may be due to inadequate hydraulic ow caused by lagging rotational speed. NOTE:
Verify actual ow on the excavator against rated performance, with a ow meter.
If engine tests meet specications and adequate torque and horsepower are available at the pump drive ex coupling, pull out the electrical tray under the operators seat to inspect the self-diagnostic display. If the EPOS trouble code display is clear, check hydraulic functions in the following sequence: Pilot pressure Negacon, negative control pressure Main relief pressure (front and rear pump) Swing pressure Port relief pressure (individual control functions; crowd, bucket, boom, travel) Power boost circuit Standard performance tests; cylinder speed, hydraulic motor (travel and swing) speed, cylinder oil-tightness "permissible drift" test
NOTE:
System specication performance tests of individual activator function are determined by ow rate through the component or circuit, not the control pressure or system pressure available to the actuator. Poor ow through the individual circuit may indicate that the component is worn beyond tolerance limits, while all other hydraulic functions are adequate.
IMPORTANT
It is suggested that the troubleshooter maintain the testing sequence of the preceding list. Checks and adjustments nearer the middle or the end of the list may depend on adequate functioning of systems tested nearer the top of the list.
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 operators control stand while checks and adjustments are made. Vent hydraulic pressure from the reservoir before breaking the seal on ttings 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. Start the engine and turn the engine speed control dial to the maximum setting. After the excavator has been operated long enough to reach normal operating temperature, back off the engine control dial to minimum rated RPM speed. With all controls in neutral, make sure the left console control stand is locked
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Return to Master Table of Contents in the down (operating) position and check pressure at the gear pump outlet port and at the joystick. If gear pump pressure is outside the tolerance specied in the table, adjust gear pump relief pressure by loosening the lock nut and turning the set screw in (clockwise) to increase pressure, or turning it out to decrease it. NOTE:
Be aware that serial number changes and variation in the joystick assemblies used on different excavators could produce slight change in actual performance characteristics. Comparison of part numbers to serial numbers stamped on your assembly may be required, if questions or doubt exists.
IMPORTANT
Top off the hydraulic uid reservoir if there is any measurable loss of hydraulic oil during test gauge and adapter tting installation. Engine RPM Minimum Speed Setting (full left) on Speed Control Dial Pilot Pressure @ Pump 40 bar 5 bar (580 psi 73 psi) Pilot Pressure - Joystick 23.5 bar 1.5 bar (341 psi 22 psi)
POWER MODE VALVE

CURRENT SIGNAL AND HYDRAULIC PRESSURE 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 operators control stand while checks and adjustments are made. The electromagnetic pressure proportioning control (EPPR) "power mode" valve is located on the underside of the pumps (not visible in the harness connections drawing, because it is underneath the assembly), near the engine/pump exible coupling, adjacent to the pump return line. To test and adjust power shift current and pressure through the power mode valve a multi-lead jumper harness is required. 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. To set up the testing equipment, turn off the engine and disconnect the single electrical lead from the power mode valve. Attach the jumper harness to the terminal on the valve, connect the test leads of the multimeter to the extra leads on the harness and reconnect the valve electrical lead. Vent the lever on top of the hydraulic tank to relieve pressure and connect an in-line "t-style" adapter to the valve pressure port. Install a 60 bar/870 psi (1,000 psi) test gauge in the adapter. Restart the engine and increase engine RPM by turning the speed control to the maximum speed setting. Warm up the engine and hydraulic system until hydraulic oil temperature is at least 45C (113F). Select Power Mode III on the Instrument Panel. Check current readings (in milliamps) on the VOM meter and hydraulic pressure gauge readings and make sure both conform to the values in the table below.
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If recorded values do not conform to the specied current or pressure in the table, back off the lock nut on the end of the valve, turn the adjusting screw 1/4 turn and re-check current and pressure. Repeat adjustment as required to obtain specied performance and retighten the valve lock nut.
Engine RPM High Idle: 2,050 RPM Current 600 20 mA Mid-range value corresponding to engine RPM for both current and hydraulic pressure readings. 0 mA Pressure 26 1 bar (377 15 psi) 36 6 bar (524 58 psi)
Mode
Power Mode III
Operating Range: 1,200 1,600 RPM 2,050 RPM
Power Mode II
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 operators control stand while checks and adjustments are made. The swing priority control valve is located inside the compartment behind the cabin. The same jumper harness used for testing the power mode (EPOS) control valve is used to test this valve. Turn off the engine, disconnect either of the electrical leads and connect the test equipment to that side of the valve. An in-line "t-style" gauge adapter can be used to connect a 60 bar/870 psi (1,000 psi) test gauge to the outlet (pressure) side of the valve. Set the engine control speed dial to maximum and warm up the engine to at least 45C (113F) before making any tests. NOTE:
Vent air from the hydraulic system before installing test equipment. Use the lever on the reservoir, while the engine is running. Pour clean replacement uid back into the system if excessive uid was lost.
To verify operation of the swing priority solenoid valve, connect test equipment and begin testing with the work mode switch set to "digging" (the state turning off the "trenching" lamp) and the engine speed control dial at the maximum RPM position. Operate the swing motor in both directions. Measure signal current and hydraulic pressure through the valve and record the highest and lowest values as the swing motor rotate clockwise and counter clockwise several times. Reset the work mode control to "trenching" mode and repeat the same tests. Valve Function / Work Mode Swing Priority / Digging Swing Priority / Trenching NOTE: Signal Voltage 0V 20 - 30 V Hydraulic Pressure 0 bar (0 psi) 20 - 40 bar (568 psi)
If recorded values do not conform to the specied current or pressure in the table, readjust as required.
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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 operators 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. Start the engine and turn the engine speed dial to maximum. When normal operating temperature is reached, Check pilot pressure and readjust it, if required; Select the Instrument Panel rear pump "pressure display"; Select Power Mode III; Stall the boom cylinder (towards the extend side); Read rear pump pressure on the Instrument Panel display.
Repeat all tests with and without "pressure up" selected through the console rocker switch and joystick button. If the 2-stage main relief valve was not set correctly and main relief high-stage pressure ("pressure up") is outside the tolerance range, begin valve adjustment by loosening the outside (widest diameter) lock nut on the relief valve. Turn the adjusting screw clockwise to increase pressure, or counterclockwise to decrease it. Pressure must be 350 bars (5075 psi), or up to 10 bars (145 psi) higher. Because one adjustment can affect the other, check low-stage main relief pressure by repeating the cylinder stall test without "pressure up." Readjust standard relief pressure by turning the inner-most (smallest diameter) screw clockwise to increase the setting, or counterclockwise to decrease it. Pressure should be at least 330 bars (4,785 psi), but less than 335 bars (4,858 psi).
IMPORTANT
Pressure adjustments and checks cannot be made if pilot pressure is outside the specied range. Refer to the pilot pump adjustment procedure if required, then proceed with any necessary adjustments to main relief pressure settings. Main Pressure and Tolerance 20 - 40 bar (290 - 580 psi) 330 bar + 5 bar (4,785 psi + 75 psi) 350 bar + 10 bar 5,075 psi + 145 psi Pilot Pressure and Tolerance 30 bar + 10 bar (435 psi + 145 psi) 30 bar + 10 bar (435 psi + 145 psi) 30 bar + 10 bar (435 psi + 145 psi)
Power Mode Mode III Mode III Mode III W/ pressure Up
Operation Neutral, No Operation Cylinder Stall Cylinder Stall
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The electrical pressure up (power boost) solenoid valve located alongside the swing priority solenoid and arm speed control solenoid, in compartment rear of the operators cab, must be operating correctly, or pressure tests and further adjustments cannot be made.
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 operators control stand while checks and adjustments are made. To perform these adjustments accurately the use of a ow meter is strongly recommended, as is consulting the factory (before starting work) to validate the need for making regulator adjustments. Vent hydraulic pressure from the reservoir before breaking the seal on ttings to install the ow meter kit. (Refer to the Flow meter Installation and Testing procedure.)
IMPORTANT
Before starting this procedure or going on to make any changes of adjustment settings, Verify engine output to the rated speed 2,050 RPM ( 50 RPM). Permanently mark setscrew positions at the current regulator control setting.
Use a scribe or other permanent marker to identify a reference point on adjusting screws with a corresponding reference on the body of the valve. The adjustment process affects a complex balance and could require some time to complete. If adjustment has to be interrupted or postponed, reference marks at the adjustment point allow immediate restoration of original performance. This adjustment procedure is normally performed: If the engine is being consistently overloaded (and engine troubleshooting shows engine performance to be at or above rated output); If reduced cylinder speed and diminished work performance provide an indication that rated, maximum pump ow may not be available (and all other troubleshooting gives no indication of other aws or hydraulic system defects); If pump output is out of balance and one pump is failing to keep up with the output ow of the other.
To check pump imbalance without a ow meter, travel the excavator forward on at, level terrain. If the machine veers off despite neutral control input and even, balanced track adjustment, the pump which supplies output to the track frame toward which the excavator is veering is weak. Refer to the illustration of the pump regulator control valve (Figure 3-102) for the location of adjustment screws (925, 628, 642). There are three different adjustments, along with the Negacon, negative control, adjustment screw (924, directly below 925 and 628). Each one of the adjustment procedures could affect the setting of the others.
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Return to Master Table of Contents Check and record the arm dump speed performance test before and after input power adjustment, whether or not a ow meter is used. NOTE:
Regulator adjustments affect total cumulative horsepower, since each regulator compensates for the output of the other. It is not necessary to adjust both regulators at the same time, but after checking or adjusting one of them, the remaining unit should also be checked.
Start the engine and turn the engine speed dial to maximum. When normal operating temperature is reached, loosen the largest diameter lock nut around the adjustment screw (628) for the outer regulator spring. Tightening the screw shifts the P/Q (Pressure/Flow) control curve to the right, and increases compensating control pressure. On the other hand, if the persistent cause of performance problems is engine overloading, decreasing the adjustment by turning the larger diameter adjusting screw (628) out will decrease pump input horsepower. 1/4 turn on the adjusting screw is equal to approximately 17 horsepower.
P
HDA3010L
Figure 12
IMPORTANT
Because changing the position of adjusting screw (628) also affects the setting of the adjustment for the inner spring, the smaller diameter adjusting screw (925), turn in the inner screw 198 (slightly more than 1/2 turn, 180) before screw (628) is backed out 1/4 turn (90). NOTE:
For each full turn of adjustment on the larger diameter screw (628), the square-tipped adjusting screw should be turned in the opposite direction 2.2 turns to avoid changing inner spring adjustment.
Pump input power adjustments are normally made in small increments, 1/4 turn (90) or less, each time. Turning the square-tipped, smaller diameter screw (925) clockwise moves the ow curve up, increasing ow and then input horsepower.
P HDA3011L
Figure 13
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Return to Master Table of Contents The adjusting screw on the opposite side of the regulator (642) affects the delivery rate (Q) of the pump. Tightening the adjusting screw decreases the maximum cut ow (as shown in Figure 8-3) while backing out the screw increases cut ow delivery rate. Balance both pumps for equal output.
P
HDA3008L
Figure 14
FLOW METER AND FLOW METER KIT INSTALLATION AND TESTING

Checking regulator and pump output, to assess the output balance between the front and rear pumps and to verify operating adjustment of each regulator, will require installation of a ow meter. 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 tting kit (or the required dimensions and specications for hoses and ttings) to allow you to install a ow meter downstream from the main pump assembly. Installation and Testing Procedure Turn off the engine and operate controls to release hydraulic pressure from the accumulator. Vent the reservoir to release all pressure from the hydraulic system. Remove guard panels from around the main pump assembly. Disconnect the main pump discharge output line. Install the input ange of the ow meter on the pump end of the output line. Cap off the unused (input) end of the pump discharge line with a blocking ange. Bolt up a pre-measured length of hydraulic hose, between the output end of the ow meter assembly and the top of the reservoir. Use appropriate ttings and adapter anges to guarantee a pressure tight seal.
NOTE:
Be sure to maintain even tightening torque on all ange ttings. Use Loctite brand PST 545 (or an alternate manufacturers hydraulic system joint seal) if required, to give an airtight seal.
An assistant who must remain at the operators control station at all times should restart the engine and run it long enough (at minimum RPM) to de-aerate the system and warm up the engine and hydraulic system to operating temperature.
Record the values of all test results in three columns, comparing 1) pump pressure (from the instrument panel display) with 2) measured ow, in gallons or liters per minute, from the installed ow meter. The third column of test results should provide a record of engine RPM measured during each of the following tests with the engine speed control dial set at maximum, the power mode selector at Power Mode III and the work mode selector at digging mode:
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Return to Master Table of Contents Unloaded maximum engine speed baseline test (all controls in neutral). Front pump test operate travel right lever. Record values at all specied pressures. Rear pump test operate travel left lever. Record values at all specied pressures.
Record the values for each of the three tests (neutral, travel right and travel left) at the following pump pressure levels, with travel speed control set at high speed. Engine RPM Pressure 100 kg/cm2 (1,422 psi) 135 kg/cm2 (1,930 psi) 180 kg/cm2 (2,560 psi) 240 kg/cm2 (3,413 psi) 320 kg/cm2 (4,550 psi)* *See Note, below Flow
Compare recorded values with output shown in the P-Q curve in the specications section of this book. If test results do not measure up to specied 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. NOTE:
When testing bucket and swing functions, read maximum ow tests at 330 kg/cm2 (4,785 psi), not 350 kg/cm2 (5075 psi).
SWING SYSTEM TROUBLESHOOTING

PRECAUTIONS/INITIAL CHECKS 1. 2. 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. Stop work and park the excavator at the rst indication of: 1. 2. 3. Equipment breakdown Inadequate control response Erratic performance
Stop the machine, put the boom and arm in the inoperative (overnight park) position and begin by making the fastest, simplest checks rst: Check oil level. Check for overheating, oil leaks, external oil cooler clogging or broken fan belt. Consult service record for prior repair/service work.
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Return to Master Table of Contents Drain some tank oil to a clean, clear container. Look for metal shavings/grit, cloudiness/water or foam/air bubbles in the oil. Check for wobble through the engine/pump ex coupling. Run engine with the pump input hydraulic power control nut turned to the lowest power to check the engine. Investigate unusual operating noises or vibration. Check for loose bolts, connections.
SWING RELIEF VALVE CHECKING AND ADJUSTMENT Make a check of operating pressures through the swing relief valve if: 1. The swing motor fails to turn. Swings in one direction only. Swings but continues to coast. There is drifting on a slope.
Check operation by connecting: A. Two 600 bar (8,700 psi) pressure gauges to the inlet and outlet measuring ports on top of the swing motor. Pressure should be between 280 and 290 bar (4,060 psi and 4,205 psi), with both swing locks engaged. With swing locks released, during full acceleration and deceleration, pressure should approach 250 bar (3,625 psi) in each direction. B. Connect a 60 bar (870 psi) pressure gauge at the SH port of the hydraulic brake. Pressure should always stay at or above 4 bar (58 psi) when operating swing, boom or arm. C. Connect a 10 bar (145 psi) gauge at the motor makeup valve. Pressure should stay consistently above 2.5 bar (36 psi). If pressure falls below the recommended minimum level, forceful acceleration of the swing motor could lead to cavitation of the circuit and stalling, slowed rotation, noise and possible damage.
2.
If main inlet and outlet pressures were off in the preceding tests in Step 1, adjust swing relief valve pressure. Following adjustment, repeat the operating pressure tests (with gauges connected to the inlet and outlet test ports on top of the swing motor) and check pressures with the swing locks engaged and released. If pressure adjustment fails to restore adequate performance, proceed to the Troubleshooting Swing table.
3.
If pressure tests were at recommended levels through the main inlet and outlet ports, and through the SH port of the swing brake, the causes of poor swing performance could include a faulty swing motor, drive train overloading or gearbox defect, or a problem in the brake assembly or swing control valve. Proceed to the troubleshooting information in the next procedure. If pressure through the SH port was tested below the minimum 4 bar (58 psi) level, check the shuttle valve in the rear compartment behind cabin. When pressure through the port is at the recommended level, the brake release valve should disengage the swing brake, allowing the swing motor to rotate the excavator. If pressure adjustment to the valve has been restored but the brake still fails to release, the brake piston or friction plate may be frozen, requiring disassembly of the motor and parts repair/ replacement.
4.
If pressure tested at the motor makeup valve falls below recommended minimum level, and consequent problems with cavitation, stalling and surging are observed, check the restriction valve. If
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Return to Master Table of Contents pressure adjustment to the valve has been restored but if problems with cavitation continues, disassemble the upper swing motor housing and clean or replace assembly components as required. NOTE:
If all tested pressures are at or above recommended levels, and there are no mechanical problems in the drive train or in the motor/brake assembly, the problem will require further hydraulic troubleshooting. Its also possible that a defective joystick, an intermittent short in an electrical control circuit or a problem in the EPOS-V circuit is causing diminished swing performance. Pull out the EPOS-V indicator panel from underneath the operators seat and perform the self-diagnosis test. If the display panel reads code 0.2, it is reporting that the swing priority proportional valve is not functioning, except in the minimum fail-safe mode. Refer to the Electrical section of this book for more information.
TROUBLESHOOTING SWING GEARBOX

Problem Swing motor fails to operate and: Three pressure tests at motor, brake or makeup valve show low reading (s). Possible Causes Swing relief valve defective Brake release valve defective Motor makeup valve defective. Remedies Adjust pressure to recommended range in affected valve. OR Disassemble and clean valve assembly. Replace all valve components that show damage. If swing and left travel are restored but right travel stops working, replace or repair P1 pump. Check for binding. Disassemble and repair. Disassemble / Repair pilot pressure swing spool (305) and / or swing control valve. Test motor drain rate. Replace / Repair motor. Refer to Swing Gear Troubleshooting procedure. Check above list; then replace oil, test motor drain rate and check for 02 reading (EPOS-V self-test). Clean and repair piping or repair or replace pump P1. Reset controls or reverse piping.
All three pressure checks are OK but left travel also fails to run. All three pressure tests are OK, but machine fails to swing at all.
Exchange front and rear pump inlet and outlet hoses to test pump function. Brake assembly or motor friction plate failing to release. Pilot (control) pressure low or swing control valve stuck. Swing motor defective. Gear train defective.
Swing functions but only at reduced RPM.
Causes listed above could also produce dragging swing, OR hot or wrong oil OR worn-out parts. Low output at P1 pump or external pilot piping leaks/is clogged. Inlet / outlet piping reversed.
Left travel reduced.
speed
is
also
Swing control reversed.
movement
is
S0702170K Page 20
Return to Master Table of Contents Problem Machine swings but continues coasting on past stopping point. Possible Causes Swing control valve spool not centered. Pilot pressure may be outside range. Swing relief valve may be faulty. Swing movement is in one direction only. Check to see that pilot pressure is the same right and left. Swing control valve spool may be stuck. Swing relief valve may be faulty. No rotation and: Pressure at swing motor inlet increases. Remedies Replace return spring; clean/ repair valve piston and spool. Disassemble, clean or replace pilot relief valve or pilot valve. Repair/Replace swing relief valve. If pilot pressure is unequal, clean or repair piping or repair/ replace valve. Repair/Replace the swing control valve. Repair/Replace the swing relief valve. Check brake engagement and disengagement; check release pressure. Replace broken gears and drive train assemblies. Reduce load weight. Replace swing motor. Repair/Replace broken or faulty assemblies. Troubleshoot hydraulic system.
Swing brake not releasing.
Pressure at swing motor inlet shows no increase, and the swing motor is making irregular noises. Pressure at swing motor inlet shown no increase, but without irregular noises from the swing motor. Oil Leakage: From drive shaft From bolted connections or other assembled surfaces. Excess heat: Gearbox casing becomes excessively hot, with or without irregular noise (s), during operation.
Internal damage to gearbox drive train. Overload. Swing motor drive shaft damage. Internal damage to gearbox drive train. Hydraulic problem. pump or valve
Oil seal damaged Assembly compound (joint sealer) old and not sealing, bolt not tight or ange warped.
Replace oil seal Disassemble and check mating surfaces. Reapply Loctite; torque bolts to specications. Replace oil; rell to specied level. Repair or replace gearbox.
Low oil level. Bearings or gears worn but not completely inoperative.
S0702170K Page 21
TROUBLESHOOTING HYDRAULIC PROBLEMS

Problem Attachment cylinders, swing and travel motors are all inoperable. Loud noises are heard from main pump assembly. Attachment cylinders, swing and travel motors are all inoperable. No usual or loud noises can be heard. Possible Causes Main pump (s) malfunction Low oil level in hydraulic system Main pump inlet (oil supply) piping or hose damaged Pilot pump malfunction Pilot cutoff solenoid stuck Pilot cutoff switch faulty Engine/pump ex coupling damaged Main pump (s) damaged or worn Main relief valve pressure off Low oil level in hydraulic system Hydraulic reservoir intake strainer clogged Pump inlet (supply side) piping or hose allowing air into hydraulic system Oil cooler clogged or air circulation to cooler blocked Cooling fan belt tension too loose Relief valve set too low Relief valve in constant use Hydraulic oil severely neglected or incorrect for application Overload relief valve malfunction Oil leak at make-up valve Control valve spool damaged Dirt in control valve spool Actuator (joystick, foot pedal) damaged or worn Internal seal leak in cylinder Cylinder rod damaged Pilot valve or piping malfunction Mechanical linkage frozen, loose or damaged Center joint damaged. Parking brake not releasing. Travel motor worn or damaged. Travel motor pilot piping damaged. Remedies Repair or replace Rell Repair or replace Repair or replace Repair or replace Repair or replace Replace ex coupling Repair or replace Readjust pressure Rell Clean Tighten connection
Sluggish performance of all hydraulic functions attachment, swing and travel.
Oil temperature high.
abnormally
Clean Readjust belt tension Readjust valve Reduce or slow work load or cycling rate Replace oil Readjust or replace Clean, repair Repair or replace Clean or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace. Repair or replace. Repair or replace. Repair or replace.
One circuit in hydraulic system inoperable.
Travel motors inoperable.
S0702170K Page 22
Return to Master Table of Contents Problem Travel motors slowly. operate very Possible Causes Track tension poorly adjusted Low oil in idlers or rollers. Travel brake dragging. Track frame out of alignment, deformed or twisted. Swing brake not releasing. Relief valve malfunction. Pilot piping damaged. Swing gear, bearing or mounting loose or worn. Lubricant worn away, inadequate. Swing relief valve may be faulty. Remedies Readjust tension Rell. Repair Repair Repair or replace Repair or replace Repair or replace Repair or replace Grease Repair/Replace the swing relief valve.
Swing motor inoperable.
Swing motor operates unevenly.
TROUBLESHOOTING CONTROL VALVE

Check control valve problems only after other hydraulic circuit operational tests have been made. Refer to the Troubleshooting Baseline Recommendations procedure. Pump ow, pilot pressure, Negacon pressure, main relief pressure, and port relief pressure should all be checked before starting to work on the control valve. Make sure the hydraulic system is topped up to the required level and free of oil leaks or air in the system that could cause cavitation problems. Problem Main Relief Valve Possible Causes Particulate contamination. Broken or damaged spring. Adjusting screw loose. Main poppet sticking. Clogged orice in pilot passage to control valve. Excessive clearance between casing and spool. Spool does not return to neutral/ sticking spool. Spool does not return to neutral because of dirt or other contaminants. Broken or damaged spring. Main relief or port relief not operating properly. Impurities in pilot circuit. Remedies Disassemble, clean poppet. Replace Readjust Repair/replace Clean/replace Replace spool or casing. Check secondary pilot pressure. Clean Replace See above Clean
main
Cylinder goes down in spool neutral.
S0702170K Page 23
Return to Master Table of Contents Problem Cylinder drops before start at boom up operation Possible Causes Rod check valve damaged or clogged. Poppet sticking. Broken or damaged spring Excessive clearance between spool or casing. Sticking spool. Broken or damaged spring. Main or port relief valve damaged. Sticking spool. Solenoid valve faulty. Priority valve faulty or spool sticking. Broken or deformed spring. Excess clearance between right and left casing and valve spool. Clogged spool passage. Main poppet or pilot poppet stuck open. Poppet seat damaged or pilot piston sticking to main poppet. Loose lock nut and adjusting screw. Components worn out, past wear limits. Remedies Clean/replace Clean/replace Replace Check pilot pressure replace spool or casing. Clean/replace Replace Check pressure/replace Clean/replace Replace Check pilot pressure. Replace Clean/replace Clean/replace, replace lter.
Slow operation or response
and/or
Swing priority correctly
not
operating
Boom and arm cylinders do not perform normally in combined operation
Relief valve malfunctions: Pressure does not increase at all. Irregular or uneven pressure.
Clean/replace Clean/replace Readjust Replace
TROUBLESHOOTING TRAVEL CONTROL VALVE

Problem Secondary pressure does not increase. Possible Causes Low primary pressure. Broken spring. Spool sticking. Excess spool to casing clearance. Worn or loose universal joint (handle) subassembly. Dirt, other interference between valve parts. Return line pressure too high. Remedies Check primary pressure. Replace spring. Clean, repair or replace. Replace spool casing. Repair or replace subassembly. Clean, repair or replace. Redirect return line. U-joint
Secondary pressure too high.
S0702170K Page 24
Return to Master Table of Contents Problem Secondary pressure does not hold steady. Possible Causes Dirt, other interference between valve parts, or worn spool sticking intermittently. Interference or binding on spool return spring. Interference, restriction or unsteady pressure in tank return line. Air bubbles in piping (temporary) or air leak. Look for evidence of leaking oil. Remedies Clean, repair or replace. Clean, repair or replace. Repair or re-route tank return line. Vent air, or repair leak.
NOTE:
TROUBLESHOOTING JOYSTICK CONTROL VALVE

Problem Secondary pressure does not increase Possible Causes Remedies Low primary pressure Check primary pressure 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 subassembly Secondary pressure too high Dirt, other interference between Clean, repair or replace valve parts Return line pressure too high Redirect return line Secondary pressure does not Dirt, other interference between Clean, repair or replace hold steady valve parts, or worn spool sticking intermittently Interference or binding on spool Clean, repair or replace return spring Unsteady pressure in tank Redirect return line return line Air bubbles in piping Vent air, or repair leak (temporary) or air leak NOTE: Look for evidence of leaking oil to help locate damaged seals or gaskets that could be the cause of air leaks.
S0702170K Page 25
S0702170K Page 26
S0703010K
1ACCUMULATOR
CAUTION!
ACCUMULATOR
MODEL Solar 300LC-V Solar 300LL Solar 340LC-V Solar 420LC-V Solar 470LC-V
S0703010K
SERIAL NUMBER RANGE 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up
Models continued on back of cover.
Copyright 2001 Daewoo November 2001 Accumulator S0703010K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Specications .......................................................................................... 4
S0703010K Page 2
Accumulator
GENERAL DESCRIPTION
The accumulator is a gas-charged storage device designed to hold a reserve quantity of hydraulic uid 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. In a hydraulic circuit, minor variations or lags in pump output that might otherwise cause unsteady or irregular operation are made up from the supply of pressurized oil in the accumulator. Reference Number 1 2 3 4 Description Screw Plug Steel Pressure Vessel Diaphragm Fluid Valve
1 2
4
ARS1790L
Figure 1
Accumulators are solidly constructed to resist the high operating pressures of the uids they contain. There are only three main moving parts: a plug at the top allows pre-charging or expelling gas from the compressible, pre-charged upper chamber; a valve assembly at the bottom of the accumulator for passing hydraulic uid in and out, and an elastic diaphragm to separate the two chambers. The exible diaphragm changes shape to conform to the changing pressures and volumes of the two uids in the upper and lower chambers. There are six possible positions the diaphragm can be in and they are as follows: 1. With no gas charge in the upper chamber 0 bar (0 psi, empty) and no oil in the bottom 0 bar (0 psi, dry) the elastic diaphragm hangs loosely. When the pre-pressure charge of gas (usually nitrogen) is introduced through the port at the top of the accumulator, the diaphragm expands to maximum size. The valve button in the center of the diaphragm pushes into the uid opening in the bottom chamber, sealing off the lower valve. If the pressure of the gas charge exceeds system oil pressure, no uid enters the accumulator. The button also keeps the diaphragm from protruding into the lower valve opening.
Pressure Fluid Nitrogen
2.
4 Figure 2
6
ARS1800L
Accumulator
S0703010K Page 3
NOTE:
Pre-charge pressure is referred to as the "P1" pressure. The accumulator manufacturers "P1" rated pressure should be stamped or marked on the accumulators rating plate. Annual checks of actual pre-charge pressure should be made by tapping a hydraulic pressure gauge (and 3-way adapter coupling) into the valve on the bottom of the accumulator. When hydraulic uid is pushed out the lower valve opening by the pressure of the gas charge on the other side of the diaphragm - and there is no counter-pressure from system oil - the valve button on the bottom of the diaphragm eventually seals off the lower oil passage. Just after the needle on the gauge reaches its highest point (when there is 0 bar (0 psi) resistance from hydraulic system pressure) pressure on the gauge will drop sharply to zero, as the accumulator is completely emptied of oil and the diaphragm button closes.
Record the highest gauge reading and compare to the "P1" rated pre-charge pressure on the accumulator manufacturers data label. Repeat this test at least once a year to verify proper functioning of the accumulator. 3. 4. As hydraulic system pressure overcomes accumulator pre-charge pressure, the exible diaphragm begins to retract upward. When system oil is at highest working pressure and the accumulator lls to maximum reserve capacity, the exible diaphragm is pushed up into the top of the upper chamber. The highest working pressure is sometimes referred to as the "P3" pressure and can also be referenced on the manufacturers data label on the exterior of the accumulator. 5. If system oil pressure begins to fall off or is momentarily checked or interrupted, the energy stored on the other side of the diaphragm, in the form of compressed gas, pushes oil back out of the lower chamber, maintaining oil pressure of the circuit. With minimal system pressure, an equilibrium point may be reached in which accumulator pre-charge pressure and hydraulic system oil pressure achieve a rough balance. In this condition a minimal amount of oil is stored in the accumulator.
6.
SPECIFICATIONS Accumulator Nitrogen Charge
Model Solar 300LC-V Solar 300LL Solar 340LC-V Solar 420LC-V Solar 470LC-V
Volume
10 kg/cm2 (142 psi)
320 cc (19.5 in3)
S0703010K Page 4
Accumulator
S0704080K
1CENTER JOINT (SWIVEL)

CAUTION!
CENTER JOINT (SWIVEL)

Copyright 2001 Daewoo November 2001 Center Joint (Swivel) S0704080K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Parts List ................................................................................................. 4 Troubleshooting, Testing and Adjustment....................................................... 5 Inspection................................................................................................ 5 Testing..................................................................................................... 5 Disassembly ................................................................................................... 6 Reassembly.................................................................................................... 6
S0704080K Page 2
Center Joint (Swivel)
GENERAL DESCRIPTION
The center joint (swivel) is designed to allow hydraulic oil from the upper structure to ow to components in the lower structure. It is capable of allowing continuous 360 rotation of the upper structure in relationship to the lower structure.
S0704080K Page 3
PARTS LIST
10K
10B 27 10A 18
10L 10M
10D 10E 10C
10C 10C
10G
10H
10I
10J
ARS1730L
Figure 1 Reference Number 10A 10B 10C 10D 10E 10F 10G Reference Number 10H 10I 10J 10K 10L 10M
Description Body Spindle Seal O-ring Thrust Plate Retaining Ring O-ring
Description Cover Spring Washer Bolt Plug Shim Shim
S0704080K Page 4

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 uid leakage, complete overhaul and repair or replacement of the center joint may be required. TESTING To check pressure through the center joint, make up a test kit from the following equipment list: 700 bar (10,000 psi) pressure gauge Adapters, connectors, piping and ange block-off plates conforming to those used in high pressure piping connections of the excavator. A high pressure relief valve with a setting pressure 1.5 times maximum system pressure. A stop valve A manually operated, in-line changeover valve.
Relief Valve (1.5x) High Pressure Pump Manually-Operated Changeover Valve Swivel Joint Body (Outer) Swivel Joint Stem (Inner) Pressure Gauge
Stop Valve
Install the change over valve upstream from one of the stem high-pressure ports. Connect the pressure gauge downstream from one of the body ports. Install the stop valve between the change-over valve and the stem of the center joint. Other components should be installed according to the layout in the block diagram. The test kit is used to pressurize the center swivel above normal working pressure and lock in the higher pressure (as the stop valve is closed manually) for a leak down test. NOTE:
Tank
0370
Figure 2
The same type of kit can also be made up for the drain port (return line) side of the center joint. Use appropriate piping, connectors, test gauges, etc., and follow the same block diagram general layout (Figure 2).
S0704080K Page 5
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 blockoff 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. 1. 2. 3. 4. Clean off the exterior of the swivel joint after it has been removed. Scribe or otherwise mark a line across the cover and the body of the center joint, to allow reassembly in the same conguration. Unbolt the four 12 mm fasteners holding the cover. Use a vise or V-block to hold the assembly in place. Remove the cover, withdraw the O-ring and remove the retaining ring holding the thrust plate, taking care to support the spindle assembly, so that it will not separate and fall out when retaining ring is removed. If the spindle assembly doesnt separate easily when the thrust plate and retaining ring are removed, use a wooden block and hammer to drive it out of the housing. O-rings and seals should be replaced whenever the assembly is being overhauled or rebuilt. For repair procedures or emergency tear down, use a thin but rounded-tip, smooth-edge scraper or spatula to remove O-rings or seals, to avoid causing damage to those that must be reused. NOTE:
5. 6.
The "backup ring" shown in the assembly drawing (above the swivel joint spindle lower seals) should not be overlooked. It is tucked behind the top slip ring, doubled up inside the same groove in the body of the spindle.
7.
Before reassembling the center swivel, visually inspect ball bearing surfaces for visible signs of wear, damage or discoloration and replace any worn component. Check clearance between the spindle and thrust plate. Replace any component that shows more than 0.5 mm (0.020") of visible wear. Clearance between the spindle and body of the center swivel must be tight. Replace or repair either component if there is more than 0.1 mm (0.0039") of measurable wear.
REASSEMBLY
1. Pre-lubricate O-rings with hydraulic oil, white grease or petroleum jelly.
CAUTION!
Apply a very light lm 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. Seals may be damaged if the stem is pushed in too quickly. 2. Thoroughly clean all other component surfaces of dirt or grease prior to reassembly.
S0704080K Page 6
3. 4. 5.
Reverse disassembly steps for reassembly. Clean threads of fasteners before pre-applying Loctite #243 to the threads, and before torquing the thrust plate and cover bolts. Pre-ll the center swivel with clean hydraulic uid prior to reassembly of high-pressure and drain line piping. Clean and pre-ll piping line ends to reduce the amount of air in the system. Bleed air from the hydraulic system and verify hydraulic tank uid level before returning the excavator to service.
S0704080K Page 7
S0704080K Page 8
S0705000 R3
1CYLINDERS
CAUTION!
CYLINDERS
MODEL Solar 130LC-V Solar 130W-V Solar 170LC-V Solar 170W-V Solar 200W-V Solar 220LC-V Solar 250LC-V Solar 290LC-V Solar 300LC-V Solar 300LL Solar 330LC-V Solar 340LC-V Solar 400LC-V Solar 420LC-V Solar 450LC-V Solar 470LC-V
S0705000
SERIAL NUMBER RANGE 0001 and Up 0001 and Up 1001 and Up 1001 and Up 0001 and Up 0001 and Up 1001 and Up 0001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up 1001 and Up
Copyright 2001 Daewoo December 2001 Cylinders S0705000 Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Theory of Operation ................................................................................ 3 Parts List ................................................................................................. 4 Special Tools and Materials............................................................................ 6 Piston Nut................................................................................................ 6 Piston Jig................................................................................................. 8 Disassembly ................................................................................................. 10 Reassembly.................................................................................................. 16
S0705000 Page 2
Cylinders
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. Arm cylinders have a cushion or stopper for operation in both directions. This type of cylinder is shown in the upper drawing. THEORY OF OPERATION 1. 2. 3. Piston Oil Path A Oil Path B
Cylinder piston rods are extended or retracted by oil ow to the back side of the cylinder (shown as ("oil path A") or to the front of the cylinder ("oil path B"). The cylinder rod is extended as oil ow is pumped through the circuit to the back side of the piston. The force (F1) of the piston stroke can be expressed by the formula below, where P = circuit oil pressure and the inside diameter of the cylinder is expressed by B (Figure 1). F1 = P x B2 4 (P: Pressure, = 3.14, B: Cylinder Inside Diameter) 1. 2. 3. 4. Cylinder Inside Diameter - B Oil Path A Oil Path B Rod Diameter
Figure 1
When the cylinder rod is retracted, oil ow through the circuit from the pump to the front side of the cylinder generates a force (F2) that can be expressed by the formula in which the diameter of the piston rod is expressed by R, and the other two terms are the same as in the preceding expression. F2 = P x (B2-R2) 4
Figure 2
Cylinders
S0705000 Page 3
Return to Master Table of Contents 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. Q1 = S x (B2) 4 Q2 = S x (B2-R2) 4 Q1 > Q2 PARTS LIST The following parts list is a partial listing only; for full and complete parts list information, refer to the Hydraulic Equipment Component Parts List Cross section in Figure 4 shows an arm cylinder. Cross section in Figure 5 shows a boom cylinder. The bucket and boom cylinders are identical and differ only in the attached pipes.
Figure 3
Figure 4
Figure 5
S0705000 Page 4
Cylinders
Return to Master Table of Contents Reference Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description Bushing Dust Wiper Retaining Ring U-Packing Buffer Seal Rod Bushing Bolt Retaining Ring Rod Cover O-ring O-ring Backup Ring Piston Rod Cylinder Tube Cushion Ring Reference Number 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Description Piston Slide Ring Wear Ring Slipper Seal O-ring Backup Ring Piston Nut Set Screw Cushion Plunger Bushing Check Valve Spring Support Spring Plug Stop Ring
Cylinders
S0705000 Page 5
B R (R15 ~ R20)
S0705000 Page 6
PISTON NUT
C E A
(C3 ~ C5)
HBOJ040I
Figure 6
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Cylinders
Oil Quence
Cylinders A 110.0 mm (4.33 in) B 69.0 mm (2.72 in) C 9.0 mm (0.35 in) D 4.5 mm (0.18 in) E 30.0 mm (1.18 in) F 300.0 mm (11.81 in) G 15.0 mm (0.59 in) 130.0 mm (5.12 in) 90.0 mm (3.54 in) 11.0 mm (0.43 in) 4.5 mm (0.18 in) 35.0 mm (1.38 in) 350.0 mm (13.78 in) 15.0 mm (0.59 in) S130W-V (ARM) S170LC-V (BUCKET) S170W-V (BOOM) S200W-V (BOOM) S200LC-V (BOOM) S130W-V (BOOM) S170W-V (BUCKET) S130W-V (BUCKET) 120.0 mm (4.72 in) 115.0 mm (4.53 in) 85.0 mm (3.35 in) 75.0 mm (2.95 in) 11.0 mm (0.43 in) 11.0 mm (0.43 in) 4.5 mm (0.18 in) 4.5 mm (0.18 in) 30.0 mm (1.18 in) 30.0 mm (1.18 in) 300.0 mm (11.81 in) 300.0 mm (11.81 in) 15.0 mm (0.59 in) 15.0 mm (0.59 in) 140.0 mm (5.51 in) 102.0 mm (4.02 in) 11.0 mm (0.43 in) 4.5 mm (0.18 in) 35.0 mm (1.38 in) 350.0 mm (13.78 in) 15.0 mm (0.59 in) 125.0 mm (4.92 in) 102.0 mm (4.02 in) 11.0 mm (0.43 in) 4.5 mm (0.18 in) 35.0 mm (1.38 in) 350.0 mm (13.78 in) 15.0 mm (0.59 in) 140.0 mm (5.51 in) 107.0 mm (4.21 in) 11.0 mm (0.43 in) 4.5 mm (0.18 in) 35.0 mm (1.38 in) 350.0 mm (13.78 in) 15.0 mm (0.59 in) 140.0 mm (5.51 in) 140.0 mm (5.51 in) 130.0 mm (5.12 in) 130.0 mm (5.12 in) 92.0 mm (3.62 in) 98.0 mm (3.86 in) 105.0 mm (4.13 in) 115.0 mm (4.53 in) 11.0 mm (0.43 in) 11.0 mm (0.43 in) 11.0 mm (0.43 in) 11.0 mm (0.43 in) 4.5 mm (0.18 in) 4.5 mm (0.18 in) 4.5 mm (0.18 in) 4.5 mm (0.18 in) 35.0 mm (1.38 in) 35.0 mm (1.38 in) 35.0 mm (1.38 in) 35.0 mm (1.38 in) 350.0 mm (13.78 in) 350.0 mm (13.78 in) 350.0 mm (13.78 in) 350.0 mm (13.78 in) 15.0 mm (0.59 in) 15.0 mm (0.59 in) 15.0 mm (0.59 in) 15.0 mm (0.59 in)
MODEL
CYLINDER
MODEL (CYLINDER) S55-V (BOOM, BUCKET)
S55-V
ARM
ARM
S130-V
BOOM
BUCKET
ARM
S220LC-V
BUCKET
ARM
S330-V
BOOM
S170LC-V (ARM) S200W-V (ARM) S250LC-V (BOOM, ARM, BUCKET) S290LC-V (BOOM) S170LC-V (BOOM) S200W-V (BUCKET) S290LC-V (ARM) S360-V (ARM) S400LC-V (BOOM, BUCKET) S450LC-V (BOOM, BUCKET) S360-V (BUCKET) S400LC-V (BUCKET)
S400LC-V
ARM
S200W-V
DOZER
S170W-V (DOZER, OUTRIGGER) S200W-V (OUTRIGGER)
S0705000 Page 7
S170W-V
ARM
S0705000 Page 8
PISTON JIG
(2) B
H R = F/2 E
A D C R (R15 ~ 20) F
I G
HBOJ050I
Figure 7
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Cylinders
Oil Quence
Cylinders
A 63.0 mm (2.48 in) 80.0 mm (3.15 in) 80.0 mm (3.15 in) 75.0 mm (2.95 in) 70.0 mm (2.76 in) 12.0 mm (0.47 in) 16.0 mm (0.63 in) 25.0 mm (0.98 in) 65.0 mm (2.56 in) 30.0 mm (1.18 in) 300.0 mm (11.81 in) 15.0 mm (0.59 in) 12.0 mm (0.47 in) 15.0 mm (0.59 in) 27.0 mm (1.06 in) 55.0 mm (2.17 in) 30.0 mm (1.18 in) 320.0 mm (12.60 in) 15.0 mm (0.59 in) 12.0 mm (0.47 in) 15.0 mm (0.59 in) 29.0 mm (1.14 in) 55.0 mm (2.17 in) 30.0 mm (1.18 in) 320.0 mm (12.60 in) 15.0 mm (0.59 in) 15.0 mm (0.59 in) 14.0 mm (0.55 in) 12.0 mm (0.47 in) 12.0 mm (0.47 in) 16.0 mm (0.63 in) 25.0 mm (0.98 in) 55.0 mm (2.17 in) 30.0 mm (1.18 in) 320.0 mm (12.60 in) 15.0 mm (0.59 in) 15.0 mm (0.59 in) S130W-V (ARM) S170LC-V (BUCKET) S130W-V (BOOM) S130W-V (BUCKET) 12.0 mm (0.47 in) 15.0 mm (0.59 in) 22.0 mm (0.87 in) 50.0 mm (1.97 in) 30.0 mm (1.18 in) 320.0 mm (12.60 in) 15.0 mm (0.59 in) 12.0 mm (0.47 in) B C D E F G H I MODEL (CYLINDER) S55-V (BUCKET) 110.0 mm (4.33 in) 14.0 mm (0.55 in) 17.0 mm (0.67 in) 40.0 mm (1.57 in) 75.0 mm (2.95 in) 32.0 mm (1.26 in) 350.0 mm (13.78 in) 15.0 mm (0.59 in) 15.0 mm (0.59 in) S170LC-V (ARM) S200W-V (ARM) S250LC-V (BOOM, ARM, BUCKET) S290LC-V (BOOM, BUCKET) 15.0 mm (0.59 in) 15.0 mm (0.59 in) S170LC-V (BOOM) S200W-V (BUCKET) S200LC-V (BUCKET) 350.0 mm (13.78 in) 350.0 mm (13.78 in) 15.0 mm (0.59 in) 15.0 mm (0.59 in) S170W-V (DOZER, OUTRIGGER) S200W-V (DOZER) 30.0 mm (1.18 in) 50.0 mm (1.97 in) 14.0 mm (0.55 in) 16.0 mm (0.63 in) 33.0 mm (1.30 in) 65.0 mm (2.56 in) 32.0 mm (1.26 in) 96.0 mm (3.78 in) 14.0 mm (0.55 in) 17.0 mm (0.67 in) 35.0 mm (1.38 in) 65.0 mm (2.56 in)
MODEL
CYLINDER
ARM
S55-V
BOOM
ARM
S130-V
BOOM
BUCKET
ARM
S220LC-V
BUCKET
S200W-V
OUTRIGGER
S290LC-V
ARM
120.0 mm (4.72 in)
14.0 mm (0.55 in)
18.0 mm (0.71 in)
46.0 mm (1.81 in)
80.0 mm (3.15 in)
35.0 mm (1.38 in)
350.0 mm (13.78 in)
15.0 mm (0.59 in)
15.0 mm (0.59 in)
S330-V (BOOM, BUCKET) S360-V (BOOM, BUCKET)
S330LC-V
ARM
130.0 mm (5.12 in)
14.0 mm (0.55 in)
20.0 mm (0.79 in)
50.0 mm (1.97 in)
90.0 mm (3.54 in)
35.0 mm (1.38 in)
350.0 mm (13.78 in)
15.0 mm (0.59 in)
20.0 mm (0.79 in)
S360-V (ARM) S400LC-V (ARM) S400LC-V (BOOM) S400LC-V (BUCKET) S450LC-V (BOOM, BUCKET)
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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 uid back into the system if excessive uid is lost. 1. Following removal of cylinder from excavator attachment, support cylinder on some type of sturdy work platform and drain all oil. Rotate cylinder so that piping ports are on top, to allow trapped air to vent.
Figure 8 2. Position piston rod so that it is extended approximately one half meter (20").
Figure 9 3. Loosen bolts (7) on the end of cylinder. NOTE:
Wrap a cloth or other protective material around piston rod, to avoid possibility of accidentally scratching or scoring rod surface while fasteners are being loosened and removed. Component parts (numbered in parentheses) are keyed to Figure 4.
Figure 10
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Cylinders
Return to Master Table of Contents 4. 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 nal disassembly.
Figure 11 5. Begin withdrawing piston rod assembly, away from cylinder. Attach a lifting support when nal 1/3 of rod is still inside barrel of cylinder. Prepare support blocks for piston rod before it has been completely withdrawn.
Figure 12 6. Lower piston rod to support blocks and detach wear ring (outer surface) (18) from end of rod.
Figure 13
Cylinders
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Return to Master Table of Contents 7. Immobilize piston rod by inserting a wooden or other non-scoring, non-metallic support through end of rod.
Figure 14 8. Loosen set screw by using a socket wrench.
HAOF340L
Figure 15 9. 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 16
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Cylinders
Return to Master Table of Contents 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 17 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.
Figure 18 12. Use a dull, rounded-tip tool to pry off Oring (11) and backup ring (12).
HAOF37OL
Figure 19
Cylinders
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Return to Master Table of Contents 13. Find a screwdriver with an appropriate width tip to facilitate removal of slipper seal (19), wear ring (18) and slide ring (17) from piston (16).
Figure 20 14. Pull off O-ring (20) and backup ring (21) from cylinder head.
HAOF38OS
Figure 21 15. During disassembly of cylinder head, be careful not to damage buffer seal (5) and U-packing (4).
HAOF39OL
Figure 22
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Cylinders
Return to Master Table of Contents 16. Disassemble retaining ring (3) and dust wiper (2). Separate retaining ring (8) and rod bushing (6).
Figure 23 17. Force out pin bushing (1) from body of cylinder.
Figure 24
Cylinders
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REASSEMBLY IMPORTANT
Replace any part that shows evidence of damage or excessive wear. Replacement of all O-rings and exible seals is strongly recommended. Before starting the cylinder reassembly procedure, all parts should be thoroughly cleaned and dried, and/or prelubricated with clean hydraulic uid. Prepare the work area beforehand to maintain cleanliness during the reassembly procedure. NOTE:
Reassemble the subassemblies of the cylinder in the following order: 1. 2. 3. 4. Body of the cylinder Piston rod Piston assembly Cylinder head assembly
1.
Reassemble pin bushing (1) to piston rod (13) and body of cylinder (14). Figure 25
2.
Following reassembly of rod cover components, install the dust wiper (2) and rod bushing (6) to the rod cover (9). Insert retaining rings (3 and 8).
Figure 26
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Cylinders
Return to Master Table of Contents 3. Pre-lubricate O-rings and seals before reassembly (Figure 27).
Figure 27 4. Before starting to rebuild piston assembly, heat slipper seal for 5 minutes in an oil bath warmed to 150 - 180C (302 356F). Use special slipper seal jig (third item in list of specialized tools at the beginning of this procedure) to attach seal. Cool seal by pushing a retracting jig against seal for several minutes. Apply a strip of clean, see-through sealing tape around slipper seal to keep it free of dust. Figure 28 5. Immobilize piston rod on solid support blocks. Assemble O-ring (20) and backup ring (21). Prepare to attach rod cover assembly to piston rod. Push rod cover by tightening piston nut (22).
Figure 29
Cylinders
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Return to Master Table of Contents 6. Assemble cushion ring (15) and attach piston assembly to piston rod.
Figure 30 7. Use specially fabricate or factory-sourced tool to tighten piston nut (22).
Figure 31 8. Assemble wear ring (18), slide ring (17) and set screw (23) to piston assembly. Reference Number 1 Description Set Screw
Figure 32 9. Immobilize body reassembly. of cylinder before
Figure 33
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Cylinders
Return to Master Table of Contents 10. Pre-apply fastener locking compound (Loctite #242 or #243 or an alternate manufacturers equivalent product) to all end cover retaining bolts. Wrap a protective cushion around end of rod while tightening fasteners, to prevent possible damage to polished surface of rod, should a wrench slip during retightening.
Figure 34
Cylinders
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Cylinders
S0707270K
1SWING MOTOR (TOSHIBA MFC200)

CAUTION!
SWING MOTOR (TOSHIBA MFC200)S0707270K

Copyright 2001 Daewoo December 2001 Swing Motor (Toshiba MFC200) S0707270K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Theory of Operation ................................................................................ 3 Parts List ............................................................................................... 10 Specications ........................................................................................ 12 Special Tools and Materials.......................................................................... 13 Special Tools ......................................................................................... 13 Troubleshooting, Testing and Adjustment..................................................... 14 Removal ....................................................................................................... 16 Handling Method ................................................................................... 16 Disassembly ................................................................................................. 17 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 22 Reassembly.................................................................................................. 22 Installation .................................................................................................... 29 Start-up Procedures ..................................................................................... 30
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Swing Motor (Toshiba MFC200)
GENERAL DESCRIPTION
THEORY OF OPERATION The swing drive motor is an axial piston motor (MFC200). The motor also contains the following components; 1. 2. 3. 4. 5. 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 intergal drive shaft. Nine piston assemblies (9) are housed in the cylinder block (27). Both ends of the cylinder block (27) are supported by bearings (4 and 25). Piston assembly (9) is guided by return plate (8) and backing spring (6) to slide on cam/swash plate (7). The strength of scrowave (18) and the hydraulic power which actuates bush (16), cause the mating surfaces of balance plate (24) and cylinder block (27) pressed together. Mechanical brake plates (10 and 11) used for braking are installed between the outer surface of cylinder block (27) and housing (28). Lining plates (10) are splined to the cylinder block. Plates (11) are splined to the housing. The brake plates are forced together by piston (13) and eighteen springs (15). This conguration results in the brake being "spring applied" and "hydraulically released." Installed in the motor cover (19) are the following items; Relief valve (45) for cushioning function. Make-up valves (36, 37 and 38) for cavitation elimination. Bypass valve (30) for the elimination of vibration when stopping.
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1.
Hydraulic Motor Operation
Figure 1 Reference Number 1 2 3 Description Valve Plate Shoe Swash Plate Reference Number 4 5 Description Cylinder Block Piston
The cross sectional view of the swing motor, Figure 1, show most of the main components of an axialpiston type hydraulic motor. Arrows indicating direction of ow and other graphic symbols provide a general guide for understanding basic operation. When high-pressure oil enters the cylinder through the inlet port of the valve plate the sliding piston inside the cylinder is driven back, generating force "F" against the shoe behind the piston. Force "F" acts in two different directions. Force F1 exerts pressure directly on the swash plate (3) to generate oil ow through the motor, while force F2 pushes laterally - at a right angle - against the drive shaft, providing the rotational energy to turn the cylinder block around the drive shaft. All nine pistons in the cylinder block have equal width bore, length and volume. They are congured in a concentric layout around the drive shaft, as shown in the cross section end-view in Figure 1. As oil is forced through the inlet port, pistons rotating past the pressurized (supply) side of the motor (indicated as the shaded cylinders) transmit drive torque - one after the next, each in turn - to the swash plate (through F1, direct output force) and to the cylinder block (F2, lateral force to keep the block rotating). If oil ow to the motor is directed to the opposite port (so that the supply side becomes the exhaust side and vice versa), the rotation of the motor is reversed. If oil ow to the motor is directed to the opposite port (so that the supply side becomes the exhaust side and vice versa), the rotation of the motor is reversed.
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Trench mode allows the operator to "prioritize" hydraulic oil ow between swing function and boom and arm function. Turning "ON" the trench mode boosts oil ow to swing circuit components, increasing swing speed, as boom up/arm dump speed is reduced. If trench mode is turned "OFF" - diminishing the size of the opening through the swing priority valve - boom/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.
IMPORTANT
The trench mode setting only has a noticeable effect if both functions are used at the same time, when the right and the left joysticks are each engaged simultaneously, to control swing and boom/arm functions. When the trench mode is engaged, an engaged voltage signal to the solenoid valve shifts the "swing priority" spool valve to increase oil ow through the swing motor. With trench mode "OFF," voltage is disengaged while current ow is reduced, shifting the spool in the priority valve for increased oil ow to the boom/arm side of the circuit. Make-up Valve Operation 1. Half brake condition (Condition that relief valve (45) does not operate) When reducing swing speed by half after rapidly accelerating upper structure, supply oil from pump to port (A) is suddenly reduced, but a supply oil demand is still present due to inerta of the upper structure. This causes pressure (c) to turn into negative pressure, since the the motor starts to act like a pump. Since the motor is now acting as a pump, make-up oil is needed to supply oil in (c). However, if pressure at port (B) is lower than the operating pressure of relief valve (45), the supply oil from port (A) to (c) passes through port (B) and ows out to the control valve. so that absolutely needed oil quantity of (c) is insufcient with the only oil quantity from control valve (control valve is half lever position so that oil quantity from pump is controlled.). To prevent it, insufcient oil quantity from make-up port is supplied by installing make-up check (36). 2. When brake operates (Condition that relief valve (45) operates) If lever is set to neutral by rapid operation at condition of (1), supplying oil from pump to port (A) is zero, but swing structure turns by inertia force. In this case, relief valve (45) of port (B) operates and oil sent from relief valve passes through oil passages (g) and (h), push make-up check (36) of port (A), and is supplied to oil passages (b) and (c), but oil quantity is insufcient as much as oil quantity which is leaked from motor case drain, and so to protect it, open make-up check (36) from make-up port, and cavitation is prevented by supplying oil to passage (b) and (c).
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Super Shockless Relief Valve Operation (Relief Valve Section Drawing)
Figure 2 1. When starting Pressure oil supplied to port (A) by operation of control valve can not reach normal swing because of large inertia of swing structure, some oil ows through relief valve (45) and oil passages (i) and (h), pushes and opens check of port (B), and ows out to port (B). Oil of port (A) makes resistance against spring (49) force, pushes and opens poppet (48), passes through passage (i) between seat (47) and poppet (48), and ows out to passage (h). 2. When braking (When cushioning) When setting control valve to neutral, return oil passage of motor is closed. Just after operating it, motor which turns with big inertia force and works pumping tries to charge oil from port (A) to discharge oil to port (B), but return oil passage of control valve is closed, so that pressure of port (B) increases. Increased pressure of port (B) makes resistance against spring (49) force, pushes and opens poppet (48), so that oil passes through oil passages (g) and (h) from port (B), pushes and opens make-up check (36), and ows into (c). In this process, it is stopped by continuously absorbing inertia energy of turning structure. Also in pressure increasing process of above mentioned, high pressure oil charged to front chamber of poppet (48) ows through circumferential orice (j) of poppet (48) into front chamber of poppet (54). As orice (k) is installed in poppet (54), the shoulder part of it is contacted on the stepped surface of piston (50) by spring load (54). Pressure oil owed into the front chamber of poppet (54) passes through orice (k)(m) and (l), ows into piston chamber (n), and pushes piston (54) to the left. At this time, if the difference pressure (P1-P2) between the front chamber pressure (P1) of orice (k) and the spring chamber pressure (P2) is bigger than spring installing load (F)/poppet area (A), poppet (54) moves to the right, the stopper of the groove part shut the orice (l), and the oil owed to piston chamber is stopped. Then the pressure (P2) of spring chamber is equal to (P1), poppet (54) is moved to the left by the spring (55) load, so that again oil is owed from orice (m) to (l). Thus oil regulating valve controls intake oil quantity owing to piston chamber (n), and controls the moving hour till the piston is contacted to the shoulder of liner (52).
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As piston (50) is moving like above mentioned, spring (49) load is increased from low load to high load, cushion relief operation is actuated at low pressure rst, then it is increased to the rated pressure after a few hours have passed. By this slowly increased pressure, shock of motor decreases when starting or stopping. Bypass Valve Operation (Bypass Valve Section Drawing)
Figure 3 When stopping swing structure after moving it by operating control valve, as it tries to continuously turn by inertia force, hydraulic motor operates pumping, and brake pressure is generated at one port. If it is port (A), as this brake pressure oil ows through orice (a3) and (a2) into rear chamber of check (64) of side (A), side (A) check (64) pushes side (B) check (64), which is installed symmetrically, to the left side till it is contacted to side (A) seat (62), closes bypass passage in the process of reducing speed of swing structure. After this, swing structure is stopped, but it reverses by brake pressure, pressure of side (B) increases, side (B) check (64) tries to push side (A) check (64), which is installed symmetrically, but oil of rear chamber of check (64) discharges slowly by operating of oil regulating valve consisted of side (A) poppet (65) and spring (66), side (B) check (64) moves slowly, at this interval, pressure oil ows through orice (b1) into center chamber, and bypasses through orice (a1) to side (A) port. After this, side (B) check (64) moves to the position where bypass passage is closed by being compressed to side (B) seat (62). Like this, by generating process of reverse pressure of side (B) port, pressure oil ow is not stopped and reversing is prevented by bypassing this pressure to side (A) port.
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Swing Brake Operation The swing brake is normally held in the applied position - preventing the upper deck revolving superstructure from rotating - whenever the hydraulic system is not operated (pressurized). The brake system is automatically released whenever the swing controls are engaged to swing in one direction or the other.
Figure 4
IMPORTANT
Along with the swing brake, a 2-position positive swing lock has also been provided. It should be secured whenever the upper deck revolving superstructure must be locked down and positively kept from rotating - including maintenance and/or repair intervals. (Do not rely on the swing brake alone to hold the superstructure in position for repairs, transport, maintenance or normal storage.) 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 (5), 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.
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Time Delay Valve (Time Delay Valve Section Drawing)
Figure 5 Pressure over mechanical brake releasing pressure always exists in (PG) port. 1. Condition that driving shaft is locked by operation of mechanical brake In case that pressure in (SH) port does not exist, spool (73) is pushed to the end of right side by spring (77) load and stops the oil ow owing from port (PG) to port (PB). 2. Condition that mechanical brake is released In case that signal pressure ows into port (SH), spool (73) moves to left side and oil ows through port (PG) and (PB) into brake releasing chamber. 3. When delay function is operated When pressure oil owing into port (SH) is stopped at the condition of (2), spool (73) is pushed to the end of right side by spring load (77), and closes port (PG) and (PB). Pressure oil of port (PB) ows out to port (Dr). At this time, when the difference pressure (P3-P4) between the front chamber pressure (P3) of orice (o) and spring chamber pressure (P4) is bigger than spring (69) installation load (F)/poppet (70) area (A), poppet (70) is moved to left side, then stopper part of slot part of it closes passage (p), and stops the oil ow owing into front chamber of orice (o). Then spring chamber pressure (P4) equals (P3), then poppet (70) is moved to right side by spring (68) force, and oil ows from passage (p) to orice (q) again. This oil quantity owing to port (Dr) is controlled by the oil regulating valve and time is regulated till piston (13) is in the condition (1).
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PARTS LIST
Figure 6
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Reference Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Description Snap ring Inner Ring Oil Seal Tapered Roller Bearing Collar Backing Spring Cam Plate Return Plate Piston Assembly Lining Plate Plate O-ring Piston O-ring Spring Bush Teon Ring Scrowave Cover O-ring Cap Parallel Pin Piston
Reference Number 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
Description Balance Plate Needle Bearing Snap Ring Cylinder Housing Plug Bypass Valve Assembly Back-up Ring O-ring O-ring O-ring Back-up Ring Check Spring Cap Time Delay Valve Hex. Socket Bolt O-ring O-ring Cap O-ring Relief Assembly Hex. Socket Bolt
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SPECIFICATIONS Swing Motor Theoritical Motor Displacement Working Pressure Brake Torque PG Port Supplying Pressure Ratating Direction Allowable Viscosity Range Allowable Temperature Range Mass Allowable Drain Pressure SH Port Selector Switching Pressure Hydraulic Timer Setting Hour Specication 186.7 cm /rev 27.9 MPA 834 (at Backpressure 0 MPa) 3.9 MPa (100% Release Pressure) Allowable Pressure 4.9 MPa B Port Inow : Clockwise A Port Inow : Counterclockwise 10 ~ 1000 mm2/s -30 ~ +80C About 60 kg Max 0.3 MPa Cranking 1.27 MPa Allowable Pressure 4.9 MPa 6.5 1.5 S (VG# 46.50C)
3
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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
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If abnormality is nded 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 Motor does not rotate Possible Cause Motor internal damaged Remedy Check uid drain quantity. If the uid quantity supplied to motor is almost all of uid drain quantity, it is necessary to disassemble and check it because the possibilty of damage is large. Motor internal damaged Refer to Inspection Parts List on page -16. Open inlet and outlet port of motor, apply pilot pressure of 3.9 - 4.9 Mpa to brake release port, and then check the turning of output shaft with torque of about 30 - 40 Nm over one revolution smoothly. If it does not turn smoothly with the torque described above, it is necessary to disassemble and check it because the possibilty of damage is large. Setting pressure of relief valve in circuit poor Slip is very big Sliding surface parts of motor and high pressure seal parts worn or damaged uid temperature too high and motor internal leakage too big Replace damaged parts or motor assembly. Check load pressure by pressure guage. Reset it to setting pressure. Check uid drain quantity. If uid drain quantity is over 2.5 l/min, it is necessary to disassemble and check it. Refer to Inspection Parts List on page -16. Check uid temperature. Lower uid temperature.
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Problem Torque is poor & Abnormal noise
Possible Cause Sliding surface parts worn or damaged
Remedy Open inlet and outlet port of motor, apply pilot pressure of 3.9 - 4.9 Mpa to brake release port, and then check the turning of output shaft with torque of about 30 - 40 Nm over one revolution smoothly. If it does not turn smoothly with the torque described above, it is necessary to disassemble and check it because the possibilty of damage is large. Check the parts of the articles from (a) to (e) of Inspection Parts List on page -16 and bearings and replace if they are abnormal. Check load pressure by pressure guage. Reset it to setting pressure. Check whether metalic foreign material is in uid drain of motor and drain lter. If metalic material is found, disassemble and check motor internal because the possibility of its damage is large. Repair or replace damaged parts. Replace motor.
Setting pressure of relief valve in circuit poor Motor internal damaged
Air in uid mixed Fasening parts loose
Check uid in tank and motor case. Bleed air fully. Check pipe laying parts, fastening part bolts, motor fastening bolts, and each motor fastening part bolts. Fasten suitable tightening torque. Check whether metalic foreign material is in motor uid drain and drain lter, and check the turning of output shaft with torque of about 30 - 40 Nm over one revolution smoothly. If metalic material is found or it does not turn smoothly with the torque described at left, it is necessary to disassemble and check it because the possibilty of damage is large.
Abnomal heat
Motor sliding and rotating parts stuck
Assembling parts leaking
O-ring damaged Seal surface damaged Bolt loose
Repair or replace damaged parts. Replace motor. Replace O-ring. Repair seal surface or replace seal. Check bolts Fasten suitable tightening torque. Repair or Replace motor.
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Problem Oil seal leaking
Possible Cause Oil seal lip part damaged or worn Shaft seal part damaged or worn Pressure of case abnormal
Remedy
Check pressure in case and drain quantity Pressure in case is made lower than 0.3Mpa. If drain is high, disassemble and check it. Replace oil seal. Repair or replace damaged parts. Replace motor assembly.
Inspection Parts List No. a b c d e f INSPECTION PARTS Wear of sliding part of balance plate(24) Damage of sliding part of cam plate(7) Damage of sliding part of piston assembly(9) Wear of piston circumferencial surface of piston assembly(9) Wear of piston hole of cylinder(27) Damage of teon ring(17) CORRECTION Repair or replace parts Repair parts or replace motor Repair parts or replace motor Repair parts or replace motor Replace motor Replace parts
REMOVAL
HANDLING METHOD When transporting and storing, set motor down vertically by pointing drive shaft downwards. When lifting motor, always attach a lifting-eye to make-up port in center of motor cover. Do not attach sling or other lifting device to relief valve or timer. This could result in them begin deformed and/or malfunctioning.
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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. When disconnecting hoses from component, always work after allowing pressurized air and oil to vent. Disconnecting hoses from component that are under pressure can cause seriuos injury from oil squirting out. Special tool or measuring apparatus are used to disassembly, reassembly, inspection, repair etc. of component. Using an inappropriate tool can cause wound or damage of component. When performing disassembly, reassembly, inspection, repair, etc. of this component, be careful not to drop components. It can cause personal injury or damage to component parts. When performing disassembly, reassembly, inspection, repair etc. of this component, do not touch threads with bare hands. It can cause injury. After reassembling, verify operational performance and do not use it, if it does not operate properly. Improper operation can cause damage to other components. 1. Remove the following valve assemblies from motor cover (19). Relief valve assembly (45) (hex hole size 14 mm). Cap (38) (hex hole size 14 mm), spring (37), check (36) and Bypass valve assembly (30) (hex hole size 10) installed in motor cover. Loosen socket bolt (40) (hex hole size 5 mm) and disassemble oil pressure timer (39).
NOTE:
Figure 10 Relief assembly (45), cap (38), spring (37), check (36), bypass valve assembly (30), oil pressure timer (39) which are disassembled should be reassembled in the same position.
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2.
Match mark cover (19) and housing (28) so that they can be properly oriented during reassembly.
Figure 11 3. With motor output shaft pointing down, remove four socket head bolts (46) (hex hole size 17 mm) and cover (19) from housing.
Figure 12 4. Remove snap ring (26), inner race of needle bearing (25) and balance plate (24). Remove piston (23) from balance plate (24). NOTE:
5.
Be careful not to scratch the sliding surface of balance plate (24) or not to deform it by excessive force. Match mark balance plate (24) with cover (19). Note assembly direction of the balance plate (24) against cover (19).
NOTE:
Figure 13
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6.
Remove O-ring (14) from cover (19).
Figure 14 7. Remove bush (16) attached in Teon ring (17) and scrowave (18) from cover (19).
Figure 15 8. Remove springs (15) from piston (13). NOTE:
Match mark springs (15) with piston (13).
Figure 16 9. Piston (13) will not come out of housing (28) due to sliding resistance of O-rings (12 and 14). Remove it using tap holes (M6) in piston. remove piston (13) as in the right gure. NOTE:
Position the fulcrum outside of the inner diameter of housing (28).
Figure 17
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10.
Disassembly of lining plates and plates Remove lining plate (10) and plates (11).
Figure 18 11. Disassembly of cylinder assembly Holding cylinder (27) by the end part, remove cylinder assembly from housing (28).
NOTE: NOTE:
Be careful not to drop cylinder (27) as it is slippery. The remains in housing (28) are outer race of taper roller bearing (4) and oil seal (3). Keep the sliding surface (A) of cylinder (27) covered until installation to protect it from damages. Mark or number piston holes of cylinder (27) and piston assemblies (9) for identication of original position at reassembly, and install them in the original position when reassembling them.
NOTE:
Figure 19
NOTE:
12.
Disassembly of taper roller bearing outer race Remove taper roller bearing outer race (4) from housing (28). Push out oil seal (3) using driver and hammer.
NOTE:
Do not reuse oil seal (3).
Figure 20
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13.
Disassembly of cylinder assembly A. Disassembly of inner ring and taper roller bearing Squeeze out snap ring (1) using marking off pin, and pull out taper roller bearing inner race (4) and inner ring (2) at a time using bearing puller.
Figure 21 B. Remove collar (5) from cylinder (27). Remove cam plate (7), return plate (8) and piston assembly (9) from cylinder (27) at a time.
Figure 22 C. Remove cam plate (7) from sliding surface of piston assembly (9) like sliding.
NOTE:
Be careful not to damage cam plate (7) and sliding surface of piston assembly (9).
Figure 23 D. Remove spring cylinder (27). plate (6) from
Figure 24
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For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
REASSEMBLY
Preparation details When reassembling, rst carry out the following details. 1. Check if each part is damaged when using or disassembling. if it is damaged, remove any damages with ne grading oil stone or sand paper according to necessity. Then thoroughly clean it with a suitable cleaning oil and dry it with moisture free compressed air. Figure 25 2. 3. Replace seal kit with new one. Lap sliding surfaces of piston assemblies (9), cam plate (7) and balance plate (24) with #2, 000 sand paper on the surface plate.
Figure 26 4. When reassembling sliding parts, apply clean hydraulic oil to them.
Figure 27
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Reassembly of Cylinder Assembly 1. Apply hydraulic oil to round part (contact part of backing spring (6)) of cylinder (27) and insert backing spring (6).
Figure 28 2. Insert piston assembly (9) in the hole of return plate (8).
Figure 29 3. Install piston assembly (9) and return plate (8) together into cylinder (27). NOTE:
Install piston assembly (9) into the holes of cylinder (27) in the original position. When reassembling, apply hydraulic oil to the piston holes of cylinder (27).
NOTE:
Figure 30
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4.
Apply hydraulic oil to the sliding surface of shoe of piston assembly (9) and install cam plate (7) to cylinder (27). Insert collar (5) to cylinder (27).
Figure 31 5. Press t inner race of taper roller bearing (4) to cylinder by using special tool and press. NOTE:
When pressing, wrap the surface of cylinder (27) with a lint free cloth or paper to protect it from damaging.
Figure 32 6. After cleaning and drying the reassembling part of cylinder (27), apply a thin coat of Loctite (515, 518 or equivalent) to it and press t inner ring (2) dried cleanly to it by using special tool. Install snap ring (1). NOTE:
Use extreme care not to get Loctite on the roller part of taper roller bearing (4). Clean the remained Loctite between inner ring (2) and taper roller bearing (4).
Figure 33
NOTE:
Reassembly of Oil Seal Clean and dry the reassembling part of seal of housing (28). Dry the outer surface of oil seal (3), apply a thin coat of sealing compound (Three bond kk "1211" white or equivalent) to it and press t it to housing (28) by using special tool.
Figure 34
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NOTE:
Be careful of the reassembling direction of oil seal (3).
Figure 35 Reassembly of Taper Roller Bearing Outer Race Install taper roller bearing outer race (4) to 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) with hand, and slowly install cylinder assembly to housing (28). NOTE:
When installing cylinder assembly, check if backing spring (6) is inserted in the spot facing part of return plate (8). When installing cylinder assembly, as the spline of cylinder (27) is out from the under part of housing (28), put a support of 30-50mm under the under part of housing (28). Check if the end part of cylinder (27) is lower of about 15.3mm then the end part of housing (28). If it is less lower, as cam plate (7) is not installed to the spot facing of housing (28) in the original place, slowly lean cylinder (28) to lower the high part of cylinder, slightly wave cylinder up and down, and install cam plate (7).
NOTE:
Figure 37
NOTE:
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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) to housing (28) and O-ring (14) to piston (13). NOTE:
Apply grease to O-ring (12) and (14).
Figure 39 Reassembly of Brake Piston Apply hydraulic oil to the circumferential sliding surface of piton (13) and install it to housing (28). NOTE:
As there is an interference between piston (13) and O-ring (12) and (14), when installing piston (13), mount the whole piston (13) horizontally and push it in housing (28) with hand at a time.
Figure 40
Reassembly of Spring Install spring (15) to piston (13) of brake part. NOTE:
Install spring (15) at the original position where it was disassembled before.
Figure 41
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Reassembly of Balance Plate Install scrowave (18) and bush (16) with Teon ring (17) to bush hole of cover (19). Install balance plate (24) in which piston (23) is inserted to cover (19).
Figure 42 NOTE:
Be careful of the reassembling direction, which was marked before disassembling, of balance plate (24) and cover (19). Fully apply grease to piston (23) and pin (22) (for stopping turning of balance plate) of cover (19) and install balance plate to cover part.
NOTE:
Figure 43 Reassembly of Inner Race Press t needle bearing (25) inner race to cover (19) and install snap ring (26).
Figure 44 Reassembly of O-ring Install O-ring (14) to cover (19). NOTE:
Apply grease to O-ring (14).
Figure 45
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Applying of Liquid Packing Clean and dry the mating surface of housing (28) against cover (19), and apply liquid packing (Three bond kk "1211" white or equivalent) to it like right gure.
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. NOTE:
Align and install cover (19) to housing (28) according to the installation position marked before disassembling. At this time the clearance between housing (28) and cover (19) is about 4mm.
Figure 47
NOTE:
Tightening of Bolt (Tightening Of Cover (19) And Housing (28)) Tighten bolt (46) (hex hole size17) with torque of 392 Nm. NOTE:
At this time four bolts should be equally and slightly tightened to align housing (28) and cover (19) straight.
Figure 48
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Reassembly of Relief Valve Assembly, etc. Install relief valve assembly (45) (hex hole size 14) to cover (19) with torque of 137Nm. Install check (36) and spring (37) to cover (19) and tighten cap (38) (hex hole size) to cover (19) with torque of 137 Nm. Tighten bypass valve assembly (30) (hex hole size 10) to cover (19) with torque of 78 Nm. Tighten time relay valve (39) to housing with torque of 12 Nm by means of hex socket bolt (40) (hex hole size 5). NOTE:
Install relief valve assembly (45), cap (38), spring (37), check (36), bypass valve assembly (30), and time relay valve (39) to the original position which was disassembled before.
Figure 49
Conrming of Reassembly Open inlet and outlet port of motor, apply pilot pressure of 3.9 - 4.9 Mpa to brake release port, and then check the turning of output shaft with torque of about 30 - 40 Nm over one revolution smoothly. If it does not turn, readjust it by disassembling because it is improperly reassembled. At this time open drain port also. NOTE:
After reassembling hydraulic motor, check the setting pressure of relief valve (45).
Figure 50
INSTALLATION
Piping Dimensions for piping is already decided in outside drawing. Piping is to be hose or steel part. Also when piping, detach cap seal of rubber of port part. Because drain pipe is decreased pressure in motor case, uses large diameter pipe. Also when connecting return pipe other components, return oil is squirted out suddenly, abnormal back pressure of pressure in motor case should be below 0.3 MPa.
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START-UP PROCEDURES
Hydraulic Oil Use recommended hydraulic oil listed in the Operation and Maintenance Manual. Preliminary Operation Make sure that all hoses and pipes are ushed and free of contamination. Check all ttings and connections in the circuit to be sure that they are properly tighten and connected. Bleed air from motor case, when lling case with hydraulic oil. If motor is operated without hydraulic oil, it can result in internal parts being damage. After fully lling motor with oil, operate it at a no load condition, and low speed, for 10 - 15 minutes. Check for abnormal noises or vibration when operating. Slowly operate motor at a higher speed and load. Relief Valve The relationship between adjusting oil pressure of relief valve and turning the adjustment screw is as follows, and it is very difcult to conrm. Do not adjust pressure unless absolutely necessary. Pressure variation for 0.1 mm of screw advancement, is about 0.4 MPa.
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S0707315K
1TRAVEL MOTOR (WITH GEARBOX)

CAUTION!
TRAVEL MOTOR (WITH GEARBOX)S0707315K

Copyright 2001 Daewoo December 2001 Travel Motor (with Gearbox) S0707315K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Theory of Operation ................................................................................ 4 Parts List ............................................................................................... 10 Specications ........................................................................................ 13 Special Tools and Materials.......................................................................... 15 Special Tools ......................................................................................... 15 Troubleshooting, Testing and Adjustment..................................................... 21 Hydraulic Motor ..................................................................................... 21 Travel Reduction Gear........................................................................... 23 Disassembly ................................................................................................. 24 General Caution Matters ....................................................................... 24 Reduction Gear Part ............................................................................. 24 Hydraulic Motor Part ............................................................................. 27 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 32 Maintenance Standard .......................................................................... 32 Reassembly.................................................................................................. 36 General Caution Matters ....................................................................... 36 Motor Part ............................................................................................. 36 Reduction Gear ..................................................................................... 42 Installation .................................................................................................... 49 Check .................................................................................................... 49 Fitting .................................................................................................... 49 Piping .................................................................................................... 49 Gear Oil................................................................................................. 50 General Caution Matters ....................................................................... 50
S0707315K Page 2
Travel Motor (with Gearbox)
GENERAL DESCRIPTION
1. 2. Travelling device consists of hydraulic motor part and reduction gear part. Hydraulic motor part consists of the following ve items. 3. Rotary part generating rotating force Cross over relief valve part Negative brake part Counter balance valve part Swash tilting part
Reduction gear part consists of two speed differential gear and graphic symbols are as follows.
Am
Dr
q max A B q min
Bm
N
Relief valve par t
Pi
Pi
Dr
Negative brake par t Rotary part 2nd 1st
Counter balance valve part
Swash tilting par t
Hydraulic motor par t
Reduction gear par t

ARS3920L
Figure 1
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THEORY OF OPERATION Hydraulic Motor 1. Operation of rotating force generation
High pressure oil supplied from hydraulic pump ows through valve casing (14) and valve plate (11) into cylinder block (06).(Refer to Figure 11 for indicating number). Structure makes this high pressure oil ow to one side against the connected line Y-Y of top and bottom dead center of piston (10). This high pressure oil acts on piston like above gure and generates force F1(F1=P x A (P:Supply pressure, A:Pressure area)). This force F1 generates perpendicular force N1 and radial force W1 against swash plate (12) which has tilting angle . W1 generates torque T (T = W1 x R1) against the line Y-Y of bottom and top dead center of piston like above gure. The resultant( W1 x R1) of torques which are generated from pistons (4 - 5ea) of high pressure side by high pressure oil generates rotating force. This torque is transmitted to cylinder (06) through piston, and then rotating force is transmitted to drive shaft because cylinder block is combined with drive shaft by spline.
12
10
Y W1 R1 f1 O W1
Cylinder
Piston
N1 F1 P
Drive Shaft
High pressure
Low pressure ARS4530L
Figure 2
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2.
Operation of relief valve Relief valve performs the following two functions. A. B. When the hydraulic motor is operated, the relief valve keeps pressure and passes the surplus oil of motor inlet part to outlet part in relation to acceleration of inertial matter. When inertial matter is stopped, brake pressure can be generated to outlet part, so that equipment can be stopped forcedly.
Always chamber A is connected with port A of motor, when pressure of port A rises and exceeds setting pressure of spring pressing poppet A, poppet A is opened and hydraulic oil ows from chamber A to port B.
Port A Chamber A
Port B
Poppet A
ARS4480L
Figure 3 3. Operation of negative brake Pressure entered through counter balance spool (15) in valve casing acts to brake piston (44) and negative brake releases brake. When pressure does not act, brake is always activated. Brake force is generated by friction force of separate plate (48) which is xed by pin (32) pressed in shaft casing and friction plate (49) which is connected with shaft casing, brake piston (44) and spline of cylinder block (06). When pressure does not act to brake piston part, brake springs press brake piston and oil in brake chamber ows through orice to drain of motor. At this time, brake piston presses separate plate and friction plate against shaft casing by pressing force of ten brake springs (45) and generates friction force. By this friction force, cylinder block and drive shaft connected by spline are xed and act as brake.
32 06 49 48 46 47 44 30 45
11
ARS4490L
Figure 4
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4.
Counter balance valve
Av port is connected with hydraulic pump and Bv port is connected with tank. Oil supplied from pump ows to Av, to Cv and to C', presses and opens poppet of check valve, ows to L and to Am, and is supplied to hydraulic motor. Even though oil tries to turn the motor, it is locked with negative brake. Pressure of oil discharged from pump rises, and it is transmitted through passage G to spring chamber M, and pressure of chamber M exceeds spring force keeping spool to neutral, then spool moves to right. Oil in chamber N ows through orice I to chamber Dv, drains from port Bv to tank, and spool moves to left, then oil ows to K, to Dv, and to Bv. Passages of Cv, H and P are constructed, so that Pressure of oil discharged from pump Av is transmitted to port P. Hydraulic oil in chamber N drains through orice and clearance, so that changing operation of spool becomes slowly. When discharging pressure of pump lowers, spool moves to left by spring of chamber N side, so that hydraulic oil, as spool moves to the left, ows through orice I' to chamber Cv and drains to port Av. If pressure of port Av lowers to pressure of tank, as pressure of chamber M is pressure of tank and so it is the same as pressure of chamber N, spool returns to neutral.
AM
BM
M G Cv I' Dv
Av
Bv
ARS4500L
Figure 5
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5.
Operation of tilting part Capacity of travelling motor varies with the change of swash plate (12) tilting angle and the change of tilting angle is achieved by tilting valve. A. External pilot pressure: Pi = 0 (Large tilting) If pilot pressure does not act to tilting valve, the position of swash plate (12) is in large tilting. Ball-swash (61) supports swash plate (12) at the apposite side of piston-swash (58) from base of shaft center line, and acting point of hydraulic force coming into piston (10) is always in swash piston side against center of ball-swash (61), and so swash plate (12) is close to the bottom surface of housing, and then oil in piston-swash (58) drains through passage like gure.
12
04
26 58 10 09 08
External pilot pressure
Pi =0
39
40
60
27
33
34
35
51
ARS4510L
Figure 6
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B.
External pilot pressure: Pi 20kgf/cm2 (Small tilting) If pilot pressure acts to tilting valve, force acting to spool (34) is stronger than spring (33), and so spool (34) moves to left. High pressure oil ows through port Sa and Sb of tilting valve and passages, and acts to piston-swash (58), and the position of swash plate (12) is in small tilting. Hydraulic force acting to piston-swash (58) is larger than the hydraulic force acting to swash plate (12) by piston (10) at piston-swash (58) side by basing on ballswash (61), and so swash plate (12) moves to the end of shoulder by basing on ballswash (61) and xes.
12
o
31
04
26 58 10 09 08
External pilot pressure
Pi _ > 20 kgf/cm
39
40
60
27
33
34
35
51
ARS4520L
Figure 7
Reduction Gear 1. Operation Reduction gear consists of planetary differential combined device combining planetary device and differential device. It is to obtain the turning of housing by changing high speed low torque turning movement of hydraulic motor to low speed high torque. 2. Theory of operation A. If turning sun gear (S) from input shaft, planetary gear (P) rotates and revolves by connecting to xed ring gear (R). This revolution movement is transmitted to carrier (C) and so torque is transmitted. Reduction ratio
R P2 I1 = 1 = ----------------S P1
ARS3930L
R P1
P2
Input Shaft
S C
Figure 8 Planetary Device
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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. Reduction ratio
1 I2 = -----------------------------R2 P2 1 --------------------R1 P1
R2 P1 P2
R1
Input Shaft
C
ARS3940L
Figure 9 Differential Device B. If turning sun gear (S) from input shaft, each gear among S, P1 and R1 starts planetary motion and revolution of gear P1 rotates carrier C1. Rotation of carrier C raises differential motion among gears R1, R2, P1, and P2, and rotates ring gear (R1). This ring gear (R1) rotates housing because it is combined with housing. Reduction ratio:
R2 P2 1 + --------------------S P1 I = I1 I2 = ------------------------------R2 P2 --------------------R1 P1
ARS3950L
R1 P1 P2
Input Shaft
Output Shaft
Figure 10 Differential Combined Device
NOTE:
Rotating direction: Input shaft is opposite direction to output shaft.
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PARTS LIST Hydraulic Motor
ARS3960L
Figure 11
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Reference Number 101 102 103 106 107 108 111 114 116 121 122 131 201 272 281 303 304 350 361 362 363 364 365 367 368 369 381 382 383 384 401 402 435 451 452 461
Description Shaft Roller Bearing Needle Bearing Spacer - Bearing Stop Ring Stop Ring Cylinder Block Spring Cylinder Spacer Piston and Shoe Assembly Bush and Push Plate Assembly Valve Plate Swash Assembly Shaft Casing Name Plate Valve Casing Seal Cover Relief Valve Assembly Spool - C.B. Valve Spring - C.B. Valve Orice Screw Damping Check Assembly Cap - C.B. Valve (Left) Hex. Socket Bolt Hex. Socket Bolt O-ring Plunger- C.B. Valve Stopper - Check Back Up Ring Spring - Check Hex. Socket Bolt Hex. Socket Bolt Lock Ring Valve Plate Pin Support Pin Plug
Reference Number 464 471 472 485 491 501 502 503 504 505 506 507 508 509 512 513 514 531 533 534 541 542 543 545 546 567 568 571 572 702 705 707 708 709 741 742
Description HP Plug O-ring O-ring O-ring Oil Seal Swash Piston Swash Piston Stopper (Left) O-ring Swash Rod Lock Screw Hex. Nut O-ring O-ring Back Up Ring Back Up Ring Stopper (S) Swash Spool Swash Spring O-ring Seat Stopper Ball Orice Screw Orice Screw HP Plug O-ring Plug O-ring Brake Piston Brake Spring Piston Ring 252 Piston Ring 278 Brake Pin Separator Plate Friction Plate
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Reduction Gear
Parts No. : 5405-1008A Shaft
ARS3970L
Figure 12
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Reference Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Description Housing Cover Ring Gear No. 1 Ring Gear No. 2 Coupling Gear Cluster Gear Sun Gear Coupling Carrier Thrust Bearing Shaft Pin Pin Thrust Plate Shim Spacer
Reference Number 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Description Thrust Needle Bearing Angular Bearing Floating Seal Needle Roller Snap Ring Hex. Socket Head Bolt Hex. Bolt Plug Shaft Casing Plug Stopper Spacer Collar Thrust Washer Hex. Head Bolt O-ring
SPECIFICATIONS Travel Motor Motor displacement Reduction ratio Total displacement Working pressure Working ow Output torque Speed Gear oil Weight Specication 174/105 cc/rev 66.67 11600/7033 cc/rev 330 kg/cm2 248 l/min 6092/3694 kgm 21.3/35.2 rpm 4.3 l/min 415 kg
S0707315K Page 13
Tightening Torque Chart Section No. 14 27 28 35 Hydraulic motor part 41 39, 43 53 54 55 56 22 24 Reduction gear part 26 31 33 Name Relief valve Plug HP Plug Plug HP Plug Orice screw Hex socket bolt Hex socket bolt Hex socket bolt Hex socket bolt Hex socket bolt Plug Plug Hex head bolt Hex head bolt: Reamer Standard M33 NPTF 1/16 PF 1/2 PF 3/8 PF 1/4 NPTF 1/16 M12x30L M10x30L M16x50L M16x120L M20x40L PT1/2 NPTF 1/16 M10x25L M12x120L B 36 mm 4 mm 27 mm 8 mm 19 mm 4 mm 10 mm 8 mm 14 mm 14 mm 17 mm 10 mm 4 mm 14 mm 17 mm Tightening torque (kgcm) 1, 700 - 1, 900 70 - 110 1, 100 750 370 70 1, 000 670 2, 400 2, 400 7, 300 20 580 70 - 110 690 10 1, 520 10
B
Figure 13
B
ARS3980L
S0707315K Page 14
SPECIAL TOOLS
JIG 1
JIG 2
JIG 3
JIG 4
JIG 5
JIG 6
ARS3990L
Figure 14
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JIG 7
JIG 8
JIG 9
JIG 10
JIG 11
JIG 12
ARS4000L
Figure 15
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JIG 13
JIG 14
JIG 15
JIG 16
JIG 17
JIG 18
JIG 19 & 20
ARS4010L
Figure 16
S0707315K Page 17
Tools JIG 1 JIG 2 JIG 3 JIG 4 JIG 5 JIG 6 JIG 7 JIG 8 JIG 9 JIG 10
Applicable Parts Angular ball bearing (18) Coupling gear (5), Housing (1), Shaft casing (25) Carrier (9), Shaft (11) Thrust washer (17) Cluster gear (6) Pin (12) Pin (13)
Tools JIG 11 JIG 12 JIG 13 JIG 14 JIG 15 JIG 16 JIG 17 JIG 18 JIG 19 JIG 20
Applicable Parts Coupling gear (5), Shaft casing (25), Thrust bearing (10) Cover (2), Ring gear No.1 (3) Housing (1) Floating seal (19) Bolt (33), Travel device Shaft casing (25) Cover (2) Coupling (8), Ring gear No.2 (4), Carrier (9) Cluster gear (6) Carrier (9)
Reduction Gear Part Section Tool Name Hex L-wrench Hex wrench Socket wrench Torque wrench Impact gun Plastic hammer Copper hammer Eye bolt M20 M10 x 1.5 Depth micrometer Measurement range: 0 - 50 mm Minimum scale: 0.01 mm Punch, vise, pliers Driver 2ea 3ea Standard Nominal dimension; 4mm, 10mm Nominal dimension; 17mm Nominal dimension; 14mm, 17mm Nominal dimension; 2, 000mm, 7, 500mm Remark Plug (24) and (26)
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Sub material
Loctite
Loctite 262 Loctite depend Loctite 567
Grease Cleaning oil Gear oil Seal tape Etc. Air pressure Oil bath Vacuum cleaner 6 kg/cm2 Heating temperature: over 120C Shell Spirax
Disulfuric molybdenum group
SAE #90 - #140
S0707315K Page 19
Hydraulic Motor Part Tool name Hex L- wrench B Dimension 4 mm 8 mm 10 mm 14 mm Socket wrench spanner 19 mm 27 mm 36 mm Snap ring pliers (For hole or shaft) Plastic hammer (Also wood hammer is possible) Steel bar (7x7x200) Monkey spanner Torque wrench Driver Jig for assembling of oil seal Induction heating device for bearing Bearing puller Jig for disassembling of motor Seal tape Oil seal (31) Roller bearing (02) Roller bearing (02) Nominal dimension: 500 mm, 3000 mm Needle bearing (03), pin (26, 32) Applying part name Plug (27), Orice, Screw (39, 43) Hex socket bolt (54), Plug (35) Hex socket bolt (53) Hex socket bolt (55, 56) HP Plug (41) HP Plug (28) Relief valve (14) Stop ring (05, 50)
B
Figure 17
B
ARS3980L
S0707315K Page 20

HYDRAULIC MOTOR General caution matters 1. 2. 3. Before working, judge the abnormal phenomena well and be careful whether there are other causes or not except motor. As the causes of wear have lots of cases with mixing of foreign materials, when disassembling, be careful not to mix foreign materials. As internal parts machine accurately, be careful in handling and not to damage.
Inspection method of abnormality of hydraulic motor 1. 2. 3. Loosen drain plug and check hydraulic oil in case. Check of existence of abnormal noise. Check whether abnormal noises occur in motor itself. Measurement of each part pressure
Before disassembling, measure the circuit pressures to hydraulic motor and check existence of abnormality. Cause and remedy of trouble Problem Travelling device fails to operate. Motor pressure does not increase. Possible Cause Remedy
Oil is bypassed at relief valve(14). Check spring damaged Counter balance valve spring damaged Passage in valve casing cracked Contact surface of check worn abnormally Clearance between valve casing and counter balance spool is big. Coupling of reduction gear damaged
Replace or repair relief valve. Replace check spring. Replace counter balance valve spring. Replace valve casing. Replace check. Replace valve casing or counter balance spool. Replace coupling after disassembling reduction gear. Clean or replace orice screw. Replace piston ring. Replace friction and separation plate. Replace sliding surfaces. Clean or replace orice screw. Replace gear after disassembling reduction gear.
Pressure increases but hydraulic motor does not rotate.
Orice screw(43) plugged Piston ring (46) and (47) damaged Friction and separation plate stuck Sliding surfaces stuck Orice screw in counter balance spool plugged Gear of reduction gear damaged
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Problem Possible Cause Rated swing speed is not reached. Swing speed low Quantity of inow oil low Oil temperature too high Excessively large abnormal oil leaks Each sliding surface worn or damaged Tilting angle (from large to small) is not switched. - Orice of small tilting side plugged - Abnormal leak of small tilting chamber (shaft casing, swash piston, too large clearance of stopper 'L') Rated operating power is not reached. Pressure low Setting pressure of relief valve low
Remedy
Check hydraulic circuit to motor. Lower oil temperature. Replace or repair abnormal parts. Replace or repair abnormal parts. - Clean or replace orice. - Replace abnormal parts.
Adjust pressure. Replace or repair sliding parts
Brake is released Each sliding surface worn or damaged but operating power abnormally is low. Brake operation is difcult. Brake torque low Friction and separation plate worn Brake spring damaged Brake does operate. not Parts in brake stuck
Replace worn parts. Replace brake spring. Replace parts.
Tilting angle does not switched. Tilting angle does not switched. Orice of tilting passage of shaft casing plugged Tilting angle adjusting spool(34) and case stuck Abnormal oil leaks from excessive clearance between shaft casing and swash piston(58) stopper Swash piston outer diameter or spherical part stuck High pressure selection valve in valve casing does not operate. Clean or replace orice. Replace or repair abnormal parts.
Oil leaks Oil seal(34) leaks Oil seal or sliding parts of shaft damaged Internal pressure of case high Leaks from assembling surface O-ring damaged Bolt or plug loose Remove foreign materials after replacing damaged parts. Check drain line of equipment. Replace O-ring. Tighten rated torque.
Major sliding surfaces are stuck.
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Problem Piston and shoe Shoe and swash plate Piston and cylinder Cylinder and valve plate Pressure and spherical bush TRAVEL REDUCTION GEAR General caution matters 1. 2. 3. 4.
Possible Cause Excessive load swing of motor Temperature increasing Roughness of sliding surfaces poor Hydraulic oil and lubricating poor
Remedy Check relief valve operation. Check circuit. Replace or repair abnormal parts. Replace hydraulic oil.
Check whether damages occur in transportation. Check whether bolts are loose or rated oil quantities ll. When working, close piping port. Before fitting pipe, fill oil in case of motor part adequately.
Problem Possible Cause Remedy Temperature of reduction gear housing is high.(Over 60C of ambient temperature) Gear oil insufcient. Bearing damaged. Gear is damaged is is Lubricating poor due to insufcient gear oil Heat due to bearing damaged Fill gear oil in rated quantity. Replace bearing. Replace gear.
Heat due to pitting or damaging of gear tooth Leakage phenomena occur. Assembling surfaces leak Bolt loose Liquid gasket is not applied. Plug loose Seal tape is not wound Leaks from oating seal surface of housing Sliding surface damaged or stuck O-ring damaged Casting surface cracked
Tighten rated torque. Tighten rated torque after applying liquid gasket. Tighten rated torque. Apply seal tape. Replace Replace Replace
Leaks from plug
Abnormal noises occur.; Disassemble reduction gear and replace abnormal parts after inspecting parts.
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DISASSEMBLY
GENERAL CAUTION MATTERS 1. 2. 3. 4. 5. 6. 7. 8. 9. Select clean disassembling place. Put rubber plate on the work bench and prevent parts from damaging. Clean dirt and foreign materials from reduction gear and motor part. 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. Numbers of () of part names indicate part numbers of reduction gear and motor drawing. Piping side of motor indicates rear side and output side indicates front side. Before applying Loctite, surely remove oil from two surfaces completely by using Loctite 587 and uniting them. When tightening bolt, apply Loctite 262 to bolt tap part and tighten rated torque by using torque wrench. (Apply when assembling reduction gear only) When using hammer, use plastic hammer surely. After cleaning each part, blow dry with moisture free air. But do not clean friction plate by cleaning oil.
REDUCTION GEAR PART 1. Put hydraulic motor side of traveling device on assembling jig (15, Figure 14), fasten 4 bolts (M20x50L), and x hydraulic motor to assembling jig. Hex bolt of cover (2); Loosen reamer bolt (33) and plug (24).
2.
Figure 18 3. Remove cover (2) from ring gear No. 1 (3) by using jig (12).
Figure 19
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4.
Remove carrier subassembly from housing (1) by using (jig8) or eye bolt (M10x1.5) and rope and put and align hole of jig (3) and shaft (11).
Figure 20 5. Remove calking mark of carrier (9) and pull pin by using pulling tap (M6x1) of pin (12). Tap and drop shaft under jig (3) by using copper hammer.
6.
Figure 21 7. Pull cluster gear (6) and remove thrust washer (17), needle roller (20) and spacer (16).
Figure 22 8. Remove gear oil in housing (1) by using vacuum cleaner.
Figure 23
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9. 10. 11.
Remove ring gear No. 1 (3) from housing (1) by using jig (12). Loosen Hex hole head bolt (22) by using wrench (size B17). Remove coupling gear subassembly from shaft casing by using bolts (3ea, M10x1.5x70) and coupling gear pulling tap.
Figure 24 12. Put it with coupling gear subassembly facing ground by using eye bolts (2ea, M10).
Figure 25 13. Remove snap ring (21) by using driver.
Figure 26 14. Remove coupling gear (5) from ring gear No. 2 (4).
Figure 27
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15.
Remove housing (1) from shaft casing by using eye bolts (3ea, M10x1.5), rope and crane and put it with the mating surface to ring gear No. 1 (3) facing ground.
Figure 28 16. 17. Pull out oating seal (19) from housing by using drive and separate O-ring and seal. Pull out oating seal (19) from shaft casing by using drive and separate O-ring and seal.
Figure 29 HYDRAULIC MOTOR PART Disassembly of Motor 1. Remove stop ring (50) from shaft by using pliers.
Figure 30
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2.
Remove relief valve (14).
Figure 31 3. Remove hex socket bolt (56) from shaft casing and remove valve plate (11) from valve casing. Remove O-ring and remove orice screw (39) and (43). NOTE:
4.
(39, 1ea 1.5)(43, 1ea 1.5)
Figure 32 5. Remove brake spring (45). NOTE:
(Spring, 10ea)(Hole, 11ea)
Figure 33 6. 7. 8. Remove brake piston (44) from shaft casing. Remove piston ring 47 (278) and 46 (252) from brake piston (44). Turn disassembling and reassembling jig 90' and set it with shaft direction from horizontal to vertical.
Figure 34
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9. 10.
Remove cylinder subassembly. Turn disassembling and reassembling jig 90 and set it with shaft direction from vertical to horizontal.
Figure 35 11. Remove swash plate (12).
Figure 36 12. 13. 14. Remove tilting piston (58). Remove two swash balls (61). Remove snap ring (62) by using snap ring pliers.
Figure 37 15. Remove drive shaft subassembly. NOTE:
Lightly tap and remove cylindrical roller and outer race of bearing (02) by using copper bar and plastic hammer.
16. 17. 18.
Remove oil seal (31). Remove xing pin (32) of separate plate. Remove four plugs (27) from shaft casing.
Figure 38
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Disassembly of Cylinder Subassembly 1. Remove pressure plate (07) and piston shoe (10) from cylinder.
Figure 39 2. Remove friction plate (49) and separate plate (48) from cylinder.
Figure 40 3. Remove cylinder spring (08), spacer (09) and spherical bush (07) from cylinder block (06).
Figure 41
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Disassembly of Valve Casing 1. 2. 3. Remove drain HP plug (28)with O-ring. Remove O-ring (30) from valve casing. Remove tilting spool (34), tilting spring (33) and O-ring (60) and remove plug with Oring (51).
Figure 42 4. Remove hex socket bolt (53, 54) with which cap R (24) and cap L (25) are tightened.
Figure 43 5. Remove spring (17), O-ring (29) and backup ring (57) from stopper (23) and remove plunger (18) from valve casing.
Figure 44
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6. 7. 8.
Remove CB valve spool (15), stopper (20), shim (19) and spring (22). Remove left and right orice screws (16) of CB valve spool (15). Remove HP plug (41) with O-ring (42). NOTE:
5 places
Figure 45 9. 10. Remove seat (36), ball (37), stopper (38) and HP plug (41) with O-ring (42). Remove needle bearing (03). NOTE: 11. 12.
Use plastic hammer and copper bar.
Remove pin (26). Remove plug (27) from valve casing (13).
Disassembling Of Drive Shaft Subassembly 1. 2. Remove stopper ring (05) by using pliers. Remove cylindrical roller bearing (02) by using bearing puller and remove bearing spacer from drive shaft (01). Figure 46

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.
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Changing Standard of Hydraulic Motor Part Parts name and inspection item Clearance between piston and cylinder bore Vertical direction vibration of piston and shoe Shoe thickness Height difference between spherical bush and pressure plate Free length of cylinder spring Drive spline Over pin diameter (4.5) of drive shaft Cylinder spline Over pin diameter (4.5) of spline inside of cylinder and spherical bush Thickness of separate plate Thickness of friction plate Free length of brake spring Base tangent length of cylinder outside (7 each) Over pin diameter (4.5) of inside gear of friction plate Swash plate/ shoe Cylinder valve plate Roughness of sliding Swash plate/ surface swash plate support Pressure plate/ spherical bush Roller bearing/needle bearing O-ring/Oil seal Kinds of bolt Piston ring Standard dimension 0.035 0.05 5.5 13.5 47.9 43.91 49.06 35.25 3.3 2.3 46.6 49.97 145.77 0.8S 1.6S 0.8S 6.3sS 1.6S Recommend ed value of replacement 0.06 0.3 5.3 13 47.3 43.31 48.46 35.75 3 2.1 45.97 49.37 146.37 3.2S 3.2S 3.2S 12.5S Joint lapping 6.3S If there are aking on sliding surface, replace. When disassembling, replace as a rule. If there are crushing parts, replace. If there are signs of sticking or deforming, replace. Lap each Lap Replace with set Replace Even if one each of recommended value of replacement is not reached, replace. Replace Remedy
Replace
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1.
Clearance between piston and cylinder bore: D-d
Figure 47 2. Thickness of shoe: t
Figure 48 3. Vibration of vertical direction of piston and shoe :
Figure 49 4. Height difference of spherical bush and pressure plate : H-h
Figure 50
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Parts Inspection and Inspection Standard of Reduction Gear 1. 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. Inspection and inspection standard: It is a rule to change damaged parts unconditionally. Standard 0.160 - 0.320 0.200 - 0.395 0.200 - 0.395 0.200 - 0.608 0.1-0.2 386.106 368.514 337.482 337.678 63.259 - 63.344 65.845 - 65.930 27.791 - 27.858 Pitting size of one each is over 1 mm. Area rate:10% Flaking, pressing marks, and other damages 0.3 - 0.7 Standard of replacement 1 1 1 1.3 0.5 Remark
2.
Inspection item Backlash Sun gear + Cluster gear Cluster gear + Ring gear No.1 Cluster gear + Ring gear No.2 Ring gear No.2 + Coupling gear Coupling + Sun gear spline OPD Ring gear No.1 Ring gear No.2 Base tangent length Each kind of gear Cluster gear No.1 Cluster gear No.2 Sun Pitting
4 Teeth 4 Teeth 4 Teeth
Crack Angular ball bearing
Carrier assembly
Clearance between cluster gear and thrust washer Smoothing turn and noise of cluster gear Floating Seal seal O-ring Thrust bearing
1.2
Gear oil
5 5.5 6 Shell spirax 90EP or SAE#90 API Service GL-4 class
Damage of sliding surface Damage Below 4.7 Below 5.2 Below 5.7 First service: 500 Hour Second service: Every 2, 000 Hour - Hour is standard of engine hour meter - But, change unconditionally when disassembling.
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REASSEMBLY
GENERAL CAUTION MATTERS 1. 2. 3. After cleaning each part cleanly, blow dry with moisture free air. with cleaning oil. When fastening each part, tighten tightening torque. When using hammer, surely use plastic hammer. But friction plate is not cleaned
MOTOR PART Reassembling of Drive Shaft Subassembly 1. After installing bearing spacer (04) to drive shaft, install cylindrical roller bearing (02) by means of heat t. NOTE:
Use induction heater to heat t of cylindrical roller bearing and adjust temperature to about 100C. Be careful not to damage oil seal contacting part of drive shaft.
Figure 51
NOTE:
2.
Install stopper ring (05) by using pliers. NOTE:
Be careful of direction of stopper. (Round direction is bearing side.)
Figure 52 Reassembling of Valve Casing Subassembly 1. Tighten ve plugs (27) to valve casing (13) by rated tightening torque. NOTE: NOTE: 2.
After winding seal tape and applying Loctite to plug, install it. Tightening torque: 70 - 110 kgcm
Press pin (26). NOTE:
Height of pin should be 5 mm from contacting surface of valve plate by using hammer.
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3.
Install needle bearing (03). NOTE:
Use plastic hammer and copper bar.
Figure 53 4. Install seat (36), ball (37), stopper (38) and HP plug (41) with O-ring (42) according to the order. NOTE:
Be careful of installing order and direction of seat and stopper. Tightening torque: 370 kgcm
NOTE: 5.
Install HP plug (41) with O-ring (42). NOTE: NOTE:
Five places Tightening torque: 370 kgcm

Figure 54
6.
Tighten orice screws (16)of right and left of CB valve spool (15) by rated tightening torque. NOTE:
Tightening torque: 70 kgcm
7.
Install CB valve spool (15), stopper (20), shim (19), and spring (22) to valve casing according to order.
Figure 55
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8.
Insert plunger (18) to valve casing and install spring (17), O-ring (29), stopper (23) with backup ring (57). NOTE:
Be careful of order of O-ring and backup ring.
Figure 56 9. Tighten cap R (24) and cap L (25) by means of hex socket bolts (53, 54). NOTE: NOTE:
When installing, cap R and L should not be changed. Tightening torque: M12: 1, 000 kgcm - (67) M10: 670 kgcm - (68)
Figure 57 10. After tighten plug (35) with O-ring (51) by rated tightening torque, insert tilting spool (34), tilting spring (33), and O-ring (60). NOTE: 11. 12. 13.
Tightening torque: 750 kgcm
Install name plate (52). Insert O-ring (30) to valve casing Tighten drain plug (28) with O-ring (29) by rated tightening torque. NOTE:
Tightening torque: 1, 100 kgcm

Figure 58
Reassembling of Cylinder Subassembly 1. Install cylinder spring (08), spacer (09), and spherical bush (07) to cylinder (06). NOTE:
Align cylinder and spline of spherical bush.
Figure 59
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2.
Install friction plate (49) and separate plate (48) to cylinder.
Figure 60 3. After inserting piston shoe (10) to pressure plate (07), install it to cylinder.
Figure 61 Reassembling of Motor 1. Tighten four plugs (27) to shaft casing by rated tightening torque. NOTE: NOTE: 2.
After winding seal tape and applying Loctite to plug, install it. Tightening torque: 70 - 110 kgcm
Press pin (32) for xing of separate plate by using hammer and round bar. NOTE:
Pin (26, 4ea): Set height to 19 mm from machining surface of shaft casing.
3.
Install oil seal (31). NOTE:
Install carefully not to damage lip by using assembling jig.
Figure 62
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4.
Install drive shaft subassembly NOTE:
Slightly tap and install outer race of cylindrical roller bearing (02) by using copper bar and plastic hammer.
5.
Install snap ring (62). NOTE:
Install snap ring (62) of which rounded surface faces bearing side.
6. 7.
Install two swash balls (61). Figure 63 Install tilting piston (58).
Figure 64 8. Install swash plate (12). NOTE: NOTE: 9.
Apply grease to sliding surface of swash plate. Check if swash plate moves smoothly.
Turn disassembling and reassembling jig to 90 and direction of shaft should be from horizontal to vertical. NOTE:
Be careful not to drop swash plate from swash plate support.

Figure 65
10.
Install cylinder subassembly. NOTE:
Align hole of separate plate to pin and install.
11.
Turn disassembling and reassembling jig to 90 and direction of shaft should be from vertical to horizontal. Install piston ring 46 (252) and 47 (278) to brake piston (4).
12.
Figure 66
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13.
Install brake piston to shaft casing. NOTE:
Be careful of installing direction of brake piston.
Figure 67 14. Install brake spring (45). NOTE: NOTE: 15.
Quantity: Spring (10ea), Hole (11ea). Do not install at highest top portion of brake piston.
After tightening orice screw (39) and (43) by rated tightening torque, insert O-ring (40). NOTE: NOTE:
Quantity and size: (39):1ea, 1.5 (43):1ea, 1.5 Tightening torque: 70kgcm
Figure 68
16.
After inserting valve plate (11) to valve casing, tighten it to shaft casing by means of hex socket bolt (56). NOTE:
(1) Apply grease to back surface of valve plate not to drop valve plate. (2) When installing valve plate to shaft casing, use crane. (3) Install valve plate of which F5 hole faces inlet and outlet ports side of valve casing. (4) Apply grease to tilting spool side of tilting spring not to drop tilting spring. (5) Tightening torque: 2, 400 kgcm
Figure 69
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17.
Tighten relief valve (14) by rated tightening torque. NOTE:
Tightening torque: 1, 800100 kgcm
18.
Install stop ring (50) to shaft by using pliers. NOTE:
Be careful of direction of stop ring. (Round direction is bearing side.)
Figure 70 REDUCTION GEAR Reassembling of Angular Ball Bearing (18) of Housing (1) Part 1. 2. Adjust oil bath temperature to 1005C. Fully submerge housing (1) into oil bath by using two eye bolts of M10 and crane. At this time, be careful not to contact bottom of housing (1) to bottom of oil bath. NOTE: 3.
Prevent uneven heat.
Take out housing (1) and position on assembling stand. Wipe off oil by using clean rag and insert angular ball bearing (18) in order. NOTE:
Be careful not to change top and bottom direction of bearing.

Hammer
4.
Tap and completely contact end surface of angular ball bearing (18) and housing (1) seat by using jig (1) and hammer like gure (1).
Housing Jig1
ARS4350L
Figure 71
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Selection Method of Shim (15) Thickness 1. Position coupling gear (5) on working stand like gure (2) and measure dimension "A" by using jig (2) or jig (11). Calculate "T1". T1= A - B
T1 Coupling gear ARS4360L Jig2 or Jig11 B A Depth micrometer
2.
Figure 72 3. 4. Position housing on jig (13) like gure (3) and measure "C" by using jig (2). Calculate "T2".
D Housing Jig2 C Depth micrometer
T2= E + C - D
Jig13
ARS4370L
Figure 73 5. 6. Position shaft casing (25) like gure (4) and measure "F" by using jig (2) or jig (11). Calculate "T3". 7. T3= F - D
F T3 D Jig2 or Jig11
Calculate "T". T= (T1 + T3 + 0.1) - T2
8.
Select shim (15) thickness "Ts" with value "T" from below table. Method is to decide most approximate value. Part No. 2114-1647-1 2114-1647-2 2114-1647-3 2114-1647-4 2114-1647-5 2114-1647-6 2114-1647-7 2114-1647-8 Ts 1.2 1.4 1.6 1.8 2.0 2.3 2.5 2.8 Figure 74
Hydraulic Motor Assembly ARS4380L
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T2
Reassembling of Floating Seal (19) 1. Position shaft casing (25), of which mating part against housing (1) faces upward, on jig (16) by using two eye bolts and crane and fasten with two M20 bolts. Apply grease lightly to O-ring of oating seal (19). Insert oating seal (19) to groove of shaft casing O-ring not to damage seal surface with care by using jig (14). NOTE:
O-ring
Floating seal
Pay attention to intruding of foreign materials. Pay attention to damaging of Oring.
Hydraulic Motor Assembly ARS4400L
Figure 75
2.
Position housing (1), of which mating surface against ring gear No.1 (3) faces upward, on working stand like gure (6) by using crane. Apply grease lightly to O-ring of oating seal (19). Insert oating seal (19) to groove of shaft casing O-ring not to damage seal surface with care like means of clause 13. NOTE:
Floating seal
O-ring
Housing
Pay attention to intruding of foreign materials. Pay attention to damaging of Oring.
ASS4390L
Figure 76
Reassembling of Housing (1) and Shaft Casing (25) 1. After tightening two eye bolts to housing (1), lift by using crane, make sure whether tting part of inner race of angular ball bearing (18) and shaft casing (25) is aligned, and then insert housing (1) slowly. At this time, when angular ball bearing (18) can not be inserted well, tap contacting surface of housing (1) against ring gear No.1 by using copper hammer and insert NOTE:
Do not tap by force.
Reassembling of Stopper (27) 1. Position stopper (27) on outer race surface of angular ball bearing (18), after slightly applying Loctite 262 to screw of bolt (31), tighten with rated tightening torque by using socket wrench and torque wrench. Install remained three stoppers by the same means. NOTE:
Tightening torque: 69010kgcm
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Reassembling of Coupling Gear (5) and Ring Gear No.2 (4) 1. Position ring gear No.2 (4) on working stand like gure 7 and install coupling gear (5) from upside. After squeezing snap ring (21) in ring groove of ring gear No.2 (4) by hand and adjust completely.
Snap ring
Ring gear No.2
Coupling gear
ARS4410L
Figure 77
Reassembling of Coupling Gear Subassembly and Housing Subassembly 1. Lift coupling gear subassembly by using two eye bolts (M10) and crane. After slightly applying grease to one side of shim (15) of thickness Ts selected clause 12, insert to contact this side to coupling gear (5). NOTE: 2.
Be careful not to drop shim from coupling gear (5)
After checking lap reaming hole of coupling gear (5) and shaft casing (25), slowly position on shaft casing (25). Temporarily fasten coupling gear subassembly with four bolts (M20). Measure prepressure of angular ball bearing by using spring balance and tap of M20 bolt of shaft casing. If prepressure is appropriate, drive pin (13) by using jig (8). Close two points of end surface of pin (13) hole of coupling gear (5) with 180' space by using punch and prevent pin (13) from dropping. NOTE:
Refer to Figure 78.
3.
After slightly applying Loctite 262 to tap part of hex socket bolt (22), tighten with rated torque by using torque wrench. NOTE:
Tightening torque: 7, 300kgcm
Reassembling of Carrier Subassembly 1. Position carrier (9), of which pin (12) hole side faces downward, on jig (3) to crisscross hole of jig (3) and gear assembling hole of carrier (9) about 10 mm. Place jig (4) near by carrier (9). Position on jig (4) to make oil groove of washer (17) face downward (carrier). Position cluster gear (6) on thrust washer (17) to make No.1 spur gear face downward, insert jig (5) to cluster gear (6). Insert twenty ve needle rollers (20) between cluster gear (6) and jig (5). Insert spacer (16) on them and insert twenty ve needle rollers (20). NOTE:
Three cluster gears in carrier subassembly should be same phase. That is, The same English characters among the carved marks of English characters A, B, C, and D should be assembled among themselves. Pay attention to the 25ea of needle roller bearing.
NOTE: 2.
After moving horizontally the whole except jig (4) in cluster subassembly to carrier (9), make jig (5) be inserted to hole of carrier (9).
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3. 4.
Place on cluster gear (6) to make oil groove of thrust washer (27) face upward (carrier). Check pin (12) hole of shaft (11) and pin (12) hole of carrier (9) by the naked eye, after aligning them in a straight line, lightly tap shaft (11) by using copper hammer, align jig (5) to hole of jig (3), and pull out under jig (3). NOTE:
At this time, prop jig (5) with rag from bottom not to fall rst.
5.
Check pin (12) hole of shaft (11) and pin (12) hole of carrier (9) by the naked eye. At this time, if holes are crisscrossed, align them by using jig (6). Drive pin (12) to 1 mm below the surface of carrier (9) by using hammer and jig (9). Close end surface of pin (12) hole of carrier (9) with two points of 180 space like Figure 78 by using punch and prevent pin (12) from coming out. Install the remaining two cluster gears (6) by repeating the upper clauses from one to four. Turn over carrier subassembly of which cluster No.1 spur gear faces downward. When nishing installation completely, draw lines on the upper surface of carrier (9) like below gure to mate cluster gear phase easily. At this time, three lines should all be parallel.
Hammer
Punch
6.
Pin ARS4420L
Figure 78
7. 8.
Spur gear No.1
Carrier
ARS4430L
Figure 79 Decision of Cluster Gear (6) Phase 1. Make mark "C" of cluster gear (6) of carrier subassembly face like gure (9). NOTE:
It is when phase indicated mark is "C".
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Phase mating line
2.
Insert jig (19) to make spline side face upward like on the state of gure (9). NOTE:
A Jig19
A Carrier Cluster gear
At this time, cluster gear (6) phase should not be changed at clause (28).
ARS4440L
Reassembly of Housing (1) and Ring Gear No.1 (3) 1. 2.
Figure 80
Insert thrust bearing (10) Ttb = 5.5 (parts no: 2114-1647-2) to shaft casing (25). Slightly apply grease to spline part of coupling (8). Insert coupling (8) to hydraulic motor shaft. Insert sun gear (7) being adjusted to spline part of coupling (8). NOTE:
Jig (18) can be used.
3.
Take carrier subassembly down slowly by using M10 eye bolts and crane and make ring gear No.2 (4) align tooth NOTE:
Jig (18) can be used.
4. 5.
Completely clean oil from mating surfaces between ring gear No.2 (4) and housing (1) by using cleaning oil and evenly apply Loctite 587. Lift ring gear No.1 (3) by using M10 two eye bolts and crane, check simultaneous machining lot No. of housing (1) and side surface of ring gear No.1 (3) and put down to make tooth of cluster No.1 spur gear and ring gear No.1 align. Insert jig (5) to M10x1.5 four bolts (33) and temporarily fasten. Turn the whole reduction gear by hand by using jig (20) for inspection. At this time, if kinds of gear do not turn, take out carrier subassembly, check phase, and then recheck turning of kinds of gear after reassembling. Even though kinds of gear turn, if there are noises or turning is irregular, as there are interference between bottom surface of carrier (9) and top surface of coupling gear (5), take out carrier subassembly and reassemble after inspection.
6.
Selection of Thrust Bearing (10) Thickness 1. Measure (G) (H), and (I) of gure (10) by using depth gauge and jig (11). At this time, measure four points and (I) is calculated with the biggest value.
J Depth micrometer Jig11 Carrier
Ring gear No.1
ARS4450L
Figure 81
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Jig11
Depth micrometer G
Carrier Ring gear No.1 ARS4460L
Figure 82 NOTE:
If the difference of (I) among four points is over 0.3, reassembly of carrier subassembly is wrong or there is interference of bottom surface of carrier, so that take out carrier subassembly and check whether there is interference.
Cover
2.
Calculate (T4). T4 = I - G Figure 83

ARS4470L
3.
Calculate (T5). T5 = H - T4 - (0.3 ~ 0.7)
4.
Select thickness (TTB), which belong to T5, of thrust bearing from below table. Part No. 2114-1647-1 2114-1647-2 2114-1647-3 2114-1647-4 TTB 1.2 1.4 1.6 1.8
5. 6.
In case that T5 is over 6 and below 4.5, change TTB = 5.5 (part no: 2114-1647-2) of clause (31) to another and select with method of clause (34)- (37) (But, do not use TTB=4.5). After slightly applying grease to surface of bearing (10) selected from clause (39) and oil groove faces carrier subassembly, press t to cover (2) by using copper hammer. Press t thrust plate (14) to be stuck to cover (2) by using hammer. Fill gear oil with specic quantity. NOTE:
7.
Specic quantity: 4.3 liters
8.
Loosen M10x1.5 bolts temporarily fastened at clause (35). After completely clean oil from mating surface of ring gear No.1 (3) and cover (2) by using cleaning oil, evenly apply Loctite 587. After Tightening jig (17) to level tap hole of cover (2) and lifting it, position it to ring gear No.1 (3). Tighten thirty hex head bolts (33, M10) with specic torque by using torque wrench. NOTE:
Specic torque: 1, 52010 kgcm
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9.
Wind seal tape to tap part of plug (24) and tighten it to cover (2) with specic torque by using torque wrench. NOTE:
Specic torque: 660 kgcm
10.
Coat with specic paint except guide surface of hydraulic motor, tap part of bolt and contact part of sprocket.
INSTALLATION
CHECK Check the following items before tting and manage it if it is abnormal. Checking Items Are there any damages when transporting? Are there any loose bolts? Managing Matters Report to Q/C Department. Tighten rated torque. (Refer to Tightening Torque Chart on page -14) Refer to Oil Filling on page -50
Is gear oil lled with rated quantity? After leveling motor indicated in outside dimension drawing (2401-6198) (Set level mark horizontally.), it is normal if oil ows out. FITTING 1.
Fitting part of motor machines as 380m6+0.057 , and so tting part of equipment machines as +0.021 380F7+0.119 . +0.062
2.
Do not impact on motor and install it by means of bolts.
PIPING 1. Turning direction is indicated in outside dimension drawing. Be careful of piping direction. Turning direction
A B
Inlet A B 2.
Outlet B A
Direction seeing from drive shaft Right turning Left turning
Bm
Cover piping port with plug when transporting, and be careful not to insert welding and cutting scales, etc. in it.
ARS4640L
Figure 84
3.
Two drain pipes are covered with plug. Use an upper pipe between two pipes. Fill fully hydraulic oil in motor casing before piping. Pipe to lower drain pressure under 2 kg/cm2.
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4.
If sand particle or metal powder are mixed in hydraulic oil, wear of sliding surfaces are excessively and it causes sticking, so that use lter of 10m in circuit.
GEAR OIL Kinds of Oil Use GL-4 GRADE of service grouping API of SAE #90 equivalent. Do not use with mixing of oil of other kinds. Oil Drain Turn motor to position oil drain port to low side, then drain oil. (If level plug is loosened, oil drains rapidly.) Oil Filling Set LEVEL mark on cover horizontally, then ll 4.3 liters of oil. GENERAL CAUTION MATTERS 1. 2. Be careful whether there are loosened bolts or oil leaks. Be careful of casing temperature in operation. There is no problem if atmospheric temperatures are about below +60C (90F).
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S0708315K
1MAIN PUMP (KAWASAKI)

CAUTION!
MAIN PUMP (KAWASAKI)

Copyright 2001 Daewoo October 2001 Main Pump (Kawasaki) S0708315K Page 1
TABLE OF CONTENTS
Swash Plate Type K5V Series Axial Piston Pump.......................................... 4 Type Designation..................................................................................... 4 Specications .......................................................................................... 5 Construction and Function ...................................................................... 6 Construction .................................................................................... 6 Function .......................................................................................... 6 Cautions for Operation ............................................................................ 8 Installation ....................................................................................... 8 Cautions for Pipings ........................................................................ 8 Cautions for Filters .......................................................................... 9 Working Oil and Temperature Range ............................................ 10 Operational Cautions .................................................................... 10 Oil lling and Air Venting ............................................................... 11 Cautions in Starting Operation ...................................................... 11 Troubleshooting..................................................................................... 11 General Cautions .......................................................................... 11 Check of Pump Proper for Abnormalities ...................................... 11 Overload of Prime Mover .............................................................. 12 Extreme Decrease of Pump Delivery Flow and Non-increase of Delivery Pressure .......................................................................... 12 Abnormal Noises and Abnormal Vibrations .................................. 13 Construction of Tandem Type Duplex Pump ......................................... 14 Tools...................................................................................................... 16 Axial Piston Pump Disassembling......................................................... 18 Axial Piston Pump Reassembling ......................................................... 22 Axial Pump Maintenance Criteria.......................................................... 25 Worn Part Replacement Criteria ................................................... 25 Correction Criteria for Cylinder, Valve Plate and Swash Plate (Shoe Plate) ................................................................................. 25 Tightening Torques ........................................................................ 26
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Main Pump (Kawasaki)
Regulator for K5V, K3V Series of Kawasaki Swash Plate Type Axial Piston Pump........................................................... 27 Type Description ................................................................................... 27 Parts List ............................................................................................... 28 Regulator Function Diagram ......................................................... 28 Regulator Exploded View .............................................................. 29 Construction of Regulator ............................................................. 30 Outline................................................................................................... 32 Horsepower Control ...................................................................... 32 Flow Control .................................................................................. 33 Specications ........................................................................................ 33 Functional Explanations ........................................................................ 34 Negative Flow Control ................................................................... 34 Total Horsepower Control ............................................................. 35 Variable Horsepower Control ........................................................ 37 Adjustment of Maximum and Minimum Flows....................................... 38 Adjustment of Maximum Flow ....................................................... 38 Adjustment of Minimum Flow ........................................................ 38 Summary of Regulator Adjustment Values ................................... 39 Fault Finding and Remedies on Regulator............................................ 39 Prime Mover is Overloaded .......................................................... 39 Maximum Flow Is Not Available .................................................... 39 Preparation for Disassembly ................................................................. 41 Tools...................................................................................................... 41 Regulator Disassembly ......................................................................... 42 Regulator Reassembly.......................................................................... 45 Tightening Torque.................................................................................. 48
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SWASH PLATE TYPE K5V SERIES AXIAL PISTON PUMP

TYPE DESIGNATION
K5V 140 DT - 1C9 R - 9N01

Regulator type: For more details, see the instruction manual for the regulator.
Shaft rotation viewed from shaft end. R : Clockwise L : Counterclockwise
Design series number
- : DT P : DTD
S : Single pump DT : Tandem type double-pump
Size
K5V series
ARS0120L
Figure 1
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SPECIFICATIONS
Item Size Displacement Rated Pressure Max. Max. *1 Max. for self-priming *2 Single Double Type Oil temp range Oil viscosity range Recommended lter *1 *2
Specication 140 140 cm3/ rev 34.3 MPa (350 kgf/cm2) 37.7 MPa (385 kgf/cm2) 2,500 min-1 2,150 min-1 130 kg Mineral working oil -20 ~ +95 C 10~1,000 cSt (mm2/s) 10m
Speed Weight
Working Oil
These are the maximum speeds for the closed-circuit specications. For the closed-circuit specications, consult us in advance. These are the speeds when the suction pressure is 0 kgf/cm2.
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CONSTRUCTION AND FUNCTION Construction This pump assy consists of two pumps connected by spline coupling (114). The two pumps can be driven simultaneously as the rotation of the prime mover is transferred by the drive shaft (F) (111) on the front side. The suction and discharge ports are integrated at the connecting part of the two pumps, i.e. in valve block (312) : The suction port serves for both the front pump and the rear pump. Function The pumps may be classied roughly into the rotary group performing a rotary motion and working as the major part of the whole pump function: the swash plate group that varies the delivery rates: and the valve cover group that changes over oil suction and discharge. 1. Rotary Group The rotary group consists of drive shaft (F, Figure 24) (111), cylinder block (141), piston shoes (151,152), set plate (153), spherical bush (156) and cylinder spring (157). The drive shaft is supported by bearing (123,124) at its both ends. The shoe is caulked to the piston to form a spherical coupling. It has a pocket to relieve thrust force generated by loading pressure and to take hydraulic balance so that it slides lightly over the shoe plate (211). The sub group composed by a piston and a shoe is pressed against the shoe plate by the action of the cylinder spring via a retainer and a spherical bush. Similarly, the cylinder block is pressed against valve plate (313) by the action of the cylinder spring. 2. Swash Plate Group The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bush (214), tilting pin (531) and servo piston (532). The swash plate is a cylindrical part formed on the opposite side of the sliding surface of the shoe and is supported by the swash support. If the servo piston moves to the right and left as hydraulic force controlled by the regulator is admitted to hydraulic chamber located on both sides of the servo piston, the swash plate slides over the swash plate support via the spherical part of the tilting pin to change the tilting angle ().
Figure 2 Swash Plate Group
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3.
Valve Block Group The valve block group consists of valve block (312), valve plate (313) and valve plate pin (885). The valve plate having two melon-shaped ports is xed to the valve block and feeds and collects oil to and from the cylinder block. The oil changed over by the valve plate is connected to an external pipeline by way of valve block. Now, if the drive shaft is driven by a prime mover (electric motor, engine, etc.), it Figure 3 Swash Plate Group rotates the cylinder block via a spline linkage at the same time. If the swash plate is tilted as in Fig1. the pistons arranged in the cylinder block make a reciprocating motion with respect to the cylinder block, while they revolve with the cylinder block. If you pay attention to a single piston, it performs a motion away from the valve plate (oil sucking process) within 180 degrees, and makes a motion towards the valve plate (or oil discharging process) in the rest of 180 degrees. When the swash plate has a tilting angle of zero, the piston makes no stroke and discharges no oil.
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CAUTIONS FOR OPERATION Installation Item Installed Direction External load to shaft end Caution Install the pump with the drive shaft horizontal in general. Apply neither radial nor thrust load externally to the pump shaft end in general. When a belt of gear drive is to be adopted or any equivalent load applied, consult us, explaining the specications. Since the shaft end splined section has been applied with rust preventing paint, remove it with cleaning liquid before using the pump, and apply lubricant, such as molybdenum disulde, before tting this section to the coupling. When cleaning liquid is used, pay attention not to sprinkle liquid on oil seal sections. Couple the pump drive shaft with the prime mover shaft with a exible coupling in general. For centering between the coupling and drive shaft, keep the alignment within 0.03mm. For the tightening torques of the pump tting bolts, refer to the values of their respective sizes shown in attached list1. Applied Type All types All types
Removal of rust preventing paint
All types
Coupling & centering of pump Tightening of pump tting bolts Cautions for Pipings Item Rotating direction & delivery direction
All types
All types
Caution For the variable pump, these indications depend on the command method of the regulator. For each application of the pump, refer to the indications shown without fail in the outside dimension drawing. Carry out acid pickling and ushing of the suction / delivery pipings and tank fully. Especially, clean the suction piping thoroughly. In tting the pipings, prevent the suction and delivery ports of the pump from being forcedly-stressed. Also avoid sudden bending as much as possible. Refer to attached list 1 tightening torque list in tightening the tting bolts. Raise the drain piping of the pump higher than the pump and then lead it to the tank, as shown in the following gures.
Applied Type All types
Sanitation pipings
of
All types
Fitting of suction / delivery pipings
All types
Drain piping
All types
Drain pressure
For the tandem type double-pump, t the drain piping to the front pump rst as far as possible. It is desirable to provide a lter in the drain line. Remember that the allowable internal casing pressure of this pump is normally less than 1 kgf/
Tandem type pumps All types
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Cautions for Filters The most conclusive factor to prevent the pumps and other components from damaging and to lengthen their life-spans is whether pollution control of their working oil is carried out fully or not. A lter of 10m should be provided in the circuit without fail. Item Tilting-to-one circuit side Caution In this circuit, do not fail to provide a lter of 10m in the actuator return pipe. The following gure shows examples. In addition, provide a lter of 80 to150 mesh at the suction side. Applied Type All types of tilting-to-one side pumps
Tilting-to-both side circuit
It is ideal to provide a lter of 10 in the booster line as shown in (a) of the following gure, but there are also a number of experiences to provide lters of 10m in the ushing circuits. Anyway, provide a ler of 80-150 mesh at the suction side of the booster pump.
All types of tilting-to-both side pumps
Contamination
The relation between contamination and the pump's life-span is very ununderstandable and the latter depends largely on the kind and nature of dust. Especially, mixing of sand causes any pump to lessen its life-span remarkably. On the premises that sand is not mixed the recommended range is class 9 or better in NAS class, and 2 to 4 mmg/100cc or lessin millipoise pollution grade.
All types
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Working Oil and Temperature Range Item Kind of oil Caution Use generally-used working oil that is added with bubbling preventive agent, antioxidant, anti corrosives, sec. and has a high viscosity index. For the open circuit, the recommended working viscosity range is 10 to 200 cSt. For the close circuit or when used as a motor, the range of 10 to 1000 cSt can be available, but the range of 10 to 200 cSt is desirable, considering the optimum efciency. The temperature range is limited approximately to -20C to 80C by oil seals, O-rings, etc. It is desirable to use oil at a temperature lower than 65C as low as possible, considering deterioration of working oil, seals and so on. Applied Type All types
Optimum viscosity & temperature of working oil
All types
Working oil other than mineral oil Operational Cautions Item Laid-up for a long period
When any working oil of phosphate, water-glycol, fatty acid ester or so on is to be used, do not fail to consult us in advance.
All types
Caution It is not recommendable that the pump/motor is laid-up for a long period (one year or more) without being operated. During such period, rotate it sometimes even for a short time. When it is laid-up independently, it is effective even to turn its shaft manually. If the laid-up period is longer it is necessary to overhaul it. The rotating direction is as indicated by the arrow plate. If it must be changed during its life-span, consult us.
Applied Type All types
Change of rotating direction
All types
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Oil lling and Air Venting Item Oil lling Caution Fill the pump casing with oil without fail. Inside the pump there are the high-speed sliding parts, such as bearings, pistons/ shoes, retainer, etc. If not lled with oil, these parts may suffer from serious troubles, such as seizures damage When air is left in the circuit or pump, it may cause any malfunction or damage. Vent air completely without fail. Applied Type All types
Air venting
All types
Cautions in Starting Operation 1. 2. 3. 4. 5. 6. Check pipings for being tted completely. Check that the rotating and suction / delivery directions are correct. Before starting the prime mover, make the pump free of any load. After starting, continue the idle running for a while to vent air from the circuit completely. Check the pump and pipings for oil leaks and abnormal vibrations. When the pump is attached to the gear box, check the box for full oil level with its oil level gage.
TROUBLESHOOTING General Cautions This section describes the countermeasures to be taken if any abnormality is detected during the operation of the Kawasaki swash plate type axial piston pump. The general cautions are as follows: 1. 2. Consider the condition before starting work. Judge the nature of the abnormality, before starting work. Especially, judge if it is a problem in the circuit or caused by the regulator or attached valves and determine that something is wrong truly with the pump or not. Read the maintenance manual well before disassembling and then follow the right disassembling procedures. Even when any section is to be disassembled, pay attention not to make dust enter into the pump. Since the parts are nished nely, handle them carefully not to damage it.
3. 4. 5.
Check of Pump Proper for Abnormalities The pump is often tted with regulator, accessory valves and associated pump, and so it is very difcult to nd the cause of the failure. Investigate the following principal check item, and the abnormal point will be revealed. 1. Check of lter and drain oil Check lter elements for a great deal of abnormal impurities. Since the shoes and cylinder may give worn metal particles, a small quantity may be detected there. However if a great deal of metal particles are found in lters, it is considered that shoes may be damaged. Similarly, check drain oil in the pump casing.
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2.
Existence of abnormal noises or vibrations Check the pump proper for abnormal noises and vibrations. If any, investigate if it is a noise of a regular frequency, such as hunting of the regulator or the relief valve of the accessory valve, or not. If it is an abnormal vibration or noise, it may result from cavitation or a damage inside the pump.
3.
Case where two pumps are used For the circuit with two simples pumps or motors or for the duplex pump, exchange the piping of one pump with that of the other one. With the results of this exchange, it will be determined if the trouble is the problem of the circuit downstream the pump or not.
4.
Pressure Measurement at Various Points If the failure is problem in control, do not overhaul the pump recklessly, but measure pressures at various part to investigate the abnormal position.
Overload of Prime Mover Cause Is not the speed-pressure higher than their specied values? Is not the torque setting of the regulator higher? Seizure or damage of a part inside the pump. Wrong tting of the regulator piping. Countermeasure Set them as specied. Reinvestigate the regulator. Replace the damaged part. Remark
See the instruction manual of the regulator. Check the lter and drain oil for abnormal worn metal particles.
Correct the regulator piping.
Extreme Decrease of Pump Delivery Flow and Non-increase of Delivery Pressure Cause Failure of the regulator. Seizure or damage of a part inside the pump. Failure of the associated pump. Countermeasure Repair the regulator. Replace the damaged part. Replace the damaged part. Remark See the instruction manual of the regulator. Check the lters and drain oil. Remove the associated pump and check the shaft coupling. See the instruction manual of the accessory valves.
Failure of the accessory valve.
Wrong tting of the regulator piping.
Check the accessory valves. (Especially check the poppets, seats and springs). Correct the regulator piping.
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Abnormal Noises and Abnormal Vibrations Cause Cavitation Countermeasure Prevention from cavitation. Check working oil for emulsion. Remark Low boost press. Failure of the associated pump. Air leakage at the suction pipe. Increased suction resistance. Damage in the caulking suction of the shoe. Cranking of the cylinder. Wrong installation of the pump. Hunting of the regulator. Hunting of the relief valve of the accessory valve. Replace the piston shoe, plate, etc. Replace the cylinder. Correct installation. Repair the regulator. Repair the accessory valve.
See the instruction manual of the regulator. See the instruction manual of the accessory valve.
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CONSTRUCTION OF TANDEM TYPE DUPLEX PUMP
04
Tightening Torque Flange Socket (4-M6x1.0) 6.9 Nm (70kgf.cm)
401
141
152
314
Valve plate for c.clockwise rotation
151
885 466 725
719
114 124 313
954 312 901 792 534
Valve plate for clockwise rotation
983 981 157 728 467
702 724 548 531
Apply adhesive (No 1305N of Threebond make)
156
214 532
153
732
211
789
212
535
806 953 886 717 406 261 111
774 824 127 710 123 251 490

Apply (Sealup L101) to the all sealsurface circumferential
ARS0190L
Figure 4
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Reference Number 04 111 113 114 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 262 271 312 313 314 325 401 406
Description Gear Pump Drive Shaft (F) Drive Shaft (R) Spline Coupling 1st Gear (for DTP) Roller Bearing Needle Bearing Bearing Spacer Cylinder Block Piston Shoe Set Plate Spherical Bush Cylinder Spring Shoe Plate Swash Plate Tilting Bush Swash Plate Support Seal Cover (F) Seal Cover (R) Pump Casing Valve Block Valve Plate (R) Valve Plate (L) Valve Casing Hexagon Socket Head Bolt Hexagon Socket Head Bolt
Reference Number 466 468 531 532 534 535 548 702 710 717 719 724 725 728 732 774 789 792 808 824 885 886 901 953 954 981 983
Description VP Plug VP Plug Tilting Pin Servo Piston Stopper (L) Stopper (S) Feed Back Pin O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring Oil Seal Back Up Ring Back Up Ring Nut Snap Ring Valve Plate Pin Spring Pin Eye Bolt Set Screw Set Screw Name Plate Pin
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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 pump type. Necessary tool (Marked with O) Pump type K5V80 K5V140 Hexagon socket head bolt
Tool name & size
Part name Hexagon socket head setscrew M4 M5 M6 M8 M10 M12,M14 M16,M18 M20
Name Allen wrench
B 2 2.5 3 4 5 6 8 10 12 14 17 19 21 22
PT plug (PT thread)
PO plug (PF thread)
O O O O
O O O
M5 M6 M8 M10 M12 M14 M16, M18
BP-1/16 BP-1/8 BP-1/4 BP-3/8 BP-1/2 BP-3/4 BP-1
PO-1/4 PO-3/8 PO-1/2 PO-3/4 PO-1, 1 /4, 11/2

1
O O
M20, M22 M24, M27 M30
PO-2
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Tool name & size Name Double ring spanner, Socket wrench, Double (single) open end spanner. B 19 22 24 27 30 36 41 50 55 Adjustable wrench Screwdriver Hammer Pliers Steel bar Torque wrench angle
Necessary tool (Marked with O) K5V80 O K5V140 O O O O O Hexagon headed bolt M12 M16 M18 M20
Part name Hexagon nut M12 M16 M18 M20 VP plug (PF thread) VP-1/4 VP-3/8 VP-1/2 VP-3/4 VP-1 VP-11/4 VP-11/2
O O O O O O
O O O O O O
Medium size, 1 set Minus type screwdriver, medium size, 2 sets Plastic hammer, 1 set For snap ring, TSR-160 Steel bar of key material approx. 10x8x200 Capable of tightening with the specied torques
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AXIAL PISTON PUMP DISASSEMBLING For disassembling the pump, read this section thoroughly and then disassemble it in the following sequence. The gures 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 the single pump and tandem type double-pump. Disassemble the pump, referring to the contents for its appropriate type. In addition, for the double-pump, take care not to mix up parts of one pump with the same ones of the other pump. 1. Select place suitable to disassembling.
IMPORTANT
Select clean place. Spread rubber sheet, cloth or so on overhaul workbench top to prevent parts from being damaged. 2. 3. Remove dust, rust, etc., from pump surfaces with cleaning oil or so on. Remove drain port plug (468) and let oil out of pump casing.
IMPORTANT
For tandem type pump, remove plugs from both front and rear pumps. 4. Remove hexagon socket head bolts (412, 413) and remove regulator.
IMPORTANT
Refer to instruction manual regulator for its disassembling. 5. of
Loosen hexagon socket head bolts (401) which tighten swash plate support (251), pump casing (271) and valve block (312).
IMPORTANT
If gear pump and so on are tted to rear face of pump, remove them before starting this work.
Figure 5
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6.
Place pump horizontally on workbench with its regulator-tting surface down, and separate pump casing (271) from valve block (312).
IMPORTANT
Before bringing this surface down, spread rubber sheet on workbench without fail to prevent this surface from being damaged. Figure 6 7. Pull cylinder (141) out of pump casing (271) straightly over drive shaft (111). Pull out also pistons (151), set plate (153), spherical bush (156) and cylinder springs (157) simutaneously.
IMPORTANT
Take care not to damage sliding surfaces of cylinder, spherical bush, shoes, swash plate, etc. Figure 7 8. Remove hexagon socket head bolts (406) and then seal cover (F) (261).
IMPORTANT
Fit bolt into pulling-out tapped hole of seal cover (F), and cover can be removed easily. Since oil seal is tted on seal cover (F), take care not to damage it in removing cover. 9. Remove hexagon socket head bolts (408) and then seal cover (R) (262). NOTE: Figure 8
In case tting a gear pump, rst, remove gear pump.
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10.
Tapping lightly tting ange section of swash plate support (251) on its pump casing side, 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. Tapping lightly shaft ends of drive shafts (111, 113) with plastic hammer, take out drive shafts from swash plate supports.
Figure 11 13. Remove valve plates (314, 314) from valve block (312).
IMPORTANT
These may be removed in work 6.
Figure 12
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14.
If necessary, remove stopper (L) (534), stopper (S) (535), servo piston (532) and tilting pin (531) from pump casing (271), and needle bearing (124) and splined coupling (114) from valve block (312).
IMPORTANT
In removing tilting pin, use a protector to prevent pin head from being damaged. Since locktight is applied to tting areas of tilting pin and servo piston, take care not to damage servo piston. Do not remove needle bearing as far as possible, except when it is considered to be out of its life span. Do not loosen hexagon nuts of valve block and swash plate support. If loosened, ow setting will be changed.
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AXIAL PISTON PUMP REASSEMBLING For reassembling reverse the disassembling procedures, paying attention to the following items. 1. Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance. Clean each part fully with cleaning oil and dry it with compressed air. Do not fail to apply clean working oil to sliding sections, bearings, etc. before assembling them. In principle, replace seal parts, such as O-rings, oil seals, etc. For tting bolts, plug, etc., prepare a torque wrench or so on, and tighten them with torques shown in Tightening Torques on page 26. For the double-pump, take care not to mix up parts of the front pump with those of the rear pump.
Fit swash plate support (251) to pump casing (271), tapping the former lightly with a hammer.
IMPORTANT
After servo piston, tilting pin, stopper (L) and stopper (S) are removed, t them soon to pump casing in advance for reassembling. In tightening servo piston and tilting pin, use a protector to prevent tilting pin head and feedback pin from being damaged. In addition, apply Lock-tight (medium strength) to their threaded sections. 2. Place pump casing with its regulator-tting surface down, t tilting bush of swash plate to tilting pin (531), and t swash plate (212) to swash plate support (251) correctly.
Figure 13
IMPORTANT
Conrm with ngers of both hands that swash plate can be removed smoothly. Apply grease to sliding sections of swash plate and swash plate support, and drive shaft can be tted easily. Figure 14
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3.
To swash plate support (251), t drive shaft (111) set with bearing (123), bearing spacer (!27) and snap ring (824).
IMPORTANT
Do not tap drives shaft with hammer or so on. Assemble them into support, tapping outer race of bearing lightly with plastic hammer. Fit them fully, using steel bar or so on. 4. Assemble seal cover (F) (261) to pump casing (271) and x it with hexagon socket head bolts (406).
Figure 15
IMPORTANT
Apply grease lightly to oil seal in seal cover (F). Assemble oil seal, taking full care not to damage it. For tandem type pump, t rear cover (263) and seal cover (262) similarly. 5. Assemble piston cylinder subassembly (cylinder (141), piston subassembly (151, 152), set plate (153), spherical bush (156) and cylinder spring (157). Fit spline phases of retainer and cylinder. Then insert piston cylinder subassembly into pump casing. Figure 16
Figure 17
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6.
Fit valve plate (313) to valve block (312), entering pin in to pin hole.
IMPORTANT
Take care not to mistake suction / delivery directions of valve plate.
Figure 18 7. Fit valve block (312) to pump casing (271) and tighten hexagon socket head bolts (401).
IMPORTANT
At rst assemble this at rear pump side, and this work will be easy. Take care not to mistake direction of valve block. Clockwise rotation (viewed from input shaft side) - Fit block with regulator up and with delivery ange left, viewed from front side. Counterclockwise rotation (viewed from input shaft side) - Fit block with regulator up and with delivery ange right, viewed from front side. 8. Putting feedback pin of tilting pin into feedback lever of regulator, t regulator and tighten hexagon socket head bolts (412, 413). Figure 19
IMPORTANT
Take care not to mistake regulator of front pump for that of rear pump. 9. Fit drain port plug (468). This is the end of reassembling procedures. Figure 20
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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 damaged seriously in appearance, replace it without fail. Pump Type K3V63/K5V80 K5V140 Standard dimension / Recommended replacement value
Part name & inspection item
Countermeasures
Clearance between piston & cylinder bore (D-d)
0.028 / 0.056
0.043 / 0.070
Replace piston or cylinder
Play between piston & shoe-caulking section ()
0-0.1 / 0.3
0-0.1 / 0.3
Replace assembly of piston & shoe
Thickness of shoe (t) 3.9 / 3.7 4.9 / 4.7 Replace assembly of piston & shoe
Free height of cylinder spring (L) 31.3 / 30.5 41.1 / 40.3
Replace cylinder spring
Combined height of set plate & spherical bush (H-h)
19.0 / 18.3
23.0 / 22.0
Replace retainer or set plate
Correction Criteria for Cylinder, Valve Plate and Swash Plate (Shoe Plate)
Surface roughness for valve plate (sliding face), swash plate (shoe plate area) & cylinder (sliding face)
Surface roughness necessary to be corrected Standard surface roughness (Corrected value)
3-Z 0.4-Z or lower (Lapping)
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Tightening Torques
Part name Hexagon socket head bolt (Material:SCM 435)
Size M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 PT 1/16 PT 1/8 PT 1/4 PT 3/8 PT 1/2 PF 1/4 PF 1/2 PF 3/4 PF 1 PF 11/4 PF 11/2
PT plug (Material :S45C) Wind a seal tape 11/2 to 2 turns round the plug.
Tightening torque 70 kgf cm 120 kgf cm 300 kgf cm 580 kgf cm 1,000 kgf cm 1,600 kgf cm 2,400 kgf cm 3,400 kgf cm 4,400 kgf cm 70 kgf cm 105 kgf cm 175 kgf cm 350 kgf cm 500 kgf cm 300 kgf cm 1,000 kgf cm 1,500 kgf cm 1,900 kgf cm 2,700 kgf cm 2,800 kgf cm
Tool name B=4 B=5 B=6 B=8 B=10 B=12 B=14 B=14 B=17 B=4 B=5 B=6 B=8 B=10 B=6 B=10 B=14 B=17 B=17 B=17
Allen wrench
Do.
Do.
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REGULATOR FOR K5V, K3V SERIES OF KAWASAKI SWASH PLATE TYPE AXIAL PISTON PUMP
TYPE DESCRIPTION
KR3 G - 9 N 01
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 C : Negative flow control (With 2-stage max. flow control) D: Positive flow control (With flow cut function) Kind of horsepower control 1 : Constant horsepower control 2 : Total cumulative horsepower control 4 : High pressure cut-off control 5 : Constant horsepower control + High pressure cut-off control 6 : Total cumulative horsepower control + High pressure cut-off control 7 : Total cumulative horsepower control + Variable horsepower control Size 6 : K3V63 G : K3V112 H : K3V140 & K3V180 Regulator for K3V series pump
ARS0200L
Figure 21
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REGULATOR EXPLODED VIEW
Figure 22
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CONSTRUCTION OF REGULATOR
Figure 23
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Reference Number 412 413 436 438 496 531 548 601 611 612 613 614 615 621 622 623 624 625 626 627 628 629 630 631 641 643 644 645 646 651
Description Hexagon Socket Head Screw Hexagon Socket Head Screw Hexagon Socket Head Screw Hexagon Socket Head Screw Plug Tilting Pin Feedback Pin Casing Feedback Lever Lever (1) Lever (2) Fulcrum Plug Adjusting Plug Compensating Piston Piston Case Compensating Rod Spring Seat (C) Outer Spring ( Inner Spring Adjusting Ring (C) Adjusting Screw (C) Cover (C) Lock Nut PF Sleeve Pilot Cover Pilot Piston Spring Seat Adjusting Ring (Q) Pilot Spring Sleeve
Reference Number 652 653 654 655 656 708 722 724 725 728 730 732 733 734 735 755 756 763 801 814 836 858 874 875 887 897 898 924 925
Description Spool Spring Seat Return Spring Set Spring Block Cover O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring Nut Snap Ring Snap Ring Locking Ring Pin Pin Pin Pin Pin Adjusting Screw Adjusting Screw (QI)
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OUTLINE The regulator for the K3V Series Kawasaki in-line type axial piston pump has various models to satisfy various kinds of specications required. Therefore, the customer can select the appropriate model to its intended application. Horsepower Control
Code
Control Type Constant horsepower control
Control Curve
Function & Features According to the rise of delivery pressure of a pump, the tilting angle of the pump is automatically torque control is achieved. According to the rise of delivery pressure of a pump, the tilting angle of the pump is automatically torque control is achieved. (compensation control) The total horsepower control can be achieved by decreasing the horsepower of a pump depending upon the pressure of its companion pump.
Total horsepower control
P2 Companion pump pressure
Pressure cut-off 4
High pressure cut-off
Horsepower control pressure cut-off Total horsepower control pressure cut-off
If the pressure rises above the set value, the pump outlet ow is automatically decreased by the pressure cut-off control.
Variable horsepower control
Variable horsepower control can be obtained by supplying pilot pressure or electric current.
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Flow Control
Code
Control Type
Control Curve
Function & Features
Manual ow control Lever stroke
With the manual control, the outlet ow can be freely controlled.
Positive ow control Pilot pressure
Positive ow control can be carried out by using the pilot pressure.
Negative ow control
Negative ow control can be carried out by using the pilot pressure. Two-stage max. ow control can be obtained by supplying external pilot pressure. (only in negative ow control)
2-stage max. ow control C
One ow control and one horsepower control can be combined for use. When these controls function simultaneously, the lower tilting angle (lower ow) will prevail through the mechanical calculation mentioned below. SPECIFICATIONS Working oil: Wear-resistant hydraulic working oil, ISO VG 32, 46 & 68 Temperature range: -20 C ~ +95C Viscosity range: 10~1000 cSt (During normal operation: 10 ~ 200 cSt) Miscellaneous: With proportional pressure reducing valve (In case of type KR3*-9***)
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FUNCTIONAL EXPLANATIONS The regulator for Kawasaki inline axial piston pump K3V Series consists of the following control functions. 1. 2. 3. Negative ow control Total cumulative horsepower control Variable horsepower control
Regulator Function Diagram
Figure 24
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Negative Flow Control By changing the pilot pressure Pi, the pump tilting angle (delivery ow) is regulated arbitrarily, as shown on the Figure 25. This regulator is of the negative ow control in which the delivery ow Q decreases as the pilot pressure Pi rises. With this mechanism, when the pilot pressure corresponding to the ow required for the work is commanded, the pump discharges the required ow only, and so it does not consume the power uselessly. 1. Functional Explanation A. Flow reducing Function Figure 25
As the pilot pressure Pi rises, the pilot piston (643) moves to the right to a position where the force of the pilot spring (646) balances with the hydraulic force. The groove (A) in the pilot piston is tted with the pin (875) that is xed to lever 2 (613). Therefore, when the pilot piston moves, lever2 rotates around the fulcrum of point B (xed by the fulcrum plug (614) and pin (875). Since the large-hole section (C, Figure 24) of lever 2 contains a protruding pin (897) xed to the feedback lever(611), the pin (897) moves to the right as lever 2 rotates. Since the opposing-at section (D) of the feedback lever is tted with the pin (548) xed by the tilting pin (531) that swings the swash plate, the feedback lever rotates around the fulcrum of point D, as the pin (897) moves. Since the feedback lever is connected with the spool (652) via the pin (874), the spool moves to the right. The movement of the spool causes the delivery pressure P1 to connect to port C liter through the spool and to be admitted to the large-diameter section of the servo position. The delivery pressure P1 that is constantly admitted to the small-diameter section of the servo piston moves the servo piston to the right due to the area difference, resulting in decrease of the tilting angle. When the servo piston moves to the right, point D also moves to the right. The spool is tted with the return spring (654) and is tensioned to the left at all times, and so the pin (897) is pressed against the large-hole section (C) of lever2. Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the spool is shifted to the left. This causes the opening between the sleeve (651) and spool (652) to close slowly, and the servo piston comes to a complete stop when it closes completely. B. Flow Increasing Function As the pilot pressure Pi decreases, the pilot piston (643) moves to the left by the action of the pilot spring (646) and causes lever 2 (613) to rotate around the fulcrum of point B. Since the pin (897) is pressed against the large-hole section (C) of lever 2 by the action of the return spring (654) via the spool (652), pin (874), and feedback lever (611), the feedback lever rotates around the fulcrum of point D as lever 2 rotates, and shifts the spool to the left. Port C liter opens a way to the tank port as the spool moves. This deprives the large-diameter section of the servo piston of pressure, and shifts the servo piston to the left by the discharge pressure P1 in the smalldiameter section, resulting in an increase in the ow rate. As the servo piston moves, point D also moves to the left, the feedback lever rotates around the fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve is closed.
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2.
Adjustment of ow control characteristic The ow 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 26. NOTE:
Adjusting values are shown in the attached Table. See Summary of Regulator Adjustment Values on page -39.
Figure 26
Total Horsepower Control The regulator decreases the pump tilting angle (delivery ow) automatically to limit the input torque within a certain value with a rise in the delivery pressure P1 of the self pump and the delivery pressure P2 of the companion pump. (The input horsepower is constant when the speed is constant.) Since the regulator is of the simultaneous total horsepower type that operates by the sum of load pressures of the two pumps in the tandem double-pump system, the prime mover is automatically prevented from being overloaded, irrespective of the load condition of the two pumps, when horsepower control is under way. 1. Functional explanation Since this regulator is of the simultaneous total horsepower type, it controls the tilting angles (displacement volumes) of the two pumps to the same values as represented by the following equation: T in = P1 x q/2 + P2 x q/2 = (P1 + P2) x q/2
Figure 27
The horsepower control function is the same as the ow control function and is summarized in the following. (For detailed behaviors of respective parts, refer to the section of ow control). A. Overload Preventive Function When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it acts on the stepped part of the compensating piston (621). It presses the compensating rod (623) to the right till the force of the outer spring (625) and inner spring (626) balances with the hydraulic force. The movement of the compensating rod is transmitted to Lever 1 via pin (875). Lever 1 rotates around the pin (875) (E) xed to the casing (601). Since the large-hole section (F) of Lever 1 contains a protruding pin (897) xed to the feedback lever (611), the feedback lever rotates around the fulcrum of Point D as Lever 1 rotates, and then the spool (652) is shifted to the right. As the spool moves, the delivery pressure P1 is
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admitted to the large-diameter section of the servo piston via Port C liter, causes the servo piston move to the right, reduces the pump delivery ow 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. B. Flow Reset Function As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases, the compensating rod (623) is pushed back by the action of the springs (625 & 626) to rotate Lever 1 around point E. Rotating of Lever 1 causes the feedback lever to rotate around the fulcrum of point D and then the spool to move to the left. As a result, Port C liter opens a way to the tank port. This causes the servo piston to move to the left and the pump's delivery rate to increase. The movement of the servo piston is transmitted to the spool by the action of the feedback mechanism to move it till the opening between the spool and sleeve is closed. 2. Low tilting angle (low ow) command preferential function As mentioned above, ow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large-hole sections (C & F) of levers 1 and 2. However, since sections C and F have the pins (4) protruding from the large hole (8), only the lever lessening the tilting angle contacts the pin (897); the hole (8) in the lever of a larger tilting angle command is freed without contacting the pin (897). Such a mechanical selection method permits preference of the lower tilting angle command of the ow control and horsepower control. 3. Adjustment of Input horsepower Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both the front and rear pumps, when changing the horsepower set values. The pressure change values by adjustment are based on two pumps pressurized at the same time, and the values will be doubled when only one pump is loaded. A. Adjustment of outer springs Adjust it by loosening the hexagon nut (630) and by tightening (or loosening) the adjusting screw C (628). Tightening the screw shifts the control chart to the right and increases the input horsepower as shown in the Figure 28. Since turning the adjusting screw C by N turns changes the setting of the inner spring, return the adjusting screw CI (925) by NxA turns at rst. Figure 28
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B.
Adjustment of inner spring Adjust it by loosening the hexagon nut (801) and by tightening (or loosening) the adjusting screw Cl (925). Tightening the screw increases the ow and then the input horsepower as shown in the Figure 29.
Figure 29 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. Only one proportional pressure reducing valve is provided. However, the secondary pressure Pf (power shift pressure) is admitted to the horsepower control section of each pump regulator through the pump's internal path to shift it to the same set horsepower level. This function permits arbitrary setting of the Pump output power, thereby providing the optimum power level according to the operating condition. 1. Functional explanation The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown in the Figure 30. As the power shift pressure Pf rises, the compensating rod (623) moves to the right via the pin (898) and compensating piston (621). This decreases the pump tilting angle and then the set horsepower in the same way as explained in the overload preventive function of the horsepower control. On the contrary, the set horsepower rises as the power shift pressure Pf falls.
Figure 30
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ADJUSTMENT OF MAXIMUM AND MINIMUM FLOWS The regulator can adjust the maximum and minimum ows with the adjusting screws. NOTE:
Their respective adjustment values are shown in the attached Table. See Summary of Regulator Adjustment Values on page -39.
Adjustment of Maximum Flow Adjust it by loosening the hexagon nut (809) and by tightening (or loosening) the set screw (954). The maximum ow only is adjusted without changing other control characteristics.
Figure 31 Adjustment of Minimum Flow Adjust it by loosening the hexagon nut (909) and by tightening (or loosening) the hexagonal socket head set screw (953). Similarly to the adjustment of the maximum ow, other characteristics are not chanced. However, remember that, if tightened too much, the required horsepower during the maximum delivery pressure (or during relieving) may increase. Figure 32
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Summary of Regulator Adjustment Values Item Speed Adjustment of Maximum Flow Tightening amount of adjusting screw (954) Flow change amount Tightening amount of adjusting screw (953) Flow change amount Tightening amount of adjusting screw (C) (628) Compensating control starting pressure change amount Input torque change amount A Tightening amount of adjusting screw (QI) (925) Compensating control starting pressure change amount Input torque change amount Tightening amount of adjusting screw (924) Flow control starting pressure change amount Flow change amount Specication 2200 min-1 +1/4 Turn -3.5 L/min +1/4 Turn +3.5 L/min +1/4 Turn +19 kgf/cm2 +3 kgf m 1.9 +1/4 Turn +27 kgf/cm2 +2.5 kgf m +1/4 Turn +1.5 kgf/cm2 +8 L/min
Adjustment of Minimum Flow
Adjustment of Input Horsepower
Adjustment of outer spring
Adjustment of inner spring
Adjustment characteristic
of
ow
control
FAULT FINDING AND REMEDIES ON REGULATOR In case a functional fault probably resulting from the regulator occurs, disassemble and inspect it, referring to the maintenance manual. Prime Mover is Overloaded Determine which is faulty, the front pump or rear pump, by loading each pump independently. When both pumps are found faulty, investigate the following (1) and (2). Begin investigation with (3), when only one pump is found faulty. (1) and (2) are only for cases of the variable horsepower control. 1. 2. Check that the power shift command current I is normal. The power shift pressure is low: - Check the amplier dither. - Replace the proportional pressure reducing valve. The compensating piston (621) and compensating rod (623) are stuck with each other: - Disassemble and clean the regulator. The Pin (898) is stuck: - Disassemble and clean the regulator.
3. 4.
Maximum Flow Is Not Available 1. Check that the pilot pressure Pi is normal.
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2. 3. 4. 5.
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: - Disassemble and clean the regulator. The spool (COV) (637) is stuck: - Disassemble and clean the regulator. NOTE:
Replace faulty parts that are deeply scord. (1) and (2) are only for cases of the pilot control. (4) is only for cases of the 2-stage max. ow control. (5) is only for cases of the cut-off control.
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PREPARATION FOR DISASSEMBLY 1. Since the regulator consists of small precision-nished 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. The numbers in parentheses after part names represent those in the construction drawings on Figure 22 and Figure 23.
2.
TOOLS
Name
Description 4,5,6 (Dimension B mm)
Allen wrench
Socket wrench, double-ended (single-ended) wrench Adjustable wrench Screw driver Plastic hammer Torque wrench Pliers Steel bar Pincers Bolt
Small size (max. 36 mm)
2 sets for stop ring 4 mm or less in dia., L=100mm M4, L=about 50 mm
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REGULATOR DISASSEMBLY 1. Choose a plate for disassembly.
CAUTION!
1. Choose a clean place. 2. Spread rubber sheet, cloth, or so on top of work-bench to prevent parts from being damaged. 2. 3. Remove dust, rust, etc. from surfaces of regulator with clean oil. Remove hexagon socket head screws (412,413) and remove regulator main body from pump main body.
IMPORTANT
Take care not to lose O-ring.
Figure 33 4. Remove hexagon socket head screws (488) and remove cover (C) (629).
IMPORTANT
Cover (C) is tted with adjusting screw (C), (QI) (628, 925), adjusting ring (C) (627), lock nut (630), hexagon nut (801) and adjusting screw (924). Do not loosen these screws and nuts. If they are loosened, adjusted pressure-ow setting will vary. Figure 34 5. After removing cover (C) (629) subassembly, take out outer spring (625), inner spring (626) and spring seat (C) (624) from compensating section. Then draw out adjusting ring (Q) (645), pilot spring (646) and spring seat (644) from pilot section.
IMPORTANT
Adjusting ring (Q) (645) can easily be drawn out with M4 bolt. Figure 35
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6.
Remove hexagon socket head screws (436, 438) and remove pilot cover (641). After removing pilot cover, take out set spring (655) from pilot section.
Figure 36 7. Remove snap ring (814) and take out spring seat (653), return spring (654) and sleeve (651).
IMPORTANT
Sleeve (651) is tted with snap ring (836). When removing snap ring (814), return spring (654) may pop out. Take cae not to lose it. Figure 37 8. Remove locking ring (858) and take out fulcrum plug (614) and adjusting plug (615).
Figure 38
IMPORTANT
Fulcrum plug (614) and adjusting plug (615) can easily be taken out with M6 bolt.
Figure 39
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9.
Remove lever (2) (613). Do not draw out pin (875).
IMPORTANT
Work will be promoted by using pincers or so on.
Figure 40 10. Draw out pin (874) and remove feedback lever (611).
Figure 41
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).
Figure 42
11. 12. 13.
Remove lever (1) (612). Do not draw out pin (875). Draw out pilot piston (643) and spool (652). Draw out piston case (622), compensating piston (621) and compensating rod (623). This completes operation. NOTE:
Since component parts are small, take care not to lose them.
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REGULATOR REASSEMBLY For assembly, reverse disassembly procedures, but pay attention to the following. 1. 2. 3. Always repair parts that were scored at disassembly. Get replacement parts ready beforehand. Mixing of foreign matter will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place. Always tighten bolts, plugs, etc. to their specied torques. Do not fail to coat sliding surfaces with clean hydraulic oil before assembly. Replace seals such as O-rings with new ones as a rule.
Put compensating rod (623) into compensating hole of casing (601). Put pin force-tted in lever (1) (612) into groove of compensating rod and t lever (1) to pin force-tted in casing. Fit spool (652) and sleeve (651) into hole in spool of casing.
IMPORTANT
Conrm that spool and sleeve slide smoothly in casing without binding. Pay attention to orientation of spool.
Figure 43 4. Fit feedback lever (611), matching its pin hole with pin hole in spool. Then insert pin (874).
IMPORTANT
Insert pin in feedback lever a little to ease operation. Take care not to mistake direction of feedback lever. 5. Put pilot piston (643) into pilot hole of casing. Figure 44
IMPORTANT
Conrm that pilot piston smoothly without binding. slides
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6.
Put pin force-tted in lever (2) (613) into groove of pilot piston. Then x lever (2).
Figure 45 7. Fit fulcrum plug (614) so that pin forcetted in fulcrum plug (614) can be put into pin hole of lever (2). Then x locking ring (858). Insert adjusting plug (615) and t locking ring.
8.
IMPORTANT
Take care not to mistake inserting holes for fulcrum plug and adjusting plug. At this point in time move feedback lever to conrm that it has no large play and is free from binding. 9. Fit return spring (654) and spring seat (653) into spool hole and attach snap ring (814). Figure 46
Figure 47
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10.
Fit set spring (655) to spool hole and put compensating piston (621) and piston case (622) into compensating hole. Fit pilot cover (641) and tighten it with hexagonal socket head screws (436, 438).
Figure 48 11. Put spring seat (644), pilot spring (646) and adjusting ring (Q) (645) into pilot hole. Then x spring seat (624), inner spring (626) and outer spring (625) into compensating hole.
IMPORTANT
When tting spring seat, take care not to mistake direction of spring seat. Figure 49 12. Install cover (C) (629) tted with adjusting screws (628) (925), adjusting ring (C) (627), lock nut (630), hexagon nut (801) and adjusting screw (924). Then tighten them with hexagonal socket head screws (438). This completes assembly.
Figure 50
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TIGHTENING TORQUE
Part Name Hexagon socket head bolt (Material: SCM 435)
PT lling plug (Material: S45C) Wind a seal tape 1 1/2 to 2 turns round the plug. PO plug (Material: S35C)
Size M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 PT 1/16 PT 1/8 PT 1/4 PT 3/8 PT 1/2 PF 1/4 PF 1/2 PF 3/4 PF 1 PF 1 1/4 PF 1 1/2
Tightening Torque 70 kgfcm 120 kgfcm 300 kgfcm 580 kgfcm 1,000 kgfcm 1,600 kgfcm 2,400 kgfcm 3,400 kgfcm 4,400 kgfcm 70 kgfcm 105 kgfcm 175 kgfcm 350 kgfcm 500 kgfcm 300 kgfcm 1,000 kgfcm 1,500 kgfcm 1,900 kgfcm 2,700 kgfcm 2,800 kgfcm
Tool Name B=4 5 6 7 8 10 12 14 17 4 5 6 8 10 6 10 14 17 17 17
Allen wrench
Do.
Do.
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S0709401K
1MAIN CONTROL VALVE (KAYABA)

CAUTION!
MAIN CONTROL VALVE (KAYABA)S0709401K

MODEL Solar 300LC-V Solar 340LC-V SERIAL NUMBER RANGE 1001 and Up 1001 and Up
Copyright 2002 Daewoo January 2002 Main Control Valve (Kayaba) S0709401K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Theory of Operation ................................................................................ 3 Parts List ............................................................................................... 27 Specications ........................................................................................ 36 Troubleshooting, Testing and Adjustment..................................................... 37 General ................................................................................................. 37 Relief Valve ........................................................................................... 38 Hydraulic System Adjustment of Relief Valve .................................................................... 38 Disassembly ................................................................................................. 40 General Instructions for Disassembly ................................................... 40 Disassembling Procedure ..................................................................... 40 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 46 Cleaning ................................................................................................ 46 Inspection.............................................................................................. 46 Reassembly.................................................................................................. 47 Instructions for Reassembly.................................................................. 47 Procedure of Subassembly Reassembling Procedure of Control Valve Body................................... 49 Installation .................................................................................................... 54 Start-up Procedures ..................................................................................... 54
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Main Control Valve (Kayaba)
GENERAL DESCRIPTION
THEORY OF OPERATION When All Spools are in Neutral 1. Neutral Passage
The oil supplied from the port (P1, Figure 1 and Figure 2) ows from the neutral passage (L1) through the low pressure relief valve orice (Lc1) to tank passage (Ta) and ows into the ports (T1, T2, and T3). The oil supplied from the port (P1) ows from the neutral passage (R1) through the low pressure relief valve orice (Rc1) to tank passage (Ta) and ows into the ports (T1, T2, and T3). The pressures of the low pressure relief valve upper chambers (L2 and R2) reach through the ports (ps1 and ps2) to the pump and control the displacements of the pumps (P1 and P2). If too much oil ows into the neutral passages, the low pressure relief valves act and prevent the ports (P1 and P2) from raising the pressures.
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Figure 1
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Figure 2
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2.
Signal Passage
The oil supplied from the port (PP, Figure 2 and Figure 3) ows through the orice (Lc3) to port (PT) and simultaneously ows through the land (Lc4), the passage (5), and land (Rc3) into the tank passage (Ta). The some oil supplied from the port (PP) ows through the orice (Lc5) into port (PA), and also ows through passages (L4)(7) and (R4) to the bucket spool land (Rc4) and ows into drain passage (DR). The oil passed through the orice (Lc6) ows from the land (Lc7) to the tank passage (Ta) or passes through the passage (4) to the travel spool land (Rc5) and ows into the tank passage (Ta).
Figure 3
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Single Operation 1. Travel Spool Switching
When switching the travel spool by increasing the pressure of the travel (section 1, Figure 4) pilot port (Pb1 (Pa1)), the oil supplied from the port (P1) passes through the neutral passage (L1) to the spool head and ows to the port (B1 (A1)). The return oil passes through the port (A1 (B1)) to the spool head and return to the tank passage (Ta). When switching the travel spool by increasing the pressure of the travel (section 6) pilot port (Pb6 (Pa6)), the oil supplied from the port (P2) passes through the neutral passage (R1) to the spool head or passage (S6-1) and ows to the port (B6 (A6)). At this time, the pressure of parallel passage (R3) and passage (S6-1) is same, and so poppet (S6-2) is not opened. The return oil passes through the port (A6 (B6)) to the spool head and return to the tank passage (Ta). If either one of travel spool (section 1) or (section 6) is switched, land (Lc4) or (Rc3) is closed. Oil supplied from port (PP) does not ow into tank passage, so that the pressure of port (PT) rises. 2. Spare Spool Switching
When switching the spare spool by increasing the pressure of the spare (section 2, Figure 4) pilot port (Pb2 (Pa2)), neutral passage (L1) is closed. The oil supplied from the port (P1) passes through the parallel passage (L3), road check valve (S2-2), passage (S2-1), and spool head and ows to port (B2 (A2)). The return oil passes through the port (A2 (B2)) to the spool head and return to the tank passage (Ta). In case that oil is supplied from port (P4), it passes through load check valve (S2-2) and is combined at passage (S-1).
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Figure 4
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3.
Swing Spool Switching
When switching the swing spool by increasing the pressure of the swing (section 3, Figure 5) pilot port (Pb3 (Pa3)), the neutral port (L1) is closed. The oil supplied from the port (P1) ows through the parallel passage (L3), the load check valve (S3-1), passage (S3-1) and the spool head to the port (B3 (A3)). The return oil passes through the port (A3 (B3)) to the spool head and returned to the tank passage (Ta). 4. Bucket Spool Switching
Oil ow direction of bucket section of this valve against pilot port is different from other section because it has a regeneration function. A. Dump
When the bucket spool is switched by increasing the pressure of the bucket (section 7, Figure 5) pilot port (Pa7), the neutral passage (R1) is closed. The oil supplied from the port (P2) ows through the parallel passage (R3), the load check valve (S7-2), the passage (S7-1), the spool head and into the port (B7). The oil returns through the port (A7) and the spool head to the tank passage (Ta).
Figure 5
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B.
Crowd
When the bucket spool is switched by increasing the pressure of the bucket (section 7, Figure 6) pilot port (Pb7), the neutral passage (R1) is closed. The oil supplied from the port (P2) ows through the parallel passage (R3), the load check valve (S7-2), the passage (S7-1), the spool head and into the port (A7). The oil ows through the port (B 7) and the one oil returns through the spool head to the tank passage (Ta) and the other oil passes through spool inside, push up load check, and then is combined at port (A7).
Figure 6
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5.
Boom Spool Switching A. Neutral
This valve has the antidrift valve which is installed on the bottom side of the boom 1 cylinder. When neutral, the poppet (AD1, Figure 7) is surely closed by the port (A8) pressure which is sent through the passage (AD2) and the spool (AD3) and to the spring chamber (AD4).
Figure 7
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B.
Boom Up (2 Speed Junction)
When the boom 1 spool is switched by increasing the pressure of the boom 1 (section 8, Figure 8) pilot port (Pa8), the neutral passage (R1) is closed. The oil supplied from the port (P2) passes through the parallel passage (R3) and the load check valve (S8-2) to the spool head and ows into the port (A8). When the boom 2 spool is switched by increasing the pressure of the boom 2 (section 4) pilot port (Pb4) also, the neutral passage (L1) is closed. The oil supplied from the port (P1) passes through the parallel passage (L3), the load check valve (S4-2), the spool head, and to the passage (6) and joins at the port (A8). The return oil ows from the port (B8) to the spool head and returns to the tank passage (Ta).
Figure 8
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C.
Boom Down (Regeneration)
When the boom 1 (section 8, Figure 9) spool is switched by increasing the pressure of the boom 1 pilot port (Pb8), the neutral passage (R1) is closed. The oil supplied from the port (P2) passes through the parallel passage (R3) and the load check valve (S8-2) to the spool head and ows into the port (B8). When the spool (AD3) of the antidrift valve is switched by increasing the pressure of the port (P2) also, the poppet (AD1) is opened by the decreasing of the pressure of the spring chamber (AD4), and the return oil from the port (A8) returns to the tank passage. Some of the return oil opens the poppet (S8-3) in the boom 1 spool, passes through the passage (S8-2), joins at the port (B7), and then prevents the cavitation of the cylinder rod side.
Figure 9
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6.
Arm Spool Switching A. Neutral
This valve has the antidrift valve which is installed on the rod side of the arm 1 cylinder. When neutral, the poppet (AD1, Figure 10) is surely closed by the port (A5) pressure which is sent through the passage (AD2) and the spool (AD3) and to the spring chamber (AD4).
Figure 10
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B.
Arm Crowd (2 Speed Junction)
When the arm 1 spool is switched by increasing the pressure of the arm 1 (section 5, Figure 11) pilot port (Pb5), the oil supplied from the port (P1) ows through the neutral passage (L1), the load check valve (S5-2), the passage (S5-1) and the spool head and into the port (B5). When the arm 2 spool is switched by increasing the pressure of the arm 2 (section 9) pilot port (pb9) also, the oil supplied from the port (P2) passes through the neutral passage (R1), the load check valve (S9-1), the passage (S9-2), and the spool head and to the passage (8) and joins at the port (B5). The return oil from the port (B5) passes through regeneration check in spool and ows to port B to regenerate, and some oil returns through variable regeneration release valve to tank (Ta). (Refer to section 2-2)
Figure 11
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C.
Arm Crowd (Variable Regeneration)
When crowding arm, after the return oil from port (A5, Figure 12) passes through notch (a), the one oil returns through xed orice (d), passage (e) and variable orice (f) and to tank passage (Ta), and the other oil ows through xed orice (b), regeneration check (c), and xed orice (i) in arm 1 spool, and joins to bridge passage (S5-1). From here, if load pressure of port (B) is increased, it passes through regeneration release valve piston (g) and pushes regeneration release spool (h), as a result the area of variable orice (f) is increased, and the oil returning to tank (Ta) is increased, and partly the oil to regenerate in port (B5) is decreased.
Figure 12
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D.
Arm Dump (2 Speed Junction)
When the arm 1 spool is switched by increasing the pressure of the arm 1 (section 5, Figure 13) pilot port (Pa5), the oil supplied from the port (P1) ows through the neutral passage (L1), the load check valve (S5-2), the passage (S5-1) and the spool head and into the port (A5). The oil supplied from the port (P2) passes through the neutral passage (R1), the load check valve (S9-2), the passage (S9-1), the spool head and the passage (8) and joins at the port (A5). The return oil from port (B5) returns through the spool head to the tank passage (Ta).
Figure 13 7. Parallel Orice for Arm
The orice, which is installed in the parallel passage for the arm 1 of this valve, controls arm speed when operating the combined operation. The oil supplied from parallel passage (L3, Figure 14) of arm 1 (section 5) pushes and opens poppet (S-3), after passes through orice (Lc8) of variable orice A54 spool, and then is connected to passage (L5, Figure 3). From here, the ow of orice (Lc8) can be varied by increasing the pressure against pilot poppet (Pc3). Figure 14
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8.
Relief Valve A. Main Relief Valve
The oil supplied from the port (P1, Figure 15) passes through the poppet (LP), the oil supplied from the port (P2) passes through the poppet (RP) and the passage (3) also, and join at the main relief valve. The highest pressure of the pump (P1) and (P2) is controlled by acting of main relief valve. B. Over Load Relief Valve
The over load relief valve, which is installed in each cylinder port of the boom Figure 15 1, arm 1 and bucket, prevent the pressure of the actuator from increasing extremely high by the foreign strength. This relief valve, when the pressure of the cylinder port is a negative pressure, has the function to prevent the cavitation by sucking the oil from the tank also. Combined Operation 1. Travel Combined Operation
When applying the operation except travel simultaneously while applying travel left and right operating simultaneously (while forward traveling, backward traveling, or pivot turning) or when applying travel left and right operating simultaneously while applying the operation except travel, the oil supplied from the port (PP, Figure 16) is disconnected with the tank passage (Ta) at the signal land part of the section of the exception of travel switched with the land (Lc4) (Lc7) (Rc3) (Rc), and the pressure of the signal passage increases up to the relief setting pressure of the pressure source for signal. By increasing of the signal pressure, the travel straight spool is switched and the pressures of the ports (PT) (PA) increase. When the travel straight spool is switched, the oil supplied from the port (P1) ows from the neutral passage (L1) to the travel (section 1), and simultaneously ows through the passage (2), the travel straight spool head and the neutral passage (R1) and into the travel (section 6). The oil supplied from the port (P2) ows through the travel straight spool and the passage (1) into the parallel passage (L3). If the section load pressure except the travel is higher than the travel (section 6) load pressure, some of the oil supplied from the port (P2) pushes and opens the poppet (S6-2), passes through the orice of the head of the poppet, and joins with the passage (S6-1). Because the travel (section 1 and 6) is activated by the oil supplied from the port (P1) and the implement except the travel is activated by the oil supplied from the port (P2), when applying the combined operation with the travel left and right simultaneous operation and the implement operation except the travel, the travel is prevented from veering.
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Figure 16
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2.
Bucket Combined Operation
Priority control valve is installed in bucket section (section 7, Figure 17) of this valve to control the ow entering into bucket when operating combined operation with section (travel, boom 1, arm 2) of P2 side. If the pressure of port (Pi) is increased when operating bucket, piston (S7-6) is pressed, piston (S7-5) and plug (S7-4) are pressed, and then poppet assembly (S7-2) is seated closely on the seat of valve housing. Therefore the oil owed from parallel passage (R3) presses the poppet (S7-3) in the poppet assembly and ows into passage (S7-1). As a result, passage diameter of operating combined operation is smaller than passage diameter of operating single operation and then the oil owing to port (A7, B7) is reduced, and the remaining oil passes through parallel passage (R3) and primarily ows to section being operated at P2 side simultaneously.
Figure 17
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Antidrift Valve The antidrift valve is installed in the cylinder port of the arm rod (boom bottom) side to prevent the arm (boom) cylinder from natural lowering. (As a representative arm side (A5) is shown.) 1. Neutral condition (A5, Figure 18 port keeping condition) The keeping pressure of A5 port is sent through the passage (a), the passage (b), the passage (c), and into the spring chamber (d) of poppet (1). At this time the pressure oil of A5 port is surely cut off by seat part S1 and seat part S2.
Figure 18 2. Cut off condition of passage of (A5, Figure 19) port and spring chamber A. B. C. If pc1 port is pressed, piston 2 is moved and spring 3 acts. Spring 3 activates poppet 4. And then by acting of poppet 4, A5 port and spring chamber (d) is cut off by T1 part.
Figure 19 3. Operating condition of main poppet A. If again piston (2, Figure 20) acts, spring chamber (d) is led through passage (c) and passage (e) and to drain chamber (DR) by T2 part. Spring chamber becomes drain pressure and main poppet 1 acts.
B.
Figure 20
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Main Relief Valve 1. This relief valve is inserted between the neutral passage "HP" and the low pressure passage "LP" and oil ows through orice of main poppet "C" and lls inside space "D". Main poppet "C" is completely seated to sleeve "E" because area "B" is larger than area "A".
Figure 21 2. When pressure of neutral passage "HP" reaches spring pressure setting of pilot poppet, pilot poppet "F" opens. Oil ows around poppet and through drill hole "G" and reaches low pressure passage "LP".
Figure 22 3. When pilot poppet opens, pressure of "D" decreases, main poppet "C" opens, and oil ows to direct passage "LP".
Figure 23
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4.
Pressure up operation If pressure is given to pilot port "PH", piston "H" moves to the position set by plug "I". With this, pressure of pilot spring increases, and so pressure of "HP" increases.
Figure 24 Overload Relief Valve (69, Total: Six Places) 1. This relief valve is inserted between cylinder port "HP" and low pressure passage "LP" and oil ows through orice of piston "C" and lls inside space "G". Owing to the difference between "A" and "B" in area on which the hydraulic pressure acts sleeve "K" and main poppet "D" are seated closely.
Figure 25 2. When pressure of cylinder port "HP" reaches spring pressure setting of pilot poppet, pilot poppet "E" opens. Oil ows around poppet, through drill hole "H", and into low pressure passage "LP".
Figure 26
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3.
As the pilot poppet (E) opens, the oil ows through the orice (I) of piston "C", so that differential pressure is generated between passage "HP" and back of piston "C", and piston "C" is moved and seated with poppet "E".
Figure 27 4. Oil which ow from passage "HP" to the back of poppet "D" lls the ring shape clearance of poppet "D" and piston "C" and orice "F", so that differential pressure increases. As a result, poppet "D" opens and oil ows to direct passage "LP".
Figure 28 5. Sucking operation This relief valve has the antivoid unit which is installed in the cylinder port (HP) and supplies oil when cavitation is generated. If pressure of cylinder port "HP" is lower than low pressure side "LP", sleeve "K" opens by differential area of "A" and "B". Oil owed from lower pressure side "LP" enters cylinder port "HP" and prevents cavitation.
Figure 29
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Low Pressure Relief Valve (70, Total: Two Places) 1. Generation of signal pressure
Oil supplied from pump port (P1 (P2)) ows through neutral passage (L1 (R1)), low pressure relief passage (L2 (R2)), orice (Lc1 (Rc1)) to tank passage (At). At this time, pressure generated at passage (L2 (R2)) by orice (Lc1 (Rc1)) moves to low pressure relief signal port (Ps1 (Ps2)). If main spool of the upper reaches of L2 (R2)) operates, signal pressure of Ps1 (Ps2) decreases because oil owing to L2 (R2) decreases.
Figure 30
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2.
Relief operation
If excessive oil ows into passage (L2 (R2)), pressure generated at passage (L2 (R2)) by orice (Lc1 (Rc1)) goes to back chamber of poppet and poppet operates by the difference of pressurized area between passage and back chamber. By the operation of this poppet, oil ows from passage through plug and drill hole to tank passage (At). By it, the generation of excessive pressure of low pressure relief signal port is prevented.
Figure 31
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PARTS LIST
72
72
74 71 B A 78
69 75 90 37 90 43 C D E F G H 37 I 75 89,88 73 37 72 J K 68 K J 69 C D E F G H I
76
74 76
B 72
52 75 92
52
75 69 37 69
92 VIEW X
77,81
ARS4580L
Figure 32
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63
13
70
SECTION A1-A1
7 8 15 16 17 5 8
SECTION A-A
X - 41 Y - 42
70
72 57 33 32
7 8 8 8 8 8 12 2 3
SECTION L-L 4 5 6 61 62
X - 41 Y - 42
SECTION B-B SECTION K-K ARS4570L
Figure 33
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32 31 30 31 29 28 18
34
35
38 39 40
22 2
SECTION C-C SECTION D-D
3 45 36 50 91
34 38 39 35 SECTION E-E
67
44 105
51
35 36
49 F1
47
SECTION G-G SECTION F-F 72 36 36 104 103 102 100 9 8 7 6 5 01 4 34 53 55 35 54 SECTION I-I SECTION J-J ARS4590L SECTION H-H 72
60
DETAIL F1
Figure 34
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Reference Number 1 2 3 4 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
Description Valve Housing Spool Assembly (Arm2) Spool Assembly (Boom1) Spool Assembly (Bucket) Spool Assembly (Travel) Spool Assembly (Straight Travel) O-ring Cap Cap Valve Housing Spool Assembly (Arm1) Spool Assembly (Boom2) Spool Assembly (Swing) Spool Assembly (Option) Cap Spool Spring Seat Spring Spool End O-ring Plug O-ring Spring Spool Assembly O-ring Back-up Ring Poppet Spring Poppet Spring O-ring Flange Poppet Spring Spacer Assembly O-ring O-ring Flange Poppet Spring Plug
Reference Number 47 48 49 50 51 52 53 54 55 57 60 61 62 63 65 66 67 68-70 71 72 73-78 79 80 81 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
Description O-ring Spring Poppet Steel Ball Poppet Flange Spacer O-ring Back-up Ring Spacer Plug Assembly Plug O-ring Orice Plug O-ring O-ring Anti-draft Valve Assembly Relief Valve Assembly Plug Assembly Plug Assembly Socket Head Bolt Name Plate Drive Screw Washer Cap O-ring Plug Assembly Plug Plug Assembly Plug Assembly Plug Piston Body Piston Spring Sleeve Poppet Assembly Socket Head Bolt O-ring Back-up Ring O-ring Plug Assembly
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Spool Assembly (2, Arm 2) Reference Number 1 2 3 4 Description Spool Spring Seat Spring Spool End
Figure 35 Spool Assembly (3, Boom1) Reference Number 1 2 3 4 5 6 7 8 9 Description Spool Spring Seat Spring Spool End Plug Poppet Spring O-ring Back-up Ring
Figure 36
Spool Assembly (4, Bucket) Reference Number 1 2 3 4 5 6 7 8 9 Description Spool Spring Seat Spring Spool End Plug Poppet Spring O-ring Back-up Ring
Figure 37
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Spool Assembly (5, Travel) Reference Number 1 2 3 4 Description Spool Spring Seat Spring Spool End
Figure 38 Spool Assembly (6, Straight Travel) Reference Number 1 2 3 4 Description Spool Spring Seat Spring Spool End
Figure 39 Spool Assembly (14, Arm1) Reference Number 1 2 3 4 5 6 7 8 9 Description Spool Spring Seat Spring Spool End Plug Poppet Spring O-ring Back-up Ring
Figure 40
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Spool Assembly (15, Boom 2) Reference Number 1 2 3 4 Description Spool Spring Seat Spring Spool End
Figure 41 Spool Assembly (16, Swing) Reference Number 1 2 3 4 Description Spool Spring Seat Spring Spool End
Figure 42 Spool Assembly (17, Option) Reference Number 1 2 3 4 Description Spool Spring Seat Spring Spool End
Figure 43 Spool Assembly (20, Arm Regeneration Release Valvle) Reference Number 1 2 3 Description Spool Sleeve Piston
Figure 44
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Spacer Assembly (40) Reference Number 1 2 3 4 Description Spacer O-ring Back-up Ring O-ring
Figure 45 Plug Assembly (60) Reference Number 1 2 3 4 Description Plug O-ring O-ring O-ring
Figure 46
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Anti-draft Valve Assembly (67)
Figure 47 Reference Number 1 2 3 4 5 6 7 8 9 Description Body Poppet Plug Piston Spool Sleeve Spring Spirng O-ring Reference Number 10 11 12 13 14 15 16 17 Description O-ring Back-up Ring Back-up Ring O-ring Plug Assembly Plug Assembly Spring Seat Steel Ball
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Relief Valve Assembly (70) Reference Number 1 2 3 4 5 6 Description Plug Spring Poppet Sleeve O-ring O-ring Figure 48 Plug Assembly (90) Reference Number 1 2 3 4 Description Plug O-ring O-ring Back-up Ring
Figure 49 SPECIFICATIONS Control Valve Rated Flow Max. Pressure Allowable Back Pressure Allowable Working Temperature Range Specication 270 liter/min. 50 liter.min at Neutral 34.3 MPa Peak Pressure: Below 1.5 MPa Normal Pressure: Below 0.5 MPa -20 ~ 90C Peak Max: 100C (Seal is used nitrile rubber.)
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GENERAL Problem Spool does not stroke. Possible Cause Hydraulic oil excessively hot. Hydraulic oil contaminated. Over tightened piping port ttings. Valve housing deformed assembling. Pressure too high. when Remedy Remove blockage in oil piping. Change oil passages. Check torque. and clean oil
Spool bent. Return spring damaged. Spring or cap crisscrossed. Valve temperature uneven. Dirt in valve. Lack of pilot pressure. Fail to keep load Cylinder leaks. Spool leaks. Overload relief valve leaks. Antidrift valve leaks.
Loosen assembling bolts and check. Check pump port pressure and cylinder port pressure with pressure gauge. Replace valve assembly. Replace damaged parts. Loosen, center, and retighten cap. Warm up entire system. Clean valve (ushing). Check pilot valve and pilot relief pressure. Check seal parts of cylinder. Check spool. Clean valve housing and relief valve seat parts. Remove antidrift valve and clean every seat parts. If seat parts are damaged, replace poppet or lap poppet and seat parts. If draft valve is malfunction, replace spool and sleeve at the same time. Remove and clean check valve. Remove poppet or lap poppet and seat parts.
Load drops when changing the spool from neutral to up.
Dirt in load check valve. Poppet or seat parts in check valve scratched.
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RELIEF VALVE Problem Pressure does not rise. Relief pressure unstable Possible Cause Stuck main poppet, sleeve or pilot poppet opened or dirt in seat part. Seat parts of pilot poppet damaged. Piston or main poppet stuck. Relief pressure incorrect. is Seat parts worn due to dust. Lock nut and adjuster loose. Relief valve seat parts damaged Every parts stuck due to dust O-ring worn. Replace adjuster or O-ring. Reset pressure and tighten lock nut in rated torque. Replace relief valve. Remedy Replace relief valve.
Oil leaks
HYDRAULIC SYSTEM Problem Hydraulic system is malfunction or does not operate. Possible Cause Hydraulic pump failed. Relief valve failed. Some kinds of cylinders failed. Pump load pressure too high. Valve cracked. Spool does not fully stroke. Hydraulic oil level in tank too low. Filter in circuit plugged. Circuit piping twisted. Remedy Check pressure or replace pump. Replace pump. Repair or replace. Check circuit pressure. Replace valve assembly. Check spool operation. Add hydraulic oil. Clean or replace lter. Check piping.
ADJUSTMENT OF RELIEF VALVE Main Relief Valve 1. 2. 3. Connect a accurate pressure gauge to inlet port. Start the engine and maintain the rated pump speed. Switch the control valve spool and read the pressure gauge from the stroke end of the cylinder. NOTE: 4.
Replace the spool of the actuator if the setting pressure of the over load relief valve is higher than the setting pressure of the main relief valve.
High pressure adjustment (1st stage) (refer to gure of page 32/63) A. Loosen lock nut (7) and tighten plug (8) until piston contacts the step (* mark) of plug (6). Plug (8) should be torqued below 19.6 N*M. While plug (8) is tightened, plug (6) should not be turned. The distance A (Page 32/63) should be above 4 mm. Tighten lock nut (7).
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B.
Loosen lock nut (4) and turn adjusting plug (6) clockwise to raise relief pressure at the state of 4-1. Turn adjusting plug (6) counterclockwise to lower relief pressure. One turn varies 28.4 MPa. Tighten lock nut (4) after pressure has been adjusted.
5.
Low pressure adjustment (second stage) Loosen lock nut (7) and turn adjusting plug (8) counterclockwise to lower relief pressure at the state of 4. One turn varies 21.3 MPa. Tighten lock nut (7) after pressure has been adjusted.
6.
Recheck the setting pressure by raising pressure once more.
Over Load Relief Valve
IMPORTANT
If the pressure of the main relief valve is higher than the setting pressure of it, change it to the main relief valve assembly setting without adjusting the over load relief valve. 1. 2. 3. 4. Switch the control valve spool and read the pressure gauge from the stroke end of the cylinder. Loosen lock nut (3) and turn adjusting plug clockwise to raise pressure. Item number 69: six places One turn varies 21.2 MPa. Tighten lock nut (3) after pressure has been adjusted. Lock nut (3) should be torqued to 27.5-31.4 N*m. Recheck the setting pressure by raising pressure once more.
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DISASSEMBLY
GENERAL INSTRUCTIONS FOR DISASSEMBLY 1. Stop engine when pressure of actuator is not indicated. It is dangerous to disassemble control valve while it has a pressure because high pressure oil can squirt out or components can spring. When partially disassemble control valve which is on machine, be careful the following caution.
CAUTION!
When disassemble short cap assembly while pressure is not released fully or bucket is not lowered to ground, it is very dangerous because poppet of antidrift valve spring out and bucket is dropped simultaneously, so that lower bucket to ground and release pressure fully before disassembling. 2. 3. 4. 5. 6. Release air pressure in tank. Clean all of the exterior surfaces of the valve prior to disassembly and protect it from dirt and foreign materials. Attach labels to the disassembled parts to know reassembling position. Replace all sealing parts such as O-ring and back-up ring with a new ones. Do not replace spool as it is engaged with valve housing selectively.
DISASSEMBLING PROCEDURE Parts number is based on the parts list. Disassembly of Main Spool Part 1. 2. 3. 4. Loosen socket head bolt (74, two places per each section, width across at: 8) and remove cap (8, ten places). Loosen plug assembly (72, width across at: 8) and plug (91, width across at: 22) according to necessity. Remove O-ring (7, one place per each section) from valve housing (1, 13). Remove each spool under subassembly conditions from valve housing.
IMPORTANT
1. When remove spool, be careful not to damage. 2. Attach label to each spool in order to set it to correct position when reassembling. 5. 6. Loosen socket head bolt (74, two places per each section, width across at: 8) and remove cap (12, ten places). Remove O-ring (7, one place per each section) from valve housing (1, 13).
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7.
Disassembly of spool
IMPORTANT
1. Work with spool gripped in vise with wood (see Figure 50) not to scratch in outside diameter of spool. 2. Because Loctite is applied to screw part of spool end, heat screw part of outside surface of spool with industrial drier and melt Loctite. 3. Heat spool until spool end is loosened easily immediately after heating it to 200 - 250C. 4. If it is over heated, change spring to new one. A. B. Loosen spool end (width across at: 8) of spool assembly (2-6, 14-17) and remove spring seat and spring. There are poppet, spring and plug in spool of spool assembly, but if disassembly is unnecessary, do not remove them. If disassembly is necessary, heat spool outside surface, melt Loctite in screw part and remove plug. When reassembling, change O-ring and backup ring to new ones.
Figure 50
Disassembly of Arm 1 Para Spool Turn 1. 2. 3. 4. Loosen socket head bolt (78, width across at: 5) and remove cap (18). Remove O-ring (23) from cap (18). Remove spool (19) from valve housing under subassembly conditions. Disassembly of spool
IMPORTANT
1. Work with spool gripped in vise with wood (see Figure 50) not to scratch in outside diameter of spool. 2. Because Loctite is applied to screw part of spool end, heat screw part of outside surface of spool with industrial drier and melt Loctite. 3. Heat spool until spool end is loosened easily immediately after heating it to 200 - 250'C. 4. If it is over heated, change spring to new one. A. Loosen spool end (22, width across at: 5) of spool (19) and remove spring seat (20) and spring (21).
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Disassembly of Arm Regeneration Release Valve Part Small parts in assembly are indicated to (parental number - son number).
CAUTION!
1. When loosening plug, it is dangerous because parts can be spring out by internal remaining pressure. 2. Loosen plug slowly, check if there is a resistance by remaining pressure and remove. 1. 2. 3. 4. Loosen plug (24, width across at: 32) and remove O-ring (25). Remove spring (26) and spool (27-1) from sleeve (27-2). Remove sleeve (27-2) from valve housing. Remove piston (27-3), O-ring (30) and back-up ring (31) from sleeve (27-2).
Disassembly of Rod Check Valve Part
CAUTION!
1. When loosening plug, it is dangerous because parts can be spring out by internal remaining pressure. 2. Loosen plug slowly, check if there is a resistance by remaining pressure and remove. 1. 2. Loosen socket head bolt (75, four places per each section, width across at: 8) and remove ange (37, seven places). Remove spring (35), poppet (34) (poppet (51)), O-ring (36) from valve housing.
IMPORTANT
Be careful there are not poppet and spring in travel straight valve section (section H-H). 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Loosen socket head bolt (75, width across at: 8) and remove ange (52, two places). Remove spacer (53) from valve housing and remove O-ring (54) and back up ring (55) from spacer (53). Remove spring (35) and poppet (34) from valve housing. Remove plug (72, width across at: 8) (section C-C). Remove spring (33) and poppet (32) from valve housing. Remove plug (72, width across at: 8) (section L-L). Remove spacer (57), spring (33) and poppet (32) from valve housing. Remove plug (92, width across at: 36) (section G-G). Loosen socket head bolt (73, four places, width across at: 8) and remove ange (43). Remove spring (45), poppet (44) and O-ring (36) from valve housing.
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13. 14. 15. 16. 17. 18.
Loosen plug (46, width across at: 27) and remove O-ring (47). Remove spring (48) and poppet (49) from valve housing. Loosen socket head bolt (101, four places, width across at: 8) from body (96, one places). Remove body (96) from valve housing. Remove sleeve (99) and remove piston (97), spring (98), poppet assembly (100), back up ring (103), and O-ring (104). Remove O-ring (36). Grip body (96) in vise, loosen plug (94), and remove piston (95) and O-ring (102).
Disassembly of Antidrift Valve Small parts in assembly is indicated to (parental number - son number).
CAUTION!
1. When removing antidrift valve seat, it is dangerous that parts like seal can spring out by internal remaining pressure. 2. Loosen socket head bolt slowly, check if there is a resistance by remaining pressure and remove. 1. 2. 3. 4. 5. 6. Loosen socket head bolt assembly (76, four places per section, width across at: 8) and remove antidrift valve assembly (67, two places). Remove O-ring (41, 42) from valve housing and remove O-ring (40-4) from spacer assembly. Screw socket head bolt (78, M6*1) to spacer and remove spacer assembly (40) from valve housing. Remove O-ring (40-2) and back up ring (40-3). Remove spring (39) and poppet (38) from valve housing. Disassembly of antidrift valve assembly
CAUTION!
1. If inner parts of antidrift valve are removed while it is on the valve housing, it is dangerous that parts can spring out by inner remaining pressure. 2. Loosen plug assembly (67-14) and plug (67-3) slowly, check if there is a resistance by remaining pressure and remove. A. B. C. D. E. F. Loosen plug assembly (67-14, width across at: 38) and remove O-ring. Remove piston (67-4), spool (67-5), and spring (67-7). Loosen plug (67-3, width across at: 38) and remove O-ring. Remove sleeve (67-6) and poppet (67-2) from body and remove O-ring (67-9, 10) and back up ring (67-11, 12) from outside diameter of sleeve. Pull spring seat (67-16) and spring (67-8) from hole inside. Loosen plug assembly (67-15) according to the necessity.
But do not remove steel ball (67-14) because it is pressed in body.
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Disassembly of Relief Valve
CAUTION!
1. When removing relief valve, loosen plug attached in body and remove it. 2. Do not loosen adjusting plug for set pressure and lock nut. 3. If adjusting plug for set pressure is turned, it is dangerous because set pressure is varied. 1. 2. 3. Loosen over load relief valve (69, six places, width across at: 32). Loosen main relief valve (68, width across at: 32). Loosen relief valve assembly (70, two places, width across at: 32) and remove O-ring (70- 5, 6).
Disassembly of Spare Section Part 1. 2. Loosen socket head bolt (75, width across at: 8) and remove cap (88, two places) and remove Oring (89). Loosen plug assembly (87, two places, width across at: 24) and remove O-ring and back up ring.
Disassembly of Miscellaneous Plug Kind 1. 2. 3. 4. 5. 6. Loosen plug assembly (60, width across at: 27) and remove O-ring (section J-J). Loosen plug (61, width across at: 22) and remove O-ring (62) (section K-K). Loosen orice plug (63, width across at: 5) (section A1-A1). Loosen plug assembly (92, width across at: 36) and remove O-ring. Loosen plug assembly (71, width across at: 6) and remove O-ring. Loosen plug assembly (72, width across at: 8) and remove O-ring.
Disassembly of Valve Housing Combined Bolt
IMPORTANT
1. Do not disassemble combined bolt (77) if it is unnecessary. 2. If it is necessary to disassemble it, work with putting it on the horizontal work bench. 3. Prepare spare O-ring (65, 66). 1. 2. Loosen socket head bolt (77, eight places, width across at: 14) and remove washer (81, eight places). Remove O-ring (65, 66) of valve housing mating surface.
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Disassembly of Main Relief Valve This unit should be replaced by assembly. When replacing it, loosen plug (1, Width Across Flat: 32) by using spanner, etc., and remove O-ring (2). If oil is leaked in nut (4), loosen nut (4) and plug (1), and replace O-ring (3). And if oil is leaked in nut (7)loosen nut (7) and plug (8), and replace O-ring (3).
Figure 51 Disassembly of Overload Relief Valve This unit should be replaced by assembly. When replacing it, loosen plug (1, Width across at: 32) by using spanner, etc., and remove O-ring (2). If oil is leaked in nut (4), loosen nut (4) and plug (1), and replace Oring (3). And if oil is leaked in nut (7)loosen nut (7) and plug (8), and replace O-ring (3).
Figure 52
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This unit should be replaced by assembly. When replacing it, loosen cap (1, width across at: 31.75) by using spanner, etc., and remove O-ring (2). If oil is leaked in adjusting kit (3), loosen adjusting kit (3), and replace O-ring (4).
IMPORTANT
When disassembling adjuster kit, be careful not to spring out parts or lose poppet because of spring. Disassembly of Low Pressure Relief Valve This unit has the press t portion (D) so that it should be replaced by assembly.
Figure 53

CLEANING Clean all parts thoroughly using a suitable cleaning uid 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 the other defects. 1. 2. 3. Inspect load check seat surface of valve housing for scratches, scores, dirt, notches and corrosion. Remove small scratches with oilstone. Inspect exterior surface of spool for scratches and notches. Remove small scratches with oilstone. Sliding parts should be moved lightly and foreign materials should be removed in all grooves and passages.
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4. 5. 6. 7.
Replace any springs that are damaged, heavy deformed or worn. If relief valve malfunction, inspect it by relief valve maintenance procedure (see page ). Replace all O-rings and backup rings with new ones. After disassembling cap or plug, check whether there are paint chips around body hole or plug. If paint chips penetrate into valve, they can cause malfunction or leak of valve.
REASSEMBLY
INSTRUCTIONS FOR REASSEMBLY Handling Instructions of O-ring 1. 2. 3. 4. Do not use O-ring which has plastic defect or scratch when handling. Apply grease or hydraulic oil to the installing position of O-ring and O-ring to install smoothly. Do not stretch O-ring beyond permanent set. When installing O-ring, be careful not to twist it. (Twisted O-ring, which is difcult to return to its original form naturally after installing it, cause leak.)
Handling Instructions for Spool 1. 2. Rated torque should be kept because over torque of screw part cause malfunction of spool. Be careful that each spool, spring and spool end should be reassembled like before disassembling.
Applying method of Adhesive Male and female screw parts of parts which need to adhere.
CAUTION!
When working with adhesive, work at the place which is well ventilated. 1. Cleaning (removal of fat) Remove the fat with steam of acetate or ether, etc. or clean with alkali cleanser. 2. Dry Dry the adhesive surface with cleaned air or naturally. If it is not dried completely adhesive effect is dropped. 3. Primer painting Slightly spray Loctite primer T effect promoter to adhesive surface and leave it for three or ve minutes to dry. 4. Adhesive applying Slightly apply adhesive (Loctite #274 or equivalent) to two or three threads of spool female inlet. At this time, be careful not to touch applying part to spring seat.
S0709401K Page 47
PROCEDURE OF SUBASSEMBLY
IMPORTANT
Check number of each part, installing position and tools needed before reassembling. Reassembly of Spool Assembly (Main Spool) 1. 2. Apply adhesive to thread part of spool (2-6, 14-17) and install spring seat, spring and spool end. After gripping spool in vise with wood (which is used when disassembling it) and tighten spool end with rated torque. Tightening torque: 20-22 Nm
IMPORTANT
1. Be careful not to penetrate adhesive into spool inside by applying it over. 2. Be careful that spool operation become deteriorated If torque is so big when tightening spool end. 3. When reassembling it+A56 be careful because spring is two kinds. Reassembly of Arm 1 Para Turn Spool Assembly 1. 2. Apply adhesive to thread part of spool (19) and install spring seat (20), spring (21) and spool end (22). After gripping spool in vise with wood (which is used when disassembling it) and tighten spool end with rated torque. Tightening torque: 19-22 Nm
IMPORTANT
1. Be careful not to penetrate adhesive into spool inside by applying it over. 2. Be careful that spool operation become deteriorated If torque is so big when tightening spool end. Reassembly of Antidrift Valve Assembly 1. Install O-ring (67-9, 10) and back up ring (67-11, 12) on the circumferential groove of sleeve (67-6).
IMPORTANT
1. Be careful of installing position of O-ring and back up ring. 2. If they are reversed O-ring is damaged and natural lowering of actuator can be increased. 2. Insert poppet (67-2) and spool (67-5) in the sleeve hole.
S0709401K Page 48
3.
Install spring seat (67-16) on small diameter of poppet end part, insert spring (67-8) and insert them with sleeve to body (67-1).
IMPORTANT
It Is better to apply grease to the seat surface to install spring and spring seat to seat of poppet surely. 4. 5. 6. 7. Install spring (67-7) and piston (67-4) to plug (67-3). Tighten plug assembly (67-14) which O-ring is installed to plug (67-3). Tightening torque: 147 - 157 Nm Install O-ring (67-13) to plug (67-3) and tighten it to body (67-1). Tightening torque: 147 - 157 Nm Tighten plug assembly (67-15) with O-ring to body (67-1). Tightening torque: 14 - 18 Nm
REASSEMBLING PROCEDURE OF CONTROL VALVE BODY Reassembling of Relief Valve
CAUTION!
When reassembling safety valve, tighten plug which is installed to body surely. Do not tighten plug for set pressure or lock nut. If plug for set pressure is turned, it is dangerous because set pressure is varied. 1. 2. 3. Screw main relief valve (68) and tighten it. Tightening torque: Tightening torque: 78 - 88 Nm Screw over load relief valve (69, six places) to each section and tighten them. Tightening torque: 78 88 Nm Install spring seat (67-16) on small diameter of poppet end part, insert spring (67-8) and insert them with sleeve to body (67-1). Tightening torque: 103 - 113 Nm
Reassembling of Road Check Valve 1. Install O-ring (36) to arm (1, 2, section D-D), boom (1, 2, section E-E) and swing section (section F-F) and install poppet (34) and spring (35). Mount ange (37) and tighten socket head bolt (75). Tightening torque: 58 - 64 Nm Install O-ring (36) to travel section (section H-H) and install poppet (51) and spring (35). Mount ange (37) and tighten socket head bolt (75). Tightening torque: 58 - 64 Nm Install O-ring (36) to travel straight section (section H-H). Mount ange (37) and tighten socket head bolt (75). Tightening torque: 58 - 64 Nm
2. 3.
S0709401K Page 49
4.
Install poppet (51) and spring (35) to common (section I-I) and insert spacer (53) which O-ring (54) and back up ring (55) are installed to. Tightening torque: 39- 44 Nm
IMPORTANT
1. Be careful of installing position of O-ring and back up ring. 2. If they are reversed O-ring is damaged and oil leak can be caused. 5. Install O-ring (36) to spare section (section G-G) and install poppet (44) and spring (45). Mount ange (43) and tighten socket head bolt (96). Tightening torque: 58 - 64 Nm. Tighten ange assembly (92) with O-ring. Tightening torque: 205-227 Nm Insert poppet (49) and spring (48) to travel section (section G-G). Tighten plug (46) with O-ring (47). Tightening torque: 107-117 Nm Bucket section (section F-F) Insert piston (95) and O-ring (102) to plug (94) and tighten it to body (96). Tightening torque: 103-113 Nm. Insert back up ring (103), O-ring (104), spring (98) and poppet assembly (100) to sleeve (99) and install it to body (96). Install O-ring (36) to valve housing and tighten body by means of socket head bolt (101). Tightening torque: 58-64 Nm 8. 9. Insert poppet (32) and spring (33) to arm 1 para turn part (section C-C). Tighten plug assembly (72) with O-ring. Tightening torque: 73-79 Nm Insert poppet (32), spring (33), and spacer (57) to arm 2 para turn part (section L-L). Tighten plug assembly (72) with O-ring. Tightening torque: 73-79 Nm
6. 7.
Reassembling of Antidrift Valve 1. 2. Install O-ring (41, 42) to the surfaces of antidrift valve assembly of arm 1 section (section D-D) and boom 1 section (section E-E). Insert poppet (32) and spring (39). Install spacer assembly (40) which O-ring and back up ring are installed to.
IMPORTANT
1. Be careful of installing position of O-ring and back up ring. 2. If they are reversed O-ring is damaged and oil leak can be caused. 3. Check installing of O-ring (40-4) of spacer assembly and be careful of installing direction. 3. Install antidrift valve assembly (67, two places) and tighten it by means of socket head bolt. Tightening torque: 39-44 Nm
Reassembling of Spare Section Part 1. 2. Install O-ring (89) to cap (88, two places) and tighten it by means of socket head bolt (76). Tightening torque: 58-64 Nm Install O-ring and back up ring to plug assembly (87, two places) and tighten it. Tightening torque: 78-88 Nm
S0709401K Page 50
Reassembling of Arm Regeneration Release Valve 1. 2. 3. Install O-ring (30) and back up ring (31, two places) to sleeve (28). Install piston (29) and spool (27) to sleeve and Insert it to valve housing. Install O-ring (25) to plug (27), insert spring (26) to it and tighten it to valve housing. Tightening torque: 103-113 Nm
Reassembling of Arm 1 Paraturn Spool 1. Install spool of subassembly condition (19) to valve housing.
IMPORTANT
After inserting spool, slide it and check if it is good sliding condition. 2. Install O-ring (23) to cap (18) and tighten it by means of socket head bolt (78). Tightening torque: 8.8-10.8 Nm
Reassembling of Main Spool 1. 2. Install O-ring to the mating surface of cap of valve housing. Install spool of subassembly condition (2-6, 14-17) to the same position before.
IMPORTANT
1. Align spool to hole and insert it slowly. 2. After inserting spool, slide it and check if it is good sliding condition without a crash. 3. If insert spool when it is bad sliding condition with a crash, it causes malfunction of spool. 3. 4. 5. 6. Install cap (12, ten places) and tighten it by means of socket head bolt (74). A129 Install cap (8, ten places) and tighten it by means of socket head bolt (74). Tightening torque: 39-44 Nm Install O-ring to plug assembly (72) and tighten it to two sides of cap of travel straight section (section H-H). Install O-ring (62) to plug assembly (91) and tighten it to the long cap of spare section (section G-G). Install O-ring (62) to plug assembly (105) and tighten it to the short cap of spare section (section G-G).
IMPORTANT
1. When tightening plug to cap, be careful not to over tighten. 2. If it is over tighten, threads of cap can be damaged.
S0709401K Page 51
Reassembling of Miscellaneous Plug Kinds 1. 2. 3. 4. 5. 6. Install O-ring to plug assembly (60) and tighten it. Tightening torque: 103-113 Nm Install O-ring (62) to plug assembly (61) and tighten it. Tightening torque: 39-44 Nm Tighten orice plug (63). Tightening torque: 14-18 Nm Install O-ring to plug assembly (92) and tighten it. Tightening torque: 205-227 Nm Install O-ring to plug assembly (71) and tighten it. Tightening torque: 14-18 Nm Install O-ring to plug assembly (72) and tighten it. Tightening torque: 73-79 Nm
Reassembly of Main Relief Valve Check if there are dirt and paint chips around threads of plug (1, 6, 8) and nut (4, 7), replace O-ring with new one. Clean the installing part of relief valve of valve housing, install it, and then tighten plug (1, width across at:32). Tightening torque: 78-88 Nm Also, when disassembling plug, adjust pressure by referring Main Relief Valve on page -38. NOTE:
The torque values are based on the use of lubricated threads.
Figure 54
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Reassembling of Overload Relief Valve Check whether there are dirt and paint chips around cap (1) and install O-ring with a new one. Clean the installing part of relief valve of valve housing, install relief valve, and tighten cap (1). Torque: 78-88N*M If adjusting kit is disassembled, Clean around threads and adjust pressure by section 6-5-2). NOTE:
Figure 55 Reassembling of Low Pressure Relief Valve Check whether there are dirt and paint chips around plug (1) and replace O-ring (3) with new one. Install new O-ring (4) to sleeve (2). Clean the installing part of relief valve of valve housing and tighten plug (1, width across at: 32) of relief valve. Torque: 103-113 Nm NOTE:
Figure 56
S0709401K Page 53
INSTALLATION
1. 2. 3. 4. Be careful not to give other foreign strength to control valve by pipe laying. Tighten the assembling bolts alternately and evenly to the specied torque. If welding procedures are being performed near control valve that could be damaged by weld spatters and heat, be careful and use adequate shielding protection in front of valve. Valve ports should be covered with caps, plugs or tape to protect the disconnected openings from dust and other foreign materials until pipe laying work is started.
START-UP PROCEDURES
1. 2. 3. 4. 5. Before operating machine, make sure that oil passages and hydraulic oil are clean. Hydraulic oil of which aniline point is 82-113C should be used for hydraulic system. Relief valve pressure should not be raised above setting pressure. The difference between main relief valve setting pressure and over load relief valve setting pressure should be set over 2.0 MPa. Before operating machine, hydraulic system should be fully warmed up. If machine is operated with cold hydraulic oil and valve, be careful of the followings for preventing from sticking by heat shock of spool. NOTE:
Do not operate main relief valve or over load relief valve suddenly and continuously. Cycle oil through all actuators and warms up cold hydraulic oil in the lines and components uniformly. Slight or compound work should not be suddenly operated at cold weather because heat is developed partly at all the throttles.
NOTE:
S0709401K Page 54
S0709451K
1PILOT CONTROL VALVE (WORK LEVER / JOYSTICK)

CAUTION!
PILOT CONTROL VALVE (WORK LEVER / JOYSTICK)S0709451K

MODEL Solar 300LC-V Solar 340LC-V Solar 420LC-V Solar 470LC-V SERIAL NUMBER RANGE 1001 and Up 1001 and Up 1001 and Up 1001 and Up
Copyright 2001 Daewoo December 2001 Pilot Control Valve (Work Lever / Joystick) S0709451K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Theory of Operation ................................................................................ 3 Structure .......................................................................................... 3 Function ........................................................................................... 3 Parts List ................................................................................................. 4 Specications .......................................................................................... 5 Torques ............................................................................................ 5 Performance..................................................................................... 6 Removal ......................................................................................................... 6 Disassembly ................................................................................................... 9 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 13 Reassembly.................................................................................................. 14 Installation .................................................................................................... 19 Start-up Procedures ..................................................................................... 20
S0709451K Page 2
Pilot Control Valve (Work Lever / Joystick)
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. Gear pump pressure is used for operating control spools. Function 1. Neutral Mode When the lever is in neutral mode, the spool is thrust upward by return spring, and the force of balancing spring, which determines the secondary discharge pressure, is not transmitted to the spool. The input port is closed and the pressure of the output port is the same as the pressure of the tank port T. 2. Control Mode When push rod is pushed, the balance spring begins to compress, and spring force is conveyed to the spool. Ports P and T are then connected together and the pilot pressure is conveyed to the area. Output pressure works on the bottom of the spool, thrusting the spool upward until it is balanced with the power of the balance spring. The secondary pressure (output pressure), therefore, changes in proportion to the compression force of the balance spring.
S0709451K Page 3
PARTS LIST
30
29 28 26 27 23 24 13 22 21 17 31 15 16 36 32 33 34 35 1 2 3 5 4
ARS2260L
25 14 20 19 18 12 11 8 10 9
7 6
Figure 1
S0709451K Page 4
Reference Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Description Case Plug Plug O-ring O-ring Spool Shim Spring Spring Seat Spring Stopper Stopper Spring Push Rod Spring Spring Seat Stopper Plug
Description O-ring Rod Seal Plate Boot Joint Assembly Swash Plate Hex Nut Handle Bar Nut Boot Spring Pin Handle Assembly Bushing Terminal Seal Wire Housing Holder Rear Clip Band
SPECIFICATIONS Pilot Control Valve Type Pressure / Stroke Weight Torques Reference Number 2 3 24 25 27 Bolt Size PT 1/8 PF 3/8 M14 M14 M14 Tool Torque Specication Pilot Control (2-Stage Joystick) (1,3) 28 kg/cm2 @ 6.5 mm Stroke (398 psi @ 0.256 in. Stroke) (2,4) 28 kg/cm2 @ 7.5 mm Stroke (398 psi @ 0.295 in. Stroke) 4.8 kg (10.58 lb)
8 mm L-Wrench 24 mm Spanner 22 mm Spanner 22 mm Spanner
500 kgcm (36.2 ft lb) 1,240 kgcm (89.7 ft lb) 1,240 kgcm (89.7 ft lb) 1,240 kgcm (89.7 ft lb)
S0709451K Page 5
Performance
ARS2270L
Figure 2
REMOVAL
WARNING!
Figure 3
4. 5. 6.
Disconnect negative (-) battery cable leading to frame from battery.
S0709451K Page 6
7. 8.
Remove four bolts and washers (2, Figure 4) and cover (1). Pull cap (5, Figure 4) out and remove two screws, two bolts and washers (6) and cover (3). Remove three screws, one bolt and washers (7, Figure 4) and cover (4).
3 6
2 7 4
9.
ARS2910L
Figure 4 10. Remove four bolts (3, Figure 5) and cover (2), and pull remote control valve LH (1) out. Tag and disconnect hoses from remote control valve LH (1, Figure 5). Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component.
2 3
11.
ARS2920L
Figure 5 12. 13. Remove four bolts and washer (2, Figure 6), and cover (2). Pull cap (5, Figure 6) out and remove screw, three bolts and washers (6) and cover (3). Remove two screws, two bolts and washers (7 and 8, Figure 6) and cover (4).
6 3 7 1 4 2
14.
5 8
ARS2930L
Figure 6
S0709451K Page 7
15.
Remove four bolts (3, Figure 7) and cover (2), and pull remote control valve RH (1) out. Tag and disconnect hoses from remote control valve RH (1, Figure 7). Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component.
2
16.
ARS2920L
Figure 7
S0709451K Page 8
DISASSEMBLY
1. Lift up the boot (28) and pull the switch cord through the hole in the case (1).
Figure 8
Figure 9 2. Loosen nut (27) from hex nut (25) and remove handle assembly (30).
Figure 10
S0709451K Page 9
3.
Remove hex nut (25) and swash plate (24).
Figure 11 4. Remove joint (23) from case (1).
Figure 12 5. Remove plate (21).
Figure 13 6. Press spring (10) and remove plug (18).
Figure 14
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7.
Remove pressure reduction valve (6, 7, 8, 9, 11) and spring (10).
IMPORTANT
Mark valve disassembling position (port).
Figure 15 8. Remove plug (3) and four plugs (2).
Figure 16 9. Remove stopper (11) from reduction valve (6, 7, 8, 9, 11). pressure
Figure 17 10. Remove spool (6), spring seat (9), spring (8) and shim (7).
Figure 18
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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
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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.
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REASSEMBLY
1. Tighten plug (3) slowly. NOTE:
Tightening torque: 350 kgcm (25.3 ft lb).
Tighten four plugs (2). NOTE: NOTE:
Use Loctite #592 pipe sealant on plugs. Tightening torque 150 kgcm (10.9 ft lb).
Figure 22 2. Install shim (7), spring (8), spring seat (9), and spool (6).
Figure 23 3. Press spring (9) and install stopper (11).
Figure 24
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4.
Install spring (10) in case (1) and pressure reducing valve assembly (6, 7, 8, 9, 11).
Figure 25 5. Install seal (20) on plug (18).
Figure 26 6. Install O-ring (19) on plug (18).
Figure 27 7. Install push rod (14) on plug (18).
Figure 28
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8.
Install spring (13) on stopper (12).
Figure 29 9. 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
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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 kgcm (89.7 ft lb).
Figure 34 14. Pull cord and tube out through hole of hex nut (25).
Figure 35 15. Align the direction of handle (30) and tighten hex nut (25) and nut (27). NOTE:
Tightening torque 1,240 kgcm (89.7 ft lb).
Figure 36
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16.
Grease joint (23), swash plate (24) and push rod (14).
Figure 37 17. Install boot (28).
Figure 38
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INSTALLATION
1. 2. 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).
3 2
ARS2920L
Figure 39 3. 4. Install two screws, two bolts and washers (7 and 8, Figure 40) and cover (4). Install a screw, three bolts and washers (6, Figure 40) and cover (3). Push cap (5) into cover (3). Install four bolts and washers (2, Figure 40) and cover (1).
6 3 7 1 4 2
5.
5 8
ARS2930L
Figure 40 6. 7. Connect hoses as tagged during removal to remote control valve LH (1, Figure 41). Position remote control valve LH (1, Figure 41) on control stand and install four bolts and washers (3), and cover (2).
3 2
ARS2920L
Figure 41
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8. 9.
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). Install four bolts and washers (2, Figure 42), and cover (1).
3 6
2 7 4
10.
ARS2910L
Figure 42
START-UP PROCEDURES
1. 2. Start engine and set throttle at "LOW IDLE". Set safety lever on "UNLOCK" position.
HAOB290L
Figure 43 3. Slowly cycle boom, arm, bucket cylinders and swing motor about ve times without a load to vent air from pilot lines. Do this for 5 minutes.
ARO0470L
Figure 44
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S0709820K
1TRAVEL CONTROL VALVE (WITH DAMPER)

CAUTION!
TRAVEL CONTROL VALVE (WITH DAMPER)S0709820K

Copyright 2001 Daewoo December 2001 Travel Control Valve (With Damper) S0709820K Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Theory of Operation ................................................................................ 3 Pressure Reducing Valve................................................................. 3 Operating Theory of Damper Mechanism........................................ 5 Parts List ................................................................................................. 6 Specication............................................................................................ 7 Torque ..................................................................................................... 7 Troubleshooting, Testing and Adjustment....................................................... 8 Removal ......................................................................................................... 9 Disassembly ................................................................................................. 11 Cleaning and Inspection (Wear Limits and Tolerances) ............................... 17 Reassembly.................................................................................................. 18 Installation .................................................................................................... 23 Start-up Procedures ..................................................................................... 24
S0709820K Page 2
Travel Control Valve (With Damper)
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.
5 6 1
4 2
ARS1810L
Figure 1 Reference Number 1 2 3 Description Remote Control Valve Pilot Pump Main Pump Reference Number 4 5 6 Description Control Valve Hydraulic Motor Hydraulic Cylinder
Pressure Reducing Valve 1. Neutral Condition If pedal is in neutral, spool is pushed up by return spring and spring seat. Port (P) is blocked by bottom part of spool and four operating ports (left forward and backward, right forward and backward) are connected to port (T) through inner hole of spool. 2. Half Operation Condition If pedal is moved, push rod moves down, and they transmit this force through spring seat and control spring to spool. If spool is moved, primary pressure is transmitted through an inner hole of spool to operating port. If lever is stopped in middle position, compressed control spring force and secondary pressure transmitted through hole acts at bottom part of spool, balance is maintained by hydraulic force acted upward, and then this pressure is transmitted to traveling spool of control valve. That is,
S0709820K Page 3
primary pressure is transmitted to operating port as secondary pressure equivalent to control spring force compressed by spool. 3. 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. Primary pressure is transmitted through inner hole of spool to operating port, secondary pressure transmitted through spool overcomes control spring force and pushes spool up, but spool is restricted by push rod and does not move any more. That is, when pedal lever is moved to a maximum, control spring does not function, spool is restricted by push rod, and then primary pressure equalizes to secondary pressure.
SECONDARY PRESSURE (kgf/cm2)
40
160 OPERATING TORQUE (kgf.cm)

ARS1840L
271.5
117.6 Operating Torque 100.5
49.5 5.51 0 10.5 Secondary Pressure 4.80.5 5.5
PUSH-ROD STROKE (mm)

Figure 2
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Operating Theory of Damper Mechanism 1. 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 owed through orice to oil pressure vibration prevention chamber of upper part of low pressure, at this time, ball check valve becomes closing condition because high pressure operates to vibration prevention chamber of lower part.
1
12.5
ARS1820L
Figure 3 2. Operation When Neutral Condition Operating Lever In

1 2 3 4
Climbing restoring force acting on push rod, raises piston in oil pressure prevention chamber and compresses upper oil pressure prevention chamber. This compression operation of upper oil pressure prevention chamber prevents the push rod from quickly rising by restoring spring, and the damping force is generated.
Upper vibration prevention chamber Lower vibration prevention chamber
ARS1830L
Figure 4
S0709820K Page 5
PARTS LIST
19
20
30
29
28
33
32 24 23 22 16 21 13
25 26 3 36 14 15 17 18
12 11
19 20
9 6 5 7 4 3 10 8
37
35
34
2
ARS1850L
Figure 5
1
Figure 6
ARS1860L
S0709820K Page 6
Reference Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Description Body (1) Body (2) Plug Plug Spring Seat Spring Spring Seat Spool Stopper Spring Rod Guide O-ring Snap Ring Push Rod Spring Pin Seal Steel Ball Spring Plate
Description Snap Ring Plug O-ring Rod Seal Dust Deal Cover Wrench Bolt Cam Bushing Camshaft Set Screw Set Screw Hex Nut Bellows Space O-ring O-ring Wrench Bolt
SPECIFICATION Travel Control Valve Type Pressure / Stroke Weight Specication Pilot Control (With Damper) 27 kg/cm2 @ 4.8 mm Stroke (384 psi @ 1.890 in. Stroke) 7.8 kg (17.2 lb)
TORQUE Part Reference Number 26 30 32 37 Bolt Size M6 M8 M10 M10 Tool 5 mm L-Wrench 4 mm L-Wrench 17 mm Spanner 8 mm L-Wrench Tightening Torque 88 kgcm (6.37 ft lb) 100 kgcm (7.23 ft lb) 440 kgcm (31.8 ft lb) 440 kgcm (31.8 ft lb)
S0709820K Page 7

At times pinpointing the source of the problem may be difcult. 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. Possible problems other than the ones listed are not being specied but that is not to say that these are the only possible problems that can occur. The technician must diagnose the problem, considering all possible causes and repair the source of the malfunction. Problem Secondary pressure will not increase. Possible Cause Low primary pressure. Defective secondary pressure select spring. Gap between spool and casing is abnormally large. Defective operating parts and components. Jamming of interconnected parts. Unstable tank line pressure. Air in hydraulic lines. High tank line pressure. Jamming of unconnected parts. Jamming of interconnected parts. Worn damping piston and housing. Defective/damaged check valve. Worn damping piston orice. Defective interconnected components. Restricted movement of damping piston. Plugged orice. Remedy Adjust primary pressure. Replace with new spring. Replace spool casing assembly. Disassemble/reassemble and replace defective parts. Repair/replace cause of jamming. Install direct line to hydraulic tank. Vent air from system. Install direct line to hydraulic tank. Repair/replace cause of jamming. Repair/replace cause of jamming. Replace damping piston and housing assembly. Disassemble and examine check valve. Replace damping piston. Repair/replace defective parts. Repair/replace damaged piston. Replace related parts.
Unstable secondary pressure. Abnormally high secondary pressure. No damping.
Damping piston feels heavy.
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REMOVAL
WARNING!
Figure 7
4. 5. 6. 7. 8.
Disconnect negative (-) battery cable leading to frame from battery. Remove cabin under cover by loosening bolts. Tag and disconnect hoses from pedal valve (1, Figure 8). Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component.
2 1
ARS2940L
Figure 8 9. 10. Remove rubber boots (1, Figure 9). Remove four bolts and washers (2, Figure 9), pedal brackets (3), and levers (4).
4 2 1 3 3
ARS2950L
Figure 9
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11.
Remove four bolts and washers (2, Figure 10), and pedal valve (1).
2 1
ARS2940L
Figure 10
S0709820K Page 10
DISASSEMBLY IMPORTANT
1. 2. 3. 4. 5. 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. All parts must be carefully reassembled and not be forced. Damaged parts will cause oil leaks and poor performance of the equipment. Do not leave parts exposed to air during or after disassembly. Exposed parts will come in contact with contaminants and will cause rust and damage. Remove bellows (33).
1.
Figure 11 2. Remove set screw (30) by using L wrench.
Figure 12
S0709820K Page 11
3.
Remove cam shaft (29) and bushing (28) from cam (27).
Figure 13
Figure 14 4. Remove cam (27) from cover (25).
Figure 15 5. Loosen wrench bolt (26) by using tool.
Figure 16
S0709820K Page 12
6.
Remove cover (25) from body (1 and 2).
Figure 17 7. Remove plug assembly (21 - 24) with push rod assembly (14 - 20).
Figure 18 8. Remove snap ring (13).
IMPORTANT
Be careful not to spring rod guide (11).
Figure 19 9. Remove rod guide (11).
Figure 20
S0709820K Page 13
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 Page 14
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
S0709820K Page 15
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 Page 16

1. Cleaning disassembled parts. 1. 2. 2. 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. Be sure to use clean, uncontaminated solvent when cleaning precision parts. Clean parts thoroughly by gently turning the solvent. Dry and clean each part with a clean cloth. Do not use compressed air to dry parts. Foreign material and moisture present in compressed air may cause damage or rust.
Anti-corrosive treatment of disassembled parts. Apply an anti-corrosive lubricant to all disassembled parts. Leaving cleaned parts exposed to contaminants and moisture in the air will cause rust and may cause poor equipment performance.
S0709820K Page 17
REASSEMBLY IMPORTANT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 1. 2. 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 ne sandpaper to clean it off. Replace all O-rings and NHU packings with new ones. Use care when assembling O-rings and NHU packings. Apply a light coat of approved lubricant to aid in smooth assembly. Tighten all bolts to the specied torque rating as outlined in the torque table. Seal all opens ports to prevent foreign material from entering the valve assembly. All precision parts must be handled with great care and all parts must be reassembled to their original position. All parts must be carefully reassembled and not be forced. Damaged parts will cause oil leaks and poor performance of the equipment. Do not leave parts exposed to air during or after disassembly. Exposed parts will come in contact with contaminants and will cause rust and damage. Grease must be applied to the top portion of each push rod. Grease must be lled into each grease cup. Spray Anti-rust lubricant into each bellows. Clean body (1 and 2) and all parts. Install spring (10) on body (1 and 2).
Figure 33
S0709820K Page 18
3.
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 4. Install O-ring (22) on outside diameter of plug (21) and check plug whether it is abnormal.
Figure 35 5. Install spring seat (7), spring (6) and spring seat (5) on spool (8).
Figure 36 6. Install O-ring (12) on rod guide (11).
Figure 37
S0709820K Page 19
7.
Install steel ball (17), spring (18), plate (19) and spring pin (15) on push rod (14).
Figure 38 8. Install snap ring (20) on push rod assembly (14 - 19).
Figure 39 9. Install seal (16) on push rod (14).
Figure 40 10. After installing spool assembly (5 - 9) on body (1 and 2), insert rod guide (11) and install snap ring (13).
Figure 41
S0709820K Page 20
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:
Figure 44 14. Put cam (27) on cover (25) and install cam shaft (29).
IMPORTANT
Check whether there is a play of cam.
Figure 45
S0709820K Page 21
15.
Tighten set screw (30) on center of cam (27) not to loose cam (27) and cam shaft (29) by using wrench. NOTE:
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.
IMPORTANT
Check whether there is a play of cam. NOTE:

Figure 47
17.
Install bellows.
Figure 48
S0709820K Page 22
INSTALLATION
1. Position pedal valve (1, Figure 49) on cabin oor plate and install four bolts and washers (2).
2 1
ARS2940L
Figure 49 2. 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).
2 1 3 3
ARS2950L
3.
Figure 50 4. 5. Connect hoses as tagged during removal to pedal valve (1, Figure 51). Install cabin under cover by tightening bolts.
2 1
ARS2940L
Figure 51
S0709820K Page 23
START-UP PROCEDURES
1. 2. Start engine and set throttle at "LOW IDLE". Set safety lever on "UNLOCK" position.
HAOB290L
Figure 52 3. Slowly push and pull both travel lever about ve times without a load to vent air from pilot lines.
HAOB903L
Figure 53
S0709820K Page 24
S0792160K
2HYDRAULIC SCHEMATIC (S300LC-V)

CAUTION!
HYDRAULIC SCHEMATIC (S300LC-V)

MODEL Solar 300-V 1001 and Up SERIAL NUMBER RANGE
Copyright 2001 Daewoo December 2001 Hydraulic Schematic (S300LC-V) Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Solar 300LC-V................................................................................................ 4
Hydraulic Schematic (S300LC-V) Page 2
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
SOLAR 300LC-V
DR2 DR1 Pi2 of Pump DR3 ps2 T2 T1 T3 ps1 Pi1 of Pump
C2 E E
C2
pc1 A5
Pi1 T V2
Pi1 T V2
pb9
ARM2
ARM1
B5 pb5
pa9 pc2 pa5 A8 B8 B4 pb8 pa8 B7 A7 pb7 pa7 Pi B6 A6 pb6 pc3
BOOM1
BOOM2
pb4 pa4 B3
BKT
SWING
A3 pb3 pa3 B2
OPT TR(L)
A2 pb2 P4 pa2 B1
pa6
TR(R)
A1 pb1 pa1
VALVE(LEFT)
P2 P3 PH of Sol. v/v SWING MOTOR SH pr PH PA PP PT P1
VALVE(RIGHT)
Travel high speed
A1 500k (FRONT) SENSOR
Psv a4
A2 a2 500k SENSOR
Swing Priority
PH Pressure up
pc3
a1
TR2
PH
SP
(REAR) T
10u
177u ps1
Pi1
Pi2 ps2
G2 P1 P2 SHUTTLE VALVE S1
ENGINE
40k B1 Dr1 B3 Dr3 A3
a3
Figure 2
V2 T
TRAVEL MOTOR (R)

C2 A FORWARD Am Dr
q2 min.
Pi1
pc1 A5 GA
A LEFT
Mu
RIGHT B
GB Bm N Pi Pi Dr
ARM1
B5 pb5
BACKWARD B
q1 max.
Pi1 of Pump
Am A BACKWARD Dr Au
Pi
Pi
Dr
PG pa5 pc3 B4 SH
FORWARD B
BOOM2
pb4 C/V PA pa4 B3
q2 min. q1 ma x.
SWING
A3 Bm pb3 4 pa3 B2 3 Pi Dr 1 2
Dr
TRAVEL MOTOR (L)
OPT
A2 pb2 P4 pa2 B1 2 1 2 3 2 4 3 4 1
TR(R)
A1 pb1 pa1 1
VALVE(RIGHT)
T P T P T P T P
OPT. PEDAL 1 1 LEFT 2 RIGHT 1
SWING 3 RIGHT LEFT
ARM 4 2 DUMP CROWD
L.TRAVEL 1 2 FORWARD BACKWARD pb6 pa6
R.TRAVEL 3 FORWARD BACKWARD pa1
BOOM 4 2 UP DOWN
BUCKET 1 3 DUMP CROWD
pb1
pb9 Travel high speed
xO xI
xB cA xA
Pressure up
Swing Priority
PH
pc3
pb5
x
T
SP
9
(RH) pa5 A
A1
A2
A3
A4
A5
A6
A7
A8
A
To Front
x x x
TR2
PH
B1 pa3
S1
B2 B3 pb3 pa5
B4 pb5
B5 pa8
B6
B7
B8 pb7
(LH) T B pa9
pb8 pa7
SOL. V/V P2
pc1
Pi
pc2
P2 SHUTTLE VALVE S1 P1 P ACC G1 P C4 T
C1 T A pa2
C3 ps1
C2 Pi1 of pump
SOLAR 300LC-V
ARS1450L
1ELECTRICAL SYSTEM
S0802220K
1ELECTRICAL SYSTEM
CAUTION!
ELECTRICAL SYSTEM
Copyright 2001 Daewoo October 2001 Electrical System S0802220K Page 1
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.......................................................................................... 13 Monitoring System ....................................................................................... 14 Instrument Panel ................................................................................... 15 Monitoring System Schematic .............................................................. 16 Operation...................................................................................................... 18 Instruments ........................................................................................... 18 Warning and Indicator Lights........................................................................ 20 Initial Operation ............................................................................................ 22 Mode Select Switch...................................................................................... 23 Graphic Information Area Display ................................................................ 24 Overview ............................................................................................... 24 Main Menus for the Graphic Display Area............................................. 25 Menu Selection Buttons ........................................................................ 25 Main Menu.................................................................................................... 26 Language setting................................................................................... 26 Time Setting .......................................................................................... 26 Filter/Oil information .............................................................................. 27 Special Menu................................................................................................ 28 Entering/Accessing and Exiting/Escaping Menus ................................. 28 Special Menu Selections....................................................................... 29 Electronic Hydraulic Control System (e-EPOS) ........................................... 42 Control System Schematic.................................................................... 42 Power Mode Control..................................................................................... 44
S0802220K Page 2
Electrical System
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 ................................................................................... 54 Engine Control Dial ...................................................................................... 55 Engine Control Circuit Diagram.................................................................... 57 Automatic Deceleration Control (Auto Idle Control)...................................... 58 Engine Overheat Protection System ............................................................ 59 Power Boost Mode ....................................................................................... 60 Operation .............................................................................................. 60 Power Boost Control - Circuit Diagram ................................................. 61 Automatic Travel Speed Control ................................................................... 62 Automatic Travel Speed Control - Circuit Diagram ................................ 63 Engine Control Device - Adjustment ............................................................ 64 Self-diagnostic Function ............................................................................... 67 e-EPOS Controller ................................................................................ 67 Engine Throttle Controller ............................................................................ 69 Wiper System ............................................................................................... 70 Wiper Circuit.......................................................................................... 70 Wiper Operation .................................................................................... 70 Window Washer Operation ................................................................... 71 Lighting System............................................................................................ 72 Lighting System Circuit Diagram........................................................... 72 Kind of Light .......................................................................................... 73 Operation .............................................................................................. 73 Overload Warning Device............................................................................. 74 Overload Warning Device Circuit Diagram............................................ 74
Electrical System
S0802220K Page 3
TROUBLESHOOTING - ELECTRICAL SYSTEM

Problem Battery will not stay charged. Battery does not charge. Possible Causes Internal battery short. Short in other part of circuit. Battery worn out or defective. Defective alternator or belt. Cable connection loose or severely corroded. Circuit ground corroded or weak. Engine speed potentiometer or dial defective. Engine control cable broken or loose. Engine control motor defective or not connected. Engine throttle controller defective or not connected. Blown fuse. Remedies Replace battery. Repair wiring or replace component. Replace battery. Repair or replace. Repair or replace.
Engine rpm not controllable.
Repair or replace. Repair or replace. Repair connection or replace component. Repair connection or replace component. Replace fuse. Check connections and circuit components for shorts or other damage. Repair or replace. Replace fuse. Check connections and circuit components for shorts or other damage. Repair or replace. Repair or replace. Replace. Replace. Replace fuse. Check connections and circuit components for shorts or other damage. Repair or replace. Repair or replace. Replace. Replace.
Power mode selection does not change.
Wiring harness or connector defective or damaged. Blown fuse.
Work mode selection does not change.
Instrument Panel switch broken. Wiring harness or connector defective or damaged. e-EPOS controller defective. Speed sensor defective. Blown fuse.
Instrument Panel switch broken. Wiring harness or connector defective or damaged. e-EPOS controller defective. Solenoid valve defective.
S0802220K Page 4
Electrical System
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 rectier. The electric wiring used in the system is easily identiable by the insulator color. The color symbols used in the electrical system are listed in the following chart. Electric Wire Color Symbol W G Or B L Lg Color White Green Orange Black Blue Light green Symbol R Gr P Y Br V Color Red Gray Pink Yellow Brown Violet
NOTE:
RW: Red wire with White stripe R - Base Color, W - Stripe Color
NOTE:
0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2
Electrical System
S0802220K Page 5
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" position, electric current is supplied to the following components through battery (1) fusible link (3) fuse (6). 1. 2. 3. 4. Cabin light, fuel pump switch, No. 1 terminal of DC-DC converter (backup for car stereo memory) "B" terminal of starter switch and No. 22 terminal of air conditioner control panel. No. 17 terminal of instrument panel (back up for instrument panel). Power terminal "B" of engine stop motor.
When the starter switch (5) is in the preheat, on and start positions, the current ows from the battery (1) fusible link (3) fuse (6) starter switch (5) "B" terminal/starter switch (5) "BR" terminal battery relay (2) "BR" terminal which activates the coil of the battery relay and the electric supply system is energized. When the battery relays contacts are connected, all electric devices can be operated. While the engine is not running, the electric power for all electric devices are supplied by the battery. Once the engine is started the power is supplied from the alternator (7).
ACC B R2 R1
5
BR 0.5G
6 8 4
3 2
B BR E A
8
12V 150AH + 12V 150AH +
R(I)
B(B+)
PST OFF PREHEAT ON START
TML
1
B BR R1 R2 C ACC
7
R F E E
ARS0010L
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Number 1 2 3 4 Description Battery Battery Relay Fusible Link Circuit Breaker Reference Number 5 6 7 8 Description Starter Switch Fuse Box Alternator Diode
S0802220K Page 6
Electrical System
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 ow from the battery (1, Figure 2) fusible link (3) "B" terminal of the starter switch (5) "C" terminal of the starter switch (5) "C" terminal of the starter relay (8) "D" terminal of starter relay (8) "S" terminal of starter controller (7) "E" terminal of the starter controller (7) ground. The contact point "B" and "PP" of starter relay (8) are connected, the pinion gear of the starter (9) is pushed forward and makes contact with the ring gear of the ywheel and the internal contacts of the starter are connected. The current ows from the battery (1) "A" terminal of the battery relay (2) "B" terminal of the battery relay (2, Figure 2) "B" terminal of the starter (9). The starter motor is rotated and the engine is started.
7
N P B S E D
8
PP C B
11
A
ACC B R2
BR R1
5 6
2
B BR E A
R(I)
P(R)
PST OFF
TML
BR
R1
R2
ACC
SG
PREHEAT ON START
R F E E
10
1
ARS0020L
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING Reference Number 1 2 3 4 5 6 Description Battery Battery Relay Fusible Link Circuit Breaker Starter Switch Fuse Box Reference Number 7 8 9 10 11 Description Starter Controller Starter Relay Starter Alternator Diode
Electrical System
S0802220K Page 7
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. Once the frequency equivalent to 500 rpm is sensed the connection between "S" and "E" terminals and the connection between "B" and "PP" terminals are opened. As a result the rotation of the starter (9) is stopped. Once the engine is running, the starter (9) will not operate even if the starter switch (5) is moved to the start position, preventing possible damage to the starter. Operation of the Start Circuit (2) - Immediately After Start
7
N P B S E D
8
PP B C B
11
A
ACC B R2
BR R1
5 6
2
B BR A
11
R(I) B( P(R)
PST OFF
TML
BR
R1
R2
ACC
PREHEAT ON START
R F E E
10
ARS0030L
Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START Reference Number 1 2 3 4 5 6 Reference Number 7 8 9 10 11
Description Battery Battery Relay Fusible Link Circuit Breaker Starter Switch Fuse Box
Description Starter Controller Starter Relay Starter Alternator Diode
S0802220K Page 8
Electrical 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 ows 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) ground and the contact points of the preheat relay are closed. When the contact points of the preheat relay (7) are closed, the heating coils of the air heating device are heated by current owing from the battery (1) battery relay (2) preheat relay (7) air heater (8) ground. The preheat time is approximately 19 seconds. A built-in timer in the instrument panel will activate an indicator light approximately 19 seconds after the preheat process has been selected. Even after the starter switch (5) has been moved to the start position the current will continue to ow through the "R2" terminal of the starter switch (5) to the coil of the preheat relay (7) without disruption of the preheat process.
3 6 9
CN7-9 ACC PREHEAT L4 CN7-6 R2 R1 BR B C B
4 2
A
5
BR
10
B + +
10 7
H
STARTER SWITCH CONNECTION

PST OFF PREHEAT ON START TML B BR R1 R2 C ACC
ARS0040L
Figure 4 ENGINE PREHEAT CIRCUIT Reference Number 1 2 3 4 5 Description Battery Battery Relay Fusible Link Circuit Breaker Starter Switch Reference Number 6 7 8 9 10 Description Fuse Box Preheat Relay Air Heater Indicator Lamp Diode
Electrical System
S0802220K Page 9
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 motors speed and changes motors revolution to reciprocation. The fuel shut off lever is pushed or pulled by this change. When the start switch is in the "ON" position, the engine stop motor rotates 180 and comes to a stop due to the cam switch. When the start switch is in the "OFF" position, the engine stop motor moves 180 from the running mode position and is stopped by the cam switch.
A P1 P2 A B E 87a 30 87 85 86

8
0.5G
6
ACC B R2 R1 BR C
3 5 4
B BR
2
A
1
ARS0050L
Figure 5 ENGINE STOP CIRCUIT Reference Number 1 2 3 4 5 Description Battery Battery Relay Fusible Link Circuit Breaker Starter Switch Reference Number 6 7 8 9 Description Fuse Box Diode Engine Stop Relay Engine Stop Motor
S0802220K Page 10
Electrical System
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 owing from the battery (1) fusible link (2) "B" terminal of starter switch (3) "ACC" terminal of starter switch (3) "86" terminal of engine stop relay (5) "85" terminal of engine stop relay (5) ground. As a result, the engine stop motor (6) is rotated by the current ow from the battery (1) fusible link (2) "B" terminal of the engine stop motor (6) "P2" terminal of engine stop motor (6) "87" terminal of engine stop relay (5) "30" terminal of the engine stop relay (5) "A" terminal of engine stop motor (6) "E" terminal of engine stop motor (6) ground. The engine stop motor opens (pushes) the fuel shut off lever of the fuel injection pump and the system is in the running mode. The engine stop motor rotates 180 and comes to a stop due to the cam switch which shuts off the current to the motor. When the starter switch is in the "ON" position, the internal components of the engine stop motors cam switch is in running mode position.
A P1 P2 A B E 87a 30 87 85 86

5
0.5G
4
ACC B A P1 P2 A B E R2 R1 BR C
2 3
+ +
ENGINE RUNNING MODE
ARS0060L
Figure 6 ENGINE STOP CIRCUIT - RUNNING MODE Reference Number 1 2 3 Description Battery Fusible Link Starter Switch Reference Number 4 5 6 Description Fuse Box Engine Stop Relay Engine Stop Motor
Electrical System
S0802220K Page 11
Operation In Engine Stop Mode When the starter switch (3) is in the "OFF" position, the electric current ow 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) fusible link (2) "B" terminal of engine stop motor (6) "P1" terminal of engine stop motor (6) "87a" terminal of engine stop relay (5) "30" terminal of engine stop relay (5) "A" terminal of engine stop motor (6) "E" terminal of engine stop motor (6) ground and the motor is rotated. The shut off lever of the fuel injection pump, linked to the engine stop motor by a cable, is moved to the close (pull) position and the engine is stopped. The engine stop motor moves 180 from the running mode position and is stopped by the internal cam switch which cuts off the current to the motor. When the starter switch is in the "OFF" position, the internal components of the engine stop motors cam switch is in the stop mode position.
A P1 P2 A B E 87a 30 87 85 86

5
0.5G
4
ACC B A P1 P2 A B E R2 R1 BR C
2 3
+ +
ENGINE STOP MODE
ARS0070L
Figure 7 ENGINE STOP CIRCUIT - STOP MODE Reference Number 1 2 3 Description Battery Fusible Link Starter Switch Reference Number 4 5 6 Description Fuse Box Engine Stop Relay Engine Stop Motor
S0802220K Page 12
Electrical System
CHARGING SYSTEM
When the starter switch (5) is turned to the "ON" position, an initial excited current ows to the eld 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. The current ows from the "B" terminal of alternator (7) circuit breaker (4) battery relay (2) battery (1). The alternator also supplies electric current to other electrical components. When the alternator (7) starts to operate, a current ows from the "R(I)" terminal of alternator diode (8) battery relay (2) coil securing a path for the charging current to the battery (1). Thus preventing the possibility of a high voltage build up and possible damage to the electric system.
ACC B R2 R1
5
BR 0 .5 G
6 8 4
3 2
B BR E A
8
12V 150AH + 12V 150AH +

R(I)
B(B+)
P(R)
1
SG
R F E E
ARS0080L
Figure 8 CHARGING CIRCUIT Reference Number 1 2 3 4 Description Battery Battery Relay Fusible Link Circuit Breaker Reference Number 5 6 7 8 Description Starter Switch Fuse Box Alternator Diode
Electrical System
S0802220K Page 13
MONITORING SYSTEM
ARS0090L
Figure 9 Reference Number 1 2 3 4 5 6 7 8 Description Instrument Panel Battery Engine Speed Sensor Return Filter Switch Pilot Filter Switch e-EPOS Controller Alternator Warning Buzzer Reference Number 9 10 11 12 13 14 Description Pump Discharge Pressure Sensor Engine Coolant Temperature Sensor Fuel Sensor Air Cleaner Indicator Engine Oil Pressure Switch Light Switch
The monitoring system displays the various data and warning signals onto the instrument panel by processing the information gathered from the e-EPOS controller. It displays information selected by the operator.
S0802220K Page 14
Electrical System
INSTRUMENT PANEL
ARO0100L
Figure 10 Gauges Engine Coolant Gauge Fuel Gauge Multi-function Gauge & Graphic Information Area Digital Clock Service Hour Meter 8. 9. 10. 11. Warning Lights Temp. 6. 7. Charge Warning Light Engine Oil Warning Light Coolant Light Temp. Pressure 13. Warning 14. 15. 12. Mode Select Switches Power Mode Select Switch (Up Arrow Button) Trenching Mode Switch (Down Button) Auto Idle Switch (Enter Button) Display Select (Escape Button) Switch Select Arrow
1. 2. 3. 4. 5.
Preheat Completion Light Work Light Indicator Light Overload Warning Light
When the engine starter switch is turned to the "I" (ON) position, all bands of gauges, indicator lights of switches/buttons and indicator/warning lights will turn "ON" and the alarm buzzer will sound for about 2 seconds. During this time, a moving excavator will appear on the digital clock and graphic information area (3 and 4, Figure 10).
Electrical System
S0802220K Page 15
MONITORING SYSTEM SCHEMATIC
1 21
9 10 + -
2 3 4
R1 B
8 11 L1 L2 L3 L4 L5 L6 6 17
19 18
B
ILLUMINATION
16
EL
19 20
5 6
+ SIG + SIG -
BR E
CN4-1 CN4-2
A CN4-3 CN4-4
WARNING LAMP L1 : BATTERY CHARGE L2 : ENG. OIL PRESS L3 : WATER TEMP. L4 : PREHEAT L5 : WORK LAMP L6 : OVER LOAD
20
CN4-5 CN4-6
17
7 8
CN4-7 CN4-8
LCD DISPLAY PANEL WATER TEMPERATURE FUEL LEVEL
CN4-16
9
GRAPHIC DISPLAY
CN4-17
10
CN3-4 CN3-5
22
CN3-9 CN3-10
POWER DISPLAY ESC
5 3
CN3-11 CN3-12 CN3-8
TxD TxD RxD RxD
RS-422
CN3-1 CN3-2 CN3-3
R(I)
CN2-1 CN2-11 CN2-12 CN2-13 CN2-14
15
11 12 13 14
ARS0110L
Figure 11
S0802220K Page 16
Electrical System
Description Instrument Panel Pilot Buzzer Light Switch Start Switch Front Pump Pressure Sensor Rear Pump Pressure Sensor Engine Coolant Temperature Sensor Fuel Gauge Engine Speed Sensor Hydraulic Oil Temp. Sensor
Reference Number 11 12 13 14 15 16 17 18 19 20 21 22
Description Engine Oil Pressure Switch Air Cleaner Indicator Return Filter Switch Pilot Filter Switch Alternator e-EPOS Controller Battery Battery Relay Circuit Breaker Fusible Link Fuse Box Check Connector
Electrical System
S0802220K Page 17
OPERATION
INSTRUMENTS Sensor Specication Function Display Input Terminal Input Specication 41C (106F) 1,372 ohms 61C (142F) 855 ohms Engine Coolant Temperature
107C 105C WHITE
RED
GREEN
CN4-5 CN4-6
102C (216F) 160 ohms 105C (221F) 147 ohms 107C (225F) 128 ohms
C
61C 41C
ARS0780L
GREEN RED
F
CN4-7 1/10 LCD Blinking over 5K ohms FULL under 525 ohms
Fuel Level
E
1/10
ARS0790L
CN4-8
N = 146 f / 60 (S300LC-V)
02/05
Tachometer
[MO] 11:30A
CN4-16 CN4-17
N = 146 f / 60 (S300LL) N = 152 f / 60 (S340LC-V) N = 152 f / 60 (S420LC-V) N = 152 f / 60 (S470LC-V) N = Engine speed (rpm) F = Frequency of engine speed sensor (Hz)
ENG SPEED
1950 RPM
ARO0160L
02/05
Voltmeter
[MO] 11:30A
CN7-9 CN7-19 0 - 32 VDC
BATTERY
28.5
VOLT
ARO0180L
S0802220K Page 18
Electrical System
Sensor Specication Function Display Input Terminal Input Specication
02/05
Main pump discharge pressure (front pump)
[MO] 11:30A
CN4-1 CN4-2 V = 0.00816 x P + 1.0 V: Sensor output voltage (V) P: Displayed pressure (Bar) CN4-3 CN4-4
FRONT PUMP
320 BAR
ARO0190L
Main pump discharge pressure (rear pump)
02/05
[MO] 11:30A
REAR PUMP
313 BAR
ARO0200L
Electrical System
S0802220K Page 19
WARNING AND INDICATOR LIGHTS

Description Symbol Input Terminal Operation Lights up when not charging [R(I) terminal output drops below 121V] and over charging [R(I) terminal output increase over 33 V]. Remarks
Charge
CN2 - 1
Lights up before engine start up and shut off once engine is running.
HAOA610L
Engine Oil Pressure

HAOA620L
CN2 - 11
Lights up when engine oil pressure switch is turned "ON" (Oil pressure drops below 0.7 kg/ cm2 (10 psi).
After starting engine, if engine oil pressure is insufcient after 8 seconds, a warning buzzer will sound.
Engine Coolant Temperature

HAOD350L
CN4 - 5 CN 4 - 6
Lights up when the resistance of engine coolant temperature sensor drops below 128 ohms.
Preheat
CN7 - 6
Lights up when preheat process is completed. (Approximately 19 seconds from start)
HAOA639L
Work Light
CN2 - 7
Lights up when work light switch is turned "ON."
S0802220K Page 20
Electrical System
Description
Symbol
Input Terminal
Operation Lights up when lifting load exceeds limit. (When the over load warning switch is turned "ON," output voltage increases over reading in remarks.)
Remarks Warning buzzer will sound. 2.80 V (S300LC-V) 2.80 V (S300LL) 2.80 V (S340LC-V) 2.88 V (S420LC-V) 2.80 V (S470LC-V)
Overload (Optional)
ARO0220L
CN1 - 3 CN1 - 4
Graphic Information Area
02/05
[MO] 11:30A
2059 RPM
Air Cleaner
Air Cleaner CLOGGED!!

ARO0210L
CN2 - 12
Lights up when air cleaner is clogged
Symbol is blinking.
02/05
[MO] 11:30A
2059 RPM
Return Filter
Return Filter CLOGGED!!

ARO0230L
CN2 - 13
Lights up when return lter pressure increases over 1.5 kg/cm2 (21 psi).
Symbol is blinking.
02/05
[MO] 11:30A
2059 RPM
Pilot Filter
Pilot Filter CLOGGED!!

ARO0240L
CN2 - 14
Lights up when pilot lter pressure increases over 1.0 kg/cm2 (14 psi).
Symbol is blinking.
Electrical System
S0802220K Page 21
INITIAL OPERATION
Item Initial Operation Input (Terminal) When battery voltage is input to CN7 - 9 (starter switch is turned from "OFF" to "ON" position). Output (Operation and initial setting mode) All LCD, LED and warning lights are turned on and turned off after about 2 seconds. NOTE: Warning buzzer is activated and turned off after about 2 seconds. Power mode: Previous setting mode. Work Mode: Previous setting mode. Auto Idle: High Output (Activation). Numerical display: Engine speed. Clock: Current time display.
Refer to the clock setting method of operation manual for time setting.
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Electrical System
MODE SELECT SWITCH

Power Mode / Trenching Mode Switch Output Check (Operation mode display LED) ON OFF ON OFF e-EPOS Output Pump Discharge Volume Control Swing Priority Valve Current Solenoid Valve (mA) Variable Output 0 ON OFF
Operation Mode
7-Segment Display 9x 7x x2 x0
Power Mode Work Mode
Power Mode Standard Mode Trenching Mode Digging Mode
Auto Idle Switch Operation Mode Auto Idle Activation Cancellation Output Check (Operation mode display LED) ON OFF e-EPOS Output (CN1 - 7 Terminal) H (11 1.5V) L (0 - 1V)
Electrical System
S0802220K Page 23
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.
02/05
[MO] 11:30A
ENG SPEED
2059
RPM
POWER
AUTO
DISPLAY
ESC
4
ARS0800L
Figure 12
1. 2. 3. 4.
Selection Buttons Up Arrow Button Down Arrow Button Enter Button Escape Button
5.
Graphic Display Area Letter Information Display Department
S0802220K Page 24
Electrical System
MAIN MENUS FOR THE GRAPHIC DISPLAY AREA 1. 2. Main menu: Language setting, Time setting, Filter/Oil information Special menu: Information of machine status, failure information, Information of machine operation.
MENU SELECTION BUTTONS 1. 2. 3. 4. Up Arrow Button ( , 1 on Figure 12): Move the cursor to up, left and previous screen. , 2 on Figure 12): Move the cursor to down, right and next screen.
Down Arrow Button (
Enter Button ( , 3 on Figure 12): Move the menu to selected mode. When setting the menu, this button is used to function as the select button. Escape Button (ESC, 4 on Figure 12): Move a screen to previous menu or main menu.
Electrical System
S0802220K Page 25
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 setting, time setting, or lter/oil information) to the operator. Refer to the "Operation and Maintenance Manual" for details.
MAIN MENU
1 Language Set Clock Filter / Oil Info

ARO0330L
Figure 13 LANGUAGE SETTING This mode is used for setting desired language.
LANGUAGE
Fra n c a i s Deutsch
S et :
Figure 14 TIME SETTING This mode is used for setting time on the digital clock.
4
E ngli sh
ARO0341L
SET CLOCK
02 : 30 P 2001 02 / 15
:+
Figure 15
:MOVE
ARO0380L
S0802220K Page 26
Electrical System
FILTER/OIL INFORMATION This mode displays total operating hours of lters and oils. After changing the lter and oil, reset the operating hour and then the operating hours until the next service interval can be easily checked.
1.Fuel Filter Hrs: 0232 Reset:

ARO0400L
Figure 16
Menu Display Order and Icon Explanation
1. Fuel Filter 8. Coolant Water

Figure 17
2. Air Cleaner 7. Hydraulic Oil
3. Engine Oil Filter 6. Engine Oil
4. Return Filter 5. Pilot Filter

ARO0410L
Electrical System
S0802220K Page 27
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; 1. 2. 3. Machine status. Failure information. Information on machine operation
ENTERING/ACCESSING AND EXITING/ESCAPING MENUS Entering/Accessing Menus
ARO0250L
Figure 18 When normal mode screen is displayed, if the enter button ( , 3) and escape button (ESC, 4) are pressed simultaneously for more than 3 seconds, normal mode screen (Figure 19) will be changed to special menu screen (Figure 20). Normal Mode Screen NOTE:
Normal mode screen can display many kinds of display mode by selecting, for example, engine revolution (RPM), battery voltage (V), front pump pressure (BAR), rear pump pressure (BAR) and so on by selecting.
02/05
[MO] 11:30A
ENG SPEED
1950 RPM
ARO0160L
Figure 19
S0802220K Page 28
Electrical System
Special Menu Screen NOTE:
Displayed language on the special menu screen consists of Korean and English. If any language except for Korean is selected during language selection mode of main menu, only English will be displayed on special menu screen.
SPECIAL MENU
achine I nfo 1 F ai lur e I nfo Op e r a t in g H r s

ARS0850L
Figure 20
Exiting/Escaping Menus 1. 2. 3. If escape button (ESC, 4 on Figure 18) is pressed for more than 1 second, the special menu screen will be returned to the normal mode screen. If this special menu is "ON" without any activity, for more than 20 seconds, it will turn to the normal mode screen. After the turning starter switch to the "OFF" position, turn it back to the "ON" position, and the normal mode screen displayed once again.
SPECIAL MENU SELECTIONS Sub-menu Selection Method Various sub-menus can be selected by pressing "Up ( , 1 on Figure 18)" and "Down ( , 2 on Figure 18)" button. Move the cursor to desired menu and a selected menu will be inverse displayed. When the selected menu is inverse displayed, press the "Enter ( , 3 on Figure 18)" button for menu selection. Figure 21 Information of Machine Status 1. Entering Sub-menus: When cursor is located on "Machine Info" of special menu screen, press "Enter ( , 3 on Figure 18)" button and the "Machine Info Sub-menu" will be displayed. Exiting Sub-menus: If escape button (ESC, 4 on Figure 18) is pressed for more than 1 second, display will be turned to previous sub-menu. Figure 22
SPECIAL MENU
achine I nfo 1 F ai lur e I nfo Op e r a t in g H r s

ARS0850L
MACHINE INFO
2.
E PPR C urrent 1 Dial Vol t ag e T P S Vol t ag e

ARS0820L
Electrical System
S0802220K Page 29
Contents of Machine Status Display Item of Machine State Information 1. EPPR Current 2. Dial Voltage 3. TPS Voltage 1. Alternator 8. Pressure (Px) 2. Power Max 9. E/G Oil Press. 3. Work/Travel 10. Air Cleaner Sel. 4. Input State 4. Hi Speed Sel. 11. Return Filter 5. Auto Travel 12. Pilot Filter 6. Work Lamp 13. OWD Select 7. Pressure (Py) 1. Relief Press Up 4. Spare Out 1 5. Output 2. High Speed 5. Spare Out 2 State 3. Swing Priority 6. Hydraulic Oil Temp 7. Boom Pressure (Opt) 8. T/M Pressure (Wheel Type) Sub-menu Selections Display "mA" "mV" "mV" Remarks EPPR valve current Dial voltage TPS voltage Input status delivered from switches and sensors to eEPOS controller is displayed as on or off. On or Off * Number 3 (Work/Travel sel.) is used only wheel type machine. * Number 13 (OWD Select) is optional part. On or Off C (F) BAR BAR Output status delivered from eEPOS controller to solenoid valves is displayed as on or off. Hydraulic oil temperature. On machine with overload warning device, it displays cylinder pressure. At this machine, it is always displayed as "O."
EPPPR Current Dial Voltage TPS Voltage
I n p ut State O ut p ut State Hyd. O il Te mp.
B oo m Pre ss T /M Pre ss
ARS0860L
Figure 23
S0802220K Page 30
Electrical System
Display Example: Machine Status Information 1. EPPR Valve Current
EPPR CURRENT
598
Figure 24 2. Dial Voltage
mA
ARS0870L
DIAL VOLTAGE
2089 mV
ARS0880L
Figure 25 3. TPS Voltage Output voltage of potentiometer built into engine control motor.
TPS VOLTAGE
2095 mV
ARS0890L
Figure 26
Electrical System
S0802220K Page 31
4.
Input Status "YES" or "NO" for alternators generation (Generation: "ON"/ Non-generation: "OFF"), selection status of select switch (Selection: "ON"/ Non-selection: "OFF") and the other statuses of on/off type sensors.
M AC H I N E I N F O
I nput State 4 O utput State H yd. O il Te m p

ARS1780L
Figure 27
1. Alternator : OFF 2. Power Max. : ON 3. Work/Travel Sel. : OFF
4 . Hi S p ee d Sel. : OFF 5 . Au to Travel : ON 6 . Work L a mp : OFF
13. OW D Sele c t : OFF
7 . Pre ss u re ( P y) : OFF 8 . Pre ss u re ( Px ) : ON 9 . E / G O i l Pre s . : OFF
1 0 . A i r C leaner : OFF 11. R et u rn F i lter : ON 12. P i lot F i lter : OFF

ARS0900L
Figure 28
S0802220K Page 32
Electrical System
5.
Output Status: Output status of solenoid valves and spare valves are displayed. (Output: "ON"/ Nonoutput: "OFF")
1. Relief Pess Up : OFF 2. High Speed : ON 3. Swing Priority : OFF

Figure 29
4 . Spare Out 1 : OFF 5 . Spare Out 2 : ON

ARS0920L
6.
Hydraulic Oil Temperature
HYD. OIL TEMP

LOW HIGH
ARS0870L
Figure 30 Display Specication BAR Graph Display 1/6 BAR Lit 1/6 ~ 2/6 BAR Lit 1/6 ~ 3/6 BAR Lit 1/6 ~ 4/6 BAR Lit 1/6 ~ 5/6 BAR Lit 1/6 ~ 6/6 BAR Lit CN 3 - 4 CN 3 - 5 Input Terminal Sensor Input Specication Over 1,510 745 ~ 1,510 332 ~ 745 244 ~ 332 181 ~ 244 Under 181 Remarks Below 30C (Below 86F) 31 ~ 50C (87 - 122F) 51 ~ 75C (123 - 167F) 76 ~ 85C (168 - 185F) 86 ~ 95C (186 - 203F) Over 96C (Over 204F)
Electrical System
S0802220K Page 33
7.
Boom Pressure (Optional) On machine with OWD (Overload Warning Device), detected pressure from boom 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. V = 0.00816P + 1
BOOM PRESSURE
205 BAR
ARS0940L
V: Output voltage of pressure sensor (V). P: Displayed pressure (Bar). NOTE:
Figure 31
At standard machine, "0 BAR" is always displayed.
Failure Information 1. Entering Sub-menus: When a cursor is located in "Failure Info" of special menu screen press enter button ( , 3 on Figure 18) and "Failure Info" screen is displayed. Exiting Sub-menus: If escape button (ESC, 4 on Figure 18) is pressed for more than 1 second, this information screen will be returned to previous screen.
SPECIAL MENU
2.
M achine I nfo 1 ai lur e I nfo 2 Op e r a t in g I nfo 3

ARS0930L
Figure 32 * Real-time Failure: Current status of failure is displayed. * Failure Log: Memorized record failure is displayed. of past
FA I L U R E I N F O
* Delete Fail Log: This mode is used to delete all of the memorized record of past failure. Figure 33
R ealtime F ail F ail ur e L og D elete F ail L og

ARS0950L
S0802220K Page 34
Electrical System
A.
Current failure information Current status of failure is displayed (Failure code, failure contents). When a number of failures are produced, failure information can be checked by using "PRV" ( , 1 on Figure 18) or "NXT" ( , 2 on Figure 18) button. * CODE: 12: Unique code of failure information. * 01/02: A serial number of current failure/ total quantity of failure. This example shows one of two failures.
REALTIME FAIL
C OD E :1 2 Press up s/v open

P R V:
Figure 34
NX T:
0 1/ 0 2
ARS0960L
B.
Past failure information Memorized record of past failure is displayed (Failure code, failure contents). When a number of failures are produced, failure information can be checked by using "PRV" ( , 1 on Figure 18) or "NXT" ( , 2 on Figure 18) button.
FAILURE LOG
C O D E :12 N:001 0075 Hr Press up s/v open

P R V:
Figure 35
N XT:
01/01
ARS0980L
NOTE:
" N: xxx " : "xxx" means that the totally counted number of the same failure. " xxxx Hr " : It will display the operation hour until the failure is generated. (Above example screen shows that breaking of a wire of pressure solenoid valve is generated at 75Hr.)
Electrical System
S0802220K Page 35
C.
Failure record deletion This mode is used to delete the memorized record of past failure. If this mode is selected, all records will be deleted. When "YES" ( , 3 on Figure 18) button is pressed, the memorized record will be deleted. At this time, deletion signal will be displayed and the screen will move to previous menu after deletion. This screen will be displayed during 3 seconds. When "NO" (ESC, 4 on Figure 18) button is pressed, the screen will recover to previous menu without deletion.
FA I L U R E L O G
All Fail Log will be D ELE T E .

Y E S:
Figure 36
NO: ESC
ARS0970L
Code Description of Failure Information Code 0x 1x 2x 3x 8x State Short Circuit Open circuit Output error Output error Communication
S0802220K Page 36
Electrical System
Display Contents of Failure Information Code Code Contents Cause Communication error between e-EPOS controller and instrument panel Short Circuit Short Circuit Short Circuit Cut off output current (0 mA) Operation Reset Procedure Automatic reset when problem is corrected After correcting problem, turn start switch from "OFF" to "ON."
82 01 02 03
Communication Err!! EPPR v/v short Press Up s/v short Swing pri. s/v short
* Note
Electrical System
S0802220K Page 37
Code
Contents EPPR v/v open Press Up s/v open Swing pri. s/v open Dial Voltage Err (H) Dial Voltage Err (L) TPS Voltage Err (H) TPS Voltage Err (L) Fpump Sensor Err (H) Fpump Sensor Err (L) Rpump Sensor Err (H) Rpump Sensor Err (L)
Cause Open Circuit Open Circuit Open Circuit Output voltage Over 4.60.2 V Output voltage Over 0.40.2 V Output voltage Over 4.60.2 V Output voltage Over 0.40.2 V Output voltage Over 4.60.2 V Output voltage Over 0.40.2 V Output voltage Over 4.60.2 V Output voltage Over 0.40.2 V Under 106720Hz (On condition that alternator output exceeds over 121V) Sensors resistance between two terminals is under 150100 Sensors resistance between two terminals is under 6.50.5 k Output voltage of alternator exceeds 33 V for more than 3 seconds When the output voltage is maintained under 181 for more than 3 seconds (On condition that speed sensor output exceeds over 1,067Hz)
Operation Cut off EPPR v/ v current (0 mA) Cut off EPPR v/ v current (0 mA) -
Reset Procedure
11 12 13 21 22 23 24 25 26 27 28 29
Automatic reset when problem is corrected
Speed Sensor Err
31 32 33
Fuel shot to GND
Fuel Sensor open
Alternator too high
34
Alternator too low
NOTE:
1.
If a communication error is generated during operation, the power mode, work mode and auto idle mode will be maintained at the last mode setting before the failure took place until the unit is shutdown. When start switch is turned to the "ON" position during a period of a communication error, the e-EPOS controller will operate in the following modes. Power mode: Standard mode
2.
S0802220K Page 38
Electrical System
3. 4.
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. 1. Operating Hour Information A. Entering Sub-menus: When a cursor is located in "Operating Info" of special menu screen (Figure 37) press enter button( , 3 on Figure 18) and "Operating Info" screen will be displayed (Figure 38).
SPECIAL MENU
M achine I nfo 1 F ai lur e I nfo 2 Op e r a t in g I nfo 3

ARS0990L
Figure 37 B. Information screen of operation (Figure 38). machine
OPERATING INFO
O perating Hrs R eset Hrs

ARS1000L
Figure 38 C. D. Operation Hour Screen Exiting Sub-menus: If escape button (ESC, 4 on Figure 18) is pressed for more than 1 second, this information screen will be returned to previous screen.
OPERATING HRS
1. P ower : 0345 H r 2 . Tre nching : 01 9 0 H r 3. A ut o I dl e : 0 227 H r

ARS1330L
Figure 39
Electrical System
S0802220K Page 39
Information contents of operation hour Item Power Mode Trenching Mode Auto Idle Information Contents Operation hours used power mode are displayed. Operation hours used trenching mode are displayed. Operation hours used auto idle status are displayed. Detection Method Power mode switch (Instrument panel) "ON" status & Alternator signal (CN2-1) Trenching mode switch (Instrument panel) - "ON" status & Alternator signal (CN2-1) Auto idle switch (Instrument panel) - "ON" status & Alternator signal (CN2-1) Low speed: High speed s/v "OFF" status & travel pressure switch "Py" (control valve) - "ON" status High speed: High speed s/v & travel pressure switch "Py" (control valve) "ON" status
Travel Speed: - Low speed - High speed
Operation hours used low speed and high speed are displayed
Hydraulic Oil Temperature Distribution (C (F))
Temperature of hydraulic oil is classied 6 steps. And operation hours of each step are displayed Under 30C (87F) 31 ~ 50C (88 - 123F) 51 ~ 75C (124 - 168F) 76 ~ 85C (169 - 186F) 86 ~ 95C (187 - 203F) Over 96C (204F) Temperature of coolant is classied 6 steps. And operation hours of each step are displayed Under 40C (105F) 41 ~ 60C (106 - 141F) 61 ~ 85C (142 - 186F) 86 ~ 95C (187 - 204F) 96 ~ 105C (205 - 222F) Over 106C (223F)
The resistance delivered from temperature sensor of hydraulic oil is classied 6 steps. And operation hours of each step are displayed. (Alternator output)
Coolant Temperature Distribution (C (F))
The resistance delivered from coolant sensor is classied 6 steps. And operation hours of each step are displayed. (Alternator output)
S0802220K Page 40
Electrical System
Menu Selection of Operation Hour Information
1. Power : 0345 Hr 2. Trenching : 0190 Hr 3. Auto Idle : 0227 Hr
4. Tr av el Sp eed High : 0012 Hr L ow : 0059 Hr
6 . C ool a nt Te m p ( C ) 40 : 0030 Hr 41 ~ 6 0 : 0045 Hr

Figure 40 2. Operation hour reset A. Entering Sub-menus: When cursor is located in "Reset Hrs" of information screen of operation hour press enter button ( , 3 on Figure 18) and "Reset Hrs" screen will be displayed.
5. H y d. O il Te m p ( C ) 30 : 0030 Hr 31 ~ 50 : 0045 Hr
ARS1010L
OPERATING INFO
O perating Hrs R eset Hrs

ARS1001L
Figure 41 B. C. Reset screen of operation hour Exiting Sub-menus: If escape button (ESC, 4 on Figure 18) is pressed for more than 1 second, this information screen will be returned to previous screen.
RESET HRS
NOTE:
When "YES" ( , 3 on Figure 18) button is pressed, operation hours will reset. At this time, resetting signal will be displayed and the screen will move to previous menu after resetting. When "NO" (ESC, 4) button is pressed, the screen will recover to previous menu without resetting.
All Operating H ours will be D E L ETE .

Y ES :
Figure 42
N O : ES C
ARS1020L
NOTE:
Electrical System
S0802220K Page 41
ELECTRONIC HYDRAULIC CONTROL SYSTEM (E-EPOS)

CONTROL SYSTEM SCHEMATIC
7 3
(Wheel)
11
12
P
N
5 19 10
13
(Pump control signal) (Potentiometer signal)
(Drive signal)
(Engine speed sensor signal) (Throttle signal) (Engine throttle control signal)
(Switch signal)
15
(Throttle command) (Coolant water temp. signal)
17
Hi Lo
1
(Mode select signal) (Auto idle signal) (Machine information)
Sensors
18
30L
Figure 43
S0802220K Page 42
Electrical System
Description Instrument Panel Engine Control Motor Engine Main Hydraulic Pump Control Pump Control Valve Pressure Switch Pump Pressure Sensor Engine Speed Sensor Electro-magnetic Proportional Pressure Reducing Valve (E.P.P.R. Valve)
Reference Number 11 12 13 14 15 16 17 18 19
Description Solenoid Valve (Pressure Up) Solenoid Valve (Swing Priority) Solenoid Valve (High Speed) Travel Motor Engine Throttle Control Engine Control Dial e-EPOS Controller Auto Travel Select Switch Boost Switch (Right Work Lever)
Electrical System
S0802220K Page 43
POWER MODE CONTROL

6 3
(Wheel type)
P
4
N
9 10 1
(Potentiometer signal) (Drive signal) (Pump control signa g l)
(Engine speed sensor signal)
17
(Throttle Position signal)

(Engine throttle control signal)
15
Hi
(Throttle signal) (Power mode switch signal)
Low
16
20
ARS1040L
Figure 44 Reference Number 1 2 3 4 5 6 Description Instrument Panel (Power Mode Selection Switch) Engine Control Motor Engine Main Hydraulic Pump Control Pump Control Valve Reference Number 9 10 15 16 17 20 Description Engine Speed Sensor E.P.P.R. Valve Engine Throttle Controller Engine Control Dial e-EPOS Controller Work / Travel Selection Switch (Wheel Type)
The power mode switch permits the selection of the appropriate engine power depending on the working condition. One of the two, Power Mode or Standard Mode, setting can be selected. When the engine start switch is turned "ON," the last setting before "OFF" will be maintained. The desired mode can be selected by pressing the select button on the instrument panel. When the power mode is selected, the indicator lamp will turn "ON" to display the selected mode.
S0802220K Page 44
Electrical System
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 Output (%) OPERATION 1. Power Mode
Standard Mode Approximately 85%
Power Mode 100%
This mode should be selected for high speed work. In this mode the engine output is most efciently utilized due to the discharged oil volume being controlled based on the equivalent horsepower curve at various loaded pressures. The e-EPOS controller compares the target engine speed with the actual engine speed and controls the signal to the E.P.P.R. (Electric Proportional Pressure Reducing) valve which in turn varies the pump output quantity. If the load increases, the engine speed will fall below the rated speed. When this occurs, the controller senses this decrease and immediately reduces the pump discharge volume to maintain the engine speed at the rated level. Figure 45
ARO0260L
On the other hand, if the load is decreased the controller increases the discharge volume of the pump to maintain the engine speed at the rated level. By repeating these control operations, the engine speed is maintained at the rated speed so that maximum power can be generated. In Power Mode, the controller receives engine speed signals from the engine speed sensor and the throttle position sensor (sensor is built into engine control motor) and converts it to an operating signal current and is then transferred to the pumps E.P.P.R valve. At this time the E.P.P.R. valve converts the electric signal to the corresponding control pressure and sends it to the two pumps, adjusting the pump discharge volume to the desired level.
Electrical System
S0802220K Page 45
B Figure 46 Reference Number A B C Reference Number D
D
HDA6020L
Description Engine Horsepower (hp) Engine Speed (rpm) Pump Discharge Volume (lpm)
Description Pump Discharge Pressure (kg/cm2)
2.
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. The current to the E.P.P.R. valve is shut off and pump discharge volume is controlled by pump regulator.
D
ARS1050L
Figure 47
S0802220K Page 46
Electrical System
Reference Number A B C
Description Engine Horsepower (hp) Engine Speed (rpm) Pump Discharge Volume (lpm)
Reference Number D
Description Pump Discharge Pressure (kg/cm2)
Electrical System
S0802220K Page 47
POWER MODE CONTROL - CIRCUIT DIAGRAM
10 A
10A
3 5
9 10 19 20 CN4-16 CN4-17
20A
2 1
4
CN1-1 CN1-2 CN1-8 CN1-9
RxD RxD TxD TxD CN7
1 2 4 5 3
CN3-9 CN3-11 CN3-12 CN3-8
TxD TxD RxD RxD
RS-422
CN1-10 9 CN1-19 4 4 15 16 S-MODE A/I MODE CN1-5 CN1-7 CN4-10 CN4-11 (+) (-) CN2 CN4-12 CN4-13 CN4 CN1 CN2 CN3 1 2 3 12 1 2 3 CW LOW HIGH
10
M 5 3 2 1 5 8 7 6
7
(+ ( )
TERMINAL NO
8 7 6 5 4 2 1 5 4 3 10 9 18 17 14 13 10 9 12 11 10 9 8 6 8 7 6 5 4 3 2 1
(CN4)
(CN3) (CN7)
10
16 15
11 10
21
19 18 1 7
16
15 14
11
(CN2)
(CN1)
ARS1060L
Figure 48
S0802220K Page 48
Electrical System
Reference Number 1 2 3 4 5
Description Battery Battery Relay Fuse e-EPOS Controller Instrument Panel
Reference Number 6 7 8 9
Description Engine Speed Sensor Engine Throttle Controller Engine Control Motor Engine Control Dial
Electrical System
S0802220K Page 49
TRENCHING MODE CONTROL
Main Relief v/v
6 12
3
(Wheel)
(Potentiometer signal)
(Drive signal)
17
(Engine throttle control signal)
Hi
15
(Throttle signal)
Lo
16
ARS1070L
(Trenching mode switch signal)
Figure 49 Reference Number 1 2 3 4 5 Description Instrument Panel (Trenching Mode Select Switch) Engine Control Motor Engine Main Hydraulic Pump Control Pump Reference Number 6 12 15 16 17 Description Control Valve Solenoid Valve Engine Throttle Control Engine Control Dial e-EPOS Controller
Depending on the working condition, one of two work modes, "DIGGING" or "TRENCHING" can be selected from the instrument panel. When the engine start switch is turned "ON," the last setting before "OFF" will be maintained. Depending on the trenching mode selected, the control valve solenoid adjusts the assignment of hydraulic oil ow to each device on the equipment.
S0802220K Page 50
Electrical System
OPERATION 1. 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. 2. Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles. The voltage is assigned to the swing priority control valve activating the swing control valve restricting the ow of oil to the boom and the arm.
ARO0270L
Figure 50
Electrical System
S0802220K Page 51
TRENCHING MODE CONTROL - CIRCUIT DIAGRAM
10A
3 5
9 10
20A
2 1
4
19 20 CN1-1 CN1-2 CN1-8 CN1-9
RxD TxD CN7
1 2 5 3
CN3-9 CN3-10 CN3-11 CN3-12 CN3-8
TxD TxD RxD RxD
CN1-14 RS-422
CN4 CN1 CN2 CN3
TERMINAL NO
6 5 3 2 1 5 4 2 1 10 9 18 17 16 15 14 12 11 10 12 11 10 7 6 8 7 6 5 4 3 2 1
14 13
(CN4)
(CN3) (CN7)
10
17 16
14
13
12
11
21
18 17
16
15
13
12
11
(CN2)
(CN1)
ARS1080L
Figure 51 Reference Number 1 2 3 Description Battery Battery Relay Fuse Reference Number 4 5 6 Description e-EPOS Controller Instrument Panel Solenoid Valve (Swing Priority)
S0802220K Page 52
Electrical System
ENGINE CONTROL SYSTEM

(Feedback Signal)
15 16
(Command Signal)
3
(Drive Signal)
10A
BATT. RELAY
9 5 M 5 RETRACT 3 1 5 8 (+) 5V 6 (-) 1 5V (+) 2 3 (-) 12 1 3 CW LOW 4 17 OVER HEAT 10 AUTO IDLE COMMAND
e-EPOS CONTROLLER
BATTERY
16
ARS1090L
2
Figure 52 Reference Number 2 3
15
Description Engine Control Motor Engine
Reference Number 15 16
Description Engine Throttle Controller 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. The engine throttle controller then compares the input voltage from the engine speed dial with the feedback signal from the throttle position sensor built into the engine control motor and drives the motor to the position set by the control dial. When the command signal and the potentiometer feed back signals are the same the engine controller shuts off the current to the control motor. The engine control motor cable is a solid type and is connected to the engine fuel injection control lever. The engine speed is controlled by the movement of the fuel injection lever which is directly linked with the rotation of the control motor.
Electrical System
S0802220K Page 53
ENGINE CONTROL MOTOR
CIRCUIT DIAGRAM
(GREEN)
P4
P1(Gr)
P2(P)
P3(L)
M (YELLOW) (RETRACT) ACCEL (GRAY) (PINK) (BLUE) DECEL (EXTEND)
P5
P1 P2 P3
P4(G)
P5(Y)
+ -
Vs
(5.0V)
Vp
ARS1100L
Figure 53 Reference Number 1 2 3 Description 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. If an abnormal load (worn or kinked control cable) is sensed in the control motor, the engine controller cuts off the electric current owing to the engine control motor to protect the system. In such a case, the engine control motor will not operate even though the engine control dial is moved. The starter switch should be turned off and the cause of abnormal load should be repaired and the starter switch can be turned on again. The engine control dial can once again be used to control the engine speed.
IMPORTANT
When the engine control motor has been replaced or repaired refer to Adjusting the Engine Control Device for correct adjustment of the engine control system. The engine will not perform to its maximum efciency if it is not adjusted properly.
S0802220K Page 54
Electrical System
ENGINE CONTROL DIAL
1st STEP
7th STEP
13th STEP
CCW MECHANICAL STOP
( 10 )
( 10 )
CW MECHANICAL STOP
(V) 5 4.0V 4 3 2 2.5V
1.0V 1 0 CCW STOP 1ST 2nd 7th 12th 13th CW STOP SETUP
2 3
VIEW ( POTENTIOMETER BOTTOM)

1 2 3
HDA6033L
Figure 54
Reference Number 1 2
Description Knob Potentiometer (Variable Resistor)
Electrical System
S0802220K Page 55
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.
S0802220K Page 56
Electrical System
ENGINE CONTROL CIRCUIT DIAGRAM
ARS1110L
Figure 55 Reference Number 1 2 3 4 5 6 Description Battery Battery Relay Fuse e-EPOS Controller Instrument Panel Engine Speed Sensor Reference Number 7 8 9 10 11 Description Engine Throttle Controller Engine Control Motor Engine Control Dial Pressure Switch (Py Port) Pressure Switch (Px Port)
Electrical System
S0802220K Page 57
AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL)

(Feedback Signal)
16
15
M
2
(Drive Signal)
(Command Signal)
7 17 7
Auto deceleration Switch Signal
ARS1120L
Figure 56 Reference Number 1 2 3 7 Description Instrument Panel Engine Control Motor Engine Pressure Switch Reference Number 15 16 17 Description Engine Throttle Controller Engine Control Dial e-EPOS Controller
If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed is automatically lowered. Once the controls are operated and work is being started the machine will be restored to the previous settings. As a result, noise and fuel consumption will be reduced. This function can be selected or cancelled through the Auto Idle Select Switch on the instrument panel. The initial setting at start-up is with this switch in the select position. Approximately 4 seconds after this function is selected, if all work levers are in the neutral position, the e-EPOS controller sends an automatic reduction signal to the throttle controller. When the engine throttle controller receives this signal, it is compared with the signal set by the engine control dial. The lower of the two signals is selected and the engine control motor is adjusted to this engine speed. The neutral status of the machine is detected by the two pressure switches in the control valve. When the work levers are in the neutral position, the switch is in the off position.
S0802220K Page 58
Electrical System
ENGINE OVERHEAT PROTECTION SYSTEM
3 5 1 21
(Pump control signal)
10
(Potentiometer signal)
(Drive signal)
15
17
Engine overheat signal Engine overheat signal
ARS1130L
Figure 57 Reference Number 1 2 3 4 5 Reference Number 10 15 17 21
Description Instrument Panel Engine Control Motor Engine Main Pump Control Pump
Description E.P.P.R. Valve Engine Throttle Controller e-EPOS Controller Warning Buzzer
When the engine coolant temperature increases to over 107C (225F), the sensor mounted in the coolant line will send a signal to the instrument panel. A overheat signal is also sent to the e-EPOS controller and the overheat warning buzzer will sound. The e-EPOS controller will send a signal to the engine throttle controller and the engine speed is adjusted to standard mode. The engine throttle controller will signal the engine control motor to decrease the engine speed. When the coolant is overheated, the warning buzzer will sound, standard mode is selected and low engine speed will be selected. When the coolant temperature falls below 95C (203F), normal operation will resume.
Electrical System
S0802220K Page 59
POWER BOOST MODE

OPERATION
Main Relief v/v
4 19 17
(Button Signal)
ARS1140L
Figure 58 Reference Number 3 4 5 6 Description Engine Main Pump Control Pump Control Valve Reference Number 11 17 19 Description Solenoid Valve e-EPOS Controller Power Boost Switch (Top of Right Work Lever)
The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation ability. When the switch button on top of the right work lever is pressed during work, the e-EPOS controller will activate the power boost solenoid valve and increase the relief valve pressure from 330 - 350 kg/cm2 (4,700 - 5,000 psi). The excavation ability is increased by approximately 6%. NOTE:
Do not use this switch for more than 10 seconds.
S0802220K Page 60
Electrical System
POWER BOOST CONTROL - CIRCUIT DIAGRAM
10A
3 5
20A
9 10
1
19 20
4
CN1-1 CN1-2 CN1-8 CN1-9
6
RxD 1 2 RxD 4 TxD 5 TxD 3 CN7 CN3-9 CN3-10 CN3-11 CN3-12 CN3-8 TxD TxD RxD RxD CN1-13 RS-422
7
CN2-3 CN4 CN1
TERMINAL NO
8 1 3 10 9 18 17 14 13 11 9 11 10 9 8 7 6 20 8 7 6 5 1 11
17 16
(CN4)
(CN3) (CN7)
10
16 15
12
10
21 20
17
14 13
12
11
(CN2)
(CN1)
ARS1150L
Figure 59 Reference Number 1 2 3 4 Reference Number 5 6 7
Description Battery Battery Relay Fuse e-EPOS Controller
Description Instrument Panel Solenoid Valve (Pressure Up) Power Boost Switch (Top of Right Work Lever)
Electrical System
S0802220K Page 61
AUTOMATIC TRAVEL SPEED CONTROL

6 3 6
8 14 13 5
17 16
Hi Low
ARS1160L
Figure 60 Reference Number 3 4 6 7 8 Description Engine Main Pump Control Valve Pressure Switch (Py) Pump Pressure Sensor Reference Number 13 14 16 17 20 Description Solenoid Valve (High speed) Travel Motor Engine Control Dial e-EPOS Controller Selection Switch For Automatic Travel
If the automatic travel speed control switch is set to the "OFF" position, the travel motor will run in the Ispeed (low speed) range. If the selection switch is set to the "I" position, the travel motor will run in the IIspeed (high speed) range. If the selection switch is set to the "II" position, the e-EPOS controller will monitor the main pump discharge pressure and automatically select the "ON" - "OFF" status of the II speed travel solenoid valve based on the travel load. The travel speed is changed between the I-speed and the II-speed mode. The travel load is monitored by the two pressure sensors in the discharge lines of the front (upper) and rear (lower) pumps. When the travel load is high (pressure over 300 kg/cm2 (4,300 psi) the solenoid valve is turned "OFF" and I-speed (low) is selected. In the case when the travel load is low (pressure under 160 kg/ cm2 (2,280 psi), the solenoid valve will be turned "ON" and the II-speed will be selected. But, if the engine speed control switch dial is set below approximately 1400 rpm, the travel speed will be set to I-speed mode.
S0802220K Page 62
Electrical System
AUTOMATIC TRAVEL SPEED CONTROL - CIRCUIT DIAGRAM
10A
10A
20A
2 1
5 6 7
9 4
SIG CN4-1 + SIG CN4-2 CN4-3 CN4-4
4
CN1-1 CN1-2 CN1-8 CN1-9
6
10 15 16 17 14 CN4-10 CN4-11 1 2 12 1 2 3 CN1-12
5 8 7 6
(+) (-) CN2
(+) (-)
LOW
HIGH
9
CN2-5 CN2-6 (MANUAL) (AUTO) 6 3 10
0 I
8
2 9
II
CN4 CN1 CN2 CN3
TERMINAL NO
8 7 6 5 4 2 1 5 4 3 2 1
18 17 16
14 13
10
12
11
10
(CN4)
(CN3)
10
16 15
11 10
21
18 17
15 14 13
12
11
(CN2)
(CN1)
ARS1170L
Figure 61 Reference Number 1 2 3 4 5 Reference Number 6 7 8 9 10
Description Battery Battery Relay Fuse e-EPOS Controller Pressure Sensor (Front Pump)
Description Pressure Sensor (Rear Pump) Engine Throttle Controller Automatic Travel Select Switch Engine Control Dial Solenoid Valve (High Speed)
Electrical System
S0802220K Page 63
ENGINE CONTROL DEVICE - ADJUSTMENT

Engine speed adjustment should be made by following the procedures listed below. (Under no load conditions) 1. Adjusting The High Idle Speed 1. Turn the starter switch to the "ON" position. Select Power Mode from the instrument panel. Turn the Engine Speed Control dial to the "MAX" position to reduce the (3) motor cable to the shortest length. Adjust the (3) motor cable linked with the (2) bracket so that the engine governor lever touches the maximum position of the stopper.
2. 2.
Adjusting The Low Idle Speed 1. Turn the engine speed control dial to the "MIN" position so that the (3) motor cable is extended to the maximum length. (The maximum stroke range for the lever and cable is 37.0 mm (1.46 in).) Check that the engine governor is at the minimum stopper position and the cable slack is acceptable. A. If the lever is not in the minimum position and touching the stopper, move the (3) cable to one hole lower on the lever. If the cable slack is excessive, move the (3) cable to one hole above the original hole on the lever. Repeat above steps 1 and 2. B. Shorten the (3) motor cable 1 - 1.25 mm (0.0394 - 0.0591 in) by turning the cable adjustment nut for motor cable (3), 2/3 - 1 turn in the high idle position.
2. 3.
3.
Adjusting The Automatic Deceleration System and Power Mode (First perform Adjustments 1 and 2 before performing this adjustment.) 1. Set the following switches to the "ON" position as shown in the following table. Adjust the engine speed by slowly turning the variable resister screw. (VR1) Variable Resistor VR1 Dial Position and Mode Setting Engine Speed Setting S300LC-V - 1400 50 rpm S300LL - 1400 50 rpm S340LC-V - 1200 50 rpm
ENGINE SPEED
ARS1180L
Mode Automatic Deceleration (Auto Idle)
S420LC-V - 1200 50 rpm S470LC-V - 1200 50 rpm
S0802220K Page 64
Electrical System
ARS1440L
Figure 63 Reference Number 1 2
Description VR1 (Automatic Deceleration Adjusting Variable Resister) Name Plate
Electrical System
S0802220K Page 65
Figure 64 Reference Number 1 2 Reference Number 3 4
Description Engine - Fuel Control Lever Area Control Motor Cable Bracket
Description Engine Speed Control Cable To Engine Control Motor
S0802220K Page 66
Electrical System
SELF-DIAGNOSTIC FUNCTION
E-EPOS CONTROLLER The system operation status and malfunction codes can be checked through the display on top of the eEPOS controller box in the drawer under the operators seat.
2 5 6
4
Figure 65 Reference Number 1 2 3 Description Upper Digit Lower Digit Engine Speed Monitor LED (Flash Interval Increases With Engine Speed.)
3
ARS1190L
Reference Number 4 5 6
Description Power Monitor (Stays On While Power Is In Normal Range,) Communication Monitor LED (Flash when normal condition)
1.
Power Monitor This LED is turned off when the input voltage to the e-EPOS controller is below 18.5 1 V or above 32.5 1 V. Stays on while in normal range.
2.
Engine Speed Monitor This LED light ashes according to the engine speed. The ashing interval is proportional to the engine speed.
3.
Communication Monitor These LED lamps ash when normal state of communication between main controller and instrument panel.
Electrical System
S0802220K Page 67
4.
Normal Operation Display Readout Mode Selection Display Readout Upper Digit Lower Digit Operation Status
Power Mode
HAOH340L
Normal Operation Power Mode
Power Mode Standard Mode

HAOH350L
Normal Operation Standard Mode
Digging
HAOH370L
Normal Operation Digging Mode
Work Mode Trenching

HAOH380L
Normal Operation Trenching Mode
5.
Malfunction Display and Reset Procedure The malfunction codes displayed on the top of the e-EPOS controller and reset procedure are the same with failure information codes a part of failure information. Refer to the failure information part of letter information display for details.
S0802220K Page 68
Electrical System
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." Throttle Controller Input Signal Dial Voltage < Motor Potentiometer Voltage Dial Voltage > Motor Potentiometer Voltage Dial Voltage = Motor Potentiometer Voltage LED Status Status While Control Motor Is Operating (Increasing rpm) While Control Motor Is Operating (Decreasing rpm) Control Motor Stopped Motor Overload (Cut Off Motor Current) Abnormal Controller Power Voltage (Low Or No Input) Brightly Lit NOTE: O ON Red X O X X Green X O X X X OFF Yellow O O O O X Voltage At Control Motor Terminal Approximately +24 V Approximately 24 V 0V 0V 0V
1. 2. 3.
Control Motor Voltage is Measured at throttle controller 4 (+) and 5 (-) terminals. Yellow LED indicates power status (ON, OFF). To protect the control motor from overloads, the control motor automatically cuts off supply voltage to the motor when there is a heavy load on the motor and the possibility of motor damage or burn out exists. After the malfunction is corrected, turn the starter switch from "OFF" to the "ON" position and normal operation will resume.
4.
Electrical System
S0802220K Page 69
WIPER SYSTEM
WIPER CIRCUIT
3
10A 10A
7
B S + 4 5 E M
4
1 2 3 6 6 3 10 0 I II 9 2
2 1
5
0 5 10 I 9 1 +
P -
ARS1200L
Figure 66 Reference Number 1 2 3 4 Description Battery Battery Relay Fuse Wiper Switch Reference Number 5 6 7 8 Description Washer Switch Wiper Timer Wiper Motor Window Washer
WIPER OPERATION Intermittent Operation (I - position) When the wiper switch (4) is turned "I" position, the current ows from the fuse (3) "B" terminal of wiper motor (7) "L" terminal of wiper motor (7) "5" terminal of wiper timer (6) "6" terminal of wiper timer (6) ground and the wiper motor operates intermittently by the timer built in wiper timer. (On: approximately 1 second, Off: approximately 5 seconds) Continuous Operation (II - Position) When the wiper switch (4) is turned "I" position, the current ows from the fuse (3) "B" terminal of wiper motor (7) "L" terminal of wiper motor (7) No. 5 terminal of wiper timer (6) No. 6 terminal of wiper timer (6) ground and the contact points No. 5 and No. 6 of wiper timer (6) are connected continuously, the wiper motor operates continuously.
S0802220K Page 70
Electrical System
When the wiper switch (4) is turned "OFF," the current ows 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) "S" terminal of wiper motor (7) "B" terminal of wiper motor (7) and the wiper motor is stopped at the auto stop position. WINDOW WASHER OPERATION When the window washer switch is turned "ON," the current ows from the fuse (3) No. 1 terminal of washer switch (5) No. 5 terminal of washer switch (5) "+" terminal of window washer (8) ground and windshield washer uid is sprayed.
Electrical System
S0802220K Page 71
LIGHTING SYSTEM
LIGHTING SYSTEM CIRCUIT DIAGRAM
(FR) 87a 30
(RR)
(FML)
87 85 86
18
(RL)
19 *
(FMR)
(FL)
10 *
87a 30 87 0 85 86 6 3 10 II 9 30A
* 17
(FR)
6 *
2
(FL)
9 * * 16
(RH)
20A (LH) 87a 30 87 (RH) 85 86
* 13
5*
7 1 10 0 I 9 5 10A
15
(LH) 87a 87 (RH) 6 85 86 3 10
7
30 0 I II
4
2 9 10A
14
(LH)
12
CN2-7 CN3-9 CN3-10 CN3-11 CN3-12 CN3-8 CN7-1
11
CN7-9 10A L5
ARS1210L
Figure 67
S0802220K Page 72
Electrical System
Reference Number 1 2 3 4 *5 6 7 8 *9
Description Battery Battery Relay Fuse Box Light Switch Warning Light Switch Cabin Light Switch Headlight Relay (Work Light Indicate Light) Work Light Relay Front Cabin Light Relay
Reference Number *10 11 12 *13 14 15 *16 *17 *18 *19
Description Rear Cabin Light Relay Instrument Panel e-EPOS Controller Rotating Warning Light Headlight (2 ea.) Work Light (2 ea.) Additional Work Light (2 ea.) Front Cabin Light (2 ea.) Front Cabin Light (4 ea.) Rear Cabin Light (2 ea.)
NOTE:
The "*" mark (5, 9, 10, 13, 16, 17, 18, 19) are optional parts.
KIND OF LIGHT The lighting system is consists of headlights, work lights, cabin lights (optional), rotating warning light (optional), relays and switches. OPERATION
Switch
Position 1
Connected Terminal of switch 2-6 Terminal 2-6 Terminal
Activated Relay Headlight Relay Work Relay Front Relay Front Relay Rear Relay Cabin Cabin Cabin Light Light Light
Lit Light Illumination Light of Switch Illumination Light of Switch Headlight (2 Ea.) Work Light (2 Ea.), Additional Work Light (2 Ea.) Indicator Light of Work Light (L5) Front Cabin Light (2 Ea.) or Front Cabin Light (4 Ea.) Front Cabin Light (2 Ea.) or Front Cabin Light (4 Ea.) Rear Cabin Light (2 Ea.) Rotating Warning Light
Light Switch
2-3 Terminal
1 Cabin Light Switch
2-6 Terminal 2-6 Terminal
2 2-3 Terminal
Warning Light Switch
5-1 Terminal
Electrical System
S0802220K Page 73
OVERLOAD WARNING DEVICE

OVERLOAD WARNING DEVICE CIRCUIT DIAGRAM
3 2 4 1
ARS1260L
Figure 68 Reference Number 1 2 3 Description Battery Battery Relay Fuse Box Reference Number 4 5 6 Description e-EPOS Controller OWD Select Switch Pressure Sensor
S0802220K Page 74
Electrical System
S0892160K
1ELECTRICAL SCHEMATIC (S300LC-V)

CAUTION!
ELECTRICAL SCHEMATIC (S300LC-V)

MODEL Solar 300LC-V 1001 and Up SERIAL NUMBER RANGE
Copyright 2001 Daewoo December 2001 Electrical Schematic (S300LC-V) S0892160k Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3 Solar 300LC-V................................................................................................ 4
S0892160k Page 2
Electrical Schematic (S300LC-V)
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
S0892160k Page 3
SOLAR 300LC-V
Figure 2
S0892160k Page 4
SOLAR 300LC-V
ARS1270L
S0892160k Page 5
S0892160k Page 6
1ATTACHMENTS
S0902000
1BOOM AND ARM
CAUTION!
BOOM AND ARM

MODEL Solar 290LC-V Solar 300LC-V
S0902000
SERIAL NUMBER RANGE 0001 and Up 1001 and Up
Copyright 1998 Daewoo September 1998 Boom and Arm S0902000 Page 1
TABLE OF CONTENTS
Front Attachment Pin Specications .............................................................. 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 Page 2
Boom and Arm
FRONT ATTACHMENT PIN SPECIFICATIONS

The table below has a complete listing of dimensional specications for all mounting pins used on the front attachment. NOTE:
Some mounting pins must be drilled and tapped for lubrication ttings and piping, or may have other required specications. Consult Daewoo After Sales Service for information on wear tolerances and replacement limits for mounting pins.
Mounting Pin A B C D E F G H I J K Diameter, mm (Inches) 105 mm (4.134") 90 mm (3.543") 90 mm (3.543") 100 mm (3.937") 90 mm (3.543") 90 mm (3.543") 80 mm (3.150") 90 mm (3.543") 90 mm (3.543") 90 mm (3.543") 90 mm (3.543") Length, mm (Inches) 1001 mm (39.409") 890 mm (35.039") 266 mm (10.472") 636 mm (25.039") 266 mm (10.472") 244 mm (9.606") 512 mm (20.157") 512 mm (20.157") 593 mm (23.346") 593 mm (23.346") 244 mm (9.606")
J I
F
HAOF300L
Figure 1
Boom and Arm
S0902000 Page 3
FRONT ATTACHMENT - REMOVAL AND INSTALLATION IMPORTANT

Always break down the front attachment by removing outermost sections rst - the bucket before the arm, the arm before the boom. Reinstallation of the attachment should begin with the boom and end with the bucket. Refer to the appropriate Bucket section for its removal and installation procedure before going onto the initial step of the front attachment removal or installation procedure. ARM REMOVAL PROCEDURE
WARNING!
This procedure is only intended for routine removal or replacement of the attachment, while working under normal, safe operating conditions. In the event of a major structural collapse of some part of the attachment, an accident or complete loss of attachment hydraulic function, DO 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. Keep clear of hydraulic lines that may have uid escaping at high pressure it can cause severe or even fatal injuries. Complete the bucket end removal procedure by pulling out the two bucket linkage pins and the bucket cylinder mounting pin, on the arm. Use an assist crane or hoist to lift the cylinder and relieve weight on mounting pins. Park the excavator away from obstructions and all trafc on clear, at, 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. Place the blocking directly in front of the excavator and make sure that it will not be unbalanced with an initial weight load that is all to one end, under the arm point. Shut off the engine and release hydraulic system pressure - move any of the control levers with the engine off to release pressure built up in the accumulator. Manually vent residual hydraulic pressure in the tank by moving the lever near the cap, on top of the reservoir.
WARNING!
Secure the swing lock and tag and lock out controls in the operators cab to keep anyone from moving or inadvertently starting the engine. Restrict access to the work site while sections of the attachment are in the air, or while they are being supported by the assist crane. The safe lifting capacity of the assist crane or hoist that is used must exceed the weight of the heaviest section of the attachment, the boom (approximately 2,000 kg [4,400 lb], not including the weight of accessories or xtures).
S0902000 Page 4
Boom and Arm
Return to Master Table of Contents Before beginning the disassembly of attachment mounting pins, disconnect the arm cylinder hydraulic hose couplings and put a clean plug in the end of each one. Use any and all reasonable precautions necessary to avoid introducing dirt or other contaminants into the hydraulic system. Wipe down coupling points before disconnecting hydraulic lines and use evaporative-type solvent spray cleaner. Tag and mark hoses for reassembly, if necessary. Place a sling under the arm cylinder (the cylinder used to extend and retract the attachment arm, pinned to the top of the boom). Lift the sling so that the weight load on the rod end of the arm cylinder (pinned to the ears on the inner end of the arm) is released. Prepare blocking under the arm that will securely support the weight of the arm and arm cylinder.
CAUTION!
To make sure that the polished surfaces of cylinder rod ends will not suffer accidental damage during disassembly or removal procedures, wrap exposed rod surfaces (especially those of boom cylinders) with a protective covering material. Immediately following disassembly and removal, cylinder rods should always be fully retracted. This eases handling problems and also avoids possible damage. Remove retainers on the end of the mounting pin for the arm cylinder rod end. Use the assist crane to relieve the weight load and withdraw the pin. Lower the arm down to the blocking support for any continued disassembly procedures.
Boom and Arm
S0902000 Page 5
Return to Master Table of Contents BOOM REMOVAL PROCEDURE NOTE:
Boom removal may be simplied if the shell of the operators cab is taken off the turntable deck rst. Refer to the Operators 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. Attach the assist crane sling to the body of either boom cylinder, break the mounting pin connection to the boom by tapping through the pin from the same side of the boom and repeat for the opposite cylinder. Release hydraulic pressure and disconnect line couplings as previously outlined in the Arm Removal Procedure, observing the same precautions. Disconnect wiring for work light assemblies and any other accessory lines or connections. Locate the sling of the assist crane near the center of gravity, optimum lift point for the boom, and use the crane to take pressure off the boom foot pin. Drive out the pin after disassembling retainers and carefully lift away the boom.
WARNING!
Traveling the excavator, swinging the turntable or movement over bumps or sloping, uneven surfaces could all produce loss of control and possible accidents or injuries, if the turntable deck has been unbalanced by removal of weight from one end only. To maintain stability, the counterweight should be removed whenever the front attachment is taken off the machine.
S0902000 Page 6
Boom and Arm
INSTALLATION
ARM INSTALLATION PROCEDURE Re-attach the base of the arm cylinder to the mounting point on top of the boom.
WARNING!
Before assembling the front attachment, make sure that the individual boom, arm and bucket sections are all compatible and can be used safely for work intended. 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. Begin with the arm securely supported on blocking in front of the excavator. Pre-grease the mounting pin for the rod end of the arm cylinder and push it through the ears on the end of the arm. Attach a sling around that mounting pin and lift the arm with an assist crane until it is in position for the boom-arm pin connection to be made. Relieve hydraulic pressure from all points of the system before any hydraulic lines are opened, then carefully assemble hydraulic connections to the arm cylinder. Remove the sling from around the rod end arm cylinder pin, withdraw the pin and lift the body of the arm cylinder to re-pin the mounting connection. BOOM INSTALLATION PROCEDURE Before reassembling the attachment, make sure to inspect all bushings and pivot points of each section. To avoid damaging the seats, bushings should never be hammered or chiseled out of their seats. Installation is otherwise a reversal of the removal procedures.
Boom and Arm
S0902000 Page 7
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 Page 8
Boom and Arm
S0904005K
1BUCKET
CAUTION!
BUCKET
Copyright 2001 Daewoo November 2001 Bucket Page 1
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............................................................................... 9 Reversing the Bucket ............................................................................ 10
Bucket Page 2
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: Lock pins protrude unevenly on one side. Lock pins have been worn down so far that they no longer make full contact through the length of the pin hole. Lock washers or pins show obvious damage or weakness. Wear points on the working surfaces of tooth points - pits, cracks, chips or craters - are larger than 8 mm to 10 mm (1/3" to 1/2") across.
HAOC680L
Figure 1 1. On a routine basis, inspect the bucket teeth to make sure that tooth wear or breakage has not developed. Do not allow the replaceable bucket teeth to wear down to the point that the bucket adapter is exposed. See Figure 4. To replace a tooth (1, Figure 2), use a hammer and punch to drive the locking pin (2) and lock washer (3) out of the tooth adapter (4). Once the worn tooth has been removed, use a putty knife to scrape the adapter as clean as possible. Slide the new tooth into position and insert the lock washer. Insert the locking pin into the tooth and with a hammer, drive the pin in until the lock washer seats in the locking groove.
2.
3.
Figure 2
4. 5.
Bucket Page 3
TYPE 2
WARNING!
Due to the possibility of ying 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 rmly on the ground. Place wooden blocks under front of bucket. Shut the engine off and lock out the hydraulic controls before working on the bucket. Inspect locking pin assembly and replace it if the following conditions exist; 1. 2. 3. The locking pin is too short when both surfaces are aligned. The rubber has been torn and bosses of the steel balls are liable to slip off. Pressing steel ball causes the boss to go inside.
1/3T T
HAOE380L
Figure 3
HAOC680L
Figure 4
Bucket Page 4
1.
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. Once the worn tooth has been removed, use a putty knife to scrape adapter as clean as possible. Slide new tooth into position and insert locking pin assembly. Figure 5
1 2
2.
3.
HAOE370L
4.
Bucket Page 5
BUCKET O-RING REPLACEMENT WARNING!

Due to possibility of ying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins. 1. Inspect the bucket O-rings on a routine basis. If worn or damaged, replacement is necessary.
ARO1350L
Figure 6 2. Roll the old O-ring (1, Figure 7) onto the boss (2) around the bucket pin (3). Remove the bucket pin and move the arm or bucket link (4) out of the way.
ARO1390L
Figure 7 3. Remove the old O-ring and temporarily install the new O-ring (1, Figure 8) onto the bucket boss (2). Make sure that the O-ring groove on both the bucket link (4) and boss have been cleaned. Realign the arm or link with the bucket pin hole and insert the bucket pin (3, Figure 7).
4.
ARO1391L
Figure 8
Bucket Page 6
5.
Roll the new O-ring (1, Figure 9) into the O-ring groove.
ARO1392L
Figure 9
Bucket Page 7
BUCKET SHIMMING PROCEDURES

NEW BUCKET INSTALLATION 1. 2. 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.
WARNING!
To check end play (side-to-side) clearance at bucket attachment point, the bucket must be free to move but at all other times lower it to the ground or use support blocks to immobilize this assembly. Shut off engine and tag and lock out controls to prevent movement during this procedure. Shimming Procedures for Installed Bucket 1. With bucket attached, curl bucket and arm outward and lower boom so that bucket teeth are pointing away from excavator, just a few inches off ground. This position provides easy accessibility for dimensional measurements. Force bucket to one side and check for end play (side-to-side) clearance under O-rings at attachment point. Total clearance should be 1 mm (0.04 in.) between side face of boss and inside edge of ear bushing (Y, Figure 10). Too tight a t (less than 1 mm (0.04 in.)) can cause excessive wear while too much clearance may produce excessive noise and potentially hazardous slack control. Recheck end play by forcing bucket towards opposite side and repeating clearance measurements. If an adjustment is required, remove two jam nuts (1, Figure 10) and bolt (2) from pin (3). Add or remove shims (4) as required. Use equal amount of shims on each side. Install bolt (2) and two jam nuts (1). Jam nuts must clear boss by 1 - 2 mm (0.04 - 0.08 in.) at point (X).
2.
"Y"
"X"
3.
3 4 2
4.
ARO1710L
Figure 10
Bucket Page 8
BUCKET ATTACHMENT, REMOVAL AND REVERSAL

DETACHING THE BUCKET Park the excavator away from obstructions on clear, at, level ground. Lower the bucket carefully to preassembled blocking on the ground. Brace the bucket so that there is no load weight on the pin connecting the bucket and arm. Disassemble the fasteners on the end of the bucket pin and pull out the pin. If the pin sticks and resists normal withdrawal, there may be a load on it. Raise and lower the arm slightly until an unstressed pin position is located.
CAUTION!
Use care pulling out the pin to avoid damaging the dust seals on either end of the arm. When the pin has been withdrawn, move the operating joystick slightly to take weight off the remaining link pin. Disassemble the link pin end retainers and pull out the pin. Lift the arm away from the bucket so that the bucket can be carried away or another end attachment can be put on the excavator. ATTACHING THE BUCKET Carefully inspect all parts before reassembling the bucket linkage. Look for cracks or any other evidence of physical damage and replace any seal or O-ring that is not in like-new condition. Pre-lube linkage pins before reassembly. Use an old cylinder rod, a long breaker bar or a similar, relatively thin diameter support bar for making the rst (temporary) pin connection, between the bucket and arm. If the support bar is straight, the arm can be raised and the bucket will hang level, allowing direct insertion of the bucket ear-attachment linkage pin.
Figure 11
Bucket Page 9
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 ngers into pin holes. The attachment or bucket could shift position and cause a severe injury. Match holes by visually lining them up. Use the sharptipped, soft point of a pencil or a similar tool to check for high spots or irregularities. REVERSING THE BUCKET Follow instructions for "Detaching the Bucket" and remove both the bucket and link pins. Rotate the bucket 180 to change bucket conguration. This procedure is greatly simplied if some type of rotating or swiveling support can be used, on the ground underneath the bucket. Follow instructions for "Bucket Attachment" to replace pins.
WARNING!
Bucket curl and dump levers must be used in opposite directions, after the bucket has been reversed.
Figure 12
Bucket Page 10

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What safety precautions should be followed when operating an excavator?

What safety precautions should be followed when operating an excavator?

What parts need to be inspected before reattaching a bucket?

What parts need to be inspected before reattaching a bucket?

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1TRACK EXCAVATOR SAFETY

TRACK EXCAVATOR SAFETYS0102000

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Track Excavator Safety

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TO THE OPERATOR OF A DAEWOO EXCAVATOR DANGER!

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SAFETY ALERT SYMBOL

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GENERAL SAFETY ESSENTIALS

LOCATION OF SAFETY LABELS

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SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING IN DIGGING MODE DANGER!

Track Excavator Safety

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WORK SITE PRECAUTIONS

Track Excavator Safety

Track Excavator Safety

Track Excavator Safety

Track Excavator Safety

Asbestos dust can be HAZARDOUS to your health if it is inhaled.

Track Excavator Safety

Track Excavator Safety

Track Excavator Safety

Track Excavator Safety

Track Excavator Safety

Track Excavator Safety

Track Excavator Safety

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Track Excavator Safety

OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES THE SKIN

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Track Excavator Safety

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SHIPPING AND TRANSPORTATION

LIFTING WITH SLING WARNING!

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Track Excavator Safety

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1SPECIFICATIONS FOR SOLAR 300LC-V

SPECIFICATIONS FOR SOLAR 300LC-V

Specifications for Solar 300LC-V

Specifications for Solar 300LC-V

Specifications for Solar 300LC-V

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Specifications for Solar 300LC-V

Specifications for Solar 300LC-V

Specifications for Solar 300LC-V

WORKING RANGE WARNING!

Specifications for Solar 300LC-V