Daewoo Doosan Solar 220LC-III Shop Manual 2023-7100E-1 – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Solar 220LC-III Shop Manual 2023-7100E-1 – PDF DOWNLOAD
Solar 220LC-III
Shop Manual
2023-71 00E-1
Serial Number 1039 and Up
December 1996
Accessory Applications:
- The excavator has been primarily designed for moving earth with a bucket.
- For use as a grapple or for other object handling, contact Daewoo. Liftingwork applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading.
- DO NOT use the machine for activities for which it was not intended.
- DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration.
- Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.
- Refer to Page 3-3 for additional information on Falling Object Protective Structures (F.O.P.S.) and other reinforcement systems.
Lifting Capacity Rating Configuration:
- Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration.
- Loads must be balanced and supported evenly.
- Use taglines to keep the load steady if wind conditions and large surface area are a problem.
- Work crew hand signals, individual tasks and safe procedures should all be universally understood before the lift is made.
NOTE:
- Before using the excavator to make lifts check for regulations that could apply.
- Regulations may require that all heavy lifting be done with single purpose equipment specifically designed for making lifts, or other local restrictions may apply.
- Making heavy lifts with a general purpose excavator that can be used for digging, loading, grading or other work may be expressly forbidden.
- Always follow all instructions, guidelines and restrictions for Safe Lifting in the Operation and Maintenance and Shop Manuals.
Locations of Safety Labels:
- Always keep these labels clean.
- If they are lost or damaged, replace them with a new label. There are other labels in addition to the safety labels that follow so handle them in the same way.
- Safety labels may be available in languages other than English.
- To find out what labels are available, contact your Daewoo distributor.
TABLE OF CONTENTS:
Daewoo Doosan Solar 220LC-III Shop Manual 2023-7100E-1 – PDF DOWNLOAD
SAFETY
To the Operator of a Daewoo Excavator ………………………………………. 1-1
General Safety Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Locations of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Summary of Work-site and Lifting Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Operation …………………………………………………………… 1-7
Equipment ………………………………………………………….. 1-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Shipping and Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Excavator Rated Lift Capacity Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SPECIFICATIONS
Excavator Machinery Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Excavator Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Engine Performance Curves (per KS-R1004 Standard) …………………………….. 2-3
Hydraulic System Component Specifications …………………………………… 2-4
Hydraulic Pump Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Working Range Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Excavator Rated Lift Capacity Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Summary of Safety Precautions for Lifting in “Leveling Mode I” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Performance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
UPPER STRUCTURE
Operator’s Cab Removal Procedure ………………………………………… 3-1
Falling Object Protective Structures (F.O.P.S.) ………………………………….. 3-3
Front Attachment Pin Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Bucket Tooth Inspection and Replacement ……………………………………. 3-5
Shimming Bucket Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Bucket Attachment, Removal and Reversal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Removal and Installation of the Front Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Attachment Cylinders, Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ,
Operation of Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Welding Precautions and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Engine Components and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Counterweight Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Fuel Tank Removal and Installation ………………………………………… 3-24
Engine Cooling System: Radiator/Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Swing Bearing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Center Joint (Swivel) Overhaul/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Operation of Working Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
220LC~I I I Shop Manual – Revision 1
Main Pump Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Pump Regulator Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Hydraulic System General Precautions ………………………………………. 3-47
Maintenance Service and Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Troubleshooting – Main Pump …………. -: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Main Pump Parts List ……….. .’ ……………………………………….. 3-49
Main Pump Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Reassembly of Main Pumps and Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Pump Regulator Parts List ………………………………………………. 3-56
Pump Regulator Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Swing Motor Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Swing Motor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Rebuilding the Swing Motor – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Swing Motor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Swing Motor Gearbox (Final Drive) Parts List ………………………………….. 3-77
Swing Motor Gearbox (Final Drive) Disassembly ……………………………….. 3-79
Swing Motor Gearbox (Final Drive) Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Main Control Valve Disassembly …………………………………………… 3-90
Main Control Valve Reassembly …………………………………………… 3-101
Electronic Proportional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 O
LOWER STRUCTURE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Travel Motor and Reduction Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Track Frame Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Travel Motor Assembly …………………………………………………. 4-4
Travel Motor Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Travel Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Travel Motor Gearbox (Final Drive) …………………………………………. 4-9
Travel Motor and Gearbox Disassembly, Overhaul and Reassembly …………………… 4-12
Front Idler Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Upper Roller ……………………………………………………….. 4-39
Track Spring and Track Adjusting Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Service Standards for Lower Travel Frame Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Track Tensioning …………………………………………………….. 4-45
ELECTRICAL SYSTEM
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
24 Volt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Engine Start-up and Shutdown …………………………………………….. 5-3
Cylinder Preheat – Intake Air Electrical Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Alternator Circuit ……………………………………………………… 5-5
Low Current Electrical Circuits …………………………………………….. 5-7
Climate Control (Air Conditioning) Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Power Mode System Operating Components …………………………………… 5-11
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Instrument Panel LED Displays and Input Terminal Connections ………………………. 5-14
Instrument Panel Connector Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Instrument Panel Selector Switches …………………………………………. 5-15
Instrument Panel Coolant Overheating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Instrument Panel Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Instrument Panel Engine Oil Pressure Circuit …………………………………… 5-16
Start-up Electrical Test Circuit ……………………………………………… 5-16
Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
220LC-III Shop Manual – Revision 1
Hydraulic Pump Discharge Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Power Mode Circuit Instrument Panel Summary …………………………………. 5-18
Power Mode System Basic Operation ………………………………………… 5-19
Power Mode
Power Mode II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Power Mode I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Swing Priority Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Swing and Arm Dump Combined Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Swing Priority and Arm Crowd Recovery Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Loading Work Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Leveling Work Mode II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Boom Up, Arm Crowd and Bucket Crowd Combined Operation ………… ,. . . . . . . . . . . . . . . . 5-30
Leveling Mode I: Boom Up and Arm Crowd Combined Operation ……………………… 5-31
Forward Travel: Swing During Straight Travel …………………………………… 5-32
Forward Travel: Arm Operation or Boom Operation While Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Bucket Operation While Traveling …………………………………………… 5-34
ENGINE
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Wear Limits/Specifications, Major Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Engine Oil Pump Overhaul and Rebuilding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Fuel Injection Pump Installation, Alignment and Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Cylinder Headbolt Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Engine Throttle Controller ………………………………………………… 6-12
Engine Speed Sensor ………………………………………………….. 6-14
INSPECTION, MAINTENANCE AND ADJUSTMENT
Periodic Inspection and Maintenance ………………………………………… 7-1
Maintenance Intervals ………………………………………………….. 7-2
Table of Recommended Lubricants ………………………………………….. 7-3
Inspection and Maintenance ………………………………………………. 7-4
General Maintenance Procedures ………………………………………….. 7-17
General Maintenance …………………………………………………… 7-19
Torque Wrench Extension Tools ……………… , …………………………… 7-20
Flange and Thread Sealant Assembly Compounds ……………………………….. 7-22
Welding Precautions and Guidelines ………………………………………… 7-24
Service Standards for Lower Travel Frame Components ……………………………. 7-25
Hydraulic System Cleanliness and Oil Leaks …………………………………… 7-29
Reference Notes for Foldout Wiring Harness Illustrations …………………………… 7-30
220LC-1II Shop Manual – Revision 1 iii
TESTING, TROUBLESHOOTING AND ADJUSTING
Procedural Troubleshooting Baseline Recommendations …………………………… 8-1
Pilot Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Power Mode Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Boom/Swing Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Negacon, Negative Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Pressure Up Valve …………………………………………………….. 8-6
Pump Input Power Control ……………………………………………….. 8-7
Flow Meter and Flow Meter Kit Installation and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Troubleshooting – Swing System …… ; …………………………………….. 8-10
Troubleshooting – Hydraulic Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Troubleshooting – Control Valve ……………………………………………. 8-20
Troubleshooting -Travel Control Valve ……………………………………….. 8-22
Troubleshooting – Joystick Control Valve ………………… : . . . . . . . . . . . . . . . . . . . . . . . 8-23
Troubleshooting – Engine Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Troubleshooting – Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
EPOS-111 Self-diagnostic Codes ……………………………………………. 8-29
Engine Throttle Controller ………………………………………………… 8-31
Service Points and Test Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Slow Return Valve …………………………………………………….. 8-3
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