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Daewoo Solar 225LC-V Shop Manual

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Solar 225LC-V

Shop Manual

023-00058E

Serial Number 1001 and Up

October 2002

Daewoo reserves the right to improve our products in a continuing process to provide the best possible

product to the market place. These improvements can be implemented at any time with no obligation to

change materials on previously sold products. It is recommended that consumers periodically contact their

distributors for recent documentation on purchased equipment.

This documentation may include attachments and optional equipment that is not available in your

machine's package. Please call your distributor for additional items that you may require.

Illustrations used throughout this manual are used only as a representation of the actual piece of

equipment, and may vary from the actual item.

023-00058E Shop Manual

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Summary of Contents for Daewoo Solar 225LC-V

Page 1 Serial Number 1001 and Up October 2002 Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
Page 3 Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Pub. No. 023-00058E...
Page 5 1TABLE OF CONTENTS Safety Track Excavator Safety................S0102000 Specifications Specifications for Solar 225LC-V............S0205015K General Maintenance General Maintenance Procedures ............S0302000 Standard Torques ..................S0309000 Upper Structure Cab ..................... S0402040K Counterweight..................S0403050K Fuel Tank.................... S0405005K Fuel Transfer Pump ................S0405500 Swing Bearing..................S0407000 Swing Reduction Gearbox ..............S0408015K Lower Structure and Chassis Track Assembly ..................S0505030...
Page 6 Main Pump (With Regulator) ..............S0708320 Main Control Valve (Kayaba).............. S0709401K Pilot Control Valve (Work Lever / Joystick)......... S0709451K Travel Control Valve (With Damper)........... S0709820K Hydraulic Schematic (Solar 225LC-V/225NLC-V) ......S0792105K Electrical System Electrical System ................S0802220K Electrical Schematic (Solar 225LC-V/225NLC-V)....... S0892105K Attachments Boom and Arm..................S0902010...
Page 7 1SAFETY...
Page 9 Solar 130LC-V 0001 and Up Solar 170LC-V 1001 and Up Solar 220LC-V 0001 and Up Solar 220N-V 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 250LC-V 1001 and Up Solar 255LC-V 1001 and Up...
Page 10: Table Of Contents
TABLE OF CONTENTS To the Operator of a Daewoo Excavator ............3 General Safety Essentials ................6 Location of Safety Labels ................6 Summary of Safety Precautions for Lifting in Digging Mode ......7 Unauthorized Modifications ................8 General Hazard Information ................8 Before Starting Engine .................
Page 11 TO THE OPERATOR OF A DAEWOO EXCAVATOR DANGER! Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
Page 12 In no event should you or others engage in prohibited uses or actions as described in this manual. Daewoo delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
Page 13 Safety precautions are described in SAFETY from page -6 on. Daewoo cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.
Page 14: General Safety Essentials
The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for other object handling, contact Daewoo for proper installation and application. Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading.
Page 15: Summary Of Safety Precautions For Lifting In Digging Mode
If you need more information or have any questions or concerns about safe operating procedures or working the excavator correctly in a particular application or in the specific conditions of your individual operating environment, please consult your local Daewoo representative.
Page 16: Unauthorized Modifications
For safety’s sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised.
Page 17 INSIDE OPERATOR'S COMPARTMENT When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
Page 18 MOUNTING AND DISMOUNTING Before getting on or off the machine, if there is any oil. grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.
Page 19 FUEL, OIL AND HYDRAULIC FLUID FIRE HAZARDS Fuel, oil and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well-ventilated area.
Page 20 ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. Materials containing asbestos fiber can be present on work site. Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage. To prevent lung damage from asbestos fiber, observe following precautions;...
Page 21 FIRE EXTINGUISHER AND FIRST AID KIT As a precaution if any injury or fire should occur, always do the following. • Be sure that fire extinguishers have been provided and read the labels to ensure that you know now to use them.
Page 22 If any glass on the machine is broken, replace it with new glass immediately. ATTACHMENT PRECAUTIONS Option kits are available through your dealer. Contact Daewoo for information on available one-way (single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because Daewoo cannot anticipate, identify or test all of the attachments that owners may wish to install on their machines, please contact Daewoo for authorization and approval of attachments, and their compatibility with options kits.
Page 23 INDOOR VENTILATION Engine exhaust gases cause fatal accidents, unconsciousness, loss alertness, judgement and motor control and serious injury. Make sure there is adequate ventilation before starting the engine in any enclosed area. You should also be aware of open windows, doors or ductwork into which exhaust may be carried, or blown by the wind, exposing others to danger.
Page 24: Before Starting Engine
BEFORE STARTING ENGINE WORK SITE PRECAUTIONS Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation.
Page 25 Minimum levels of insurance coverage, work permits or certification, physical barriers around the work site or restricted hours of operation may be mandated by governing authorities. There may also be regulations, guidelines, standards or restrictions on equipment that may have to be followed for local requirements. There may also be regulations related to performing certain kinds of work.
Page 26 ENGINE STARTING Walk around your machine before getting in the operator’s cab. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated.
Page 27: Machine Operation
MACHINE OPERATION WHEN SWINGING OR CHANGING DIRECTION OF TRAVEL Before operating the machine or the work equipment, always observe following precautions to prevent serious injury or death. • When changing the direction of travel from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing the direction of travel.
Page 28 TRAVEL PRECAUTIONS Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops when the machine is traveling. It will be impossible to operate the steering. Attachment control levers should not be operated while traveling. Do not change selected travel mode (FAST/SLOW) while traveling.
Page 29 TRAVELING ON SLOPES Never jump onto a machine that is running away to stop it. There is danger of serious injury. Traveling on slopes could result in the machine tipping over or slipping. On hills, banks or slopes, carry the bucket approximately 20 - 30 cm (8 - 12 in) above the ground. In case of an emergency, quickly lower the bucket to the ground to help stop the machine.
Page 30 PROHIBITED OPERATIONS Do not dig the work face under an overhand. This may cause the overhand to collapse and fall on top of the machine. Figure 21 Do not carry out deep digging under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
Page 31 PRECAUTIONS FOR OPERATION Be careful not to go close to the edge of a cliff by mistake. Use the machine only for its main purpose. Using it for other purposes will cause failures. To ensure an ample view, do as follows: •...
Page 32 AVOID HIGH-VOLTAGE CABLES Serious injury or death can result from contact or proximity to high-voltage electric lines. The bucket does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to stay away from power lines not clearly visible to the operator.
Page 33 OPERATIONS ON SLOPES When working on slopes. there is danger that the machine may lose its balance and turn over, when swinging, or when work equipment is operated. Always carry out these operations carefully. Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded.
Page 34: Maintenance
Warning tags, for controls are available from 190-00695 Daewoo distributors. ARO1320L Figure 27 CLEAN BEFORE INSPECTION OR MAINTENANCE Clean the machine before carrying out inspection and maintenance. This prevents dirt from getting into the machine and also ensures safety during maintenance.
Page 35 PROPER TOOLS Use only tools suited to the task. Using damaged, low qualify, faulty, or makeshift tools could cause personal injury. There is danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness.
Page 36 BURN PREVENTION When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
Page 37 Remove all flammable objects and provide a fire extinguisher. WARNING FOR COUNTERWEIGHT AND FRONT ATTACHMENT REMOVAL DANGER! Daewoo warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
Page 38 PRECAUTIONS FOR REMOVAL, INSTALLATION, AND STORAGE OF ATTACHMENTS Before starting removal and installation of attachments, decide the team leader. Do not allow anyone except the authorized workers close to the machine or attachment. Place attachments that have been removed from the machine in a safe place so that they do not fall.
Page 39 CRUSHING PREVENTION AND CUTTING PREVENTION You should always have at least two people working together if the engine must be run during service. One person needs to remain in the operator’s seat, ready to work the controls or stop the machine and shut off the engine.
Page 40 If necessary depending on the type of failure, please contact your Daewoo distributor for repairs. PRECAUTIONS WITH HIGH PRESSURE LINE, TUBES AND HOSES When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released from the circuit.
Page 41 WASTE MATERIALS Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities.
Page 42: Battery
BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following; • Do not smoke or bring any flame near the battery. •...
Page 43 BOOST STARTING OR CHARGING ENGINE BATTERIES If any mistake is made in the method of connecting the booster cables, it may cause an explosion or fire. Always do the following; • Turn off all electrical equipment before connecting leads battery. This includes electrical...
Page 44: Towing
• If the engine on the problem machine will not start or there is a failure in the brake system. always contact your HAOC910L Daewoo distributor. Figure 41 • Never between towing machine and the towed machine during the towing operation.
Page 45: Shipping And Transportation
SHIPPING AND TRANSPORTATION OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.
Page 46 S0102000 Track Excavator Safety Page 38...
Page 47 1SPECIFICATIONS...
Page 49 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. SPECIFICATIONS FOR SOLAR 225LC-VS0205015K MODEL SERIAL NUMBER RANGE Solar 225LC-V 1001 and UP Copyright 2002 Daewoo October 2002 Specifications for Solar 225LC-V S0205015K Page 1...
Page 50 Cylinder Performance Tests ..............21 Boom Cylinders Test ..............21 Arm Cylinder Test ................21 Bucket Cylinder Test ..............21 Hydraulic Cylinder Natural Drop Test ..........21 Travel Motor Jack-up Test .............. 21 S0205015K Specifications for Solar 225LC-V Page 2...
Page 51: General Description
The excavator has three main component sections: • The Upper Turntable • The Lower Undercarriage and Track Frames • The Excavator Front-end Attachment The following illustration identifies main components and their locations. (See Figure 1 on page -4.) Specifications for Solar 225LC-V S0205015K Page 3...
Page 52: Component Locations
Return to Master Table of Contents COMPONENT LOCATIONS BBO0060L Figure 1 S0205015K Specifications for Solar 225LC-V Page 4...
Page 53 12. ARM CYLINDER 30. SIDE CUTTER 13. BOOM 31. BUCKET 14. BOOM CYLINDER 32. PUSH LINK 15. CAB 33. GUIDE LINK 16. SEAT 34. BUCKET CYLINDER 17. CENTER JOINT 35. ARM 18. SWING MOTOR Specifications for Solar 225LC-V S0205015K Page 5...
Page 54 Return to Master Table of Contents S0205015K Specifications for Solar 225LC-V Page 6...
Page 55: General Dimensions
3,690 mm (12’ 1'') 2,710 mm (8’ 11'') 1,350 mm (4’ 5'') 1,360 mm (4’ 6'') 2,390 mm (7’ 10'') 2,990 mm (9’ 10'') 600 mm (23.62 in) 480 mm (18.90 in) 3,000 mm (9’ 10'') Specifications for Solar 225LC-V S0205015K Page 7...
Page 56: Working Range
The actual value for dimension "L" Digging Reach, depends on the stability and support provided by ground conditions. Digging too far underneath the excavator if soil conditions are wet, loose or unstable can collapse ground support, which could cause injury and/or equipment damage. BBS0050L Figure 3 S0205015K Specifications for Solar 225LC-V Page 8...
Page 57 (5' 10") (3' 11") (5' 8") (0.3' 11") (1' 7") 3,440 mm 3,340 mm 3,580 mm 3,570 mm 3,630 mm Min. Swing Radius (11' 3") (10' 11") (11' 9") (11' 8") (11' 10") Specifications for Solar 225LC-V S0205015K Page 9...
Page 58: General Specifications
(6.4 psi) shoe - Optional 700 mm (28") 0.39 kg/cm (5.5 psi) shoe - Optional 800 mm (32") 0.35 kg/cm (5.0 psi) shoe - Optional 900 mm (35") 0.31 kg/cm (4.4 psi) shoe - S0205015K Specifications for Solar 225LC-V Page 10...
Page 59 Track Shipping Length 4,440 mm (14’ 7") Transport Trailer Capacity 30 tons (33 short tons), minimum load capacity Transport Loading Ramp 15° angle CAUTION: Refer to Transport Maximum Procedure for Allowable Slope Safe Shipping Instructions. Specifications for Solar 225LC-V S0205015K Page 11...
Page 60: Engine Performance Curves (Per Din 6270 Standard)
Return to Master Table of Contents ENGINE PERFORMANCE CURVES (PER DIN 6270 STANDARD) BBS0060L Figure 4 S0205015K Specifications for Solar 225LC-V Page 12...
Page 61 DIN 6270 150 ps @ 1,950 rpm Power (148 hp @ 1,950 rpm) 61.5 kg•m @ 1,400 rpm Max. Torque (443 ft lb @ 1,400 rpm) 163 g/ps•h Fuel Consumption (Rated) (5.75 oz/hp•h) Specifications for Solar 225LC-V S0205015K Page 13...
Page 62: Approximate Weight Of Workload Materials
--------------------- --------------------- granular (2,583 lb/yd Cement, Portland, DRY 1,362 kg/m --------------------- --------------------- clinkers (2,295 lb/yd Dolomite, crushed 1,522 kg/m --------------------- --------------------- (2,565 lb/yd Earth, loamy, DRY, 1,202 kg/m --------------------- --------------------- loose (2,025 lb/yd S0205015K Specifications for Solar 225LC-V Page 14...
Page 63 929 kg/m --------------------- --------------------- (1,566 lb/yd Snow, light density 529 kg/m --------------------- --------------------- (891 lb/yd Sand, DRY, loose 1,522 kg/m --------------------- --------------------- (2,565 lb/yd Sand, WET, packed 1,922 kg/m --------------------- --------------------- (3,240 lb/yd Specifications for Solar 225LC-V S0205015K Page 15...
Page 64 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Shale, broken 1,362 kg/m --------------------- --------------------- (2,295 lb/yd Sulphur, broken 529 kg/m --------------------- --------------------- (1,620 lb/yd S0205015K Specifications for Solar 225LC-V Page 16...
Page 65: Performance Tests
35.0 ±2.0 33.0 ±1.2 Travel Speed High sec. 13.5 ±1.0 12.5 ±1.0 20 m (65.62 ft) sec. 23.5 ±1.5 22.5 ±1.5 Travel Deviation mm (in) 150 (6) 150 (6) 20 m (65.62 ft) Specifications for Solar 225LC-V S0205015K Page 17...
Page 66: Excavator Performance Standards
Operate both travel levers at the fully engaged position and measure the time it takes to cross 20 m (65' 7- 1/2"). Compare measured results against the standard for new machines: S0205015K Specifications for Solar 225LC-V Page 18...
Page 67: Travel Deviation
(Figure A greater amount of deviation is allowed with the travel control set for high speed. RATE OF TRAVEL MAX. DISTANCE High Speed 150 mm (6 in) Low Speed 150 mm (6 in) Specifications for Solar 225LC-V S0205015K Page 19...
Page 68: Swing Speed And Deceleration Force Test
Maximum distance should be less than 900 mm (35.43"), in both Power Mode and Standard Mode. Reference Description ARS4650L Number Figure 8 Start Swing 90° Swing Swing Force Swing Stop S0205015K Specifications for Solar 225LC-V Page 20...
Page 69: Cylinder Performance Tests
OPERATION STANDARD MODE POWER MODE High Speed 18.0 - 21.0 seconds 17.3 - 18.7 seconds Low Speed 33.0 - 37.0 seconds 31.8 - 34.2 seconds Specifications for Solar 225LC-V S0205015K Page 21...
Page 70 Return to Master Table of Contents S0205015K Specifications for Solar 225LC-V Page 22...
Page 71 1GENERAL MAINTENANCE...
Page 73 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. GENERAL MAINTENANCE PROCEDURESS0302000 MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES Copyright 2002 Daewoo May 2002 General Maintenance Procedures S0302000 Page 1...
Page 74 TABLE OF CONTENTS Welding Precautions and Guidelines ............. 3 Hydraulic System - General Precautions ............4 Maintenance Service and Repair Procedure ..........5 General Precautions ................5 Hydraulic System Cleanliness and Oil Leaks..........6 Maintenance Precautions for Hydraulic System Service ......6 Oil Leakage Precautions .................
Page 75: Welding Precautions And Guidelines
(that is not always readily visible) could be caused. Always consult Daewoo After Sales Service before welding on integral components (loader arm, frames, car body, track frames, turntable, attachment, etc.) of the machine. It is possible that some types of structurally critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make sure there are no hidden cracks or damage, before the machine can be returned to service.
Page 76: Hydraulic System - General Precautions
CAUTION! Observe the following safety precautions: Use extra caution and adequate safety shielding when welding near fuel and oil tanks, batteries, hydraulic piping lines or other fire hazards. Never weld when the engine is running. Battery cables must be disconnected before the welding procedure is started.
Page 77: Maintenance Service And Repair Procedure
IMPORTANT Hydraulic system operating conditions (repetitive cycling, heavy work loads, fluid circulating under high pressure) make it extremely critical that dust, grit or any other type of contamination be kept out of the system. Observe fluid and filter change maintenance interval recommendations and always pre-clean any exterior surface of the system before it is exposed to air.
Page 78: Hydraulic System Cleanliness And Oil Leaks
HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS MAINTENANCE PRECAUTIONS FOR HYDRAULIC SYSTEM SERVICE Whenever maintenance, repairs or any other type of troubleshooting or service is being performed, it’s important to remember that the hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating fluid - must be protected from contamination.
Page 79: Cleaning And Inspection
NOTE: Grease seals before assembly. Figure 1 CLEANING AND INSPECTION GENERAL GUIDELINES All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as thrust bearing, matched parts, etc.
Page 80: Bearing Inspection
scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle and allow leakage.
Page 81 Normal Bearing Smooth even surfaces with no discoloration or marks. Figure 2 Bent Cage Cage damage due to improper handling or tool usage. Replace bearing. Figure 3 Figure 4 Galling Metal smears on roller ends due to overheat, lubricant failure or overload. Replace bearing - check seals and check for proper lubrication.
Page 82 Abrasive Step Wear Pattern on roller ends caused by fine abrasives. Clean all parts and housings, check all parts and housings, check seals and bearings and replace if leaking, rough or noisy. Figure 6 Etching Bearing surfaces appear gray or grayish black in color with related etching away of material usually at roller spacing.
Page 83 Fatigue Spalling Flaking of surface metal resulting from fatigue. Replace bearing - clean all related parts. Figure 10 Brinelling Surface indentations in raceway caused by rollers either under impact loading or vibration while the bearing is not rotating. Replace bearing if rough or noisy. Figure 11 Cage Wear Wear around outside diameter of cage and roller...
Page 84 Cracked Inner Race Race cracked due to improper fit, cocking or poor bearing seat. Replace all parts and housings, check seals and bearings and replace if leaking. Figure 14 Smears Smearing of metal due to slippage caused by poor fitting, lubrication, overheating, overloads or handling damage.
Page 85 Heat Discoloration Heat discoloration can range from faint yellow to dark blue resulting from overload or incorrect lubrication. Excessive heat can cause softening of races or rollers. To check for loss of temper on races or rollers, a simple file test may be made. A file drawn over a tempered part will grab and cut metal, whereas a file drawn over a hard part will glide readily with no metal cutting.
Page 86 S0302000 General Maintenance Procedures Page 14...
Page 87 Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. STANDARD TORQUESS0309000 MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES Copyright 2002 Daewoo May 2002 Standard Torques S0309000 Page 1...
Page 88 TABLE OF CONTENTS Torque Values for Standard Metric Fasteners ..........3 Torque Values for Standard U.S. Fasteners ........... 4 Type 8 Phosphate Coated Hardware ............. 6 Torque Values for Hose Clamps ..............7 Torque Values for Split Flanges..............8 Torque Wrench Extension Tools..............9 Torque Multiplication ................
Page 89 TORQUE VALUES FOR STANDARD METRIC FASTENERS The units for the torque values are kg•m (ft lb). NOTE: Grade Dia. x Pitch (mm) 10.9 12.9 (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48...
Page 90: Torque Values For Standard U.s. Fasteners
TORQUE VALUES FOR STANDARD U.S. FASTENERS S.A.E. BOLT HEAD TYPE DESCRIPTION GRADE MARKING WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD. 1 OR 2 Low or Medium Carbon Steel Not Heat Treated. WILL HAVE THREE RADIAL LINES. Quenched and Tempered Medium Carbon Steel. WILL HAVE 6 RADIAL LINES.
Page 91 The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are not given NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED (WET) THREADS; VALUES SHOULD BE INCREASED 1/3 FOR NONLUBRICATED (DRY) THREADS. HEAT TREATED MATERIAL GRADE 5 AND GRADE 8 GRADE 5 GRADE 8 THREAD SIZE...
Page 92: Type 8 Phosphate Coated Hardware
TYPE 8 PHOSPHATE COATED HARDWARE This chart provides tightening torque for general purpose applications using original equipment standard hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases, original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru hardened flat washers (Rockwell "C"...
Page 93: Torque Values For Hose Clamps
TORQUE VALUES FOR HOSE CLAMPS The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator, air cleaner, operating lever boots, hydraulic system, etc.). TORQUE RADIATOR, AIR CLEANER, HYDRAULIC SYSTEM BOOTS, ETC. CLAMP TYPE AND SIZE KILOGRAM KILOGRAM INCH POUNDS...
Page 94: Torque Values For Split Flanges
TORQUE VALUES FOR SPLIT FLANGES The following chart provides the tightening torques for split flange connections used in hydraulic systems. Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly. NOTE: Over torquing bolts will damage the flanges and/or bolts, which may cause leakage. BOLT TORQUE FLANGE BOLT...
Page 95: Torque Wrench Extension Tools
TORQUE WRENCH EXTENSION TOOLS Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force to achieve recommended tightening torque values. Common problems that could occur as a result are: • Recommended torque exceeds the measuring capacity of the torque wrench. •...
Page 96: Other Uses For Torque Wrench Extension Tools
Use the information on this page as a general guide in selecting specific formulas that will meet the particular requirements of individual assembly installations. Daewoo does not specifically endorse a specific manufacturer or brand name but the following table of "Loctite" applications is included for which cross-references to other makers’...
Page 97 I. "Loctite" Fastener Adhesives Break-away Cure Strength Product Application Color Removal (in lb) of Sealer Alone Low strength for 6 mm (1/4") or Purple Hand tools smaller fasteners. Medium strength for 6 mm (1/4") and Blue Hand tools larger fasteners. Heat/260°C (500°F) High strength...
Page 98 IV. "Loctite" retaining compounds Product Application Color Notes For bushings, sleeves, press-fit bearings, Use Locquic "N" primer for splines and collars. For gaps to 0.0002 mm Green increased bond strength and all (0.005"), temperatures to 121°C (250°F). cold temperature applications. For high temperatures to 232°C (450°F).
Page 99 1UPPER STRUCTURE...
Page 101 Solar 140W-V 1001 and Up Solar 160W-V 1001 and Up Solar 180W-V 1001 and Up Solar 210W-V 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 255LC-V 1001 and Up Solar 300LC-V 1001 and Up...
Page 102 TABLE OF CONTENTS Removal ......................3 Installation ...................... 6 S0402040K Page 2...
Page 103 REMOVAL CAUTION! Avoid disassembling cab if there are strong wind gusts, which could catch large surface area of cab shell and push it sideways during lift. Park on firm and level ground. Lower front attachment (bucket) to the ground. Shut down engine. Set safety lever on "RELEASED"...
Page 104 12. Remove floor mat. 13. Remove operator’s seat (1, Figure 2). NOTE: Be careful not to damage seat covering. 14. Remove duct covers (2, 3 and 4, Figure 2). When removing cover (2) disconnect hour meter connector cigar lighter connector. Disconnect main harness...
Page 105 21. Remove three bolts (2, Figure 5) after disconnect speaker wire and antenna wire. Remove stereo assembly. 22. Disconnect cab lamp wiring connector. 23. Disconnect cabin ground cable (7, Figure ARS1540L Figure 5 24. Remove four mounting nuts from four corners of cabin floor (2, Figure 6).
Page 106 INSTALLATION Using a suitable lifting device, attach slings to four lift points on top of cab (Figure 7). NOTE: Cab weighs approximately 290 kg (639 lb). Lower cab into position on cab floor Figure 8 Install four mounting nuts on four corners of cabin floor (2, Figure 9).
Page 107 Install stereo assembly with bolts (2, Figure 10) after connect speaker wire and antenna wire. ARS1540L Figure 10 10. Install right side dash cover (4, Figure 11) with bolts (1, Figure 10). 11. Install left side dash cover (3, Figure 11) with bolts (1, Figure 10).
Page 108 15. Install side panel (6, Figure 13) and pocket (5). 16. Install cover (4, Figure 13) and connect main harness. Install cover (3). Connect hour meter connector and cigar lighter connect of cover (2). 17. Install cover (2, Figure 13). 18.
Page 109 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. COUNTERWEIGHT S0403050K MODEL SERIAL NUMBER RANGE Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 255LC-V 1001 and Up...
Page 110 Return to Master Table of Contents TABLE OF CONTENTS General......................3 Removal ......................5 Installation ...................... 7 S0403050K Counterweight Page 2...
Page 111 Return to Master Table of Contents GENERAL DANGER! Daewoo warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
Page 112 Return to Master Table of Contents WARNING! If the turntable deck has been unbalanced by removal of weight from one end only, traveling the excavator, swinging the turntable, movement over bumps or sloping and uneven surfaces could cause loss of control and possible accidents or injuries. To maintain stability the counterweight should be removed whenever the front attachment is taken off the machine.
Page 113 Return to Master Table of Contents REMOVAL Park on firm and level ground. Lower front attachment (bucket) to the ground. Shut down engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while Figure 3 performing maintenance, extreme care.
Page 114 Return to Master Table of Contents 12. Remove two caps (1, Figure 4) from counterweight (2). 13. Install two lifting eyes in lifting holes (3, Figure 4). Model Lifting Eye Size Solar 225LC-V Solar 225NLC-V Solar 255LC-V Solar 300LC-V M48x5.0 Solar 300LL Solar 340LC-V...
Page 115 NOTE: Tighten bolts (4 , Figure 5 ) to BDS0220L values shown in following table. Figure 5 Model Bolt Torque Solar 225LC-V Solar 255LC-V Solar 300LC-V 250 kg•m Solar 300LL (1,807 ft lb) Solar 340LC-V Solar 420LC-V Solar 470LC-V 150 kg•m...
Page 116 Return to Master Table of Contents S0403050K Counterweight Page 8...
Page 117 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. FUEL TANK S0405005K MODEL SERIAL NUMBER RANGE Solar 225LC-V 1001 and Up Copyright 2002 Daewoo October 2002 Fuel Tank S0405005K Page 1...
Page 118 TABLE OF CONTENTS General Description..................3 Parts List ....................4 Specifications ..................5 Removal ......................6 Installation ....................10 Start-up Procedures ..................12 S0405005K Fuel Tank Page 2...
Page 119: General Description
GENERAL DESCRIPTION WARNING! Engine fuel is highly flammable and potentially explosive. To prevent possible injury and/or damage to equipment, extinguish or move to a safe distance all potential fire hazards. Fuel Tank S0405005K Page 3...
Page 120: Parts List
PARTS LIST BBS0080L Figure 1 S0405005K Fuel Tank Page 4...
Page 121: Specifications
Reference Reference Description Description Number Number Fuel Tank O-ring Plug Cover Level Gauge Bolt (M10x1.5x25) O-ring Spring Washer Clip Drain Cock O-ring Bolt (M16x2.0x60) Bolt (M8x1.25x12) Shim Spacer Shim Plug Fuel Filter SPECIFICATIONS Fuel tank capacity is 350 liters (93 U.S. gal). Fuel Tank S0405005K Page 5...
Page 122: Removal
REMOVAL Look at fuel level display (Figure 2) on instrument panel in operator’s cab to see what it displays. The display is divided into GREEN separated segments, each representing 10 percent of total fuel supply. Also look at level gauge on side of tank to estimate volume of fuel left in tank.
Page 123 Lower front attachment (bucket) to the ground. Shut down engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while performing maintenance, Figure 4 extreme care. Always have one person in the cab at all times. Never leave the cab with the engine running.
Page 124 13. Place a large enough container under fuel tank to collect remaining fuel. Open drain valve (Figure 6) at bottom of tank and drain. NOTE: Fuel tank capacity is 350 liters (93 U.S. gal). Figure 6 14. Tag and disconnect fuel supply line (1, Figure 7) and fuel return line (2) from Fuel tank (3) and carefully drain remaining fuel from lines.
Page 125 18. Remove four bolts (1 and 2, Figure 9), clamp (6) and stay (3) from fuel tank and frame. Remove four bolts (4) and cover (5) from fuel tank. ASS1220L Figure 9 19. Install two 12 mm eye bolts in threaded holes (1 and 2, Figure 10).
Page 126: Installation
INSTALLATION Install two 12 mm eye bolts in threaded holes (1 and 2, Figure 11). Using a suitable lifting device, sling eye bolts. Set fuel tank (3, Figure 11) into position. Install six bolts and washers (4) finger tight, to secure tank to frame. The clear level gauge on the NOTE: side of the tank is easily...
Page 127 Connect wires as tagged to fuel sensor (1, Figure 13) on side of fuel tank (2). If equipped, connect components to the fuel filter pump port (3, Figure 13) on side of fuel tank (2). ASS1210L Figure 13 Connect as tagged, fuel supply line (1, Figure 14) and fuel return line (2) to fuel tank (3).
Page 128: Start-Up Procedures
START-UP PROCEDURES If engine does not start, the fuel system may need priming. Prime the fuel system using the following procedure; Loosen plug (Figure 16) on top of fuel filter head. Figure 16 Unscrew and pump hand operated primer pump (Figure 17) by fuel injection pump. Pump primer until fuel is present at plug hole in fuel filter head.
Page 129 0001 and Up Solar 130W-V 0001 and Up Solar 140W-V 1001 and Up Solar 160W-V 1001 and Up Solar 170LC-V 1001 and Up Models continued on back of cover. Copyright 2002 Daewoo December 2002 Fuel Transfer Pump S0405500 Page 1...
Page 130 Solar 210W-V 1001 and Up Solar 220LC-V 0001 and Up Solar 220LL 1001 and Up Solar 220N-V 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 250LC-V 1001 and Up Solar 255LC-V 1001 and Up...
Page 131: General Description
GENERAL DESCRIPTION THEORY OF OPERATION Figure 1 Reference Reference Description Description Number Number Motor Inlet Hose Pump Outlet Hose Pump Cover Check Valve Rotor and Vane Strainer Cap Fuel pump consists of motor, pump, switch and hose assembly. Figure 2 Fuel Transfer Pump S0405500 Page 3...
Page 132: Troubleshooting
TROUBLESHOOTING On some pumps the ON-OFF switch is installed separately at a remote location. A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it from damage. OPEN TEMP: 150 ±5°C (302 ±41°F). After circuit is automatically shut off due to NOTE: overheating the pump will stop running.
Page 133: Replacement Of Rear Cover
Insert vane, with the circled edge of vane facing in the counterclockwise direction. (Detail A) Insert O-ring again at reassembly of pump cover. Figure 6 REPLACEMENT OF REAR COVER Brush assembly and a thermal limiter are installed in the rear cover. If you find any damage, replace them with new ones.
Page 134: Replacement Of Armature
REPLACEMENT OF ARMATURE You can replace only the armature in case motor was damaged by a short circuit. Remove the switch cover and rear cover, than remove the armature from the housing. Remove the pump cover and remove the rotor and vane.
Page 135 Solar 130LC-V 0001 and Up Solar 170LC-V 1001 and Up Solar 220LC-V 0001 and Up Solar 220LL 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 250LC-V 1001 and Up Solar 255LC-V 1001 and Up...
Page 136 TABLE OF CONTENTS Swing Bearing Maintenance ................3 Operating Recommendation ..............3 Measuring Swing Bearing Axial Play ............3 Measuring Bearing Lateral Play .............. 3 Swing Bearing Basic Operation .............. 4 Rebuilding Swing Bearing ............... 4 S0407000 Swing Bearing Page 2...
Page 137: Swing Bearing Maintenance
SWING BEARING MAINTENANCE OPERATING RECOMMENDATION The service life of the swing bearing may be extended if a conscious, daily effort is made to equalize usage over both ends of the excavator. If the excavator is used in the same operating configuration day in and day out (for example, with the travel motors always under the counterweight, or with the attachment over one side of the machine more than the other), the bearing’s service life could be reduced.
Page 138: Swing Bearing Basic Operation
SWING BEARING BASIC OPERATION The swing bearing, which connects the upper structure with the lower structure, consists of a inner ring, outer ring and ball bearings. During swing movement, power from the swing motor is transferred to the pinion by planetary gears connected to gears on the inner ring, which is fixed in the undercarriage.
Page 139 Lift outer ring and check that inner ring can move freely. See Figure 5, if not, replace seal (3, Figure 4) and/or seal (4, Figure 4). Figure 5 Turn inner ring and use magnet bar (1, Figure 6) to remove steel balls (2). Figure 6 Turn inner ring and use wire (1, Figure 7) to remove retainers (2).
Page 140 S0407000 Swing Bearing Page 6...
Page 141 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. SWING REDUCTION GEARBOXS0408015K MODEL SERIAL NUMBER RANGE Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Copyright 2002 Daewoo October 2002...
Page 142 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Parts List ....................4 Specifications ..................5 Special Tools and Materials................6 Special Tools ................... 6 Drive Shaft Front Bearing Jig ............6 Oil Seal Insert Jig................
Page 143: General Description
Return to Master Table of Contents GENERAL DESCRIPTION THEORY OF OPERATION The swing motor final drive is a two-step planetary gearbox with two planet gears, two sun gears and two- step output reduction. The planetary gear engages with the ring gear. The pinion gear is connected with the output shaft and spline.
Page 144: Parts List
Return to Master Table of Contents PARTS LIST BBS0010L Figure 1 S0408015K Swing Reduction Gearbox Page 4...
Page 145: Specifications
Return to Master Table of Contents Reference Reference Description Description Number Number Casting Sun Gear No .2 Drive Shaft Knock Pin Plate Carrier No .1 Roller Bearing Cover Plate Planet Gear No .1 Pin Assy No .1 Oil Seal Socket Bolt Roller Bearing Sun Gear No .1 Ring Gear...
Page 146: Special Tools And Materials
Return to Master Table of Contents SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS Drive Shaft Front Bearing Jig Dimension Measurement 100.0 mm (3.94 in) Dia. 80.0 - 80.30 mm (3.15 - 3.16 in) Figure 2 Oil Seal Insert Jig Dimension Measurement 155.0 mm (6.10 in) Dia.
Page 147: Troubleshooting, Testing And Adjustment
Return to Master Table of Contents TROUBLESHOOTING, TESTING AND ADJUSTMENT Symptoms Possible Causes Remedies 1. No rotation and – a. Pressure at swing motor inlet Swing brake not releasing Check brake engagement increases and disengagement, check release pressure Internal damage to gearbox Replace broken gears, drive train drive train assemblies...
Page 148: Removal
Return to Master Table of Contents REMOVAL Lower bucket to ground. Shut engine down and remove key from starter switch. WARNING! engine must while performing maintenance, extreme care. Always have one person in the cab at all times. Never leave the cab with the engine Figure 5 running.
Page 149: Disassembly
— if special tools shown on the preceding page are used. These can be ordered through Daewoo After Sales Service, or individual jigs can be fabricated at a local machine shop to the specifications shown.
Page 150 Return to Master Table of Contents Tighten 10 mm ring bolts into the rim of the carrier, 180 degrees apart. Use a hoist or other lifting assist to separate the No. 1 carrier assembly from the gearbox, with the No. 1 differential gear still attached. Figure 10 Begin disassembly of the No.
Page 151 Return to Master Table of Contents Install 10 mm ring bolts and use them to lift out and separate the No. 2 carrier assembly. Figure 14 Remove the thrust ring, in order to begin disassembly of the No. 2 carrier. Position the carrier vertically, as shown in the photograph.
Page 152 Return to Master Table of Contents 11. Pry away the front cover plate oil seal and the O-ring (29). The oil seal should normally be replaced each time the cover plate is removed. Inspect the O-ring carefully for any evidence of distortion, hardening or other damage.
Page 153 Return to Master Table of Contents 15. Carefully inspect the drive shaft for any evidence of abnormal or excessive wear on remaining surfaces or components. No further tear down of the assembly is normally required, unless exceptional damage has occurred. Figure 22 Swing Reduction Gearbox S0408015K...
Page 154: Cleaning And Inspection (Wear Limits And Tolerances)
Return to Master Table of Contents CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Inspect all components in the assembly. Pay particular attention to oil seals, lock and spring pins and fastener bolts.
Page 155: Reassembly
Return to Master Table of Contents REASSEMBLY Position the drive shaft and drive shaft front bearing jig. (Refer to “Special Tools and Materials” on page 6 for the illustration and dimensional specifications of the bearing jig.) The bearing jig is used to establish the specified 80 mm (+ 0.3 mm, - 0.0 mm) installation distance (or 3.1496") between the end of the drive shaft and the...
Page 156 Return to Master Table of Contents Install the stop ring. Figure 27 Install the thrust plate. Figure 28 Turn the assembly and check the distance between the end of the drive shaft and the sealing ring. It should be 80 mm (+0.3 mm, - 0.0 mm, or 3.1496").
Page 157 Return to Master Table of Contents 10. Install the assembled drive shaft, with the bearings and other components in proper position, to the gearbox housing. Figure 31 11. Attach the O-ring. Figure 32 12. Install the oil seal in the front cover. The contact surface of the oil NOTE: seal can be damaged if the oil...
Page 158 Return to Master Table of Contents 14. Position the No. 2 carrier as shown in the photograph. Position thrust washer as shown, in the carrier pin hole, and assemble the thrust washer to the carrier. Figure 35 15. Attach the No. 2 differential gears. Mount the upper thrust washer and then the lower thrust washer.
Page 159 Return to Master Table of Contents 18. Use a punch to make two strikes on the spring pin. Figure 39 19. Install the thrust ring. Figure 40 20. Reposition the assembly on top of the workbench. The drive shaft should be facing down.
Page 160 Return to Master Table of Contents 22. Before bolting up the assembly with provided fasteners (16 mm x 150 mm), verify gear alignment by checking the position of the reference marks made in step 5 of the Swing Motor Gearbox (Final Drive) Disassembly procedure,...
Page 161 Return to Master Table of Contents 26. Lay out the No. 1 carrier on the workbench. Align the holes of the carrier and the spring pins of the No. 2 pins, and press them into place with a press. Figure 47 27.
Page 162 Return to Master Table of Contents 30. Install the needle cage and differential gear. Figure 51 31. Install the upper side plates and stop rings, to about 2 mm (or 0.079"). Figure 52 32. Hold the No. 1 carrier assembly stationary and verify that the center side plate is positioned correctly in the recess of the No.
Page 163 Return to Master Table of Contents 34. Apply an even, thin, continuous bead of Silicone flexible sealant to the contact surfaces of the swing motor and the ring gear. noncorrosive type silicone, formulated for increased oil resistance, is recommended. Figure 55 35.
Page 164: Installation
Return to Master Table of Contents INSTALLATION Coat pinion gear with grease. Refer to operation manual for specifications. Make sure alignment pin (6) is installed in flange of swing reduction gearbox (5). Using a suitable lifting device, sling swing motor (1, Figure 57) and position swing motor and reduction gearbox (5) as an assembly on unit.
Page 165 1LOWER STRUCTURE AND CHASSIS...
Page 167 Remember, that ultimately safety is your own personal responsibility. TRACK ASSEMBLY S0505030 MODEL SERIAL NUMBER RANGE Solar 220LC-V 0001 and Up Soalr 225LC-V 1001 and Up Soalr 225NLC-V 1001 and Up Copyright 1999 Daewoo March 1999 Track Assembly S0505030 Page 1...
Page 168 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Track Tension ....................3 Cleaning and Inspection (Wear Limits and Tolerances) ......... 5 Track Shoes and Links ................... 9 Parts List ....................9 Track Removal..................10 Track Installation ................... 11 Front Idler Roller...................
Page 169 Return to Master Table of Contents GENERAL DESCRIPTION The track assembly is composed of the following major components: Track Front Idler Roller Upper Roller Lower Roller Track Spring and Track Adjustment Cylinder TRACK TENSION WARNING! Safely measuring track tension requires two people. One person must be in the operator's seat, running the controls to keep one side frame in the air, while the other person makes dimensional checks.
Page 170 Return to Master Table of Contents Measuring the distance (A, Figure 2) between the bottom of the side frame and the top of the lowest crawler shoe. Recommended tension for operation over most types of terrain is 320 - 340 mm (12.60 - 13.38 in) NOTE: This...
Page 171 Return to Master Table of Contents CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) CAUTION! Refer to the "Welding Precautions and Guidelines" information in "General Maintenance Procedures" section for general recommendations and specific safety precautions, before starting any lower travel frame component rebuilding procedure. The tables that follow provide factory-specified dimensional limits (as-new condition, recommended service and replacement limit) for lower travel frame components.
Page 172 Return to Master Table of Contents Normal Recommended Limit for Use Component / Reference Dimensions Reference (New) Limit for (Repair - P or Dimension Maintenance Replace - R) Track link, master pin bushing, 59.0 mm 57.0 mm 54.0 mm [R] master bushing (2.32 in) (2.24 in)
Page 173 Return to Master Table of Contents Normal Recommended Limit for Use Component / Reference Dimensions Reference (New) Limit for (Repair - P or Dimension Maintenance Replace - R) Figure 9 47.0 mm 46.50 mm 46.20 mm [R] Upper roller, axle (1.85 in) (1.83 in) (1.82 in)
Page 174 Return to Master Table of Contents Normal Recommended Limit for Use Component / Reference Dimensions Reference (New) Limit for (Repair - P or Dimension Maintenance Replace - R) HDA7018L Figure 11 Front idler, axle 75.0 mm 74.50 mm 74.20 mm [R] (2.95 in) (2.93 in) (2.92 in)
Page 175 Return to Master Table of Contents TRACK SHOES AND LINKS PARTS LIST Figure 13 Reference Reference Description Description Number Number Track Link Assembly Pin; Lock Link; Track (R.H.) Bushing Link; Track (L.H.) Bushing; Master Link; Master (R.H.) Pin; Master Link; Master (L.H.) Shoe 500 mm (19.69 in) Shoe 600 mm (23.62 in) Bolt...
Page 176 Return to Master Table of Contents TRACK REMOVAL Position machine on a smooth level surface with adequate room for forward and reverse travel. Relieve track tension. Refer to "Track Tension" in this section for procedure. Move machine until master link (1) is positioned at approximately 10 o’clock from top position on travel reduction gearbox.
Page 177 Return to Master Table of Contents TRACK INSTALLATION Lay rebuilt or new track into position under track frame. End of track should be positioned under front idler roller. With upper structure at 90° to track frame. Use bucket and boom to raise track frame off blocking.
Page 178 Return to Master Table of Contents FRONT IDLER ROLLER PARTS LIST Figure 19 Reference Reference Description Description Number Number Bearing Axle Plug Group Seal Idler O-ring Bushing S0505030 Track Assembly Page 12...
Page 179 Return to Master Table of Contents FRONT IDLER ROLLER DISASSEMBLY Remove plug (2, Figure 20) and drain oil from roller assembly (1). Figure 20 Separate the pin (3, Figure 21) from the bearing (1). Figure 21 Use a press to remove the bearing from the axle.
Page 180 Return to Master Table of Contents Detach the group seal (6, Figure 23) from the idler (7) and bearing (1). Figure 23 Use a press to separate the axle (5, Figure 24), O-ring (4) and bearing (1). Figure 24 Remove bushing (8, Figure 25) with the press and special tool (ST-1909).
Page 181 Return to Master Table of Contents FRONT IDLER ROLLER REASSEMBLY Degrease, clean and dry all parts before reassembly. Insert bushing (8, Figure 26) into the idler (7). Grease O-ring (4, Figure 26) and insert it into the axle. Align the bearing (1, Figure 26) and axle (5) holes and pin (3) them together.
Page 182 Return to Master Table of Contents LOWER ROLLER PARTS LIST Figure 29 Reference Reference Description Description Number Number Group Seal O-ring Bushing Collar Plug Axle Spring Washer Roller Bolt S0505030 Track Assembly Page 16...
Page 183 Return to Master Table of Contents LOWER ROLLER REMOVAL Relieve track tension. Refer to "Track Tension" in this section for procedure. Swing upper structure at 90° to frame. Using bucket raise track off ground and place blocking under frame. Remove four bolts and lower roller assembly from track frame.
Page 184 Return to Master Table of Contents Detach O-rings (2, Figure 33) from the axle. Separate group seals (6, Figure 33) from the collar and roller (5). Detach collar (3, Figure 33) and O-rings (2) from the axle, using a press. Figure 33 LOWER ROLLER REASSEMBLY Degrease, clean and dry all parts before...
Page 185 Return to Master Table of Contents Insert group seals (6, Figure 36) into the roller (5) and collar (3). NOTE: Apply clean engine oil to the joint side of the group seal. Apply grease to the group seal O-ring. Slide the axle inside the roller. Figure 36 Install the collar (3, Figure 37), O-ring (2), and pin (1) on the remaining side.
Page 186 Return to Master Table of Contents UPPER ROLLER PARTS LIST Figure 39 Reference Reference Description Description Number Number Plug Axle Bolt Group Seal Cover Bracket Bolt Bushing Washer O-ring Roller Lock Washer S0505030 Track Assembly Page 20...
Page 187 Return to Master Table of Contents UPPER ROLLER REMOVAL Relieve track tension. See This will allow track to be raised so that links clear top of roller. Position a bottle jack on top of track frame and apply pressure to track shoe. Remove mounting hardware holding upper roller assembly to track frame.
Page 188 Return to Master Table of Contents Separate the group seal (8, Figure 44) from the roller and bracket (9). Figure 44 Separate the bushing (10, Figure 45) from the roller with a press and special tool (ST-1919). Figure 45 S0505030 Track Assembly Page 22...
Page 189 Return to Master Table of Contents UPPER ROLLER REASSEMBLY Degrease, clean and dry all parts before reassembly. Insert bushing (10, Figure 46) into the roller (6). Figure 46 Insert group seal (8, Figure 47) into the roller (6) and bushing. NOTE: Apply clean engine oil to the joint side of the group seal.
Page 190 Return to Master Table of Contents Tighten plug (1, Figure 49). Figure 49 S0505030 Track Assembly Page 24...
Page 191 Return to Master Table of Contents TRACK SPRING AND TRACK ADJUSTING CYLINDER PARTS LIST Figure 50 Reference Reference Description Description Number Number Piston Rod Flange Piston Ring Backup Ring Valve Packing Bolt Retaining Ring Plate Yoke O-ring Socket Bolt Cylinder Flange Spring O-ring...
Page 192 Return to Master Table of Contents S0505030 Track Assembly Page 26...
Page 193 1ENGINE AND DRIVE TRAIN...
Page 195 Solar 140W-V 1001 and Up Solar 160W-V 1001 and Up Solar 180W-V 1001 and Up Solar 210W-V 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 255LC-V 1001 and Up Solar 300LC-V 1001 and Up...
Page 196 TABLE OF CONTENTS General Description..................3 Refrigerant Circulation..................5 Control Panel....................7 Control Specifications..................8 Temperature Level Control and Display............9 Air Discharge According to Path Selection........... 10 Air-conditioning System Circuit Diagram............12 Troubleshooting .................... 14 Weight of R134a Gas Used In Machines ............. 17 Refrigerant System Repairs .................
Page 197: General Description
GENERAL DESCRIPTION ARO0550L Figure 1 The heater and air-conditioner are combined into one unit in the rear cover behind the operator's seat. If necessary, the operator can control inner temperature using the operation panel installed in the right hand control stand. The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator’s cab.
Page 198 WARNING! If using compressed air to clean the element, make sure that proper eye protection is worn. NOTE: All right and left call outs are based on the operator being seated in the operator’s seat facing the front. Turn the key cylinder (1, Figure 2) to open cover (2, Figure 2) behind operator’s seat.
Page 199: Refrigerant Circulation
REFRIGERANT CIRCULATION HDA6046L Figure 4 Reference Reference Description Description Number Number Evaporator Compressor Expansion Valve Blower Fan Condenser Receiver Dryer Condenser Fan Air-Conditioner S0605060K Page 5...
Page 200 Shading Temperature Refrigerant State High High Pressure Gas High High Pressure Liquid Low Pressure Liquid High High Pressure Gas/Liquid Low Pressure Gas • Refrigerant (R134a) is compressed to approximately 15.0 kg/cm (213 psi) within the compressor. • The compressed refrigerant flows into the condenser at high temperature (approximately 80°C (176°F)).
Page 201: Control Panel
CONTROL PANEL ARO0501L Figure 5 INPUT OUTPUT CONTROL PANEL DISPLAY TEMPERATURE SENSOR LOW SPEED RELAY BLOWER OFF SW MID SPEED RELAY MOTOR A / C SW VENT SW HIGH SPEED RELAY DEF. SW TEMP. CONTROL HEAT SW MIX DOOR ACTUATOR CONTROL FRE SW PANEL...
Page 202: Control Specifications
CONTROL SPECIFICATIONS Control Item Control Switch Control Specifications Temperature "COOL" Switch MAX COOL Control "WARM" Switch 100% MAX HOT HDA6049L Figure 7 Temperature control switch consists of a 24 step variable selector. The display uses 7, Green / Red two- color LEDs to display the selected temperature.
Page 203: Temperature Level Control And Display
TEMPERATURE LEVEL CONTROL AND DISPLAY Position Step LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Sensor Remark Voltage Green Green Green Green Green Green Green 4.50 V ±0.2 MAX. COOL Green Green Green Green Green Green Green...
Page 204: Air Discharge According To Path Selection
AIR DISCHARGE ACCORDING TO PATH SELECTION Face, Rear, and Defroster ARS1280L Figure 10 Foot ARS1290L Figure 11 S0605060K Air-Conditioner Page 10...
Page 205 Face and Defroster ARS1300L Figure 12 Air-Conditioner S0605060K Page 11...
Page 206: Air-Conditioning System Circuit Diagram
AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM 15-1 15-2 15-3 15-4 15-5 LED 1~12 HIGH 15-6 MODE SELECT VENT AIR MODE 15-7 RECIRCLE/FRESH FOOT BLOWER SPEED TEMP. CONTROL (WARM) (COOL) 15-8 15-9 FOOT HRS 26P AMP MIC 13P + 250 4P HRS NO.GT7A-26PD-DS 26P AMP MIC 13P 12 11 25 24...
Page 207 Reference Reference Description Description Number Number Battery Compressor Battery Relay A/C Control Panel Fusible Link A/C Unit Circuit Breaker 15-1 Blower Motor Fuse 15-2 Resister Lamp Switch 15-3 High Speed Relay Condenser Fan Relay 15-4 Mid Speed Relay Condenser Fan Motor 15-5 Low Speed Relay Compressor Relay...
Page 208 TROUBLESHOOTING Refrigerant Pressure Check HDA6074L Figure 14 Open all doors and windows. Install manifold gauge set. Start engine and maintain engine speed at 1,800 - 2,000 rpm. Check high / low pressure of refrigerant. High Pressure: 8.0 - 10.0 kg/cm (114 - 142 psi) Low Pressure: Approximately 1.0 kg/cm (14 psi)
Page 209 High Pressure: Approximately 20 - 25 kg/cm (285 - 356 psi) Low Pressure: Approximately 2.5 - 3.5 kg/cm (36 - 50 psi) Possible Cause: Air in system. Recover any remaining refrigerant. Vacuum out system. Recharge system. NOTE: If the system has been exposed to the air for a long period of time, replace the receiver dryer.
Page 210 High Pressure: Over 7.0 - 11.0 kg/cm (100 - 156 psi) Low Pressure: 4.0 - 6.0 kg/cm (57 - 85 psi) Possible Cause: Low refrigerant pressure due to poor compressor compression Inspect and replace compressor if necessary. S0605060K Air-Conditioner Page 16...
Page 211: Weight Of R134A Gas Used In Machines
950 ±20 grams (33 ±0.7 oz.) Solar 220LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 220LL 850 ±20 grams (30 ±0.7 oz.) Solar 225LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 225NLC-V 850 ±20 grams (30 ±0.7 oz.) Solar 250LC-V 850 ±20 grams (30 ±0.7 oz.)
Page 212 Model Weight of Gas Solar 300LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 300LL 850 ±20 grams (30 ±0.7 oz.) Solar 330-III 1250 ±20 grams (44 ±0.7 oz.) Solar 330LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 340LC-V 850 ±20 grams (30 ±0.7 oz.) Solar 400LC-III 1250 ±20 grams (44 ±0.7 oz.) Solar 400LC-V...
Page 213: Refrigerant System Repairs
REFRIGERANT SYSTEM REPAIRS WARNING! Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately flush with clean, running water and consult a physician. Select a clean and well ventilated area to work. The refrigerant container is under high pressure and should be stored below 40°C (104°F).
Page 214: Repair And Replacement Procedure
The new refrigerant oil (PAG type) has a high moisture absorption characteristic. When the refrigerant system vacuum seal has been broken, immediately plug up all openings to prevent moisture from entering into the system. When joining unions which use O-ring seals, lightly coat O-rings with refrigerant oil. Be careful not to drip oil on the threads of the nut.
Page 215 INSTALL REPAIR TOOL RECOVER REFRIGERANT REPAIR / REPLACE DEFECTIVE PARTS VACUUM SYSTEM (OVER 5 MINUTES) CHECK SYSTEM FOR AIR LEAKAGE REPAIR VACUUM SYSTEM (OVER 20 MINUTES) CHARGE SYSTEM (APPROXIMATELY 100 g) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL (Standard Capacity less Initial Charge) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL...
Page 216: Refrigerant Recovery
REFRIGERANT RECOVERY Reference Description Number To Compressor Low Pressure Side High Pressure Side From Receiver Refrigerant Recovery Tank Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. HDA6067L Figure 17 NOTE: Be careful not to switch the connections for the low and high pressure valves.
Page 217: Leakage Check
Check system for vacuum leak. Allow system to sit for 10 minutes and check whether the system is holding the pressure. If the pressure has dropped, it must be repaired before proceeding to the next step. Vacuuming Procedure If the system is holding the pressure and it has not changed for 10 minutes, vacuum out the system for an additional 20 minutes.
Page 218: Refrigerant Charging
Charge system until the low side gauge dial indicates a pressure of 1 kg/cm (14 psi) and close the high side valve. Using a refrigerant leak detector or soapy water check each joint for leakage. Reference Description Number Refrigerant Leak Detection Device If a leak is detected, check for O-ring damage or correct tightening torque and...
Page 219 Reference Description Number To Compressor Low Pressure Side High Pressure Side From Receiver Refrigerant Supply Container Charge the system by opening the manifold gauge low side valve. HDA6072L Figure 22 Initial charge amount: 100 g (3.5 ounces). If refrigerant does not flow freely into system, try starting engine first before operating air-conditioner.
Page 220: Inspecting System For Leakage
Shut off engine and close refrigerant supply container adapter valve. Disconnect manifold gauge hoses from vehicle. INSPECTING SYSTEM FOR LEAKAGE After completing charging procedures, clean all joints and connections with a clean dry cloth. Using a refrigerant leak detecting device or soapy water, inspect system for leaks starting from the high pressure side.
Page 221 0001 and Up Solar 220LC-V 0001 and Up Solar 220LL 1001 and Up Solar 220N-V 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Models continued on back of cover. Copyright 2002 Daewoo November 2002 Drive Coupling (Main Pump)
Page 222 MODEL SERIAL NUMBER RANGE Solar 250LC-V 1001 and Up Solar 255LC-V 1001 and Up Solar 280LC-III 0001 and Up Solar 290LC-V 0001 and Up Solar 290LL 1001 and Up Solar 330LC-III 0001 and Up Solar 330LC-V 1001 and Up Solar 400LC-III 0001 and Up Solar 400LC-V 1001 and Up...
Page 223: Drive Coupling
DRIVE COUPLING When installing the main pump on the engine, it is very important to properly adjust clearance between the face of the coupling hub and end of pump drive shaft ("Measurement H" shown in the following procedure) to a specific value. Figure 1 thru Figure 3, show typical drive coupling installations.
Page 224: Special Tools
SPECIAL TOOLS KAWASAKI / TONG MYUNG PUMP TOOL NOTE: This tool is also used for the Sauer Sundstrand Pump for the DD80L. This tool is used to control the distance between the end of the pump drive shaft and the front face of the drive coupling hub (Figure 4 and Figure 9).
Page 225 RELIEF RELIEF KNURL HAAA8350 Figure 5 Dimensional Details for Figure 5 Dimension Measurement Models 18 ±0.1 mm DD80L (0.7087 ±0.0039 in) 5.5 ±0.1 mm S330LC-III, S330LC-V, S400LC-III, S400LC-V, (0.2165 ±0.0039 in) S450LC-V 20.0 mm (0.787 in) 7.0 mm (0.275 in) 11.0 mm (0.433 in) Radius 18.0 mm (0.708 in) Radius 30.0 mm (1.181 in) Radius...
Page 226 RELIEF RELIEF KNURL HAAA8360 Figure 6 Dimensional Details for Figure 6 Dimension Measurement Models S170LC-III, S200W-V, S220LC-III, S220LC-V, 10.5 ±0.1 mm S220LL, S220N-V, S225LC-V, S225NLC-V, (0.4134 ±0.0039 in) S250LC-V, S255LC-V 2.0 ±0.1 mm S170LC-V, S170W-V (0.0787 ±0.0039 in) 1.0 ±0.1 mm S140W-V, S160W-V (0.0394 ±0.0039 in) 5.0 ±0.1 mm...
Page 227: Uchida Pump Tool
UCHIDA PUMP TOOL This tool is used to control the distance between the shoulder on the pump drive shaft and the rear face of the drive coupling hub (Figure 7 and Figure 10). This distance will be referred to as "Measurement H"...
Page 228: Drive Coupling Installation
DRIVE COUPLING INSTALLATION Whenever the drive coupling for main pump is installed, the following mounting dimensions and installation procedures must be observed. NOTE: If these procedures are not followed, noise will occur and/or the service life of drive coupling or main pump will be reduced. Figure 9 DRIVE COUPLING INSTALLATION (KAWASAKI / TONG MYUNG PUMP) S0609000 Drive Coupling (Main Pump)
Page 229 Figure 10 DRIVE COUPLING INSTALLATION (UCHIDA PUMP) Drive Coupling (Main Pump) S0609000 Page 9...
Page 230 Table 1 Parts Information and Torque for Figure 9 and Figure 10 Reference Torque Description Qty. Number (See Table 2 and 3) Spring Pin Insert Bolt Flywheel Spring Pin Insert Bolt Pump Shaft Clamping Screw Element S0609000 Drive Coupling (Main Pump) Page 10...
Page 231 Specification for "Measurement H," from front hub face to pump shaft end, and TIGHTENING TORQUE of bolts and screws written in the "Table 2" must be observed. Table 2 Specification for "Measurement H" and Torque (Refer to Figure 9) Coupling Part Torque Value for Torque Value for Model...
Page 232 Table 3 Specification for "Measurement H" for Wheel Excavator (Refer to Figure 10) Model Coupling part Height (H) number (mm) (kg•m) (kg•m) S130W-III 15.5 - 16.5 21 - 23 kg•m 10 - 12 kg•m 2414-9021 (0.610 - 0.650 in) (152 - 166 ft lb) (72 - 87 ft lb) S130W-V S0609000...
Page 233: Installation Procedure
INSTALLATION PROCEDURE NOTE: Refer to Figure 9 and Figure 10 while using following procedure. Install spring pin (1) and attach insert (2) with bolt (3) to engine flywheel (4). NOTE: Tighten bolts to value "Ta" in the tables. Install two spring pins (5) and attach insert (6) to hub (7) bolts (8).
Page 234 S0609000 Drive Coupling (Main Pump) Page 14...
Page 235 1HYDRAULICS...
Page 237 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENT S0702170K MODEL SERIAL NUMBER RANGE Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 255LC-V 1001 and Up...
Page 238 TABLE OF CONTENTS Hydraulic System - General Notes ..............4 Hydraulic Schematic..................5 General Notes ..................5 Operation of Working Components ..............6 Boom Operating Circuit................6 Boom Up Circuit ..................6 Boom Down Circuit ................. 6 Arm Operating Circuit ................7 Arm Crowd Circuit ...................
Page 239 Checks and Adjustments ..............17 Pump Input Power Control ................19 Pump Regulator Adjustment ..............19 (Models Solar 225LC-V, 225NLC-V, 300LC-V, and 300LL).... 22 (Model Solar 255LC-V) ..............23 Flow Meter and Flow Meter Kit Installation and Testing ....... 24 Installation and Testing Procedure..........
Page 240: Hydraulic System - General Notes
HYDRAULIC SYSTEM - GENERAL NOTES ARS1690L Figure 1 The hydraulic system has several improvements over conventional hydraulic systems - including cross- sensing total horsepower control - to maximize output efficiency. The system features an electronically controlled output optimization system, which allows the operator to choose between two, distinctly different power modes: high-output/rapid cycling maximum-speed power mode, and a standard power mode for most types of general operation.
Page 241: Hydraulic Schematic
HYDRAULIC SCHEMATIC The hydraulic schematic(s) is available in the "Hydraulic and Electrical Schematic Shop Manual." This manual is a collection of diagrams and schematics for a number of models. GENERAL NOTES When referring to the schematic, refer to the following items: •...
Page 242: Operation Of Working Components
OPERATION OF WORKING COMPONENTS BOOM OPERATING CIRCUIT The boom operating circuit includes the right and left main hydraulic pumps (both halves of the main pump assembly), both sides of the control valve and the boom cylinder. The circuit operates in boom down mode through the first shift position and through the second shift position in boom up mode.
Page 243: Arm Operating Circuit
ARM OPERATING CIRCUIT The arm operating circuit includes both the right and left hydraulic main pumps, the right and left halves of the control valve, a slow return orifice, and the arm cylinder. The circuit can be operated in the two-stage speed control mode which works through both halves of the control valve and doubles the volume of oil flowing to the cylinder.
Page 244: Bucket Operating Circuit
BUCKET OPERATING CIRCUIT The bucket operating circuit includes the left main pump, the left half of the control valve and the bucket cylinder. 360 kg/cm (5,112 psi) overload relief valves located at BKT and BKTD 1 ports of the control valve protect the circuit and its components from damage.
Page 245: Right Swing Operating Circuit
RIGHT SWING OPERATING CIRCUIT When the swing control lever is pushed to the right swing position, pilot pressure from the left side pilot valve is directed to the right side pump CONTROL regulator and right half of the control valve. VALVE(L) Output flow from the right pump is then directed through the PR and SWR ports of the control...
Page 246: Forward Travel Circuit
FORWARD TRAVEL CIRCUIT When the right and left travel control levers are TRAVEL TRAVEL pushed forward, output from both of the main MOTOR(L) MOTOR(R) pumps is directed through the PR, PL, TRRF, and TRLF ports on the control valve, through CENTER JOINT the upper works center joint, to the travel motors on each side of the machine.
Page 247 • at 1,950 rpm with no load (Models Solar 300LC-V, 300LL) • at 1,950 rpm stall load (Models Solar 225LC-V, 300LC-V, 300LL) • at 2,000 rpm stall load (Model Solar 225NLC-V, 255LC-V) If engine rpm drops excessively with a load or fails to surpass rated speed (1,900 rpm), performance problems may be due to inadequate hydraulic flow caused by lagging rotational speed.
Page 248: Pilot Pressure
PILOT PRESSURE ADJUSTMENT AND TESTING WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made. Vent hydraulic pressure from the reservoir before breaking the seal on fittings to install two in-line "t-style" adapters and test gauges (60 bar/1,000 psi) at the gear pump outlet port, and at the joystick control valve pilot line.
Page 249 Hydraulic System Troubleshooting, Testing and S0702170K Adjustment Page 13...
Page 250: Power Mode Valve
The jumper harness (which is available through Daewoo After Sales Service, or could be spliced together from commonly available, purchased parts) has extra leads so that a VOM meter can be connected to the circuit.
Page 251 1/4 turn and re-check current and pressure. Repeat adjustment as required to obtain specified performance and retighten the valve lock nut. (Model Solar 225LC-V) Mode Engine RPM...
Page 252: Swing Priority Valve
SWING PRIORITY VALVE CONTROL VALVE PRESSURE AND CURRENT ADJUSTMENTS WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made. The swing priority control valve is located inside the compartment behind the cabin.
Page 253: Pressure Up Valve
PRESSURE UP VALVE CHECKS AND ADJUSTMENTS WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made. Vent hydraulic pressure from the reservoir to install an in-line "t-style" adapter and test gauge (60 bar/1,000 psi) at the pilot pump signal port relief valve outlet.
Page 254 NOTE: The electrical pressure up (power boost) solenoid valve located alongside the swing priority solenoid and arm speed control solenoid, in compartment rear of the operator’s cab, must be operating correctly, or pressure tests and further adjustments cannot be made. S0702170K Hydraulic System Troubleshooting, Testing and Page 18...
Page 255: Pump Input Power Control
PUMP INPUT POWER CONTROL PUMP REGULATOR ADJUSTMENT WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator’s control stand while checks and adjustments are made. To perform these adjustments accurately the use of a flow meter is strongly recommended, as is consulting the factory (before starting work) to validate the need for making regulator adjustments.
Page 256 Figure 12 Refer to the illustration of the pump regulator control valve (Figure 12) for the location of adjustment screws (1, 2 and 3). There are two different adjustments, along with the Negacon, negative control, adjustment screw (3, directly below 1 and 2). Each one of the adjustment procedures could affect the setting of the others.
Page 257 Start the engine and turn the engine speed dial maximum. When normal operating temperature is reached, loosen the largest diameter lock nut around the adjustment screw (2) for the outer regulator spring. Tightening the screw shifts the P/Q (Pressure/Flow) control curve to the right, and increases compensating control pressure.
Page 258: (Models Solar 225Lc-V, 225Nlc-V, 300Lc-V, And 300Ll)
(Models Solar 225LC-V, 225NLC-V, 300LC-V, and 300LL) The adjusting screw (1, Figure 16) affects the delivery rate (Q) of the pump. Tightening the adjusting screw decreases the maximum cut flow (as shown in Figure 15) while backing out the screw increases cut flow delivery rate.
Page 259: (Model Solar 255Lc-V)
(Model Solar 255LC-V) The adjusting screw (1, Figure 17) affects the delivery rate (Q) of the pump. Tightening the adjusting screw decreases the maximum cut flow (as shown in Figure 18) while backing out the screw increases cut flow delivery rate. Balance both pumps for equal output.
Page 260: Flow Meter And Flow Meter Kit Installation And Testing
The After Sales Service department of the nearest local Daewoo dealer can assist you with these tests or, if you prefer carrying out your own testing, they should be able to help in putting together a hose and fitting kit (or the required dimensions and specifications for hoses and fittings) to allow you to install a flow meter downstream from the main pump assembly.
Page 261 Compare recorded values with output shown in the P-Q curve in the specifications section of this book. If test results do not measure up to specified values, pump output tests can be repeated using different control levers. Recheck front pump operation while stroking the bucket cylinder out lever, and the rear pump by actuating the swing control lever.
Page 262: Swing System Troubleshooting
SWING SYSTEM TROUBLESHOOTING PRECAUTIONS/INITIAL CHECKS Stop work. Release all weight or any type of load safely before proceeding. Avoid risking injury or adding to damage. Shut down engine and disengage control functions until initial tests are ready to be made. WARNING Prevent possible injury and/or loss of operating control.
Page 263 Proceed to the troubleshooting information in the next procedure. (Models Solar 225LC-V, 300LC-V, and 300LL) If pressure through the “SH” port was tested below the minimum 13 bar (190 psi) level, check the shuttle valve in the rear compartment behind cabin.
Page 264: Troubleshooting - Swing Gearbox
TROUBLESHOOTING – SWING GEARBOX Problem Possible Causes Remedies Swing motor fails to operate and: Three pressure tests at motor, Swing relief valve defective Adjust pressure to brake or makeup valve show low Brake release valve defective recommended range in affected reading(s).
Page 265 Problem Possible Causes Remedies No rotation and: Pressure at swing motor inlet Swing brake not releasing. Check brake engagement and increases. disengagement; check release pressure. Internal damage to gearbox Replace broken gears and drive drive train. train assemblies. Overload. Reduce load weight. Pressure at swing motor inlet Swing motor drive shaft Replace swing motor.
Page 266: Troubleshooting - Hydraulic Problems
TROUBLESHOOTING – HYDRAULIC PROBLEMS Problem Possible Causes Remedies Attachment cylinders, swing and Main pump(s) malfunction. Repair or replace. travel motors are all inoperable. Low oil level in hydraulic system. Refill. Loud noises are heard from Main pump inlet (oil supply) Repair or replace.
Page 267 Problem Possible Causes Remedies Travel motors operate very Track tension poorly adjusted Readjust tension Refill. slowly. Low oil in idlers or rollers. Travel brake dragging. Repair. Track frame out of alignment, Repair. deformed or twisted. Swing motor inoperable. Swing brake not releasing. Repair or replace.
Page 268: Troubleshooting - Control Valve
TROUBLESHOOTING – CONTROL VALVE Check control valve problems only after other hydraulic circuit operational tests have been made. Refer to the “Troubleshooting Baseline Recommendations” procedure. Pump flow, pilot pressure, Negacon pressure, main relief pressure, and port relief pressure should all be checked before starting to work on the control valve.
Page 269 Problem Possible Causes Remedies Irregular or uneven pressure. Poppet seat damaged or pilot Clean/replace. piston sticking to main poppet. Loose lock nut and adjusting Readjust. screw. Components worn out, past Replace. wear limits. Hydraulic System Troubleshooting, Testing and S0702170K Adjustment Page 33...
Page 270: Troubleshooting - Travel Control Valve
TROUBLESHOOTING – TRAVEL CONTROL VALVE Problem Possible Causes Remedies Secondary pressure does not Low primary pressure. Check primary pressure. increase. Broken spring. Replace spring. Spool sticking. Clean, repair or replace. Excess spool to casing Replace spool casing. clearance. Worn or loose universal joint Repair or replace U-joint (handle) subassembly.
Page 271: Troubleshooting - Joystick Control Valve
TROUBLESHOOTING – JOYSTICK CONTROL VALVE Problem Possible Causes Remedies Secondary pressure does not Low primary pressure. Check primary pressure. increase. Broken spring. Replace spring. Spool sticking. Clean, repair or replace. Excess spool to casing Replace spool casing. clearance. Worn or loose handle Repair or replace handle subassembly.
Page 272 S0702170K Hydraulic System Troubleshooting, Testing and Page 36 Adjustment...
Page 273 Solar 140W-V 1001 and Up Solar 160W-V 1001 and Up Solar 180W-V 1001 and Up Solar 210W-V 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 255LC-V 1001 and Up Solar 300LC-V 1001 and Up...
Page 274 TABLE OF CONTENTS General Description..................3 Specifications ..................4 S0703010K Accumulator Page 2...
Page 275 GENERAL DESCRIPTION The accumulator is a gas-charged storage device designed to hold a reserve quantity of hydraulic fluid under pressure. Accumulators are used in hydraulic circuits in much the same way that condensers (or capacitors) are used to collect, store and maintain electrical charge in a circuit.
Page 276 NOTE: Pre-charge pressure is referred to as the "P1" pressure. The accumulator manufacturer’s "P1" rated pressure should be stamped or marked on the accumulator’s rating plate. Annual checks of actual pre-charge pressure should be made by tapping a hydraulic pressure gauge (and 3-way adapter coupling) into the valve on the bottom of the accumulator.
Page 277 8 kg/cm² Solar 210W-V S/N 0001 and Up Transmission (114 psi) (45.77 in 750 cc 10 kg/cm² Solar 225LC-V S/N 1001 and Up Pilot / Travel (142 psi) (45.77 in 750 cc 10 kg/cm² Solar 225NLC-V S/N 1001 and Up...
Page 278 Charge Model Serial Number System Volume Pressure 320 cc 10 kg/cm² Solar 470LC-V S/N 1001 thru 1049 Pilot / Travel (142 psi) (19.53 in 750 cc 10 kg/cm² Solar 470LC-V S/N 1050 and Up Pilot / Travel (142 psi)) (45.77 in S0703010K Accumulator Page 6...
Page 279 MODEL SERIAL NUMBER RANGE Solar 170LC-V 1001 and Up Solar 220LC-V 0001 and Up Solar 220LL 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 250LC-V 1001 and Up Solar 255LC-V 1001 and Up Copyright 2002 Daewoo...
Page 280 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Parts List ....................4 Type 1 ....................4 Type 2 ....................6 Troubleshooting, Testing and Adjustment............8 Inspection....................8 Testing..................... 8 Disassembly ....................9 Reassembly....................10 S0704010 Center Joint (Swivel) Page 2...
Page 281: General Description
Return to Master Table of Contents GENERAL DESCRIPTION The center joint (swivel) is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure. It is capable of allowing continuous 360° rotation of the upper structure in relationship to the lower structure.
Page 282: Parts List
Return to Master Table of Contents PARTS LIST Type 1 MODEL SERIAL NUMBER RANGE Solar 220LC-V 0001 thru 0125 Solar 220LL 1001 and 1125 HAOF410L Figure 1 S0704010 Center Joint (Swivel) Page 4...
Page 283 Return to Master Table of Contents Reference Reference Description Description Number Number Center Joint Body Center Joint Stem Bearings Plate O-ring Bearings Thrust Plate Seals Cover Center Joint (Swivel) S0704010 Page 5...
Page 284: Type 2
MODEL SERIAL NUMBER RANGE Solar 170LC-V 1001 and Up Solar 220LC-V 0126 and Up Solar 220LL 1126 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 250LC-V 1001 and Up Solar 255LC-V 1001 and Up Figure 1...
Page 285 Return to Master Table of Contents Reference Reference Description Description Number Number 10-1 Center Joint Body 10-9 O-ring 1BP-100 10-2 Spindle 10-10 O-ring 1BG-120 10-3 Cover 10-11 Plug PT3/4 10-4 Spacer 10-12 Ring; Retaining 10-5 Shim 10-13 Bolt M12x1.75x30 10-6 Shim 10-14 Washer;...
Page 286: Troubleshooting, Testing And Adjustment
Return to Master Table of Contents TROUBLESHOOTING, TESTING AND ADJUSTMENT INSPECTION The center joint should be checked for evidence of external oil leakage every 2,000 operating hours. Leaking or defective O-rings are an indication that dirt and other contaminants could be getting inside the assembly, which will promote accelerated, abnormal wear and may cause early failure of the assembly.
Page 287: Disassembly
Return to Master Table of Contents DISASSEMBLY Refer to the assembly drawing of the swivel joint for component references (Figure 1). IMPORTANT Do not unbolt the center joint from the lower car body until an adequate number of piping block- off plates are available, for disconnected piping lines.
Page 288: Reassembly
Return to Master Table of Contents REASSEMBLY Pre-lubricate O-rings with hydraulic oil, white grease or petroleum jelly. CAUTION! Apply a very light film of white grease or petroleum jelly to the lower rim of the stem and inner surface of the center swivel body. Apply slow, even-handed pressure, using both hands, to slowly push the stem into the body.
Page 289 Solar 180W-V 1001 and Up Solar 200W-V 0001 and Up Solar 210W-V 1001 and Up Solar 220LC-V 0001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 250LC-V 1001 and Up Solar 255LC-V 1001 and Up...
Page 290 MODEL SERIAL NUMBER RANGE Solar 330LC-V 1001 and Up Solar 340LC-V 1001 and Up Solar 400LC-V 1001 and Up Solar 420LC-V 1001 and Up Solar 450LC-V 1001 and Up Solar 470LC-V 1001 and Up TABLE OF CONTENTS General Description..................3 Theory of Operation ................
Page 291: General Description
GENERAL DESCRIPTION Two essentially similar types of hydraulic cylinders are used on the excavator. The cylinder that is used to operate the excavator boom or bucket is equipped with a rod stopper, which acts as a cushion only when the cylinder rod is fully retracted (and the bucket is pulled close to the arm). This type of cylinder is shown in the lower drawing.
Page 292: Parts List
Because the volume of oil needed to lengthen the cylinder rod (Q1) is greater than the volume of oil required to retract the cylinder rod, it takes more time to decrease cylinder stroke length than it does to lengthen it. = S x π(B Figure 3 = S x π(B...
Page 293 Reference Reference Description Description Number Number Bushing Piston Dust Wiper Slide Ring Retaining Ring Wear Ring U-Packing Slipper Seal Buffer Seal O-ring Rod Bushing Backup Ring Bolt Piston Nut Retaining Ring Set Screw Rod Cover Cushion Plunger O-ring Bushing O-ring Check Valve Backup Ring Spring Support...
Page 294: Special Tools And Materials
SPECIAL TOOLS AND MATERIALS PISTON NUT -0.1 -0.2 (C3~C5) ∅ Through Hole R(R15 ~ R20) ARS4730L Figure 6 Material SM45C (AISI 1045) Rockwell Harden from 22 - 27 Oil Quench S0705000 Cylinders Page 6...
Page 295 MODEL CYLINDER øA øB MODEL (CYLINDER) S55-V (BOOM, BOOM {OPT}) 110 mm 69 mm 12 mm 5 mm S55-V PLUS (SWING) (4.33 in) (2.72 in) (0.47 in) (0.20 in) S75-V (BUCKET) 100 mm 58 mm 12 mm 5 mm S55-V SWING (3.94 in) (2.23 in)
Page 296 MODEL CYLINDER øA øB MODEL (CYLINDER) S255LC-V (ARM) S290LL (BOOM, BUCKET) S330LC-V (BUCKET (OP), BOOM, BUCKET) 145 mm 105 mm 12 mm 5 mm S250LC-V S340LC-V (BUCKET (OP), (5.71 in) (4.13 in) (0.47 in) (0.20 in) BOOM, BUCKET) S370LC-V (BUCKET (OP), BUCKET) S390LL (BOOM, BUCKET) S290LC-V (ARM)
Page 297 Cylinders S0705000 Page 9...
Page 298: Piston Jig
PISTON JIG 2-∅"B" ∅ Through Hole R(R15~20) ARS4740L Figure 7 Material SM45C (AISI 1045) Rockwell Harden from 22 - 27 Oil Quench S0705000 Cylinders Page 10...
Page 299 MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER) BOOM 80.0 mm 11.0 mm 45.0 mm 110.0 mm S55 (BOOM (OP)) (3.15 in) (0.43 in) (1.77 in) (4.33 in) S55W-V (BOOM) SWING 58.0 mm 11.0 mm 38.0 mm 80.0 mm MEGA 300 (P/S) (2.28 in) (0.43 in)
Page 300 MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER) 150 mm 13 mm 103 mm 180 mm S450LC-V S470LC-V (ARM) (5.91 in) (0.51 in) (4.06 in) (7.09 in) S55-V (ARM, BUCEKT) 63 mm 11 mm 43 mm 90 mm S55W-V S55W-V (BUCKET) (2.48 in) (0.43 in)
Page 301 Cylinders S0705000 Page 13...
Page 302: Steel Bush Jig
STEEL BUSH JIG (∅20) ARS4750L Figure 8 Material: SM45C which is done thermal refining <QT> Hrc 22 - 28 Undefined Chamfer C/R = 0.5 Max. Place: Finally work to used DNMG Tip <Nose R0.4> S0705000 Cylinders Page 14...
Page 303 MODEL CYLINDER -0.05 øB (±0.1) +0.05 Part MODEL (CYLINDER) øA -0.15 50 mm 65 mm 30 mm S55W-V (BOOM) BOOM (1.97 in) (2.56 in) (1.18 in) S55-V PLUS (SWING) 40 mm 50 mm 20 mm S55-V SWING (1.58 in) (1.97 in) (0.79 in) 65 mm 70 mm...
Page 304 MODEL CYLINDER -0.05 øB (±0.1) +0.05 Part MODEL (CYLINDER) øA -0.15 S210W-V (ARM) S290LC-V (S/ARM, ARM) S290LL (BOOM, BUCKET) S300LC-V (S/ARM, ARM) 90 mm 105 mm 40 mm 6.5 mm MEGA 250-III (BUCKET) (3.54 in) (4.13 in) (1.58 in) (0.26 in) MEGA 400 (LIFT (H/C), BUCKET) MEGA 400-V (LIFT (H/C))
Page 305 MODEL CYLINDER -0.05 øB (±0.1) +0.05 Part MODEL (CYLINDER) øA -0.15 120 mm 140 m 75 mm 11 mm S470LC-V (ARM) (4.72 in) (5.51 in) (2.95 in) (0.43 in) S400LC-V (ARM, BOOM (H/C), BUCKET) S420LC-V (ARM, BOOM 110 mm 130 mm 70 mm 11 mm S450LC-V...
Page 306: Dust Wiper Jig
DUST WIPER JIG ARS4760L Figure 9 Material: SM45C which is done thermal refining <QT> Hrc 22 - 28 Undefined Chamfer C/R = 0.5 Max. Place: Finally work to used DNMG Tip <Nose R0.4> S0705000 Cylinders Page 18...
Page 307 -0.2 -0.2 MODEL CYLINDER MODEL (CYLINDER) øA øB -0.3 -0.3 -0.1 35 mm 47 mm 6 mm TILT (1.38 in) (1.85 in) (0.24 in) 45 mm 57 mm 0.5 mm 6 mm DD80L DOZER DD80L (ANGLE) (1.77 in) (2.24 in) (0.02 in) (0.24 in) 45 mm...
Page 308 -0.2 -0.2 MODEL CYLINDER øA øB MODEL (CYLINDER) -0.3 -0.3 -0.1 S210W-V (ARM) S220N-V (ARM (OP)) 95 mm 109 mm 6 mm 7 mm S225LC-V (ARM) (3.74 in) (4.29 in) (0.24 in) (2.28 in) S225NLC-V (ARM) S290LC-V (BOOM) S300LC-V (BOOM) S220LC-V 85 mm 99 mm...
Page 309 -0.2 -0.2 MODEL CYLINDER MODEL (CYLINDER) øA øB -0.3 -0.3 -0.1 120 mm 136 mm 9 mm 7 mm ARM (STICK) (4.72 in) (5.35 in) (0.35 in) (2.28 in) BOOM 100 mm 114 mm 6 mm 7 mm S290LL (HOIST) (3.94 in) (4.49 in) (0.24 in)
Page 310 -0.2 -0.2 MODEL CYLINDER MODEL (CYLINDER) øA øB -0.3 -0.3 -0.1 S130W-V (S/ARM) S130LC-V (BOOM (OP)) S140W-V (ARM) 75 mm 89 mm 6 mm 7 mm S140W-V (BOOM) (2.95 in) (3.50 in) (0.24 in) (2.28 in) S160W-V (BOOM) S170W-V (BUCKET) S220LC-V (BUCKET) S130W-V S220LL (BUCKET (HEEL))
Page 311 Cylinders S0705000 Page 23...
Page 312: Slipper Seal Jig
SLIPPER SEAL JIG (B+40) ARS4770L Figure 10 S0705000 Cylinders Page 24...
Page 313 +0.2 +0.2 MODEL CYLINDER MODEL (CYLINDER) øA +0.1 +0.1 85 mm 32 mm S55W-V (ARM) (3.35 in) (1.26 in) 110 mm 21.5 mm S55-V (BOOM (OP)) BOOM (4.33 in) (0.85 in) S55W-V (BOOM) S55-V S55W-V (BUCKET, SWING) 80 mm 30 mm SWING S55-V PLUS (BUCKET) (3.15 in)
Page 314 +0.2 +0.2 MODEL CYLINDER MODEL (CYLINDER) øA +0.1 +0.1 S140W-V (ARTI.) 180 mm 41.5 mm S160W-V (ARTI.) (7.09 in) (1.63 in) S290LL (ARM (STICK)) S400LC-V S420LC-V (ARM) 160 mm 34.5 mm BUCKET S420LC-V (BUCKET) (6.30 in) (1.36 in) 190 mm 41.5 mm S450-V S470LC-V (ARM)
Page 315 Cylinders S0705000 Page 27...
Page 316: Slipper Seal Straightening Jig
SLIPPER SEAL STRAIGHTENING JIG ∅ ARS4780L Figure 11 S0705000 Cylinders Page 28...
Page 317 +0.2 MODEL CYLINDER MODEL (CYLINDER) øA +0.1 85 mm S55W-V (ARM) (3.35 in) 110 mm S55-V (BOOM (OP)) BOOM (4.33 in) S55W-V (BOOM) S55-V S55W-V (BUCKET, SWING) 80 mm SWING S55-V PLUS (BUCKET) (3.15 in) MEGA 300-III P/S 100 mm S55W-V (DOZER) DOZER (3.94 in)
Page 318 +0.2 MODEL CYLINDER MODEL (CYLINDER) øA +0.1 S140W-V (ARTI.) 180 mm S160W-V (ARTI.) (7.09 in) S420LC-V (ARM) S400LC-V S290LL (ARM (STICK)) 160 mm BUCKET S420LC-V (BUCKET) (6.30 in) 190 mm S450LC-V S470LC-V (ARM) (7.48 in) S55-V PLUS (SWING) S70-III (BOOM) S80W-III (BOOM) S130W-V (S/ARM) S130-V (BOOM (OP))
Page 319: Disassembly
DISASSEMBLY CAUTION! Vent air from the hydraulic system before disconnecting cylinder piping connections. Use the lever on the reservoir, while the engine is running. Discharge the hydraulic accumulator and vent residual tank pressure after the engine is shut off. Pour clean replacement fluid back into the system if excessive fluid is lost.
Page 320 Tap two bolts into cover of cylinder head, 180° apart. Tighten them in a staggered, even sequence, to back off piston rod end cover from edge of cylinder wall. Look for adequate clearance between cover and end of cylinder wall before using a plastic or other soft-faced hammer for final disassembly.
Page 321 Figure 19 Fabricate or purchase a piston nut removal wrench. (Dimensions are called off at beginning of this procedure. This tool may also be ordered through your local Daewoo Parts distributor). Remove nut from end of piston. Figure 20 Cylinders S0705000...
Page 322 10. Use second piston tool described at beginning of this procedure to separate piston. Detach cushion ring (15), taking care not to damage cushion ring. Figure 21 11. Use a plastic hammer to evenly pull off rod cover (9) from end of piston rod. Be careful not to damage rod bushing (6) and dust wiper, U-packing and other seals.
Page 323 14. Pull off O-ring (20) and backup ring (21) from cylinder head. HAOF38OS Figure 25 15. During disassembly of cylinder head, be careful not to damage buffer seal (5) and U-packing (4). HAOF39OL Figure 26 16. Disassemble retaining ring (3) and dust wiper (2).
Page 324 17. Force out pin bushing (1) from body of cylinder. Figure 28 S0705000 Cylinders Page 36...
Page 325: Assembly
ASSEMBLY IMPORTANT Replace any part that shows evidence of damage or excessive wear. Replacement of all O-rings and flexible seals is strongly recommended. Before starting the cylinder assembly procedure, all parts should be thoroughly cleaned and dried, and/or prelubricated with clean hydraulic fluid. Prepare the work area beforehand to maintain cleanliness during the assembly procedure.
Page 326 Pre-lubricate O-rings and seals before assembly (Figure 31). Figure 31 Before starting to rebuild piston assembly, heat slipper seal for 5 minutes in an oil bath warmed to 150°-180°C (302°-356°F). Use special slipper seal jig (third item in list of specialized tools at the beginning of this procedure) to attach seal.
Page 327 Use specially fabricate or factory-sourced tool to tighten piston nut (22). Figure 35 Assemble wear ring (18), slide ring (17) and set screw (23) to piston assembly. Reference Description Number Set Screw Figure 36 Immobilize body cylinder before assembly. Figure 37 10.
Page 328 S0705000 Cylinders Page 40...
Page 329 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. SWING MOTOR S0707200 MODEL SERIAL NUMBER RANGE Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 250LC-V 1001 and Up...
Page 330 Swing Motor Anti-cavitation Make-up Valve ..........4 Relief Valve ..................... 5 Swing Brake Operation ................5 Parts List (Model Solar 250LC-V, 255LC-V)..........8 Parts List (Models Solar 225LC-V, 225NLC-V, 290LC-V, and 290LL) ................10 Specifications (Model Solar 225LC-V, 225NLC-V)........ 12 Specifications (Models Solar 250LC-V, 255LC-V, 290LC-V, and 290LL) ................
Page 331: Theory Of Operation
Return to Master Table of Contents GENERAL DESCRIPTION THEORY OF OPERATION Figure 1 Reference Reference Description Description Number Number Valve Plate Cylinder Block Shoe Piston Swash Plate The cross sectional views of the swing motor, show most of the main components of an axial-piston type hydraulic motor.
Page 332: Swing Motor Anti-Cavitation Make-Up Valve
Return to Master Table of Contents If oil flow to the motor is directed to the opposite port (so that the supply side becomes the exhaust side and vice versa), the rotation of the motor is reversed. Trench mode allows the operator to "prioritize" hydraulic oil flow between swing function and boom and arm function.
Page 333: Swing Brake Operation
Return to Master Table of Contents RELIEF VALVE The relief valve is one in a set of two, and is Item "51" of the swing motor assembly. Return line pressure (the normal pressurization of the hydraulic reservoir, also referred to as "tank pressure") pushes the valve piston to open ports "R"...
Page 334 Return to Master Table of Contents Figure 3 The swing brake is applied when the brake spring (Item 712, Figure 3) locks up the friction plate (742), split plate (743) and swing motor casing (301), preventing the motor drive shaft from turning. When hydraulic pressure is forced to the back side of the brake piston, the friction plate and swing motor casing are separated, releasing the brake.
Page 335 Return to Master Table of Contents Swing Motor S0707200 Page 7...
Page 336: Parts List (Model Solar 250Lc-V, 255Lc-V)
Return to Master Table of Contents PARTS LIST (Model Solar 250LC-V, 255LC-V) Figure 4 S0707200 Swing Motor Page 8...
Page 337 Return to Master Table of Contents Reference Reference Description Description Number Number Brake Valve Ring Snap Relief Valve Ring Snap S/R Valve Block Roller Bearing Drive Shaft Roller Bearing Spacer Pin Spring Cylinder Block VP Plug Spherical Bush VP Plug Cylinder Spring RO Plug Push Rod...
Page 338: Parts List (Models Solar 225Lc-V, 225Nlc-V, 290Lc-V, And 290Ll)
Return to Master Table of Contents PARTS LIST (Models Solar 225LC-V, 225NLC-V, 290LC-V, and 290LL) Figure 5 S0707200 Swing Motor Page 10...
Page 339 Return to Master Table of Contents Reference Reference Description Description Number Number Brake Valve Lock Ring Relief Valve Lock Ring Drive Shaft Roller Bearing Spacer Roller Bearing Cylinder Block Pin Spring Spherical Bushing VP Plug Cylinder Spring VP Plug Push Rod RO Plug Spacer (F) O-ring...
Page 340: Specifications (Model Solar 225Lc-V, 225Nlc-V)
Return to Master Table of Contents SPECIFICATIONS (Model Solar 225LC-V, 225NLC-V) Swing Motor Specification Type Axial Piston Displacement 128 cc/rev (7.81in /rev) Crossover Relief Valve Setting 280 kg/cm² (4,000 psi) Maximum Supply Flow Rate @ 1640 rpm 210 liters per minute (55 U.S. gal. per minute) Max.
Page 341 Return to Master Table of Contents SPECIAL TOOLS Figure 6 Swing Motor S0707200 Page 13...
Page 342: Disassembly
Return to Master Table of Contents DISASSEMBLY The area where the motor is going to be rebuilt should be well lighted, clean and protected from dust and/or wind gusts that could carry grit or dust. Use a rubber mat or other protective covering on the workbench area to prevent damage or scratching of any precision machined components.
Page 343 Return to Master Table of Contents Make two permanent marks on exterior of motor to indicate assembly position of motor casing (301) and upper valve casing (303). Figure 9 Disassemble brake valve (31) from side of casing. Figure 10 Loosen remove relief valve...
Page 344 Return to Master Table of Contents Loosen and remove all four socket head bolts (401) and separate upper valve casing (303) from lower casing (301). Valve plate (131) inside upper NOTE: valve casing (303) must be separated from assembly but take extra care to make sure that it is not scratched or damaged by an accidental fall,...
Page 345 Return to Master Table of Contents 11. Reposition motor so that end of drive shaft faces out to one side. Pull out cylinder block (111) and disassemble pistons (121), retainer plate (123), spherical bushing (113), front spacer (117) and shoe plate (124).
Page 346 Return to Master Table of Contents 14. Separate casing and drive shaft (101). Tap upper end of drive shaft with a soft-faced, plastic hammer. To avoid damaging drive shaft, do not use excessive force. Figure 19 15. Tap bearing race out of casing. Figure 20 16.
Page 347 Return to Master Table of Contents NOTE: Final disassembly of individual components may also require: Disassemble oil seal from the front cover if they were not separated during removal. Apply force (2, Figure 22) and use a plug (1) to hammer through drive shaft opening in cover.
Page 348 Return to Master Table of Contents Relief valves can be replaced in sets by ordering one part number through your authorized Daewoo dealer/parts distributor. To disassemble relief valves, pull out plug (201, Figure 5), disassemble bushing (343), spring (322) and spring seat (331) from rod (303).
Page 349: Cleaning And Inspection (Wear Limits And Tolerances)
Return to Master Table of Contents CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) Inspect all components and precision surfaces, to confirm that they haven’t been worn beyond service limits. Refer to table below for dimensional specifications. All parts should be cleaned, air-dried and re-lubricated with clean, approved-type hydraulic fluid, before final reassembly or as the final step after the unit has been put back together.
Page 350 Return to Master Table of Contents Replacement Standard Value mm Item Recommended mm Remedy (In) (In) Clearance between piston 0.028 mm 0.058 mm Replace piston or and the cylinder bore (D) (0.0011") (0.0023") cylinder Clearance between piston 0 mm 0.3 mm Replace piston or and shoe socket (d) (0.00")
Page 351: Reassembly
Return to Master Table of Contents REASSEMBLY Reassembly of the motor is basically accomplished by reversing disassembly steps. Use a torque wrench to make sure that assembly fasteners are tightened to specified values. Always begin a bolt tightening sequence from the innermost part of the assembly, working outward toward the ends in careful, even rotation.
Page 352 Return to Master Table of Contents Reassemble drive shaft (101, Figure 5), roller bearing (443) and lower casing (301). Pay attention to bearing alignment inside bore of case. Make sure it is fully seated. Figure 30 There is a "right side" and "wrong side" on oil seal.
Page 353 Return to Master Table of Contents Use snap-ring pliers to replace lock ring (437) into lower casing (301). Figure 34 Turn motor sideways and assemble shoe plate (124), placing it in motor housing in same position it was in before removal. Using grease on assembled side can help keep individual components in place.
Page 354 Return to Master Table of Contents 11. Put cylinder block (111) and retainer plate (123) back in motor. Spherical bushing and grooves of cylinder block splines should fit together without undue difficulty. (Do not try to force or pound parts together.) Figure 38 12.
Page 355 Return to Master Table of Contents 15. Reinstall brake springs, making sure that each gets fully seated on piston. Figure 42 16. Tap roller bearing (444) race back into upper valve casing (303), using hammer and copper rod specified in tool list. Figure 43 17.
Page 356 Return to Master Table of Contents 19. Put plungers (351), springs (355), O-rings (488), and RO plugs (469) back in casing. Make sure that both plungers are free to move back and forth. Figure 46 20. Reassemble relief valves (51) by putting rod, spring, stop and piston back together, then turning plunger side of valve up to reassemble...
Page 357 Return to Master Table of Contents 22. Replace VP plugs (464, 468) and O-rings (485, 487) on each of the three plugs. Reinstall the brake cutoff valve (31). Figure 50 Swing Motor S0707200 Page 29...
Page 358 Return to Master Table of Contents S0707200 Swing Motor Page 30...
Page 359 MODEL SERIAL NUMBER RANGE Solar 220LC-V 0111 and Up Solar 220LL 1002 and Up Solar 220N-V 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Copyright 1999 Daewoo March 1999 Travel Motor (With Gearbox) (GM35VL) S0707330...
Page 360 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Travel Motor Parts List................10 Travel Reduction Gearbox Parts List ............. 12 Specifications ..................14 Troubleshooting, Testing and Adjustment............. 16 General Notice ..................16 Troubleshooting..................
Page 361: Theory Of Operation
Return to Master Table of Contents GENERAL DESCRIPTION THEORY OF OPERATION Refer to the assembly cross-section at the end. Travel motor consists of the hydraulic motor and reduction gearbox. Hydraulic motor consists of the rotary part, cross relief valve, negative brake, counter balance valve and tilting parts.
Page 362 Return to Master Table of Contents Hydraulic Motor Operation Hydraulic Motor operation. Figure 2 The high pressure oil from the hydraulic pump goes to the cylinder block (104) through the rear flange (101) of the motor and the brake valve device and the timing plate (109). This high pressure oil acts only on the single side of the line Y1-Y2 which connects the bottom dead center and the top dead center of the piston (105) stroke.
Page 363 Return to Master Table of Contents Brake Valve During Travel. Figure 3 If the pressure oil is supplied from port A, this oil opens the valve (130), flows into the inlet port C of the hydraulic motor, and turns the hydraulic motor. At the same time, the oil, which flows from a small hole of the spool (126) to the chamber b through passage a, exerts pressure on the spool section, and moves the spool to the left over spring (128) force.
Page 364 Return to Master Table of Contents When Stopping by Deceleration Figure 4 If the pressure oil supplied by the port A is cut off during drive. there will be no hydraulic force. Then, the spool (126) returns to the right (neutral position) through the stopper (125) by the spring (128). The hydraulic oil in chamber b goes through passage a into port A, and back pressure, which is generated by throttling of passage a controls the return speed of spool (126).
Page 365 Return to Master Table of Contents Parking Brake During Travel. If the pressure oil is supplied by the brake valve, the brake valve spool of the hydraulic motor part is operated, and the passage into the parking brake is opened. So the pressure oil flows into the cylinder a which consists of a spindle and a piston.
Page 366 Return to Master Table of Contents High and Low Speed Switching Device At low speed (If the pilot pressure is lower than 10 kg•m (72 ft lb)). Figure 7 If pilot pressure is not applied from port A (If the pressure is lower than 10 kg•m (72 ft lb)), the valve (163) is pushed to the left by the spring (I66) force, the pressure oil from the supply port B is blocked, and the oil of the chamber C flows through the valve (l63) into the motor case.
Page 367 Return to Master Table of Contents Reduction Gearbox Operation This reduction gear is a combined system of planetary gear and differential gear, It reduces rotational speed, while increasing output torque of the hydraulic motor, and rotates the gear case. Planetary gear If the sun gear (S) connected to the input shaft rotates, the planetary gear (P) turns (P1)
Page 368: Travel Motor Parts List
Return to Master Table of Contents TRAVEL MOTOR PARTS LIST Figure 12 S0707330 Travel Motor (With Gearbox) (GM35VL) Page 10...
Page 369 Return to Master Table of Contents Reference Reference Description Description Number Number Travel Motor O-ring 1BP22 Shaft O-ring 1BP18 Plate; Swash Ring; Backup Block; Cylinder Ring; Backup Piston and Shoe Assembly O-ring 1BP29 Piston Seal; Piston Shoe Flange; Rear Plate; Retainer Spool Ball;...
Page 370: Travel Reduction Gearbox Parts List
Return to Master Table of Contents TRAVEL REDUCTION GEARBOX PARTS LIST Figure 13 S0707330 Travel Motor (With Gearbox) (GM35VL) Page 12...
Page 371 Return to Master Table of Contents Reference Reference Description Description Number Number Travel Reduction Gear Ring; Snap Bearing; A/Ball Spindle Bearing; T/R Flange; Holder Bearing; Needle RV Gear Kit Ring; Snap RV Gear A O-ring 1BP8 RV Gear B O-ring 1AG230 Gear;...
Page 372: Specifications
Return to Master Table of Contents SPECIFICATIONS Name Plate Identification GM 35 VL - A - 75/130 - 4 HAOZ670S Figure 14 Reference Description Number Design Number (Product Classification Number) Volume Classification Number (cc/rev) Deceleration Classification Number (A=1/56) Model Classification Number Size Number Machine Type Symbol S0707330...
Page 373 Return to Master Table of Contents Specifications Component specifications are shown in following table. Item Specification 60 kg•m Rated Torque (434 ft lb) Max Rotation Rate 3500 rpm Reduction Rate 1:66 140.50 cc Max Output/rev (8.57 in Operating Rotation 2800 rpm 350 kg/cm Max Output Pressure (4,978 psi)
Page 374: Troubleshooting, Testing And Adjustment
Return to Master Table of Contents TROUBLESHOOTING, TESTING AND ADJUSTMENT GENERAL NOTICE Check whether the same trouble has occurred before. Handle each part being careful not to damage especially sliding surface of components, gear, bearing and pin parts. Be careful not to insert dirt, rust, or rusted parts inside the parts. TROUBLESHOOTING Refer to the following tables.
Page 375 Troubleshooting Check Item Cause Remedies A. Travel motor does not rotate Discharge pressure rises Overloading Remove overload Brake piston has been backed Refer to “B” Negative brake is on The oil passage of valve or motor Replace the valve casing was cracked, so the release or motor casing presure dose not rise Dirt clogged, release...
Page 376 Troubleshooting Check Item Cause Remedies B. Negative brake is not released Replace the Brake piston moves lightly Brake piston sticking and does not work brake piston casing The surface of spline and pin is lough Friction and seperate Replace the plate swings lightly faulty parts Brake stuck or deformed...
Page 377 Troubleshooting Check Item Cause Remedies D. Oil leakage Screw the bolt Loose bolt with the standard torque. Disassemble and Liquid packing was not applied. apply again. Oil leaks out assembled surface O-ring damaged or Reassemble a has not been inserted new O-ring Assembled surface is not clean, Replace O-ring...
Page 378: Disassembly
Return to Master Table of Contents DISASSEMBLY PREPARATION FOR TRAVEL MOTOR AND REDUCTION GEAR DISASSEMBLY The travel motor and gear box should be removed from machine assembly. Once the unit is removed, place the assembly in an appropriate work area. Figure 15 Remove twelve allen head bolts (343) from rear flange assembly.
Page 379 Return to Master Table of Contents Remove timing plate (109), parallel pin (341), twelve springs (113) and ball bearing (150) from rear flange (301) and motor housing. Figure 18 Drain gear oil from reduction gear housing. Turn gear assembly around so that reduction gear cover is facing up.
Page 380: Travel Motor Rear Flange Disassembly
Return to Master Table of Contents TRAVEL MOTOR REAR FLANGE DISASSEMBLY Spool Disassembly Remove plug (324) from rear flange (301). Remove O-ring (336) from plug (324). Figure 21 Remove two springs (328) and two stoppers (325) with two spools (3). Figure 22 Check Valve Disassembly Remove two plugs (326) from rear flange...
Page 381 Return to Master Table of Contents Remove springs (330) and valves (327) from two flanges (301). Remove O-ring (337) from plug (326). Figure 24 Two Speed Switching Valve Disassembly Remove plug (357) from rear flange (301). Figure 25 Remove spool (363) and spring (366) from rear flange (301) Remove O-ring (355) from plug (357).
Page 382 Return to Master Table of Contents Remove piston (381) from rear flange (301) Figure 28 Remove two plugs (382). Remove O-rings (383 and 384) from plug (382). Figure 29 Remove steel ball (385) from each plug hole (301). Figure 30 Relief Valve Disassembly Remove plug (204) from sleeve (202).
Page 383 Return to Master Table of Contents Remove seam (205) from plug (204). Figure 32 Remove spring retainer (203), spring (206), valve (201) from sleeve (202). Figure 33 Figure 34 Figure 35 Travel Motor (With Gearbox) (GM35VL) S0707330 Page 25...
Page 384: Travel Motor Internal Parts Disassembly
Return to Master Table of Contents Remove piston seal A (220) from valve B (201). Disassemble another side of sleeve in the same way. NOTE: In this disassembling, in case of replacing internal part of sleeve (202), if any parts except O-ring (210) or piston seal (221) are needed to replace, for it will necessitate the resetting of...
Page 385 Return to Master Table of Contents Motor Internal Parts Disassembly Position motor laterally. (Incline motor 90°.) Drain oil in motor. By holding cylinder block (104) with both hand, take out from spindle (2). Remove companion plate (116) and friction plate (115) by two respectively that are attached around circumference of removed cylinder block (104).
Page 386 Return to Master Table of Contents Take speed switching piston assembly (piston (161), shoe (162)) and spring (163) by blowing compressed air through passage of spindle (2). Figure 43 Cylinder Block Disassembly Positioning cylinder block (104) on work bench and holding down putting the holding metal fitting (1) on washer (110) and remove C type snap ring (145).
Page 387 Return to Master Table of Contents Spur Gear Disassembly Remove three C type snap rings (25) for shaft from crankshaft (9). Figure 47 Remove three spur gear from crankshaft (9). Remove coupling (15) from shaft (102). Figure 48 Travel Motor (With Gearbox) (GM35VL) S0707330 Page 29...
Page 388 Return to Master Table of Contents Hold Flange Disassembly Rotate motor in opposite direction Fix by tightening two stationary metal fitting to hub (1) and spindle (2). At this time, tighten for stationary metal fittings to be positioned in symmetry. Rotate motor in opposite direction.
Page 389 Return to Master Table of Contents Remove hold flange (3) from spindle (2). Rotate motor in opposite direction. 10. Remove two stationary metal fitting. Figure 51 11. Install eye bolt (M16) to spindle (2), and hook the eye bolt, and remove from hub by hanging it with crane.
Page 390 Return to Master Table of Contents Take out floating seal (hub) from hub (1) Rotate running motor in opposite direction. From cove (8) side of hub (1), by tapping lightly with sharp tip punch (B) and hammer (A), remove ball bearing (C) (21) and hub (1).
Page 391 Return to Master Table of Contents Putting screw driver on the outer edge of oil seal (A) in spindle (2), by tapping with hammer, remove oil seal. (132). Figure 57 Bearing (149) Disassembly Putting clamping metal fitting {II} (D) on the press work bench, and put shaft into it.
Page 392: Cleaning And Inspection (Wear Limits And Tolerances)
Return to Master Table of Contents CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) GENERAL INSPECTION Check following inspection list before assembling, correct any problems if any signs of damage are visible. Inspection Item Remedies Are there any signs of damage caused by Contact service center.
Page 393: Tightening Torque List
Return to Master Table of Contents TIGHTENING TORQUE LIST Tightening Part No. Name Screw Dimension Quantity Torque Bolt With Hexagon Hole M24 (P3.0) 72.3 ±11 kg•m (523 ±7 ft lb) Plug With Hexagon Hole PF 1/2 10 ±2 kg•m (72 ±14 ft lb) Bolt With Hexagon Hole M12 (P1.75) 10.4 ±1.6 kg•m...
Page 394 Return to Master Table of Contents Component and Standard Value for Signs of Wear Inspection Item Value Replacement Shaft • Contacting face with oil seal (132) worn. • Spline part worn. Swash plate • Burning marks. Cylinder block • Spline part worn. •...
Page 395: Reassembly
Return to Master Table of Contents REASSEMBLY GENERAL INSTRUCTIONS FOR REASSEMBLY General Notes Clean parts with cleaning solution and dry with compressed air. Do not use cloth that may leave cloth fibers on parts. Use the torque values provided to securely tighten all bolts, plugs and screws using a torque wrench.
Page 396 Return to Master Table of Contents Install stopper (325) and spring (328) into plug (324) and insert into flange assembly. Tighten two plugs to specified torque. Tightening Torque: 45 ±9 kg•m (325 ±65 ft lb) Figure 61 Two Speed Switching Valve Reassembly Install O-ring to plug (357).
Page 397 Return to Master Table of Contents Internal Parts Reassembly (SRV) Insert two steel balls (385) into rear flange (301). Install two O-rings (383 and 384) on plug (382). Figure 64 Install two plugs (382) into rear flange (301) and tighten to specified torque. •...
Page 398 Return to Master Table of Contents Install piston seal (A) (220) at valve (B) (201). Figure 68 Insert valve (201), spring (206), spring retainer (203) into sleeve (202), and install plug (204) with seam (205) into assembly and tighten to specified torque. Tightening Torque: 10 ±2 kg•m (72 ±14 ft lb) Figure 69...
Page 399 Return to Master Table of Contents Repeat procedure for the other side. Figure 72 Travel Motor (With Gearbox) (GM35VL) S0707330 Page 41...
Page 400: Travel Reduction Gear Reassembly
Return to Master Table of Contents TRAVEL REDUCTION GEAR REASSEMBLY Hub Reassembly Place hub (1) on work bench. Press in the outer race of ball bearing (A) (21) into hub (D) (1) by using jig (C) and hammer (B). Figure 73 Assemble floating seal (B) (31) into hub (D) (1).
Page 401 Return to Master Table of Contents Hub and Spindle Reassembly Install two eye bolts (M16) to spindle (2) at opposite ends to distribute the weight evenly. Use a lifting device slowly lower spindle (2) into hub (1). Insert two stationary metal fittings to hub (1) and spindle (2) and tighten.
Page 402 Return to Master Table of Contents Insert ball bearing (21) into hub (1). Insert outer races of three roller bearings (22). Figure 79 Install hold flange (3) at spindle (2). Figure 80 Coat locktite #638 at spindle (2) threads. Place flat washers (37) in the three bolt holes of the flange (3).
Page 403 Return to Master Table of Contents 11. Install shim (13) into holding flange. 12. Install snap ring (20) to hold flange. Figure 83 13. Align the mating marks of the three spur gears (7) and press into the respective crankshaft (9). Figure 84 14.
Page 404 Return to Master Table of Contents Figure 87 16. Turn motor assembly so that the motor side is facing up. 17. Insert oil seal (132) into spindle (2). Figure 88 18. Heat bearing (B, Figure 89) (149) and press shaft (B) (102) into bearing. Figure 89 S0707330 Travel Motor (With Gearbox) (GM35VL)
Page 405 Return to Master Table of Contents Piston Assembly (161 and 162) Reassembly Coat grease on spring (193) and install into piston assembly. Coat piston assembly with hydraulic oil and install into piston hole of spindle (2). Inserting two pins (171) and two pivot (167) into spindle.
Page 406 Return to Master Table of Contents Motor Reassembly Insert five needle type rollers (151) into cylinder block (104) and place collar (111) and thrust ball (108) on it. Put piston pin assembly (105 and 106) into retainer plate (107). Figure 94 Coating hydraulic oil on piston assembly and install into cylinder block (104).
Page 407: Gear Holding Flange Gap Measurement And Adjustment
Return to Master Table of Contents GEAR HOLDING FLANGE GAP MEASUREMENT AND ADJUSTMENT Install main bearing pre-load adjustment jig (C, Figure 97) at spindle (D) (2). Using a torque wrench (A) tighten special nut (B) on main bearing adjustment jig to specified torque.
Page 408: Rv Gear Gap Measurement And Adjustment
Return to Master Table of Contents RV GEAR GAP MEASUREMENT AND ADJUSTMENT Tap lightly together with press metal fitting (A, Figure 100) and hammer, the outer wheel of conical roller bearing (B) (22) that is attached to crankshaft (9) of RV gear assembly (C).
Page 409: Travel Motor And Reduction Gear Reassembly
Return to Master Table of Contents TRAVEL MOTOR AND REDUCTION GEAR REASSEMBLY Insert friction plate (115) and companion plate (116) alternately into cylinder block. IMPORTANT Install friction plate (115) after soaking it in operating oil. CAUTION! Be careful not to mistake the order of Figure 101 friction plate and companion plate.
Page 410 Return to Master Table of Contents Fill reduction gear housing with hydraulic oil. Install two O-rings (29 and 27), two parallel pins (42) into spindle (2). Install rear flange (301) to spindle by aligning rear flange with aligning pins. Figure 104 Install rear flange (301) to spindle (2).
Page 411: Reduction Gear Cover Reassembly
Return to Master Table of Contents REDUCTION GEAR COVER REASSEMBLY Insert coupling gear (15). Coat a generous amount of grease onto steel ball (36) and place ball on concave part of input gear (6). Attach O-ring (30) on cover (8). Install two eye bolts into threaded holes on cover (8).
Page 412 Return to Master Table of Contents Install O-ring (43) to drain / fill holes on cover. 10. Install and tighten plugs (33) to cover (8). Tightening Torque: 10 ±2 kg•m (72 ±14 ft lb) Figure 110 Figure 111 S0707330 Travel Motor (With Gearbox) (GM35VL) Page 54...
Page 413 Remember, that ultimately safety is your own personal responsibility. MAIN PUMP (WITH REGULATOR)S0708320 MODEL SERIAL NUMBER RANGE Solar 220LC-V 0001 and Up Solar 220LL 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 250LC-V 1001 and Up Solar 255LC-V 1001 and Up...
Page 414 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Gear (Pilot) Pump ................... 5 Relief Valve ..................... 5 Pump Regulator Description ..............6 Horsepower Control ................6 Power Shift Control ................. 6 Negative Oil Discharge (Pump Bypass) Control ........6 Pump Regulator Operation ..............
Page 415 Return to Master Table of Contents GENERAL DESCRIPTION Figure 1 The main pump assembly contains two variable displacement axial piston pumps connected in series, driven through a flexible coupling off the back of the engine. A regulator mounted on each pump controls the flow output of that pump.
Page 416 Return to Master Table of Contents Models: Solar 220LC-V, 220LL, 225LC-V, 250LC-V Main Pump Output: 106.0 cc/rev (6.47 in /rev) (1 pump) Gear (Pilot) Pump Output: 15 cc/rev Pilot Pump Relief Valve: Relief pressure set at 40 kg/cm (569 psi). Model: Solar 255LC-V Main Pump Output: 112.0 cc/rev (6.83 in /rev) (1 pump)
Page 417: Gear (Pilot) Pump
Return to Master Table of Contents TO LEFT SIDE OF TO RIGHT SIDE OF CONTROL VALVE CONTROL VALVE Pz3 Pz4 500k 500k (FRONT) (REAR) SENSOR SENSOR ENGINE HJA3002L Figure 3 GEAR (PILOT) PUMP The pilot pump is a gear-type pump, driven off the output end of the second main pump.
Page 418: Pump Regulator Description
Return to Master Table of Contents PUMP REGULATOR DESCRIPTION A regulator control valve is integrally-mounted to the housing of each of the two variable displacement hydraulic pumps (Figure 1). The regulator valves perform the task of controlling the rate of pump discharge for the main pump assembly.
Page 419: Pump Regulator Operation
Return to Master Table of Contents PUMP REGULATOR OPERATION The relationship between Pump Displacement Flow (Q on the vertical axis) and Pilot Pressure (Pi on the horizontal axis). Pump output discharge controlled increasing decreasing pilot pump pressure (Figure 7). Figure 7 Main Pump (With Regulator) S0708320 Page 7...
Page 420 Return to Master Table of Contents NOTE: Component parts (numbered in parentheses) correspond to those in Figure 8. Figure 8 S0708320 Main Pump (With Regulator) Page 8...
Page 421: Pump Output Decrease
Return to Master Table of Contents PUMP OUTPUT DECREASE When pilot pressure (Pi) increases, the pilot piston (643) shifts toward the right, stopping at that point at which pilot pressure and the force of the return spring (646) cancel each other out. Movement of the pilot piston pushes the pin (875) attached to the feedback lever assembly (613, 611, 897) around the "B-point plug"...
Page 422 Return to Master Table of Contents OVERLOAD PROTECTION Overload protection occurs automatically, in response to increased pressure on the piston (621) and compensator rod (623). Whenever the discharge pressure of Pump 1 and Pump 2 (P1 and P2) are increased beyond a certain point, the higher pressure acts on the piston and compensator rod (621 and 623), pushing both toward the right, until hydraulic pressure and the return force of the inner and outer springs balance out.
Page 423: Pump Input Power Control Adjustment
Return to Master Table of Contents PUMP INPUT POWER CONTROL ADJUSTMENT IMPORTANT Input horsepower adjustments that are made to one pump should also be carried out on the remaining pump, so that both are adjusted to the same input range. Horsepower control characteristics can be changed by loosening the large, thin nut (630) on the end of the regulator.
Page 424 Return to Master Table of Contents PARTS LIST Main Pump Figure 13 S0708320 Main Pump (With Regulator) Page 12...
Page 425 Return to Master Table of Contents Reference Reference Description Description Number Number Gear Pump VP Plug Electronic Proportioning Expander Valve Tilting Pin Shaft (F) Servo Piston Shaft (R) Stopper (L) Spline Coupling Stopper (S) Roller Bearing Seat Needle Bearing Spacer Bearing Spacer Stopper Cylinder Block...
Page 426 Return to Master Table of Contents Pump Regulator Figure 14 S0708320 Main Pump (With Regulator) Page 14...
Page 427 Return to Master Table of Contents Reference Reference Description Description Number Number Socket Bolt Spring Seat Socket Bolt Return Spring Socket Bolt Set Spring Socket Bolt Cover Expander Pf Piston Casing O-ring Feedback Lever O-ring Lever (1) O-ring Lever (2) O-ring Portion Plug O-ring...
Page 428: Specifications
15 cc/rev (0.9 in /rev) Max Flow Rate: 30 lpm (8 gpm) Relief Valve: 40 kg/cm (569 psi) Model: SOLAR 225LC-V Main Pump Quantity: Displacement: 108.7 cc/rev (6.63 in /rev) Max Flow Rate: 215 lpm x 2 pumps (57 gpm x 2 pumps)
Page 429 Return to Master Table of Contents Model: SOLAR 255LC-V Main Pump Quantity: Displacement: 122 cc/rev (6.47 in /rev) Max Flow Rate: 224 lpm x 2 pumps (59 gpm x 2 pumps) Flow Regulator Type: Negative Control Pressurization: Air Breather Weight: 134 kg (295 lb) Pilot Pump Displacement:...
Page 430: Hydraulic Pump Performance Characteristics
Pilot Pump Displacement 15 cc/rev (0.9 in /rev) Pilot Pump Pressure 40 kg/cm (569 psi) Main Pump Pressure/Flow Output (Model: SOLAR 225LC-V) Engine Speed 1950 rpm (High Mode) 1800 rpm (Standard Mode) Pump Input Horsepower 135.0 ps (133 hp) (High Output 115.0 ps (113 hp) (Standard...
Page 431 Return to Master Table of Contents (Models: SOLAR 220LC-V, 220LL, AND 250LC-V) Figure 15 Main Pump (With Regulator) S0708320 Page 19...
Page 432 Return to Master Table of Contents (Model: SOLAR 225LC-V) BBS0030L Figure 16 S0708320 Main Pump (With Regulator) Page 20...
Page 433 Return to Master Table of Contents (Model: SOLAR 225NLC-V) P-Mode INPUT rpm : 2000rpm INPUT POWER (INCLUDING GEAR PUMP) : 132PS INPUT TORQUE (INCLUDING GEAR PUMP) : 47.3Kg.m S-Mode INPUT rpm : 1850rpm INPUT POWER (INCLUDING GEAR PUMP) : 103PS INPUT TORQUE (INCLUDING GEAR PUMP) : 39.9Kg.m BDS0180L Figure 17...
Page 434 Return to Master Table of Contents (Model: SOLAR 255LC-V) 10.0K 144K 2000 rpm 224L 222L 1900 rpm 10.0K 213L 119K 211L 216K 120L 192K 121L 350K 350K 33.8K Pd= 80 K at Q=max 33.8K DISCHARGE PRESSURE; P (kgf/cm ) PILOT PRESSURE; Pi (kgf/cm ) AYS0070L Figure 18 S0708320...
Page 435: Troubleshooting, Testing And Adjustment
Return to Master Table of Contents TROUBLESHOOTING, TESTING AND ADJUSTMENT MAIN PUMP Problem Possible Causes Remedies Engine overloading Engine RPM control off Readjust RPM control Pump regulator set too high Readjust Pump inner parts worn or damaged Look for impurities or particles inside the filter and rebuild, replace pump components, as required Pump regulator piping clogged or leaking...
Page 436: Disassembly
Return to Master Table of Contents DISASSEMBLY GENERAL DISASSEMBLY This procedure assumes that the main pump assembly will be removed from the upper deck plate. Use the eye bolts in the center valve block assembly to move the valve block and the assembled pumps (still bolted together) to the prepared work area.
Page 437: Main Pump Disassembly
Return to Master Table of Contents When pilot pump and valve regulators have been removed from assembly, the two pump cylinder blocks (271) can be unbolted from center valve support plate (251) and valve block (312). A total of eight 17 mm allen-head hex bolts hold pump assemblies together - four on each side.
Page 438 Return to Master Table of Contents Unscrew two allen-head hex head bolts from front seal cover plate (261). To separate cover plate from rest of assembly, screw 6 mm cap screws into threaded holes tapped into cover. Tighten all four cap screws in a slow, staggered tightening sequence, taking wrench off of each cap screw after just a fraction of a turn and...
Page 439: Pump Regulator Disassembly
Return to Master Table of Contents NOTE: If a complete tear down and reassembly is being performed, the only parts which should NOT be loosened or removed are the hex nut (808) spring pin servo piston stoppers in the swash plate supports. (The pre- discharge value would...
Page 440 Return to Master Table of Contents Remove four hex-head allen-style bolts (436, 438) and pilot cover (641) from the regulator casing. Remove and inspect O- rings (725, 730, 732, 734) found between the cover and regulator casing. Remove feed back lever set spring (655) and adjusting screw bushing (647).
Page 441 Return to Master Table of Contents Remove adjusting ring (645) from bore by threading a 4 mm x 50 mm bolt into center of adjusting ring and gently pulling it out. Remove and inspect O-ring (728). The shim (649), pilot spring (646) and spring seat (644) will become loose and slide out of the bore.
Page 442 Return to Master Table of Contents Remove pilot piston (643) from bore. Figure 33 10. Disassemble feedback lever (611) assembly by separating side levers (612, 613). A 2 mm punch can be used to drive out pins (875) from levers. Figure 34 11.
Page 443: Cleaning And Inspection (Wear Limits And Tolerances)
Return to Master Table of Contents CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) Inspect all components and precision surfaces to confirm that they haven’t been worn NOTE: beyond service limits. Check the table below for dimensional specifications. All parts should be cleaned, air-dried and re-lubricated with clean, approved-type hydraulic fluid, before final reassembly or as the final step after the unit has been put back together again.
Page 444 Return to Master Table of Contents Service Standards for Replacing Worn Parts NOTE: When parts exceed the standard, replace them. When there is conspicuous surface damage, it is always safer to replace parts, whether standards are exceeded or not. Reference Standard Value Replacement Item...
Page 445: Reassembly
Return to Master Table of Contents REASSEMBLY PUMP REGULATOR REASSEMBLY Install O-ring (733) and compensator piston (621) to piston case (622). Insert assembly into compensator bore. Insert compensator piston rod (623) into piston bore. Figure 38 Assemble lever (612) to casing using pin (875).
Page 446 Return to Master Table of Contents Attach feedback lever (611) to spool (652) using pin (874). Figure 41 NOTE: The notched portion of spool should face down when mated into feedback lever for correct pin alignment.(Figure 42) 1, 2 - Feedback lever (611) 3 - Spool (652) HAOF220L Figure 42...
Page 447 Return to Master Table of Contents Assemble lever (613) onto feedback lever (611). NOTE: Make certain pin (875) at the lower portion of lever (613) is properly mated with groove in piston (643). Figure 44 Install O-rings (755) onto portion (614) and adjusting (615) plugs.
Page 448 Return to Master Table of Contents 10. Install O-ring (728) onto adjusting ring (645). Insert spring seat (644), pilot spring (646) and adjusting ring (645) into adjusting ring bore. Figure 47 11. Insert spring seat (624), outer spring (625) and inner spring (626) into Pf piston bore. Install O-rings (756, 763) into pilot piston lower cover (629).
Page 449: Main Pump Reassembly
Return to Master Table of Contents 14. Insert adjusting screw bushing (647) into pilot piston bore. Install O-rings (725, 730, 732, 734) into their proper locations. Mount pilot cover (641) onto regulator casing by using four hex-head allen-style bolts (436, 438). NOTE: Cover mounting bolts (436, 438) are uneven in length and...
Page 450 Return to Master Table of Contents Subassemble drive shaft (111 or 113) with roller bearing (123), bearing spacer (127) and snap ring (824). Install drive shaft into swash plate support (251). IMPORTANT Do not use excessive force, hammer blows or other mechanical advantage to re-install the drive shaft.
Page 451 Return to Master Table of Contents Assemble pistons (151) and shoes (152) and cylinder parts push plate (153), round bushing (156) and spacer (158) in cylinder (141) and install assembly in pump casing. Mount valve plate (313 or 314) on valve block (312) and verify valve plate inlet and outlet port alignment.
Page 452 Return to Master Table of Contents S0708320 Main Pump (With Regulator) Page 40...
Page 453 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MAIN CONTROL VALVE (KAYABA)S0709401K MODEL SERIAL NUMBER RANGE Solar 225LC-V 1001 and Up Solar 255LC-V 1001 and Up Solar 300LC-V 1001 and Up...
Page 454 TABLE OF CONTENTS General Description..................5 When All Spools are in Neutral ............... 5 Neutral Passage................5 Signal Passage ................8 Single Operation ................... 10 Travel Spool Shifting ..............10 Spare Spool Shifting ..............10 Swing Spool Shifting ..............12 Bucket Spool Shifting ..............
Page 455 Spool Assembly (17, Option) ............36 Spool Assembly (20, Arm Regeneration Release Valve ....36 Spacer Assembly (40)..............37 Plug Assembly (60)................ 37 Anti-draft Valve Assembly (67)............38 Relief Valve Assembly (70) ............39 Plug Assembly (90)................ 39 Specifications ..................39 Troubleshooting, Testing and Adjustment.............
Page 456 Instructions for Reassembly..............50 Handling Instructions of O-ring ............50 Handling Instructions for Spool ............50 Application Method of Loctite............51 Procedure of Subassembly ..............51 Reassembly of Spool Assembly (Main Spool) ....... 51 Reassembly of Arm 1 Para Turn Spool Assembly ......52 Reassembly of Antidrift Valve Assembly........
Page 457: When All Spools Are In Neutral
GENERAL DESCRIPTION WHEN ALL SPOOLS ARE IN NEUTRAL Neutral Passage Oil supplied to port (P1, Figure 1 and Figure 2) flows through neutral passage (L1) to low pressure relief valve orifice (Lc1), to tank passage (Ta) and returns to ports (T1, T2, and T3). Oil supplied to port (P1) flows through neutral passage (R1), to low pressure relief valve orifice (Rc1), then to tank passage (Ta), and returns to ports (T1, T2, and T3).
Page 458 Figure 1 S0709401K Main Control Valve (Kayaba) Page 6...
Page 459 Figure 2 Main Control Valve (Kayaba) S0709401K Page 7...
Page 460 Signal Passage Oil supplied to port (PP, Figure 2 and Figure 3) flows through orifice (Lc3) to port (PT) and simultaneously flows through land (Lc4), passage (5), and land (Rc3) into tank passage (Ta). The same oil supplied to port (PP), then flows through orifice (Lc5) into port (PA), and it also flows through passages (L4)(7) and (R4) to bucket spool land (Rc4) and then flows into drain passage (DR).
Page 461 Main Control Valve (Kayaba) S0709401K Page 9...
Page 462: Travel Spool Shifting
SINGLE OPERATION Travel Spool Shifting When shifting travel spool by increasing pressure of travel (section 1, Figure 4) pilot port (Pb1 (Pa1)), oil supplied to port (P1) flows through neutral passage (L1) to spool and flows to port (B1 (A1)). Return oil flows through port (A1 (B1)), to spool and returns to tank passage (Ta).
Page 463 Figure 4 Main Control Valve (Kayaba) S0709401K Page 11...
Page 464: Swing Spool Shifting
Swing Spool Shifting When shifting swing spool by increasing pressure of swing (section 3, Figure 5) pilot port (Pb3 (Pa3)), neutral port (L1) is closed. Oil supplied to port (P1) flows through parallel passage (L3), load check valve (S3-2), passage (S3-1) and spool, it then flows to port (B3 (A3)). Return oil flows through port (A3 (B3)) to spool and is returned to tank passage (Ta).
Page 465 Crowd When bucket spool is shifted by increasing pressure of bucket (section 7, Figure 6) pilot port (Pb7), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3), load check valve (S7-2), passage (S7-1), spool and into port (A7). Oil flows through port (B7) and one portion of the oil returns through spool to tank passage (Ta), and the other portion of oil flows through inside of spool, and pushes up load check, and then is combined at port (A7).
Page 466: Boom Spool Shifting
Boom Spool Shifting Neutral This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder. When in neutral, poppet (AD1, Figure 7) is closed by port (A8) pressure that is sent through passage (AD2), spool (AD3) to spring chamber (AD4).
Page 467 Boom Up (2 Speed Junction) When boom 1 spool is shifted by increasing pressure of boom 1 (section 8, Figure 8) pilot port (Pa8), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3) and load check valve (S8-2) to spool and flows into port (A8).
Page 468 Boom Down (Regeneration) When boom 1 (section 8, Figure 9) spool is shifted by increasing pressure of boom 1 pilot port (Pb8), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3) and load check valve (S8-2) to spool and flows into port (B8). When spool (AD3) of antidrift valve is shifted by increasing pressure of port (P2), poppet (AD1) is opened by decreasing of pressure of spring chamber (AD4), and return oil from port (A8) flows to tank passage.
Page 469: Arm Spool Shifting
Arm Spool Shifting Neutral This valve also works with an anti drift valve that is installed on rod side of the arm cylinder. When in neutral, poppet (AD1, Figure 10) is closed by port (A5) pressure that is sent through passage (AD2), spool (AD3) and to spring chamber (AD4).
Page 470 Arm Crowd (2 Speed Junction) When arm 1 spool is shifted by increasing pressure of arm 1 (section 5, Figure 11) pilot port (Pb5), oil supplied to port (P1) flows through neutral passage (L1), load check valve (S5-2), passage (S5-1) and spool into port (B5).
Page 471 Arm Crowd (Variable Regeneration) When crowding arm, after return oil from port (A5, Figure 12) flows through notch (a), one portion of the oil returns through fixed orifice (d), passage (e) and variable orifice (f) and to tank passage (Ta). The other portion of the oil flows through fixed orifice (b), regeneration check (c), and fixed orifice (i) in arm 1 spool, and joins in bridge passage (S5-1).
Page 472: Parallel Orifice For Arm
Arm Dump (2 Speed Junction) When arm 1 spool is shifted by increasing pressure of arm 1 (section 5, Figure 13) pilot port (Pa5), oil supplied to port (P1) flows through neutral passage (L1), load check valve (S5-2), passage (S5-1) and spool and into port (A5).
Page 473 Relief Valve Main Relief Valve Oil supplied to port (P1, Figure 15) flows through poppet (LP). Oil supplied to port (P2) flows through poppet (RP) and passage (3). They join at the main relief valve. The highest pressure of pump (P1) and (P2) is controlled by reaction of main relief valve.
Page 474 COMBINED OPERATION When the unit is in operation the control valve spools will function differently, depending upon the type of operation and work being done. The following spools are use for straight travel Section 6: Travel Section 1: Travel Section ST: Straight Travel When only traveling straight and no other functions are activated the following will occur: Straight travel Pump 1: 100% (Section 1: Travel)
Page 475 Figure 16 Main Control Valve (Kayaba) S0709401K Page 23...
Page 476: Bucket Combined Operation
Bucket Combined Operation A priority control valve is installed in bucket section 7, Figure 17). This valve controls oil flow entering into bucket when operating during a combined operation with travel, boom 1, and arm 2 sections, on P2 side. If pressure at port (Pi) is increased when operating bucket, piston (S7-6), piston (S7-5) and plug (S7-4) are pressed, and poppet assembly (S7-2) is seated on valve housing.
Page 477 ANTIDRIFT VALVE The antidrift valve is installed in cylinder port of arm rod (boom bottom) side to prevent arm (boom) cylinder from natural lowering. (As a representative arm side (A5) is shown.) Neutral condition (A5, Figure 18 port keeping condition) The holding pressure of A5 port is sent through passage (a, b, and c), and into spring chamber (d) of poppet (1).
Page 478: Main Relief Valve
MAIN RELIEF VALVE The main relief valve is located between neutral oil passage (HP, Figure 21) and low pressure oil passage (LP). Pressurized oil flows into neutral oil passage (HP) through orifice in the main poppet (C) to fill internal cavity (D).
Page 479: Overload Relief Valve (69, Total: Six Places)
OVERLOAD RELIEF VALVE (69, TOTAL: SIX PLACES) The overload relief valve is located between cylinder port (HP) and low pressure oil passage (LP). Pressurized oil at cylinder port (HP), flows through an orifice in piston (C), to fill internal cavity (G).
Page 480: Low Pressure Relief Valve (70, Total: Two Places)
Sucking operation An anti void unit is installed in cylinder port (HP) to prevent the development of cavitation. If pressure at cylinder port (HP) becomes lower than that of oil passage (LP), sleeve (K) moves so that oil is supplied from the low pressure oil passage (LP) to cylinder port (HP) to eliminate cavitation.
Page 481: Relief Operation
Relief Operation If excessive oil flows into passage (L2 (R2)), pressure generated at passage (L2 (R2)) by orifice (Lc1 (Rc1)) goes to back chamber of poppet, and poppet operates by the difference of pressurized area between passage and back chamber. By operation of this poppet, oil flows from passage through plug and drill hole to tank passage (Ta).
Page 482 PARTS LIST 89,88 75 69 77,81 VIEW X ARS4580L Figure 32 S0709401K Main Control Valve (Kayaba) Page 30...
Page 483 SECTION A1-A1 X - 41 SECTION A-A Y - 42 SECTION L-L 61 62 SECTION B-B X - 41 Y - 42 SECTION K-K ARS4570L Figure 33 Main Control Valve (Kayaba) S0709401K Page 31...
Page 484 38 39 40 22 2 SECTION C-C SECTION D-D SECTION E-E SECTION G-G SECTION F-F SECTION H-H DETAIL F1 53 55 SECTION J-J SECTION I-I ARS4590L Figure 34 S0709401K Main Control Valve (Kayaba) Page 32...
Page 485 Reference Reference Description Description Number Number Valve Housing O-ring Spool Assembly (Arm2) Spring Spool Assembly (Boom1) Poppet Spool Assembly (Bucket) Steel Ball Spool Assembly (Travel) Poppet Spool Assembly Flange (Straight Travel) Spacer O-ring O-ring Backup Ring Spacer Valve Housing Plug Assembly Spool Assembly (Arm1) Plug Spool Assembly (Boom2)
Page 486: Spool Assembly (2, Arm 2)
Spool Assembly (2, Arm 2) Reference Description Number Spool Spring Seat Spring Spool End Figure 35 Spool Assembly (3, Boom1) Reference Description Number Spool Spring Seat Spring Spool End Plug Poppet Spring Figure 36 O-ring Backup Ring Spool Assembly (4, Bucket) Reference Description Number...
Page 487: Spool Assembly (5, Travel)
Spool Assembly (5, Travel) Reference Description Number Spool Spring Seat Spring Spool End Figure 38 Spool Assembly (6, Straight Travel) Reference Description Number Spool Spring Seat Spring Spool End Figure 39 Spool Assembly (14, Arm1) Reference Description Number Spool Spring Seat Spring Spool End Plug...
Page 488: Spool Assembly (15, Boom 2)
Spool Assembly (15, Boom 2) Reference Description Number Spool Spring Seat Spring Spool End Figure 41 Spool Assembly (16, Swing) Reference Description Number Spool Spring Seat Spring Spool End Figure 42 Spool Assembly (17, Option) Reference Description Number Spool Spring Seat Spring Spool End Figure 43...
Page 489: Spacer Assembly (40)
Spacer Assembly (40) Reference Description Number Spacer O-ring Backup Ring O-ring Figure 45 Plug Assembly (60) Reference Description Number Plug O-ring O-ring O-ring Figure 46 Main Control Valve (Kayaba) S0709401K Page 37...
Page 490: Anti-Draft Valve Assembly (67)
Anti-draft Valve Assembly (67) Figure 47 Reference Reference Description Description Number Number Body O-ring Poppet Backup Ring Plug Backup Ring Piston O-ring Spool Plug Assembly Sleeve Plug Assembly Spring Spring Seat Spring Steel Ball O-ring S0709401K Main Control Valve (Kayaba) Page 38...
Page 491: Relief Valve Assembly (70)
Relief Valve Assembly (70) Reference Description Number Plug Spring Poppet Sleeve O-ring O-ring Figure 48 Plug Assembly (90) Reference Description Number Plug O-ring O-ring Backup Ring Figure 49 SPECIFICATIONS Control Valve Specification Rated Flow 270 liter/min (71 gal/min) 50 liter/min (13 gal/min) at Neutral Max.
Page 492: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT GENERAL Problem Possible Cause Remedy Spool does not stroke. Hydraulic oil excessively hot. Remove blockage in oil piping. Hydraulic oil contaminated. Change oil and clean oil passages. Over tightened piping port fittings. Check torque. Valve housing deformed when Remove assembling bolts and assembling.
Page 493: Adjustment Of Relief Valve
RELIEF VALVE Problem Possible Cause Remedy Pressure does not rise. Stuck main poppet, sleeve or pilot Replace relief valve. poppet opened or dirt in seat part. Relief pressure unstable Seat parts of pilot poppet damaged. Piston or main poppet stuck. Relief pressure is Seat parts worn due to dust.
Page 494: Over Load Relief Valve
Loosen lock nut (4) and turn adjusting plug (6) clockwise to raise relief pressure of preceding step. Turn adjusting plug (6) counterclockwise to lower relief pressure. One turn varies pressure by approximately 28.4 MPa [9289.59 kg/cm² (4,120 psi)]. Tighten lock nut (4) after pressure has been adjusted.
Page 495: Disassembly
DISASSEMBLY GENERAL INSTRUCTIONS FOR DISASSEMBLY Shut down engine when pressure of actuator is not indicated. It is dangerous to disassemble control valve while it is under pressure. High pressure oil can squirt out or components can spring out. When partially disassembling control valve that is on machine, be careful to follow the following caution.
Page 496 Disassembly of spool IMPORTANT Work with spool gripped in vise with wood (see Figure 50) not to scratch outside diameter of spool. Because Loctite applied threaded portion of spool end, heat outside surface spool with industrial drier to release Loctite. Figure 50 Heat spool until spool end is easily loosened, and remove immediately...
Page 497: Disassembly Of Arm Regeneration Release Valve Part
Disassembly of Arm Regeneration Release Valve Part Small parts in assembly are indicated to (parental number - son number). CAUTION! When removing a plug, when pressure is not fully released, or bucket is not lowered to ground, is very dangerous. A part in the valve may spring out and drop the bucket at the same time. Always lower bucket to ground and fully release pressure before disassembling.
Page 498: Disassembly Of Antidrift Valve
14. Remove spring (48) and poppet (49) from valve housing. 15. Remove socket head bolt (101, four places, width across flats: 8 mm) from body (96, one places). 16. Remove body (96) from valve housing. Remove sleeve (99), piston (97), spring (98), poppet assembly (100), backup ring (103), and O-ring (104).
Page 499: Disassembly Of Relief Valve
Disassembly of Relief Valve CAUTION! Removing relief valve, when pressure is not fully released, or bucket is not lowered to ground, is very dangerous. A part in the valve may spring out and drop the bucket at the same time. Always lower bucket to ground and fully release pressure before disassembling.
Page 500: Disassembly Of Main Relief Valve
Disassembly of Main Relief Valve This relief valve should be replaced as an assembly. When replacing it, remove plug (1, width across flats: 32 mm), and O-ring (2). If oil is leaking from nut (4), remove nut (4) and plug (1), and replace O-ring (3). If oil is leaking from nut (7), remove nut (7) and plug (8), and replace O-ring (3).
Page 501: Disassembly Of Low Pressure Relief Valve
This relief valve should be replaced as an assembly. When replacing it, Remove cap (1, width across flats: 31.75 mm) and O-ring (2). If oil is leaking from adjusting kit (3), remove adjusting kit (3), and replace O-ring (4). IMPORTANT When disassembling adjuster kit, be careful not to let parts spring out or lose poppet because of spring force.
Page 502: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) CLEANING Clean all parts thoroughly using a suitable cleaning fluid and dry them with moisture free compressed air. Put them on a clean paper or a vinyl for inspection. INSPECTION Inspect all parts for scratches, notches and other defects. Inspect load check seat surface of valve housing for scratches, scores, dirt, notches and corrosion.
Page 503: Application Method Of Loctite
Application Method of Loctite Male and female screw threads of parts which need to adhere. CAUTION! When working with Loctite, work in a place that is well ventilated. Cleaning (removal of grease) Remove grease with steam, acetate, etc. or clean with an alkali cleanser. Dry Loctite surface with moisture free air or naturally.
Page 504: Reassembly Of Arm 1 Para Turn Spool Assembly
Reassembly of Arm 1 Para Turn Spool Assembly Apply Loctite to threaded portion of spool (19) and install spring seat (20), spring (21) and spool end (22). After gripping spool in vise with wood (that is used when disassembling it), tighten spool end. Tightening torque: 1.94 - 2.24 kg•m (14 - 16 ft lb).
Page 505: Reassembly Procedure Of Control Valve Body
REASSEMBLY PROCEDURE OF CONTROL VALVE BODY Reassembly of Relief Valve CAUTION! When reassembling safety valve, securely tighten plug that is installed in body. Do not loosen adjusting plug for pressure setting or lock nut. Adjusting plug for pressure setting is dangerous because pressure setting will be changed which may result in a dangerous situation.
Page 506: Reassembly Of Antidrift Valve
Install O-ring (36) in valve housing and fasten body by means of socket head bolt (101). Tightening torque: 5.91 - 6.53 kg•m (43 - 47 ft lb) Insert poppet (32) and spring (33) in arm 1 para turn part (section C-C). Install plug assembly (72) with O-ring.
Page 507: Reassembly Of Main Spool
Reassembly of Main Spool Install O-ring on mating surface of valve housing cap. Install spool of subassembly condition (2-6, 14-17) in same positions that they were remove from during disassembly IMPORTANT Align spool with hole and insert it slowly. After inserting spool, check to see if it slides easily. If spool is inserted when it is in a poor operating condition with a scratch, it can cause a malfunction of the spool.
Page 508 Figure 54 S0709401K Main Control Valve (Kayaba) Page 56...
Page 509: Reassembly Of Overload Relief Valve
Reassembly of Overload Relief Valve Check if there is dirt and paint chips around cap (1). Replace O-ring with new one. Clean installation portion of relief valve and valve housing. Install relief valve and tighten cap (1). Torque: 78 - 88N*M [7.95 - 8.97 kg•m (58 - 65 ft lb)].
Page 510: Installation
INSTALLATION Be careful not to apply stress on control valve when attaching piping and hoses. Unnecessary stress may cause spools to bind and the control valve from functioning properly. Tighten the assembling bolts alternately and evenly to the specified torque. If welding procedures are being performed near the control valve, the valve could damaged by weld spatter and heat.
Page 511 Solar 140W-V 1001 and Up Solar 160W-V 1001 and Up Solar 180W-V 1001 and Up Solar 210W-V 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 255LC-V 1001 and Up Solar 300LC-V 1001 and Up...
Page 512 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Structure ..................3 Function ................... 3 Parts List ....................4 Specifications ..................5 Torques .................... 5 Performance..................6 Removal ......................6 Disassembly ....................9 Cleaning and Inspection (Wear Limits and Tolerances) ....... 13 Reassembly....................
Page 513: Structure
GENERAL DESCRIPTION THEORY OF OPERATION Structure The remote control valve contains four push rods, spring holders, spools and return springs, which are located in the valve casing. The valve works as a pressure reduction valve. The housing has six ports, which include input port P, tank port T, and four secondary pressure ports. The electric horn switch is installed in the valve handle.
Page 514 PARTS LIST ARS2260L Figure 1 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 4...
Page 515: Specifications
Reference Reference Description Description Number Number Case O-ring Plug Rod Seal Plug Plate O-ring Boot O-ring Joint Assembly Spool Swash Plate Shim Hex Nut Spring Handle Bar Spring Seat Spring Boot Stopper Spring Pin Stopper Handle Assembly Spring Bushing Push Rod Terminal Spring Seal Wire...
Page 516: Performance
Performance ARS2270L Figure 2 REMOVAL Park on firm and level ground. Lower front attachment (bucket) to the ground. Shut down engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while Figure 3 performing maintenance, extreme care. Always have one person in the cab at all times.
Page 517 11. Remove four bolts and washers (2, Figure 4) and cover (1). 12. Pull cap (5, Figure 4) out and remove two screws, two bolts and washers (6) and cover (3). 13. Remove three screws, one bolt and washers (7, Figure 4) and cover (4). ARS2910L Figure 4 14.
Page 518 19. Remove four bolts (3, Figure 7) and cover (2), and pull remote control valve R.H. (1) out. 20. Tag and disconnect hoses from remote control valve R.H. (1, Figure 7). Plug and hoses ports prevent contamination from entering hydraulic system or component.
Page 519: Disassembly
DISASSEMBLY Lift up the boot (28) and pull the switch cord through the hole in the case (1). Figure 8 Figure 9 Loosen nut (27) from hex nut (25) and remove handle assembly (30). Figure 10 Pilot Control Valve (Work Lever / Joystick) S0709451K Page 9...
Page 520 Remove hex nut (25) and swash plate (24). Figure 11 Remove joint (23) from case (1). Figure 12 Remove plate (21). Figure 13 Press spring (10) and remove plug (18). Figure 14 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 10...
Page 521 Remove pressure reduction valve (6, 7, 8, 9, 11) and spring (10). IMPORTANT Mark valve disassembling position (port). Figure 15 Remove plug (3) and four plugs (2). Figure 16 Remove stopper (11) from pressure reduction valve (6, 7, 8, 9, 11). Figure 17 10.
Page 522 11. Remove push rod (14) and plug (18). Figure 19 12. Remove O-ring (19) from plug (18). Figure 20 13. Remove seal (20) from plug (18). Figure 21 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 12...
Page 523: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Clean all parts and dry them with compressed air. Keep all parts free from dust. Lubricate all moving parts. Pilot Control Valve (Work Lever / Joystick) S0709451K Page 13...
Page 524: Reassembly
REASSEMBLY Tighten plug (3) slowly. NOTE: Tightening torque: 350 kg•cm (25 ft lb). Tighten four plugs (2). Use Loctite #592 pipe sealant NOTE: on plugs. NOTE: Tightening torque 150 kg•cm (11 ft lb). Figure 22 Install shim (7), spring (8), spring seat (9), and spool (6).
Page 525 Install spring (10) in case (1) and pressure reducing valve assembly (6, 7, 8, 9, 11). Figure 25 Install seal (20) on plug (18). Figure 26 Install O-ring (19) on plug (18). Figure 27 Install push rod (14) on plug (18). Figure 28 Pilot Control Valve (Work Lever / Joystick) S0709451K...
Page 526 Install spring (13) on stopper (12). Figure 29 Position stopper (12) and spring (13) on pressure reducing valve. Figure 30 10. Install plug (18) in case (1). Figure 31 11. Install plate (21) and tighten joint (23). Figure 32 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 16...
Page 527 12. Install swash plate (24) on joint (23). Figure 33 13. Install hex nut (25) and tighten swash plate (24). Tightening torque 1,240 kg•cm NOTE: (90 ft lb). Figure 34 14. Pull cord and tube out through hole of hex nut (25).
Page 528 16. Grease joint (23), swash plate (24) and push rod (14). Figure 37 17. Install boot (28). Figure 38 S0709451K Pilot Control Valve (Work Lever / Joystick) Page 18...
Page 529: Installation
INSTALLATION Connect hoses as tagged during removal to remote control valve R.H. (1, Figure 39). Position remote control valve R.H. (1, Figure 39) on control stand and install four bolts and washers (3) and cover (2). ARS2920L Figure 39 Install two screws, two bolts and washers (7 and 8, Figure 40) and cover (4).
Page 530: Start-Up Procedures
Install three screws, one bolts and washers (7, Figure 42), and cover (4). Install two screws, two bolts and washers (6, Figure 42), and cover (3). Push cap (5) into cover (3). 10. Install four bolts and washers (2, Figure 42), and cover (1).
Page 531 Remember, that ultimately safety is your own personal responsibility. TRAVEL CONTROL VALVE (WITH DAMPER)S0709820K MODEL SERIAL NUMBER RANGE Solar 75-V 1001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 255LC-V 1001 and Up Solar 300LC-V...
Page 532 TABLE OF CONTENTS General Description..................3 Theory of Operation ................3 Pressure Reducing Valve..............3 Operating Theory of Damper Mechanism........5 Parts List ....................6 Specification.................... 7 Torque ..................... 7 Troubleshooting, Testing and Adjustment............8 Removal ......................9 Disassembly ....................11 Cleaning and Inspection (Wear Limits and Tolerances) .......
Page 533: General Description
GENERAL DESCRIPTION THEORY OF OPERATION The damper valve is divided into two areas of operation. There is the pressure reducing valve (a) and the damper mechanism (b). The following hydraulic circuit is an example of a remotely located control valve. ARS1810L Figure 1 Reference...
Page 534 primary pressure is transmitted to operating port as secondary pressure equivalent to control spring force compressed by spool. Full Operating Condition If pedal is moved to a maximum, bottom part of push rod presses spool seat to a maximum, and compresses control spring to a maximum.
Page 535: Operating Theory Of Damper Mechanism
Operating Theory of Damper Mechanism Operation When Operating Lever When pushing pedal, pushing force pushing push rod and spool presses cylinder, return spring and hydraulic oil in cylinder is compressed, piston coming down with push rod compresses vibration prevention chamber of lower part, oil of vibration prevention chamber of lower part is flowed through orifice to oil pressure vibration prevention chamber of upper part...
Page 536 PARTS LIST ARS1850L Figure 5 ARS1860L Figure 6 S0709820K Travel Control Valve (With Damper) Page 6...
Page 537: Specification
Reference Reference Description Description Number Number Body (1) Snap Ring Body (2) Plug Plug O-ring Plug Rod Seal Spring Seat Dust Deal Spring Cover Spring Seat Wrench Bolt Spool Stopper Bushing Spring Camshaft Rod Guide Set Screw O-ring Set Screw Snap Ring Hex Nut Push Rod...
Page 538: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT At times pinpointing the source of the problem may be difficult. The following table lists some possible problems, causes and remedies. Refer to this table for possible causes and remedies to help in correcting problems. The table only lists general problems, causes and remedies. Often the problem is not caused by the failure of a single part but, may be the result of a combination of problems from related parts and their components.
Page 539: Removal
REMOVAL Park on firm and level ground. Lower front attachment (bucket) to the ground. Shut down engine. Set safety lever on "RELEASED" position. Turn starter switch "ON." WARNING! engine must while Figure 7 performing maintenance, extreme care. Always have one person in the cab at all times.
Page 540 13. Remove rubber boots (1, Figure 9). 14. Remove four bolts and washers (2, Figure 9), pedal brackets (3) with levers. ARS2951L Figure 9 15. Remove four bolts and washers (2, Figure 10), and pedal valve (1). ARS2940L Figure 10 S0709820K Travel Control Valve (With Damper) Page 10...
Page 541: Disassembly
DISASSEMBLY IMPORTANT Prepare a clean, well lit, stable work bench where disassembly can be performed. Prepare the necessary tools, materials and a container in which disassembled parts can be stored. All precision parts must be handled with great care and all parts must be reassembled to their original position.
Page 542 Remove cam shaft (29) and bushing (28) from cam (27). Figure 13 Figure 14 Remove cam (27) from cover (25). Figure 15 Remove wrench bolt (26) by using tool. Figure 16 S0709820K Travel Control Valve (With Damper) Page 12...
Page 543 Remove cover (25) from body (1 and 2). Figure 17 Remove plug assembly (21 - 24) with push rod assembly (14 - 20). Figure 18 Remove snap ring (13). IMPORTANT Be careful not to spring rod guide (11). Figure 19 Remove rod guide (11).
Page 544 10. Remove spool assembly (5 - 9). Figure 21 11. Remove spring (10). Figure 22 12. Remove stopper (9), spring (6) and spring seat (7) from spool assembly (5 - 9). Figure 23 Figure 24 S0709820K Travel Control Valve (With Damper) Page 14...
Page 545 13. Remove plug assembly (21 - 24) from push rod assembly (14 - 20). Figure 25 14. Remove seal (23 and 24) from plug (21). Figure 26 15. Remove O-ring (22) from plug (21). Figure 27 16. Remove seal (16) from push rod (14). Figure 28 Travel Control Valve (With Damper) S0709820K...
Page 546 17. Remove snap ring (20) from push rod (14). Figure 29 18. Remove plate (19) from push rod (14). Figure 30 19. Remove spring (18) from push rod (14). Figure 31 20. Remove steel ball (17) from push rod (14). Figure 32 S0709820K Travel Control Valve (With Damper)
Page 547: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) Cleaning disassembled parts. Place parts in a container with cleaning solvent. • Allow all parts to soak in solvent until grease and other foreign substances have dissolved and become loose, before cleaning. • Contaminated cleaning solvent may cause damage to parts and may cause poor equipment performance.
Page 548: Assembly
ASSEMBLY IMPORTANT Prepare a clean, well lit, stable work bench where assembly can be performed. Prepare the tools and materials necessary for the assembly process. Inspect all parts, making sure that all parts are free from dirt and damage. If minor surface scratches are visible, use a very fine crocus cloth to clean it off.
Page 549 Clean plug (21) with thinner, inspect burrs and install rod seal (23) and dust seal (24) on both sides of plug by using tool. Figure 34 Install O-ring (22) on outside diameter of plug (21) and check plug whether it is abnormal.
Page 550 Install steel ball (17), spring (18), plate (19) and spring pin (15) on push rod (14). Figure 38 Install snap ring (20) on push rod assembly (14 - 19). Figure 39 Install seal (16) on push rod (14). Figure 40 10.
Page 551 11. Install plug assembly (21 - 24) with push rod assembly (14 - 20) on body (1 and 2). Figure 42 12. Install cover (25) on the upside of body (1 and 2). Figure 43 13. Tighten wrench bolt (26). Tightening torque: 88 kg•cm NOTE: (7 ft lb).
Page 552 15. Tighten set screw (30) on center of cam (27) not to loose cam (27) and cam shaft (29) by using wrench. Tightening torque: 88 kg•cm NOTE: (7 ft lb). Figure 46 16. One side holds L wrench and the other side holds spanner and tighten set screw (31) and hex nut (32) attached to cam (27) not to loose.
Page 553: Installation
INSTALLATION Position pedal valve (1, Figure 49) on cabin floor plate and install four bolts and washers (2). ARS2940L Figure 49 Install pedal brackets (3) and levers (4, Figure 50) on pedal valve and install four bolts and washers (2). Install rubber boots (1, Figure 50).
Page 554: Start-Up Procedures
START-UP PROCEDURES Start engine and set throttle at "LOW IDLE." Set safety lever on "UNLOCK" position. HAOB290L Figure 52 Slowly push and pull both travel lever about five times without a load to vent air from pilot lines. HAOB903L Figure 53 S0709820K Travel Control Valve (With Damper) Page 24...
Page 555 Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. HYDRAULIC SCHEMATIC (SOLAR 225LC-V/225NLC-V)S0792105K MODEL SERIAL NUMBER RANGE Solar 225LC-V...
Page 556 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Solar 225LC-V....................4 Solar 225NLC-V ..................... 6 S0792105K Hydraulic Schematic (Solar 225LC-V/225NLC-V) Page 2...
Page 557 Schematic(s) presented in this section are laid out on facing pages. An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together to make a complete schematic. Figure 1 Hydraulic Schematic (Solar 225LC-V/225NLC-V) S0792105K Page 3...
Page 558 Return to Master Table of Contents SOLAR 225LC-V Figure 2 S0792105K Hydraulic Schematic (Solar 225LC-V/225NLC-V) Page 4...
Page 559 Return to Master Table of Contents SOLAR 225LC-V Hydraulic Schematic (Solar 225LC-V/225NLC-V) S0792105K Page 5...
Page 560 Return to Master Table of Contents SOLAR 225NLC-V Figure 3 S0792105K Hydraulic Schematic (Solar 225LC-V/225NLC-V) Page 6...
Page 561 Return to Master Table of Contents SOLAR 225NLC-V Hydraulic Schematic (Solar 225LC-V/225NLC-V) S0792105K Page 7...
Page 562 Return to Master Table of Contents S0792105K Hydraulic Schematic (Solar 225LC-V/225NLC-V) Page 8...
Page 563 1ELECTRICAL SYSTEM...
Page 565 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. ELECTRICAL SYSTEMS0802220K MODEL SERIAL NUMBER RANGE Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Solar 255LC-V 1001 and Up...
Page 566 TABLE OF CONTENTS Troubleshooting - Electrical System ............... 4 Overview ......................5 Electric Supply System .................. 6 Engine Starting Circuit ................... 7 Operation During Start Process .............. 7 Operation After Start Process ..............8 Engine Preheating System................9 Engine Stop System..................10 Charging System..................
Page 567 Operation ....................45 Power Mode Control - Circuit Diagram ............48 Work Mode Control ..................50 Operation ....................51 Work Mode Control - Circuit Diagram ............52 Engine Control System................. 53 Engine Control Motor ................... 55 Engine Control Dial ..................56 Engine Control Circuit Diagram..............
Page 568: Troubleshooting - Electrical System
TROUBLESHOOTING - ELECTRICAL SYSTEM Problem Possible Causes Remedies Battery will not stay Internal battery short. Replace battery. charged. Short in other part of circuit. Repair wiring or replace component. Battery does not Battery worn out or defective. Replace battery. charge. Defective alternator or belt.
Page 569: Overview
OVERVIEW The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24 volts with the exception of the car stereo and the air-conditioning control actuator. The system contains two 12 volt batteries connected in series and a three phase AC generator with a rectifier. The electric wiring used in the system is easily identifiable by the insulator color.
Page 570: Electric Supply System
ELECTRIC SUPPLY SYSTEM The electric power circuit supplies electric current to each electric component. It consists of a battery, battery relay, starter switch, circuit breaker, fusible link and fuse box. The negative terminal of the battery is grounded to the vehicle body. Even when the starter switch (5) is in the "OFF"...
Page 571: Engine Starting Circuit
ENGINE STARTING CIRCUIT OPERATION DURING START PROCESS When the starter switch is turned to the start position, the "S" and "E" terminals of the starter controller (7) are connected. At this time the contacts in the starter relay (8) are closed by the current flow from the battery (1, Figure 2) →...
Page 572: Operation After Start Process
OPERATION AFTER START PROCESS Once the engine has been started, the belt driven alternator (10) generates a current. The output generated by the alternator (10) is a square wave pulse voltage through the "P" terminal and the frequency of the pulse voltage is proportional to the rotation of the alternator. The starter controller (7) monitors the frequency of the output current.
Page 573: Engine Preheating System
ENGINE PREHEATING SYSTEM An air heater (8) device is installed in the intake manifold of the engine. When the starter switch (5) is turned to the "Preheat" position, the current flows from the battery (1) → fusible link (3) → "B" terminal of starter switch (5) → "R1" terminal of starter switch (5) → "C" terminal of preheat relay (7) →...
Page 574: Engine Stop System
ENGINE STOP SYSTEM The engine stop circuit consists of a starter switch (5), engine stop motor (9) and engine stop relay (8). There are two modes of operation - engine running and engine stop. The worm gear built into the motor reduces the engine stop motor’s speed and changes motor’s revolution to reciprocation.
Page 575 Operation In Engine Running Mode When the starter switch (3) is turned to the "ON" position, the contact points "30" and "87" of the engine stop relay (5) are closed due to current flowing from the battery (1) → fusible link (2) → "B" terminal of starter switch (3) →...
Page 576 Operation In Engine Stop Mode When the starter switch (3) is in the "OFF" position, the electric current flow to the coil of the engine stop relay (5) is shut off. As a result, the "30" and "87a" contact point of the engine stop relay are connected and current is supplied to the engine stop motor from the battery (1) →...
Page 577: Charging System
CHARGING SYSTEM When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this condition the alternator (7) starts charging.
Page 578: Monitoring System
MONITORING SYSTEM ARS0090L Figure 9 Reference Reference Description Description Number Number Instrument Panel Pump Discharge Pressure Sensor Battery Engine Coolant Engine Speed Sensor Temperature Sensor Return Filter Switch Fuel Sensor Pilot Filter Switch Air Cleaner Indicator e-EPOS Controller Engine Oil Pressure Switch Alternator Light Switch Warning Buzzer...
Page 579: Instrument Panel
INSTRUMENT PANEL ARO0100L Figure 10 Gauges Warning Lights Mode Select Switches 1. Engine Coolant 6. Charge Warning Light 12. Power Mode Select Switch Temperature (Up Arrow Button) 7. Engine Oil Pressure Gauge Warning Light 13. Trenching Mode Select 2. Fuel Gauge Switch (Down Arrow Button) 8.
Page 580: Monitoring System Schematic
MONITORING SYSTEM SCHEMATIC R1 B ILLUMINATION CN4-1 CN4-2 CN4-3 CN4-4 WARNING LAMP L1 : BATTERY CHARGE L2 : ENG. OIL PRESS CN4-5 L3 : WATER TEMP. CN4-6 L4 : PREHEAT L5 : WORK LAMP L6 : OVER LOAD CN4-7 CN4-8 LCD DISPLAY PANEL WATER TEMPERATURE FUEL LEVEL...
Page 581 Reference Reference Description Description Number Number Instrument Panel Engine Oil Pressure Switch Pilot Buzzer Air Cleaner Indicator Light Switch Return Filter Switch Start Switch Pilot Filter Switch Front Pump Pressure Alternator Sensor e-EPOS Controller Rear Pump Pressure Battery Sensor Battery Relay Engine Coolant Circuit Breaker Temperature Sensor...
Page 582: Operation
OPERATION INSTRUMENTS Sensor Specification Function Display Input Input Specification Terminal 41°C (106°F) → 1,372 ohms GREEN 61°C (142°F) → 855 ohms Engine CN4-5 WHITE 102°C (216°F)→ 160 ohms 107°C Coolant CN4-6 105°C (221°F) → 147 Temperature 105°C ohms 107°C (225°F) → 128 61°C 41°C ohms...
Page 583 Sensor Specification Function Display Input Input Specification Terminal 02/05 [MO] 11:30A Main pump CN4-1 FRONT PUMP discharge pressure CN4-2 (front pump) V = 0.00816 x P + 1.0 V: Sensor output voltage ARO0190L P: Displayed pressure (Bar) 02/05 [MO] 11:30A Main pump discharge CN4-3...
Page 584: Warning And Indicator Lights
WARNING AND INDICATOR LIGHTS Input Description Symbol Operation Remarks Terminal Lights up when not charging [R(I) Lights up before terminal output engine start up and Charge CN2 - 1 drops below 12±1V] shut off once engine and over charging is running. [R(I) terminal output increase over 33 V].
Page 585 Input Description Symbol Operation Remarks Terminal Warning buzzer will sound. Lights up when 2.68 V (S225LC-V) lifting load exceeds 2.80 V (S225NLC-V) limit. (When the over load warning 2.80 V (S255LC-V) CN1 - 3 Overload switch is turned (Optional) 2.80 V (S300LC-V) CN1 - 4 "ON,"...
Page 586: Initial Operation
INITIAL OPERATION Item Input (Terminal) Output (Operation and initial setting mode) Initial When battery voltage is input • All LCD, LED and warning lights are turned on Operation to CN7 - 9 (starter switch is and turned off after about 2 seconds. turned from "OFF"...
Page 587: Mode Select Switch
MODE SELECT SWITCH Power Mode / Trenching Mode Switch e-EPOS Output Output Check Pump Discharge (Operation Operation Mode Volume Control Swing Priority 7-Segment mode display Valve Current Solenoid Valve Display LED) (mA) Power Power Mode Variable Output Mode Standard Mode Work Mode Trenching Mode Digging Mode...
Page 588: Graphic Information Area Display
GRAPHIC INFORMATION AREA DISPLAY OVERVIEW Many kinds of condition of machine are displayed on the letter information display department. The information display department is divided into two menus. One is main menu for user and the other is special menu for specialist. These menus can be moved from normal display mode by the combination of select buttons.
Page 589: Main Menus For The Graphic Display Area
MAIN MENUS FOR THE GRAPHIC DISPLAY AREA Main menu: Language setting, Time setting, Filter/Oil information Special menu: Information of machine status, failure information, Information of machine operation. MENU SELECTION BUTTONS Up Arrow Button ( , 1 on Figure 12): Move the cursor to up, left and previous screen. Down Arrow Button ( , 2 on Figure 12): Move the cursor to down, right and next screen.
Page 590: Main Menu
MAIN MENU When the "ESC" button is pressed for more than 3 seconds, the main menu screen is displayed. Main menu offers three sub-menus (language M A I N M E N U setting, time setting, or filter/oil information) to the operator.
Page 591: Filter/Oil Information
FILTER/OIL INFORMATION This mode displays total operating hours of filters and oils. After changing the filter and oil, reset the operating hour and then the operating hours until the next service interval can be easily 1.Fuel Filter checked. Hrs: 0232 Reset: ARO0400L Figure 16 Menu Display Order and Icon Explanation...
Page 592: Special Menu
SPECIAL MENU In this menu, many types of operating conditions and functions can be accessed and disp[layed, including the e-EPOS controller. This menu is mainly used for machine testing and failure diagnostics. The special menu offers three sub-menus; Machine status. Failure information.
Page 593: Special Menu Selections
Special Menu Screen NOTE: Displayed language on the special menu screen consists SPECIAL MENU of Korean and English. achine Info If any language except for Korean selected during Failure Info language selection mode of main menu, only English will be Operating Hrs displayed on special menu screen.
Page 594 Contents of Machine Status Display Item of Machine State Information Display Remarks 1. EPPR Current "mA" EPPR valve current 2. Dial Voltage "mV" Dial voltage 3. TPS Voltage "mV" TPS voltage 1. Alternator 8. Pressure (Px) Input status delivered from 2.
Page 595 Display Example: Machine Status Information EPPR Valve Current EPPR CURRENT ARS0870L Figure 24 Dial Voltage DIAL VOLTAGE 2089 ARS0880L Figure 25 TPS Voltage Output voltage of potentiometer built into engine control motor. TPS VOLTAGE 2095 ARS0890L Figure 26 Electrical System S0802220K Page 31...
Page 596 Input Status "YES" or "NO" for alternator’s generation (Generation: "ON"/ Nongeneration: M AC H I N E I N F O "OFF"), selection status of select switch (Selection: "ON"/ Nonselection: "OFF") Input State and the other statuses of on/off type sensors.
Page 597 Output Status: Output status of solenoid valves and spare valves are displayed. (Output: "ON"/ Nonoutput: "OFF") Relief Pess Up Spare Out 1 : OFF : OFF High Speed Spare Out 2 : ON : ON Swing Priority : OFF ARS0920L Figure 29 Hydraulic Oil Temperature HYD.
Page 598 Boom Pressure (Optional) On machine with OWD (Overload Warning Device), detected pressure from boom BOOM PRESSURE cylinder is displayed with numeric values (Unit: Bar). The relative equation between the, output voltage of pressure sensor, and the pressure of boom cylinder, is as follows. •...
Page 599 Current failure information Current status of failure is displayed (Failure code, failure contents). REALTIME FAIL When a number of failures are produced, failure information can be C O D E : 1 2 checked by using "PRV" ( , 1 on Press up s/v open Figure 18) or "NXT"...
Page 600 Failure record deletion This mode is used to delete the memorized record of past failure. If FA I L U R E L O G this mode is selected, all records will be deleted. A l l F a i l L o g When "YES"...
Page 601 Display Contents of Failure Information Code Reset Code Contents Cause Operation Procedure Communication error Automatic reset between e-EPOS Communication Err!! * Note when problem is controller and instrument corrected panel After correcting EPPR v/v short Short Circuit problem, turn Press Up s/v short Short Circuit Cut off output start switch...
Page 602 Reset Code Contents Cause Operation Procedure EPPR v/v open Open Circuit Press Up s/v open Open Circuit Swing pri. s/v open Open Circuit Output voltage Over Dial Voltage Err (H) 4.6 ±0.2 V Output voltage Over Dial Voltage Err (L) 4.6 ±0.2 V Output voltage Over Cut off EPPR v/...
Page 603 • Work mode: Digging mode • Auto idle: "ON" (Selection state) The above mentioned two statuses are applicable to normal condition of an e-EPOS controller. Under the abnormal condition of an e-EPOS controller, communication cable or instrument panel failure, "Failure code: 82" can be generated. Information of Machine Operation Accumulated operation hour of each mode and status is displayed.
Page 604 Information contents of operation hour Item Information Contents Detection Method Power mode switch (Instrument panel) - Operation hours used power mode Power Mode "ON" status and Alternator signal are displayed. (CN2-1) Trenching mode switch (Instrument Trenching Operation hours used trenching panel) - "ON"...
Page 605 Menu Selection of Operation Hour Information 1. Power : 0345 Hr 4. Travel Speed High : 0012 Hr 2. Trenching : 0190 Hr 3. Auto Idle : 0227 Hr Low : 0059 Hr 5. Hyd. Oil Temp (°C) 6. Coolant Temp (°C) 40 ↓...
Page 606: Electronic Hydraulic Control System (E-Epos)
ELECTRONIC HYDRAULIC CONTROL SYSTEM (e-EPOS) CONTROL SYSTEM SCHEMATIC (Wheel) (Pump control signal) (Engine speed sensor signal) (Switch signal) (Throttle signal) (Engine throttle control signal) (Throttle command) (Coolant water temp. signal) (Mode select signal) (Auto idle signal) (Machine information) Figure 43 S0802220K Electrical System Page 42...
Page 607 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Pressure Engine Control Motor Solenoid Valve (Swing Engine Priority) Main Hydraulic Pump Solenoid Valve (High Control Pump Speed) Control Valve Travel Motor Pressure Switch Engine Throttle Control Pump Pressure Sensor Engine Control Dial Engine Speed Sensor e-EPOS Controller...
Page 608: Power Mode Control
POWER MODE CONTROL (Wheel type) (Pump control signal) (Engine speed sensor signal) (Throttle Position signal) (Engine throttle control signal) (Throttle signal) (Power mode switch signal) ARS1040L Figure 44 Reference Reference Description Description Number Number Instrument Panel (Power Engine Speed Sensor Mode Selection Switch) E.P.P.R.
Page 609: Operation
The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by the operator. The pump output in each mode is determined by the mode selection and is listed in the following table Mode Standard Mode Power Mode...
Page 610 HDA6020L Figure 46 Reference Reference Description Description Number Number Engine Horsepower (hp) Pump Discharge Pressure (kg/cm Engine Speed (rpm) Pump Discharge Volume (lpm) Standard Mode Standard Mode is used for general work. When this mode is selected it will reduce noise and fuel consumption in comparison with Power Mode.
Page 611 Reference Reference Description Description Number Number Engine Horsepower (hp) Pump Discharge Pressure (kg/cm Engine Speed (rpm) Pump Discharge Volume (lpm) Electrical System S0802220K Page 47...
Page 612: Power Mode Control - Circuit Diagram
POWER MODE CONTROL - CIRCUIT DIAGRAM CN1-1 CN1-2 CN1-8 CN1-9 CN4-16 CN4-17 CN3-9 CN3-10 RS-422 CN3-11 CN3-12 CN3-8 P/V(A) CN1-10 CN1-19 S-MODE CN1-5 A/I MODE CN1-7 CN4-10 CN4-11 RETRACT (+) (+) (-) (-) HIGH CN4-12 CN4-13 TERMINAL NO 10 9 8 16 15 13 12 (CN4)
Page 613 Reference Reference Description Description Number Number Battery Engine Speed Sensor Battery Relay Engine Throttle Controller Fuse Engine Control Motor e-EPOS Controller Engine Control Dial Instrument Panel Electrical System S0802220K Page 49...
Page 614: Work Mode Control
WORK MODE CONTROL Main Relief v/v (Wheel) (Engine throttle control signal) (Throttle signal) (Trenching mode switch signal) ARS1070L Figure 49 Reference Reference Description Description Number Number Instrument Panel (Trenching Control Valve Mode Select Switch) Solenoid Valve Engine Control Motor Engine Throttle Control Engine Engine Control Dial Main Hydraulic Pump...
Page 615: Operation
OPERATION Digging Mode This mode is used for general digging work, loading work and ground leveling work requiring quick stops. The current to the solenoid valve for swing priority is shut off. Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles.
Page 616: Work Mode Control - Circuit Diagram
WORK MODE CONTROL - CIRCUIT DIAGRAM CN1-1 CN1-2 CN1-8 CN1-9 CN3-9 CN1-14 CN3-10 RS-422 CN3-11 CN3-12 CN3-8 TERMINAL NO 6 5 4 18 17 (CN4) (CN3) (CN7) (CN1) (CN2) ARS1080L Figure 51 Reference Reference Description Description Number Number Battery e-EPOS Controller Battery Relay Instrument Panel Fuse...
Page 617: Engine Control System
ENGINE CONTROL SYSTEM (Feedback Signal) (Drive Signal) (Command Signal) BATT. RELAY AUTO IDLE COMMAND e-EPOS CONTROLLER OVER HEAT BATTERY RETRACT ARS1090L Figure 52 Reference Reference Description Description Number Number Engine Control Motor Engine Throttle Controller Engine Engine Control Dial When the engine control dial is moved the output voltage changes according to the dial position. This signal is input to the engine throttle controller.
Page 618 S0802220K Electrical System Page 54...
Page 619: Engine Control Motor
ENGINE CONTROL MOTOR CIRCUIT DIAGRAM (GREEN) P1(Gr) P2(P) P3(L) (YELLOW) (RETRACT) (GRAY) ACCEL (PINK) P4(G) P5(Y) (5.0V) (BLUE) DECEL (EXTEND) ARS1100L Figure 53 Reference Description Number Motor Assembly Cable Spring Assembly The engine control motor uses a D.C. motor with a built in potentiometer to sense the position of the control cable.
Page 620: Engine Control Dial
ENGINE CONTROL DIAL 7th STEP 13th STEP 1st STEP ( 10 ) ( 10 ) MECHANICAL MECHANICAL STOP STOP 4.0V 2.5V 1.0V SETUP 1ST 2nd 12th 13th STOP STOP VIEW ( POTENTIOMETER BOTTOM) HDA6033L Figure 54 Reference Description Number Knob Potentiometer (Variable Resistor) S0802220K...
Page 621 The engine control dial has a built in potentiometer. When the control knob is moved the output voltage (through terminals 2 and 3) will vary from the 5 V supplied from the throttle controller as shown in the graph. Electrical System S0802220K Page 57...
Page 622: Engine Control Circuit Diagram
ENGINE CONTROL CIRCUIT DIAGRAM ARS1110L Figure 55 Reference Reference Description Description Number Number Battery Engine Throttle Controller Battery Relay Engine Control Motor Fuse Engine Control Dial e-EPOS Controller Pressure Switch (Py Port) Instrument Panel Pressure Switch (Px Port) Engine Speed Sensor S0802220K Electrical System Page 58...
Page 623: Automatic Deceleration Control (Auto Idle Control)
AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL) (Feedback Signal) (Drive Signal) (Command Signal) Auto deceleration Switch Signal ARS1120L Figure 56 Reference Reference Description Description Number Number Instrument Panel Engine Throttle Controller Engine Control Motor Engine Control Dial Engine e-EPOS Controller Pressure Switch If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed is automatically lowered.
Page 624: Engine Overheat Protection System
ENGINE OVERHEAT PROTECTION SYSTEM (Pump control signal) Engine overheat signal Engine overheat signal ARS1130L Figure 57 Reference Reference Description Description Number Number Instrument Panel E.P.P.R. Valve Engine Control Motor Engine Throttle Controller Engine e-EPOS Controller Main Pump Warning Buzzer Control Pump When the engine coolant temperature increases to over 107°C (225°F), the sensor mounted in the coolant line will send a signal to the instrument panel.
Page 625: Power Boost Mode
POWER BOOST MODE OPERATION Main Relief v/v (Button Signal) ARS1140L Figure 58 Reference Reference Description Description Number Number Engine Solenoid Valve Main Pump e-EPOS Controller Control Pump Power Boost Switch (Top of Right Work Lever) Control Valve The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation ability.
Page 626: Power Boost Control - Circuit Diagram
POWER BOOST CONTROL - CIRCUIT DIAGRAM CN1-1 CN1-2 CN1-8 CN1-9 CN3-9 CN1-13 CN3-10 RS-422 CN3-11 CN3-12 CN3-8 CN2-3 TERMINAL NO 18 17 14 13 (CN4) (CN3) (CN7) 16 15 (CN1) (CN2) ARS1150L Figure 59 Reference Reference Description Description Number Number Battery Instrument Panel Battery Relay...
Page 627: Automatic Travel Speed Control
AUTOMATIC TRAVEL SPEED CONTROL ARS1160L Figure 60 Reference Reference Description Description Number Number Engine Solenoid Valve (High speed) Main Pump Travel Motor Control Valve Engine Control Dial Pressure Switch (Py) e-EPOS Controller Pump Pressure Sensor Selection Switch For Automatic Travel If the automatic travel speed control switch is set to the "OFF"...
Page 628: Automatic Travel Speed Control - Circuit Diagram
AUTOMATIC TRAVEL SPEED CONTROL - CIRCUIT DIAGRAM CN1-1 CN4-1 CN1-2 CN4-2 CN4-3 CN1-8 CN4-4 CN1-9 CN1-12 CN4-10 CN4-11 HIGH (MANUAL) CN2-5 CN2-6 (AUTO) TERMINAL NO 10 9 (CN4) (CN3) 11 10 15 14 13 (CN1) (CN2) ARS1170L Figure 61 Reference Reference Description Description...
Page 629: Engine Control Device - Adjustment
ENGINE CONTROL DEVICE - ADJUSTMENT Engine speed adjustment should be made by following the procedures listed below. (Under no load conditions) Adjusting The High Idle Speed Turn the starter switch to the "ON" position. Select Power Mode from the instrument panel. Turn the engine speed control dial to the "HIGH IDLE"...
Page 630 Variable Mode Dial Position and Mode Setting Engine Speed Setting Resistor Automatic Refer to throttle controller Deceleration name plate (3, Figure 64). (Auto Idle) ENGINE SPEED ARS1180L Standard Refer to throttle controller Mode name plate (3, Figure 64). ENGINE SPEED ARS1181L ARS1441L Figure 64...
Page 631 Figure 65 Reference Reference Description Description Number Number Engine - Fuel Control Lever Engine Speed Control Cable Area To Engine Control Motor Control Motor Cable Bracket Electrical System S0802220K Page 67...
Page 632: Self-Diagnostic Function
SELF-DIAGNOSTIC FUNCTION E-EPOS CONTROLLER The system operation status and malfunction codes can be checked through the display on top of the e- EPOS controller box in the drawer under the operator’s seat. ARS1190L Figure 66 Reference Reference Description Description Number Number Upper Digit Power Monitor (Stays On...
Page 633 Normal Operation Display Readout Display Readout Mode Selection Operation Status Upper Digit Lower Digit Normal Operation Power Mode Power Mode HAOH340L Power Mode Normal Operation Standard Mode Standard Mode HAOH350L Normal Operation Digging Digging Mode HAOH370L Work Mode Normal Operation Trenching Trenching Mode HAOH380L...
Page 634: Engine Throttle Controller
ENGINE THROTTLE CONTROLLER Under the rubber cap on the surface of the engine controller, there are three LEDs. Based on the equipment status the following LEDs will turn "ON." LED Status Voltage At Throttle Controller Status Control Motor Input Signal Green Yellow Terminal...
Page 635: Wiper System
WIPER SYSTEM WIPER CIRCUIT ARS1200L Figure 67 Reference Reference Description Description Number Number Battery Washer Switch Battery Relay Wiper Timer Fuse Wiper Motor Wiper Switch Window Washer WIPER OPERATION Intermittent Operation (I - position) When the wiper switch (4) is turned "I" position, the current flows from the fuse (3) → "B" terminal of wiper motor (7) →...
Page 636: Window Washer Operation
When the wiper switch (4) is turned "OFF," the current flows from the fuse (3) → "B" terminal of wiper motor (7) → "L" terminal of wiper motor (7) → No. 5 terminal of wiper timer (6) → No. 4 terminal of wiper timer (6) →...
Page 637 Electrical System S0802220K Page 73...
Page 638: Lighting System
LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM (FR) (RR) (FML) (RL) (FMR) (FL) (FR) (FL) (RH) (LH) (RH) (LH) (RH) (LH) CN7-9 CN2-7 CN7-1 CN3-9 CN3-10 CN3-11 CN3-12 CN3-8 ARS1210L Figure 68 S0802220K Electrical System Page 74...
Page 639: Kind Of Light
Reference Reference Description Description Number Number Battery Rear Cabin Light Relay Battery Relay Instrument Panel Fuse Box e-EPOS Controller Light Switch Rotating Warning Light Warning Light Switch Headlight (2 ea.) Cabin Light Switch Work Light (2 ea.) Headlight Relay (Work Light Additional Work Light (2 ea.) Indicate Light) Front Cabin Light (2 ea.)
Page 640: Overload Warning Device
OVERLOAD WARNING DEVICE OVERLOAD WARNING DEVICE CIRCUIT DIAGRAM ARS1260L Figure 69 Reference Reference Description Description Number Number Battery e-EPOS Controller Battery Relay OWD Select Switch Fuse Box Pressure Sensor S0802220K Electrical System Page 76...
Page 641 Always use tools and equipment that is in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. ELECTRICAL SCHEMATIC (SOLAR 225LC-V/225NLC-V)S0892105K MODEL SERIAL NUMBER RANGE Solar 225LC-V...
Page 642 Return to Master Table of Contents TABLE OF CONTENTS General Description..................3 Solar 225LC-V....................4 Solar 225NLC-V ..................... 6 S0892105K Electrical Schematic (Solar 225LC-V/225NLC-V) Page 2...
Page 643 Schematic(s) presented in this section are laid out on facing pages. An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together to make a complete schematic. Figure 1 Electrical Schematic (Solar 225LC-V/225NLC-V) S0892105K Page 3...
Page 644 Return to Master Table of Contents SOLAR 225LC-V Figure 2 S0892105K Electrical Schematic (Solar 225LC-V/225NLC-V) Page 4...
Page 645 Return to Master Table of Contents Model Solar 225LC-V Name ELECTRICAL DIAGRAM NO. 599-00035 DAEWOO HEAVY INDUSTRIES LTD. Electrical Schematic (Solar 225LC-V/225NLC-V) S0892105K Page 5...
Page 646 Return to Master Table of Contents SOLAR 225NLC-V POWER DISPLAY AUTO MENU Figure 3 S0892105K Electrical Schematic (Solar 225LC-V/225NLC-V) Page 6...
Page 647 Return to Master Table of Contents S225NLC-V Electrical Schematic (Solar 225LC-V/225NLC-V) S0892105K Page 7...
Page 648 Return to Master Table of Contents S0892105K Electrical Schematic (Solar 225LC-V/225NLC-V) Page 8...
Page 649 1ATTACHMENTS...
Page 651 Remember, that ultimately safety is your own personal responsibility. BOOM AND ARM S0902010 MODEL SERIAL NUMBER RANGE Solar 220LC-V 0001 and Up Solar 225LC-V 1001 and Up Solar 225NLC-V 1001 and Up Copyright 2002 Daewoo January 2002 Boom and Arm...
Page 652 TABLE OF CONTENTS Front Attachment Pin Specifications .............. 3 Front Attachment - Removal and Installation ..........4 Arm Removal Procedure................. 4 Boom Removal Procedure ..............6 Installation ...................... 7 Arm Installation Procedure..............7 Boom Installation Procedure ..............7 Start-up Procedures ..................8 S0902010 Boom and Arm Page 2...
Page 653 NOTE: Some mounting pins must be drilled and tapped for lubrication fittings and piping, or may have other required specifications. Consult Daewoo After Sales Service for information on wear tolerances and replacement limits for mounting pins. Mounting Pin Diameter, mm (Inches) Length, mm (Inches) 90.0 mm (3.54 in)
Page 654: Front Attachment - Removal And Installation
NOT proceed with attachment disassembly unless you are completely sure of what you are doing. Please call your local Daewoo distributor or Daewoo After Sales Service for assistance. DO NOT allow personnel to stand underneath a weakened or only partially supported attachment section.
Page 655 Park the excavator away from obstructions and all traffic on clear, flat, level ground. Extend the arm cylinder and crowd the arm into the boom. Partially retract the boom cylinder so that the boom is stretched out in front of the excavator, as low to the ground as possible, with the arm crowded under the boom. The tip of the arm point should be lowered to secure blocking that will safely support the weight of the arm.
Page 656: Boom Removal Procedure
BOOM REMOVAL PROCEDURE NOTE: Boom removal may be simplified if the shell of the operator’s cab is taken off the turntable deck first. Refer to the Operator’s Cab Removal procedure before continuing, if both components are to be removed from the excavator. After the bucket, arm and arm cylinder have been removed, lower the end of the boom to a stable, secure blocking support.
Page 657: Installation
Refer to the General Safety Pages, Lift Ratings, Working Range Diagrams and Weights of Materials sections in the Operation and Maintenance Manual. Consult your dealer or Daewoo After Sales Service for more information if you have any questions or require more information.
Page 658: Start-Up Procedures
START-UP PROCEDURES Once the boom has been serviced, it should be lubricated as outlined in the initial start-up procedures of the operation manual. Refer to the appropriate operation and maintenance manual for unit. S0902010 Boom and Arm Page 8...
Page 659 Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. BUCKET S0904015K MODEL SERIAL NUMBER RANGE Solar 225LC-V 1001 and Up Solar 255LC-V 1001 and Up Copyright 2002 Daewoo October 2002...
Page 660 TABLE OF CONTENTS Bucket Tooth Inspection and Replacement ............ 3 Type 1...................... 3 Type 2...................... 4 Bucket O-ring Replacement ................6 Bucket Shimming Procedures ................ 8 New Bucket Installation ................8 Shimming Procedures for Installed Bucket ........8 Bucket Attachment, Removal and Reversal ........... 9 Detaching the Bucket ................
Page 661: Bucket Tooth Inspection And Replacement
BUCKET TOOTH INSPECTION AND REPLACEMENT There are several different types of attachment methods for replaceable bucket teeth. Some of the most common types are shown in the following drawings. Bucket teeth are usually replaced in sets but it may sometimes be necessary to replace individual teeth. TYPE 1 Look for the following indications of wear or damage: •...
Page 662 TYPE 2 WARNING! Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing bucket teeth. Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground. Place wooden blocks under front of bucket.
Page 663 On a routine basis, inspect bucket teeth to make sure that tooth wear or breakage has not developed. Do not allow replaceable bucket teeth to wear down to a point that bucket adapter is exposed. See Figure 4. To replace a tooth, use a hammer (1, Figure 5) and punch (2) to drive locking pin assembly out of tooth and tooth adapter.
Page 664: Bucket O-Ring Replacement
BUCKET O-RING REPLACEMENT WARNING! Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins. Inspect the bucket O-rings on a routine basis. If worn or damaged, replacement is necessary. BBO0030L Figure 6 Roll the old O-ring (1, Figure 7) onto the boss (2) around the bucket pin (3).
Page 665 Roll the new O-ring (1, Figure 9) into the O-ring groove. BBO0022L Figure 9 Bucket S0904015K Page 7...
Page 666: Bucket Shimming Procedures
BUCKET SHIMMING PROCEDURES NEW BUCKET INSTALLATION If a new bucket is being installed on the excavator, measure the inside dimension between the bucket ears and the outside dimension across the arm mounting boss. Subtract the clearance on both sides from the difference of the two and shim accordingly, prior to assembly.
Page 667: Bucket Attachment, Removal And Reversal
BUCKET ATTACHMENT, REMOVAL AND REVERSAL DETACHING THE BUCKET Park the excavator away from obstructions on clear, flat, level ground. Lower the bucket carefully to pre- assembled blocking on the ground. Brace the bucket so that there is no load weight on the pin connecting the bucket and arm.
Page 668: Reversing The Bucket
When the link pin has been installed, withdraw the temporary support rod from the bucket pin holes, lower and raise the arm and boom and install the bucket pin. WARNING! When making linkage alignments, never insert fingers into holes. attachment or bucket could shift position and cause a severe injury.
Page 669 HAS THIS BEEN DISCUSSED WITH A DAEWOO SERVICE REPRESENTATIVE: IF YES - WHO: (It is advised to discuss this with a Daewoo service representative to ensure that the above correction is appropriate and valid.) Mail to: Daewoo Heavy Industries America Corporation...

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