Daewoo Solar 210W-V Wheel Excavator Shop Manual 023-00064E – 2002 PDF Repair Guide

Description

The Daewoo Solar 210W-V Shop Manual is the complete workshop repair guide for the Solar 210W-V wheel excavator, covering serial number 1001 and up. Issued by Daewoo Heavy Industries under document number 023-00064E, this 824-page PDF takes a technician through every major system on the machine – from the Daewoo DB58TIS turbocharged diesel engine and ZF 2HL-100 transmission to the Toshiba DX28 main control valve, swing motor, travel motor, front and rear axles, and the full hydraulic and electrical schematics.

File Details

• Manual type: Shop Manual (workshop service and repair)
• Brand: Daewoo Heavy Industries Ltd.
• Model: Solar 210W-V wheel excavator
• Document number: 023-00064E
• Serial number coverage: 1001 and Up
• Language: English
• File format: PDF
• Page count: 824 pages
• Publication date: 2002 (individual sections carry 1999, 2000, 2001 and 2002 revision dates)

Chapters Covered in the Daewoo Solar 210W-V Shop Manual

The manual is divided into the standard Daewoo shop manual groups, each carrying its own section number so a technician can jump straight to the system in front of them:

• Safety – Wheel Excavator Safety (S0102025K): safety alert symbols, general hazard information, before starting engine, machine operation, maintenance, battery, towing, shipping and lifting with sling.
• Specifications – Specifications for Solar 210W-V (S0202045K): component location, general dimensions, working range, hydraulic cylinders, engine specifications and performance curves, approximate weight of workload materials, general specifications, hydraulic system component specifications and performance tests.
• General Maintenance – General Maintenance Procedures (S0302000) and Standard Torques (S0309000): welding precautions, hydraulic system cleanliness and oil leaks, bearing inspection, torque values for standard metric and U.S. fasteners, hose clamps, split flanges and torque wrench extension tools.
• Upper Structure – Cab (S0402040K), Counterweight (S0403015K), Fuel Tank (S0405075K), Fuel Transfer Pump (S0405500), Swing Bearing (S0407010) and Swing Reduction Gearbox (S0408040).
• Lower Structure and Chassis – Ram Lock Valve Operation (S0503000).
• Engine and Drive Train – Front Axle (S0602100), Transmission ZF 2HL-100 (S0602110), Air-Conditioner (S0605060K) and Drive Coupling / Main Pump (S0609000).
• Hydraulics – Hydraulic System Troubleshooting, Testing and Adjustment (S0702115K), Accumulator (S0703010K), 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 (S0709440), Pilot Control Valve / Work Lever / Joystick (S0709451K), Steering Valve (S0709710), Dozer Control Valve (S0709905K) and Hydraulic Schematic (S0792101K).
• Electrical System – Electrical System (S0802125K) and Electrical Schematic (S0892101K): electric supply, engine starting and preheat, engine stop, charging, monitoring system, instrument panel, control unit, e-EPOS electronic hydraulic control, power mode control, work mode control, engine control system, auto idle, power boost, cruise control, self-diagnostic function, wiper system and overload warning device.
• Attachments – Boom and Arm (S0902080) and Bucket (S0904000).

What this gives a technician is not a general overview but a working document. Every section follows the same pattern Daewoo used in its dealer workshops: theory of operation first, then removal, disassembly, cleaning and inspection with wear limits and tolerances, reassembly, installation and start-up procedures. Torque values, relief pressures, adjustment screws and wear limits appear in the same pages as the procedure that needs them, so the reader is not flipping between a repair chapter and a separate specification book.

Engine, Transmission and Axle Work

The engine and drive train group covers the Daewoo DB58TIS four-cycle in-line six-cylinder turbocharged water-cooled diesel in full specification detail – 102 mm x 118 mm bore and stroke, 5,785 cc displacement, 19.5:1 compression ratio and 157 ps at 2,200 rpm – together with its performance curves and fuel system data. The transmission chapter deals with the ZF 2HL-100 two-speed power shift planetary unit, including the input shaft and brake assembly, clutch, planetary carrier, helical gear, shift lever, shift lock versions A and B, final drive, rear axle and differential gear. The front axle chapter covers the planetary ends and the differential gear with measured shim thickness calculations, backlash adjustment, contact pattern checking and the multi-disc brake piston clearance table, so axle rebuilds can be completed to specification rather than by feel.

Hydraulics and Electrical Coverage

The hydraulic group is the deepest part of this Solar 210W-V shop manual. It includes the full troubleshooting, testing and adjustment procedure with a specified test sequence – pilot pressure, negative control pressure, main relief pressure, swing pressure, port relief pressure, power boost and standard performance tests – followed by individual chapters for the accumulator, center joint, cylinders, swing motor, travel motor, tandem main pump with regulators, brake supply valve, counterbalance valve, Toshiba DX28 main control valve, pilot control valve, steering valve and dozer control valve. Because it is a wheeled machine, the manual also carries the complete hydraulic schematic for the Solar 210W-V, including mono boom and articulated boom configurations.

On the electrical side the document covers the 24 V system end to end: batteries, battery relay, starter switch, fusible link, circuit breaker and fuse box, starting and preheat circuits, the engine stop motor circuit, charging system, monitoring system and instrument panel. The e-EPOS electronic hydraulic control system is documented with its power mode control, work mode control, engine throttle controller, throttle position sensor adjustment tables and the self-diagnostic failure code list. The electrical schematic for the Solar 210W-V is included as its own section.

Who This Daewoo Solar 210W-V Shop Manual Is For

This is the reference for anyone maintaining, repairing or rebuilding a Solar 210W-V wheel excavator – independent heavy equipment mechanics, fleet workshops, technical colleges and owners who do their own servicing. The procedures assume the reader has the machine in front of them and access to the special tools named in the text, and the safety group at the front sets out the lifting, blocking, pressure-release and lockout precautions that apply before any of it begins. Sections reference companion service literature for the operation and maintenance side, but everything needed for the mechanical, hydraulic and electrical repair work is contained in these pages.

Get the Complete Daewoo Solar 210W-V Shop Manual

With this manual on hand, the jobs it supports are broad: rebuilding the ZF 2HL-100 transmission, re-shimming and setting backlash in the front or rear axle differential, diagnosing a swing or travel motor that will not rotate, adjusting main relief and power boost pressure, tracing a faulty circuit through the instrument panel or e-EPOS controller, repacking a boom, arm or bucket cylinder, and setting bucket pin end play correctly. Correct procedures and the right torque and pressure values are what separate a repair that lasts from one that returns – and on a machine this size the difference is expensive.

IMAGES PREVIEW

The Daewoo Solar 210W-V Shop Manual 023-00064E is delivered as an instant PDF download after checkout. There is no shipping, no waiting for a parcel and no physical book to keep clean in the workshop. Open it on a laptop, tablet or phone at the machine, print only the pages you need for the job in front of you, and keep the rest of the 824 pages for the next repair.