Complete official service manual for Doosan / Daewoo Solar 470LC-V Excavator, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Daewoo Solar 470LC-V Excavator workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Daewoo Solar 470LC-V Shop Manual.pdf
Solar 470LC-V Operation and Maintenance Manual 022-00022E Serial Number 1001 and Up.pdf
HYDRAULIC CIRCUIT S420LC-V.pdf
MDOOS470OPEK.zip
S470 DİAGRAM.pdf
S470 MAZOT POMPA.pdf
Total Pages: 631 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
To the Operator of a Daewoo Excavator .. 3
General Safety Essentials .. 5
Location of Safety Labels … 5
Summary of Safety Precautions for Lifting in Digging Mode .. 6
Work-site Precautions .. 7
Operation.. 9
Equipment .. 14
Maintenance… 18
Shipping and Transportation… 21
Lifting With Sling… 21
Daewoo Solar 470LC-V Shop Manual…2
Safety…2
Track Excavator Safety…3
To the Operator of a Daewoo Excavator…5
General Safety Essentials…7
Location of Safety Labels…7
Summary of Safety Precautions for Lifting in Digging Mode…8
Work Site Precautions…9
Operation…11
Equipment…16
Maintenance…20
Shipping and Transportation…23
Lifting with Sling…23
Specifications…25
Specifications for Solar 470LC-V…26
General Description…28
Component Locations…29
General Dimensions…32
Working Range…33
General Specifications…35
Engine Performance Curves (Per KS-R1004 Standard)…37
Approximate Weight of Workload Materials…39
Performance Tests…42
Excavator Performance Standards…43
General Maintenance…48
General Maintenance Procedures …49
Welding Precautions and Guidelines…51
Hydraulic System – General Precautions…52
Maintenance Service and Repair Procedure…53
Hydraulic System Cleanliness and Oil Leaks…54
Cleaning and Inspection…55
Standard Torques…63
Torque Values for Standard Metric Fasteners…65
Torque Values for Standard U.S. Fasteners…66
Type 8 Phosphate Coated Hardware…68
Torque Values for Hose Clamps…69
Torque Values for Split Flanges…70
Torque Wrench Extension Tools…71
Upper Structure…75
Cab…76
Removal…78
Installation…81
Counterweight…84
General…86
Removal…88
Installation…89
Fuel Tank…90
General Description…92
Removal…95
Installation…98
Start-up Procedures…100
Fuel Transfer Pump…102
General Description…104
Troubleshooting…105
Replacement of Rotor and Vane…105
Replacement of Rear Cover…106
Replacement of Armature…107
Swing Bearing…108
Swing Bearing Maintenance…110
Swing Reduction Gearbox…114
General Descriptio…116
Special Tools and Materials…119
Troubleshooting, Testing and Adjustment…121
Removal…122
Diassembly…124
Cleaning and Inspection (Wear Limits and Tolerances)…127
Reassembly…129
Installation…134
Lower Structure and Chassis…136
Track Assembly…137
General Description…139
Track Tension…139
Cleaning and Inspection (Wear Limits and Tolerances)…141
Track Shoes and Links…145
Front Idler Roller…148
Lower Roller…153
Upper Roller…158
Track Spring and Track Adjusting Cylinder…165
Engine and Drive Train…167
Air-conditioner…168
Refrigerant Circulation…170
Control Panel…172
Control Specifications…173
Temperature Level Control and Display…174
Air Discharge According To Path Selection…175
Air-conditioning System Circuit Diagram…177
Troubleshooting…179
Refrigerant System Repairs…182
Drive Coupling (Main Pump)…190
Drive Coupling…192
Special Tools…193
Drive Coupling Installation…195
Hydraulics…200
Hydraulic System Troubleshooting, Testing and Adjustement…201
Hydraulic System – General Notes…204
Hydraulic Schematic…205
Operation of Working Components…206
Procedural Troubleshooting Baseline Recommendations…211
Pilot Pressure…212
Power Mode Valve…213
Boom/Front Priority Valve…214
Pressure Up Valve…215
Pump Input Power Control…217
Flow Meter and Flow Meter Kit Installation and Testing…220
Swing System Troubleshooting…222
Troubleshooting – Swing Gearbox…224
Troubleshooting – Hydraulic Problems…225
Troubleshooting – Control Valve…227
Troubleshooting – Travel Control Valve…228
Troubleshooting – Joystick Control Valve…229
Accumulator…231
General Descriptio…233
Center Joint (Swivel)…235
General Descriptio…237
Troubleshooting, Testing and Adjustment…239
Disassembly…240
Reassembly…240
Cylinders…243
General Description…245
Special Tools and Materials…248
Diassembly…252
Reassembly…258
Swing Motor…263
General Description…265
Special Tools…273
Disassembly…274
Cleaning and Inspection (Wear Limits and Tolerances)…281
Reassembly…283
Travel Motor (With Gearbox) (A6V160HD)…291
General Description…293
Travel Motor Disassembly…313
Travel Motor Speed Reduction Gearbox Disassembly…327
Cleaning and Inspection (Wear Limits and Tolerances)…336
Travel Motor Speed Reduction Gearbox Reassembly…337
Travel Motor Reassembly…347
Main Pump (Rexroth)…351
Sectional View…354
General Repair Guidelines…356
Seal Kits and Sub-assemblies…357
Sealing The Drive Shaft…362
Gear Pump Sealing…364
Remove the Control Housing…365
Control Module…369
Removing The Controller…371
Valve Plate With Valves…373
Remove The Rotary Groups…374
Remove The Intermediate Wheel…377
Remove Auxiliary Drive…379
Inspection Hints…381
Re-fitting The Rotary Group…386
Pump Assembly…387
Hydraulic Component – Measurement "D"…390
Fit Control Housing…395
Assembly of The Intermediate Wheel…398
Fit The Gear Pump…399
Fit The Cover / Auxiliary Drive…400
Assembly Guidelines for Tightening Torques…401
Main Control Valve (Kayaba)…403
General Description…405
Troubleshooting, Testing and Adjustment…436
Diassembly…439
Cleaning and Inspection (Wear Limits and Tolerances)…444
Reassembly…445
Installation…451
Start-up Procedures…451
Pilot Control Valve (Work Lever.Joystick)…453
General Description…455
Removal…458
Disassembly…460
Cleaning and Inspection (Wear Limits and Tolerances)…464
Reassembly…465
Installation…470
Start-up Procedures…470
Travel Control Valve (With Damper)…473
General Description…475
Troubleshooting, Testomg amd Adjustment…480
Removal…481
Disassembly…483
Cleaning and Inspection (Wear Lmits and Tolerances)…489
Reassembly…490
Installation…495
Start-up Procedures…496
Hydraulic Schematic (S470LC-V)…497
General Description…499
Solar 470LC-V…500
Electrical System…503
Electrical System…504
Troubleshooting – Electrical System…507
Overview…508
Electric Supply System…509
Engine Starting Circuit…510
Engine Preheating System…512
Engine Stop System…513
Charging System…516
Monitoring System…517
Operation…521
Warning and Indicator Lights…523
Initial Operation…525
Mode Select Switch…526
Graphic Information Area Display…527
Main Menu…529
Special Menu…531
Electronic Hydraulic Control System (e-EPOS)…545
Power Mode Control…547
Power Mode Control – Circuit Diagram…551
Trenching Mode Control…553
Trenching Mode Control – Circuit Diagram…555
Engine Control System…556
Engine Control Motor…557
Engine Control Dial…558
Engine Control Circuit Diagram…560
Automatic Deceleration Control (Auto Idle Control)…561
Engine Overheat Protection System…562
Power Boost Mode…563
Automatic Travel Speed Control…565
Engine Control Device – Adjustment…567
Self-diagnostic Function…570
Engine Throttle Controller…572
Wiper System…573
Lighting System…575
Overload Warning Device…577
Electrical Schematic (S470LC-V)…578
General Description…580
Solar 470LC-V…581
Attachments…584
Boom and Arm…585
Front Attachment Pin Specifications…587
Front Attachment – Removal and Inspection…588
Installation…591
Start-up Procedures…592
Bucket…593
Bucket Tooth Inspection and Replacement…595
Bucket O-ring Replacement…598
Bucket Shimming Procdures…600
Bucket Attachment, Removal and Reversal…601
HYDRAULIC CIRCUIT S420LC-V…603
S470 DİAGRAM…604
S470 MAZOT POMPA…605
Solar 470LC-V Operation and Maintenance Manual 022-00022E Serial Number 1001 and Up…606
Safety…612
To the Operator of a Daewoo Excavator…612
Learn the Signal Words Used with the Safety Alert Symbol…614
Location of Safety Labels…615
1. Warnings for operation, inspection and maintenance (190-00688, 190-00092)…616
2. Warnings for high voltage (190-00689, 190-00096)…616
3. Warnings when opening a front window (190-00690, 190-00093)…616
4. warnings for a high pressure cylinder (190-00122)…617
5. Warnings when adjusting track tension (2190-3386A, 190-00521)…617
6. WARNINGs FOR LEAVING OPERATOR’S SEAT (190-00693, 190-00094)…618
7. Warnings for batteries maintenance (2190-2533A, 190-00100)…618
8. Warnings for high temperature hydraulic oil (190-00691, 190-00097)…619
9. Warnings for hot Coolant (190-00692, 190-00097)…619
10. Warnings for handling an accumulator (190-00703, 190-00099)…619
11. WARNINGS FOR ROTATING PARTS (190-00694, 190-00095, 190-00557)…620
12. Warning tag – used when inspection and maintenance (190-00695, 190-00098)…620
13. warning for a hot surface (19000648)…621
14. caution for hood (190-00522)…621
15. keep out of the swing area (2190-3379, 190-00090)…621
16. Warnings for front attachments (190-00652)…622
Summary of Safety Precautions for Lifting in Digging Mode…623
Unauthorized Modifications…624
General Hazard Information…624
Safety Rules…624
Safety Features…624
Inside Operator's Compartment…625
Clothing and Personal Protective Items…625
Mounting and Dismounting…626
Fuel, Oil and Hydraulic Fluid Fire Hazards…627
Precautions When Handling Fluids at High Temperature…627
Asbestos dust hazard prevention…628
Injury from Work Equipment…628
Fire Extinguisher and First Aid Kit…629
Protection from Falling or Flying Objects…629
Attachment Precautions…630
Accumulator…630
Indoor Ventilation…631
Emergency Exit…631
Before Starting Engine…632
Work Site Precautions…632
Checks Before Starting Engine…633
Engine Starting…634
Before Operating Machine…634
Machine Operation…635
When Swinging or Changing Direction of Travel…635
Travel Precautions…635
Traveling on Slopes…636
Prohibited Operations…637
Precautions for Operation…637
Avoid High-voltage Cables…638
Operate Carefully on Snow, Ice and in Very Cold Temperatures…638
Operations on Slopes…639
Parking Machine…639
Never Let Anyone Ride on Attachment…639
Maintenance…640
Warning Tag…640
Clean Before Inspection or Maintenance…640
Proper Tools…641
Use of Lighting…641
Fire Prevention and Explosion Prevention…641
Burn Prevention…642
Welding Repairs…643
Precautions for Removal, Installation, and Storage of Attachments…643
Precautions when Working on Machine…644
Lock Inspection Covers…644
Crushing Prevention and Cutting Prevention…644
Track Tension Adjustments Require Caution…645
Supports and Blocking for Work Equipment…645
Action When Abnormally Is Found During Inspection…646
Precautions with High Pressure Line, Tubes and Hoses…646
Waste Materials…647
Battery…648
Battery Hazard Prevention…648
Boost Starting or Charging Engine Batteries…649
Towing…650
Precautions When Towing…650
Shipping and Transportation…651
Obey State and Local Over-the-Road Regulations…651
Excavator Rated Lift Capacity Tables…652
Operating Controls…658
Component Locations…659
Operator’s Area…661
Operational Controls and Panels…662
1. Starter Switch…663
2. Engine Speed Control Dial…663
3. light Switch…664
4. Wiper Switch…664
5. Windshield Washer Switch…665
6. Travel Speed Selection Switch…665
7. Stereo On/Off Switch…666
8. Cab Work Light Switch (Optional)…666
9. Warning Light Switch (Optional)…666
10. Travel/Swing Alarm Switch (Optional)…667
11. Overload Warning Switch (Optional)…667
12. Heater and Air Conditioner Control Panel…668
13. Cigar Lighter…668
14. Power Socket for 12 Volt…668
15. Horn Switch (Left-hand Work Lever (Joystick))…669
16. Booster Switch (Right-Hand work lever (Joystick))…669
17. Breaker Switch (Right-Hand Work Lever (Joystick))…669
18. Instrument Panel…669
19. Safety Lever…670
Instrument Panel…671
Functional check…672
1. Engine Coolant Temperature Gauge…672
2. Fuel Gauge…672
3. Multifunction Gauge and Graphic Information Area…673
4. Digital Clock…673
5. Hour Meter…673
6. Charge Warning Light…674
7. Engine Oil Pressure Warning Light…674
8. Coolant Temperature Warning Light…674
9. Preheating Completion Light…675
10. Work Light Indicator Light…675
11. Overload Warning Light (Optional)…675
Multifunction Gauge and Graphic Information…676
Communication Indicator…676
Communication Error Warning…677
1. Engine Speed…677
2. Battery Voltage…677
3. Front Hydraulic Pump Pressure…678
4. Rear Hydraulic Pump Pressure…678
5. Abnormal State Warning of Filters…679
Mode Selection Buttons…680
1. Power Mode Selection Button…680
2. Trenching Mode Selection Button…681
3. Auto Idle Selection Button…681
4. Display Selection Button…682
Setting Method for Main Menu…683
Main Menu…683
Language…684
Set Clock…684
Filter / Oil Info…685
Heater and Air Conditioner Control Panel…687
Location of Controls and Vents…687
Operation Panel…688
1. Fan and Air-conditioner Switch…688
2. Fan Speed Selection Switches…689
3. Temperature Control Switch…689
4. Air Outlet Selection Switch…690
5. Ventilation Selection Switch…691
Memory Function of Used Mode…691
Additional Operating Instructions…691
Stereo…692
Security and Area Code Setting…692
Order to Set Up Security and Area Code…692
Front Panel…693
1. Power/Volume Control Knob…693
2. Sound Mode Selection Button…693
3. Band Selection Switch…694
4. Tuning Up/Down…694
5 & 6. Auto Memory and Preset Scan Button / Preset Station Button…695
7. Tape Slot…695
8. Tape Ejection Button…695
9. Cassette and Program Buttons…696
10. Security Warning LED…696
11. Scan…696
12. LCD…697
Care of Stereo…697
Fuse Boxes…699
Miscellaneous Electrical Devices…700
1. Cab Light…700
2. Pilot Cutoff Switch…700
3. Circuit Breaker…700
4. Fusible Link…701
Seat Adjustment…702
1. Forward / Backward Adjustment (Figure 83)…702
2. Adjusting the Seat's Tilt and Seat Height (Figure 83)…702
3. Weight Adjustment (Figure 83)…702
4. Adjusting Reclining (Figure 83)…702
5. Moving the Total Seat Setting Forward/Backward (Figure 83)…703
6. Angle Adjustment of Armrest (Figure 84)…703
7. Headrest (Figure 84)…703
Seat Belt…704
Seat Belt Locking and Unlocking…704
Ceiling Cover…705
Opening the Ceiling Cover…705
Closing the Ceiling Cover…705
Front Windows…706
Front Upper Window…706
Front Bottom Window…708
Door Side Latch…709
Miscellaneous Access Covers and Doors…710
Side Door…710
Battery Box Door…710
Engine Cover…710
Cab Storage Compartments…711
Ashtray…711
Emergency Glass Breaking Tool…712
Operation…714
To Handle a New Excavator…714
Lubrication and filters…714
Starting and Stopping the Engine…715
Inspection Before Starting Engine…715
Operational Checks Before Starting Engine…715
Engine Start…717
Cold Weather Starting…719
Starting Engine With a Booster Cable…721
Hydraulic System Warm-up…723
Hydraulic System Warm-Up – Cold Weather…724
Engine Shut Down…725
Check and Confirmation After Stopping Engine…726
Safety Lever…727
Travel…728
Automatic Travel Speed Control…728
General Travel Instructions…729
Travel Control Lever Operation…731
Operating Instructions…733
Engine Speed Control…733
Mode Selection…735
Work Levers (ISO Style)…737
Operating Precautions…738
Working in Water…742
Parking Excavator…743
Towing Procedure…744
Hydraulic Breaker…745
Selection of Hydraulic Breaker…745
Hydraulic Hoses and Tubing for Breaker…745
Hydraulic Breaker Operation…745
To activate breaker;…747
Hydraulic Oil and Filter Service Intervals…748
Operating Techniques…749
Lifting…749
Operation Under Unusual Conditions…751
Operation In Extreme Cold…751
Operation In Extreme Heat…751
Operation In Dusty Or Sandy Areas…752
Operation In Rainy or Humid Conditions…753
Operation In Salt Water Areas…753
Operation at High Altitudes…753
Inspection, Maintenance and Adjustment…754
Serial Numbers…755
Safety Precautions…755
Preliminary Work Machine Setup for Maintenance…756
Table of Recommended Lubricants…758
Fluid Capacities…760
Lubrication and Service Chart…760
Maintenance Intervals…763
10 Hour / Daily Service…763
50 Hour / Weekly Service…763
250 Hour / Monthly Service…763
500 Hour / 3 Month Service…764
1000 Hour / 6 Month service…764
2000 Hour / Yearly Service…764
4000 Hour / Biennial Service…764
10 Hour / Daily Service…765
Grease Boom, Arm and Front Attachment Pins (for first 100 hours)…765
Check Engine Oil Level…765
Check Level of Hydraulic Oil Tank…766
Check for Leaks in the Hydraulic System…767
Check Fuel Level…768
Check for Leaks in the Fuel System…768
Check Water Separator and Drain Water As Required…769
Check Oil Level of Swing Reduction Device…770
Clean Dust Net in Front of Oil Cooler…771
Check Cooling System and Refill As Required…771
Check Level of Window Washer Liquid…772
Inspect the Bucket Teeth and Side Cutters for Signs of Wear…772
Inspect Engine Fan Blade…772
Check Air Intake System…773
Inspect Seat Belt for Proper Operation…773
Inspect the Structure for Cracks and Faulty Welds…773
Check the Operation of All Switches…773
Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights…773
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operati…774
Check Operation of All Controls…774
50 Hour / Weekly Service…775
Perform All 10 Hour / Daily Service Checks…775
Grease Boom, Arm and Front Attachment Pins…775
Grease Swing Bearing…777
Drain Water and Sediment from Fuel Filter…778
Drain Water and Sediment from Fuel Tank…778
Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)…778
Change Engine Oil and Filter (After First 50 Hours)…778
Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, R…778
250 Hour / Monthly Service…779
Perform All 10 hour / daily and 50 Operating Hour Service Checks…779
Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours)…779
Clean Outer Element of Two Stage Air Cleaner…779
Check Engine Fan Belt Tension…780
Check Engine Fan Belt Wear…781
Change Engine Oil and Filter…782
Check Oil Level In Travel Reduction Device (One on Each Side of Unit)…783
Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 250 Hours)…783
Replace Full Flow Hydraulic Oil Filter (After First 250 Hours)…783
Change Pilot Filter (After First 250 Hours)…783
Inspect Pins and Bushings of the Front End Attachments for Signs of Wear…783
Check the Fluid Levels in the Batteries and the Battery Charge Levels…783
Inspect for Any Loose or Missing Nuts and Bolts…783
Inspect Fuel System Hose Clamps…783
500 Hour / 3 Month Service…784
Perform All Daily (10 Hour), 50, and 250 Operating Hour Service Checks…784
Grease Swing Gear and Pinion…784
Replace Full Flow Hydraulic Oil Filter…785
Change Pilot Filter…786
Clean Air Conditioning Filter…787
Clean Radiator, Oil Cooler, Intercooler and Air Conditioner Condenser Core…788
Replace Outer and Inner Air Cleaner Elements…789
Change Fuel Filter…790
1000 Hour / 6 Month Service…792
Perform All Daily (10 Hour), 50, 250 and 500 Operating Hour Service Checks…792
Grease Swing Reduction Device…792
Change Swing Reduction Device Oil…792
Change Oil in Travel Reduction Device (One on Each Side of Unit)…793
Change Radiator Coolant…794
Clean Fuel Injection Priming Pump Strainer…795
Check Air Conditioner Refrigerant…796
Check and Adjust Engine **…797
2000 Hour / Yearly Service…798
Perform All Daily, 50, 250, 500 and 1,000 Operating Hour Service Checks…798
Check Alternator and Starter**…798
Check All Rubber Anti-vibration Shock Mounts…798
Perform and Record the Results of the Cycle Time Tests…798
Inspect Machine to Check for Cracked or Broken Welds or Other Structural Damage…798
Check, Adjust Valve Clearance **…798
Check Head Bolt Torques…798
Hydraulic Oil Exchange and Suction Strainer Cleaning…798
4000 Hour / Biennial Service…801
Major Parts – Periodic Replacement…801
Venting and Priming Hydraulic System…802
Main System Pump…802
Hydraulic Cylinders…802
Swing Motor…803
Air Release of Travel Motor…803
General Venting…803
Handling of Accumulator…804
Fuel Transfer Pump (Option)…805
Electrical System…807
Battery…807
Fuses…809
Air Conditioning System…811
Check Control Panel…811
Check Air Conditioner Hoses…811
Check Condenser…811
Check Magnetic Clutch…811
Check Belt Tension…811
Bucket…812
Bucket Tooth Replacement…812
Bucket O-ring Replacement…813
Bucket Shimming Procedures…815
New Bucket Installation…815
Shimming Procedures for Installed Bucket…815
Track Tension…816
Bolt and Nut Inspection…818
Maintenance in Special Conditions…819
Long Term Storage…820
Transportation…822
Extension and Retraction of Track Frames…822
General Description of Components…822
Frame Retraction…823
Frame Extension…824
Loading and Unloading…825
Lifting With Sling…828
Troubleshooting…830
Engine…830
Hydraulic System…831
Swing System…832
Travel System…833
Electrical System…833
Specification…836
Standard Specification…836
Overall Dimensions…837
Working Range…838
Approximate Weight of Workload Materials…839
Index…842
Daewoo Solar 470LC-V Excavator Repair Service Manual