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Daewoo Doosan Solar 225LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
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Daewoo Doosan Solar 225LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Solar 225LL
Shop Manual
023-00078E
Serial Number 1001 and Up
023-00078E
Serial Number 1001 and Up
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Description
Daewoo Doosan Solar 225LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Solar 225LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Solar 225LL
Shop Manual
023-00078E
Serial Number 1001 and Up
023-00078E
Serial Number 1001 and Up
GENERAL SAFETY ESSENTIALS :
ACCESSORY APPLICATIONS
- The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN for proper installation and application. Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading.
- DO NOT use the machine for activities for which it was not intended. DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration. Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.
LIFTING CAPACITY RATING CONFIGURATION :
- Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration. Loads must be balanced and supported evenly.
- Use tag lines 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.
TABLE OF CONTENTS:
Daewoo Doosan Solar 225LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Publication Request for Proposed Revision............................................................................... 7 Safety.................................................................................................................. 9 Track Excavator Safety S0102015K.................................................................................... 11 To the Operator of a DOOSAN Daewoo Excavator.................................................................... 13 Learn Signal Words Used With Safety Alert Symbol............................................................ 15 General Safety Essentials....................................................................................... 16 Accessory Applications...................................................................................... 16 Lifting Capacity Rating Configuration....................................................................... 16 Location of Safety Labels....................................................................................... 16 Summary of Safety Precautions for Lifting in Digging Mode....................................................... 17 Unauthorized Modifications...................................................................................... 18 General Hazard Information...................................................................................... 18 Safety Rules................................................................................................ 18 Safety Features............................................................................................. 18 Inside Operator's Compartment............................................................................... 19 Clothing and Personal Protective Items...................................................................... 19 Breathing Masks, Ear Protection May Be Required............................................................. 20 Vibration Level Information................................................................................. 20 Mounting and Dismounting.................................................................................... 20 Fuel, Oil and Hydraulic Fluid Fire Hazards.................................................................. 21 Precautions When Handling Fluids at High Temperature........................................................ 21 Asbestos Dust Hazard Prevention............................................................................. 22 Injury from Work Equipment.................................................................................. 22 Fire Extinguisher and First Aid Kit......................................................................... 23 Protection from Falling or Flying Objects................................................................... 23 Attachment Precautions...................................................................................... 24 Accumulator................................................................................................. 24 Indoor Ventilation.......................................................................................... 25 Emergency Exit.............................................................................................. 25 Before Starting Engine.......................................................................................... 26 Work Site Precautions....................................................................................... 26 Checks Before Starting Engine............................................................................... 27 Engine Starting............................................................................................. 28 Before Operating Machine.................................................................................... 28 Machine Operation............................................................................................... 29 When Swinging or Changing Direction of Travel............................................................... 29 Travel Precautions.......................................................................................... 30 Traveling on Slopes......................................................................................... 31 Prohibited Operations....................................................................................... 31 Precautions for Operation................................................................................... 32 Avoid High Voltage Cables................................................................................... 33 Operate Carefully on Snow, Ice and in Very Cold Temperatures................................................ 33 Operations on Slopes........................................................................................ 34 Parking Machine............................................................................................. 34 Never Let Anyone Ride on Attachment......................................................................... 34 Maintenance..................................................................................................... 35 Warning Tag................................................................................................. 35 Clean Before Inspection or Maintenance...................................................................... 35 Proper Tools................................................................................................ 36 Use of Lighting............................................................................................. 36 Fire Prevention and Explosion Prevention.................................................................... 36 Burn Prevention............................................................................................. 37 Welding Repairs............................................................................................. 38 Warning for Counterweight and Front Attachment Removal...................................................... 38 Precautions for Removal, Installation, and Storage of Attachments........................................... 39 Precautions When Working on Machine......................................................................... 39 Lock Inspection Covers...................................................................................... 39 Crushing Prevention and Cutting Prevention.................................................................. 40 Track Tension Adjustments Require Caution................................................................... 40 Supports and Blocking for Work Equipment.................................................................... 40 Action When Abnormally Is Found During Inspection........................................................... 41 Precautions with High-pressure Line, Tubes and Hoses........................................................ 41 Waste Materials............................................................................................. 42 Battery......................................................................................................... 43 Battery Hazard Prevention................................................................................... 43 Boost Starting or Charging Engine Batteries................................................................. 44 Towing.......................................................................................................... 45 Precautions When Towing..................................................................................... 45 Shipping and Transportation..................................................................................... 46 Obey State and Local Over-the-Road Regulations.............................................................. 46 Lifting With Sling.............................................................................................. 46 Specifications.......................................................................................................... 47 Specifications for Solar 225LL S0202150K............................................................................ 49 General Description............................................................................................. 51 General Dimensions.............................................................................................. 54 Dimensions and Working Range.................................................................................... 56 General Specifications.......................................................................................... 57 Engine Performance Curves (Per DIN6270 Standard)............................................................... 58 Approximate Weight of Workload Materials........................................................................ 60 Performance Tests............................................................................................... 62 Excavator Performance Standards................................................................................. 63 Test Conditions............................................................................................. 63 Travel Speed and Travel Motor Balance (Steering Deviation) Tests............................................ 63 Speed Test.............................................................................................. 63 Travel Deviation........................................................................................ 64 Swing Speed Test........................................................................................ 65 Swing Force Test........................................................................................ 65 Cylinder Performance Tests.................................................................................. 66 Boom Cylinders Test..................................................................................... 66 Stick Cylinder Test..................................................................................... 66 Heel Cylinder Test...................................................................................... 66 Hydraulic Cylinder Natural Drop Test.................................................................... 66 Travel Motor Jack-up Test............................................................................... 66 General Maintenance..................................................................................................... 67 General Maintenance Procedures S0302000............................................................................. 69 Welding Precautions and Guidelines.............................................................................. 71 Hydraulic System General Precautions.......................................................................... 72 Maintenance Service and Repair Procedure........................................................................ 73 General Precautions......................................................................................... 73 Hydraulic System Cleanliness and Oil Leaks...................................................................... 74 Maintenance Precautions for Hydraulic System Service........................................................ 74 Oil Leakage Precautions..................................................................................... 74 Cleaning and Inspection......................................................................................... 75 General Guidelines.......................................................................................... 75 Bearing inspection.......................................................................................... 76 Normal Bearing.......................................................................................... 77 Bent Cage............................................................................................... 77 Galling................................................................................................. 77 Abrasive Step Wear...................................................................................... 78 Etching................................................................................................. 78 Misalignment............................................................................................ 78 Indentations............................................................................................ 78 Fatigue Spalling........................................................................................ 79 Brinelling.............................................................................................. 79 Cage Wear............................................................................................... 79 Abrasive Roller Wear.................................................................................... 79 Cracked Inner Race...................................................................................... 80 Smears.................................................................................................. 80 Frettage................................................................................................ 80 Heat Discoloration...................................................................................... 81 Stain Discoloration..................................................................................... 81 Standard Torques S0309000........................................................................................... 83 Torque Values for Standard Metric Fasteners..................................................................... 85 Torque Values for Standard U.S. Fasteners....................................................................... 86 Type 8 Phosphate Coated Hardware................................................................................ 88 Torque Values for Hose Clamps................................................................................... 89 Torque Values for Split Flanges................................................................................. 90 Torque Wrench Extension Tools................................................................................... 91 Torque Multiplication....................................................................................... 91 Other Uses for Torque Wrench Extension Tools................................................................ 92 Tightening Torque Specifications (Metric)................................................................... 92 I. "Loctite" Fastener Adhesives......................................................................... 93 II. "Loctite" Pipe Thread Sealant....................................................................... 93 III. "Loctite" gasket/flange sealer..................................................................... 93 IV. "Loctite" retaining compounds....................................................................... 94 V. "Loctite" Adhesives.................................................................................. 94 Upper Structure......................................................................................................... 95 Cabin S0402040K..................................................................................................... 97 Removal......................................................................................................... 99 Installation....................................................................................................102 Counterweight S0403000..............................................................................................105 General.........................................................................................................107 Removal.........................................................................................................109 Installation....................................................................................................111 Fuel Tank S0405050..................................................................................................113 General Description.............................................................................................115 Parts List..................................................................................................116 Specifications..............................................................................................117 Removal.........................................................................................................118 Installation....................................................................................................122 Start-up Procedures.............................................................................................124 Swing Bearing S0407000..............................................................................................125 Swing Bearing Maintenance.......................................................................................127 Operating Recommendation....................................................................................127 Measuring Swing Bearing Axial Play..........................................................................127 Measuring Bearing Lateral Play..............................................................................127 Swing Bearing Basic Operation...............................................................................128 Rebuilding Swing Bearing....................................................................................128 Swing Reduction Gearbox S0408015K...................................................................................131 General Description.............................................................................................133 Theory of Operation.........................................................................................133 Parts List..................................................................................................134 Specifications..............................................................................................135 Special Tools and Materials.....................................................................................136 Special Tools...............................................................................................136 Drive Shaft Front Bearing Jig...........................................................................136 Oil Seal Insert Jig.....................................................................................136 Spring Pin Insert Jig...................................................................................136 Troubleshooting, Testing and Adjustment.........................................................................137 Removal.........................................................................................................138 Disassembly.....................................................................................................139 Cleaning and Inspection (Wear Limits and Tolerances)............................................................144 Reassembly......................................................................................................145 Installation....................................................................................................154 Lower Structure and Chassis.............................................................................................155 Track Assembly S0505045K............................................................................................157 General Description.............................................................................................159 Specifications..............................................................................................159 Track Link..............................................................................................159 Track Shoe..............................................................................................159 Lower Rollers...........................................................................................159 Lower Rollers...........................................................................................159 Front Idler.............................................................................................159 Track Tension...................................................................................................160 Cleaning and Inspection (Wear Limits and Tolerances)............................................................162 Track Shoes and Links...........................................................................................165 Parts List..................................................................................................165 Track Removal...............................................................................................166 Track Installation..........................................................................................167 Front Idler Roller..............................................................................................168 Parts List..................................................................................................168 Front Idler Roller Disassembly..............................................................................169 Front Idler Roller Reassembly...............................................................................171 Upper and Lower Roller..........................................................................................172 Parts List..................................................................................................172 Lower Roller Removal........................................................................................173 Lower Roller Disassembly....................................................................................173 Lower Roller Reassembly.....................................................................................174 Lower Roller Installation...................................................................................175 Upper Roller....................................................................................................176 Parts List..................................................................................................176 Upper Roller Removal........................................................................................177 Upper Roller Disassembly....................................................................................177 Upper Roller Reassembly.....................................................................................178 Track Spring and Track Adjusting Cylinder.......................................................................180 Parts List..................................................................................................180 Engine and Drive Train..................................................................................................181 Air Conditioner S0605060K...........................................................................................183 General Description.............................................................................................185 Refrigerant Circulation.........................................................................................187 Control Panel...................................................................................................189 Control Specifications..........................................................................................190 Temperature Level Control and Display...........................................................................191 Air Discharge According to Path Selection.......................................................................192 Face, Rear, and Defroster...................................................................................192 Foot........................................................................................................192 Face and Defroster..........................................................................................193 Air-conditioning System Circuit Diagram.........................................................................194 Troubleshooting.................................................................................................196 Refrigerant Pressure Check..................................................................................196 Weight of R134a Gas Used In Machines............................................................................198 Refrigerant System Repairs......................................................................................200 Refrigerant Safe Handling Procedures........................................................................200 Repair and Replacement Procedure............................................................................201 Refrigerant Recovery........................................................................................203 Vacuuming Refrigerant System................................................................................203 Leakage Check...............................................................................................205 Refrigerant Charging........................................................................................205 Inspecting System for Leakage...............................................................................207 Drive Coupling (Main Pump) S0609000.................................................................................209 Drive Coupling..................................................................................................211 Special Tools...................................................................................................212 Kawasaki / Tong Myung Pump Tool.............................................................................212 Uchida Pump Tool............................................................................................215 Drive Coupling Installation.....................................................................................217 Installation Procedure......................................................................................222 Hydraulics..............................................................................................................223 Hydraulic System Troubleshooting, Testing and Adjustment S0702210K..................................................225 Hydraulic System - General Notes................................................................................228 Hydraulic Schematic.............................................................................................229 General Notes...............................................................................................229 Operation of Working Components.................................................................................230 Boom Operating Circuit......................................................................................230 Boom Up Circuit.............................................................................................230 Boom Down Circuit...........................................................................................230 Arm Operating Circuit.......................................................................................231 Arm Crowd Circuit...........................................................................................231 Arm Dump Circuit............................................................................................232 Bucket Operating Circuit....................................................................................232 Bucket Crowd Circuit........................................................................................232 Bucket Dump Circuit.........................................................................................233 Swing Operating Circuit.....................................................................................233 Right Swing Operating Circuit...............................................................................233 Left Swing Operating Circuit................................................................................233 Swing Relief Valve and Makeup Valve.........................................................................233 Travel Operating Circuit....................................................................................234 Forward Travel Circuit......................................................................................234 Reverse Travel Circuit......................................................................................234 Procedural Troubleshooting Baseline Recommendations.............................................................234 Initial Checks and Tests to Establish Operating Condition of the Excavator..................................234 Triage Summary..........................................................................................234 Pilot Pressure..................................................................................................236 Adjustment and Testing......................................................................................236 Power Mode Valve................................................................................................237 Current Signal and Hydraulic Pressure Adjustments...........................................................237 Swing Priority Valve............................................................................................239 Control Valve Pressure and Current Adjustments..............................................................239 Pressure Up Valve...............................................................................................240 Checks and Adjustments......................................................................................240 Pump Input Power Control........................................................................................241 Pump Regulator Adjustment...................................................................................241 Flow Meter and Flow Meter Kit Installation and Testing..........................................................243 Installation and Testing Procedure..........................................................................243 Swing System Troubleshooting....................................................................................244 Precautions/Initial Checks..................................................................................244 Swing Relief Valve Checking and Adjustment..................................................................245 Troubleshooting - Swing Gearbox.................................................................................246 Troubleshooting – Hydraulic Problems............................................................................248 Troubleshooting – Control Valve.................................................................................249 Troubleshooting – Travel Control Valve..........................................................................251 Troubleshooting – Joystick Control Valve........................................................................251 Accumulator S0703010K...............................................................................................253 General Description.............................................................................................255 Specifications..............................................................................................256 Center Joint (Swivel) S0704010......................................................................................259 General Description.............................................................................................261 Parts List..................................................................................................262 Type 1..................................................................................................262 Type 2..................................................................................................264 Troubleshooting, Testing and Adjustment.........................................................................266 Inspection..................................................................................................266 Testing.....................................................................................................266 Disassembly.....................................................................................................267 Reassembly......................................................................................................268 Cylinders S0705000..................................................................................................269 General Description.............................................................................................271 Theory of Operation.........................................................................................271 Parts List..................................................................................................272 Special Tools and Materials.....................................................................................274 Piston Nut..................................................................................................274 Piston Jig..................................................................................................278 Steel Bushing Jig...........................................................................................282 Dust Wiper Jig..............................................................................................286 Slipper Seal Jig............................................................................................292 Slipper Seal Straightening Jig..............................................................................296 Disassembly.....................................................................................................299 Assembly........................................................................................................305 Swing Motor S0707200................................................................................................309 General Description.............................................................................................311 Theory of Operation.........................................................................................311 Swing Motor Anticavitation Makeup Valve.....................................................................312 Relief Valve................................................................................................313 Swing Brake Operation.......................................................................................313 Parts List (Model Solar 250LC-V, 255LC-V)...................................................................316 Parts List (Models Solar 225LC-V, 225NLC-V, 290LC-V, and 290LL).............................................318 Specifications (Model Solar 225LC-V, 225NLC-V)..............................................................320 Specifications (Models Solar 250LC-V, 255LC-V, 290LC-V, and 290LL)..........................................320 Special Tools...................................................................................................321 Disassembly.....................................................................................................322 Cleaning and Inspection (Wear Limits and Tolerances)............................................................329 Reassembly......................................................................................................331 Travel Motor (With Gearbox) (TM40VC) S0707331K......................................................................339 General Description.............................................................................................341 Theory of Operation.........................................................................................341 Hydraulic Motor Operation...............................................................................342 Reduction Gearbox Operation.............................................................................347 Travel Motor Parts List.....................................................................................348 Travel Reduction Gearbox Parts List.........................................................................350 Specifications..............................................................................................352 Name Plate Identification...............................................................................352 Specifications..........................................................................................353 Recommended Bolt, Plug Sizes and Torques................................................................353 Troubleshooting, Testing and Adjustment.........................................................................354 General Notice..............................................................................................354 Troubleshooting.............................................................................................354 Disassembly.....................................................................................................358 Preparation for Travel Motor and Reduction Gear Disassembly.................................................358 Travel Motor Rear Flange Disassembly........................................................................360 Spool Disassembly.......................................................................................360 Check Valve Disassembly.................................................................................360 Two Speed Switching Valve Disassembly...................................................................361 Disassembly of Internal Parts (SRV).....................................................................361 Relief Valve Disassembly................................................................................362 Travel Motor Internal Parts Disassembly.....................................................................364 Parking Brake Parts Disassembly.........................................................................364 Motor Internal Parts Disassembly........................................................................365 Cylinder Block Disassembly..............................................................................366 Input Gear Disassembly..................................................................................366 Spur Gear Disassembly...................................................................................367 Hold Flange Disassembly.................................................................................368 Ball Bearing, RV Gear Assembly, and Pin Disassembly.....................................................369 Spindle Disassembly.....................................................................................370 Bearing (149) Disassembly...............................................................................371 Cleaning and Inspection (Wear Limits and Tolerances)............................................................372 General Inspection..........................................................................................372 Gear Oil....................................................................................................372 General Notice..............................................................................................372 Tightening Torque List......................................................................................373 Wear Limits.................................................................................................373 Reassembly......................................................................................................375 General Instructions for Reassembly.........................................................................375 Travel Motor Rear Flange Reassembly.........................................................................375 Check Valve Reassembly..................................................................................375 Spool Reassembly........................................................................................375 Two Speed Switching Valve Reassembly....................................................................376 Internal Parts Reassembly (SRV).........................................................................377 Relief Valve Reassembly.................................................................................377 Travel Reduction Gear Reassembly............................................................................380 Hub Reassembly..........................................................................................380 Spindle Reassembly......................................................................................380 Hub and Spindle Reassembly..............................................................................381 RV Gear Reassembly......................................................................................381 Piston Assembly (161 and 162) Reassembly................................................................385 Cylinder Block Internal Parts Reassembly................................................................385 Motor Reassembly........................................................................................386 Gear Holding Flange Gap Measurement and Adjustment..........................................................387 RV Gear Gap Measurement and Adjustment......................................................................388 Travel Motor and Reduction Gear Reassembly..................................................................389 Reduction Gear Cover Reassembly.............................................................................391 Grapple Rotate Motor S0707400.......................................................................................393 General Description.............................................................................................395 General Notes...............................................................................................395 Torqmotor™ Features.........................................................................................396 Parts List..................................................................................................398 Special Tools and Materials.....................................................................................399 Special Tools...............................................................................................399 Tools and Materials Required for Servicing..................................................................400 Torque Chart................................................................................................401 Troubleshooting, Testing and Adjustment.........................................................................402 Preliminary Checks..........................................................................................402 Hydraulic Components........................................................................................402 Disassembly and Inspection (Preparation Before Disassembly).................................................403 Disassembly.....................................................................................................405 Reassembly......................................................................................................414 One Piece Stator Reassembly.................................................................................426 Two Piece Stator Reassembly.................................................................................427 Start-up Procedures.............................................................................................429 Hydraulic Fluid.............................................................................................429 Main Pump (With Regulator) S0708320.................................................................................431 General Description.............................................................................................433 Gear (Pilot) Pump...........................................................................................435 Relief Valve................................................................................................435 Pump Regulator Description..................................................................................436 Horsepower Control..........................................................................................436 Power Shift Control.........................................................................................436 Negative Oil Discharge (Pump Bypass) Control................................................................436 Pump Regulator Operation....................................................................................437 Pump Output Decrease........................................................................................439 Pump Discharge Decrease.....................................................................................439 Pump Discharge Increase.....................................................................................439 Horsepower Control..........................................................................................439 Overload Protection.........................................................................................440 Regulator Adjustment........................................................................................440 Pump Input Power Control Adjustment.........................................................................441 Electric Proportional Reducing Valve....................................................................441 Parts List..................................................................................................442 Main Pump...............................................................................................442 Pump Regulator..........................................................................................444 Specifications..............................................................................................446 Models: SOLAR 220LC-V, 220LL, AND 250LC-V...............................................................446 Model: SOLAR 225LC-V....................................................................................446 Model: SOLAR 225NLC-V...................................................................................446 Model: SOLAR 255LC-V....................................................................................447 Hydraulic Pump Performance Characteristics..................................................................448 Main Pump Pressure/Flow Output (Models: SOLAR 220LC-V (S/N 1001 thru 2018), 220LL (S/N 1001 thru .......448 Main Pump Pressure/Flow Output (Models: SOLAR 220LC-V (S/N 2019 and Up), 220LL (S/N 1084 and Up),.......448 Main Pump Pressure/Flow Output (Model: SOLAR 225LC-V)...................................................448 Main Pump Pressure/Flow Output (Models: SOLAR 225NLC-V).................................................448 Main Pump Pressure/Flow Output (Model: SOLAR 255LC-V)...................................................449 Troubleshooting, Testing and Adjustment.........................................................................455 Main Pump...................................................................................................455 Disassembly.....................................................................................................456 General Disassembly.........................................................................................456 Main Pump Disassembly.......................................................................................457 Pump Regulator Disassembly..................................................................................459 Cleaning and Inspection (Wear Limits and Tolerances)............................................................463 Service Standards for Replacing Worn Parts..................................................................464 Reassembly......................................................................................................465 Pump Regulator Reassembly...................................................................................465 Main Pump Reassembly........................................................................................469 Main Control Valve S0709400.........................................................................................473 Control Valve Operation.........................................................................................476 Swing Priority Circuit......................................................................................476 Arm Priority Circuit........................................................................................477 Bucket (Junction) Circuit...................................................................................478 Straight Traveling Circuit..................................................................................479 Plunger Replacement.........................................................................................481 Main Relief Valve...........................................................................................482 Overload Relief Valve.......................................................................................483 Arm Load Holding Valve......................................................................................485 Boom Load Holding Valve.....................................................................................488 Arm Regeneration............................................................................................490 Boom Regeneration...........................................................................................492 Foot Relief Valve...........................................................................................493 Parts List..................................................................................................494 Main Plunger Element....................................................................................494 Main Relief Valve.......................................................................................495 Overload Relief Valve...................................................................................496 Bucket Unity Check......................................................................................497 Boom Load Holding Valve.................................................................................498 Boom Unity Check........................................................................................498 Arm Regeneration Valve..................................................................................499 Foot Relief Valve.......................................................................................499 Arm Priority Valve [Ap Valve]...........................................................................499 Check Valve [Tr, Am-2]..................................................................................500 Check Valve [Opt, Bkt, Bm-1, Bm-2]......................................................................500 Check Valve.............................................................................................500 Check Valve.............................................................................................501 Cap.....................................................................................................501 Check Valve [Tl]........................................................................................501 Check Valve [Sw]........................................................................................502 Check Valve [Am-1]......................................................................................502 Straight Travel Selector Valve..........................................................................502 Swing Priority Valve [Sp Valve].........................................................................503 Center Bypass Valve [Cb Valve]..........................................................................503 Arm Load Holding Valve..................................................................................504 Specifications..............................................................................................504 Control Valve Drawing and Hydraulic Circuit.....................................................................505 Disassembly and Reassembly......................................................................................510 General Disassembly.........................................................................................510 General Reassembly..........................................................................................510 Main Plunger Element - Disassembly and Assembly.............................................................511 Tool........................................................................................................511 Main Relief Valve...........................................................................................514 Main Relief Valve Adjustment................................................................................515 Main Relief Valve - Reassembly..........................................................................515 High-pressure Adjustment................................................................................516 Low-pressure Adjustment.................................................................................516 Overload Relief Valve.......................................................................................517 Arm Load Holding Valve......................................................................................519 Check Valve Main Body...................................................................................519 Cover Assembly..........................................................................................520 Boom Load Holding Valve.....................................................................................522 Arm Regeneration Valve......................................................................................524 Bucket Unity Check..........................................................................................525 Foot Relief Valve...........................................................................................526 Center Bypass Valve (CB Valve)..............................................................................527 Boom Parallel Switch Valve..................................................................................528 Tool........................................................................................................528 Swing Priority Valve........................................................................................530 Pilot Switch Element....................................................................................531 Boom Unity Check Valve......................................................................................532 Straight Travel Selector Valve..............................................................................533 Check Valve - Locations.....................................................................................534 Check Valve.................................................................................................535 A: Check Valve (Main Relief Valve, TS)..................................................................535 B: Check Valve (P2).....................................................................................535 C: Check Valve [TR, AM-2]...............................................................................536 D: Check Valve [OPT, BKT, BM-1, BM-2]...................................................................536 E: Check Valve [TL].....................................................................................537 F: Check Valve [SW].....................................................................................538 G: Check Valve [AM-1]...................................................................................539 Pilot Control Valve (Work Lever / Joystick) S0709450................................................................541 General Description.............................................................................................543 Theory of Operation.........................................................................................543 Neutral Mode............................................................................................543 Control Mode............................................................................................543 Parts List..................................................................................................544 Specifications..............................................................................................545 Torques.................................................................................................545 Performance.............................................................................................546 Hydraulic Specifications....................................................................................546 Special Tools...................................................................................................547 Disassembly.....................................................................................................548 Reassembly......................................................................................................553 Travel Control Valve (With Damper) S0709820K........................................................................559 General Description.............................................................................................561 Theory of Operation.........................................................................................561 Pressure Reducing Valve.................................................................................561 Operating Theory of Damper Mechanism....................................................................563 Parts List..................................................................................................564 Specification...............................................................................................565 Torque......................................................................................................565 Troubleshooting, Testing and Adjustment.........................................................................566 Removal.........................................................................................................567 Disassembly.....................................................................................................569 Cleaning and Inspection (Wear Limits and Tolerances)............................................................575 assembly........................................................................................................576 Installation....................................................................................................581 Startup Procedures.............................................................................................582 Hydraulic Schematic (S225LL) S0792025K..............................................................................583 General Description.............................................................................................585 Solar 225LL (S/N 1001 thru 1002)................................................................................586 Solar 225LL (S/N 1003 and Up)...................................................................................588 Electrical System.......................................................................................................591 Electrical System S0802220K.........................................................................................593 Troubleshooting - Electrical System.............................................................................597 Overview........................................................................................................598 Electric Wire Color.........................................................................................598 Electric Supply System..........................................................................................599 Engine Starting Circuit.........................................................................................600 Operation During Start Process..............................................................................600 Operation After Start Process...............................................................................601 Operation of the Start Circuit (2) - Immediately After Start............................................601 Engine Preheating and After Start Heating System................................................................602 Preheat Cycle...............................................................................................602 After Start Heating Cycle...................................................................................602 Engine Stop System..............................................................................................604 Operation In Engine Running Mode............................................................................605 Operation In Engine Stop Mode...............................................................................606 Charging System.................................................................................................607 Monitoring System...............................................................................................608 Instrument Panel............................................................................................609 Monitoring System Schematic.................................................................................610 Operation.......................................................................................................612 Instruments.................................................................................................612 Warning and Indicator Lights....................................................................................614 Initial Operation...............................................................................................616 Mode Selector Switch............................................................................................617 Power Mode / Trenching Mode Switch..........................................................................617 Auto Idle Switch............................................................................................617 Graphic Information Area Display................................................................................618 Overview....................................................................................................618 Main Menus for the Graphic Display Area.....................................................................619 Menu Selector Buttons.......................................................................................619 Main Menu.......................................................................................................620 Language Setting............................................................................................620 Time Setting................................................................................................620 Filter/Oil Information......................................................................................621 Menu Display Order and Icon Explanation.................................................................621 Special Menu....................................................................................................622 Entering/Accessing and Exiting/Escaping Menus...............................................................622 Entering/Accessing Menus................................................................................622 Exiting/Escaping Menus..................................................................................623 Special Menu Selections.....................................................................................623 Information of Machine Status...........................................................................623 Failure Information.....................................................................................628 Information of Machine Operation........................................................................632 Electronic Hydraulic Control System (e- EPOS)...................................................................636 Control System Schematic....................................................................................636 Power Mode Control..............................................................................................638 Operation...................................................................................................639 1. Power Mode...........................................................................................639 2. Standard Mode........................................................................................641 Power Mode Control - Circuit Diagram............................................................................642 Work Mode Control...............................................................................................644 Operation...................................................................................................645 1. Digging Mode.........................................................................................645 2. Trenching Mode.......................................................................................645 Work Mode Control - Circuit Diagram.............................................................................646 Engine Control System...........................................................................................647 Engine Control Motor............................................................................................649 Engine Control Dial.............................................................................................650 Engine Control Circuit Diagram..................................................................................652 Automatic Deceleration Control (Auto Idle Control)..............................................................653 Engine Overheat Protection System...............................................................................654 Power Boost Mode................................................................................................655 Operation...................................................................................................655 Power Boost Control - Circuit Diagram.......................................................................656 Automatic Travel Speed Control..................................................................................657 Automatic Travel Speed Control - Circuit Diagram............................................................658 Engine Control Device - Adjustment..............................................................................659 Self-diagnostic Function........................................................................................663 e-EPOS Controller...........................................................................................663 Engine Throttle Controller......................................................................................665 Wiper System....................................................................................................666 Wiper Circuit...............................................................................................666 Wiper Operation.............................................................................................666 Intermittent Operation (I - position)...................................................................666 Continuous Operation (II - Position)....................................................................666 Window Washer Operation.....................................................................................667 Lighting System.................................................................................................668 Lighting System Circuit Diagram.............................................................................668 Kind of Light...............................................................................................669 Operation...................................................................................................669 Overload Warning Device.........................................................................................670 Overload Warning Device Circuit Diagram.....................................................................670 Electrical Schematic (S225LL) S0892025K.............................................................................671 General Description.............................................................................................673 Solar 225LL.....................................................................................................674 Attachments.............................................................................................................677 Boom and Stick S0902020.............................................................................................679 Front Attachment Specifications.................................................................................681 Pin Specifications..........................................................................................681 Size and Weight Specifications..............................................................................681 Front Attachment - Removal and Installation.....................................................................682 Stick Removal Procedure.....................................................................................682 Boom Removal Procedure......................................................................................684 Installation....................................................................................................685 Stick Installation Procedure................................................................................685 Boom Installation Procedure.................................................................................685 Start-up Procedures.............................................................................................686
DAEWOO DOOSAN SOLAR 225LL EXCAVATOR LOG LOADER SHOP MANUAL – PDF DOWNLOAD:
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