Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
DAEWOO DOOSAN SOLAR 55V PLUS EXCAVATOR SHOP MANUAL Serial Number 1001 and Up – PDF DOWNLOAD
Original price was: $90.00.$29.95Current price is: $29.95.
DAEWOO DOOSAN SOLAR 55V PLUS EXCAVATOR SHOP MANUAL Serial Number 1001 and Up – PDF DOWNLOAD
023-00045AE
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
DAEWOO DOOSAN SOLAR 55V PLUS EXCAVATOR SHOP MANUAL Serial Number 1001 and Up – PDF DOWNLOAD
DESCRIPTION:
DAEWOO DOOSAN SOLAR 55V PLUS EXCAVATOR SHOP MANUAL Serial Number 1001 and Up – 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.
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 specifically 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.
TABLE OF CONTENTS:
DAEWOO DOOSAN SOLAR 55V PLUS EXCAVATOR SHOP MANUAL Serial Number 1001 and Up – PDF DOWNLOAD
Publication Request for Proposed Revision..................................................................... 7 Safety........................................................................................................ 9 Track Excavator Safety S0102035K.......................................................................... 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............................................................ 19 Breathing Masks, Ear Protection May Be Required................................................... 20 Vibration Level Information....................................................................... 20 Mounting and Dismounting.......................................................................... 21 Fuel, Oil and Hydraulic Fluid Fire Hazards........................................................ 22 Precautions When Handling Fluids at High Temperature.............................................. 22 Asbestos Dust Hazard Prevention................................................................... 23 Injury from Work Equipment........................................................................ 23 Fire Extinguisher and First Aid Kit............................................................... 24 Protection from Falling or Flying Objects......................................................... 24 Attachment Precautions............................................................................ 25 Accumulator....................................................................................... 25 Indoor Ventilation................................................................................ 26 Emergency Exit.................................................................................... 26 Before Starting Engine................................................................................ 27 Work Site Precautions............................................................................. 27 Checks Before Starting Engine..................................................................... 28 Engine Starting................................................................................... 29 Before Operating Machine.......................................................................... 29 Machine Operation..................................................................................... 30 When Swinging or Changing Direction of Travel..................................................... 30 Travel Precautions................................................................................ 31 Traveling on Slopes............................................................................... 32 Prohibited Operations............................................................................. 32 Precautions for Operation......................................................................... 33 Avoid High Voltage Cables......................................................................... 34 Operate Carefully on Snow, Ice and in Very Cold Temperatures...................................... 34 Operations on Slopes.............................................................................. 35 Parking Machine................................................................................... 35 Never Let Anyone Ride on Attachment............................................................... 35 Maintenance........................................................................................... 36 Warning Tag....................................................................................... 36 Clean Before Inspection or Maintenance............................................................ 36 Proper Tools...................................................................................... 37 Use of Lighting................................................................................... 37 Fire Prevention and Explosion Prevention.......................................................... 37 Burn Prevention................................................................................... 38 Welding Repairs................................................................................... 39 Warning for Counterweight and Front Attachment Removal............................................ 39 Precautions for Removal, Installation, and Storage of Attachments................................. 40 Precautions when Working on Machine............................................................... 40 Lock Inspection Covers............................................................................ 40 Crushing Prevention and Cutting Prevention........................................................ 41 Track Tension Adjustments Require Caution......................................................... 41 Supports and Blocking for Work Equipment.......................................................... 41 Action When Abnormally Is Found During Inspection................................................. 42 Precautions with High-pressure Line, Tubes and Hoses.............................................. 42 Waste Materials................................................................................... 43 Battery............................................................................................... 44 Battery Hazard Prevention......................................................................... 44 Starting Engine With a Booster Cable.............................................................. 45 Connecting the Booster Battery................................................................ 46 Disconnecting the Booster Battery............................................................. 46 Towing................................................................................................ 47 Precautions When Towing........................................................................... 47 Shipping and Transportation........................................................................... 48 Obey State and Local Over-the-Road Regulations.................................................... 48 Lifting With Sling.................................................................................... 48 Specifications................................................................................................ 49 Specifications for Solar 55-V PLUS S0202035K.............................................................. 51 General Description................................................................................... 53 Component Locations................................................................................... 54 General Dimensions.................................................................................... 56 Working Range......................................................................................... 58 General Specifications................................................................................ 60 Weight Table.......................................................................................... 62 Machine Number........................................................................................ 63 Working Attachments................................................................................... 64 Pin and Bushing Wear Limits....................................................................... 64 Cross-section of Pins............................................................................. 66 Measuring Cylinder Drift.......................................................................... 69 Measuring Speed................................................................................... 70 General Maintenance........................................................................................... 73 General Maintenance Procedures S0302000................................................................... 75 Welding Precautions and Guidelines.................................................................... 77 Hydraulic System General Precautions................................................................ 78 Maintenance Service and Repair Procedure.............................................................. 79 General Precautions............................................................................... 79 Hydraulic System Cleanliness and Oil Leaks............................................................ 80 Maintenance Precautions for Hydraulic System Service.............................................. 80 Oil Leakage Precautions........................................................................... 80 Cleaning and Inspection............................................................................... 81 General Guidelines................................................................................ 81 Bearing inspection................................................................................ 82 Normal Bearing................................................................................ 83 Bent Cage..................................................................................... 83 Galling....................................................................................... 83 Abrasive Step Wear............................................................................ 84 Etching....................................................................................... 84 Misalignment.................................................................................. 84 Indentations.................................................................................. 84 Fatigue Spalling.............................................................................. 85 Brinelling.................................................................................... 85 Cage Wear..................................................................................... 85 Abrasive Roller Wear.......................................................................... 85 Cracked Inner Race............................................................................ 86 Smears........................................................................................ 86 Frettage...................................................................................... 86 Heat Discoloration............................................................................ 87 Stain Discoloration........................................................................... 87 Standard Torques S0309000................................................................................. 89 Torque Values for Standard Metric Fasteners........................................................... 91 Torque Values for Standard U.S. Fasteners............................................................. 92 Type 8 Phosphate Coated Hardware...................................................................... 94 Torque Values for Hose Clamps......................................................................... 95 Torque Values for Split Flanges....................................................................... 96 Torque Wrench Extension Tools......................................................................... 97 Torque Multiplication............................................................................. 97 Other Uses for Torque Wrench Extension Tools...................................................... 98 Tightening Torque Specifications (Metric)......................................................... 98 I. "Loctite" Fastener Adhesives............................................................... 99 II. "Loctite" Pipe Thread Sealant............................................................. 99 III. "Loctite" gasket/flange sealer........................................................... 99 IV. "Loctite" retaining compounds.............................................................100 V. "Loctite" Adhesives........................................................................100 Upper Structure...............................................................................................101 Lower Structure and Chassis...................................................................................103 Track Assembly S0505070...................................................................................105 General Description...................................................................................107 Track Tension.........................................................................................107 Track Assembly........................................................................................110 Parts List........................................................................................110 Track Shoes and Links.................................................................................112 Parts List........................................................................................112 Track Removal.....................................................................................113 Tra1ck Installation...............................................................................114 Front Idler Roller....................................................................................115 Parts List........................................................................................115 Front Idler Roller Disassembly....................................................................116 Front Idler Roller Reassembly.....................................................................117 Lower Roller..........................................................................................119 Parts List........................................................................................119 Lower Roller Removal..............................................................................120 Lower Roller Installation.........................................................................120 Upper Roller..........................................................................................121 Parts List........................................................................................121 Upper Roller Removal..............................................................................122 Upper Roller Disassembly..........................................................................122 Upper Roller Reassembly...........................................................................122 Track Spring and Track Adjusting Cylinder.............................................................123 Parts List........................................................................................123 Engine and Drive Train........................................................................................125 Air Conditioner S0605015..................................................................................127 General Description...................................................................................129 Refrigerant Circulation...............................................................................130 Air-conditioning System Circuit Diagram...............................................................132 Troubleshooting.......................................................................................133 Refrigerant Pressure Check........................................................................133 Weight of R134a Gas Used In Machines..................................................................136 Refrigerant System Repairs............................................................................138 Refrigerant Safe Handling Procedures..............................................................138 Repair and Replacement Procedure..................................................................139 Refrigerant Recovery..............................................................................141 Vacuuming Refrigerant System......................................................................141 Leakage Check.....................................................................................143 Refrigerant Charging..............................................................................143 Inspecting System for Leakage.....................................................................145 Hydraulics....................................................................................................147 Accumulator S0703010K.....................................................................................149 General Description...................................................................................151 Specifications....................................................................................152 Center Joint (Swivel) S0704050............................................................................155 General Description...................................................................................157 Parts List........................................................................................158 Troubleshooting, Testing and Adjustment...............................................................160 Inspection........................................................................................160 Testing...........................................................................................160 Disassembly...........................................................................................161 Reassembly............................................................................................162 Cylinders S0705000........................................................................................163 General Description...................................................................................165 Theory of Operation...............................................................................165 Parts List........................................................................................166 Special Tools and Materials...........................................................................168 Piston Nut........................................................................................168 Piston Jig........................................................................................172 Steel Bushing Jig.................................................................................176 Dust Wiper Jig....................................................................................180 Slipper Seal Jig..................................................................................186 Slipper Seal Straightening Jig....................................................................190 Disassembly...........................................................................................193 Assembly..............................................................................................199 Travel Motor S0707370 R1..................................................................................203 General...............................................................................................206 Configuration.....................................................................................206 Features..........................................................................................206 Structural Diagram of the Travelling System.......................................................207 Structural Diagram of the Axial Piston Motor......................................................208 Operating Principle...................................................................................209 When Travelling...................................................................................209 When Counterbalance Operates......................................................................210 When Brake Functions..............................................................................211 Operating Principle of Parking Brake..............................................................212 2 Speed Limiting Function.........................................................................213 Parts List............................................................................................216 Hydraulic Motor...................................................................................216 Reduction Gear....................................................................................218 Special Tools and Materials...........................................................................220 Standard Tools....................................................................................220 Equipment and Materials...........................................................................220 Measuring Devices.................................................................................221 Manufacturing Tools...............................................................................222 Travel Motor Workbench........................................................................222 Fixture.......................................................................................222 Holder (I)....................................................................................222 Holder (II)...................................................................................222 Holder (III)..................................................................................223 Holder (IV)...................................................................................223 Steel Rod.....................................................................................223 Bearing Preload Adjuster......................................................................223 Aluminum Rod..................................................................................224 PF Eyebolt....................................................................................224 Eyebolt.......................................................................................224 F/S Installation Tool (I).....................................................................224 F/S Installation Tool (II)....................................................................225 F/S Installation Tool (III)...................................................................225 Cover Removable Tool..........................................................................225 Slice.........................................................................................225 Tightening Torque.................................................................................226 Weight Table......................................................................................227 Travel Motor Troubleshooting..........................................................................227 Travel Motor......................................................................................227 Counterbalance Valve..............................................................................228 Relief Valve......................................................................................228 2-Speed Change Over...............................................................................229 Parking Brake.....................................................................................229 Disassembly...........................................................................................230 Preparations......................................................................................230 Workbench Preparations........................................................................230 Preparation of Tools and Materials............................................................230 General Suggestions When Working..................................................................230 Disassembly Procedure.............................................................................231 Washing GM motor..............................................................................231 GM Motor Installation.........................................................................231 Lubricating Oil Extraction....................................................................232 Cover Removal.................................................................................233 Input Gear Removal............................................................................235 Spur Gear Removal.............................................................................235 Rear Flange Removal...........................................................................236 Removing Parts from the Rear Flange...........................................................237 Disassembly of Plugs Inside Rear Flange.......................................................238 Disassembling Valve (For 2-Speed Control).....................................................240 Remove Hex Socket Plug........................................................................240 Disassembling Valve for Parking Brake.........................................................240 Disassembling Parking Brake...................................................................241 Disassembling Hydraulic Motor.................................................................242 Removal of Spring Inside Cylinder Block.......................................................243 Removal of Swash Plate........................................................................244 Removing Ball Bearing From Shaft..............................................................245 Removing Hold Flange..........................................................................245 Fixture Removal...............................................................................247 Removing Spindle..............................................................................247 Removal of Ball Bearing, RV Gear Assembly, and Pin............................................248 Ball Bearing Removal..........................................................................248 Disassembling Spindle Fittings................................................................249 Disassembling Hold Flange.....................................................................249 Washing.......................................................................................250 Finish Washing................................................................................250 Service Preparations..................................................................................252 Seals.............................................................................................252 Service Standards for Parts Subject to Wear.......................................................252 Assembly..............................................................................................254 Preparation.......................................................................................254 General Suggestions When Working..................................................................254 Assembly Procedure................................................................................254 Hub Section Assembly..........................................................................255 Spindle Assembly..............................................................................256 Mount RV Gear Assembly........................................................................257 Hold Flange Mounting..........................................................................258 Tightening Reamer Bolts and Hex Socket Head Bolts.............................................259 Install Retaining Rings.......................................................................260 Spur Gear Assembly............................................................................261 Mounting Oil Seal.............................................................................261 Shaft Assembly................................................................................262 Assembly of Cylinder Block Interior...........................................................263 Assembly of Hydraulic Motor Parts.............................................................264 Assembly of Parking Brake Section.............................................................264 Assembly of Brake Valve Parts in Rear Flange..................................................265 Assembly of Rear Flange Mounted Parts.........................................................266 Connection of Rear Flange with Spindle........................................................268 Input Gear Assembly...........................................................................269 Cover Assembly................................................................................270 Remove Assembled GM Motor from Workbench......................................................271 Preload Adjustment of Ball Bearing............................................................271 Adjusting Axial Clearance on Tapered Roller Bearing...........................................272 Performance Confirmation Test.........................................................................274 Required Measuring Devices........................................................................274 Test Procedure....................................................................................274 Clearance Adjustment Part Dimensions..................................................................275 Swing Motor S0707380......................................................................................277 Swing Motor...........................................................................................279 Motor.............................................................................................279 Valve Casing......................................................................................280 Relief Valve......................................................................................280 Troubleshooting.......................................................................................282 Main Pump S0708370........................................................................................283 General Description...................................................................................285 Description of Ports..............................................................................286 Operation Principle and Function of Components........................................................287 Components of the Pump............................................................................287 Operation Principle...............................................................................289 Adjustment............................................................................................291 Installation..........................................................................................292 Driving...............................................................................................292 Hydraulic Oil.........................................................................................292 Procedures for Test Operation.........................................................................292 Maintenance and Protection............................................................................294 Checking Filters......................................................................................294 Filter Replacement....................................................................................294 Replacement of Hydraulic Oil..........................................................................295 Hydraulic Fluid Leakage Check.........................................................................295 Diagnosis of Troubles and Actions to be Taken.........................................................296 Diagnosis of Troubles with the Pump...............................................................296 Solenoid Valve and Relief Valve...................................................................297 Disassembling and Reassembling hydraulic pump.........................................................298 Necessary Tools and Jigs..........................................................................298 Tools.........................................................................................298 Jigs..........................................................................................298 Reminders for Disassembly and Assembly............................................................298 Disassembling Procedure...........................................................................299 Solenoid Valve Disassembly....................................................................299 Gear Pump Disassembly.........................................................................299 Main Pump Disassembly.........................................................................300 Rotary Group Removal..........................................................................301 Axle Removal..................................................................................301 Cover Disassembly.............................................................................303 Disassembling Cylinder........................................................................304 Gear Pump Disassembly.........................................................................305 Disassemble Solenoid Valves...................................................................308 Standard Values for Maintenance...................................................................310 Reassembly Procedure..............................................................................312 Assembling Tilting Plate......................................................................312 Assembling the Drive Axle.....................................................................314 Assembling Control Spring.....................................................................316 Assembling Relief Valve.......................................................................319 Assembling of the Gear Pump...................................................................322 Assembling Gear Pump (G1).....................................................................325 Assembling Solenoid Valves....................................................................328 Main Control Valve S0709465K..............................................................................331 Specifications........................................................................................334 Internal Construction.................................................................................338 Construction of Relief and makeup Valves..............................................................340 Relief Valve......................................................................................340 Makeup Valve......................................................................................341 Overload Relief Valve.............................................................................341 Operation.............................................................................................342 Operation in Neutral Position.....................................................................342 Operation for Travel..............................................................................344 Boom Operation....................................................................................348 Bucket Operation..................................................................................354 Arm Operation.....................................................................................358 Boom/Swing Operation..............................................................................362 Swing Operation...................................................................................364 Combined Operation (Actuation of Forward Travel Valve)............................................366 Actuation of Relief Valve (MRV)...................................................................368 Actuation of Overload Relief Valve (ORV)..........................................................369 Function and Operation of Makeup Valve............................................................370 Detail Views of Major Components..................................................................370 Disassembly...........................................................................................381 Valve Handling Guide..............................................................................381 Disassembly of Relief Valve (MRV), Overload Relief Valve (ORV), and Anticavitation Valve (ACV)....382 Check Valve Disassembly...........................................................................383 Pressure Relief Load Check Valve Disassembly......................................................383 Anticavitation Valve Disassembly..................................................................383 Relief Valve Disassembly..........................................................................384 Overload Relief Valve Disassembly.................................................................384 Other Components Disassembly......................................................................384 Joint Body Disassembly............................................................................384 Disassembly Precautions...........................................................................385 Assembly..............................................................................................386 Assembly Precautions..............................................................................386 Guide for Assembly of Each Part...................................................................386 Table 4.......................................................................................387 Criteria for Maintenance..............................................................................388 Inspection of Spare Parts.........................................................................388 Troubleshooting and Remedies......................................................................389 Control Valve.....................................................................................389 Relief Valve......................................................................................390 Pilot Control Valve (Work Lever / Joystick) S0709470......................................................391 General Description...................................................................................393 Theory of Operation...............................................................................393 Neutral Mode..................................................................................393 Control Mode..................................................................................393 Parts List........................................................................................394 Specifications....................................................................................396 Performance...................................................................................396 Hydraulic Specifications..........................................................................396 Special Tools.........................................................................................397 Disassembly...........................................................................................398 Reassembly............................................................................................403 Hydraulic Schematic (Solar 55-V PLUS) S0792095K...........................................................409 General Description...................................................................................411 Solar 55-V PLUS (S/N 1001 thru 1200, 31201 thru 32135)................................................412 Solar 55-V PLUS (S/N 32136 and Up)....................................................................414 Electrical System.............................................................................................417 Electrical System S0802085K...............................................................................419 Overview..............................................................................................421 Electric Wire Color...............................................................................421 Electric Supply System................................................................................422 Engine Starting Circuit...............................................................................424 Operation During Starting Process.................................................................424 Operation of the Starter Circuit (1) - During Start Process...................................425 Operation After Start Process.....................................................................426 Operation of the Starting Circuit (2) - Immediately After Start...............................427 Engine Preheating System..............................................................................428 Engine Stop System....................................................................................430 Charging System.......................................................................................431 Instrument System.....................................................................................432 Instrument Panel..................................................................................433 Function Check....................................................................................433 Operation.........................................................................................434 Gauge.........................................................................................434 Warning Lights................................................................................435 Circuit Diagram of Instrument Panel...............................................................436 Control Unit......................................................................................437 Circuit Diagram...............................................................................437 Performance Specification.....................................................................438 Electrical Schematic (Solar 55-V PLUS) S0892095K..........................................................439 General Description...................................................................................441 Solar 55-V PLUS (S/N 1001 thru 1200, 31201 thru 32135)................................................442 Solar 55-V PLUS (S/N 32136 and Up)....................................................................444 Attachments...................................................................................................447 Bucket S0904000...........................................................................................449 Bucket Tooth Inspection and Replacement...............................................................451 Type 1............................................................................................451 Type 2............................................................................................452 Type 3............................................................................................453 Bucket O-ring Replacement.............................................................................455 Type 1............................................................................................455 Type 2............................................................................................456 Bucket Shimming Procedures............................................................................458 New Bucket Installation...........................................................................458 Type 1............................................................................................458 Shimming Procedures for Installed Bucket......................................................458 Type 2............................................................................................459 Shimming Procedures for Installed Bucket......................................................459 Bucket Attachment, Removal and Reversal...............................................................460 Detaching the Bucket..............................................................................460 Attaching the bucket..............................................................................460 Reversing the Bucket..............................................................................461
DAEWOO DOOSAN SOLAR 55V PLUS EXCAVATOR SHOP MANUAL SERIAL NUMBER 1001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M
