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Page 3

General Maintenance Procedures

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WELDING PRECAUTIONS AND GUIDELINES

IMPORTANT

To avoid accidents, personal injury and the possibility of causing damage to the excavator or to
components, welding must only be performed by properly trained and qualified personnel, who
possess the correct certification (when required) for the specific welding fabrication or
specialized repair being performed.

WARNING!

Structural elements of the excavator may be built from a variety of steels. These could contain
unique alloys or may have been heat treated to obtain particular strength characteristics. It is
extremely important that welding repairs on these types of steel are performed with the proper
procedures and equipment. If repairs are performed incorrectly, structural weakening or other
damage to the excavator (that is not always readily visible) could be caused. Always consult
Daewoo After Sales Service before welding on integral components (car body, track frames,
turntable, attachment) of the excavator. It is possible that some types of structurally critical
repairs may require Magnetic Particle or Liquid Penetrant testing, to make sure there are no
hidden cracks or damage, before the excavator can be returned to service.

CAUTION!

Always perform welding procedures with the proper safety equipment on hand. Adequate
ventilation and a dry work area are absolutely essential. Keep a fire extinguisher nearby and
always wear protective clothing and the recommended type of eye protection.

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Содержание Solar 200W-V

Страница 1: ...Shop Manual 2023 7139E Serial Number 0001 and Up March 2000 Solar 200W V...

Страница 2: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Pub No 2023 7139E...

Страница 3: ......

Страница 4: ...S0402020 Counterweight S0403000 Fuel Tank S0405070 Swing Bearing S0407010 Swing Reduction Gearbox S0408040 Lower Structure and Chassis Ram Lock Valve Operation S0503000 Engine and Drive Train Front Ax...

Страница 5: ...ake Supply Valve S0709220 Counterbalance Valve S0709300 Main Control Valve Toshiba dx28 60 S0709440 Remote Control Valve Work Lever Joystick S0709450 Steering Valve S0709710 Hydraulic Schematic Solar...

Страница 6: ...Return to Master Table of Contents 1SAFETY...

Страница 7: ...p 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 safel...

Страница 8: ...ts TABLE OF CONTENTS To the Operator of a Daewoo Excavator 3 General Safety Essentials 5 Location of Safety Labels 5 Summary of Safety Precautions for Lifting in Digging Mode 6 Work site Precautions 7...

Страница 9: ...ocation of Safety Labels on page 5 3 Summary of Safety Precautions for Lifting in Digging Mode on page 6 4 Work site Precautions on page 7 5 Operation on page 9 6 Equipment on page 14 7 Maintenance on...

Страница 10: ...l Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents Always observe safety precautions and follow recommended pr...

Страница 11: ...vel on a firm supporting surface with hooks and slings attached in approved configuration Loads must be balanced and su pported evenly Us e ta glines to k eep the load s teady if wi nd co nditions and...

Страница 12: ...EM parts with the correct authorized or genuine Daewoo part For example not taking the time to replace fasteners bolts or nuts with the correct replacement parts could lead to a condition in which the...

Страница 13: ...es as a guideline only Depending upon the voltage in the line and atmospheric conditions strong current shocks can occur with the boom or bucket as far away as 4 6 m 13 20 ft from the power line Very...

Страница 14: ...erous situations by moving around the work site while making excavations Go on to another digging area b efore steep overhangs a re f ormed Working a round d eep pi ts o r along high walls or trenchin...

Страница 15: ...rk site or restricted hours of operation may be mandated by governing authorities There may also be guidelines standards or restrictions on equ ipment tha t may b e u sed to perform c ertain k inds of...

Страница 16: ...recently or is being operated in extremely cold temperatures could require a warm up or maintenance service prior to start up Check gauges and monitor displays for normal operation prior to starting t...

Страница 17: ...ould also be a ware of open wi ndows doors or duc twork in to whi ch e xhaust ma y b e carried or blown by the wind exposing others to danger ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZAR...

Страница 18: ...ttery This includes electrical s witches on t he b attery c harger or boost starting equipment When boost starting fr om an other mac hine or vehicle do not allow the two machines to touch Wear s afet...

Страница 19: ...e l ower str ucture or working assemblies of the attachment is at risk of be ing caught be tween mo ving parts of th e machine Never al low anyone to ride o n a ny part o f th e machine or attachment...

Страница 20: ...ontrols are in the OFF position the control stand lock lever must be engaged Release the left console to disable all pilot circuit control functions Insert the swing lock pin and engage all brakes and...

Страница 21: ...uard over the windshield may be required The windshield guard may or may not be OPS certified depending upon the specific application and working situation Laminate glass protection for the front side...

Страница 22: ...t all times Keep well clear of rotating parts Pinch point hazards such as cooling fan and alternator drive belts could catch hair jewelry or oversize or very loose clothing Safety la bels must be repl...

Страница 23: ...protection THE OPERATOR S CAB AND TURNTABLE DECK SHOULD BE KEPT CLEAN Cleaning off accumulations of grease and dirt helps extend equipment service life Cleaning also provides an opportunity to in spec...

Страница 24: ...t can create an explosive spark DISCONNECT BATTERIES FOR ELECTRICAL SERVICE BEFORE ELECTRICAL WELDING Remove cable to negative terminal first when disconnecting cable Connect positive terminal cables...

Страница 25: ...COOLING OR HYDRAULIC SYSTEMS Wait for the engine to cool off after normal operation Park the excavator on a firm level surface and lower all equipment before shutting down and switching OFF controls...

Страница 26: ...ing torques and recommended assembly compounds and always use the correct part Poor or incorrect fastener connections can dangerously weaken assemblies DISPOSE OF ALL PETROLEUM BASED OILS AND FLUIDS P...

Страница 27: ...or transport The hauling vehicle trailer and load must all be in compliance with local regulations governing the intended shipping route Partial disassembly or tear down of the excavator may be necess...

Страница 28: ...S0102020 Page 22 Wheel Excavator Safety Return to Master Table of Contents...

Страница 29: ...Return to Master Table of Contents 1SPECIFICATIONS...

Страница 30: ...Return to Master Table of Contents...

Страница 31: ...mmendations 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 eq...

Страница 32: ...te Weight of Workload Materials 14 General Specifications 17 Hydraulic System Component Specifications 18 System Component Specifications 19 Drive System 19 Swing Mechanism 19 Brake System 20 Steering...

Страница 33: ...able of Contents GENERAL DESCRIPTION The excavator has three main component sections The Upper Turntable The Lower Undercarriage and Power Train The Excavator Front end Attachment The following illust...

Страница 34: ...Page 4 Specifications for Solar 200W V Return to Master Table of Contents COMPONENT LOCATION Figure 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 H...

Страница 35: ...ic Oil Tank 8 Pumps 9 Counterweight 10 Engine 11 Muffler 12 Control Valve 13 Swing Motor 14 Center Joint 15 Swing Bearing 16 Boom Cylinder 17 Boom 18 Arm Cylinder 19 Arm 20 Bucket Cylinder 21 Link 22...

Страница 36: ...750 mm 108 27 in F Ground Clearance 340 mm 13 39 in G Frame Clearance 1 259 mm 49 57 in H Engine Cover Height 2 524 mm 99 37 in I Upper Housing Width 2 490 mm 98 03 in J Wheel Base 2 850 mm 112 20 in...

Страница 37: ...S0202040 Page 7 Specifications for Solar 200W V Return to Master Table of Contents...

Страница 38: ...S0202040 Page 8 Specifications for Solar 200W V Return to Master Table of Contents WORKING RANGE A B D C HBOK651L Figure 3...

Страница 39: ...2 400 mm 7 10 2 000 mm 6 7 BUCKET 0 75 0 75 0 75 0 75 A Maximum Digging Radius 9 960 mm 32 8 9 423 mm 30 11 8 941 mm 29 4 8 625 mm 28 4 B Maximum Digging Depth 6 620 mm 21 9 6 122 mm 20 1 5 641 mm 18...

Страница 40: ...100 mm 3 94 in Stroke 1 280 mm 50 39 in 1 536 mm 60 47 in 1 050 mm 41 34 in 175 mm 6 89 in 391 mm 15 39 in 153 mm 6 02 in Rod Dia 85 mm 3 35 in 95 mm 3 74 in 75 mm 2 95 in 80 mm 3 15 in 80 mm 3 15 in...

Страница 41: ...200 RPM Cylinder No Load Test Pressure Cylinder Firing Order 1 5 3 6 2 4 Engine Valve Cold Lash Adjustment 0 4 mm 0 0157 in intake exhaust Valve Timing Intake Open 10 BTDC Intake Close 42 ABDC Exhaus...

Страница 42: ...20 qt Engine Oil Pressure 4 kg cm2 56 9 psi Engine Oil American Petroleum Institute SAE Class CC CD or better Class CD II CE CF 4 CG 4 Coolant Capacity Engine only 12 l 12 7 qt Engine Coolant Thermos...

Страница 43: ...SPECIFICATION BAROMETIC PRESSURE 760 mm Hg 20 COOLING FAN 625 0 mm dia 24 61 in dia SUCKER ALTERNATOR 24V x 50A AIR CLEANER INSTALLED MUFFLER INSTALLED PERFORMANCE STANDARD KS R1004 POWER MAX RATED 1...

Страница 44: ...LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb...

Страница 45: ...3 240 lb yd3 Limestone graded above 2 1 282 kg m3 2 160 lb yd3 Limestone graded 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3...

Страница 46: ...le of Contents Shale broken 1 362 kg m3 2 295 lb yd3 Sulphur broken 529 kg m3 1 620 lb yd3 MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB...

Страница 47: ...13 06 metric tons 14 40 tons 13 07 metric tons 14 41 tons Arm 10 10 metric tons 11 13 tons 12 29 metric tons 13 55 tons 12 29 metric tons 13 55 tons 13 65 metric tons 15 05 tons Dozer Blade Width 2 44...

Страница 48: ...m 1 Travel Option Bucket Boom 1 Arm 2 360 kg cm2 5 119 psi Boom Arm Bucket Dozer Outrigger Remote Travel Control Valve Type Pressure Stroke Pilot Control 30 kg cm2 427 psi at 30 pedal angle Remote Imp...

Страница 49: ...ard Type Tire Rim Disc Offset Double 10 00 20 14PR OTR Tube 7 5V x 20 165 0 mm 6 50 in Tire and Wheel Option Type Tire Rim Disc Offset Wide Single 18 19 5 14PR OTR Tubeless 14 00 x 19 5 90 0 mm 3 54 i...

Страница 50: ...pe Brake Torque Brake Release Pressure Pilot Pressure Wet Disc 63 0 kg m 455 68 ft lbs 23 0 kg sq cm 327 psi Swing Safety Lock Type Manual Pin Locking Motor Accessory Brake Time Delayer Make Up Valve...

Страница 51: ...le Bore Size Rod Size Stroke Maximum Pressure 100 0 mm 3 94 in 50 0 mm 1 97 in 88 0 mm 3 46 in 180 0 kg sq cm 2 560 psi CHOCKING SYSTEM Chocking Valve Maker Model Maximum Working Pressure Check Valve...

Страница 52: ...de Boom Up seconds 2 9 0 3 3 2 0 3 Down seconds 2 4 0 3 2 4 0 3 Arm Dump seconds 2 6 0 3 2 9 0 3 Crowd seconds 3 0 0 3 3 4 0 3 Bucket Dump seconds 2 1 0 3 2 3 0 3 Crowd seconds 2 5 0 3 2 6 0 3 Dozer U...

Страница 53: ...uld be performed on a flat level firmly supporting ground surface 2 All r ecommended ap plicable ma intenance an d adj ustment s ervice s hould b e c ompleted p rior t o testing 3 Hydraulic fluid and...

Страница 54: ...D TESTS 1 Block up all wheels securely 2 Check that RPM at drive shaft is above 2 720 RPM at high speed and above 707 30 RPM at low speed 1 Travel Motor 2 Transmission 3 Propeller Shaft 4 Front Axle 5...

Страница 55: ...and Power Mode S SWING FORCE TEST With the bo om ar m a nd bucket in the s ame position as for the swing speed test rotate the turntable s o th at th e bo om i s evenly ce ntered pointing s traight a...

Страница 56: ...et Cylinder Test Start with the b oom up a nd the teeth of the bucket hanging vertically 500 mm 1 1 2 to 2 above the ground Dump and crowd the bucket several times and average results for both standar...

Страница 57: ...Return to Master Table of Contents 1GENERAL MAINTENANCE...

Страница 58: ...Return to Master Table of Contents...

Страница 59: ...mmendations 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 eq...

Страница 60: ...ns and Guidelines 3 Hydraulic System General Precautions 4 Maintenance Service and Repair Procedure 5 General Precautions 5 Hydraulic System Cleanliness And Oil Leaks 6 Maintenance Precautions for Hyd...

Страница 61: ...t welding repairs on these types of steel are performed with the proper procedures and equipment If repairs are performed incorrectly structural weakening or other damage to the excavator that is not...

Страница 62: ...g with clean hydraulic fluid is recommended Vibration irregular or difficult movement or unusual noise from any part of the hydraulic system could be an indication of air in the system as well as many...

Страница 63: ...ication of air leaking into the circuit Refer to the appropriate Troubleshooting s ection for co mponent or uni t for procedures or it m ay be e vidence o f a defective pump The gear type pilot pump c...

Страница 64: ...penings of flanges manifolds and piping Do not allow cleaning solvents or other fluids to mix with the oil in the system Use clean oil to flush any traces of solvent or other residue before reassembly...

Страница 65: ...m across bearing to avoid spinning bearings that are not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully i nspect all bear i...

Страница 66: ...efully examine the condition of the be arings and all of its components for wear and damage Once the bearing is removed clean all parts thoroughly using a suitable cleaning solution If the bearing is...

Страница 67: ...su rfaces wi th no dis coloration or marks Bent Cage Cage damage due to i mproper handling or tool usage Replace bearing Galling Metal smears o n r oller en ds du e t o o verheat lubricant failure or...

Страница 68: ...gray or grayish black in color with r elated etching away o f m aterial usually at roller spacing Replace be arings c heck seals and c heck for proper lubrication Misalignment Outer race misalignment...

Страница 69: ...im pact l oading or v ibration while the bearing is not rotating Replace bearing if rough or noisy Cage Wear Wear around outside diameter of cage and roller pockets ca used b y a brasive material an...

Страница 70: ...leaking Smears Smearing of me tal due to s lippage c aused b y poor f itting lub rication o verheating o verloads or handling damage Replace b earings c lean r elated par ts an d check for proper fit...

Страница 71: ...e drawn over a tempered part will grab and cut metal whereas a fil e dr awn over a har d pa rt wi ll glide r eadily with no metal cutting Replace bea ring if o ver heating damage is indicated Check se...

Страница 72: ...S0302000 Page 14 General Maintenance Procedures Return to Master Table of Contents...

Страница 73: ...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 sa...

Страница 74: ...d Metric Fasteners 3 Torque Values for Standard U S Fasteners 4 Type 8 Phosphate Coated Hardware 6 Torque Values for Hose Clamps 7 Torque Values for Split Flanges 8 Torque Wrench Extension Tools 9 Tor...

Страница 75: ...33 11 50 83 17 12 00 86 79 17 00 122 96 20 00 144 66 M14 x 1 5 4 10 29 65 4 30 31 10 6 60 47 73 5 70 41 22 8 30 60 03 7 50 54 24 11 10 80 28 12 50 90 41 13 00 94 02 18 50 11 26 22 00 158 12 M16 x Std...

Страница 76: ...d jam nuts are used 0 70 when Molykote white lead or similar mixtures are used as lubricants 0 75 when parkerized bolts or nuts are used 0 85 when cadmium plated bolts or nuts and zinc bolts w waxed z...

Страница 77: ...DASHES ON HEAD FOOT POUNDS Ft Lbs NEWTON METER N m FOOT POUNDS Ft Lbs NEWTON METER N m 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3...

Страница 78: ...n The torques shown below also apply to the following 1 Phosphate coated bolts used in tapped holes in steel or gray iron 2 Phosphate c oated bolts u sed wi th phosphate c oated prevailing to rque nut...

Страница 79: ...rating lever boots hydraulic system etc CLAMP TYPE AND SIZE TORQUE PLUS OR MINUS 5 lbf in 0 1 kg m RADIATOR AIR CLEANER BOOTS ETC HYDRAULICSYSTEM KILOGRAM METER kg m INCH POUNDS In Lbs KILOGRAM METER...

Страница 80: ...OTE Overtorquing bolts will damage the flanges and or bolts which may cause leakage Inside diameter of flange on end of hydraulic tube or hose fitting NOTE Values stated in chart are for Standard Pres...

Страница 81: ...lt and the bac k handle end of the tor que wrench doubles the tightening force on the bolt It also halves the indicated reading on the scale or dial of the to rque wr ench T o accurately adjust or con...

Страница 82: ...the ne eded degree of precision and accuracy To allow the assembly or mechanism to accept a torque wrench welding a nut or other adapter on the end of a linkage shaft or other leverage point will allo...

Страница 83: ...larger Red Heat 260 C 500 F Remove HOT 210 Product Application Color Removal Required Setup 545 No filler non clog formula for high pressure hydraulic systems Over application will not restrict or fo...

Страница 84: ...strength and all cold temperature applications 620 For high temperatures to 232 C 450 F Green Same as 609 above 680 For high strength bonds and tight clearance gaps to 0 00008 mm 0 002 Green Same as 6...

Страница 85: ...Return to Master Table of Contents 1UPPER STRUCTURE...

Страница 86: ...Return to Master Table of Contents...

Страница 87: ...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 tha...

Страница 88: ...S0402020 Page 2 Cab Return to Master Table of Contents TABLE OF CONTENTS Removal 3 Installation 5 Window and Gasket Replacement 8 Falling Object Protective Structures F O P S 9...

Страница 89: ...ing C Radio antenna and connections D Wiper washer connections NOTE Control console wiring harnesses and hydraulic piping lines that pass through the floor of the cab do not need to be disassembled NO...

Страница 90: ...ct 3 12 Disconnect wiper moto r co nnector and front window washer hose located at floor plate bottom 13 Remove tw o r ubber sto ps 2 Figu re 3 used i n s toring the f ront l ower gl ass Remove bol ts...

Страница 91: ...mm 1 2 above deck hei ght Chec k tha t all el ectrical connections have been disconnected and all other items unbolted 22 Continue lifting with the as sist cr ane to remove the cab shell Lower the she...

Страница 92: ...und cable 2 Figure 2 8 Connect cab lamp wiring connector 9 Connect s peaker wi re to r ight s ide c over 4 Figure 3 10 Connect sp eaker wir e ste reo wir e an d antenna wi re c onnector to left s ide...

Страница 93: ...an d 8 Figu re 2 located at right side of cab NOTE Connect d uct wi ring c onnector before installing air duct 3 15 Connect hour meter connector and install duct covers 5 6 7 and 9 Figure 2 16 Instal...

Страница 94: ...glass for assembly A s harp c urving me tal h ook an d or a straight poi nted awl c an b e he lpful i n e asing win dow glass into position Start from the bottom of the frame and work up IMPORTANT Wh...

Страница 95: ...projections Operator Protective Structures O P S are designed to p rovide additional barrier protection around the operator s cab area For example using a sh earing attachment on the excavator for dem...

Страница 96: ...BUY NOW Then Instant Download the Complete Manual Thank you very much Have questions Please write to me aservicemanuapdf yahoo com...

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