Wrenching on a 2004 Daewoo Solar 300LL or 225LL track excavator? This 696-page Daewoo Solar 300LL, Solar 225LL shop manual PDF (OEM #023-00079E) breaks down the whole machine, swing bearing to travel motor. Inside: factory hydraulic schematics tracing the boom, arm, bucket, swing, and travel circuits, plus a full electrical schematic for the wiring side. You also get step-by-step teardown and reassembly for the Kawasaki main pump, Toshiba MFC200 swing motor, travel motors with gearboxes, and the main control valve, backed by a complete troubleshooting, testing, and adjustment section. Real numbers, too: gauge your 700 mm track shoes against the 18.0 mm new dimension and swap them at the 10.0 mm limit, then top off the 435-liter fuel tank. Quit chasing specs on forums. Bookmarked with a live text layer; search any spec, jump to any section, on any device.
What's Inside This Daewoo Solar 300LL, Solar 225LL Manual
| System | Pages | Key Topics |
|---|---|---|
| Publication Request for Proposed Revision | 7-8 | - |
| Safety | 9-46 | Track Excavator Safety S0102015K |
| Specifications | 47-68 | Specifications for Solar 300LL S0202160K |
| General Maintenance | 69-96 | General Maintenance Procedures S0302000, Standard Torques S0309000 |
| Upper Structure | 97-162 | Cab S0402040K, Counterweight S0403000, Fuel Tank S0405050, Fuel Transfer Pump S0405500, Swing Bearing S0407000, Swing Reduction Gear S0408070K |
| Lower Structure and Chassis | 163-184 | Track Assembly S0505010 |
| Engine and Drive Train | 185-222 | Air Conditioner S0605060K, Drive Coupling (Main Pump) S0609010K |
| Hydraulic System Troubleshooting, Testing and Adjustment | 223-260 | Boom Operating Circuit, Arm Operating Circuit, Bucket Operating Circuit, Swing Operating Circuit, Travel Operating Circuit |
| Accumulator | 261-266 | Gas-Charged Storage, Diaphragm, Precharge Pressure, Specifications |
| Center Joint (Swivel) | 267-274 | Hydraulic Oil Flow, 360 Degree Rotation, Inspection, Disassembly, Reassembly |
| Cylinders | 275-314 | Rod Stopper, Cushioning, Disassembly, Assembly, Piston Nut, Slipper Seal |
| Swing Motor (Toshiba MFC200) | 315-346 | Axial Piston Motor, Mechanical Brake, Makeup Valve, Relief Valve, Bypass Valve, Time Delay Valve |
| Travel Motor (with Gearbox) | 347-436 | Axial Piston Motor, Reduction Gear, Counter Balance Valve, Swash Tilting Assembly, Disassembly, Reassembly |
| Main Pump (Kawasaki) | 437-484 | Tandem Type Duplex Pump, Axial Piston Pump Disassembling, Axial Piston Pump Reassembling, Maintenance Criteria, Regulator Construction, Regulator Disassembly, Tightening Torques |
| Main Control Valve | 485-570 | Swing Priority Circuit, Arm Priority Circuit, Bucket Junction Circuit, Straight Traveling Circuit, Main Relief Valve, Overload Relief Valve |
| Travel Control Valve (with Damper) | 571-594 | General Description, Theory of Operation, Troubleshooting Testing and Adjustment, Removal, Disassembly, Cleaning and Inspection, Assembly, Installation |
| Hydraulic Schematic (Solar 300LL) | 595-600 | Hydraulic Schematic S0792035K, General Notes |
| Electrical System | 601-686 | Electrical System S0802220K, Electrical Schematic (Solar 300LL) S0892035K |
| Attachments | 687-696 | Boom and Stick S0902140K |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fuel Tank Capacity | 435 liters (115 U.S. gal.) | p. 119 |
| Standard 700 mm shoe (B) - Normal (New) Dimension | 18.0 mm (0.71 in) | p. 169 |
| Standard 700 mm shoe (B) - Recommended Limit for Maintenance | 14.0 mm (0.55 in) | p. 169 |
| Air filter cleaning interval | 500 hours | p. 189 |
| Torque Value for Ta | 44 - 49 kg·m (318 - 354 ft lb) | p. 221 |
| Torque Value for Tb | 20 - 22 kg·m (145 - 159 ft lb) | p. 221 |
| Power Mode Valve Current | 600 ±20 mA | p. 239 |
| Power Mode Valve Pressure | 4 ±2 bar (58 ±29 psi) | p. 239 |
| Hex socket bolt (22) tightening torque | 7,300 ±20 kg•cm | p. 369 |
| Hex head bolt (31) tightening torque | 690 ± 10 kg•cm | p. 369 |
| Engine Rated Output | 200 ps @ 1,900 rpm | p. 57 |
| Hydraulic Oil Tank Capacity | 205 liters | p. 57 |
Daewoo Solar 300LL, Solar 225LL Common Problems This Manual Covers
Daewoo Solar 300LL hydraulic functions weak and slow, boom and bucket lose power under load
Check hydraulic oil level in the reservoir; a low level pulls air into the pump inlet and kills power. Inspect the suction strainer for sludge and check every supply line clamp for air leaks. Test main relief pressure on the Solar 300LL against the 330 kg/cm2 spec on page 63; adjust or repair the relief valve if it reads low.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 63Hydraulic oil temperature climbs abnormally high during normal digging, power fades as machine heats up
Clean the oil cooler fins with compressed air and clear debris blocking airflow through the side screens. Verify hydraulic oil level; the Solar 300LL tank holds 205 liters, and running low speeds up heat buildup. Work through the high oil temperature checks starting on page 223, and change the hydraulic filter if the oil looks dark or smells burnt.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 223Track keeps derailing and undercarriage components wearing fast after work in muddy conditions
Measure grouser height on the standard 700 mm shoes; replace at 10.0 mm (0.39 in), and plan work once you hit the 14.0 mm maintenance limit on page 169. Measure front idler tread wear too, replacing at 188 mm (7.401 in) per page 172. Adjust track tension and wash mud out of the undercarriage daily to slow pin and bushing wear.
Manual Section: Lower Structure and Chassis p. 169Swing motor feels weak, machine swings but keeps coasting past the stop point
Test swing relief pressure with both swing locks engaged; you want 280 to 290 bar (4,060 to 4,205 psi) per page 251. Verify hydraulic brake release pressure reaches at least 13 bar (190 psi). If both pressure checks pass and the machine still coasts, inspect the swing motor makeup valve and time delay valve for sticking or wear.
Manual Section: Swing System Troubleshooting p. 251Engine hard to start, runs rough at idle with black smoke under load
Drain water and sediment from the fuel tank and replace both fuel filters before chasing anything else; contaminated fuel causes most hard starting and black smoke complaints. Clean the air filter element every 500 hours per the schedule on page 189, sooner in dusty conditions. Inspect intake hoses and clamps for cracks letting unfiltered air past the element.
Manual Section: Engine and Drive Train p. 189Frequently Asked Questions
What does code 0.2 mean on a Daewoo Solar 300LL?
If the e-EPOS indicator panel displays code "0.2," it indicates that the swing priority proportional valve is not functioning, except in the minimum "fail-safe" mode. You should refer to the Electrical section of the manual for more information. p. 251
How do I troubleshoot hydraulic pressure issues on a Solar 300LL?
To troubleshoot hydraulic pressure, first check the engine speed under load to ensure it meets the rated 1,900 rpm. If engine performance is adequate, inspect the e-EPOS self-diagnostic display and then check hydraulic functions in the following sequence: pilot pressure, negative control pressure, main relief pressure, swing pressure, port relief pressure, power boost circuit, and finally standard performance tests. p. 235
How do I check for error codes on a Daewoo Solar 300LL?
You can check the system operation status and malfunction codes through the display on top of the e-EPOS controller box, which is located in the drawer under the operator's seat. p. 673
What is the tightening torque for the main relief valve on the main control valve?
The tightening torque for the main relief valve on the main control valve is 10 kg•m (72 ft lb). p. 527
What is the recommended gear oil for the travel motor gearbox?
The recommended gear oil for the travel motor gearbox is GL-4 grade of service grouping API of SAE #90 equivalent. Do not mix oil of other types. p. 398
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