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