Complete service manual for Daewoo / Doosan Solar 225LC-V Excavator, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Daewoo 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.
...
022-00032E - Daewoo Solar 225LC-V Operation and Maintenance Manual.pdf
023-00058E - Daewoo 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