Complete official service manual for DAEWOO / DOOSAN SOLAR 180W-V EXCAVATOR, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
DAEWOO SOLAR 180W-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.
023-00068E – DAEWOO SOLAR 180W-V SHOP MANUAL (Serial Number 1001 and Up).pdf
SENS180 Electrical System.pdf
Total Pages: 988 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
Safety
Wheel Excavator Safety … S0102025K
Specifications
Specifications for Solar 180W-V … S0202065K
General Maintenance
General Maintenance Procedures …S0302000
Standard Torques ..S0309000
Upper Structure
Cab … S0402040K
Counterweight… S0403015K
Fuel Tank.. S0405105K
Fuel Transfer Pump …S0405500
Swing Bearing..S0407010
Swing Reduction Gearbox …S0408050
Lower Structure and Chassis
Ram Lock Valve Operation..S0503000
Engine and Drive Train
Front Axle (ZF-Axle) ..S0602120
Rear Axle (ZF-Axle) …S0602130
Air-Conditioner.. S0605060K
Transmission (ZF 2HL-100)…S0607050
Drive Coupling (Main Pump)… S0609010K
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment … S0702155K
Accumulator.. S0703010K
Center Joint (Swivel)..S0704070
Cylinders..S0705000
Swing Motor…S0707260
Travel Motor.. S0707351K
Main Pump.. S0708307K
Brake Supply Valve …S0709220
Counterbalance Valve …S0709300
Main Control Valve (Toshiba DX28) ..S0709440
Pilot Control Valve (Work Lever / Joystick)… S0709451K
Steering Valve …S0709710
Dozer Control Valve.. S0709905K
Hydraulic Schematic (SOLAR 180W-V) … S0792142K
Electrical System
Electrical System .. S0802125K
Electrical Schematic (Solar 180W-V).. S0892145K
Attachments
Boom and Arm…S0902120
Bucket..S0904000
Publication Request for Proposed Revision
023-00068E – DAEWOO SOLAR 180W-V SHOP MANUAL (Serial Number 1001 and Up)…2
Safety…8
Wheel Excavator Safety S0102025K…10
To the Operator of a Daewoo Excavator…12
Learn the Signal Words Used with the Safety Alert Symbol…14
General Safety Essentials…15
Accessory Applications…15
Lifting Capacity Rating Configuration…15
Location of Safety Labels…15
Summary of Safety Precautions for Lifting in Digging Mode…16
Unauthorized Modifications…17
General Hazard Information…17
Safety Rules…17
Safety Features…17
Inside Operator's Compartment…18
Clothing and Personal Protective Items…19
Breathing Masks, Ear Protection May be Required…19
Mounting and Dismounting…20
Fuel, Oil and Hydraulic Fluid Fire Hazards…21
Precautions When Handling Fluids at High Temperature…21
Asbestos Dust Hazard Prevention…22
Injury from Work Equipment…22
Fire Extinguisher and First Aid Kit…23
Protection from Falling or Flying Objects…23
Attachment Precautions…24
Accumulator…24
Indoor Ventilation…25
Emergency Exit…25
Before Starting Engine…26
Work Site Precautions…26
Checks Before Starting Engine…27
Engine Starting…28
Before Operating Machine…28
Machine Operation…29
When Swinging or Changing Direction of Travel…29
Travel Precautions…29
Traveling on Slopes…30
Prohibited Operations…31
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…38
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…46
Specifications for Solar 180W-V S0202065K…48
General Description…50
Component Location…51
General Dimensions…54
Dimensions…54
Working Range…55
Hydraulic Cylinders…58
Engine Specifications…59
Engine Performance Curves (Per KS-R1004 Standard)…61
Approximate Weight of Workload Materials…63
General Specifications…66
Hydraulic System Component Specifications…68
System Component Specifications…69
Drive System…69
Swing Mechanism…69
Brake System…70
Steering System…70
Chocking System…70
Performance Tests and Standards…71
Standards…71
Tests…72
Test Conditions…72
Travel Speed Tests…73
Swing Speed Test…74
Swing Speed Test…74
Swing Force Test…74
Cylinder Performance Tests…75
Boom Cylinders Test…75
Arm Cylinder Test…75
Bucket Cylinder Test…75
Hydraulic Cylinder Natural Drop Test…75
General Maintenance…76
General Maintenance Procedures S0302000…78
Welding Precautions and Guidelines…80
Hydraulic System – General Precautions…81
Maintenance Service and Repair Procedure…82
General Precautions…82
Hydraulic System Cleanliness and Oil Leaks…83
Maintenance Precautions for Hydraulic System Service…83
Oil Leakage Precautions…83
Cleaning and Inspection…84
General Guidelines…84
Bearing inspection…85
Standard Torques S0309000…92
Torque Values for Standard Metric Fasteners…94
Torque Values for Standard U.S. Fasteners…95
Type 8 Phosphate Coated Hardware…97
Torque Values for Hose Clamps…98
Torque Values for Split Flanges…99
Torque Wrench Extension Tools…100
Torque Multiplication…100
Other Uses for Torque Wrench Extension Tools…101
Tightening Torque Specifications (Metric)…101
Upper Structure…104
Cab S0402040K…106
Removal…108
Installation…111
Counterweight S0403015K…114
General…116
Removal…118
Installation…120
Fuel Tank S0405105K…122
General Description…124
Parts List…125
Specifications…126
Removal…127
Installation…132
Start-up Procedures…135
Fuel Transfer Pump S0405500…136
General Description…138
Theory of Operation…138
Troubleshooting…139
Replacement of Rotor and Vane…139
Replacement of Rear Cover…140
Replacement of Armature…141
Swing Bearing S0407010…142
Swing Bearing Maintenance…144
Operating Recommendation…144
Measuring Swing Bearing Axial Play…144
Measuring Bearing Lateral Play…144
Swing Bearing Basic Operation…145
Rebuilding Swing Bearing…145
Swing Reduction Gearbox S0408050…148
General Description…150
Theory of Operation…150
Parts List…151
Specifications…152
Special Tools and Materials…153
Special Tools…153
Troubleshooting, Testing and Adjustment…155
Removal…156
Disassembly…158
Cleaning and Inspection (Wear Limits and Tolerances)…161
Reassembly…163
Installation…168
Lower Structure and Chassis…170
Ram Lock Valve Operation S0503000…172
Theory of Operation…174
Engine and Drive Train…176
Front Axle (ZF-Axle) S0602120…178
APL-B755…183
Inscriptions On the Model Identification Plate (For ZF-Axles)…184
Examples of Gear-tooth Contact Patterns for the Gleason Gear-tooth System…185
Lubrication and Maintenance Instructions…188
Oil Quality…188
Oil Change…188
List of Lubricants TE-ML 05…191
Brake Lining – Wear Test On ZF-Axles of the Series AP (L) – B 700…192
Carry Out Wear Test…192
Dimension "X" – Dimension "Y" = Actual Value (Piston Stroke + Wear)…193
Special Tools…194
Final Drive – Disassembly…202
Planetary Carrier…202
Internal Gear…204
Hub…208
Steering Knuckle Hull…209
Double joint Shaft…211
Axle Housing…212
Final Drive – Reassembly…213
Axle Housing and Double joint Shaft…213
Steering Knuckle Hull…216
Adjusting Steering Knuckle Bearing…217
Check Rolling Resistance of the Steering Knuckle Bearing…220
Hub – Wheel Bearing…220
Adjust and Check the Rolling Moment of the Wheel Bearing…220
Internal Gear…225
Multidisk Brake…237
Planetary Gears…244
Illustrated Table…248
Drive Unit / Differential Disassembly…249
Disassemble Differential…249
Disassemble Differential…252
Remove Drive Pinion…253
Drive Unit / differential – Reassembly…256
Determine Thickness of Shim – To Obtain A Correct Contact Pattern…256
Install Drive Pinion…261
Adjust Rolling Moment of the Drive Pinion Bearing…262
Complete and Install Differential…266
Determine and Adjust Backlash of the Crown…272
Check Contact Pattern…275
Only for Version – 100% Lock Install Shut off Slide and Piston…276
Axle Bolting…277
Mount Final Drive…279
Illustrated Tables…281
Steering Assembly – Disassembly…285
Remove Tie Rod…285
Remove Piston and Cylinder…287
Steering Assembly – Reassembly…290
Install Guide, Cylinder and Piston…290
Adjust Track and Steering Lock…294
Illustrated Table…304
Rear Axle (ZF-Axle) S0602130…306
Examples of Gear-tooth-contact Patterns for the Gleason Gear-tooth System…309
Ideals Tooth-contact Pattern I.E. Pinion Distance Is Correct…309
Inscriptions on the Model Identification Plate (For ZF-Axles)…312
Lubrication and Maintenance Instructions…312
Technical Data…313
Adjustment Values Final Drive…314
Drive Unit/differential…314
Brake Lining Wearing Test…314
Carry Out the Wearing Test…315
Special Tools…316
Final Drive (Planetary) Disassembly…321
Loosen Slotted Nut…323
Drive Unit – Differential Disassembly…328
Remove Differential…328
Dismantle Differential…329
Remove Drive Pinion…331
Cleaning and Inspection (Wear Limits and Tolerances)…334
Drive Unit – Differential Reassembly…335
Drive Pinon…335
Complete and Install Differential…342
Final Drive (Planetary) Reassembly…350
Hub Carrier…350
Hub…351
Internal Gear…355
Tighten Slotted Nut…359
Multi disk Brake…361
Planetary Carrier…365
Air-Conditioner S0605060K…370
General Description…372
Refrigerant Circulation…374
Control Panel…376
Control Specifications…377
Temperature Level Control and Display…378
Air Discharge According to Path Selection…379
Air-conditioning System Circuit Diagram…381
Troubleshooting…383
Weight of R134a Gas Used In Machines…385
Refrigerant System Repairs…387
Refrigerant Safe Handling Procedures…387
Repair and Replacement Procedure…388
Refrigerant Recovery…390
Vacuuming Refrigerant System…390
Leakage Check…391
Refrigerant Charging…392
Inspecting System For Leakage…394
Transmission (ZF 2HL100) S0607050…396
Transmission Design and Options…399
Power Flow…399
Transmission Design…399
Shift Control…400
Instructions for Starting, Operation and Maintenance…401
Oil Capacity…401
Admitted Oils…401
Installation View and Instructions for the Oil Filling Procedure…402
Gearbox and Axle…402
Instructions for Moving the Vehicle or An Emergency Towing…404
Examples of Gear-tooth-contact Patterns for the Gleason Gear-tooth System…405
Disassembly…408
Separate Gearbox From Axle…408
Remove Shifting Clutches…409
Remove and Dismantle Planetary Drive…417
Remove and Dismantle Declutch Unit and Spur Gear…418
Dismantle Shift Lock…423
Disassemble Final Drive, Axle Carrier and Differential…425
Assembly…431
Axle Carrier, Final Drive and Differential Version "A" – Gearbox Attached on the Axle…431
Install Helical Gear and Declutch Unit…445
Complete and Install Planetary Carrier…448
Pre-assemble and Install Clutch (Road Gear)…450
Install Brake (Cross-country Gear)…460
Install Drive Casing…464
Pre-assemble and Mount Shift Lock…468
Pre-assemble and Install Control Spool…469
Install Lubricating Oil Pump…471
Mount Screw Plugs and Oil Lines…474
Mount Gearbox on the ZF-axle…475
Disassemble Final Drive…477
Install Final Drive…480
Drive Coupling (Main Pump) S0609010K…486
Drive Coupling…488
Special Tools…491
Drive Coupling Installation…493
Installation Procedure…495
Hydraulics…496
Hydraulic System Troubleshooting, Testing and Adjustment S0702155K…498
Hydraulic System – General Notes…501
Hydraulic Schematic…502
General Notes…502
Operation of Working Components…503
Boom Operating Circuit…503
Boom Up Circuit…503
Boom Down Circuit…503
Arm Operating Circuit…504
Arm Crowd Circuit…504
Arm Dump Circuit…504
Bucket Operating Circuit…505
Bucket Crowd Circuit…505
Bucket Dump Circuit…505
Swing Operating Circuit…505
Right Swing Operating Circuit…506
Left Swing Operating Circuit…506
Swing Relief Valve and Make-up Valve…506
Travel Operating Circuit…506
Forward Travel Circuit…507
Reverse Travel Circuit…507
Procedural Troubleshooting Baseline Recommendations…508
Initial Checks and Tests to Establish Operating Condition of the Excavator…508
Pilot Pressure…509
Adjustment and Testing…509
Power Mode Valve…510
Current Signal and Hydraulic Pressure Adjustments…510
Boom/Front Priority Valve…511
Control Valve Pressure and Current Adjustments…511
Pressure Up Valve…512
Checks and Adjustments…512
Pump Input Power Control…514
Pump Regulator Adjustment…514
Flow Meter and Flow Meter Kit Installation and Testing…517
Swing System Troubleshooting…519
Precautions/Initial Checks…519
Swing Relief Valve Checking and Adjustment…519
Troubleshooting – Swing Gearbox…521
Troubleshooting – Hydraulic Problems…523
Troubleshooting – Control Valve…525
Troubleshooting – Travel Control Valve…527
Troubleshooting – Joystick Control Valve…528
Accumulator S0703010K…530
General Description…532
Specifications…533
Center Joint (Swivel) S0704070…536
General Description…538
Parts List…539
Troubleshooting, Testing and Adjustment…541
Inspection…541
Testing…541
Disassembly…542
Reassembly…543
Cylinders S0705000…544
General Description…546
Theory of Operation…546
Parts List…547
Special Tools and Materials…549
Piston Nut…549
Piston Jig…553
Steel bush Jig…557
Dust Wiper Jig…561
Slipper Seal Jig…567
Slipper Seal Straightening Jig…571
Disassembly…574
Assembly…580
Swing Motor S0707260…584
General Description…586
Theory of Operation…586
Swing Motor Anti-cavitation Make-up Valve…587
Relief Valve…588
Swing Brake Operation…589
Parts List (Solar 140W-V, 160W-V)…591
Parts List (Solar 170LC-V, 170W-V, 175LC-V, 180W-V, 450LC-V, 470LC-V)…593
Specifications…595
Special Tools (Solar 140W-V, 160W-V)…596
Special Tools (Solar 170LC-V, 170W-V, 180W-V)…597
Special Tools (Solar 450LC-V, 470LC-V)…598
Disassembly…599
Cleaning and Inspection (Wear Limits and Tolerances)…606
Reassembly…608
Travel Motor S0707351K…616
Sectional View…619
Seal Kits and Component Groups…620
Seal Kits and Component groups / Replace Seal Nut…623
Sealing the Drive Shaft…625
Sealing of the Control Parts…627
Sealing of the Relief Valve / Counter- Balance Valve…630
Spare Parts List Counter-Balance Valve…631
Spare Parts list Brake Release Valve (Pos. 50)…632
Shuttle Valve (Pos. 25)…633
Disassembly of the Port Plate…634
Remove of the Positioning Piston…636
Remove Rotary Group…638
Exchanging of the rotary group…640
Complete Rotary Group…640
Rotary Group…640
Inspection Notes…642
Rotary Group Assembly…645
Rotary Group Adjustment (see service information)…648
Assembly of the Port Plate…650
Tightening Torques…652
Safety Regulations…654
General Advice…654
Before starting…654
Start…654
Hydraulic Equipment…655
Main Pump S0708307K…656
Section…659
General Repair Guidelines…660
Seal Kits and Sub-assemblies…662
Sealing the Drive Shaft…666
Gear Pump Sealing…669
Remove the control housing…670
Control Module…673
Removing the Controller…675
Valve Plate with Valves…677
Remove the Rotary Groups…678
Dismantling the Rotary Group…681
Remove the Intermediate Wheel…683
Remove Auxiliary Drive…685
Inspection Hints…688
Complete rotary group…691
Re-fitting the rotary group…693
Pump Assembly…695
Assembly guideline:…697
Hydraulic Component – Measurement "D"…698
Fit Control Housing…702
Assembly of the intermediate wheel…707
Fit the Gear Pump…709
Fit the Cover / Auxiliary Drive…710
Tightening Torques…711
Brake Supply Valve S0709220…714
Parts List…717
Specifications…718
Counterbalance Valve S0709300…720
General Description…722
While Operating to Run Forward…722
While Operating to Stop…722
While Operating to Back…722
Adjustment of Relief Valve…723
Troubleshooting…724
Counterbalance Valve…725
Recommended Tools…725
Disassembly…725
Order of Disassembly and Torque Values…726
Reassembly…727
Main Control Valve (Toshiba DX28) S0709440…732
Control Valve Operation…736
Arm Priority Circuit…737
Bucket (Junction) Circuit…739
Main Relief Valve…741
Overload Relief Valve…742
Arm Load Holding Valve…744
Boom Load Holding Valve…747
Arm Regeneration…749
Boom Regeneration…751
Foot Relief Valve…752
Parts List…753
Specifications…762
Control Valve Drawing and Hydraulic Circuit…763
Disassembly and Reassembly…768
General Disassembly…768
General Reassembly…768
Plunger Replacement…769
Main Plunger Element – Disassembly and Assembly…770
Tool…770
Main Relief Valve…773
Overload Relief Valve…776
Arm Load Holding Valve…778
Boom Load Holding Valve…781
Arm Regeneration Valve…783
Bucket Unity Check…784
Foot Relief Valve…785
Center Bypass Valve (CB Valve)…786
Boom Parallel Switch Valve…787
Boom Unity Check Valve…789
Check Valve – Locations…790
Check Valve…791
Pilot Control Valve (Work Lever / Joystick) S0709451K…794
General Description…796
Theory of Operation…796
Parts List…797
Specifications…798
Removal…799
Disassembly…802
Cleaning and Inspection (Wear Limits and Tolerances)…806
Reassembly…807
Installation…812
Start-up Procedures…813
Steering Valve S0709710…814
General Description…816
Theory of Operation…817
Parts List…819
Specifications…820
Special Tools and Materials…821
Special Tools…821
Disassembly…823
Reassembly…832
Dozer Control Valve S0709905K…846
Parts List…848
Specifications…849
Hydraulic Schematic (SOLAR 180W-V) S0792142K…850
General Description…852
Solar 180W-V with Standard Boom…853
Solar 180W-V with Articulated Boom…855
Electrical System…858
Electrical System S0802125K…860
Troubleshooting – Electrical System…865
Overview…866
Electric Supply System…867
Engine Starting Circuit…868
Operation During Start Process…868
Operation After Start Process…869
Engine Preheating System…870
Engine Stop System…871
Charging System…874
Monitoring System…876
Instrument Panel…878
Monitoring System Schematic…880
Operation…882
Instruments…882
Warning and Indicator Lights…884
Control Unit…886
Operation Schematic…886
Operation Specification…887
Console Warning Light…888
Initial Operation…890
Mode Select Switch…891
Power Mode / Trenching Mode Switch…891
Auto Idle Switch…891
Graphic Information Area Display…892
Overview…892
Main Menus for the Graphic Display Area…893
Menu Selection Buttons…893
Main Menu…894
Language setting…894
Time Setting…894
Filter/Oil information…895
Special Menu…896
Entering/Accessing and Exiting/Escaping Menus…896
Special Menu Selections…897
Electronic Hydraulic Control System (e-EPOS)…910
Power Mode Control…912
Operation…913
Throttle Position Sensor…916
Power Mode Control – Circuit Diagram…917
Work Mode Control…919
Operation…920
Work Mode Control – Circuit Diagram…921
Engine Control System…922
Engine Control Motor…923
Engine Control Dial…924
Engine Control Circuit Diagram…925
Automatic Deceleration Control (Auto Idle Control)…926
Automatic Deceleration Control Circuit…927
Operation…928
Engine Overheat Protection System…929
Power Boost Mode…930
Operation…930
Power Boost Control – Circuit Diagram…931
Cruise Control…933
Run Method…934
Cancel…934
Cruise Operation…934
Cruise Control Circuit…935
Adjusting Method of Engine Control Unit…937
Adjusting Method of Engine Control System…937
Adjusting Method of Engine RPM…939
Adjustment of TPS (Throttle Position Sensor)…944
Self-diagnostic Function…949
e-EPOS Controller…949
Engine Throttle Controller…953
Wiper System…955
Wiper Circuit…955
Wiper Operation…955
Window Washer Operation…956
Overload Warning Device…957
Overload Warning Device Circuit Diagram…957
Electrical Schematic (Solar 180W-V) S0892145K…958
General Description…960
Solar 180W-V…961
Attachments…964
Boom and Arm S0902120…966
Front Attachment Pin Specifications…968
Front Attachment – Removal and Installation…969
Arm Removal Procedure…969
Boom Removal Procedure…971
Installation…972
Arm Installation Procedure…972
Boom Installation Procedure…972
Start-up Procedures…973
Bucket S0904000…974
Bucket Tooth Inspection and Replacement…976
Type 1…976
Type 2…977
Type 3…978
Bucket O-ring Replacement…980
Type 1…980
Type 2…981
Bucket Shimming Procedures…983
New Bucket Installation…983
Type 1…983
Type 2…984
Bucket Attachment, Removal and Reversal…985
Detaching the Bucket…985
Attaching The bucket…985
Reversing the Bucket…986
Publication Request for Proposed Revision…988
SENS180 Electrical System…990
DAEWOO SOLAR 180W-V EXCAVATOR Service Repair Manual