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Daewoo Excavator Solar 225NLC-V Shop Manual 023-00062E – PDF
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Description
Daewoo Excavator Solar 225NLC-V Shop Manual 023-00062E – PDF DOWNLOAD
FILE DETAILS:
Daewoo Excavator Solar 225NLC-V Shop Manual 023-00062E – PDF DOWNLOAD
Language : English
Pages : 684
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Daewoo Excavator Solar 225NLC-V Shop Manual 023-00062E – PDF DOWNLOAD
Safety.................................................................................... 7 Track Excavator Safety S0102000....................................................... 9 To the Operator of a Daewoo Excavator............................................. 11 Learn the Signal Words Used with the Safety Alert Symbol...................... 13 General Safety Essentials......................................................... 14 Accessory Applications........................................................ 14 Lifting Capacity Rating Configuration......................................... 14 Location of Safety Labels......................................................... 14 Summary of Safety Precautions for Lifting in Digging Mode......................... 15 Unauthorized Modifications........................................................ 16 General Hazard Information........................................................ 16 Safety Rules.................................................................. 16 Safety Features............................................................... 16 Inside Operator's Compartment................................................. 17 Clothing and Personal Protective Items........................................ 17 Breathing Masks, Ear Protection May Be Required............................... 17 Mounting and Dismounting...................................................... 18 Fuel, Oil and Hydraulic Fluid Fire Hazards.................................... 19 Precautions When Handling Fluids at High Temperature.......................... 19 Asbestos Dust Hazard Prevention............................................... 20 Injury from Work Equipment.................................................... 20 Fire Extinguisher and First Aid Kit........................................... 21 Protection from Falling or Flying Objects..................................... 21 Attachment Precautions........................................................ 22 Accumulator................................................................... 22 Indoor Ventilation............................................................ 23 Emergency Exit................................................................ 23 Before Starting Engine............................................................ 24 Work Site Precautions......................................................... 24 Checks Before Starting Engine................................................. 25 Engine Starting............................................................... 26 Before Operating Machine...................................................... 26 Machine Operation................................................................. 27 When Swinging or Changing Direction of Travel................................. 27 Travel Precautions............................................................ 28 Traveling on Slopes........................................................... 29 Prohibited Operations......................................................... 30 Precautions for Operation..................................................... 31 Avoid High-voltage Cables..................................................... 32 Operate Carefully on Snow, Ice and in Very Cold Temperatures.................. 32 Operations on Slopes.......................................................... 33 Parking Machine............................................................... 33 Never Let Anyone Ride on Attachment........................................... 33 Maintenance....................................................................... 34 Warning Tag................................................................... 34 Clean Before Inspection or Maintenance........................................ 34 Proper Tools.................................................................. 35 Use of Lighting............................................................... 35 Fire Prevention and Explosion Prevention...................................... 35 Burn Prevention............................................................... 36 Welding Repairs............................................................... 37 Warning for Counterweight and Front Attachment Removal........................ 37 Precautions for Removal, Installation, and Storage of Attachments............. 38 Precautions when Working on Machine........................................... 38 Lock Inspection Covers........................................................ 38 Crushing Prevention and Cutting Prevention.................................... 39 Track Tension Adjustments Require Caution..................................... 39 Supports and Blocking for Work Equipment...................................... 39 Action When Abnormally Is Found During Inspection............................. 40 Precautions with High Pressure Line, Tubes and Hoses.......................... 40 Waste Materials............................................................... 41 Battery........................................................................... 42 Battery Hazard Prevention..................................................... 42 Boost Starting or Charging Engine Batteries................................... 43 Towing............................................................................ 44 Precautions When Towing....................................................... 44 Shipping and Transportation....................................................... 45 Obey State and Local Over-the-Road Regulations................................ 45 Lifting With Sling................................................................ 45 Specifications............................................................................ 47 Specifications for Solar 225NLC-V S0205016K........................................... 49 General Description............................................................... 51 Component Locations............................................................... 52 General Dimensions................................................................ 54 Working Range..................................................................... 56 General Specifications............................................................ 58 Engine Performance Curves (Per DIN6270 Standard)................................. 60 Approximate Weight of Workload Materials.......................................... 62 Performance Tests................................................................. 65 Excavator Performance Standards................................................... 66 Test Conditions............................................................... 66 Travel Speed and Travel Motor Balance (Steering Deviation) Tests.............. 66 Swing Speed and Deceleration Force Test....................................... 68 Cylinder Performance Tests.................................................... 69 General Maintenance....................................................................... 71 General Maintenance Procedures S0302000............................................... 73 Welding Precautions and Guidelines................................................ 75 Hydraulic System - General Precautions............................................ 76 Maintenance Service and Repair Procedure.......................................... 77 General Precautions........................................................... 77 Hydraulic System Cleanliness and Oil Leaks........................................ 78 Maintenance Precautions for Hydraulic System Service.......................... 78 Oil Leakage Precautions....................................................... 78 Cleaning and Inspection........................................................... 79 General Guidelines............................................................ 79 Bearing inspection............................................................ 80 Standard Torques S0309000............................................................. 87 Torque Values for Standard Metric Fasteners....................................... 89 Torque Values for Standard U.S. Fasteners......................................... 90 Type 8 Phosphate Coated Hardware.................................................. 92 Torque Values for Hose Clamps..................................................... 93 Torque Values for Split Flanges................................................... 94 Torque Wrench Extension Tools..................................................... 95 Torque Multiplication......................................................... 95 Other Uses for Torque Wrench Extension Tools.................................. 96 Tightening Torque Specifications (Metric)..................................... 96 Upper Structure........................................................................... 99 Cab S0402040K.........................................................................101 Removal...........................................................................103 Installation......................................................................106 Counterweight S0403050K...............................................................109 General...........................................................................111 Removal...........................................................................113 Installation......................................................................115 Fuel Tank S0405006K...................................................................117 General Description...............................................................119 Parts List....................................................................120 Specifications................................................................121 Removal...........................................................................122 Installation......................................................................126 Start-up Procedures...............................................................128 Fuel Transfer Pump S0405500...........................................................129 General Description...............................................................131 Theory of Operation...........................................................131 Troubleshooting...................................................................132 Replacement of Rotor and Vane.....................................................132 Replacement of Rear Cover.........................................................133 Replacement of Armature...........................................................134 Swing Bearing S0407000................................................................135 Swing Bearing Maintenance.........................................................137 Operating Recommendation......................................................137 Measuring Swing Bearing Axial Play............................................137 Measuring Bearing Lateral Play................................................137 Swing Bearing Basic Operation.................................................138 Rebuilding Swing Bearing......................................................138 Swing Reduction Gearbox S0408015K.....................................................141 General Description...............................................................143 Theory of Operation...........................................................143 Parts List....................................................................144 Specifications................................................................145 Special Tools and Materials.......................................................146 Special Tools.................................................................146 Troubleshooting, Testing and Adjustment...........................................147 Removal...........................................................................148 Disassembly.......................................................................149 Cleaning and Inspection (Wear Limits and Tolerances)..............................154 Reassembly........................................................................155 Installation......................................................................164 Lower Structure and Chassis...............................................................165 Track Assembly S0505030...............................................................167 General Description...............................................................169 Track Tension.....................................................................169 Cleaning and Inspection (Wear Limits and Tolerances)..............................171 Track Shoes and Links.............................................................175 Parts List....................................................................175 Track Removal.................................................................176 Track Installation............................................................177 Front Idler Roller................................................................178 Parts List....................................................................178 Front Idler Roller Disassembly................................................179 Front Idler Roller Reassembly.................................................181 Lower Roller......................................................................182 Parts List....................................................................182 Lower Roller Removal..........................................................183 Lower Roller Disassembly......................................................183 Lower Roller Reassembly.......................................................184 Lower Roller Installation.....................................................185 Upper Roller......................................................................186 Parts List....................................................................186 Upper Roller Removal..........................................................187 Upper Roller Disassembly......................................................187 Upper Roller Reassembly.......................................................188 Track Spring and Track Adjusting Cylinder.........................................190 Parts List....................................................................190 Engine and Drive Train....................................................................193 Air-Conditioner S0605060K.............................................................195 General Description...............................................................197 Refrigerant Circulation...........................................................199 Control Panel.....................................................................201 Control Specifications............................................................202 Temperature Level Control and Display.............................................203 Air Discharge According to Path Selection.........................................204 Air-conditioning System Circuit Diagram...........................................206 Troubleshooting...................................................................208 Weight of R134a Gas Used In Machines..............................................210 Refrigerant System Repairs........................................................212 Refrigerant Safe Handling Procedures..........................................212 Repair and Replacement Procedure..............................................213 Refrigerant Recovery..........................................................215 Vacuuming Refrigerant System..................................................215 Leakage Check.................................................................216 Refrigerant Charging..........................................................217 Inspecting System For Leakage.................................................219 Drive Coupling (Main Pump) S0609000...................................................221 Drive Coupling....................................................................223 Special Tools.....................................................................224 Kawasaki / Tong Myung Pump Tool...............................................224 Uchida Pump Tool..............................................................227 Drive Coupling Installation.......................................................228 Installation Procedure........................................................233 Hydraulics................................................................................235 Hydraulic System Troubleshooting, Testing and Adjustment S0702170K....................237 Hydraulic System - General Notes..................................................240 Hydraulic Schematic...............................................................241 General Notes.................................................................241 Operation of Working Components...................................................242 Boom Operating Circuit........................................................242 Boom Up Circuit...............................................................242 Boom Down Circuit.............................................................242 Arm Operating Circuit.........................................................243 Arm Crowd Circuit.............................................................243 Arm Dump Circuit..............................................................243 Bucket Operating Circuit......................................................244 Bucket Crowd Circuit..........................................................244 Bucket Dump Circuit...........................................................244 Swing Operating Circuit.......................................................244 Right Swing Operating Circuit.................................................245 Left Swing Operating Circuit..................................................245 Swing Relief Valve and Make-up Valve..........................................245 Travel Operating Circuit......................................................245 Forward Travel Circuit........................................................246 Reverse Travel Circuit........................................................246 Procedural Troubleshooting Baseline Recommendations...............................246 Initial Checks and Tests to Establish Operating Condition of the Excavator....246 Pilot Pressure....................................................................248 Adjustment and Testing........................................................248 Power Mode Valve..................................................................250 Current Signal and Hydraulic Pressure Adjustments.............................250 Swing Priority Valve..............................................................252 Control Valve Pressure and Current Adjustments................................252 Pressure Up Valve.................................................................253 Checks and Adjustments........................................................253 Pump Input Power Control..........................................................255 Pump Regulator Adjustment.....................................................255 Flow Meter and Flow Meter Kit Installation and Testing............................260 Swing System Troubleshooting......................................................262 Precautions/Initial Checks....................................................262 Swing Relief Valve Checking and Adjustment....................................262 Troubleshooting – Swing Gearbox...................................................264 Troubleshooting – Hydraulic Problems..............................................266 Troubleshooting – Control Valve...................................................268 Troubleshooting – Travel Control Valve............................................270 Troubleshooting – Joystick Control Valve..........................................271 Accumulator S0703010K.................................................................273 General Description...............................................................275 Specifications................................................................276 Center Joint (Swivel) S0704010........................................................279 General Description...............................................................281 Parts List....................................................................282 Troubleshooting, Testing and Adjustment...........................................286 Inspection....................................................................286 Testing.......................................................................286 Disassembly.......................................................................287 Reassembly........................................................................288 Cylinders S0705000....................................................................289 General Description...............................................................291 Theory of Operation...........................................................291 Parts List....................................................................292 Special Tools and Materials.......................................................294 Piston Nut....................................................................294 Piston Jig....................................................................298 Steel bush Jig................................................................302 Dust Wiper Jig................................................................306 Slipper Seal Jig..............................................................312 Slipper Seal Straightening Jig................................................316 Disassembly.......................................................................319 Assembly..........................................................................325 Swing Motor S0707200..................................................................329 General Description...............................................................331 Theory of Operation...........................................................331 Swing Motor Anti-cavitation Make-up Valve.....................................332 Relief Valve..................................................................333 Swing Brake Operation.........................................................333 Parts List (Model Solar 250LC-V, 255LC-V).....................................336 Parts List (Models Solar 225LC-V, 225NLC-V, 290LC-V, and 290LL)...............338 Specifications (Model Solar 225LC-V, 225NLC-V)................................340 Specifications (Models Solar 250LC-V, 255LC-V, 290LC-V, and 290LL)............340 Special Tools.....................................................................341 Disassembly.......................................................................342 Cleaning and Inspection (Wear Limits and Tolerances)..............................349 Reassembly........................................................................351 Travel Motor (With Gearbox) (GM35VL) S0707330.........................................359 General Description...............................................................361 Theory of Operation...........................................................361 Travel Motor Parts List.......................................................368 Travel Reduction Gearbox Parts List...........................................370 Specifications................................................................372 Troubleshooting, Testing and Adjustment...........................................374 General Notice................................................................374 Troubleshooting...............................................................374 Disassembly.......................................................................378 Preparation for Travel Motor and Reduction Gear Disassembly...................378 Travel Motor Rear Flange Disassembly..........................................380 Travel Motor Internal Parts Disassembly.......................................384 Cleaning and Inspection (Wear Limits and Tolerances)..............................392 General Inspection............................................................392 Gear Oil......................................................................392 General Notice................................................................392 Tightening Torque List........................................................393 Wear Limits...................................................................393 Reassembly........................................................................395 General Instructions for Reassembly...........................................395 Travel Motor Rear Flange Reassembly...........................................395 Travel Reduction Gear Reassembly..............................................400 Gear Holding Flange Gap Measurement and Adjustment............................407 RV Gear Gap Measurement and Adjustment........................................408 Travel Motor and Reduction Gear Reassembly....................................409 Reduction Gear Cover Reassembly...............................................411 Main Pump (With Regulator) S0708320...................................................413 General Description...............................................................415 Gear (Pilot) Pump.............................................................417 Relief Valve..................................................................417 Pump Regulator Description....................................................418 Horsepower Control............................................................418 Power Shift Control...........................................................418 Negative Oil Discharge (Pump Bypass) Control..................................418 Pump Regulator Operation......................................................419 Pump Output Decrease..........................................................421 Pump Discharge Decrease.......................................................421 Pump Discharge Increase.......................................................421 Horsepower Control............................................................421 Overload Protection...........................................................422 Regulator Adjustment..........................................................422 Pump Input Power Control Adjustment...........................................423 Parts List....................................................................424 Specifications................................................................428 Hydraulic Pump Performance Characteristics....................................430 Troubleshooting, Testing and Adjustment...........................................435 Main Pump.....................................................................435 Disassembly.......................................................................436 General Disassembly...........................................................436 Main Pump Disassembly.........................................................437 Pump Regulator Disassembly....................................................439 Cleaning and Inspection (Wear Limits and Tolerances)..............................443 Reassembly........................................................................445 Pump Regulator Reassembly.....................................................445 Main Pump Reassembly..........................................................449 Main Control Valve S0709400...........................................................453 Control Valve Operation...........................................................456 Swing Priority Circuit........................................................456 Arm Priority Circuit..........................................................457 Bucket (Junction) Circuit.....................................................458 Straight Traveling Circuit....................................................459 Plunger Replacement...........................................................461 Main Relief Valve.............................................................462 Overload Relief Valve.........................................................463 Arm Load Holding Valve........................................................465 Boom Load Holding Valve.......................................................468 Arm Regeneration..............................................................470 Boom Regeneration.............................................................472 Foot Relief Valve.............................................................473 Parts List....................................................................474 Specifications................................................................484 Control Valve Drawing and Hydraulic Circuit.......................................485 Disassembly and Reassembly........................................................490 General Disassembly...........................................................490 General Reassembly............................................................490 Main Plunger Element - Disassembly and Assembly...............................491 Tool..........................................................................491 Main Relief Valve.............................................................494 Main Relief Valve Adjustment..................................................495 Overload Relief Valve.........................................................497 Arm Load Holding Valve........................................................499 Boom Load Holding Valve.......................................................502 Arm Regeneration Valve........................................................504 Bucket Unity Check............................................................505 Foot Relief Valve.............................................................506 Center Bypass Valve (CB Valve)................................................507 Boom Parallel Switch Valve....................................................508 Tool..........................................................................508 Swing Priority Valve..........................................................510 Boom Unity Check Valve........................................................512 Straight Travel Selector Valve................................................513 Check Valve - Locations.......................................................514 Check Valve...................................................................515 Pilot Control Valve (Work Lever / Joystick) S0709451K.................................521 General Description...............................................................523 Theory of Operation...........................................................523 Parts List....................................................................524 Specifications................................................................525 Removal...........................................................................526 Disassembly.......................................................................529 Cleaning and Inspection (Wear Limits and Tolerances)..............................533 Reassembly........................................................................534 Installation......................................................................539 Start-up Procedures...............................................................540 Travel Control Valve (With Damper) S0709820K..........................................541 General Description...............................................................543 Theory of Operation...........................................................543 Parts List....................................................................546 Specification.................................................................547 Torque........................................................................547 Troubleshooting, Testing and Adjustment...........................................548 Removal...........................................................................549 Disassembly.......................................................................551 Cleaning and Inspection (Wear Limits and Tolerances)..............................557 assembly..........................................................................558 Installation......................................................................563 Start-up Procedures...............................................................564 Hydraulic Schematic (Solar 225LC-V/225NLC-V) S0792105K................................565 General Description...............................................................567 Solar 225LC-V.....................................................................568 Solar 225NLC-V....................................................................570 Electrical System.........................................................................573 Electrical System S0802220K...........................................................575 Troubleshooting - Electrical System...............................................578 Overview..........................................................................579 Electric Supply System............................................................580 Engine Starting Circuit...........................................................581 Operation During Start Process................................................581 Operation After Start Process.................................................582 Engine Preheating System..........................................................583 Engine Stop System................................................................584 Charging System...................................................................587 Monitoring System.................................................................588 Instrument Panel..............................................................589 Monitoring System Schematic...................................................590 Operation.........................................................................592 Instruments...................................................................592 Warning and Indicator Lights......................................................594 Initial Operation.................................................................596 Mode Select Switch................................................................597 Graphic Information Area Display..................................................598 Overview......................................................................598 Main Menus for the Graphic Display Area.......................................599 Menu Selection Buttons........................................................599 Main Menu.........................................................................600 Language setting..............................................................600 Time Setting..................................................................600 Filter/Oil information........................................................601 Special Menu......................................................................602 Entering/Accessing and Exiting/Escaping Menus.................................602 Special Menu Selections.......................................................603 Electronic Hydraulic Control System (eEPOS)......................................616 Control System Schematic......................................................616 Power Mode Control................................................................618 Operation.....................................................................619 Power Mode Control - Circuit Diagram..............................................622 Work Mode Control.................................................................624 Operation.....................................................................625 Work Mode Control - Circuit Diagram...............................................626 Engine Control System.............................................................627 Engine Control Motor..............................................................629 Engine Control Dial...............................................................630 Engine Control Circuit Diagram....................................................632 Automatic Deceleration Control (Auto Idle Control)................................633 Engine Overheat Protection System.................................................634 Power Boost Mode..................................................................635 Operation.....................................................................635 Power Boost Control - Circuit Diagram.........................................636 Automatic Travel Speed Control....................................................637 Automatic Travel Speed Control - Circuit Diagram..............................638 Engine Control Device - Adjustment................................................639 Self-diagnostic Function..........................................................642 e-EPOS Controller.............................................................642 Engine Throttle Controller........................................................644 Wiper System......................................................................645 Wiper Circuit.................................................................645 Wiper Operation...............................................................645 Window Washer Operation.......................................................646 Lighting System...................................................................648 Lighting System Circuit Diagram...............................................648 Kind of Light.................................................................649 Operation.....................................................................649 Overload Warning Device...........................................................650 Overload Warning Device Circuit Diagram.......................................650 Electrical Schematic (Solar 225LC-V/225NLC-V) S0892105K...............................651 General Description...............................................................653 Solar 225LC-V.....................................................................654 Solar 225NLC-V....................................................................656 Attachments...............................................................................659 Boom and Arm S0902010.................................................................661 Front Attachment Pin Specifications...............................................663 Front Attachment - Removal and Installation.......................................664 Arm Removal Procedure.........................................................664 Boom Removal Procedure........................................................666 Installation......................................................................667 Arm Installation Procedure....................................................667 Boom Installation Procedure...................................................667 Start-up Procedures...............................................................668 Bucket S0904000.......................................................................669 Bucket Tooth Inspection and Replacement...........................................671 Type 1........................................................................671 Type 2........................................................................672 Type 3........................................................................673 Bucket O-ring Replacement.........................................................675 Type 1........................................................................675 Type 2........................................................................676 Bucket Shimming Procedures........................................................678 New Bucket Installation.......................................................678 Type 1........................................................................678 Type 2........................................................................679 Bucket Attachment, Removal and Reversal...........................................680 Detaching the Bucket..........................................................680 Attaching The bucket..........................................................680 Reversing the Bucket..........................................................681 Publication Request for Proposed Revision.................................................683
S.S 06/24
