Complete repair service manual for Daewoo Solar 210W-V Excavator, with all the workshop information to maintain, diagnostic, repair, and rebuild like professional mechanics.

Daewoo Solar 210W-V Excavator 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.

023-00064E - Daewoo Solar 210W-V SHOP MANUAL (Serial Number 1001 and Up).pdf
CENS21WV0002.pdf
S210W-V_HYD_CIRCUIT.pdf

Total Pages: 824 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
Safety
Wheel Excavator Safety ... S0102025K
Specifications
Specifications for Solar 210W-V ... S0202045K
General Maintenance
General Maintenance Procedures ...S0302000
Standard Torques ..S0309000
Upper Structure
Cab ... S0402040K
Counterweight... S0403015K
Fuel Tank.. S0405075K
Fuel Transfer Pump ...S0405500
Swing Bearing..S0407010
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
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
Hydraulic Schematic (Solar 210W-V) ... S0792101K
Electrical System
Electrical System .. S0802125K
Electrical Schematic (Solar 210W-V).. S0892101K
Attachments
Boom and Arm...S0902080
Bucket..S0904000
Publication Request for Proposed Revision

023-00064E - Daewoo Solar 210W-V SHOP MANUAL (Serial Number 1001 and Up)...2
  Safety...8
    Wheel Excavator Safety S0102025K...10
      To the Operator of a Daewoo Excavator...12
        Learn the Signal Words Used with the Safety Alert Symbol...14
      General Safety Essentials...15
        Accessory Applications...15
        Lifting Capacity Rating Configuration...15
      Location of Safety Labels...15
      Summary of Safety Precautions for Lifting in Digging Mode...16
      Unauthorized Modifications...17
      General Hazard Information...17
        Safety Rules...17
        Safety Features...17
        Inside Operator's Compartment...18
        Clothing and Personal Protective Items...19
        Breathing Masks, Ear Protection May be Required...19
        Mounting and Dismounting...20
        Fuel, Oil and Hydraulic Fluid Fire Hazards...21
        Precautions When Handling Fluids at High Temperature...21
        Asbestos Dust Hazard Prevention...22
        Injury from Work Equipment...22
        Fire Extinguisher and First Aid Kit...23
        Protection from Falling or Flying Objects...23
        Attachment Precautions...24
        Accumulator...24
        Indoor Ventilation...25
        Emergency Exit...25
      Before Starting Engine...26
        Work Site Precautions...26
        Checks Before Starting Engine...27
        Engine Starting...28
        Before Operating Machine...28
      Machine Operation...29
        When Swinging or Changing Direction of Travel...29
        Travel Precautions...29
        Traveling on Slopes...30
        Prohibited Operations...31
        Precautions for Operation...31
        Avoid High-voltage Cables...32
        Operate Carefully on Snow, Ice and in Very Cold Temperatures...32
        Operations on Slopes...33
        Parking Machine...33
        Never Let Anyone Ride on Attachment...33
      Maintenance...34
        Warning Tag...34
        Clean Before Inspection or Maintenance...34
        Proper Tools...35
        Use of Lighting...35
        Fire Prevention and Explosion Prevention...35
        Burn Prevention...36
        Welding Repairs...37
        Warning for Counterweight and Front Attachment Removal...37
        Precautions for Removal, Installation, and Storage of Attachments...38
        Precautions when Working on Machine...38
        Lock Inspection Covers...38
        Crushing Prevention and Cutting Prevention...38
        Supports and Blocking for Work Equipment...39
        Action When Abnormally Is Found During Inspection...40
        Precautions with High Pressure Line, Tubes and Hoses...40
        Waste Materials...41
      Battery...42
        Battery Hazard Prevention...42
        Boost Starting or Charging Engine Batteries...43
      Towing...44
        Precautions When Towing...44
      Shipping and Transportation...45
        Obey State and Local Over-the-Road Regulations...45
      Lifting With Sling...45
  Specifications...46
    Specifications for Solar 210W-V S0202045K...48
      General Description...50
      Component Location...51
      General Dimensions...53
        Dimensions...53
        Working Range...55
      Hydraulic Cylinders...59
      Engine Specifications...61
      Engine Performance Curves (DIN 6270 Standard)...63
      Approximate Weight of Workload Materials...65
      General Specifications...69
      Hydraulic System Component Specifications...71
      System Component Specifications...73
        Drive System...73
        Swing Mechanism...73
        Brake System...74
        Steering System...74
        Chocking System...75
      Performance Tests and Standards...76
        Standards...76
        Tests...77
        Test Conditions...77
        Travel Speed Tests...78
        Swing Speed Test...79
        Swing Speed Test...79
        Swing Force Test...79
        Cylinder Performance Tests...80
        Boom Cylinders Test...80
        Arm Cylinder Test...80
        Bucket Cylinder Test...80
        Hydraulic Cylinder Natural Drop Test...80
  General Maintenance...82
    General Maintenance Procedures S0302000...84
      Welding Precautions and Guidelines...86
      Hydraulic System - General Precautions...87
      Maintenance Service and Repair Procedure...88
        General Precautions...88
      Hydraulic System Cleanliness and Oil Leaks...89
        Maintenance Precautions for Hydraulic System Service...89
        Oil Leakage Precautions...89
      Cleaning and Inspection...90
        General Guidelines...90
        Bearing inspection...91
    Standard Torques S0309000...98
      Torque Values for Standard Metric Fasteners...100
      Torque Values for Standard U.S. Fasteners...101
      Type 8 Phosphate Coated Hardware...103
      Torque Values for Hose Clamps...104
      Torque Values for Split Flanges...105
      Torque Wrench Extension Tools...106
        Torque Multiplication...106
        Other Uses for Torque Wrench Extension Tools...107
        Tightening Torque Specifications (Metric)...107
  Upper Structure...110
    Cab S0402040K...112
      Removal...114
      Installation...117
    Counterweight S0403015K...120
      General...122
      Removal...124
      Installation...126
    Fuel Tank S0405075K...128
      General Description...130
        Parts List...131
        Specifications...132
      Removal...133
      Installation...137
      Start-up Procedures...139
    Fuel Transfer Pump S0405500...140
      General Description...142
        Theory of Operation...142
      Troubleshooting...143
      Replacement of Rotor and Vane...143
      Replacement of Rear Cover...144
      Replacement of Armature...145
    Swing Bearing S0407010...146
      Swing Bearing Maintenance...148
        Operating Recommendation...148
        Measuring Swing Bearing Axial Play...148
        Measuring Bearing Lateral Play...148
        Swing Bearing Basic Operation...149
        Rebuilding Swing Bearing...149
    Swing Reduction Gearbox S0408040...152
      General Description...154
        Theory of Operation...154
        Parts List...155
        Specifications...156
      Special Tools and Materials...157
        Special Tools...157
      Troubleshooting, Testing and Adjustment...158
      Removal...159
      Disassembly...161
      Cleaning and Inspection (Wear Limits and Tolerances)...166
      Reassembly...167
      Installation...176
  Lower Structure and Chassis...178
    Ram Lock Valve Operation S0503000...180
      Theory of Operation...182
  Engine and Drive Train...184
    Front Axle S0602100...186
      Special Tools...188
        Hub Nut Tool...188
      Disassembly...189
        Planetary End...189
        Differential Gear...196
      Cleaning and Inspection (Wear Limits and Tolerances)...201
      Reassembly...202
        Differential Gear...202
        Planetary End...213
      Start-up Procedures...228
        Axle Lubrication...228
    Transmission (ZF2HL-100) S0602110...230
      Transmission Operation...233
      Special Tools...234
        Hub Nut Tool...234
      Transmission Disassembly...235
        Detaching Drive (Input) Housing...235
        Disassembly of Input Shaft and Brake Assembly...236
        Disassembly of Clutch...238
        Disassembly of Planetary Carrier...243
        Disassembly of Shift Lever and Helical Gear...244
        Disassembly of Shift Lock (Version A)...249
        Disassembly of Shift Lock (Version B)...251
      Final Drive Disassembly...253
      Rear Axle Disassembly...257
      Differential Gear Disassembly...264
      Cleaning and Inspection (Wear Limits and Tolerances)...269
      Differential Gear Reassembly...270
      Rear Axle Reassembly...282
      Final Drive Reassembly...297
      Transmission Reassembly...302
        Reassembly of Helical Gear...302
        Reassembly of Shift Lever...304
        Reassembly of Planetary Carrier...305
        Adjusting Shift Lever...307
        Pre assembling and Installing Clutch...308
        Checking Clutch...315
        Reassembly of Brake and Input Shaft Assembly...316
        Installing Drive (Input) Housing...320
        Assembly of Shift Lock (Version A)...323
        Assembly of Shift Lock (Version B)...327
        Installing Oil Pump...329
        Installing Screw Plugs and Oil Lines...332
      Start-up Procedures...333
        Axle Lubrication...333
        Lubrication...333
    Air-Conditioner S0605060K...334
      General Description...336
      Refrigerant Circulation...338
      Control Panel...340
      Control Specifications...341
      Temperature Level Control and Display...342
      Air Discharge According to Path Selection...343
      Air-conditioning System Circuit Diagram...345
      Troubleshooting...347
      Weight of R134a Gas Used In Machines...350
      Refrigerant System Repairs...352
        Refrigerant Safe Handling Procedures...352
        Repair and Replacement Procedure...353
        Refrigerant Recovery...355
        Vacuuming Refrigerant System...355
        Leakage Check...356
        Refrigerant Charging...357
        Inspecting System For Leakage...359
    Drive Coupling (Main Pump) S0609000...360
      Drive Coupling...362
      Special Tools...363
        Kawasaki / Tong Myung Pump Tool...363
        Uchida Pump Tool...366
      Drive Coupling Installation...367
        Installation Procedure...372
  Hydraulics...374
    Hydraulic System Troubleshooting, Testing and Adjustment S0702115K...376
      Hydraulic System - General Notes...379
      Operation of Working Components...380
        Boom Operating Circuit...380
        Boom Up Circuit...380
        Boom Down Circuit...380
        Arm Operating Circuit...381
        Arm Crowd Circuit...381
        Arm Dump Circuit...382
        Bucket Operating Circuit...382
        Bucket Crowd Circuit...382
        Bucket Dump Circuit...383
        Swing Operating Circuit...384
        Right Swing Operating Circuit...384
        Left Swing Operating Circuit...384
        Swing Relief Valve and Make-up Valve...384
      Procedural Troubleshooting Baseline Recommendations...385
        Initial Checks and Tests to Establish Operating Condition of the Excavator...385
      Pilot Pressure...386
        Adjustment and Testing...386
      Power Mode Valve...387
        Current Signal and Hydraulic Pressure Adjustments...387
      Boom/Swing Priority Valve...388
        Control Valve Pressure and Current Adjustments...388
      Pressure Up Valve...389
        Checks and Adjustments...389
      Pump Input Power Control...390
        Pump Regulator Adjustment...390
      Flow Meter and Flow Meter Kit Installation and Testing...393
      Swing System Troubleshooting...394
        Precautions/Initial Checks...394
        Swing Relief Valve Checking and Adjustment...394
      Troubleshooting - Swing Gearbox...396
      Troubleshooting - Hydraulic Problems...397
      Troubleshooting - Control Valve...399
      Troubleshooting - Joystick Control Valve...400
    Accumulator S0703010K...402
      General Description...404
        Specifications...405
    Center Joint (Swivel) S0704070...408
      General Description...410
        Parts List...411
      Troubleshooting, Testing and Adjustment...413
        Inspection...413
        Testing...413
      Disassembly...414
      Reassembly...415
    Cylinders S0705000...416
      General Description...418
        Theory of Operation...418
        Parts List...419
      Special Tools and Materials...421
        Piston Nut...421
        Piston Jig...425
        Steel bush Jig...429
        Dust Wiper Jig...433
        Slipper Seal Jig...439
        Slipper Seal Straightening Jig...443
      Disassembly...446
      Assembly...452
    Swing Motor S0707250...456
      General Description...458
        Theory of Operation...458
        Swing Motor Anti-cavitation Make-up Valve...459
        Relief Valve...460
        Swing Brake Operation...460
        Parts List...463
        Specifications...465
      Special Tools...466
      Disassembly...467
      Cleaning and Inspection (Wear Limits and Tolerances)...474
      Reassembly...476
    Travel Motor S0707350...484
      General Description...487
        Theory of Operation...487
        Parts List...489
        Specifications...490
      Travel Motor General Disassembly and Reassembly Instructions...491
        Recommended Tools...491
        Precautions for Disassembly and Assembly...491
      Disassembly of Travel Motor...492
        Appearance of Motor...492
        Removal of counterbalance Valve...492
        Removal of Outer Piping...493
        Removal of Stroke Limiter...494
        Removal of Oil Seal...495
        Removal of Control Unit...495
        Removal of Control Valve...497
        Disassemble Control Valve...499
        Disassemble Stroke Limiter...500
        Reassemble Stroke Limiter...501
        Reassemble Control Valve...501
        Installation of Control Valve...502
      Reassembly of Travel Motor...505
        Assembly of Control Unit...505
        Installation of Oil Seal...507
        Installation of Stroke Limiter...508
        Installation of Outer Piping...508
        Installation of Counterbalance Valve...509
    Main Pump (With Regulator, Steering Pump and Brake Pump) S0708430...510
      General Description...513
        Gear (Pilot) Pump...515
        Relief Valve...515
        Pump Regulator Description...516
        Horsepower Control...516
        Power Shift Control...516
        Negative Oil Discharge (Pump Bypass) Control...516
        Pump Regulator Operation...517
        Pump Output Decrease...519
        Pump Discharge Decrease...519
        Pump Discharge Increase...519
        Horsepower Control...519
        Overload Protection...520
        Regulator Adjustment...520
        Pump Input Power Control Adjustment...521
        Parts List...523
        Specifications...528
        Hydraulic Pump Performance Characteristics...529
      Troubleshooting, Testing and Adjustment...530
        Main Pump...530
      Disassembly...531
        General Disassembly...531
        Main Pump Disassembly...532
        Pump Regulator Disassembly...534
      Cleaning and Inspection (Wear Limits and Tolerances)...538
      Reassembly...540
        Pump Regulator Reassembly...540
        Main Pump Reassembly...544
    Brake Supply Valve S0709220...548
      Parts List...551
      Specifications...552
    Counterbalance Valve S0709300...554
      General Description...556
        While Operating to Run Forward...556
        While Operating to Stop...556
        While Operating to Back...556
        Adjustment of Relief Valve...557
      Troubleshooting...558
      Counterbalance Valve...559
        Recommended Tools...559
        Disassembly...559
        Order of Disassembly and Torque Values...560
        Reassembly...561
    Main Control Valve (Toshiba DX28) S0709440...566
      Control Valve Operation...570
        Arm Priority Circuit...571
        Bucket (Junction) Circuit...573
        Main Relief Valve...575
        Overload Relief Valve...576
        Arm Load Holding Valve...578
        Boom Load Holding Valve...581
        Arm Regeneration...583
        Boom Regeneration...585
        Foot Relief Valve...586
        Parts List...587
        Specifications...596
      Control Valve Drawing and Hydraulic Circuit...597
      Disassembly and Reassembly...602
        General Disassembly...602
        General Reassembly...602
        Plunger Replacement...603
        Main Plunger Element - Disassembly and Assembly...604
        Tool...604
        Main Relief Valve...607
        Overload Relief Valve...610
        Arm Load Holding Valve...612
        Boom Load Holding Valve...615
        Arm Regeneration Valve...617
        Bucket Unity Check...618
        Foot Relief Valve...619
        Center Bypass Valve (CB Valve)...620
        Boom Parallel Switch Valve...621
        Boom Unity Check Valve...623
        Check Valve - Locations...624
        Check Valve...625
    Pilot Control Valve (Work Lever / Joystick) S0709451K...628
      General Description...630
        Theory of Operation...630
        Parts List...631
        Specifications...632
      Removal...633
      Disassembly...636
      Cleaning and Inspection (Wear Limits and Tolerances)...640
      Reassembly...641
      Installation...646
      Start-up Procedures...647
    Steering Valve S0709710...648
      General Description...650
        Theory of Operation...651
        Parts List...653
        Specifications...654
      Special Tools and Materials...655
        Special Tools...655
      Disassembly...657
      Reassembly...666
    Dozer Control Valve S0709905K...680
      Parts List...682
      Specifications...683
    Hydraulic Schematic (Solar 210W-V) S0792101K...684
      General Description...686
      Solar 210W-V...687
      General Notes...691
  Electrical System...692
    Electrical System S0802125K...694
      Troubleshooting - Electrical System...698
      Overview...699
      Electric Supply System...700
      Engine Starting Circuit...701
        Operation During Start Process...701
        Operation After Start Process...702
      Engine Preheating System...703
      Engine Stop System...704
      Charging System...707
      Monitoring System...709
        Instrument Panel...711
        Monitoring System Schematic...713
      Operation...715
        Instruments...715
      Warning and Indicator Lights...717
      Control Unit...719
        Operation Schematic...719
        Operation Specification...720
      Console Warning Light...721
      Initial Operation...723
      Mode Select Switch...724
      Graphic Information Area Display...725
        Overview...725
        Main Menus for the Graphic Display Area...726
        Menu Selection Buttons...726
      Main Menu...727
        Language setting...727
        Time Setting...727
        Filter/Oil information...728
      Special Menu...729
        Entering/Accessing and Exiting/Escaping Menus...729
        Special Menu Selections...730
      Electronic Hydraulic Control System (e-EPOS)...743
      Power Mode Control...745
        Operation...746
      Throttle Position Sensor...749
      Power Mode Control - Circuit Diagram...751
      Work Mode Control...753
        Operation...754
      Work Mode Control - Circuit Diagram...755
      Engine Control System...757
      Engine Control Motor...758
      Engine Control Dial...759
      Engine Control Circuit Diagram...761
      Automatic Deceleration Control (Auto Idle Control)...762
      Automatic Deceleration Control Circuit...763
        Operation...764
      Engine Overheat Protection System...765
      Power Boost Mode...766
        Operation...766
        Power Boost Control - Circuit Diagram...767
      Cruise Control...769
        Cruise Control Circuit...771
      Adjusting Method of Engine Control Unit...773
        Adjusting Method of Engine Control System...773
        Adjusting Method of Engine RPM...775
        Adjustment of TPS (Throttle Position Sensor)...780
      Self-diagnostic Function...785
        e-EPOS Controller...785
      Engine Throttle Controller...789
      Wiper System...791
        Wiper Circuit...791
        Wiper Operation...791
        Window Washer Operation...792
      Overload Warning Device...793
        Overload Warning Device Circuit Diagram...793
    Electrical Schematic (Solar 210W-V) S0892101K...794
      General Description...796
      Solar 210W-V...797
  Attachments...800
    Boom and Arm S0902080...802
      Front Attachment Pin Specifications...804
      Front Attachment - Removal and Installation...805
        Arm Removal Procedure...805
        Boom Removal Procedure...807
      Installation...808
        Arm Installation Procedure...808
        Boom Installation Procedure...808
      Start-up Procedures...809
    Bucket S0904000...810
      Bucket Tooth Inspection and Replacement...812
        Type 1...812
        Type 2...813
        Type 3...814
      Bucket O-ring Replacement...816
        Type 1...816
        Type 2...817
      Bucket Shimming Procedures...819
        New Bucket Installation...819
        Type 1...819
        Type 2...820
      Bucket Attachment, Removal and Reversal...821
        Detaching the Bucket...821
        Attaching The bucket...821
        Reversing the Bucket...822
  Publication Request for Proposed Revision...824
CENS21WV0002...826
S210W-V_HYD_CIRCUIT...827
  Model...827

Daewoo Solar 210W-V Excavator Repair Service Manual