Daewoo Excavator Solar 220LL Shop Manual 2023-7134E – PDF

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Daewoo Excavator Solar 220LL Shop Manual 2023-7134E – PDF DOWNLOAD

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Daewoo Excavator Solar 220LL Shop Manual 2023-7134E – PDF DOWNLOAD

Language : English
Pages : 576
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Daewoo Excavator Solar 220LL Shop Manual 2023-7134E – PDF DOWNLOAD

Safety................................................................................................  7
	Track Excavator Safety S0102010...................................................................  9
		To the Operator of a Daewoo Excavator......................................................... 11
			Learn the Signal Words Used with the Safety Alert Symbol.................................. 11
		General Safety Essentials..................................................................... 13
			Accessory Applications.................................................................... 13
			Lifting Capacity Rating Configuration..................................................... 13
		Location of Safety Labels..................................................................... 13
		Summary of Safety Precautions for Lifting in Digging Mode..................................... 14
			Unauthorized Modifications................................................................ 14
		Work-site Precautions......................................................................... 15
			Attachment Precautions.................................................................... 15
			Avoid High-voltage Cables................................................................. 15
			Be Aware of Height Obstacles.............................................................. 15
			Use Care on Loose Support................................................................. 15
			Use Solid Support Blocking................................................................ 16
			Overhangs Are Dangerous................................................................... 16
			Sloping Terrain Requires Caution.......................................................... 16
			Stay Alert for People Moving through the Work Area........................................ 16
			Be Aware of and Conform to Local Regulations.............................................. 17
		Operation..................................................................................... 17
			Operate While Seated at the Operator’s Station ONLY....................................... 17
			Before Starting the Engine................................................................ 17
			Never Use Ether Starting Aids............................................................. 18
			Mounting and Dismounting.................................................................. 18
			Observe General Safety Rules.............................................................. 18
			Engine Ventilation........................................................................ 18
			Asbestos Dust Hazard Prevention........................................................... 18
			Take Time to Provide Good Visibility...................................................... 19
			Fuel, Oil and Hydraulic Fluid Fire Hazards................................................ 19
			Boost Starting or Charging Engine Batteries............................................... 19
			Travel Controls May Produce Reversed Operations........................................... 20
			Keep "Pinch Point" Areas Clear - Use Caution in Reverse & Swing........................... 20
			Travel Precautions........................................................................ 20
			Operate Carefully on Snow and Ice and in Very Cold Temperatures........................... 20
			Parking the Machine....................................................................... 21
			Shutdown Control Functions................................................................ 21
			Additional Operational Comments........................................................... 21
		Equipment..................................................................................... 22
			Rough Operation May Require Use of Certified Safety Equipment............................. 22
			Install Additional Safety Equipment If Conditions Require................................. 22
			Movement Alarms........................................................................... 22
			Seat Belts Should Be Used at All Times.................................................... 23
			Window Glass Breaking Tool................................................................ 23
			Keep a Fire Extinguisher at Hand.......................................................... 23
			Maintain Standard Safety Equipment in Good Condition...................................... 23
			Safety - critical Parts Must Be Replaced Periodically..................................... 23
			Hydraulic Cylinder Seals Require Periodic Replacement..................................... 24
			High Pressure Hydraulic Lines Can Store a Great Deal of Energy............................ 24
			The Operator’s Cab and Turntable Deck Should Be Kept Clean................................ 24
			Wear Eye Protection and Safety Clothing................................................... 24
			Breathing Masks, Ear Protection May Be Required........................................... 24
			Battery Electrolyte and Explosive Gases Can Be Lethal..................................... 25
			Disconnect Batteries for Electrical Service Before Electrical Welding..................... 25
			Use Low Heat Portable Lighting............................................................ 25
		Maintenance................................................................................... 26
			Use Warning Tag Control Lockout Procedures During Service................................. 26
			Do not Run the Engine If Repairs or Work Is Being Performed Alone......................... 26
			Always Use Adequate Equipment Supports and Blocking....................................... 26
			Do not Work on Hot Engines or Hot Cooling or Hydraulic Systems............................ 26
			Cool-down Is Required Prior to Radiator or Reservoir Checks............................... 27
			Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous.................................... 27
			Obtain immediate medical attention if pressurized oil pierces the skin.................... 27
			Use Correct Replacement Fasteners Tightened to Proper Torque.............................. 27
			Dispose of All Petroleum-based Oils and Fluids Properly................................... 28
			Track Tension Adjustments Require Caution................................................. 28
			Do not attempt repairs you do not understand. There is no disgrace in asking for help..... 28
			All Welding Should Be Performed By Qualified Welder....................................... 28
			Cylinders................................................................................. 28
			Hydraulic Cylinders, Pins and Bushings.................................................... 29
		Shipping and Transportation................................................................... 30
			Obey State and Local Over-the-Road Regulations............................................ 30
		Lifting With Sling............................................................................ 30
Specifications........................................................................................ 31
	Specifications for Solar 220LL S0205010........................................................... 33
		General Description........................................................................... 35
		General Dimensions............................................................................ 38
		Dimensions and Working Range.................................................................. 40
		General Specifications........................................................................ 41
		Engine Performance Curve...................................................................... 42
		Performance Tests............................................................................. 43
		Excavator Performance Standards............................................................... 44
			Test Conditions........................................................................... 44
			Travel Speed and Travel Motor Balance (Steering Deviation) Tests.......................... 44
			Cylinder Performance Tests................................................................ 47
General Maintenance................................................................................... 49
	General Maintenance Procedures S0302000........................................................... 51
		Welding Precautions and Guidelines............................................................ 53
		Hydraulic System - General Precautions........................................................ 54
		Maintenance Service and Repair Procedure...................................................... 55
			General Precautions....................................................................... 55
		Hydraulic System Cleanliness And Oil Leaks.................................................... 56
			Maintenance Precautions for Hydraulic System Service...................................... 56
			Oil Leakage Precautions................................................................... 56
		Cleaning and Inspection....................................................................... 57
			Genral Guidelines......................................................................... 57
			Bearing inspection........................................................................ 58
	Standard Torques S0309000......................................................................... 65
		Torque Values for Standard Metric Fasteners................................................... 67
		Torque Values for Standard U.S. Fasteners..................................................... 68
		Type 8 Phosphate Coated Hardware.............................................................. 70
		Torque Values for Hose Clamps................................................................. 71
		Torque Values for Split Flanges............................................................... 72
		Torque Wrench Extension Tools................................................................. 73
			Torque Multiplication..................................................................... 73
			Other Uses for Torque Wrench Extension Tools.............................................. 74
			Tightening Torque Specifications (Metric)................................................. 74
Upper Structure....................................................................................... 77
	Cab S0402000...................................................................................... 79
		Removal....................................................................................... 81
		Installation.................................................................................. 83
		Window and Gasket Replacement................................................................. 86
		Falling Object Protective Structures (F.O.P.S.)............................................... 87
	Counterweight S0403000............................................................................ 89
		General....................................................................................... 91
		Removal....................................................................................... 93
		Installation.................................................................................. 94
	Fuel Tank S0405050................................................................................ 97
		General Description........................................................................... 99
			Parts List................................................................................100
			Specifications............................................................................101
		Removal.......................................................................................102
		Installation..................................................................................106
		Start-up Procedures...........................................................................108
	Swing Bearing S0407000............................................................................109
		Swing Bearing Maintenance.....................................................................111
			Operating Recommendation..................................................................111
			Measuring Swing Bearing Axial Play........................................................111
			Measuring Bearing Lateral Play............................................................111
			Swing Bearing Basic Operation.............................................................112
			Rebuilding Swing Bearing..................................................................112
	Swing Reduction Gearbox (RG10D20B-1) S0408010.....................................................115
		General Description...........................................................................117
			Theory of Operation.......................................................................117
			Parts List................................................................................118
			Specifications............................................................................119
		Special Tools and Materials...................................................................120
			Special Tools.............................................................................120
		Troubleshooting, Testing and Adjustment.......................................................121
		Removal.......................................................................................122
		Disassembly...................................................................................123
		Cleaning and Inspection (Wear Limits and Tolerances)..........................................128
		Reassembly....................................................................................129
		Installation..................................................................................138
Lower Structure and Chassis...........................................................................139
	Track Assembly S0505040...........................................................................141
		General Description...........................................................................143
			Specifications............................................................................143
		Track Tension.................................................................................144
		Cleaning and Inspection (Wear Limits and Tolerances)..........................................146
		Track Shoes and Links.........................................................................149
			Parts List................................................................................149
			Track Removal.............................................................................150
			Track Installation........................................................................151
		Front Idler Roller............................................................................152
			Parts List................................................................................152
			Front Idler Roller Disassembly............................................................153
			Front Idler Roller Reassembly.............................................................155
		Upper and Lower Roller........................................................................156
			Parts List................................................................................156
			Lower Roller Removal......................................................................157
			Lower Roller Disassembly..................................................................157
			Lower Roller Reassembly...................................................................158
			Lower Roller Installation.................................................................159
			Upper Roller Removal......................................................................160
			Upper Roller Disassembly..................................................................160
			Upper Roller Reassembly...................................................................160
		Track Spring and Track Adjusting Cylinder.....................................................161
			Parts List................................................................................161
Engine and Drive Train................................................................................163
	Air-Conditioner S0605010..........................................................................165
		General Description...........................................................................167
		Refrigerant Circulation.......................................................................168
		Control Panel.................................................................................170
		Control Specifications........................................................................171
		Temperature Level Control and Display.........................................................172
		Air Discharge According to Path Selection.....................................................173
		Air-conditioning System Circuit Diagram.......................................................176
		Troubleshooting...............................................................................178
		Refrigerant System Repairs....................................................................181
			Refrigerant Safe Handling Procedures......................................................181
			Repair and Replacement Procedure..........................................................182
			Refrigerant Recovery......................................................................184
			Vacuuming Refrigerant System..............................................................184
			Leakage Check.............................................................................185
			Refrigerant Charging......................................................................186
			Inspecting System For Leakage.............................................................188
Hydraulics............................................................................................189
	Hydraulic System Troubleshooting, Testing and Adjustment S0702070.................................191
		Hydraulic System - General Notes..............................................................194
		Hydraulic Schematic...........................................................................195
			General Notes.............................................................................195
		Operation of Working Components...............................................................196
			Boom Operating Circuit....................................................................196
			Boom Up Circuit...........................................................................196
			Boom Down Circuit.........................................................................196
			Arm Operating Circuit.....................................................................197
			Arm Crowd Circuit.........................................................................197
			Arm Dump Circuit..........................................................................197
			Bucket Operating Circuit..................................................................198
			Bucket Crowd Circuit......................................................................198
			Bucket Dump Circuit.......................................................................198
			Swing Operating Circuit...................................................................199
			Right Swing Operating Circuit.............................................................199
			Left Swing Operating Circuit..............................................................199
			Swing Relief Valve and Make-up Valve......................................................199
			Travel Operating Circuit..................................................................200
			Forward Travel Circuit....................................................................200
			Reverse Travel Circuit....................................................................200
		Procedural Troubleshooting Baseline Recommendations...........................................201
			Initial Checks and Tests to Establish Operating Condition of the Excavator................201
		Pilot Pressure................................................................................202
			Adjustment and Testing....................................................................202
		Power Mode Valve..............................................................................203
			Current Signal and Hydraulic Pressure Adjustments.........................................203
		Boom/Swing Priority Valve.....................................................................204
			Control Valve Pressure and Current Adjustments............................................204
		Pressure Up Valve.............................................................................206
			Checks and Adjustments....................................................................206
		Pump Input Power Control......................................................................207
			Pump Regulator Adjustment.................................................................207
		Flow Meter and Flow Meter Kit Installation and Testing........................................209
		Swing System Troubleshooting..................................................................210
			Precautions/Initial Checks................................................................210
			Swing Relief Valve Checking and Adjustment................................................211
		Troubleshooting - Swing Gearbox...............................................................212
		Troubleshooting – Hydraulic Problems..........................................................214
		Troubleshooting – Control Valve...............................................................215
		Troubleshooting – Travel Control Valve........................................................216
		Troubleshooting – Joystick Control Valve......................................................217
	Accumulator S0703000..............................................................................219
		General Description...........................................................................221
			Specifications............................................................................222
		Accumulator Charging..........................................................................223
			Charging the Accumulator with Nitrogen....................................................223
	Center Joint (Swivel) S0704010....................................................................225
		General Description...........................................................................227
			Parts List................................................................................228
		Troubleshooting, Testing and Adjustment.......................................................230
			Inspection................................................................................230
			Testing...................................................................................230
		Disassembly...................................................................................231
		Reassembly....................................................................................232
	Swing Motor S0707210..............................................................................233
		General Description...........................................................................235
			Theory of Operation.......................................................................235
			Swing Motor Anti-cavitation Make-up Valve.................................................236
			Relief Valve..............................................................................237
			Swing Brake Operation.....................................................................237
			Parts List................................................................................239
			Specifications............................................................................241
		Special Tools.................................................................................242
		Disassembly...................................................................................243
		Cleaning and Inspection (Wear Limits and Tolerances)..........................................250
		Reassembly....................................................................................252
	Travel Motor (With Gearbox) (GM35VL) S0707330.....................................................259
		General Description...........................................................................261
			Theory of Operation.......................................................................261
			Travel Motor Parts List...................................................................268
			Travel Reduction Gearbox Parts List.......................................................270
			Specifications............................................................................272
		Troubleshooting, Testing and Adjustment.......................................................274
			General Notice............................................................................274
			Troubleshooting...........................................................................274
		Disassembly...................................................................................278
			Preparation for Travel Motor and Reduction Gear Disassembly...............................278
			Travel Motor Rear Flange Disassembly......................................................280
			Travel Motor Internal Parts Disassembly...................................................284
		Cleaning and Inspection (Wear Limits and Tolerances)..........................................292
			General Inspection........................................................................292
			Gear Oil..................................................................................292
			General Notice............................................................................292
			Tightening Torque List....................................................................293
			Wear Limits...............................................................................294
		Reassembly....................................................................................296
			General Instructions for Reassembly.......................................................296
			Travel Motor Rear Flange Reassembly.......................................................296
			Travel Reduction Gear Reassembly..........................................................301
			Gear Holding Flange Gap Measurement and Adjustment........................................308
			RV Gear Gap Measurement and Adjustment....................................................309
			Travel Motor and Reduction Gear Reassembly................................................310
			Reduction Gear Cover Reassembly...........................................................312
	Grapple Rotate Motor S0707400.....................................................................315
		General Description...........................................................................317
			General Notes.............................................................................317
			Torqmotor™ Features.......................................................................318
			Parts List................................................................................320
		Special Tools and Materials...................................................................321
			Special Tools.............................................................................321
			Tools and Materials Required for Servicing................................................322
			Torque Chart..............................................................................323
		Troubleshooting, Testing and Adjustment.......................................................324
			Preliminary Checks........................................................................324
			Hydraulic Components......................................................................324
			Disassembly and Inspection (Preparation Before Disassembly)...............................325
		Disassembly...................................................................................327
		Reassembly....................................................................................336
			One Piece Stator Reassembly...............................................................348
			Two Piece Stator Reassembly...............................................................349
		Start-Up Procedures...........................................................................351
			Hydraulic Fluid...........................................................................351
	Main Pump (With Regulator) S0708320...............................................................353
		General Description...........................................................................355
			Gear (Pilot) Pump.........................................................................357
			Relief Valve..............................................................................357
			Pump Regulator Description................................................................358
			Horsepower Control........................................................................358
			Power Shift Control.......................................................................358
			Negative Oil Discharge (Pump Bypass) Control..............................................358
			Pump Regulator Operation..................................................................359
			Pump Output Decrease......................................................................361
			Pump Discharge Decrease...................................................................361
			Pump Discharge Increase...................................................................361
			Horsepower Control........................................................................361
			Overload Protection.......................................................................362
			Regulator Adjustment......................................................................362
			Pump Input Power Control Adjustment.......................................................363
			Parts List................................................................................364
			Specifications............................................................................368
			Hydraulic Pump Performance Characteristics................................................368
		Troubleshooting, Testing and Adjustment.......................................................370
			Main Pump.................................................................................370
		Disassembly...................................................................................371
			General Disassembly.......................................................................371
			Main Pump Disassembly.....................................................................372
			Pump Regulator Disassembly................................................................374
		Cleaning and Inspection (Wear Limits and Tolerances)..........................................378
		Reassembly....................................................................................380
			Pump Regulator Reassembly.................................................................380
			Main Pump Reassembly......................................................................384
	Main Control Valve S0709400.......................................................................387
		Control Valve Operation.......................................................................390
			Swing Priority Circuit....................................................................390
			Arm Priority Circuit......................................................................391
			Bucket (Junction) Circuit.................................................................392
			Straight Travelling Circuit...............................................................393
			Plunger Replacement.......................................................................395
			Main Relief Valve.........................................................................396
			Overload Relief Valve.....................................................................397
			Arm Load Holding Valve....................................................................399
			Boom Load Holding Valve...................................................................402
			Arm Regeneration..........................................................................404
			Boom Regeneration.........................................................................406
			Foot Relief Valve.........................................................................407
			Parts List................................................................................408
			Specifications............................................................................418
		Control Valve Drawing and Hydraulic Circuit...................................................419
		Disassembly and Reassembly....................................................................424
			General Disassembly.......................................................................424
			General Reassembly........................................................................424
			Main Plunger Element - Disassembly and Assembly...........................................425
			Tool......................................................................................425
			Main Relief Valve.........................................................................428
			Main Relief Valve Adjustment..............................................................429
			Overload Relief Valve.....................................................................431
			Arm Load Holding Valve....................................................................433
			Boom Load Holding Valve...................................................................436
			Arm Regeneration Valve....................................................................438
			Bucket Unity Check........................................................................439
			Foot Relief Valve.........................................................................440
			Center Bypass Valve (CB Valve)............................................................441
			Boom Parallel Switch Valve................................................................442
			Tool......................................................................................442
			Swing Priority Valve......................................................................444
			Boom Unity Check Valve....................................................................446
			Straight Travel Selector Valve............................................................447
			Check Valve - Locations...................................................................448
			Check Valve...............................................................................449
	Remote Control Valve (Work Lever / Joystick) S0709450.............................................455
		General Description...........................................................................457
			Theory of Operation.......................................................................457
			Parts List................................................................................458
			Specifications............................................................................459
			Hydraulic Specifications..................................................................460
		Special Tools.................................................................................461
		Disassembly...................................................................................462
		Reassembly....................................................................................467
	Travel Control Valve (RCV8C4015A) S0709800........................................................473
		General Description...........................................................................475
			Theory of Operation.......................................................................475
			Parts List................................................................................478
			Specifications............................................................................479
			Torque Table..............................................................................479
		Special Tools and Materials...................................................................480
			Special Tools.............................................................................480
		Troubleshooting, Testing and Adjustment.......................................................482
		Disassembly...................................................................................483
		Cleaning and Inspection (Wear Limits and Tolerances)..........................................490
		Reassembly....................................................................................491
	Hydraulic Schematic (S220LL) S0792020.............................................................501
		General Description...........................................................................503
		Solar 220LL...................................................................................504
Electrical System.....................................................................................507
	Electrical System S0802035........................................................................509
		Troubleshooting - Electrical System...........................................................512
		Wiring Harness Illustrations..................................................................513
		Overview......................................................................................513
		Electric Supply System........................................................................514
		Engine Starting Circuit.......................................................................515
			Operation During Start Process............................................................515
			Operation After Start Process.............................................................516
		Engine Preheating System......................................................................517
		Engine Stop System............................................................................518
		Charging System...............................................................................522
		Monitoring System.............................................................................523
		Instrument Panel..............................................................................524
		Function Check................................................................................525
			Monitoring System Schematic...............................................................525
		Operation.....................................................................................527
			Instruments...............................................................................527
		Mode Select Switch............................................................................529
		Pilot Lamp....................................................................................530
		Initial Operation.............................................................................531
		Electronic Hydraulic Control System (Epos - V)................................................532
		Power Mode Control............................................................................534
			Operation.................................................................................535
		Power Mode Control - Circuit Diagram..........................................................539
		Work Mode Control.............................................................................540
			Operation.................................................................................541
		Work Mode Control - Circuit Diagram...........................................................542
		Engine Control System.........................................................................543
		Engine Control Motor..........................................................................544
		Engine Control Dial...........................................................................545
		Engine Control Circuit Diagram................................................................546
		Automatic Deceleration Control (Auto Idle Control)............................................547
		Engine Overheat Protection System.............................................................548
		Power Boost Mode..............................................................................549
			Operation.................................................................................549
			Power Boost Control - Circuit Diagram.....................................................550
		Automatic Travel Speed Control................................................................551
			Automatic Travel Speed Control - Circuit Diagram..........................................552
		Engine Control Device - Adjustment............................................................553
		Self-diagnostic Function......................................................................556
			EPOS-V Controller.........................................................................556
		Engine Throttle Controller....................................................................560
	Electrical Schematic (S220LL) S0892020............................................................561
		General Description...........................................................................563
		Solar 220LL...................................................................................564
Attachments...........................................................................................567
	Boom and Stick S0902020...........................................................................569
		Front Attachment Specifications...............................................................571
			Pin Specifications........................................................................571
			Size and Weight Specifications............................................................571
		Front Attachment - Removal and Installation...................................................572
			Stick Removal Procedure...................................................................572
			Boom Removal Procedure....................................................................574
		Installation..................................................................................575
			Stick Installation Procedure..............................................................575
			Boom Installation Procedure...............................................................575
		Start-up Procedures...........................................................................576

S.S 06/24