PDF Shop Manual Daewoo SOLAR 010 Hydraulic Excavator - 2 MB
This comprehensive shop manual provides complete repair and service information for the Daewoo SOLAR 010 Hydraulic Excavator.
It covers all major systems, including the engine, hydraulics, and electrical components.
Step-by-step procedures, detailed diagrams, and specifications make this manual an indispensable tool for professional technicians.
Perform any repair with confidence using this factory-level guide.
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2022-7153E
Oct. 1997
Shop Manual
HYDRAULIC EXCAVATOR
SOLAR 010
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1. SAFETY
1.5 EQUIPMENT
1. Rough Operation May Require Use of Certified Safety Equipment
Work in mines, tunnels, deep pits or on loose or wet surfaces could produce danger from falling rock,
roll over or hazardous flying objects.
Any reinforcement system that is installed on the machine must pass safety and certification standards
and carry appropriate labeling and rating information.
Never attempt to alter or modify any type of protective structure reinforcement system, by drilling
holes, welding or remounting or relocating fasteners. Any serious impact or damage to the system
requires a complete integrity reevaluation. Reinstallation, recertification and/or replacement of the sys-
tem may be necessary.
2. Install Additional Safety Equipment If Conditions Require
When working with a breaker or in some shear work applications, a front guard 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 or rear windows may also be recommended depending
upon particular site conditions.
Contact your Daewoo distributor for a available safety guards and/or recommendations if there is any
danger of getting hit by objects that could strike the operator’s cab. Make sure that all other work site
crew members are kept well away from the excavator and safe from potential hazards.
3. Movement Alarms
If the excavator is equipped with an audible travel movement alarm or visible swing movement
alarm(strobe light), test the alarm on a daily basis. The audible alarm should sound as soon as the
travel system is engaged. The strobe light should begin to flash as soon as the swing system is
engaged.
4. Keep a Fire Extinguisher at Hand
It is recommended that an appropriately sized(2.27 kg [5 lb] or larger) multi-purpose “A/B/C” fire extin-
guisher be mounted in the cab. Check and service the fire extinguisher at regular intervals and make
sure that all work site crew members are adequately trained in its use.
5. Maintain Standard Safety Equipment in Good Condition
Machinery guards and body panel covers must be in place at 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 labels must be replaced if they are damaged or become unreadable. The information on labels
gives work crew members an important safety reminder exactly where it will do the most good.
-8-
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2. SPECIFICATIONS
2.6 HYDRAULIC SYSTEM COMPONENT SPECIFICATIONS
Manin Pump
Quantity 1
Displacement 4.1 cc/rev (0.25 cu in)
Max Flow Rate 10 M/min B 2
Relief Pressure 150 kg/cm2 (2,133 psi)
Bucket 180 kg/cm2 (2,560 psi)
Arm 190 kg/cm2 (2,702 psi)
Control Valve
P1 Spools* Dozer
Travel, right
Boom swing
Boom
Bucket
P2 Spools* Auxiliary
Travel, left
Arm
Swing
*Diameter 10 mm(0.39 in)
Relief Valves (Main) 2 X 150 kg/cm2(2,133 psi)
Hydraulic Cylinders
Boom Arm Bucket Dozer Boom swing
Quantity 1 1 1 1 1
Inner Diameter mm (in) 50 (1.97) 55 (2.16) 50 (1.97) 50 (1.97) 50 (1.97)
Stroke mm (in) 300 (11.82) 315 (11.22) 285 (2.75) 70 (14.57) 370 (11.82)
Rod, outer dia. mm (in) 25 (.98) 30 (1.18) 25 (.98) 25 (.98) 25 (.98)
Cylinder length, 555 (21.8) 540 (21.2) 505 (19.8) 330 (13.0) 588 (23.1)
retracted mm (in)
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5. CONTROL VALVE
5.2 DISASSEMBLY
1. Detach and separate hydraulic lines and linkage
from control valve. See Figure 5-1.
Figure 5-1
2. Loosen and remove plugs from cylinder and
tank ports. See Figure 5-2.
Figure 5-2
3. Remove accessory valves (overload relief, com-
bination relief and anti-cavitation valves). See
Figure 5-3.
NOTE : Replace accessory valves when defective,
and use new O-rings when reusing valves.
Figure 5-3
4. Remove plugs from valve body.
See Figure 5-4.
Figure 5-4
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6. SWING MOTOR
6.3 BRAKE VALVE DISASSEMBLY
1. Remove lock nuts. See Figure 6-6.
Figure 6-6
2. Unscrew adjusting screws. See Figure 6-7.
Figure 6-7
3. Loosen plug. See Figure 6-8.
Figure 6-8
4. Remove plug and pull out ball, ball guide, spring,
spring seat and sleeve.
See Figure 6-9.
Figure 6-9
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6. SWIG MOTOR
8. Remove pinion gear by pressing it out of the
bearing housing or by tapping it with plastic
hammer from the motor assembly side. See
Figure 6-36.
Figure 6-36
9. Remove eight hex socket bolts and remove front
retainer from bearing housing. Remove X-ring
and back up ring from front retainer, using a tool
with a sharp end such as a driver. See Figure 6-
37.
Figure 6-37
10. Remove ball bearing from bearing housing by
inserting a metal rod in the flange side of the
bearing housing and tapping evenly with ham-
mer on outer frame of ball bearing. See Figure
6-38.
Figure 6-38
11. Remove roller bearing from bearing housing by
inserting metal rod in motor side of bearing
housing and tapping evenly with hammer on
outer frame of roller bearing. See Figure 6-39.
Figure 6-39
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7. TRAVEL MOTOR
TOOL NAME TOOL REMARKS
ø160
7.5°+0.2
ø141.1°+0.1
ø137.8°+0.1
Floating seal Jig
15
20
0.5
15°
R 0.2 ø132
ø170
Vinyl chloride
Pincette
Air
Lubricating oil EP 90, 220cc API GL - 4 or equivalent
Puller
Grease
Seal tape
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7. TRAVEL MOTOR
4. Remove plug (37). Remove O-ring (38) from
plug (37). See Figure 7-28.
Figure 7-28
5. Remove plugs (42 & 62). See Figure 7-29.
Figure 7-29
7.4.2 Inspection and Repair
1. Clean parts in an approved, clean solvent and
dry with compressed air.
2. Keep parts clean and protected from dust and
any foreign material.
3. Replace O-rings.
7.4.3 Assembly
1. Wind seal tape around plugs (42 & 62) and
install to end cover (27). See Figure 7-30.
Figure 7-30
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7. TRAVEL MOTOR
14. Install snap ring (24). See Figure 7-64.
Figure 7-64
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8. ENGINE
8.3.4 Checking Cylinder Injection Interval
1. Align punch mark on control rack with pump
reference face on housing. See Figure 8-11.
2. Turn pump by hand to check No. 1 and No.
2 cylinder timing.
3. Adjust timing using plunger shims. Rack mark
Fuel control rack Reference
face
Figure 8-11
8.3.5 Delivery Valve Tightness Test
1. Install a 1,000kg / cm2 (14,223 psi)pressure gauge on delivery valve holder.
2. Apply 120kg / cm2 (1,707 psi) of pressure to fuel pump and measure time needed for pressure to
drop from 100 kg / cm2 (1,422 psi) to 90 kg / cm2 (1,280 psi). Standards are shown in the table below.
Pump speed 200 rpm
Pressure drop standard 20 seconds or more
Pressure drop limit 5 seconds or less
3. If specifications are not met, replace plunger and delivery valve.
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9. ELECTRICAL SYSTEM
9.5 TESTING STARTER
1. With starter pinion extened and with pinion
pressed back slightly to take up any play in Dimension
Pressin the pinion
engagement linkage, measure gap between
pinon and pinion stopper. The gap should be
0.3-1. 5 mm (0.012-0.016 in). See Figure 9-6.
Measuring of dimension
Figure 9-6
2. Adjust stroke of magnetic plunger by installing
shim [(0.5 mm (0.0197 in) or 0.8 mm (0.0315
in)]. See Figure 9-7.
Adjusting shim
(0.5mm, 0.8mm)
Figure 9-7
3. Check that clearance between flywheel ring
gear and starter motor pinion is 3-5 mm 3-5mm (0.1181-0.1969 in.)
(0.1181-0.1969 in). See Figure 9-8.
Ring gear
Pinion
Figure 9-8
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