Complete repair service manual for Daewoo/Doosan Solar S200W-V Excavators with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Daewoo Solar S200W-V Excavators 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.
2023-7139E – Daewoo Solar S200W-V Shop Manual (Serial Number 0001 and Up).pdf
SHOP MAN.-TRAVEL MOTOR-MAIN PUMP.pdf
TENSOLRV0002 Solar V Model.pdf
TENSOLRV0004 Solar V Model.pdf
ELECTRIC SYSTEM OF SOLAR-V.pdf
Total Pages: 711 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Safety
Wheel Excavator Safety …S0102020
Specifications
Specifications for Solar 200W-V …S0202040
General Maintenance
General Maintenance Procedures …S0302000
Standard Torques …S0309000
Upper Structure
Cab …S0402020
Counterweight…S0403000
Fuel Tank…S0405070
Swing Bearing…S0407010
Swing Reduction Gearbox …S0408040
Lower Structure and Chassis
Ram Lock Valve Operation…S0503000
Engine and Drive Train
Front Axle …S0602100
Transmission, Final Drive and Rear Axle …S0602110
Air-Conditioner…S0605010
Drive Coupling (Main Pump)…S0609000
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment …S0702110
Accumulator…S0703000
Center Joint (Swivel)…S0704070
Cylinders…S0705000
Swing Motor…S0707250
Travel Motor…S0707350
MAin Pump (With Regulator, Steering Pump and Brake Pump) …S0708430
Brake Supply Valve …S0709220
Counterbalance Valve …S0709300
Main Control Valve (Toshiba dx28-60) …S0709440
Remote Control Valve (Work Lever / Joystick) …S0709450
Steering Valve …S0709710
Hydraulic Schematic (Solar 200W-V) …S0792100
Electrical System
Electrical System …S0802120
Electrical Schematic (Solar 200W-V)…S0892100
Attachments
Boom and Arm…S0902080
Bucket…S0904000
2023-7139E – Deawoo Solar S200W-V Shop Manual (Serial Number 0001 and Up)…2
Safety…8
Wheel Excavator Safety S0102020…10
To the Operator of a Daewoo Excavator…12
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…15
Work-site Precautions…16
Attachment Precautions…16
Avoid High-voltage Cables…16
Before Starting to Dig, Contact Authorities…16
Be Aware of Height Obstacles…16
Use Care on Loose Support…17
Use Solid Support Blocking…17
Overhangs Are Dangerous…17
Sloping Terrain Requires Caution…17
Stay Alert for People Moving through the Work Area…18
Be Aware of and Conform to Local Regulations…18
Operation…18
Operate While Seated at the Operator’s Station ONLY…18
Before Starting the Engine…19
Never Use Ether Starting Aids…19
Mounting and Dismounting…19
Observe General Safety Rules…20
Engine Ventilation…20
Asbestos Dust Hazard Prevention…20
Take Time to Provide Good Visibility…20
Fuel, Oil and Hydraulic Fluid Fire Hazards…21
Boost Starting or Charging Engine Batteries…21
Travel Controls May Produce Reversed Operations…22
Keep "Pinch Point" Areas Clear – Use Caution in Reverse & Swing…22
Travel Precautions…22
Operate Carefully on Snow and Ice and in Very Cold Temperatures…22
Parking the Machine…23
Shutdown Control Functions…23
Equipment…23
Rough Operation May Require Use of Certified Safety Equipment…23
Install Additional Safety Equipment If Conditions Require…24
Movement Alarms…24
Seat Belts Should Be Used at All Times…24
Window Glass Breaking Tool…25
Keep a Fire Extinguisher at Hand…25
Maintain Standard Safety Equipment in Good Condition…25
Safety-critical Parts Must Be Replaced Periodically…25
Hydraulic Cylinder Seals Require Periodic Replacement…26
High Pressure Hydraulic Lines Can Store a Great Deal of Energy…26
The Operator’s Cab and Turntable Deck Should Be Kept Clean…26
Wear Eye Protection and Safety Clothing…26
Breathing Masks, Ear Protection May Be Required…26
Battery Electrolyte and Explosive Gases Can Be Lethal…27
Disconnect Batteries for Electrical Service Before Electrical Welding…27
Use Low Heat Portable Lighting…27
Maintenance…27
Use Warning Tag Control Lockout Procedures During Service…27
Do not Run the Engine If Repairs or Work Is Being Performed Alone…28
Always Use Adequate Equipment Supports and Blocking…28
Do not Work on Hot Engines or Hot Cooling or Hydraulic Systems…28
Cool-down Is Required Prior to Radiator or Reservoir Checks…28
Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous…29
Obtain immediate medical attention if pressurized oil pierces the skin…29
Use Correct Replacement Fasteners Tightened to Proper Torque…29
Dispose of All Petroleum-based Oils and Fluids Properly…29
Shipping and Transportation…30
Obey State and Local Over-the-Road Regulations…30
Specifications…32
Specifications for Solar 200W-V S0202040…34
General Description…36
Component Location…37
General Dimensions…39
Dimensions…39
Working Range…41
Hydraulic Cylinders…43
Engine Specifications…44
Engine Performance Curves (Per KS-R1004 Standard)…46
Approximate Weight of Workload Materials…47
General Specifications…50
Hydraulic System Component Specifications…51
System Component Specifications…52
Drive System…52
Swing Mechanism…52
Brake System…53
Steering System…54
Chocking System…54
Performance Tests and Standards…55
Standards…55
Tests…56
Test Conditions…56
Travel Speed Tests…57
Swing Speed Test…58
Swing Speed Test…58
Swing Force Test…58
Cylinder Performance Tests…59
Boom Cylinders Test…59
Arm Cylinder Test…59
Hydraulic Cylinder Natural Drop Test…59
General Maintenance…60
General Maintenance Procedures S0302000…62
Welding Precautions and Guidelines…64
Hydraulic System – General Precautions…65
Maintenance Service and Repair Procedure…66
General Precautions…66
Hydraulic System Cleanliness And Oil Leaks…67
Maintenance Precautions for Hydraulic System Service…67
Oil Leakage Precautions…67
Cleaning and Inspection…68
General Guidelines…68
Bearing inspection…69
Standard Torques S0309000…76
Torque Values for Standard Metric Fasteners…78
Torque Values for Standard U.S. Fasteners…79
Type 8 Phosphate Coated Hardware…81
Torque Values for Hose Clamps…82
Torque Values for Split Flanges…83
Torque Wrench Extension Tools…84
Torque Multiplication…84
Other Uses for Torque Wrench Extension Tools…85
Tightening Torque Specifications (Metric)…85
Upper Structure…88
Cab S0402020…90
Removal…92
Installation…94
Window and Gasket Replacement…97
Falling Object Protective Structures (F.O.P.S.)…98
Counterweight S0403000…100
General…102
Removal…104
Installation…105
Fuel Tank S0405070…108
General Description…110
Parts List…111
Specifications…112
Removal…113
Installation…116
Start-up Procedures…117
Swing Bearing S0407010…118
Swing Bearing Maintenance…120
Operating Recommendation…120
Measuring Swing Bearing Axial Play…120
Measuring Bearing Lateral Play…120
Swing Bearing Basic Operation…121
Rebuilding Swing Bearing…121
Swing Reduction Gearbox S0408040…124
General Description…126
Theory of Operation…126
Parts List…127
Specifications…128
Special Tools and Materials…129
Special Tools…129
Troubleshooting, Testing and Adjustment…130
Removal…131
Disassembly…132
Cleaning and Inspection (Wear Limits and Tolerances)…137
Reassembly…138
Installation…147
Lower Structure and Chassis…148
Ram Lock Valve Operation S0503000…150
Theory of Operation…152
Engine and Drive Train…154
Front Axle S0602100…156
Special Tools…158
Hub Nut Tool…158
Disassembly…159
Planetary End…159
Differential Gear…166
Cleaning and Inspection (Wear Limits and Tolerances)…171
Reassembly…172
Differential Gear…172
Planetary End…183
Start-up Procedures…198
Axle Lubrication…198
Transmission, Final Drive and Rear Axle S0602110…200
Transmission Operation…203
Special Tools…204
Hub Nut Tool…204
Transmission Disassembly…205
Detaching Drive (Input) Housing…205
Disassembly of Input Shaft and Brake Assembly…206
Disassembly of Clutch…208
Disassembly of Planetary Carrier…213
Disassembly of Shift Lever and Helical Gear…214
Disassembly of Shift Lock (Version A)…219
Disassembly of Shift Lock (Version B)…221
Final Drive Disassembly…223
Rear Axle Disassembly…227
Differential Gear Disassembly…234
Cleaning and Inspection (Wear Limits and Tolerances)…239
Differential Gear Reassembly…240
Rear Axle Reassembly…252
Final Drive Reassembly…267
Transmission Reassembly…272
Reassembly of Helical Gear…272
Reassembly of Shift Lever…274
Reassembly of Planetary Carrier…275
Adjusting Shift Lever…277
Preassembling and Installing Clutch…278
Checking Clutch…285
Reassembly of Brake and Input Shaft Assembly…286
Installing Drive (Input) Housing…290
Assembly of Shift Lock (Version A)…293
Assembly of Shift Lock (Version B)…297
Installing Oil Pump…299
Installing Screw Plugs and Oil Lines…302
Start-up Procedures…303
Axle Lubrication…303
Lubrication…303
Air-Conditioner S0605010…304
General Description…306
Refrigerant Circulation…307
Control Panel…309
Control Specifications…310
Temperature Level Control and Display…311
Air Discharge According to Path Selection…312
Air-conditioning System Circuit Diagram…315
Troubleshooting…317
Refrigerant System Repairs…320
Refrigerant Safe Handling Procedures…320
Repair and Replacement Procedure…321
Refrigerant Recovery…323
Vacuuming Refrigerant System…323
Leakage Check…324
Refrigerant Charging…325
Inspecting System For Leakage…327
Drive Coupling (Main Pump) S0609000…328
Drive Coupling…330
Special Tools…331
Kawasaki Pump Tool…331
Uchida Pump Tool…333
Drive Coupling Installation…334
Installation Procedure…338
Hydraulics…340
Hydraulic System Troubleshooting, Testing and Adjustment S0702110…342
Hydraulic System – General Notes…345
Operation of Working Components…346
Boom Operating Circuit…346
Boom Up Circuit…346
Boom Down Circuit…346
Arm Operating Circuit…347
Arm Crowd Circuit…347
Arm Dump Circuit…347
Bucket Operating Circuit…348
Bucket Crowd Circuit…348
Bucket Dump Circuit…348
Swing Operating Circuit…349
Right Swing Operating Circuit…349
Left Swing Operating Circuit…349
Swing Relief Valve and Make-up Valve…349
Procedural Troubleshooting Baseline Recommendations…350
Initial Checks and Tests to Establish Operating Condition of the Excavator…350
Pilot Pressure…351
Adjustment and Testing…351
Power Mode Valve…352
Current Signal and Hydraulic Pressure Adjustments…352
Boom/Swing Priority Valve…353
Control Valve Pressure and Current Adjustments…353
Pressure Up Valve…355
Checks and Adjustments…355
Pump Input Power Control…356
Pump Regulator Adjustment…356
Flow Meter and Flow Meter Kit Installation and Testing…358
Swing System Troubleshooting…359
Precautions/Initial Checks…359
Swing Relief Valve Checking and Adjustment…360
Troubleshooting – Swing Gearbox…361
Troubleshooting – Hydraulic Problems…362
Troubleshooting – Control Valve…364
Troubleshooting – Joystick Control Valve…365
Accumulator S0703000…366
General Description…368
Specifications…369
Accumulator Charging…370
Charging the Accumulator with Nitrogen…370
Center Joint (Swivel) S0704070…372
General Description…374
Parts List…375
Troubleshooting, Testing and Adjustment…377
Inspection…377
Testing…377
Disassembly…378
Reassembly…379
Cylinders S0705000…380
General Description…382
Theory of Operation…382
Parts List…383
Special Tools and Materials…385
Piston Nut…385
Piston Jig…387
Disassembly…390
Reassembly…396
Swing Motor S0707250…400
General Description…402
Theory of Operation…402
Swing Motor Anti-cavitation Make-up Valve…403
Relief Valve…404
Swing Brake Operation…404
Parts List…407
Specifications…409
Special Tools…410
Disassembly…411
Cleaning and Inspection (Wear Limits and Tolerances)…418
Reassembly…420
Travel Motor S0707350…428
General Description…430
Theory of Operation…430
Parts List…431
Specifications…431
Travel Motor General Disassembly and Reassembly Instructions…432
Recommended Tools…432
Precautions for Disassembly and Assembly…432
Disassembly of Travel Motor…433
Appearance of Motor…433
Removal of counterbalance Valve…433
Removal of Outer Piping…434
Removal of Stroke Limiter…435
Removal of Oil Seal…436
Removal of Control Unit…436
Removal of Control Valve…438
Disassemble Control Valve…440
Disassemble Stroke Limiter…441
Reassemble Stroke Limiter…442
Reassemble Control Valve…442
Installation of Control Valve…443
Reassembly of Travel Motor…446
Assembly of Control Unit…446
Installation of Oil Seal…448
Installation of Stroke Limiter…449
Installation of Outer Piping…449
Installation of Counterbalance Valve…450
MAin Pump (With Regulator, Steering Pump and Brake Pump) S0708430…452
General Description…455
Gear (Pilot) Pump…457
Relief Valve…457
Pump Regulator Description…458
Horsepower Control…458
Power Shift Control…458
Negative Oil Discharge (Pump Bypass) Control…458
Pump Regulator Operation…459
Pump Output Decrease…461
Pump Discharge Decrease…461
Pump Discharge Increase…461
Horsepower Control…461
Overload Protection…462
Regulator Adjustment…462
Pump Input Power Control Adjustment…463
Parts List…465
Specifications…470
Hydraulic Pump Performance Characteristics…471
Troubleshooting, Testing and Adjustment…473
Main Pump…473
Disassembly…474
General Disassembly…474
Main Pump Disassembly…475
Pump Regulator Disassembly…477
Cleaning and Inspection (Wear Limits and Tolerances)…481
Reassembly…483
Pump Regulator Reassembly…483
Main Pump Reassembly…487
Brake Supply Valve S0709220…490
Parts List…493
Specifications…494
Counterbalance Valve S0709300…496
General Description…498
While Operating to Run Forward…498
While Operating to Stop…498
While Operating to Back…498
Adjustment of Relief Valve…499
Troubleshooting…500
Counterbalance Valve…501
Recommended Tools…501
Disassembly…501
Order of Disassembly and Torque Values…502
Reassembly…503
Main Control Valve (Toshiba dx28-60) S0709440…508
Control Valve Operation…512
Arm Priority Circuit…513
Bucket (Junction) Circuit…515
Main Relief Valve…517
Overload Relief Valve…518
Arm Load Holding Valve…520
Boom Load Holding Valve…523
Arm Regeneration…525
Boom Regeneration…527
Foot Relief Valve…528
Parts List…529
Specifications…538
Control Valve Drawing and Hydraulic Circuit…539
Disassembly and Reassembly…544
General Disassembly…544
General Reassembly…544
Plunger Replacement…545
Main Plunger Element – Disassembly and Assembly…546
Tool…546
Main Relief Valve…549
Overload Relief Valve…552
Arm Load Holding Valve…554
Boom Load Holding Valve…557
Arm Regeneration Valve…559
Bucket Unity Check…560
Foot Relief Valve…561
Center Bypass Valve (CB Valve)…562
Boom Parallel Switch Valve…563
Boom Unity Check Valve…565
Check Valve – Locations…566
Check Valve…567
Remote Control Valve (Work Lever / Joystick) S0709450…570
General Description…572
Theory of Operation…572
Parts List…573
Specifications…574
Hydraulic Specifications…575
Special Tools…576
Disassembly…577
Reassembly…582
Steering Valve S0709710…588
General Description…590
Theory of Operation…591
Parts List…593
Specifications…594
Disassembly and Reassembly…595
Tools Needed…595
Valve Disassembly…596
Valve Reassembly…602
Hydraulic Schematic (Solar 200W-V) S0792100…614
General Description…616
Solar 200W-V…617
General Notes…619
Electrical System…620
Electrical System S0802120…622
Troubleshooting – Electrical System…625
Wiring Harness Illustrations…626
Overview…626
Electric Supply System…627
Engine Starting Circuit…629
Operation During Start Process…629
Operation After Start Process…631
Engine Preheating System…633
Engine Stop System…634
Charging System…638
Monitoring System…639
Instrument Panel and Steering Console…640
iNstrument Panel and Steering Console Function Check…641
Monitoring System Schematic…643
Operation…645
Instruments…645
Mode Select Switch…646
Pilot Lamp…647
Initial Operation…648
Electronic Hydraulic Control System (EPOS – V)…649
Power Mode Control…651
Operation…653
Throttle Position Sensor…657
Power Mode Control – Circuit Diagram…658
Work Mode Control…659
Operation…660
Work Mode Control – Circuit Diagram…661
Engine Control System…662
Engine Control Motor…663
Engine Speed Control Dial…664
Engine Control Circuit Diagram…665
Automatic Deceleration Control (Auto Idle Control)…666
Engine Overheat Protection System…667
Power Boost Mode…668
Operation…668
Power Boost Control – Circuit Diagram…669
Cruise Control…671
Function…671
Cruse Control Circuit…673
Adjusting Method of Engine Control Unit…674
Adjusting Method of Engine Control System…674
Adjusting Method of Engine RPM…676
Adjustment of TPS (Throttle Position Sensor) (Refer to Figure 46 thru Figure 48)…682
Self-diagnostic Function…685
EPOS-V Controller…685
Engine Throttle Controller…689
Electrical Schematic (Solar 200W-V) S0892100…690
General Description…692
Solar 200W-V…693
Attachments…696
Boom and Arm S0902080…698
Front Attachment Pin Specifications…700
Front Attachment – Removal and Installation…701
Arm Removal Procedure…701
Boom Removal Procedure…703
Installation…704
Arm Installation Procedure…704
Boom Installation Procedure…704
Start-up Procedures…705
Bucket S0904000…706
Bucket Tooth Inspection and Replacement…708
Bucket O-ring Replacement…709
Bucket Shimming Procedures…711
New Bucket Installation…711
Shimming Procedures for Installed Bucket…711
Bucket Attachment, Removal and Reversal…712
Detaching the Bucket…712
Attaching The bucket…712
Reversing the Bucket…713
ELECTRIC SYSTEM OF SOLAR-V…714
SHOP MAN.-TRAVEL MOTOR-MAIN PUMP…816
TENSOLRV0002 Solar V Model…878
TENSOLRV0004 Solar V Model…1162
Daewoo Solar S200W-V Excavators Repair Service Manual