Complete repair service manual for Daewoo/Doosan Solar S200W-V Excavators with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Daewoo Solar S200W-V Excavators workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

2023-7139E - Daewoo Solar S200W-V Shop Manual (Serial Number 0001 and Up).pdf
SHOP MAN.-TRAVEL MOTOR-MAIN PUMP.pdf
TENSOLRV0002 Solar V Model.pdf
TENSOLRV0004 Solar V Model.pdf
ELECTRIC SYSTEM OF SOLAR-V.pdf

Total Pages: 711 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
Safety
Wheel Excavator Safety ...S0102020
Specifications
Specifications for Solar 200W-V ...S0202040
General Maintenance
General Maintenance Procedures ...S0302000
Standard Torques ...S0309000
Upper Structure
Cab ...S0402020
Counterweight...S0403000
Fuel Tank...S0405070
Swing Bearing...S0407010
Swing Reduction Gearbox ...S0408040
Lower Structure and Chassis
Ram Lock Valve Operation...S0503000
Engine and Drive Train
Front Axle ...S0602100
Transmission, Final Drive and Rear Axle ...S0602110
Air-Conditioner...S0605010
Drive Coupling (Main Pump)...S0609000
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ...S0702110
Accumulator...S0703000
Center Joint (Swivel)...S0704070
Cylinders...S0705000
Swing Motor...S0707250
Travel Motor...S0707350
MAin Pump (With Regulator, Steering Pump and Brake Pump) ...S0708430
Brake Supply Valve ...S0709220
Counterbalance Valve ...S0709300
Main Control Valve (Toshiba dx28-60) ...S0709440
Remote Control Valve (Work Lever / Joystick) ...S0709450
Steering Valve ...S0709710
Hydraulic Schematic (Solar 200W-V) ...S0792100
Electrical System
Electrical System ...S0802120
Electrical Schematic (Solar 200W-V)...S0892100
Attachments
Boom and Arm...S0902080
Bucket...S0904000

2023-7139E - Deawoo Solar S200W-V Shop Manual (Serial Number 0001 and Up)...2
  Safety...8
    Wheel Excavator Safety S0102020...10
      To the Operator of a Daewoo Excavator...12
        Learn the Signal Words Used with the Safety Alert Symbol...13
      General Safety Essentials...14
        Accessory Applications...14
        Lifting Capacity Rating Configuration...14
      Location of Safety Labels...14
      Summary of Safety Precautions for Lifting in Digging Mode...15
        Unauthorized Modifications...15
      Work-site Precautions...16
        Attachment Precautions...16
        Avoid High-voltage Cables...16
        Before Starting to Dig, Contact Authorities...16
        Be Aware of Height Obstacles...16
        Use Care on Loose Support...17
        Use Solid Support Blocking...17
        Overhangs Are Dangerous...17
        Sloping Terrain Requires Caution...17
        Stay Alert for People Moving through the Work Area...18
        Be Aware of and Conform to Local Regulations...18
      Operation...18
        Operate While Seated at the Operator’s Station ONLY...18
        Before Starting the Engine...19
        Never Use Ether Starting Aids...19
        Mounting and Dismounting...19
        Observe General Safety Rules...20
        Engine Ventilation...20
        Asbestos Dust Hazard Prevention...20
        Take Time to Provide Good Visibility...20
        Fuel, Oil and Hydraulic Fluid Fire Hazards...21
        Boost Starting or Charging Engine Batteries...21
        Travel Controls May Produce Reversed Operations...22
        Keep "Pinch Point" Areas Clear - Use Caution in Reverse & Swing...22
        Travel Precautions...22
        Operate Carefully on Snow and Ice and in Very Cold Temperatures...22
        Parking the Machine...23
        Shutdown Control Functions...23
      Equipment...23
        Rough Operation May Require Use of Certified Safety Equipment...23
        Install Additional Safety Equipment If Conditions Require...24
        Movement Alarms...24
        Seat Belts Should Be Used at All Times...24
        Window Glass Breaking Tool...25
        Keep a Fire Extinguisher at Hand...25
        Maintain Standard Safety Equipment in Good Condition...25
        Safety-critical Parts Must Be Replaced Periodically...25
        Hydraulic Cylinder Seals Require Periodic Replacement...26
        High Pressure Hydraulic Lines Can Store a Great Deal of Energy...26
        The Operator’s Cab and Turntable Deck Should Be Kept Clean...26
        Wear Eye Protection and Safety Clothing...26
        Breathing Masks, Ear Protection May Be Required...26
        Battery Electrolyte and Explosive Gases Can Be Lethal...27
        Disconnect Batteries for Electrical Service Before Electrical Welding...27
        Use Low Heat Portable Lighting...27
      Maintenance...27
        Use Warning Tag Control Lockout Procedures During Service...27
        Do not Run the Engine If Repairs or Work Is Being Performed Alone...28
        Always Use Adequate Equipment Supports and Blocking...28
        Do not Work on Hot Engines or Hot Cooling or Hydraulic Systems...28
        Cool-down Is Required Prior to Radiator or Reservoir Checks...28
        Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous...29
        Obtain immediate medical attention if pressurized oil pierces the skin...29
        Use Correct Replacement Fasteners Tightened to Proper Torque...29
        Dispose of All Petroleum-based Oils and Fluids Properly...29
      Shipping and Transportation...30
        Obey State and Local Over-the-Road Regulations...30
  Specifications...32
    Specifications for Solar 200W-V S0202040...34
      General Description...36
      Component Location...37
      General Dimensions...39
        Dimensions...39
        Working Range...41
      Hydraulic Cylinders...43
      Engine Specifications...44
      Engine Performance Curves (Per KS-R1004 Standard)...46
      Approximate Weight of Workload Materials...47
      General Specifications...50
      Hydraulic System Component Specifications...51
      System Component Specifications...52
        Drive System...52
        Swing Mechanism...52
        Brake System...53
        Steering System...54
        Chocking System...54
      Performance Tests and Standards...55
        Standards...55
        Tests...56
        Test Conditions...56
        Travel Speed Tests...57
        Swing Speed Test...58
        Swing Speed Test...58
        Swing Force Test...58
        Cylinder Performance Tests...59
        Boom Cylinders Test...59
        Arm Cylinder Test...59
        Hydraulic Cylinder Natural Drop Test...59
  General Maintenance...60
    General Maintenance Procedures S0302000...62
      Welding Precautions and Guidelines...64
      Hydraulic System - General Precautions...65
      Maintenance Service and Repair Procedure...66
        General Precautions...66
      Hydraulic System Cleanliness And Oil Leaks...67
        Maintenance Precautions for Hydraulic System Service...67
        Oil Leakage Precautions...67
      Cleaning and Inspection...68
        General Guidelines...68
        Bearing inspection...69
    Standard Torques S0309000...76
      Torque Values for Standard Metric Fasteners...78
      Torque Values for Standard U.S. Fasteners...79
      Type 8 Phosphate Coated Hardware...81
      Torque Values for Hose Clamps...82
      Torque Values for Split Flanges...83
      Torque Wrench Extension Tools...84
        Torque Multiplication...84
        Other Uses for Torque Wrench Extension Tools...85
        Tightening Torque Specifications (Metric)...85
  Upper Structure...88
    Cab S0402020...90
      Removal...92
      Installation...94
      Window and Gasket Replacement...97
      Falling Object Protective Structures (F.O.P.S.)...98
    Counterweight S0403000...100
      General...102
      Removal...104
      Installation...105
    Fuel Tank S0405070...108
      General Description...110
        Parts List...111
        Specifications...112
      Removal...113
      Installation...116
      Start-up Procedures...117
    Swing Bearing S0407010...118
      Swing Bearing Maintenance...120
        Operating Recommendation...120
        Measuring Swing Bearing Axial Play...120
        Measuring Bearing Lateral Play...120
        Swing Bearing Basic Operation...121
        Rebuilding Swing Bearing...121
    Swing Reduction Gearbox S0408040...124
      General Description...126
        Theory of Operation...126
        Parts List...127
        Specifications...128
      Special Tools and Materials...129
        Special Tools...129
      Troubleshooting, Testing and Adjustment...130
      Removal...131
      Disassembly...132
      Cleaning and Inspection (Wear Limits and Tolerances)...137
      Reassembly...138
      Installation...147
  Lower Structure and Chassis...148
    Ram Lock Valve Operation S0503000...150
      Theory of Operation...152
  Engine and Drive Train...154
    Front Axle S0602100...156
      Special Tools...158
        Hub Nut Tool...158
      Disassembly...159
        Planetary End...159
        Differential Gear...166
      Cleaning and Inspection (Wear Limits and Tolerances)...171
      Reassembly...172
        Differential Gear...172
        Planetary End...183
      Start-up Procedures...198
        Axle Lubrication...198
    Transmission, Final Drive and Rear Axle S0602110...200
      Transmission Operation...203
      Special Tools...204
        Hub Nut Tool...204
      Transmission Disassembly...205
        Detaching Drive (Input) Housing...205
        Disassembly of Input Shaft and Brake Assembly...206
        Disassembly of Clutch...208
        Disassembly of Planetary Carrier...213
        Disassembly of Shift Lever and Helical Gear...214
        Disassembly of Shift Lock (Version A)...219
        Disassembly of Shift Lock (Version B)...221
      Final Drive Disassembly...223
      Rear Axle Disassembly...227
      Differential Gear Disassembly...234
      Cleaning and Inspection (Wear Limits and Tolerances)...239
      Differential Gear Reassembly...240
      Rear Axle Reassembly...252
      Final Drive Reassembly...267
      Transmission Reassembly...272
        Reassembly of Helical Gear...272
        Reassembly of Shift Lever...274
        Reassembly of Planetary Carrier...275
        Adjusting Shift Lever...277
        Preassembling and Installing Clutch...278
        Checking Clutch...285
        Reassembly of Brake and Input Shaft Assembly...286
        Installing Drive (Input) Housing...290
        Assembly of Shift Lock (Version A)...293
        Assembly of Shift Lock (Version B)...297
        Installing Oil Pump...299
        Installing Screw Plugs and Oil Lines...302
      Start-up Procedures...303
        Axle Lubrication...303
        Lubrication...303
    Air-Conditioner S0605010...304
      General Description...306
      Refrigerant Circulation...307
      Control Panel...309
      Control Specifications...310
      Temperature Level Control and Display...311
      Air Discharge According to Path Selection...312
      Air-conditioning System Circuit Diagram...315
      Troubleshooting...317
      Refrigerant System Repairs...320
        Refrigerant Safe Handling Procedures...320
        Repair and Replacement Procedure...321
        Refrigerant Recovery...323
        Vacuuming Refrigerant System...323
        Leakage Check...324
        Refrigerant Charging...325
        Inspecting System For Leakage...327
    Drive Coupling (Main Pump) S0609000...328
      Drive Coupling...330
      Special Tools...331
        Kawasaki Pump Tool...331
        Uchida Pump Tool...333
      Drive Coupling Installation...334
        Installation Procedure...338
  Hydraulics...340
    Hydraulic System Troubleshooting, Testing and Adjustment S0702110...342
      Hydraulic System - General Notes...345
      Operation of Working Components...346
        Boom Operating Circuit...346
        Boom Up Circuit...346
        Boom Down Circuit...346
        Arm Operating Circuit...347
        Arm Crowd Circuit...347
        Arm Dump Circuit...347
        Bucket Operating Circuit...348
        Bucket Crowd Circuit...348
        Bucket Dump Circuit...348
        Swing Operating Circuit...349
        Right Swing Operating Circuit...349
        Left Swing Operating Circuit...349
        Swing Relief Valve and Make-up Valve...349
      Procedural Troubleshooting Baseline Recommendations...350
        Initial Checks and Tests to Establish Operating Condition of the Excavator...350
      Pilot Pressure...351
        Adjustment and Testing...351
      Power Mode Valve...352
        Current Signal and Hydraulic Pressure Adjustments...352
      Boom/Swing Priority Valve...353
        Control Valve Pressure and Current Adjustments...353
      Pressure Up Valve...355
        Checks and Adjustments...355
      Pump Input Power Control...356
        Pump Regulator Adjustment...356
      Flow Meter and Flow Meter Kit Installation and Testing...358
      Swing System Troubleshooting...359
        Precautions/Initial Checks...359
        Swing Relief Valve Checking and Adjustment...360
      Troubleshooting – Swing Gearbox...361
      Troubleshooting – Hydraulic Problems...362
      Troubleshooting – Control Valve...364
      Troubleshooting – Joystick Control Valve...365
    Accumulator S0703000...366
      General Description...368
        Specifications...369
      Accumulator Charging...370
        Charging the Accumulator with Nitrogen...370
    Center Joint (Swivel) S0704070...372
      General Description...374
        Parts List...375
      Troubleshooting, Testing and Adjustment...377
        Inspection...377
        Testing...377
      Disassembly...378
      Reassembly...379
    Cylinders S0705000...380
      General Description...382
        Theory of Operation...382
        Parts List...383
      Special Tools and Materials...385
        Piston Nut...385
        Piston Jig...387
      Disassembly...390
      Reassembly...396
    Swing Motor S0707250...400
      General Description...402
        Theory of Operation...402
        Swing Motor Anti-cavitation Make-up Valve...403
        Relief Valve...404
        Swing Brake Operation...404
        Parts List...407
        Specifications...409
      Special Tools...410
      Disassembly...411
      Cleaning and Inspection (Wear Limits and Tolerances)...418
      Reassembly...420
    Travel Motor S0707350...428
      General Description...430
        Theory of Operation...430
        Parts List...431
        Specifications...431
      Travel Motor General Disassembly and Reassembly Instructions...432
        Recommended Tools...432
        Precautions for Disassembly and Assembly...432
      Disassembly of Travel Motor...433
        Appearance of Motor...433
        Removal of counterbalance Valve...433
        Removal of Outer Piping...434
        Removal of Stroke Limiter...435
        Removal of Oil Seal...436
        Removal of Control Unit...436
        Removal of Control Valve...438
        Disassemble Control Valve...440
        Disassemble Stroke Limiter...441
        Reassemble Stroke Limiter...442
        Reassemble Control Valve...442
        Installation of Control Valve...443
      Reassembly of Travel Motor...446
        Assembly of Control Unit...446
        Installation of Oil Seal...448
        Installation of Stroke Limiter...449
        Installation of Outer Piping...449
        Installation of Counterbalance Valve...450
    MAin Pump (With Regulator, Steering Pump and Brake Pump) S0708430...452
      General Description...455
        Gear (Pilot) Pump...457
        Relief Valve...457
        Pump Regulator Description...458
        Horsepower Control...458
        Power Shift Control...458
        Negative Oil Discharge (Pump Bypass) Control...458
        Pump Regulator Operation...459
        Pump Output Decrease...461
        Pump Discharge Decrease...461
        Pump Discharge Increase...461
        Horsepower Control...461
        Overload Protection...462
        Regulator Adjustment...462
        Pump Input Power Control Adjustment...463
        Parts List...465
        Specifications...470
        Hydraulic Pump Performance Characteristics...471
      Troubleshooting, Testing and Adjustment...473
        Main Pump...473
      Disassembly...474
        General Disassembly...474
        Main Pump Disassembly...475
        Pump Regulator Disassembly...477
      Cleaning and Inspection (Wear Limits and Tolerances)...481
      Reassembly...483
        Pump Regulator Reassembly...483
        Main Pump Reassembly...487
    Brake Supply Valve S0709220...490
      Parts List...493
      Specifications...494
    Counterbalance Valve S0709300...496
      General Description...498
        While Operating to Run Forward...498
        While Operating to Stop...498
        While Operating to Back...498
        Adjustment of Relief Valve...499
      Troubleshooting...500
      Counterbalance Valve...501
        Recommended Tools...501
        Disassembly...501
        Order of Disassembly and Torque Values...502
        Reassembly...503
    Main Control Valve (Toshiba dx28-60) S0709440...508
      Control Valve Operation...512
        Arm Priority Circuit...513
        Bucket (Junction) Circuit...515
        Main Relief Valve...517
        Overload Relief Valve...518
        Arm Load Holding Valve...520
        Boom Load Holding Valve...523
        Arm Regeneration...525
        Boom Regeneration...527
        Foot Relief Valve...528
        Parts List...529
        Specifications...538
      Control Valve Drawing and Hydraulic Circuit...539
      Disassembly and Reassembly...544
        General Disassembly...544
        General Reassembly...544
        Plunger Replacement...545
        Main Plunger Element - Disassembly and Assembly...546
        Tool...546
        Main Relief Valve...549
        Overload Relief Valve...552
        Arm Load Holding Valve...554
        Boom Load Holding Valve...557
        Arm Regeneration Valve...559
        Bucket Unity Check...560
        Foot Relief Valve...561
        Center Bypass Valve (CB Valve)...562
        Boom Parallel Switch Valve...563
        Boom Unity Check Valve...565
        Check Valve - Locations...566
        Check Valve...567
    Remote Control Valve (Work Lever / Joystick) S0709450...570
      General Description...572
        Theory of Operation...572
        Parts List...573
        Specifications...574
        Hydraulic Specifications...575
      Special Tools...576
      Disassembly...577
      Reassembly...582
    Steering Valve S0709710...588
      General Description...590
        Theory of Operation...591
        Parts List...593
        Specifications...594
      Disassembly and Reassembly...595
        Tools Needed...595
        Valve Disassembly...596
        Valve Reassembly...602
    Hydraulic Schematic (Solar 200W-V) S0792100...614
      General Description...616
      Solar 200W-V...617
        General Notes...619
  Electrical System...620
    Electrical System S0802120...622
      Troubleshooting - Electrical System...625
      Wiring Harness Illustrations...626
      Overview...626
      Electric Supply System...627
      Engine Starting Circuit...629
        Operation During Start Process...629
        Operation After Start Process...631
      Engine Preheating System...633
      Engine Stop System...634
      Charging System...638
      Monitoring System...639
      Instrument Panel and Steering Console...640
        iNstrument Panel and Steering Console Function Check...641
      Monitoring System Schematic...643
      Operation...645
        Instruments...645
      Mode Select Switch...646
      Pilot Lamp...647
      Initial Operation...648
      Electronic Hydraulic Control System (EPOS - V)...649
      Power Mode Control...651
        Operation...653
      Throttle Position Sensor...657
      Power Mode Control - Circuit Diagram...658
      Work Mode Control...659
        Operation...660
      Work Mode Control - Circuit Diagram...661
      Engine Control System...662
      Engine Control Motor...663
      Engine Speed Control Dial...664
      Engine Control Circuit Diagram...665
      Automatic Deceleration Control (Auto Idle Control)...666
      Engine Overheat Protection System...667
      Power Boost Mode...668
        Operation...668
        Power Boost Control - Circuit Diagram...669
      Cruise Control...671
        Function...671
        Cruse Control Circuit...673
      Adjusting Method of Engine Control Unit...674
        Adjusting Method of Engine Control System...674
        Adjusting Method of Engine RPM...676
        Adjustment of TPS (Throttle Position Sensor) (Refer to Figure 46 thru Figure 48)...682
      Self-diagnostic Function...685
        EPOS-V Controller...685
      Engine Throttle Controller...689
    Electrical Schematic (Solar 200W-V) S0892100...690
      General Description...692
      Solar 200W-V...693
  Attachments...696
    Boom and Arm S0902080...698
      Front Attachment Pin Specifications...700
      Front Attachment - Removal and Installation...701
        Arm Removal Procedure...701
        Boom Removal Procedure...703
      Installation...704
        Arm Installation Procedure...704
        Boom Installation Procedure...704
      Start-up Procedures...705
    Bucket S0904000...706
      Bucket Tooth Inspection and Replacement...708
      Bucket O-ring Replacement...709
      Bucket Shimming Procedures...711
        New Bucket Installation...711
        Shimming Procedures for Installed Bucket...711
      Bucket Attachment, Removal and Reversal...712
        Detaching the Bucket...712
        Attaching The bucket...712
        Reversing the Bucket...713
ELECTRIC SYSTEM OF SOLAR-V...714
SHOP MAN.-TRAVEL MOTOR-MAIN PUMP...816
TENSOLRV0002 Solar V Model...878
TENSOLRV0004 Solar V Model...1162

Daewoo Solar S200W-V Excavators Repair Service Manual