PDF Shop Manual Daewoo Solar 225LL Excavator - 2 MB
This is the complete factory shop manual for the Daewoo Solar 225LL Excavator.
It provides comprehensive, step-by-step instructions for all repair and maintenance procedures.
With detailed diagrams and specifications, this manual is an essential tool for any mechanic working on this machine.
Ensure all your repairs are done correctly and efficiently with this indispensable guide.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
Solar 225LL
Shop Manual
023-00078E
Serial Number 1001 and Up
Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine’s package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
023-00078E Shop Manual
--- Page 3 ---
S0102015K
1TRACK EXCAVATOR
SAFETY
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TRACK EXCAVATOR SAFETYS0102015K
MODEL SERIAL NUMBER RANGE
Solar 225LL 1001 and Up
Solar 300LL 1001 and Up
Copyright 2004 Daewoo
June 2004
Track Excavator Safety S0102015K
Page 1
--- Page 4 ---
FUEL, OIL AND HYDRAULIC FLUID FIRE
HAZARDS
Fuel, oil and antifreeze will catch fire if it is
brought close to a flame. Fuel is particularly
flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the
machine only in a well ventilated area. The
machine must be parked with controls, lights
and switches turned "OFF." The engine must be
"OFF" and any flames, glowing embers,
auxiliary heating units or spark causing
equipment must be doused, turned "OFF" and/
or kept well clear of the machine.
Static electricity can produce dangerous sparks
at the fuel filling nozzle. In very cold, dry Figure 3
weather or other conditions that could produce a
static discharge, keep the tip of the fuel nozzle
in constant contact with the neck of the fuel
filling nozzle, to provide a ground.
Keep fuel and other fluid reservoir caps tight
and do not start the engine until caps have been
secured.
PRECAUTIONS WHEN HANDLING FLUIDS
AT HIGH TEMPERATURE
Immediately after operations are stopped, the
coolant, engine oil, and hydraulic oil are at high
temperature and the radiator and hydraulic tank
are still under pressure. Attempting to remove
the cap, drain the oil or coolant, or replace the
filters may lead to serious burns. Always wait for
the temperature to go down, and follow the
specified procedures when carrying out these
operations.
HAOA050L
Figure 4
To prevent hot coolant from spurting out, shut
down engine, wait for the coolant to cool, then
loosen the cap slowly to relieve the pressure.
To prevent hot oil from spurting out, shut down
engine, wait for the oil to cool, then loosen the
cap slowly to relieve the pressure.
HAOA060L
Figure 5
Track Excavator Safety S0102015K
Page 11
--- Page 5 ---
TRAVELING ON SLOPES
Never jump onto a machine that is running away to stop it. There is danger of serious injury.
Traveling on slopes could result in the machine tipping over or slipping.
On hills, banks or slopes, carry the bucket approximately 20 - 30 cm (8 - 12 in) above the ground. In case
of an emergency, quickly lower the bucket to the ground to help stop the machine.
20~30
Cm
Cm
20~30
BUO0030L BUO0040L
Figure 18 Figure 19
Do not travel on grass, fallen leaves, or wet steel
plates. Even slight slopes may cause the
machine to slip to the side, so travel at low
speed and make sure that the machine is
always traveling directly up or down the slope.
Avoid changing the direction of travel on a slope.
This could result in tipping or side slipping of the
machine.
When possible, operate the machine up slopes
and down slopes. Avoid operating the machine
across the slope, when possible.
Figure 20
PROHIBITED OPERATIONS
Do not dig the work face under an overhang.
This may cause the overhang to collapse and
fall on top of the machine.
Figure 21
Track Excavator Safety S0102015K
Page 21
--- Page 6 ---
ACTION WHEN ABNORMALLY IS FOUND DURING INSPECTION
If any abnormality is found during inspection, always carry out repairs. In particular, if the machine is used
when there are still problems with the brake or work equipment systems, it may lead to serious injury.
If necessary depending on the type of failure, please contact your Daewoo distributor for repairs.
PRECAUTIONS WITH HIGH-PRESSURE LINE, TUBES AND HOSES
When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released
from the circuit. Failure to release the pressure may lead to serious injury. Always do the following;
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized components can be difficult to see but
pressurized oil has enough force to pierce the skin and cause serious injury. Always use a piece
of wood or cardboard to check for suspected hydraulic leaks. Never use your hands or expose
your fingers.
• Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install lines, tubes or
hoses that are bent or damaged.
• Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration,
rubbing against other parts, and excessive heat during operation.
– If any of the following conditions are found, replace the part.
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure of strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.
NOTE: Refer to "Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)"
in Operation and Maintenance Manual, for additional European regulations.
X X O
HAOA420L
Figure 37
Track Excavator Safety S0102015K
Page 31
--- Page 7 ---
GENERAL DESCRIPTION
The excavator has three main component sections:
• The Upper Turntable
• The Lower Undercarriage and Track Frames
• The Excavator Front-end Attachment
The following illustration identifies main components and their locations. (See Figure 1 on page -4.)
Specifications for Solar 225LL S0202150K
Page 3
--- Page 8 ---
LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS
Gypsum, calcined, 961 kg/m3
--------------------- ---------------------
(heated, powder) (1,620 lb/yd3)
Gypsum, crushed to 3 1,522 kg/m3
--------------------- ---------------------
inch size (2,565 lb/yd3)
Gravel, DRY, packed 1,810 kg/m3
--------------------- ---------------------
fragments (3,051 lb/yd3)
Gravel, WET, packed 1,922 kg/m3
--------------------- ---------------------
fragments (3,240 lb/yd3)
Limestone, graded 1,282 kg/m3
--------------------- ---------------------
above 2 (2,160 lb/yd3)
Limestone, graded 1,362 kg/m3
--------------------- ---------------------
1-1/2 or 2 (2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulphur, broken --------------------- ---------------------
(1,620 lb/yd3)
Specifications for Solar 225LL S0202150K
Page 13
--- Page 9 ---
WELDING PRECAUTIONS AND GUIDELINES
IMPORTANT
To avoid accidents, personal injury and the possibility of causing damage to the machine or to
components, welding must only be performed by properly trained and qualified personnel, who
possess the correct certification (when required) for the specific welding fabrication or
specialized repair being performed.
WARNING!
Structural elements of the machine may be built from a variety of steels. These could contain
unique alloys or may have been heat treated to obtain particular strength characteristics. It is
extremely important that welding repairs on these types of steel are performed with the proper
procedures and equipment. If repairs are performed incorrectly, structural weakening or other
damage to the machine (that is not always readily visible) could be caused. Always consult
Daewoo After Sales Service before welding on integral components (loader arm, frames, car
body, track frames, turntable, attachment, etc.) of the machine. It is possible that some types of
structurally critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make
sure there are no hidden cracks or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety equipment on hand. Adequate
ventilation and a dry work area are absolutely essential. Keep a fire extinguisher nearby and
always wear protective clothing and the recommended type of eye protection.
General Maintenance Procedures S0302000
Page 3
--- Page 10 ---
Heat Discoloration
Heat discoloration can range from faint yellow to
dark blue resulting from overload or incorrect
lubrication.
Excessive heat can cause softening of races or
rollers.
To check for loss of temper on races or rollers, a
simple file test may be made. A file drawn over a
tempered part will grab and cut metal, whereas
a file drawn over a hard part will glide readily
with no metal cutting.
Figure 17
Replace bearing if over heating damage is
indicated. Check seals and other related parts
for damage.
Stain Discoloration
Discoloration can range from light brown to
black caused by incorrect lubrication or
moisture.
if the stain can be removed by light polishing or
if no evidence of overheating is visible, the
bearing can be reused.
Check seals and other related parts for damage.
Figure 18
General Maintenance Procedures S0302000
Page 13
--- Page 11 ---
TORQUE WRENCH EXTENSION TOOLS
Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning
force to achieve recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of the torque wrench.
• Specialized sockets do not fit the adapter on the front end (nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the torque wrench impossible.
• A unique application requires fabrication of an adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one of the proceeding needs or situations, if
the right extension tool is used or fabricated.
TORQUE MULTIPLICATION
A wrench extension tool can be used to
increase the tightening force on a high capacity
nut or bolt.
For example, doubling the distance between the
bolt and the back (handle) end of the torque
wrench doubles the tightening force on the bolt.
It also halves the indicated reading on the scale
or dial of the torque wrench. To accurately
adjust or convert indicated scale or dial
readings, use the following formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench Figure 1
scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque).
A = Length of the torque wrench (between the center of the nut or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque wrench, and the indicated torque on the dial
reads "150 ft lb," the real force applied to the bolt is 300 ft lb:
AxT 12 x 300 3600
I= = = = 150
A+B 12 + 12 24
NOTE: The formula assumes that there is no added deflection or "give" in the joint between the
extension and torque wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly straight (for example, an extension made
to go around an obstruction, to allow access to a difficult to tighten fastener), the materials and
methods used must be solid enough to transmit full tightening torque.
Standard Torques S0309000
Page 9
--- Page 12 ---
21. Remove three bolts (2, Figure 5) after
disconnecting the speaker and antenna
wires. Remove stereo assembly.
22. Disconnect cab light wiring connector. 2
23. Disconnect cab ground cable (7, Figure 2).
1
ARS1540L
Figure 5
24. Remove four mounting nuts from four
corners of cab floor (2, Figure 6). 1
25. Remove four hex bolts (3, Figure 6) from
door side of cab floor.
26. Remove two hex bolts (1, Figure 6) from 2
right side of cab floor and one bolt (4) from
front of cab floor. 4
Quantity Description
4 16 mm hex nuts at each
corner of the cab
4 10 mm x 1.5 hex bolts at
the door side of the cab 3
3 10 mm x 1.5 mm hex HAOF270L
head bolts, 2 on the right Figure 6
side of the cab and 1
under the front window.
27. Using a suitable lifting device, attach slings
to four lift points on top of cab (Figure 7).
NOTE: Cab weighs approximately 290
kg (640 lb).
28. Lift the cab approximately 25 - 50 mm (1" -
2") above the deck height. Check that all
the electrical connections have been
disconnected and all other items unbolted.
29. Continue lifting with the assist crane to
remove the cab shell. Lower the shell to a
prepared safe blocking support.
Figure 7
Cab S0402040K
Page 5
--- Page 13 ---
INSTALLATION
1. Raise engine compartment cover.
2. Using suitable lifting device capable of
handling load, raise counterweight (2,
Figure 6) into position just above support
frame (6) leaving counterweight
suspended. Verify that counterweight is
level and even.
NOTE: Leave counterweight (2, Figure
6) suspended 3 mm (0.125")
above support frame (6) until all
four mounting bolts (4) are
started in counterweight
mounting holes.
3. Slide spacers/washers (5, Figure 6) onto
bolts (4). Apply Loctite #242 to mounting
bolt threads.
4. Install four bolts (4, Figure 6) with spacers/
washers (5) into counterweight until
spacers contact support frame. Fully lower
counterweight onto support frame and
finish tightening bolts.
NOTE: Tighten bolts (4, Figure 6) to Figure 6
values shown in following table.
Model Bolt Torque
Solar 130LC-V 115 kg•m
Solar 140LC-V (830 ft lb)
Solar 170LC-V
Solar 170W-V
Solar 200W-V 150 kg•m
Solar 220LC-V (1,080 ft lb)
Solar 220LL
Solar 225LL
Solar 290LC-V
408 kg•m
Solar 290LL
(2,950 ft lb)
Solar 300LL
Solar 250LC-V
Solar 330LC-V 250 kg•m
Solar 400LC-V (1,810 ft lb)
Solar 450LC-V
5. Remove lifting device and lifting eyes from counterweight lifting holes (3, Figure 6).
6. Install two caps (1, Figure 6) in lifting holes (3).
Counterweight S0403000
Page 7
--- Page 14 ---
Return to Master Table of Contents
20. Install two 12 mm eyebolts in threaded
holes at that bolts (1 and 2, Figure 11)
come out of. Using a suitable lifting device,
sling eyebolts.
21. Remove four bolts and washers (4) holding
tank (3) to frame. Lift tank 25 mm (1") and
make sure it is balanced. Make sure that
there are no other electrical wires or hoses
connected to tank. Completely remove
tank after inspection.
NOTE: The clear level gauge on the
side of the tank is easily
damaged. Be careful of
obstacles and wind gusts.
22. Remove shims (5).
Figure 11
NOTE: If tank is to be reused note
position and amount of shims
used for each mounting bolt
location.
Fuel Tank \S0405050
Page 9
--- Page 15 ---
Return to Master Table of Contents
S0408015K
1SWING REDUCTION
GEARBOX
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
SWING REDUCTION GEARBOXS0408015K
MODEL SERIAL NUMBER RANGE
Solar 225LC-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 225LL 1001 and Up
Copyright 2004 Daewoo
June 2004
Swing Reduction Gearbox S0408015K
Page 1
--- Page 16 ---
Return to Master Table of Contents
7. Install 10 mm ring bolts and use them to lift
out and separate the No. 2 carrier
assembly.
Figure 14
8. Remove the thrust ring, in order to begin
disassembly of the No. 2 carrier. Position
the carrier vertically, as shown in the
photograph. Insert an appropriate tool
through the hole in the back side of the
carrier. Hammer out the spring pin (31), so
that pin No. 2 (14) can be withdrawn.
Remove the upper and lower (18, 19) side
plates of the differential gears.
Figure 15
IMPORTANT
Pin No. 2 should not be reused.
Replace it with a new component.
Further disassembly of the carrier is
generally not required, unless there
is evidence of unusual damage or
excessive wear.
9. Disassemble the ring gear. Tighten two
16 mm bolts into the holes shown in the Figure 16
photograph. Separate the ring gear using
even force.
10. Before turning the gearbox end for end
(180°, so that the drive shaft is facing up,
as shown in the photograph) remove the 4
pipes and lock pins (21). Lock pins (21)
should not require further disassembly.
Loosen the mounting bolts (26) and detach
the front cover plate (1).
Figure 17
Swing Reduction Gearbox S0408015K
Page 11
--- Page 17 ---
Return to Master Table of Contents
26. Lay out the No. 1 carrier on the
workbench. Align the holes of the carrier
and the spring pins of the No. 2 pins, and
press them into place with a press.
Figure 47
27. Install spring pins using the spring pin
insert jig, as in step 17 (preceding) and
punch two notches off each spring pin.
Figure 48
28. Install lower side plates.
NOTE: The upper and lower side
plates have different
thicknesses. Lower side plates
are approximately 1 mm (0.39")
thick.
Figure 49
29. Install the center side plate to about 1 mm,
or 0.39."
Figure 50
Swing Reduction Gearbox S0408015K
Page 21
--- Page 18 ---
Terrain Type Distance "A"
Normal 320 ~ 340 mm (12.60 ~ 13.38 in)
Muddy 340 - 380 mm (13.38 - 14.96 in)
Gravel, Rocky, Sand or Snow 380 mm (14.96 in)
WARNING!
The track adjusting mechanism is under very high-pressure. NEVER release pressure too
suddenly. The grease cylinder valve should never be backed off more than 1 complete turn
from the fully tightened down position. Bleed off pressure slowly and keep your body away
from the valve at all times.
5. Track tension adjustments are made
through the grease fitting (1, Figure 3) in 2
3
the middle of each side frame. Adding
grease increases the length of an
adjustment cylinder (2). The longer the
adjustment cylinder, the greater the
pressure on the tension spring pushing the
track idler wheel outward.
6. If there is not enough slack or clearance in
the tracks and the adjustment is too tight,
the idler wheel and adjusting cylinder can 1
be retracted by bleeding off grease thru HAOC760L
hole in adjustment cylinder (2, Figure 3). Figure 3
Track Assembly S0505045K
Page 5
--- Page 19 ---
FRONT IDLER ROLLER REASSEMBLY
1. Degrease, clean and dry all parts before
reassembly. Insert bushing (8, Figure 24)
into the idler (7).
2. Grease O-ring (4, Figure 24) and insert it
into the axle.
3. Align the bearing (1, Figure 24) and axle
(5) holes and pin (3) them together.
Figure 24
4. Install group seal (6, Figure 25) inside the
idler (7) and bearing (1).
NOTE: Apply clean engine oil to the
joint side of the group seal.
Apply grease to the group seal
O-ring.
Figure 25
5. Install idler (7, Figure 26) on the axle.
6. Install bearing (1, Figure 26) and pin (3) to
the axle.
NOTE: Fill the idler assembly with new
engine oil with approximately
260 cc (8.79 oz).
Figure 26
Track Assembly S0505045K
Page 15
--- Page 20 ---
TRACK SPRING AND TRACK ADJUSTING CYLINDER
PARTS LIST
Figure 48
Reference Reference
Description Description
Number Number
1 Piston Rod 11 Flange
2 Piston Ring 12 Nut
3 Backup Ring 13 Valve
4 Packing 14 Bolt
5 Retaining Ring 15 Plate
6 Rod 16 Yoke
7 O-ring 17 Socket Bolt
8 Cylinder 18 Flange
9 Spring 19 O-ring
10 Spacer
Track Assembly S0505045K
Page 25
--- Page 21 ---
CONTROL PANEL
ARO0501L
Figure 5
INPUT CONTROL OUTPUT
PANEL
DISPLAY
TEMPERATURE
SENSOR
LOW SPEED RELAY
OFF SW MID SPEED RELAY BLOWER
MOTOR
A / C SW
VENT SW HIGH SPEED RELAY
DEF. SW
HEAT SW A/C TEMP. CONTROL MIX DOOR
ACTUATOR
FRE SW CONTROL
REC SW PANEL VENT ACTUATOR VENT CONTROL
LOW SW
MID SW DEF. ACTUATOR FOOT / DEF.
HI SW
COOL SW INTAKE RECYCLE/FRESH
ACTUATOR AIR CONTROL
WARM SW
TEMPERATURE COMP. RELAY COMPRESSOR
CONTROL ACTUATOR
CONDENSER CONDENSER
FAN RELAY FAN
HDA6048L
Figure 6
Air Conditioner S0605060K
Page 7
--- Page 22 ---
Model Weight of Gas
Solar 250LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 255LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 280LC-III 1250 ±20 grams (44 ±0.7 oz)
Solar 290LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 290LL 850 ±20 grams (30 ±0.7 oz)
Solar 300LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 300LL 850 ±20 grams (30 ±0.7 oz)
Solar 330-III 1250 ±20 grams (44 ±0.7 oz)
Solar 330LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 340LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 400LC-III 1250 ±20 grams (44 ±0.7 oz)
Solar 400LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 420LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 450LC-III 1250 ±20 grams (44 ±0.7 oz)
Solar 450LC-V 850 ±20 grams (30 ±0.7 oz)