Complete service manual for Daewoo Solar S140W-V, S160W-V Excavator, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Daewoo 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.

Daewoo 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