Page 1 Return to Master Table of Contents HYDRAULICS...
Page 2 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENT MODEL SERIAL NUMBER RANGE Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2001 Daewoo...
Page 3: Table Of Contents
Return to Master Table of Contents TABLE OF CONTENTS Hydraulic System - General Notes ..............4 Hydraulic Schematic..................5 General Notes ..................5 Operation of Working Components ..............6 Boom Operating Circuit................6 Boom Up Circuit ..................6 Boom Down Circuit ................. 6 Arm Operating Circuit ................
Page 4 Return to Master Table of Contents Pump Regulator Adjustment ..............17 Flow Meter and Flow Meter Kit Installation and Testing ....... 20 Swing System Troubleshooting ..............22 Precautions/Initial Checks..............22 Swing Relief Valve Checking and Adjustment........22 Troubleshooting - Swing Gearbox ..............24 Troubleshooting - Hydraulic Problems............
Page 5: Hydraulic System - General Notes
Return to Master Table of Contents HYDRAULIC SYSTEM - GENERAL NOTES HAOF420L Figure 1 Pattern of Drawing (Solar 470LC-V) The hydraulic system has several improvements over conventional hydraulic systems - including cross- sensing total horsepower control - to maximize output efﬁciency. The system features an electronically controlled output optimization system, which allows the operator to choose between three, distinctly different power modes: high-output/rapid cycling maximum-speed power mode, low fuel consumption/low-noise light duty power mode, and a standard power mode for most types...
Page 6: Hydraulic Schematic
Return to Master Table of Contents HYDRAULIC SCHEMATIC The hydraulic schematic(s) is available in the "Hydraulic and Electrcial Schematic Shop Manual." This manual is a collection of diagrams and schematics for a number of models. GENERAL NOTES When refering to the schematic, refer to the following items: •...
Page 7: Operation Of Working Components
Return to Master Table of Contents OPERATION OF WORKING COMPONENTS BOOM OPERATING CIRCUIT The boom operating circuit includes the right and left main hydraulic pumps (both halves of the main pump assembly), both sides of the control valve and the boom cylinder. The circuit operates in boom down mode through the ﬁrst shift position and through the second shift position in boom up mode.
Page 8: Arm Operating Circuit
Return to Master Table of Contents ARM OPERATING CIRCUIT The arm operating circuit includes both the right and left hydraulic main pumps, the both sides of the control valve, arm regen. valve, and the arm cylinder. The circuit can be operated in the two-stage speed control mode which works through both halves of the control valve and doubles the volume of oil ﬂowing to the cylinder.
Page 9: Bucket Operating Circuit
Return to Master Table of Contents BUCKET OPERATING CIRCUIT The bucket operating circuit includes the right and left main pumps, the both sides of the control valve and the bucket cylinder. 360 kg/cm (5,112 psi) overload relief valves located at crowd and dump cylinder ports on BUCKET of the control valve protect the circuit and its components from damage.
Page 10: Right Swing Operating Circuit
Return to Master Table of Contents RIGHT SWING OPERATING CIRCUIT When the swing control lever is pushed to the right swing position, pilot pressure from the left side pilot valve is directed to SWING spool of the control valve. Output ﬂow from PUMP(R) is goes to the swing motor.
Page 11: Forward Travel Circuit
Return to Master Table of Contents FORWARD TRAVEL CIRCUIT TRAVEL TRAVEL MOTOR(R) When the right and left travel control levers are MOTOR(L) pushed forward, output from both of the main pumps is directed through the TRAVEL (R) and TRAVEL (L) spools on the control valve, through CENTER JOINT the upper works center joint, to the travel motors on each side of the machine.
Page 12: Procedural Troubleshooting Baseline Recommendations
Return to Master Table of Contents PROCEDURAL TROUBLESHOOTING BASELINE RECOMMENDATIONS INITIAL CHECKS AND TESTS TO ESTABLISH OPERATING CONDITION OF THE EXCAVATOR Triage Summary An excavator that fails to deliver designed performance should be checked for the following: • Hydraulic ﬂow, ﬁrst, and •...
Page 13: Pilot Pressure
Return to Master Table of Contents PILOT PRESSURE ADJUSTMENT AND TESTING WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made.
Page 14: Power Mode Valve
The jumper harness (which is available through Daewoo After Sales Service, or could be spliced together from commonly available, purchased parts) has extra leads so that a VOM meter can be connected to the circuit.
Page 15: Boom/Front Priority Valve
Return to Master Table of Contents BOOM/FRONT PRIORITY VALVE CONTROL VALVE PRESSURE AND CURRENT ADJUSTMENTS WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made.
Page 16: Pressure Up Valve
Return to Master Table of Contents PRESSURE UP VALVE CHECKS AND ADJUSTMENTS WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made.
Page 17 Return to Master Table of Contents NOTE: The electrical pressure up (power boost) solenoid valve located alongside the swing priority solenoid and arm speed control solenoid, in compartment rear of the operator’s cab, must be operating correctly, or pressure tests and further adjustments cannot be made.
Page 18: Pump Input Power Control
Return to Master Table of Contents PUMP INPUT POWER CONTROL PUMP REGULATOR ADJUSTMENT WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made.
Page 19 Return to Master Table of Contents ASS0320L Figure 12 Refer to the illustration of the pump regulator control valve (Figure 12) for the location of adjustment screws (1, 2 and 3). There are three different adjustments, Qmax, Pd-Q, adjustment screws (1, 2 and 3). Each one of the adjustment procedures could affect the setting of the others.
Page 20 Return to Master Table of Contents Start the engine and turn the engine speed dial maximum. When normal operating temperature reached, adjust screw clockwise to shft the Pi-Q control valve curve decrease componsating control pressure. 1/2 turn on the adjusting screw is equal to approximately -0.7 kgf/cm of Pi.
Page 21: Flow Meter And Flow Meter Kit Installation And Testing
ﬂow meter. The After Sales Service department of the nearest local Daewoo dealer can assist you with these tests or, if you prefer carrying out your own testing, they should be able to help in putting together a hose and ﬁtting kit (or the required dimensions and speciﬁcations for hoses and ﬁttings) to allow you to install a ﬂow meter...
Page 22 Return to Master Table of Contents Compare recorded values with output shown in the P-Q curve in the speciﬁcations section of this book. If test results do not measure up to speciﬁed values, pump output tests can be repeated using different control levers.
Page 23: Swing System Troubleshooting
Return to Master Table of Contents SWING SYSTEM TROUBLESHOOTING PRECAUTIONS/INITIAL CHECKS Stop work. Release all weight or any type of load safely before proceeding. Avoid risking injury or adding to damage. Turn off engine and disengage control functions until initial tests are ready to be made. WARNING Prevent possible injury and/or loss of operating control.
Page 24 Return to Master Table of Contents Pressure should stay consistently above 2.5 bar (36 psi). If pressure falls below the recommended minimum level, forceful acceleration of the swing motor could lead to cavitation of the circuit and stalling, slowed rotation, noise and possible damage. If main inlet and outlet pressures were off in the preceding tests in Step 1, adjust swing relief valve pressure.
Page 25: Troubleshooting - Swing Gearbox
Return to Master Table of Contents TROUBLESHOOTING - SWING GEARBOX Problem Possible Causes Remedies Swing motor fails to operate and: Three pressure tests at motor, Swing relief valve defective Adjust pressure brake or makeup valve show low Brake release valve defective recommended range in affected reading(s).
Page 26: Troubleshooting - Hydraulic Problems
Return to Master Table of Contents Problem Possible Causes Remedies Swing movement is in one If pilot pressure is unequal, Check to see that pilot pressure direction only. clean or repair piping or repair/ is the same right and left. replace valve.
Page 27 Return to Master Table of Contents Problem Possible Causes Remedies Sluggish performance of all Main pump(s) damaged or worn Repair or replace hydraulic functions - attachment, Main relief valve pressure off Readjust pressure swing and travel. Low oil level in hydraulic system Reﬁll Hydraulic reservoir...
Page 28: Troubleshooting - Control Valve
Return to Master Table of Contents Problem Possible Causes Remedies Swing motor operates unevenly. Swing gear, bearing or mounting Repair or replace loose or worn. Lubricant worn away, Grease inadequate. Repair/Replace the swing relief Swing relief valve may be faulty. valve.
Page 29: Troubleshooting - Travel Control Valve
Return to Master Table of Contents Problem Possible Causes Remedies Swing priority not operating Sticking spool. Clean/replace correctly Solenoid valve faulty. Replace Boom and arm cylinders do not Priority valve faulty or spool Check pilot pressure. perform normally in combined sticking.
Page 30: Troubleshooting - Joystick Control Valve
Return to Master Table of Contents TROUBLESHOOTING - JOYSTICK CONTROL VALVE Problem Possible Causes Remedies Secondary pressure does not Low primary pressure Check primary pressure increase Broken spring Replace spring Spool sticking Clean, repair or replace Excess spool casing Replace spool casing clearance Worn loose...
Page 31 Return to Master Table of Contents Hydraulic System Troubleshooting, Testing and Page 30 Adjustment...
Page 32 SERIAL NUMBER RANGE Solar 300LC-V 1001 and Up Solar 300LL 1001 and Up Solar 340LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 470LC-V 1001 and Up Models continued on back of cover. Copyright 2001 Daewoo November 2001 Accumulator...
Page 33 TABLE OF CONTENTS General Description ..................3 Speciﬁcations ..................4 S0703010K Accumulator Page 2...
Page 34 GENERAL DESCRIPTION The accumulator is a gas-charged storage device designed to hold a reserve quantity of hydraulic ﬂuid under pressure. Accumulators are used in hydraulic circuits in much the same way that condensers (or capacitors) are used to collect, store and maintain electrical charge in a circuit.
Page 35 In this condition a minimal amount of oil is stored in the accumulator. SPECIFICATIONS Accumulator Model Nitrogen Charge Volume Solar 300LC-V Solar 300LL Solar 340LC-V 10 kg/cm (142 psi) 320 cc (19.5 in Solar 420LC-V Solar 470LC-V S0703010K Accumulator Page 4...
Page 36 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. CENTER JOINT (SWIVEL) MODEL SERIAL NUMBER RANGE Solar 470LC-V 1001 and Up Copyright 2001 Daewoo November 2001 Center Joint (Swivel) S0704090K Page 1...
Page 37 TABLE OF CONTENTS General Description ..................3 Parts List ....................4 Troubleshooting, Testing and Adjustment............5 Inspection....................5 Testing..................... 5 Disassembly ....................6 Reassembly....................6 S0704090K Center Joint (Swivel) Page 2...
Page 38: General Description
GENERAL DESCRIPTION The center joint (swivel) is designed to allow hydraulic oil from the upper structure to ﬂow to components in the lower structure. It is capable of allowing continuous 360˚ rotation of the upper structure in relationship to the lower structure.
Page 39: Parts List
PARTS LIST Figure 1 Reference Reference Description Description Number Number Center Joint Body Hex Bolt Spindle Spring Washer O-ring Plug Slipper Seal Plug O-ring Spring Washer Cover Bolt S0704090K Center Joint (Swivel) Page 4...
Page 40: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT INSPECTION The center joint should be checked for evidence of external oil leakage every 2,000 hour of operation. Leaking or defective O-rings are an indication that dirt and other contaminants could be getting inside the assembly, which will promote accelerated, abnormal wear and may cause early failure of the assembly. If internal seals or other sliding surface components are worn and there is internal ﬂuid leakage, complete overhaul and repair or replacement of the center joint may be required.
Page 41: Disassembly
DISASSEMBLY Refer to the assembly drawing of the swivel joint for component references (Figure 1). IMPORTANT Do not unbolt the center joint from the lower car body until an adequate number of piping block- off plates are available, for disconnected piping lines. Be sure that system pressure has been vented - including the hydraulic accumulator and tank reserve pressure - before disassembly is started.
Page 42 Clean threads of fasteners before pre-applying Loctite #243 to the threads, and before torquing the cover bolts. Pre-ﬁll the center swivel with clean hydraulic ﬂuid prior to reassembly of high-pressure and drain line piping. Clean and pre-ﬁll piping line ends to reduce the amount of air in the system. Bleed air from the hydraulic system and verify hydraulic tank ﬂuid level before returning the excavator to service.
Page 43 S0704090K Center Joint (Swivel) Page 8...
Page 44 Solar 300LL 1001 and Up Solar 330LC-V 1001 and Up Solar 340LC-V 1001 and Up Solar 400LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2001 Daewoo December 2001...
Page 45 Return to Master Table of Contents TABLE OF CONTENTS General Description ..................3 Theory of Operation ................3 Parts List ....................4 Special Tools and Materials................6 Piston Nut....................6 Piston Jig....................8 Disassembly ....................10 Reassembly....................16 S0705000 Cylinders Page 2...
Page 46: General Description
Return to Master Table of Contents GENERAL DESCRIPTION Two essentially similar types of hydraulic cylinders are used on the excavator. The cylinder that is used to operate the excavator boom or bucket is equipped with a rod stopper, which acts as a cushion only when the cylinder rod is fully retracted (and the bucket is pulled close to the arm).
Page 47: Parts List
Return to Master Table of Contents Because the volume of oil needed to lengthen the cylinder rod (Q1) is greater than the volume of oil required to retract the cylinder rod, it takes more time to decrease cylinder stroke length than it does to lengthen it.
Page 48 Return to Master Table of Contents Reference Reference Description Description Number Number Bushing Piston Dust Wiper Slide Ring Retaining Ring Wear Ring U-Packing Slipper Seal Buffer Seal O-ring Rod Bushing Backup Ring Bolt Piston Nut Retaining Ring Set Screw Rod Cover Cushion Plunger O-ring Bushing...
Page 49: Special Tools And Materials
Return to Master Table of Contents SPECIAL TOOLS AND MATERIALS PISTON NUT S0705000 Cylinders Page 6...
Page 50 Return to Master Table of Contents Cylinders S0705000 Page 7...
Page 51: Piston Jig
Return to Master Table of Contents PISTON JIG S0705000 Cylinders Page 8...
Page 52 Return to Master Table of Contents Cylinders S0705000 Page 9...
Page 53: Disassembly
Return to Master Table of Contents DISASSEMBLY CAUTION! Vent air from the hydraulic system before disconnecting cylinder piping connections. Use the lever on the reservoir, while the engine is running. Discharge the hydraulic accumulator and vent residual tank pressure after the engine is shut off. Pour clean replacement ﬂuid back into the system if excessive ﬂuid is lost.
Page 54 Return to Master Table of Contents Tap two bolts into cover of cylinder head, 180° apart. Tighten them in a staggered, even sequence, to back off piston rod end cover from edge of cylinder wall. Look for adequate clearance between cover and end of cylinder wall before using a plastic or other soft-faced hammer for ﬁnal disassembly.
Page 55 Figure 15 Fabricate or purchase a piston nut removal wrench. (Dimensions are called off at beginning of this procedure. This tool may also be ordered through your local Daewoo Parts distributor). Remove nut from end of piston. Figure 16 S0705000 Cylinders...
Page 56 Return to Master Table of Contents 10. Use second piston tool described at beginning of this procedure to separate piston. Detach cushion ring (15), taking care not to damage cushion ring. Figure 17 11. Use a plastic hammer to evenly pull off rod cover (9) from end of piston rod.
Page 57 Return to Master Table of Contents 13. Find a screwdriver with an appropriate width tip to facilitate removal of slipper seal (19), wear ring (18) and slide ring (17) from piston (16). Figure 20 14. Pull off O-ring (20) and backup ring (21) from cylinder head.
Page 58 Return to Master Table of Contents 16. Disassemble retaining ring (3) and dust wiper (2). Separate retaining ring (8) and rod bushing (6). Figure 23 17. Force out pin bushing (1) from body of cylinder. Figure 24 Cylinders S0705000 Page 15...
Page 59: Reassembly
Return to Master Table of Contents REASSEMBLY IMPORTANT Replace any part that shows evidence of damage or excessive wear. Replacement of all O-rings and ﬂexible seals is strongly recommended. Before starting the cylinder reassembly procedure, all parts should be thoroughly cleaned and dried, and/or prelubricated with clean hydraulic ﬂuid. Prepare the work area beforehand to maintain cleanliness during the reassembly procedure.
Page 60 Return to Master Table of Contents Pre-lubricate O-rings and seals before reassembly (Figure 27). Figure 27 Before starting to rebuild piston assembly, heat slipper seal for 5 minutes in an oil bath warmed to 150° - 180°C (302° - 356°F). Use special slipper seal jig (third item in list of specialized tools at the beginning of this procedure) to attach seal.
Page 61 Return to Master Table of Contents Assemble cushion ring (15) and attach piston assembly to piston rod. Figure 30 Use specially fabricate or factory-sourced tool to tighten piston nut (22). Figure 31 Assemble wear ring (18), slide ring (17) and set screw (23) to piston assembly. Reference Description Number...
Page 62 Return to Master Table of Contents 10. Pre-apply fastener locking compound (Loctite #242 or #243 or an alternate manufacturer’s equivalent product) to all cover retaining bolts. Wrap protective cushion around end of rod while tightening fasteners, to prevent possible damage to polished surface of rod, should a wrench slip during retightening.
Page 63 Return to Master Table of Contents S0705000 Cylinders Page 20...
Page 64 Remember, that ultimately safety is your own personal responsibility. SWING MOTOR S0707260 MODEL SERIAL NUMBER RANGE Solar 170LC-V 1001 and Up Solar 170W-V 1001 and Up Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo January 2002 Swing Motor S0707260 Page 1...
Page 65 TABLE OF CONTENTS General Description ..................3 Theory of Operation ................3 Swing Motor Anti-cavitation Make-up Valve ..........4 Relief Valve ..................... 5 Swing Brake Operation ................5 Parts List ....................8 Speciﬁcations ..................10 Special Tools ....................11 Disassembly ....................12 Cleaning and Inspection (Wear Limits and Tolerances) .......
Page 66: General Description
GENERAL DESCRIPTION THEORY OF OPERATION Figure 1 Reference Reference Description Description Number Number Valve Plate Cylinder Block Shoe Piston Swash Plate The cross sectional views of the swing motor, show most of the main components of an axial-piston type hydraulic motor. Arrows indicating direction of ﬂow and other graphic symbols provide a general guide for understanding basic operation (Figure 1).
Page 67: Swing Motor Anti-Cavitation Make-Up Valve
If oil ﬂow to the motor is directed to the opposite port (so that the supply side becomes the exhaust side and vice versa), the rotation of the motor is reversed. Trench mode allows the operator to "prioritize" hydraulic oil ﬂow between swing function and boom and arm function.
Page 68: Relief Valve
RELIEF VALVE The relief valve is one in a set of two, and is Item "51" of the swing motor assembly. Return line pressure (the normal pressurization of the hydraulic reservoir, also referred to as "tank pressure") pushes the valve piston to open ports "R"...
Page 69 Figure 3 The swing brake is applied when the brake spring (Item 712, Figure 3) locks up the friction plate (742), split plate (743) and swing motor casing (301), preventing the motor drive shaft from turning. When hydraulic pressure is forced to the back side of the brake piston, the friction plate and swing motor casing are separated, releasing the brake.
Page 70 Swing Motor S0707260 Page 7...
Page 71: Parts List
PARTS LIST HAAA4340 Figure 4 S0707260 Swing Motor Page 8...
Page 72 Reference Reference Description Description Number Number Brake Valve Socket Bolt 31-1 O-ring Snap Ring 31-2 O-ring Snap Ring Relief Valve Snap Ring 51-1 O-ring Snap Ring 51-2 Backup Ring Roller Bearing Reactionless Swing Valve Roller Bearing 52-1 O-ring Spring Pin Drive Shaft VP Plug Spacer...
Page 73: Specifications
SPECIFICATIONS Item Speciﬁcation Solar 170W-V Solar 170LC-V Solar 220LC-V Solar 220LL Type Axial Piston Axial Piston Displacement 121.6 cc/rev 128.0 cc/rev (18.85 in /rev.) (7.81 in /rev.) Crossover Relief Valve 280 kg/cm 280 kg/cm Setting (3,980 psi) (3,980 psi) Maximum Supply Flow Rate 227 lpm 210 lpm @ 2000 rpm...
Page 74: Special Tools
SPECIAL TOOLS Figure 5 Swing Motor S0707260 Page 11...
Page 75: Disassembly
DISASSEMBLY The area where the motor is going to be rebuilt should be well lighted, clean and protected from dust and/or wind gusts that could carry grit or dust. Use a rubber mat or other protective overlay on workbench area to prevent damaging or scratching any precision machined components. IMPORTANT Clean all of the exterior surfaces of the motor before disassembly.
Page 76 Make two permanent marks on exterior of motor to indicate assembly position of motor casing (301) and upper valve casing (303). Figure 8 Disassemble brake valve (31) from side of casing. Figure 9 Loosen remove relief valve assemblies (51) from upper valve casing (303).
Page 77 Loosen and remove all four socket head bolts (401) and separate upper valve casing (303) from lower casing (301). NOTE: Valve plate (131) inside upper valve casing (303) must be separated from assembly but take extra care to make sure that it is not scratched or damaged by an accidental fall, after cover is removed.
Page 78 11. Reposition motor so that end of drive shaft faces out to one side. Pull out cylinder block (111) and disassemble pistons (121), retainer plate (123), spherical bushing (113), front spacer (117) and shoe plate (124). Be careful not to make any scratches or leave nicks on reciprocating parts.
Page 79 14. Separate casing and drive shaft (101). Tap upper end of drive shaft with a soft-faced, plastic hammer. To avoid damaging drive shaft, do not use excessive force. Figure 18 15. Tap bearing race out of casing. Figure 19 16. Disassembly of motor has now been completed, unless there is any reason to suppose that drive shaft bearing has become excessively worn.
Page 80 NOTE: Final disassembly of individual components may also require: Disassemble oil seal from the front cover if they were not separated during removal. Apply force (2, Figure 21) and use a plug (1) to hammer through drive shaft opening in cover. Reference Description Number...
Page 81 Relief valves can be replaced in sets by ordering one part number through your authorized Daewoo dealer/parts distributor. To disassemble relief valves, pull out plug (201, Figure 4), disassemble bushing (343), spring (322) and spring seat (331) from rod (303). Position valve housing facing...
Page 82: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) Inspect all components and precision surfaces, to conﬁrm that they haven’t been worn beyond service limits. Refer to table below for dimensional speciﬁcations. All parts should be cleaned, air-dried and re-lubricated with clean, approved-type hydraulic ﬂuid, before ﬁnal reassembly or as the ﬁnal step after the unit has been put back together.
Page 83 Service Standards for Replacing Worn Parts When parts exceed the standard, replace them. When there is conspicuous surface NOTE: damage, it is always safer to replace parts, whether standards are exceeded or not. Standard Value Replacement Item Remedy mm (In) Limit mm (In) Clearance between cylinder 0.028 mm...
Page 84: Reassembly
REASSEMBLY Reassembly of the motor is basically accomplished by reversing disassembly steps. Use a torque wrench to make sure that assembly fasteners are tightened to speciﬁed values. Always begin a bolt tightening sequence from the innermost part of the assembly, working outward toward the ends in careful, even rotation.
Page 85 Reassemble drive shaft (101, Figure 4), roller bearing (443) and lower casing (301). Pay attention to bearing alignment inside bore of case. Make sure it is fully seated. Figure 29 There is a "right side" and "wrong side" on oil seal. Be careful that you install seal inside cover with correct side facing in.
Page 86 Use snap-ring pliers to replace lock ring (437) into lower casing (301). Figure 33 Turn motor sideways and assemble shoe plate (124), placing it in motor housing in same position it was in before removal. Using grease on assembled side can help keep individual components in place.
Page 87 11. Put cylinder block (111) and retainer plate (123) back in motor. Spherical bushing and grooves of cylinder block splines should ﬁt together without undue difﬁculty. (Do not try to force or pound parts together.) Figure 37 12. Turn motor so that front cover side (304) is down.
Page 88 15. Reinstall brake springs, making sure that each gets fully seated on piston. Figure 41 16. Tap roller bearing (444) race back into upper valve casing (303), using hammer and copper rod speciﬁed in tool list. Figure 42 17. Assemble valve plate (131), O-ring and upper valve casing...
Page 89 19. Put plungers (351), springs (355), O-rings (488), and RO plugs (469) back in casing. Make sure that both plungers are free to move back and forth. Figure 45 20. Reassemble relief valves (51) by putting rod, spring, stop and piston back together, then turning plunger side of valve up to reassemble valve...
Page 90 22. Replace the VP plugs (464, 468) and O- rings (485, 487) on each of the three plugs. Reinstall the brake cutoff valve (31). Figure 49 Swing Motor S0707260 Page 27...
Page 91 S0707260 Swing Motor Page 28...
Page 92 Remember, that ultimately safety is your own personal responsibility. TRAVEL MOTOR (WITH GEARBOX) (A6V160HD)S0707365 MODEL SERIAL NUMBER RANGE Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up Copyright 2002 Daewoo January 2002 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 1...
Page 93 TABLE OF CONTENTS General Description ..................4 Theory of Operation ................4 Reduction Gearbox Operation ..............5 Parts List ....................7 Speciﬁcations ..................15 Tightening Torques................16 Travel Motor Disassembly ................18 Sectional View..................18 Seal Kits and Component Groups............19 Sealing Drive Shaft ................
Page 94: General Description
GENERAL DESCRIPTION THEORY OF OPERATION Refer to the assembly cross-section at the end. Travel motor consists of the hydraulic motor and reduction gearbox. Hydraulic motor consists of the rotary part, cross relief valve, negative brake, counter balance valve and tilting parts. The reduction gearbox consists of a 3-speed planetary gearbox. The next ﬁgure shows the motor as a symbol.
Page 95 HYDRAULIC MOTOR OPERATION Hydraulic Motor operation. Figure 2 The high pressure oil from the hydraulic pump goes to the cylinder block (104) through the rear ﬂange (101) of the motor and the brake valve device and the timing plate (109). This high pressure oil acts only on the single side of the line Y1-Y2 which connects the bottom dead center and the top dead center of the piston (105) stroke.
Page 96 Brake Valve During Travel. Figure 3 If the pressure oil is supplied from port A, this oil opens the valve (130), ﬂows into the inlet port C of the hydraulic motor, and turns the hydraulic motor. At the same time, the oil, which ﬂows from a small hole of the spool (126) to the chamber b through passage a, exerts pressure on the spool section, and moves the spool to the left over spring (128) force.
Page 97 When Stopping by Deceleration. Figure 4 If the pressure oil supplied by the port A is cut off during drive. there will be no hydraulic force. Then, the spool (126) returns to the right (neutral position) through the stopper (125) by the spring (128).
Page 98 Parking Brake During Travel. If the pressure oil is supplied by the brake valve, the brake valve spool of the hydraulic motor part is operated, and the passage into the parking brake is opened. So the pressure oil ﬂows into the cylinder a which consists of a spindle and a piston.
Page 99 During Braking. If the pressure of the cylinder drops below kg/cm because pressure oil of the brake valve is blocked, the piston (112) returns by the spring (113) force. If the piston (112) is pushed by the spring force, the separator plate (116) and the friction plate (115) are pushed to the spindle of the reduction device.
Page 100 4. High and Low Speed Switching Device At low speed (If the pilot pressure is lower than 10 kg/cm Figure 7 If pilot pressure is not applied from port A (If the pressure is lower than 10 kg/cm ), the valve (163) is pushed to the left by the spring (I66) force, the pressure oil from the supply port B is blocked, and the oil of the chamber C ﬂows through the valve (l63) into the motor case.
Page 101 At high speed (If the pilot pressure is higher than 20 kg/cm Figure 8 If pilot pressure is supplied from port A (If the pressure is higher than 20 kg/cm ), the valve (163) is pushed to the right bv the spring (166) force, the pressure oil from the supply port B goes through valve (163) into the chamber C.
Page 102: Reduction Gearbox Operation
REDUCTION GEARBOX OPERATION This reduction gear is a combined system of planetary gear and differential gear, It reduces rotational speed, while increasing output torque of the hydraulic motor, and rotates the gear case. Planetary gear If the sun gear (S) connected to the input shaft rotates, the planetary gear (P) turns (P1) (P2)
Page 103: Parts List
PARTS LIST Travel Motor HTS6331 Figure 12 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 12...
Page 104 Reference Reference Description Qty. Description Qty. Number Number 6315-- Travel Motor Back Up Plate Rotary Group O-ring Control Rocking Screw Housing Threaded Pin Retaining Ring Seal Lock Nut Shaft Seal Ring S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 13...
Page 105 Travel Motor - Rotary Group HTS6321 Figure 13 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 14...
Page 106 Reference Reference Description Qty. Description Qty. Number Number 6325-- Rotary Group Retaining Plate Rotary Screw Cylinder Drive Shaft Control Lens Shim Center Pin Back Up Plate Piston Retaining Ring Steel Sealing Ring Tapered Roller Bearing Adjustment Shim Tapered Roller Pressure Spring Bearing Travel Motor (With Gearbox) (A6V160HD) S0707365...
Page 107 Travel Motor - Control HTS6331 Figure 14 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 16...
Page 108 Reference Reference Description Qty. Description Qty. Number Number 6335-- Control Bush Brake Valve Socket - Head Screw Throttle Pin Socket - Head Valve Screw Pressure Control Socket - Head Valve Screw Pressure Relief Cylinder Pin Valve Rocking Screw Port Plate Rocking Screw Positioning Piston O-ring...
Page 109 Travel Motor Speed Reduction Gearbox Assembly 3033 Figure 15 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 18...
Page 110 Reference Description Qty. Reference Description Qty. Number Number Washer Brake Shaft Breather Plug O-ring Screw Disc Cover Set Ring, Steel O-ring Ring, Backup O-ring Sun Gear O-ring 1st Red Ass’y Ring, Spiral Sun Gear Piston 2nd Red Gear Spring Ass’y Spacer Screw, Uni 5931 Circlip...
Page 111: Specifications
SPECIFICATIONS Name Plate Identiﬁcation A6VE 160 HZ3 / 63W - V Z L - 220B - S Reference Description Number Unit With CBV, Brake Release Valve & Relief Valves Incooporated Beginning of Regulation At Max Displacement 2 hole Flange Drive Shaft 45 mm Diameter Viton Seals Alternating Direction of Rotation Series...
Page 112: Tightening Torques
Component speciﬁcations are shown in following table. Item Unit Speciﬁcation Rated Torque kg•m 81.5 Max Rotation Rate 3680@99 cc/rev Max Output/rev cc/rev Operating Rotation 2900 Max Output Pressure kg/cm 2 Speed Switching Pressure Auto. Switching kg/cm Parking Brake Torque kg•m 11.140 kg•m Parking Brake Releasing Pressure kg/cm...
Page 113 Tightening Torques For Locking Screws Vsti (Metric ISO Fine Thread) Thread Size Designation Tightening Torques Tightening Torques (Ib.ft) (Nm) M 8 x 1 VSTI 8x1 -ED/SA M 10 x 1 VSTI 10x1 M 12 x 1,5 VSTI 12x1,5 M 14 x 1,5 VSTI 14x1,5 M 16 x 1,5 VSTI 16x1,5...
Page 114: Travel Motor Disassembly
TRAVEL MOTOR DISASSEMBLY SECTIONAL VIEW HTS063S Figure 16 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 23...
Page 115: Seal Kits And Component Groups
SEAL KITS AND COMPONENT GROUPS Observe the following notices NOTE: when carrying out repair work at hydraulic aggregates! HTS001S Figure 17 Close points hydaulic aggregates. HTS002S Figure 18 Replace all seals. NOTE: Use only original Hydromatik spare parts. HTS003S Figure 19 Check all seal and sliding surfaces for w ear.
Page 116 Full up hydaulic aggregates with hydraulic oil before start-up. HTS005S Figure 21 Seal kit for drive shaft. HTS006S Figure 22 External seal kit. HTS007S Figure 23 Housing. HTS008S Figure 24 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 25...
Page 117 Complete rotary group. HTS009S Figure 25 Port plate with control piston and counter- balance valve. HTS010S Figure 26 10. Relief valve / Make up check valve. HTS011S Figure 27 11. Replace seal nut. NOTE: First measure record setting height. HTS012S Figure 28 S0707365 Travel Motor (With Gearbox) (A6V160HD)
Page 118: Sealing Drive Shaft
12. When tightening, counter hold setting screw, then check setting height. HTS013S Figure 29 SEALING DRIVE SHAFT HTS014S Figure 30 Protecting the drive shaft. Remove retaining ring and shim. HTS015S Figure 31 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 27...
Page 119: Sealing Control Parts
Screw in sheet metal screw into the holes ﬁtted with rubber. Pull out seal with pliers. HTS016S Figure 32 Press in shaft seal and shim with bush to stop. Pay attention to pressing depth! NOTE: * Mark for pressing depth. Assemble retaining ring.
Page 120: Disassembly Port Plate
Inspect O-ring. HTS021S Figure 36 DISASSEMBLY PORT PLATE Note dimension X. Remove Q -screw. HTS023S Figure 37 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 29...
Page 121 For disassembly of the port plate, swivel always rotary group to zero position. Piston rings to hang out the cylinder boring. Swivel rotary group to zero position with screw Q max. HTS024S Figure 38 Port plate. Mark position. Loosen screws. Remove.
Page 122 Braking valve. HTS027S Figure 41 Throttle pin. HTS028S Figure 42 Valve. HTS029S Figure 43 10. Pressure control valve. HTS030S Figure 44 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 31...
Page 123 11. Pressure relief valve. HTS031S Figure 45 12. Positioning piston. HTS032S Figure 46 13. H-Z- control. HTS033S Figure 47 14. Check valve. HTS034S Figure 48 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 32...
Page 124 HTS035S Figure 49 HTS036S Figure 50 15. Screw in threaded pin into center pin. 16. Fix the cylinder with disc and locknut. HTS037S Figure 51 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 33...
Page 125: Exchanging Rotary Group
17. Press out rotary group. If the bearings are used again NOTE: do not hit on the drive shaft. HTS038S Figure 52 EXCHANGING ROTARY GROUP Complete rotary group. NOTE: Setting hydraulic part necessary. HTS039S Figure 53 Rotary group. • Mechanical part; Adjust drive shaft with bearing.
Page 126 Disassemble retaining plate. screws are glued . Use Torx- NOTE: tools. HTS042S Figure 56 Free of corrosion, erosion or fretting; No damage to splines or keyways. HTS043S Figure 57 Pistons; No scoring and no pittings. HTS044S Figure 58 Center pin; No scoring and no pittings. HTS045S Figure 59 Travel Motor (With Gearbox) (A6V160HD)
Page 127 Retaining plate; No scoring evidence of wear. HTS046S Figure 60 10. Cylinder block / control lens; Bores free of scoring, no evidence of wear. Faces smooth and even, free of cracks and scoring. HTS047S Figure 61 11. Control housing; Sliding surface and side guides free of scoring and no wear.
Page 128: Travel Motor Speed Reduction Gearbox Disassembly
TRAVEL MOTOR SPEED REDUCTION GEARBOX DISASSEMBLY Drain gear oil and remove travel motor and O-ring. Remove motor ﬂange (8 socket bolts, M16 x 35 ). Figure 64. 3034 Figure 64 Remove O-ring from motor ﬂange. Figure 3035 Figure 65 Remove O-ring from hub groove. Figure 66. 3036 Figure 66 Travel Motor (With Gearbox) (A6V160HD)
Page 129 Attach disc (B, Figure 67) to spring retainer; fasten pusher (A) to hub and install screw rod (C). 3037 Figure 67 Remove circlip from hub groove using pliers. Figure 68. 3038 Figure 68 Remove jig and circlip. Figure 69. 3039 Figure 69 S0707365 Travel Motor (With Gearbox) (A6V160HD)
Page 130 Remove spring retainer. Figure 70. 3040 Figure 70 Pull spring from groove. Figure 71. 3041 Figure 71 10. Blow air into brake port hole and remove brake piston using pliers. Figure 72. 3042 Figure 72 11. Remove brake shaft. Figure 73. 3043 Figure 73 Travel Motor (With Gearbox) (A6V160HD)
Page 131 12. Remove disc. Figure 74. 3044 Figure 74 13. Remove O-ring and backup ring. Figure 75. 3045 Figure 75 14. Turn reduction gear assembly over and remove 2 plugs (M22 x 1.5). Figure 76. 3046 Figure 76 15. Remove 16 socket bolts (M14 x 40). Figure 3047 Figure 77 S0707365...
Page 132 16. Remove end cover, using puller. Figure 78. 3048 Figure 78 17. Remove O-ring from end cover groove. Figure 79. 3049 Figure 79 18. Remove ﬁrst sun gear. Figure 80. 3050 Figure 80 19. Remove ﬁrst planetary gear assembly. Figure 81. 3051 Figure 81 Travel Motor (With Gearbox) (A6V160HD)
Page 133 20. Remove second sun gear. Figure 82. 3052 Figure 82 21. Remove second planetary gear assembly. Figure 83. 3053 Figure 83 22. Remove third sun gear. Figure 84. 3054 Figure 84 23. Loosen bolts (4, M 30 x 150) from third planetary gear assembly.
Page 134 24. Remove bolts. Figure 86. 3056 Figure 86 25. Seperate hub from reduction gear housing, using press and stopper. Figure 87. remove main ball NOTE: bearing. 3057 Figure 87 26. Remove third shift assembly from hub. Figure 88. 3058 Figure 88 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 43...
Page 135 27. Remove bushing from hub using a jig. Figure 89. 3059 Figure 89 28. Remove bearing inner race and spacer from hub, using puller. Figure 90. 3060 Figure 90 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 44...
Page 136 29. Remove gasket. Figure 91. 3061 Figure 91 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 45...
Page 137: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Gearbox Inspection If a gear is damaged, replace the damaged gear and the interlocking gear next to it. If one planetary gear is damaged, replace the entire planetary gear assembly.
Page 138: Travel Motor Speed Reduction Gearbox Reassembly
TRAVEL MOTOR SPEED REDUCTION GEARBOX REASSEMBLY Install seal to jig. Figure 92. HTS3062S 3062 Figure 92 Install jig to housing. Figure 93. 3063 Figure 93 Clean seal surface. Figure 94. 3064 Figure 94 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 47...
Page 139 Install seal to hub using jig used in Step 1. Figure 95. 3065 Figure 95 Apply lubricant to seal surface. Figure 96. 3066 Figure 96 Support ball bearing housing with spacers (1 and 2, Figure 97) and install bearing into housing.
Page 140 Install hub to housing. Figure 99. 3069 Figure 99 Press hub into housing using a press and a stopper. Figure 100. 3070 Figure 100 10. Install four bushings using a press. Figure 101. 3071 Figure 101 11. Assemble planetary gear assembly. Figure 102.
Page 141 12. Install four planetary gear assemblies, using press. Figure 103. 3073 Figure 103 13. Tighten gear planetary gear assembly to 150 Nm (110.7 ft lb). Figure 104. 3074 Figure 104 14. Assemble third shift sun gear. Figure 105. 3075 Figure 105 15.
Page 142 16. Place planetary gear carrier on hub. Figure 107. 3077 Figure 107 17. Press planetary gear carrier into hub. Figure 108. 3078 Figure 108 18. Apply loctite to planetary gear carrier fastening bolts. 19. Install and tighten bolts. Figure 109. NOTE: In next step, the O-ring and backup rings are different.
Page 143 21. Install end cover to housing. Apply Loctite 243 to bolts and NOTE: torque to 10 Nm (7.38 ft lb). Figure 111 3081 Figure 111 22. Tighten plugs to 6 - 8 Nm (4.42 - 5.90 ft lb). Figure 112. 3082 Figure 112 23.
Page 144 25. Install ﬁrst shift sun gear. Figure 115. 3085 Figure 115 26. Install O-ring (1, Figure 116) and backup ring (2) into hub groove. The O-ring and backup rings are NOTE: different. Be careful not to switch them. 3086 Figure 116 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 53...
Page 145 27. Install brake shaft while turning the reduction gear assembly. Figure 117. 3087 Figure 117 28. Install brake disc assembly, starting with a copper disc (seven pieces) and alternating with steel discs (six pieces). Figure 118 and Figure 119. 3088 Figure 118 3089 Figure 119...
Page 146 30. Install circlip using circlip pliers. Figure 121. 3091 Figure 121 31. Install O-ring to hub groove. Figure 122. 3092 Figure 122 32. Place brake piston inside hub being careful not to damage seal. Figure 123. 3093 Figure 123 33. Insert springs into brake piston holes. Figure 124.
Page 147 34. Install retainer disc. Figure 125. 3095 Figure 125 35. Install O-ring to motor ﬂange groove. Figure 126. 3096 Figure 126 36. Tighten motor ﬂange to hub. Figure 127. 3097 Figure 127 S0707365 Travel Motor (With Gearbox) (A6V160HD) Page 56...
Page 148: Travel Motor Reassembly
TRAVEL MOTOR REASSEMBLY ROTARY GROUP ASSEMBLY Rotary group completely assembled ready for assembly. Figure 128 Place assembly sleeve. HTS051S Figure 129 Warm up housing to 80˚C (176˚F). HTS052S Figure 130 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 57...
Page 149: Rotary Group Adjustment (See Serve Information)
Insert rotary group into housing to seat position. HTS053S Figure 131 Fix zero position of cylinder with Q screw. Disassemble cylinder ﬁxing screw. Insert O-ring. HTS054S Figure 132 ROTARY GROUP ADJUSTMENT (SEE SERVE INFORMATION) Determine cylinder swivel range to max. angle with screw.
Page 150 Disc. HTS056S Figure 134 Place centering disc. HTS057S Figure 135 Mount measuring device. HTS058S Figure 136 Check dimention X. HTS059S Figure 137 Travel Motor (With Gearbox) (A6V160HD) S0707365 Page 59...
Page 151: Assembly Of Port Plate
ASSEMBLY OF PORT PLATE Stick control lens in sliding surface with grease. Assemble in reversal order. Mount port plate. HTS060S Figure 138 Assemble port plate. NOTE: Take care of assembly design! Tighten ﬁxing screws with torque. Set Q crew to dimention (*). Assemble plug.

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