Complete service manual for Deawoo Solar 170W-V Excavator, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Deawoo Solar 170W-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 170W-V Excavator Shop Manual.pdf

Total Pages: 872 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
Safety
Wheel Excavator Safety ..S0102020
Specifications
Specifications for Solar 170W-V ..S0202060
General Maintenance
General Maintenance Procedures ...S0302000
Standard Torques ..S0309000
Upper Structure
Cab ..S0402020
Counterweight..S0403000
Fuel Tank...S0405100
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 ..S0602120
Rear Axle ...S0602130
Service Brake ..S0603010
Air-Conditioner...S0605010
Transmission (ZF 2HL-100)...S0607050
Drive Coupling (Main Pump)..S0609000
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ..S0702150
Accumulator...S0703000
Center Joint (Swivel)..S0704070
Cylinders..S0705000
Swing Motor...S0707260
Travel Motor...S0707350
Main Pump...S0708305
Brake Supply Valve ...S0709220
Counterbalance Valve ...S0709300
Main Control Valve (Toshiba DX28-60) ...S0709440
Pilot Control Valve (Work Lever / Joystick)..S0709450
Steering Valve ...S0709710
Dozer Control Valve...S0709900
Hydraulic Schematic (Solar 170W-V) ..S0792140
Electrical System
Electrical System ...S0802160
Electrical Schematic (Solar 170W-V)...S0892140
Attachments
Boom and Arm...S0902120
Bucket..S0904000

Safety..7
  Wheel Excavator Safety S0102020..9
    To the Operator of a Daewoo Excavator..11
      Learn the Signal Words Used with the Safety Alert Symbol..12
    General Safety Essentials..13
      Accessory Applications..13
      Lifting Capacity Rating Configuration..13
    Location of Safety Labels..13
    Summary of Safety Precautions for Lifting in Digging Mode..14
      Unauthorized Modifications..14
    Work-site Precautions..15
      Attachment Precautions..15
      Avoid High-voltage Cables..15
      Before Starting to Dig, Contact Authorities..15
      Be Aware of Height Obstacles..15
      Use Care on Loose Support..16
      Use Solid Support Blocking..16
      Overhangs Are Dangerous..16
      Sloping Terrain Requires Caution..16
      Stay Alert for People Moving through the Work Area..17
      Be Aware of and Conform to Local Regulations..17
    Operation..17
      Operate While Seated at the Operator’s Station ONLY..17
      Before Starting the Engine..18
      Never Use Ether Starting Aids..18
      Mounting and Dismounting..18
      Observe General Safety Rules..19
      Engine Ventilation..19
      Asbestos Dust Hazard Prevention..19
      Take Time to Provide Good Visibility..19
      Fuel, Oil and Hydraulic Fluid Fire Hazards..20
      Boost Starting or Charging Engine Batteries..20
      Travel Controls May Produce Reversed Operations..21
      Keep "Pinch Point" Areas Clear - Use Caution in Reverse and Swing..21
      Travel Precautions..21
      Operate Carefully on Snow and Ice and in Very Cold Temperatures..21
      Parking the Machine..22
      Shutdown Control Functions..22
    Equipment..22
      Rough Operation May Require Use of Certified Safety Equipment..22
      Install Additional Safety Equipment If Conditions Require..23
      Movement Alarms..23
      Seat Belts Should Be Used at All Times..23
      Window Glass Breaking Tool..24
      Keep a Fire Extinguisher at Hand..24
      Maintain Standard Safety Equipment in Good Condition..24
      Safety-critical Parts Must Be Replaced Periodically..24
      Hydraulic Cylinder Seals Require Periodic Replacement..25
      High Pressure Hydraulic Lines Can Store a Great Deal of Energy..25
      The Operator’s Cab and Turntable Deck Should Be Kept Clean..25
      Wear Eye Protection and Safety Clothing..25
      Breathing Masks, Ear Protection May Be Required..25
      Battery Electrolyte and Explosive Gases Can Be Lethal..26
      Disconnect Batteries for Electrical Service Before Electrical Welding..26
      Use Low Heat Portable Lighting..26
    Maintenance..26
      Use Warning Tag Control Lockout Procedures During Service..26
      Do not Run the Engine If Repairs or Work Is Being Performed Alone..27
      Always Use Adequate Equipment Supports and Blocking..27
      Do not Work on Hot Engines or Hot Cooling or Hydraulic Systems..27
      Cool-down Is Required Prior to Radiator or Reservoir Checks..27
      Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous..28
      Obtain immediate medical attention if pressurized oil pierces the skin..28
      Use Correct Replacement Fasteners Tightened to Proper Torque..28
      Dispose of All Petroleum-based Oils and Fluids Properly..28
    Shipping and Transportation..29
      Obey State and Local Over-the-Road Regulations..29
Specifications..31
  Specifications for Solar 170W-V S0202060..33
    General Description..35
    Component Location..36
    General Dimensions..39
      Dimensions..39
      Working Range..40
    Hydraulic Cylinders..41
    Engine Specifications..42
    Engine Performance Curves (Per KSR1004 Standard)..44
    Approximate Weight of Workload Materials..46
    General Specifications..49
    Hydraulic System Component Specifications..51
    System Component Specifications..52
      Drive System..52
      Swing Mechanism..52
      Brake System..53
      Steering System..53
      Chocking System..53
    Performance Tests and Standards..54
      Standards..54
      Tests..55
      Test Conditions..55
      Travel Speed Tests..56
      Swing Speed Test..57
      Swing Speed Test..57
      Swing Force Test..57
      Cylinder Performance Tests..58
      Boom Cylinders Test..58
      Arm Cylinder Test..58
      Bucket Cylinder Test..58
      Hydraulic Cylinder Natural Drop Test..58
General Maintenance..59
  General Maintenance Procedures S0302000..61
    Welding Precautions and Guidelines..63
    Hydraulic System - General Precautions..64
    Maintenance Service and Repair Procedure..65
      General Precautions..65
    Hydraulic System Cleanliness and Oil Leaks..66
      Maintenance Precautions for Hydraulic System Service..66
      Oil Leakage Precautions..66
    Cleaning and Inspection..67
      General Guidelines..67
      Bearing inspection..68
  Standard Torques S0309000..75
    Torque Values for Standard Metric Fasteners..77
    Torque Values for Standard U.S. Fasteners..78
    Type 8 Phosphate Coated Hardware..80
    Torque Values for Hose Clamps..81
    Torque Values for Split Flanges..82
    Torque Wrench Extension Tools..83
      Torque Multiplication..83
      Other Uses for Torque Wrench Extension Tools..84
      Tightening Torque Specifications (Metric)..84
Upper Structure..87
  Cab S0402020..89
    Removal..91
    Installation..93
    Window and Gasket Replacement..96
    Falling Object Protective Structures (F.O.P.S.)..97
  Counterweight S0403000..99
    General..101
    Removal..103
    Installation..104
  Fuel Tank S0405100..107
    General Description..109
      Parts List..110
      Specifications..111
    Removal..112
    Installation..115
    Start-up Procedures..116
  Fuel Transfer Pump S0405500..117
    General Description..119
      Theory of Operation..119
    Replacement of Rotor and Vane..120
    Replacement of Rear Cover..120
    Replacement of Amateur..121
  Swing Bearing S0407010..123
    Swing Bearing Maintenance..125
      Operating Recommendation..125
      Measuring Swing Bearing Axial Play..125
      Measuring Bearing Lateral Play..125
      Swing Bearing Basic Operation..126
      Rebuilding Swing Bearing..126
  Swing Reduction Gearbox S0408050..129
    General Description..131
      Theory of Operation..131
      Parts List..132
      Specifications..133
    Special Tools and Materials..134
      Special Tools..134
    Troubleshooting, Testing and Adjustment..136
    Removal..137
    Disassembly..139
    Cleaning and Inspection (Wear Limits and Tolerances)..0
    Reassembly..0
    Installation..0
Lower Structure and Chassis..0
  Ram Lock Valve Operation S0503000..0
    Theory of Operation..0
Engine and Drive Train..0
  Front Axle S0602120..0
    APL-B755..0
    Inscriptions On the Model Identification Plate (For Zf-axles)..0
    Examples of Gear-tooth Contact Patterns for the Gleason Gear-tooth System..0
    Lubrication and Maintenance Instructions..0
      Oil Quality..0
      Oil Change..0
    List of Lubricants TE-ML 05..0
      Brake Lining - Wear Test On Zf-axles of the Series AP (L) - B 700..0
      Carry Out Wear Test..0
      Dimension "X" - Dimension "Y" = Actual Value (Piston Stroke + Wear)..0
    Special Tools..0
    Final Drive - Disassembly..0
      Planetary Carrier..0
      Internal Gear..0
      Hub..0
      Steering Knuckle Hull..0
      Double-joint Shaft..0
      Axle Housing..0
    Final Drive - Reassembly..0
      Axle Housing and Double-joint Shaft..0
      Steering Knuckle Hull..0
      Adjusting Steering Knuckle Bearing..0
      Check Rolling Resistance of the Steering Knuckle Bearing..0
      Hub - Wheel Bearing..0
      Adjust and Check the Rolling Moment of the Wheel Bearing..0
      Internal Gear..0
      Multi-disk Brake..0
      Planetary Gears..0
      Illustrated Table..0
    Drive Unit/ Differential Disassembly..0
      Disassemble Differential..0
      Disassemble Differential..0
      Remove Drive Pinion..0
    Drive Unit/differential - Reassembly..0
      Determine Thickness of Shim - To Obtain A Correct Contact Pattern..0
      Install Drive Pinion..0
      Adjust Rolling Moment of the Drive Pinion Bearing..0
      Complete and Install Differential..0
      Determine and Adjust Backlash of the Crown..0
      Check Contact Pattern..0
      Only for Version - 100% Lock Install Shut-off Slide and Piston..0
      Axle Bolting..0
      Mount Final Drive..0
      Illustrated Tables..0
    Steering Assembly - Disassembly..0
      Remove Tie Rod..0
      Remove Piston and Cylinder..0
    Steering Assembly - Reassembly..0
      Install Guide, Cylinder and Piston..0
      Adjust Track and Steering Lock..0
      Illustrated Table..0
  Rear Axle S0602130..0
    Examples of Gear-tooth-contact Patterns for the Gleason Gear-tooth System..0
      Ideals Tooth-contact Pattern I.E. Pinion Distance Is Correct..0
    Inscriptions on the Model Identification Plate (For ZF-axles)..0
      Lubrication and Maintenance Instructions..0
      Technical Data..0
      Adjustment Values Final Drive..0
      Drive Unit/differential..0
      Brake Lining Wearing Test..0
      Carry Out the Wearing Test..0
    Special Tools..0
    Final Drive (Planetary) Disassembly..0
      Loosen Slotted Nut..0
    Drive Unit - Differential Disassembly..0
      Remove Differential..0
      Dismantle Differential..0
      Remove Drive Pinion..0
    Cleaning and Inspection (Wear Limits and Tolerances)..0
    Drive Unit - Differential Reassembly..0
      Drive Pinon..0
      Complete and Install Differential..0
    Final Drive (Planetary) Reassembly..0
      Hub Carrier..0
      Hub..0
      Internal Gear..0
      Tighten Slotted Nut..0
      Multi-disk Brake..0
      Planetary Carrier..0
  Service Brake S0603010..0
    Measuring Wear of Brake Disc..0
      Special Tool..0
      When to Measure Brake Disc Wear..0
      How to Measure Brake Disc Wear...0
      Maximum Allowable Value of "X" - "Y"..0
  Air-Conditioner S0605010..0
    General Description..0
    Refrigerant Circulation..0
    Control Panel..0
    Control Specifications..0
    Temperature Level Control and Display..0
    Air Discharge According to Path Selection..0
    Air-conditioning System Circuit Diagram..0
    Troubleshooting..0
    Weight of R134a Gas Used In Machines..0
    Refrigerant System Repairs..0
      Refrigerant Safe Handling Procedures..0
      Repair and Replacement Procedure..0
      Refrigerant Recovery..0
      Vacuuming Refrigerant System..0
      Leakage Check..0
      Refrigerant Charging..0
      Inspecting System For Leakage..0
  Transmission (ZF 2HL100) S0607050..0
    Transmission Design and Options..0
      Power Flow..0
      Transmission Design..0
      Shift Control..0
    Instructions for Starting, Operation and Maintenance..0
      Oil Capacity..0
      Admitted Oils..0
    Installation View and Instructions for the Oil Filling Procedure..0
      Gearbox and Axle..0
    Instructions for Moving the Vehicle or An Emergency Towing..0
    Examples of Gear-tooth-contact Patterns for the Gleason Gear-tooth System..0
    Disassembly..0
      Separate Gearbox From Axle..0
      Remove Shifting Clutches..0
      Remove and Dismantle Planetary Drive..0
      Remove and Dismantle Declutch Unit and Spur Gear..0
      Dismantle Shift Lock..0
      Disassemble Final Drive, Axle Carrier and Differential..0
    Reassembly..0
      Axle Carrier, Final Drive and Differential Version "A" - Gearbox Attached on the Axle..0
      Install Helical Gear and Declutch Unit..0
      Complete and Install Planetary Carrier..0
      Pre-assemble and Install Clutch (Road Gear)..0
      Install Brake (Cross-country Gear)..0
      Install Drive Casing..0
      Pre-assemble and Mount Shift Lock..0
      Pre-assemble and Install Control Spool..0
      Install Lubricating Oil Pump..0
      Mount Screw Plugs and Oil Lines..0
      Mount Gearbox on the ZF-axle..0
      Disassemble Final Drive..0
      Install Final Drive..0
  Drive Coupling (Main Pump) S0609000..0
    Drive Coupling..0
    Special Tools..0
      Kawasaki Pump Tool..0
      Uchida Pump Tool..0
    Drive Coupling Installation..0
      Installation Procedure..0
Hydraulics..0
  Hydraulic System Troubleshooting, Testing and Adjustment S0702150..0
    Hydraulic System - General Notes..0
    Operation of Working Components..0
      Boom Operating Circuit..0
      Boom Up Circuit..0
      Boom Down Circuit..0
      Arm Operating Circuit..0
      Arm Crowd Circuit..0
      Arm Dump Circuit..0
      Bucket Operating Circuit..0
      Bucket Crowd Circuit..0
      Bucket Dump Circuit..0
      Swing Operating Circuit..0
      Right Swing Operating Circuit..0
      Left Swing Operating Circuit..0
      Swing Relief Valve and Make-up Valve..0
    Procedural Troubleshooting Baseline Recommendations..0
      Initial Checks and Tests to Establish Operating Condition of the Excavator..0
    Pilot Pressure..0
      Adjustment and Testing..0
    Power Mode Valve..0
      Current Signal and Hydraulic Pressure Adjustments..0
    Boom/Swing Priority Valve..0
      Control Valve Pressure and Current Adjustments..0
    Pressure Up Valve..0
      Checks and Adjustments..0
    Pump Input Power Control..0
      Pump Regulator Adjustment..0
    Flow Meter and Flow Meter Kit Installation and Testing..0
    Swing System Troubleshooting..0
      Precautions/Initial Checks..0
      Swing Relief Valve Checking and Adjustment..0
    Troubleshooting - Swing Gearbox..0
    Troubleshooting - Hydraulic Problems..0
    Troubleshooting - Control Valve..0
    Troubleshooting - Joystick Control Valve..0
  Accumulator S0703000..0
    General Description..0
      Specifications..0
    Accumulator Charging..0
      Charging the Accumulator with Nitrogen..0
  Center Joint (Swivel) S0704070..0
    General Description..0
      Parts List..0
    Troubleshooting, Testing and Adjustment..0
      Inspection..0
      Testing..0
    Disassembly..0
    Reassembly..0
  Cylinders S0705000..0
    General Description..0
      Theory of Operation..0
      Parts List..0
    Special Tools and Materials..0
      Piston Nut..0
      Piston Jig..0
    Disassembly..0
    Reassembly..0
  Swing Motor S0707260..0
    General Description..0
      Theory of Operation..0
      Swing Motor Anti-cavitation Make-up Valve..0
      Relief Valve..0
      Swing Brake Operation..0
      Parts List..0
      Specifications..0
    Special Tools..0
    Disassembly..0
    Cleaning and Inspection (Wear Limits and Tolerances)..0
    Reassembly..0
  Travel Motor S0707350..0
    General Description..0
      Theory of Operation..0
      Parts List..0
      Specifications..0
    Travel Motor General Disassembly and Reassembly Instructions..0
      Recommended Tools..0
      Precautions for Disassembly and Assembly..0
    Disassembly of Travel Motor..0
      Appearance of Motor..0
      Removal of counterbalance Valve..0
      Removal of Outer Piping..0
      Removal of Stroke Limiter..0
      Removal of Oil Seal..0
      Removal of Control Unit..0
      Removal of Control Valve..0
      Disassemble Control Valve..0
      Disassemble Stroke Limiter..0
      Reassemble Stroke Limiter..0
      Reassemble Control Valve..0
      Installation of Control Valve..0
    Reassembly of Travel Motor..0
      Assembly of Control Unit..0
      Installation of Oil Seal..0
      Installation of Stroke Limiter..0
      Installation of Outer Piping..0
      Installation of Counterbalance Valve..0
  Main Pump S0708305..0
    General Description..0
      Composition..0
      Parts List..0
    Special Tools and Materials..0
      Special Tools..0
    Troubleshooting, Testing and Adjustment..0
    Disassembly..0
      General Disassembly..0
      Piston Pump Disassembly..0
      Control Parts Disassembly (Servo Case "AS")..0
    Cleaning and Inspection (Wear Limits and Tolerances)..0
      Piston Pump Inspection and Parts Substitution..0
    Reassembly..0
      Reassembly Piston Pump..0
      Reassembly Control Part..0
      Reassembly TVC Valve..0
      General Reassembly..0
      Shim Adjustment..0
  Brake Supply Valve S0709220..0
    Parts List..0
    Specifications..0
  Counterbalance Valve S0709300..0
    General Description..0
      While Operating to Run Forward..0
      While Operating to Stop..0
      While Operating to Back..0
      Adjustment of Relief Valve..0
    Troubleshooting..0
    Counterbalance Valve..0
      Recommended Tools..0
      Disassembly..0
      Order of Disassembly and Torque Values..0
      Reassembly..0
  Main Control Valve (Toshiba DX28-60) S0709440..0
    Control Valve Operation..0
      Arm Priority Circuit..0
      Bucket (Junction) Circuit..0
      Main Relief Valve..0
      Overload Relief Valve..0
      Arm Load Holding Valve..0
      Boom Load Holding Valve..0
      Arm Regeneration..0
      Boom Regeneration..0
      Foot Relief Valve..0
      Parts List..0
      Specifications..0
    Control Valve Drawing and Hydraulic Circuit..0
    Disassembly and Reassembly..0
      General Disassembly..0
      General Reassembly..0
      Plunger Replacement..0
      Main Plunger Element - Disassembly and Assembly..0
      Tool..0
      Main Relief Valve..0
      Overload Relief Valve..0
      Arm Load Holding Valve..0
      Boom Load Holding Valve..0
      Arm Regeneration Valve..0
      Bucket Unity Check..0
      Foot Relief Valve..0
      Center Bypass Valve (CB Valve)..0
      Boom Parallel Switch Valve..0
      Boom Unity Check Valve..0
      Check Valve - Locations..0
      Check Valve..0
  Pilot Control Valve (Work Lever / Joystick) S0709450..0
    General Description..0
      Theory of Operation..0
      Parts List..0
      Specifications..0
      Hydraulic Specifications..0
    Special Tools..0
    Disassembly..0
    Reassembly..0
  Steering Valve S0709710..0
    General Description..0
      Theory of Operation..0
      Parts List..0
      Specifications..0
    Special Tools and Materials..0
      Special Tools..0
    Disassembly..0
    Reassembly..0
  Dozer Control Valve S0709900..0
    Parts List..0
    Specifications..0
  Hydraulic Schematic (Solar 170W-V) S0792140..0
    General Description..0
    Solar 170W-V with Standard Boom..0
    Solar 170W-V with Articulated Boom..0
      General Notes..0
Electrical System..0
  Electrical System S0802160..0
    Troubleshooting - Electrical System..0
    Wiring Harness Illustrations..0
    Overview..0
    Electric Supply System..0
    Engine Starting Circuit..0
      Operation During Start Process..0
      Operation After Start Process..0
    Engine Preheating System..0
    Engine Stop System..0
    Charging System..0
    Monitoring System..0
    Instrument Panel and Steering Console..0
      iNstrument Panel and Steering Console Function Check..0
    Monitoring System Schematic..0
    Operation..0
      Instruments..0
    Mode Select Switch..0
    Pilot Lights..0
    Initial Operation..0
    Electronic Hydraulic Control System (EPOSV)..0
    Power Mode Control..0
      Operation..0
    Throttle Position Sensor..0
    Power Mode Control - Circuit Diagram..0
    Work Mode Control..0
      Operation..0
    Work Mode Control - Circuit Diagram..0
    Engine Control System..0
    Engine Control Motor..0
    Engine Speed Control Dial..0
    Engine Control Circuit Diagram..0
    Automatic Deceleration Control (Auto Idle Control)..0
    Engine Overheat Protection System..0
    Power Boost Mode..0
      Operation..0
      Power Boost Control - Circuit Diagram..0
    Cruise Control..0
      Function..0
      Cruse Control Circuit..0
    Adjusting Method of Engine Control Unit..0
      Adjusting Method of Engine Control System..0
      Adjusting Method of Engine RPM..0
      Adjustment of TPS (Throttle Position Sensor)..0
    Self-diagnostic Function..0
      EPOS-V Controller..0
    Engine Throttle Controller..0
  Electrical Schematic (Solar 170W-V) S0892140..0
    General Description..0
    Solar 170W-V..0
Attachments..0
  Boom and Arm S0902120..0
    Front Attachment Pin Specifications..0
    Front Attachment - Removal and Installation..0
      Arm Removal Procedure..0
      Boom Removal Procedure..0
    Installation..0
      Arm Installation Procedure..0
      Boom Installation Procedure..0
    Start-up Procedures..0
  Bucket S0904000..0
    Bucket Tooth Inspection and Replacement..0
      Type 1..0
      Type 2..0
      Type 3..0
    Bucket O-ring Replacement..0
      Type 1..0
      Type 2..0
    Bucket Shimming Procedures..0
      New Bucket Installation..0
      Type 1..0
      Type 2..0
    Bucket Attachment, Removal and Reversal..0
      Detaching the Bucket..0
      Attaching The bucket..0
      Reversing the Bucket..0
s0792140.pdf..0
  Hydraulic Schematic (Solar 170W-V) S0792140..0
    General Description..0
    Solar 170W-V with Standard Boom..0
    Solar 170W-V with Articulated Boom..0
      General Notes..0

Deawoo Solar 170W-V Excavator Repair Service Manual