Doosan Excavator Solar 170-III Shop Manual 2023-7089E – PDF DOWNLOAD

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Doosan Excavator Solar 170-III Shop Manual 2023-7089E – PDF DOWNLOAD

DESCRIPTION:

Doosan Excavator Solar 170-III Shop Manual 2023-7089E – PDF DOWNLOAD

Solar 170-111
Shop Manual
2023-7089E
Serial Number 0001 and Up
May 1997

Accessory Applications:

• The excavator has been designed primarily for moving earth with a bucket.
• For use as a grapple or for other object handling, contact Daewoo.
• Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading.
• DO NOT use the machine for activities for which it was not intended.
• DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration.
• Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.

Lifting Capacity Rating Configuration:

• Lifting-mode capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration.
• Loads must be balanced and supported evenly. Use taglines to keep the load steady if wind conditions and large surface area are a problem.
• Work crew hand signals, individual tasks and safe procedures should all be universally understood before the lift is made.

IMPORTANT:

• Before using the excavator to make lifts, check regulations that could apply.
• They may require that all heavy lifting be done with single purpose equipment specifically designed for making lifts.
• Making heavy lifts with a general purpose excavator that can be used for digging, loading, grading or other work may be expressly forbidden.
• Always follow all instructions, guidelines and restrictions for Safe Lifting in the Operation and Maintenance and Shop Manuals.

TABLE OF CONTENTS:

Doosan Excavator Solar 170-III Shop Manual 2023-7089E – PDF DOWNLOAD

SAFETY
To the Operator of a Daewoo Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Safety Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Locations of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Summary of Safe Lifting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Work-site Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 o
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Shipping and Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Excavator Lift Capacity Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SPECIFICATIONS
Excavator Machinery Plan ………………………………………………. 2-1
Excavator Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Excavator Engine Performance Curves (KS-R1004 Standard ) ………………………. 2-3
Hydraulic System Component Specifications ………………………………….. 2-4
Hydraulic Pump Performance Characteristics …………………………………. 2-6
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
General Dimensions ………………………………………………….. 2-8
Working Range Diagram ……………………………………………….. 2-9
Reference Table – Approximate Weight of Workload Materials ………………………. 2-1 O
Excavator Lift Capacity Tables ……………………………………………. 2-12
Performance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
UPPER STRUCTURE
Operator’s Cab Removal Procedure ……………………………………….. 3-1
Falling Object Protective Structures (F.O.P.S.) …………………………………. 3-3
Front Attachment Pin Specifications ……………………………………….. 3-4
Bucket Tooth Inspection and Replacement …………………………………… 3-5
Shimming Bucket Linkage ………………………………………………. 3-6
Bucket Attachment, Removal and Reversal …………………………………… 3-7
Removal and Installation of the Front Attachment ………………………………. 3-8
Engine Components ………………………………………………….. 3-11
Fuel Tank Removal and Installation ………………………………………… 3-12
Engine Cooling System: Radiator/Oil Cooler ………………………………….. 3-13
Counterweight Removal and Installation …………………………………….. 3-14
Hydraulic System Schematic …………………………………………….. 3-16
Hydraulic System Description ……………………………………………. 3-17
Operation of Working Components ………………………………………… 3-18
Hydraulic System General Precautions ……………………………………… 3-22
Maintenance Service and Repair Procedures …………………………………. 3-23
Welding Precautions and Guidelines ……………………………………….. 3-24
Accumulator ……………………………………………………….. 3-25
Hydraulic Cylinder Operation …………………………………………….. 3-27
Hydraulic Attachment Cylinder Assembly and Parts List ………………………….. 3-28
Hydraulic Cylinder Disassembly and Assembly ………………………………… 3-29
170-111 Shop Manual
Cylinder Reassembly . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … … … … …. . . 3-33
Swing Bearing Maintenance . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … . .. . .. . .. . .. . . . 3-35
Swing Bearing Rebuild . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … … … … … . . . 3-36
Center Joint (Swivel) Overhaul/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. 3-38
Main Pump Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Pump Regulator Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Main Pump Parts List . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … … … … .. .. . . 3-49
Main Pump Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . … .. 3-50
Reassembly of Main Pumps and Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 3-53
Pump Regulator Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Pump Regulator Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Swing Motor Basic Operation ……………………………………………. 3-62
Swing Motor Parts List ………………………………………………… 3-65
Swing Motor Disassembly . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … . .. . .. . .. . .. . . . 3-66
Swing Motor Reassembly . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … . .. . .. . .. . .. . . . 3-71
Swing Reduction Gearbox Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. 3-77
Swing Reduction Gearbox Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . … .. 3-78
Control Valve Section Views and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Main Control Valve Disassembly .. … . .. . .. . .. . .. . … … … … … … …………. . 3-92
Main Control Valve Reassembly ………………………………………….. 3-102
Remote Control Valve Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
Remote Control Valve Assembly and Parts List . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . … .. 3-111
Remote Control Valve Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 3-113
Travel Control Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . 3-120
Travel Control Valve Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 3-121
LOWER STRUCTURE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Travel Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Travel Motor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Front Idler Roller Parts List . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … … … … .. . . . . 4-28
Lower Roller Parts List . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … … … … .. . . . . 4-31
Upper Roller Assembly and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Track Spring and Track Adjusting Cylinder Assembly and Parts List …………………… 4-36
Service Standards for Lower Travel Frame Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Track Tensioning . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … … … … . . .. . . 4-41
ELECTRICAL SYSTEM
General Description . . . . . . . . . . . . . . . . . . . . .. . … .. . .. . .. . .. . .. . … … … … .. .. . . 5-1
24 Volt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Engine Start-up and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . 5-3
Cylinder Preheat – Intake Air Electrical Heater ………………………………… 5-4
Alternator Circuit …………………………………………………….. 5-5
Low Current Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . 5-7
Wiring Color Code for Electrical Schematic Diagrams . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . 5-8
Climate Control (Air Conditioning) Circuit . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . 5-9
Power Mode System Operating Components . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . … .. 5-11
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . .. . … .. . .. . .. . .. . .. . … … … … . . .. . . 5-12
Instrument Panel LED Displays and Input Terminal Connections …………………….. 5-14
Instrument Panel Connector Arrangement ……………………………………. 5-14
Instrument Panel Selector Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . .. 5-15
Instrument Panel Coolant Overheating Circuit . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . … .. 5-15
Instrument Panel Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . . . 5-15
Instrument Panel Engine Oil Pressure Circuit . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . .. . … .. 5-16
Start-up Electrical Test Circuit . . . . . . . . . . . . . .. . .. . .. . .. . .. . .. . … … . .. . .. . .. . . . . . . 5-16
ii 170-111 Shop Manual
Interior Lighting ……………………………………………………… 5-16
Hydraulic Pump Discharge Pressure Sensor ………………………………….. 5-16
Power Mode Circuit Instrument Panel Summary ……………………………….. 5-18
Power Mode System Basic Operation ………………………………………. 5-19
Power Mode 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Power Mode 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Power Mode I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Swing Priority Circuit ………………………………………………….. 5-25
Swing and Arm Dump Combined Operation ………………………………….. 5-26
Swing Priority and Arm Crowd Recovery Function ………………………………. 5-27
Loading Work Mode ………………………………………………….. 5-28
Leveling Mode I I …………………………………………………….. 5-29
Boom Up, Arm Crowd and Bucket Crowd Combined Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Leveling Mode I: Boom Up and Arm Crowd Combined Operation ……………………. 5-31
Forward Travel: Swing During Straight Travel ………………………………….. 5-32
Forward Travel: Arm Operation or Boom Operation While Traveling …………………… 5-33
Electrical Wiring Diagram ………………………………………………. 5-35
ENGINE
Engine Specifications …………………………………………………. 6-1
Wear Limits of Major Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Engine Oil Pump Rebuild ………………………………………………. 6-5
Fuel Injection Pump ………………………………………………….. 6-6
Cylinder Head Bolt Torques ……………………………………………… 6-8
Engine Control System ………………………………………………… 6-9
Engine T hrottle Controller ………………………………………………. 6-11
Pressure Increase Operation …………………………………………….. 6-13
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Engine Control Circuit …………………………………………………. 6-15
INSPECTION, MAINTENANCE AND ADJUSTMENT
Periodic Inspection and Maintenance ………………………………………. 7-1
Maintenance Intervals …………………………………………………. 7-2
Table of Recommended Lubricants ………………………………………… 7-3
Inspection and Maintenance …………………………………………….. 7-4
Daily or Every 1 0 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Weekly or Every 50 Operating Hours ………………………………………. 7-9
150 Operating Hours ………………………………………………….. 7-1 O
Monthly or Every 250 Operating Hours ……………………………………… 7-11
T hree Months or Every 500 Operating Hours …………………………………. 7-13
Six Months or Every 1,000 Operating Hours ………………………………….. 7-14
Annually or Every 2,000 Operating Hours ……………………………………. 7-15
General Maintenance Procedures …………………………………………. 7-16
Torque Specifications …………………………………………………. 7-18
Torque Wrench Extension Tools …………………………………………… 7-19
Flange and T hread Sealant Assembly Compounds ……………………………… 7-21
Welding Precautions and Guidelines ……………………………………….. 7-23
Hydraulic System Cleanliness and Oil Leaks ………………………………….. 7-24
170-111 Shop Manual iii
TESTING, TROUBLESHOOTING AND ADJUSTING
Troubleshooting Recommendations ………………………………………… 8-1
Troubleshooting – Engine Problems ……………………………………….. 8-2
EPOS-111 Self-diagnostic Codes …………………………………………… 8-6
Engine T hrottle Controller ………………………………………………. 8-8
Troubleshooting Electrical System ……………………………………….. 8-10
Flow Meter and Flow Meter Kit Installation and Testing …………………………… 8-11
Pilot Pressure ………………………………………………………. 8-12
Negacon, Negative Control ……………………………………………… 8-13
Power Mode Valve …………………………………………………… 8-14
Boom/Swing Priority ………………………………………………….. 8-15
Pressure Up Valve …………………………………………………… 8-16
Pump Input Power Control ……………………………………………… 8-17
Swing System Troubleshooting …………………………………………… 8-19
Troubleshooting – Hydraulic Problems ………………………………………. 8-21
Troubleshooting – Control Valve ………………………………………….. 8-23
Troubleshooting – Travel Control Valve ………………………………………. 8-25
Troubleshooting – Joystick Control Valve …………………………………….. 8-26
Troubleshooting – Swing System ………………………………………….. 8-27
Troubleshooting – Swing Gearbox …………………………………………. 8-28
INDEX …………………………………………………………….. 9-1
iv
DOOSAN EXCAVATOR SOLAR 170-III SHOP MANUAL 2023-7089E – PDF DOWNLOAD:

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