Daewoo Doosan Solar 220LC-III Shop Manual 2023-7100E – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Solar 220LC-III Shop Manual 2023-7100E – PDF DOWNLOAD
Solar 220LC-III
Shop Manual
2023-7100E
Serial Number 0001 thru 1038
March 1996
Basic Excavator:
Operating Safety:
The safety information on the following pages is organized into five topic sections:
I. General Safety Essentials
II. Operation
Ill. Equipment
IV. Maintenance
V. Shipping and Transportation
General Safety Essentials:
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 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.
Lifting:
- Lifting Mode 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.
Locations of Safety Labels:
- Always keep these labels clean.
- If they are lost or damaged, attach them again or 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 – PDF DOWNLOAD
To the Operator of a Daewoo Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Basic Excavator Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Safety Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Locations of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Summary of Safe “Lifting Mode” Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Shipping and Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Solar 220LC-III Excavator Rated Lift Capacity Tables ……………………………… 1-13
SPECIFICATIONS
Excavator Machinery Plan ……………………………………………….. 2-1
Solar 220LC-III Excavator Engine Specifications …………………………………. 2-2
Engine Performance Curves ………………………………………………. 2-3
Hydraulic System Component Specifications …………………………………… 2-4
Hydraulic Pump Performance Characteristics …………………………………… 2-5
General Dimensions ……………………………………………………. 2-6
Solar 220LC-III Specifications …………………………………………….. 2-7
Working Range Diagram ………………………………………………… 2-9
Load Weight, Bucket Size and Approved Arm Length Table …………………………. 2-10
Approximate Weight of Workload Materials …………………………………….. 2-11
Solar 220LC-I I I Excavator Rated Lift Capacity Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Summary of Safe “Lifting Mode” Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Excavator Performance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
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 …………………………….. 3-11
Operation of Hydraulic Cylinders ………………………………………….. 3-12
Cylinder Assembly and 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
220LC-III Shop Manual SAFETY
Swing Bearing Maintenance ……………………………………………… 3-28
Center Joint (Swivel) Overhaul/Repair ………………………………………. 3-29
Hydraulic System General Notes ………………………………………….. 3-33
Operation of Working Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Main Pump Assembly Description …………………………………………. 3-39
Pump Regulator Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Hydraulic System General Precautions ………………………………………. 3-47
Maintenance Service and Repair Procedure …………………………………… 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 Final Drive (Gearbox) Parts List ………………………………….. 3-77
Swing Motor Final Drive (Gearbox) Disassembly ……………………………….. 3-79
Swing Motor Final Drive (Gearbox) Reassembly ………………………………… 3-83
Control Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Control Valve Disassembly ………………………………………………. 3-100
Pump Flow Control Regulator ……………………………………………. 3-105
Electronic Proportional Control Valve ……………………………………….. 3-106
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 Final Drive (Gearbox) …………………………………………. 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
ii SAFETY 220LC-III Shop Manual
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
Hydraulic Pump Discharge Pressure Sensor …………………………………… 5-16
Power Mode Circuit Instrument Panel Summary …………………………………. 5-18
Power Mode System Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Power Mode Ill ……………………………………………………….. 5-20
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 ……………………………………………………. 5-29
Boom Up, Arm Crowd and Bucket Crowd Combined Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Lifting Mode: 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/Specification, 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
Daily or Every 1 O Operating Hours ………………………………………… 7-4
Weekly or Every 50 Operating Hours ………………………………………. 7-10
150 Operating Hours …………………………………………………. 7-11
Monthly or Every 250 Operating Hours ……………………………………… 7-12
Three Months or Every 500 Operating Hours …………………………………. 7-13
Six Months or Every 1,000 Operating Hours ………………………………….. 7-15
Annually or Every 2,000 Operating Hours ……………………………………. 7-15
General Maintenance Procedures ………………………………………….. 7-17
Tightening Torque Specifications …………………………………………… 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-III Shop Manual SAFETY iii
TESTING, TROUBLESHOOTING AND ADJUSTING
Procedural Troubleshooting Baseline Recommendations …………………………… 8-1
Pilot Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Power Mode Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Boom/Swing Priority ……………………………………………………. 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
Swing System Troubleshooting …………………………………………….. 8-1 O
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
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