PDF Parts Manual Daewoo Doosan Solar 015 Plus Solar 018-VT Excavator - 1010 KB
This is the official parts manual for the Daewoo Doosan Solar 015 Plus and Solar 018-VT excavators.
It contains detailed exploded views of all machine components, allowing for easy identification of every nut, bolt, and assembly.
With correct part numbers readily available, you can streamline your ordering process and get the right parts the first time.
This PDF is a crucial tool for any mechanic or parts department servicing these compact excavators.
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--- Page 1 ---
Solar 015 PLUS
& Solar 018-VT
Shop Manual
K1000237E
Serial Number 30001 and Up
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
K1000237E Shop Manual
--- Page 3 ---
S0102040
R1
1TRACK EXCAVATOR
SAFETY
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that are in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TRACK EXCAVATOR SAFETYS0102040
MODEL SERIAL NUMBER RANGE
Solar 015 0001 and Up
Solar 015 PLUS 1001 thru 1157, 20001 thru 20065, 20066 thru 30000, 30001
and Up
Solar 018-VT 30001 and Up
Copyright DOOSAN 2004
May 2004
Track Excavator Safety S0102040
Page 1
--- Page 4 ---
NEVER USE ETHER STARTING AIDS
An electric grid type manifold heater is used for
cold starting. The glowing heater element can
cause ether or other starting fluid to detonate,
causing injury.
Figure 9
MOUNTING AND DISMOUNTING
NEVER get on or off a moving machine. Do not
jump on/off. The entry/egress path must be
clear of mud, oil and spills and mounting
hardware must be kept tight and secure.
Always use handholds, steps or track shoes and
maintain at least 3-point contact of hands and
feet. Never use controls as handholds.
NEVER get up from the operator's seat or leave
the operator's station and dismount the machine
if the engine is running.
Figure 10
OBSERVE GENERAL SAFETY RULES
Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be
allowed to operate or perform maintenance or service on the excavator.
All personnel at the work site must be aware of assigned individual responsibilities and tasks.
Communication and hand signals used must be understood by everyone.
Terrain and soil conditions at the work site, approaching traffic, weather related hazards and any above or
below ground obstacles or hazards must be observed and monitored by all work crew members.
ENGINE VENTILATION
Engine exhaust gases can cause fatal
accidents, and unconsciousness, loss of
alertness, judgement and motor control and
serious injury.
Make sure of adequate ventilation before
starting the engine in any enclosed area.
You should also be aware of open windows,
doors or ductwork into which exhaust may be
carried, or blown by the wind, exposing others to
danger. HAOA070L
Figure 11
Track Excavator Safety S0102040
Page 11
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MAINTENANCE
KEEP MACHINE CLEAN AT ALL TIMES
Keep machine free of oil and grease at all times.
Water will damage the electrical system. Never
use water or steam on the inside of the cabin, in
the engine compartment or in any location
where it may reach sensors, connectors or other
electrical components.
HFB1030L
Figure 25
USE WARNING TAG CONTROL LOCKOUT
PROCEDURES DURING SERVICE
Alert others that service or maintenance is
being performed and tag operator's cabin
controls - and other machine areas if required -
with a warning notice. OSHA mandated control WARNING
lever lockout can be made with any OSHA
certified lockout device and a length of chain or
cable to keep the left-hand control console in the
fully raised, nonactive position.
Warning tags for controls are available from HAOC920L
DOOSAN distributors.
Figure 26
DO NOT RUN THE ENGINE IF REPAIRS OR
WORK IS BEING PERFORMED ALONE
You should always have at least two people
working together if the engine must be run
during service. One person needs to remain in
the operator's seat, ready to work the controls or
stop the machine and shut off the engine.
ALWAYS USE ADEQUATE EQUIPMENT
SUPPORTS AND BLOCKING
Do not allow weight or equipment loads to
remain suspended. Lower everything to the
ground before leaving the operator's seat. Do
not use hollow, cracked or unsteady, wobbling
weight supports. Do not work under any
90 ~ 100
equipment supported solely by a lift jack. When
inspecting or performing service under a
machine that is jacked up, keep boom at a 90°-
100°angle to the arm and chock tracks securely.
HBOH810L
Figure 27
Track Excavator Safety S0102040
Page 21
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GENERAL DESCRIPTION
The excavator has three main component sections:
• The Upper Turntable
• The Lower Undercarriage and Track Frames
• The Excavator Front End Attachment
The following illustration identifies main components and their locations. (See Figure 1 on page -4.)
Specifications for Solar 015 PLUS / Solar 018-VT S0202140
Page 3
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Reference Description Machine Type
Solar 015 PLUS Solar 018-VT
Boom Type (One Piece) 1,690 mm (66.53 in)
850 mm 1,100 mm 850 mm 1,100 mm
Arm Type
(33.46 in) (43.30 in) (33.46 in) (43.30 in)
Bucket Type (SAE) 0.04 m3
A Max. Digging Reach 3,700 mm 3,920 mm 3,700 mm 3,920 mm
(145.67 in) (153.62 in) (145.67 in) (153.62 in)
B Max. Digging Reach 3,605 mm 3,850 mm 3,565 mm 3,595 mm
(Ground) (141.93 in) (151.57 in) (140.35 in) (141.54 in)
C Max. Digging Depth 2,140 mm 2,385 mm 2,075 mm 2,325 mm
(84.25 in) (93.90 in) (81.69 in) (91.53 in)
D Max. Loading Height 2,245 mm 2,420 mm 2,310 mm 2,485 mm
(88.39 in) (95.28 in) (90.95 in) (97.83 in)
E Min. Loading Height 1,225 mm 1,085 mm 1,285 mm 1,500 mm
(48.23 in) (42.72 in) (50.59 in) (59.06 in)
F Max. Digging Height 3,400 mm 3,560 mm 3,465 mm 3,625 mm
(133.86 in) (140.16 in) (136.42 in) (142.72 in)
G Max. Bucket Pin Height 2,830 mm 3,005 mm 2,870 mm 3,045 mm
(111.42 in) (118.31 in) (113.00 in) (119.89 in)
H Max. Vertical Wall 1,630 mm 1,845 mm 1,565 mm 1,780 mm
Depth (64.17 in) (72.64 in) (61.61 in) (70.08 in)
I Min. Swing Radius 1,500 mm 1,670 mm 1,500 mm 1,670 mm
(59.06 in) (65.75 in) (59.06 in) (65.75 in)
d Bucket Angle 159 ° 159 ° 159 ° 159 °
Specifications for Solar 015 PLUS / Solar 018-VT S0202140
Page 13
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BOOM SWING TEST
With the boom, arm and bucket in the same
position as for the swing speed test with the
boom evenly centered between the side frames,
pointing straight ahead. Use the controls to 75
swing the boom to one side then back to the
center. Measure the time it takes for the boom to
swing to the maximum position (75° from the
center). Repeat the process for the other side.
S/N 30001 and Up
Left 5.3 sec. 50
Right 3.8 sec.
AKS1300L
Figure 7
CYLINDER PERFORMANCE TESTS
NOTE: All tests are performed with standard boom, arm and bucket configuration. The bucket
must be empty.
Boom Cylinders Test
The starting points for the test are with the boom and arm extended away from the excavator, and the
bucket curled inward. The arm cylinder must be fully retracted; boom and bucket cylinders must be
extended. Test movement in both directions, several times, and average results.
Arm Cylinder Test
Start with the boom up and the arm cylinder fully retracted. Test movement in both directions several times,
between the "crowd" and "dump" positions, and average the results of both tests.
Bucket Cylinder Test
Start with the boom up and the teeth of the bucket hanging vertically, 500 mm (1.5' - 2') above the ground.
Dump and crowd the bucket several times, and average results.
Dozer Blade Cylinder
Start with the blade in the rest position on level ground. Test the movement of the blade cylinder several
times. Measure the times it takes for the blade to move from the level ground rest position to the up position
and back down to the rest position on level ground.
Move the excavator to a spot where the blade can be moved up and down through the full stroke. Start with
the blade in the lowest position. Test the movement of the blade cylinder several times. Measure the times
it takes for the blade to move through the full stroke from the lowest position to the highest position and
back down to the lowest position.
Specifications for Solar 015 PLUS / Solar 018-VT S0202140
Page 23
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IMPORTANT
Hydraulic system operating conditions (repetitive cycling, heavy work loads, fluid circulating
under high-pressure) make it extremely critical that dust, grit or any other type of contamination
be kept out of the system. Observe fluid and filter change maintenance interval
recommendations and always preclean any exterior surface of the system before it is exposed to
air. For example, the reservoir fill cap and neck area, hoses that have to be disassembled, and
the covers and external surfaces of filter canisters should all be cleaned before disassembly.
MAINTENANCE SERVICE AND REPAIR PROCEDURE
GENERAL PRECAUTIONS
Fluid level and condition should always be checked whenever any other type of maintenance service or
repair is being performed.
NOTE: If the unit is being used in an extreme temperature environment (in subfreezing climates or
in high temperature, high humidity tropical conditions), frequent purging of moisture
condensation from the hydraulic reservoir drain tap must be a regular and frequent part of
the operating routine. In more moderate, temperate climates, draining reservoir sediment
and moisture may not be required more than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring or visible fluid contamination at every oil
change. Abrasive grit or dust particles will cause discoloration and darkening of the fluid. Visible
accumulations of dirt or grit could be an indication that filters are overloaded (and will require more
frequent replacement) or that disintegrating bearings or other component failures in the hydraulic circuit
may be imminent or have already occurred. Open the drain plugs on the main pump casings and check
and compare drain oil in the pumps. Look for evidence of grit or metallic particles.
Vibration or unusual noise during operation could be an indication of air leaking into the circuit (Refer to the
appropriate Troubleshooting section for component or unit for procedures.), or it may be evidence of a
defective pump. The gear type pilot pump could be defective, causing low pilot pressure, or a main pump
broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown on the multidisplay digital gauge on
the Instrument Panel ("F-Pump" and "R-Pump") will be reduced as a result of a
mechanical problem inside the pump. However, pressure loss could also be due to
cavitation or air leakage, or other faults in the hydraulic system.
Check the exterior case drain oil in the main pumps. If no metallic particles are found, make sure there is
no air in the system. Unbolt and remove the tank return drain line from the top part of the swing motor, both
travel motors and each main pump. If there is air in any one of the drain lines, carefully prefill the assembly
before bolting together the drain line piping connections. Run the system at low rpm.
General Maintenance Procedures S0302000
Page 5
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S0309000
R1
1STANDARD TORQUES
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that are in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
STANDARD TORQUESS0309000
MODEL SERIAL NUMBER RANGE
ALL MODELS ALL RANGES
Copyright DOOSAN 2002
May 2002
Standard Torques S0309000
Page 1
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I. "Loctite" Fastener Adhesives
Breakaway Cure
Product Application Color Removal Strength (in lb)
of Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
242 or Medium strength for 6 mm (1/4") and
Blue Hand tools 80
243 larger fasteners.
High strength for high grade Heat/260°C (500°F)
262 fasteners subject to shock, stress Red Remove HOT 160
and vibration. (NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
II. "Loctite" Pipe Thread Sealant
Product Application Color Removal Required Setup
"No-filler/nonclog" formula for high-pressure 4 Hours (or 1/2 hour
545 hydraulic systems. Over application will not Purple Hand tools with Locquic "T"
restrict or foul system components. Primer)
4 Hours (or 1/2 hour
Solvent resistant, higher viscosity tapered
656 White Hand tools with Locquic "T"
thread sealer.
Primer)
III. "Loctite" gasket/flange sealer
Product Application Color Notes
Gasket eliminator specifically made for Use Locquic "N" primer for fast
518 aluminum flanges/surfaces. For hydraulic Red (1/2 - 4 hours) setup. Unprimed
systems to 34,475 kPa (5,000 psi). setup 4 - 24 hours.
Low-pressure/wide-gap gasket eliminator Use Locquic "N" primer for faster
504 compound. Fills gaps to 0.0012 mm (0.030"), Orange (1/2 - 4 hours) setup. Unprimed
cures to rigid seal. setup 4 - 24 hours.
General purpose, fast setup, flexible-cure Use Locquic "N" primer for faster
515 gasket eliminator. For nonrigid assemblies Purple (1/4 - 2 hours) setup. Unprimed
subject to shock, vibration or deflection. setup 1 - 12 hours.
Standard Torques S0309000
Page 11
--- Page 12 ---
2. Measure the distance (A, Figure 2)
between the rolling surface of the track
roller and the contact surface of the
crawler.
NOTE: This measurement can be
thrown off if there is too much
mud or dirt or other material in
the track assembly. Clean off
the tracks before checking
clearance.
Figure 2
A. For rubber crawlers
It is accepted if the distance between
the rolling surface of the track roller
and the contact surface of the crawler
is 10 - 15 mm (0.39 - 0.59 in).
3. Too little sag in the crawler track can cause
excessive component wear. The
recommended adjustment can also be too
tight causing accelerated stress and wear
if ground conditions are wet, marshy or
muddy, or if the ground is hard and full of
rocks or gravel.
Figure 3
WARNING!
The track adjusting mechanism is under very high-pressure. NEVER release pressure too
suddenly. The grease cylinder valve should never be backed off more than 1 complete turn
from the fully tightened down position. Bleed off pressure slowly and keep your body away
from the valve at all times.
Track Assembly S0505130K
Page 5
--- Page 13 ---
3. Use a steel bar for leverage and slide the
rubber track assembly over the idler
assembly.
4. Apply track tension. Refer to "Track
Tension" in this section for procedure.
Figure 16
Track Assembly S0505130K
Page 15
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Starter .......................................................................................... 135
Starter .......................................................................................... 135
Dynamo........................................................................................ 136
Alternator ..................................................................................... 136
Alternator ..................................................................................... 136
Regulator ..................................................................................... 136
Glow Plug (Quick Heat Type) ....................................................... 137
Glow Plug Indicator (Quick Heat Type) for L2 .............................. 137
Glow Plug Indicator (Quick Heat Type) for L3 .............................. 137
Fuel Cutoff Solenoid .................................................................... 137
Fuel Cutoff Solenoid .................................................................... 137
Tightening Torque Chart and Sealant Chart ....................................... 138
Control Timer ............................................................................... 138
Glow Plug Timer .......................................................................... 138
Glow Plug Relay .......................................................................... 138
Tightening Torque for Common Bolts and Nuts .................................. 139
Tightening Torque for Common Plugs................................................. 140
Sealant Chart ...................................................................................... 140
Engine S0601010K
Page 9
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ENGINE SPECIFICATIONS
Item
Model
L2A L2C L2E L3A L3C L3E
Engine Type 4-cycle, Water Cooled, Vertical, Diesel
Firing Order 1-2 1-3-2
Compression Ratio 23:1
General
Combustion Chamber Swirl Chamber
61 kg 75 kg
Dry Weight
(134 lb) (165 lb)
Number of Cylinders 2 3
(2.56 x 2.76 in)
(2.56 x 2.76 in)
(2.76 - 2.76 in)
(2.99 - 2.76 in)
(2.76 - 2.76 in)
(2.99 - 2.76 in)
65 x 70 mm
70 x 70 mm
76 x 70 mm
65 x 70 mm
70 x 70 mm
76 x 70 mm
Bore x Stroke
Cylinders
464 cc 538 cc 635 cc 696 cc 808 cc 952 cc
Total Displacement (28.32 (32.83 (38.75 (42.47 (49.31 (58.09
in3) in3) in3) in3) in3) in3)
Maximum Power
Maximum Torque
Performance See the engine performance curves.
Specific Fuel
Consumption
In every direction 30° in a short time (within
List Ability 25° continuous
(to lower limit of oil level) 30 min.)
Injection Pump Bosch NC type
Fuel System Nozzle Throttle type
Fuel JIS No. 2 or No. 3 Diesel Fuel
Lubricating Method Forced Lubrication
Oil Filtration Paper Element Filter (Full-flow Type)
3.0/1.5 liters
Lubrication (0.79 - 0.40 U.S. gal.)
Oil Capacity
System Upper Limit/Lower Limit 2.4/1.4 liters 3.6/1.8 liters
(Excluding 0.5 liters (0.13 (0.63/0.37 U.S. gal.) (0.95 - 0.48 U.S. gal.)
U.S. gal.) for oil filter)
or 4.8/3.0 liters
(1.3 - 0.79 U.S. gal.)
Cooling Method Forced water circulation with pressurized radiator.
Cooling Coolant Capacity
System 1.20 liters 1.80 liters
(Except Radiator and
(0.32 U.S. gal.) (0.48 U.S. gal.)
Hose)
Alternator 12 V @ 15 A or 12 V @ 40 A
Accessories Starting Motor 12 V @ 1.2 kW or 12 V @ 0.6 kW
Battery 45 Ah or more 60 Ah or more
Engine S0601010K
Page 19
--- Page 17 ---
2. Lower limit of engine speed can be
adjusted with LOW-SPEED stopper bolt.
3. Never remove sealing cap unnecessarily
to adjust torque spring setting. For proper
disassembly procedure see “Torque
Spring” on page 90.
CAUTION!
Warm up engine (until coolant
temperature rises up to 50°C (122°F)
Figure 31 HIGH SPEED AND LOW SPEED SET
or above) before adjusting engine
BOLTS
speeds.
4. While running engine for speed
adjustment, check engine for exhaust gas
leak, water leak, oil leak, and fuel leak.
5. After adjustment, perform engine
acceleration and deceleration test to
confirm that engine is free from hunting
and smoking.
Checking and Adjustment of Nozzles
To check and adjust injection nozzles, use
following procedure:
1. Injection start pressure.
A. Remove nozzle assembly to be
tested from cylinder head and set
nozzle on nozzle tester.
Perform air bleeding by moving tester
hart file up and down.
B. Operate handle at a speed of 60 rpm
or more and read gauge pressure of Figure 32 TESTING INJECTION START PRES-
fuel injected from nozzle. SURE
NOTE: Injection start pressure: 140+10
-0
+140
kg/cm2 (1,990 -0 psi).
C. If reading of gauge pressure is not
within specified range, disassemble
nozzle and vary thickness of
adjusting shim.
Increasing or decreasing shim
thickness by 0.1 mm (0.0039 in) will
cause injection pressure to vary
about 10 kg/cm2 (142 psi).
Engine S0601010K
Page 29
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ENGINE
SPECIAL TOOLS
Use Tool Name Sketch Referential Page
Removal and installation Piston pin setting tool
of piston pin
ST332400
Measurement of Compression gauge
cylinder compression adapter
ST332270
Removal and installation Oil pressure switch
of oil pressure switch socket wrench (26)
MD998054
Repair of valve seat Valve seat cutter pilot
Valve seat cutter, 45°
Valve seat cutter, 60°
Valve seat cutter, 30°
Engine S0601010K
Page 39
--- Page 19 ---
1. Repair of valve face.
If valve face is found worn down, resurface
with a valve refacer. If margin of resurfaced
valve exceeds service limit, replace valve.
2. Repair of valve stem end.
If valve stem end has been indented by