Daewoo Excavator Solar 225LL Shop Manual 023-00078E – PDF

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Daewoo Excavator Solar 225LL Shop Manual 023-00078E – PDF DOWNLOAD 

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Daewoo Excavator Solar 225LL Shop Manual 023-00078E – PDF DOWNLOAD 

Language : English
Pages : 688
Downloadable : Yes
File Type : PDF

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Daewoo Excavator Solar 225LL Shop Manual 023-00078E – PDF DOWNLOAD 

Publication Request for Proposed Revision.................................................  7
Safety....................................................................................  9
	Track Excavator Safety S0102015K...................................................... 11
		To the Operator of a Daewoo Excavator............................................. 13
			Learn the Signal Words Used with the Safety Alert Symbol...................... 15
		General Safety Essentials......................................................... 16
			Accessory Applications........................................................ 16
			Lifting Capacity Rating Configuration......................................... 16
		Location of Safety Labels......................................................... 16
		Summary of Safety Precautions for Lifting in Digging Mode......................... 17
		Unauthorized Modifications........................................................ 18
		General Hazard Information........................................................ 18
			Safety Rules.................................................................. 18
			Safety Features............................................................... 18
			Inside Operator's Compartment................................................. 19
			Clothing and Personal Protective Items........................................ 19
			Breathing Masks, Ear Protection May Be Required............................... 20
			Vibration Level Information................................................... 20
			Mounting and Dismounting...................................................... 20
			Fuel, Oil and Hydraulic Fluid Fire Hazards.................................... 21
			Precautions When Handling Fluids at High Temperature.......................... 21
			Asbestos Dust Hazard Prevention............................................... 22
			Injury from Work Equipment.................................................... 22
			Fire Extinguisher and First Aid Kit........................................... 23
			Protection from Falling or Flying Objects..................................... 23
			Attachment Precautions........................................................ 24
			Accumulator................................................................... 24
			Indoor Ventilation............................................................ 25
			Emergency Exit................................................................ 25
		Before Starting Engine............................................................ 26
			Work Site Precautions......................................................... 26
			Checks Before Starting Engine................................................. 27
			Engine Starting............................................................... 28
			Before Operating Machine...................................................... 28
		Machine Operation................................................................. 29
			When Swinging or Changing Direction of Travel................................. 29
			Travel Precautions............................................................ 30
			Traveling on Slopes........................................................... 31
			Prohibited Operations......................................................... 31
			Precautions for Operation..................................................... 32
			Avoid High Voltage Cables..................................................... 33
			Operate Carefully on Snow, Ice and in Very Cold Temperatures.................. 33
			Operations on Slopes.......................................................... 34
			Parking Machine............................................................... 34
			Never Let Anyone Ride on Attachment........................................... 34
		Maintenance....................................................................... 35
			Warning Tag................................................................... 35
			Clean Before Inspection or Maintenance........................................ 35
			Proper Tools.................................................................. 36
			Use of Lighting............................................................... 36
			Fire Prevention and Explosion Prevention...................................... 36
			Burn Prevention............................................................... 37
			Welding Repairs............................................................... 38
			Warning for Counterweight and Front Attachment Removal........................ 38
			Precautions for Removal, Installation, and Storage of Attachments............. 39
			Precautions When Working on Machine........................................... 39
			Lock Inspection Covers........................................................ 39
			Crushing Prevention and Cutting Prevention.................................... 40
			Track Tension Adjustments Require Caution..................................... 40
			Supports and Blocking for Work Equipment...................................... 40
			Action When Abnormally Is Found During Inspection............................. 41
			Precautions with Highpressure Line, Tubes and Hoses.......................... 41
			Waste Materials............................................................... 42
		Battery........................................................................... 43
			Battery Hazard Prevention..................................................... 43
			Boost Starting or Charging Engine Batteries................................... 44
		Towing............................................................................ 45
			Precautions When Towing....................................................... 45
		Shipping and Transportation....................................................... 46
			Obey State and Local OvertheRoad Regulations................................ 46
		Lifting With Sling................................................................ 46
Specifications............................................................................ 47
	Specifications for Solar 225LL S0202150K.............................................. 49
		General Description............................................................... 51
		General Dimensions................................................................ 54
		Dimensions and Working Range...................................................... 56
		General Specifications............................................................ 57
		Engine Performance Curves (Per DIN6270 Standard)................................. 58
		Approximate Weight of Workload Materials.......................................... 60
		Performance Tests................................................................. 62
		Excavator Performance Standards................................................... 63
			Test Conditions............................................................... 63
			Travel Speed and Travel Motor Balance (Steering Deviation) Tests.............. 63
			Cylinder Performance Tests.................................................... 66
General Maintenance....................................................................... 67
	General Maintenance Procedures S0302000............................................... 69
		Welding Precautions and Guidelines................................................ 71
		Hydraulic System  General Precautions............................................ 72
		Maintenance Service and Repair Procedure.......................................... 73
			General Precautions........................................................... 73
		Hydraulic System Cleanliness and Oil Leaks........................................ 74
			Maintenance Precautions for Hydraulic System Service.......................... 74
			Oil Leakage Precautions....................................................... 74
		Cleaning and Inspection........................................................... 75
			General Guidelines............................................................ 75
			Bearing inspection............................................................ 76
	Standard Torques S0309000............................................................. 83
		Torque Values for Standard Metric Fasteners....................................... 85
		Torque Values for Standard U.S. Fasteners......................................... 86
		Type 8 Phosphate Coated Hardware.................................................. 88
		Torque Values for Hose Clamps..................................................... 89
		Torque Values for Split Flanges................................................... 90
		Torque Wrench Extension Tools..................................................... 91
			Torque Multiplication......................................................... 91
			Other Uses for Torque Wrench Extension Tools.................................. 92
			Tightening Torque Specifications (Metric)..................................... 92
Upper Structure........................................................................... 95
	Cab S0402040K......................................................................... 97
		Removal........................................................................... 99
		Installation......................................................................102
	Counterweight S0403000................................................................105
		General...........................................................................107
		Removal...........................................................................109
		Installation......................................................................111
	Fuel Tank \S0405050...................................................................113
		General Description...............................................................115
			Parts List....................................................................116
			Specifications................................................................117
		Removal...........................................................................118
		Installation......................................................................122
		Startup Procedures...............................................................124
	Swing Bearing S0407000................................................................125
		Swing Bearing Maintenance.........................................................127
			Operating Recommendation......................................................127
			Measuring Swing Bearing Axial Play............................................127
			Measuring Bearing Lateral Play................................................127
			Swing Bearing Basic Operation.................................................128
			Rebuilding Swing Bearing......................................................128
	Swing Reduction Gearbox S0408015K.....................................................131
		General Description...............................................................133
			Theory of Operation...........................................................133
			Parts List....................................................................134
			Specifications................................................................135
		Special Tools and Materials.......................................................136
			Special Tools.................................................................136
		Troubleshooting, Testing and Adjustment...........................................137
		Removal...........................................................................138
		Disassembly.......................................................................139
		Cleaning and Inspection (Wear Limits and Tolerances)..............................144
		Reassembly........................................................................145
		Installation......................................................................154
Lower Structure and Chassis...............................................................155
	Track Assembly S0505045K..............................................................157
		General Description...............................................................159
			Specifications................................................................159
		Track Tension.....................................................................160
		Cleaning and Inspection (Wear Limits and Tolerances)..............................162
		Track Shoes and Links.............................................................165
			Parts List....................................................................165
			Track Removal.................................................................166
			Track Installation............................................................167
		Front Idler Roller................................................................168
			Parts List....................................................................168
			Front Idler Roller Disassembly................................................169
			Front Idler Roller Reassembly.................................................171
		Upper and Lower Roller............................................................172
			Parts List....................................................................172
			Lower Roller Removal..........................................................173
			Lower Roller Disassembly......................................................173
			Lower Roller Reassembly.......................................................174
			Lower Roller Installation.....................................................175
		Upper Roller......................................................................176
			Parts List....................................................................176
			Upper Roller Removal..........................................................177
			Upper Roller Disassembly......................................................177
			Upper Roller Reassembly.......................................................179
		Track Spring and Track Adjusting Cylinder.........................................181
			Parts List....................................................................181
Engine and Drive Train....................................................................183
	Air Conditioner S0605060K.............................................................185
		General Description...............................................................187
		Refrigerant Circulation...........................................................189
		Control Panel.....................................................................191
		Control Specifications............................................................192
		Temperature Level Control and Display.............................................193
		Air Discharge According to Path Selection.........................................194
		Airconditioning System Circuit Diagram...........................................196
		Troubleshooting...................................................................198
		Weight of R134a Gas Used In Machines..............................................200
		Refrigerant System Repairs........................................................202
			Refrigerant Safe Handling Procedures..........................................202
			Repair and Replacement Procedure..............................................203
			Refrigerant Recovery..........................................................205
			Vacuuming Refrigerant System..................................................205
			Leakage Check.................................................................207
			Refrigerant Charging..........................................................207
			Inspecting System for Leakage.................................................209
	Drive Coupling (Main Pump) S0609000...................................................211
		Drive Coupling....................................................................213
		Special Tools.....................................................................214
			Kawasaki / Tong Myung Pump Tool...............................................214
			Uchida Pump Tool..............................................................217
		Drive Coupling Installation.......................................................219
			Installation Procedure........................................................224
Hydraulics................................................................................225
	Hydraulic System Troubleshooting, Testing and Adjustment S0702210K....................227
		Hydraulic System  General Notes..................................................230
		Hydraulic Schematic...............................................................231
			General Notes.................................................................231
		Operation of Working Components...................................................232
			Boom Operating Circuit........................................................232
			Boom Up Circuit...............................................................232
			Boom Down Circuit.............................................................232
			Arm Operating Circuit.........................................................233
			Arm Crowd Circuit.............................................................233
			Arm Dump Circuit..............................................................234
			Bucket Operating Circuit......................................................234
			Bucket Crowd Circuit..........................................................234
			Bucket Dump Circuit...........................................................235
			Swing Operating Circuit.......................................................235
			Right Swing Operating Circuit.................................................235
			Left Swing Operating Circuit..................................................235
			Swing Relief Valve and Makeup Valve...........................................235
			Travel Operating Circuit......................................................236
			Forward Travel Circuit........................................................236
			Reverse Travel Circuit........................................................236
		Procedural Troubleshooting Baseline Recommendations...............................236
			Initial Checks and Tests to Establish Operating Condition of the Excavator....236
		Pilot Pressure....................................................................238
			Adjustment and Testing........................................................238
		Power Mode Valve..................................................................239
			Current Signal and Hydraulic Pressure Adjustments.............................239
		Swing Priority Valve..............................................................241
			Control Valve Pressure and Current Adjustments................................241
		Pressure Up Valve.................................................................242
			Checks and Adjustments........................................................242
		Pump Input Power Control..........................................................243
			Pump Regulator Adjustment.....................................................243
		Flow Meter and Flow Meter Kit Installation and Testing............................245
		Swing System Troubleshooting......................................................246
			Precautions/Initial Checks....................................................246
			Swing Relief Valve Checking and Adjustment....................................247
		Troubleshooting  Swing Gearbox...................................................248
		Troubleshooting – Hydraulic Problems..............................................250
		Troubleshooting – Control Valve...................................................251
		Troubleshooting – Travel Control Valve............................................252
		Troubleshooting – Joystick Control Valve..........................................253
	Accumulator S0703010K.................................................................255
		General Description...............................................................257
			Specifications................................................................258
	Center Joint (Swivel) S0704010........................................................261
		General Description...............................................................263
			Parts List....................................................................264
		Troubleshooting, Testing and Adjustment...........................................268
			Inspection....................................................................268
			Testing.......................................................................268
		Disassembly.......................................................................269
		Reassembly........................................................................270
	Cylinders S0705000....................................................................271
		General Description...............................................................273
			Theory of Operation...........................................................273
			Parts List....................................................................274
		Special Tools and Materials.......................................................276
			Piston Nut....................................................................276
			Piston Jig....................................................................280
			Steel Bushing Jig.............................................................284
			Dust Wiper Jig................................................................288
			Slipper Seal Jig..............................................................294
			Slipper Seal Straightening Jig................................................298
		Disassembly.......................................................................301
		Assembly..........................................................................307
	Swing Motor S0707200..................................................................311
		General Description...............................................................313
			Theory of Operation...........................................................313
			Swing Motor Anticavitation Makeup Valve.......................................314
			Relief Valve..................................................................315
			Swing Brake Operation.........................................................315
			Parts List (Model Solar 250LCV, 255LCV).....................................318
			Parts List (Models Solar 225LCV, 225NLCV, 290LCV, and 290LL)...............320
			Specifications (Model Solar 225LCV, 225NLCV)................................322
			Specifications (Models Solar 250LCV, 255LCV, 290LCV, and 290LL)............322
		Special Tools.....................................................................323
		Disassembly.......................................................................324
		Cleaning and Inspection (Wear Limits and Tolerances)..............................331
		Reassembly........................................................................333
	Travel Motor (With Gearbox) (TM40VC) S0707331K........................................341
		General Description...............................................................343
			Theory of Operation...........................................................343
			Travel Motor Parts List.......................................................350
			Travel Reduction Gearbox Parts List...........................................352
			Specifications................................................................354
		Troubleshooting, Testing and Adjustment...........................................356
			General Notice................................................................356
			Troubleshooting...............................................................356
		Disassembly.......................................................................360
			Preparation for Travel Motor and Reduction Gear Disassembly...................360
			Travel Motor Rear Flange Disassembly..........................................362
			Travel Motor Internal Parts Disassembly.......................................366
		Cleaning and Inspection (Wear Limits and Tolerances)..............................374
			General Inspection............................................................374
			Gear Oil......................................................................374
			General Notice................................................................374
			Tightening Torque List........................................................375
			Wear Limits...................................................................375
		Reassembly........................................................................377
			General Instructions for Reassembly...........................................377
			Travel Motor Rear Flange Reassembly...........................................377
			Travel Reduction Gear Reassembly..............................................382
			Gear Holding Flange Gap Measurement and Adjustment............................389
			RV Gear Gap Measurement and Adjustment........................................390
			Travel Motor and Reduction Gear Reassembly....................................391
			Reduction Gear Cover Reassembly...............................................393
	Grapple Rotate Motor S0707400.........................................................395
		General Description...............................................................397
			General Notes.................................................................397
			Torqmotor™ Features...........................................................398
			Parts List....................................................................400
		Special Tools and Materials.......................................................401
			Special Tools.................................................................401
			Tools and Materials Required for Servicing....................................402
			Torque Chart..................................................................403
		Troubleshooting, Testing and Adjustment...........................................404
			Preliminary Checks............................................................404
			Hydraulic Components..........................................................404
			Disassembly and Inspection (Preparation Before Disassembly)...................405
		Disassembly.......................................................................407
		Reassembly........................................................................416
			One Piece Stator Reassembly...................................................428
			Two Piece Stator Reassembly...................................................429
		Startup Procedures...............................................................431
			Hydraulic Fluid...............................................................431
	Main Pump (With Regulator) S0708320...................................................433
		General Description...............................................................435
			Gear (Pilot) Pump.............................................................437
			Relief Valve..................................................................437
			Pump Regulator Description....................................................438
			Horsepower Control............................................................438
			Power Shift Control...........................................................438
			Negative Oil Discharge (Pump Bypass) Control..................................438
			Pump Regulator Operation......................................................439
			Pump Output Decrease..........................................................441
			Pump Discharge Decrease.......................................................441
			Pump Discharge Increase.......................................................441
			Horsepower Control............................................................441
			Overload Protection...........................................................442
			Regulator Adjustment..........................................................442
			Pump Input Power Control Adjustment...........................................443
			Parts List....................................................................444
			Specifications................................................................448
			Hydraulic Pump Performance Characteristics....................................450
		Troubleshooting, Testing and Adjustment...........................................457
			Main Pump.....................................................................457
		Disassembly.......................................................................458
			General Disassembly...........................................................458
			Main Pump Disassembly.........................................................459
			Pump Regulator Disassembly....................................................461
		Cleaning and Inspection (Wear Limits and Tolerances)..............................465
		Reassembly........................................................................467
			Pump Regulator Reassembly.....................................................467
			Main Pump Reassembly..........................................................471
	Main Control Valve S0709400...........................................................475
		Control Valve Operation...........................................................478
			Swing Priority Circuit........................................................478
			Arm Priority Circuit..........................................................479
			Bucket (Junction) Circuit.....................................................480
			Straight Traveling Circuit....................................................481
			Plunger Replacement...........................................................483
			Main Relief Valve.............................................................484
			Overload Relief Valve.........................................................485
			Arm Load Holding Valve........................................................487
			Boom Load Holding Valve.......................................................490
			Arm Regeneration..............................................................492
			Boom Regeneration.............................................................494
			Foot Relief Valve.............................................................495
			Parts List....................................................................496
			Specifications................................................................506
		Control Valve Drawing and Hydraulic Circuit.......................................507
		Disassembly and Reassembly........................................................512
			General Disassembly...........................................................512
			General Reassembly............................................................512
			Main Plunger Element  Disassembly and Assembly...............................513
			Tool..........................................................................513
			Main Relief Valve.............................................................516
			Main Relief Valve Adjustment..................................................517
			Overload Relief Valve.........................................................519
			Arm Load Holding Valve........................................................521
			Boom Load Holding Valve.......................................................524
			Arm Regeneration Valve........................................................526
			Bucket Unity Check............................................................527
			Foot Relief Valve.............................................................528
			Center Bypass Valve (CB Valve)................................................529
			Boom Parallel Switch Valve....................................................530
			Tool..........................................................................530
			Swing Priority Valve..........................................................532
			Boom Unity Check Valve........................................................534
			Straight Travel Selector Valve................................................535
			Check Valve  Locations.......................................................536
			Check Valve...................................................................537
	Pilot Control Valve (Work Lever / Joystick) S0709450..................................543
		General Description...............................................................545
			Theory of Operation...........................................................545
			Parts List....................................................................546
			Specifications................................................................547
			Hydraulic Specifications......................................................548
		Special Tools.....................................................................549
		Disassembly.......................................................................550
		Reassembly........................................................................555
	Travel Control Valve (With Damper) S0709820K..........................................561
		General Description...............................................................563
			Theory of Operation...........................................................563
			Parts List....................................................................566
			Specification.................................................................567
			Torque........................................................................567
		Troubleshooting, Testing and Adjustment...........................................568
		Removal...........................................................................569
		Disassembly.......................................................................571
		Cleaning and Inspection (Wear Limits and Tolerances)..............................577
		assembly..........................................................................578
		Installation......................................................................583
		Startup Procedures...............................................................584
	Hydraulic Schematic (S225LL) S0792025K................................................585
		General Description...............................................................587
		Solar 225LL (S/N 1001 thru 1002)..................................................588
		Solar 225LL (S/N 1003 and Up).....................................................590
Electrical System.........................................................................593
	Electrical System S0802220K...........................................................595
		Troubleshooting  Electrical System...............................................599
		Overview..........................................................................600
		Electric Supply System............................................................601
		Engine Starting Circuit...........................................................602
			Operation During Start Process................................................602
			Operation After Start Process.................................................603
		Engine Preheating and After Start Heating System..................................604
		Engine Stop System................................................................606
		Charging System...................................................................609
		Monitoring System.................................................................610
			Instrument Panel..............................................................611
			Monitoring System Schematic...................................................612
		Operation.........................................................................614
			Instruments...................................................................614
		Warning and Indicator Lights......................................................616
		Initial Operation.................................................................618
		Mode Selector Switch..............................................................619
		Graphic Information Area Display..................................................620
			Overview......................................................................620
			Main Menus for the Graphic Display Area.......................................621
			Menu Selector Buttons.........................................................621
		Main Menu.........................................................................622
			Language Setting..............................................................622
			Time Setting..................................................................622
			Filter/Oil Information........................................................623
		Special Menu......................................................................624
			Entering/Accessing and Exiting/Escaping Menus.................................624
			Special Menu Selections.......................................................625
		Electronic Hydraulic Control System (eEPOS)......................................638
			Control System Schematic......................................................638
		Power Mode Control................................................................640
			Operation.....................................................................641
		Power Mode Control  Circuit Diagram..............................................644
		Work Mode Control.................................................................646
			Operation.....................................................................647
		Work Mode Control  Circuit Diagram...............................................648
		Engine Control System.............................................................649
		Engine Control Motor..............................................................651
		Engine Control Dial...............................................................652
		Engine Control Circuit Diagram....................................................654
		Automatic Deceleration Control (Auto Idle Control)................................655
		Engine Overheat Protection System.................................................656
		Power Boost Mode..................................................................657
			Operation.....................................................................657
			Power Boost Control  Circuit Diagram.........................................658
		Automatic Travel Speed Control....................................................659
			Automatic Travel Speed Control  Circuit Diagram..............................660
		Engine Control Device  Adjustment................................................661
		Selfdiagnostic Function..........................................................665
			eEPOS Controller.............................................................665
		Engine Throttle Controller........................................................667
		Wiper System......................................................................668
			Wiper Circuit.................................................................668
			Wiper Operation...............................................................668
			Window Washer Operation.......................................................669
		Lighting System...................................................................670
			Lighting System Circuit Diagram...............................................670
			Kind of Light.................................................................671
			Operation.....................................................................671
		Overload Warning Device...........................................................672
			Overload Warning Device Circuit Diagram.......................................672
	Electrical Schematic (S225LL) S0892025K...............................................673
		General Description...............................................................675
		Solar 225LL.......................................................................676
Attachments...............................................................................679
	Boom and Stick S0902020...............................................................681
		Front Attachment Specifications...................................................683
			Pin Specifications............................................................683
			Size and Weight Specifications................................................683
		Front Attachment  Removal and Installation.......................................684
			Stick Removal Procedure.......................................................684
			Boom Removal Procedure........................................................686
		Installation......................................................................687
			Stick Installation Procedure..................................................687
			Boom Installation Procedure...................................................687
		Startup Procedures...............................................................688

S.S 06/24