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DAEWOO DOOSAN 55 W V PLUS EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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DAEWOO DOOSAN 55 W V PLUS EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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Description
DAEWOO DOOSAN 55 W V PLUS EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
DESCRIPTION:
DAEWOO DOOSAN 55 W V PLUS EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item
TO THE OPERATOR OF A DAEWOO EXCAVATOR
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. “General Safety Essentials” on page 5
2. “Location of Safety Labels” on page 5
3. “Summary of Safety Precautions for Lifting” on page 5
4. “Work-site Precautions” on page 6
5. “Operation” on page 9
6. “Equipment” on page 14
7. “Maintenance” on page 17
8. “Shipping and Transportation” on page 20
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 configuration, 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 configuration. 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 firm supporting surface, with hooks and slings attached in approved configuration. 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.
TABLE OF CONTENTS:
DAEWOO DOOSAN 55 W V PLUS EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Table Of Contents............................................................................................. 5 Publication Request for Proposed Revision..................................................................... 7 Safety........................................................................................................ 9 Wheel Excavator Safety.................................................................................... 11 To the Operator of a DOOSAN Daewoo Excavator.......................................................... 13 Learn Signal Words Used With Safety Alert Symbol.................................................. 15 General Safety Essentials............................................................................. 16 Accessory Applications............................................................................ 16 Lifting Capacity Rating Configuration............................................................. 16 Location of Safety Labels............................................................................. 16 Summary of Safety Precautions for Lifting in Digging Mode............................................. 17 Unauthorized Modifications............................................................................ 18 General Hazard Information............................................................................ 18 Safety Rules...................................................................................... 18 Safety Features................................................................................... 18 Inside Operator's Compartment..................................................................... 19 Clothing and Personal Protective Items............................................................ 20 Breathing Masks, Ear Protection May be Required................................................... 20 Mounting and Dismounting.......................................................................... 20 Fuel, Oil and Hydraulic Fluid Fire Hazards........................................................ 21 Precautions When Handling Fluids at High Temperature.............................................. 21 Asbestos Dust Hazard Prevention................................................................... 22 Injury from Work Equipment........................................................................ 22 Fire Extinguisher and First Aid Kit............................................................... 23 Protection from Falling or Flying Objects......................................................... 23 Attachment Precautions............................................................................ 24 Accumulator....................................................................................... 24 Indoor Ventilation................................................................................ 25 Emergency Exit.................................................................................... 25 Before Starting Engine................................................................................ 26 Work Site Precautions............................................................................. 26 Checks Before Starting Engine..................................................................... 27 Engine Starting................................................................................... 28 Before Operating Machine.......................................................................... 28 Machine Operation..................................................................................... 29 When Swinging or Changing Direction of Travel..................................................... 29 Travel Precautions................................................................................ 29 Traveling on Slopes............................................................................... 30 Prohibited Operations............................................................................. 31 Precautions for Operation......................................................................... 31 Avoid High Voltage Cables......................................................................... 32 Operate Carefully on Snow, Ice and in Very Cold Temperatures...................................... 32 Operations on Slopes.............................................................................. 33 Parking Machine................................................................................... 33 Never Let Anyone Ride on Attachment............................................................... 33 Maintenance........................................................................................... 34 Warning Tag....................................................................................... 34 Clean Before Inspection or Maintenance............................................................ 34 Proper Tools...................................................................................... 35 Use of Lighting................................................................................... 35 Fire Prevention and Explosion Prevention.......................................................... 35 Burn Prevention................................................................................... 36 Welding Repairs................................................................................... 37 Warning for Counterweight and Front Attachment Removal............................................ 37 Precautions for Removal, Installation, and Storage of Attachments................................. 38 Precautions when Working on Machine............................................................... 38 Lock Inspection Covers............................................................................ 38 Crushing Prevention and Cutting Prevention........................................................ 39 Supports and Blocking for Work Equipment.......................................................... 39 Action When Abnormally Is Found During Inspection................................................. 39 Precautions with High-pressure Line, Tubes and Hoses.............................................. 40 Waste Materials................................................................................... 41 Battery............................................................................................... 42 Battery Hazard Prevention......................................................................... 42 Boost Starting or Charging Engine Batteries....................................................... 43 Towing................................................................................................ 44 Precautions When Towing........................................................................... 44 Shipping and Transportation........................................................................... 45 Obey State and Local Over-the-Road Regulations.................................................... 45 Lifting With Sling.................................................................................... 45 Specifications................................................................................................ 47 Specifications for Solar 55W-V PLUS....................................................................... 49 General Description................................................................................... 51 Component Locations................................................................................... 52 General Dimensions.................................................................................... 54 Working Range......................................................................................... 56 General Specifications................................................................................ 58 Weight Table.......................................................................................... 60 Working Attachments................................................................................... 62 Pin and Bushing Wear Limits....................................................................... 62 Measuring Cylinder Drift.......................................................................... 64 Measuring Speed................................................................................... 65 General Maintenance........................................................................................... 67 General Maintenance Procedures............................................................................ 69 Welding Precautions and Guidelines.................................................................... 71 Hydraulic System General Precautions................................................................ 72 Maintenance Service and Repair Procedure.............................................................. 73 General Precautions............................................................................... 73 Hydraulic System Cleanliness and Oil Leaks............................................................ 74 Maintenance Precautions for Hydraulic System Service.............................................. 74 Oil Leakage Precautions........................................................................... 74 Cleaning and Inspection............................................................................... 75 General Guidelines................................................................................ 75 Bearing inspection................................................................................ 76 Normal Bearing................................................................................ 77 Bent Cage..................................................................................... 77 Galling....................................................................................... 77 Abrasive Step Wear............................................................................ 78 Etching....................................................................................... 78 Misalignment.................................................................................. 78 Indentations.................................................................................. 78 Fatigue Spalling.............................................................................. 79 Brinelling.................................................................................... 79 Cage Wear..................................................................................... 79 Abrasive Roller Wear.......................................................................... 79 Cracked Inner Race............................................................................ 80 Smears........................................................................................ 80 Frettage...................................................................................... 80 Heat Discoloration............................................................................ 81 Stain Discoloration........................................................................... 81 Standard Torques.......................................................................................... 83 Torque Values for Standard Metric Fasteners........................................................... 85 Torque Values for Standard U.S. Fasteners............................................................. 86 Type 8 Phosphate Coated Hardware...................................................................... 88 Torque Values for Hose Clamps......................................................................... 89 Torque Values for Split Flanges....................................................................... 90 Torque Wrench Extension Tools......................................................................... 91 Torque Multiplication............................................................................. 91 Other Uses for Torque Wrench Extension Tools...................................................... 92 Tightening Torque Specifications (Metric)......................................................... 92 I. "Loctite" Fastener Adhesives............................................................... 93 II. "Loctite" Pipe Thread Sealant............................................................. 93 III. "Loctite" gasket/flange sealer........................................................... 93 IV. "Loctite" retaining compounds............................................................. 94 V. "Loctite" Adhesives........................................................................ 94 Upper Structure............................................................................................... 95 Counterweight............................................................................................. 97 General............................................................................................... 99 Removal...............................................................................................101 Installation..........................................................................................103 Fuel Transfer Pump........................................................................................105 General Description...................................................................................107 Theory of Operation...............................................................................107 Troubleshooting.......................................................................................108 Replacement of Rotor and Vane.........................................................................108 Replacement of Rear Cover.............................................................................109 Replacement of Armature...............................................................................110 Swing Bearing.............................................................................................111 Swing Bearing Maintenance.............................................................................113 Operating Recommendation..........................................................................113 Measuring Swing Bearing Axial Play................................................................113 Measuring Bearing Lateral Play....................................................................113 Swing Bearing Basic Operation.....................................................................114 Rebuilding Swing Bearing..........................................................................114 Swing Reduction Gearbox...................................................................................117 General Description...................................................................................119 Theory of Operation...............................................................................119 Parts List........................................................................................120 Special Tools and Materials...........................................................................122 Special Tools.....................................................................................122 Troubleshooting, Testing and Adjustment...............................................................123 Removal...............................................................................................124 Disassembly...........................................................................................126 Reassembly............................................................................................127 Installation..........................................................................................129 Lower Structure and Chassis...................................................................................131 Ram Lock Valve Operation..................................................................................133 Theory of Operation...................................................................................135 Engine and Drive Train........................................................................................137 Drive Axle (Clark-Hurth)..................................................................................139 Introduction..........................................................................................141 Introductory Statement............................................................................141 Special Tool..........................................................................................142 Trouble Shooting......................................................................................151 Clark-Hurth Axle Identification.......................................................................154 Data Plate........................................................................................154 Maintenance Points....................................................................................155 Maintenance Intervals.................................................................................155 Conversion Tables.....................................................................................156 Tightening Torques....................................................................................156 Brakes................................................................................................157 Safety Brake..........................................................................................160 Adjustment........................................................................................163 Wheel Hub.............................................................................................165 Wheel Hub onto Axle Housing...........................................................................167 Epicycloidal Reduction 4.25...........................................................................169 Epicycloidal Reduction 5.25...........................................................................171 Articulation 271-278..................................................................................173 Steering Cylinder.....................................................................................178 Disassembly - Assembly (T11 bis A, B, C - (See page 9))..........................................179 Bevel Pinion Support..................................................................................181 Adjustments of Bevel Gear Set.........................................................................188 Taper Roller Bearings of Differential.................................................................190 Disassembling of Differential.........................................................................193 Assembling of the Differential........................................................................195 Self Locking Differential.............................................................................197 NoSpin................................................................................................199 Hydraulic Differential Lock...........................................................................201 Air Conditioner...........................................................................................205 General Description...................................................................................207 Refrigerant Circulation...............................................................................208 Air-conditioning System Circuit Diagram...............................................................210 Troubleshooting.......................................................................................211 Refrigerant Pressure Check........................................................................211 Weight of R134a Gas Used In Machines..................................................................214 Refrigerant System Repairs............................................................................216 Refrigerant Safe Handling Procedures..............................................................216 Repair and Replacement Procedure..................................................................217 Refrigerant Recovery..............................................................................219 Vacuuming Refrigerant System......................................................................219 Leakage Check.....................................................................................220 Refrigerant Charging..............................................................................221 Inspecting System for Leakage.....................................................................223 Transmission (Spicer Clark- Hurth)........................................................................225 Introduction..........................................................................................227 Introductory Remarks..............................................................................227 Maintenance and Lubricant.............................................................................228 Maintenance Points................................................................................228 Data Plate........................................................................................228 Maintenance Intervals.............................................................................229 Conversion Tables.................................................................................229 Tightening Torques................................................................................229 Diagrams of Reduction Unit and Exploded Views.........................................................230 Diagram...........................................................................................230 Reduction Gear....................................................................................231 First Gear........................................................................................232 Second Gear.......................................................................................233 Disassembly of Directly Flanged Reduction Gear 357....................................................234 Removal of Hydraulic Gear Control.....................................................................235 Disassembly of Directly Flanged Reduction Gear 357....................................................237 Assembly of Directly Flanged Reduction Gear 357.......................................................247 Installation of Hydraulic Gear Control................................................................258 Drive Coupling (Main Pump)................................................................................259 Drive Coupling........................................................................................261 Special Tools.........................................................................................262 Kawasaki / Tong Myung Pump Tool...................................................................262 Uchida Pump Tool..................................................................................265 Drive Coupling Installation...........................................................................267 Installation Procedure............................................................................272 Hydraulics....................................................................................................273 Hydraulic System Troubleshooting, Testing and Adjustment..................................................275 Hydraulic System......................................................................................277 Outline...........................................................................................277 Major Components..................................................................................278 Hydraulic Schematic (Solar 55W-V PLUS)............................................................280 Control Valve Operation...........................................................................282 Circuit Operation.................................................................................283 Boom..........................................................................................283 Arm...........................................................................................283 Bucket........................................................................................283 Swing.........................................................................................284 Boom Swing....................................................................................284 Blade.........................................................................................285 Travel........................................................................................285 Simultaneous Operation of Boom Up and Arm Retract.............................................286 Simultaneous Operation of Boom Up and Bucket..................................................286 PTO...........................................................................................286 Accumulator...............................................................................................287 General Description...................................................................................289 Specifications....................................................................................290 Center Joint (Swivel).....................................................................................293 General Description...................................................................................295 Parts List........................................................................................296 Troubleshooting, Testing and Adjustment...............................................................298 Inspection........................................................................................298 Testing...........................................................................................298 Disassembly...........................................................................................299 Reassembly............................................................................................300 Cylinders.................................................................................................301 General Description...................................................................................303 Theory of Operation...............................................................................303 Parts List........................................................................................304 Special Tools and Materials...........................................................................306 Piston Nut........................................................................................306 Piston Jig........................................................................................310 Steel Bushing Jig.................................................................................314 Dust Wiper Jig....................................................................................318 Slipper Seal Jig..................................................................................324 Slipper Seal Straightening Jig....................................................................328 Disassembly...........................................................................................331 Assembly..............................................................................................337 Travel Motor..............................................................................................341 Sectional View........................................................................................344 Seal Kits and Component Groups........................................................................345 Seal Kits and Component groups / Replace Seal Nut.....................................................348 Sealing the Drive Shaft...............................................................................350 Sealing of the Control Parts..........................................................................352 Sealing of the Relief Valve / Counter- balance Valve..................................................355 Spare Parts List Counter-balance Valve................................................................356 Spare Parts list Brake Release Valve (Pos. 50)........................................................357 Shuttle Valve (Pos. 25)...........................................................................358 Disassembly of the Port Plate.........................................................................359 Remove of the Positioning Piston......................................................................361 Remove Rotary Group...................................................................................363 Exchanging of the rotary group........................................................................365 Complete Rotary Group.............................................................................365 Rotary Group......................................................................................365 Inspection Notes......................................................................................367 Rotary Group Assembly.................................................................................370 Rotary Group Adjustment (see service information).....................................................373 Assembly of the Port Plate............................................................................375 Tightening Torques....................................................................................377 Tightening torques for shaft bolts (Metric ISO Standard Thread)...................................377 Tightening Torques for Locking Screws VSTI (Metric ISO fine thread)...............................377 Tightening Torques for Seal-lock Nuts (Metric ISO-Standard Thread)................................378 Tightening Torques for Cross-slotted Lens Head Screws DIN 7985 (Metric ISO-Standard Thread).......378 Safety Regulations....................................................................................379 General Advice....................................................................................379 Before starting...................................................................................379 Start.............................................................................................379 Hydraulic Equipment...............................................................................380 Swing Motor...............................................................................................381 Swing Motor...........................................................................................383 Motor.............................................................................................383 Valve Casing......................................................................................384 Relief Valve......................................................................................384 Troubleshooting.......................................................................................386 Main Pump.................................................................................................387 General Description...................................................................................389 Description of Ports..............................................................................390 Operation Principle and Function of Components........................................................391 Components of the Pump............................................................................391 Operation Principle...............................................................................392 Adjustment............................................................................................394 Installation..........................................................................................395 Driving...............................................................................................395 Hydraulic Oil.........................................................................................395 Procedures for Test Operation.........................................................................395 Maintenance and Protection............................................................................397 Checking Filters......................................................................................397 Filter Replacement....................................................................................397 Replacement of Hydraulic Oil..........................................................................398 Hydraulic Fluid Leakage Check.........................................................................398 Diagnosis of Troubles and Actions to be Taken.........................................................399 Diagnosis of Troubles with the Pump...............................................................399 Disassembling and Reassembling hydraulic pump.........................................................401 Necessary Tools and Jigs..........................................................................401 Tools.........................................................................................401 Jigs..........................................................................................401 Reminders for Disassembly and Assembly............................................................401 Disassembling Procedure...........................................................................402 Gear Pump Disassembly.........................................................................402 Main Pump Disassembly.........................................................................403 Rotary Group Removal..........................................................................404 Axle Removal..................................................................................404 Cover Disassembly.............................................................................406 Disassembling Cylinder........................................................................407 Gear Pump Disassembly.........................................................................407 Standard Values for Maintenance...................................................................411 Reassembly Procedure..............................................................................413 Assembling Tilting Plate......................................................................413 Assembling the Drive Axle.....................................................................414 Assembling Control Spring.....................................................................416 Assembling Relief Valve.......................................................................419 Assembling of the Gear Pump...................................................................421 Assembling Gear Pump (G1).....................................................................424 Main Control Valve........................................................................................429 Specifications........................................................................................432 Internal Construction.................................................................................436 Construction of Relief and makeup Valves..............................................................438 Relief Valve......................................................................................438 Makeup Valve......................................................................................439 Overload Relief Valve.............................................................................439 Operation.............................................................................................440 Operation in Neutral Position.....................................................................440 Operation for Travel..............................................................................442 Boom Operation....................................................................................446 Bucket Operation..................................................................................452 Arm Operation.....................................................................................456 Boom Swing Operation..............................................................................460 Swing Operation...................................................................................462 Combined Operation (Actuation of Inlet (P1, P2) Valve)............................................464 Actuation of Relief Valve (MRV)...................................................................466 Actuation of Overload Relief Valve (ORV)..........................................................467 Function and Operation of Makeup Valve............................................................468 Detail Views of Major Components..................................................................468 Disassembly...........................................................................................479 Valve Handling Guide..............................................................................479 Disassembly of Relief Valve (MRV), Overload Relief Valve (ORV), and Anticavitation Valve (ACV)....480 Check Valve Disassembly...........................................................................481 Pressure Relief Load Check Valve Disassembly......................................................481 Anticavitation Valve Disassembly..................................................................481 Relief Valve Disassembly..........................................................................482 Overload Relief Valve Disassembly.................................................................482 Other Components Disassembly......................................................................482 Joint Body Disassembly............................................................................482 Disassembly Precautions...........................................................................483 Assembly..............................................................................................484 Assembly Precautions..............................................................................484 Guide for Assembly of Each Part...................................................................484 Table 1.......................................................................................485 Criteria for Maintenance..............................................................................486 Inspection of Spare Parts.........................................................................486 Troubleshooting and Remedies......................................................................487 Control Valve.....................................................................................487 Relief Valve......................................................................................488 Pilot Control Valve (Work Lever / Joystick)...............................................................489 General Description...................................................................................491 Theory of Operation...............................................................................491 Neutral Mode..................................................................................491 Control Mode..................................................................................491 Parts List........................................................................................492 Specifications....................................................................................494 Performance...................................................................................494 Hydraulic Specifications..........................................................................494 Special Tools.........................................................................................495 Disassembly...........................................................................................496 Reassembly............................................................................................501 Hydraulic Schematic (Solar 55W-V PLUS)....................................................................507 General Description...................................................................................509 Solar 55W-V PLUS......................................................................................510 Electrical System.............................................................................................513 Electrical System.........................................................................................515 Overview..............................................................................................517 Electric Wire Color...............................................................................517 Electric Supply System................................................................................518 Engine Starting Circuit...............................................................................520 Operation During Starting Process.................................................................520 Operation of the Starter Circuit (1) - During Start Process...................................521 Operation After Start Process.....................................................................522 Operation of the Starting Circuit (2) - Immediately After Start...............................523 Engine Preheating System..............................................................................524 Engine Stop System....................................................................................526 Charging System.......................................................................................528 Instrument System.....................................................................................530 Instrument Panel..................................................................................531 Function Check....................................................................................531 Operation.........................................................................................533 Gauge.........................................................................................533 Warning Lights................................................................................534 Circuit Diagram of Instrument Panel...............................................................536 Circuit Diagram of Control Unit...................................................................538 Control Unit......................................................................................539 Performance Specification.....................................................................539 Electrical Schematic (Solar 55W-V PLUS)...................................................................541 General Description...................................................................................543 Solar 55W-V PLUS......................................................................................544 Attachments...................................................................................................547 Bucket....................................................................................................549 Bucket Tooth Inspection and Replacement...............................................................551 Type 1............................................................................................551 Type 2............................................................................................552 Type 3............................................................................................553 Bucket O-ring Replacement.............................................................................555 Type 1............................................................................................555 Type 2............................................................................................556 Bucket Shimming Procedures............................................................................558 New Bucket Installation...........................................................................558 Type 1............................................................................................558 Shimming Procedures for Installed Bucket......................................................558 Type 2............................................................................................559 Shimming Procedures for Installed Bucket......................................................559 Bucket Attachment, Removal and Reversal...............................................................560 Detaching the Bucket..............................................................................560 Attaching the bucket..............................................................................560 Reversing the Bucket..............................................................................561
DAEWOO DOOSAN 55 W V PLUS EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:
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