Complete official service manual for Daweoo / Doosan Solar 225LC-V Excavator, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Daweoo Solar 225LC-V Excavator workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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022-00032E – Daewoo Solar 225LC-V Operation and Maintenance Manual.pdf
023-00058E – Daweoo Solar 225LC-V Excavator Shop Manual (Serial Number 1001 and Up).pdf
ELECTRIC CIRCUIT.pdf
ELECTRIC CIRCUIT CHANGING.pdf
HYDRAULIC CIRCUIT.pdf
INJ. PUMP CALIBRATION DATA.pdf
PERFORMANCE SPECIFICATION.pdf
S220LC-3 Wiring.pdf
S220LC-5 Wiring.pdf
Total Pages/Size: 756 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
1TABLE OF CONTENTS
Safety
Track Excavator Safety..S0102000
Specifications
Specifications for Solar 225LC-V.. S0205015K
General Maintenance
General Maintenance Procedures …S0302000
Standard Torques ..S0309000
Upper Structure
Cab … S0402040K
Counterweight… S0403050K
Fuel Tank.. S0405005K
Fuel Transfer Pump …S0405500
Swing Bearing..S0407000
Swing Reduction Gearbox .. S0408015K
Lower Structure and Chassis
Track Assembly …S0505030
Engine and Drive Train
Air-Conditioner.. S0605060K
Drive Coupling (Main Pump)..S0609000
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment … S0702170K
Accumulator.. S0703010K
Center Joint (Swivel)..S0704010
Cylinders..S0705000
Swing Motor…S0707200
Travel Motor (With Gearbox) (GM35VL)..S0707330
Main Pump (With Regulator) …S0708320
Main Control Valve (Kayaba).. S0709401K
Pilot Control Valve (Work Lever / Joystick)… S0709451K
Travel Control Valve (With Damper)… S0709820K
Hydraulic Schematic (Solar 225LC-V/225NLC-V) .. S0792105K
Electrical System
Electrical System .. S0802220K
Electrical Schematic (Solar 225LC-V/225NLC-V)… S0892105K
Attachments
Boom and Arm…S0902010
Bucket… S0904015K
Publication Request for Proposed Revision
022-00032E – Daewoo Solar 225LC-V Operation and Maintenance Manual….2
Safety….8
To the Operator of a Daewoo Excavator….8
Location of Safety Labels….11
Summary of Safety Precautions for Lifting in Digging Mode….19
Unauthorized Modifications….20
General Hazard Information….20
Before Starting Engine….28
Machine Operation….31
Maintenance….36
Battery….44
Towing….46
Shipping and Transportation….47
Excavator Rated Lift Capacity Tables….48
Operating Controls….64
Component Locations….65
Operator’s Area….67
Operational Controls and Panels….68
Instrument Panel….77
Multifunction Gauge and Graphic Information….82
Mode Selection Buttons….86
Setting Method for Main Menu….89
Heater and Air Conditioner Control Panel….93
Stereo….98
Fuse Boxes….105
Miscellaneous Electrical Devices….106
Seat Adjustment….108
Seat Belt….110
Ceiling Cover….111
Front Windows….112
Door Side Latch….115
Miscellaneous Access Covers and Doors….116
Cab Storage Compartments….117
Ashtray….117
Emergency Glass Breaking Tool….118
Operation….120
To Handle a New Excavator….120
Starting and Stopping the Engine….121
Safety Lever….133
Travel….134
Operating Instructions….139
Operating Precautions….144
Parking Excavator….149
Towing Procedure….150
Hydraulic Breaker….151
Operating Techniques….155
Operation Under Unusual Conditions….157
Inspection, Maintenance and Adjustment….160
Preliminary Work Machine Setup for Maintenance….162
Table of Recommended Lubricants….164
Fluid Capacities….166
Lubrication and Service Chart….166
Maintenance Intervals….169
10 Hour / Daily Service….171
50 Hour / Weekly Service….181
250 Hour / Monthly Service….185
500 Hour / 3 Month Service….190
1000 Hour / 6 Month Service….198
2000 Hour / Yearly Service….204
4000 Hour / Biennial Service….207
12,000 Hour / Six Year Service….208
Venting and Priming Hydraulic System….209
Handling of Accumulator….211
Fuel Transfer Pump (Option)….212
Electrical System….214
Air Conditioning System….218
Bucket….219
Bucket Shimming Procedures….222
Track Tension….223
Bolt and Nut Inspection….225
Maintenance in Special Conditions….226
Long Term Storage….227
Transportation….228
Loading and Unloading….228
Lifting With Sling….231
Troubleshooting….232
Engine….232
Hydraulic System….233
Swing System….234
Travel System….235
Electrical System….235
Specification….238
Standard Specification….238
Overall Dimensions….239
Working Range….240
Approximate Weight of Workload Materials….241
Index….244
023-00058E – Daweoo Solar 225LC-V Excavator Shop Manual (Serial Number 1001 and Up)….250
Safety….256
Track Excavator Safety S0102000….258
To the Operator of a Daewoo Excavator….260
Learn the Signal Words Used with the Safety Alert Symbol….262
General Safety Essentials….263
Accessory Applications….263
Lifting Capacity Rating Configuration….263
Location of Safety Labels….263
Summary of Safety Precautions for Lifting in Digging Mode….264
Unauthorized Modifications….265
General Hazard Information….265
Safety Rules….265
Safety Features….265
Inside Operator's Compartment….266
Clothing and Personal Protective Items….266
Breathing Masks, Ear Protection May Be Required….266
Mounting and Dismounting….267
Fuel, Oil and Hydraulic Fluid Fire Hazards….268
Precautions When Handling Fluids at High Temperature….268
Asbestos Dust Hazard Prevention….269
Injury from Work Equipment….269
Fire Extinguisher and First Aid Kit….270
Protection from Falling or Flying Objects….270
Attachment Precautions….271
Accumulator….271
Indoor Ventilation….272
Emergency Exit….272
Before Starting Engine….273
Work Site Precautions….273
Checks Before Starting Engine….274
Engine Starting….275
Before Operating Machine….275
Machine Operation….276
When Swinging or Changing Direction of Travel….276
Travel Precautions….277
Traveling on Slopes….278
Prohibited Operations….279
Precautions for Operation….280
Avoid High-voltage Cables….281
Operate Carefully on Snow, Ice and in Very Cold Temperatures….281
Operations on Slopes….282
Parking Machine….282
Never Let Anyone Ride on Attachment….282
Maintenance….283
Warning Tag….283
Clean Before Inspection or Maintenance….283
Proper Tools….284
Use of Lighting….284
Fire Prevention and Explosion Prevention….284
Burn Prevention….285
Welding Repairs….286
Warning for Counterweight and Front Attachment Removal….286
Precautions for Removal, Installation, and Storage of Attachments….287
Precautions when Working on Machine….287
Lock Inspection Covers….287
Crushing Prevention and Cutting Prevention….288
Track Tension Adjustments Require Caution….288
Supports and Blocking for Work Equipment….288
Action When Abnormally Is Found During Inspection….289
Precautions with High Pressure Line, Tubes and Hoses….289
Waste Materials….290
Battery….291
Battery Hazard Prevention….291
Boost Starting or Charging Engine Batteries….292
Towing….293
Precautions When Towing….293
Shipping and Transportation….294
Obey State and Local Over-the-Road Regulations….294
Lifting With Sling….294
Specifications….296
Specifications for Solar 225LC-V S0205015K….298
General Description….300
Component Locations….301
General Dimensions….304
Working Range….305
General Specifications….307
Engine Performance Curves (Per DIN 6270 Standard)….309
Approximate Weight of Workload Materials….311
Performance Tests….314
Excavator Performance Standards….315
Test Conditions….315
Travel Speed and Travel Motor Balance (Steering Deviation) Tests….315
Swing Speed and Deceleration Force Test….317
Cylinder Performance Tests….318
General Maintenance….320
General Maintenance Procedures S0302000….322
Welding Precautions and Guidelines….324
Hydraulic System – General Precautions….325
Maintenance Service and Repair Procedure….326
General Precautions….326
Hydraulic System Cleanliness and Oil Leaks….327
Maintenance Precautions for Hydraulic System Service….327
Oil Leakage Precautions….327
Cleaning and Inspection….328
General Guidelines….328
Bearing inspection….329
Standard Torques S0309000….336
Torque Values for Standard Metric Fasteners….338
Torque Values for Standard U.S. Fasteners….339
Type 8 Phosphate Coated Hardware….341
Torque Values for Hose Clamps….342
Torque Values for Split Flanges….343
Torque Wrench Extension Tools….344
Torque Multiplication….344
Other Uses for Torque Wrench Extension Tools….345
Tightening Torque Specifications (Metric)….345
Upper Structure….348
Cab S0402040K….350
Removal….352
Installation….355
Counterweight S0403050K….358
General….360
Removal….362
Installation….364
Fuel Tank S0405005K….366
General Description….368
Parts List….369
Specifications….370
Removal….371
Installation….375
Start-up Procedures….377
Fuel Transfer Pump S0405500….378
General Description….380
Theory of Operation….380
Troubleshooting….381
Replacement of Rotor and Vane….381
Replacement of Rear Cover….382
Replacement of Armature….383
Swing Bearing S0407000….384
Swing Bearing Maintenance….386
Operating Recommendation….386
Measuring Swing Bearing Axial Play….386
Measuring Bearing Lateral Play….386
Swing Bearing Basic Operation….387
Rebuilding Swing Bearing….387
Swing Reduction Gearbox S0408015K….390
General Description….392
Theory of Operation….392
Parts List….393
Specifications….394
Special Tools and Materials….395
Special Tools….395
Troubleshooting, Testing and Adjustment….396
Removal….397
Disassembly….398
Cleaning and Inspection (Wear Limits and Tolerances)….403
Reassembly….404
Installation….413
Lower Structure and Chassis….414
Track Assembly S0505030….416
General Description….418
Track Tension….418
Cleaning and Inspection (Wear Limits and Tolerances)….420
Track Shoes and Links….424
Parts List….424
Track Removal….425
Track Installation….426
Front Idler Roller….427
Parts List….427
Front Idler Roller Disassembly….428
Front Idler Roller Reassembly….430
Lower Roller….431
Parts List….431
Lower Roller Removal….432
Lower Roller Disassembly….432
Lower Roller Reassembly….433
Lower Roller Installation….434
Upper Roller….435
Parts List….435
Upper Roller Removal….436
Upper Roller Disassembly….436
Upper Roller Reassembly….438
Track Spring and Track Adjusting Cylinder….440
Parts List….440
Engine and Drive Train….442
Air-Conditioner S0605060K….444
General Description….446
Refrigerant Circulation….448
Control Panel….450
Control Specifications….451
Temperature Level Control and Display….452
Air Discharge According to Path Selection….453
Air-conditioning System Circuit Diagram….455
Troubleshooting….457
Weight of R134a Gas Used In Machines….460
Refrigerant System Repairs….462
Refrigerant Safe Handling Procedures….462
Repair and Replacement Procedure….463
Refrigerant Recovery….465
Vacuuming Refrigerant System….465
Leakage Check….466
Refrigerant Charging….467
Inspecting System For Leakage….469
Drive Coupling (Main Pump) S0609000….470
Drive Coupling….472
Special Tools….473
Kawasaki / Tong Myung Pump Tool….473
Uchida Pump Tool….476
Drive Coupling Installation….477
Installation Procedure….482
Hydraulics….484
Hydraulic System Troubleshooting, Testing and Adjustment S0702170K….486
Hydraulic System – General Notes….489
Hydraulic Schematic….490
General Notes….490
Operation of Working Components….491
Boom Operating Circuit….491
Boom Up Circuit….491
Boom Down Circuit….491
Arm Operating Circuit….492
Arm Crowd Circuit….492
Arm Dump Circuit….492
Bucket Operating Circuit….493
Bucket Crowd Circuit….493
Bucket Dump Circuit….493
Swing Operating Circuit….493
Right Swing Operating Circuit….494
Left Swing Operating Circuit….494
Swing Relief Valve and Make-up Valve….494
Travel Operating Circuit….494
Forward Travel Circuit….495
Reverse Travel Circuit….495
Procedural Troubleshooting Baseline Recommendations….495
Initial Checks and Tests to Establish Operating Condition of the Excavator….495
Pilot Pressure….497
Adjustment and Testing….497
Power Mode Valve….499
Current Signal and Hydraulic Pressure Adjustments….499
Swing Priority Valve….501
Control Valve Pressure and Current Adjustments….501
Pressure Up Valve….502
Checks and Adjustments….502
Pump Input Power Control….504
Pump Regulator Adjustment….504
Flow Meter and Flow Meter Kit Installation and Testing….509
Swing System Troubleshooting….511
Precautions/Initial Checks….511
Swing Relief Valve Checking and Adjustment….511
Troubleshooting – Swing Gearbox….513
Troubleshooting – Hydraulic Problems….515
Troubleshooting – Control Valve….517
Troubleshooting – Travel Control Valve….519
Troubleshooting – Joystick Control Valve….520
Accumulator S0703010K….522
General Description….524
Specifications….525
Center Joint (Swivel) S0704010….528
General Description….530
Parts List….531
Troubleshooting, Testing and Adjustment….535
Inspection….535
Testing….535
Disassembly….536
Reassembly….537
Cylinders S0705000….538
General Description….540
Theory of Operation….540
Parts List….541
Special Tools and Materials….543
Piston Nut….543
Piston Jig….547
Steel bush Jig….551
Dust Wiper Jig….555
Slipper Seal Jig….561
Slipper Seal Straightening Jig….565
Disassembly….568
Assembly….574
Swing Motor S0707200….578
General Description….580
Theory of Operation….580
Swing Motor Anti-cavitation Make-up Valve….581
Relief Valve….582
Swing Brake Operation….582
Parts List (Model Solar 250LC-V, 255LC-V)….585
Parts List (Models Solar 225LC-V, 225NLC-V, 290LC-V, and 290LL)….587
Specifications (Model Solar 225LC-V, 225NLC-V)….589
Specifications (Models Solar 250LC-V, 255LC-V, 290LC-V, and 290LL)….589
Special Tools….590
Disassembly….591
Cleaning and Inspection (Wear Limits and Tolerances)….598
Reassembly….600
Travel Motor (With Gearbox) (GM35VL) S0707330….608
General Description….610
Theory of Operation….610
Travel Motor Parts List….617
Travel Reduction Gearbox Parts List….619
Specifications….621
Troubleshooting, Testing and Adjustment….623
General Notice….623
Troubleshooting….623
Disassembly….627
Preparation for Travel Motor and Reduction Gear Disassembly….627
Travel Motor Rear Flange Disassembly….629
Travel Motor Internal Parts Disassembly….633
Cleaning and Inspection (Wear Limits and Tolerances)….641
General Inspection….641
Gear Oil….641
General Notice….641
Tightening Torque List….642
Wear Limits….642
Reassembly….644
General Instructions for Reassembly….644
Travel Motor Rear Flange Reassembly….644
Travel Reduction Gear Reassembly….649
Gear Holding Flange Gap Measurement and Adjustment….656
RV Gear Gap Measurement and Adjustment….657
Travel Motor and Reduction Gear Reassembly….658
Reduction Gear Cover Reassembly….660
Main Pump (With Regulator) S0708320….662
General Description….664
Gear (Pilot) Pump….666
Relief Valve….666
Pump Regulator Description….667
Horsepower Control….667
Power Shift Control….667
Negative Oil Discharge (Pump Bypass) Control….667
Pump Regulator Operation….668
Pump Output Decrease….670
Pump Discharge Decrease….670
Pump Discharge Increase….670
Horsepower Control….670
Overload Protection….671
Regulator Adjustment….671
Pump Input Power Control Adjustment….672
Parts List….673
Specifications….677
Hydraulic Pump Performance Characteristics….679
Troubleshooting, Testing and Adjustment….684
Main Pump….684
Disassembly….685
General Disassembly….685
Main Pump Disassembly….686
Pump Regulator Disassembly….688
Cleaning and Inspection (Wear Limits and Tolerances)….692
Reassembly….694
Pump Regulator Reassembly….694
Main Pump Reassembly….698
Main Control Valve (Kayaba) S0709401K….702
General Description….706
When All Spools are in Neutral….706
Single Operation….711
Combined Operation….723
Antidrift Valve….726
Main Relief Valve….727
Overload Relief Valve (69, Total: Six Places)….728
Low Pressure Relief Valve (70, Total: Two Places)….729
Parts List….731
Specifications….740
Troubleshooting, Testing and Adjustment….741
General….741
Relief Valve….742
Hydraulic System….742
Adjustment of Relief Valve….742
Disassembly….744
General Instructions for Disassembly….744
Cleaning and Inspection (Wear Limits and Tolerances)….751
Cleaning….751
Inspection….751
Reassembly….751
Instructions for Reassembly….751
Procedure of Subassembly….752
Reassembly Procedure of Control Valve Body….754
Installation….759
Start-up Procedures….759
Pilot Control Valve (Work Lever / Joystick) S0709451K….760
General Description….762
Theory of Operation….762
Parts List….763
Specifications….764
Removal….765
Disassembly….768
Cleaning and Inspection (Wear Limits and Tolerances)….772
Reassembly….773
Installation….778
Start-up Procedures….779
Travel Control Valve (With Damper) S0709820K….780
General Description….782
Theory of Operation….782
Parts List….785
Specification….786
Torque….786
Troubleshooting, Testing and Adjustment….787
Removal….788
Disassembly….790
Cleaning and Inspection (Wear Limits and Tolerances)….796
assembly….797
Installation….802
Start-up Procedures….803
Hydraulic Schematic (Solar 225LC-V/225NLC-V) S0792105K….804
General Description….806
Solar 225LC-V….807
Solar 225NLC-V….809
Electrical System….812
Electrical System S0802220K….814
Troubleshooting – Electrical System….817
Overview….818
Electric Supply System….819
Engine Starting Circuit….820
Operation During Start Process….820
Operation After Start Process….821
Engine Preheating System….822
Engine Stop System….823
Charging System….826
Monitoring System….827
Instrument Panel….828
Monitoring System Schematic….829
Operation….831
Instruments….831
Warning and Indicator Lights….833
Initial Operation….835
Mode Select Switch….836
Graphic Information Area Display….837
Overview….837
Main Menus for the Graphic Display Area….838
Menu Selection Buttons….838
Main Menu….839
Language setting….839
Time Setting….839
Filter/Oil information….840
Special Menu….841
Entering/Accessing and Exiting/Escaping Menus….841
Special Menu Selections….842
Electronic Hydraulic Control System (eEPOS)….855
Control System Schematic….855
Power Mode Control….857
Operation….858
Power Mode Control – Circuit Diagram….861
Work Mode Control….863
Operation….864
Work Mode Control – Circuit Diagram….865
Engine Control System….866
Engine Control Motor….868
Engine Control Dial….869
Engine Control Circuit Diagram….871
Automatic Deceleration Control (Auto Idle Control)….872
Engine Overheat Protection System….873
Power Boost Mode….874
Operation….874
Power Boost Control – Circuit Diagram….875
Automatic Travel Speed Control….876
Automatic Travel Speed Control – Circuit Diagram….877
Engine Control Device – Adjustment….878
Self-diagnostic Function….881
e-EPOS Controller….881
Engine Throttle Controller….883
Wiper System….884
Wiper Circuit….884
Wiper Operation….884
Window Washer Operation….885
Lighting System….887
Lighting System Circuit Diagram….887
Kind of Light….888
Operation….888
Overload Warning Device….889
Overload Warning Device Circuit Diagram….889
Electrical Schematic (Solar 225LC-V/225NLC-V) S0892105K….890
General Description….892
Solar 225LC-V….893
Solar 225NLC-V….895
Attachments….898
Boom and Arm S0902010….900
Front Attachment Pin Specifications….902
Front Attachment – Removal and Installation….903
Arm Removal Procedure….903
Boom Removal Procedure….905
Installation….906
Arm Installation Procedure….906
Boom Installation Procedure….906
Start-up Procedures….907
Bucket S0904015K….908
Bucket Tooth Inspection and Replacement….910
Type 1….910
Type 2….911
Bucket O-ring Replacement….913
Bucket Shimming Procedures….915
New Bucket Installation….915
Bucket Attachment, Removal and Reversal….916
Detaching the Bucket….916
Attaching The bucket….916
Reversing the Bucket….917
Publication Request for Proposed Revision….918
ELECTRIC CIRCUIT CHANGING….920
ELECTRIC CIRCUIT….921
HYDRAULIC CIRCUIT….922
INJ. PUMP CALIBRATION DATA….923
PERFORMANCE SPECIFICATION….925
S220LC-3 Wiring….926
S220LC-5 Wiring….927
Daweoo Solar 225LC-V Excavator Repair Service Manual