Tài liệu sửa chữa bảo dưỡng máy đào DAEWOO DOOSAN SOLAR 55V Tài liệu sửa chữa bảo dưỡng máy đào DAEWOO DOOSAN SOLAR 55V Tài liệu sửa chữa bảo dưỡng máy đào DAEWOO DOOSAN SOLAR 55V Tài liệu sửa chữa bảo dưỡng máy đào DAEWOO DOOSAN SOLAR 55V Tài liệu sửa chữa bảo dưỡng máy đào DAEWOO DOOSAN SOLAR 55V Tài liệu sửa chữa bảo dưỡng máy đào DAEWOO DOOSAN SOLAR 55V Tài liệu sửa chữa bảo dưỡng máy đào DAEWOO DOOSAN SOLAR 55V
Solar 55-V Plus Shop Manual 023-00045AE Serial Number 1001 and Up Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place These improvements can be implemented at any time with no obligation to change materials on previously sold products It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment This documentation may include attachments and optional equipment that is not available in your machine's package Please call your distributor for additional items that you may require Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item 023-00045AE Shop Manual 1TABLE OF CONTENTS Publication Request for Proposed Revision Safety Track Excavator Safety S0102035K Specifications Specifications for Solar 55-V PLUS S0202035K General Maintenance General Maintenance Procedures S0302000 Standard Torques S0309000 Upper Structure Lower Structure and Chassis Track Assembly .S0505070 Engine and Drive Train Air Conditioner .S0605015 Hydraulics Accumulator S0703010K Center Joint (Swivel) S0704050 Cylinders S0705000 Travel Motor S0707370 R1 Swing Motor S0707380 Main Pump S0708370 Main Control Valve S0709465K Pilot Control Valve (Work Lever / Joystick) S0709470 Hydraulic Schematic (Solar 55-V PLUS) S0792095K Table of Contents Page I Electrical System Electrical System S0802085K Electrical Schematic (Solar 55-V PLUS) S0892095K Attachments Bucket S0904000 Table of Contents Page II 1SAFETY S0102035K 1TRACK EXCAVATOR SAFETY CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember, that ultimately safety is your own personal responsibility TRACK EXCAVATOR SAFETYS0102035K MODEL SERIAL NUMBER RANGE Solar 55-V PLUS 1001 and Up Solar 75-V PLUS 1001 and Up Copyright 2004 Daewoo January 2004 Track Excavator Safety S0102035K Page TABLE OF CONTENTS To the Operator of a Daewoo Excavator Learn the Signal Words Used with the Safety Alert Symbol General Safety Essentials Accessory Applications Lifting Capacity Rating Configuration Location of Safety Labels Summary of Safety Precautions for Lifting in Digging Mode Unauthorized Modifications 10 General Hazard Information 10 Safety Rules 10 Safety Features 10 Inside Operator's Compartment 11 Clothing and Personal Protective Items 11 Breathing Masks, Ear Protection May Be Required 12 Vibration Level Information 12 Mounting and Dismounting 13 Fuel, Oil and Hydraulic Fluid Fire Hazards 14 Precautions When Handling Fluids at High Temperature 14 Asbestos Dust Hazard Prevention 15 Injury from Work Equipment 15 Fire Extinguisher and First Aid Kit 16 Protection from Falling or Flying Objects 16 Attachment Precautions 17 Accumulator 17 Indoor Ventilation 18 Emergency Exit 18 Before Starting Engine 19 Work Site Precautions 19 Checks Before Starting Engine 20 Engine Starting 21 S0102035K Page Track Excavator Safety Before Operating Machine 21 Machine Operation 22 When Swinging or Changing Direction of Travel 22 Travel Precautions 23 Traveling on Slopes 24 Prohibited Operations 24 Precautions for Operation 25 Avoid High-voltage Cables 26 Operate Carefully on Snow, Ice and in Very Cold Temperatures 26 Operations on Slopes 27 Parking Machine 27 Never Let Anyone Ride on Attachment 27 Maintenance 28 Warning Tag 28 Clean Before Inspection or Maintenance 28 Proper Tools 29 Use of Lighting 29 Fire Prevention and Explosion Prevention 29 Burn Prevention 30 Welding Repairs 31 Warning for Counterweight and Front Attachment Removal 31 Precautions for Removal, Installation, and Storage of Attachments 32 Precautions when Working on Machine 32 Lock Inspection Covers 32 Crushing Prevention and Cutting Prevention 33 Track Tension Adjustments Require Caution 33 Supports and Blocking for Work Equipment 33 Action When Abnormally Is Found During Inspection 34 Precautions with High-pressure Line, Tubes and Hoses 34 Waste Materials 35 Battery 36 Battery Hazard Prevention 36 Starting Engine With a Booster Cable 37 Track Excavator Safety S0102035K Page Connecting the Booster Battery 38 Disconnecting the Booster Battery 38 Towing 39 Precautions When Towing 39 Shipping and Transportation 40 Obey State and Local Over-the-Road Regulations 40 Lifting With Sling 40 S0102035K Page Track Excavator Safety S0904000 R4 1BUCKET CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember, that ultimately safety is your own personal responsibility BUCKET S0904000 MODEL SERIAL NUMBER RANGE Solar 015 0001 and Up Solar 015 PLUS 1001 thru 1157, 20001 thru 20065, 20066 and Up Solar 130LC-V 0001 and Up Solar 130W-V 0001 and Up Solar 140LC-V 1001 and Up Solar 140W-V 1001 and Up Solar 160W-V 1001 and Up Solar 170LC-V 1001 and Up Solar 170W-V 1001 and Up Solar 180W-V 1001 and Up Solar 200W-V 0001 and Up Solar 210W-V 1001 and Up Solar 220LC-V 0001 and Up Solar 225NLC-V 1001 and Up Solar 250LC-V 1001 and Up Solar 255LC-V 1001 and Up Solar 290LC-V 0001 and Up Solar 330LC-V 1001 and Up Solar 400LC-V 1001 and Up Models continued on back of cover Copyright 2004 Daewoo January 2004 Bucket S0904000 Page MODEL Solar 450LC-V SERIAL NUMBER RANGE 1001 and Up Solar 55 0001 and Up Solar 55-V PLUS 1001 and Up Solar 55W-V PLUS 1001 and Up Solar 75-V 1001 and Up TABLE OF CONTENTS Bucket Tooth Inspection and Replacement Type Type Type Bucket O-ring Replacement Type Type Bucket Shimming Procedures 10 New Bucket Installation 10 Type 10 Type 11 Bucket Attachment, Removal and Reversal 12 Detaching the Bucket 12 Attaching the bucket 12 Reversing the Bucket 13 S0904000 Page Bucket BUCKET TOOTH INSPECTION AND REPLACEMENT There are several different types of attachment methods for replaceable bucket teeth Some of the most common types are shown in the following drawings Bucket teeth are usually replaced in sets but it may sometimes be necessary to replace individual teeth TYPE Look for the following indications of wear or damage: • Lock pins protrude unevenly on one side • Lock pins have been worn down so far that they no longer make full contact through the length of the pin hole • Lock washers or pins show obvious damage or weakness • Wear points on the working surfaces of tooth points - pits, cracks, chips or craters - are larger than - 10 mm (1/3" - 1/2") across HAOC680L Figure 1 On a routine basis, inspect the bucket teeth to make sure that tooth wear or breakage has not developed Do not allow the replaceable bucket teeth to wear down to the point that the bucket adapter is exposed See Figure To replace a tooth (1, Figure 4), use a hammer and punch to drive the locking pin (2) and lock washer (3) out of the tooth adapter (4) Once the worn tooth has been removed, use a putty knife to scrape the adapter as clean as possible Slide the new tooth into position and insert the lock washer Insert the locking pin into the tooth and with a hammer, drive the pin in until the lock washer seats in the locking groove Bucket Figure S0904000 Page TYPE WARNING! Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing bucket teeth Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground Shut the engine off and lock out the hydraulic controls before working on the bucket NOTE: These instructions are only for Daewoo OEM buckets If you are using other manufacturers buckets, refer to their specific instructions Figure On a routine basis, inspect the bucket teeth to make sure that tooth wear or breakage has not developed Do not allow the replaceable bucket teeth to wear down to the point that the bucket is exposed See Figure To replace a tooth, remove bolts, lock washers and plain washers from seat Remove tooth and shim(s) from bucket See Figure Once the worn tooth has been removed, use a putty knife to scrape bucket as clean as possible S0904000 Page Figure Bucket Slide the new tooth into position and insert shims Shim tooth until gap is less than "X" [0.5 mm (0.020 in)] See Figure 5 Secure tooth and shim into position with seat, plain washers, lock washers and bolts Figure TYPE WARNING! Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing bucket teeth Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground Place wooden blocks under front of bucket Shut the engine off and lock out the hydraulic controls before working on the bucket Inspect locking pin assembly and replace it if the following conditions exist; The locking pin is too short when both surfaces are aligned The rubber has been torn and bosses of the steel balls are liable to slip off Pressing steel ball causes the boss to go inside X X 1/3T T X HAOE380L Figure Bucket S0904000 Page HAOC680L Figure On a routine basis, inspect bucket teeth to make sure that tooth wear or breakage has not developed Do not allow replaceable bucket teeth to wear down to a point that bucket adapter is exposed See Figure To replace a tooth, use a hammer (1, Figure 8) and punch (2) to drive locking pin assembly out of tooth and tooth adapter Once the worn tooth has been removed, use a putty knife to scrape adapter as clean as possible Slide new tooth into position and insert locking pin assembly S0904000 Page HAOE370L Figure Bucket BUCKET O-RING REPLACEMENT TYPE WARNING! Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins Inspect the bucket O-rings on a routine basis If worn or damaged, replacement is necessary HAOH640I Figure Roll the old O-ring (1, Figure 10) onto the boss (2) around the bucket pin (3) Remove the bucket pin and move the arm or bucket link (4) out of the way HAOC710L Figure 10 Remove the old O-ring and temporarily install the new O-ring (1, Figure 11) onto the bucket boss (2) Make sure that the O-ring groove on both the bucket link (4) and boss have been cleaned Realign the arm or link with the bucket pin hole and insert the bucket pin (3, Figure 10) HAOC701L Figure 11 Bucket S0904000 Page Roll the new O-ring (1, Figure 12) into the O-ring groove HAOC720L Figure 12 TYPE WARNING! Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins Inspect the bucket O-rings on a routine basis If worn or damaged, replacement is necessary HAOE360L Figure 13 Roll the old O-ring (1, Figure 10) onto the bushing (2) around the bucket pin (3) Remove the bucket pin and move the arm or bucket link (4) out of the way HAOC710L Figure 14 S0904000 Page Bucket Remove the old O-ring and temporarily install the new O-ring (1, Figure 11) onto the bucket bushing (2) Make sure that the O-ring groove on both the bucket link (3) and bushing have been cleaned Realign the arm or link with the bucket pin hole and insert the bucket pin (3, Figure 10) HAOC700L Figure 15 Roll the new O-ring (1, Figure 12) into the O-ring groove HAOC720L Figure 16 Bucket S0904000 Page BUCKET SHIMMING PROCEDURES NEW BUCKET INSTALLATION If a new bucket is being installed on the excavator, measure the inside dimension between the bucket ears and the outside dimension across the arm mounting boss Subtract the clearance on both sides from the difference of the two and shim accordingly, before assembly WARNING! To check end play (side-to-side) clearance at bucket attachment point, the bucket must be free to move but at all other times lower it to the ground or use support blocks to immobilize this assembly Shut off engine and tag and lock out controls to prevent movement during this procedure TYPE Shimming Procedures for Installed Bucket With bucket attached, curl bucket and arm outward and lower boom so that bucket teeth are pointing away from excavator, just a few inches off ground This position provides easy accessibility for dimensional measurements Force bucket to one side and check for end play (side-to-side) clearance under O-rings at attachment point Total clearance should be mm (0.04 in) between side face of boss and inside edge of ear bushing (Y, Figure 17) Too tight a fit (less than mm (0.04 in)) can cause excessive wear while too much clearance may produce excessive noise and potentially hazardous slack control Recheck end play by forcing bucket towards opposite side and repeating clearance measurements If an adjustment is required, remove two jam nuts (1, Figure 17) and bolt (2) from pin (3) Add or remove shims (4) as required Use equal amount of shims on each side Install bolt (2) and two jam nuts (1) Jam nuts must clear boss by - mm (0.04 - 0.08 in) at point (X) S0904000 Page 10 Figure 17 Bucket TYPE Shimming Procedures for Installed Bucket With bucket attached, curl bucket and arm outward and lower boom so that bucket teeth are pointing away from excavator, just a few inches off ground This position provides easy accessibility for dimensional measurements Force bucket to one side and check for end play (side-to-side) clearance under O-rings at attachment point Clearance should be between 0.2 - 0.7 mm (0.0078 - 0.0275 in) on each end of arm boss, between side face of boss and inside edge of ear bushing Too tight a fit can cause excessive wear while too much clearance may produce excessive noise and potentially hazardous slack control Recheck end play by forcing bucket towards opposite side and repeating clearance measurements HAOE361L Figure 18 If an adjustment is required, remove bolt (Figure 17) and pin Add or remove shims as required Install pin and bolt Torque bolts to 42 Nm / 4.3 kg•m (31 ft lb) Bucket S0904000 Page 11 BUCKET ATTACHMENT, REMOVAL AND REVERSAL DETACHING THE BUCKET Park the excavator away from obstructions on clear, flat, level ground Lower the bucket carefully to preassembled blocking on the ground Brace the bucket so that there is no load weight on the pin connecting the bucket and arm Disassemble the fasteners on the end of the bucket pin and pull out the pin If the pin sticks and resists normal withdrawal, there may be a load on it Raise and lower the arm slightly until the unstressed pin position is located CAUTION! Use care pulling out the pin to avoid damaging the dust seals on either end of the arm When the pin has been withdrawn, move the operating joystick slightly to take weight off the remaining link pin Disassemble the link pin end retainers and pull out the pin Lift the arm away from the bucket so that the bucket can be carried away or another end attachment can be put on the excavator ATTACHING THE BUCKET Carefully inspect all parts before reassembling the bucket linkage Look for cracks or any other evidence of physical damage and replace any seal or O-ring that is not in like-new condition Prelube linkage pins before assembly Use an old cylinder rod, a long breaker bar or a similar, relatively thin diameter support bar for making the first (temporary) pin connection, between the bucket and arm If the support bar is straight, the arm can be raised and the bucket will hang level, allowing direct insertion of the bucket ear-attachment linkage pin Figure 19 S0904000 Page 12 Bucket When the link pin has been installed, withdraw the temporary support rod from the bucket pin holes, lower and raise the arm and boom and install the bucket pin WARNING! When making linkage alignments, never insert fingers into pin holes The attachment or bucket could shift position and cause a severe injury Match holes by visually lining them up Use the sharp tipped, soft point of a pencil or a similar tool to check for high spots or irregularities REVERSING THE BUCKET Follow instructions for "Detaching the Bucket" and remove both the bucket and link pins Rotate the bucket 180° to change bucket configuration This procedure is greatly simplified if some type of rotating or swiveling support can be used, on the ground underneath the bucket Follow instructions for "Bucket Attachment" to replace pins WARNING! Figure 20 Bucket curl and dump levers must be used in opposite directions, after the bucket has been reversed Bucket S0904000 Page 13