Daewoo Solar 225LC-V Shop Manual Download Page 18 | Manualshive

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S0102000
Page 10

Track Excavator Safety

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.

Never jump on or off the machine. In particular, never get on or off a moving machine. These actions may
lead to serious injury.

When getting on or off the machine, always face the machine, and maintain three-point contact (both feet
and one hand or one foot and both hands) with the handrails, steps, and track shoes to ensure that you
support yourself securely.

Never hold any control levers when getting on or off the machine.

Apply the door lock securely. If you grip the handrail inside the door when moving on top of the track shoes,
and the door lock is not applied securely, the door may move and cause you to fall.

Use the points marked by arrows in the diagram when getting on or off the machine.

Figure 2

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Summary of Contents for Solar 225LC-V

Page 1: ...sumers 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 var...

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Page 3: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Solar 225LC V Serial Number 1001 and Up Pub No 023 00058E Pub No 023 00058E ...

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Page 5: ...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 Engine and Drive Train Air Conditioner S0605060K Drive Coupling Main Pump S0609000 Hydraulics Hydraulic System Troubleshooting Testing and Adjustment S0702170K Accumulator S0703010K Center Joint ...

Page 6: ... 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 Bucket S0904015K Publication Request for Proposed Revision ...

Page 7: ...1SAFETY ...

Page 8: ......

Page 9: ...oad Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE 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 Solar 290LC V 0001 and Up Solar 300LC V 1001 and Up Solar 300LL 1001 and Up Solar 330LC V 1001...

Page 10: ...al 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 16 Machine Operation 19 Maintenance 26 Battery 34 Towing 36 Shipping and Transportation 37 Lifting With Sling 37 ...

Page 11: ...g Mode on page 7 4 Unauthorized Modifications on page 8 5 General Hazard Information on page 8 6 Before Starting Engine on page 16 7 Machine Operation on page 19 8 Maintenance on page 26 9 Battery on page 34 10 Towing on page 36 11 Shipping and Transportation on page 37 12 Lifting With Sling on page 37 DANGER Unsafe use of the excavator could lead to serious injury or death Operating procedures ma...

Page 12: ...tions given in this manual apply only to intended uses of the machine If you use your machine for any unintended uses that are not specifically prohibited you must be sure that it is safe for any others 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 t...

Page 13: ...bout the safety of some procedures contact a DAEWOO distributor SAFETY ALERT SYMBOL Be Prepared Get To Know All Operating and Safety Instructions This is the Safety Alert Symbol Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents Always observe safety precautions and follow recommended procedures CAUTION This wo...

Page 14: ...a firm supporting surface with hooks and slings attached in approved configuration Loads must be balanced and supported evenly Use taglines to keep the load steady if wind conditions and large surface area are a problem Work crew hand signals individual tasks and safe procedures should all be universally understood before the lift is made LOCATION OF SAFETY LABELS Location of safety labels decals ...

Page 15: ...ng work DANGER Unsafe use of the excavator while making rated lifts could cause serious potentially fatal injuries or extensive damage to the machine or nearby property Do not let anyone operate the machine unless they ve been properly trained and understand the information in the Operation and Maintenance Manual WARNING NEVER wrap a tagline around your hands or body NEVER rely on taglines or make...

Page 16: ... feeling well if you are taking medication that makes you feel sleepy if you have been drinking or if you are suffering from emotional problems These problems will interfere with your sense of judgement in emergencies and may cause accidents When working with another operator or with a person on work site traffic duty be sure that all personnel know the nature of the work and understand all hand s...

Page 17: ...at this may lead to a serious accident When operating the machine do not put your hands or head out of the window When standing up from the operator s seat always place safety lock lever securely in the LOCK position If you accidentally touch the work equipment levers when they are not locked the machine may suddenly move and cause serous injury or damage When leaving the machine lower the work eq...

Page 18: ...erious injury When getting on or off the machine always face the machine and maintain three point contact both feet and one hand or one foot and both hands with the handrails steps and track shoes to ensure that you support yourself securely Never hold any control levers when getting on or off the machine Apply the door lock securely If you grip the handrail inside the door when moving on top of t...

Page 19: ... the fuel nozzle in constant contact with the neck of the fuel filling nozzle to provide a ground Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured PRECAUTIONS WHEN HANDLING FLUIDS AT HIGH TEMPERATURE Immediately after operations are stopped the coolant engine oil and hydraulic oil are at high temperature and the radiator and hydraulic tank are...

Page 20: ...to keep down the dust Work on the machine or component with the wind at your back whenever possible Always observe any rules and regulations related to the work site and working environment INJURY FROM WORK EQUIPMENT Do not enter or put your hand arm or any other part of your body between movable parts such as between the work equipment and cylinders or between the machine and work equipment If th...

Page 21: ...the machine catches fire it may lead to serious personal injury or death If a fire occurs during operation escape from the machine as follows Turn the starter switch OFF and shut down engine If there is time use the fire extinguisher to extinguish as much of the fire as possible Use the handrails and steps to escape from the machine The above is the basic method for escaping from the machine but c...

Page 22: ...le 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 ACCUMULATOR The pilot control system is equipped with an accumulator For a bri...

Page 23: ... windows doors or ductwork into which exhaust may be carried or blown by the wind exposing others to danger EMERGENCY EXIT This machine is equipped with a glass breaking tool It is behind the operator seat in the upper right corner of the cab This tool can be used in case of an emergency situation that requires the breaking of glass to exit from the operator s cabin Grip the handle firmly and use ...

Page 24: ... and take other steps to prevent people from coming close to or entering the work site If people come close to a moving machine they may be hit or caught by the machine and this may lead to serious personal injury or death Water lines gas lines phone lines and high voltage electrical lines may be buried under the work site Contact each utility and identify their locations Be careful not to damage ...

Page 25: ...l the head guard FOPS if working in areas where there is danger of falling rocks CHECKS BEFORE STARTING ENGINE Every day before starting the engine for the first time carry out the following checks If these checks are not carried out properly there is danger of serious injury Completely remove all wood chips leaves grass paper and other flammable materials accumulated in the engine compartment and...

Page 26: ...y after starting the engine it may result in a delay in discovering abnormalities in the machine and this may lead to personal injury or damage to the machine Carry out the checks in an open area where there are no obstructions Do not let anyone near the machine when carrying out the checks Check the operating condition of the equipment and the actuation of the bucket arm boom travel and swing sys...

Page 27: ...n of travel Sound the horn to warn people in the area Check that there is no one in the area around the machine There are blind spots behind the machine so if necessary swing the upper structure to check that there is no one behind the machine before traveling in reverse When operating in areas that may be hazardous or have poor visibility designate a person to direct work site traffic Ensure that...

Page 28: ...lope or obstacle that causes the machine to tilt 10 degrees or more to the right or left or 30 degrees or more from front to rear Do not operate the steering suddenly The work equipment may hit the ground and cause the machine to lose its balance and this may damage the machine or structures in the area When traveling on rough ground travel at low speed and avoid sudden changes in direction Always...

Page 29: ...er the bucket to the ground to help stop the machine Do not travel on grass fallen leaves or wet steel plates Even slight slopes may cause the machine to slip to the side so travel at low speed and make sure that the machine is always traveling directly up or down the slope Avoid changing the direction of travel on a slope This could result in tipping or side slipping of the machine When possible ...

Page 30: ...ken terrain can cause dangerous side load conditions and possible tipover and injury Travel without a load or a balanced load may also be hazardous Never relay on lift jacks or other inadequate supports when work is being done Block tracks fore and aft to prevent any movement When using the machine to prevent accidents caused by damage to the work equipment and overturning because of an excessive ...

Page 31: ...s poor such as in fog mist snow and rain Wait for the visibility to improve to a level which causes no problems for the operation To avoid hitting the work equipment always do the following When working in tunnels on bridges under electric wires or when parking the machine or carrying out other operations in places with limited height be extremely careful not to hit the bucket or other parts To pr...

Page 32: ...ATE CAREFULLY ON SNOW ICE AND IN VERY COLD TEMPERATURES In icy cold weather avoid sudden travel movements and stay away from even slight slopes The machine could skid off to one side very easily Snow accumulation could hide or obscure potential hazards Use care while operating or while using the machine to clear snow Warming up the engine for a short period may be necessary to avoid operating with...

Page 33: ...al water accumulation or runoff If parking on inclines is unavoidable block the crawler tracks to prevent movement Lower the bucket or other working attachment completely to the ground or to an overnight support saddle There should be no possibility of unintended or accidental movement When parking on public roads provide fences signs flags or lights and put up any other necessary signs to ensure ...

Page 34: ...so there is danger that you may get dirt or mud in your eyes or that you may slip and injure yourself When washing the machine do the following Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your ski...

Page 35: ...aking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store oily rags and other flammable material in a protective container Do not smoke while you refuel the machine or while you are in a refueling area Do not smoke in battery charging areas or in a...

Page 36: ...s to cool before you drain the cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only after the engine has been stopped Make sure that the hydraulic tank filter plug is cool before you remove it with your bare hand Remove the hydraulic tank filter plug slowly to relieve pressure Relie...

Page 37: ... cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent If heat is applied directly to rubber hoses or piping under pressure they may suddenly break so cover them with a fireproof covering Wear protective clothing Make sure there is good ventilation Remo...

Page 38: ...he following Do not spill oil or grease Do not leave tools laying about Watch your step when walking Never jump down from the machine When getting on or off the machine use the steps and handrails and maintain a three point contact both feet and one hand or both hands and one foot to support yourself securely If the job requires it wear protective clothing To prevent injury from slipping or fallin...

Page 39: ... The loose retainer pin can injure personnel Make sure that the area is clear of people when you strike a retainer pin To avoid injury to your eyes wear protective glasses when you strike a retainer pin TRACK TENSION ADJUSTMENTS REQUIRE CAUTION Never turn out the track tension grease fitting nut To release pressure from the crawler frame track tension assembly you should NEVER attempt to disassemb...

Page 40: ...ized oil has enough force to pierce the skin and cause serious injury Always use a piece of wood or cardboard to check for suspected hydraulic leaks Never use your hands or expose your fingers Do not bend high pressure lines Do not strike high pressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly to pre...

Page 41: ...ntaminant and may only be disposed of at approved collection facilities To prevent pollution of the environment always do the following Never dump waste oil in a sewer system rivers etc Always put oil drained from your machine in containers Never drain oil directly onto the ground Obey appropriate laws and regulations when disposing of harmful materials such as oil fuel solvent filters and batteri...

Page 42: ...ities of water and see a doctor at once If you accidentally drink battery electrolyte drink a large quantity of water or milk raw egg or vegetable oil Call a doctor or poison prevention center immediately When cleaning the top surface of the battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely If the battery ...

Page 43: ...o series connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections must be made between the nonseries connected positive terminals and between the negative terminal of the booster battery and the metal frame of the machine being boosted or charged Refer to the proced...

Page 44: ...ing rope to the left and right hooks and secure in position If the engine on the problem machine will not start or there is a failure in the brake system always contact your Daewoo distributor Never go between the towing machine and the towed machine during the towing operation It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no place where the...

Page 45: ...rmation on partial disassembly Refer to the Transportation and Shipping section of this Operation and Maintenance Manual for information on loading unloading and towing LIFTING WITH SLING 1 Refer to Specification section of Operation and Maintenance Manual for information on weight and dimensions 2 Use properly rated cables and slings for lifting 3 Position machine for a level lift 4 Lifting cable...

Page 46: ...S0102000 Page 38 Track Excavator Safety ...

Page 47: ...1SPECIFICATIONS ...

Page 48: ......

Page 49: ...recommendations and safe shop practices outlined in the front of this manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and UP Copyright 2002 Daewoo October 2002 ...

Page 50: ...te Weight of Workload Materials 14 Performance Tests 17 Excavator Performance Standards 18 Test Conditions 18 Travel Speed and Travel Motor Balance Steering Deviation Tests 18 Speed Test 18 Travel Deviation 19 Swing Speed and Deceleration Force Test 20 Swing Speed Test 20 Swing Deceleration Force Test 20 Cylinder Performance Tests 21 Boom Cylinders Test 21 Arm Cylinder Test 21 Bucket Cylinder Test...

Page 51: ... of Contents 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 ...

Page 52: ...K Page 4 Specifications for Solar 225LC V Return to Master Table of Contents COMPONENT LOCATIONS Figure 1 1 2 3 4 5 6 11 10 9 7 8 34 33 32 31 30 29 35 14 15 16 17 18 19 28 27 26 25 24 23 22 21 20 13 12 BBO0060L ...

Page 53: ... AND OIL COOLER 10 AIR CLEANER 11 CONTROL VALVES 12 ARM CYLINDER 13 BOOM 14 BOOM CYLINDER 15 CAB 16 SEAT 17 CENTER JOINT 18 SWING MOTOR 19 PRECLEANER 20 TRAVEL MOTOR 21 LOWER ROLLER 22 UPPER ROLLER 23 TRACK GUIDE 24 TRACK ADJUSTER 25 IDLER 26 TRACK LINK AND SHOE 27 TRAVEL LEVER 28 WORK LEVER JOYSTICK CONTROLS 29 TOOTH POINT 30 SIDE CUTTER 31 BUCKET 32 PUSH LINK 33 GUIDE LINK 34 BUCKET CYLINDER 35 ...

Page 54: ...S0205015K Page 6 Specifications for Solar 225LC V Return to Master Table of Contents ...

Page 55: ...8 FT ARM A 9 530 mm 31 3 9 550 mm 31 4 9 540 mm 31 4 B 2 750 mm 9 C 6 780 mm 22 3 6 800 mm 22 4 6 790 mm 22 3 D 3 645 mm 11 12 E 4 440 mm 14 7 F 1 105 mm 3 8 G 3 228 mm 11 0 3 030 mm 9 11 3 690 mm 12 1 H 2 710 mm 8 11 I 1 350 mm 4 5 J 1 360 mm 4 6 K 2 390 mm 7 10 L 2 990 mm 9 10 M 600 mm 23 62 in N 480 mm 18 90 in O 3 000 mm 9 10 B C A D E F G J K L M N O I H BBO0050L Figure 2 ...

Page 56: ...ARNING 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 ...

Page 57: ...ight 5 875 mm 19 3 6 435 mm 21 1 6 885 mm 22 7 6 795 mm 22 3 7 020 mm 23 02 F Max Digging Height 8 720 mm 28 7 9 370 mm 30 9 9 825 mm 32 2 9 570 mm 31 8 9 870 mm 32 4 G Max Bucket Pin Height 7 360 mm 24 2 7 920 mm 25 11 8 370 mm 27 5 8 280 mm 27 2 8 500 mm 27 0 H Max Vertical Wall 4 670 mm 15 3 5 650 mm 18 6 6 035 mm 19 9 6 045 mm 19 10 6 560 mm 21 6 I Max Radius Vertical 5 450 mm 17 10 4 710 mm 1...

Page 58: ... 13 090 lb Lower below Swing Bearing 7 850 0 kg 17 270 lb Digging Forces Bucket Cylinder 119 KN or 12 100 kg 26 620 lb with 2 900 mm 9 6 arm 117 KN or 12 000 kg 26 400 lb with 2 400 mm 7 10 arm Arm Cylinder 100 KN or 10 200 kg 22 400 lb with 2 900 mm 9 6 arm 121 KN or 12 300 kg 27 060 lb with 2 400 mm 7 10 arm Fuel Tank Capacity 350 liters 92 5 gal Hydraulic System Capacity 240 liters 63 4 gal Hyd...

Page 59: ...550 mm 31 4 Overall Shipping Width standard shoes 2 990 mm 9 10 Overall Shipping Height to top of cylinder hose 3 030 mm 9 11 Track Shipping Length 4 440 mm 14 7 Transport Trailer Capacity 30 tons 33 short tons minimum load capacity Transport Loading Ramp Allowable Slope 15 angle CAUTION Refer to Transport Maximum Procedure for Safe Shipping Instructions ...

Page 60: ...S0205015K Page 12 Specifications for Solar 225LC V Return to Master Table of Contents ENGINE PERFORMANCE CURVES PER DIN 6270 STANDARD BBS0060L Figure 4 ...

Page 61: ...e Model DB58TIS Barometric Pressure 760 mmHg 20 C 68 F Cooling Fan 625 mm SUCKER 24 6 in Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard DIN 6270 Power 150 ps 1 950 rpm 148 hp 1 950 rpm Max Torque 61 5 kg m 1 400 rpm 443 ft lb 1 400 rpm Fuel Consumption Rated 163 g ps h 5 75 oz hp h ...

Page 62: ...50 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry size 449 kg m3 756 lb yd3 Coal bituminous slack piled 801 kg m3 1 350 lb yd3 Coal bituminous r of m piled 881 kg m3 1 485 lb yd3 Coal anthracite 897 kg m3 1 512 lb yd3 Clay DRY in ...

Page 63: ...m3 3 240 lb yd3 Limestone graded above 2 1 282 kg m3 2 160 lb yd3 Limestone graded 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1 282 kg m3 2 160 lb yd3 Salt 929 kg m3 1 566 lb yd3 Snow light density 529 kg m3 891 lb yd3 Sand DRY loose 1 522 kg m3 2 565 lb yd3 Sand WET packed 1 922 kg m3 3 240 lb yd3 MATERIAL ...

Page 64: ...able of Contents Shale broken 1 362 kg m3 2 295 lb yd3 Sulphur broken 529 kg m3 1 620 lb yd3 MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS ...

Page 65: ... Standard Mode Power Mode Boom Up sec 3 3 0 4 3 0 0 4 Down sec 2 5 0 3 2 3 0 4 Arm Dump sec 2 7 0 3 2 6 0 4 Crowd sec 3 7 0 4 3 5 0 4 Bucket Dump sec 2 4 0 3 2 3 0 4 Crowd sec 3 9 0 4 3 6 0 4 Swing 3 Revolutions sec 16 0 1 5 14 6 1 5 Jack Up Speed 3 Turns High sec 19 5 1 5 18 0 0 7 Low sec 35 0 2 0 33 0 1 2 Travel Speed 20 m 65 62 ft High sec 13 5 1 0 12 5 1 0 Low sec 23 5 1 5 22 5 1 5 Travel Devi...

Page 66: ...135 F 4 Run all tests with the engine speed control set to maximum RPM 5 Repeat tests with Power Mode engine control settings at both Standard Mode standard work mode and Power Mode high speed mode Travel speed tests should also be repeated at both high and low speed TRAVEL SPEED AND TRAVEL MOTOR BALANCE STEERING DEVIATION TESTS Speed Test Prepare the excavator for travel speed tests by extending ...

Page 67: ... travel motor uniformity Deviation distance should always be measured at the 20 m 65 7 1 2 finish line Repeat the test in reverse to measure in both directions with starting point becoming the finish line and vice versa Figure 6 A greater amount of deviation is allowed with the travel control set for high speed RATE OF TRAVEL TIME STANDARD MODE POWER MODE High Speed 13 5 1 0 seconds 12 5 1 0 secon...

Page 68: ...celeration Force Test With the boom arm and bucket in the same position as for the swing speed test rotate the turntable so that the boom is evenly centered between the side frames pointing straight ahead Locate the 90 reference point perpendicular to the boom Mark the turntable and undercarriage with paint at the 90 point Make several attempts to rotate the turntable exactly 90 starting from the ...

Page 69: ...gainst the specified performance standard for new cylinders put a full load of dirt in the bucket and move the attachment cylinders so that the arm cylinder is extended 20 50 mm 1 2 and boom cylinders are retracted the same amount 20 50 mm 1 2 The top of the bucket should be approximately 2 m 6 7 off the ground Turn off the engine and measure cylinder drop after 5 minutes Bucket cylinder should no...

Page 70: ...S0205015K Page 22 Specifications for Solar 225LC V Return to Master Table of Contents ...

Page 71: ...1GENERAL MAINTENANCE ...

Page 72: ......

Page 73: ...and safe shop practices outlined in the front of this manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES Copyright 2002 Daewoo May 2002 ...

Page 74: ... 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 6 Cleaning and Inspection 7 General Guidelines 7 Bearing inspection 8 ...

Page 75: ...types of steel are performed with the proper procedures and equipment If repairs are performed incorrectly structural weakening or other damage to the machine 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...

Page 76: ...nded Vibration irregular or difficult movement or unusual noise from any part of the hydraulic system could be an indication of air in the system and many other types of problems As a general precaution and to help minimize the risk of potential long term damage allow the engine to run at no load idle speed immediately after initial start up Hydraulic fluid will circulate releasing any air that ma...

Page 77: ...ing into the circuit Refer to the appropriate Troubleshooting section for component or unit for procedures or it may be evidence of a defective pump The gear type pilot pump could be defective causing low pilot pressure or a main pump broken shoe or piston could be responsible NOTE If equipped indicated operating pressure as shown on the multidisplay digital gauge on the Instrument Panel F Pump an...

Page 78: ...olds and piping Do not allow cleaning solvents or other fluids to mix with the oil in the system Use clean oil to flush any traces of solvent or other residue before reassembly If metal or rubber fragments are found in the system flush and replace all fluid in the system and troubleshoot the circuit to identify the source of contamination OIL LEAKAGE PRECAUTIONS Oil that is visibly seeping from jo...

Page 79: ...o avoid spinning bearings that are not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully inspect all bearing rollers cages and cups for wear chipping or nicks to determine condition Do not replace a bearing cone or cup individually without replacing mating cup or cone at the same time After inspection dip bearings in light w...

Page 80: ... examine the condition of the bearings and all of its components for wear and damage Once the bearing is removed clean all parts thoroughly using a suitable cleaning solution If the bearing is excessively dirty soak the bearing assembly in a light solution and move the bearing around until all lubricants and or foreign materials are dissolved and the parts are thoroughly clean When drying bearings...

Page 81: ...ith no discoloration or marks Bent Cage Cage damage due to improper handling or tool usage Replace bearing Galling Metal smears on roller ends due to overheat lubricant failure or overload Replace bearing check seals and check for proper lubrication Figure 2 Figure 3 Figure 4 Figure 5 ...

Page 82: ...ack in color with related etching away of material usually at roller spacing Replace bearings check seals and check for proper lubrication Misalignment Outer race misalignment due to foreign object Clean related parts and replace bearing Make sure races are properly seated Indentations Surface depressions on race and rollers caused by hard particles of foreign materials Clean all parts and housing...

Page 83: ...ng or vibration while the bearing is not rotating Replace bearing if rough or noisy Cage Wear Wear around outside diameter of cage and roller pockets caused by abrasive material and inefficient lubrication Replace bearings check seals Abrasive Roller Wear Pattern on races and rollers caused by fine abrasives Clean all parts and housings check seals and bearings and replace if leaking rough or nois...

Page 84: ...ars Smearing of metal due to slippage caused by poor fitting lubrication overheating overloads or handling damage Replace bearings clean related parts and check for proper fit and lubrication Replace shaft if damaged Frettage Corrosion set up by small relative movement of parts with no lubrication Replace bearing Clean all related parts Check seals and check for proper lubrication Figure 14 Figure...

Page 85: ...n over a tempered part will grab and cut metal whereas a file drawn over a hard part will glide readily with no metal cutting Replace bearing if over heating damage is indicated Check seals and other related parts for damage Stain Discoloration Discoloration can range from light brown to black caused by incorrect lubrication or moisture if the stain can be removed by light polishing or if no evide...

Page 86: ...S0302000 Page 14 General Maintenance Procedures ...

Page 87: ...es outlined in the front of this manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES Copyright 2002 Daewoo May 2002 ...

Page 88: ...s 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 9 Other Uses for Torque Wrench Extension Tools 10 Tightening Torque Specifications Metric 10 ...

Page 89: ...2 00 86 79 17 00 122 96 20 00 144 66 M14 x 1 5 4 10 29 65 4 30 31 10 6 60 47 73 5 70 41 22 8 30 60 03 7 50 54 24 11 10 80 28 12 50 90 41 13 00 94 02 18 50 11 26 22 00 158 12 M16 x Std 5 60 40 50 6 00 43 39 9 00 65 09 8 00 57 86 11 50 83 17 10 50 75 94 15 50 112 11 17 90 129 47 18 50 133 81 26 00 188 05 31 00 224 22 M16 x 1 5 6 20 44 84 6 50 47 01 9 70 70 16 8 60 62 20 12 50 90 41 11 30 81 73 17 00...

Page 90: ...sed 0 70 when Molykote white lead or similar mixtures are used as lubricants 0 75 when parkerized bolts or nuts are used 0 85 when cadmium plated bolts or nuts and zinc bolts w waxed zinc nuts are used 0 90 when hardened surfaces are used under the nut or bolt head NOTE When reusing bolts and nuts in service use minimum torque values TYPE S A E GRADE DESCRIPTION BOLT HEAD MARKING 1 1 OR 2 WILL HAV...

Page 91: ...OT POUNDS ft lb NEWTON METER N m FOOT POUNDS ft lb NEWTON METER N m 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 7 8 9 7 8 14 1 8 1 14 1 1 8 7 1 1 8 12 1 1 4 7 1 1 4 12 1 3 8 6 1 3 8 12 1 1 2 6 1 1 2 12 1 3 4 5 2 4 1 2 6 7 13 15 24 27 38 42 58 65 84 93 115 130 205 240 305 334 455 510 610 685 860 955 1130 1290 1400 1690 2370 3...

Page 92: ...ues shown below also apply to the following 1 Phosphate coated bolts used in tapped holes in steel or gray iron 2 Phosphate coated bolts used with phosphate coated prevailing torque nuts nuts with distorted threads or plastic inserts 3 Phosphate coated bolts used with copper plated weld nuts Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required to...

Page 93: ... boots hydraulic system etc CLAMP TYPE AND SIZE TORQUE RADIATOR AIR CLEANER BOOTS ETC HYDRAULIC SYSTEM KILOGRAM METER kg m INCH POUNDS in lb KILOGRAM METER kg m INCH POUNDS in lb T Bolt Any Diameter Worm Drive Under 44 mm 1 3 4 in Open Diameter Worm Drive Over 44 mm 1 3 4 in Open Diameter Worm Drive All Ultra Tite 0 68 0 72 0 2 0 3 0 5 0 6 0 6 0 7 59 63 20 30 40 50 50 60 0 5 0 6 0 5 0 6 40 50 40 5...

Page 94: ... bolts will damage the flanges and or bolts which may cause leakage Inside diameter of flange on end of hydraulic tube or hose fitting NOTE Values stated in chart are for Standard Pressure Series Code 61 Split Flanges FLANGE SIZE BOLT SIZE BOLT TORQUE KILOGRAM METER kg m FOOT POUNDS ft lb 1 2 3 4 1 1 1 4 1 1 2 2 2 1 2 3 3 1 2 5 16 3 8 3 8 7 16 1 2 1 2 1 2 5 8 5 8 2 1 2 5 3 0 3 7 3 7 4 8 4 8 6 2 6 ...

Page 95: ...le end of the torque wrench doubles the tightening force on the bolt It also halves the indicated reading on the scale or dial of the torque wrench To accurately adjust or convert indicated scale or dial readings use the following formula I A x T A B where I Indicated force shown on the torque wrench scale or dial T Tightening force applied to the nut or bolt actual Torque A Length of the torque w...

Page 96: ...ion and accuracy To allow the assembly or mechanism to accept a torque wrench welding a nut or other adapter on the end of a linkage shaft or other leverage point will allow turning the shaft or assembly manually TIGHTENING TORQUE SPECIFICATIONS METRIC For coated threads prelubricated assemblies CAUTION Disassembly overhaul and replacement of components on the machine installation of new or replac...

Page 97: ...C 500 F Remove HOT 210 Product Application Color Removal Required Setup 545 No filler non clog formula for high pressure hydraulic systems Over application will not restrict or foul system components Purple Hand tools 4 Hours or 1 2 hour with Locquic T Primer 656 Solvent resistant higher viscosity tapered thread sealer White Hand tools 4 Hours or 1 2 hour with Locquic T Primer Product Application ...

Page 98: ... cold temperature applications 620 For high temperatures to 232 C 450 F Green Same as 609 above 680 For high strength bonds and tight clearance gaps to 0 00008 mm 0 002 Green Same as 609 above Product Application Color Notes 380 Black Max instant adhesive for shock and vibration resistant bonds Black May take 120 hours to reach full cure strength 454 Adhesive for porous surfaces Clear Full strengt...

Page 99: ...1UPPER STRUCTURE ...

Page 100: ......

Page 101: ... equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE 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 Solar 300LL 1001 and Up Solar 340LC V 1001 and Up Solar 42...

Page 102: ...S0402040K Page 2 Cab TABLE OF CONTENTS Removal 3 Installation 6 ...

Page 103: ...by disconnecting wiring connectors for A Cab interior lighting B External light wiring C Radio antenna and connections D Wiper washer connections NOTE Control console wiring harnesses and hydraulic piping lines that pass through the floor of the cab do not need to be disassembled NOTE If unit is equipped with a cab protective structure for forestry or hazardous working conditions it must be remove...

Page 104: ... located at right side of cab Disconnect duct wiring connector before removing duct 2 17 Disconnect washer hose located at floor plate bottom 18 Remove cover 5 Figure 4 on left side dash cover 3 and bolts 1 Figure 5 NOTE When removing cover disconnect speaker wire 19 Remove two rubber stops 2 Figure 4 used in storing the front lower glass Remove bolts 1 from the rear left and right dash covers Rem...

Page 105: ...ing a suitable lifting device attach slings to four lift points on top of cab Figure 7 NOTE Cab weighs approximately 290 kg 639 lb 28 Lift cab from 25 50 mm 1 2 above deck height Check that all electrical connections have been disconnected and all other items unbolted 29 Continue lifting with the assist crane to remove the cab shell Lower the shell to a pre prepared safe blocking support Quantity ...

Page 106: ...all four hex bolts 3 Figure 9 in door side of cabin floor 5 Install two hex bolts 1 Figure 9 in right side of cabin floor and one bolt 4 in front of cab floor 6 Once cab is mounted to floor unhook lifting device 7 Connect cabin ground cable 7 Figure 2 8 Connect cab light wiring connector Quantity Description 4 16 mm hex nuts at each corner of the cab 4 10 mm x 1 5 hex bolts at the door side of the...

Page 107: ...ith bolts 1 Figure 10 Install two rubbers 2 Figure 11 12 Install cover 5 Figure 11 on left side dash cover 3 NOTE Connect speaker wire before installing cover 13 Connect washer hose located at floor plate bottom 14 Install air duct 3 2 and 1 Figure 12 located at right side of cab NOTE Connect wire connector of duct 2 Figure 12 1 1 2 2 ARS1540L Figure 10 1 1 2 2 3 3 4 4 5 5 2 2 ARS1530L Figure 11 1...

Page 108: ...rness Install cover 3 Connect hour meter connector and cigar lighter connect of cover 2 17 Install cover 2 Figure 13 18 Install operator s seat 1 Figure 13 NOTE Be careful not to damage seat covering 19 Install floor mat 20 Connect negative battery cable leading to frame from battery 1 4 5 6 2 3 7 BCS0720L Figure 13 ...

Page 109: ...ays 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Solar 225NLC V 1001 and Up Solar 255LC V 1001 and Up Solar 300LC V 1001 and Up Solar 300LL 1001 and Up Solar 340LC V 1001 and Up Solar 420LC V 1001 and Up ...

Page 110: ...S0403050K Page 2 Counterweight Return to Master Table of Contents TABLE OF CONTENTS General 3 Removal 5 Installation 7 ...

Page 111: ...rweight 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 Daewoo is not liable for any misuse Never remove the counterweight or front attachment unless the upper structure is in line with the lower structure Never rotate the upper structure once the counterweight or front attachmen...

Page 112: ... the swing lock if equipped to hold the deck in place and always go backwards up the loading ramp The counterweight end of the deck has to get on the trailer first while the cab is still going up the ramp Figure 1 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...

Page 113: ...ks in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery 11 Raise engine compartment cover WARNING If engine must be run while performing maintenance use extreme care Always have one person in t...

Page 114: ...st crane as soon as lifting slings are taut 15 Remove four bolts 4 Figure 4 and washers spacers 5 from counterweight 2 NOTE Heat bolts if necessary to free them 16 When bolts 4 Figure 4 and washers spacers 5 have been removed lift counterweight 2 a very short distance above support frame 6 and stop Check slings and make sure counterweight is being supported evenly Model Lifting Eye Size Solar 225L...

Page 115: ...igure 5 onto bolts 4 Apply Loctite 242 to mounting bolt threads 4 Install four bolts 4 Figure 5 with washers spacers 5 into counterweight until washers spacers contact support frame Fully lower counterweight onto support frame and finish tightening bolts NOTE Tighten bolts 4 Figure 5 to values shown in following table 5 Remove lifting device and lifting eyes from counterweight lifting holes 3 Figu...

Page 116: ...S0403050K Page 8 Counterweight Return to Master Table of Contents ...

Page 117: ... the front of this manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Copyright 2002 Daewoo October 2002 ...

Page 118: ...S0405005K Page 2 Fuel Tank TABLE OF CONTENTS General Description 3 Parts List 4 Specifications 5 Removal 6 Installation 10 Start up Procedures 12 ...

Page 119: ...3 Fuel Tank 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 ...

Page 120: ...S0405005K Page 4 Fuel Tank PARTS LIST 3 7 5 6 4 10 9 23 8 12 11 1 13 16 13 16 19 27 FRONT 14 18 18 22 22 BBS0080L Figure 1 ...

Page 121: ...S gal Reference Number Description 1 Fuel Tank 3 O ring 4 Cover 5 Bolt M10x1 5x25 6 Spring Washer 7 Drain Cock 8 Bolt M16x2 0x60 9 Shim 10 Shim 11 Fuel Filter 12 Cap 13 Plug 14 Level Gauge 16 O ring 18 Clip 19 O ring 22 Bolt M8x1 25x12 23 Spacer 27 Plug Reference Number Description ...

Page 122: ... representing 10 percent of total fuel supply Also look at level gauge on side of tank to estimate volume of fuel left in tank NOTE If possible work excavator until available fuel supply in tank has been run down as far as possible 2 Park on firm and level ground and swing turntable to approximately a 90 with respect to tracks See Figure 3 ARO0150L GREEN RED F E Figure 2 ARS1550L Figure 3 ...

Page 123: ... Set safety lever on LOCK position 9 Turn key to OFF position and remove from starter switch 10 Hang maintenance warning tag on controls 11 Disconnect negative battery cable leading to frame from battery 12 Clean area around fuel tank fill cap 1 Figure 5 Open fuel cap WARNING If engine must be run while performing maintenance use extreme care Always have one person in the cab at all times Never le...

Page 124: ...onnect fuel supply line 1 Figure 7 and fuel return line 2 from Fuel tank 3 and carefully drain remaining fuel from lines 15 Remove clamp 4 Figure 7 holding fuel return line 2 to tank 3 16 Tag and disconnect wires leading to fuel sensor 1 Figure 8 on side of fuel tank 2 17 If equipped remove components from fuel filler pump port 3 Figure 8 on side of fuel tank 2 Figure 6 2 1 4 3 ASS1200L Figure 7 2...

Page 125: ...rs 4 Figure 10 holding tank 3 to frame Lift tank 25 mm 1 in and make sure it is balanced Make sure that there are no other electrical wires or hoses connected to tank Completely remove tank after inspection NOTE The clear level gauge on the side of the tank is easily damaged Be careful of obstacles and wind gusts 21 Remove shims 5 Figure 10 NOTE If tank is to be reused note position and amount of ...

Page 126: ...clear level gauge on the side of the tank is easily damaged Be careful of obstacles and wind gusts 3 Install shims 5 Figure 11 as needed to prevent tank 3 from rocking or stress from mounting bolts 4 4 Tighten mounting bolts 4 Figure 11 after shims are installed NOTE Bolt torque is 27 kg m 5 Install four bolts 4 Figure 12 and cover 5 on fuel tank Install four bolts 1 and 2 clamp 6 and stay 3 on fu...

Page 127: ... Connect as tagged fuel supply line 1 Figure 14 and fuel return line 2 to fuel tank 3 9 Install clamp 4 Figure 14 to hold fuel return line 2 to tank 3 10 Make sure fuel tank drain valve Figure 15 on bottom of tank is closed 11 Fill fuel tank and check for signs of leaks Correct any problems found 12 Connect negative battery cable to battery 2 ASS1210L 3 1 Figure 13 2 1 4 3 ASS1200L Figure 14 Figur...

Page 128: ...el filter head 2 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 3 Tighten plug in fuel filter head 4 Continue to pump primer pump until a strong resistance is felt Screw primer pump knob back into housing 5 Start engine and look for signs of leaks 6 Repeat procedure if necessary Figure 16 Figure 17 ...

Page 129: ...onsibility MODEL SERIAL NUMBER RANGE Mega 130 0001 and Up Mega 160 0001 and Up Mega 200 III 1001 and Up Mega 200 V Tier I II 1001 and Up Mega 250 III 1001 and Up Mega 250 V Tier I 1001 thru 2000 Mega 250 V Tier II 2001 and Up Mega 300 V Tier I 1001 thru 2000 Mega 300 V Tier II 2001 and Up Mega 400 III PLUS 1001 and Up Mega 400 V 1001 and Up Mega 500 V 1001 thru 2000 Mega 500 V Tier II 2001 and Up ...

Page 130: ...r 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 Solar 290LC V 0001 and Up Solar 290LL 1001 and Up Solar 300LC V 1001 and Up Solar 300LL 1001 and Up Solar 330LC V 1001 and Up Solar 340LC V 1001 and Up Solar 400LC V 1001 and Up Solar 420LC V 1001 an...

Page 131: ...HEORY OF OPERATION Fuel pump consists of motor pump switch and hose assembly Figure 1 Reference Number Description 1 Motor 2 Pump 2 1 Pump Cover 2 2 Rotor and Vane 3 Inlet Hose 4 Outlet Hose 5 Check Valve 6 Strainer Cap Reference Number Description Figure 2 ...

Page 132: ...o or very close to zero the motor is bad and must be replaced On units equipped with a toggle switch check the resistance through the toggle switch while the switch is in the ON position If continuity is not present the switch is bad Be sure to check resistance through the motor REPLACEMENT OF ROTOR AND VANE If dirt or other foreign materials enter pump during operation it can become lodged betwee...

Page 133: ...mbly and a thermal limiter are installed in the rear cover If you find any damage replace them with new ones Remove the switch cover and screw M5 x L95 from the rear cover Remove cover At reassembly of rear cover widen the space of brush and insert it to the armature Then fit the hole of screw in the housing Be careful when installing screw The cover screw may be attracted by the motor magnet Figu...

Page 134: ...over than remove the armature from the housing Remove the pump cover and remove the rotor and vane Insert a new armature into the housing Refer to Replacement of Rear Cover on page 5 for installation of rear cover Fit the rotor in the shaft flute of armature Insert vane to the rotor being careful for the direction Refer to Replacement of Rotor and Vane on page 4 Figure 8 ...

Page 135: ...is your own personal responsibility MODEL SERIAL NUMBER RANGE Solar 75 V 1001 and Up 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 Solar 290LC V 0001 and Up Solar 290LL 1001 and Up Solar 300LC V 1001 and Up Solar 300LL 1001 and Up Solar 33...

Page 136: ... Swing Bearing 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 ...

Page 137: ...ents at 4 points 90 apart around the circumference of the bearing Figure 1 Record and keep all measurements Play in the bearing should increase minimally from one inspection to the next Eventually however as the bearing begins to approach the limit of its service life clearance increases become much more pronounced and the actual measured play in the bearing could exceed twice the value that was m...

Page 138: ...ed to the pinion by planetary gears connected to gears on the inner ring which is fixed in the undercarriage Ball bearings turn the outer ring REBUILDING SWING BEARING 1 Remove tip of tapered pin 1 Figure 3 using grinder and tap lightly to remove debris 2 Remove plug 1 Figure 4 using a M10 x 1 25 bolt 2 Reference Number Description 1 Ball 2 Seal A 3 Seal B 4 Retainer 5 Retainer 6 Outer Ring 7 Inne...

Page 139: ... 6 to remove steel balls 2 5 Turn inner ring and use wire 1 Figure 7 to remove retainers 2 6 Assemble in reverse order of disassembly and then adjust the gap between the steel balls and retainers using the following guidelines Assemble steel ball retainer A and retainer B to bearing if gap is too wide adjust by moving steel balls or by replacing one of the retainers Figure 5 Figure 6 Figure 7 Figu...

Page 140: ...S0407000 Page 6 Swing Bearing ...

Page 141: ...op practices outlined in the front of this manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Solar 225NLC V 1001 and Up Copyright 2002 Daewoo October 2002 ...

Page 142: ...ory 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 6 Spring Pin Insert Jig 6 Troubleshooting Testing and Adjustment 7 Removal 8 Disassembly 9 Cleaning and Inspection Wear Limits and Tolerances 14 Reassembly 15 Installation 24 ...

Page 143: ...s 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 The final drive reduces swing motor RPM in order to increase swing motor output torque The available maximum swing speed 12 3 RPM provides a fast turning rate for efficient rapid work cycling with more than adequate power for good acceleration ...

Page 144: ...S0408015K Page 4 Swing Reduction Gearbox Return to Master Table of Contents PARTS LIST 29 30 23 24 22 11 20 14 13 12 9 11 15 10 8 7 27 4 2 3 33 5 1 16 17 19 18 25 31 28 32 26 BBS0010L Figure 1 ...

Page 145: ...her No 3 18 Sun Gear No 2 19 Knock Pin 20 Carrier No 1 21 22 Planet Gear No 1 23 Pin Assy No 1 24 Socket Bolt 25 Sun Gear No 1 26 Snap Ring 27 Plug 28 Plug 29 Level Gage Pipe 30 Level Gage 31 Washer Diuble Tab 32 Pipe 33 Bolt Hex HD Reference Number Description Swing Reduction Gearbox Specification Drive Type Two Stage Planetary Gear Reduction Ratio 19 64 Maximum Output Speed 83 6 rpm Maximum Outp...

Page 146: ... Front Bearing Jig Oil Seal Insert Jig Spring Pin Insert Jig Dimension Measurement A 100 0 mm 3 94 in Dia B 80 0 80 30 mm 3 15 3 16 in Dimension Measurement A 155 0 mm 6 10 in Dia B 140 0 mm 5 51 in Dia C 2 50 mm 0 10 in Dimension Measurement A 7 50 mm 0 30 in Dia B 15 0 mm 0 59 in C 4 50 mm 0 18 in Dia Figure 2 Figure 3 Figure 4 ...

Page 147: ... damage to gearbox Repair replace broken or drive train faulty assemblies c Pressure at swing motor inlet shows Hydraulic pump or valve broken Troubleshoot hydraulic no increase but without irregular system noises from the swing motor 2 Oil leakage a From drive shaft Oil seal damaged Replace oil seal b From bolted connections or other Assembly compound joint sealer Disassemble and check assembled ...

Page 148: ...ntamination from entering hydraulic system or component 8 Disconnect tube 2 from drain valve 3 9 Remove eleven bolts and washers 4 Figure 6 holding swing reduction gearbox 5 to frame 10 Using a suitable lifting device sling swing motor 1 Figure 6 and remove swing motor and reduction gearbox 5 as an assembly from unit NOTE A drain valve 3 Figure 6 and tube are located on side of gearbox Be careful ...

Page 149: ...ar oil from the swing motor final drive prior to removal of the gearbox 2 Loosen and remove the retaining bolts from around the rim of the gearbox Separate the gearbox and swing motor from the excavator 3 Remove the No 1 sun gear as shown IMPORTANT Use a clean dry container with at least 8 liters or 2 gallons capacity to catch gear oil A clean container allows an evaluation to be made of the used ...

Page 150: ...mbly positions of the differential gears and pins prior to disassembly Use a permanent marking pen removable paint or another available marking tool that will not cause any surface damage Remove the side plate 19 the No 1 differential gears 7 the needle cage bearing 24 and the remaining side plate 18 NOTE Use additional locating marks for reassembly reference on the side plates or other parts of t...

Page 151: ... 18 19 side plates of the differential gears 9 Disassemble the ring gear Tighten two 16 mm bolts into the holes shown in the photograph Separate the ring gear using even force 10 Before turning the gearbox end for end 180 so that the drive shaft is facing up as shown in the photograph remove the 4 pipes and lock pins 21 Lock pins 21 should not require further disassembly Loosen the mounting bolts ...

Page 152: ...er soft faced hammer if there is any sticking or resistance 13 Remove the thrust plate 14 Further disassembly of the drive shaft requires the use of a hydraulic press Use the drive shaft front bearing jig to separate the bearing and front seal 11 Remove the stop ring 34 on the opposite end of the drive shaft in order to remove the smaller bearing 23 on the inner end of the drive shaft Make an inde...

Page 153: ... 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 ...

Page 154: ... Inspect all components in the assembly Pay particular attention to oil seals lock and spring pins and fastener bolts Using new replacement parts for these components is recommended whenever there is any doubt at all about the condition or serviceability of original parts 1 Distance L Figure 23 between face of thrust button and end of outer bore of drive shaft should be 135 mm 5 315 If not replace...

Page 155: ...face with a small amount of grease and install the O ring inside the seal ring 3 Preheat the outer bearing in an oil bath or other type of heater to between 80 and 100 C 176 to 212 F Heat expansion should allow installation of the bearing on the drive shaft using a hammer Check the reference mark made on the old bearing to make sure the bearing is not inverted during the installation The 80 mm bea...

Page 156: ...late 8 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 9 Position the gearbox housing horizontally Make sure that the inside of the housing is clean and free of any stray contaminant particles Figure 27 Figure 28 Figure 29 Figure 30 ...

Page 157: ...x housing 11 Attach the O ring 12 Install the oil seal in the front cover NOTE The contact surface of the oil seal can be damaged if the oil seal is installed carelessly Lubricate the contact surface and make sure it is pressed in straight 13 Install the front cover retaining bolts and tighten them in even rotation to the specified torque value Figure 31 Figure 32 Figure 33 Figure 34 ...

Page 158: ...ble the thrust washer to the carrier 15 Attach the No 2 differential gears Mount the upper thrust washer and then the lower thrust washer 16 Insert the No 2 pin into the spring pin then into the hole in the No 2 carrier 17 Use the spring pin insert jig dimensional specifications follow the Parts List at the beginning of this section to attach the spring pin Figure 35 Figure 36 Figure 37 Figure 38 ...

Page 159: ...n the assembly on top of the workbench The drive shaft should be facing down 21 Push lock pins into the four holes in the gearbox housing Apply an even thin continuous bead of Silicone flexible sealant to the contact surfaces of the housing and the ring gear A noncorrosive increased oil resistance silicone formula is recommended Figure 39 Figure 40 Figure 41 Figure 42 ...

Page 160: ... in step 5 of the Swing Motor Gearbox Final Drive Disassembly procedure immediately preceding this section Slip flat washers under the mounting bolts and be careful not to damage any of the mating surfaces between the gearbox and swing motor 23 Install the 4 pipes into the upper portion of the lock pins 24 Attach the No 2 carrier assembly in the ring gear 25 Install the No 2 sun gear Figure 43 Fig...

Page 161: ...press them into place with a press 27 Install spring pins using the spring pin insert jig as in step 17 preceding and punch two notches off each spring pin 28 Install lower side plates NOTE The upper and lower side plates have different thicknesses Lower side plates are approximately 1 mm 0 39 thick 29 Install the center side plate to about 1 mm or 0 39 Figure 47 Figure 48 Figure 49 Figure 50 ...

Page 162: ... and differential gear 31 Install the upper side plates and stop rings to about 2 mm or 0 079 32 Hold the No 1 carrier assembly stationary and verify that the center side plate is positioned correctly in the recess of the No 2 sun gear 33 Install the No 1 sun gear Figure 51 Figure 52 Figure 53 Figure 54 ...

Page 163: ... for increased oil resistance is recommended 35 Install the stop ring on the drive shaft of the swing motor Verify alignment of spline grooves before assembling the motor and gearbox Tighten assembly bolts to the specified torque value using an even staggered sequence 36 Use teflon tape or some other similar thread sealant on the gearbox drain plug prior to installation Fill the gearbox with 6 lit...

Page 164: ...a suitable lifting device sling swing motor 1 Figure 57 and position swing motor and reduction gearbox 5 as an assembly on unit 4 Install eleven bolts and washers 4 Figure 57 to secure swing reduction gearbox 5 to frame NOTE Apply Loctite 262 to bolt threads 5 Connect tube 2 to drain valve 3 6 Connect hoses as tagged during removal to swing motor 1 Figure 57 7 Fill swing reduction gearbox with oil...

Page 165: ...1LOWER STRUCTURE AND CHASSIS ...

Page 166: ......

Page 167: ...he front of this manual or those contained within this section 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 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 ...

Page 168: ...Track Installation 11 Front Idler Roller 12 Parts List 12 Front Idler Roller Disassembly 13 Front Idler Roller Reassembly 15 Lower Roller 16 Parts List 16 Lower Roller Removal 17 Lower Roller Disassembly 17 Lower Roller Reassembly 18 Lower Roller Installation 19 Upper Roller 20 Parts List 20 Upper Roller Removal 21 Upper Roller Disassembly 21 Upper Roller Reassembly 23 Track Spring and Track Adjus...

Page 169: ...measurement 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 Take all necessary precautions to make sure the machine won t move or shift position during service Warm up the engine to prevent stalls travel the excavator to an area that provides l...

Page 170: ...oximately 380 mm 14 96 in for operation over gravel rocky terrain or over sand or snow 5 Track tension adjustments are made through the grease fitting 1 Figure 3 in the middle of each side frame Adding grease increases the length of an adjustment cylinder 2 The longer the adjustment cylinder the greater the pressure on the tension spring pushing the track idler wheel outward 6 If there is not enou...

Page 171: ...ures section for general recommendations and specific safety precautions before starting any lower travel frame component rebuilding procedure Component Reference Dimensions Reference Normal New Dimension Recommended Limit for Maintenance Limit for Use Repair P or Replace R Standard S220LC V 600 mm 23 62 in Shoe S225LC V 600 mm 23 62 in Shoe S225NLC V 500 mm 19 69 in Shoe A 21 0 mm 0 83 in B 14 0 ...

Page 172: ...34 in Master pin Lower roller axle A 70 mm 2 756 in 68 60 mm 2 70 in 68 30 mm R 2 69 in Lower roller bushing A 70 mm 2 756 in 70 5 mm 2 776 in 70 70 mm R 2 78 in Axle bushing clearance 1 0 mm 0 039 in 1 50 mm 0 06 in Gap between bushing and side collar Total amount for both sides B 1 0 mm 0 039 in 1 80 mm 0 07 in Flange thickness B 4 30 mm 0 17 in 3 80 mm 0 15 in 3 50 mm 0 14 in Lower roller dimen...

Page 173: ...46 50 mm 1 83 in 46 20 mm R 1 82 in Upper roller bushing A 47 0 mm 1 85 in 47 50 mm 1 87 in 48 0 mm 1 89 in Axle bushing clearance 1 0 mm 0 039 in 1 20 mm R 0 05 in Gap between bushing and side collar B 1 0 mm 0 04 in 1 50 mm 0 06 in Flange thickness B 6 50 mm 0 26 in 6 0 mm 0 24 in 5 70 mm 0 22 in Upper roller A 183 0 mm 7 20 in B 80 0 mm 3 15 in C 142 mm 5 591 in 136 0 mm 5 35 in 130 mm P 5 118 ...

Page 174: ... in 76 0 mm R 2 99 in Axle bushing clearance 1 0 mm 0 039 in 1 8 mm 0 071 in Gap between bushing and side collar Total amount for both sides B 1 0 mm 0 039 in 1 50 mm 0 06 in Bushing flange thickness B 7 0 mm 0 276 in 6 5 mm R 0 256 in Front idler A 160 0 mm 6 30 in 150 0 mm 5 91 in 140 0 mm P 5 51 in B 85 0 mm 3 35 in 75 0 mm 2 95 in 65 0 mm P 2 56 in C 520 0 mm 20 47 in 504 0 mm 19 84 in 494 0 m...

Page 175: ...S LIST Figure 13 Reference Number Description 1 Track Link Assembly 2 Link Track R H 3 Link Track L H 4 Link Master R H 5 Link Master L H 6 Pin 7 Spacer 8 Pin Lock 9 Bushing 10 Bushing Master 11 Pin Master 12 Shoe 500 mm 19 69 in Shoe 600 mm 23 62 in 13 Bolt 14 Nut Reference Number Description ...

Page 176: ... 4 Remove four nuts and bolts 2 holding shoe to link Remove enough shoes to make access to lock pin easier NOTE Support track shoes with blocking so that when master pin 4 is removed tack will not fall 5 Straighten lock pin 3 and remove it from master pin 4 Discard lock pin 6 Remove master pin from master links 7 Move unit forward until entire track is laying on ground NOTE Do not drive unit off t...

Page 177: ...th blocking removed lower track frame onto track Make sure all rollers are properly positioned on track 4 Move unit backwards while feeding track up over front idler roller Continue to pull track back until it engages drive sprocket 5 Align master links and install master pin 6 Insert new lock pin in master pin Bend end of pin over so it is pointing in opposite direction of other end as shown 7 Ap...

Page 178: ... Track Assembly Return to Master Table of Contents FRONT IDLER ROLLER PARTS LIST Figure 19 Reference Number Description 1 Bearing 2 Plug 3 Pin 4 O ring 5 Axle 6 Group Seal 7 Idler 8 Bushing Reference Number Description ...

Page 179: ...ER DISASSEMBLY 1 Remove plug 2 Figure 20 and drain oil from roller assembly 1 2 Separate the pin 3 Figure 21 from the bearing 1 3 Use a press to remove the bearing from the axle Separate the O ring 4 Figure 22 from the axle and insert it into the bearing Figure 20 Figure 21 Figure 22 ...

Page 180: ...able of Contents 4 Detach the group seal 6 Figure 23 from the idler 7 and bearing 1 5 Use a press to separate the axle 5 Figure 24 O ring 4 and bearing 1 6 Remove bushing 8 Figure 25 with the press and special tool ST 1909 Figure 23 Figure 24 Figure 25 ...

Page 181: ... Align the bearing 1 Figure 26 and axle 5 holes and pin 3 them together 4 Install group seal 6 Figure 27 inside the idler 7 and bearing 1 NOTE Apply clean engine oil to the joint side of the group seal Apply grease to the group seal O ring 5 Install idler 7 Figure 28 on the axle 6 Install bearing 1 Figure 28 and pin 3 to the axle NOTE Fill the idler assembly with new engine oil with approximately ...

Page 182: ...sembly Return to Master Table of Contents LOWER ROLLER PARTS LIST Figure 29 Reference Number Description 1 Pin 2 O ring 3 Collar 4 Axle 5 Roller 6 Group Seal 7 Bushing 8 Plug 9 Spring Washer 10 Bolt Reference Number Description ...

Page 183: ...embly from track frame There is an alignment pin on each end of lower roller assembly NOTE To gain access to some rollers the link guard may have to be removed Remove four spring washers and bolts to remove guard NOTE If additional track clearance is required remove upper rollers before raising track LOWER ROLLER DISASSEMBLY 1 Remove plug from the collar and drain oil 2 Pull the pin 1 Figure 31 fr...

Page 184: ... and roller 5 6 Detach collar 3 Figure 33 and O rings 2 from the axle using a press LOWER ROLLER REASSEMBLY 1 Degrease clean and dry all parts before reassembly Insert bushing 7 Figure 34 into roller 2 Apply grease to the O rings 2 Figure 34 and insert into axle 3 Align collar 3 Figure 35 and axle 4 pin holes and pin 1 the collar Figure 33 Figure 34 Figure 35 ...

Page 185: ... Slide the axle inside the roller 6 Install the collar 3 Figure 37 O ring 2 and pin 1 on the remaining side 7 Fill with clean engine oil with approximately 300 cc 10 1 fluid ounces LOWER ROLLER INSTALLATION 1 Install four bolts to hold lower roller assembly to track frame NOTE To gain access to some rollers a link guard may have to be removed Remove four spring washers and bolts to remove guard Fi...

Page 186: ...urn to Master Table of Contents UPPER ROLLER PARTS LIST Figure 39 Reference Number Description 1 Plug 2 Bolt 3 Cover 4 Bolt 5 Washer 6 Roller 7 Axle 8 Group Seal 9 Bracket 10 Bushing 11 O ring 12 Lock Washer Reference Number Description ...

Page 187: ...sition a bottle jack on top of track frame and apply pressure to track shoe 3 Remove mounting hardware holding upper roller assembly to track frame UPPER ROLLER DISASSEMBLY 1 Remove the plug 1 Figure 41 from the cover and drain oil 2 Remove the bolts and cover 3 Figure 42 Detach bolts 4 and washer 5 3 Separate the roller 6 Figure 43 from the axle 7 Figure 40 Figure 41 Figure 42 Figure 43 ...

Page 188: ...k Assembly Return to Master Table of Contents 4 Separate the group seal 8 Figure 44 from the roller and bracket 9 5 Separate the bushing 10 Figure 45 from the roller with a press and special tool ST 1919 Figure 44 Figure 45 ...

Page 189: ... 47 into the roller 6 and bushing NOTE Apply clean engine oil to the joint side of the group seal Apply grease to the group seal O ring 3 Install the axle washer 5 Figure 48 and bolt 4 4 Attach group seal 8 Figure 39 to the roller 6 Figure 48 and cover 3 5 Insert the O ring 11 Figure 48 to the cover Attach cover 3 and bolt 2 to the roller 6 Fill with 200 cc 6 8 fluid ounces of engine oil Figure 46...

Page 190: ...S0505030 Page 24 Track Assembly Return to Master Table of Contents 7 Tighten plug 1 Figure 49 Figure 49 ...

Page 191: ...JUSTING CYLINDER PARTS LIST Figure 50 Reference Number Description 1 Piston Rod 2 Piston Ring 3 Backup Ring 4 Packing 5 Retaining Ring 6 Rod 7 O ring 8 Cylinder 9 Spring 10 Spacer 11 Flange 12 Nut 13 Valve 14 Bolt 15 Plate 16 Yoke 17 Socket Bolt 18 Flange 19 O ring Reference Number Description ...

Page 192: ...S0505030 Page 26 Track Assembly Return to Master Table of Contents ...

Page 193: ...1ENGINE AND DRIVE TRAIN ...

Page 194: ......

Page 195: ...fting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE 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 Solar 300LL 1001 and Up Solar 340LC V 10...

Page 196: ...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 19 Refrigerant Safe Handling Procedures 19 Repair and Replacement Procedure 20 Refrigerant Recovery 22 Vacuuming Refrigerant System 22 Leakage Check 23 Refrigerant Charging 24 Inspecting System For Leakage 26 ...

Page 197: ... air filtration system which filters out dirt and dust particles from air being circulated into operator s cab This filter should be cleaned out every 500 hours NOTE In the event that the unit is being operated in a dusty environment the cleaning and replacement should be performed more frequently If filter element is damaged replace damaged filter by a new one WARNING All service and inspection o...

Page 198: ...re 3 and inspect for any damage 6 Use compressed air to clean filter element If filter element is very dirty use a mild soap or detergent and water to clean it NOTE If water was used to clean filter be certain it is completely dry before installing NOTE When assembling the filter again install so that the arrow on top of filter is facing the inside of the cab NOTE Refer to appropriate Operation an...

Page 199: ...onditioner REFRIGERANT CIRCULATION 1 2 3 4 5 6 HDA6046L Figure 4 Reference Number Description 1 Evaporator 2 Expansion Valve 3 Condenser 4 Condenser Fan 5 Compressor 6 Blower Fan 7 Receiver Dryer Reference Number Description ...

Page 200: ...air surrounding the evaporator creating a cooling effect and changes from the gas to the liquid state The refrigerant once again flows into the compressor in the gaseous state and the process is repeated Shading Temperature Refrigerant State High High Pressure Gas High High Pressure Liquid Low Low Pressure Liquid High High Pressure Gas Liquid Low Low Pressure Gas WARNING Refrigerant gas is pressur...

Page 201: ...PUT CONTROL PANEL OUTPUT A C CONTROL PANEL DISPLAY LOW SPEED RELAY TEMPERATURE SENSOR MID SPEED RELAY HIGH SPEED RELAY BLOWER MOTOR VENT ACTUATOR DEF ACTUATOR INTAKE ACTUATOR COMP RELAY CONDENSER FAN RELAY MIX DOOR VENT CONTROL FOOT DEF RECYCLE FRESH AIR CONTROL COMPRESSOR CONDENSER FAN TEMPERATURE CONTROL ACTUATOR HDA6048L TEMP CONTROL ACTUATOR Figure 6 ...

Page 202: ... consists of a 24 step variable selector The display uses 7 Green Red two color LEDs to display the selected temperature Blower Fan Speed Control OFF Switch LOW Switch MID Switch HI Switch Compressor Control Temperature Sensor 100 50 0 MAX HOT MAX COOL HDA6049L Figure 7 HI RELAY MID RELAY LOW RELAY OFF LOW MID HI HDA6050L Figure 8 COMP OFF COMP ON 1 5 C 4 0 C HDA6051L Figure 9 ...

Page 203: ...n Green 3 28 V 0 2 8 Red Red Green Green Green Green Green 3 11 V 0 2 9 Red Red Red Green Green Green Green 2 93 V 0 2 10 Red Red Red Green Green Green Green 2 76 V 0 2 11 Red Red Red Green Green Green Green 2 59 V 0 2 12 Red Red Red Red Green Green Green 2 41 V 0 2 13 Red Red Red Red Green Green Green 2 24 V 0 2 14 Red Red Red Red Green Green Green 2 07 V 0 2 15 Red Red Red Red Red Green Green 1 ...

Page 204: ...S0605060K Page 10 Air Conditioner AIR DISCHARGE ACCORDING TO PATH SELECTION Face Rear and Defroster Foot ARS1280L Figure 10 ARS1290L Figure 11 ...

Page 205: ...S0605060K Page 11 Air Conditioner Face and Defroster ARS1300L Figure 12 ...

Page 206: ...6 HRS 26P 14 9 2 7 15 9 26 16 CN5 16 2 1 4 15 4 5 6 1 2 COOL 15 CN5 AMP MIC 13P 13 6 12 11 4 5 10 9 3 7 8 2 1 15 8 M 15 1 87 9 87a 87 M 85 8 87a 7 10 30 BLOWER SPEED TEMP CONTROL RECIRCLE FRESH AIR MODE 86 10 MODE SELECT 7 VENT 23 21 20 14 17 DEF 8 3 FOOT 18 19 8 9 REC 10 FRE 13 LOW 11 30 LED 1 12 22 9 13 3 5 11 12 HIGH MID M 14 15 3 15 6 0 I 6 II 3 5 2 20A 10A 30A 4 B E BR 3 15 2 15 7 M 15 6 M 15...

Page 207: ...Relay 10 Foot Defrost Control Actuator 11 Receiver Dryer Low High Pressure Cut Off Switch 12 Diode 13 Compressor 14 A C Control Panel 15 A C Unit 15 1 Blower Motor 15 2 Resister 15 3 High Speed Relay 15 4 Mid Speed Relay 15 5 Low Speed Relay 15 6 Recirculate Fresh Air Control Actuator 15 7 Vent Actuator 15 8 Temperature Control Actuator 15 9 Temperature Sensor Evaporator Reference Number Descripti...

Page 208: ...dy 1 Check for traces of refrigerant oil Yes Reassemble using correct tightening torque No Go to next step 2 Using a leak detection device or soapy water check for refrigerant leakage at all major components and joints Yes Repair leaking component No Recharge system to correct pressure 2 High Pressure Over 23 kg cm2 327 psi Low Pressure Approximately 2 5 3 0 kg cm2 36 43 psi Possible Cause Overcha...

Page 209: ...1 3 46 9 psi Yes Moisture in system replace receiver dryer No Contaminated system replace expansion valve Replace evaporator core assembly 5 High Pressure Over 6 18 kg cm2 85 256 psi Low Pressure 500 mmHg Negative Pressure Dial indicator needle unstable Possible Cause Moisture in system has iced up the expansion valve NOTE When the absorbed moisture freezes the pressure readings may look normal Ca...

Page 210: ...ir Conditioner 7 High Pressure Over 7 0 11 0 kg cm2 100 156 psi Low Pressure 4 0 6 0 kg cm2 57 85 psi Possible Cause Low refrigerant pressure due to poor compressor compression Inspect and replace compressor if necessary ...

Page 211: ...lar 70 III 800 20 grams 28 0 7 oz Solar 75 V 750 20 grams 26 0 7 oz Solar 130 III 950 20 grams 33 0 7 oz Solar 130LC V 850 20 grams 30 0 7 oz Solar 130W III 950 20 grams 33 0 7 oz Solar 130W V 850 20 grams 30 0 7 oz Solar 140W V 850 20 grams 30 0 7 oz Solar 160W V 850 20 grams 30 0 7 oz Solar 170LC V 850 20 grams 30 0 7 oz Solar 170W III 1100 20 grams 38 0 7 oz Solar 180W V 850 20 grams 30 0 7 oz ...

Page 212: ...s 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 850 20 grams 30 0 7 oz Solar 420LC V 850 20 grams 30 0 7 oz Solar 450LC III 1250 20 grams 44 0 7 oz Solar 450LC V 850 20 grams 30 0 7 oz Solar 470LC V 850 20 grams 30 0 7 oz Model Weight of Gas ...

Page 213: ...tem standards require new tools equipment and parts DO NOT attempt to use equipment use in servicing the old refrigerant system 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 i...

Page 214: ...refrigerant system with the engine running do not open the high pressure valve on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose 10 When releasing the high pressure hose after completing the charging process quickly disconnect the hose to minimize refrigerant released to the air REPAIR AND REPLACEMENT PROCEDURE 1 Work Procedure A Before repairing or repla...

Page 215: ...OR AIR LEAKAGE 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 RUN SYSTEM RECOVER REFRIGERANT IN CHARGING HOSE REMOVE REPAIR TOOLS REPAIR HDA6067L Figure 16 ...

Page 216: ...auge dials indicates 0 kg cm2 0 psi VACUUMING REFRIGERANT SYSTEM 1 Vacuuming Procedure NOTE When the A C system has been exposed to the air it must be vacuumed out Perform vacuum process for 30 minutes for complete moisture and air evacuation A Attach the manifold gauges and vacuum pump to the refrigerant system as shown B Turn on the vacuum pump and open both valves C When the low pressure gauge ...

Page 217: ...ockwise most position with the puncture pin retracted and the mounting disk is in the raised position B Attach the manifold gauge center hose to the valve assembly C Turn the disc in the clockwise direction and securely mount valve onto refrigerant container D Turn the valve handle in the clockwise direction and puncture the container seal with the pin E Once the can has been punctured turn the ha...

Page 218: ... CHARGING 1 Perform the vacuuming procedure vacuum holding and leaking tests as described in the proceeding headings NOTE First charge the refrigerant system with 100g 3 5 ounces of refrigerant with the engine off Then using the manifold gauges as a guide fully charge the system with the engine running When exchanging refrigerant containers press the manifold gauge low side valve to eliminate air ...

Page 219: ...low pressure side valve Reference Number Description 1 To Compressor 2 Low Pressure Side 3 High Pressure Side 4 From Receiver 5 Refrigerant Supply Container WARNING When charging refrigerant system with the engine running Always keep refrigerant supply container in the upright position Never open the high side pressure valve Gauge Dial Standard Reading High Side Gauge 13 20 kg cm2 185 285 psi Low ...

Page 220: ...rate test Inspection Procedure 1 High Pressure Side Compressor outlet condenser inlet receiver dryer inlet air conditioner unit inlet 2 Low pressure side Compressor inlet air conditioner unit outlet 3 Compressor Compressor shaft area bolt hole area and magnetic clutch area 4 Receiver dryer Pressure switch and plug area 5 Connection valve area Inspect all valve areas Verify all valves are capped to...

Page 221: ...your own personal responsibility MODEL SERIAL NUMBER RANGE DD80L 0001 and Up Solar 130LC III 0001 and Up Solar 130LC V 0001 and Up Solar 130W III 0001 and Up Solar 130W V 0001 and Up Solar 140W V 1001 and Up Solar 160W V 1001 and Up Solar 170LC III 0001 and Up Solar 170W III 0001 and Up Solar 170W V 1001 and Up Solar 200W III 0001 and Up Solar 200W V 0001 and Up Solar 210W V 1001 and Up Solar 220L...

Page 222: ...g Installation 8 Installation Procedure 13 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 Solar 450 III 0001 and Up Solar 450LC V 0001 and Up MODEL SERIAL NUMBER RANGE ...

Page 223: ...y 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 Figure 1 KAWASAKI OR TONG MYUNG Figure 2 UCHIDA Figure 3 SAUER SUNDSTRAND ...

Page 224: ...ump drive shaft and the front face of the drive coupling hub Figure 4 and Figure 9 This distance will be referred to as Measurement H in the installation instructions that follow NOTE In manufacturing drawings Figure 5 and Figure 6 dimension A and B equal the Measurement H The two tools shown are designed to be used on various models of equipment Only one end of the tool is used for a specific mod...

Page 225: ... 0 1 mm 0 7087 0 0039 in DD80L B 5 5 0 1 mm 0 2165 0 0039 in S330LC III S330LC V S400LC III S400LC V S450LC V C 20 0 mm 0 787 in D 7 0 mm 0 275 in E 11 0 mm 0 433 in Radius F 18 0 mm 0 708 in Radius G 30 0 mm 1 181 in Radius H 1 0 mm 0 039 in x 45 Chamfer KNURL RELIEF RELIEF A B C D E F G H HAAA8350 Figure 5 ...

Page 226: ... V S225LC V S225NLC V S250LC V S255LC V 2 0 0 1 mm 0 0787 0 0039 in S170LC V S170W V 1 0 0 1 mm 0 0394 0 0039 in S140W V S160W V B 5 0 0 1 mm 0 1969 0 0039 in S280LC III S290LC V S290LL C 20 0 mm 0 787 in D 7 0 mm 0 275 in E 12 0 mm 0 472 in Radius F 14 50 mm 0 570 in Radius G 25 0 mm 0 984 in Radius H 1 0 mm 0 039 in x 45 Chamfer C RELIEF KNURL RELIEF HAAA8360 A B D E F G H Figure 6 ...

Page 227: ...ll be referred to as Measurement H in the installation instructions that follow NOTE In manufacturing drawing Figure 8 dimension A equals Measurement H Dimensional Details for Figure 8 Dimension Measurement Models A 16 0 1 mm 0 6299 0 0039 in S130W III S130W V B 8 mm 0 315 in C 60 mm 2 362 in D 40 mm 1 575 in E 55 mm 2 165 in F 40 mm 1 575 in G 5 0 mm 0 196 in Radius H TAP M10X1 5 Figure 7 A B C D...

Page 228: ... 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 ...

Page 229: ...S0609000 Page 9 Drive Coupling Main Pump Figure 10 DRIVE COUPLING INSTALLATION UCHIDA PUMP ...

Page 230: ... Information and Torque for Figure 9 and Figure 10 Reference Number Description Qty Torque See Table 2 and 3 1 Spring Pin 4 2 Insert 4 3 Bolt 4 Ta 4 Flywheel 1 5 Spring Pin 8 6 Insert 4 7 Hub 1 8 Bolt 4 Ta 9 Pump Shaft 1 10 Clamping Screw 2 Tb 11 Element 1 ...

Page 231: ... 9042 2 5 3 5 mm 0 098 0 138 in 21 23 kg m 152 166 ft lb 10 12 kg m 72 87 ft lb S170W III 2414 9025 Note 2 21 23 kg m 152 166 ft lb 10 12 kg m 72 87 ft lb S200W III S220LC III 2414 9008A 10 0 11 0 mm 0 394 0 433 in 21 23 kg m 152 166 ft lb 10 12 kg m 72 87 ft lb S220LC V S220N V S220LL S225LC V S225NLC V S200W V 2414 9041 10 0 11 0 mm 0 394 0 433 in 21 23 kg m 152 166 ft lb 10 12 kg m 72 87 ft lb ...

Page 232: ...Pump Table 3 Specification for Measurement H for Wheel Excavator Refer to Figure 10 Model Coupling part number Height H mm Ta kg m Tb kg m S130W III 2414 9021 15 5 16 5 0 610 0 650 in 21 23 kg m 152 166 ft lb 10 12 kg m 72 87 ft lb S130W V ...

Page 233: ...g screws to value Tb in the tables NOTE Coat clamping screws 10 with Loctite 262 5 Install element 11 between inserts 2 on engine flywheel 4 6 Install main pump and hub 7 by pushing it softly into element 11 7 Attach flywheel cover pump housing to flywheel housing with bolts CAUTION 1 Bolts 3 and 8 are coated against loosening with a bonding compound Do not use any additional bonding compounds oil...

Page 234: ...S0609000 Page 14 Drive Coupling Main Pump ...

Page 235: ...1HYDRAULICS ...

Page 236: ......

Page 237: ...tices outlined in the front of this manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Solar 225NLC V 1001 and Up Solar 255LC V 1001 and Up Solar 300LC V 100...

Page 238: ...mp Circuit 8 Swing Operating Circuit 8 Right Swing Operating Circuit 9 Left Swing Operating Circuit 9 Swing Relief Valve and Make up Valve 9 Travel Operating Circuit 9 Forward Travel Circuit 10 Reverse Travel Circuit 10 Procedural Troubleshooting Baseline Recommendations 10 Initial Checks and Tests to Establish Operating Condition of the Excavator 10 Triage Summary 10 Pilot Pressure 12 Adjustment ...

Page 239: ...del Solar 255LC V 23 Flow Meter and Flow Meter Kit Installation and Testing 24 Installation and Testing Procedure 24 Swing System Troubleshooting 26 Precautions Initial Checks 26 Swing Relief Valve Checking and Adjustment 26 Troubleshooting Swing Gearbox 28 Troubleshooting Hydraulic Problems 30 Troubleshooting Control Valve 32 Troubleshooting Travel Control Valve 34 Troubleshooting Joystick Contro...

Page 240: ...ency 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 Electronic management of hydraulic control valves assists in optimizing the application speed and overall operator control of...

Page 241: ...rcuit for these functions the output of both pumps can be combined allowing higher speed operation Boom up arm crowd and dumping functions can operate in any one of the two available power modes the standard or general duty mode the high speed rapid cycling mode Whenever the right travel or left travel control spools are shifted output from the main pump assembly flows through the center joint to ...

Page 242: ...condary boom up pilot pressure that is transmitted to the BOOM1 and BOOM2 spools of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 100 130 psi boom control valve spools open and oil from both pumps goes to the boom cylinder BOOM DOWN CIRCUIT When the boom control lever is pushed forward the right side pilot valve generates secondary boom down pilot pressure that ...

Page 243: ... the AM1 and AM2 spools of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 100 130 psi the arm control valve spools AM1 and AM2 open Output flow from both halves of the pump assembly is directed to the arm cylinder When working in the arm crowd mode under certain conditions oil in the arm cylinder could suddenly be forced out by the weight of the arm and bucket In...

Page 244: ...pump flows to the bucket cylinder BUCKET DUMP CIRCUIT When the bucket control lever is put in the dump mode the bucket control valve spool in the left half of the control valve opens to supply oil from the left main pump to the cylinder SWING OPERATING CIRCUIT The swing operating circuit consists of the right main pump in the pump assembly the right half of the control valve and the swing motor To...

Page 245: ...ALVE AND MAKE UP VALVE Whenever the spool is shifted to the neutral mode during swing operation the possibility exists that surge pressure in the circuit caused by inertial momentum of the upper works and correspondingly reduced pressure at the opposite motor port could produce cavitation in the circuit To keep that from happening a 285 kg cm2 4 052 psi relief valve is installed in the swing motor...

Page 246: ...e control valve through the upper works center joint to the travel motors PROCEDURAL TROUBLESHOOTING BASELINE RECOMMENDATIONS INITIAL CHECKS AND TESTS TO ESTABLISH OPERATING CONDITION OF THE EXCAVATOR Triage Summary An excavator that fails to deliver designed performance should be checked for the following Hydraulic flow first and Hydraulic pressure afterwards in a specified order of priority thro...

Page 247: ...perator s seat to inspect the self diagnostic display If the EPOS trouble code display is clear check hydraulic functions in the following sequence Pilot pressure Negacon negative control pressure Main relief pressure front and rear pump Swing pressure Port relief pressure individual control functions boom arm bucket swing and travel Power boost circuit Standard performance tests cylinder speed hy...

Page 248: ... tolerance specified in the table adjust gear pump relief pressure by loosening the lock nut and turning the set screw in clockwise to increase pressure or turning it out to decrease it NOTE Be aware that serial number changes and variation in the joystick assemblies used on different excavators could produce slight change in actual performance characteristics Comparison of part numbers to serial ...

Page 249: ...S0702170K Page 13 Hydraulic System Troubleshooting Testing and Adjustment ...

Page 250: ...nnect the single electrical lead from the power mode valve Attach the jumper harness to the terminal on the valve connect the test leads of the multimeter to the extra leads on the harness and reconnect the valve electrical lead Vent the lever on top of the hydraulic tank to relieve pressure and connect an in line t style adapter to the valve pressure port Install a 60 bar 1 000 psi test gauge in ...

Page 251: ...lic pressure readings 29 4 bar 420 58 psi Standard Mode High Idle 1 950 rpm 0 mA 0 bar Mode Engine RPM Current Pressure Power Mode High Idle 2 150 rpm 600 20 mA Mid range value corresponding to engine rpm for both current and hydraulic pressure readings 4 2 bar 58 29 psi Standard Mode High Idle 2 000 rpm 0 mA 36 6 bar 522 87 psi Mode Engine RPM Current Pressure Power Mode High Idle 2 150 rpm 600 2...

Page 252: ...luid back into the system if excessive fluid was lost To verify operation of the swing priority solenoid valve connect test equipment and begin testing with the work mode switch set to digging the state turning off the trenching lamp and the engine speed control dial at the maximum rpm position Operate the swing motor in both directions Measure signal current and hydraulic pressure through the val...

Page 253: ...t Pressure must be 350 bars 5075 psi or up to 10 bars 145 psi higher Because one adjustment can affect the other check low stage main relief pressure by repeating the cylinder stall test without pressure up Readjust standard relief pressure by turning the inner most smallest diameter screw clockwise to increase the setting or counterclockwise to decrease it Pressure should be at least 330 bars 4 7...

Page 254: ...stment 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 ...

Page 255: ...stently overloaded and engine troubleshooting shows engine performance to be at or above rated output If reduced cylinder speed and diminished work performance provide an indication that rated maximum pump flow may not be available and all other troubleshooting gives no indication of other flaws or hydraulic system defects If pump output is out of balance and one pump is failing to keep up with th...

Page 256: ...elow 1 and 2 Each one of the adjustment procedures could affect the setting of the others Check and record the arm dump speed performance test before and after input power adjustment whether or not a flow meter is used NOTE Regulator adjustments affect total cumulative horsepower since each regulator compensates for the output of the other It is not necessary to adjust both regulators at the same ...

Page 257: ... horsepower 1 4 turn on the adjusting screw is equal to approximately 17 horsepower NOTE For each full turn of adjustment on the larger diameter screw 2 the square tipped adjusting screw should be turned in the opposite direction 2 2 turns to avoid changing inner spring adjustment Pump input power adjustments are normally made in small increments 1 4 turn 90 or less each time Turning the square ti...

Page 258: ... 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 Balance both pumps for equal output Q P HDA3008L Figure 15 Figure 16 ...

Page 259: ...he 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 Q P HDA3008L Figure 17 B AYS0090L 1 Figure 18 ...

Page 260: ...ate fittings and adapter flanges to guarantee a pressure tight seal NOTE Be sure to maintain even tightening torque on all flange fittings Use Loctite brand PST 545 or an alternate manufacturer s hydraulic system joint seal if required to give an airtight seal An assistant who must remain at the operator s control station at all times should restart the engine and run it long enough at minimum rpm...

Page 261: ...s 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 NOTE When testing bucket and swing functions read maximum flow tests at 330 kg cm2 4 785 psi not 350 kg cm2 5075 psi ...

Page 262: ...ne Investigate unusual operating noises or vibration Check for loose bolts connections SWING RELIEF VALVE CHECKING AND ADJUSTMENT Make a check of operating pressures through the swing relief valve if The swing motor fails to turn Swings in one direction only Swings but continues to coast There is drifting on a slope 1 Check operation by connecting A Two 600 bar 8 700 psi pressure gauges to the inl...

Page 263: ... release the brake piston or friction plate may be frozen requiring disassembly of the motor and parts repair replacement Model Solar 255LC V If pressure through the SH port was tested below the minimum 13 bar 190 psi level check the pressure through PA port of the control valve When pressure through the port is at the recommended level the brake release valve should disengage the swing brake allo...

Page 264: ... motor drain rate Replace Repair motor Gear train defective Refer to Swing Gear Troubleshooting procedure Swing functions but only at reduced rpm Causes listed above could also produce dragging swing OR hot or wrong oil OR worn out parts Check above list then replace oil test motor drain rate and check for 03 reading e EPOS self test Left travel speed is also reduced Low output at P1 pump or exter...

Page 265: ...broken or faulty assemblies Pressure at swing motor inlet shown no increase but without irregular noises from the swing motor Hydraulic pump or valve problem Troubleshoot hydraulic system Oil Leakage From drive shaft From bolted connections or other assembled surfaces Oil seal damaged Assembly compound joint sealer old and not sealing bolt not tight or flange warped Replace oil seal Disassemble an...

Page 266: ...r clogged Clean Pump inlet supply side piping or hose allowing air into hydraulic system Tighten connection Oil temperature abnormally high Oil cooler clogged or air circulation to cooler blocked Clean Cooling fan belt tension too loose Readjust belt tension Relief valve set too low Readjust valve Relief valve in constant use Reduce or slow work load or cycling rate Hydraulic oil severely neglecte...

Page 267: ...me out of alignment deformed or twisted Repair Swing motor inoperable Swing brake not releasing Repair or replace Relief valve malfunction Repair or replace Pilot piping damaged Repair or replace Swing motor operates unevenly Swing gear bearing or mounting loose or worn Repair or replace Lubricant worn away inadequate Grease Swing relief valve may be faulty Repair Replace the swing relief valve Pr...

Page 268: ...to neutral sticking spool Check secondary pilot pressure Spool does not return to neutral because of dirt or other contaminants Clean Broken or damaged spring Replace Main relief or port relief not operating properly See above Impurities in pilot circuit Clean Cylinder drops before start at boom up operation Rod check valve damaged or clogged Clean replace Poppet sticking Clean replace Broken or d...

Page 269: ...ng Testing and Adjustment Irregular or uneven pressure Poppet seat damaged or pilot piston sticking to main poppet Clean replace Loose lock nut and adjusting screw Readjust Components worn out past wear limits Replace Problem Possible Causes Remedies ...

Page 270: ... or replace U joint subassembly Secondary pressure too high Dirt other interference between valve parts Clean repair or replace Return line pressure too high Redirect return line Secondary pressure does not hold steady Dirt other interference between valve parts or worn spool sticking intermittently Clean repair or replace Interference or binding on spool return spring Clean repair or replace Inte...

Page 271: ...ssembly Secondary pressure too high Dirt other interference between valve parts Clean repair or replace Return line pressure too high Redirect return line Secondary pressure does not hold steady Dirt other interference between valve parts or worn spool sticking intermittently Clean repair or replace Interference or binding on spool return spring Clean repair or replace Unsteady pressure in tank re...

Page 272: ...S0702170K Page 36 Hydraulic System Troubleshooting Testing and Adjustment ...

Page 273: ... ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE Mega 200 V Tier I II 1001 and Up Mega 250 V Tier II 2001 and Up Solar 55 0001 and Up Solar 55 V Plus 1001 and Up Solar 75 V 1001 and Up 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 Sola...

Page 274: ...S0703010K Page 2 Accumulator TABLE OF CONTENTS General Description 3 Specifications 4 ...

Page 275: ...n and out and an elastic diaphragm to separate the two chambers The flexible diaphragm changes shape to conform to the changing pressures and volumes of the two fluids in the upper and lower chambers There are six possible positions the diaphragm can be in and they are as follows 1 With no gas charge in the upper chamber 0 bar 0 psi empty and no oil in the bottom 0 bar 0 psi dry the elastic diaphr...

Page 276: ...pressure and the accumulator fills to maximum reserve capacity the flexible diaphragm is pushed up into the top of the upper chamber The highest working pressure is sometimes referred to as the P3 pressure and can also be referenced on the manufacturer s data label on the exterior of the accumulator 5 If system oil pressure begins to fall off or is momentarily checked or interrupted the energy sto...

Page 277: ...on 8 kg cm 114 psi 750 cc 45 77 in3 Solar 225LC V S N 1001 and Up Pilot Travel 10 kg cm 142 psi 750 cc 45 77 in3 Solar 225NLC V S N 1001 and Up Pilot Travel 10 kg cm 142 psi 750 cc 45 77 in3 Solar 255LC V S N 1001 thru 1002 Pilot Travel 10 kg cm 142 psi 320 cc 19 53 in3 Solar 255LC V S N 1003 and Up Pilot Travel 10 kg cm 142 psi 750 cc 45 77 in3 Solar 300LC V S N 1001 thru 1099 Pilot Travel 10 kg ...

Page 278: ...Accumulator Solar 470LC V S N 1001 thru 1049 Pilot Travel 10 kg cm 142 psi 320 cc 19 53 in3 Solar 470LC V S N 1050 and Up Pilot Travel 10 kg cm 142 psi 750 cc 45 77 in3 Model Serial Number System Charge Pressure Volume ...

Page 279: ...thin this section 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 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...

Page 280: ...Center Joint Swivel 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 ...

Page 281: ...tents 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: ...010 Page 4 Center Joint Swivel 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 1 2 3 4 5 9 8 7 6 10 1N HAOF410L Figure 1 ...

Page 283: ...nter Joint Swivel Return to Master Table of Contents Reference Number Description 1 Center Joint Body 2 Bearings 3 O ring 4 Thrust Plate 5 Cover 6 Center Joint Stem 7 Plate 8 Bearings 9 Seals Reference Number Description ...

Page 284: ...Master Table of Contents 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: ...on 10 1 Center Joint Body 10 2 Spindle 10 3 Cover 10 4 Spacer 10 5 Shim 10 6 Shim 10 7 Seal Slipper 10 8 O ring 1AP 120 10 9 O ring 1BP 100 10 10 O ring 1BG 120 10 11 Plug PT3 4 10 12 Ring Retaining 10 13 Bolt M12x1 75x30 10 14 Washer Spring M12 23 Washer Spring 29 Bolt Reference Number Description ...

Page 286: ...piping connections of the excavator A high pressure relief valve with a setting pressure 1 5 times maximum system pressure A stop valve A manually operated in line change over valve Install the change over valve upstream from one of the stem high pressure ports Connect the pressure gauge downstream from one of the body ports Install the stop valve between the change over valve and the stem of the ...

Page 287: ...dures or emergency tear down use a thin but rounded tip smooth edge scraper or spatula to remove O rings or seals to avoid causing damage to those that must be reused NOTE The backup ring shown in the assembly drawing above the swivel joint stem lower seals should not be overlooked It is tucked behind the top slip ring doubled up inside the same groove in the body of the stem 7 Before reassembling...

Page 288: ...cover bolts 5 Pre fill the center swivel with clean hydraulic fluid before reassembly of high pressure and drain line piping Clean and pre fill piping line ends to reduce the amount of air in the system Bleed air from the hydraulic system and verify hydraulic tank fluid level before returning the excavator to service CAUTION Apply a very light film of white grease or petroleum jelly to the lower r...

Page 289: ...onal responsibility MODEL SERIAL NUMBER RANGE Solar 55 0001 and Up Solar 55 V Plus 1001 and Up Solar 75 V 1001 and Up Solar 130LC V 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 Solar 170W V 1001 and Up 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 Sol...

Page 290: ...s 6 Piston Nut 6 Piston Jig 10 Steel bush Jig 14 Dust Wiper Jig 18 Slipper Seal Jig 24 Slipper Seal Straightening Jig 28 Disassembly 31 Assembly 37 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 MODEL SERIAL NUMBER RANGE ...

Page 291: ...hown as oil path A or to the front of the cylinder oil path B The cylinder rod is extended as oil flow is pumped through the circuit to the back side of the piston The force F1 of the piston stroke can be expressed by the formula below where P circuit oil pressure and the inside diameter of the cylinder is expressed by B Figure 1 P Pressure p 3 14 B Cylinder Inside Diameter When the cylinder rod i...

Page 292: ...t does to lengthen it Q1 Q2 PARTS LIST The following parts list is a partial listing only for full and complete parts list information refer to the Hydraulic Equipment Component Parts List Cross section in Figure 4 shows an arm cylinder Cross section in Figure 5 shows a boom cylinder The bucket and boom cylinders are identical and differ only in the attached pipes Q1 S x π B2 4 Q2 S x π B2 R2 4 Fi...

Page 293: ...lt 8 Retaining Ring 9 Rod Cover 10 O ring 11 O ring 12 Backup Ring 13 Piston Rod 14 Cylinder Tube 15 Cushion Ring 16 Piston 17 Slide Ring 18 Wear Ring 19 Slipper Seal 20 O ring 21 Backup Ring 22 Piston Nut 23 Set Screw 24 Cushion Plunger 25 Bushing 26 Check Valve 27 Spring Support 28 Spring 29 Plug 30 Stop Ring Reference Number Description ...

Page 294: ... Page 6 Cylinders SPECIAL TOOLS AND MATERIALS PISTON NUT B A D C 0 2 0 1 0 2 0 1 R R15 R20 C3 C5 35 350 ARS4730L 15 4 R 0 5 Through Hole 8 Figure 6 Material SM45C AISI 1045 Rockwell Harden from 22 27 Oil Quench ...

Page 295: ...ON BOOM OP 125 mm 4 92 in 85 mm 3 35 in 12 mm 0 47 in 5 mm 0 20 in S130W V ARM S130W V NEW BOOM S130LC V SHORT ARM S140W V ARM S140W V BOOM S140W V OUTRIGGER S160W V BOOM S160W V OUTRIGGER S170W V BUCKET S220LC V BUCKET S220LL BUCKET S225LC V BUCKET S225NLC V BUCKET BUCKET 115 mm 4 53 in 75 mm 2 95 in 12 mm 0 47 in 5 mm 0 20 in S140W V BUCKET S160W V BUCKET S220LL ARM 147 mm 5 79 in 107 mm 4 21 in...

Page 296: ...46 in 5 mm 0 20 in S55 V PLUS ARM BOOM S75 V ARM SWIVNG S80W II ARM 120 mm 4 72 in 79 mm 3 11 in 10 mm 0 39 in 5 mm 0 20 in S70 III ARM S80W II BOOM MEGA 130 III LIFT S140W V DOZER S160W V DOZER BOOM 120 mm 4 72 in 79 mm 3 11 in 10 mm 0 39 in 5 mm 0 20 in S70 III BOOM DOZER S75 V DOZER S130LC V DOZER MEGA 200 III TC BUCKET MEGA 130 III BUCKET BUCKET 110 mm 4 33 in 69 mm 2 72 in 10 mm 0 39 in 5 mm ...

Page 297: ...S0705000 Page 9 Cylinders ...

Page 298: ...S0705000 Page 10 Cylinders PISTON JIG C 35 A 30 R R15 20 2 B D R F 2 Through Hole 8 15 ARS4740L 4 R5 Figure 7 Material SM45C AISI 1045 Rockwell Harden from 22 27 Oil Quench ...

Page 299: ...0LC V ARM 110 mm 4 33 in 13 mm 0 51 in 76 mm 2 99 in 140 mm 5 51 in S210W V ARM S220LC V BOOM S220N V ARM OP S225NLC V BOOM S225NLC V ARM OP S250LC V ARM S255LC V ARM S290LC V BOOM BUCKET S300LC V BOOM BUCKET BUCKET 90 mm 3 54 in 11 mm 0 43 in 63 mm 2 48 in 115 mm 4 53 in S70 III BOOM S75 V SWING S80W II BOOM S130W V ARM EURO S130LC V S ARM BOOM OP ARM S160W V ARM S170LC V BOOM S170W V BUCKET BOOM...

Page 300: ...mm 3 78 in 13 mm 0 51 in 69 mm 2 72 in 130 mm 5 12 in S170LC V ARM S180W V ARM S180W V O R DOZER S200W V O R DOZER S210W V O R DOZER S250LC V BUCKET BOOM S255LC V BUCKET BOOM BUCKET 80 mm 3 15 in 11 mm 0 43 in 58 mm 2 28 in 110 mm 4 33 in S55 V PLUS BOOM SWING S70 III BOOM S80W II BOOM S130W V ARM S130LC V S ARM BOOM OP S140W V ARM S140W V BOOM S140W V O R S160W V ARM S160W V O R S180W V BUCKET S2...

Page 301: ...S0705000 Page 13 Cylinders ...

Page 302: ...ge 14 Cylinders STEEL BUSH JIG 20 A 20 5 A F 15 1 B 40 E ARS4750L B 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 1 ...

Page 303: ...0 mm 1 58 in 0 S75 V DOZER BUCKET 50 mm 1 97 in 60 mm 2 36 in 25 mm 0 98 in 5 mm 0 20 in H C S55 V ARM S55 V PLUS ARM BOOM BUCKET S75 V BUCKET BUCKET 55 mm 2 17 in 68 mm 2 68 in 30 mm 1 18 in 5 5 mm 0 22 in K C S80W II BUCKET K C S130LC V DOZER 60 mm 2 36 in 70 mm 2 76 in 30 mm 1 18 in S140W V DOZER S160W V DOZER BUCKET 65 mm 2 56 in 80 mm 3 15 in 30 mm 1 18 in 6 mm 0 24 in S70 III ARM BOOM S75 V ...

Page 304: ...S250LC V ARM BUCKET S255LC V ARM BUCKET MEGA 160 BUCKET MEGA 200 III BUCKET MEGA 200 BUCKET MEGA 300 BUCKET MEGA 300 V LIFT BUCKET 65 mm 2 56 in 80 mm 3 15 in 35 mm 1 38 in 6 5 mm 0 26 in S210W V BUCKET S250LC V BOOM 90 mm 3 54 in 105 mm 4 13 in 40 mm 1 58 in 7 mm 0 28 in S255LC V BOOM S290LC V S BUCKET BOOM BUCKET S300LC V S BUCKET BOOM BUCKET S290LL ARM STICK 100 mm 3 94 in 115 mm 4 53 in 70 mm ...

Page 305: ...US DOZER S80W II BUCKET 50 mm 1 97 in 60 mm 2 36 in 25 mm 0 98 in 5 5 mm 0 22 in H C S130W V BOOM 71 mm 2 80 in 86 mm 3 39 in 40 mm 1 58 in 6 5 mm 0 26 in S130LC V BOOM BOOM OP S140W V BOOM S160W V BOOM ARM EURO 71 mm 2 80 in 86 mm 3 39 in 40 mm 1 58 in 7 mm 0 28 in S130W V ARM S130LC V S ARM ARM S140W V ARM S160W V ARM S180W V ARM BOOM BUCKET S140W V O R 60 mm 2 36 in 75 mm 2 95 in 30 mm 1 18 in ...

Page 306: ...ers DUST WIPER JIG D C DIA B 40 15 3 C1 5 DIA B DIA A DIA A 20 R0 2 1 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 1 ...

Page 307: ... 2 76 in 84 mm 3 31 in 5 5 mm 0 22 in 6 mm 0 24 in S80W III BOOM S130W V BOOM S130LC V BOOM MEGA 160 III BUCKET BUCKET 55 mm 2 17 in 69 mm 2 72 in 5 mm 0 20 in 6 mm 0 24 in S55 V ARM BOOM BOOM OP BUCKET S55 V PLUS BUCKET SWING S55W V ARM S75 V BUCKET S80W III BUCKET MEGA 130 III LIFT DOZER 60 mm 2 36 in 74 mm 2 91 in 5 mm 0 20 in 6 mm 0 24 in S55W V BOOM S55 V PLUS ARM BOOM S75 V ARM SWING DOZER S...

Page 308: ...P 95 mm 3 74 in 109 mm 4 29 in 6 mm 0 24 in 7 mm 2 28 in S225NLC V ARM OP BOOM OP 80 mm 3 15 in 94 mm 3 70 in 6 mm 0 24 in 7 mm 2 28 in S225NLC V BOOM OP S250LC V ARM 100 mm 3 94 in 114 mm 4 49 in 6 mm 0 24 in 7 mm 2 28 in S255LC V ARM S360LC V BOOM BUCKET BUCKET OP S340LC V BOOM BUCKET BUCKET OP S370LC V BUCKET BUCKET OP S290LL BOOM HOIST BUCKET HEEL BOOM 90 mm 3 54 in 104 mm 4 10 in 6 mm 0 24 in...

Page 309: ... mm 4 33 in 126 mm 4 96 in 6 mm 0 24 in 7 mm 2 28 in S420LC V BUCKET S450LC V ARM 130 mm 5 12 in 146 mm 5 75 in 6 5 mm 0 26 in 7 mm 2 28 in S470LC V ARM BOOM 115 mm 4 53 in 131 mm 5 16 in 6 mm 0 24 in 7 mm 2 28 in S140W V ARTI S160W V ARTI BUCKET 115 mm 4 53 in 131 mm 5 16 in 6 mm 0 24 in 7 mm 2 28 in S55W V ARMS 55 mm 2 17 in 69 mm 2 72 in 5 mm 0 20 in 6 mm 0 24 in SWING 40 mm 1 58 in 52 mm 2 05 ...

Page 310: ...W V BUCKET S160W V BUCKET S140W V OR 70 mm 2 76 in 84 mm 3 31 in 0 5 mm 0 02 in 6 mm 0 24 in S160W V O R S170W V ARM 90 mm 3 54 in 104 mm 4 10 in 6 mm 0 24 in 7 mm 2 28 in S180W V ARM S220LL BOOM HOIST S250LC V BOOM BUCKET S255LC V BOOM BUCKET S290LC V BUCKET S BUCKET S300LC V BUCKET S BUCKET BOOM 80 mm 3 15 in 94 mm 3 70 in 6 mm 0 24 in 7 mm 2 28 in S180W V BOOM BUCKET 75 mm 2 95 in 89 mm 3 50 in...

Page 311: ...S0705000 Page 23 Cylinders ...

Page 312: ...S0705000 Page 24 Cylinders SLIPPER SEAL JIG ARS4770L A 2 A A 14 B B 40 5 R 1 0 R1 1 0 Figure 10 ...

Page 313: ... mm 1 12 in S170W V BOOM S180W V BOOM S210W V BUCKET S220LC V BUCKET S220LL BUCKET HEEL S225LC V BUCKET S225NLC V BUCKET S220LC V BOOM 120 mm 4 72 in 28 5 mm 1 12 in S220N V BUCKET OP S225LC V BOOM S225NLC V BUCKET OP S225NLC V BOOM S220LL ARM STICK 165 mm 6 50 in 34 5 mm 1 36 in S400LC V BOOM S420LC V BOOM S250LC V ARM 140 mm 5 51 in 28 5 mm 1 12 in S220LL BOOM HOIST S255LC V ARM S290 V BOOM BUCK...

Page 314: ...RM S140W V BOOM S140W V O R S160W V ARM S160W V BOOM S160W V O R S170W V BUCKET S180W V BUCKET BOOM 100 mm 3 94 in 28 5 mm 1 12 in S70 III ARM DOZER S75 V DOZER S80W III ARM S130W V BOOM S130LC V BOOM OP S140W V DOZER S160W V DOZER BUCKET 95 mm 3 74 in 28 5 mm 1 12 in S140W V BUCKET S160W V BUCKET S170W V ARM 125 mm 4 92 in 28 5 mm 1 12 in S1480W V ARM S200W V BOOM 135 mm 5 32 in 28 5 mm 1 12 in S...

Page 315: ...S0705000 Page 27 Cylinders ...

Page 316: ...S0705000 Page 28 Cylinders SLIPPER SEAL STRAIGHTENING JIG ARS4780L 2 R1 50 25 100 A 15 A 2 5 R 2 C 1 Figure 11 ...

Page 317: ... S180W V BOOM S210W V BUCKET S220LC V BUCKET S220LL BUCKET HEEL S225LC V BUCKET S225NLC V BUCKET S220LC V BOOM 120 mm 4 72 in S220N V BUCKET OP S225LC V BUCKET OP S225NLC V BUCKET OP S225NLC V BOOM S220LL ARM STICK 165 mm 6 50 in S400LC V BOOM S420LC V BOOM S250LC V ARM 140 mm 5 51 in S220LL BOOM HOIST S255LC V ARM S290 V BOOM BUCKET S BUCKET S300LC V BOOM BUCKET S BUCKET BOOM 130 mm 5 12 in S250L...

Page 318: ...140W V ARM S140W V BOOM S140W V O R S160W V ARM S160W V BOOM S160W V O R S170W V BUCKET S180W V BUCKET BOOM 100 mm 3 94 in S70 III ARM DOZER S75 V DOZER S80W III ARM S130W V BOOM S130 V BOOM S140W V DOZER S160W V DOZER BUCKET 95 mm 3 74 in S140W V BUCKET S160W V BUCKET S170W V ARM 125 mm 4 92 in S180W V ARM S200W V BOOM 135 mm 5 32 in S210W V ARM S210W V BOOM S220LC V ARM S220N V ARM OP S225LC V A...

Page 319: ... or other protective material around piston rod to avoid possibility of accidentally scratching or scoring rod surface while fasteners are being loosened and removed Component parts numbered in parentheses are keyed to Figure 4 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 hydraul...

Page 320: ...nd of cylinder wall before using a plastic or other soft faced hammer for final disassembly 5 Begin withdrawing piston rod assembly away from cylinder Attach a lifting support when final 1 3 of rod is still inside barrel of cylinder Prepare support blocks for piston rod before it has been completely withdrawn 6 Lower piston rod to support blocks and detach wear ring outer surface 18 from end of ro...

Page 321: ...through end of rod 8 Remove set screw by using a socket wrench 9 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 18 HAOF340L Figure 19 Figure 20 ...

Page 322: ...mer 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 12 Use a dull rounded tip tool to pry off O ring 11 and backup ring 12 13 Find a screwdriver with an appropriate width tip to facilitate removal of slipper seal 19 wear ring 18 and slide ring 17 from piston 16 Figure 21 Figure 22 HAOF37OL Figure 23 Figure 24 ...

Page 323: ...ring 21 from cylinder head 15 During disassembly of cylinder head be careful not to damage buffer seal 5 and U packing 4 16 Disassemble retaining ring 3 and dust wiper 2 Separate retaining ring 8 and rod bushing 6 HAOF38OS Figure 25 HAOF39OL Figure 26 Figure 27 ...

Page 324: ...S0705000 Page 36 Cylinders 17 Force out pin bushing 1 from body of cylinder Figure 28 ...

Page 325: ...ts install dust wiper 2 and rod bushing 6 to rod cover 9 Insert retaining rings 3 and 8 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 ...

Page 326: ...inning of this procedure to attach seal Cool seal by pushing a retracting jig against seal for several minutes Apply a strip of clean see through sealing tape around slipper seal to keep it free of dust 5 Immobilize piston rod on solid support blocks Assemble O ring 20 and backup ring 21 Prepare to attach rod cover assembly to piston rod Push rod cover by tightening piston nut 22 6 Assemble cushio...

Page 327: ...r before assembly 10 Pre apply fastener locking compound Loctite 242 or 243 or an alternate manufacturer s equivalent product to all end cover retaining bolts Wrap a protective cushion around end of rod while tightening fasteners to prevent possible damage to polished surface of rod should a wrench slip during retightening Reference Number Description 1 Set Screw Figure 35 Figure 36 Figure 37 Figu...

Page 328: ...S0705000 Page 40 Cylinders ...

Page 329: ...within this section 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Solar 225NLC V 1001 and Up Solar 250LC V 1001 and Up Solar 255LC V 1001 and Up Solar 290LC V 0001 and Up Solar 290LL 1001 and Up Cop...

Page 330: ... 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 12 Special Tools 13 Disassembly 14 Cleaning and Inspection Wear Limits and Tolerances 21 Reassembly 23 ...

Page 331: ...ure directly on the swash plate Item 3 to generate oil flow through the motor while force F2 pushes laterally at a right angle against the drive shaft providing the rotational energy to turn the cylinder block around the drive shaft All nine pistons in the cylinder block have equal width bore length and volume They are configured in a concentric layout around the drive shaft as shown in the cross ...

Page 332: ...ltage is disengaged while current flow is reduced shifting the spool in the priority valve for increased oil flow to the boom arm side of the circuit SWING MOTOR ANTI CAVITATION MAKE UP VALVE Unlike those designs for hydraulic swing motor application which incorporate a separate external counterbalance valve the problem of motor rotational speed overtaking or surpassing oil flow rate at the motor ...

Page 333: ...A2 is set against spring pressure inside the valve opening the relief valve until pressure at the spring chamber g momentarily reduces g chamber pressure Pg Pg subsequently increases until the piston reaches the end of travel inside the valve bore at h After the piston reaches h and its normally closed pressurized operating position pressure through the valve can be continually increased up to the...

Page 334: ...ide of the brake piston the friction plate and swing motor casing are separated releasing the brake IMPORTANT Along with the swing brake a 2 position positive swing lock has also been provided It should be secured whenever the upper deck revolving superstructure must be locked down and positively kept from rotating including maintenance and or repair intervals Do not rely on the swing brake alone ...

Page 335: ...S0707200 Page 7 Swing Motor Return to Master Table of Contents ...

Page 336: ...S0707200 Page 8 Swing Motor Return to Master Table of Contents PARTS LIST Model Solar 250LC V 255LC V Figure 4 ...

Page 337: ...r 124 Shoe Plate 131 Valve Plate K 301 Casing 303 Valve Casing K 304 Front Cover 351 Plunger K 355 Spring 401 Socket Bolt 432 Ring Snap 433 Ring Snap 437 Ring Snap 438 Ring Snap 443 Roller Bearing 444 Roller Bearing 451 Pin Spring 464 VP Plug 468 VP Plug 469 RO Plug 471 O ring 472 O ring 485 O ring 487 O ring 488 O ring 491 Oil Seal 702 Brake Piston 706 O ring 707 O ring 712 Brake Piston 742 Frict...

Page 338: ...S0707200 Page 10 Swing Motor Return to Master Table of Contents PARTS LIST Models Solar 225LC V 225NLC V 290LC V and 290LL Figure 5 ...

Page 339: ... Shoe Plate 131 Valve Plate 301 Lower Casing 303 Upper Valve Casing 304 Front Cover 351 Plunger 355 Spring 401 Socket Head Cover Bolt 432 Stop Ring 433 Stop Ring 437 Lock Ring 438 Lock Ring 443 Roller Bearing 444 Roller Bearing 451 Pin Spring 464 VP Plug 468 VP Plug 469 RO Plug 471 O ring 472 O ring 485 O ring 487 O ring 488 O ring 491 Oil Seal 702 Brake Piston 706 O ring 707 O ring 712 Brake Spri...

Page 340: ...cm 4 000 psi Maximum Supply Flow Rate 1640 rpm 210 liters per minute 55 U S gal per minute Max Motor Shaft Speed 1 640 rpm Rated Motor Shaft Torque 63 kg m 456 ft lb Weight 56 5 kg 125 lb Swing Motor Specification Type Axial Piston Displacement 169 40 cc 26 26 in3 Crossover Relief Valve Setting 285 290 kg cm2 250 liter min 4 054 4 125 psi 66 0 gpm Maximum Supply Flow Rate 2000 rpm 265 liter min 70...

Page 341: ...S0707200 Page 13 Swing Motor Return to Master Table of Contents SPECIAL TOOLS Figure 6 ...

Page 342: ...n oil residue from hands and clothing promptly and do not allow used oil containers to accumulate 3 After oil has been drained completely motor should be positioned so that exposed end of drive shaft faces downwards IMPORTANT Clean all of the exterior surfaces of the motor before disassembly There should not be any visible dirt grease or other type of accumulation on the outside of the casing Clea...

Page 343: ...nd upper valve casing 303 5 Disassemble brake valve 31 from side of casing 6 Loosen and remove relief valve assemblies 51 from upper valve casing 303 7 Remove RO plug 469 from upper valve casing 303 That will allow subsequent separation of spring 355 and plunger 351 IMPORTANT Use extra care to avoid damaging the plunger seat Figure 9 Figure 10 Figure 11 Figure 12 ...

Page 344: ... an accidental fall after cover is removed 9 Remove all twenty brake springs NOTE If brake springs are to be reused and not replaced check and record spring free height If a test stand is available check height of all twenty springs under consistent loading Replace all springs that show excessive variation or weakness 10 Disassemble brake piston assembly using special tool and corresponding piston...

Page 345: ...ife could be extended incrementally by maintaining previous wear pattern relationships by avoiding new ones 12 Pull out friction plates 742 and separator plates 743 from area behind cylinder block 13 Remove lock ring 437 from around drive shaft Use a large enough pair of snap ring pliers to properly tension ring and pull it away from locking groove Use extra caution in pulling off front cover 304 ...

Page 346: ...p bearing race out of casing 16 Disassembly of motor has now been completed unless there is any reason to suppose that drive shaft bearing has become excessively worn If it is necessary replace bearing by pulling away stop ring 432 and spacer 106 Put drive shaft in a press to separate bearing cage from drive shaft Reference Number Description 1 Press 2 Drive Shaft 3 Roller Bearing 4 Base of Press ...

Page 347: ... 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 B If upper bearing is going to be replaced whether as a general precaution as part of normal rebuilding or because of unmistakable wear separate bearing from cover Reference Number Description 1 Plug 2 Apply Force Figure 22 Figure 23 Figure 24 ...

Page 348: ...istributor To disassemble relief valves pull out plug 201 Figure 5 disassemble bushing 343 spring 322 and spring seat 331 from rod 303 Position valve housing facing down and separate piston 302 rod 303 spring 321 spring seat 331 and plunger 301 IMPORTANT Do not touch the adjusting screw and lock nut Replace the valve as a complete unit if any parts have been damaged Figure 25 ...

Page 349: ...mmended unless motor has had minimal use Inspect O rings and oil seals very carefully for cuts nicks brittleness or softness or any other type of damage or distortion before final reassembly 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 NOTE Spherical bushing and push plate must al...

Page 350: ... mm 0 0023 Replace piston or cylinder Clearance between piston and shoe socket d 0 mm 0 00 0 3 mm 0 0118 Replace piston or shoe assembly Thickness of shoe t 5 5 mm 0 2166 5 3 mm 0 2087 Replace piston or shoe assembly Height of retainer and rounded bushing assembly H h 6 5 mm 0 256 6 0 mm 0 236 Replace set spherical bushing and retainer Thickness of friction plate 4 0 mm 0 157 3 6 mm 0 142 Replace ...

Page 351: ... roller bearings were not disassembled go onto next phase of assembly Bearing reassembly begins with replacement of stop ring 432 Figure 5 and its accompanying Parts List and spacer 106 on drive shaft 101 Make sure that bearing raceways collars are facing right direction The drawing shows one side of the bearing collar 1 Figure 29 marked R which should be assembled next to spacer 2 on lower end of...

Page 352: ... and wrong side on oil seal Be careful that you install seal inside cover with correct side facing in 5 Before replacing O ring 471 in lower casing 301 grease O ring and or inside of groove very lightly to facilitate assembly and to help protect O ring from accidental damage 6 Put a little grease on lip of front cover oil seal before replacing front cover and tapping it lightly into place with pla...

Page 353: ...efore removal Using grease on assembled side can help keep individual components in place 9 Carefully examine cylinder block for any evidence of damage around rotating parts Put push rods 116 and front spacer 117 back into cylinder block and replace spherical bushing 113 10 Using reference notes or marks made earlier replace all of the pistons and shoes 121 122 back in their original cylinder bore...

Page 354: ...separator plates 743 and two friction plates 742 which should be positioned as shown in drawing below with clearance towards side of casing with brake valve 1 Figure 39 13 Very lightly grease larger O rings 706 and 707 Figure 5 before replacing them in casing 301 14 Position brake piston 1 Figure 41 in casing The diagram shows position of four piston grooves 2 in relation to valve connected side 3...

Page 355: ...hows R part 2 Figure 44 of the valve plate turned away from mounting flanges 1 on side of valve plate Lightly grease O ring to help keep it in place during assembly 18 Bolt up two halves of motor casing 301 and 303 Figure 5 Be careful not to lose or damage O ring Tighten four 20 mm socket head bolts using a progressive even rotation Make sure that all brake springs are fully seated and that valve ...

Page 356: ...le relief valves 51 by putting rod spring stop and piston back together then turning plunger side of valve up to reassemble valve body and all components of piston spring seat spring bushing retainer O ring and plug 21 Before replacing relief valves 51 in upper valve casing 303 install backup rings and O rings IMPORTANT Be careful not to damage the plunger and spring seat Figure 46 Figure 47 Figur...

Page 357: ...S0707200 Page 29 Swing Motor 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 ...

Page 358: ...S0707200 Page 30 Swing Motor Return to Master Table of Contents ...

Page 359: ... the front of this manual or those contained within this section 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 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...

Page 360: ...uction Gear Disassembly 20 Travel Motor Rear Flange Disassembly 22 Travel Motor Internal Parts Disassembly 26 Cleaning and Inspection Wear Limits and Tolerances 34 General Inspection 34 Gear Oil 34 General Notice 34 Tightening Torque List 35 Wear Limits 35 Reassembly 37 General Instructions for Reassembly 37 Travel Motor Rear Flange Reassembly 37 Travel Reduction Gear Reassembly 42 Gear Holding Fl...

Page 361: ...o 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 The reduction gearbox consists of a 3 speed planetary gearbox Figure 1 shows the motor as a symbol Figure 1 ...

Page 362: ...stroke The oil after flowing into the side of the cylinder block 104 exerts force on each piston 4 or S pieces and generates force F p kg cm x A cm2 The force F is exerted on the swash plate 103 as the swash plate 103 is tilted with respect to the driving shaft 102 by a degrees the force F is divided into two resultant forces F2 and F3 Among these forces radial force F3 develops torque T F3 x ri w...

Page 363: ... spool moves port D at the return side of the motor and part B at the tank are connected together by a hole in the spool and the motor turns as the return oil from motor flows into the tank By the movement of spool 126 the pressure oil goes into port P and S In port P the pressure oil releases the parking brake force and moves the piston of parking brake In port S the pressure oil goes into chambe...

Page 364: ...tral position hydraulic motor stops because all passages are closed completely Like this the spool s returning speed controls the return oil from motor gradually according to the spool s shape and stops the hydraulic motor As the hydraulic motor rotates because of inertia force it tries to absorb the hydraulic oil But hydraulic oil cannot be supplied because the oil is blocked So the hydraulic mot...

Page 365: ...ting on the hydraulic motor s cylinders is released If the pressure rises above 45 kg cm2 640 psi the pressure is reduced by the reduction valve and the pressure at the chamber a is fixed at 45 kg cm2 640 psi A safety valve which is set up at 100 kg cm2 1 422 psi as a limit is installed to the reduction valve B During Braking If the pressure of the cylinder drops below 11 kg cm2 156 psi because th...

Page 366: ...peed because the swash plate 103 is tilted to the maximum angle and the piston stroke volume is maximized B At high speed If the pilot pressure is higher than 20 kg m 145 ft lb If pilot pressure is supplied from port A If the pressure is higher than 20 kg m 145 ft lb the valve 163 is pushed to the right bv the spring 166 force the pressure oil from the supply port B goes through valve 163 into the...

Page 367: ...ferential gear If the carrier combined to the input shaft rotates the planetary gears Pl P2 turn If the gear ratios between R and P1 Pl and P2 are properly different the co axial gears P1 and P2 transmit torque by generating different rotation with the gear D 3 Combined device of planetary and differential device If the sun gear S and R and P1 and the carrier rotates by the planetary motion of the...

Page 368: ...S0707330 Page 10 Travel Motor With Gearbox GM35VL Return to Master Table of Contents TRAVEL MOTOR PARTS LIST Figure 12 ...

Page 369: ...ton Two Speed 162 Shoe Two Speed 167 Pivot 171 Pin Parallel 193 Spring Relief Valve Assembly 201 Valve 202 Sleeve 203 Retainer Spring 204 Plug 205 Shim 208 O ring 1BP16 209 O ring 1BP22 210 O ring 1BP18 211 Ring Backup 217 Ring Backup 219 O ring 1BP29 220 Seal Piston 301 Flange Rear 323 Spool 324 Plug 325 Stopper 326 Plug 327 Valve 328 Spring 330 Spring 336 O ring 1BP32 337 O ring 1BP22A 341 Pin P...

Page 370: ...S0707330 Page 12 Travel Motor With Gearbox GM35VL Return to Master Table of Contents TRAVEL REDUCTION GEARBOX PARTS LIST Figure 13 ...

Page 371: ...r B 6 Gear Input 7 Gear Spur 8 Cover 9 Crank Shaft 12 Spacer 13 Distance Piece 15 Coupling 17 Pin 19 Bolt Socket M24x70 20 Ring Snap 21 Bearing A Ball 22 Bearing T R 23 Bearing Needle 25 Ring Snap 27 O ring 1BP8 29 O ring 1AG230 30 O ring 1AP335 31 Seal Floating 33 Plug 34 Pin Parallel 35 Bolt Socket M12x32 36 Ball Steel 37 Washer Plain 42 Pin Parallel 43 O ring 1 Bp18 Reference Number Description...

Page 372: ... Name Plate Identification Reference Number Description 1 Design Number Product Classification Number 2 Volume Classification Number cc rev 3 Deceleration Classification Number A 1 56 4 Model Classification Number 5 Size Number 6 Machine Type Symbol GM 35 VL A 75 130 4 1 2 3 4 5 6 HAOZ670S Figure 14 ...

Page 373: ...to Switching Parking Brake Torque 40 6 kg m 294 ft lb Parking Brake Releasing Pressure 6 0 kg cm2 85 34 psi Reference Number Description Dimension Tightening Torque 19 Bolt with Hexagon Hole M24 P3 0 72 3 11 33 Plug with Hexagon Hole PF 1 2 10 2 35 Bolt with Hexagon Hole M12 P1 75 10 4 1 6 202 Sleeve PF 1 25 5 204 Plug PF 1 2 10 5 324 Plug M36 P1 5 26 4 326 Plug M36 P1 5 45 9 343 Bolt with Hexagon...

Page 374: ...AND ADJUSTMENT GENERAL NOTICE a Check whether the same trouble has occurred before b 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: ...failed Check the relief valve Hydraulic motor failed Gear damaged Replace Motor Replace the reduction gear Replace the reduction gear The oil passage of valve or motor casing was cracked so the release presure dose not rise Replace the valve or motor casing Dirt clogged release pressure does not rise Oil leaks from the seal part of brake piston and the brake piston does not work Check the brake pi...

Page 376: ...s not work Faulted circuit Connect the line so that the release pressure becomes down Brake stuck or deformed Replace the faulty parts Replace the brake piston casing Yes Yes No Brake piston stirs Spring failed or sticked Friction plate separate plate swings lightly No No No No Yes Yes Yes Yes Yes HAOP680l Brake piston sticked and does not work The surface of spline is lough and plate deformed Fri...

Page 377: ... from the casing Oil leaks from the floating seal Oil leaks from the plug Fill the recommended gear oil Replace the bearing Replace HAOP690l Driving surface failed and sticked Replace Replace O ring damaged and creeping so it can E Temperature of casing is high If the oil temperature rises above 90 it is unusual Reduction gearbox generates heat Gear oil is insufficient Bearing damaged Brake piston...

Page 378: ...DUCTION GEAR DISASSEMBLY 1 The travel motor and gear box should be removed from the machine as an assembly Once the unit is removed place the assembly in an appropriate work area 2 Remove twelve allen head bolts 343 from rear flange assembly 3 Remove travel motor rear flange assembly 301 from spindle 2 Figure 15 Figure 16 Figure 17 ...

Page 379: ...ngs 113 and ball bearing 150 from rear flange 301 and motor housing 5 Drain gear oil from reduction gear housing 6 Turn gear assembly around so that reduction gear cover is facing up 7 Install two eye bolts to the screw holes 8 Remove cover 8 by installing hooks to the eye bolts and lift using a lifting device Figure 18 Figure 19 Figure 20 ...

Page 380: ...TRAVEL MOTOR REAR FLANGE DISASSEMBLY Spool Disassembly 1 Remove plug 324 from rear flange 301 Remove O ring 336 from plug 324 2 Remove two springs 328 and two stoppers 325 with two spools 3 Check Valve Disassembly 1 Remove two plugs 326 from rear flange 301 Figure 21 Figure 22 Figure 23 ...

Page 381: ...es 301 3 Remove O ring 337 from plug 326 Two Speed Switching Valve Disassembly 1 Remove plug 357 from rear flange 301 2 Remove spool 363 and spring 366 from rear flange 301 3 Remove O ring 355 from plug 357 Disassembly of Internal Parts SRV 1 Remove two plugs 380 2 Remove O ring 359 from plug 380 Figure 24 Figure 25 Figure 26 Figure 27 ...

Page 382: ...3 Remove piston 381 from rear flange 301 4 Remove two plugs 382 5 Remove O rings 383 and 384 from plug 382 6 Remove steel ball 385 from each plug hole 301 Relief Valve Disassembly 1 Remove plug 204 from sleeve 202 2 Remove O ring 210 from plug 204 Figure 28 Figure 29 Figure 30 Figure 31 ...

Page 383: ...age 25 Travel Motor With Gearbox GM35VL Return to Master Table of Contents 3 Remove seam 205 from plug 204 4 Remove spring retainer 203 spring 206 valve 201 from sleeve 202 Figure 32 Figure 33 Figure 34 Figure 35 ...

Page 384: ...ve 202 if any parts except O ring 210 or piston seal 221 are needed to replace for it will necessitate the resetting of relief pressure only one part cannot be replaced but must be replaced by relief valve TRAVEL MOTOR INTERNAL PARTS DISASSEMBLY Parking Brake Parts Disassembly 1 Blowing compressed air into through passage hole for parking brake of spindle 2 and pull out piston 112 2 Remove O ring ...

Page 385: ...ndle 2 4 Remove companion plate 116 and friction plate 115 by two respectively that are attached around circumference of removed cylinder block 104 5 Separate piston assembly piston 105 shoe 106 collar 111 five needle type rollers 151 that are attached on removed cylinder block 104 6 Take out swash plate 103 from the inside of spindle 2 7 Take out shaft 102 8 Take out two pivot 167 and two paralle...

Page 386: ...Disassembly 1 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 2 Loosen the press until spring force is released 3 Take out C type snap ring 145 for hole washer 110 spring 114 in turn from the inside of cylinder block 104 Input Gear Disassembly 1 Remove steel ball 36 and input gear 6 from coupling 15 Fig...

Page 387: ...Gearbox GM35VL Return to Master Table of Contents Spur Gear Disassembly 1 Remove three C type snap rings 25 for shaft from crankshaft 9 2 Remove three spur gear 7 from crankshaft 9 3 Remove coupling 15 from shaft 102 Figure 47 Figure 48 ...

Page 388: ...for stationary metal fittings to be positioned in symmetry 3 Rotate motor in opposite direction 4 Remove snap ring 20 distance pieces three respectively from hold flange 3 5 Cut caulked part at upper part of parallel pin hole 6 Install pulling jig of parallel pin 34 and pull out parallel pin 34 up to the end face of hold flange 3 6 places 7 Loosen bolt with hexagon hole 19 Loosening torque more th...

Page 389: ...2 and hook the eye bolt and remove from hub by hanging it with crane Ball Bearing RV Gear Assembly and Pin Disassembly 1 By tapping with sharp tip punch B and hammer A at pin C 17 s end part remove ball bearing D 21 from hub 1 At this time RV gear assembly RV gear A 4 RV gear B 5 crankshaft 9 conical roller bearing 22 needle type roller bearing 23 with support along with pin 17 can be taken out to...

Page 390: ... direction 4 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 Spindle Disassembly 1 Take out floating seal 31 from spindle 2 2 Take out the outer lace of conical roller bearing 22 from spindle 2 3 Take out conical roller bearing 22 s outer lace from hold flange 3 Figure 54 Figure 55 Figure 56 ...

Page 391: ...he outer edge of oil seal A in spindle 2 by tapping with hammer remove oil seal 132 Bearing 149 Disassembly 1 Putting clamping metal fitting II D on the press work bench and put shaft into it 2 Remove deep ditch ball bearing C Figure 58 149 with holding down the shaft tip B parts by a press A Figure 57 Figure 58 ...

Page 392: ...acing down and drain oil 3 Refill oil Turn the motor so that the inlet and level gauge are placed on the location as shown in the installation dimensions then refill oil till the oil overflows from the level gauge Make sure that the motor is in the horizontal position of the shaft direction GENERAL NOTICE 1 Be careful for oil leakage and looseness of bolt 2 Be careful of the temperature of casing ...

Page 393: ...ft lb 343 Bolt With Hexagon Hole M16 P2 0 12 25 7 4 kg m 186 29 ft lb 346 Plug PT 1 4 2 3 0 5 kg m 523 7 ft lb 352 Plug PT 1 4 2 3 0 5 kg m 22 4 ft lb 354 Plug With Hexagon Hole NPTF 1 16 8 1 0 0 25 kg m 7 23 1 81 ft lb 357 Plug PF 1 2 2 10 0 25 kg m 72 1 81 ft lb 380 Plug PF 3 8 2 6 1 kg m 43 7 ft lb 382 Plug PF 1 8 2 1 5 0 25 kg m 10 85 1 81 ft lb 398 Plug With Hexagon PF 1 8 4 1 25 0 25 kg m 9 ...

Page 394: ...e 0 150 mm 0 0059 in Retainer plate Circle end face uneven wear Thrust ball Timing plate Sphere sliding part with retainer plate 107 uneven wear Sticking phenomena and uneven wear on sliding face Thrust ball Timing plate Sphere sliding part with retainer plate 107 uneven wear Sticking phenomena and uneven wear on sliding face Deep ditch ball bearing Press trace Braking phenomena appeared Uneven we...

Page 395: ...se a plastic hammer to prevent any damage to the parts D The number in parentheses after part name corresponds to the part number in the parts list First Reassemble the hydraulic motor section then the reduction gearbox section TRAVEL MOTOR REAR FLANGE REASSEMBLY Check Valve Reassembly 1 Assemble O ring 337 to plug 326 2 Assemble spring 330 and valve 327 into plug and lightly coat with grease 3 In...

Page 396: ...mbly 4 Tighten two plugs to specified torque Tightening Torque 45 9 kg m 325 65 ft lb Two Speed Switching Valve Reassembly 1 Install O ring to plug 357 2 Place spring 366 in spool 363 and insert into flange assembly 301 3 Install plug 357 into flange assembly 301 and tighten to specified torque Tightening Torque 10 2 kg m 72 14 ft lb Figure 61 Figure 62 Figure 63 ...

Page 397: ...tighten to specified torque Tightening Torque 1 5 0 25 kg m 10 85 1 81 ft lb 4 Insert piston 381 into rear flange 301 5 Install O ring 359 into plug 380 6 Install plug 380 into rear flange 301 and tighten to specified torque Tightening Torque 6 1 kg m 43 7 ft lb Relief Valve Reassembly 1 Install O rings 208 209 and 219 backup ring 211 and 217 on slip ring 202 2 Install O ring 210 on plug 204 3 Put...

Page 398: ...Contents 4 Install piston seal A 220 at valve B 201 5 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 68 Figure 69 Figure 70 Figure 71 ...

Page 399: ...S0707330 Page 41 Travel Motor With Gearbox GM35VL Return to Master Table of Contents 6 Repeat procedure for the other side Figure 72 ...

Page 400: ...EDUCTION GEAR REASSEMBLY Hub Reassembly 1 Place hub 1 on work bench 2 Press in the outer race of ball bearing A 21 into hub D 1 by using jig C and hammer B 3 Assemble floating seal B 31 into hub D 1 Spindle Reassembly 1 Assemble floating seal B 31 into spindle D 2 Figure 73 Figure 74 Figure 75 ...

Page 401: ... 1 3 Insert two stationary metal fittings to hub 1 and spindle 2 and tighten 4 Turn motor in opposite direction and position the cover side upward 5 Place three bearing races 22 to their respective locations within the spindle 2 RV Gear Reassembly 1 Install lifting tool A Figure 78 to RV gear assembly 2 Using a lifting device lower RV gear assembly it into spindle 2 3 Insert twenty four pins 17 be...

Page 402: ...all hold flange 3 at spindle 2 7 Coat locktite 638 at spindle 2 threads 8 Place flat washers 37 in the three bolt holes of the flange 3 Tightening Torque 20 kg m 145 ft lb 9 Hammer six parallel pins with an air chisel until it reaches pin hole bottom 10 Tighten allen head bolt 19 to specified torque Tightening Torque 72 3 kg m 523 ft lb Figure 79 Figure 80 Figure 81 Figure 82 ...

Page 403: ...olding flange 12 Install snap ring 20 to hold flange 13 Align the mating marks of the three spur gears 7 and press into the respective crankshaft 9 14 Mating mark positions of spur gear 15 Install snap ring 25 to each of the three crankshafts snap ring groove A Figure 87 Figure 83 Figure 84 Figure 85 Figure 86 ...

Page 404: ...rbox GM35VL Return to Master Table of Contents 16 Turn motor assembly so that the motor side is facing up 17 Insert oil seal 132 into spindle 2 18 Heat bearing B Figure 89 149 and press shaft B 102 into bearing Figure 87 Figure 88 Figure 89 ...

Page 405: ...nto piston hole of spindle 2 3 Inserting two pins 171 and two pivot 167 into spindle 4 Lightly coat grease onto spherical surface Cylinder Block Internal Parts Reassembly 1 Place cylinder block 104 on the press work bench 2 Put washer 110 spring 114 washer 110 into cylinder block 104 3 Place cylinder block assembly on work bench and press metal fitting on washer 114 and install C type snap ring 14...

Page 406: ...oil on piston assembly and install into cylinder block 104 4 Coat sliding face of shoe 106 and spherical surface of thrust ball 108 with hydraulic oil 5 Assemble swash plate 103 thrust ball 108 collar 111 retainer plate 107 needle type roller 151 cylinder block 104 piston assembly 105 6 Install lifting jig onto spline part of shaft 102 and lift assembly 7 Insert assembly onto motor shaft by slowly...

Page 407: ...depth micrometer 1 Figure 98 3 Since B dimension of the adjustment jig is known calculate C dimension by subtracting B from A A Measured value B Known dimension of jig body C Calculated clearance 4 Obtain D dimension of gear holding flange 3 Figure 99 If the dimension D exceeds C 0 02 it is necessary to adjust the dimension If the dimension D is greater than the limits cut the surface with a lathe...

Page 408: ...s attached to crankshaft 9 of RV gear assembly C 2 Install the thinnest shim 13 into hold flange 3 assemble snap ring 20 into snap ring groove 3 Tap lightly around the snap ring with hammer 4 Measure clearance by inserting thickness gage between snap ring 20 and shim 13 5 Subtract from this value the known value of the shim already inserted to obtain the required shim thickness Select a shim which...

Page 409: ...tall piston 112 into spindle 2 5 Install ball bearing 150 timing plate 109 parallel pin 341 and twelve springs 113 into rear flange 301 IMPORTANT Install friction plate 115 after soaking it in operating oil CAUTION Be careful not to mistake the order of friction plate and companion plate If mistaken there is possibility to weaken the parking brake IMPORTANT Coat twelve springs 113 and timing plate...

Page 410: ...Install rear flange 301 to spindle by aligning rear flange with aligning pins 1 Install rear flange 301 to spindle 2 Tighten twelve bolts 343 to specified torque 2 Install O ring 355 to plug 357 and install in drain port Tightening Torque 10 2 kg m 72 14 ft lb 3 Install relief valve to rear flange 301 4 Tighten to specified torque Tightening Torque 25 5 kg m 181 36 ft lb Figure 104 Figure 105 Figu...

Page 411: ...se onto steel ball 36 and place ball on concave part of input gear 6 3 Attach O ring 30 on cover 8 4 Install two eye bolts into threaded holes on cover 8 5 Lift cover 8 and install to hub 1 6 Tighten twelve allen head bolts 35 to specified torque 7 Fill with lubricating oil 5 40 liters 1 4 U S gal 8 Tightening Torque 10 4 1 6 kg m 75 12 ft lb Figure 107 Figure 108 Figure 109 ...

Page 412: ...ravel Motor With Gearbox GM35VL Return to Master Table of Contents 9 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 ...

Page 413: ...r those contained within this section 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 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...

Page 414: ...ase 9 Pump Discharge Decrease 9 Pump Discharge Increase 9 Horsepower Control 9 Overload Protection 10 Regulator Adjustment 10 Pump Input Power Control Adjustment 11 Parts List 12 Specifications 16 Hydraulic Pump Performance Characteristics 18 Troubleshooting Testing and Adjustment 23 Main Pump 23 Disassembly 24 General Disassembly 24 Main Pump Disassembly 25 Pump Regulator Disassembly 27 Cleaning ...

Page 415: ...ns at the same rate as engine rpm The cylinder block and pistons revolve around the drive shaft producing oil flow through the pump whenever the angle of the swash plate is tilted past the 0 degree vertical angle Whenever the pump swash plate angle is at 0 degrees piston stroke length is reduced to 0 and there is no output from the pump The swash plate group includes the shoe plate swash plate sup...

Page 416: ...in Pump Output 106 0 cc rev 6 47 in3 rev 1 pump Gear Pilot Pump Output 15 cc rev Pilot Pump Relief Valve Relief pressure set at 40 kg cm2 569 psi Model Solar 255LC V Main Pump Output 112 0 cc rev 6 83 in3 rev 1 pump Gear Pilot Pump Output 15 cc rev Pilot Pump Relief Valve Relief pressure set at 40 kg cm2 569 psi Figure 2 ...

Page 417: ...o maintain a flow of oil independent of main pump oil flow output for the operation of control valves RELIEF VALVE When the discharge pressure of the pilot pump exceeds 40 kg cm2 569 psi the ball and spool at the top of the valve shift to the right maintaining pressure below the targeted 40 kg cm2 569 psi limit as excess oil returns to the drain port ENGINE Fl Pz1 Pi1 FRONT REAR 500k A1 A2 a1 a2 S...

Page 418: ... constant directly proportional to the input rotational speed rpm of the engine POWER SHIFT CONTROL This design feature modifies the total available power output of the hydraulic system through microprocessor controlled application of electronic controls Supplementary electronic control of the hydraulic system provides increased operating flexibility The electronic proportional reducing valve thro...

Page 419: ...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 is controlled by increasing or decreasing pilot pump pressure Figure 7 Figure 7 ...

Page 420: ...S0708320 Page 8 Main Pump With Regulator Return to Master Table of Contents NOTE Component parts numbered in parentheses correspond to those in Figure 8 Figure 8 ...

Page 421: ...ool moves toward the right in response to differences in servo pressure the servo piston moves to the right resulting in a decreased swash plate tilt angle and reduced pump output flow The system is balanced and control movement of the spool and servo piston stops when the outermost spool 652 and spool sleeve 651 close into each other shutting off oil movement PUMP DISCHARGE INCREASE When pilot pr...

Page 422: ...ischarge flow REGULATOR ADJUSTMENT Maximum and minimum discharge flow horsepower control characteristics and discharge control characteristics can all be modified by changing the position of adjustment screws built into the pump housing Figure 1 and the end plate of the regulator valve Figure 8 Maximum and minimum discharge flow can be modified by loosening lock nuts 808 Figure 1 To decrease maxim...

Page 423: ...the original setting Changing the adjustment position of the inner screw 1 4 turn affects the working resistance of the inner spring Increases in oil flow of approximately 10 lpm 0 04 gpm and about 4 8 kg m 35 ft lb of input torque are the result The third adjustment screw on the side of the regulator 924 can be repositioned after the smaller lock nut 801 is loosened Changing the position of the t...

Page 424: ...S0708320 Page 12 Main Pump With Regulator Return to Master Table of Contents PARTS LIST Main Pump Figure 13 ...

Page 425: ...Plate 261 Seal Cover F 263 Rear Cover 271 Pump Casing 312 Valve Block 313 Valve Plate R 314 Valve Plate L 325 Valve Casing 401 Socket Bolt 406 Socket Bolt 407 Socket Bolt 413 Socket Bolt 466 VP Plug 468 VP Plug 490 Expander 531 Tilting Pin 532 Servo Piston 534 Stopper L 535 Stopper S 541 Seat 542 Spacer 543 Stopper 544 Stopper 545 Steel Ball 548 Feedback Pin 702 O ring 710 O ring 717 O ring 719 O ...

Page 426: ...S0708320 Page 14 Main Pump With Regulator Return to Master Table of Contents Pump Regulator Figure 14 ...

Page 427: ...sting Ring C 628 Adjusting Screw C 629 Cover C 630 Lock Nut 631 Pf Sleeve 641 Pilot Cover 643 Pilot Piston 644 Spring Seat Q 645 Adjusting Ring Q 646 Pilot Spring 647 Adjusting Screw Bushing 651 Sleeve 652 Spool 653 Spring Seat 654 Return Spring 655 Set Spring 656 Cover 674 Pf Piston 708 O ring 722 O ring 724 O ring 725 O ring 728 O ring 730 O ring 732 O ring 733 O ring 734 O ring 735 O ring 755 O...

Page 428: ...8 gpm Relief Valve 40 kg cm2 569 psi Main Pump Quantity 2 Displacement 108 7 cc rev 6 63 in3 rev Max Flow Rate 215 lpm x 2 pumps 57 gpm x 2 pumps Flow Regulator Type Negative Control Pressurization Air Breather Weight 132 kg 291 lb Pilot Pump Displacement 15 cc rev 0 9 in3 rev Max Flow Rate 30 lpm 8 gpm Relief Valve 40 kg cm2 569 psi Main Pump Quantity 2 Displacement 108 7 cc rev 6 63 in3 rev Max ...

Page 429: ... Main Pump Quantity 2 Displacement 122 cc rev 6 47 in3 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 15 cc rev 0 9 in3 rev Max Flow Rate 30 lpm 8 gpm Relief Valve 40 kg cm2 569 psi ...

Page 430: ... Speed 1950 rpm High Mode 1800 rpm Standard Mode Pump Input Horsepower 135 0 ps 133 hp High Output Power Mode III 115 0 ps 113 hp Standard Output Power Mode II Main Pump Total Displacement 108 7 cc 6 63 in3 x 2 pumps Main Pump Pressure 350 kg cm2 4 550 psi for pressure up Pilot Pump Displacement 15 cc rev 0 9 in3 rev Pilot Pump Pressure 40 kg cm2 569 psi Engine Speed 2000 rpm Power Mode 1850 rpm S...

Page 431: ...S0708320 Page 19 Main Pump With Regulator Return to Master Table of Contents Models SOLAR 220LC V 220LL AND 250LC V Figure 15 ...

Page 432: ...S0708320 Page 20 Main Pump With Regulator Return to Master Table of Contents Model SOLAR 225LC V BBS0030L Figure 16 ...

Page 433: ...le 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: ...FLOW Q l min 2 0 0 0 r p m 1 9 0 0 r p m 0 0 10 50 20 100 30 150 40 200 100 100 100 150 150 150 200 200 200 10 0K 224L 222L P i Q C U R V E 211L 119K 192K 121L 33 8K 40L 144K 350 250 300 216K 120L 60L 350K 72L 350K 1900 rpm 38L 33 8K Pd 80 K at Q max 162PS 2000rpm 213L 10 0K I 0 m A P f 0 K 132PS 1900rpm 2000 rpm I 6 0 0 m A P f 2 9 K AYS0070L Figure 18 ...

Page 435: ... regulator faulty or piping Repair or replace regulator or piping reduced pressure does clogged leaking or kinked not increase Pump inner parts worn or damaged Look for particles inside the filter and rebuild or replace pump components Gear pump pilot pump worn or Check pilot pressure and make sure pilot faulty piston spool and or QMC are not sticking before repairing or replacing pilot pump Acces...

Page 436: ... has been thought by some to pose a health risk Clean oil residue from hands and clothing promptly and do not allow used oil containers to accumulate NOTE Main Pump component parts numbered in parentheses are keyed to Figure 14 1 Loosen socket bolts 412 413 to begin separation of regulator valves from two pumps NOTE See Pump Regulator Disassembly on page 27 of this section for disassembly procedur...

Page 437: ...sings NOTE When pump assembly has been disassembled to three main component sections center valve block front pump and rear pump the procedure can be continued in either one of two ways Because both pumps on either side of the center valve block are identical both can be disassembled simultaneously repeating the same steps on opposite ends of the assembly at the same time If the rebuilding procedu...

Page 438: ...a slow staggered tightening sequence taking wrench off of each cap screw after just a fraction of a turn and proceeding to next in regular rotation until cover drops out 3 Separate pump casing 271 from support plate 251 by tapping lightly with a plastic hammer Be careful not to damage either mating surface or O ring 717 4 Withdraw drive shaft 111 and 113 on opposite sides of center valve block fro...

Page 439: ...ced with new parts if they are excessively worn or have been damaged PUMP REGULATOR DISASSEMBLY 1 Remove four hex head allen style bolts 412 413 and pump regulator assembly from pump body Remove and inspect O ring gaskets 708 724 found between regulator casing and pump body NOTE The regulator mounting bolts are uneven in length and should be noted and replaced to the same location Once the regulat...

Page 440: ...gth and should be noted and replaced to the same location The pilot cover is under pressure from feed back lever set spring and care should be used when removing it 3 Remove snap ring 814 spring seat 653 and return spring 654 from feed back lever spool 652 4 Remove pin 898 and Pf sleeve 631 from compensator piston bore 5 Remove four hex head allen style bolts 438 and pilot piston lower cover 629 f...

Page 441: ...Remove four hex head allen style bolts 438 and cover 656 from opposite side of portion and adjusting plugs Remove and inspect O rings 722 735 8 Remove two snap rings 858 portion plug 614 and adjusting plug 615 from bore A 4 mm x 50 mm bolt can be threaded into these plugs and gently pulled out if they do not freely slide out of the bore Remove and inspect O rings 755 NOTE The portion plug 614 and ...

Page 442: ...613 A 2 mm punch can be used to drive out pins 875 from levers 11 Remove piston case 622 compensator piston 621 and piston rod 623 from piston bore Remove and inspect O ring 733 from piston case 622 12 Remove spool 652 and sleeve 651 from bore by driving out pin 874 This will release feedback lever 611 from housing Inspect snap ring 836 on sleeve Figure 33 Figure 34 Figure 35 Figure 36 ...

Page 443: ... fluid before final reassembly or as the final step after the unit has been put back together again Replacement of all O rings and oil seals with new parts is generally recommended unless pump has had very few operating hours of use NOTE Rounded bushings and push plates must always be replaced in sets If either one requires replacement also replace the other 1 Clearance Between Piston and Cylinder...

Page 444: ...n before final reassembly if any must be reused Reference Number Item Standard Value mm In Replacement Limit mm In Remedy 1 Clearance between cylinder bore and piston D d 0 0390 mm 0 0015 in 0 0670 mm 0 0026 in Replace piston or cylinder 2 Free length of cylinder spring L 41 10 mm 1 62 in 40 30 mm 1 59 in Replace spring 3 Thickness of shoe t 5 4 mm 0 2126 in 4 80 mm 0 19 in Replace piston shoe ass...

Page 445: ...ompensator piston 621 to piston case 622 Insert assembly into compensator bore 2 Insert compensator piston rod 623 into piston bore 3 Assemble lever 612 to casing using pin 875 4 Install snap ring 836 onto spool sleeve 651 and insert sleeve into spool bore Insert spool 652 into sleeve already installed in block Figure 38 Figure 39 Figure 40 ...

Page 446: ...ach feedback lever 611 to spool 652 using pin 874 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 6 Insert pilot piston 643 into bore Figure 41 2 3 1 HAOF220L Figure 42 Figure 43 ...

Page 447: ...ston 643 8 Install O rings 755 onto portion 614 and adjusting 615 plugs Insert pin 875 into portion plug Install both plugs into their proper bore and secure with snap rings 858 NOTE Be certain to install plugs into correct bore Feedback lever should move freely and not bind up 9 Install O rings 722 735 into cover and mount cover 656 onto block using four hex head allen style bolts 438 Figure 44 F...

Page 448: ...at 624 outer spring 625 and inner spring 626 into Pf piston bore Install O rings 756 763 into pilot piston lower cover 629 Mount cover onto regulator casing by using four allen head bolts 438 12 Install Pf sleeve 631 and pin 898 into compensator piston bore 13 Install return spring 654 spring seat 653 and snap ring 814 onto feed back lever spool 652 Insert feed back lever set spring 655 around spo...

Page 449: ...aced to their proper location MAIN PUMP REASSEMBLY NOTE Reassembly should be done by reversing disassembly steps 1 Begin reassembly with servo piston 532 tilting pin 531 and feedback pin 538 at top of pump case Use Loctite 609 to hold tilting pin and servo piston if those parts have been disassembled 2 Bolt swash plate support 251 to pump casing 271 Tighten four allen head mounting bolts 3 Turn pu...

Page 450: ...ing on end of drive shaft with plastic hammer Use brass rod as a drift to push outer wheel into final position Install snap ring 824 6 Grease O ring 710 and oil seal 774 for protection then install seal cover 261 and tighten mounting screws IMPORTANT Do not use excessive force hammer blows or other mechanical advantage to re install the drive shaft The subassembly can be returned to place with onl...

Page 451: ... 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 8 When both front and rear pump have been completely reassembled verify direction of valve block Install rear pump first 9 Install regulators after pump assembly is bolted together and replace case drain plugs Figure 56 Figure 57 Figure 58 Figure 59 ...

Page 452: ...S0708320 Page 40 Main Pump With Regulator Return to Master Table of Contents ...

Page 453: ...is manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Solar 255LC V 1001 and Up Solar 300LC V 1001 and Up Solar 340LC V 1001 and Up Copyright 2002 Daewoo Nov...

Page 454: ...arallel Orifice for Arm 20 Relief Valve 21 Combined Operation 22 Bucket Combined Operation 24 Antidrift Valve 25 Main Relief Valve 26 Overload Relief Valve 69 Total Six Places 27 Low Pressure Relief Valve 70 Total Two Places 28 Generation of Signal Pressure 28 Relief Operation 29 Parts List 30 Spool Assembly 2 Arm 2 34 Spool Assembly 3 Boom1 34 Spool Assembly 4 Bucket 34 Spool Assembly 5 Travel 35...

Page 455: ...42 Disassembly 43 General Instructions for Disassembly 43 Disassembly of Main Spool Part 43 Disassembly of Arm 1 Para Spool Turn 44 Disassembly of Arm Regeneration Release Valve Part 45 Disassembly of Rod Check Valve Part 45 Disassembly of Antidrift Valve 46 Disassembly of Relief Valve 47 Disassembly of Spare Section Part 47 Disassembly of Miscellaneous Plug Kind 47 Disassembly of Valve Housing Co...

Page 456: ...drift Valve Assembly 52 Reassembly Procedure of Control Valve Body 53 Reassembly of Relief Valve 53 Reassembly of Load Check Valve 53 Reassembly of Antidrift Valve 54 Reassembly of Spare Section Part 54 Reassembly of Arm Regeneration Release Valve 54 Reassembly of Arm 1 Para turn Spool 54 Reassembly of Main Spool 55 Reassembly of Miscellaneous Plug Kinds 55 Reassembly of Main Relief Valve 55 Reass...

Page 457: ...o 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 The pressures of low pressure relief valve upper chambers L2 and R2 reach through ports ps1 and ps2 to pumps and control displacement of pumps P1 and P2 If too much oil flows into neutral passages low pressure relief valves...

Page 458: ...S0709401K Page 6 Main Control Valve Kayaba Figure 1 ...

Page 459: ...S0709401K Page 7 Main Control Valve Kayaba Figure 2 ...

Page 460: ...nd land Rc3 into tank passage Ta 2 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 3 The oil passing through orifice Lc6 flows through land Lc7 to tank passage Ta or flows through passage 4 to travel spool land Rc5 and then flows into tank passage Ta Figure 3 ...

Page 461: ...S0709401K Page 9 Main Control Valve Kayaba ...

Page 462: ...rallel passage R3 and passage S6 1 are equal so poppet S6 2 does not open Return oil flows through port A6 B6 to spool and returns to tank passage Ta 3 When shifting either spool section 1 or 6 land Lc4 or Rc3 is closed Oil supplied from port PP does not flow into tank passage so that pressure at port PT rises Spare Spool Shifting 1 When shifting spare spool by increasing pressure of spare section...

Page 463: ...S0709401K Page 11 Main Control Valve Kayaba Figure 4 ...

Page 464: ... A3 B3 to spool and is returned to tank passage Ta Bucket Spool Shifting 1 Oil flow control in bucket section portion of valve is different from other sections because it has a regeneration function that works against pilot port pressure A Dump When bucket spool is shifted by increasing pressure of bucket section 7 Figure 5 pilot port Pa7 neutral passage R1 is closed Oil supplied to port P2 flows ...

Page 465: ... 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 Figure 6 ...

Page 466: ...fting 1 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 Figure 7 ...

Page 467: ...rt P2 flows through parallel passage R3 and load check valve S8 2 to spool and flows into port A8 When boom 2 spool is shifted by increasing pressure of boom 2 section 4 pilot port Pb4 neutral passage L1 is closed Oil supplied to port P1 flows through parallel passage L3 load check valve S4 2 spool and to passage 6 and joins at port A8 Return oil flows from port B8 to spool and returns to tank pas...

Page 468: ...gh 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 Some return oil opens poppet S8 3 in boom 1 spool flows through passage S8 2 joins at port B7 and then prevents cavitatio...

Page 469: ...fting 1 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 Figure 10 ...

Page 470: ...d spool into port B5 When arm 2 spool is shifted by increasing pressure of arm 2 section 9 pilot port pb9 oil supplied to port P2 flows through neutral passage R1 load check valve S9 1 passage S9 2 and spool to passage 8 and joins at port B5 The return oil from port B5 flows through regeneration check valve in spool and then flows to port B to regenerate and some oil returns through variable regen...

Page 471: ... 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 From there if load pressure of port B is increased it flows through regeneration release valve piston g and pushes regeneration release spool h as a result area of variable orifice f is increased and oil returning to tank Ta is increased an...

Page 472: ...S9 1 spool and passage 8 and joins at port A5 Return oil from port B5 returns through spool to tank passage Ta Parallel Orifice for Arm The orifice that is installed in parallel passage for arm 1 controls arm speed when operating in a combined operation Oil supplied from parallel passage L3 Figure 14 of arm 1 section 5 pushes open poppet S5 3 It then flows through orifice Lc8 of variable orifice s...

Page 473: ...f valve The highest pressure of pump P1 and P2 is controlled by reaction of main relief valve 2 Over Load Relief Valve The over load relief valve that is installed in each cylinder port of boom 1 arm 1 and bucket prevents pressure of actuator from increasing extremely high from outside forces This relief valve when pressure of cylinder port is negative has a function to prevent cavitation by drawi...

Page 474: ...vel Pump 2 50 Section 6 Travel 50 If there is no travel straight circuit machine will travel in zig zag manner PT closed The oil passage is closed at the signal land Lc4 Lc7 Rc3 and Rc5 PA closed The oil passage is closed at the signal land like PT Signal passage pressure Rises up to relief pressure Straight Travel spool shifting If straight Travel spool is shifted pump 1 supplies oil to Section 1...

Page 475: ...S0709401K Page 23 Main Control Valve Kayaba Figure 16 ...

Page 476: ... piston S7 6 piston S7 5 and plug S7 4 are pressed and poppet assembly S7 2 is seated on valve housing This causes oil flowing from parallel passage R3 to open poppet S7 3 in poppet assembly and flow into passage S7 1 As a result passage diameter is smaller during combined operation than passage diameter during a single operation This smaller passage reduces flow of oil to port A7 B7 Remaining oil...

Page 477: ...om port A5 is cut off by seat S1 and seat S2 2 Cut off condition of passage of port A5 Figure 19 and spring chamber A If port pc1 is pressurized piston 2 is moved and spool 3 reacts B Spool 3 activates poppet 4 C And then by moving poppet 4 port A5 and spring chamber d is cut off by seat S1 3 Operating condition of main poppet A If again piston 2 Figure 20 reacts even more to pressure at port pc1 ...

Page 478: ...l oil passage HP rises and exceeds relief valve setting pilot poppet F opens Pressurized oil flows through pilot poppet F into low pressure oil passage LP passing through hole G 3 As pilot poppet F opens pressure in internal cavity D lowers to move main poppet C so that pressurized oil flows into neutral oil passage HP and directly into low pressure oil passage LP 4 Pressure up operation If pressu...

Page 479: ...sure in cylinder port HP rises and exceeds the relief valve setting pilot poppet E opens Pressurized oil then flows through pilot poppet E into low pressure oil passage LP passing through hole H 3 As pilot poppet E opens pressurized oil flows through orifice I so that pressure on back of piston C lowers to move piston C As a result piston C seats on pilot poppet E 4 Pressurized oil in passage HP f...

Page 480: ...nder port HP to eliminate cavitation LOW PRESSURE RELIEF VALVE 70 TOTAL TWO PLACES Generation of Signal Pressure Oil supplied from pump port P1 P2 flows through neutral passage L1 R1 low pressure relief valve passage L2 R2 and orifice Lc1 Rc1 to tank passage Ta Now pressure generated at passage L2 R2 by orifice Lc1 Rc1 moves to low pressure relief signal port Ps1 Ps2 If main spool of upper reaches...

Page 481: ... 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 By this action generation of excessive pressure in low pressure relief signal port is prevented Figure 31 ...

Page 482: ... Main Control Valve Kayaba PARTS LIST 75 69 37 69 92 77 81 75 52 74 76 L L B B A A C D E F G H I C D E F G H I K K 71 74 78 72 37 69 90 72 75 37 90 69 43 72 75 89 88 73 37 72 92 68 52 76 J J X VIEW X ARS4580L Figure 32 ...

Page 483: ...K Page 31 Main Control Valve Kayaba Figure 33 8 15 16 17 5 70 13 7 8 12 8 8 8 8 8 70 2 3 4 5 6 7 1 63 SECTION A1 A1 61 62 33 32 72 57 SECTION A A SECTION B B SECTION L L SECTION K K X 41 Y 42 X 41 Y 42 ARS4570L ...

Page 484: ...00 7 6 5 103 104 36 SECTION C C SECTION D D SECTION E E SECTION G G SECTION H H SECTION J J SECTION I I DETAIL F1 F1 SECTION F F 34 35 53 55 54 51 35 36 36 72 72 47 49 50 45 36 44 91 105 67 38 39 35 3 34 35 34 38 39 40 32 28 29 22 2 18 31 30 31 ARS4590L Figure 34 ...

Page 485: ...35 Spring 36 O ring 37 Flange 38 Poppet 39 Spring 40 Spacer Assembly 41 O ring 42 O ring 43 Flange 44 Poppet 45 Spring 46 Plug 47 O ring 48 Spring 49 Poppet 50 Steel Ball 51 Poppet 52 Flange 53 Spacer 54 O ring 55 Backup Ring 57 Spacer 60 Plug Assembly 61 Plug 62 O ring 63 Orifice Plug 65 O ring 66 O ring 67 Anti draft Valve Assembly 68 70 Relief Valve Assembly 71 Plug Assembly 72 Plug Assembly 73...

Page 486: ...ber Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End 5 Plug 6 Poppet 7 Spring 8 O ring 9 Backup Ring Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End 5 Plug 6 Poppet 7 Spring 8 O ring 9 Backup Ring Figure 35 Figure 36 Figure 37 ...

Page 487: ...ssembly 14 Arm1 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End 5 Plug 6 Poppet 7 Spring 8 O ring 9 Backup Ring Figure 38 Figure 39 Figure 40 ...

Page 488: ...m Regeneration Release Valve Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Sleeve 3 Piston Figure 41 Figure 42 Figure 43 Figure 44 ...

Page 489: ...37 Main Control Valve Kayaba Spacer Assembly 40 Plug Assembly 60 Reference Number Description 1 Spacer 2 O ring 3 Backup Ring 4 O ring Reference Number Description 1 Plug 2 O ring 3 O ring 4 O ring Figure 45 Figure 46 ...

Page 490: ...embly 67 Figure 47 Reference Number Description 1 Body 2 Poppet 3 Plug 4 Piston 5 Spool 6 Sleeve 7 Spring 8 Spring 9 O ring 10 O ring 11 Backup Ring 12 Backup Ring 13 O ring 14 Plug Assembly 15 Plug Assembly 16 Spring Seat 17 Steel Ball Reference Number Description ...

Page 491: ...g 2 O ring 3 O ring 4 Backup Ring Control Valve Specification Rated Flow 270 liter min 71 gal min 50 liter min 13 gal min at Neutral Max Pressure 34 3 MPa 349 76 kg cm 4 975 psi Allowable Back Pressure Peak Pressure Below 1 5 MPa 15 30 kg cm 218 psi Normal Pressure Below 0 5 MPa 5 10 kg cm 73 psi Allowable Working Temperature Range 20 90 C 4 194 F Peak Max 100 C 212 F Seal is used nitrile rubber F...

Page 492: ...r cap crisscrossed Remove center and retighten cap Valve temperature uneven Warm up entire system Dirt in valve Clean valve flushing Lack of pilot pressure Check pilot valve and pilot relief pressure Fail to keep load Cylinder leaks Check seal parts of cylinder Spool leaks Check spool Overload relief valve leaks Clean valve housing and relief valve seat parts Antidrift valve leaks Remove antidrift...

Page 493: ...ble Cause Remedy Pressure does not rise Stuck main poppet sleeve or pilot poppet opened or dirt in seat part Replace relief valve Relief pressure unstable Seat parts of pilot poppet damaged Piston or main poppet stuck Relief pressure is incorrect Seat parts worn due to dust Lock nut and adjuster loose Reset pressure and tighten lock nut in rated torque Oil leaks Relief valve seat parts damaged Rep...

Page 494: ...m 3 090 psi Tighten lock nut 7 after pressure has been adjusted 6 Recheck pressure setting by raising pressure once more Over Load Relief Valve 1 Shift control valve spool and read pressure gauge from stroke end of cylinder 2 Loosen lock nut 3 and turn adjusting plug clockwise to raise pressure Item number 69 six places One turn varies pressure by approximately 21 2 MPa 216 18 kg cm 3 075 psi 3 Ti...

Page 495: ... shown as assembly part number further part number Disassembly of Main Spool Part 1 Remove socket head bolt 74 two places per each section width across flats 8 mm and cap 8 ten places 2 Remove plug assembly 72 width across flats 8 mm and plug 91 width across flats 22 mm according to necessity 3 Remove O ring 7 one place per each section from valve housing 1 and 13 4 Remove all spool subassemblies ...

Page 496: ...22 width across flats 5 mm spring seat 20 and spring 21 from spool 19 IMPORTANT Work with spool gripped in vise with wood see Figure 50 not to scratch outside diameter of spool Because Loctite is applied to threaded portion of spool end heat outside surface of spool with industrial drier to release Loctite Heat spool until spool end is easily loosened and remove immediately after heating it to 200...

Page 497: ...ion C C 7 Remove spring 33 and poppet 32 from valve housing 8 Remove plug 72 width across flats 8 mm section L L 9 Remove spacer 57 spring 33 and poppet 32 from valve housing 10 Remove plug 92 width across flats 36 mm section G G 11 Remove socket head bolt 73 four places width across flats 8 mm and flange 43 12 Remove spring 45 poppet 44 and O ring 36 from valve housing 13 Remove plug 46 width acr...

Page 498: ...Remove plug assembly 67 14 width across flats 38 mm and O ring B Remove piston 67 4 spool 67 5 and spring 67 7 C Remove plug 67 3 width across flats 38 mm and O ring D Remove sleeve 67 6 and poppet 67 2 from body Remove O ring 67 9 10 and backup ring 67 11 12 from outside diameter of sleeve E Pull spring seat 67 16 and spring 67 8 out of inside hole F Remove plug assembly 67 15 if necessary NOTE B...

Page 499: ...ats 36 mm and O ring 5 Remove plug assembly 71 width across flats 6 mm and O ring 6 Remove plug assembly 72 width across flats 8 mm and O ring Disassembly of Valve Housing Combined Bolt 1 Remove socket head bolt 77 eight places width across flats 14 mm and washer 81 eight places 2 Remove O ring 65 66 from valve housing mating surface CAUTION Removing relief valve when pressure is not fully release...

Page 500: ...ut 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 Disassembly of Overload 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...

Page 501: ... 75 mm and O ring 2 If oil is leaking from adjusting kit 3 remove adjusting kit 3 and replace O ring 4 Disassembly of Low Pressure Relief Valve This unit has press fit portion D so that it should be replaced by assembly IMPORTANT When disassembling adjuster kit be careful not to let parts spring out or lose poppet because of spring force Figure 53 ...

Page 502: ...unction inspect it using relief valve maintenance procedure 6 Replace all O rings and backup rings with new 7 After disassembling cap or plug check whether there are paint chips around body hole or plug If paint chips penetrate into valve they can cause malfunction or valve to leak REASSEMBLY INSTRUCTIONS FOR REASSEMBLY Handling Instructions of O ring 1 Do not use O ring which has any defect or sc...

Page 503: ...le inlet At this time be careful not to touch applying part to spring seat PROCEDURE OF SUBASSEMBLY Reassembly of Spool Assembly Main Spool 1 Apply Loctite to threaded portion of spool 2 6 14 17 and install spring seat spring and spool end 2 After gripping spool in vise with wood that is used when disassembling it tighten spool end Tightening torque 2 04 2 24 kg m 15 16 ft lb CAUTION When working ...

Page 504: ...1 4 Install spring 67 7 and piston 67 4 in plug 67 3 5 Tighten plug assembly 67 14 with O ring installed on plug 67 3 Tightening torque 14 99 16 01 kg m 108 116 ft lb 6 Install O ring 67 13 on plug 67 3 Install it in body 67 1 Tightening torque 14 99 16 01 kg m 108 116 ft lb 7 Tighten plug assembly 67 15 with O ring in body 67 1 Tightening torque 1 43 1 84 kg m 10 13 ft lb IMPORTANT Be careful not...

Page 505: ... 47 ft lb 4 Install poppet 51 and spring 35 in common section I I Insert spacer 53 with O ring 54 and backup ring 55 Tightening torque 3 98 4 49 kg m 29 32 ft lb 5 Install O ring 36 on spare section section G G Install poppet 44 and spring 45 Mount flange 43 and install socket head bolt 96 Tightening torque 5 91 6 53 kg m 43 47 ft lb 6 Tighten flange assembly 92 with O ring Tightening torque 20 90...

Page 506: ...l O ring 89 on cap 88 two places and fasten it in place with socket head bolt 76 Tightening torque 5 91 6 53 kg m 43 47 ft lb 2 Install O ring and backup ring on plug assembly 87 two places Install plug assembly Tightening torque 7 95 8 97 kg m 58 65 ft lb Reassembly of Arm Regeneration Release Valve 1 Install O ring 30 and backup ring 31 two places on sleeve 28 2 Install piston 29 and spool 27 on...

Page 507: ...ft lb 3 Tighten orifice plug 63 Tightening torque 1 43 1 84 kg m 10 33 13 28 ft lb 4 Install O ring on plug assembly 92 and install Tightening torque 20 90 23 15 kg m 151 167 ft lb 5 Install O ring on plug assembly 71 and install Tightening torque 1 43 1 84 kg m 10 13 ft lb 6 Install O ring on plug assembly 72 and install Tightening torque 7 44 8 06 kg m 54 58 ft lb Reassembly of Main Relief Valve...

Page 508: ...S0709401K Page 56 Main Control Valve Kayaba Figure 54 ...

Page 509: ...assembled adjust pressure by referring to Over Load Relief Valve on page 42 NOTE The torque values are based on use of lubricated threads Reassembly of Low Pressure Relief Valve Check if there is dirt and paint chips around plug 1 Replace O ring 3 with new one Install new O ring 4 on sleeve 2 Clean installation portion of relief valve and valve housing Tighten plug 1 width across flats 32 mm of re...

Page 510: ...ES 1 Before operating machine make sure that oil passages and hydraulic oil are clean 2 Hydraulic oil of which annealing point is 82 113 C 180 235 F should be used in the hydraulic system 3 Relief valve pressure should not be raised above specified pressure setting 4 The difference between main relief valve setting pressure and over load relief valve setting pressure should not be over 2 0 MPa 20 ...

Page 511: ...s 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 MODEL SERIAL NUMBER RANGE Solar 75 V 1001 and Up 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 2...

Page 512: ... 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 14 Installation 19 Start up Procedures 20 ...

Page 513: ...neutral mode the spool is thrust upward by return spring and the force of balancing spring which determines the secondary discharge pressure is not transmitted to the spool The input port is closed and the pressure of the output port is the same as the pressure of the tank port T 2 Control Mode When push rod is pushed the balance spring begins to compress and spring force is conveyed to the spool ...

Page 514: ...S0709451K Page 4 Pilot Control Valve Work Lever Joystick PARTS LIST 30 29 26 23 24 13 22 21 17 31 15 16 36 32 33 34 35 1 2 3 5 4 6 7 9 10 8 28 27 25 14 19 18 12 11 20 ARS2260L Figure 1 ...

Page 515: ... 29 Spring Pin 30 Handle Assembly 31 Bushing 32 Terminal 33 Seal Wire 34 Housing 35 Holder Rear 36 Clip Band Reference Number Description Pilot Control Valve Specification Type Pilot Control 2 Stage Joystick Pressure Stroke 1 3 28 kg cm2 6 5 mm Stroke 398 psi 0 256 in Stroke 2 4 28 kg cm2 7 5 mm Stroke 398 psi 0 295 in Stroke Weight 4 8 kg 11 lb Reference Number Bolt Size Tool Torque 2 PT 1 8 5 mm...

Page 516: ...s joysticks in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery WARNING If engine must be run while performing maintenance use extreme care Always have one person in the cab at all times Never...

Page 517: ... 2 and pull remote control valve L H 1 out 15 Tag and disconnect hoses from remote control valve L H 1 Figure 5 Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component 16 Remove four bolts and washer 2 Figure 6 and cover 2 17 Pull cap 5 Figure 6 out and remove screw three bolts and washers 6 and cover 3 18 Remove two screws two bolts and washers 7 and 8 Fi...

Page 518: ...e 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 cap hoses and ports to prevent contamination from entering hydraulic system or component 1 2 3 ARS2920L Figure 7 ...

Page 519: ...Pilot Control Valve Work Lever Joystick DISASSEMBLY 1 Lift up the boot 28 and pull the switch cord through the hole in the case 1 2 Loosen nut 27 from hex nut 25 and remove handle assembly 30 Figure 8 Figure 9 Figure 10 ...

Page 520: ...Page 10 Pilot Control Valve Work Lever Joystick 3 Remove hex nut 25 and swash plate 24 4 Remove joint 23 from case 1 5 Remove plate 21 6 Press spring 10 and remove plug 18 Figure 11 Figure 12 Figure 13 Figure 14 ...

Page 521: ... reduction valve 6 7 8 9 11 and spring 10 8 Remove plug 3 and four plugs 2 9 Remove stopper 11 from pressure reduction valve 6 7 8 9 11 10 Remove spool 6 spring seat 9 spring 8 and shim 7 IMPORTANT Mark valve disassembling position port Figure 15 Figure 16 Figure 17 Figure 18 ...

Page 522: ...S0709451K Page 12 Pilot Control Valve Work Lever Joystick 11 Remove push rod 14 and plug 18 12 Remove O ring 19 from plug 18 13 Remove seal 20 from plug 18 Figure 19 Figure 20 Figure 21 ...

Page 523: ...ick 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 ...

Page 524: ...lug 3 slowly NOTE Tightening torque 350 kg cm 25 ft lb Tighten four plugs 2 NOTE Use Loctite 592 pipe sealant on plugs NOTE Tightening torque 150 kg cm 11 ft lb 2 Install shim 7 spring 8 spring seat 9 and spool 6 3 Press spring 9 and install stopper 11 Figure 22 Figure 23 Figure 24 ...

Page 525: ...alve Work Lever Joystick 4 Install spring 10 in case 1 and pressure reducing valve assembly 6 7 8 9 11 5 Install seal 20 on plug 18 6 Install O ring 19 on plug 18 7 Install push rod 14 on plug 18 Figure 25 Figure 26 Figure 27 Figure 28 ...

Page 526: ... Valve Work Lever Joystick 8 Install spring 13 on stopper 12 9 Position stopper 12 and spring 13 on pressure reducing valve 10 Install plug 18 in case 1 11 Install plate 21 and tighten joint 23 Figure 29 Figure 30 Figure 31 Figure 32 ...

Page 527: ...3 Install hex nut 25 and tighten swash plate 24 NOTE Tightening torque 1 240 kg cm 90 ft lb 14 Pull cord and tube out through hole of hex nut 25 15 Align the direction of handle 30 and tighten hex nut 25 and nut 27 NOTE Tightening torque 1 240 kg cm 90 ft lb Figure 33 Figure 34 Figure 35 Figure 36 ...

Page 528: ...S0709451K Page 18 Pilot Control Valve Work Lever Joystick 16 Grease joint 23 swash plate 24 and push rod 14 17 Install boot 28 Figure 37 Figure 38 ...

Page 529: ...rews two bolts and washers 7 and 8 Figure 40 and cover 4 4 Install a screw three bolts and washers 6 Figure 40 and cover 3 Push cap 5 into cover 3 5 Install four bolts and washers 2 Figure 40 and cover 1 6 Connect hoses as tagged during removal to remote control valve L H 1 Figure 41 7 Position remote control valve L H 1 Figure 41 on control stand and install four bolts and washers 3 and cover 2 1...

Page 530: ... Push cap 5 into cover 3 10 Install four bolts and washers 2 Figure 42 and cover 1 START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly cycle boom arm bucket cylinders and swing motor about five times without a load to vent air from pilot lines Do this for 5 minutes 5 6 3 7 1 2 4 ARS2910L Figure 42 HAOB290L Figure 43 ARO0470L Figure 44 ...

Page 531: ...ays 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 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 1001 and Up Solar 300LL 1001 and Up Solar 340LC V 1001 and Up Sol...

Page 532: ...eory 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 17 assembly 18 Installation 23 Start up Procedures 24 ...

Page 533: ... port T through inner hole of spool 2 Half Operation Condition If pedal is moved push rod moves down and they transmit this force through spring seat and control spring to spool If spool is moved primary pressure is transmitted through an inner hole of spool to operating port If lever is stopped in middle position compressed control spring force and secondary pressure transmitted through hole acts...

Page 534: ...itted through inner hole of spool to operating port secondary pressure transmitted through spool overcomes control spring force and pushes spool up but spool is restricted by push rod and does not move any more That is when pedal lever is moved to a maximum control spring does not function spool is restricted by push rod and then primary pressure equalizes to secondary pressure PUSH ROD STROKE mm ...

Page 535: ...hamber of upper part of low pressure at this time ball check valve becomes closing condition because high pressure operates to vibration prevention chamber of lower part 2 Operation When Operating Lever In Neutral Condition Climbing restoring force acting on push rod raises piston in oil pressure prevention chamber and compresses upper oil pressure prevention chamber This compression operation of ...

Page 536: ...820K Page 6 Travel Control Valve With Damper PARTS LIST 32 24 23 22 16 21 13 12 11 9 5 4 3 10 8 6 7 19 20 17 18 14 15 3 36 25 26 19 20 30 29 28 33 37 1 35 34 2 ARS1850L Figure 5 P T 1 2 3 4 ARS1860L Figure 6 ...

Page 537: ...4 Dust Deal 25 Cover 26 Wrench Bolt 27 Cam 28 Bushing 29 Camshaft 30 Set Screw 31 Set Screw 32 Hex Nut 33 Bellows 34 Space 35 O ring 36 O ring 37 Wrench Bolt Reference Number Description Travel Control Valve Specification Type Pilot Control With Damper Pressure Stroke 27 kg cm2 4 8 mm Stroke 384 psi 1 890 in Stroke Weight 7 8 kg 17 lb Part Reference Number Bolt Size Tool Tightening Torque 26 M6 5 ...

Page 538: ...imary pressure Defective secondary pressure select spring Replace with new spring Gap between spool and casing is abnormally large Replace spool casing assembly Defective operating parts and components Disassemble reassemble and replace defective parts Unstable secondary pressure Jamming of interconnected parts Repair replace cause of jamming Unstable tank line pressure Install direct line to hydr...

Page 539: ...ey to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery 11 Remove cabin under cover by loosening bolts 12 Tag and disconnect hoses from pedal valve 1 Figure 8 Plug and cap hoses and ports to prevent contamination from entering hydraulic system or component WARNING If engine must be run while per...

Page 540: ...lve With Damper 13 Remove rubber boots 1 Figure 9 14 Remove four bolts and washers 2 Figure 9 pedal brackets 3 with levers 15 Remove four bolts and washers 2 Figure 10 and pedal valve 1 1 2 1 ARS2951L 3 3 Figure 9 1 2 ARS2940L Figure 10 ...

Page 541: ...tainer in which disassembled parts can be stored 3 All precision parts must be handled with great care and all parts must be reassembled to their original position 4 All parts must be carefully reassembled and not be forced Damaged parts will cause oil leaks and poor performance of the equipment 5 Do not leave parts exposed to air during or after disassembly Exposed parts will come in contact with...

Page 542: ...09820K Page 12 Travel Control Valve With Damper 3 Remove cam shaft 29 and bushing 28 from cam 27 4 Remove cam 27 from cover 25 5 Remove wrench bolt 26 by using tool Figure 13 Figure 14 Figure 15 Figure 16 ...

Page 543: ...e With Damper 6 Remove cover 25 from body 1 and 2 7 Remove plug assembly 21 24 with push rod assembly 14 20 8 Remove snap ring 13 9 Remove rod guide 11 IMPORTANT Be careful not to spring rod guide 11 Figure 17 Figure 18 Figure 19 Figure 20 ...

Page 544: ...9820K Page 14 Travel Control Valve With Damper 10 Remove spool assembly 5 9 11 Remove spring 10 12 Remove stopper 9 spring 6 and spring seat 7 from spool assembly 5 9 Figure 21 Figure 22 Figure 23 Figure 24 ...

Page 545: ...ntrol Valve With Damper 13 Remove plug assembly 21 24 from push rod assembly 14 20 14 Remove seal 23 and 24 from plug 21 15 Remove O ring 22 from plug 21 16 Remove seal 16 from push rod 14 Figure 25 Figure 26 Figure 27 Figure 28 ...

Page 546: ...vel Control Valve With Damper 17 Remove snap ring 20 from push rod 14 18 Remove plate 19 from push rod 14 19 Remove spring 18 from push rod 14 20 Remove steel ball 17 from push rod 14 Figure 29 Figure 30 Figure 31 Figure 32 ...

Page 547: ...nd may cause poor equipment performance Be sure to use clean uncontaminated solvent when cleaning precision parts 2 Clean parts thoroughly by gently turning the solvent Dry and clean each part with a clean cloth Do not use compressed air to dry parts Foreign material and moisture present in compressed air may cause damage or rust 2 Anti corrosive treatment of disassembled parts Apply an anti corro...

Page 548: ...f approved lubricant to aid in smooth assembly 6 Tighten all bolts to the specified torque rating as outlined in the torque table 7 Seal all opens ports to prevent foreign material from entering the valve assembly 8 All precision parts must be handled with great care and all parts must be reassembled to their original position 9 All parts must be carefully reassembled and not be forced Damaged par...

Page 549: ...install rod seal 23 and dust seal 24 on both sides of plug by using tool 4 Install O ring 22 on outside diameter of plug 21 and check plug whether it is abnormal 5 Install spring seat 7 spring 6 and spring seat 5 on spool 8 6 Install O ring 12 on rod guide 11 Figure 34 Figure 35 Figure 36 Figure 37 ...

Page 550: ... spring 18 plate 19 and spring pin 15 on push rod 14 8 Install snap ring 20 on push rod assembly 14 19 9 Install seal 16 on push rod 14 10 After installing spool assembly 5 9 on body 1 and 2 insert rod guide 11 and install snap ring 13 Figure 38 Figure 39 Figure 40 Figure 41 ...

Page 551: ...sh rod assembly 14 20 on body 1 and 2 12 Install cover 25 on the upside of body 1 and 2 13 Tighten wrench bolt 26 NOTE Tightening torque 88 kg cm 7 ft lb 14 Put cam 27 on cover 25 and install cam shaft 29 IMPORTANT Check whether there is a play of cam Figure 42 Figure 43 Figure 44 Figure 45 ...

Page 552: ... 29 by using wrench NOTE Tightening torque 88 kg cm 7 ft lb 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 NOTE Tightening torque 440 kg cm 32 ft lb 17 Install bellows IMPORTANT Check whether there is a play of cam Figure 46 Figure 47 Figure 48 ...

Page 553: ...s and washers 2 2 Install pedal brackets 3 and levers 4 Figure 50 on pedal valve and install four bolts and washers 2 3 Install rubber boots 1 Figure 50 4 Connect hoses as tagged during removal to pedal valve 1 Figure 51 5 Install cabin under cover by tightening bolts 1 2 ARS2940L Figure 49 1 2 1 ARS2951L 3 3 Figure 50 1 2 ARS2940L Figure 51 ...

Page 554: ...amper START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly push and pull both travel lever about five times without a load to vent air from pilot lines Figure 52 HAOB290L Figure 53 HAOB903L ...

Page 555: ...y recommendations and safe shop practices outlined in the front of this manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Solar 225NLC V 1001 and Up Copyrig...

Page 556: ...S0792105K Page 2 Hydraulic Schematic Solar 225LC V 225NLC V Return to Master Table of Contents TABLE OF CONTENTS General Description 3 Solar 225LC V 4 Solar 225NLC V 6 ...

Page 557: ...turn to Master Table of Contents GENERAL DESCRIPTION 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 ...

Page 558: ...S0792105K Page 4 Hydraulic Schematic Solar 225LC V 225NLC V Return to Master Table of Contents SOLAR 225LC V Figure 2 ...

Page 559: ...S0792105K Page 5 Hydraulic Schematic Solar 225LC V 225NLC V Return to Master Table of Contents BBS0070L SOLAR 225LC V ...

Page 560: ...S0792105K Page 6 Hydraulic Schematic Solar 225LC V 225NLC V Return to Master Table of Contents SOLAR 225NLC V Figure 3 ...

Page 561: ...S0792105K Page 7 Hydraulic Schematic Solar 225LC V 225NLC V Return to Master Table of Contents BDS0110L SOLAR 225NLC V ...

Page 562: ...S0792105K Page 8 Hydraulic Schematic Solar 225LC V 225NLC V Return to Master Table of Contents ...

Page 563: ...1ELECTRICAL SYSTEM ...

Page 564: ......

Page 565: ...s 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Solar 225NLC V 1001 and Up Solar 255LC V 1001 and Up Solar 300LC V 1001 and Up Solar 300LL 1001 and Up Solar 340LC V 1001 and Up Solar 420LC V 1001 and Up Solar 470LC ...

Page 566: ...nel 15 Monitoring System Schematic 16 Operation 18 Instruments 18 Warning and Indicator Lights 20 Initial Operation 22 Mode Select Switch 23 Graphic Information Area Display 24 Overview 24 Main Menus for the Graphic Display Area 25 Menu Selection Buttons 25 Main Menu 26 Language setting 26 Time Setting 26 Filter Oil information 27 Special Menu 28 Entering Accessing and Exiting Escaping Menus 28 Sp...

Page 567: ...eat Protection System 60 Power Boost Mode 61 Operation 61 Power Boost Control Circuit Diagram 62 Automatic Travel Speed Control 63 Automatic Travel Speed Control Circuit Diagram 64 Engine Control Device Adjustment 65 Self diagnostic Function 68 e EPOS Controller 68 Engine Throttle Controller 70 Wiper System 71 Wiper Circuit 71 Wiper Operation 71 Window Washer Operation 72 Lighting System 74 Lighti...

Page 568: ...nt Engine throttle controller defective or not connected Repair connection or replace component Blown fuse Replace fuse Check connections and circuit components for shorts or other damage Wiring harness or connector defective or damaged Repair or replace Power mode selection does not change Blown fuse Replace fuse Check connections and circuit components for shorts or other damage Instrument Panel...

Page 569: ... and a three phase AC generator with a rectifier The electric wiring used in the system is easily identifiable by the insulator color The color symbols used in the electrical system are listed in the following chart Electric Wire Color NOTE RW Red wire with White stripe R Base Color W Stripe Color NOTE 0 85G Nominal sectional area of wire core less insulator 0 85 mm2 Symbol Color W White G Green O...

Page 570: ...ine stop motor When the starter switch 5 is in the preheat on and start positions the current flows from the battery 1 fusible link 3 fuse 6 starter switch 5 B terminal starter switch 5 BR terminal battery relay 2 BR terminal which activates the coil of the battery relay and the electric supply system is energized When the battery relay s contacts are connected all electric devices can be operated...

Page 571: ...ter relay 8 are connected the pinion gear of the starter 9 is pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter are connected The current flows from the battery 1 A terminal of the battery relay 2 B terminal of the battery relay 2 Figure 2 B terminal of the starter 9 The starter motor is rotated and the engine is started 4 BR PST B START P...

Page 572: ... and PP terminals are opened As a result the rotation of the starter 9 is stopped Once the engine is running the starter 9 will not operate even if the starter switch 5 is moved to the start position preventing possible damage to the starter Operation of the Start Circuit 2 Immediately After Start BR TML START ON PREHEAT PST OFF B ACC R2 R1 C R E F E 10 B R1 R I 6 R2 5 P R 11 4 BR B 11 P B ACC E N...

Page 573: ...he preheat time is approximately 19 seconds A built in timer in the instrument panel will activate an indicator light approximately 19 seconds after the preheat process has been selected Even after the starter switch 5 has been moved to the start position the current will continue to flow through the R2 terminal of the starter switch 5 to the coil of the preheat relay 7 without disruption of the p...

Page 574: ... is in the ON position the engine stop motor rotates 180 and comes to a stop due to the cam switch When the start switch is in the OFF position the engine stop motor moves 180 from the running mode position and is stopped by the cam switch E 9 6 8 A B P2 A P1 85 87 87a E 7 1 R1 ACC R2 B C BR 4 5 START 3 BR B 2 A 0 5G STARTER SWITCH CONNECTION 30 86 PREHEAT OFF ON PST TML B BR R1 R2 C ACC ARS0050L ...

Page 575: ...relay 5 A terminal of engine stop motor 6 E terminal of engine stop motor 6 ground The engine stop motor opens pushes the fuel shut off lever of the fuel injection pump and the system is in the running mode The engine stop motor rotates 180 and comes to a stop due to the cam switch which shuts off the current to the motor When the starter switch is in the ON position the internal components of the...

Page 576: ...he shut off lever of the fuel injection pump linked to the engine stop motor by a cable is moved to the close pull position and the engine is stopped The engine stop motor moves 180 from the running mode position and is stopped by the internal cam switch which cuts off the current to the motor When the starter switch is in the OFF position the internal components of the engine stop motor s cam swi...

Page 577: ...ectrical components When the alternator 7 starts to operate a current flows from the R I terminal of alternator diode 8 battery relay 2 coil securing a path for the charging current to the battery 1 Thus preventing the possibility of a high voltage build up and possible damage to the electric system STARTER SWITCH CONNECTION TML START ON PREHEAT OFF PST B BR R1 C R2 ACC R E F E SG B B 8 R I P R 7 ...

Page 578: ...splays information selected by the operator ARS0090L Figure 9 Reference Number Description 1 Instrument Panel 2 Battery 3 Engine Speed Sensor 4 Return Filter Switch 5 Pilot Filter Switch 6 e EPOS Controller 7 Alternator 8 Warning Buzzer 9 Pump Discharge Pressure Sensor 10 Engine Coolant Temperature Sensor 11 Fuel Sensor 12 Air Cleaner Indicator 13 Engine Oil Pressure Switch 14 Light Switch Referen...

Page 579: ...n area 3 and 4 Figure 10 Gauges Warning Lights Mode Select Switches 1 Engine Coolant Temperature Gauge 2 Fuel Gauge 3 Multifunction Gauge and Graphic Information Area 4 Digital Clock 5 Service Hour Meter 6 Charge Warning Light 7 Engine Oil Pressure Warning Light 8 Coolant Temp Warning Light 9 Preheat Completion Light 10 Work Light Indicator Light 11 Overload Warning Light 12 Power Mode Select Swit...

Page 580: ...VER LOAD L3 WATER TEMP L4 PREHEAT L5 WORK LAMP L1 BATTERY CHARGE L2 ENG OIL PRESS 8 7 ILLUMINATION EL 5 20 6 SIG 19 SIG L4 L1 L2 L3 6 17 L6 L5 11 1 9 10 2 22 CN2 13 CN2 14 CN2 11 CN2 12 CN2 1 RS 422 CN3 12 CN3 8 RxD CN3 11 CN3 10 RxD TxD CN3 9 TxD CN3 1 CN3 3 CN3 2 3 CN4 4 17 CN3 5 CN3 4 CN4 17 CN4 16 CN4 7 CN4 8 CN4 5 CN4 6 20 19 CN4 3 CN4 1 CN4 2 16 E BR 4 R1 B 18 B A 21 ARS0110L Figure 11 ...

Page 581: ...essure Sensor 7 Engine Coolant Temperature Sensor 8 Fuel Gauge 9 Engine Speed Sensor 10 Hydraulic Oil Temp Sensor 11 Engine Oil Pressure Switch 12 Air Cleaner Indicator 13 Return Filter Switch 14 Pilot Filter Switch 15 Alternator 16 e EPOS Controller 17 Battery 18 Battery Relay 19 Circuit Breaker 20 Fusible Link 21 Fuse Box 22 Check Connector Reference Number Description ...

Page 582: ...N4 8 1 10 LCD Blinking over 5K ohms FULL under 525 ohms Tachometer CN4 16 CN4 17 N 129 f 60 S225LC V N 129 f 60 S225NLC V N 129 f 60 S255LC V N 146 f 60 S300LC V N 146 f 60 S300LL N 152 f 60 S340LC V N 152 f 60 S420LC V N 152 f 60 S470LC V N Engine speed rpm f Frequency of engine speed sensor Hz Voltmeter CN7 9 CN7 19 0 32 VDC WHITE GREEN RED ARS0780L H C 107 C 105 C 61 C 41 C ARS0790L GREEN RED F...

Page 583: ...N4 2 V 0 00816 x P 1 0 V Sensor output voltage V P Displayed pressure Bar Main pump discharge pressure rear pump CN4 3 CN4 4 Function Display Sensor Specification Input Terminal Input Specification FRONT PUMP 02 05 MO 11 30A BAR 320 ARO0190L REAR PUMP 02 05 MO 11 30A BAR 313 ARO0200L ...

Page 584: ...essure CN2 11 Lights up when engine oil pressure switch is turned ON Oil pressure drops below 0 7 kg cm2 10 psi After starting engine if engine oil pressure is insufficient after 8 seconds a warning buzzer will sound Engine Coolant Temperature CN4 5 CN 4 6 Lights up when the resistance of engine coolant temperature sensor drops below 128 ohms Preheat CN7 6 Lights up when preheat process is complet...

Page 585: ...0LC V Graphic Information Area Air Cleaner CN2 12 Lights up when air cleaner is clogged Symbol is blinking Return Filter CN2 13 Lights up when return filter pressure increases over 1 5 kg cm2 21 psi Symbol is blinking Pilot Filter CN2 14 Lights up when pilot filter pressure increases over 1 0 kg cm2 14 psi Symbol is blinking Description Symbol Input Terminal Operation Remarks ARO0220L 2059 RPM 02 ...

Page 586: ... Initial Operation When battery voltage is input to CN7 9 starter switch is turned from OFF to ON position All LCD LED and warning lights are turned on and turned off after about 2 seconds Warning buzzer is activated and turned off after about 2 seconds Power mode Standard mode Work Mode Digging mode Auto Idle High Output Activation Numerical display Engine speed Clock Current time display ...

Page 587: ...tput Pump Discharge Volume Control Valve Current mA Swing Priority Solenoid Valve 7 Segment Display Power Mode Power Mode ON Variable Output 9 x Standard Mode OFF 0 7 x Work Mode Trenching Mode ON ON x 2 Digging Mode OFF OFF x 0 Operation Mode Output Check Operation mode display LED e EPOS Output CN1 7 Terminal Auto Idle Activation ON H 11 1 5V Cancellation OFF L 0 1V ...

Page 588: ...vided 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 Selection Buttons Graphic Display Area 1 Up Arrow Button 2 Down Arrow Button 3 Enter Button 4 Escape Button 5 Letter Information Display Department ENG SPEED 02 05 MO 11 30A POWER AUTO ESC DISPLAY RPM 2059 1 2 3 4 ARS0800...

Page 589: ...of machine operation MENU SELECTION BUTTONS 1 Up Arrow Button 1 on Figure 12 Move the cursor to up left and previous screen 2 Down Arrow Button 2 on Figure 12 Move the cursor to down right and next screen 3 Enter Button 3 on Figure 12 Move the menu to selected mode When setting the menu this button is used to function as the select button 4 Escape Button ESC 4 on Figure 12 Move a screen to previou...

Page 590: ...lter oil information to the operator Refer to the Operation and Maintenance Manual for details LANGUAGE SETTING This mode is used for setting desired language TIME SETTING This mode is used for setting time on the digital clock MAIN MENU ARO0330L Language Set Clock Filter Oil Info 1 Figure 13 LANGUAGE ARO0341L Deutsch Set 4 English Francais Figure 14 SET CLOCK ARO0380L 02 30 P 2001 02 15 MOVE Figu...

Page 591: ... reset the operating hour and then the operating hours until the next service interval can be easily checked Menu Display Order and Icon Explanation ARO0400L Hrs 0232 Reset 1 Fuel Filter Figure 16 1 2 3 4 5 6 7 8 1 Fuel Filter 2 Air Cleaner 3 Engine Oil Filter 4 Return Filter 5 Pilot Filter 6 Engine Oil 7 Hydraulic Oil 8 Coolant Water ARO0410L Figure 17 ...

Page 592: ...CESSING AND EXITING ESCAPING MENUS Entering Accessing Menus When normal mode screen is displayed if the enter button 3 and escape button ESC 4 are pressed simultaneously for more than 3 seconds normal mode screen Figure 19 will be changed to special menu screen Figure 20 Normal Mode Screen NOTE Normal mode screen can display many kinds of display mode by selecting for example engine revolution RPM...

Page 593: ... once again SPECIAL MENU SELECTIONS Sub menu Selection Method Various sub menus can be selected by pressing Up 1 on Figure 18 and Down 2 on Figure 18 button Move the cursor to desired menu and a selected menu will be inverse displayed When the selected menu is inverse displayed press the Enter 3 on Figure 18 button for menu selection Information of Machine Status 1 Entering Sub menus When cursor i...

Page 594: ... Max 9 E G Oil Press 3 Work Travel Solenoid 10 Air Cleaner 4 Hi Speed Solenoid 11 Return Filter 5 Auto Travel 12 Pilot Filter 6 Work Lamp 13 OWD Select 7 Pressure Py 5 Output State 1 Relief Press Up 4 Spare Out 1 On or Off Output status delivered from e EPOS controller to solenoid valves is displayed as on or off 2 High Speed 5 Spare Out 2 3 Swing Priority 6 Hydraulic Oil Temp C F Hydraulic oil te...

Page 595: ...chine Status Information 1 EPPR Valve Current 2 Dial Voltage 3 TPS Voltage Output voltage of potentiometer built into engine control motor EPPR CURRENT ARS0870L mA 598 Figure 24 DIAL VOLTAGE ARS0880L mV 2089 Figure 25 TPS VOLTAGE ARS0890L mV 2095 Figure 26 ...

Page 596: ...on OFF and the other statuses of on off type sensors MACHINE INFO ARS1780L Input State Output State Hyd Oil Temp 4 Figure 27 1 Alternator OFF 2 Power Max ON 3 Work Travel Sel OFF 4 Hi Speed Sel OFF 5 Auto Travel ON 6 Work Lamp OFF 13 OWD Select OFF 7 Pressure Py OFF 8 Pressure Px ON 9 E G Oil Pres OFF 10 Air Cleaner OFF 11 Return Filter ON 12 Pilot Filter OFF ARS0900L Figure 28 ...

Page 597: ...marks 1 6 BAR Lit CN 3 4 CN 3 5 Over 1 510 Ω Below 30 C Below 86 F 1 6 2 6 BAR Lit 745 1 510 Ω 31 50 C 87 122 F 1 6 3 6 BAR Lit 332 745 Ω 51 75 C 123 167 F 1 6 4 6 BAR Lit 244 332 Ω 76 85 C 168 185 F 1 6 5 6 BAR Lit 181 244 Ω 86 95 C 186 203 F 1 6 6 6 BAR Lit Under 181 Ω Over 96 C Over 204 F 1 Relief Pess Up OFF 2 High Speed ON 3 Swing Priority OFF 4 Spare Out 1 OFF 5 Spare Out 2 ON ARS0920L Figur...

Page 598: ...a cursor is located in Failure Info of special menu screen press enter button 3 on Figure 18 and Failure Info screen is displayed 2 Exiting Sub menus If escape button ESC 4 on Figure 18 is pressed for more than 1 second this information screen will be returned to previous screen Real time Failure Current status of failure is displayed Failure Log Memorized record of past failure is displayed Delet...

Page 599: ...lure information Memorized record of past failure is displayed Failure code failure contents When a number of failures are produced failure information can be checked by using PRV 1 on Figure 18 or NXT 2 on Figure 18 button NOTE N xxx xxx means that the totally counted number of the same failure xxxx Hr It will display the operation hour until the failure is generated Above example screen shows th...

Page 600: ...At this time deletion signal will be displayed and the screen will move to previous menu after deletion This screen will be displayed during 3 seconds When NO ESC 4 on Figure 18 button is pressed the screen will recover to previous menu without deletion Code Description of Failure Information Code State 0 x Short Circuit 1 x Open circuit 2 x Output error 3 x Output error 8 x Communication FAILURE ...

Page 601: ...e 82 Communication Err Communication error between e EPOS controller and instrument panel Note Automatic reset when problem is corrected 01 EPPR v v short Short Circuit Cut off output current 0 mA After correcting problem turn start switch from OFF to ON 02 Press Up s v short Short Circuit 03 Swing pri s v short Short Circuit ...

Page 602: ...put voltage Over 4 6 0 2 V Cut off EPPR v v current 0 mA 24 TPS Voltage Err L Output voltage Over 4 6 0 2 V Cut off EPPR v v current 0 mA 25 Fpump Sensor Err H Output voltage Over 4 6 0 2 V 26 Fpump Sensor Err L Output voltage Over 4 6 0 2 V 27 Rpump Sensor Err H Output voltage Over 4 6 0 2 V 28 Rpump Sensor Err L Output voltage Over 4 6 0 2 V 29 Speed Sensor Err Under 1067 20Hz On condition that ...

Page 603: ...tion A Entering Sub menus When a cursor is located in Operating Info of special menu screen Figure 37 press enter button 3 on Figure 18 and Operating Info screen will be displayed Figure 38 B Information screen of machine operation Figure 38 C Operation Hour Screen D Exiting Sub menus If escape button ESC 4 on Figure 18 is pressed for more than 1 second this information screen will be returned to ...

Page 604: ...witch Py control valve ON status High speed High speed s v and travel pressure switch Py control valve ON status Hydraulic Oil Temperature Distribution C F Temperature of hydraulic oil is classified 6 steps and operation hours of each step are displayed Under 30 C 87 F 31 50 C 88 123 F 51 75 C 124 168 F 76 85 C 169 186 F 86 95 C 187 203 F Over 96 C 204 F The resistance delivered from temperature s...

Page 605: ...turned to previous screen NOTE When YES 3 on Figure 18 button is pressed operation hours will reset At this time resetting signal will be displayed and the screen will move to previous menu after resetting NOTE When NO ESC 4 button is pressed the screen will recover to previous menu without resetting 1 Power 0345 Hr 2 Trenching 0190 Hr 3 Auto Idle 0227 Hr 4 Travel Speed High 0012 Hr Low 0059 Hr 6 ...

Page 606: ...l 19 Mode select signal Machine information Auto idle signal Sensors 18 Engine speed sensor signal Engine throttle control signal Drive signal Potentiometer signal Coolant water temp signal Throttle command Lo 15 Hi 9 N Switch signal Throttle signal 17 Pump control signal 4 10 5 P 3 7 11 13 1 12 30L Figure 43 ...

Page 607: ...h 8 Pump Pressure Sensor 9 Engine Speed Sensor 10 Electro magnetic Proportional Pressure Reducing Valve E P P R Valve 11 Solenoid Valve Pressure Up 12 Solenoid Valve Swing Priority 13 Solenoid Valve High Speed 14 Travel Motor 15 Engine Throttle Control 16 Engine Control Dial 17 e EPOS Controller 18 Auto Travel Select Switch 19 Boost Switch Right Work Lever Reference Number Description ...

Page 608: ...he indicator lamp will turn ON to display the selected mode Wheel type Power mode switch signal 1 Potentiometer signal Pump control signal g 15 Low Throttle signal Hi 16 Engine throttle control signal Throttle Position signal Engine speed sensor signal Drive signal 20 17 10 9 N P 3 4 6 5 6 ARS1040L Figure 44 Reference Number Description 1 Instrument Panel Power Mode Selection Switch 2 Engine Contr...

Page 609: ...elow the rated speed When this occurs the controller senses this decrease and immediately reduces the pump discharge volume to maintain the engine speed at the rated level On the other hand if the load is decreased the controller increases the discharge volume of the pump to maintain the engine speed at the rated level By repeating these control operations the engine speed is maintained at the rat...

Page 610: ...mption in comparison with Power Mode The current to the E P P R valve is shut off and pump discharge volume is controlled by pump regulator A B C D HDA6020L Figure 46 Reference Number Description A Engine Horsepower hp B Engine Speed rpm C Pump Discharge Volume lpm D Pump Discharge Pressure kg cm2 Reference Number Description A B C D HDA6022L Figure 47 ...

Page 611: ...S0802220K Page 47 Electrical System Reference Number Description A Engine Horsepower hp B Engine Speed rpm C Pump Discharge Volume lpm D Pump Discharge Pressure kg cm2 Reference Number Description ...

Page 612: ...11 9 9 10 8 11 CN3 9 10 11 12 14 15 13 17 16 CN1 6 5 7 8 6 4 3 2 1 20 18 19 11 CN7 14 16 15 13 12 CN3 11 CN3 10 CN3 9 CN3 12 CN3 8 CN1 7 CN1 5 CN4 11 CN4 10 CN4 13 CN4 12 LOW 1 1 5 2 3 1 4 CN2 3 12 2 2 3 1 10 9 8 7 2 3 CW 9 HIGH 7 16 15 RxD TxD RxD TxD CN7 3 5 4 2 1 A I MODE S MODE CN3 4 6 5 3 2 CN1 CN2 1 CN4 CN1 19 RS 422 TxD RxD RxD TxD CN1 10 10 P V A CN4 17 CN4 16 20 19 5 6 20A CN1 9 CN1 8 4 C...

Page 613: ...ystem Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dial Reference Number Description ...

Page 614: ...id adjusts the assignment of hydraulic oil flow to each device on the equipment Wheel Engine throttle control signal Trenching mode switch signal 15 Throttle signal Hi Lo Potentiometer signal Drive signal 17 16 1 P 3 4 Main Relief v v 6 6 12 ARS1070L Figure 49 Reference Number Description 1 Instrument Panel Trenching Mode Select Switch 2 Engine Control Motor 3 Engine 4 Main Hydraulic Pump 5 Contro...

Page 615: ...ick stops The current to the solenoid valve for swing priority is shut off 2 Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles The voltage is assigned to the swing priority control valve activating the swing control valve restricting the flow of oil to the boom and the arm ARO0270L Figure 50 ...

Page 616: ...5 16 7 6 2 1 4 5 2 1 11 3 13 2 12 1 9 8 10 14 6 5 4 7 CN7 1 13 3 2 CN3 CN4 CN2 3 20 19 1 5 2 10A CN7 TxD RxD 10 9 5 2 20A 3 TxD RxD RxD TxD CN3 8 CN3 11 CN3 12 CN3 10 CN3 9 CN1 9 CN1 14 RS 422 CN1 1 CN1 2 CN1 8 4 1 6 ARS1080L Figure 51 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Solenoid Valve Swing Priority Reference Number Description ...

Page 617: ...eter feed back signals are the same the engine controller shuts off the current to the control motor The engine control motor cable is a solid type and is connected to the engine fuel injection control lever The engine speed is controlled by the movement of the fuel injection lever which is directly linked with the rotation of the control motor e EPOS CONTROLLER 5V 2 RETRACT M 10A 1 3 15 6 8 5V 5 ...

Page 618: ...S0802220K Page 54 Electrical System ...

Page 619: ...er switch should be turned off and the cause of abnormal load should be repaired and the starter switch can be turned on again The engine control dial can once again be used to control the engine speed Reference Number Description 1 Motor Assembly 2 Cable 3 Spring Assembly IMPORTANT When the engine control motor has been replaced or repaired refer to Adjusting the Engine Control Device for correct...

Page 620: ...Number Description 1 Knob 2 Potentiometer Variable Resistor 2 1 1 1 VIEW POTENTIOMETER BOTTOM 1st STEP 10 10 7th STEP 13th STEP CCW MECHANICAL STOP CW MECHANICAL STOP 2 3 2 3 1 2 3 4 2 5V 1 0V 4 0V 1ST 2nd 7th 12th 13th CW STOP CCW STOP 5 SETUP V 0 HDA6033L Figure 54 ...

Page 621: ...rical System 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 ...

Page 622: ... 55 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dial 10 Pressure Switch Py Port 11 Pressure Switch Px Port Reference Number Description ...

Page 623: ...vers are in the neutral position the e EPOS controller sends an automatic reduction signal to the throttle controller When the engine throttle controller receives this signal it is compared with the signal set by the engine control dial The lower of the two signals is selected and the engine control motor is adjusted to this engine speed The neutral status of the machine is detected by the two pre...

Page 624: ...e throttle controller will signal the engine control motor to decrease the engine speed When the coolant is overheated the warning buzzer will sound standard mode is selected and low engine speed will be selected When the coolant temperature falls below 95 C 203 F normal operation will resume Engine overheat signal Engine overheat signal 21 15 1 Pump control signal Drive signal Potentiometer signa...

Page 625: ... activate the power boost solenoid valve and increase the relief valve pressure from 330 350 kg cm2 4 700 5 000 psi The excavation ability is increased by approximately 6 NOTE Do not use this switch for more than 10 seconds Button Signal 19 17 3 4 Main Relief v v 5 ARS1140L Figure 58 Reference Number Description 3 Engine 4 Main Pump 5 Control Pump 6 Control Valve 11 Solenoid Valve 17 e EPOS Contro...

Page 626: ... CN3 11 12 13 14 17 CN1 6 7 8 6 3 4 1 2 20 11 16 CN7 CN1 1 CN4 1 3 10 7 8 9 CN1 CN3 11 CN3 12 CN3 8 CN3 10 CN3 9 RxD RxD RS 422 TxD TxD 5 6 1 CN2 3 7 6 CN1 13 CN1 9 CN1 2 CN1 8 4 1 3 20A 2 ARS1150L Figure 59 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Solenoid Valve Pressure Up 7 Power Boost Switch Top of Right Work Lever Reference Number ...

Page 627: ... monitored by the two pressure sensors in the discharge lines of the front upper and rear lower pumps When the travel load is high pressure over 300 kg cm2 4 300 psi the solenoid valve is turned OFF and I speed low is selected In the case when the travel load is low pressure under 160 kg cm2 2 280 psi the solenoid valve will be turned ON and the II speed will be selected But if the engine speed co...

Page 628: ...1 2 17 14 4 9 10 15 16 1 LOW CN4 10 CN4 11 8 CN3 CN4 CN2 6 CN2 5 0 II 3 10 I 6 AUTO MANUAL 9 2 CN1 12 SIG 6 SIG 5 CN4 2 CN4 4 CN4 3 CN4 1 10A CN1 8 CN1 9 CN1 1 CN1 2 4 3 20A 2 1 ARS1170L Figure 61 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Pressure Sensor Front Pump 6 Pressure Sensor Rear Pump 7 Engine Throttle Controller 8 Automatic Travel Select Switch 9 ...

Page 629: ...m stopper position and the cable slack is acceptable 3 A If the lever is not in the minimum position and touching the stopper move the 3 cable to one hole lower on the lever If the cable slack is excessive move the 3 cable to one hole above the original hole on the lever Repeat above steps 1 and 2 B Shorten the 3 motor cable 1 1 25 mm 0 0394 0 0591 in by turning the cable adjustment nut for motor ...

Page 630: ...dle VR1 Refer to throttle controller name plate 3 Figure 64 Standard Mode VR2 Refer to throttle controller name plate 3 Figure 64 Reference Number Description 1 VR1 Automatic Deceleration Adjusting Variable Resistor 2 VR2 Stand Mode Adjusting Variable Resistor 3 Name Plate ENGINE SPEED ARS1180L ENGINE SPEED ARS1181L 1 3 ARS1441L 2 Figure 64 ...

Page 631: ...Page 67 Electrical System Figure 65 Reference Number Description 1 Engine Fuel Control Lever Area 2 Control Motor Cable Bracket 3 Engine Speed Control Cable 4 To Engine Control Motor Reference Number Description ...

Page 632: ...e in normal range 2 Engine Speed Monitor This LED light flashes according to the engine speed The flashing interval is proportional to the engine speed 3 Communication Monitor These LED lamps flash when normal state of communication between main controller and instrument panel 1 2 4 3 5 6 ARS1190L Figure 66 Reference Number Description 1 Upper Digit 2 Lower Digit 3 Engine Speed Monitor LED Flash I...

Page 633: ...ure information codes a part of failure information Refer to the failure information part of letter information display for details Mode Selection Display Readout Operation Status Upper Digit Lower Digit Power Mode Power Mode Normal Operation Power Mode Standard Mode Normal Operation Standard Mode Work Mode Digging Normal Operation Digging Mode Trenching Normal Operation Trenching Mode HAOH340L HA...

Page 634: ...ossibility of motor damage or burn out exists 4 After the malfunction is corrected turn the starter switch from OFF to the ON position and normal operation will resume Throttle Controller Input Signal Status LED Status Voltage At Control Motor Terminal Red Green Yellow Dial Voltage Motor Potentiometer Voltage While Control Motor Is Operating Increasing rpm X O Approximately 24 V Dial Voltage Motor...

Page 635: ...ely 5 seconds Continuous Operation II Position When the wiper switch 4 is turned I position 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 6 terminal of wiper timer 6 ground and the contact points No 5 and No 6 of wiper timer 6 are connected continuously the wiper motor operates continuously 7 M S B E 1 P 8 10 5 I 9 4 4 6...

Page 636: ...mer 6 No 4 terminal of wiper timer 6 S terminal of wiper motor 7 B terminal of wiper motor 7 and the wiper motor is stopped at the auto stop position WINDOW WASHER OPERATION When the window washer switch is turned ON the current flows from the fuse 3 No 1 terminal of washer switch 5 No 5 terminal of washer switch 5 terminal of window washer 8 ground and windshield washer fluid is sprayed ...

Page 637: ...S0802220K Page 73 Electrical System ...

Page 638: ...12 CN3 10 CN3 9 CN3 12 CN3 11 CN3 8 CN7 1 L5 CN7 9 11 10A 15 RH 14 LH LH RH RH 16 LH 17 FL FR FMR 18 FL FR FML 30 86 87 85 7 87a 3 10 II 6 I 4 0 86 30 85 87a 87 8 13 1 7 10 9 2 10A 5 I 5 0 9 10A 20A 1 2 2 9 9 87 87a 85 3 II 10 30 86 6 0 6 85 10 87a 87 86 30 3 30A RL RR 19 ARS1210L Figure 68 ...

Page 639: ...ea 15 Work Light 2 ea 16 Additional Work Light 2 ea 17 Front Cabin Light 2 ea 18 Front Cabin Light 4 ea 19 Rear Cabin Light 2 ea Reference Number Description Switch Position Connected Terminal of switch Activated Relay Lit Light Light Switch 1 2 6 Terminal Illumination Light of Switch 2 2 6 Terminal Illumination Light of Switch 2 3 Terminal Headlight Relay Headlight 2 Ea Work Relay Work Light 2 Ea...

Page 640: ...OAD WARNING DEVICE OVERLOAD WARNING DEVICE CIRCUIT DIAGRAM 5 6 4 2 1 3 ARS1260L Figure 69 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 e EPOS Controller 5 OWD Select Switch 6 Pressure Sensor Reference Number Description ...

Page 641: ...ety recommendations and safe shop practices outlined in the front of this manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Solar 225NLC V 1001 and Up Copyr...

Page 642: ...S0892105K Page 2 Electrical Schematic Solar 225LC V 225NLC V Return to Master Table of Contents TABLE OF CONTENTS General Description 3 Solar 225LC V 4 Solar 225NLC V 6 ...

Page 643: ...eturn to Master Table of Contents GENERAL DESCRIPTION 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 ...

Page 644: ...S0892105K Page 4 Electrical Schematic Solar 225LC V 225NLC V Return to Master Table of Contents SOLAR 225LC V Figure 2 ...

Page 645: ...S0892105K Page 5 Electrical Schematic Solar 225LC V 225NLC V Return to Master Table of Contents ELECTRICAL DIAGRAM DAEWOO HEAVY INDUSTRIES LTD NO 599 00035 Model Solar 225LC V Name HAAD4191 ...

Page 646: ...S0892105K Page 6 Electrical Schematic Solar 225LC V 225NLC V Return to Master Table of Contents SOLAR 225NLC V POWER AUTO MENU DISPLAY Figure 3 ...

Page 647: ...S0892105K Page 7 Electrical Schematic Solar 225LC V 225NLC V Return to Master Table of Contents BDS0190L S225NLC V ...

Page 648: ...S0892105K Page 8 Electrical Schematic Solar 225LC V 225NLC V Return to Master Table of Contents ...

Page 649: ...1ATTACHMENTS ...

Page 650: ......

Page 651: ...ual or those contained within this section 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 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 ...

Page 652: ...F 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 ...

Page 653: ... information on wear tolerances and replacement limits for mounting pins Mounting Pin Diameter mm Inches Length mm Inches A 90 0 mm 3 54 in 792 0 mm 31 18 in B 80 0 mm 3 15 in 792 0 mm 31 18 in C 80 0 mm 3 15 in 225 0 mm 8 86 in D 90 0 mm 3 54 in 529 0 mm 20 83 in E 80 0 mm 3 15 in 225 0 mm 8 86 in F 80 0 mm 3 15 in 211 0 mm 8 31 in G 71 0 mm 2 80 in 448 0 mm 17 64 in H 80 0 mm 3 15 in 448 0 mm 17...

Page 654: ...e with the lower structure Never rotate the upper structure once the counterweight or front attachment has been removed IMPORTANT Always break down the front attachment by removing outermost sections first the bucket before the arm the arm before the boom Reinstallation of the attachment should begin with the boom and end with the bucket WARNING This procedure is only intended for routine removal ...

Page 655: ...bly if necessary Place a sling under the arm cylinder the cylinder used to extend and retract the attachment arm pinned to the top of the boom Lift the sling so that the weight load on the rod end of the arm cylinder pinned to the ears on the inner end of the arm is released Prepare blocking under the arm that will securely support the weight of the arm and arm cylinder Remove retainers on the end...

Page 656: ...raulic pressure and disconnect line couplings as previously outlined in the Arm Removal Procedure observing the same precautions Disconnect wiring for work light assemblies and any other accessory lines or connections Locate the sling of the assist crane near the center of gravity optimum lift point for the boom and use the crane to take pressure off the boom foot pin Drive out the pin after disas...

Page 657: ... sling from around the rod end arm cylinder pin withdraw the pin and lift the body of the arm cylinder to re pin the mounting connection BOOM INSTALLATION PROCEDURE Before reassembling the attachment make sure to inspect all bushings and pivot points of each section To avoid damaging the seats bushings should never be hammered or chiseled out of their seats Installation is otherwise a reversal of ...

Page 658: ... and Arm 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 ...

Page 659: ... manual or those contained within this section 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 MODEL SERIAL NUMBER RANGE Solar 225LC V 1001 and Up Solar 255LC V 1001 and Up Copyright 2002 Daewoo October 2002 ...

Page 660: ...d 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 9 Attaching The bucket 9 Reversing the Bucket 10 ...

Page 661: ... points on the working surfaces of tooth points pits cracks chips or craters are larger than 8 mm to 10 mm 1 3 to 1 2 across 1 On a routine basis inspect the bucket teeth to make sure that tooth wear or breakage has not developed Do not allow the replaceable bucket teeth to wear down to the point that the bucket adapter is exposed See Figure 4 2 To replace a tooth 1 Figure 2 use a hammer and punch...

Page 662: ...ing steel ball causes the boss to go inside 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 Shut the engine off and lock out the hydraulic controls before working on the...

Page 663: ...o wear down to a point that bucket adapter is exposed See Figure 4 2 To replace a tooth use a hammer 1 Figure 5 and punch 2 to drive locking pin assembly out of tooth and tooth adapter 3 Once the worn tooth has been removed use a putty knife to scrape adapter as clean as possible 4 Slide new tooth into position and insert locking pin assembly 1 2 HAOE370L Figure 5 ...

Page 664: ...the way 3 Remove the old O ring and temporarily install the new O ring 1 Figure 8 onto the bucket boss 2 Make sure that the O ring groove on both the bucket link 4 and boss have been cleaned 4 Realign the arm or link with the bucket pin hole and insert the bucket pin 3 Figure 7 WARNING Due to possibility of flying metal objects always wear safety helmet protective gloves and eye protection when ch...

Page 665: ...S0904015K Page 7 Bucket 5 Roll the new O ring 1 Figure 9 into the O ring groove BBO0022L 1 Figure 9 ...

Page 666: ...arance should be 1 mm 0 04 in between side face of boss and inside edge of ear bushing Y Figure 10 Too tight a fit less than 1 mm 0 04 in can cause excessive wear while too much clearance may produce excessive noise and potentially hazardous slack control 3 Recheck end play by forcing bucket towards opposite side and repeating clearance measurements 4 If an adjustment is required remove two jam nu...

Page 667: ...ssemble the link pin end retainers and pull out the pin Lift the arm away from the bucket so that the bucket can be carried away or another end attachment can be put on the excavator ATTACHING THE BUCKET Carefully inspect all parts before reassembling the bucket linkage Look for cracks or any other evidence of physical damage and replace any seal or O ring that is not in like new condition Pre lub...

Page 668: ... simplified if some type of rotating or swiveling support can be used on the ground underneath the bucket Follow instructions for Bucket Attachment to replace pins WARNING When making linkage alignments never insert fingers into pin holes The attachment or bucket could shift position and cause a severe injury Match holes by visually lining them up Use the sharp tipped soft point of a pencil or a s...

Page 669: ...REET ADDRESS TELEPHONE CITY FAX STATE PROVINCE COUNTRY NAME MACHINE MODEL SERIAL NUMBER MANUAL NUMBER SHOP MANUAL SECTION NUMBER PROPOSED DESCRIPTION OF CORRECTION AND OR SUGGESTION Use additional paper if needed Please include copy of current manual pages for reference Attach any photos or illustrations If digital photos are available e mail them to Bill Bernhardt dhiac com If possible use 1024 x...

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