Daewoo Solar S140W-V Excavator - Repair, Service and Maintenance Manual

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DAEWOO SOLAR S140W-V EXCAVATOR - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, to excavator Daewoo Solar S140W-V.
 

CONTENTS:

SAFETY
- Wheel Excavator Safety S0102025K
-- To the Operator of a Daewoo Excavator
-- Learn the Signal Words Used with the Safety Alert Symbol
-- General Safety Essentials
-- Accessory Applications
-- Lifting Capacity Rating Configuration
-- Location of Safety Labels
-- Summary of Safety Precautions for Lifting in Digging Mode
-- Unauthorized Modifications
-- General Hazard Information
-- Safety Rules
-- Safety Features
-- Inside Operator's Compartment
-- Clothing and Personal Protective Items
-- Breathing Masks, Ear Protection May be Required
-- Mounting and Dismounting
-- Fuel, Oil and Hydraulic Fluid Fire Hazards
-- Precautions When Handling Fluids at High Temperature
-- Asbestos Dust Hazard Prevention
-- Injury from Work Equipment
-- Fire Extinguisher and First Aid Kit
-- Protection from Falling or Flying Objects
-- Attachment Precautions
-- Accumulator
-- Indoor Ventilation
-- Emergency Exit
-- Before Starting Engine
-- Work Site Precautions
-- Checks Before Starting Engine
-- Engine Starting
-- Before Operating Machine
-- Machine Operation
-- When Swinging or Changing Direction of Travel
-- Travel Precautions
-- Traveling on Slopes
-- Prohibited Operations
-- Precautions for Operation
-- Avoid High-voltage Cables
-- Operate Carefully on Snow, Ice and in Very Cold Temperatures
-- Operations on Slopes
-- Parking Machine
-- Never Let Anyone Ride on Attachment
-- Maintenance
-- Warning Tag
-- Clean Before Inspection or Maintenance
-- Proper Tools
-- Use of Lighting
-- Fire Prevention and Explosion Prevention
-- Burn Prevention
-- Welding Repairs
-- Warning for Counterweight and Front Attachment Removal
-- Precautions for Removal, Installation, and Storage of Attachments
-- Precautions when Working on Machine
-- Lock Inspection Covers
-- Crushing Prevention and Cutting Prevention
-- Supports and Blocking for Work Equipment
-- Action When Abnormally Is Found During Inspection
-- Precautions with High Pressure Line, Tubes and Hoses
-- Waste Materials
-- Battery
-- Battery Hazard Prevention
-- Boost Starting or Charging Engine Batteries
-- Towing
-- Precautions When Towing
-- Shipping and Transportation
-- Obey State and Local Over-the-Road Regulations
-- Lifting With Sling
SPECIFICATIONS
- Specifications for S140W-V / 160W-V S0202055K
-- General Description
-- Component Location
-- SOLAR 140W-V
-- General Dimensions
-- Working Range
-- SOLAR 160W-V
-- General Dimensions
-- Working Range
-- Front Linkage Pin Size
-- Hydraulic Cylinders
-- Engine Specifications
-- Engine Performance Curves (Per DIN 6270 Standard)
-- Approximate Weight of Workload Materials
-- General Specifications
-- Hydraulic System Component Specifications
-- System Component Specifications
-- Drive System
-- Swing Mechanism
-- Brake System
-- Steering System
-- Chocking System
-- Performance Tests and Standards
-- Standards
-- Tests
-- Test Conditions
-- Travel Speed Tests
-- Swing Speed Test
-- Swing Speed Test
-- Swing Deceleration Force Test
-- Cylinder Performance Tests
-- Boom Cylinders Test
-- Arm Cylinder Test
-- Bucket Cylinder Test
-- Hydraulic Cylinder Natural Drop Test
GENERAL MAINTENANCE
- General Maintenance Procedures S0302000
-- Welding Precautions and Guidelines
-- Hydraulic System - General Precautions
-- Maintenance Service and Repair Procedure
-- General Precautions
-- Hydraulic System Cleanliness and Oil Leaks
-- Maintenance Precautions for Hydraulic System Service
-- Oil Leakage Precautions
-- Cleaning and Inspection
-- General Guidelines
-- Bearing inspection
- Standard Torques S0309000
-- Torque Values for Standard Metric Fasteners
-- Torque Values for Standard U.S. Fasteners
-- Type 8 Phosphate Coated Hardware
-- Torque Values for Hose Clamps
-- Torque Values for Split Flanges
-- Torque Wrench Extension Tools
-- Torque Multiplication
-- Other Uses for Torque Wrench Extension Tools
-- Tightening Torque Specifications (Metric)
UPPER STRUCTURE
- Cab S0402040K
-- Removal
-- Installation
- Counterweight S0403015K
-- General
-- Removal
-- Installation
- Fuel Tank S0405045K
-- General Description
-- Parts List
-- Specifications
-- Removal
-- Installation
-- Start-up Procedures
- Fuel Transfer Pump S0405500
-- General Description
-- Theory of Operation
-- Troubleshooting
-- Replacement of Rotor and Vane
-- Replacement of Rear Cover
-- Replacement of Armature
- Swing Bearing S0407010
-- Swing Bearing Maintenance
-- Operating Recommendation
-- Measuring Swing Bearing Axial Play
-- Measuring Bearing Lateral Play
-- Swing Bearing Basic Operation
-- Rebuilding Swing Bearing
- Swing Reduction Gearbox S0408025K
-- General Description
-- Theory of Operation
-- Parts List
-- Special Tools and Materials
-- Special Tools
-- Troubleshooting, Testing and Adjustment
-- Removal
-- Disassembly
-- Reassembly
-- Installation
LOWER STRUCTURE AND CHASSIS
- Ram Lock Valve Operation S0503000
-- Theory of Operation
ENGINE AND DRIVE TRAIN
- Front Axle (Dana) S0602055K
-- Introduction
-- Introductory Remarks
-- Maintenance and Lubricant
-- Definition of Viewpoints
-- Data Plate
-- Maintenance Points
-- Maintenance Intervals
-- Adjustment and Checks
-- Tightening Torques
-- Screw-locking, Sealing and Lubricating Materials
-- Notes on Safety Precautions
-- Checking Wear and Replacing Brake Disks
-- Disassembly of Brake Units
-- Assembly of Brake Units
-- Steering Case
-- Removal and Disassembly
-- Assembly and Installation
-- U-Joint
-- Notes on Safety Precautions
-- Removal and Disassembly
-- Assembly and Installation
-- Planetary Reduction
-- Disassembly
-- Assembly
-- Steering Cylinder
-- Removal
-- Installation
-- Disassembly
-- Assembly
-- Differential Unit
-- Removal and Disassembly
-- Assembly, Adjusting and Installation
-- Bevel Pinion
-- Removal
-- Adjusting and Installation
-- Special Tools
-- Troubleshooting
- Rear Axle (Dana) S0602056K
-- Introduction
-- Introductory Remarks
-- Maintenance and Lubricant
-- Definition of Viewpoints
-- Data Plate
-- Maintenance Points
-- Maintenance Intervals
-- Adjustment and Checks
-- Tightening Torques
-- Screw-locking, Sealing and Lubricating Materials
-- Notes on Safety Precautions
-- Checking Wear and Replacing Brake Disks
-- Disassembly of Brake Units
-- Assembly of Brake Units
-- Planetary Reduction and Axle Shaft
-- Notes on Safety Precautions
-- Disassembly
-- Assembly
-- Bevel Pinion
-- Removal
-- Adjusting and Installation
-- Special Tools
-- Troubleshooting
- Air-Conditioner S0605060K
-- General Description
-- Refrigerant Circulation
-- Control Panel
-- Control Specifications
-- Temperature Level Control and Display
-- Air Discharge According to Path Selection
-- Air-conditioning System Circuit Diagram
-- Troubleshooting
-- Weight of R134a Gas Used In Machines
-- Refrigerant System Repairs
-- Refrigerant Safe Handling Procedures
-- Repair and Replacement Procedure
-- Refrigerant Recovery
-- Vacuuming Refrigerant System
-- Leakage Check
-- Refrigerant Charging
-- Inspecting System For Leakage
- Transmission (ZF 2HL-100) S0607055K
-- Specifications
-- Transmission Operation
-- Transmission Disassembly
-- Detaching Drive (Input) Housing
-- Disassembling Input Shaft Assembly
-- Disassembling Planetary Drive
-- Disassembling Clutch and Spur Gear
-- Disassembling Shift Lock
-- Final Drive, Drive Shaft and Differential Disassembly
-- Transmission Reassembly
-- Shimming Drive Pinion
-- Reassembling Drive Pinion
-- Adjusting Rolling Resistance of Drive Pinion Bearing
-- Installing Differential
-- Adjusting Backlash and Bearing Preload
-- Installing Helical Gear and Clutch
-- Installing Planetary Carrier
-- Adjusting Shift Lever
-- Preassembling and Installing Clutch
-- Checking Clutch
-- Installing Brake
-- Installing Drive Casing
-- Drive Pinion / Crown Wheel Contact Pattern
-- Correct Pattern
-- Increase Pinion Distance
-- Decrease Pinion Distance
-- Transmission Governor
-- Parts List
-- Disassembly of Governor
-- Reassembly of Governor
- Drive Coupling (Main Pump) S0609000
-- Drive Coupling
-- Special Tools
-- Kawasaki / Tong Myung Pump Tool
-- Uchida Pump Tool
-- Drive Coupling Installation
-- Installation Procedure
HYDRAULICS
- Hydraulic System Troubleshooting, Testing and Adjustment S0702065K
-- Hydraulic System - General Notes
-- Hydraulic Schematic
-- General Notes
-- Operation of Working Components
-- Boom Operating Circuit
-- Boom Up Circuit
-- Boom Down Circuit
-- Arm Operating Circuit
-- Arm Crowd Circuit
-- Arm Dump Circuit
-- Bucket Operating Circuit
-- Bucket Crowd Circuit
-- Bucket Dump Circuit
-- Swing Operating Circuit
-- Right Swing Operating Circuit
-- Left Swing Operating Circuit
-- Swing Relief Valve and Make-up Valve
-- Procedural Troubleshooting Baseline Recommendations
-- Initial Checks and Tests to Establish Operating Condition of the Excavator
-- Pilot Pressure
-- Adjustment and Testing
-- Power Mode Valve
-- Current Signal and Hydraulic Pressure Adjustments
-- Swing Priority Valve
-- Control Valve Pressure and Current Adjustments
-- Pressure Up Valve
-- Checks and Adjustments
-- Pump Input Power Control
-- Pump Regulator Adjustment
-- Flow Meter and Flow Meter Kit Installation and Testing
-- Swing System Troubleshooting
-- Precautions/Initial Checks
-- Swing Relief Valve Checking and Adjustment
-- Troubleshooting - Swing Gearbox
-- Troubleshooting - Hydraulic Problems
-- Troubleshooting - Control Valve
-- Troubleshooting - Travel Pedal Valve
-- Troubleshooting - Joystick Control Valve
- Accumulator S0703010K
-- General Description
-- Specifications
- Center Joint (Swivel) S0704070
-- General Description
-- Parts List
-- Troubleshooting, Testing and Adjustment
-- Inspection
-- Testing
-- Disassembly
-- Reassembly
- Cylinders S0705000
-- General Description
-- Theory of Operation
-- Parts List
-- Special Tools and Materials
-- Piston Nut
-- Piston Jig
-- Steel bush Jig
-- Dust Wiper Jig
-- Slipper Seal Jig
-- Slipper Seal Straightening Jig
-- Disassembly
-- Assembly
- Swing Motor S0707260
-- General Description
-- Theory of Operation
-- Swing Motor Anti-cavitation Make-up Valve
-- Relief Valve
-- Swing Brake Operation
-- Parts List (Solar 140W-V, 160W-V)
-- Parts List (Solar 170LC-V, 170W-V, 450LC-V, 470LC-V)
-- Specifications
-- Special Tools (Solar 140W-V, 160W-V)
-- Special Tools (Solar 170LC-V, 170W-V)
-- Special Tools (Solar 450LC-V, 470LC-V)
-- Disassembly
-- Cleaning and Inspection (Wear Limits and Tolerances)
-- Reassembly
- Travel Motor S0707350
-- General Description
-- Theory of Operation
-- Parts List
-- Specifications
-- Travel Motor General Disassembly and Reassembly Instructions
-- Recommended Tools
-- Precautions for Disassembly and Assembly
-- Disassembly of Travel Motor
-- Appearance of Motor
-- Removal of counterbalance Valve
-- Removal of Outer Piping
-- Removal of Stroke Limiter
-- Removal of Oil Seal
-- Removal of Control Unit
-- Removal of Control Valve
-- Disassemble Control Valve
-- Disassemble Stroke Limiter
-- Reassemble Stroke Limiter
-- Reassemble Control Valve
-- Installation of Control Valve
-- Reassembly of Travel Motor
-- Assembly of Control Unit
-- Installation of Oil Seal
-- Installation of Stroke Limiter
-- Installation of Outer Piping
-- Installation of Counterbalance Valve
- Main Pump (Tongmyung) S0708306K
-- Swash Plate Type K5V Series Axial Piston Pump
-- Type Designation
-- Specifications
-- Construction and Function
-- Cautions for Operation
-- Troubleshooting
-- Construction of Tandem Type Duplex Pump
-- Tools
-- Axial Piston Pump Disassembling
-- Axial Piston Pump Reassembling
-- Axial Pump Maintenance Criteria
-- Tightening Torques
-- Regulator for T5V Series of Tongmyung Swash Plate Type Axial Piston Pump
-- Type Description
-- Construction of Regulator
-- Functional Explanations
-- Adjustment of Maximum and Minimum Flows
-- Fault Finding and Remedies on Regulator
-- Preparation for Disassembly
-- Tools
-- Regulator Disassembly
-- Regulator Reassembly
-- Tightening Torque
- Gear Pump (Steering Pump & Brake Pump) S0708435K
-- General Description
-- Theory of Operation
-- Parts List
-- Specifications
- Brake Supply Valve S0709220
-- Parts List
-- Specifications
- Counterbalance Valve S0709300
-- General Description
-- While Operating to Run Forward
-- While Operating to Stop
-- While Operating to Back
-- Adjustment of Relief Valve
-- Troubleshooting
-- Counterbalance Valve
-- Recommended Tools
-- Disassembly
-- Order of Disassembly and Torque Values
-- Reassembly
- Main Control Valve S0709416K
-- Control Valve Operation
-- Arm Priority Circuitry
-- Bucket (Junction) Circuitry
-- Straight Traveling Circuit
-- Plunger Replacement
-- Main Relief Valve
-- Overload Relief Valve
-- Arm Load Holding Valve
-- Boom Load Holding Valve
-- Arm Regeneration
-- Foot Relief Valve
-- Parts List
-- Specifications
-- Control Valve Drawing and Hydraulic Circuit
-- Disassembly and Reassembly
-- General Disassembly
-- General Reassembly
-- Main Plunger Element
-- Main Relief Valve
-- Main Relief Valve Adjustment
-- Overload Relief Valve
-- Overload Relief Valve (BM UP)
-- Arm Load Holding Valve
-- Boom Load Holding Valve
-- Arm Regeneration Valve
-- Foot Relief Valve
-- Center Bypass Valve (CB Valve)
-- Arm Parallel Switch Valve
-- Boom Unity Check Valve
-- Straight Travel Selector Valve
-- Check Valve - Locations
-- Check Valve
- Pilot Control Valve (Work Lever / Joystick) S0709451K
-- General Description
-- Theory of Operation
-- Parts List
-- Specifications
-- Removal
-- Disassembly
-- Cleaning and Inspection (Wear Limits and Tolerances)
-- Reassembly
-- Installation
-- Start-up Procedures
- Steering Valve S0709710
-- General Description
-- Theory of Operation
-- Parts List
-- Specifications
-- Special Tools and Materials
-- Special Tools
-- Disassembly
-- Reassembly
- Dozer Control Valve S0709905K
-- Parts List
-- Specifications
- Hydraulic Schematic (S140W-V / 160W-V) S0792145K
-- General Description
-- Solar 140W-V / 160W-V
ELECTRICAL SYSTEM
- Electrical System S0802125K
-- Troubleshooting - Electrical System
-- Overview
-- Electric Supply System
-- Engine Starting Circuit
-- Operation During Start Process
-- Operation After Start Process
-- Engine Preheating System
-- Engine Stop System
-- Charging System
-- Monitoring System
-- Instrument Panel
-- Monitoring System Schematic
-- Operation
-- Instruments
-- Warning and Indicator Lights
-- Control Unit
-- Operation Schematic
-- Operation Specification
-- Console Warning Light
-- Initial Operation
-- Mode Select Switch
-- Graphic Information Area Display
-- Overview
-- Main Menus for the Graphic Display Area
-- Menu Selection Buttons
-- Main Menu
-- Language setting
-- Time Setting
-- Filter/Oil information
-- Special Menu
-- Entering/Accessing and Exiting/Escaping Menus
-- Special Menu Selections
-- Electronic Hydraulic Control System (e-EPOS)
-- Power Mode Control
-- Operation
-- Throttle Position Sensor
-- Power Mode Control - Circuit Diagram
-- Work Mode Control
-- Operation
-- Work Mode Control - Circuit Diagram
-- Engine Control System
-- Engine Control Motor
-- Engine Control Dial
-- Engine Control Circuit Diagram
-- Automatic Deceleration Control (Auto Idle Control)
-- Automatic Deceleration Control Circuit
-- Operation
-- Engine Overheat Protection System
-- Power Boost Mode
-- Operation
-- Power Boost Control - Circuit Diagram
-- Cruise Control
-- Cruise Control Circuit
-- Adjusting Method of Engine Control Unit
-- Adjusting Method of Engine Control System
-- Adjusting Method of Engine RPM
-- Adjustment of TPS (Throttle Position Sensor)
-- Self-diagnostic Function
-- e-EPOS Controller
-- Engine Throttle Controller
-- Wiper System
-- Wiper Circuit
-- Wiper Operation
-- Window Washer Operation
-- Overload Warning Device
-- Overload Warning Device Circuit Diagram
- Electrical Schematic (S140W-V / 160W-V) S0892075K
-- General Description
-- Solar 140W-V / 160W-V
ATTACHMENTS
- Boom and Arm S0902060
-- Front Attachment Pin Specifications
-- Front Attachment - Removal and Installation
-- Arm Removal Procedure
-- Boom Removal Procedure
-- Front Attachment - Installation
-- Arm Installation Procedure
-- Boom Installation Procedure
-- Start-up Procedures
- Bucket S0904000
-- Bucket Tooth Inspection and Replacement
-- Type 1
-- Type 2
-- Type 3
-- Bucket O-ring Replacement
-- Type 1
-- Type 2
-- Bucket Shimming Procedures
-- New Bucket Installation
-- Type 1
-- Type 2
-- Bucket Attachment, Removal and Reversal
-- Detaching the Bucket
-- Attaching The bucket
-- Reversing the Bucket
PUBLICATION REQUEST FOR PROPOSED REVISION