Complete service manual for Deawoo Solar S140W-V, S160W-V Excavator, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Deawoo Solar S140W-V, S160W-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.
Deawoo Solar S140W-V, S160W-V Excavator Shop Manual.pdf
Total Pages: 853 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
Return to Master Table of Contents
Safety
Wheel Excavator Safety … S0102025K
Specifications
Specifications for S140W-V / 160W-V .. S0202055K
General Maintenance
General Maintenance Procedures …S0302000
Standard Torques ..S0309000
Upper Structure
Cab … S0402040K
Counterweight… S0403015K
Fuel Tank.. S0405045K
Fuel Transfer Pump …S0405500
Swing Bearing..S0407010
Swing Reduction Gearbox .. S0408025K
Lower Structure and Chassis
Ram Lock Valve Operation..S0503000
Engine and Drive Train
Front Axle (Dana) … S0602055K
Rear Axle (Dana) .. S0602056K
Air-Conditioner.. S0605060K
Transmission (ZF 2HL-100).. S0607055K
Drive Coupling (Main Pump)..S0609000
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment … S0702065K
Accumulator.. S0703010K
Center Joint (Swivel)..S0704070
Cylinders..S0705000
Swing Motor…S0707260
Travel Motor…S0707350
Main Pump (Tongmyung) … S0708306K
Gear Pump (Steering Pump & Brake Pump) .. S0708435K
Brake Supply Valve …S0709220
Counterbalance Valve …S0709300
Main Control Valve … S0709416K
Pilot Control Valve (Work Lever / Joystick)… S0709451K
Steering Valve …S0709710
Dozer Control Valve.. S0709905K
Hydraulic Schematic (S140W-V / 160W-V) .. S0792145K
Electrical System
Electrical System .. S0802125K
Electrical Schematic (S140W-V / 160W-V)… S0892075K
Attachments
Boom and Arm…S0902060
Bucket..S0904000
Publication Request for Proposed Revision
Safety…7
Wheel Excavator Safety S0102025K…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…18
Breathing Masks, Ear Protection May be Required…18
Mounting and Dismounting…19
Fuel, Oil and Hydraulic Fluid Fire Hazards…20
Precautions When Handling Fluids at High Temperature…20
Asbestos Dust Hazard Prevention…21
Injury from Work Equipment…21
Fire Extinguisher and First Aid Kit…22
Protection from Falling or Flying Objects…22
Attachment Precautions…23
Accumulator…23
Indoor Ventilation…24
Emergency Exit…24
Before Starting Engine…25
Work Site Precautions…25
Checks Before Starting Engine…26
Engine Starting…27
Before Operating Machine…27
Machine Operation…28
When Swinging or Changing Direction of Travel…28
Travel Precautions…28
Traveling on Slopes…29
Prohibited Operations…30
Precautions for Operation…30
Avoid High-voltage Cables…31
Operate Carefully on Snow, Ice and in Very Cold Temperatures…31
Operations on Slopes…32
Parking Machine…32
Never Let Anyone Ride on Attachment…32
Maintenance…33
Warning Tag…33
Clean Before Inspection or Maintenance…33
Proper Tools…34
Use of Lighting…34
Fire Prevention and Explosion Prevention…34
Burn Prevention…35
Welding Repairs…36
Warning for Counterweight and Front Attachment Removal…36
Precautions for Removal, Installation, and Storage of Attachments…37
Precautions when Working on Machine…37
Lock Inspection Covers…37
Crushing Prevention and Cutting Prevention…37
Supports and Blocking for Work Equipment…38
Action When Abnormally Is Found During Inspection…39
Precautions with High Pressure Line, Tubes and Hoses…39
Waste Materials…40
Battery…41
Battery Hazard Prevention…41
Boost Starting or Charging Engine Batteries…42
Towing…43
Precautions When Towing…43
Shipping and Transportation…44
Obey State and Local Over-the-Road Regulations…44
Lifting With Sling…44
Specifications…45
Specifications for S140W-V / 160W-V S0202055K…47
General Description…50
Component Location…51
SOLAR 140W-V…53
General Dimensions…53
Working Range…54
SOLAR 160W-V…56
General Dimensions…56
Working Range…57
Front Linkage Pin Size…59
Hydraulic Cylinders…60
Engine Specifications…61
Engine Performance Curves (Per DIN 6270 Standard)…63
Approximate Weight of Workload Materials…64
General Specifications…67
Hydraulic System Component Specifications…69
System Component Specifications…70
Drive System…70
Swing Mechanism…70
Brake System…71
Steering System…72
Chocking System…72
Performance Tests and Standards…73
Standards…73
Tests…74
Test Conditions…74
Travel Speed Tests…75
Swing Speed Test…76
Swing Speed Test…76
Swing Deceleration Force Test…76
Cylinder Performance Tests…77
Boom Cylinders Test…77
Arm Cylinder Test…77
Bucket Cylinder Test…77
Hydraulic Cylinder Natural Drop Test…77
General Maintenance…79
General Maintenance Procedures S0302000…81
Welding Precautions and Guidelines…83
Hydraulic System – General Precautions…84
Maintenance Service and Repair Procedure…85
General Precautions…85
Hydraulic System Cleanliness and Oil Leaks…86
Maintenance Precautions for Hydraulic System Service…86
Oil Leakage Precautions…86
Cleaning and Inspection…87
General Guidelines…87
Bearing inspection…88
Standard Torques S0309000…95
Torque Values for Standard Metric Fasteners…97
Torque Values for Standard U.S. Fasteners…98
Type 8 Phosphate Coated Hardware…100
Torque Values for Hose Clamps…101
Torque Values for Split Flanges…102
Torque Wrench Extension Tools…103
Torque Multiplication…103
Other Uses for Torque Wrench Extension Tools…104
Tightening Torque Specifications (Metric)…104
Upper Structure…107
Cab S0402040K…109
Removal…111
Installation…114
Counterweight S0403015K…117
General…119
Removal…121
Installation…123
Fuel Tank S0405045K…125
General Description…127
Parts List…128
Specifications…129
Removal…130
Installation…134
Start-up Procedures…136
Fuel Transfer Pump S0405500…137
General Description…139
Theory of Operation…139
Troubleshooting…140
Replacement of Rotor and Vane…140
Replacement of Rear Cover…141
Replacement of Armature…142
Swing Bearing S0407010…143
Swing Bearing Maintenance…145
Operating Recommendation…145
Measuring Swing Bearing Axial Play…145
Measuring Bearing Lateral Play…145
Swing Bearing Basic Operation…146
Rebuilding Swing Bearing…146
Swing Reduction Gearbox S0408025K…149
General Description…151
Theory of Operation…151
Parts List…152
Special Tools and Materials…154
Special Tools…154
Troubleshooting, Testing and Adjustment…155
Removal…156
Disassembly…158
Reassembly…160
Installation…162
Lower Structure and Chassis…163
Ram Lock Valve Operation S0503000…165
Theory of Operation…167
Engine and Drive Train…169
Front Axle (Dana) S0602055K…171
Introduction…174
Introductory Remarks…174
Maintenance and Lubricant…175
Definition of Viewpoints…175
Data Plate…175
Maintenance Points…176
Maintenance Intervals…177
Adjustment and Checks…177
Tightening Torques…178
Screw-locking, Sealing and Lubricating Materials…179
Notes on Safety Precautions…181
Checking Wear and Replacing Brake Disks…182
Disassembly of Brake Units…182
Assembly of Brake Units…186
Steering Case…189
Removal and Disassembly…189
Assembly and Installation…193
U-Joint…195
Notes on Safety Precautions…195
Removal and Disassembly…196
Assembly and Installation…200
Planetary Reduction…203
Disassembly…203
Assembly…209
Steering Cylinder…215
Removal…215
Installation…218
Disassembly…222
Assembly…225
Differential Unit…228
Removal and Disassembly…228
Assembly, Adjusting and Installation…234
Bevel Pinion…241
Removal…241
Adjusting and Installation…245
Special Tools…253
Troubleshooting…259
Rear Axle (Dana) S0602056K…263
Introduction…265
Introductory Remarks…265
Maintenance and Lubricant…266
Definition of Viewpoints…266
Data Plate…266
Maintenance Points…267
Maintenance Intervals…268
Adjustment and Checks…268
Tightening Torques…270
Screw-locking, Sealing and Lubricating Materials…271
Notes on Safety Precautions…273
Checking Wear and Replacing Brake Disks…274
Disassembly of Brake Units…274
Assembly of Brake Units…277
Planetary Reduction and Axle Shaft…280
Notes on Safety Precautions…280
Disassembly…281
Assembly…286
Bevel Pinion…292
Removal…292
Adjusting and Installation…297
Special Tools…306
Troubleshooting…312
Air-Conditioner S0605060K…315
General Description…317
Refrigerant Circulation…319
Control Panel…321
Control Specifications…322
Temperature Level Control and Display…323
Air Discharge According to Path Selection…324
Air-conditioning System Circuit Diagram…326
Troubleshooting…328
Weight of R134a Gas Used In Machines…331
Refrigerant System Repairs…333
Refrigerant Safe Handling Procedures…333
Repair and Replacement Procedure…334
Refrigerant Recovery…336
Vacuuming Refrigerant System…336
Leakage Check…337
Refrigerant Charging…338
Inspecting System For Leakage…340
Transmission (ZF 2HL-100) S0607055K…341
Specifications…344
Transmission Operation…345
Transmission Disassembly…346
Detaching Drive (Input) Housing…346
Disassembling Input Shaft Assembly…347
Disassembling Planetary Drive…354
Disassembling Clutch and Spur Gear…355
Disassembling Shift Lock…360
Final Drive, Drive Shaft and Differential Disassembly…362
Transmission Reassembly…367
Shimming Drive Pinion…367
Reassembling Drive Pinion…368
Adjusting Rolling Resistance of Drive Pinion Bearing…372
Installing Differential…374
Adjusting Backlash and Bearing Preload…378
Installing Helical Gear and Clutch…379
Installing Planetary Carrier…383
Adjusting Shift Lever…384
Preassembling and Installing Clutch…385
Checking Clutch…392
Installing Brake…393
Installing Drive Casing…397
Drive Pinion / Crown Wheel Contact Pattern…401
Correct Pattern…401
Increase Pinion Distance…401
Decrease Pinion Distance…402
Transmission Governor…403
Parts List…403
Disassembly of Governor…405
Reassembly of Governor…406
Drive Coupling (Main Pump) S0609000…407
Drive Coupling…409
Special Tools…410
Kawasaki / Tong Myung Pump Tool…410
Uchida Pump Tool…413
Drive Coupling Installation…414
Installation Procedure…419
Hydraulics…421
Hydraulic System Troubleshooting, Testing and Adjustment S0702065K…423
Hydraulic System – General Notes…426
Hydraulic Schematic…428
General Notes…428
Operation of Working Components…429
Boom Operating Circuit…429
Boom Up Circuit…429
Boom Down Circuit…429
Arm Operating Circuit…430
Arm Crowd Circuit…430
Arm Dump Circuit…431
Bucket Operating Circuit…431
Bucket Crowd Circuit…431
Bucket Dump Circuit…432
Swing Operating Circuit…432
Right Swing Operating Circuit…432
Left Swing Operating Circuit…433
Swing Relief Valve and Make-up Valve…433
Procedural Troubleshooting Baseline Recommendations…434
Initial Checks and Tests to Establish Operating Condition of the Excavator…434
Pilot Pressure…435
Adjustment and Testing…435
Power Mode Valve…436
Current Signal and Hydraulic Pressure Adjustments…436
Swing Priority Valve…437
Control Valve Pressure and Current Adjustments…437
Pressure Up Valve…438
Checks and Adjustments…438
Pump Input Power Control…440
Pump Regulator Adjustment…440
Flow Meter and Flow Meter Kit Installation and Testing…444
Swing System Troubleshooting…446
Precautions/Initial Checks…446
Swing Relief Valve Checking and Adjustment…446
Troubleshooting – Swing Gearbox…448
Troubleshooting – Hydraulic Problems…450
Troubleshooting – Control Valve…452
Troubleshooting – Travel Pedal Valve…454
Troubleshooting – Joystick Control Valve…455
Accumulator S0703010K…457
General Description…459
Specifications…460
Center Joint (Swivel) S0704070…463
General Description…465
Parts List…466
Troubleshooting, Testing and Adjustment…468
Inspection…468
Testing…468
Disassembly…469
Reassembly…470
Cylinders S0705000…471
General Description…473
Theory of Operation…473
Parts List…474
Special Tools and Materials…476
Piston Nut…476
Piston Jig…480
Steel bush Jig…484
Dust Wiper Jig…488
Slipper Seal Jig…494
Slipper Seal Straightening Jig…498
Disassembly…501
Assembly…507
Swing Motor S0707260…511
General Description…513
Theory of Operation…513
Swing Motor Anti-cavitation Make-up Valve…514
Relief Valve…515
Swing Brake Operation…516
Parts List (Solar 140W-V, 160W-V)…518
Parts List (Solar 170LC-V, 170W-V, 450LC-V, 470LC-V)…520
Specifications…522
Special Tools (Solar 140W-V, 160W-V)…523
Special Tools (Solar 170LC-V, 170W-V)…524
Special Tools (Solar 450LC-V, 470LC-V)…525
Disassembly…526
Cleaning and Inspection (Wear Limits and Tolerances)…533
Reassembly…535
Travel Motor S0707350…543
General Description…546
Theory of Operation…546
Parts List…548
Specifications…549
Travel Motor General Disassembly and Reassembly Instructions…550
Recommended Tools…550
Precautions for Disassembly and Assembly…550
Disassembly of Travel Motor…551
Appearance of Motor…551
Removal of counterbalance Valve…551
Removal of Outer Piping…552
Removal of Stroke Limiter…553
Removal of Oil Seal…554
Removal of Control Unit…554
Removal of Control Valve…556
Disassemble Control Valve…558
Disassemble Stroke Limiter…559
Reassemble Stroke Limiter…560
Reassemble Control Valve…560
Installation of Control Valve…561
Reassembly of Travel Motor…564
Assembly of Control Unit…564
Installation of Oil Seal…566
Installation of Stroke Limiter…567
Installation of Outer Piping…567
Installation of Counterbalance Valve…568
Main Pump (Tongmyung) S0708306K…569
Swash Plate Type K5V Series Axial Piston Pump…572
Type Designation…572
Specifications…573
Construction and Function…574
Cautions for Operation…576
Troubleshooting…579
Construction of Tandem Type Duplex Pump…582
Tools…584
Axial Piston Pump Disassembling…586
Axial Piston Pump Reassembling…590
Axial Pump Maintenance Criteria…593
Tightening Torques…594
Regulator for T5V Series of Tongmyung Swash Plate Type Axial Piston Pump…595
Type Description…595
Construction of Regulator…596
Functional Explanations…598
Adjustment of Maximum and Minimum Flows…603
Fault Finding and Remedies on Regulator…604
Preparation for Disassembly…606
Tools…606
Regulator Disassembly…607
Regulator Reassembly…610
Tightening Torque…613
Gear Pump (Steering Pump & Brake Pump) S0708435K…615
General Description…617
Theory of Operation…617
Parts List…617
Specifications…618
Brake Supply Valve S0709220…619
Parts List…622
Specifications…623
Counterbalance Valve S0709300…625
General Description…627
While Operating to Run Forward…627
While Operating to Stop…627
While Operating to Back…627
Adjustment of Relief Valve…628
Troubleshooting…629
Counterbalance Valve…630
Recommended Tools…630
Disassembly…630
Order of Disassembly and Torque Values…631
Reassembly…632
Main Control Valve S0709416K…637
Control Valve Operation…641
Arm Priority Circuitry…642
Bucket (Junction) Circuitry…644
Straight Traveling Circuit…646
Plunger Replacement…650
Main Relief Valve…651
Overload Relief Valve…652
Arm Load Holding Valve…654
Boom Load Holding Valve…657
Arm Regeneration…659
Foot Relief Valve…661
Parts List…662
Specifications…671
Control Valve Drawing and Hydraulic Circuit…672
Disassembly and Reassembly…677
General Disassembly…677
General Reassembly…677
Main Plunger Element…678
Main Relief Valve…681
Main Relief Valve Adjustment…682
Overload Relief Valve…684
Overload Relief Valve (BM UP)…686
Arm Load Holding Valve…688
Boom Load Holding Valve…691
Arm Regeneration Valve…693
Foot Relief Valve…694
Center Bypass Valve (CB Valve)…695
Arm Parallel Switch Valve…696
Boom Unity Check Valve…698
Straight Travel Selector Valve…699
Check Valve – Locations…700
Check Valve…701
Pilot Control Valve (Work Lever / Joystick) S0709451K…705
General Description…707
Theory of Operation…707
Parts List…708
Specifications…709
Removal…710
Disassembly…713
Cleaning and Inspection (Wear Limits and Tolerances)…717
Reassembly…718
Installation…723
Start-up Procedures…724
Steering Valve S0709710…725
General Description…727
Theory of Operation…728
Parts List…730
Specifications…731
Special Tools and Materials…732
Special Tools…732
Disassembly…734
Reassembly…743
Dozer Control Valve S0709905K…757
Parts List…759
Specifications…760
Hydraulic Schematic (S140W-V / 160W-V) S0792145K…761
General Description…763
Solar 140W-V / 160W-V…764
Electrical System…767
Electrical System S0802125K…769
Troubleshooting – Electrical System…773
Overview…774
Electric Supply System…775
Engine Starting Circuit…776
Operation During Start Process…776
Operation After Start Process…777
Engine Preheating System…778
Engine Stop System…779
Charging System…782
Monitoring System…784
Instrument Panel…786
Monitoring System Schematic…788
Operation…790
Instruments…790
Warning and Indicator Lights…792
Control Unit…794
Operation Schematic…794
Operation Specification…795
Console Warning Light…796
Initial Operation…798
Mode Select Switch…799
Graphic Information Area Display…800
Overview…800
Main Menus for the Graphic Display Area…801
Menu Selection Buttons…801
Main Menu…802
Language setting…802
Time Setting…802
Filter/Oil information…803
Special Menu…804
Entering/Accessing and Exiting/Escaping Menus…804
Special Menu Selections…805
Electronic Hydraulic Control System (e-EPOS)…818
Power Mode Control…820
Operation…821
Throttle Position Sensor…824
Power Mode Control – Circuit Diagram…826
Work Mode Control…828
Operation…829
Work Mode Control – Circuit Diagram…830
Engine Control System…832
Engine Control Motor…833
Engine Control Dial…834
Engine Control Circuit Diagram…836
Automatic Deceleration Control (Auto Idle Control)…837
Automatic Deceleration Control Circuit…838
Operation…839
Engine Overheat Protection System…840
Power Boost Mode…841
Operation…841
Power Boost Control – Circuit Diagram…842
Cruise Control…844
Cruise Control Circuit…846
Adjusting Method of Engine Control Unit…848
Adjusting Method of Engine Control System…848
Adjusting Method of Engine RPM…850
Adjustment of TPS (Throttle Position Sensor)…855
Self-diagnostic Function…860
e-EPOS Controller…860
Engine Throttle Controller…864
Wiper System…866
Wiper Circuit…866
Wiper Operation…866
Window Washer Operation…867
Overload Warning Device…868
Overload Warning Device Circuit Diagram…868
Electrical Schematic (S140W-V / 160W-V) S0892075K…869
General Description…871
Solar 140W-V / 160W-V…872
Attachments…875
Boom and Arm S0902060…877
Front Attachment Pin Specifications…879
Front Attachment – Removal and Installation…880
Arm Removal Procedure…880
Boom Removal Procedure…882
Front Attachment – Installation…883
Arm Installation Procedure…883
Boom Installation Procedure…883
Start-up Procedures…884
Bucket S0904000…885
Bucket Tooth Inspection and Replacement…887
Type 1…887
Type 2…888
Type 3…889
Bucket O-ring Replacement…891
Type 1…891
Type 2…892
Bucket Shimming Procedures…894
New Bucket Installation…894
Type 1…894
Type 2…895
Bucket Attachment, Removal and Reversal…896
Detaching the Bucket…896
Attaching The bucket…896
Reversing the Bucket…897
Publication Request for Proposed Revision…899
Deawoo Excavators Solar S140W-V, Solar S160W-V Repair Service Manual