Your Daewoo Solar 010 Shop Manual PDF runs 268 pages (OEM #2022-7153E) and walks you through the complete Solar 010 hydraulic excavator, from gear pump overhaul to the Yanmar TNE-series diesel rebuild. You get step-by-step disassembly and reassembly procedures for the swing motor, travel motor, and control valve, right down to brake valve inspection and speed reducer overhaul. A full troubleshooting section pins down poor output, overheating, and black exhaust smoke, while performance test standards let you verify travel and swing speed before the machine goes back to work. Set the bucket relief pressure to 180 kg/cm2 (2,560 psi) and torque the control valve spool ends to 0.4-0.5 kg-m (2.9-3.6 ft lb). Every hour this excavator sits idle costs you money. Bookmarked and keyword-searchable; download it, open it on any device in the shop, and start wrenching.
What's Inside This Daewoo SOLAR 010 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 4-14 | Accessory Applications, Modification Precautions, Work Site Precautions, Operation, Equipment, Shipping and Transportation |
| Specifications | 16-23 | General Specifications, General Dimensions, Working Range, Engine Specifications, Hydraulic System Component Specifications, Travel System |
| Hydraulic System Operation | 24-25 | Hydraulic Circuit Diagram, Pump Operation, Relief Valve Protection, Return Oil Filter |
| Gear Pump | 26-29 | Assembly Drawing, Overhauling Drawing, Pump Inspection, Bushing Repair, Gear Replacement |
| Control Valve | 30-37 | Tools, Disassembly, Assembly, Final Assembly and Testing, Pressure Adjustment |
| Swing Motor | 38-58 | Brake Valve Operation, Brake Valve Removal, Brake Valve Disassembly, Brake Valve Inspection and Cleaning, Brake Valve Reassembly, Brake Valve Installation, Swing Motor Parts Lift |
| Travel Motor | 60-81 | Tools, Travel Motor Operation, Travel Motor Overhaul, End Cover Assembly Overhaul, Speed Reducer Overhaul, Assembly |
| Engine | 82-96 | Valve Adjustment Sequence, Wear Limits, Engine Oil Pump Rebuild, Fuel Injection Pump Adjustment, Cylinder Headbolt Torque |
| Electrical System | 98-102 | Starting System, Charging System, Glow Plug System, Testing Starter, Testing Glow Plug, Testing Generator, Testing Stator Coil Continuity |
| Maintenance | 104-109 | Maintenance Intervals, Recommended Lubricants, Lubrication Points, Standard Torques, Track Maintenance |
| Troubleshooting | 112-117 | Engine Troubleshooting, Output Poor, Overheating, Black Exhaust Gas, White Exhaust, Gear Pump Troubleshooting, Travel Motor Troubleshooting |
| Performance Standard and Test | 118-120 | Performance Standards, Test Conditions, Travel Speed Test, Swing Speed Test, Cylinder Performance Tests |
| Diesel Engine Model TNE Series Introduction and Contents | 121-126 | TNE Series Overview, Model Name Breakdown, Application Category, Table of Contents |
| Engine Specifications and Performance | 127-142 | 2TNE68, 3TNE68, 3TNE74, 3TNE78A, 3TNE82A, 3TNE82, 3TNE84, 3TNE88 |
| Cross Sectional Views and Cooling/Lubrication Systems | 143-148 | Indirect Injection System, Direct Injection System, Cooling Water System, Lubrication System, Fuel System |
| Troubleshooting and Compression Pressure Diagnosis | 149-152 | Trouble Causes and Remedies, Compression Pressure Measurement, Troubleshooting Charts |
| Special Service Tools and Measuring Instruments | 153-158 | Valve Guide Tools, Piston Insertion Tools, Dial Gauges, Tachometers, Compression Gauge Kits |
| Engine, Measurement, Inspection and Adjustment | 159-202 | Cylinder Head and Valves, Piston and Connecting Rod, Crankshaft and Bearings, Battery and Electrolyte Checks, Measurement Standards |
| Engine, Disassembly and Reassembly | 203-240 | Disassembly Sequence, Piston and Connecting Rod Assembly Direction, Pushrod and Rocker Service, Reassembly Torques, Component Service Sections |
| Engine, Governor | 241-268 | Governor Case, Governor Lever and Link, Governor Shaft, O-Ring and Circlip Fitting, Adjustment |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main Pump Relief Pressure (Bucket) | 180 kg/cm² (2,560 psi) | p. 18 |
| Main Pump Relief Pressure (Arm) | 190 kg/cm² (2,702 psi) | p. 18 |
| Control valve spool end torque | 0.4-0.5 kg•m (2.9-3.6 ft lb) | p. 35 |
| Control valve spring cover bolt torque | 0.6-0.7 kg•m (4.3-5.1 ft lb) | p. 35 |
| Adjusting screw lock nut torque | 1.7 ± 0.2 kg·m (12.3 ± 1.4 ft lb) | p. 42 |
| Connector in port on motor torque | 4 ± 0.4 kg·m (29 ± 2.9 ft lb) | p. 42 |
| Torque Wrench capacity | 5.4kg•m or more | p. 60 |
| Socket Wrench size | 4.5mm | p. 60 |
| Operating Weight | 770 kg | p. 16 |
| Fuel Tank Capacity | 7.5 L | p. 16 |
| Hydraulic Tank Capacity | 12 L | p. 16 |
| Engine Displacement | 523 cm3 | p. 19 |
Daewoo SOLAR 010 Common Problems This Manual Covers
Daewoo Solar 010 hydraulic power loss, boom and bucket respond slow, machine won't build normal working pressure
Check hydraulic tank oil level first; the tank only holds 12 L, so a small leak drains it fast. Gauge main relief pressure against the 150 kg/cm2 spec on page 21 with oil at operating temperature. If pressure stays low on clean oil, inspect the gear pump for bushing and gear wear using the procedure starting on page 26.
Manual Section: Gear Pump p. 26Travel motor weak on one side, tracks noisy or jerky under load
Check oil level and pull a drain oil sample; metallic glitter means internal wear. Compare travel speed against the performance standards on page 118 before condemning anything. If the motor fails the test, overhaul it following the procedure starting on page 60; you'll need a torque wrench rated 5.4 kg•m or more.
Manual Section: Travel Motor p. 60Hydraulic oil overheats during normal digging and temperature keeps climbing within the first hour
Check oil level against the 12 L hydraulic tank capacity; low oil heats fast in a system this small. Clean cooler fins and replace a clogged return filter, located in the hydraulic system layout on page 24. Verify relief valves aren't blowing constantly; main relief should hold at 150 kg/cm2, not below it.
Manual Section: Hydraulic System Operation p. 24Engine cranks strong but won't fire after winter storage or a long layoff
Test the glow plugs and starting circuit using the electrical procedures starting on page 98; a small 523 cm3 diesel won't light off cold without them. Drain stale fuel, replace the fuel filter, and bleed the system. If it still won't fire, measure compression per the diagnosis method on page 149 and set valve clearance to 0.2 mm cold.
Manual Section: Electrical System p. 98Boom drifts down and bucket won't hold position with the controls in neutral
Cycle each cylinder fully and inspect rod seals for external leaks first. Run the cylinder performance tests on page 118 to confirm internal bypass past the piston seals. If the cylinders test clean, pull and inspect the control valve starting on page 30, torquing spool ends to 0.4-0.5 kg•m on reassembly.
Manual Section: Performance Standard and Test p. 118Tracks wear fast, come off during turns, undercarriage rattles over rough ground
Adjust track tension with a grease gun until deflection measures 10-15 mm at the midpoint, per the procedure on page 110. Inspect rollers and idlers for flat spots while you're under the machine, and grease the undercarriage points on the maintenance schedule shown on page 104.
Manual Section: Maintenance p. 110Frequently Asked Questions
What are the replacement specifications for hydraulic cylinder seals?
The manual states that cylinder drift rate should be checked at regular intervals. Overhaul seal kits for the hydraulic cylinders are available through Daewoo. p. 12
What is the standard torque for M10 bolts (grade 7T)?
For M10 bolts of 7T grade (S40C, S45C), the standard tightening torque is 4.90 to 5.70 kg•m (35.44 to 41.22 ft lb). p. 108
What is the valve adjustment clearance for the engine?
The valve adjustment clearance for the engine when cold is 0.2 mm (0.0079 inches). p. 82
What is the recommended engine oil capacity for the 2TNE68 engine?
The engine oil capacity for the 2TNE68 engine is 0.6 liters (0.63 quarts). p. 19
What is the correct fan belt tension for the engine?
The fan belt tension should be adjusted to 10 to 15 mm (0.4 to 0.6 inches) when pushed at the center between the alternator and cooling water pump. p. 86
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This is a 268-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
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