Solar 75

Solar 75-V
Shop Manual
023-00066AE
Serial Number 1001 and Up
January 2004
Daewoo 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.
023-00066AE Shop Manual

1TABLE OF CONTENTS
Safety
Track Excavator Safety....................................................................... S0102035K
Specifications
Specifications for Solar 75-V .............................................................. S0202025K
General Maintenance
General Maintenance Procedures .........................................................S0302000
Standard Torques ..................................................................................S0309000
Upper Structure
Counterweight..................................................................................... S0403005K
Fuel Tank............................................................................................ S0405015K
Swing Bearing........................................................................................S0407000
Lower Structure and Chassis

Track Assembly .................................................................................. S0505075K
Engine and Drive Train

Air Conditioner .......................................................................................S0605015
Hydraulics
Accumulator........................................................................................ S0703010K
Center Joint (Swivel)........................................................................... S0704015K
Cylinders................................................................................................S0705000
Travel Motor (with Gearbox) ............................................................... S0707355K
Swing Motor...........................................................................................S0707380
Main Pump (Rexroth).......................................................................... S0708375K
Table of Contents
Page I
Pilot Control Valve (Work Lever / Joystick)......................................... S0709453K
Main Control Valve (REXROTH) .......................................................... S709466K
Travel Control Valve (With Damper)................................................... S0709820K
Hydraulic Schematic (Solar 75-V)....................................................... S0792096K
Electrical System
Electrical System ................................................................................ S0802095K
Electrical Schematic (Solar 75-V) ....................................................... S0892096K
Attachments
Boom and Arm.................................................................................... S0902025K
Bucket....................................................................................................S0904000
Table of Contents
Page II
1SAFETY
S0102035K
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 is 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 SAFETYS0102035K
MODEL SERIAL NUMBER RANGE

Solar 55-V PLUS 1001 and Up
Copyright 2004 Daewoo

January 2004
Track Excavator Safety S0102035K

Page 1
TABLE OF CONTENTS
To the Operator of a Daewoo Excavator ........................................................ 5

Learn the Signal Words Used with the Safety Alert Symbol ................... 7
General Safety Essentials .............................................................................. 8
Accessory Applications ........................................................................... 8
Lifting Capacity Rating Configuration...................................................... 8
Location of Safety Labels ............................................................................... 8
Summary of Safety Precautions for Lifting in Digging Mode .......................... 9
Unauthorized Modifications .......................................................................... 10
General Hazard Information ......................................................................... 10
Safety Rules.......................................................................................... 10
Safety Features ..................................................................................... 10
Inside Operator's Compartment ............................................................ 11
Clothing and Personal Protective Items ................................................ 11
Breathing Masks, Ear Protection May Be Required .............................. 12
Vibration Level Information.................................................................... 12
Mounting and Dismounting ................................................................... 13
Fuel, Oil and Hydraulic Fluid Fire Hazards ........................................... 14
Precautions When Handling Fluids at High Temperature ..................... 14
Asbestos Dust Hazard Prevention ........................................................ 15
Injury from Work Equipment ................................................................. 15
Fire Extinguisher and First Aid Kit......................................................... 16
Protection from Falling or Flying Objects .............................................. 16
Attachment Precautions ........................................................................ 17
Accumulator .......................................................................................... 17
Indoor Ventilation .................................................................................. 18
Emergency Exit ..................................................................................... 18
Before Starting Engine ................................................................................. 19
Work Site Precautions........................................................................... 19
Checks Before Starting Engine ............................................................. 20
Engine Starting ..................................................................................... 21
S0102035K Track Excavator Safety

Page 2
Before Operating Machine .................................................................... 21
Machine Operation ....................................................................................... 22
When Swinging or Changing Direction of Travel ................................... 22
Travel Precautions................................................................................. 23
Traveling on Slopes ............................................................................... 24
Prohibited Operations ........................................................................... 24
Precautions for Operation ..................................................................... 25
Avoid High-voltage Cables .................................................................... 26
Operate Carefully on Snow, Ice and in Very Cold Temperatures .......... 26
Operations on Slopes............................................................................ 27
Parking Machine ................................................................................... 27
Never Let Anyone Ride on Attachment ................................................. 27
Maintenance................................................................................................. 28
Warning Tag .......................................................................................... 28
Clean Before Inspection or Maintenance .............................................. 28
Proper Tools .......................................................................................... 29
Use of Lighting ...................................................................................... 29
Fire Prevention and Explosion Prevention ............................................ 29
Burn Prevention .................................................................................... 30
Welding Repairs.................................................................................... 31
Warning for Counterweight and Front Attachment Removal ................. 31
Precautions for Removal, Installation, and Storage of Attachments ..... 32
Precautions when Working on Machine................................................ 32
Lock Inspection Covers ......................................................................... 32
Crushing Prevention and Cutting Prevention ........................................ 33
Track Tension Adjustments Require Caution......................................... 33
Supports and Blocking for Work Equipment ......................................... 33
Action When Abnormally Is Found During Inspection........................... 34
Precautions with High-pressure Line, Tubes and Hoses....................... 34
Waste Materials .................................................................................... 35
Battery.......................................................................................................... 36
Battery Hazard Prevention .................................................................... 36
Starting Engine With a Booster Cable .................................................. 37

Page 3
Connecting the Booster Battery..................................................... 38
Disconnecting the Booster Battery ................................................ 38
Towing .......................................................................................................... 39
Precautions When Towing..................................................................... 39
Shipping and Transportation ........................................................................ 40
Obey State and Local Over-the-Road Regulations............................... 40
Lifting With Sling........................................................................................... 40

Page 4
TO THE OPERATOR OF A DAEWOO EXCAVATOR
DANGER!
Unsafe use of the excavator could lead to serious injury or death. Operating procedures,
maintenance and equipment practices or traveling or shipping methods that do not follow the
safety guidelines on the following pages could cause serious, potentially fatal injuries or
extensive damage to the machine or nearby property.
Please respect the importance of taking responsibility for your own safety, and that of other people who
may be affected by your actions.
The safety information on the following pages is organized into the following sections:
1. “General Safety Essentials” on page 8
2. “Location of Safety Labels” on page 8
3. “Summary of Safety Precautions for Lifting in Digging Mode” on page 9
4. “Unauthorized Modifications” on page 10
5. “General Hazard Information” on page 10
6. “Before Starting Engine” on page 19
7. “Machine Operation” on page 22
8. “Maintenance” on page 28
9. “Battery” on page 36
10. “Towing” on page 39
11. “Shipping and Transportation” on page 40
12. “Lifting With Sling” on page 40

Page 5
WARNING!
Improper operation and maintenance of this machine can be hazardous and could result in
serious injury or death.
Operator and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in the storage compartment to the rear of the operator's seat, and have all
personnel involved in working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the machine can cause a serious
accident, if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the
machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for any others. In no event should you or others engage in prohibited uses
or actions as described in this manual.
Daewoo delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether
your product complies with the applicable standards and regulations of your country, consult
Daewoo or your Daewoo distributor before operating the machine.

Page 6
SAFETY ALERT SYMBOL
Be Prepared - Get To Know All Operating and Safety Instructions.
This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the
machine you should be alert to the potential for personal injury or accidents. Always observe
safety precautions and follow recommended procedures.
LEARN THE SIGNAL WORDS USED WITH THE SAFETY ALERT SYMBOL
The words "CAUTION," "WARNING" and "DANGER" used throughout this manual and on decals on the
machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety
is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which
signal word appears next to the "Exclamation Point" symbol.
CAUTION!
Indicates potential of a hazardous situation that, if not avoided, could result in minor or
moderate injury. It may also be used to alert against a generally unsafe practice.
WARNING!
Indicates potential of a hazardous situation that, if not avoided, could result in serious injury or
death. It may also be used to alert against a highly unsafe practice.
DANGER!
Indicates imminent hazard of a situation that, if not avoided, is very likely to cause death or
extremely serious injury. It may also be used to alert against equipment that may explode or
detonate if handled or treated carelessly.
Safety precautions are described in SAFETY from page -8 on.

Daewoo cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact a
DAEWOO distributor.

Page 7
GENERAL SAFETY ESSENTIALS
ACCESSORY APPLICATIONS
The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for
other object handling, contact Daewoo for proper installation and application. 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 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 municipal and regional regulations or statutes
that could apply. Governing ordinances may require that all heavy lifting be done with single
purpose equipment specifically designed for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that can be used for digging, loading,
grading or other work may be expressly forbidden by a regional injunction or other legal
prohibition. Always follow all of the other instructions, guidelines and restrictions for Safe
Lifting in the Operation and Maintenance Manuals.
LOCATION OF SAFETY LABELS

Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and
Maintenance Manual, and parts manual for your unit.
Always replace damaged or faded decals.

Page 8
SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING
IN DIGGING MODE
DANGER!
Unsafe use of the excavator while making rated lifts could cause serious, potentially fatal
injuries or extensive damage to the machine or nearby property. Do not let anyone operate the
machine unless they've been properly trained and understand the information in the Operation
and Maintenance Manual.
To lift safely while in Digging Mode, the following items must be evaluated by the operator and the work site
crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Taglines on opposite sides of the load can be very helpful in keeping a suspended load secure, if they are
anchored safely to control points on the ground.
WARNING!
NEVER wrap a tagline around your hands or body.
NEVER rely on taglines or make rated lifts when wind gusts are more than 48.3 km/h (30 MPH).
Be prepared for any type of wind gust when working with loads that have a large surface area.
Always engage the "Digging Mode" control on the Instrument Panel before using the excavator for lifting
work.
WARNING!
If you need more information or have any questions or concerns about safe operating
procedures or working the excavator correctly in a particular application or in the specific
conditions of your individual operating environment, please consult your local Daewoo
representative.

Page 9
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization or written approval from Daewoo can create a safety hazard,
for which the machine owner must be held responsible.
For safety's sake, replace all OEM parts with the correct authorized or genuine Daewoo part. For example,
not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a
condition in which the safety of critical assemblies is dangerously compromised.
GENERAL HAZARD INFORMATION

SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel
sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will
interfere with your sense of judgement in emergencies and may cause accidents.
When working with another operator or with a person on work site traffic duty, be sure that all personnel
know the nature of the work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
SAFETY FEATURES
Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety features such as safety lock lever and the seat
belt, and use them properly.
Never remove any safety features. Always keep them in good operating condition.
Failure to use safety features according to the instructions in the Operation and Maintenance Manual could
result in serious bodily injury.

Page 10
INSIDE OPERATOR'S COMPARTMENT
When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If
you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a
serious accident.
After using the ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to
close the ashtray. If the ashtray is left open, there is danger of fire.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not leave lighters laying around the operator's compartment. If the temperature inside the operator's
compartment becomes high, there is danger that the lighter may explode.
Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
There is danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or explosive items into the operator's cab.
To ensure safety, do not use the radio or music headphones when operating the machine. There is danger
that this may lead to a serious accident.
When operating the machine, do not put your hands or head out of the window.
When standing up from the operator's seat, always place safety lock lever securely in the "LOCK" position.
If you accidentally touch the work equipment levers when they are not locked, the machine may suddenly
move and cause serous injury or damage.
When leaving the machine, lower the work equipment completely to the ground, set safety lock lever to the
"LOCK" position and shut down engine. Use the key to lock all the equipment. Always remove the key and
take it with you.
CLOTHING AND PERSONAL PROTECTIVE

ITEMS
Contain long hair, and avoid loose clothing and
jewelry. They can catch on controls or in
protruding parts and cause serious injury or
death.
Do not wear oily clothes. They are highly
flammable.
Full eye protection, a hard hat, safety shoes and
gloves may be required at the work site.
HAOA020L
While working on the machine, never use
Figure 1
inadequate tools. They could break or slip,
causing injury, or they may not adequately
perform intended functions.
Do not forget that some risks to your health may
not be immediately apparent. Exhaust gases
and noise pollution may not be visible, but these
hazards can cause disabling or permanent
injuries.

Page 11
BREATHING MASKS, EAR PROTECTION MAY BE REQUIRED
Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise
pollution may not be visible, but these hazards can cause disabling or permanent injuries.
NOTE: The equivalent continuous A-weighted sound pressure level at the workstation for this
machine is given in the operation manual.
Measurement is obtained on a dynamic machine following the procedures and cab
conditions as described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the machinery for this machine is given in
the operation manual.
Measurement is obtained on a dynamic machine with the procedures as described in
2000/14/EC.
VIBRATION LEVEL INFORMATION

Hands/Arms: The weighted root mean square acceleration to which the hands/arms are subjected, is less
than 2.5 m/s2.
Whole body: The weighted root mean square acceleration to which the whole body is subjected, is less
than 0.5 m/s2.
Measurements are obtained on a representative machine, using measuring procedures as set forth in the
following standard: ISO 2631/1. ISO 5349, and SAE J1166.

Page 12
MOUNTING AND DISMOUNTING
Before getting on or off the machine, if there is any oil. grease, or mud on the handrails, steps, or track
shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose
bolts.
Never jump on or off the machine. In particular, never get on or off a moving machine. These actions may
lead to serious injury.
When getting on or off the machine, always face the machine, and maintain three-point contact (both feet
and one hand or one foot and both hands) with the handrails, steps, and track shoes to ensure that you
support yourself securely.
Never hold any control levers when getting on or off the machine.
Apply the door lock securely. If you grip the handrail inside the door when moving on top of the track shoes,
and the door lock is not applied securely, the door may move and cause you to fall.
Use the points marked by arrows in the diagram when getting on or off the machine.
AXO0060L
Figure 2

Page 13
FUEL, OIL AND HYDRAULIC FLUID FIRE
HAZARDS
Fuel, oil and antifreeze will catch fire if it is
brought close to a flame. Fuel is particularly
flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the
machine only in a well-ventilated area. The
machine must be parked with controls, lights
and switches turned "OFF." The engine must be
"OFF" and any flames, glowing embers,
auxiliary heating units or spark-causing
equipment must be doused, turned off and/or
kept well clear of the machine.
Static electricity can produce dangerous sparks
at the fuel filling nozzle. In very cold, dry Figure 3
weather or other conditions that could produce a
static discharge, keep the tip of the fuel nozzle
in constant contact with the neck of the fuel
filling nozzle, to provide a ground.
Keep fuel and other fluid reservoir caps tight
and do not start the engine until caps have been
secured.
PRECAUTIONS WHEN HANDLING FLUIDS

AT HIGH TEMPERATURE
Immediately after operations are stopped, the
coolant, engine oil, and hydraulic oil are at high
temperature and the radiator and hydraulic tank
are still under pressure. Attempting to remove
the cap, drain the oil or coolant, or replace the
filters may lead to serious burns. Always wait for
the temperature to go down, and follow the
specified procedures when carrying out these
operations.
HAOA050L
Figure 4
To prevent hot coolant from spurting out, shut
down engine, wait for the coolant to cool, then
loosen the cap slowly to relieve the pressure.
To prevent hot oil from spurting out, shut down
engine, wait for the oil to cool, then loosen the
cap slowly to relieve the pressure.
HAOA060L
Figure 5

Page 14
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your
health if it is inhaled. Materials containing
asbestos fiber can be present on work site.
Breathing air that contains asbestos fiber can
ultimately cause serious or fatal lung damage.
To prevent lung damage from asbestos fiber,
observe following precautions;
• Use a respirator that is approved for
use in an asbestos-laden
atmosphere. ARO1770L
• Never use compressed air for Figure 6
cleaning.
• Use water for cleaning to keep down
the dust.
• Work on the machine or component
with the wind at your back whenever
possible.
• Always observe any rules and
regulations related to the work site
and working environment.
INJURY FROM WORK EQUIPMENT

Do not enter or put your hand, arm or any other
part of your body between movable parts, such
as between the work equipment and cylinders,
or between the machine and work equipment.
If the control levers are operated, the clearance
between the machine and the work equipment
will change and this may lead to serious
damage or personal injury.
If going between movable parts is necessary,
always position and secure the work equipment HDO1010L
so that it cannot move. Figure 7

Page 15
FIRE EXTINGUISHER AND FIRST AID KIT
As a precaution if any injury or fire should occur,
always do the following.
• Be sure that fire extinguishers have
been provided and read the labels to
ensure that you know now to use
them. It is recommended that an
appropriately sized (2.27 kg [5 lb] or
larger) multipurpose "A/B/C" fire
extinguisher be mounted in the cab.
Check and service the fire HDO1009L
extinguisher at regular intervals and
Figure 8
make sure that all work site crew
members are adequately trained in
its use.
• Provide a first aid kit in the storage compartment and keep another at the work site. Check the
kit periodically and make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance service, hospital and fire department near
your telephone.
If the machine catches fire, it may lead to serious personal injury or death. If a fire occurs during operation,
escape from the machine as follows;
• Turn the starter switch "OFF" and shut down engine.
• If there is time, use the fire extinguisher to extinguish as much of the fire as possible.
• Use the handrails and steps to escape from the machine.
The above is the basic method for escaping from the machine, but changing the method may be necessary
according to the conditions, so carry out practice drills at the work site.
PROTECTION FROM FALLING OR FLYING OBJECTS

On work sites where there is danger that falling objects or flying objects may hit the operator's cab select a
guard to match the operating conditions to protect the operator.
Working in mines, tunnels, deep pits or on loose
or wet surfaces could produce danger of falling
rock or hazardous flying objects. Additional
protection for the operator's cab could be
required in the form of a FOPS (Falling Object
Protective Structure) or window guards.
HAOA110L
Figure 9

Page 16
Never attempt to alter or modify any type of
protective structure reinforcement system, by
drilling holes, welding, remounting or relocating
fasteners. Any serious impact or damage to the
system requires a complete integrity
reevaluation. Reinstallation, recertification and/
or replacement of the system may be
necessary.
Contact your Daewoo distributor for available
safety guards and/or recommendations if there
is any danger of getting hit by objects that could
strike the operator's cab. Make sure that all HAOA100L
other work site crew members are kept well Figure 10
away from the excavator and safe from possible
hazards.
For breaker operation, install a front guard and apply a laminated coating sheet to the front glass. Contact
your DAEWOO distributor for recommendations.
When carrying out demolition or cutting operation, install a front guard and top guard, and apply a
laminated coating sheet to the front glass.
When working in mines or quarries where there is danger of falling rock, install FOPS (Falling Objects
Protective Structure) and apply a laminated coating sheet to the front glass.
If any glass on the machine is broken, replace it with new glass immediately.
ATTACHMENT PRECAUTIONS
Option kits are available through your dealer. Contact Daewoo for information on available one-way
(single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because Daewoo cannot
anticipate, identify or test all of the attachments that owners may wish to install on their machines, please
contact Daewoo for authorization and approval of attachments, and their compatibility with options kits.
ACCUMULATOR
The pilot control system is equipped with an accumulator. For a brief period of time after the engine has
been shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be
activated. Activation of any controls may enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the hydraulic pressure in the system must be
released as describe in "Handling of Accumulator" in the Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas, so it is extremely dangerous if it is handled in
the wrong way. Always observe the following precautions;
• Do not drill or make any holes in the accumulator or expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching anything to it.
• When carrying out disassembly or maintenance of the accumulator, or when disposing of the
accumulator, the charged gas must be properly released. Contact your Daewoo distributor.
• Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious injuries.

Page 17
INDOOR VENTILATION
Engine exhaust gases can cause fatal
accidents, and unconsciousness, loss of
alertness, judgement and motor control and
serious injury.
Make sure there is 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. ARO1770L
Figure 11
EMERGENCY EXIT
This machine is equipped with a glass breaking
tool. It is behind the operator seat in the upper
right corner of the cab. This tool can be used in
case of an emergency situation that requires the
breaking of glass to exit from the operator's
cabin. Grip the handle firmly and use the sharp
point to break the glass.
WARNING! AXO0070L
Figure 12
Protect your eyes when breaking the
glass.

Page 18
BEFORE STARTING ENGINE
WORK SITE PRECAUTIONS
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work site, and determine the best and safest method
of operation.
Make the ground surface as hard and horizontal as possible before carrying out operations. If there is a lot
of dust and sand on the work site, spray water before starting operations.
If you need to operate on a street, protect
pedestrians and cars by designating a person
for work site traffic duty or by erecting fences
and posting "No Entry" signs around the work
site.
Erect fences, post "No Entry" signs, and take
other steps to prevent people from coming close
to or entering the work site. If people come
close to a moving machine, they may be hit or
caught by the machine, and this may lead to DAN
No En
G ER
try
serious personal injury or death.
ARO1250L
Water lines, gas lines, phone lines and
Figure 13
high-voltage electrical lines may be buried under
the work site. Contact each utility and identify
their locations. Be careful not to damage or cut
any of these lines.
Check the condition of the river bed, and the
depth and flow of the water before operating in
water or crossing a river. NEVER be in water
that is in excess of the permissible water depth.
Any type of object in the vicinity of the boom
could represent a potential hazard, or cause the
operator to react suddenly and cause an
accident. Use a spotter or signal person working
near bridges, phone lines, work site scaffolds, or
other obstructions.
Figure 14

Page 19
Minimum levels of insurance coverage, work
permits or certification, physical barriers around
the work site or restricted hours of operation
may be mandated by governing authorities.
There may also be regulations, guidelines,
standards or restrictions on equipment that may
have to be followed for local requirements.
There may also be regulations related to
performing certain kinds of work. If there is any
question about whether your machine and work
site complies with the applicable standards and
regulations contact your local authorities and
agencies.
Figure 15
Avoid entering soft ground. It will be difficult for
the machine to escape.
Avoid operating your machine to close to the edge of cliffs, overhangs, and deep ditches. The ground may
be weak in such areas. If the ground should collapse, the machine could fall or tip over and this could result
in serious injury or death.
Remember that the soil after heavy rain, blasting or after earthquakes, is weakened in these areas.
Earth laid on the ground and the soil near ditches is loose. It can collapse under the weight of vibration of
your machine and cause your machine to tip over.
Install the head guard (FOPS) if working in areas where there is danger of falling rocks.
CHECKS BEFORE STARTING ENGINE

Every day before starting the engine for the first time, carry out the following checks. If these checks are
not carried out properly, there is danger of serious injury.
Completely remove all wood chips, leaves, grass, paper and other flammable materials accumulated in the
engine compartment and around the battery. They could cause a fire. Remove any dirt from the window
glass, mirrors, handrails, and steps.
Do not leave tools or spare parts laying around in the operator's compartment. The vibration of the
machine when traveling or during operations may cause them to fall and damage or break the control
levers or switches. They may also get caught in the gap of the control levers and cause the work equipment
to malfunction or move dangerously. This may lead to unexpected accidents.
Check the coolant level, fuel level, and hydraulic tank oil level, and check for clogged air cleaner and
damage to the electrical wiring.
Adjust the operator's seat to a position where it is easy to operate the machine, and check the seat belt
and mounts for damage and wear.
Check the operation of the gauges and the angle of the mirrors, and check that the safety lever is in
"LOCKED" position.
If any abnormalities are found in the above checks, carry out repairs immediately.

Page 20
ENGINE STARTING
Walk around your machine before getting in the operator's cab. Look for evidence of leaking fluid, loose
fasteners, misaligned assemblies or any other indications of possible equipment hazard.
All equipment covers and machinery safety guards must be in place, to protect against injury while the
machine is being operated.
Look around the work site area for potential hazards, people or properly that could be at risk while
operation is in progress.
NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a
warning tag is attached to controls in the cab.
A machine that has not been used recently, or is being operated in extremely cold temperatures, could
require a warm-up or maintenance service before start-up.
Check gauges and monitor displays for normal operation before starting the engine. Listen for unusual
noises and remain alert for other potentially hazardous conditions at the start of the work cycle.
Do not short circuit the starting motor to start the engine. This is not only dangerous, but may also damage
the machine.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
BEFORE OPERATING MACHINE

If checks are not carried out properly after starting the engine, it may result in a delay in discovering
abnormalities in the machine, and this may lead to personal injury or damage to the machine.
Carry out the checks in an open area where there are no obstructions. Do not let anyone near the machine
when carrying out the checks.
• Check the operating condition of the equipment, and the actuation of the bucket, arm, boom,
travel, and swing systems.
• Check the machine for any abnormal noise, vibration, heat, smell, or abnormality with the
gauges. Check also for leakage of air, oil, and fuel.
• If any abnormality is found, repair the problem immediately. If the machine is used without
repairing the problems, it may lead to unexpected injury or failure.
• Clear all personnel from directly around machine and from the area.
• Clear all obstacles from the machine's path. Beware of hazards.
• Be sure that all windows are clean. Secure the doors and the windows in the open position or in
the shut position.
• Adjust the rear view mirrors for best visibility close to the machine. Make sure that the horn, the
travel alarm (if equipped), and all other warning devices are working properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before operating machine.
• Before moving the machine, check the position of undercarriage. The normal travel position is
with idler wheels to the front under the cab and the drive sprockets to the rear. When the
undercarriage is in the reversed position, the travel controls must be operated in opposite
directions.

Page 21
MACHINE OPERATION
WHEN SWINGING OR CHANGING
DIRECTION OF TRAVEL
Before operating the machine or the work
equipment, always observe the following
precautions to prevent serious injury or death.
• When changing the direction of travel
from forward to reverse or from
reverse to forward, reduce speed
early and stop the machine before
changing the direction of travel.
• Sound the horn to warn people in the HAOA190L
area. Figure 16
• Check that there is no one in the area
around the machine. There are blind spots behind the machine, so if necessary, swing the
upper structure to check that there is no one behind the machine before traveling in reverse.
• When operating in areas that may be hazardous or have poor visibility, designate a person to
direct work site traffic.
• Ensure that no unauthorized person can come within the turning radius or direction of travel.
Be sure to observe the above precautions even if a travel alarm or mirrors are installed.

Page 22
TRAVEL PRECAUTIONS
Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops
when the machine is traveling. It will be impossible to operate the steering.
Attachment control levers should not be operated while traveling.
Do not change selected travel mode (FAST/SLOW) while traveling.
Fold in work equipment so that the outer end of the boom is as close to the machine as possible, and is
40-50 cm (16 - 20 in) above ground.
Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope or
obstacle that causes the machine to tilt 10 degrees or more to the right or left, or 30 degrees or more from
front to rear.
Do not operate the steering suddenly. The work equipment may hit the ground and cause the machine to
lose its balance, and this may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.
Always keep to the permissible water depth. Permissible water depth is to the centerline of the upper track
rollers.
When traveling over bridges or structures on private land, check first that the bridge or structure can
withstand the weight of the machine. When traveling on public roads, check with the local authorities and
follow their instructions.
TRAVEL POSTURE INCORRECT
40 ~ 50 cm (16~20 in)
AXO0080L
Figure 17

Page 23
TRAVELING ON SLOPES
Never jump onto a machine that is running away to stop it. There is danger of serious injury.
Traveling on slopes could result in the machine tipping over or slipping.
On hills, banks or slopes, carry the bucket approximately 20 - 30 cm (8 - 12 in) above the ground. In case
of an emergency, quickly lower the bucket to the ground to help stop the machine.
AXO0090L AXO0100L
Figure 18 Figure 19
Do not travel on grass, fallen leaves, or wet steel

plates. Even slight slopes may cause the
machine to slip to the side, so travel at low
speed and make sure that the machine is
always traveling directly up or down the slope.
Avoid changing the direction of travel on a slope.
This could result in tipping or side slipping of the
machine.
When possible, operate the machine up slopes
and down slopes. Avoid operating the machine
across the slope, when possible.
Figure 20
PROHIBITED OPERATIONS
Do not dig the work face under an overhang.
This may cause the overhang to collapse and
fall on top of the machine.
X
AXO0110L
Figure 21

Page 24
Do not carry out deep digging under the front of
the machine. The ground under the machine
may collapse and cause the machine to fall.
Working heavy loads over loose, soft ground or
X
uneven, broken terrain can cause dangerous
side load conditions and possible tipover and
injury. Travel without a load or a balanced load
may also be hazardous.
Never relay on lift jacks or other inadequate
supports when work is being done. Block tracks
fore and aft to prevent any movement. AXO0120L
When using the machine, to prevent accidents Figure 22
caused by damage to the work equipment and
overturning because of an excessive load, do
not use the machine in excess of its ability (in
terms of the maximum load and stability
determined by the structure of the machine).
PRECAUTIONS FOR OPERATION

Be careful not to go close to the edge of a cliff
by mistake.
Use the machine only for its main purpose.
Using it for other purposes will cause failures.
To ensure an ample view, do as follows:
• When working in dark areas, attach
working lights and front lights to the
machine. If necessary, set up lighting
at the work site.
• Stop operations when the visibility is Figure 23
poor, such as in fog, mist, snow, and
rain. Wait for the visibility to improve
to a level which causes no problems
for the operation.
To avoid hitting the work equipment, always do the following;
• When working in tunnels, on bridges, under electric wires, or when parking the machine or
carrying out other operations in places with limited height, be extremely careful not to hit the
bucket or other parts.
• To prevent collisions, operate the machine at a safe speed when working in confined spaces,
indoors, or in crowded areas.
• Do not pass the bucket over the heads of workers or over the operator's compartment of dump
truck.

Page 25
AVOID HIGH-VOLTAGE CABLES
Serious injury or death can result from contact
or proximity to high-voltage electric lines. The
bucket does not have to make physical contact
with power lines for current to be transmitted.
Use a spotter and hand signals to stay away
from power lines not clearly visible to the
operator.
Voltage Minimum Safe Distance
6.6 kV 3 m (9' 10") AXO0130L

Figure 24
33.0 kV 4 m (13' 1")
66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")
Use these minimum distances as a guideline only. Depending upon the voltage in the line and atmospheric
conditions, strong current shocks can occur with the boom or bucket as far away as 4 - 6 m (13 - 20 ft) from
the power line. Very high voltage and rainy weather could further decrease that safety margin.
NOTE: Before starting any type of operation near power lines (either above ground or buried
cable type), you should always contact the power utility directly and work out a safety plan
with them.
OPERATE CAREFULLY ON SNOW, ICE AND IN VERY COLD TEMPERATURES

In icy cold weather avoid sudden travel movements and stay away from even slight slopes. The machine
could skid off to one side very easily.
Snow accumulation could hide or obscure potential hazards. Use care while operating or while using the
machine to clear snow.
Warming up the engine for a short period may be necessary, to avoid operating with sluggish or reduced
working capacity. The jolting shocks and impact loads caused by bumping or bottoming the boom or
attachment are more likely to cause severe stress in very cold temperatures. Reducing work cycle rate and
work load may be necessary.
When the temperature rises, frozen road surfaces become soft, so the machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare hands. If you touch a metal surface in
extremely cold weather, your skin may freeze to the metal surface.

Page 26
OPERATIONS ON SLOPES
When working on slopes. there is danger that
the machine may lose its balance and turn over,
when swinging, or when work equipment is
operated. Always carry out these operations
carefully.
Do not swing the work equipment from the uphill
side to the downhill side when the bucket is
loaded. This operation is dangerous.
If the machine has to be used on a slope, pile
the soil to make a platform that will keep the AXO0140L
machine as horizontal as possible. Figure 25
In addition, lower the bucket as far as possible,
keep it pulled into the front, and keep the swing
speed as low as possible.
PARKING MACHINE
Avoid making sudden stops, or parking the machine wherever it happens to be at the end of the work day.
Plan ahead so that the excavator will be on a firm, level ground away from traffic and away from high walls,
cliff edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable,
block the crawler tracks to prevent movement. Lower the bucket or other working attachment completely to
the ground, or to an overnight support saddle. There should be no possibility of unintended or accidental
movement.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs
to ensure that passing traffic can see the machine clearly, and park the machine so that the machine, flags,
and fences do not obstruct traffic.
After the front attachment has been lowered to an overnight storage position and all switches and
operating controls are in the "OFF" position, the safety lock lever must be set to the "LOCKED" position.
This will disable all pilot circuit control functions.
Always close the door of the operator's compartment.
NEVER LET ANYONE RIDE ON

ATTACHMENT
Never let anyone ride on any work attachment,
such as the bucket, crusher, grapple, or
clamshell (grab bucket). There is a danger of the
person falling and suffering serious injury.
ARO1310L
Figure 26

Page 27
MAINTENANCE
WARNING TAG
Alert others that service or maintenance is
being performed and tag operator's cab controls
– and other machine areas if required – with a
warning notice. OSHA mandated control lever WARNING
lockout can be made with any OSHA certified
lockout device and a length of chain or cable to DO NOT OPERATE
keep the left-hand control console in the fully when performing inspection
raised, non active position. or maintenance
Warning tags, for controls are available from 190-00695
Daewoo distributors.
ARO1320L
Figure 27
CLEAN BEFORE INSPECTION OR
MAINTENANCE
Clean the machine before carrying out inspection and maintenance. This prevents dirt from getting into the
machine and also ensures safety during maintenance.
If inspection and maintenance are carried out when the machine is dirty, it will become more difficult to
locate the problems, and also there is danger that you may get dirt or mud in your eyes or that you may slip
and injure yourself.
When washing the machine, do the following;
• Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places.
• Wear safety glasses and protective clothing when washing the machine with high-pressure
steam.
• Take action to prevent touching high-pressure water and cutting your skin or having mud fly into
your eyes.
• Do not spray water directly on electrical components (sensors, connector) (1, Figure 28). If
water gets into the electrical system, there is danger that it will cause defective operation and
malfunction.
Figure 28
Pick up any tools or hammers that are laying in the work place, wipe up any grease or oil or any other
slippery substances, and clean the area to make it possible to carry out the operation in safety. If the work
place is left untidy, you may trip or slip and suffer injury.

Page 28
PROPER TOOLS
Use only tools suited to the task. Using
damaged, low qualify, faulty, or makeshift tools
could cause personal injury. There is danger
that pieces from, chisels with crushed heads, or
hammers, may get into your eyes and cause
blindness.
HDO1037L
Figure 29
USE OF LIGHTING
When checking fuel, oil, battery electrolyte, or
window washing fluid, always use lighting with
anti-explosion specifications. If such lighting
equipment is not used, there is danger of
explosion.
If work is carried out in dark places without
using lighting, it may lead to injury, so always
use proper lighting.
Even if the place is dark, never use a lighter or
flame instead of lighting. There is danger of fire. HDO1040L
There is also danger that the battery gas may Figure 30
catch fire and cause and explosion.
FIRE PREVENTION AND EXPLOSION PREVENTION

All fuels, most lubricants and some coolant mixtures are flammable. Leaking fuel or fuel that is spilled onto
hot surfaces or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons.
Store oily rags and other flammable material in a protective container.
Do not smoke while you refuel the machine or while you are in a refueling area.
Do not smoke in battery charging areas or in areas the contain flammable material.
Clean all electrical connections and tighten all electrical connections. Check the electrical wires daily for
wires that are loose of frayed. Tighten all lose electrical wires before you operate the machine. Repair all
frayed electrical wires before you operate the machine.
Remove all flammable materials before they accumulate on the machine.
Do not weld on pipes or on tubes that contain flammable fluids. Do not flame cut on pipes or on tubes that
contain flammable fluids. Before you weld on pipes or on tubes or before you flame cut on pipes or on
tubes, clean the pipes or tubes thoroughly with a nonflammable solvent.

Page 29
BURN PREVENTION
When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then
check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit,
there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
ARO1360L
Figure 31
If the coolant level in the coolant recovery tank is below the lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Allow cooling system components to cool before you drain the cooling system.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact
the skin.
Remove the hydraulic tank filter plug only after the engine has been stopped. Make sure that the hydraulic
tank filter plug is cool before you remove it with your bare hand. Remove the hydraulic tank filter plug slowly
to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel system, or in the cooling system before you
disconnect any lines, fittings, or related items.
Batteries give off flammable fumes that can explode.
Do not smoke while you are checking the battery electrolyte levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or
the eyes.
Always wear protective glasses when you work on batteries.

Page 30
WELDING REPAIRS
When carrying out welding repairs, carry out the welding in a properly equipped place. The welding should
be performed by a qualified worker. During welding operations, there is the danger of, generation of gas,
fire, or electric shock, so never let an unqualified worker do welding.
The qualified welder must do the following;
• To prevent explosion of the battery, disconnect the battery terminals and remove batteries.
• To prevent generation of gas, remove the paint from the location of the weld.
• If hydraulic equipment, piping or places close to them are heated, a flammable gas or mist will
be generated and there is danger of it catching fire. To avoid this, never subject these places to
heat.
• Do not weld on pipes or on tubes that contain flammable fluids. Do not flame cut on pipes or on
tubes that contain flammable fluids. Before you weld on pipes or on tubes or before you flame
cut on pipes or on tubes, clean the pipes or tubes thoroughly with a nonflammable solvent.
• If heat is applied directly to rubber hoses or piping under pressure, they may suddenly break so
cover them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and provide a fire extinguisher.
WARNING FOR COUNTERWEIGHT AND FRONT ATTACHMENT REMOVAL
DANGER!
Daewoo warns any user, that the removal
of the counterweight from the machine,
front attachment or any other part, may
X
affect the stability of the machine. This
could cause unexpected movement,
resulting in death or serious injuries.
Daewoo is not liable for any misuse.
Never remove the counterweight or front
attachment unless the upper structure is X
in-line with the lower structure.
Never rotate the upper structure once the
counterweight or front attachment has
been removed.
HAAD4060
Figure 32

Page 31
PRECAUTIONS FOR REMOVAL,
INSTALLATION, AND STORAGE OF
ATTACHMENTS
Before starting removal and installation of
attachments, decide the team leader.
Do not allow anyone except the authorized
workers close to the machine or attachment.
Place attachments that have been removed
from the machine in a safe place so that they do
not fall. Put up a fence around the attachments
and take other measures to prevent HDO1041L
unauthorized persons from entering. Figure 33
PRECAUTIONS WHEN WORKING ON

MACHINE
When carrying out maintenance operations on
the machine, keep the area around your feet
clean and tidy to prevent you from falling.
Always do the following;
• Do not spill oil or grease.
• Do not leave tools laying about.
• Watch your step when walking.
Never jump down from the machine. When ARO1380L
getting on or off the machine, use the steps and Figure 34
handrails, and maintain a three-point contact
(both feet and one hand or both hands and one
foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when
working on the hood or covers, never use any
part except the inspection passage fitted with
nonslip pads.
LOCK INSPECTION COVERS

When carrying out maintenance with the inspection cover open, lock the cover securely in position with the
lock bar.
If maintenance work is carried out with the inspection cover open but not locked, there is danger that it may
suddenly close and cause injury if there is a gust of wind.

Page 32
CRUSHING PREVENTION AND CUTTING PREVENTION
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.
Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the
engine is running.
Stay clear of all rotating parts and moving parts.
Keep objects away from moving fan blades. The fan blades will throw objects and the fan blades can cut
objects.
Do not use a wire rope cable that is kinked or flayed. Wear gloves when you handle a wire rope cable.
When you strike a retainer pin, the retainer pin might fly out. The loose retainer pin can injure personnel.
Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear
protective glasses when you strike a retainer pin.
TRACK TENSION ADJUSTMENTS REQUIRE

CAUTION
Never turn out the track tension grease fitting
nut. To release pressure from the crawler frame
track tension assembly, you should NEVER
attempt to disassemble the track adjuster or
attempt to remove the grease fitting or valve
assembly.
Keep your face and body away from the valve.
Refer to the track adjustment procedure in the
Operator and Maintenance Manual or Shop
HAOA110L
Manual.
Figure 35
SUPPORTS AND BLOCKING FOR WORK

EQUIPMENT
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
equipment supported solely by a lift jack.
HDO1042L
Figure 36

Page 33
ACTION WHEN ABNORMALLY IS FOUND DURING INSPECTION
If any abnormality is found during inspection, always carry out repairs. In particular, if the machine is used
when there are still problems with the brake or work equipment systems, it may lead to serious injury.
If necessary depending on the type of failure, please contact your Daewoo distributor for repairs.
PRECAUTIONS WITH HIGH-PRESSURE LINE, TUBES AND HOSES

When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released
from the circuit. Failure to release the pressure may lead to serious injury. Always do the following;
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized components can be difficult to see but
pressurized oil has enough force to pierce the skin and cause serious injury. Always use a piece
of wood or cardboard to check for suspected hydraulic leaks. Never use your hands or expose
your fingers.
• Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install lines, tubes or
hoses that are bent or damaged.
• Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration,
rubbing against other parts, and excessive heat during operation.
– If any of the following conditions are found, replace the part.
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure of strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.
NOTE: Refer to "Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)"
in Operation and Maintenance Manual, for additional European regulations.
X X O
HAOA420L
Figure 37

Page 34
WASTE MATERIALS
Physical contact with used motor oil may pose a X
health risk. Wipe oil from your hands promptly
and wash off any remaining residue.
Used motor oil is an environmental contaminant
and may only be disposed of at approved
collection facilities. To prevent pollution of the
environment, always do the following;
• Never dump waste oil in a sewer
system, rivers, etc.
HAOA470L
• Always put oil drained from your
Figure 38
machine in containers. Never drain
oil directly onto the ground.
• Obey appropriate laws and
regulations when disposing of
harmful materials such as oil, fuel,
solvent, filters, and batteries.

Page 35
BATTERY
BATTERY HAZARD PREVENTION
Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is
highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems,
always do the following;
• Do not smoke or bring any flame near the battery.
• When working with batteries, ALWAYS wear safety glasses and rubber gloves.
• If you spill battery electrolyte on yourself or your clothes, immediately flush the area with water.
• If battery electrolyte gets into your eyes, flush them immediately with large quantities of water
and see a doctor at once.
• If you accidentally drink battery electrolyte, drink a large quantity of water or milk, raw egg or
vegetable oil. Call a doctor or poison prevention center immediately.
• When cleaning the top surface of the battery, wipe it with a clean, damp cloth. Never use
gasoline, thinner, or any other organic solvent or detergent.
• Tighten the battery caps securely.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with power from
another source. There is danger that the battery may catch fire.
• When charging the battery or starting with power from another source, let the battery electrolyte
melt and check that there is no leakage of battery electrolyte before starting the operation.
• Always remove the battery from the machine before charging.
Figure 39

Page 36
STARTING ENGINE WITH A BOOSTER
CABLE
WARNING!
1. An explosive gas is produced while
batteries are in use or being charged.
Keep flames or sparks away from the
battery area.
2. Charge batteries in a well-ventilated HAOA440L
area.
Figure 40
3. Always wear eye protection when
starting a machine with jumper
cables.
4. Improper jump starting procedures
can cause an explosion resulting in
personal injury.
5. Jump start vehicles on dry ground or
concrete. Do not jump start the
machine on a steel floor, because the
floor is always grounded.
6. When starting from another machine,
make sure the machines do not
touch.
7. Always connect the auxiliary battery
positive (+) terminal to depleted
battery positive (+) terminal first.
Then connect auxiliary battery
negative (-) terminal to the frame of
the depleted battery machine
second.
8. Connect positive cable first when
installing cables and disconnect the
negative cable first when removing.
IMPORTANT
The machine has a 12V (-) negative ground electrical system. Use the same capacity 12V booster
battery when jump starting engine.
If the battery is drained during starting procedures, jump start engine using auxiliary or booster battery
according to the following procedure.

Page 37
Connecting the Booster Battery
1. Shut down engine of the machine on a
Red
which booster battery is mounted (c,
Figure 41).
2. Connect one end of red cable (a, Figure d
c
41) to the positive (+) terminal of the
machine battery, and the other end to the
positive (+) terminal of the booster battery
(c, Figure 41). Black
e
3. Connect one end of black cable (b, Figure b
41) to the negative (-) terminal of the AXO0510L
booster battery, and then make ground Figure 41
connection to the upper frame of the
machine (e, Figure 41) to be started with
the other end of black (-) cable (b, Figure
41). When making the last connection to
upper frame, be sure to connect the cable
end as far away from the machine battery
as possible. DO NOT CONNECT
DIRECTLY TO THE NEGATIVE BATTERY
TERMINAL.
4. Start the engine
Disconnecting the Booster Battery

1. Disconnect black negative (-) cable (b,
Figure 41) from the machine frame first.
2. Disconnect the other end of black negative
(-) cable (b, Figure 41) from the booster
battery.
3. Disconnect red positive (+) cable (a,
Figure 41) from the booster battery.
4. Disconnect red positive (+) cable (a,
Figure 41) from the machine battery.

Page 38
TOWING
PRECAUTIONS WHEN TOWING
If any mistake is made in the method of
selecting or inspecting the towing wire or in the
method of towing, it may lead to serious
O
personal injury. Always do the following;
• Always use the method of towing
given in this Operation and
Maintenance Manual. Do not use any
other method.
• Use leather gloves when handling
the wire rope.
• When carrying out the preparation
work for towing with two or more
workers, determine the signals to use
X
and follow these signals correctly.
• Always fit the towing rope to the left
and right hooks and secure in
position.
• If the engine on the problem machine
will not start or there is a failure in the
brake system. always contact your HAOC910L
Daewoo distributor.
Figure 42
• Never go between the towing
machine and the towed machine
during the towing operation.
• It is dangerous to carry out towing on
slopes, so select a place where the
slope is gradual. If there is no place
where the slope is gradual, carry out
operations to reduce the angle of the
slope before starting the towing
operation.
• When towing a problem machine,
always use a wire rope with a
sufficient towing capacity.
• Do not use a frayed, kinked rope or a
rope with any loss of diameter.
• Do not use the light-weight towing
hook for towing another machine.

Page 39
SHIPPING AND TRANSPORTATION
OBEY STATE AND LOCAL OVER-THE-ROAD REGULATIONS
Check state and local restrictions regarding weight, width and length of a load before making any other
preparation for transport.
The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended
shipping route.
Partial disassembly or tear-down of the excavator may be necessary to meet travel restrictions or particular
conditions at the work site. See the Shop Manual for information on partial disassembly.
Refer to the Transportation and Shipping section of this Operation and Maintenance Manual for information
on loading, unloading and towing.
LIFTING WITH SLING
WARNING!
Improper lifting can allow load to shift and
cause injury or damage.
1. Refer to Specification section of Operation

and Maintenance Manual for information
on weight and dimensions.
2. Use properly rated cables and slings for
lifting.
3. Position machine for a level lift.
4. Lifting cables should have a long enough
length to prevent contact with the machine.
Spreader bars may be required. Figure 43
If spreader bars are used, be sure that cables
are properly secured to them and that the angle
of the cables is factored into the lift strength

Page 40
1SPECIFICATIONS
S0202025K
1SPECIFICATIONS FOR
SOLAR 75-V
CAUTION!
SPECIFICATIONS FOR SOLAR 75-VS0202025K

Solar 75-V 1001 and Up

January 2004
Specifications for Solar 75-V S0202025K

Page 1
TABLE OF CONTENTS
General Description........................................................................................ 3
Component Locations .................................................................................... 4
General Dimensions....................................................................................... 6
Working Range............................................................................................... 8
General Specifications ................................................................................. 10
Engine Performance Curves (Per DIN 6270 Standard)................................ 12
Approximate Weight of Workload Materials ................................................. 14
Performance Tests........................................................................................ 17
Excavator Performance Standards............................................................... 18
Test Conditions...................................................................................... 18
Travel Speed and Travel Motor Balance (Steering Deviation) Tests...... 18
Swing Speed and Deceleration Force Test ........................................... 20
Cylinder Performance Tests .................................................................. 21
S0202025K Specifications for Solar 75-V

Page 2
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.)

Page 3
COMPONENT LOCATIONS
2 4
11 1
3
10
9
35
8
36
38 17 18 5
34
12
33
13
29 28 15
27
26
32 16
30
31
14
37
7
24 22 25 23 20 21 19
BJS0010L
Figure 1

Page 4
1. BATTERY 20. LOWER ROLLER
2. FUEL TANK FILL CAP 21. UPPER ROLLER
3. FUEL TANK 22. TRACK GUIDE
4. HYDRAULIC OIL TANK 23. TRACK ADJUSTER
5. PUMPS 24. IDLER
6. MUFFLER 25. TRACK LINK AND SHOE
7. COUNTERWEIGHT 26. TRAVEL LEVER
8. ENGINE 27. WORK LEVER (JOYSTICK) CONTROLS
9. RADIATOR AND OIL COOLER 28. TOOTH POINT
10. AIR CLEANER 29. SIDE CUTTER
11. CONTROL VALVES 30. BUCKET
12. ARM CYLINDER 31. PUSH LINK
13. BOOM 32. GUIDE LINK
14. BOOM CYLINDER 33. BUCKET CYLINDER
15. CAB 34. ARM
16. SEAT 35. DOZER BLADE
17. CENTER JOINT 36. DOZER CYLINDER
18. SWING MOTOR 37. SWING BRACKET
19. TRAVEL MOTOR 38. BOOM SWING CYLINDER

Page 5
GENERAL DIMENSIONS
BJS0020L
Figure 2

Page 6
3.1 m (10' 2") BOOM
DIMENSION
1.8 m (5' 10") ARM 2.2 m (7' 3") ARM
A 75 °£
B 50 °£
C 1,700 mm (5' 7")
D 6,280 mm (20' 7") 5,930 mm (19' 5")

E 2,130 mm (6' 11")
F 2,775 mm (9' 1")
G 3,380 mm (11' 1")
H 650 mm (2' 2")
I 1,750 mm (5' 9")
J 2,200 mm (7' 3")
K 365 mm (1' 2")

L 2,100 mm (6' 11")
M 1,000 mm (3' 3")
N 1,100 mm (3' 7")
O 2,210 mm (7' 3")
P 2,200 mm (7' 3")
Q 422 mm (1' 5")

R 2,630 mm (8' 8")
S 3,215 mm (10' 7")

Page 7
WORKING RANGE
WARNING!
The actual value for dimension "L" Digging Reach, depends on the stability and support
provided by ground conditions. Digging too far underneath the excavator if soil conditions are
wet, loose or unstable can collapse ground support, which could cause injury and/or equipment
damage.
BJS0030L
Figure 3

Page 8
One Piece 3.1 m
Boom Type
(10.2 ft)
1.8 m 2.2 m
Dim. Arm Type
(5.9 ft) (7.2 ft)
Bucket Type
(PCSA) 0.12 m3 (0.16 yd3) or 0.28 m3 (0.37 yd3)
6,650 mm 7,020 mm
A Max. Digging Reach
(21' 9") (23' 2")
Max. Digging Reach 6,495 mm 6,880 mm
B
(Ground) (21' 3") (22' 6")
4,020 mm 4,420 mm
C Max. Digging Depth
(13' 2") (14' 6")
4,290 mm 4,525 mm
D Max. Loading Height
(14' 7") (14' 10")
6,250 mm 6,490 mm
F Max. Digging Height
(20') (21' 3")
5,300 mm 5,540 mm
G Max. Bucket Pin Height
(17' 4") (18')
2,910 mm 3,345 mm
H Max. Vertical Wall
(9' 6") (10' 11")
4,760 mm 4,825 mm
I Max. Radius Vertical
(15' 7") (15' 9")
3,625 mm 4,090 mm
J Max. Depth to 8 ft Line
(11' 10") (13' 5")
1,335 mm 1,300 mm
K Min. Radius 8 ft Line
(4' 4") (4' 3")
195 mm -250 mm
L Min. Digging Reach
(7") (-9")
2,460 mm 2,460 mm
M Min. Swing Radius
(8') (8')

Page 9
GENERAL SPECIFICATIONS
Shipping Weight 8 metric tons (17,643 lb), includes 10% fuel, boom, 1,800 mm
(5' 10") arm, 0.28 m3 backhoe bucket and standard shoes
Operating Weight Subtract weight of full fuel tank and operator.
Shipping Weights With Optional Add 20 kg (44 lb) for Rubber shoe
Track Shoes
Major Component Weights Standard Boom 410 kg (904 lb)
1,800 mm (5' 10") Arm 177 kg (390 lb)
Boom Swing Cylinder 68 kg (150 lb)
Boom Cylinder 104 kg (230 lb)
Arm Cylinder 79 kg (174 lb)
Bucket Cylinder 55 kg (121 lb)
Counterweight 860 kg (1,896 lb)
Upper Turntable 770 kg (1,698 lb)
Lower - below Swing Bearing 630 kg (1,389 lb)
Digging Forces:
Bucket Cylinder KN or 5,500 kg (12,130 lb)
Arm Cylinder KN or 4,500 kg (9,925 lb) with 1,800 mm (5' 10") standard arm
Fuel Tank Capacity 110 liters (28.5 U.S. gal)
Hydraulic System Capacity 150 liters (39.6 U.S. gal)
Hydraulic Reservoir Capacity 93 liters (24.6 U.S. gal)
Bucket Heaped Capacity Range PCSA 0.12 - 0.28 m3 (0.16 - 0.37 yd3)
IMPORTANT: Refer to the Load Weight, Bucket and Arm Length
Compatibility Table for information on which bucket sizes may be
used safely with which arm length, for load material weights.
Shoe Type Triple Grouser
Shoe Width and Optional Sizes 450 mm (18") - standard
450 mm (18") - Rubber Type - optional
Ground Pressure Ratings:
Standard 450 mm (23.6") 0.38 kg/cm2 (5.40 psi)
shoe -
Transport Dimensions
Overall Shipping Length 6,280 mm (20' 7")
(standard arm)
Overall Shipping Length 5,930 mm (19' 5")
(2.2 m (7' 3") option arm)
Overall Shipping Width 2,210 mm (7' 3")
Overall Shipping Height 2,630 mm (8' 8")

(to top of cabin)
-standard arm
Overall Shipping Height 3,215 mm (10' 7")
(to top of cylinder hose)
- 2.2 m (7' 3") option arm

Page 10
Track Shipping Length 3,380 mm (11' 1")
(To Dozer Blade)
Transport Trailer Capacity 8 tons, minimum load capacity
Transport Loading Ramp 15° angle CAUTION: Refer to Transport Maximum Procedure for
Allowable Slope Safe Shipping Instructions.

Page 11
ENGINE PERFORMANCE CURVES (PER DIN 6270
STANDARD)
BJS0040L
Figure 4

Page 12
S75-V (S/N 1001 thru 1153) (S/N 1154 and Up)
Condition Specification
Engine Model 4TNE98-DB 4TNV98-XDB
Barometric Pressure 750 mmHg (25° C (77°F)) 750 mmHg (25° C (77°F))
460 mm, SUCKER 460 mm, SUCKER
Cooling Fan
(18 in) (18 in)
Alternator 12V x 60A 12V x 60A
Air Cleaner Installed Installed
Muffler Installed Installed
Performance Standard DIN 6270

54 ps @ 1,900 rpm 55.3 ps @ 1,900 rpm
Power
(53.26 hp @ 1,900 rpm) (54.5 hp @ 1,900 rpm)
23 kg•m @ 1,425 rpm 22.5 kg•m @ 1,425 rpm
Max. Torque
(166 ft lb @ 1,425 rpm) (163 ft lb @ 1,425 rpm)
165.0 g/ps•h 165.0 g/ps•h
Fuel Consumption (Min. Rated)
(5.81 oz/hp•h) (5.81 oz/hp•h)

Page 13
APPROXIMATE WEIGHT OF WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume and mass. Exposure to rain, snow or
ground water; settling or compaction due to overhead weight, chemical or industrial processing
or changes due to thermal or chemical transformations could all increase the value of weights
listed in the table.
LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR

DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
Coke, blast furnace 433 kg/m3

--------------------- ---------------------
size (729 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(756 lb/yd3)
Coal, bituminous slack, 801 kg/m3

--------------------- ---------------------
piled (1,350 lb/yd3)
Coal, bituminous r. of 881 kg/m3

--------------------- ---------------------
m., piled (1,485 lb/yd3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
Clay, DRY, in broken 1,009 kg/m3

--------------------- ---------------------
lumps (1,701 lb/yd3)
Clay, DAMP, natural 1,746 kg/m3

--------------------- ---------------------
bed (2,943 lb/yd3)
Cement, Portland, DRY 1,506 kg/m3

--------------------- ---------------------
granular (2,583 lb/yd3)
Cement, Portland, DRY 1,362 kg/m3

--------------------- ---------------------
clinkers (2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
Earth, loamy, DRY, 1,202 kg/m3

--------------------- ---------------------
loose (2,025 lb/yd3)

Page 14
LESS LESS LESS
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy --------------------- ---------------------
(2,970 lb/yd3)
Gypsum, calcined, 961 kg/m3

--------------------- ---------------------
(heated, powder) (1,620 lb/yd3)
Gypsum, crushed to 3 1,522 kg/m3

--------------------- ---------------------
inch size (2,565 lb/yd3)
Gravel, DRY, packed 1,810 kg/m3

--------------------- ---------------------
fragments (3,051 lb/yd3)
Gravel, WET, packed 1,922 kg/m3

--------------------- ---------------------
fragments (3,240 lb/yd3)
Limestone, graded 1,282 kg/m3

--------------------- ---------------------
above 2 (2,160 lb/yd3)
Limestone, graded 1,362 kg/m3

--------------------- ---------------------
1-1/2 or 2 (2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)

Page 15
LESS LESS LESS
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulphur, broken --------------------- ---------------------
(1,620 lb/yd3)

Page 16
PERFORMANCE TESTS
1. Main Relief Pressure
normal operation: 280 kg/cm2 (3,982 psi)

2. Actuator Speeds
Operation Unit Standard Mode

Boom Up sec. 2.6 ±0.3
Down sec. 2.6 ±0.3
Arm Dump sec. 2.7 ±0.3
Crowd sec. 3.0 ±0.3
Bucket Dump sec. 2.2 ±0.3
Crowd sec. 3.2 ±0.3
Swing (3 Revolutions) sec. 19.5 ±1.5
Jack-up Speed (3 Turns) High sec. 16.0 ±1.5
Low sec. 26.0 ±2.0
Travel Speed 20 m (65.62 ft) High sec. 18.0 ±1.0
Low sec. 29.0 ±1.5
Travel Deviation 20 m (65 62 ft) High mm (in) 150 (5.91)
Low mm (in) 150 (5.91)

Page 17
EXCAVATOR PERFORMANCE STANDARDS
Evaluation of equipment performance and operating condition can be made by running the excavator
through a series of different tests, and recording results with a stop watch and tape measure.
Compare results of performance tests against the specifications and standards that follow, which are for
equipment in new or renewed condition.
TEST CONDITIONS
1. All tests should be performed on a flat, level, firmly supporting ground surface.
2. All recommended, applicable maintenance and adjustment service should be completed before
testing.
3. Hydraulic fluid and engine oil should be of appropriate viscosity for ambient weather conditions.
Warm up hydraulic oil to standard operating temperature, between 45° - 55°C (112° - 135°F).
4. Run all tests with the engine speed control set to maximum RPM.
5. Repeat tests with Power Mode engine control settings at both Standard Mode (standard work mode)
and Power Mode (high speed mode). Travel speed tests should also be repeated at both high and low
speed.
TRAVEL SPEED AND TRAVEL MOTOR BALANCE (STEERING DEVIATION) TESTS
Speed Test
Prepare the excavator for travel speed tests by extending all hydraulic cylinders - boom, arm and bucket -
to the fully extended position, shown in Figure 5.
TRAVEL POSTURE INCORRECT
40 ~ 50 cm (16~20 in)
BJO0030L
Figure 5
The lowest part of the bucket linkage should be 0.3 - 0.5 m (1' - 2') off the ground.
Mark off a 20 m (65' 7-1/2") test distance, with a 3 - 5 m (10' - 15') run-up area, and a 3 - 5 m (10' - 15', or
longer) speed run-off distance.
Travel the excavator back and forth to be sure steering is centered and side frames are perfectly parallel
with the test course.
Operate both travel levers at the fully engaged position and measure the time it takes to cross 20 m (65'
7-1/2"). Compare measured results against the standard for new machines:

Page 18
TIME
RATE OF TRAVEL
STANDARD MODE
High Speed 18.0 ±1.0 seconds
Low Speed 29.0 ±1.5 seconds
Rotate the turntable 180°. Both tests should be repeated three times. Average all results to obtain a final
value.
20 M (65' 7-1/2")
3M - 5M 3M - 5M
(10' - 15') (10' - 15')
ARS1500L
Figure 6
Travel Deviation
To check steering deviation (travel motor balance), use a long tape or rope, or the edge of an undeviating
straight road curb or other marker to verify side-to-side travel motor uniformity.
Deviation distance should always be measured at the 20 m (65' 7-1/2") "finish line." Repeat the test in
reverse to measure in both directions, with starting point becoming the finish line, and vice versa. (Figure
6)
A greater amount of deviation is allowed with the travel control set for high speed.
RATE OF TRAVEL MAX. DISTANCE

High Speed 150 mm (6 in)
Low Speed 150 mm (6 in)

Page 19
SWING SPEED AND DECELERATION FORCE TEST
Swing Speed Test
BJS1340L
Figure 7
Extend the bucket cylinder completely and retract the arm cylinder, as shown in Figure 7, to test swing
speed. The lowest point of the bucket will be approximately 1.5 m (3') off the ground.
Use paint marks at the same point on the turntable and undercarriage, or select alternate measuring
locations and use a stopwatch to time 3 full 360° rotations. The time required for 3 revolutions should be
between 15.5 and 17.5 seconds in Standard Mode, 15.5 and 17.5 seconds in Power Mode.
Swing Deceleration Force Test

With the boom, arm and bucket in the same
position as for the swing speed test, rotate the
turntable so that the boom is evenly centered
between the side frames, pointing straight
ahead. Locate the 90° reference point, 3
perpendicular to the boom. Mark the turntable 4
and undercarriage with paint at the 90° point.
Make several attempts to rotate the turntable
exactly 90°, starting from the boom straight
ahead position. Engage the swing lever and 2
brake at the 90° point, shown as "swing stop" in
Figure 8.
Record how far the turntable drifts past the stop
point, measuring the distance between paint
marks. Maximum distance should be less than
1200 mm (47-1/4"), in both Power Mode and
Standard Mode.
Reference
Description
1
HJA7007L
Number
1 Start Swing Figure 8
2 90° Swing
3 Swing Force
4 Swing Stop

Page 20
CYLINDER PERFORMANCE TESTS
NOTE: All tests are performed with standard boom, arm and bucket configuration. The bucket
should 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 should be fully retracted; boom and bucket cylinders must be
extended. Test movement in both directions, several times, and average results for both Standard Mode
and Power Mode.
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, in both standard and
extra-duty power modes.
Bucket Cylinder Test

Start with the boom up and the teeth of the bucket hanging vertically, 500 mm (1-1/2' - 2') above the
ground. Dump and crowd the bucket several times, and average results, for both standard and extra-duty
power modes.
OPERATION STANDARD MODE

Boom Up 2.6 ±0.3 seconds
Boom Down 2.6 ±0.3 seconds
Arm Dump 2.7 ±0.3 seconds
Arm Crowd 3.0 ±0.3 seconds
Bucket Dump 2.2 ±0.3 seconds
Bucket Crowd 3.2 ±0.3 seconds
Hydraulic Cylinder Natural Drop Test

To check boom and arm cylinder tightness against the specified performance standard for new cylinders,
put a full load of dirt in the bucket and move the attachment cylinders so that the arm cylinder is extended
20 - 50 mm (1" - 2") and boom cylinders are retracted the same amount, 20 - 50 mm (1" - 2"). The top of
the bucket should be approximately 2 m (6' - 7') off the ground.
Turn off the engine and measure cylinder drop after 5 minutes. Bucket cylinder should not show more than
40 mm (1.57") change, while the arm and boom cylinders should not fall more than 10 mm (0.39").
Travel Motor Jack-up Test

Test travel motor operation on each side by painting or chalking a mark on one crawler shoe, with a
corresponding mark on the travel frame. Use the attachment to jack up one side of the machine and
operate the raised travel motor. Record the number of seconds it takes the crawler shoe to make 3 full
rotations, during both high speed and low speed operation.
OPERATION STANDARD MODE

High Speed 16.0 ±1.5 seconds
Low Speed 26.0 ±2.0 seconds

Page 21
1GENERAL MAINTENANCE
S0302000
R1
1GENERAL
MAINTENANCE
PROCEDURES
CAUTION!
GENERAL MAINTENANCE PROCEDURESS0302000

ALL MODELS ALL RANGES

May 2002
General Maintenance Procedures S0302000

Page 1
TABLE OF CONTENTS
Welding Precautions and Guidelines ............................................................. 3

Hydraulic System - General Precautions ....................................................... 4
Maintenance Service and Repair Procedure ................................................. 5
General Precautions ............................................................................... 5
Hydraulic System Cleanliness and Oil Leaks................................................. 6
Maintenance Precautions for Hydraulic System Service ........................ 6
Oil Leakage Precautions ......................................................................... 6
Cleaning and Inspection................................................................................. 7
General Guidelines ................................................................................. 7
Bearing inspection .................................................................................. 8
S0302000 General Maintenance Procedures

Page 2
WELDING PRECAUTIONS AND GUIDELINES
IMPORTANT
To avoid accidents, personal injury and the possibility of causing damage to the machine or to
components, welding must only be performed by properly trained and qualified personnel, who
possess the correct certification (when required) for the specific welding fabrication or
specialized repair being performed.
WARNING!
Structural elements of the machine may be built from a variety of steels. These could contain
unique alloys or may have been heat treated to obtain particular strength characteristics. It is
extremely important that welding repairs on these types of steel are performed with the proper
procedures and equipment. If repairs are performed incorrectly, structural weakening or other
damage to the machine (that is not always readily visible) could be caused. Always consult
Daewoo After Sales Service before welding on integral components (loader arm, frames, car
body, track frames, turntable, attachment, etc.) of the machine. It is possible that some types of
structurally critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make
sure there are no hidden cracks or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety equipment on hand. Adequate
ventilation and a dry work area are absolutely essential. Keep a fire extinguisher nearby and
always wear protective clothing and the recommended type of eye protection.

Page 3
CAUTION!
Observe the following safety precautions:
1. Use extra caution and adequate safety shielding when welding near fuel and oil tanks,
batteries, hydraulic piping lines or other fire hazards.
2. Never weld when the engine is running. Battery cables must be disconnected before the
welding procedure is started.
3. Never weld on a wet or damp surface. The presence of moisture causes hydrogen
embrittlement and structural weakening of the weld.
4. If welding procedures are being performed near cylinder rods, operator's cab window areas
or any other assemblies that could be damaged by weld spatters, use adequate shielding
protection in front of the assembly.
5. During equipment setup, always attach ground cables directly to the area or component
being welded to prevent arcing through bearings, bushings, or spacers.
6. Always use correct welding rods for the type of weld being performed and observe
recommended precautions and time constraints. AWS Class E7018 welding rods for low
alloy to medium carbon steel must be used within two hours after removal from a freshly
opened container. Class E11018G welding rods for T-1 and other higher strength steel must
be used within 1/2 hour.
HYDRAULIC SYSTEM - GENERAL PRECAUTIONS

Always maintain oil level in the system at recommended levels. Assemblies that operate under heavy
loads, at high speed, with extremely precise dimensional tolerances between moving parts - pistons and
cylinders, or shoes and swash plates, for example - can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very short time when piping or hoses are
disconnected to repair leaks and/or replace damaged components. Hoses that are inadvertently switched
during disassembly (inlet for outlet and vice versa), air introduced into the system or assemblies that are
low on oil due to neglect or careless maintenance, could all produce sufficient fluid loss to cause damage.
When starting the engine (particularly after long layoff or storage intervals), make sure that all hydraulic
controls and operating circuits are in neutral, or "OFF." That will prevent pumps or other components that
may be temporarily oil-starved from being run under a load.
Replacement of any hydraulic system component could require thorough cleaning, flushing, and some
amount of prefilling with fresh, clean oil if the protective seal on replacement parts has obviously been
broken or if seal integrity may have been compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts carefully, before they are installed. If the
replacement part is bone dry (with no trace of factory prelube) or has been contaminated by dirt or by
questionable oils, flushing and prefilling with clean hydraulic fluid is recommended.
Vibration, irregular or difficult movement or unusual noise from any part of the hydraulic system could be
an indication of air in the system (and many other types of problems). As a general precaution (and to help
minimize the risk of potential long-term damage), allow the engine to run at no-load idle speed immediately
after initial start-up. Hydraulic fluid will circulate, releasing any air that may have been trapped in the
system before load demands are imposed.
A daily walk-around prestart equipment safety inspection, including a quick visual scan for any exterior
evidence of leaking hydraulic fluid, can help extend the service life of system components.

Page 4
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 sub-freezing climates
or in high temperature, high humidity tropical conditions), frequent purging of moisture
condensation from the hydraulic reservoir drain tap should 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.

Page 5
HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS
MAINTENANCE PRECAUTIONS FOR HYDRAULIC SYSTEM SERVICE
Whenever maintenance, repairs or any other type of troubleshooting or service is being performed, it's
important to remember that the hydraulic system - including both the interior and exterior surfaces of
assemblies, and every drop of operating fluid - must be protected from contamination.
Dust and other foreign contaminants are major contributors to premature wear in hydraulic circuits. The
narrow tolerances, rapidly moving parts and high operating pressures of the system require that fluid be
kept as clean as possible. The performance and dependability of the machine (and the service lift of
individual components) can be noticeably reduced if proper precautions are not observed:
• Use a safe, noncombustible, evaporative type, low-residue solvent and thoroughly clean exterior
surfaces of assemblies before any part of the circuit is opened up or disassembled.
NOTE: It's just as important to clean the cap and reservoir top before routine fluid changes or
quick checks as it is before major repairs. (Accumulated dirt attracts moisture, oil and
other fluids - and more dirt.)
• Keep dismantled parts covered during disassembly. Use clean caps, plugs or tape to protect the
disconnected openings of flanges, manifolds and piping.
• Do not allow cleaning solvents or other fluids to mix with the oil in the system. Use clean oil to
flush any traces of solvent or other residue before reassembly.
• If metal or rubber fragments are found in the system, flush and replace all fluid in the system
and troubleshoot the circuit to identify the source of contamination.
IMPORTANT
Make sure that cleaning solvents will be compatible with rubber materials used in the hydraulic
system. Many petroleum based compounds can cause swelling, softening, or other deterioration
of system sealing elements, such as O-rings, caps and other seals.
OIL LEAKAGE PRECAUTIONS

Oil that is visibly seeping from joints or seals should always serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew that air, water and dirt have an open, free
passageway through which to enter the circuit. Harsh, corrosive salt air, freezing and thawing
condensation cycles and working environments that are full of fine dust are especially hazardous. Clogging
of valve spools or external piping (especially pilot circuit piping) can gradually diminish or very suddenly
put a complete stop to normal hydraulic function. You can prevent having to make these types of repairs by
following recommended assembly procedures:
1. Use new O-rings and oil seals whenever hydraulic assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking alignment and flatness. Clean and repair
corrosion or any other damage.
3. Follow bolt torque recommendations and all other assembly requirements.

Page 6
NOTE: Grease lip seals before
assembly.
Figure 1
CLEANING AND INSPECTION

GENERAL GUIDELINES
All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or
foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting
parts such as thrust bearing, matched parts, etc.
WARNING!
Care should be exercised to avoid inhalation of vapors, exposure to skin and creating fire
hazards when using solvent type cleaners.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign
materials are dissolved and parts are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then
remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified
particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation
until bearings are thoroughly clean. To dry bearings, use moisture-free compressed air. Be careful to
direct air stream across bearing to avoid spinning bearings that are not lubricated. DO NOT SPIN
BEARINGS WHEN DRYING; bearings may be rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine
condition. Do not replace a bearing cone or cup individually without replacing mating cup or cone at
the same time. After inspection, dip bearings in light weight oil and wrap in clean lintless cloth or
paper to protect them until installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation,
scoring, pitting, cracked or chipped races. If any of these defects are found, replace bearings. Also
inspect defective bearing housing and/or shaft for grooved, galled or burred conditions that indicate
bearing has been turning in its housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and retaining rings when
unit is disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book
for replacement items. Be extremely careful when installing sealing members, to avoid cutting or

Page 7
scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite
#120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme
care not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle
and allow leakage.
When replacing lip type seals, make sure spring loaded side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking for cracks that are not visible to the eye.
Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. Replace all
gears showing cracks or spots where case hardening has worn through. Small nicks may be
removed with suitable hone. Inspect shafts and quills to make certain they have not been sprung,
bent, or splines twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or
worn.
6. Inspect bores and bearing surfaces of cast parts and machined surfaces for scratches, wear, grooves
and dirt. Remove any scratches and burrs with crocus cloth. Remove foreign material. Replace any
parts that are deeply grooved or scratched which would affect their operation.
BEARING INSPECTION
The conditions of the bearing are vital to the smooth and efficient operation of the machinery. When any
component containing bearings is disassembled, always carefully examine the condition of the bearings
and all of its components for wear and damage.
Once the bearing is removed, clean all parts thoroughly using a suitable cleaning solution. If the bearing is
excessively dirty soak the bearing assembly in a light solution and move the bearing around until all
lubricants and or foreign materials are dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be used. Be careful not to direct the air in a
direction which will force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully inspect all bearing rollers, cages and cups for
wear, chipping or nicks. If the bearing cannot be removed and is to be inspected in place, check foe
roughness of rotation, scoring, pitting, cracked or chipped races. If any of these defects are found replace
the whole bearing assembly. NEVER replace the bearing alone without replacing the mating cup or the
cone at the same time.
After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper
and protect them from moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that
indicate that the bearing has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for cracks that are not visible to the naked eye.
The following illustrations will aid in identifying and diagnosing some of the bearing related problems.
NOTE: The illustrations will only show tapered roller bearings, but the principles of identifying,
diagnosing and remedying the defects are common to all styles and types of bearings.

Page 8
Normal Bearing
Smooth even surfaces with no discoloration or
marks.
Figure 2
Bent Cage
Cage damage due to improper handling or tool
usage.
Replace bearing.
Figure 3
Figure 4
Galling
Metal smears on roller ends due to overheat,
lubricant failure or overload.
Replace bearing - check seals and check for
proper lubrication.
Figure 5

Page 9
Abrasive Step Wear
Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts
and housings, check seals and bearings and
replace if leaking, rough or noisy.
Figure 6
Etching
Bearing surfaces appear gray or grayish black
in color with related etching away of material
usually at roller spacing.
Replace bearings - check seals and check for
proper lubrication.
Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make
sure races are properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused
by hard particles of foreign materials.
Clean all parts and housings, check seals and
replace bearings if rough or noisy.
Figure 9

Page 10
Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
Figure 10
Brinelling
Surface indentations in raceway caused by
rollers either under impact loading or vibration
while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller
pockets caused by abrasive material and
inefficient lubrication.
Replace bearings - check seals.
Figure 12
Abrasive Roller Wear
Pattern on races and rollers caused by fine
abrasives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or noisy.
Figure 13

Page 11
Cracked Inner Race
Race cracked due to improper fit, cocking or
poor bearing seat.
Replace all parts and housings, check seals and
bearings and replace if leaking.
Figure 14
Smears
Smearing of metal due to slippage caused by
poor fitting, lubrication, overheating, overloads
or handling damage.
Replace bearings, clean related parts and check
for proper fit and lubrication.
Replace shaft if damaged.
Figure 15
Frettage
Corrosion set up by small relative movement of
parts with no lubrication.
Replace bearing. Clean all related parts. Check
seals and check for proper lubrication.
Figure 16

Page 12
Heat Discoloration
Heat discoloration can range from faint yellow to
dark blue resulting from overload or incorrect
lubrication.
Excessive heat can cause softening of races or
rollers.
To check for loss of temper on races or rollers, a
simple file test may be made. A file drawn over a
tempered part will grab and cut metal, whereas
a file drawn over a hard part will glide readily
with no metal cutting.
Figure 17
Replace bearing if over heating damage is
indicated. Check seals and other related parts
for damage.
Stain Discoloration
Discoloration can range from light brown to
black caused by incorrect lubrication or
moisture.
if the stain can be removed by light polishing or
if no evidence of overheating is visible, the
bearing can be reused.
Check seals and other related parts for damage.
Figure 18

Page 13
S0309000
R1
1STANDARD TORQUES
CAUTION!
STANDARD TORQUESS0309000
ALL MODELS ALL RANGES

May 2002
Standard Torques S0309000

Page 1
TABLE OF CONTENTS
Torque Values for Standard Metric Fasteners ................................................ 3

Torque Values for Standard U.S. Fasteners ................................................... 4
Type 8 Phosphate Coated Hardware ............................................................. 6
Torque Values for Hose Clamps ..................................................................... 7
Torque Values for Split Flanges...................................................................... 8
Torque Wrench Extension Tools..................................................................... 9
Torque Multiplication ............................................................................... 9
Other Uses for Torque Wrench Extension Tools ................................... 10
Tightening Torque Specifications (Metric) ............................................. 10
S0309000 Standard Torques

Page 2
TORQUE VALUES FOR STANDARD METRIC
FASTENERS
NOTE: The units for the torque values are kg•m (ft lb).
Grade
Dia. x Pitc
h (mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)

Page 3
TORQUE VALUES FOR STANDARD U.S. FASTENERS
S.A.E. BOLT HEAD
TYPE DESCRIPTION
GRADE MARKING
WILL HAVE NO MARKINGS IN THE CENTER OF THE

HEAD.
1 1 OR 2
Low or Medium Carbon Steel Not Heat Treated.
WILL HAVE THREE RADIAL LINES.

5 5
Quenched and Tempered Medium Carbon Steel.
WILL HAVE 6 RADIAL LINES.

8 8
Quenched and Tempered Special Carbon or Alloy Steel.
Recommended torque, in foot pounds, for all Standard Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE 30 engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 when finished jam nuts are used.
0.70 when Molykote, white lead or similar mixtures are used as lubricants.
0.75 when parkerized bolts or nuts are used.
0.85 when cadmium plated bolts or nuts and zinc bolts w/waxed zinc nuts are used.
0.90 when hardened surfaces are used under the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use minimum torque values.

Page 4
The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are
not given
NOTE: TORQUE VALUES LISTED THROUGHOUT THIS MANUAL ARE LUBRICATED

(WET) THREADS; VALUES SHOULD BE INCREASED 1/3 FOR NONLUBRICATED
(DRY) THREADS.
HEAT TREATED MATERIAL GRADE 5 AND GRADE 8
GRADE 5 GRADE 8
THREAD SIZE
(3 RADIAL DASHES ON HEAD) (6 RADIAL DASHES ON HEAD)
NEWTON
FOOT POUNDS FOOT POUNDS NEWTON METER
METER
(ft lb) (ft lb) (Nm)
(Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
130 176 185 251
5/8" - 18
205 278 290 393
3/4" - 10
240 312 320 434
3/4" - 16
305 414 455 617
7/8" - 9
334 454 515 698
7/8" - 14
455 617 695 942
1" - 8
510 691 785 1064
1" - 14
610 827 990 1342
1 1/8" - 7
685 929 1110 1505
1 1/8" - 12 860 1166 1400 1898
1 1/4" - 7 955 1295 1550 2102
1 1/4" - 12 1130 1532 1830 2481
1 3/8" - 6 1290 1749 2085 2827
1 3/8" - 12 1400 2034 2430 3295
1 1/2" - 6 1690 2291 2730 3701
1 1/2" - 12 2370 3213 3810 5166
1 3/4" - 5 3550 4813 5760 7810
2" - 4 1/2
NOTE: If any bolts and nuts are found loose or at values less than what the chart states, it is
recommended that the loose bolt and/or nut be replaced with a new one.

Page 5
TYPE 8 PHOSPHATE COATED HARDWARE
This chart provides tightening torque for general purpose applications using original equipment standard
hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases,
original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru
hardened flat washers (Rockwell "C" 38 - 45), all phosphate coated and assembled without supplemental
lubrication (as received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or gray iron.
2. Phosphate coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted
threads or plastic inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine
required torque.
STANDARD TORQUE ±10%

NOMINAL THREAD
DIAMETER
KILOGRAM METER FOOT POUNDS
(kg•m) (ft lb)
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
279.4 2020
1 - 1/2"
347.1 2510
1 - 3/4"
522.8 3780
2

Page 6
TORQUE VALUES FOR HOSE CLAMPS
The following chart provides the tightening torques for hose clamps used in all rubber applications
(radiator, air cleaner, operating lever boots, hydraulic system, etc.).
TORQUE
RADIATOR, AIR CLEANER,

HYDRAULIC SYSTEM
BOOTS, ETC.
CLAMP TYPE AND SIZE
KILOGRAM KILOGRAM
INCH POUNDS INCH POUNDS
METER METER
(in lb) (in lb)
(kg•m) (kg•m)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50

44 mm (1-3/4 in) Open
Diameter
Worm Drive - Over 44 mm 0.5 - 0.6 40 - 50 ------- ------

(1-3/4 in) Open Diameter
Worm Drive - All 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50

"Ultra-Tite"

Page 7
TORQUE VALUES FOR SPLIT FLANGES
The following chart provides the tightening torques for split flange connections used in hydraulic systems.
Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly.
NOTE: Over torquing bolts will damage the flanges and/or bolts, which may cause leakage.
BOLT TORQUE
FLANGE BOLT
SIZE (*) SIZE KILOGRAM METER FOOT POUNDS
(kg•m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18

3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
(*) - Inside diameter of flange on end of hydraulic tube or hose fitting.

NOTE: Values stated in chart are for Standard Pressure Series (Code 61) Split Flanges.

Page 8
TORQUE WRENCH EXTENSION TOOLS
Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning
force to achieve recommended tightening torque values.
Common problems that could occur as a result are:
• Recommended torque exceeds the measuring capacity of the torque wrench.
• Specialized sockets do not fit the adapter on the front end (nose) of the torque wrench.
• Generating adequate force on the back end (handle) of the wrench is difficult or impossible.
• Restricted access or an obstruction may make use of the torque wrench impossible.
• A unique application requires fabrication of an adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one of the proceeding needs or situations, if
the right extension tool is used or fabricated.
TORQUE MULTIPLICATION
A wrench extension tool can be used to
increase the tightening force on a high capacity
nut or bolt.
For example, doubling the distance between the
bolt and the back (handle) end of the torque
wrench doubles the tightening force on the bolt.
It also halves the indicated reading on the scale
or dial of the torque wrench. To accurately
adjust or convert indicated scale or dial
readings, use the following formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench Figure 1
scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque).
A = Length of the torque wrench (between the center of the nut or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque wrench, and the indicated torque on the dial
reads "150 ft lb," the real force applied to the bolt is 300 ft lb:
AxT 12 x 300 3600

I= = = = 150
A+B 12 + 12 24
NOTE: The formula assumes that there is no added deflection or "give" in the joint between the
extension and torque wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly straight (for example, an extension
made to go around an obstruction, to allow access to a difficult to tighten fastener), the
materials and methods used must be solid enough to transmit full tightening torque.

Page 9
OTHER USES FOR TORQUE WRENCH EXTENSION TOOLS
Torque wrench extensions are sometimes made up for reasons other than increasing leverage on a
fastener.
For example, a torque wrench and extension can be used to measure adjustment "tightness" of a linkage
or assembly. Specially fabricated extensions can be used to make very precise checks of the force
required to engage or disengage a clutch mechanism, release a spring-applied brake assembly, or "take
up" free play in most any movable linkage.
Once the value of the adjustment force is established, repeated checks at regular intervals can help to
monitor and maintain peak operating efficiency. These types of adjustment checks are especially useful if
physical measurements of linkage travel are difficult to make or will not provide the needed degree of
precision and accuracy.
To allow the assembly or mechanism to accept a torque wrench, welding a nut or other adapter on the end
of a linkage shaft or other leverage point will allow turning the shaft or assembly manually.
TIGHTENING TORQUE SPECIFICATIONS (METRIC)

(For coated threads, prelubricated assemblies.)
CAUTION!
Disassembly, overhaul and replacement of components on the machine, installation of new or
replacement parts and/or other service related maintenance may require the use of thread or
flange sealing assembly compound.
Use the information on this page as a general guide in selecting specific formulas that will meet
the particular requirements of individual assembly installations. Daewoo does not specifically
endorse a specific manufacturer or brand name but the following table of "Loctite" applications
is included for which cross-references to other makers' products should also be widely
available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of fastener adhesives, with Thread locker
sealers 222, 242/243, 262, 271, 272, or 277.

Page 10
I. "Loctite" Fastener Adhesives
Break-away
Cure Strength
Product Application Color Removal
(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.

Page 11
IV. "Loctite" retaining compounds

For bushings, sleeves, press fit bearings, Use Locquic "N" primer for
609 splines and collars. For gaps to 0.0002 mm Green increased bond strength and all
(0.005"), temperatures to 121°C (250°F). cold temperature applications.
620 For high temperatures to 232°C (450°F). Green Same as 609, above.
For high strength bonds and tight clearance
680 Green Same as 609, above.
gaps, to 0.00008 mm (0.002").
V. "Loctite" Adhesives

Black Max instant adhesive for shock and May take 120 hours to reach full
380 Black
vibration-resistant bonds. cure strength.
454 Adhesive for porous surfaces. Clear Full strength in 24 hours.
Increased strength (+50%), shock and
480 Black Full strength in 24 hours.
vibration-resistant.

Page 12
1UPPER STRUCTURE
S0403005K
1COUNTERWEIGHT
CAUTION!
COUNTERWEIGHT S0403005K

January 2004
Counterweight S0403005K
Page 1
TABLE OF CONTENTS
General........................................................................................................... 3
Removal ......................................................................................................... 5
Installation ...................................................................................................... 7
S0403005K Counterweight
Page 2
GENERAL
DANGER!
Daewoo warns any user, that the removal of
the counterweight from the machine, front
attachment or any other part, may affect
X
the stability of the machine. This could
cause unexpected movement, resulting in
death or serious injuries. Daewoo is not
liable for any misuse.
been removed.
HAAD4060
Figure 1
Before any attempt is made to begin removal or installation of the counterweight, the excavator must be
parked on a firm and level supporting surface, with no sloping surfaces or soft or muddy ground in the area
where the assist lift crane will be working. Position all accessories in the overnight storage position.
WARNING!
The weight of counterweight is given in the following table. Use only rated and approved slings
and hardware when removal or installation lifts are being made. Lifting slings, shackles and all
other hardware must be rigged safely. An assist crane that is rated above weight capacity is
required.
MODEL WEIGHT OF COUNTERWEIGHT

Solar 75-V 860 kg (1,896 lb)
Responsibility should be assigned to one person to be in charge of the lifting crew, and to verify that
required safe lifting precautions have been taken before each part of the procedure has been started.
All members of the working crew should know and understand the signals that will be used between the
lifting leader, the assist crane operator and the remainder of the work crew.
WARNING!
If the turntable deck has been unbalanced by removal of weight from one end only, traveling the
excavator, swinging the turntable, movement over bumps or sloping and uneven surfaces could
cause loss of control and possible accidents or injuries.
Page 3
To maintain stability the counterweight should
be removed whenever the front attachment is
taken off the machine.
BJS1350L
Figure 1
When loading an excavator (either track or
wheeled type) on a trailer for transport after the
front attachment has been removed, secure the
swing lock (if equipped) to hold the deck in place
and always go backwards up the loading ramp.
The counterweight end of the deck has to get on
the trailer first, while the cab is still going up the
ramp (Figure 1).
BJS1360L
Figure 2
Page 4
REMOVAL
1. Park on firm and level ground.
2. Lower front attachment (bucket) to ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch "ON."
WARNING!
If engine must be running while
performing maintenance, always use Figure 3
extreme caution. Always have one
person in the cab at all times. Never
leave the cab with engine running.
6. Fully stroke work levers (joysticks) in all

directions to relieve any pressure from
accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "OFF" position and remove
from starter switch.
9. Hang a maintenance warning tag on
controls.
10. Disconnect negative (-) battery cable
leading to frame from battery.
11. Raise engine compartment cover.
Page 5
12. Remove two caps (1, Figure 4) from
counterweight (2).
13. Install two lifting eyes in lifting holes (3,
Figure 4).
4
Model Lifting Eye Size
5 1 3
Solar 75-V M24x3.0
14. Using a suitable lifting device capable of

handling load, partially support
counterweight (2, Figure 4) before
beginning to loosen three bolts (4). Stop 2
lifting with assist crane as soon as lifting
slings are taut.
15. Remove three bolts (4, Figure 4) and
6
washers (5) from counterweight (2).
NOTE: Heat bolts if necessary, to free
them.
16. When bolts (4, Figure 4) and washers (5)
have been removed, lift counterweight (2)
a very short distance above support frame
(6) and stop. Check slings and make sure
counterweight is being supported evenly. BJS1110L
Figure 4
Page 6
INSTALLATION
1. Raise engine compartment cover.
2. Using suitable lifting device capable of
handling load, raise counterweight (2,
Figure 5) into position just above support
frame (6) leaving counterweight 4
suspended. Verify that counterweight is 1
5 3
level and even.
NOTE: Leave counterweight (2, Figure
5) suspended 3 mm (0.125")
above support frame (6) until all
three mounting bolts (4) are 2
started in counterweight
mounting holes.
3. Slide washers (5, Figure 5) onto bolts (4).
Apply Loctite #242 to mounting bolt 6
threads.
4. Install three bolts (4, Figure 5) with
washers (5) into counterweight until
washers contact support frame. Fully lower
counterweight onto support frame and
finish tightening bolts.
NOTE: Tighten bolts (4, Figure 5) to BJS1110L
values shown in following table. Figure 5
Model Bolt Torque

Solar 75-V 95 kg•m (687 ft lb)
5. Remove lifting device and lifting eyes from counterweight lifting holes (3, Figure 5).
6. Install two caps (1, Figure 5) in lifting holes (3).
7. Connect negative (-) battery cable to battery.
Page 7
S0405015K
1FUEL TANK
CAUTION!
FUEL TANK S0405015K


December 2002
Fuel Tank S0405015K

Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Start-up Procedures ....................................................................................... 6
S0405015K Fuel Tank

Page 2
GENERAL DESCRIPTION
WARNING!
Engine fuel is highly flammable and potentially explosive. To prevent possible injury and/or
damage to equipment, extinguish or move to a safe distance all potential fire hazards.
Fuel Tank S0405015K

Page 3
PARTS LIST
26
12
1
11
13
26
14
35
33
35
33
10
8
3
6
7
5
BJS1280L
Figure 1
S0405015K Fuel Tank

Page 4
Reference Reference
Description Description
Number Number
1 Fuel Tank 10 Washer (M16)
3 O-ring 11 Fuel Filter
4 Cover 12 Cap (=2188-9006A)
5 Bolt (M10x1.5x25) 13 Plug
6 Spring Washer (M10) 14 Level Gauge
7 Drain Valve 26 Bolt
8 Bolt 33 Bolt
9 Spring Washer (M16) 35 Clip
SPECIFICATIONS
Model Fuel Tank Capacity

S75-V 110 liters (29 U.S. gal)
Fuel Tank S0405015K

Page 5
START-UP PROCEDURES
If engine does not start, the fuel system may
need priming. Prime the fuel system using the
following procedure;
1. Loosen plug (Figure 2) on top of fuel filter
head.
Figure 2
2. Unscrew and pump the hand operated
primer pump (Figure 3) by the fuel
injection pump. Pump primer until fuel is
present at plug hole in fuel filter head.
3. Tighten plug in fuel filter head.
4. Continue to pump primer pump until a
strong resistance is felt. Screw the primer
pump knob back into housing.
5. Start engine and look for signs of leaks.
6. Repeat procedure if necessary.
Figure 3
S0405015K Fuel Tank

Page 6
S0407000
R1
1SWING BEARING
CAUTION!
SWING BEARING S0407000

Solar 130LC-V 0001 and Up
Solar 220LL 1001 and Up
Solar 225NLC-V 1001 and Up

January 2004
Swing Bearing S0407000

Page 1
TABLE OF CONTENTS
Swing Bearing Maintenance .......................................................................... 3

Operating Recommendation ................................................................... 3
Measuring Swing Bearing Axial Play ...................................................... 3
Measuring Bearing Lateral Play .............................................................. 3
Swing Bearing Basic Operation .............................................................. 4
Rebuilding Swing Bearing ....................................................................... 4
S0407000 Swing Bearing

Page 2
SWING BEARING MAINTENANCE
OPERATING RECOMMENDATION
The service life of the swing bearing may be extended if a conscious, daily effort is made to equalize usage
over both ends of the excavator. If the excavator is used in the same operating configuration day in and
day out (for example, with the travel motors always under the counterweight, or with the attachment over
one side of the machine more than the other), the bearing's service life could be reduced. Taking a few
minutes in the middle of each work shift to reposition the excavator, to work the opposite end of the
bearing, will provide a payoff in terms of more even, gradual rate of wear and extended service life.
MEASURING SWING BEARING AXIAL PLAY

Periodic and regular checks of bearing
displacement should be made at least twice a
year. Use a dial indicator. Push the attachment
against the ground to lift the excavator off the
ground and take measurements at 4 points, 90°
apart, around the circumference of the bearing
(Figure 1).
Record and keep all measurements. Play in the
bearing should increase minimally from one
inspection to the next. Eventually, however, as
the bearing begins to approach the limit of its
service life, clearance increases become much
more pronounced and the actual measured play
in the bearing could exceed twice the value that
was measured when the machine was new.
MEASURING BEARING LATERAL PLAY

When vertical checks are made, the side-to-side
play in the bearing can be checked by fully
Figure 1
retracting the arm and bucket cylinders and
extending the tip of the bucket as far forward as
it will go. With the excavator parked on a flat,
level surface and the bucket tip just off the
ground, push against the bucket sideways to
take up all of the lateral clearance in the
bearing. (Less than 100 lb of force should be
required to move the bucket over all the way.)
Check lateral play in both directions and record
the values. When the bearing is beginning to
approach the end of its service life, measured
lateral clearance should start to show larger and
larger increases.

Page 3
SWING BEARING BASIC OPERATION
The swing bearing, which connects the upper
structure with the lower structure, consists of a
inner ring, outer ring and ball bearings. During
swing movement, power from the swing motor is
transferred to the pinion by planetary gears
connected to gears on the inner ring, which is
fixed in the undercarriage. Ball bearings turn the
outer ring.
Reference
Description
Number
1 Ball
2 Seal A
3 Seal B
4 Retainer
5 Retainer
6 Outer Ring
7 Inner Ring
8 Tapered Pin
9 Plug
Figure 2
REBUILDING SWING BEARING
1. Remove tip of tapered pin (1, Figure 3)
using grinder and tap lightly to remove
debris.
Figure 3
2. Remove plug (1, Figure 4) using a
M10 x 1.25 bolt (2).
Figure 4
S0407000 Swing Bearing

Page 4
3. Lift outer ring and check that inner ring can
move freely. See Figure 5, if not, replace
seal (3, Figure 4) and/or seal (4, Figure 4).
Figure 5
4. Turn inner ring and use magnet bar (1,
Figure 6) to remove steel balls (2).
Figure 6
5. Turn inner ring and use wire (1, Figure 7)
to remove retainers (2).
Figure 7
6. Assemble in reverse order of disassembly
and then adjust the gap between the steel
balls and retainers using the following
guidelines:
• Assemble the steel balls, retainer (A)
and retainer (B) to the bearing.
• If the gap is too wide, adjust by
moving the steel balls or by replacing
one of the retainers.
Figure 8

Page 5
1LOWER STRUCTURE AND CHASSIS
S0505075K
1TRACK ASSEMBLY
CAUTION!
TRACK ASSEMBLY S0505075K


February 2003
Track Assembly S0505075K

Page 1
TABLE OF CONTENTS
Track Tension ................................................................................................. 3
Service Standards for Lower Travel Frame Components ............................... 6
Steel Track .............................................................................................. 6
Rubber Track ......................................................................................... 10
Track Shoes and Links ................................................................................. 15
Steel Track ............................................................................................ 15
Rubber Track ......................................................................................... 17
Idler .............................................................................................................. 18
Parts List ............................................................................................... 18
Lower Roller ................................................................................................. 20
Parts List ............................................................................................... 20
Upper Roller ................................................................................................. 24
Parts List ............................................................................................... 24
Track Spring and Adjusting Cylinder ............................................................ 26
Parts List ............................................................................................... 26
S0505075K Track Assembly

Page 2
GENERAL DESCRIPTION
The track assembly is composed of the following major components:
1. Track
2. Front Idler Roller
3. Upper Roller
4. Lower Roller
5. Track Spring and Track Adjustment Cylinder
TRACK TENSION
WARNING!
Safely measuring track tension requires two people. One person must be in the operator's seat,
running the controls to keep one side frame in the air, while the other person makes dimensional
checks. Take all necessary precautions to make sure the machine won't move or shift position
during service. Warm up the engine to prevent stalls, travel the excavator to an area that
provides level, uniform ground support and/or use support blocks when necessary.
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 shoe link pins and bushings wear with normal usage, reducing track tension. Periodic adjustment is
necessary to compensate for wear and it may also be required by working conditions.
1. Track tension is checked by jacking up one
side of the excavator. See Figure 1. Place
blocking under frame while taking
measurement.
BJS1390L
Figure 1

Page 3
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.
NOTE: For machines with rubber
crawlers (optional), checking
Figure 2
and adjustment steps and the
clearance are the same.
3. Steel tracks (Figure 3) have a 20 - 35 mm
(0.78 - 1.38 in) clearance.
Figure 3
4. Rubber tracks (Figure 4) have a 10 -
15 mm (0.39 - 0.59 in) clearance.
5. 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.
WARNING! Figure 4
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.

Page 4
6. Track tension adjustments are made
through the grease fitting (1, Figure 5) in 2
3
the middle of each side-frame. Adding
grease increases the length of an
adjustment cylinder (2). The longer the
adjustment cylinder, the greater the
pressure on the tension spring pushing the
track idler wheel outward.
7. If there is not enough slack or clearance in
the tracks and the adjustment is too tight,
the idler wheel and adjusting cylinder can 1
be retracted by bleeding off grease thru HAOC760L
hole in adjustment cylinder (2, Figure 5). Figure 5

Page 5
SERVICE STANDARDS FOR LOWER TRAVEL FRAME
COMPONENTS
CAUTION!
Refer to the "Welding Precautions and Guidelines" information in "General Maintenance
Procedures" section for general recommendations and specific safety precautions, before
starting any lower travel frame component rebuilding procedure.
The tables that follow provide factory specified dimensional limits (as new condition, recommended service
and replacement limit) for lower travel frame components.
Recommended maintenance to renew most listed components requires welding on additional material and
grinding off excess. Some components must be replaced before the service limit is exceeded. No
maintenance or renewal is possible.
Compare the values in the tables with dimensions and profiles shown in the adjacent figures.
STEEL TRACK
Normal Recommended Limit for Use

Component / Reference Dimensions Reference (New) Limit for (Repair - P or
Dimension Maintenance Replace - R)
Standard 600 mm Shoe 14 mm
A
(0.551")
10 mm
B
(0.394")
14 mm 8 mm 5 mm [P]
C
(0.551") (0.315") (0.197")
154 mm
D
(6.501")
Figure 6 450 mm
E
(17.730")
Track link, master link 74 mm 75 mm 70 mm [P]
A
(2.913") (2.955") (2.758")
17 mm 15 mm 14 mm [P]
B
(0.669") (0.590") (0.551")
154 mm 156 mm 155 mm [R]
C*
(6.067") (6.146") (6.107")
Figure 7 *Check and record the pitch of at least 5 links. Use
average of all measurements to assess required service
or action. Master links must be replaced, they cannot be
renewed or rebuilt.

Page 6
Track link, master pin bushing, 41.26 mm 40.0 mm 39.5 mm [R]
A
master bushing (1.624") (1.575") (1.555")
24.65 mm 26.0 mm 27.0 mm [R]
B
(0.970") (1.024") (1.063")
24.08 mm 22.5 mm 22.0 mm [R]
C
(0.948") (0.886") (0.866")
23.74 mm 21.5 mm 21.0 mm [R]
D*
(0.935") (0.846") (0.827")
Figure 8
* Master pin
Figure 9
40 mm 39 mm 38.9 mm [R]
Lower roller, axle A
(1.576") (1.536") (1.532")
40.3 mm 40.5 mm [R]
Lower roller, bushing A
(1.587") (1.595")
0.65 mm 0.80 mm
Axle bushing, clearance
(0.025") (0.031")
5 mm 4.7 mm 4.5 mm
Lower roller, bushing B
(0.197") (0.185") (0.177")
Lower roller dimensions 142 mm 153 mm 150 mm

A
(5.590") (6.028") (5.910")
12 mm 10 mm 9.0 mm [P]
B
(0.472") (0.394") (0.354")
125 mm 119 mm 117 mm [P]
C
(4.925") (4.688") (4.609")
155 mm 154 mm 152 mm [P]
D
(6.102") (6.067") (5.988")
Figure 10

Page 7
Figure 11
Front idler, axle 40 mm 40.5 mm 40.4 mm [R]

A
(1.576") (1.595") (1.591")
39.5 mm 39 mm [R]
Front idler, bushing A
(1.556") (1.536")
1.0 mm 1.4 mm
(0.039") (0.055")
Front idler, bushing 5 mm 4.5 mm 4.3 mm
B
(0.197") (0.177") (0.169")
Front idler 125 mm 114.5 mm 106 mm [P]
A
(4.925") (4.511") (4.176")
40 mm 36 mm 34 mm [P]
B
(1.575") (1.417") (1.339")
415 mm 407 mm 405 mm [P]
C
(16.351") (16.035") (15.957")
447 mm 445 mm 443 mm
D
(17.611") (17.533") (17.454")
Figure 12

Page 8
Figure 1
Criteria (Unit: mm [in])

No. Check Item Recommended Limit
Standard Size Limit for Use
for Maintenance
1 Wear in diameter 482 mm 480.5 mm 470.5 mm
of sprocket tooth (18.98") (18.917") (18.52")
root
2 Wear in diameter 534 mm 530 mm 526 mm
of sprocket tooth (21.024") (20.866") (20.709")
top
3 Wear in width of 30 mm 25 mm 21 mm
sprocket tooth (1.181") (0.984") (0.827")
top
4 Wear in width of 38 mm 35 mm 33 mm
sprocket tooth (1.496") (1.378") (1.299")
root

Page 9
RUBBER TRACK
20
C
A B
Wear Amount (mm)
15
10
0 500 1000 1500 2000 2500 3000

Operating Hours HKA1313L
Figure 13
Reference
Description
Number
A Concrete Surface
B Normal Use
C Dirt
The amount of friction on the rubber track shoes determines the limit of use. However, it is subject to
change depending upon the work condition and environment.

Page 10
A D
B E
F
HBOH840L
Figure 14
Reference Reference
Dimension Dimension
Number Number
A 33.5 mm D 30.0 mm
(1.32 in) (1.18 in)
B 46.5 mm E 42.0 mm
(1.83 in) (1.65 in)
C 30.0 mm F 450.0 mm
(1.18 in) (17.72 in)
Reference
Description
Number A
A Pitch 81.0 mm (3.19 in)
HKA1315L
Figure 15
Item Solar 75-V

Steel Cord Circumference Length 5,994 ±10 mm
(235.98 ±0.39 in)
Steel Cord Rigid 1000 kg
(2,205 lb)
No. of Cord 64 ±4 Coils
Operating Temperature Range -25°C - 55°C
(-13°F - 131°F)
Width x Pitch 450 x 81 mm
(17.72 x 3.19 in)

Page 11
Track link, master pin bushing, 41.26 mm 40.0 mm 39.5 mm [R]
A
master bushing (1.624") (1.575") (1.555")
24.65 mm 26.0 mm 27.0 mm [R]
B
(0.970") (1.024") (1.063")
24.08 mm 22.5 mm 22.0 mm [R]
C
(0.948") (0.886") (0.866")
23.74 mm 21.5 mm 21.0 mm [R]
D*
(0.935") (0.846") (0.827")
Figure 16
* Master pin
A
BJS1590L
Figure 17
40 mm 39 mm 38.9 mm [R]
Lower roller, axle A
(1.576") (1.536") (1.532")
40.3 mm 40.5 mm [R]
Lower roller, bushing A
(1.587") (1.595")
0.65 mm 0.80 mm
(0.025") (0.031")
5 mm 4.7 mm 4.5 mm
Lower roller, bushing B
(0.197") (0.185") (0.177")
Lower roller dimensions 170 mm

A
A
(6.693")
110 mm 108 mm 106 mm [P]
B
(4.330") (4.252") (4.173")
156 mm 154 mm 152 mm [P]
C
(6.142") (6.067") (5.988")
C B
BJS1600L
Figure 18

Page 12
Figure 19
Front idler, axle 40 mm 40.5 mm 40.4 mm [R]

A
(1.576") (1.595") (1.591")
39.5 mm 39 mm [R]
Front idler, bushing A
(1.556") (1.536")
1.0 mm 1.4 mm
(0.039") (0.055")
Front idler, bushing 5 mm 4.5 mm 4.3 mm
B
(0.197") (0.177") (0.169")
Front idler 125 mm 114.5 mm 106 mm [P]
A
(4.925") (4.511") (4.176")
55 mm 53 mm 50 mm [P]
B
(2.165") (2.086") (1.968")
415 mm 407 mm 405 mm [P]
C
(16.351") (16.035") (15.957")
447 mm 445 mm 443 mm
D
(17.611") (17.533") (17.454")
Figure 20

Page 13
Criteria (Unit: mm [in])
No. Check Item Recommended
Standard Size Limit for Limit for Use
Maintenance
1 Wear in diameter of sprocket 475.5 mm 474.0 mm 472 mm
tooth root (18.72") (18.66") (18.58")
2 Wear in diameter of sprocket 542 mm 538 mm 534 mm
tooth top (21.33") (21.18") (21.02")
3 Wear in width of sprocket tooth 40 mm 35 mm 31 mm
top (1.574") (1.377") (1.220")
4 Wear in width of sprocket tooth 55 mm 52 mm 50 mm
root (2.165") (2.047") (1.968")

Page 14
TRACK SHOES AND LINKS
STEEL TRACK
Track Removal
1. Position machine on a smooth level
surface with adequate room for forward
and reverse travel.
2. Relieve track tension. Refer to "Track
Tension" in this section for procedure.
3. Move machine until master link (1, Figure
21) is positioned at approximately 10
o'clock from top position on travel
reduction gearbox.
4. Remove four nuts and bolts (2, Figure 21)
holding shoe to link. Remove enough
shoes to make access to lock pin easier. Figure 21
NOTE: Support track shoes with
blocking so that when master
pin (4, Figure 21) is removed
tack will not fall.
5. Straighten lock pin (3, Figure 21) and
remove it from master pin (4). Discard lock
pin.
6. Remove master pin from master links.
7. Move unit forward until entire track is laying
on ground.
NOTE: Do not drive unit off track.
HAOV100L
Figure 22

Page 15
8. Rotate upper structure to 90° from track.
Use bucket and boom to raise track frame
off track.
9. Position blocking under frame.
BJS1390L
Figure 23
Track Installation
1. Lay rebuilt or new track into position under
track frame. End of track should be
positioned under front idler roller.
2. With upper structure at 90° to track frame.
off blocking.
3. With blocking removed, lower track frame
onto track. Make sure all rollers are
properly positioned on track.
BJS1390L
Figure 24
4. Move unit backwards while feeding track
up over front idler roller. Continue to pull
track back until it engages drive sprocket.
5. Align master links and install master pin.
6. Insert new lock pin in master pin. Bend
end of pin over so it is pointing in opposite
direction of other end as shown.
7. Apply track tension. Refer to "Track
HAOV101L
Figure 25

Page 16
RUBBER TRACK
Track Removal
1. Loosen track tension cylinder nut and
relieve all pressure and be certain that the
cylinder is completed retracted.
2. Use a steel bar for leverage and slide the
rubber track assembly over the idler
assembly.
Figure 26
Track Installation
1. With upper structure at 90° to track frame.
off blocking.
2. Place rubber track assembly over idler and
rollers.
BJS1390L
Figure 27
3. Use a steel bar for leverage and slide the
rubber track assembly over the idler
assembly.
4. Apply track tension. Refer to "Track
Figure 28

Page 17
IDLER
PARTS LIST
Figure 29

Page 18
Reference Reference
Description Qty. Description Qty.
Number Number
1 Idler 1 5 Bushing 2
2 Support 2 6 Pin 2
3 Axle 1 7 O-ring 2
4 Seal, Group 1 8 Plug 1

Page 19
LOWER ROLLER
PARTS LIST
Figure 30 (For Steel Track)

Page 20
Reference Reference
Number Number
1 Roller 5 Bushing
2 Axle 6 O-ring
3 Collar 7 Pin
4 Group Seal 8 Plug

Page 21
1
BJS1610L
Figure 31 (For Rubber Track)

Page 22
Reference Reference
Number Number
1 Roller 5 Bushing
2 Axle 6 O-ring
3 Collar 7 Pin
4 Group Seal 8 Plug

Page 23
UPPER ROLLER
PARTS LIST
Figure 32

Page 24
Reference Reference
Number Number
1 Roller 1 7 Stop Ring 1
2 Shaft 1 8 Stop Ring 1
3 Support 1 9 Stop Ring 1
4 Collar 1 10 Plug 1
5 Ball Bearing 1 11 Bolt 1
6 Oil Seal 1 12 Nut 1

Page 25
TRACK SPRING AND ADJUSTING CYLINDER
PARTS LIST
9
13
8
7
7
12
11
10
BJS1270L
Figure 33

Page 26
Reference Reference
Number Number
1 Rod 1 8 Packing 1
2 Cylinder 1 9 Ring: Retaining 1
3 Flange 1 10 Spring 1
4 Nut 1 11 Dust Seal 2
5 Bolt 1 12 Valve 1
6 Piston 1 13 Ring: Backup 1
7 Ring 2

Page 27
1ENGINE AND DRIVE TRAIN
Return to Master Table of Contents
S0605015
1AIR CONDITIONER
CAUTION!
AIR CONDITIONER S0605015

Solar 55 0001 and Up

January 2004
Air Conditioner S0605015

Page 1
TABLE OF CONTENTS
Refrigerant Circulation.................................................................................... 4
Air-conditioning System Circuit Diagram........................................................ 6
Troubleshooting .............................................................................................. 7
Weight of R134a Gas Used In Machines ..................................................... 10
Refrigerant System Repairs ......................................................................... 12
Refrigerant Safe Handling Procedures ................................................. 12
Repair and Replacement Procedure..................................................... 13
Refrigerant Recovery ............................................................................ 15
Vacuuming Refrigerant System............................................................. 15
Leakage Check ..................................................................................... 16
Refrigerant Charging............................................................................. 17
Inspecting System for Leakage............................................................. 19
S0605015 Air Conditioner

Page 2
GENERAL DESCRIPTION
The heater and air conditioner are built into one
housing. Moving the lever to the "A" position
provides heat, while moving the lever to the "B"
position activates the air conditioner.
When the lever in the "A" (heat) position, air is
drawn into the unit from the rear and lower
left-hand side. It is exhausted (blown out) from
the lower right-hand side. B
If the lever is moved to the "B" position, the air is A
drawn into the unit from the rear and lower
left-hand side. It is exhausted (blown out) up the
HAOD450L
right side of the cab.
Figure 1
NOTE: When you do not use the air
conditioning system, or when
you operate your machine in a
dusty environment, use the air
flow direction control lever to
stop up the drain port of the
system. If you have not used
the system for an extended
period of time with this port
open, dust may settle within the
system and reduce the system
performance.
WARNING!
All service and inspection of the air-conditioning system should be performed with the starter
switch in the "O" (OFF) position.
NOTE: Refer to appropriate operation and maintenance manual for latest service intervals.

Page 3
REFRIGERANT CIRCULATION
4
7
3
HBOI020L
Figure 1
Reference Reference
Number Number
1 Evaporator 5 Compressor
2 Expansion Valve 6 Blower Fan
3 Condenser 7 Receiver Dryer
4 Condenser Fan

Page 4
Shading Temperature Refrigerant State

High High-pressure Gas
High High-pressure Liquid
Low Low-pressure Liquid
High High-pressure Gas/Liquid
Low Low-pressure Gas
• Refrigerant (R134a) is compressed to approximately 15 kg/cm2 (210 psi) within the compressor.
• The compressed refrigerant flows into the condenser at high temperature (approximately 80°C
(176°F)).
• The refrigerant in the condenser is cooled to approximately 60° by the condenser fan. At this
time the refrigerant changes from the gas to the liquid state, even though the temperature has
only been reduced 20°C (68°F). (From 80° - 60°C (176° - 140°F)).
• The refrigerant in its liquid form is injected into the evaporator through the expansion valve. At
this time the pressure is reduced by approximately 2 kg/cm2 (28 psi) and the temperature is also
reduced. As a result, the refrigerant absorbs the heat from the air surrounding the evaporator
creating a cooling effect and changes from the gas to the liquid state.
• The refrigerant once again flows into the compressor in the gaseous state and the process is
repeated.
WARNING!
Refrigerant gas is pressurized and sealed in the air-conditioning system. Special
precautions are required for the proper recharging or release of refrigerant. Release of
refrigerant into the atmosphere is strictly regulated by law. Make sure that you are in
compliance with all mandated federal, state and municipality requirements, before starting
any service or repair of the air conditioner. Refrigerant gas used in the system must meet or
exceed specifications for R134a refrigerant, or any subsequently issued environmentally
mandated standard.

Page 5
AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM
3 2
5 4
1
6
8
7
11
12 13 10
HBOL090I
Figure 2
Reference Reference
Number Number
1 Battery 8 A/C Relay
2 Battery Relay 9 Receiver Dryer (Low/high)
3 Fusible Link Pressure Cutoff Switch
4 Fuse 10 Compressor
5 Fuse 11 A/C Unit
6 A/C Controller 12 Blower Switch
7 A/C Switch 13 Diode

Page 6
TROUBLESHOOTING
Refrigerant Pressure Check
Figure 3
1. Open all doors and windows.

2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 - 2,000 rpm.
4. Check high / low-pressure of refrigerant.
High-pressure: 8 - 10 kg/cm2 (114 - 142 psi)

1
Low-pressure: Approximately 1 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
Reassemble using correct
Yes
1 Check for traces of refrigerant oil. tightening torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major No Recharge system to correct
components and joints. pressure.
High-pressure: Over 23 kg/cm2 (327 psi)

2
Low-pressure: Approximately 2.5 - 3 kg/cm2 (35 - 42 psi)
Possible Cause: Overcharge, Frost on condenser
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.

Page 7
High-pressure: Approximately 20 - 25 kg/cm2 (285 - 355 psi)

3
Low-pressure: Approximately 2.5 - 3.5 kg/cm2 (35 - 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.
4 High-pressure: Over 6 kg/cm2 (85 psi)

Low-pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace
Yes
receiver dryer.
3. Set blower switch to "HIGH" position.
4. Turn air conditioner "OFF" and wait 10
1 minutes.
Contaminated system, replace
5. Recheck high / low-pressure readings. expansion valve.
No
High-pressure: 13 - 19 kg/cm2 (185 - 270 psi) (Replace evaporator core
assembly.)
Low-pressure: 1.5 - 3.3 kg/cm2 (21.3 - 46.9 psi)
5 High-pressure: Over 6 - 18 kg/cm2 (85 - 256 psi)

Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful
readings should be made to determine whether pressure is in normal range.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.
High-pressure: Over 22 - 23 kg/cm2 (313 - 327 psi)

6
Low-pressure: 2.5 kg/cm2 (36 psi)
Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor.
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.

Page 8
High-pressure: Over 7 - 11 kg/cm2 (100 - 156 psi)

7
Low-pressure: 4 - 6 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression
Inspect and replace compressor if necessary.

Page 9
WEIGHT OF R134A GAS USED IN MACHINES
Model Weight of Gas

Mega 130 850 ±20 grams (30 ±0.7 oz)
Mega 160 850 ±20 grams (30 ±0.7 oz)
Mega 200-III 850 ±20 grams (30 ±0.7 oz)
Mega 200-V 850 ±20 grams (30 ±0.7 oz)
Mega 250-III 850 ±20 grams (30 ±0.7 oz)
Mega 250-V (Tier I) 850 ±20 grams (30 ±0.7 oz)
Mega 250-V (Tier II) 850 ±20 grams (30 ±0.7 oz)
Mega 300-III 950 ±20 grams (33 ±0.7 oz)
Mega 300-V (Tier I) 850 ±20 grams (30 ±0.7 oz)
Mega 300-V (Tier II) 850 ±20 grams (30 ±0.7 oz)
Mega 400-III 950 ±20 grams (33 ±0.7 oz)
Mega 400-III PLUS 850 ±20 grams (30 ±0.7 oz)
Mega 400-V 850 ±20 grams (30 ±0.7 oz)
Mega 500-V 850 ±20 grams (30 ±0.7 oz)
Solar 130-III 950 ±20 grams (33 ±0.7 oz)
Solar 130LC-V 850 ±20 grams (30 ±0.7 oz)
Solar 130W-III 950 ±20 grams (33 ±0.7 oz)
Solar 130W-V 850 ±20 grams (30 ±0.7 oz)
Solar 140W-V 850 ±20 grams (30 ±0.7 oz)
Solar 160W-V 850 ±20 grams (30 ±0.7 oz)
Solar 180W-V 850 ±20 grams (30 ±0.7 oz)
Solar 200W-V 850 ±20 grams (30 ±0.7 oz)
Solar 210W-V 850 ±20 grams (30 ±0.7 oz)
Solar 220LC-III 950 ±20 grams (33 ±0.7 oz)
Solar 220LL 850 ±20 grams (30 ±0.7 oz)
Solar 225NLC-V 850 ±20 grams (30 ±0.7 oz)
Solar 290LL 850 ±20 grams (30 ±0.7 oz)

Page 10
Model Weight of Gas

Solar 300LL 850 ±20 grams (30 ±0.7 oz)
Solar 55 750 ±20 grams (26 ±0.7 oz)
Solar 55-V PLUS 750 ±20 grams (26 ±0.7 oz)
Solar 55W-V PLUS 750 ±20 grams (26 ±0.7 oz)
Solar 75-V 750 ±20 grams (26 ±0.7 oz)

Page 11
REFRIGERANT SYSTEM REPAIRS
WARNING!
Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in
contact with the skin or eyes, immediately flush with clean, running water and consult a
physician.
Select a clean and well-ventilated area to work.
The refrigerant container is under high-pressure and should be stored below 40°C (104°F). Be
careful not to drop the container from a high location
The contents are under high-pressure and should not be used with compressed air or near an
open flame.
REFRIGERANT SAFE HANDLING PROCEDURES
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
CAP & PLUG CORRECT WRONG WRONG
HDA6066L
Figure 4
The following procedures should be observed for safe handling of refrigerant during vacuum and charging
process.
1. Use an approved recovery / charging device which can safely perform vacuum and charge work
simultaneously.
2. The new refrigerant has improved cooling characteristics than the old type and care should be used
not to overcharge the system.
3. Do not over tighten connections when working on refrigerant system.
4. The new refrigerant system standards require new tools, equipment and parts. Do not attempt to use
equipment use in servicing the old refrigerant system.

Page 12
5. The new refrigerant oil (PAG type) has a high moisture absorption characteristic. When the
refrigerant system vacuum seal has been broken, immediately plug up all openings to prevent
moisture from entering into the system.
6. When joining unions which use O-ring seals, lightly coat O-rings with refrigerant oil. Be careful not to
drip oil on the threads of the nut.
7. Be certain the O-rings are seated properly on the refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine running, do not open the high-pressure valve
on the manifold gauge as the reverse flow of high-pressure refrigerant will rupture the hose.
10. When releasing the high-pressure hose after completing the charging process, quickly disconnect the
hose to minimize refrigerant released to the air.
REPAIR AND REPLACEMENT PROCEDURE

1. Work Procedure;
A. Before repairing or replacing any refrigerant components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition;
A. Run engine at maximum engine speed.
B. Select "HI" blower fan speed and select A/C switch to "ON."
C. Set the temperature control switch for maximum cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary depending on the outdoor temperatures.

Page 13
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE REPAIR
VACUUM SYSTEM (OVER 20 MINUTES)
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL

(Standard Capacity less Initial Charge)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS

HDA6067L
Figure 5

Page 14
REFRIGERANT RECOVERY
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
1. Attach the manifold gauges and the

refrigerant recovery unit to the refrigerant 5
lines as shown. HDA6067L
Figure 6
NOTE: Be careful not to switch the
connections for the low and
high-pressure valves.
2. Open the high-pressure valve slowly to release the refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see that refrigerant is not leaking out.
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50 psi), slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until the manifold gauge dials indicates 0 kg/cm2
(0 psi).
VACUUMING REFRIGERANT SYSTEM
Reference 2 3
Description
Number 1 4
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Vacuum Pump
1. Vacuuming Procedure; 5
HDA6068L
NOTE: When the A/C system has been Figure 7
exposed to the air, it must be
vacuumed out. Perform vacuum
process for 30 minutes for
complete moisture and air
evacuation.
A. Attach the manifold gauges and vacuum pump to the refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low-pressure gauge shows approximately 710 mmHg, close both valves and turn off
vacuum pump.

Page 15
2. Check system for vacuum leak;

A. Allow system to sit for 10 minutes
and check whether the system is
holding the pressure. If the pressure
has dropped, it must be repaired
before proceeding to the next step.
3. Vacuuming Procedure;
NOTE: If the system is holding the
pressure and it has not
changed for 10 minutes,
vacuum out the system for an
additional 20 minutes. Figure 8
A. Turn on the vacuum pump and slowly
open both valves.
B. Allow vacuum pump to run for
additional 20 minutes until the
low-pressure gauge dial reads
approximately 750 mmHg.
C. Close both valves and stop the
vacuum pump.
4. Installation of Refrigerant Container
Reference
Description
Number
1 Handle
2 Hose Connection
3 Mounting Disk
A. Before mounting valve on the

container, make sure the handle is in
the counter clockwise most position,
with the puncture pin retracted and
the mounting disk is in the raised Figure 9
position.
B. Attach the manifold gauge center
hose to the valve assembly.
C. Turn the disc in the clockwise direction and securely mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in the counter clockwise direction so the
refrigerant can flow into the manifold gauge center hose. At this time, do not open the low and
high-pressure valves of the manifold gauge.
F. Press the manifold gauge low side valve to eliminate the trapped air in the hose.

Page 16
LEAKAGE CHECK
NOTE: Perform the leakage check after completing vacuuming process.
1. After attaching the manifold gauge, open the high side valve.
2. Charge system until the low side gauge dial indicates a pressure of 1 kg/cm2 (14 psi) and close the
high side valve.
3. Using a refrigerant leak detector or soapy
water check each joint for leakage.
Reference
Description
Number
Refrigerant Leak
1
Detection Device
4. If a leak is detected, check for O-ring

damage or correct tightening torque and
replace or repair as necessary.
5. If no leaks are detected, proceed with the
charging process. Figure 10
WARNING!
For accurate refrigerant leak
detection, perform leak detection
procedure in a well-ventilated area.
REFRIGERANT CHARGING
1. Perform the vacuuming procedure, vacuum holding and leaking tests as described in the proceeding
headings.
NOTE: First charge the refrigerant system with 100 g (3.5 ounces) of refrigerant with the engine
off. Then using the manifold gauges as a guide fully charge the system with the engine
running.
When exchanging refrigerant containers, press the manifold gauge low side valve to
eliminate air from the charging hose.

Page 17
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
4 From Receiver
5 Refrigerant Supply
Container
2. Charge the system by opening the manifold 5

gauge low side valve. HDA6072L
Figure 11
Initial charge amount: 100 g (3.5 ounces).
3. If refrigerant does not flow freely into
system, try starting engine first before
operating air conditioner.
• Temperature control switch setting:
Maximum Cooling.
Blower Speed Setting: Hi (3 step).
Engine Speed: 1,300 - 1,500 rpm.
WARNING!
When charging refrigerant system with the engine running;
• Always keep refrigerant supply container in the upright position.
• Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge system to standard capacity.
Gauge Dial Standard Reading
High Side Gauge 13 - 20 kg/cm2

(185 - 285 psi)
Low Side Gauge 1.5 - 3.5 kg/cm2

(21 - 49 psi)
NOTE: These standards are for outside temperatures between 30° - 35°C (86° - 95°F). The
gauge readings may vary for extreme temperature conditions.
WARNING!
• When outside temperature is low, warm the refrigerant supply container with
warm water not exceeding 40°C (104°F). Do not allow water to come in contact
with the charging adapter valve handle.
• When outside temperature is high, cool off refrigerant supply container and
condenser to aid the refrigerant charging process.
5. Close low-pressure side valve.

Page 18
6. Shut off engine and close refrigerant supply container adapter valve. Disconnect manifold gauge
hoses from vehicle.
INSPECTING SYSTEM FOR LEAKAGE

After completing charging procedures, clean all
joints and connections with a clean dry cloth.
Using a refrigerant leak detecting device or
soapy water, inspect system for leaks starting
from the high-pressure side.
NOTE: When the refrigerant circulation
has been stopped the
high-pressure will start to
decrease and the low-pressure
will start to increase until they
are equalized. Starting the
inspection from the high side
will result in a accurate test. Figure 12
Reference
Description
Number
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure Side.
Compressor outlet →condenser inlet →receiver dryer inlet →air conditioner unit inlet
2. Low pressure side.
Compressor inlet →air conditioner unit outlet
3. Compressor.
Compressor shaft area, bolt hole area and magnetic clutch area.
4. Receiver dryer.
Pressure switch and plug area.
5. Connection valve area.
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air conditioner unit.
After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds
minimum.)
NOTE: When inspecting leakage from the air conditioner unit, perform the inspection in a well
ventilated area.

Page 19
1HYDRAULICS
S0703010K
1ACCUMULATOR
CAUTION!
ACCUMULATOR S0703010K
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier II) 2001 and Up
Solar 140W-V 1001 and Up
Models continued on back of cover.

January 2004
Accumulator S0703010K
Page 1
Solar 55W-V PLUS 1001 and Up
TABLE OF CONTENTS
Specifications .......................................................................................... 4
S0703010K Accumulator
Page 2
GENERAL DESCRIPTION
The accumulator is a gas-charged storage
device designed to hold a reserve quantity of 1
hydraulic fluid under pressure. Accumulators are
used in hydraulic circuits in much the same way 2
that condensers (or capacitors) are used to
collect, store and maintain electrical charge in a
circuit.
In a hydraulic circuit, minor variations or lags in
pump output that might otherwise cause
unsteady or irregular operation are made up
from the supply of pressurized oil in the 3
accumulator.
Reference
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
4
3 Diaphragm ARS1790L
4 Fluid Valve Figure 1
Accumulators are solidly constructed to resist the high operating pressures of the fluids they contain. There
are only three main moving parts: a plug at the top allows precharging or expelling gas from the
compressible, precharged upper chamber; a valve assembly at the bottom of the accumulator for passing
hydraulic fluid in and out, and an elastic diaphragm to separate the two chambers. The flexible diaphragm
changes shape to conform to the changing pressures and volumes of the two fluids in the upper and lower
chambers.
There are six possible positions the diaphragm
can be in and they are as follows: Pressure Fluid Nitrogen
1. With no gas charge in the upper chamber

0 bar (0 psi, empty) and no oil in the
bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the prepressure charge of gas
(usually nitrogen) is introduced through the
port at the top of the accumulator, the 1 2 3
diaphragm expands to maximum size. The
valve button in the center of the diaphragm
pushes into the fluid opening in the bottom
chamber, sealing off the lower valve. If the
pressure of the gas charge exceeds
system oil pressure, no fluid enters the
accumulator. The button also keeps the
diaphragm from protruding into the lower
4 5 6
valve opening. ARS1800L
Figure 2
Page 3
NOTE: Precharge pressure is referred to as the "P1" pressure. The accumulator manufacturer's
"P1" rated pressure should be stamped or marked on the accumulator's rating plate.
Annual checks of actual precharge pressure should be made by tapping a hydraulic
pressure gauge (and 3-way adapter coupling) into the valve on the bottom of the
accumulator. When hydraulic fluid is pushed out the lower valve opening by the pressure
of the gas charge on the other side of the diaphragm - and there is no counterpressure
from system oil - the valve button on the bottom of the diaphragm eventually seals off the
lower oil passage. Just after the needle on the gauge reaches its highest point (when there
is 0 bar (0 psi) resistance from hydraulic system pressure) pressure on the gauge will drop
sharply to zero, as the accumulator is completely emptied of oil and the diaphragm button
closes.
Record the highest gauge reading and compare to the "P1" rated precharge pressure on the
accumulator manufacturer's data label. Repeat this test at least once a year to verify proper
functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator precharge pressure, the flexible diaphragm
begins to retract upward.
4. When system oil is at highest working pressure and the accumulator fills to maximum reserve
capacity, the flexible diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as the "P3" pressure and can also be
referenced on the manufacturer's data label on the exterior of the accumulator.
5. If system oil pressure begins to fall off or is momentarily checked or interrupted, the energy stored on
the other side of the diaphragm, in the form of compressed gas, pushes oil back out of the lower
chamber, maintaining oil pressure of the circuit.
6. With minimal system pressure, an equilibrium point may be reached in which accumulator precharge
pressure and hydraulic system oil pressure achieve a rough balance. In this condition a minimal
amount of oil is stored in the accumulator.
SPECIFICATIONS
Charge
Model Serial Number System Volume
Pressure
Mega 200-V (Tier I 30 kg/cm2 750 cc
S/N 1001 and Up Brake System
& II) (427 psi) (45.77 in3)
Mega 200-V (Tier I 15 kg/cm2 320 cc
S/N 1001 and Up Pilot
& II) (213 psi) (19.53 in3)
30 kg/cm2 750 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Brake System
(427 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Pilot
(213 psi) (19.53 in3)
30 kg/cm2 750 cc
Mega 250-V (Tier II) S/N 2001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm2 320 cc
Mega 250-V (Tier II) S/N 2001 and Up Pilot
(213 psi) (19.53 in3)
10 kg/cm2 750 cc
Solar 140LC-V S/N 1001 and Up Pilot / Travel
(142 psi) (45.77 in3)
Solar 140W-V 30 kg/cm2 750 cc
S/N 1000 and Up Brake System
/160W-V (427 psi) (45.77 in3)
Page 4
Charge
Pressure
S/N 1000 and Up Pilot
/160W-V (213 psi) (19.53 in3)
S/N 1000 and Up Transmission
/160W-V (114 psi) (45.77 in3)
10 kg/cm2 750 cc
Solar 175LC-V S/N 1001 thru 1099 Pilot / Travel
(142 psi) (45.77 in3)
30 kg/cm2 750 cc
Solar 180W-V S/N 1001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm2 320 cc
Solar 180W-V S/N 1001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm2 750 cc
Solar 180W-V S/N 1001 and Up Transmission
(114 psi) (45.77 in3)
30 kg/cm2 750 cc
(427 psi) (45.77 in3)
15 kg/cm2 320 cc
Solar 210W-V S/N 0001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm2 750 cc
Solar 210W-V S/N 0001 and Up Transmission
(114 psi) (45.77 in3)
10 kg/cm2 750 cc
(142 psi) (45.77 in3)
10 kg/cm2 750 cc
Solar 225NLC-V S/N 1001 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm2 320 cc
(142 psi)) (19.53 in3)
10 kg/cm2 750 cc
(142 psi) (45.77 in3)
10 kg/cm2 320 cc
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
(142 psi) (45.77 in3)
10 kg/cm2 750 cc
Solar 300LL S/N 1100 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm2 320 cc
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
(142 psi)) (45.77 in3)
10 kg/cm2 320 cc
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
(142 psi)) (45.77 in3)
10 kg/cm2 320 cc
(142 psi) (19.53 in3)
Page 5
Charge
Pressure
10 kg/cm2 750 cc
(142 psi)) (45.77 in3)
10 kg/cm2 320 cc
Solar 55-V S/N 0001 and Up Pilot
(142 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 55-V PLUS S/N 1001 and Up Pilot
(142 psi) (19.53 in3)
25 kg/cm2 320 cc
(356 psi) (19.53 in3)
Pilot/Parking 15 kg/cm2 320 cc
Solar 55W-V S/N 1001 and Up
Brake (213 psi) (19.53 in3)
25 kg/cm2 320 cc
Solar 55W-V PLUS S/N 1001 and Up Brake System
(356 psi) (19.53 in3)
Pilot/Parking 15 kg/cm2 320 cc
Solar 55W-V PLUS S/N 1001 and Up
Brake (213 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 75-V S/N 1001 and Up Pilot
(142 psi) (19.53 in3)
Page 6
S0704015K
1CENTER JOINT
(SWIVEL)
CAUTION!
CENTER JOINT (SWIVEL)S0704015K


December 2002
Center Joint (Swivel) S0704015K

Page 1
TABLE OF CONTENTS
Parts List ................................................................................................. 4
Troubleshooting, Testing and Adjustment....................................................... 6
Inspection................................................................................................ 6
Testing..................................................................................................... 6
Disassembly ................................................................................................... 7
assembly ........................................................................................................ 8
S0704015K Center Joint (Swivel)

Page 2
GENERAL DESCRIPTION
The center joint (swivel) is designed to allow hydraulic oil from the upper structure to flow to components in
the lower structure.
It is capable of allowing continuous 360° rotation of the upper structure in relationship to the lower
structure.

Page 3
PARTS LIST
Figure 1

Page 4
Reference Reference
Number Number
1 Center Joint 10 Rivet
2 Seal 11 Retaining Ring
3 Name Plate 12 Seal
4 Spacer 13 O-ring
5 Body 14 O-ring
7 Cover 18 Spindle
9 Bolt, Socket

Page 5
TROUBLESHOOTING, TESTING AND ADJUSTMENT
INSPECTION
The center joint should be checked for evidence of external oil leakage every 2,000 operating hours.
Leaking or defective O-rings are an indication that dirt and other contaminants could be getting inside the
assembly, which will promote accelerated, abnormal wear and may cause early failure of the assembly.
If internal seals or other sliding surface components are worn and there is internal fluid leakage, complete
overhaul and repair or replacement of the center joint may be required.
TESTING
To check pressure through the center joint, Pressure
Gauge
make up a test kit from the following equipment

list:
• 700 bar (10,000 psi) pressure gauge.
Swivel Joint
• Adapters, connectors, piping and Body (Outer)
flange block-off plates conforming to Swivel Joint

Stem (Inner)
those used in high-pressure piping
connections of the excavator.
• A high-pressure relief valve with a
setting pressure 1.5 times maximum
Stop
system pressure. Valve
• A stop valve.
Manually-Operated
• A manually operated, in-line Changeover Valve
changeover valve.
Install the changeover valve upstream from one Relief
Valve
of the stem high-pressure ports. Connect the (1.5x)
pressure gauge downstream from one of the High Pressure

body ports. Install the stop valve between the Tank
Pump
change-over valve and the stem of the center 0370

joint. Other components should be installed Figure 2
according to the layout in the block diagram. The
test kit is used to pressurize the center swivel
above normal working pressure and lock in the
higher pressure (as the stop valve is closed
manually) for a leak down test.
NOTE: The same type of kit can also be made up for the drain port (return line) side of the center
joint. Use appropriate piping, connectors, test gauges, etc., and follow the same block
diagram general layout (Figure 2).

Page 6
DISASSEMBLY
Refer to the assembly drawing of the swivel joint for component references (Figure 1).
IMPORTANT
Do not unbolt the center joint from the lower car body until an adequate number of piping
block-off plates are available, for disconnected piping lines. Be sure that system pressure has
been vented - including the hydraulic accumulator and tank reserve pressure - before
disassembly is started.
1. Clean off the exterior of the swivel joint after it has been removed.
2. Scribe or otherwise mark a line across the cover and body of the center joint, to allow reassembly in
the same configuration.
3. Remove bolts (7) holding the cover. Use a vise or v-block to hold the assembly in place.
4. Remove spindle (5) upward from housing hub (4).
5. Remove cover (3), withdraw retaining ring (8), O-ring (12), and spacer (6).
NOTE: For removal of O-ring and backup ring, tap case with hammer and take them out
6. If the stem assembly doesn't separate easily when the thrust plate and fastener bolts are removed,
use a wooden block and hammer to drive it out of the housing.
7. Replace O-rings and seals with new, whenever the assembly is being overhauled or rebuilt.
NOTE: For repair procedures or emergency tear down, use a thin but rounded-tip, smooth-edge
scraper or spatula to remove O-rings or seals, to avoid causing damage to those that must
be reused.
8. Before assembling the center swivel, inspect ball bearing surfaces for visible signs of wear, damage
or discoloration and replace any worn component.
• Check clearance between the cover and thrust plate, and between the stem and thrust plate.
Replace any component that shows more than 0.5 mm (0.020") of visible wear.
• Clearance between the stem and body of the center swivel must be tight. Replace or repair
either component if there is more than 0.1 mm (0.0039") of measurable wear.

Page 7
ASSEMBLY
CAUTION!
Apply a very light film of white grease or petroleum jelly to the lower rim of the stem and
inner surface of the center swivel body. Apply slow, even-handed pressure, using both
hands, to slowly push the stem into the body. Seals may be damaged if the stem is pushed
in too quickly.
1. Prelubricate O-rings with hydraulic oil, white grease or petroleum jelly.

2. Thoroughly clean all other component surfaces of dirt or grease before assembly.
3. Assemble in reverse order of disassembly.
4. Clean threads of fasteners before preapplying Loctite #243 to the threads, and before torquing cover
bolts.
5. Prefill the center swivel with clean hydraulic fluid before assembly of high-pressure and drain line
piping. Clean and prefill piping line ends to reduce the amount of air in the system. Bleed air from the
hydraulic system and verify hydraulic tank fluid level before returning the excavator to service.

Page 8
S0705000
R5
1CYLINDERS
CAUTION!
CYLINDERS S0705000

January 2004
Cylinders S0705000
Page 1
TABLE OF CONTENTS
Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 4
Special Tools and Materials............................................................................ 6
Piston Nut................................................................................................ 6
Piston Jig............................................................................................... 10
Steel Bushing Jig .................................................................................. 14
Dust Wiper Jig....................................................................................... 18
Slipper Seal Jig ..................................................................................... 24
Slipper Seal Straightening Jig ............................................................... 28
Disassembly ................................................................................................. 31
Assembly...................................................................................................... 37
S0705000 Cylinders
Page 2
GENERAL DESCRIPTION
Two essentially similar types of hydraulic cylinders are used on the excavator. The cylinder that is used to
operate the excavator boom or bucket is equipped with a rod stopper, which acts as a cushion only when
the cylinder rod is fully retracted (and the bucket is pulled close to the arm). This type of cylinder is shown
in the lower drawing.
Arm cylinders have a cushion or stopper for operation in both directions. This type of cylinder is shown in
the upper drawing.
THEORY OF OPERATION
Reference
Description
Number
1 Piston
2 Oil Path A
3 Oil Path B
Cylinder piston rods are extended or retracted

by oil flow to the back side of the cylinder
(shown as ("oil path A") or to the front of the
cylinder ("oil path B").
The cylinder rod is extended as oil flow is
pumped through the circuit to the back side of
the piston. The force (F1) of the piston stroke
can be expressed by the formula below, where Figure 1
P = circuit oil pressure and the inside diameter
of the cylinder is expressed by B (Figure 1).
F1 = P x πB2
4
(P: Pressure, p = 3.14, B: Cylinder Inside Diameter)
Reference
Description
Number
1 Cylinder Inside Diameter -
B
2 Oil Path A
3 Oil Path B
4 Rod Diameter
Figure 2
When the cylinder rod is retracted, oil flow
through the circuit from the pump to the front
side of the cylinder generates a force (F2) that
can be expressed by the formula in which the
diameter of the piston rod is expressed by R,
and the other two terms are the same as in the
preceding expression.
F2 = P x π(B2-R2)
4
Cylinders S0705000
Page 3
Because the volume of oil needed to lengthen
the cylinder rod (Q1) is greater than the volume
of oil required to retract the cylinder rod, it takes
more time to decrease cylinder stroke length
than it does to lengthen it.
Q1 = S x π(B2)
4
Figure 3
Q2 = S x π(B2-R2)
4
Q1 > Q2
PARTS LIST
The following parts list is a partial listing only; for full and complete parts list information, refer to the
Hydraulic Equipment Component Parts List
Cross section in Figure 4 shows an arm cylinder.
Cross section in Figure 5 shows a boom cylinder.
The bucket and boom cylinders are identical and differ only in the attached pipes.
Figure 4
Figure 5
S0705000 Cylinders
Page 4
Reference Reference
Number Number
1 Bushing 16 Piston
2 Dust Wiper 17 Slide Ring
3 Retaining Ring 18 Wear Ring
4 U-packing 19 Slipper Seal
5 Buffer Seal 20 O-ring
6 Rod Bushing 21 Backup Ring
7 Bolt 22 Piston Nut
8 Retaining Ring 23 Set Screw
9 Rod Cover 24 Cushion Plunger
10 O-ring 25 Bushing
11 O-ring 26 Check Valve
12 Backup Ring 27 Spring Support
13 Piston Rod 28 Spring
14 Cylinder Tube 29 Plug
15 Cushion Ring 30 Stop Ring
Cylinders S0705000
Page 5
SPECIAL TOOLS AND MATERIALS
PISTON NUT
( )
15
-0.1
-0.2
C
(C3~C5)
D +0.1
+0.2
A
35
B
∅8 Through Hole
5
0.
R
R(R15 ~ R20)
4-
350
ARS4730L
Figure 6
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
S0705000 Cylinders
Page 6
MODEL CYLINDER øA øB C D MODEL (CYLINDER)
S55-V (BOOM, BOOM {OPT})
110 mm 69 mm 12 mm 5 mm
ARM S55-V PLUS (SWING)
(4.33 in) (2.72 in) (0.47 in) (0.20 in)
S75-V (BUCKET)
100 mm 58 mm 12 mm 5 mm
S55-V SWING
(3.94 in) (2.23 in) (0.47 in) (0.20 in)
S55-V PLUS (BUCKET)
110 mm 69 mm 10 mm 5 mm
BUCKET S80W-II (DOZER)
(4.33 in) (2.72 in) (0.39 in) (0.20 in)
MEGA 400 (P/S)
S130W-V (ARM (EURO))
S160W-V (ARM)
S170LC-V (BOOM)
S170W-V (BOOM)
S175LC-V (BOOM)
S180W-V (BOOM)
130 mm 90 mm 12 mm 5 mm
ARM S200W-V (BOOM)
(5.12 in) (3.54 in) (0.47 in) (0.20 in)
S200LC-V (BOOM)
S200n-V (BUCKET) (OPTION)
S210W-V (BOOM)
S220LC-V (BOOM)
S225LC-V (BOOM)
S225NLC-V (BOOM)
S225NLC-V (BUCKET) (OPTION)
S130LC-V
S130W-V (ARM)
S140LC-V S130W-V (NEW BOOM)
S130LC-V (SHORT ARM)
S140LC-V (SHORT ARM)
S140W-V (ARM)
S140W-V (BOOM)
125 mm 85 mm 12 mm 5 mm S140W-V (OUTRIGGER)
BOOM (OP)
(4.92 in) (3.35 in) (0.47 in) (0.20 in) S160W-V (BOOM)
S160W-V (OUTRIGGER)
S170W-V (BUCKET)
S220LC-V (BUCKET)
S220LL (BUCKET)
S225LC-V (BUCKET)
S225NLC-V (BUCKET)
115 mm 75 mm 12 mm 5 mm S140W-V (BUCKET)
BUCKET
(4.53 in) (2.95 in) (0.47 in) (0.20 in) S160W-V (BUCKET)
Cylinders S0705000
Page 7
S330LC-V (ARM)
S340LC-V (ARM)
S370LC-V (ARM)
147 mm 107 mm 12 mm 5 mm
ARM S400LC-V (BOOM, BUCKET)
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
S420LC-V (BOOM, BUCKET)
S200n-V (ARM (OP))
S225NLC-V (ARM (OP))
S220LL S210W-V (ARM)
142 mm 102 mm 12 mm 5 mm S220LC-V (ARM)
BOOM
(5.59 in) (4.02 in) (0.47 in) (0.20 in) S225LC-V (ARM)
S225NLC-V (ARM)
S290LC-V (BOOM)
S300LC-V (BOOM)
S170LC-V (BOOM)
125 mm 102 mm 11 mm 4.5 mm S175LC-V (BOOM)
BUCKET
S210W-V (BUCKET)
S255LC-V (ARM)
S290LL (BOOM, BUCKET)
S330LC-V (BUCKET (OP),
BOOM, BUCKET)
145 mm 105 mm 12 mm 5 mm
S250LC-V ARM S340LC-V (BUCKET (OP),
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
BOOM, BUCKET)
S370LC-V (BUCKET (OP),
BUCKET)
S290LC-V (ARM)
147 mm 107 mm 12 mm 5 mm
S290LC-V S/ARM S300LC-V (ARM, S/ARM)
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
S370LC-V (BOOM)
S140W-V (ARTI.)
155 mm 115 mm 12 mm 5 mm S160W-V (ARTI.)
S290LL ARM
(6.10 in) (4.53 in) (0.47 in) (0.20 in) S400LC-V (ARM)
S420LC-V (ARM)
170 mm 129 mm 12 mm 5 mm
S450LC-V ARM S470LC-V (ARM)
(6.69 in) (5.08 in) (0.47 in) (0.20 in)
106 mm 66 mm 12 mm 5 mm
ARM
(4.17 in) (2.60 in) (0.47 in) (0.20 in)
S55W-V
112 mm 72 mm 12 mm 5 mm S55-V PLUS (ARM, BOOM)
BOOM
(4.41 in) (2.84 in) (0.46 in) (0.20 in) S75-V (ARM, SWING)
106 mm 66 mm 12 mm 5 mm
ARM
S55W-V (4.17 in) (2.60 in) (0.47 in) (0.20 in)
PLUS 112 mm 72 mm 12 mm 5 mm S55-V PLUS (ARM, BOOM)
BOOM
(4.41 in) (2.84 in) (0.46 in) (0.20 in) S75-V (ARM, SWING)
S0705000 Cylinders
Page 8
S70-III (ARM)
S80W-II (BOOM)
120 mm 79 mm 10 mm 5 mm
ARM MEGA 130-III (LIFT)
(4.72 in) (3.11 in) (0.39 in) (0.20 in)
S140W-V (DOZER)
S160W-V (DOZER)
S70-III (BOOM, DOZER)
S80W-II S75-V (DOZER)
120 mm 79 mm 10 mm 5 mm S130LC-V (DOZER)
BOOM
(4.72 in) (3.11 in) (0.39 in) (0.20 in) S140LC-V (DOZER)
MEGA 200-III TC (BUCKET)
MEGA 130-III (BUCKET)
110 mm 69 mm 10 mm 5 mm
BUCKET S70-III (BUCKET)
(4.33 in) (2.72 in) (0.39 in) (0.20 in)
120 mm 80 mm 12 mm 5 mm
S130W-V BOOM S75-V (BOOM)
(4.72 in) (3.15 in) (0.47 in) (0.20 in)
S170LC-V (ARM)
S175LC-V (ARM)
S180W-V (ARM)
140 mm 98 mm 12 mm 5 mm
S170W-V ARM S250LC-V (BOOM, BUCKET)
(5.52 in) (3.86 in) (0.47 in) (0.20 in)
S290LC-V (S/BUCKET, BUCKET)
S300LC-V (S/ BUCKET, BUCKET)
S180W-V (DOZER)
132 mm 92 mm 12 mm 5 mm
S210W-V DOZER S180W-V (OUTRIGGER)
(5.20 in) (3.62 in) (0.47 in) (0.20 in)
S210W-V (OUTRIGGER)
P/S: Power Steering
Cylinders S0705000
Page 9
PISTON JIG
( )
15
2-∅"B"
)
F/2
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C"
35
R(R15~20)
R5
4-
30
ARS4740L
Figure 7
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
S0705000 Cylinders
Page 10
MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER)
S55 BOOM 80.0 mm 11.0 mm 45.0 mm 110.0 mm S55 (BOOM (OP))
SWING 58.0 mm 11.0 mm 38.0 mm 80.0 mm MEGA 300 (P/S)
(2.28 in) (0.43 in) (1.50 in) (3.15 in)
S55-V ARM 65.0 mm 11.0 mm 49.0 mm 90.0 mm MEGA 130-III (LIFT)
PLUS (2.56 in) (0.43 in) (1.93 in) (3.54 in) MEGA 160TC (BUCKET)
MEGA 400 (P/S)
70 mm 11 mm 51 mm 95 mm
ARM S80W-II (ARM)
(2.76 in) (0.43 in) (2.01 in) (3.74 in)
60 mm 11 mm 43 mm 85 mm S80W-II (BUCKET, DOZER)
BUCKET
(2.36 in) (0.43 in) (1.69 in) (3.35 in) S75-V (BUCKET)
S70-III S75-V (ARM, DOZER)
S130LC-V (DOZER)
70 mm 11 mm 53 mm 95 mm
DOZER S140LC-V (DOZER)
(2.76 in) (0.43 in) (2.09 in) (3.74 in)
S140W-V (DOZER)
S160W-V (DOZER)
S210W-V (ARM)
S220LC-V (BOOM)
S220N-V (ARM (OP))
S225NLC-V (BOOM)
110 mm 13 mm 76 mm 140 mm
ARM S225NLC-V (ARM (OP))
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
S250LC-V (ARM)
S255LC-V (ARM)
S70-III (BOOM)
S75-V (SWING)
S80W-II (BOOM)
S220LC-V S130LC-V (S/ARM, BOOM
(OP), ARM)
S140LC-V (S/ARM, BOOM
(OP), ARM)
90 mm 11 mm 63 mm 115 mm S160W-V (ARM)
BUCKET
(3.54 in) (0.43 in) (2.48 in) (4.53 in) S170LC-V (BOOM)
S170W-V (BUCKET, BOOM)
S175LC-V (BOOM)
S180W-V (BOOM)
S210W-V (BUCKET)
S220LC-V (BUCKET)
S225LC-V (BUCKET)
S225NLC-V (BUCKET)
MEGA 200-III (LIFT)
S290LL (BUCKET, BOOM)
S300LC-V (ARM, S/ARM)
ARM 120 mm 13 mm 85 mm 150 mm
S290LC-V S340LC-V (BUCKET, BOOM,
S/ARM (4.72 in) (0.51 in) (3.35 in) (5.91 in)
BUCKET (OP))
S370LC-V (BUCKET, BUCKET
(OP))
Cylinders S0705000
Page 11
MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER)
S140W-V (ARTI)
S160W-V (ARTI)
S340LC-V (ARM)
130 mm 13 mm 93 mm 165 mm S400LC-V (ARM, BOOM)
S330LC-V ARM
(5.12 in) (0.51 in) (3.66 in) (6.50 in) S420LC-V (ARM, BOOM,
BUCKET)
150 mm 13 mm 103 mm 180 mm
(5.91 in) (0.51 in) (4.06 in) (7.09 in)
63 mm 11 mm 43 mm 90 mm S55-V (ARM, BUCKET)
S55W-V ARM
S55W-V 63 mm 11 mm 43 mm 90 mm
ARM S55-V PLUS (BUCKET)
PLUS (2.48 in) (0.43 in) (1.69 in) (3.54 in)
S75-V (BOOM)
75 mm 11 mm 53 mm 100 mm
S130W-V BOOM S130LC-V (BOOM)
(2.95 in) (0.43 in) (2.09 in) (3.94 in)
S140LC-V (BOOM)
70 mm 11 mm 46 mm 95 mm
S140W-V BUCKET S160W-V (BUCKET)
(2.76 in) (0.43 in) (1.81 in) (3.74 in)
S170LC-V (ARM)
S175LC-V (ARM)
S180W-V (ARM)
96 mm 13 mm 69 mm 130 mm S180W-V (O/R, DOZER)
ARM
(3.78 in) (0.51 in) (2.72 in) (5.12 in) S200W-V (O/R, DOZER)
S210W-V (O/R, DOZER)
S250LC-V (BUCKET, BOOM)
S255LC-V (BUCKET, BOOM)
S55-V PLUS (BOOM, SWING)
S170W-V S70-III (BOOM)
S80W-II (BOOM)
S130W-V (ARM)
S130LC-V (S/ARM, BOOM
80 mm 11 mm 58 mm 110 mm {OP})
BUCKET
(3.15 in) (0.43 in) (2.28 in) (4.33 in) S140W-V (ARM)
S140W-V (BOOM)
S140W-V (O/R)
S160W-V (ARM)
S160W-V (O/R)
S180W-V (BUCKET)
S220LC-V (BOOM)
S220N-V (BUCKET) (OP)
90 mm 13 mm 63 mm 115 mm
S200W-V BOOM S225LC-V (BOOM)
(3.54 in) (0.51 in) (2.48 in) (4.53 in)
S225NLC-V (BOOM)
S225NLC-V (BOOM) (OP)
P/S: Power Steering
O/R: Out Rigger
S0705000 Cylinders
Page 12
Cylinders S0705000
Page 13
STEEL BUSHING JIG
(5)
"A" - 20
"B" + 40
∅"B"
∅"A"
(∅20)
15 F E
ARS4750L
Figure 8
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
S0705000 Cylinders
Page 14
MODEL CYLINDER øA-0.05 øB (±0.1) E F+0.05
0
Part MODEL (CYLINDER)
50 mm 65 mm 30 mm S55W-V (BOOM)
BOOM -
(1.97 in) (2.56 in) (1.18 in) S55-V PLUS (SWING)
40 mm 50 mm 20 mm
S55-V SWING -
(1.58 in) (1.97 in) (0.79 in)
65 mm 70 mm 30 mm
DOZER -
(2.56 in) (2.76 in) (1.18 in)
50 mm 60 mm 40 mm
DOZER 0 S75-V (DOZER)
(1.97 in) (2.36 in) (1.58 in)
S55-V (ARM)
50 mm 60 mm 25 mm 5 mm S55- V PLUS (ARM,
S70-III BUCKET H/C
(1.97 in) (2.36 in) (0.98 in) (0.20 in) BOOM, BUCKET)
S75-V (BUCKET)
55 mm 68 mm 30 mm 5.5 mm
BUCKET K/C S80W-II BUCKET (K/C)
(2.17 in) (2.68 in) (1.18 in) (0.22 in)
60 mm 70 mm 30 mm S140W-V (DOZER)
DOZER -
(2.36 in) (2.76 in) (1.18 in) S160W-V (DOZER)
S70-III (ARM, BOOM)
S130LC-V S75-V (ARM, BOOM,
SWING)
S140LC-V 65 mm 80 mm 30 mm 6 mm
BUCKET S140W-V (BUCKET)
(2.56 in) (3.15 in) (1.18 in) (0.24 in)
S160W-V (BUCKET)
MEGA 200-III (LIFT)
MEGA 200-III TC (H/C)
Cylinders S0705000
Page 15
0
S210W-V (ARM)
S290LC-V (S/ARM, ARM)
90 mm 105 mm 40 mm 6.5 mm
ARM MEGA 250-III (BUCKET)
(3.54 in) (4.13 in) (1.58 in) (0.26 in)
MEGA 400 (LIFT (H/C),
BUCKET)
MEGA 400-V (LIFT (H/C))
MEGA 500-III
S180W-V (DOZER, O/R)
S200W-V (BOOM, DOZER,
O/R)
S210W-V (BOOM, DOZER,
O/R)
S220N-V (ARM (OP),
BUCKET (OP))
S220LL S220LC-V (ARM, BOOM,
BUCKET)
S225LC-V (ARM, BOOM,
80 mm 95 mm 35 mm 6.5 mm BUCKET)
BOOM
(3.15 in) (3.74 in) (1.38 in) (0.26 in) S225NLC-V (ARM (OP),
BUCKET (OP))
S225NLC-V (ARM, BOOM,
BUCKET)
S250LC-V (ARM, BUCKET)
S255LC-V (ARM, BUCKET)
MEGA 160 (BUCKET)
MEGA 200 (BUCKET)
MEGA 300 (BUCKET)
MEGA 300-V (LIFT)
65 mm 80 mm 35 mm 6.5 mm
(2.56 in) (3.15 in) (1.38 in) (0.26 in)
S255LC-V (BOOM)
S290LC-V (S/BUCKET,
90 mm 105 mm 40 mm 7 mm
S250LC-V BOOM BOOM, BUCKET)
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
S300LC-V (S/BUCKET,
BOOM, BUCKET)
ARM 100 mm 115 mm 70 mm 6.5 mm
S290LL
(STICK) (3.94 in) (4.53 in) (2.76 in) (0.26 in)
BUCKET)
BUCKET)
BUCKET 100 mm 115 mm 45 mm 7.5 mm
S330LC-V S370LC-V (ARM, BOOM,
(OP) (3.94 in) (4.53 in) (1.77 in) (0.30 in)
BUCKET)
MEGA 300-V (BUCKET)
MEGA 400-V (BUCKET)
MEGA 500-III (LIFT (H/C))
S0705000 Cylinders
Page 16
0
120 mm 140 m 75 mm 11 mm
ARM S470LC-V (ARM)
(4.72 in) (5.51 in) (2.95 in) (0.43 in)
S400LC-V (ARM, BOOM
(H/C), BUCKET)
S420LC-V (ARM, BOOM
110 mm 130 mm 70 mm 11 mm
S450LC-V BOOM H/C (H/C), BUCKET)
(4.33 in) (5.12 in) (2.76 in) (0.43 in)
S450LC-V (BUCKET)
S470LC-V (BOOM,
BUCKET)
120 mm 140 m 70 mm 11 mm S420LC-V (BOOM (K/C))
BOOM K/C
(4.72 in) (5.51 in) (2.76 in) (0.43 in) S400LC-V (BOOM (K/C))
S55-V (ARM, BOOM (OP),
50 mm 60 mm 30 mm
BUCKET - BUCKET)
(1.97 in) (2.36 in) (1.18 in)
S55W-V S55W-V PLUS (BUCKET)
65 mm 75 mm 30 mm S55-V PLUS (DOZER)
DOZER -
(2.56 in) (2.95 in) (1.18 in) S55W-V PLUS (DOZER)
50 mm 60 mm 25 mm 5.5 mm
S80W-II BUCKET H/C
(1.97 in) (2.36 in) (0.98 in) (0.22 in)
S130LC-V (BOOM, BOOM
(OP))
71 mm 86 mm 40 mm 6.5 mm S140LC-V (BOOM, BOOM
BOOM
(2.80 in) (3.39 in) (1.58 in) (0.26 in) (OP))
S140W-V (BOOM)
S160W-V (BOOM)
S130W-V S130W-V (ARM)
ARM 71 mm 86 mm 40 mm 7 mm
S140W-V (ARM)
(EURO) (2.80 in) (3.39 in) (1.58 in) (0.28 in)
S160W-V (ARM)
S180W-V (ARM, BOOM,
BUCKET)
60 mm 75 mm 30 mm 6.5 mm
S140W-V O/R S160W-V (O/R)
(2.36 in) (2.95 in) (1.18 in) (0.26 in)
90 mm 105 mm 40 mm 6 mm
S140W-V ARTI. S160W-V (ARTI.)
(3.54 in) (4.13 in) (1.58 in) (0.24 in)
S170W-V (BOOM,
71 mm 86 mm 50 mm 6 mm BUCKET)
S170W-V ARM
(2.80 in) (3.39 in) (1.97 in) (0.24 in) S170LC-V (ARM, BOOM)
S175LC-V (ARM, BOOM)
H/C: Head Cover
K/C: Knuckle Cover
Cylinders S0705000
Page 17
DUST WIPER JIG
1.5
3-C
R0.2
1
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 9
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
S0705000 Cylinders
Page 18
MODEL CYLINDER øA-0.2 øB -0.2 C0 D MODEL (CYLINDER)
35 mm 47 mm 6 mm
TILT 0
(1.38 in) (1.85 in) (0.24 in)
45 mm 57 mm 0.5 mm 6 mm
DD80L DOZER DD80L (ANGLE)
(1.77 in) (2.24 in) (0.02 in) (0.24 in)
45 mm 57 mm 0.5 mm 6 mm
ANGLE
(1.77 in) (2.24 in) (0.02 in) (0.24 in)
55 mm 69 mm 5 mm 6 mm
ARM
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
55 mm 69 mm 5 mm 6 mm
BOOM
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
55 mm 69 mm 5 mm 6 mm
BOOM (OP)
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
S55-V
55 mm 69 mm 5 mm 6 mm
BUCKET
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
40 mm 52 mm 3.5 mm 6 mm
SWING S55W-V (SWING)
(1.58 in) (2.05 in) (0.14 in) (0.24 in)
60 mm 74 mm 7 mm 6 mm
DOZER
(2.36 in) (2.91 in) (0.28 in) (0.24 in)
65 mm 79 mm 5.5 mm 6 mm
ARM S80W-III (ARM)
(2.56 in) (3.11 in) (0.22 in) (0.24 in)
S80W-III (BOOM)
S130W-V (BOOM)
70 mm 84 mm 5.5 mm 6 mm
BOOM S130LC-V (BOOM)
(2.76 in) (3.31 in) (0.22 in) (0.24 in)
S140LC-V (BOOM)
S55-V (ARM, BOOM, BOOM
(OP), BUCKET)
S55-V PLUS (BUCKET,
55 mm 69 mm 5 mm 6 mm SWING)
BUCKET
S70-III (2.17 in) (2.72 in) (0.20 in) (0.24 in) S55W-V (ARM)
S75-V (BUCKET)
S80W-III (BUCKET)
MEGA 130-III (LIFT)
S55W-V (BOOM)
S55-V PLUS (ARM, BOOM)
S75-V (ARM, SWING
DOZER)
60 mm 74 mm 5 mm 6 mm
DOZER S140W-V (DOZER)
(2.36 in) (2.91 in) (0.20 in) (0.24 in)
S160W-V (DOZER)
MEGA 160-III (LIFT)
MEGA 200-III TC (BUCKET)
70 mm 84 mm 5 mm 6 mm
S75-V BOOM
(2.76 in) (3.31 in) (0.20 in) (0.24 in)
S55-V (DOZER)
60 mm 74 mm 7 mm 6 mm
S80-III DOZER S55-V PLUS (DOZER)
(2.36 in) (2.91 in) (2.28 in) (0.24 in)
S55W-V (DOZER)
Cylinders S0705000
Page 19
S160W-V (ARM)
80 mm 94 mm 6 mm 7 mm S170W-V (BOOM)
ARM
(3.15 in) (3.70 in) (0.24 in) (2.28 in) S220N-V (BOOM (OP))
S130LC-V S225NLC-V (BOOM (OP))
S140LC-V 70 mm 84 mm 6 mm 7 mm
BOOM
(2.76 in) (3.31 in) (0.24 in) (2.28 in)
75 mm 89 mm 6 mm 7 mm
BOOM (OP)
(2.95 in) (3.50 in) (0.24 in) (2.28 in)
S210W-V (ARM)
S220N-V (ARM (OP))
ARM
(3.74 in) (4.29 in) (0.24 in) (2.28 in) S225NLC-V (ARM)
S290LC-V (BOOM)
S220LC-V S300LC-V (BOOM)
85 mm 99 mm 6 mm 7 mm S225LC-V (BOOM)
BOOM
(3.35 in) (3.90 in) (0.24 in) (2.28 in) S225NLC-V (BOOM)
S210W-V (BUCKET)
75 mm 89 mm 6 mm 7 mm
BUCKET S225LC-V (BUCKET)
(2.95 in) (3.50 in) (0.24 in) (2.28 in)
S225NLC-V (BUCKET)
S340LC-V (ARM)
S420LC-V (BOOM)
115 mm 131 mm 6 mm 7 mm
ARM (STICK) S370LC-V (ARM)
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
S360LC-V (ARM)
S220LL S400LC-V (BOOM)
BOOM 90 mm 104 mm 6 mm 7 mm
(HOIST) (3.54 in) (4.10 in) (0.24 in) (2.28 in)
BUCKET 75 mm 89 mm 6 mm 7 mm
(HEEL) (2.95 in) (3.50 in) (0.24 in) (2.28 in)
95 mm 109 mm 6 mm 7 mm
ARM (OP) S225NLC-V (ARM (OP))
(3.74 in) (4.29 in) (0.24 in) (2.28 in)
S220N-V
80 mm 94 mm 6 mm 7 mm
BOOM (OP) S225NLC-V (BOOM (OP))
(3.15 in) (3.70 in) (0.24 in) (2.28 in)
S255LC-V (ARM)
S360LC-V (BOOM, BUCKET,
BUCKET (OP))
S340LC-V (BOOM, BUCKET,
100 mm 114 mm 6 mm 7 mm
ARM BUCKET (OP))
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
S370LC-V (BUCKET,
S250LC-V BUCKET (OP))
S290LL (BOOM (HOIST),
BUCKET (HEEL))
90 mm 104 mm 6 mm 7 mm
BOOM
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
90 mm 104 mm 6 mm 7 mm
BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
S0705000 Cylinders
Page 20
S290LC-V (S/ARM)
105 mm 121 mm 6 mm 7 mm
ARM S300LC-V (ARM, S/ARM)
(4.13 in) (4.76 in) (0.24 in) (2.28 in)
S370LC-V (BOOM)
105 mm 121 mm 6 mm 7 mm
S/ARM
(4.13 in) (4.76 in) (0.24 in) (2.28 in)
S290LC-V 95 mm 109 mm 6 mm 7 mm
BOOM
(3.74 in) (4.29 in) (0.24 in) (2.28 in)
90 mm 104 mm 6 mm 7 mm
BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
90 mm 104 mm 6 mm 7 mm
S/BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
120 mm 136 mm 9 mm 7 mm
ARM (STICK)
(4.72 in) (5.35 in) (0.35 in) (2.28 in)
BOOM 100 mm 114 mm 6 mm 7 mm
S290LL
(HOIST) (3.94 in) (4.49 in) (0.24 in) (2.28 in)
(HEEL) (3.94 in) (4.49 in) (0.24 in) (2.28 in)
115 mm 131 mm 6 mm 7 mm
ARM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
100 mm 114 mm 6 mm 7 mm
BOOM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
S360LC-V
100 mm 114 mm 6 mm 7 mm
BUCKET
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
(OP) (3.94 in) (4.49 in) (0.24 in) (2.28 in)
ARM
(4.72 in) (5.35 in) (0.35 in) (2.28 in) S290LL (ARM (STICK))
115 mm 131 mm 6 mm 7 mm
S400LC-V BOOM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
110 mm 126 mm 6 mm 7 mm
(4.33 in) (4.96 in) (0.24 in) (2.28 in)
130 mm 146 mm 6.5 mm 7 mm
ARM S470LC-V (ARM)
(5.12 in) (5.75 in) (0.26 in) (2.28 in)
115 mm 131 mm 6 mm 7 mm S140W-V (ARTI.)
S450LC-V BOOM
(4.53 in) (5.16 in) (0.24 in) (2.28 in) S160W-V (ARTI.)
115 mm 131 mm 6 mm 7 mm
BUCKET
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
55 mm 69 mm 5 mm 6 mm
ARM S55W-V PLUS (ARM)
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
40 mm 52 mm 3.5 mm 6 mm
SWING S55W-V PLUS (SWING)
(1.58 in) (2.05 in) (0.14 in) (0.24 in)
60 mm 74 mm 5 mm 6 mm
S55W-V BOOM S55W-V PLUS (BOOM)
(2.36 in) (2.91 in) (0.20 in) (0.24 in)
50 mm 62 mm 4.5 mm 6 mm
BUCKET S55W-V PLUS (BUCKET)
(1.97 in) (2.44 in) (0.18 in) (0.24 in)
60 mm 74 mm 5 mm 6 mm
DOZER S55W-V PLUS (DOZER)
(2.36 in) (2.91 in) (0.20 in) (0.24 in)
Cylinders S0705000
Page 21
65 mm 79 mm 5.5 mm 6 mm
ARM
(2.56 in) (3.11 in) (0.22 in) (0.24 in)
70 mm 84 mm 5.5 mm 6 mm
S80W-III BOOM
(2.76 in) (3.31 in) (0.22 in) (0.24 in)
55 mm 69 mm 5 mm 6 mm
BUCKET
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
S130W-V (S/ARM)
S130LC-V (BOOM (OP))
S140W-V (ARM)
ARM
S170W-V (BUCKET)
S220LC-V (BUCKET)
S130W-V S220LL (BUCKET (HEEL))
75 mm 89 mm 6 mm 7 mm
S/ARM
(2.95 in) (3.50 in) (0.24 in) (2.28 in)
70 mm 84 mm 6 mm 7 mm
BOOM
(2.76 in) (3.31 in) (0.24 in) (2.28 in)
65 mm 79 mm 6 mm 7 mm S140W-V (BUCKET)
BUCKET
70 mm 84 mm 0.5 mm 6 mm
S140W-V OR S160W-V (O/R)
(2.76 in) (3.31 in) (0.02 in) (0.24 in)
S180W-V (ARM)
S220LL (BOOM (HOIST))
90 mm 104 mm 6 mm 7 mm S255LC-V (BOOM, BUCKET)
ARM
(3.54 in) (4.10 in) (0.24 in) (2.28 in) S290LC-V (BUCKET, S/
BUCKET)
S170W-V S300LC-V (BUCKET, S/
BUCKET)
80 mm 94 mm 6 mm 7 mm
BOOM S180W-V (BOOM)
(3.15 in) (3.70 in) (0.24 in) (2.28 in)
75 mm 89 mm 6 mm 7 mm
(2.95 in) (3.50 in) (0.24 in) (2.28 in)
S200W-V BOOM
(3.35 in) (3.90 in) (0.24 in) (2.28 in) S220LC-V (BOOM)
S0705000 Cylinders
Page 22
Cylinders S0705000
Page 23
SLIPPER SEAL JIG
0
R1
R1
∅(A+2)
∅A
∅(A-14)
10°
B
(B+40)
ARS4770L
Figure 10
S0705000 Cylinders
Page 24
MODEL CYLINDER øA+0.2
+0.1 B+0.2
+0.1
MODEL (CYLINDER)
85 mm 32 mm
ARM S55W-V (ARM)
(3.35 in) (1.26 in)
110 mm 21.5 mm S55-V (BOOM (OP))
BOOM
(4.33 in) (0.85 in) S55W-V (BOOM)
S55-V S55W-V (BUCKET, SWING)
80 mm 30 mm
SWING S55-V PLUS (BUCKET)
(3.15 in) (1.18 in)
MEGA 300-III (P/S)
100 mm 18 mm
DOZER S55W-V (DOZER)
(3.94 in) (0.71 in)
90 mm 27 mm
ARM
S55-V (3.54 in) (1.06 in)
PLUS 115 mm 20 mm
BOOM
(4.53 in) (0.79 in)
85 mm 28.5 mm S55-V (ARM)
S70-III BUCKET
(3.35 in) (1.12 in) S80W-II (BUCKET, DOZER)
115 mm 25 mm
BOOM
(4.53 in) (0.90 in)
95 mm 23.5 mm
ARM
(3.74 in) (0.92 in)
S75-V
85 mm 23 mm
BUCKET
(3.35 in) (0.90 in)
110 mm 31.5 mm
SWING
(4.33 in) (1.24 in)
S170W-V (BOOM)
S180W-V (BOOM)
S130LC-V S210W-V (BUCKET)
115 mm 28.5 mm
ARM S220LC-V (BUCKET)
S140LC-V (4.53 in) (1.12 in)
S220LL (BUCKET (HEEL))
S225LC-V (BUCKET)
S225NLC-V (BUCKET)
S220N-V (BUCKET (OP))
120 mm 28.5 mm S225LC-V (BOOM)
S220LC-V BOOM
(4.72 in) (1.12 in) S225NLC-V (BUCKET (OP))
S225NLC-V (BOOM)
165 mm 34.5 mm S400LC-V (BOOM)
S220LL ARM (STICK)
(6.50 in) (1.36 in) S420LC-V (BOOM)
140 mm 28.5 mm S255LC-V (ARM)
ARM
(5.51 in) (1.12 in) S290-V (BOOM, BUCKET, S/BUCKET)
S250LC-V S300LC-V (BOOM, BUCKET. S/BUCKET)
130 mm 28.5 mm S250LC-V (BUCKET)
BOOM
(5.12 in) (1.12 in) S255LC-V (BOOM, BUCKET)
S290LL (BOOM (HOIST), BUCKET (HEEL))
S290LC-V (S/ARM)
150 mm 28.5 mm S300LC-V (ARM, S/ARM)
S290LC-V ARM
(5.91 in) (1.12 in) S340LC-V (BOOM, BUCKET, BUCKET (OP))
S360LC-V (BOOM, BUCKET, BUCKET (OP))
S370LC-V (BOOM, BUCKET, BUCKET (OP))
S340LC-V (ARM)
170 mm 34.5 mm S370LC-V (ARM)
S360LC-V ARM
(6.69 in) (1.36 in) S450LC-V (BOOM, BUCKET)
Cylinders S0705000
Page 25
+0.1 B+0.2
+0.1
MODEL (CYLINDER)
S140W-V (ARTI.)
180 mm 41.5 mm S160W-V (ARTI.)
ARM
(7.09 in) (1.63 in) S290LL (ARM (STICK))
S400LC-V S420LC-V (ARM)
160 mm 34.5 mm
(6.30 in) (1.36 in)
190 mm 41.5 mm
S450-V ARM S470LC-V (ARM)
(7.48 in) (1.63 in)
S55-V PLUS (SWING)
S70-III (BOOM)
S80W-III (BOOM)
S130W-V (S/ARM)
110 mm 28.5 mm S140W-V (ARM)
ARM
(4.33 in) (1.12 in) S140W-V (BOOM)
S140W-V (O/R)
S160W-V (ARM)
S160W-V (BOOM)
S160W-V (O/R)
S130W-V S170W-V (BUCKET)
S180W-V (BUCKET)
S70-III (ARM, DOZER)
S75-V (DOZER)
S80W-III (ARM)
100 mm 28.5 mm S130W-V (BOOM)
BOOM
(3.94 in) (1.12 in) S130LC-V (BOOM (OP))
S140W-V (DOZER)
S160W-V (DOZER)
95 mm 28.5 mm S140W-V (BUCKET)
BUCKET
(3.74 in) (1.12 in) S160W-V (BUCKET)
125 mm 28.5 mm
S170W-V ARM S1480W-V (ARM)
(4.92 in) (1.12 in)
S210W-V (ARM)
S210W-V (BOOM)
S220LC-V (ARM)
135 mm 28.5 mm
S200W-V BOOM S220N-V (ARM (OP))
(5.32 in) (1.12 in)
S225LC-V (ARM)
S225NLC-V (ARM)
P/S: Power Steering
S0705000 Cylinders
Page 26
Cylinders S0705000
Page 27
SLIPPER SEAL STRAIGHTENING JIG
1
2-C
R
2-5
∅(A+15)
∅A
1
2-R
100
25
50
ARS4780L
Figure 11
S0705000 Cylinders
Page 28
+0.1
MODEL (CYLINDER)
85 mm
ARM S55W-V (ARM)
(3.35 in)
110 mm S55-V (BOOM (OP))
BOOM
(4.33 in) S55W-V (BOOM)
S55-V S55W-V (BUCKET, SWING)
80 mm
SWING S55-V PLUS (BUCKET)
(3.15 in)
MEGA 300-III P/S
100 mm S55W-V (DOZER)
DOZER
(3.94 in) S55-V PLUS (DOZER)
90 mm
ARM
(3.54 in)
S55-V PLUS
115 mm
BOOM
(4.53 in)
115 mm
BOOM
(4.53 in)
95 mm
ARM
(3.74 in)
S75-V
85 mm
BUCKET
(3.35 in)
110 mm
SWING
(4.33 in)
S55-V (ARM)
85 mm
S70-III BUCKET S80W-III (BUCKET)
(3.35 in)
S80-III (DOZER)
S170W-V (BOOM)
S180W-V (BOOM)
S130LC-V S210W-V (BUCKET)
115 mm
ARM S220LC-V (BUCKET)
S140LC-V (4.53 in)
S220LL (BUCKET (HEEL))
S225LC-V (BUCKET)
S225NLC-V (BUCKET)
S220N-V (BUCKET (OP))
120 mm S225LC-V (BUCKET (OP))
S220LC-V BOOM
(4.72 in) S225NLC-V (BUCKET (OP))
S225NLC-V (BOOM)
165 mm S400LC-V (BOOM)
S220LL ARM (STICK)
(6.50 in) S420LC-V (BOOM)
140 mm S255LC-V (ARM)
ARM
(5.51 in) S290-V (BOOM, BUCKET, S/BUCKET)
S250LC-V S300LC-V (BOOM, BUCKET, S/BUCKET)
130 mm S250LC-V (BUCKET)
BOOM
(5.12 in) S255LC-V (BOOM, BUCKET)
S300LC-V (ARM, S/ARM)
S340LC-V (BOOM, BUCKET. BUCKET (OP))
150 mm S370LC-V (BOOM, BUCKET, BUCKET (OP))
S290LC-V ARM
(5.91 in) S290-V (S/ARM)
S360-V (BOOM, BUCKET, BUCKET (OP))
S290LL (BOOM (HOIST), BUCKET (HEEL))
S340LC-V (ARM)
170 mm S370LC-V (ARM)
S360-V ARM
(6.69 in) S470LC-V (BOOM, BUCKET)
S450-V (BOOM, BUCKET)
Cylinders S0705000
Page 29
+0.1
MODEL (CYLINDER)
S140W-V (ARTI.)
180 mm S160W-V (ARTI.)
ARM
(7.09 in) S420LC-V (ARM)
S400LC-V S290LL (ARM (STICK))
160 mm
(6.30 in)
190 mm
(7.48 in)
S55-V PLUS (SWING)
S70-III (BOOM)
S80W-III (BOOM)
S130W-V (S/ARM)
S130-V (BOOM (OP))
S140W-V (ARM)
110 mm
ARM S140W-V (BOOM)
(4.33 in)
S140W-V (O/R)
S160W-V (ARM)
S160W-V (BOOM)
S160W-V (O/R)
S130W-V S170W-V (BUCKET)
S180W-V (BUCKET)
S70-III (ARM, DOZER)
S75-V (DOZER)
S80W-III (ARM)
100 mm
BOOM S130W-V (BOOM)
(3.94 in)
S130-V (BOOM)
S140W-V (DOZER)
S160W-V (DOZER)
95 mm S140W-V (BUCKET)
BUCKET
(3.74 in) S160W-V (BUCKET)
125 mm
S170W-V ARM S180W-V (ARM)
(4.92 in)
S210W-V (ARM)
S210W-V (BOOM)
S220LC-V (ARM)
135 mm
S200W-V BOOM S220N-V (ARM (OP))
(5.32 in)
S225LC-V (ARM)
S225NLC-V (ARM)
P/S: Power Steering
S0705000 Cylinders
Page 30
DISASSEMBLY
CAUTION!
Vent air from the hydraulic system before disconnecting cylinder piping connections. Use the
lever on the reservoir, while the engine is running. Discharge the hydraulic accumulator and
vent residual tank pressure after the engine is shut off. Pour clean replacement fluid back into
the system if excessive fluid is lost.
1. Following removal of cylinder from

excavator attachment, support cylinder on
some type of sturdy work platform and
drain all oil. Rotate cylinder so that piping
ports are on top, to allow trapped air to
vent.
Figure 12
2. Position piston rod so that it is extended
approximately one half meter (20").
Figure 13
3. Remove bolts (7) on the end of cylinder.
NOTE: Wrap a cloth or other protective
material around piston rod, to
avoid possibility of accidentally
scratching or scoring rod
surface while fasteners are
being loosened and removed.
Component parts (numbered in
parentheses) are keyed to
Figure 4.
Figure 14
Cylinders S0705000
Page 31
4. Tap two bolts into cover of cylinder head,
180° apart. Tighten them in a staggered,
even sequence, to back off piston rod end
cover from edge of cylinder wall. Look for
adequate clearance between cover and
end of cylinder wall before using a plastic
or other soft-faced hammer for final
disassembly.
Figure 15
5. Begin withdrawing piston rod assembly,
away from cylinder. Attach a lifting support
when final 1/3 of rod is still inside barrel of
cylinder. Prepare support blocks for piston
rod before it has been completely
withdrawn.
Figure 16
6. Lower piston rod to support blocks and
detach wear ring (outer surface) (18) from
end of rod.
Figure 17
S0705000 Cylinders
Page 32
7. Immobilize piston rod by inserting a
wooden or other nonscoring, nonmetallic
support through end of rod.
Figure 18
8. Remove set screw by using a socket
wrench.
HAOF340L
Figure 19
9. Fabricate or purchase a piston nut removal
wrench. (Dimensions are called off at
beginning of this procedure. This tool may
also be ordered through your local
Daewoo Parts distributor). Remove nut
from end of piston.
Figure 20
Cylinders S0705000
Page 33
10. Use second piston tool described at
beginning of this procedure to separate
piston. Detach cushion ring (15), taking
care not to damage cushion ring.
Figure 21
11. Use a plastic hammer to evenly pull off rod
cover (9) from end of piston rod. Be careful
not to damage rod bushing (6) and dust
wiper, U-packing and other seals.
Figure 22
12. Use a dull, rounded-tip tool to pry off
O-ring (11) and backup ring (12).
HAOF37OL
Figure 23
13. Find a screwdriver with an appropriate
width tip to facilitate removal of slipper seal
(19), wear ring (18) and slide ring (17)
from piston (16).
Figure 24
S0705000 Cylinders
Page 34
14. Pull off O-ring (20) and backup ring (21)
from cylinder head.
HAOF38OS
Figure 25
15. During disassembly of cylinder head, be
careful not to damage buffer seal (5) and
U-packing (4).
HAOF39OL
Figure 26
16. Disassemble retaining ring (3) and dust
wiper (2). Separate retaining ring (8) and
rod bushing (6).
Figure 27
Cylinders S0705000
Page 35
17. Force out pin bushing (1) from body of
cylinder.
Figure 28
S0705000 Cylinders
Page 36
ASSEMBLY
IMPORTANT
Replace any part that shows evidence of damage or excessive wear. Replacement of all O-rings
and flexible seals is strongly recommended. Before starting the cylinder assembly procedure, all
parts should be thoroughly cleaned and dried, and/or prelubricated with clean hydraulic fluid.
Prepare the work area beforehand to maintain cleanliness during the assembly procedure.
NOTE: Assemble subassemblies of

cylinder in the following order:
1. Cylinder body
2. Piston rod
3. Piston assembly
4. Cylinder head assembly
1. Assemble pin bushing (1) to piston rod
(13) and body of cylinder (14).
Figure 29
2. Following the assembly of rod cover
components, install dust wiper (2) and rod
bushing (6) to rod cover (9). Insert
retaining rings (3 and 8).
Figure 30
Cylinders S0705000
Page 37
3. Prelubricate O-rings and seals before
assembly (Figure 31).
Figure 31
4. Before starting to rebuild piston assembly,
heat slipper seal for 5 minutes in an oil
bath warmed to 150°-180°C (302°-356°F).
Use special slipper seal jig (third item in list
of specialized tools at the beginning of this
procedure) to attach seal. Cool seal by
pushing a retracting jig against seal for
several minutes. Apply a strip of clean,
see-through sealing tape around slipper
seal to keep it free of dust.
Figure 32
5. Immobilize piston rod on solid support
blocks. Assemble O-ring (20) and backup
ring (21). Prepare to attach rod cover
assembly to piston rod. Push rod cover by
tightening piston nut (22).
Figure 33
6. Assemble cushion ring (15) and attach
piston assembly to piston rod.
Figure 34
S0705000 Cylinders
Page 38
7. Use specially fabricate or factory sourced
tool to tighten piston nut (22).
Figure 35
8. Assemble wear ring (18), slide ring (17)
and set screw (23) to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 36
9. Immobilize body of cylinder before
assembly.
Figure 37
10. Preapply fastener locking compound
(Loctite #242 or #243 or an alternate
manufacturer's equivalent product) to all
end cover retaining bolts. Wrap a
protective cushion around end of rod while
tightening fasteners, to prevent possible
damage to polished surface of rod, should
a wrench slip during retightening.
Figure 38
Cylinders S0705000
Page 39
S0707355K
1TRAVEL MOTOR
(WITH GEARBOX)
CAUTION!
TRAVEL MOTOR (WITH GEARBOX)S0707355K


December 2002
Travel Motor (with Gearbox) S0707355K

Page 1
TABLE OF CONTENTS
Travel Motor Assembly and Parts List ............................................................ 4

Travel Motor Major Components and Parts List ............................................. 7
Components............................................................................................ 7
Characteristics ........................................................................................ 7
Axial Piston Motor Major Components and Parts List .................................... 8
Travel Motor Theory of Operation................................................................... 9
Counter Relief Operation ........................................................................ 9
Braking .................................................................................................. 10
Parking Brake Operation ....................................................................... 10
Two Speed Transmission ...................................................................... 11
S0707355K Travel Motor (with Gearbox)

Page 2
Page 3
TRAVEL MOTOR ASSEMBLY AND PARTS LIST
Figure 1

Page 4
Reference Reference
Number Number
1 Gearbox 1 8 Collar 1
1-1 Housing 1 9 Spring 1
1-2 Flange Holder 1 10 Collar 1
1-3 Bearing, Angular 1 11 Retaining Ring 1
1-4 Seal, Floating 1 12 Pin 3
1-5 Seal Collar 1 13 Holder, Retainer 1
1-6 Pin 1 14 Plate, Retainer 1
1-7 15 Piston Assembly 9
1-8 Ball, Steel 105 16 Pin 2
1-9 Plug 2 17 Piston, Brake 1
1-10 Ring Nut 1 18 Disc 1
1-11 Plug 4 19 Piston Assembly ?
1-12 Holder (S/A) 1 19-1 Piston 1
1-12-1 Holder (A) 1 19-2 Shoe Assembly 1
1-12-2 Gear, Planetary A 3 20 Spring 2
1-12-3 Bearing, Needle 3 21 Spring 10
1-12-4 Race, Inner 3 22 O-ring 1
1-12-5 Thrust Washer 3 23 Backup Ring 1
1-13 Gear, Planetary B Kit 4 24 O-ring 1
1-13-1 Gear, Planetary B 1 25 Valve Plate 1
1-13-2 Bearing, Needle 1 26 Pin 1
1-13-3 Bushing (Floating) 1 27 Ball Bearing 1
1-13-4 Thrust Washer 1 28 O-ring 1
1-14 Thrust Plate 1 29 O-ring 2
1-15 Screw 4 30 Plate, Base 1
1-16 Drive Gear 1 31 Plunger Assembly 1
1-17 Sun Gear 1 31-1 Plunger 1
1-18 Retaining Ring 1 31-2 Check Valve 2
1-19 Thrust Plate 1 31-3 Spring 2
1-20 Spring Pin 3 31-4 Plug 2
1-21 Cover 1 31-5 O-ring 2
1-22 O-ring 1 32 Backup Ring 1
1-23 Plug 3 36 Spring Seat 2
1-24 Wire 1 37 Spring 2
1-25 Plug 1 38 Cap 2
1-26 Plug 2 39 O-ring 2
2 Shaft 1 40 Orifice 2
3 Ball Bearing 1 41 Spool 1
4 Oil Seal 1 42 Spring 1
5 Swash Plate 1 43 Plug 3
6 Ball, Steel 2 44 O-ring 4
7 Cylinder Block 1 45 Plug 3

Page 5
Reference Reference
Number Number
46 Plug 1 50-2-12 Backup Ring 2
47 Orifice 4 50-2-13 Shim 3
48 Bolt, Sch. 10 50-2-14 Shim 3
49 Pin 2 50-3 O-ring 3
50 Block Assembly, Relief 1 50-4 O-ring 2
50-1 Valve Body 1 50-5 Bolt, Sch. 4
50-2 Relief Valve Assembly 2 50-6 Plug 2
50-2-1 Housing, Relief 1 51 Name Plate 1
50-2-2 Poppet 1 52 Screw, Drive 2
50-2-3 Poppet Seat 1 53 Plug, Shipping 2
50-2-4 Spring Seat 1 54 Plug, Shipping 1
50-2-5 Spring 1 55 Plug 1
50-2-6 Plug 1 60 Seal Kit 1
50-2-7 O-ring 1 61 Seal Kit 1
50-2-8 O-ring 1 62 Cylinder Block 1
50-2-9 Backup Ring 2 Assembly
50-2-10 Piston, Free 1 63 Plate, Base Kit 1
50-2-11 O-ring 1 64 Thrust Plate Set 1

Page 6
TRAVEL MOTOR MAJOR COMPONENTS AND PARTS
LIST
COMPONENTS
The travel motor is an axial piston motor with a speed reducer inside. The travel motor has 6 main sections.
They are the axial piston motor, counter control valve, cross over relief valve, 2 speed transmission,
parking brake, and speed reducer. The motor changes the fluid energy of the oil from the pump into
mechanical energy, and passes high speed torque power to the speed reducer. See Figure 2
CHARACTERISTICS
The motor is made small and light by combining the motor and the speed reducer.
A counter adjustment valve makes it possible to control the speed with which oil is supplied and to prevent
reverse rotation of the motor. The counter adjustment valve and relief valve are installed in the brake
circuitry.
The relief valve also functions as a cushion to allow smooth stops and starts.
Figure 2
Reference Reference
Number Number
1 Axial Piston Motor 4 Parking Brake
2 Speed Reducer 5 Cross Overload Relief Valve
3 Counter Control Valve 6 Travel 2 Speed Transmission‘

Page 7
AXIAL PISTON MOTOR MAJOR COMPONENTS AND
PARTS LIST
The cylinder block consists of 9 pistons. The block's end surface is connected to the plate. When oil under
high-pressure (P) goes to the B port, the piston pushes the plate with power F=P A (A : piston pressure
surface). At the same time, the counter pressure against the piston generates rotation power to turn the
shaft. See Figure 3
Figure 3
Reference Reference
Number Number
1 Shaft 4 Cylinder Block
2 Rotation Angle Plate 5 Valve Plate
3 Piston

Page 8
TRAVEL MOTOR THEORY OF OPERATION
When the control valve is operated, as shown in
Figure 4, oil from the hydraulic pump goes to the
P1 port or to the brake valve. After the oil in the
P1 port opens the check valve installed in the
plunger, it passes through the M1 port into the
motor. This oil attempts to rotate the hydraulic
motor and although it flows into the M2 port, it is
stopped because of the check valve. As a result,
pump output pressure increases. On the other
hand, the hydraulic oil that gets its pressure from
the P1 port goes to the plunger end's surface
through the orifice and pushes the plunger up in
the direction of the arrow in Figure 4. When
pressure from port P1 is greater than the spring
set pressure, the plunger moves up and oil from
the M2 port passes by the notch of the plunger's
outer circumference. The oil then passes the P2
port and control valve and returns to the tank. As
a result, the hydraulic motor starts its rotation.
Figure 4
Also, if the pressure in the P1 port increases, the
plunger moves, the cross over is opened, and the
hydraulic motor has no pressure.
COUNTER RELIEF OPERATION

When the hydraulic motor's rotation is too fast,
the amount of hydraulic oil from the M1 port
becomes higher than the amount of oil that
leaves through the M2 port when the hydraulic
motor is pumping. Pressure in the P1 port then
decreases and the spring power becomes
stronger than the plunger end's surface pressure.
The plunger moves down and the notched part of
the plunger's outer circumference crosses over.
As a result, the M2 port generates pressure
which slows down the hydraulic motor's rotation.
See Figure 5
When the hydraulic motor's rotation slows down,
pressure in the P1 port increases and the
hydraulic motor starts moving because of the oil
that passes through the control valve. At this time,
because the pressure in the P1 port increases,
Figure 5
the plunger moves up and the notched part of the
plunger's outer circumference opens. The
pressure in the M2 port decreases and inner
pressure stops. Pressure is generated from the
notched part of the plunger's outer circumference
and the hydraulic motor moves at the appropriate
speed.

Page 9
BRAKING
When the control valve is in neutral. oil flow from
the hydraulic pump stops. The pressure of port
P1 and P2 is the same. The plunger moves to the
neutral position due to spring power. The notched
part of the plunger's outer circumference is
closed. See Figure 6
The inertial energy of the hydraulic motor makes
it work as a pump to increase pressure in the M2
port. The relief valve starts working because of
this pressure and pushes the hydraulic oil to the
M1 port. This absorbs the shock pressure caused
by the inertial energy of the M2 port. At the same
time, this prevents cavitation in the M1 port.
Figure 6
PARKING BRAKE OPERATION
The parking brake consists of a friction plate,
piston and spring. The cylinder block and the
friction plate are connected with the spool line.
The friction plate generates frictional force using
a spring. See Figure 7
When oil flows into the motor, the relief port of the
parking brake is opened. This oil pushes the
spring which in turn pushes the friction plate and
releases the brake. When the excavator is
parked, the relief port of the parking brake is
closed and oil in the brake chamber is drained to
the housing. The brake then works by spring
power.
Figure 7

Page 10
TWO SPEED TRANSMISSION
Low Speed
The angle plate is supported by 3 surfaces (1, 2,
and 3). Its position is changed by 2 scale balls.
See Figure 8
In first gear, the spool is moved by a spring to the
position shown. Ports Pi1 and Pi2 of the angled
plate control piston are connected. Therefore, the
power (Fp) that presses the angled plate control
piston does not operate. At this time, the
momentum (•"F + Fs1) | 1 becomes larger than
the momentum (•"Fpi + Fs2) | 0 that operates
each piston. As a result the motor moves at a
slow speed.
Figure 8

Page 11
High Speed
When the travel 2 speed transmission switch is turned on, pilot pressure moves the spool as shown in
Figure 9. Oil flows to ports M1, M2, Pi1 and Pi2. The motor power (P1 : high-pressure, P2 : low-pressure)
passes to each angled plate control piston. As a result, in the angled plate control piston, power (Fp1 =
Ap.p1, Fp2 = Ap.p2) is generated to press against the angled plate.
At that time, the momentum (•"F + Fs1) | that influences the angled plate becomes smaller than the
momentum (•"Fpi + Fs2) | 0. So the angle reaches its maximum and the motor moves at a higher speed.
Figure 9

Page 12
S0707380
1SWING MOTOR
CAUTION!
SWING MOTOR S0707380


January 2004
Swing Motor S0707380

Page 1
TABLE OF CONTENTS
Swing Motor ................................................................................................... 3

Motor ....................................................................................................... 3
Valve Casing ........................................................................................... 4
Relief Valve ............................................................................................. 4
S0707380 Swing Motor

Page 2
SWING MOTOR
MOTOR
As shown in Figure 1, high pressurized oil flowing into cylinder through intake port of valve plate (1) will
enable pistons to have hydraulic oil pressure, thus making it possible for the axle direction to have force F.
This force F will be divided through shoe (2) into force F1 in a vertical direction against the tilting plate (3)
and force F2 in a right angle against the axle. Force F2 will be transferred to cylinder block (4) through
piston, resulting in having the drive axle generate revolution force. Cylinder block has 9 pistons which are
installed geometrically: a series of pistons linking to the port which high pressurized oil enters will deliver
torque to the drive axle.When the intake direction of actuation oil is reversed, the revolution direction of
drive axle will become reversed.
Theoretical output torque T is computed with equation listed:
p = Pressure difference of effective oil (kg/cm2)

q = Quantity per revolution (cc/rev)
T= pxq
200π
Figure 1

Page 3
VALVE CASING
Revolution motor has no valve that has
counterbalancing function. For this reason, it
tends to revolve more speedily than the flow of
oil supplied to the motor. therefore, it has anti
cavity check (makeup) valve, thus supplying oil
to make up for oil insufficiency and thus
preventing cavitation which may arise from
insufficiency of supplied oil.
Figure 2
RELIEF VALVE
Figure 3
When ports is pressurized by the pressure of tank, ports P and R will stand on the situation as shown in
Figure 3, and relief will remain on actuation, until the pressure of tank, affecting spring force and the
pressurized area (A1), becomes equal to pressure (Pg) of plunger g. At this time, pressure, Pg, will go out
through orifices m and n, and then pressure of plunger g will decrease. This will result in having pistons
begin to move the right side and reach the set pressure.
P1 x A1 = Fsp + pG x A2
P1 = Fsp x Pg x A2
A1
A1: Pressurized area

Fsp: Spring force
Pg: Spring force
A2: Pressurized area

Page 4
Movement of Piston 302 towards the right side will bring braking effect to plunger h, while pressure of
plunger g will increase until a piston reaches the end of the body.
Figure 4
When a piston reaches the body, then pressure

of plunger g will rise to Ps. Pressure Ps will
change as shown in Figure 6. Pressure Ps at a
final stage:
Ps x A1 = Fsp = Ps x A2
Ps = Fsp
A1 - A2
Figure 5
Figure 6

Page 5
TROUBLESHOOTING
Symptoms Probable Causes Checks and Remedies Remedies

No revolution. Broken parts inside Check drainage - total Repair or replace broken
motor. quantity of oil supplied parts. Readjust to the
is almost equal to rated pressure.
drainage.
Defective set pressure Check load pressure, Disassemble and check,
of relief valve. using pressure gauge. if drainage exceeds 5
liters per minute.
Excessive slip. Abrasion or breakage Measure drainage. Readjust to rated
of motor components pressure.
and moving parts and/
or high-pressure
sealing areas.
Large quantity of oil Check oil temperature. Repair or replace broken
leakage from inside of parts.
motor due to high
temperature of oil.
Excessive slip. Abrasion and burnout Measure drainage - Readjust to the rated
of motor components total quantity of oil pressure.
and moving parts. supplied is almost equal
to drainage.
Defective set pressure Check load pressure, Repair or replace broken
of relief valve. using pressure gauge. parts.
Insufficient torque. Abrasion and seizure Check drainage - the Readjust to rated
motor components total quantity of oil pressure.
and moving parts. supplied is almost equal
to drainage.
Defective set pressure Check load pressure, Repair or replace
of relief valve. using pressure gauge. damaged parts.
Abnormal noise. Broken parts inside Check drainage and Execute deflation.
motor. foreign metal objects.
Incorporation of large Check oil inside tank Tighten to rated torque.
quantity of air. and motor case.
Loose joining parts. Check connecting Repair or replace
areas. damaged parts.
Abnormal heat. Burnout of motor Check drainage and Replace oil seals.
components and foreign metal objects.
moving parts circuit.
Oil leakage. Damaged oil sealing Replace seals when
areas. exceeding the rated valve
- Check and repair.
Abnormal pressure Measure pressure Replace damaged parts,
inside the case. inside case: 3 kg/cm2 if excessive.
(42 psi) or below -
Measure drainage.

Page 6
S0708375K
1MAIN PUMP
(REXROTH)
CAUTION!
MAIN PUMP (REXROTH)S0708375K


December 2002
Main Pump (Rexroth) S0708375K

Page 1
TABLE OF CONTENTS
A10 V(S)O pressure, flow and power control DFLR....................................... 4

Ports........................................................................................................ 4
Circuit Diagram ....................................................................................... 5
Function and Circuit Diagram.................................................................. 6
Function Power Control........................................................................... 8
Integrated Orifice and Damping Orifice................................................... 9
Measurement of High-pressure............................................................. 10
Adjustment of DR, FR and LR - Control................................................ 11
Adjustment of Power Control................................................................. 12
Hints for Assembling / Disassembling of the LR Valve.......................... 13
Usage of DFLR - SO128 with LUDV Mobile Blocks .............................. 14
DFLR-SO128, High-pressure Support and X-port ................................ 16
DFLR - SO 128 Pilot PRessure Port X.................................................. 17
Section ......................................................................................................... 18
Spare Parts Kits ........................................................................................... 19
Sealing Kits / Spare Parts Kits ..................................................................... 20
Sealing the Drive Shaft................................................................................. 22
Disassembly and Assembly of the Complete Unit........................................ 24
Spare Parts Kit: A10 Control Valve DFR ...................................................... 32
General Directions ................................................................................ 32
Spare Part Kit........................................................................................ 32
Fitting Note of the Control Valve - Devices............................................ 33
A10 Control Valve DFR of Pump Size 140 ................................................... 36
Disassembling and Cleaning the Control Valve............................................ 38
List / Adjustment of Taper Roller Bearing Set............................................... 43
List......................................................................................................... 43
Mechanical Flow Limiter (both stopper max. and min. flow) .......... 43
Taper Roller Bearing initial Tension....................................................... 43
Testing and set up instructions ..................................................................... 45
Tools / Auxiliary Tools / Tightening Torques ................................................. 46
S0708375K Main Pump (Rexroth)

Page 2
Tightening Torques................................................................................ 47
Installation of Pump Dump Orifice on A10 ................................................... 48
A10, S0128 regulator, orifice of for speed of backstroking of pump...... 52

Page 3
A10 V(S)O PRESSURE, FLOW AND POWER CONTROL
DFLR
PORTS
Figure 1 VIEWED A10VO, SERIES 31, CLOCKWISE
Reference Reference
Number Number
1 Power Control LR 5 Flow Control FR (•ƒp=10-22
2 Case Drain Port L bar)
Standard Setting: •ƒp=18 bar
3 Pressure Port B
6 X-Port (with Integrated Orifice
4 Pressure Control DR
(in Adapter)
Standard Setting:
A10V(S)O DFLR/31: 280 bar 7 Suction Port S

Page 4
CIRCUIT DIAGRAM
Figure 2 VIEWED FOR A10VO, SERIES 31
Reference Reference
Number Number
1 Power Control 6 Pressure Control
2 Main Control Valve (Standard: p=280 bar)
3 X-Port 7 Damping Orifice
4 Orifice 8 Control Piston
5 Flow Control 9 Counter Balance Piston and
(Standard: •ƒp=18 bar) Spring

Page 5
FUNCTION AND CIRCUIT DIAGRAM
Figure 3
Reference
Description
Number
1 Orifice res. Mobile Valve Block
2 LS Pressure or LS-Signal of Mobile
Valve Block
3 Orifice

Page 6
Figure 4
Reference Reference
Number Number
1 Spool for Power Control 7 Spring for Power Control
2 Orifice 8 Spring for Pressure Control
3 Spool for Flow Control 9 Spring for Flow Control
4 Servo Piston 10 Orifice res. Mobile Valve Block
5 Swash Plate 11 LS Pressure or LS-signal of
6 Center Pin Mobile Valve Block

Page 7
FUNCTION POWER CONTROL
Figure 5
Reference
Description
Number
1 Adjustable Spring Package of Power Control Valve
2 Eccenter
3 Cradle position i. e. displaced volume) will be restored by the eccenter
Prestress of the spring package will be changed by the eccenter
Thereby the opening pressure of the power control valve has been changed
Small swivel angle °Êhigh-pressure
Large swivel angle °Êlow-pressure

Page 8
INTEGRATED ORIFICE AND DAMPING ORIFICE
Figure 6
Reference
Description
Number
1 With Integrated Orifice in Adapter
2 Damping Orifice DR-FR
(Standard: ø 0.6 mm (0.02 in),
Slit in Longitudinal Direction: Orifice Opened
Slit in Cross Direction: Orifice Closed, SO 74)

Page 9
MEASUREMENT OF HIGH-PRESSURE
Figure 7
Reference
Description
Number
1 Measurement of High-pressure:
At this particular spot, the existing plugs (M8 x 1) can be
replaced by mini measurement connections.
NOTE: The mini - measurement connection have to be shortened according to the original length
of the plug {reach of a screw 7 mm (0.28 in)}.

Page 10
ADJUSTMENT OF DR, FR AND LR - CONTROL
Figure 8
Reference
Description
Number
1 Adjustment of Power Control
2 Adjustment of Pressure Control
3 Adjustment of Flow Control: "Stand-by" pressure measurement or
differential pressure measurement with semi swivel angle!
4 Valve axis: Flow Control
5 Valve Axis: Pressure Control

Page 11
ADJUSTMENT OF POWER CONTROL
Figure 9
Reference
Description
Number
1 End of control is adjustable by the second inner spring, clearance at
fully displaced volume (100% Vg)
2 Start of control is adjustable by the first outer spring, prestressed at
fully displaced volume (100% Vg)
3 Point of action of the second inner spring
4 Start of Control!
NOTE: Different spring packages are necessary in order to realize various characteristic curves

Page 12
HINTS FOR ASSEMBLING / DISASSEMBLING OF THE LR VALVE
Figure 10
Reference
Description
Number
1 Loosing the plug
2 By pushing the spring, the eccenter will be relieved
Assembling i.e. disassembling of the power control valve
3 Bushing
4 Eccenter Pin
NOTE: Adjustment of power control valve is unchanged!

Page 13
USAGE OF DFLR - SO128 WITH LUDV MOBILE BLOCKS
Figure 11
Reference
Description
Number
A Design of SO 128 (G-controller spool):
-DFLR - SO128, using the LUDV mobile valve block:
• M6-15 (RE 64284),
• M7-22 (RE 64287),
• SX 14 (RE Data sheet in prep.),
• SX 18 (RE 64127)
1 Axis FR 1 (G-controller spool) is used for LR-control (High pressure support
via valve spool)
2 Axis FR 2 is used for LS - signal, realized via 2. pilot pressure port X.
NOTE: DR axis was replaced by FR 2 axis, thereby the pressure cut off has to be realized via
LUDV mobile block!

Page 14
Figure 12
Reference
Description
Number
A Viewed: Detail of Mobile Valve
Block M6-15)
B Viewed: DFLR-SO128
(G - Controller Spool):)
1 Pump Line
2 LS-signal
3 Pressure Relief Valve

Page 15
DFLR-SO128, HIGH-PRESSURE SUPPORT AND X-PORT
Figure 13
Reference
Description
Number
1 High pressure support by drilled valve spool
(Q=f(d, •ƒp, v))
2 Pilot pressure port X for LS-mobile valve
block
NOTE: Pilot Oil Consumption

DFLR - SO128 Valve: approx. 3 - 5 liters (0.79 - 1.3 U.S. gal.)

Page 16
DFLR - SO 128 PILOT PRESSURE PORT X
Figure 14
Reference
Description
Number
1 Pilot Pressure Port X

Page 17
SECTION
Figure 15
Reference
Description
Number
1 Size 100 and 140 with stopper min
flow adjustable mechanically
Figure 16

Page 18
SPARE PARTS KITS
Sealing set completely (sealing sets are based
on the type of the pump, picture shows for
example A 10 VSO DFR, without pilot valve
seals). Sealing material: drive shaft sealing ring
FPM, others NBR.
BJS0140L
Figure 17
Same like K1, see picture on top. Only
difference: all material FKM
BJS0140L
Figure 18
Drive shaft: our spare part supply offers you the
following drive shaft types:
ISO - key design, SAE key design, SAE splined
design
BJS0150L
Figure 19

Page 19
Contents of kit "bearing set / miscellaneous
parts": 2 tapered roller bearings, 2 bearing
shells, adjustment shim, spacer shim, plugs,
cylindric pin to fix the valve plate.
BJS0160L
Figure 20
We offer the rotary group completely with its
cylinder with mounted pressure - pins for cw or
ccw rotating units (pls order your direction of
rotation).
BJS0170L
Figure 21
SEALING KITS / SPARE PARTS KITS

We offer swash plates for cw or ccw rotating
units in the serial design or for horse power
controlled pumps by our spare part service.
(Order your direction of rotation)
BJS0180L
Figure 22

Page 20
Figure 23 shows the control device parts without
the stopper parts. Order with stopper parts if
necessary.
BJS0190L
Figure 23
Order a checked and pre adjusted pilot valve to
control the pump for pressure compensator and
flow control. Easy handling is possible to
convert the design of the pilot valve. (Figure 24
shows valve of pump size 18.100; size 140 must
have valve size 6 - see Figure 26)
BJS0200L
Figure 24
Pilot valve design 18 - 100:
Adapter without orifice of the DFR - pilot valve, if
you use a metric pilot pipe connection X.
BJS0210L
Figure 25
Figure 26 shows the pressure compensator
disassembled as a sandwich valve (of pump
size 140). Mount on top of the pressure
compensator housing the valve housing for the
flow control.
BJS0220L
Figure 26

Page 21
SEALING THE DRIVE SHAFT
NOTE: This description shows how to change the drive shaft sealing ring but it isn't the way of
serial assembly. The sealing ring is assembled together with the taper roller bearing from
inside the pump housing normally to get a secure sealing condition. If you decide to repair
the pump in the shown way be very careful while handling so that the drive shaft wouldn't
be damaged during disassembly of the shaft sealing ring.
Disassemble of the key.
BJS0230L
Figure 27
Remove the retaining ring.
Grind screwdriver to disassemble the shaft
sealing ring carefully. Pay attention: Damages of
the drive shaft indicate leakage.
BJS0240L
Figure 28
Change the shaft seal and check the contact
surfaces (drive shaft and housing), grease
sealing ring before mounting.
BJS0250L
Figure 29

Page 22
Use installation tool for the sealing ring (see too
list on top).
BJS0260L
Figure 30
Use a suitable pipe or use the control piston of a
bigger pump size to mount the shaft seal ring
via the installation tool, but do not push it too
deep. If the shaft seal ring touches the bearing
ring you will damage the seal ring.
BJS0270L
Figure 31
Assemble the retaining ring.
BJS0280L
Figure 32
Assemble the retaining ring. Assemble the key
next by using a plastic hammer. This handling
isn't shown in pictures.
BJS0290L
Figure 33

Page 23
DISASSEMBLY AND ASSEMBLY OF THE COMPLETE
UNIT
This manual shows the handling of size 45. If
necessary changes to the other pump sizes are
shown separately.
Disassemble the pilot valve.
BJS0300L
Figure 34
Mark position of the port plate to pump housing
and remove socket screws of the port plate.
BJS0310L
Figure 35
Remove the port plate together with the valve
plate and control device parts (hold the valve
plate so that the plate can't fall down).
BJS0320L
Figure 36

Page 24
Disassemble taper roller bearing and
adjustment shim.
BJS0330L
Figure 37
Disassemble the rotary group.
BJS0340L
Figure 38
Remove the O-ring.
BJS0350L
Figure 39
Disassemble bearing shells.
BJS0360L
Figure 40

Page 25
Use bearing puller to remove outer bearing race
of front bearing.
BJS0370L
Figure 41
Remove the control plate.
BJS0380L
Figure 42
Use bearing puller to remove outer bearing race
of rear bearing.
BJS0390L
Figure 43
Remove the O-rings.
BJS0400L
Figure 44

Page 26
Disassemble the head nut of threaded pin.
BJS0410L
Figure 45
Disassemble the hexagon fixing nut and the
threaded pin.
BJS0420L
Figure 46
Disassemble the guide of control piston
(Mounting position: pilot valve side).
BJS0430L
Figure 47
Disassembly the guide of opposite piston.
BJS0440L
Figure 48

Page 27
Pull out the drive shaft.
BJS0450L
Figure 49
Remove the piston and the retaining plate.
BJS0460L
Figure 50
Remove the retaining ball.
BJS0470L
Figure 51
Compress the center spring in order to
disassemble the retaining ring (easy handling by
a helping bolt and shims).
BJS0480L
Figure 52

Page 28
Disassemble the retaining ring.
BJS0490L
Figure 53
Remaining parts of the cylinder: pins, cylinder,
shim, spring and retaining ring.
BJS0500L
Figure 54
Taper roller bearing in the cast iron pump
housing must have a initial tension with
0.......0.05 mm (0.002 in). See “Taper Roller
Bearing initial Tension” on page -43.
NOTE: Assemble the pump in reverse
order and note the following.
(Figure 55 thru Figure 62)
BJS0510L
Figure 55
Port plate (direction if rotation clockwise): Both
piston guides are glued with Loctite.
- Correct position of the valve plate (clockwise
4°): In case of series 31 the valve plate only can
be installed into the correct position.
- Grease O-rings before assembly.
BJS0520L
Figure 56

Page 29
Port plate (direction of rotation counter
clockwise): Both piston guides are glued with
Loctite.
- Correct position of the valve plate (counter
clockwise 4°): In case of series 31 the valve
plate only can be installed into the correct
position.
- Grease O-rings before assembly.
BJS0530L
Figure 57
Correct position of cradle (lubrication bore relief
on the high-pressure side), use cradle for
clockwise rotation, if counter clockwise use
cradle for counter clockwise rotation (two
different sub - assemblies).
BJS0540L
Figure 58
If it is possible to lap the cradle (sliding area of
the piston shoes) it can be possible to use the
cradle again. Notice: It is not allowed to press
out the piston connection parts out of the cradle
(scoring while fitting!)
BJS0550L
Figure 59
Connection surfaces between valve plate and
cylinder: if lapping is possible use parts again,
but after lapping procedure use a lapping paper
No. 1000 to plan the cylinder and valve plate
(plain underground totally is a must).
BJS0560L
Figure 60

Page 30
Check running conditions of the control piston.
BJS0570L
Figure 61
Check running conditions of the opposite piston.
BJS0580L
Figure 62

Page 31
SPARE PARTS KIT: A10 CONTROL VALVE DFR
GENERAL DIRECTIONS
Brueninghaus modernized the spare parts service of A10 products so that you will get spare parts much
more easily. The advertising folder RD 90124 "A10-spare part-service" gives you more information. This
pamphlet out of the spare part kit "control valve: pressure compensator and flow control DFR" show on its
backside: how to change the design to the most common type of the control valve in an easy way.
Please note: The valve must be marked with the original number after its change.
This valve will be delivered only in the Viton execution (spare part No.942 581).
Preadjustments:
DR-pressure compensator: approximately 280 bar (4,061 psi)
FR-flow control: •ƒp approximately 14 bar (203 psi)
SPARE PART KIT
1
X
3
4
BJS0980L
Figure 63
Number Description Remark

1 Plug Loctite: No. 242
2 Plug Tightening Torque:
20 Nm (15 ft lb)
3 Screws Tightening Torque:
12 Nm (9 ft lb)
4 O-ring

Page 32
FITTING NOTE OF THE CONTROL VALVE - DEVICES
Pressure compensator and flow control
DFR MA:21Nm
1 X MA:30Nm
One X - Port is plugged by Pos. 4.
orifice 0,6mm
BJS1290L
Figure 64
1 X
DFR-SO74
Orifice 0.6 mm in closed position.
BJS1300L
Figure 65

Page 33
DFR 1
Decompression orifice X-T is plugged by
Pos. 5.
BJS1310L
Figure 66
Pressure compensator DR
X
Both X - Ports are plugged by Pos. 4.

Flow control blocked.
BJS1320L
Figure 67

Page 34
Pressure compensator DR-SO74
1 X
Both X - Ports are plugged by Pos. 4.
Flow control blocked, orifice 0.6 mm
(0.02 in) in closed position (turn 90°)
BJS1330L
Figure 68

Page 35
A10 CONTROL VALVE DFR OF PUMP SIZE 140
BJS0990L
Figure 69 FR

Page 36
BJS1000L
Figure 70 DR

Page 37
DISASSEMBLING AND CLEANING THE CONTROL
VALVE
Loosen socket screws. (See “Spare Part Kit” on
page -32.)
BJS0770L
Figure 71
Remove the O-rings.
BJS0780L
Figure 72
Blow out the pulsations orifice by air pressure
out of the complete valve: pressure at drilling A,
close drilling T. Note that there is no skin
connection during blowing, look how the orifice
comes out before blowing!
BJS0790L
Figure 73

Page 38
Remove the hex nuts. First disassemble
pressure control, afterwards flow control.
BJS0800L
Figure 74
Loosen the lock nut and unscrew threaded pin.
BJS0810L
Figure 75
Disassemble the plug.
BJS0590L
Figure 76
Remove the spring collar.
BJS0600L
Figure 77

Page 39
Remove the springs.
BJS0610L
Figure 78
Remove the spring cup.
BJS0620L
Figure 79
Disassemble the plug.
BJS0630L
Figure 80
Be careful while disassembling the piston.
BJS0640L
Figure 81

Page 40
Disassemble the plug or orifice (spring area of
flow control).
BJS0650L
Figure 82
Clean housing and parts with clean fluid and dry
with air carefully.
BJS0660L
Figure 83
Check the opening of the orifice.
NOTE: Assemble pilot valve in reverse
order and note the following
(Figure 84 thru Figure 87).
BJS0670L
Figure 84
Be careful when Loctiting the orifice.
BJS0680L
Figure 85

Page 41
Check the movement of the pilot valve spools,
and drillings should not be damaged.
BJS0690L
Figure 86
Adjustments of the bypass orifice (See “Fitting
Note of the Control Valve - Devices” on
page -33.)
1. Open position of the orifice: like shown on
the picture
1. Turn the orifice 90° to close it.
BJS0700L
Figure 87
For adjustment of the pilot valve see set up
instructions (See “Testing and set up
instructions” on page -45.)
Pilot valve of pump size 140 doesn't have own
instructions. However see the given hints on top.
(See “A10 Control Valve DFR of Pump Size
140” on page -36.)
BJS0710L
Figure 88

Page 42
LIST / ADJUSTMENT OF TAPER ROLLER BEARING
SET
LIST
Mechanical Flow Limiter (both stopper max. and min. flow)
Size 18 28 45 71 100* 140*

1.09 1.58 3.23 4.69 6.16 7.06
You are rotating the threaded pin - each rotation.
* mech. stopper min. flow adjustable
TAPER ROLLER BEARING INITIAL TENSION

Note for size 18 and 28:
The small pump sizes have to be measured by using a special shim- Pos. 12- with its tolerance of
1.5°æ0.01, see detail X. This shim will be disassembled after the measurement. Measurement, thickness
of the special shim and necessary pretension all together makes the thickness of the adjustment shim
(Pos. 12).
BJS1010L
Figure 89

Page 43
special shim
BJS1020L
Figure 90 Detail X
Cast iron housing must have initial tension of the bearings: 0.......0.05 mm (0.002 in), grind Pos. 12 if
necessary.

Page 44
TESTING AND SET UP INSTRUCTIONS
DR: When pressure line is closed adjust the
pressure of the controller (if it's DFR design then
open the adjustable orifice and increase force of
the FR - spring).
BJS0720L
Figure 91
FR: If swivel angle is in the mid position adjust
differential pressure 14 bar (adjustable orifice in
the system pressure line is partly closed).
BJS0730L
Figure 92
Mechanical flow limiter: While screwing in the
threaded pin you will be able to reduce the flow
from Vg max to 35% reduction of Vg max
dependent on the size of the pump (If you need
more reduction of the flow, do not mount the
fixing hex nut. Note: to adjust the threaded pin
without the fixing hex nut do it by the existence
of the working pressure.) Adjustment list (See
“List / Adjustment of Taper Roller Bearing Set”
on page -43.)
BJS0740L
Figure 93

Page 45
TOOLS / AUXILIARY TOOLS / TIGHTENING TORQUES
For break-off plugs, normally
Figure 94 BJS0750L

Page 46
TIGHTENING TORQUES
Bolt hardness grade: 8.8; 10.9; 12.9
BJS0760L
Figure 95
Nm (ft lb) = max. tightening torques (screws lubricated µ = 0.125)
M4 M5 M6 M8 M10 M12
8.8 2.3 Nm 5 Nm 8.5 Nm 21 Nm 41 Nm 72 Nm
(2 ft lb) (4 ft lb) (6 ft lb) (16 ft lb) (30 ft lb) (53 ft lb)
10.9 3.2 Nm 7.2 Nm 12 Nm 29 Nm 58 Nm 100 Nm
12.9 4.1Nm 8.5 Nm 14.5 Nm 35 Nm 70 Nm 121 Nm
M14 M16 M18 M20 M24 M30

8.8 115 Nm 176 Nm 240 Nm 350 Nm 600 Nm 1220 Nm
10.9 165 Nm 250 Nm 350 Nm 490 Nm 840 Nm 1670 Nm
(122 ft lb) (184 ft lb) (258 ft lb) (361 ft lb) (620 ft lb) (1,232 ft lb)
12.9 195 Nm 300 Nm 410 Nm 590 Nm 990 Nm 2000 Nm
(144 ft lb) (221 ft lb) (302 ft lb) (435 ft lb) (730 ft lb) (1,475 ft lb)

Page 47
INSTALLATION OF PUMP DUMP ORIFICE ON A10
1. Remove rear plug.
Figure 96
2. Remove spool of regulator
Figure 97

Page 48
3. If spool is hard to remove, then unscrew
the regulator
Figure 98
4. Remove spool
Figure 99
5. Orifice M6 for limiting stroke speed of

pump
Figure 100

Page 49
6. Insert orifice in regulator
Figure 101
7. Tighten the orifice
Figure 102

Page 50
8. If necessary, reinstall regulator
Figure 103
Figure 104
9. Reinstall spool and rear plug
Figure 105

Page 51
A10, S0128 REGULATOR, ORIFICE OF FOR SPEED OF BACKSTROKING OF PUMP
Figure 106
Reference
Description
Number
1 Thread for orifice for pump
backstroke (ø0.8)

Page 52
S0709453K
1PILOT CONTROL
VALVE (WORK LEVER /
JOYSTICK)
CAUTION!
PILOT CONTROL VALVE (WORK LEVER / JOYSTICK)S0709453K


February 2003
Pilot Control Valve (Work Lever / Joystick) S0709453K

Page 1
TABLE OF CONTENTS
Structure .......................................................................................... 3
Function ........................................................................................... 3
Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Torques ............................................................................................ 6
Performance..................................................................................... 6
Removal ......................................................................................................... 7
Disassembly ................................................................................................... 9
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 13
Assembly...................................................................................................... 14
Installation .................................................................................................... 19
Start-up Procedures ..................................................................................... 20
S0709453K Pilot Control Valve (Work Lever / Joystick)

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
Structure
The remote control valve contains four push rods, spring holders, spools and return springs, which are
located in the valve casing. The valve works as a pressure reduction valve.
The housing has six ports, which include input port P, tank port T, and four secondary pressure ports.
The electric horn switch is installed in the valve handle. Gear pump pressure is used for operating control
spools.
Function
1. Neutral Mode
When the lever is in neutral mode, the spool is thrust upward by return spring, and the force of
balancing spring, which determines the secondary discharge pressure, is not transmitted to the
spool. The input port is closed and the pressure of the output port is the same as the pressure of the
tank port T.
2. Control Mode
When push rod is pushed, the balance spring begins to compress, and spring force is conveyed to
the spool. Ports P and T are then connected together and the pilot pressure is conveyed to the area.
Output pressure works on the bottom of the spool, thrusting the spool upward until it is balanced with
the power of the balance spring. The secondary pressure (output pressure), therefore, changes in
proportion to the compression force of the balance spring.

Page 3
PARTS LIST
30
29
28
26
27
23 25
24 14
13 20
19
22
18
21
12
17
11
31
8
15
10
16
9
36
32
33
7
34
35 6
1 2 3 5 4
ARS2260L
Figure 1

Page 4
Reference Reference
Number Number
1 Case 19 O-ring
2 Plug 20 Rod Seal
3 Plug 21 Plate
4 O-ring 22 Boot
5 O-ring 23 Joint Assembly
6 Spool 24 Swash Plate
7 Shim 25 Hex Nut
8 Spring 26 Handle Bar
9 Spring Seat 27 Nut
10 Spring 28 Boot
11 Stopper 29 Spring Pin
12 Stopper 30 Handle Assembly
13 Spring 31 Bushing
14 Push Rod 32 Terminal
15 Spring 33 Seal Wire
16 Spring Seat 34 Housing
17 Stopper 35 Holder Rear
18 Plug 36 Clip Band
SPECIFICATIONS
Pilot Control Valve Specification

Type Pilot Control
Pressure / Stroke 2
24.5 kg/cm @ 7.5 mm Stroke (348 psi @ 0.295 in Stroke)
Weight 4.8 kg (11 lb)

Page 5
Torques
Reference
Bolt Size Tool Torque
Number
2 PT 1/8 5 mm L-Wrench 150 kg•cm (11 ft lb)
3 PF 3/8 8 mm L-Wrench 500 kg•cm (36 ft lb)
24 M14 24 mm Spanner 1,240 kg•cm (90 ft lb)
Performance
(1,2,3,4)
40 40
SECONDARY PRESSURE (kg/cm )
2
OPERATING TORQUE (kg • cm)

24.5±1.5
(22.2)
17.6±3
OPERATING TORQUE
6.5±1 6.7±2
SECONDARY PRESSURE
1 7.5
0 2 4 6 8
PUSH-ROD STROKE(mm)
BJS1620L
Figure 2

Page 6
REMOVAL
WARNING!

accumulators.
controls.
11. Remove four bolts and washers (2, Figure
4) and cover (1). 1 2
12. Pull cap (5, Figure 4) out and remove two
screws, two bolts and washers (6) and 7 4
cover (3).
3
13. Remove three screws, one bolt and
washers (7, Figure 4) and cover (4).
6
5
ARS2910L
Figure 4

Page 7
14. Remove four bolts (3, Figure 5) and cover
(2), and pull remote control valve L.H. (1) 3
out.
15. Tag and disconnect hoses from remote 2
control valve L.H. (1, Figure 5). Plug and 1
cap hoses and ports to prevent
contamination from entering hydraulic
system or component.
ARS2920L
Figure 5
16. Remove four bolts and washer (2, Figure
6), and cover (2). 2
1
17. Pull cap (5, Figure 6) out and remove
screw, three bolts and washers (6) and
cover (3). 4
3
18. Remove two screws, two bolts and
washers (7 and 8, Figure 6) and cover (4).
6 7
5
8 ARS2930L
Figure 6
19. Remove four bolts (3, Figure 7) and cover

(2), and pull remote control valve R.H. (1) 3
out.
20. Tag and disconnect hoses from remote 2
control valve R.H. (1, Figure 7). Plug and 1
cap hoses and ports to prevent
contamination from entering hydraulic
system or component.
ARS2920L
Figure 7

Page 8
DISASSEMBLY
1. Lift up the boot (28) and pull the switch
cord through the hole in the case (1).
Figure 8
Figure 9
2. Loosen nut (27) from hex nut (25) and
remove handle assembly (30).
Figure 10

Page 9
3. Remove hex nut (25) and swash plate (24).
Figure 11
4. Remove joint (23) from case (1).
Figure 12
5. Remove plate (21).
Figure 13
6. Press spring (10) and remove plug (18).
Figure 14

Page 10
7. Remove pressure reduction valve (6, 7, 8,
9, 11) and spring (10).
IMPORTANT
Mark valve disassembling position
(port).
Figure 15
8. Remove plug (3) and four plugs (2).
Figure 16
9. Remove stopper (11) from pressure
reduction valve (6, 7, 8, 9, 11).
Figure 17
10. Remove spool (6), spring seat (9), spring
(8) and shim (7).
Figure 18

Page 11
11. Remove push rod (14) and plug (18).
Figure 19
12. Remove O-ring (19) from plug (18).
Figure 20
13. Remove seal (20) from plug (18).
Figure 21

Page 12
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
Clean all parts and dry them with compressed air. Keep all parts free from dust. Lubricate all moving parts.

Page 13
ASSEMBLY
1. Tighten plug (3) slowly.
NOTE: Tightening torque: 350 kg•cm
(25 ft lb).
Tighten four plugs (2).
NOTE: Use Loctite #592 pipe sealant
on plugs.
NOTE: Tightening torque 150 kg•cm
(11 ft lb).
Figure 22
2. Install shim (7), spring (8), spring seat (9),
and spool (6).
Figure 23
3. Press spring (9) and install stopper (11).
Figure 24

Page 14
4. Install spring (10) in case (1) and pressure
reducing valve assembly (6, 7, 8, 9, 11).
Figure 25
5. Install seal (20) on plug (18).
Figure 26
6. Install O-ring (19) on plug (18).
Figure 27
7. Install push rod (14) on plug (18).
Figure 28

Page 15
8. Install spring (13) on stopper (12).
Figure 29
9. Position stopper (12) and spring (13) on
pressure reducing valve.
Figure 30
10. Install plug (18) in case (1).
Figure 31
11. Install plate (21) and tighten joint (23).
Figure 32

Page 16
12. Install swash plate (24) on joint (23).
Figure 33
13. Install hex nut (25) and tighten swash plate
(24).
NOTE: Tightening torque 1,240 kg•cm
(90 ft lb).
Figure 34
14. Pull cord and tube out through hole of hex
nut (25).
Figure 35
15. Align the direction of handle (30) and
tighten hex nut (25) and nut (27).
NOTE: Tightening torque 1,240 kg•cm
(90 ft lb).
Figure 36

Page 17
16. Grease joint (23), swash plate (24) and
push rod (14).
Figure 37
17. Install boot (28).
Figure 38

Page 18
INSTALLATION
1. Connect hoses as tagged during removal
to remote control valve R.H. (1, Figure 39). 3
2. Position remote control valve R.H. (1,
Figure 39) on control stand and install four 2 1
bolts and washers (3) and cover (2).
ARS2920L
Figure 39
3. Install two screws, two bolts and washers
(7 and 8, Figure 40) and cover (4). 2
1
4. Install a screw, three bolts and washers (6,
Figure 40) and cover (3). Push cap (5) into
cover (3). 4
3
5. Install four bolts and washers (2, Figure
40) and cover (1).
6 7
5
8 ARS2930L
Figure 40
to remote control valve L.H. (1, Figure 41). 3
7. Position remote control valve L.H. (1,
Figure 41) on control stand and install four 2 1
bolts and washers (3), and cover (2).
ARS2920L
Figure 41

Page 19
8. Install three screws, one bolts and
washers (7, Figure 42), and cover (4). 1 2
9. Install two screws, two bolts and washers
(6, Figure 42), and cover (3). Push cap (5) 7 4
into cover (3).
3
10. Install four bolts and washers (2, Figure
42), and cover (1).
6
5
ARS2910L
Figure 42
START-UP PROCEDURES
1. Start engine and set throttle at "LOW
IDLE."
2. Set safety lever on "UNLOCK" position.
HAOB290L
Figure 43
3. Slowly cycle boom, arm, bucket cylinders
and swing motor about five times without a
load to vent air from pilot lines. Do this for
5 minutes.
ARO0470L
Figure 44

Page 20
S709466K
1MAIN CONTROL VALVE

(REXROTH)
CAUTION!
MAIN CONTROL VALVE (REXROTH)S709466K


December 2002
Main Control Valve (REXROTH) S709466K

Page 1
TABLE OF CONTENTS
Functional Description, Section...................................................................... 3

Assembly........................................................................................................ 5
Abnormal Operation of the Actuators
Connected to the Control Block .............................................................. 6
Abnormal Machine Operation ................................................................. 7
Visual Defects ......................................................................................... 7
Fundamental Rules ........................................................................................ 7
General Information Concerning Control Block Connection ................... 7
Removal / Installation of the SX 14 Control block .......................................... 8
General Recommendations .................................................................... 8
Removal of the SX 14 Control Block ....................................................... 8
Installation of the SX 14 Control Block.................................................... 8
Inlet and Outlet Elements Repair Procedures ................................................ 9
LS Pressure Relief Valve Replacement .................................................. 9
Flow Regulator Replacement................................................................ 10
Flow Regulator Filter Replacement................................................ 10
"Open Center" Removal ........................................................................ 11
Hydraulic Operator Removal ........................................................................ 12
Hydraulic Control Housing Removal ..................................................... 12
Control Block Disassembly / Assembly ........................................................ 13
Preliminary Operations: ........................................................................ 13
Individual pressure compensator Removal ........................................... 14
Check Valve Removal ........................................................................... 15
S709466K Main Control Valve (REXROTH)

Page 2
FUNCTIONAL DESCRIPTION, SECTION
A B
3
1
5
6 LS
T T
P
2
BJS0110L
Figure 1
Reference Reference
Number Number
1 Housing 4 Pressure Compensator
2 Spool 5 Secondary Valve
3 Check Valve 6 Plug
The SX14 directional control block basically consists of one inlet element, a number of directional valve
element.
The inlet element consists 2 fixing points and the pipe connection ports P, T, LS, M.
This element also contains all the components required for the system function, namely: a flow control
valve for the controlled unloading of the LS line and a LS relief valve for the limitation of the maximum
pressure in the system.
Each SX directional valve element is composed of a housing (1), a spool (2), two load holding check valves
(3), a pressure compensator (4), cavities (5) for secondary relief / anticavitation check valves, and
anticavitation check valves or plugs (6).
The final element has one fixing point.

Page 3
4
6
5
A
B
P LS T
3 2
BJS0120L
Figure 2
Symbol Description Symbol Description

P Pump T Tank
A, B Actuator LS Load Sensing

Page 4
ASSEMBLY
4 3
A
2
A
A
1
5
BJS0130L
Figure 3
Reference Reference
Number Number
1 Inlet Element - Open 4 Hydraulic Operator with
Center P Spool Return Via a Spring
2 Directional Valve Element 5 Flow Control Valve
3 Outlet Element with Tank 6 LS Relief Valve
Bridge 7 Secondary Valve

Page 5
TROUBLESHOOTING
IMPORTANT
Before starting any procedures of trouble shooting or removing the control block, inspect the
global machine's hydraulic system to eliminate all possible malfunctions not related to the SX 14
control block.
ABNORMAL OPERATION OF THE ACTUATORS

CONNECTED TO THE CONTROL BLOCK
Malfunction Probable Cause Additional Checks Remedy

Lack of strength at all 1 - LS pressure relief Take a pressure Replace LS pressure
actuators valve defective measurement relief valve
(See page -9)
2 - LS pressure relief Make necessary
valve out of adjustments
adjustment
Lack of force on one 1 - Secondary pressure Reset to original
actuator only relief valve out of pressure
adjustment
2 - Secondary pressure Replace secondary
relief valve blocked pressure relief valve (
"open" (return to tank)
Lack of speed in the SX 14 with "open Replace housing +
performance of a center" on the inlet piston assembly
movement or all element (if so (See page -11) and
movements equipped) (See page -13)
-Piston if the "open
center" blocked in
position P toward T
Movement performance 1 - Hydraulic operator Make necessary
slow adjustable stop nut adjustments
out of adjustment
2 - Individual Replace housing +
compensator pressure compensator
pressure blocked assembly
(See page -13)
Lack of load hold 1 - Load hold check Replace housing +
valve failure pressure compensator
assembly
(See page -13)
2 - Excessive clearance Replace housing +
between the spool assembly
housing and the (See page -13)
spool

Page 6
Simultaneous 1 - Blockage of the Remove and clean
movement malfunction individual individual compensator
compensator orifice (See page -13)
2 - Individual pressure Replace the housing +
compensator pressure compensator
blocked assembly
(See page -13)
3 - LS line leakage Replace LS flow
regulator
(See page -10)
ABNORMAL MACHINE OPERATION

Engine remains under 1 - Flow regulator Replace flow regulator
load after spools are blocked (See page -10)
returned to neutral 2 - Flow regulator filter Replace the filter
clogged (See page -10)
VISUAL DEFECTS
Spool leaking oil Spool seals defective Replace spool seals (
Oil leakage at pressure Seals defective Remove pressure relief
relief valves and plugs valve or plug and
replace seals
Oil leakage between Seals between Remove working
elements elements defective sections and replace
joints (See page -13)
Oil leaking from 1 - Seal between Replace seal
hydraulic operator housing and body (See page -12)
housing defective
2 - Seal of adjustable Replace seal
stop nut defective (See page -12)
FUNDAMENTAL RULES
GENERAL INFORMATION CONCERNING CONTROL BLOCK CONNECTION
When removing the block, all openings must be plugged immediately to prevent any contamination of the
hydraulic system.
When replacing the block, remove the plastic plugs from the openings and lines just before making the
connections.
Do not tighten connectors to a torque greater than that specified in the assembly instructions.
Check the hydraulic installation's oil quality and filtration capacity during all servicing / maintenance
operations.

Page 7
The use of Teflon tape, hemp and joint filter is prohibited.
Hydraulic lines and connections must not be under any strain whatsoever.
REMOVAL / INSTALLATION OF THE SX 14 CONTROL

BLOCK
GENERAL RECOMMENDATIONS
IMPORTANT
Before removing the SX 14 control block from the machine, the block and its surroundings must
be thoroughly cleaned with a high-pressure cleaner.
No impurities must enter the hydraulic system. Plastic plugs are to be fitted on lines and orifices
immediately following their removal.
WARNING!
Wear protective clothing and use suitable equipment to prevent accidents, particularly
concerning the hydraulic fluid.
Use the lifting eyes and suitable handling equipment.
Set all actuators connected to the machine in neutral position (on the ground, at lower limit...) to
avoid accidents which could result from uncontrolled movements of the equipment when the
hydraulic system is disconnected.
With the machine off, release the pressure remaining in the system by manipulating all of the
distribution spools. This is performed by moving the handle in all directions.
REMOVAL OF THE SX 14 CONTROL BLOCK

Install a vacuum pump on the tank to limit oil leakage when connections are removed.
After disconnecting the lines from the block, immediately fit the sealing plugs. Make sure to collect any
possible oil leakage in a suitable receptacle.
Unscrew the mounting screws and remove the control block.
INSTALLATION OF THE SX 14 CONTROL BLOCK

Contact faces must be perfectly clean.
Check the evenness of support area on the machine {Tolerance: 0.5 mm (0.02 in)}.
Check the condition of line connector seals.
Clean the block if it has been in storage for a long period of time.
Correctly place and secure the control block onto the machine with the mounting screws.

Page 8
Connect the lines to the block as per the connecting diagram and tighten to the torque specification (refer
to the table in the Data sheet).
Ensure that hoses are not twisted or rub.
Once correctly installed, the unit can be placed into operation:
- decalibrate the LS pressure relief valve before starting the machine.
- maneuver the distribution spools.
- adjust the maximum pressure using the LS pressure relief valve by holding a function at its limit.
INLET AND OUTLET ELEMENTS REPAIR

PROCEDURES
LS PRESSURE RELIEF VALVE
REPLACEMENT
NOTE: The control block does not need
to be removed from the
machine to perform this
operation.
CAUTION!
Machine off: BJS0820L
- Place all of the machine's actuators Figure 4
connected to the control block in neutral
position.
- Release stored pressure by operating all
the spools.
NOTE: Collect possible leaks with a

suitable receptacle.
On the inlet element, unscrew the LS pressure
relief valve (17 mm wrench).
Reassembly: torque: 45 ±4 Nm (33 ±3 ft lb).

Page 9
FLOW REGULATOR REPLACEMENT
operation.
CAUTION!
Machine off:
- Place all of the machine's actuators BJS0830L
connected to the control block in neutral Figure 5
position.
- Release stored pressure by operating all
the spools.
NOTE: collect possible leaks with a

On the inlet element, unscrew the flow regulator
(22 mm wrench).
Reassembly:
- Install the flow regulator on the inlet element,
and torque: 20 ±2 Nm (15 ±2 ft lb).
Flow Regulator Filter Replacement

Using pliers, extract the filter from the end of the
flow regulator. Be careful not to damage the seal
and the end of the flow regulator.
BJS0840L
Figure 6

Page 10
"OPEN CENTER" REMOVAL
operation.
CAUTION!
Machine off:
- Place all of the machine's actuators
connected to the control block in neutral
position.
- Release stored pressure by
manipulating all the spools.
NOTE: Collect possible leaks with a

BJS0850L
Figure 7
On the inlet element, remove the "open center"
plug (12 mm socket wrench).
- Replace the plug O-ring
- Torque: 100 ±10 Nm (74 ±7 ft lb).
BJS0860L
Figure 8
Remove: - 2 springs.
- Piston.
Reassemble parts in reverse order.
BJS0870L
Figure 9

Page 11
HYDRAULIC OPERATOR REMOVAL
NOTE: The control block does not need to be removed from the machine to perform this
operation.
CAUTION!
Machine off:
- Place all of the machine's actuators connected to the control block in neutral position.
- Release stored pressure by manipulating all the spools.
- Do not modify the (adjustable) stop screw setting
NOTE: Install a vacuum pump on the reservoir to limit oil leakage during this operation.
NOTE: Collect possible leaks with a suitable receptacle.
HYDRAULIC CONTROL HOUSING REMOVAL

Remove the 4 mounting screws (5 mm socket
wrench).
Reassembly:
- Replace O-ring on the body.
- Torque: 100 ±10 Nm (74 ±7 ft lb).
BJS0880L
Figure 10
Reassemble parts in reverse order.
BJS0890L
Figure 11

Page 12
CONTROL BLOCK DISASSEMBLY / ASSEMBLY
PRELIMINARY OPERATIONS:
Remove the control block from the machine
(See page -8)
Remove the 3 nuts (13 mm ring wrench)
Reassembly: torque 35 ±3 Nm (26 ±2 ft lb).
BJS0900L
Figure 12
Remove the outlet element.
BJS0910L
Figure 13
Separate the working sections from the inlet
element.
Replace the O-rings between the working
sections, the inlet element and the outlet
element.
If the inlet element is to be replaced, remove the
tie rods.
Assemble parts in reverse order, and make sure
that the tie rods are tightened to the specified
torque.
BJS0920L
Check cleanliness of the element faces before
Figure 14
reassembly.

Page 13
INDIVIDUAL PRESSURE COMPENSATOR
REMOVAL
Unscrew the compensator plug (8 mm socket
wrench).
BJS0930L
Figure 15
Remove the compensator piston.
Clean the piston's nozzle with compressed air.
Clean the condition of bore in the distribution
element body.
Reassembly:
- Replace the plug O-ring.
- torque: 60 ±6 Nm (44 ±4 ft lb).
BJS0940L
Figure 16
BJS0950L
Figure 17

Page 14
CHECK VALVE REMOVAL
Unscrew the check valve plug (5 mm Allen
wrench).
BJS0960L
Figure 18
Visually check the condition of parts and replace
the assembly if necessary.
Reassembly:
- Replace the plug O-ring.
- Torque: 30 ±3 Nm (22 ±2 ft lb).
BJS0970L
Figure 19

Page 15
S0709820K
1TRAVEL CONTROL
VALVE (WITH DAMPER)
CAUTION!
TRAVEL CONTROL VALVE (WITH DAMPER)S0709820K


January 2004
Travel Control Valve (With Damper) S0709820K

Page 1
TABLE OF CONTENTS
Pressure Reducing Valve................................................................. 3
Operating Theory of Damper Mechanism........................................ 5
Parts List ................................................................................................. 6
Specification............................................................................................ 7
Torque ..................................................................................................... 7
Troubleshooting, Testing and Adjustment....................................................... 8
Removal ......................................................................................................... 9
Disassembly ................................................................................................. 11
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 17
assembly ...................................................................................................... 18
Installation .................................................................................................... 23
Start-up Procedures ..................................................................................... 24
S0709820K Travel Control Valve (With Damper)

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
The damper valve is divided into two areas of operation. There is the pressure reducing valve (a) and the
damper mechanism (b). The following hydraulic circuit is an example of a remotely control valve.
5
6
4
2
ARS1810L
Figure 1
Reference Reference
Number Number
1 Remote Control Valve 4 Control Valve
2 Pilot Pump 5 Hydraulic Motor
3 Main Pump 6 Hydraulic Cylinder
Pressure Reducing Valve

1. Neutral Condition
If pedal is in neutral, spool is pushed up by return spring and spring seat. Port (P) is blocked by
bottom part of spool and four operating ports (left forward and backward, right forward and backward)
are connected to port (T) through inner hole of spool.
2. Half Operation Condition
If pedal is moved, push rod moves down, and they transmit this force through spring seat and control
spring to spool. If spool is moved, primary pressure is transmitted through an inner hole of spool to
operating port. If lever is stopped in middle position, compressed control spring force and secondary
pressure transmitted through hole acts at bottom part of spool, balance is maintained by hydraulic
force acted upward, and then this pressure is transmitted to traveling spool of control valve. That is,

Page 3
primary pressure is transmitted to operating port as secondary pressure equivalent to control spring
force compressed by spool.
3. Full Operating Condition
If pedal is moved to a maximum, bottom part of push rod presses spool seat to a maximum, and
compresses control spring to a maximum. Primary pressure is transmitted through inner hole of spool
to operating port, secondary pressure transmitted through spool overcomes control spring force and
pushes spool up, but spool is restricted by push rod and does not move any more. That is, when
pedal lever is moved to a maximum, control spring does not function, spool is restricted by push rod,
and then primary pressure equalizes to secondary pressure.
40 160
SECONDARY PRESSURE (kgf/cm2)
OPERATING TORQUE (kgf.cm)

117.6
27±1.5
Operating Torque 100.5
49.5
5.5±1
Secondary Pressure
0 1±0.5 4.8±0.5 5.5
PUSH-ROD STROKE (mm)

ARS1840L
Figure 2

Page 4
Operating Theory of Damper Mechanism
1 2
1. Operation When Operating Lever 12.5°
When pushing pedal, pushing force

pushing push rod and spool presses
cylinder, return spring and hydraulic oil in
cylinder is compressed, piston coming
down with push rod compresses vibration
prevention chamber of lower part, oil of
vibration prevention chamber of lower part
is flowed through orifice to oil pressure
vibration prevention chamber of upper part
of low-pressure, at this time, ball check
valve becomes closing condition because
high-pressure operates to vibration
prevention chamber of lower part.
ARS1820L
Figure 3
2. Operation When Operating Lever In
Neutral Condition
Climbing restoring force acting on push 1
rod, raises piston in oil pressure prevention
2
chamber and compresses upper oil
3
pressure prevention chamber. This
4
compression operation of upper oil
pressure prevention chamber prevents the
push rod from quickly rising by restoring
spring, and the damping force is Upper vibration
generated. prevention chamber
Lower vibration
prevention chamber
ARS1830L
Figure 4

Page 5
PARTS LIST
19 20 30 29 28 33
32
25
24 26
23 3
22 36
16 14
15
21
17
13
18
12
19
11
20
9
6
5
7
4
10
3 8
37 1 35 34 2
ARS1850L
Figure 5
P T
1 2 3 4 ARS1860L
Figure 6

Page 6
Reference Reference
Number Number
1 Body (1) 20 Retaining Ring
2 Body (2) 21 Plug
3 Plug 22 O-ring
4 Plug 23 Rod Seal
5 Spring Seat 24 Dust Deal
6 Spring 25 Cover
7 Spring Seat 26 Wrench Bolt
8 Spool 27 Cam
9 Stopper 28 Bushing
10 Spring 29 Camshaft
11 Rod Guide 30 Set Screw
12 O-ring 31 Set Screw
13 Retaining Ring 32 Hex Nut
14 Push Rod 33 Bellows
15 Spring Pin 34 Space
16 Seal 35 O-ring
17 Steel Ball 36 O-ring
18 Spring 37 Wrench Bolt
19 Plate
SPECIFICATION
Travel Control Valve Specification

Pilot Control
Type
(With Damper)
Pressure / Stroke 27 kg/cm2 @ 4.8 mm Stroke

(384 psi @ 0.1890 in Stroke)
7.8 kg
Weight
(17 lb)
TORQUE
Part Reference
Bolt Size Tool Tightening Torque
Number
88 kg•cm
26 M6 5 mm L-Wrench
(6 ft lb)
100 kg•cm
30 M8 4 mm L-Wrench
(7 ft lb)
440 kg•cm
32 M10 17 mm Spanner
(32 ft lb)
440 kg•cm
37 M10 8 mm L-Wrench
(32 ft lb)

Page 7
TROUBLESHOOTING, TESTING AND ADJUSTMENT
At times pinpointing the source of the problem may be difficult. The following table lists some possible
problems, causes and remedies. Refer to this table for possible causes and remedies to help in correcting
problems.
The table only lists general problems, causes and remedies. Often the problem is not caused by the failure
of a single part but, may be the result of a combination of problems from related parts and their
components. Possible problems other than the ones listed are not being specified but that is not to say that
these are the only possible problems that can occur. The technician must diagnose the problem,
considering all possible causes and repair the source of the malfunction.
Problem Possible Cause Remedy

Secondary pressure will not Low primary pressure. Adjust primary pressure.
increase. Defective secondary pressure Replace with new spring.
select spring.
Gap between spool and casing is Replace spool casing assembly.
abnormally large.
Defective operating parts and Disassemble/reassemble and
components. replace defective parts.
Unstable secondary Jamming of interconnected parts. Repair/replace cause of jamming.
pressure. Unstable tank line pressure. Install direct line to hydraulic tank.
Air in hydraulic lines. Vent air from system.
Abnormally high secondary High tank line pressure. Install direct line to hydraulic tank.
pressure. Jamming of unconnected parts. Repair/replace cause of jamming.
No damping. Jamming of interconnected parts. Repair/replace cause of jamming.
Worn damping piston and housing. Replace damping piston and
housing assembly.
Defective/damaged check valve. Disassemble and examine check
valve.
Worn damping piston orifice. Replace damping piston.
Damping piston feels heavy. Defective interconnected Repair/replace defective parts.
components.
Restricted movement of damping Repair/replace damaged piston.
piston.
Plugged orifice. Replace related parts.

Page 8
REMOVAL
WARNING!

accumulators.
controls.
11. Remove cabin under cover by loosening

bolts.
2
12. Tag and disconnect hoses from pedal
valve (1, Figure 8). Plug and cap hoses
and ports to prevent contamination from 1
entering hydraulic system or component.
ARS2940L
Figure 8

Page 9
13. Remove rubber boots (1, Figure 9).
9), pedal brackets (3) with levers. 1
2
1
3
3
ARS2951L
Figure 9
10), and pedal valve (1).
2
ARS2940L
Figure 10

Page 10
DISASSEMBLY
IMPORTANT
1. Prepare a clean, well lit, stable work bench where disassembly can be performed.
2. Prepare the necessary tools, materials and a container in which disassembled parts can be
stored.
3. All precision parts must be handled with great care and all parts must be reassembled to
their original position.
4. All parts must be carefully reassembled and not be forced. Damaged parts will cause oil
leaks and poor performance of the equipment.
5. Do not leave parts exposed to air during or after disassembly. Exposed parts will come in
contact with contaminants and will cause rust and damage.
NOTE: Dispose of drained fluids according to local regulations.

1. Remove bellows (33).
Figure 11
2. Remove set screw (30) by using L wrench.
Figure 12

Page 11
3. Remove cam shaft (29) and bushing (28)
from cam (27).
Figure 13
Figure 14
4. Remove cam (27) from cover (25).
Figure 15
5. Remove wrench bolt (26) by using tool.
Figure 16

Page 12
6. Remove cover (25) from body (1 and 2).
Figure 17
7. Remove plug assembly (21 - 24) with push
rod assembly (14 - 20).
Figure 18
8. Remove retaining ring (13).
IMPORTANT
Be careful not to spring rod guide
(11).
Figure 19
9. Remove rod guide (11).
Figure 20

Page 13
10. Remove spool assembly (5 - 9).
Figure 21
11. Remove spring (10).
Figure 22
12. Remove stopper (9), spring (6) and spring
seat (7) from spool assembly (5 - 9).
Figure 23
Figure 24

Page 14
13. Remove plug assembly (21 - 24) from
push rod assembly (14 - 20).
Figure 25
14. Remove seal (23 and 24) from plug (21).
Figure 26
15. Remove O-ring (22) from plug (21).
Figure 27
16. Remove seal (16) from push rod (14).
Figure 28

Page 15
17. Remove retaining ring (20) from push rod
(14).
Figure 29
18. Remove plate (19) from push rod (14).
Figure 30
19. Remove spring (18) from push rod (14).
Figure 31
20. Remove steel ball (17) from push rod (14).
Figure 32

Page 16
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
1. Cleaning disassembled parts.
1. Place parts in a container with cleaning solvent.
• Allow all parts to soak in solvent until grease and other foreign substances have dissolved and
become loose, before cleaning.
• Contaminated cleaning solvent may cause damage to parts and may cause poor equipment
performance. Be sure to use clean, uncontaminated solvent when cleaning precision parts.
2. Clean parts thoroughly by gently turning the solvent. Dry and clean each part with a clean cloth.
• Do not use compressed air to dry parts. Foreign material and moisture present in compressed
air may cause damage or rust.
2. Anticorrosive treatment of disassembled parts.
Apply an anticorrosive lubricant to all disassembled parts.
• Leaving cleaned parts exposed to contaminants and moisture in the air will cause rust and may
cause poor equipment performance.

Page 17
ASSEMBLY
IMPORTANT
1. Prepare a clean, well lit, stable work bench where assembly can be performed.
2. Prepare the tools and materials necessary for the assembly process.
3. Inspect all parts, making sure that all parts are free from dirt and damage. If minor surface
scratches are visible, use a very fine crocus cloth to clean it off.
4. Replace all O-rings and NHU packings with new ones. Use care when assembling O-rings
and NHU packings.
5. Apply a light coat of approved lubricant to aid in smooth assembly.
6. Tighten all bolts to the specified torque rating as outlined in the torque table.
7. Seal all opens ports to prevent foreign material from entering the valve assembly.
8. All precision parts must be handled with great care and all parts must be reassembled to
their original position.
9. All parts must be carefully reassembled and not be forced. Damaged parts will cause oil
leaks and poor performance of the equipment.
10. Do not leave parts exposed to air during or after disassembly. Exposed parts will come in
contact with contaminants and will cause rust and damage.
11. Grease must be applied to the top portion of each push rod.
12. Grease must be filled into each grease cup.
13. Spray Anti-rust lubricant into each bellows.
1. Clean body (1 and 2) and all parts.

2. Install spring (10) on body (1 and 2).
Figure 33

Page 18
3. Clean plug (21) with thinner, inspect for
burrs and install rod seal (23) and dust
seal (24) on both sides of plug by using
tool.
Figure 34
4. Install O-ring (22) on outside diameter of
plug (21) and check plug for abnormality.
Figure 35
5. Install spring seat (7), spring (6), and
spring seat (5) on spool (8).
Figure 36
6. Install O-ring (12) on rod guide (11).
Figure 37

Page 19
7. Install steel ball (17), spring (18), plate (19)
and spring pin (15) on push rod (14).
Figure 38
8. Install retaining ring (20) on push rod
assembly (14 - 19).
Figure 39
9. Install seal (16) on push rod (14).
Figure 40
10. After installing spool assembly (5 - 9) on
body (1 and 2), insert rod guide (11) and
install retaining ring (13).
Figure 41

Page 20
11. Install plug assembly (21 - 24) with push
rod assembly (14 - 20) on body (1 and 2).
Figure 42
12. Install cover (25) on the side of body (1
and 2) facing up.
Figure 43
13. Tighten wrench bolt (26).
(6 ft lb).
Figure 44
14. Put cam (27) on cover (25) and install cam
shaft (29).
IMPORTANT
Check whether there is a play of cam.
Figure 45

Page 21
15. Tighten set screw (30) on center of cam
(27) not to loose cam (27) and cam shaft
(29) by using wrench.
(6 ft lb).
Figure 46
16. One side holds L wrench and the other
side holds spanner and tighten set screw
(31) and hex nut (32) attached to cam (27)
not to loose.
IMPORTANT
Check whether there is a play of cam.

(32 ft lb).
Figure 47
17. Install bellows.
Figure 48

Page 22
INSTALLATION
1. Position pedal valve (1, Figure 49) on
cabin floor plate and install four bolts and
washers (2). 2
ARS2940L
Figure 49
2. Install pedal brackets (3) and levers (4,
Figure 50) on pedal valve and install four
bolts and washers (2).
1
3. Install rubber boots (1, Figure 50).
2
1
3
3
ARS2951L
Figure 50
to pedal valve (1, Figure 51).
2
5. Install cabin under cover by tightening
bolts.
1
ARS2940L
Figure 51

Page 23
START-UP PROCEDURES
1. Start engine and set throttle at "LOW
IDLE."
2. Set safety lever on "UNLOCK" position.
HAOB290L
Figure 52
3. Slowly push and pull both travel lever
about five times without a load to vent air
from pilot lines.
HAOB903L
Figure 53

Page 24
S0792096K
2HYDRAULIC
SCHEMATIC
(SOLAR 75-V)
CAUTION!
HYDRAULIC SCHEMATIC (SOLAR 75-V)S0792096K


January 2004
Hydraulic Schematic (Solar 75-V) S0792096K

Page 1
TABLE OF CONTENTS
Solar 75-V (Standard) .................................................................................... 4
Solar 75-V (Option) ........................................................................................ 6
S0792096K Hydraulic Schematic (Solar 75-V)

Page 2
GENERAL DESCRIPTION
Schematic(s) presented in this section are laid out on facing pages.
An overlapping edge has been taken into consideration so that a photocopy can be made and pasted
together to make a complete schematic.
Figure 1

Page 3
SOLAR 75-V (STANDARD)
Figure 2

Page 4
S75-V Plus (STD)
BJS1410L

Page 5
SOLAR 75-V (OPTION)
Figure 3

Page 6
S75-V Plus (OPT)
BJS1420L

Page 7
1ELECTRICAL SYSTEM
S0802095K
1ELECTRICAL SYSTEM
CAUTION!
ELECTRICAL SYSTEMS0802095K

December 2002
Electrical System S0802095K

Page 1
TABLE OF CONTENTS
Overview ........................................................................................................ 3
Electric Supply System .................................................................................. 4
Engine Starting Circuit ................................................................................... 6
Operation During Start Process .............................................................. 6
Operation After Start Process ................................................................. 8
Engine Preheating System........................................................................... 10
Engine Stop System..................................................................................... 12
Charging System.......................................................................................... 13
Instrument System ....................................................................................... 14
Instrument Panel ................................................................................... 15
Operation .............................................................................................. 17
Circuit Diagram of Instrument Panel ..................................................... 19
Control Unit ........................................................................................... 20
Engine Control System................................................................................. 22
Engine Control Circuit Diagram............................................................. 22
Engine Control Motor ................................................................................... 23
Engine Control Dial ...................................................................................... 24
Engine Overheat Protection System ............................................................ 26
S0802095K Electrical System

Page 2
OVERVIEW
The electrical system for this equipment is DC 12 volts. The rated voltage for all electric components is 12
volts. The system contains one 12 volt battery and a three phase AC generator with a rectifier. The electric
wiring used in the system is easily identifiable by the insulator color. The color symbols used in the electric
system are listed in the following chart.
Electric Wire Color
Symbol Color Symbol Color

W White R Red
G Green Gr Gray
Or Orange P Pink
B Black Y Yellow
L Blue Br Brown
Lg Light green V Violet
NOTE: RW: Red wire with White stripe

R - Base Color, W - Stripe Color
NOTE: 0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2 (0.03 in2)

Page 3
ELECTRIC SUPPLY SYSTEM
The electric power circuit supplies electric current to each electric component. It consists of a battery,
battery relay, starter switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle body.
Even when the starter switch (5) is in the "OFF" position, electric current is supplied to the following
components through battery (1) →fusible link (3) →fuse (6).
1. Cabin light, fuel pump switch, No. 11 terminal of car stereo for back up
2. "B" terminal of starter switch
3. No. 1 terminal of hour meter
When the starter switch is in the preheat, on and start positions, the current flows from the battery (1) →
fusible link (3) → fuse box (6) → starter switch (5) "B" terminal/ "BR" terminal → battery relay (2) "BR"
terminal which activates the coil of the battery relay and the electric supply system is energized.
When the battery relay's contacts are connected, the current flows from the circuit breaker (4) →fuse box
(6) and oil electric devices can be operated.
While the engine is not running, the battery supplies the electric power for all electric components. Once
the engine is started, the power is supplied from the alternator (7).

Page 4
20A
Figure 1
Reference Reference
Number Number
1 Battery 5 Starting Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker

Page 5
ENGINE STARTING CIRCUIT
OPERATION DURING START PROCESS
When the starter switch (5) is turned to the start position, the "S" and "E" terminals of the starter controller
(10) are connected. At this time the contacts in the starter relay (9) are closed by the current flow from the
battery (1) →fusible link (3) →fuse box (6) → "B" terminal of the starter switch (5) →"C" terminal of the
starter switch (5) →"C" terminal of the starter relay (9) →"D" terminal of starter relay (9) →"S" terminal of
starter controller (10) →"E" terminal of the starter controller (10) →ground.
The contact point "B" and "PP" of starter relay (9) are connected, the pinion gear of the starter (8) is
pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter
are connected.
The current flows from the battery (1) →"A" terminal of the battery relay (2) →"B" terminal of the battery
relay (2) →"B" terminal of the starter (8). The starter motor is rotated and the engine is started.

Page 6
Operation of the Starter Circuit (1) - During Start Process
N S D PP
10 C B
11
E P B
9 8
C
A
5
ACC E
C 3
6
B
R2 BR
R1
IG L P B(BATT)
IG
4 2
L B A
F
E BR
E
E
7
STARTER SWITCH CONTACT

B BR R1 R2 C ACC
OFF
HEAT
ON _ +
START 12V 100AH
1
AXS0200L
Figure 2
Reference Reference
Number Number
1 Battery 7 Alternator
2 Battery Relay 8 Starter
3 Fusible Link 9 Starter Relay
4 Circuit Breaker 10 Starter Controller
5 Starter Switch 11 Diode
6 Fuse Box

Page 7
OPERATION AFTER START PROCESS
Once the engine has been started, the belt driven alternator (7) generates a current.
The output generated by the alternator (7) is a square wave pulse voltage through the "P" terminal and the
frequency of the pulse voltage is proportional to the rotation of the alternator.
The starter controller (10) monitors the frequency of the output current. Once the frequency equivalent to
500 rpm is sensed the connection between "S" and "E" terminals of starter controller (10) as well as the
connection between "B" and "PP" terminals of starter relay (9) are opened.
As a result the rotation of the starter (8) is stopped.
Once the engine is running, the starter (8) will not operate even if the starter switch (5) is moved to the start
position, preventing possible damage to the starter.

Page 8
Operation of the Starting Circuit (2) - Immediately After Start
AXS0210L
Figure 3
Reference Reference
Number Number
1 Battery 7 Alternator
2 Battery Relay 8 Starter
3 Fusible Link 9 Starter Relay
4 Circuit Breaker 10 Starter Controller
6 Fuse Box

Page 9
ENGINE PREHEATING SYSTEM
The engine preheating system consists of a grid type resistance heater which is installed into the intake
manifold of engine to raise air temperature, a preheat timer which turns on a preheat indicator and a
preheat indicator.
When the starter switch (6) is turned to the "Preheat" position, the current flows from the battery (1) →
fusible link 1 (3) →fuse box (7) →"B" terminal of starter switch (6) →"R1" terminal of starter switch (6) →
Diode (12) →"C" terminal of preheat relay (9) →"D" terminal of preheat relay (9) →ground.
The contact points of preheat relay (9) are closed. At this time, preheat timer (8) counts preheat time.
When the contact points of preheat relay (9) are closed, the heating coils of air heater, are heated by
current flowing from the battery (1) → battery relay (2) → circuit breaker (4) → preheat relay (9) → air
heater (10) →ground.
The preheating time is approximately 15 seconds. A built-in timer in the preheat timer will activate an
indicator light installed in the instrument panel approximately 15 seconds after the preheat process has
been selected.

Page 10
AXS0220L
Figure 4
Reference Reference
Number Number
1 Battery 7 Fuse Box
2 Battery Relay 8 Preheat Timer
3 Fusible Link (1) 9 Preheat Relay
4 Fusible Link (2) 10 Air Heater
5 Circuit Breaker 11 Instrument Panel

Page 11
ENGINE STOP SYSTEM
There are two modes of operation - Engine Running and Engine Stop.
When the starter switch (4) is turned to the "ON" position, current flows from battery (1) to terminal "4" of
engine stop timer (7), and terminal "A" of engine stop solenoid (6). At this time terminals "1" and "3" of
engine stop timer (7) and are closed then terminals "B" and "PP" of engine stop relay (5) are closed for
about 1 second.
When the contact points of engine stop relay (5) are closed, the pull coil of engine stop solenoid (6) is
energized and the system is in the running mode.
Once the engine is in running mode, the hold coil of engine stop solenoid (6) will pull the plunger of engine
stop solenoid to sustain the running mode.
When the starter switch (4) is turned to “OFF” position, the hold coil of engine stop solenoid (6) is de
energized and the system is in the stop mode.
4 2
ACC C
3
B
R2 BR
R1
5 6
7
1 D PP B PULL
4
2 8 C B A HOLD
3 C
- +
12V 100AH
STARTER SWITCH CONTACT

B BR R1 R2 C ACC
OFF
HEAT
ON
START
AXS1800L
Figure 5
Reference Reference
Number Number
1 Battery 5 Engine Stop Relay
2 Fusible Link 6 Engine Stop Solenoid
3 Fuse Box 7 Engine Stop Timer

Page 12
CHARGING SYSTEM
When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of
the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this
condition the alternator (7) starts charging. The current flows from the "B" terminal of alternator (7) →
circuit breaker (4) →battery relay (2) →battery (1).
The alternator (7) also supplies electric current to other electrical components through fuse box (6).
AXS0250L
Figure 6
Reference Reference
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker

Page 13
INSTRUMENT SYSTEM
BJS1030L
Figure 7
Reference Reference
Number Number
1 Instrument Panel 6 Air Cleaner Indicator
2 Battery 7 Engine Oil Pressure Switch
3 Alternator 8 Preheat Timer
4 Engine Coolant Sensor 9 Engine Coolant
5 Control Unit Temperature Switch
The instrument system displays the equipment conditions and warning signals onto the instrument panel
by processing the information gathered from the various sensors throughout the equipment.

Page 14
INSTRUMENT PANEL
BJS1040L
Figure 8
Reference Reference
Number Number
1 Engine Coolant 6 Engine Overheat Warning
Temperature Gauge Light
2 Fuel Gauge 7 Air Cleaner Clogged
3 Hour Meter Warning Light
4 Engine Oil Pressure 8 Overload Warning Light
Warning Light 9 Preheat Completion
5 Battery Warning Light Indicator

Page 15
Function Check
When the starter switch is turned to the "ON" position, all indicator lights and warning lights will be lit for 2
seconds and the warning buzzer will sound.
If there is any light that does not go on during the function check, replace or repair.

Page 16
OPERATION
Gauge
Sensor Specification
Function Display Input
Input Specification
Terminal
C H 50°C (122°F) →over 188.2

ohms
Engine 67°C (153°F) →102 ohms
Coolant CN 6
Temperature 105°C (221°F)→32 ohms
125°C (257°F) →below
19.8 ohms
BJS1050L
E F
Empty →over 90 ohms

Fuel
CN 12 1/2 - 38 ohms
Quantity
FULL →below 10 ohms
BJS1060L
Operation
CN 1 "I" terminal of alternator
Hour
BJS1070L

Page 17
Warning Lights
Input
Description Symbol Operation Remarks
Terminal
After starting
Lights up when oil engine, if engine oil
Engine Oil pressure drops pressure is
CN 7
Pressure below 0.7 kg/cm2 (7 insufficient after 8
psi). seconds, a warning
HAOA620L
buzzer will sound.
Under normal
Lights up when not
condition, it will up
charging ("L"
before engine start
Charge CN 8 terminal output of
up and shut off
alternator drops
once engine is
below 5V)
HAOA610L
running.
Lights up when
Engine
coolant temperature
Coolant CN 11
increases over 110
Temperature
°C
HAOD350L
Lights up when air

Air Cleaner CN 5
cleaner is clogged
BJS1080L
Lights up when
lifting load exceeds
limit. (When the over Warning buzzer will
Overload load warning switch sound.
CN 2
(Optional) is turned "ON,"
output voltage 2.30 V (S75-V)
ARO0220L
increases over
reading remarks.)
Lights up when
preheat process is
Preheat CN 9 completed.
(Approximately 15
seconds from start)
HAOA639L

Page 18
CIRCUIT DIAGRAM OF INSTRUMENT PANEL
2 12
1
10
U 6
W/T GAUGE +
W
6
-
13
U 12
FUEL GAUGE + 7
F
-
15
ILLUMINATION 3 14 B
8
BR
L7 L8
4 E
9
HOUR METER (2) A
H 10
+ (1)
5
(3) 2
ENG OIL PRESS 7 3

L1 TIME DELAY
WATER TEMP 11 4 BUZZER

L3 CIRCUIT
AIR CLEANER 5 5 11
L4
OWD 2 12
L5
PREHEAT 9 7
L6
CHARGE 8 13
L2
1
3
L
AXS1830L
Figure 9
Reference Reference
Number Number
1 Instrument Panel 9 Engine Coolant
2 Lamp Switch Temperature Switch
3 Alternator 10 Air Cleaner Indicator
4 Preheat Timer 11 Control Unit
5 Battery 12 Fuse Box
6 Engine Coolant Sensor 13 Circuit Breaker
7 Fuel Sensor 14 Battery Relay
8 Engine Oil Pressure Switch 15 Fusible link

Page 19
CONTROL UNIT
Circuit Diagram
6
4
8 3 B
BR
E
7
2 A
10
ENG OIL PRESS 7 3

L1 TIME DELAY
2
WATER TEMP 11 4 BUZZER 9
L3 CIRCUIT
+
AIR CLEANER 5 5
L4 SIG
-
OWD 2 12
L5
9 7 10
PREHEAT
L6
CHARGE 8 13
L2
1
1 11
L
TERMINAL NO.
6 5 4 3 2 1
13 12 11 10 9 8 7
AXS1840L
Figure 10
Reference Reference
Number Number
1 Control Unit 7 Instrument Panel
2 Battery 8 Engine Coolant Temperature
3 Battery Relay Switch
4 Circuit Breaker 9 Pressure Switch (for OWD)
5 Fuse Box 10 OWD Select Switch
6 Engine Oil Pressure Switch 11 Alternator

Page 20
Performance Specification
No. Input Output

All warning lights warning buzzer are
1 Start Switch "ON" turned on and turned off after
approximately 2 seconds
5 ±1V below L2 turned on

2 Alternator "L" terminal
5 ±1V over L2 turned off
Engine oil pressure Warning buzzer will turned on after
Alternator "L" terminal switch: ON approximately 8 seconds
3
: 5 ±1V over state Coolant temperature Warning buzzer will turned on
switch: ON immediately
4 Switch (10) "ON" Pressure Sensor "L5" and warning buzzer will be turned
Voltage : 2.3 ± 0.1V Over on immediately.
Pressure Sensor "L5" and warning buzzer will be turn off.

Voltage : 2.3 + 0.1V Over
Voltage : 2.3 − 0.2V Below
5 Switch (10) "OFF" ----------- "L5" and warning buzzer will be turn off.

Page 21
ENGINE CONTROL SYSTEM
ENGINE CONTROL CIRCUIT DIAGRAM
87a 7
30
87
85 86
9 6
8
5 B
BR
P4 4 9 A
M 17 4
P5 5
RETRACT P3 8 1 1
(+) (+) CW LOW
P2 7 2 2
P1 6 3 3
(-) (-)
12 HIGH
9 AMP MIC 17P
2 CN2
3
1
BJS1540L
Figure 11
Reference Reference
Number Number
1 Engine Throttle Controller 6 Circuit Breaker
2 Engine Control Motor 7 Fuse Box
3 Engine Control Dial 8 Relay
4 Battery 9 Engine Coolant Temperature
5 Battery Relay Switch

Page 22
ENGINE CONTROL MOTOR
1
2 3
CIRCUIT DIAGRAM
P4
(GREEN)
P1(Gr) P2(P) P3(L) M

P5
(YELLOW)
(RETRACT) (GRAY) P1
ACCEL
(PINK) P2
P4(G) P5(Y) + Vs
-
(5.0V)
(BLUE) P3 Vp
DECEL
(EXTEND)
ARS1100L
Figure 12
Reference
Description
Number
1 Motor Assembly
2 Cable
3 Spring Assembly
The engine control motor uses a D.C. motor with a built in potentiometer to sense the position of the control
cable. If an abnormal load (worn or kinked control cable) is sensed in the control motor, the engine
controller cuts off the electric current flowing to the engine control motor to protect the system. In such a
case, the engine control motor will not operate even though the engine control dial is moved.
The starter switch should be turned off and the cause of abnormal load should be repaired and the starter
switch can be turned on again. The engine control dial can once again be used to control the engine
speed.
IMPORTANT
When the engine control motor has been replaced or repaired refer to Adjusting the Engine
Control Device for correct adjustment of the engine control system. The engine will not perform
to its maximum efficiency if it is not adjusted properly.

Page 23
ENGINE CONTROL DIAL
1st STEP 7th STEP 13th STEP
CCW ( 10 ) ( 10 ) CW
MECHANICAL MECHANICAL
STOP STOP
(V)
5
4.0V
4
3 2.5V
2
2 1.0V
1
0 SETUP
1ST 2nd 7th 12th 13th
CCW CW
STOP STOP
VIEW ( POTENTIOMETER BOTTOM)

1 2 3
HDA6033L
Figure 13
Reference
Description
Number
1 Knob
2 Potentiometer (Variable
Resistor)

Page 24
The engine control dial has a built in potentiometer. When the control knob is moved the output voltage
(through terminals 2 and 3) will vary from the 5 V supplied from the throttle controller as shown in the
graph.

Page 25
ENGINE OVERHEAT PROTECTION SYSTEM
1
C H
E F 2
P M
(Potentiometer signal)
(Drive signal)
6
5
Engine Overheat Signal
BJS1550L
Figure 14
Reference Reference
Number Number
1 Instrument Panel 4 Engine Throttle Controller
2 Engine Control Motor 5 Relay
3 Engine 6 Warning Buzzer
When the engine coolant temperature increases to over 110°C (230°F), the switch mounted in the coolant
line will send a signal to the relay. A overheat signal is also sent to the instrument panel and the overheat
warning buzzer will sound. The relay will send a signal to the engine throttle controller and the engine
throttle controller will send signal the engine control motor to decrease the engine speed.

Page 26
S0892096K
1ELECTRICAL
SCHEMATIC
(SOLAR 75-V)
CAUTION!
ELECTRICAL SCHEMATIC (SOLAR 75-V)S0892096K


January 2004
Electrical Schematic (Solar 75-V) S0892096K

Page 1
TABLE OF CONTENTS
Solar 75-V (S/N 1001 thru 1153).................................................................... 4
Solar 75-V (S/N 1154 and Up) ....................................................................... 6
S0892096K Electrical Schematic (Solar 75-V)

Page 2
GENERAL DESCRIPTION
Schematic(s) presented in this section are laid out on facing pages.
An overlapping edge has been taken into consideration so that a photocopy can be made and pasted
together to make a complete schematic.
Figure 1

Page 3
SOLAR 75-V (S/N 1001 THRU 1153)
CAR STEREO (OPTION)
SPEAKER
ANTENNA
(2541-9020)x2 (541-00013)
(RH) (LH)
- + - +
0.85GrR 8
0.85BY 18 LAMP RELAY
1 CAR STEREO 5 0.85R 0.85RG (2544-9032)
0.85GrL WORKING LAMP
0.85BW 9 (541-00014) 11 0.85B (534-00029) 0.85B 87a
30 1.25RG
0.85RL 4 14 0.85B 0.85RG 1.25RG 87
(R)
0.85B 85 86 0.5RY
3
CLOCK ROOM LAMP
0.85RG
0.5WR
(528-00039) (534-00051)
0.5B
E B 0.85R (L) 0.85B 0
0.85B
10W 0.5WR 6 I
HEAD LAMP 0.5RY 3 II

1 3 4 2
(534-00029)x2 0.5B 10
0.5WR
0.5RB
0.85B
0.5R
0.5B
- LAMP
CIGAR LIGHTER 0.5WR
(545-00002) (549-00
+ +(2190-203
0.5WR 0.5WR 0.5WR

0.85RL 0.85RL
0.85RB
10 0.85RB
U 6 0.85YL WIPER MOTOR
AVX 0.85YL WATER TEMP (538-00006)
W/T GAUGE + I
W SENDER 0 7 0.85Y
(2547-6028) 0.85LW 5
- II
I
U 12 0.85YR 0.85YR 0.85B 0.85LY
1 II 3 0.85L
FUEL GAUGE + FUEL SENDER I II
S 0.85Y
F (547-00015) 9 0.5WR
10
- M STOP 0.5B
ILLUMINATION 3 0.5WR AVX 0.5BY
E/G OIL - RUN B 0.85L WIPER SWITCH
PRESS SWITCH +(2190-2036D11)
L7 L8 (549-00073) 0
4 0.85B
AVX 0.5BL WATER TEMP
E 0.85LB 5 I
SWITCH 0.85B
0.5B 10
HOUR METER (2) 0.5B +
0.5BW 0.5B
DIODE 5
H INDICATOR WINDOW WASHER P
+ (1) (2170-1003) (2916-9002A) WASHER SWITCH
0.5R (549-00041)
-
0.85B 0.5B +(2190-2036D12)
(3) 0.5RW
ENG OIL PRESS 7 0.5BY

L1
WATER TEMP 11 0.5BL

L3 0.5BR 2 1 0.85RL 0.85RL
5 0.5BW 0.85RW
AIR CLEANER 3
L4 0.5BY 0.5LB
TIME DELAY 9 0.85RW
OWD 2 0.5Y BUZZER 1.25LR
L5 0.5BL 4 8 0.85WB
CIRCUIT 0.85LB
PREHEAT 9 0.5LB
L6 0.5Y 5 10 0.85BrW
8 11 0.85BW OVER LOAD WARNING (OP

CHARGE 0.5BR
L2 6 0.5BrY OVER LOAD
1 0.85LR 0.85LR 7 WARNING SWITCH
(2549-9115 )
+(2190-2036D25)
GAUGE PANEL OVER HEAT RELAY
0.85B 13 7 0
(539-xxxxx) (2544-9032) 5 0.
87a 0.5B 1 I
30 0.5GY CONTROL UNIT PILOT BUZZER
10 9 0
0.5LG 87 (543-00079) (2516-1104) 0.5B
0.85WB
0.5BL 85 86 0.85RL 0.85RL
+
0.85BrW PRESSURE SENSO
0.85RW SIG (OWD)
0.85BW -
0.5LB (2547-9045 )
P4 4 9 0.85GY
0.85GW
7 0 5 0.85LW
M 17 0.5LG
THROTTLE 0.85LgR 0.85LgR 1 I
P5 5 CONTROLLER 9
0.85Y 10
(543-00082) 0.5B 0.5WR HORN RELAY
DIODE 9
(2544-9032)
RETRACT HORN 1 87a
P3 0.85L 8 1 0.5GR 1 BOOM SWING SWITCH (516-00009)
(+) (+) CW LOW
0.85B (2549-9115) 30 0.85RY
P2 0.85Or 7 2 0.5G 2
+(2190-2584D6) 0.85RB 87
P1 0.85Gr 6 3 0.5GB 3 0.85LgR
(-) (-) H.F 0.85B
12 0.85B HIGH 85 86 0.5Gr
AMP MIC 17P
DIODE 10
ENG CONTROL DIAL 0.5B

ENG COTROL CN2 BOOM SWING
MOTOR (2552-1004 )
SOLENOID VALVE x 2
(523-00013)
0.85B
0.5Gr
87
0.85RG 0.85LB 0.85BrW 0.85BrW 8

1 0.5BL 0.85WL (2) (1) 0.85WY
DIODE 4
0.5B 8
2 0.5Or E L DUCT/DEF 0.85WG
2 DEF DUCT/DEF SWITCH RESISTOR
3 0.5P OFF 0.85W (545-00005) 0.85B
CW ACTUATOR (549-00044)
3 DUCT +(132-00022)
M (2213-9002) 1
TEMP. CONTROL DIAL 7 8 9 12 BREAKER
(552-00004) 10 0.85GW E L M H SOLENOID VALVE
+(132-00022) OFF
11 0.85G
1.25LR 0.85LR 3 AIRCON
CONTROLLER 2 0.85BW 1
0.85BW AVX 0.85LW
5 (543-00042) 2 HIGH SPEED SWITCH
1 0.85LW (2549-9115)
6 LOW PRESS HIGH PRESS 3
4 +(2190-2036D13)
CUT OFF SWITCH CUT OFF SWITCH M
HEATER BLOWER SWITCH 0.85B 7 0
0.85B RECEIVER DRIER 5
(549-00043) HEATER
(2204-6032) +(132-00022) (920-00093) 0.85YR 1 I
0.85YG 4 9
0.5B 10
DIODE 7
0.85YG 5
DIODE 6
0.85LW 1
0.85B
0.85LY 2 0.85B
1.25LR
3
AVX 0.85B
0.85LB HIGH SPEED PILOT CUT

COMPRESSOR
0.85LB + - 0.85B (2208-6012B) SOLENOID VALVE OFF SWITCH
E L M H
M (549-00046)
0.85YG NO
OFF C
AIRCON UNIT
DIODE 8
1 (920-00047) NC
2
0.85B
3 0.85B
AIRCON BLOWER SWITCH
PILOT CUT OFF
(549-00043) +(132-00022) SOLENOID VALVE
AIRCON (OPTION)
Figure 2

Page 4
1.25LW AVX 1.25LW COM
87a
30
M
87 1.25WG
Y AVX 1.25WG NO NO
86 85
AVX 1.25B B NC COM
1.25B
0.5LR
30 1.25RG
ENG STOP MOTOR
ENG STOP RELAY
86 0.5RY (2544-9032)
0
0.5WR 6 I 2 0.85RG
0.5RY 3 II
0.5B 10 9 0.5WR
1.25WG
0.85B
0.85LW
0.85GB
0.85RB
0.85RY
0.85RL
0.85Y
0.85L
- LAMP SWITCH
GAR LIGHTER 0.5WR
0.85R
(549-00040) STARTER
545-00002)
+ +(2190-2036D4) CONTROLLER STARTER RELAY
1 2 3 4 5 6 7 8 (2523-9005 )
STARTER (2544-1023 )
0.85LR
0.5WR 10A 10A 10A 10A 10A 10A 10A 10A
SWITCH N S D PP 5BW
0.85RL 0.85Br
(2549-1152)
15 16 17 5W ACC
0.85RB
DIODE 3
FUSE BOX 2WR C B 5W
2WR B C
(2510-1008)
0.85B
2WR E P B
0.85RY
0.85W
0.85Y
0.85WG
0 7 0.85Y 2W
0.85LR
0.85BY
5 BR R2
1.25WG
5W
0.85LW
R1
0.85Br
I
18 19 20
1 II 3 0.85L
15A 15A 15A 15A 20A 20A
0 9 0.5WR
B 9 10 11 12 13 14
WIPER SWITCH
0.85GY
1.25RG
1.25LR
0.85LB
+(2190-2036D11)
0.85W
O.85R
(549-00073) 0
1 0.85L
0.85LB 5 I
0.85BG
0.5B 10 9 0.5WR
+ 0.85B D PP AVX 5L
DIODE 5
0.85BW
WASHER
DIODE 1
P
DIODE 2
02A) WASHER SWITCH
(549-00041) C B
-
0.85B 0.5B +(2190-2036D12) AIR HEATER
PREHEAT RELAY (129915-77050 )
3
(2544-1023 )
0.85LW 1 PREHEAT
TIMER
0.85RL 0.5LB 4 (537-00010)
0.85RW
5W
2
0.85B
0.5LB
1.25LR
0.85LB 5W
OVER LOAD WARNING (OPT)

OVER LOAD
0.85WG
0.85RW
0.85LW
0.85RY
0.5WR
0.85Br
WARNING SWITCH
0.85Y
2WR
(2549-9115 )
AVX 5BW
5W
+(2190-2036D25)
7 0 FUSIBLE LINK 2 C
5 0.5BrY
(527-00004) B
0.5B 1 I 30B
10 9 0.5WR 5W 5W
0.5B
45A
0.85RL FUSIBLE LINK 1

+
0.85BrW PRESSURE SENSOR (2527-1023A)
SIG A
(OWD)
0.85BW - (2547-9045 ) 2WR 2R
27A STARTER
CIRCUIT BREAKER BATTERY RELAY 12V 2.3KW
(2527-9004) (2544-9025)
B A 30B 30B
8W
1.25Br BR
HORN RELAY
(2544-9032) 1.25B E
HORN 1 + -
87a
516-00009) 12V 100AH
30 0.85RY
0.85RB 87 BATTERY (2506-1104 )
H.F 0.85B HORN SW
85 86 0.5Gr (ON JOYSTICK R.H)
0.5B
0.5RY
BREAKER RELAY
0.5Gr
(2544-9032) HORN/BREAKER SW
87a (ON JOYSTICK L.H) AVX 8W
30 0.5G 0.5RY AVX 1.25WG
0.85BrW 0.85BrW 87 AVX 1.25RW
WY 86 7 0 5 0.5RY AVX 1.25RB
DIODE 4
0.5B 85 0.5Y
1 I IG L P B(BATT)
0.85B 10 9
0.5B 0.5WR
BREAKER BREAKER SELECT SWITCH 0 7

SOLENOID VALVE (2549-9115) 0.85RY 5 TRAVEL ALRAM
+(2190-2036D1) I 1 SELECT SWITCH
IG
0.85WR 9 10 0.5B (2549-9115)
+(2190-2036Dx)
HIGH SPEED SWITCH
(2549-9115) MICRO SWITCH (R.H) L
+(2190-2036D13) (549-00006)
85B 7 0 F
5 0.85YR 0.85YL +
0.85Y E
0.85YR 1 I
-
DIODE 11
0.5B 10 9 0.5WR
MICRO SWITCH (L.H) ALTERNATOR E
DIODE 7
BUZZER AVX 8B
(549-00006) 12V 60A
(2516-1124)
0.85B 0.85YR 0.85YL
0.85B
HIGH SPEED PILOT CUT 7 0 5

SOLENOID VALVE OFF SWITCH
0.85R 1 I TRAVEL ALRAM (OPTION)
(549-00046)
10 9
0.85B 0.5B
0.85YG NO
C 0.85Y
DIODE 8
NC ROTATING BEACON ROTATING

BEACON SWITCH
(2RL006846-101)
0.85B (2549-9115)
0.85B HELLA
+(2190-2036D10)
PILOT CUT OFF
SOLENOID VALVE ROTATING BEACON (OPTION)
SOLAR 75-V
BJS1560L

Page 5
SOLAR 75-V (S/N 1154 AND UP)
CAR STEREO (OPTION)
2B
SPEAKER
ANTENNA
(2541-9020)x2 (541-00013)
(RH) (LH)
0.85RG
- + - +
0.85GrR 8
0.85BY 18 LAMP RELAY
1 CAR STEREO 5 0.85RG 0.85RG (2544-9032)
0.85GrL WORKING LAMP
0.85BW 9 (541-00014) 11 0.85B (534-00029) 0.85B 87a
30 1.25RG
4 14 0.85B 0.85RG 1.25RG 87
0.85RL
(R)
0.85B 85 86 0.5RY
3
CLOCK ROOM LAMP
0.85RG
0.5WR
(528-00039) (534-00051)
0.5B
E B 0.85RG (L) 0.85B 0
0.85B
10W 0.5WR 6 I
HEAD LAMP 0.5RY 3 II

1 3 4 2
(534-00029)x2 0.5B 10
0.5WR
0.5RG
0.5RB
0.85B
0.5B
- LAMP SW
CIGAR LIGHTER 0.5WR
(545-00002) (549-000
+ +(2190-2036
0.5WR 0.5WR 0.5WR

0.85RL 0.85RL
0.85RB
10 0.85RB
U 6 0.85YL WIPER MOTOR
AVX 0.85YL WATER TEMP (538-00006)
W/T GAUGE + I
W SENDER 0 7 0.85Y
(2547-6028) 0.85LW 5
- II
I
U 12 0.85YR 0.85YR 0.85B 0.85LY
1 II 3 0.85L
FUEL GAUGE + FUEL SENDER I II
S 0.85Y
F (547-00015) 9 0.5WR
10
- M STOP 0.5B
ILLUMINATION 3 0.5WR AVX 0.5BY
E/G OIL - RUN B 0.85L WIPER SWITCH
PRESS SWITCH +(2190-2036D11)
L7 L8 (549-00073) 0
4 0.85B 1
AVX 0.5BL WATER TEMP
E 0.85LB 5 I
SWITCH 0.85B
0.5B 10 9
HOUR METER (2) 0.5B +
0.5BW 0.5B
DIODE 5
H INDICATOR WINDOW WASHER P
+ (1) (2170-1003) (2916-9002A) WASHER SWITCH
0.5RG (549-00041)
-
0.85B 0.5B +(2190-2036D12)
(3) 0.5RW
ENG OIL PRESS 7 0.5BY

L1
DIODE 11
WATER TEMP 11 0.5BG
L3 0.5BR 2 1 0.85RL 0.85RL
5 0.5BW 0.85RW
AIR CLEANER 3
L4 0.5BY 0.5LB
TIME DELAY 9 0.85RW
OWD 2 0.5Y BUZZER 1.25LR
L5 0.5BL 4 8 0.85WB
CIRCUIT 0.85LB
PREHEAT 9 0.5LB
L6 0.5Y 5 10 0.85BrW
8 11 0.85BW OVER LOAD WARNING (OPT

CHARGE 0.5BR
L2 6 0.5BrY OVER LOAD
1 0.85LR 0.85LR 7 WARNING SWITCH
(2549-9115 )
+(2190-2036D25)
GAUGE PANEL OVER HEAT RELAY
0.85B 13 7 0
(539-00053) (2544-9032) 5 0.5B
87a 0.5B 1 I
30 0.5GY CONTROL UNIT PILOT BUZZER
10 9 0.5W
0.5LG 87 (543-00079) (2516-1104) 0.5B
0.85WB
0.5BL 85 86 0.85RL 0.85RL
+
0.85BrW PRESSURE SENSOR
0.85RW SIG (OWD)
0.85BW -
0.5LB (2547-9045 )
P4 4 9 0.85GY
0.85GW
7 0 5 0.85LW
M 17 0.5LG
THROTTLE 0.85LgR 0.85LgR 1 I
P5 5 CONTROLLER 9
0.85Y 10
(543-00082) 0.5B 0.5WR HORN RELAY
DIODE 9
(2544-9032)
RETRACT HORN 1 87a
P3 0.85L 8 1 0.5GR 1 BOOM SWING SWITCH (516-00009)
(+) (+) CW LOW
0.85B (2549-9115) 30 0.85RY
P2 0.85Or 7 2 0.5G 2
+(2190-2584D6) 0.85RB 87
P1 0.85Gr 6 3 0.5GB 3 0.85LgR
(-) (-) H.F 0.85B
12 0.85B HIGH 85 86 0.5Gr
AMP MIC 17P
DIODE 10
ENG CONTROL DIAL 0.5B

ENG COTROL CN2 BOOM SWING
MOTOR (2552-1004 )
SOLENOID VALVE x 2
(523-00013) BREAKER
0.85B
(2549-911
+(2190-2036
7 0
0.85RG 0.85LB 0.85BrW 0.85BrW 1 I

1 0.5BL 0.85WL 10
DIODE 4
2 0.5Or E L DUCT/DEF 0.85WG
3 2 DEF DUCT/DEF SWITCH 0.85B
0.5P OFF (549-00044) 0.85W
CW ACTUATOR
3 DUCT +(132-00022)
M (2213-9002) 1
TEMP. CONTROL DIAL 7 8 9 12 BREAKER
M
(552-00004) 10 0.85GW E L M H 0.85B SOLENOID VALVE
+(132-00022) OFF HEATER
11 0.85G
1.25LR 0.85LR 3 AIRCON (920-00093)
CONTROLLER 2 0.85BW 1
0.85BW AVX 0.85LW
5 (543-00042) 2 HIGH SPEED SWITCH
1 0.85LW (2549-9115)
6 LOW PRESS HIGH PRESS 3
4 +(2190-2036D13)
CUT OFF SWITCH CUT OFF SWITCH HEATER BLOWER SWITCH 7 0 5
0.85B RECEIVER DRIER (549-00043) 0
(2204-6032) +(132-00022) 0.85YR 1 I
0.85YG 4 9 0.
0.5B 10
DIODE 7
0.85YG 5
DIODE 6
0.85LW 1
0.85B
0.85LY 2 0.85B
1.25LR
3
AVX 0.85B
0.85LB HIGH SPEED PILOT CUT

COMPRESSOR
0.85LB + - 0.85B (2208-6012B) SOLENOID VALVE OFF SWITCH
E L M H
M (549-00046)
0.85YG NO
OFF C
AIRCON UNIT 0
DIODE 8
1 (920-00047) NC
2
0.85B
3 0.85B
AIRCON BLOWER SWITCH
PILOT CUT OFF
(549-00043) +(132-00022) SOLENOID VALVE
AIRCON (OPTION)
Figure 3

Page 6
FUEL PUMP
(2401-1276A)
2B - + 2R
P
E/G STOP TIMER E/G STOP RELAY E/G STOP SOLENOID

0.85RG (129211-77920) (2544-1023 ) (1119233-77932)
1 0.85Y D PP AVX 3RW B PULL
4
AY
2 0.85RW C B 3W A HOLD
3 C
30 1.25RG
DIODE 12
3W
3B
86 0.5RY DIODE 11
0.85LR 0.85LR
0
0.5WR 6 I 2 0.85RG
0.5RY 3 II
0.5B 10 9 0.5WR
0.85B
2R/0.85RG
0.85LW
0.85GB
0.85RB
0.85RY
0.85RL
0.85Y
0.85L
- LAMP SWITCH
CIGAR LIGHTER 0.5WR STARTER
(545-00002) (549-00040)
+ +(2190-2036D4) CONTROLLER STARTER RELAY
1 2 3 4 5 6 7 8 (2523-9005 )
STARTER (2544-1023 )
0.85LR
0.5WR 10A 10A 10A 10A 10A 10A 10A 10A
SWITCH N S D PP 5BW
0.85RL 0.85Br
(2549-1152)
15 16 17 5W ACC
0.85RB
DIODE 3
FUSE BOX 2WR C B 5W
2WR B C
(2510-1008)
0.85B
2WR E P B
0.85RY
0.85W
0.85Y
0.85WG
0 7 0.85Y 2W
0.85LR
0.85BY
5 BR R2
5W
0.85LW
R1
0.85Br
I
18 19 20
1 II 3 0.85L
15A 15A 15A 15A 20A 20A
10 9 0.5WR
5B 9 10 11 12 13 14
WIPER SWITCH
0.85GY
1.25RG
1.25LR
0.85LB
+(2190-2036D11)
0.85W
(549-00073) 0
1 0.85L
2R/0.85RG
0.85LB 5 I
0.85BG
0.5B 10 9 0.5WR
+ 0.85B D PP AVX 5L
DIODE 5
0.85BW
W WASHER
DIODE 1
P
DIODE 2
002A) WASHER SWITCH
(549-00041) C B
-
0.85B 0.5B +(2190-2036D12) AIR HEATER
PREHEAT RELAY (129915-77050 )
3
(2544-1023 )
0.85LW 1 PREHEAT
TIMER
0.85RL 0.5LB 4 (537-00010)
0.85RW
5W
2
0.85B
0.5LB
1.25LR
0.85LB 5W
OVER LOAD WARNING (OPT)

OVER LOAD
0.85WG
0.85RW
0.85LW
0.85RY
0.5WR
0.85Br
WARNING SWITCH
0.85Y
2WR
(2549-9115 )
AVX 5BW
5W
+(2190-2036D25)
7 0 FUSIBLE LINK 2 C
5 0.5BrY
(527-00004) B
0.5B 1 I 30B
10 9 0.5WR 5W 5W
0.5B
45A
0.85RL FUSIBLE LINK 1

+
0.85BrW PRESSURE SENSOR (2527-1023A)
SIG A
(OWD)
0.85BW - (2547-9045 ) 2WR 2R
27A STARTER
CIRCUIT BREAKER BATTERY RELAY 12V 2.3KW
(2527-9004) (2544-9025)
B A 30B 30B
8W
1.25Br BR
HORN RELAY
(2544-9032) 1.25B E
HORN 1 + -
87a
(516-00009) 12V 100AH
30 0.85RY
0.85RB 87 BATTERY (2506-1104 )
H.F 0.85B HORN SW
85 86 0.5Gr (ON JOYSTICK L.H)
0.5B
0.5RY
BREAKER SWITCH
(2549-9115)
+(2190-2036D1) HORN/BREAKER SW
(ON JOYSTICK R.H) AVX 8W
7 0 5 0.85Gr 0.5RY AVX 1.25WG
0.85BrW 0.85BrW 1 I
AVX 1.25RW
10 9 0.5WR
AVX 1.25RB
DIODE 4
IG L P B(BATT)
0.85B
BREAKER 19bar
0.85B SOLENOID VALVE 0 7 0.85YR 0.85RL +
0.85RY 5
I 1 -
TRAVEL PRESS 0.85B IG
0.85WR 9 10 0.5B
SWITCH BUZZER
HIGH SPEED SWITCH (2549-9112) (516-00011)
(2549-9115) TRAVEL ALRAM L
+(2190-2036D13) SELECT SWITCH
7 0 (2549-9115) F
5
0.85Y +(2190-2584D13) E
0.85YR 1 I
0.5B 10 9 0.5WR
ALTERNATOR E
DIODE 7
AVX 8B
TRAVEL ALRAM (OPTION) 12V 60A
0.85B
0.85B
HIGH SPEED PILOT CUT 7 0 5

SOLENOID VALVE OFF SWITCH
0.85R 1 I
(549-00046)
10 9
0.85B 0.5B
0.85YG NO
C 0.85Y NOTE
1. DIODE PART NO
DIODE 8
NC ROTATING BEACON ROTATING

BEACON SWITCH DIODE 1,11 ; 2548-1026
(2RL006846-101)
0.85B (2549-9115) DIODE 2~10 ; 2548-1027
0.85B HELLA
+(2190-2036D10)
PILOT CUT OFF
SOLENOID VALVE ROTATING BEACON (OPTION)
LAMP NO. FOR GAUGE PANEL
TERMINAL NO. FOR CONTROL UNIT

STARTER SWITCH CONNECTION
L1 WATER & GAUGE PANEL
B BR R1 R2 C ACC TEMP 6 5 4 3 2 1
L2
OFF L3 FUEL
HEAT L4
ON HOUR
L5 METER
START L6
SOLAR 75-V
13 12 11 10 9 8 7
BJS1630L

Page 7
1ATTACHMENTS
S0902025K
1BOOM AND ARM
CAUTION!
BOOM AND ARM S0902025K


May 2002
Boom and Arm S0902025K

Page 1
TABLE OF CONTENTS
Front Attachment Pin Specifications .............................................................. 3

Front Attachment - Removal and Installation ................................................. 4
Arm Removal Procedure......................................................................... 4
Boom Removal Procedure ...................................................................... 6
Installation ...................................................................................................... 7
Arm Installation Procedure...................................................................... 7
Boom Installation Procedure ................................................................... 7
Start-up Procedures ....................................................................................... 8
S0902025K Boom and Arm

Page 2
FRONT ATTACHMENT PIN SPECIFICATIONS
The table below has a complete listing of dimensional specifications for all mounting pins used on the front
attachment.
NOTE: Some mounting pins must be drilled and tapped for lubrication fittings and piping, or may
have other required specifications. Consult Daewoo After Sales Service for information on
wear tolerances and replacement limits for mounting pins.
D C B A Q P
F E
G H I J K L N O M
BJS0050L
Figure 1
Mounting Pin Diameter, mm (Inches) Length, mm (Inches)

A 65 mm (2.55 in) 229 mm (9.01 in)
B 50 mm (1.96 in) 172 mm (6.77 in)
C 65 mm (2.55 in) 259 mm (10.19 in)
D 65 mm (2.55 in) 203 mm (7.99 in)
E 60 mm (2.36 in) 339 mm (13.34 in)
F 65 mm (2.55 in) 189 mm (7.44 in)
G 50 mm (1.96 in) 167 mm (6.57 in)
H 45 mm (1.77 in) 291 mm (11.45 in)
I 45 mm (1.77 in) 348 mm (13.70 in)
J 55 mm (2.16 in) 291 mm (11.45 in)
K 45 mm (1.77 in) 348 mm (13.70 in)
L 65 mm (2.55 in) 216 mm (8.50 in)
M 65 mm (2.55 in) 217 mm (8.54 in)
N 50 mm (1.96 in) 201 mm (7.91 in)
O 50 mm (1.96 in) 181 mm (7.12 in)
P 90 mm (3.54 in) 472 mm (18.58 in)
Q 65 mm (2.55 in) 480 mm (18.89 in)

Page 3
FRONT ATTACHMENT - REMOVAL AND
INSTALLATION
DANGER!
Daewoo warns any user, that the removal of
the counterweight from the machine, front
attachment or any other part, may affect
X
the stability of the machine. This could
cause unexpected movement, resulting in
death or serious injuries. Daewoo is not
liable for any misuse.
been removed.
HAAD4060
Figure 2
IMPORTANT
Always break down the front attachment by removing outermost sections first - the bucket
before the arm, the arm before the boom. Reinstallation of the attachment should begin with the
boom and end with the bucket.
Refer to the appropriate Bucket section for its removal and installation procedure before going onto the
initial step of the front attachment removal or installation procedure.
ARM REMOVAL PROCEDURE
WARNING!
This procedure is only intended for routine removal or replacement of the attachment, while
working under normal, safe operating conditions. In the event of a major structural collapse of
some part of the attachment, an accident or complete loss of attachment hydraulic function, Do
not proceed with attachment disassembly unless you are completely sure of what you are doing.
Please call your local Daewoo distributor or Daewoo After Sales Service for assistance. Do not
allow personnel to stand underneath a weakened or only partially supported attachment section.
Keep clear of hydraulic lines that may have fluid escaping at high-pressure - it can cause severe
or even fatal injuries.
Complete the bucket end removal procedure by pulling out the two bucket linkage pins and the bucket
cylinder mounting pin, on the arm. Use an assist crane or hoist to lift the cylinder and relieve weight on
mounting pins.

Page 4
Park the excavator away from obstructions and all traffic on clear, flat, level ground. Extend the arm
cylinder and crowd the arm into the boom. Partially retract the boom cylinder so that the boom is stretched
out in front of the excavator, as low to the ground as possible, with the arm crowded under the boom.
The tip of the arm point should be lowered to secure blocking that will safely support the weight of the arm.
Place the blocking directly in front of the excavator and make sure that it will not be unbalanced with an
initial weight load that is all to one end, under the arm point.
Shut off the engine and release hydraulic system pressure - move any of the control levers with the engine
off to release pressure built up in the accumulator. Manually vent residual hydraulic pressure in the tank by
moving the lever near the cap, on top of the reservoir.
WARNING!
Secure the swing lock and tag and lock out controls in the operator's cab to keep anyone from
moving or inadvertently starting the engine. Restrict access to the work site while sections of
the attachment are in the air, or while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must exceed the weight of the heaviest
section of the attachment, the boom (approximately 2,700 kg (5,950 lb), not including the weight
of accessories or fixtures).
Before beginning the disassembly of attachment mounting pins, disconnect the arm cylinder hydraulic
hose couplings and put a clean plug in the end of each one. Use any and all reasonable precautions
necessary to avoid introducing dirt or other contaminants into the hydraulic system. Wipe down coupling
points before disconnecting hydraulic lines and use evaporative type solvent spray cleaner. Tag and mark
hoses for reassembly, if necessary.
Place a sling under the arm cylinder (the cylinder used to extend and retract the attachment arm, pinned to
the top of the boom). Lift the sling so that the weight load on the rod end of the arm cylinder (pinned to the
ears on the inner end of the arm) is released. Prepare blocking under the arm that will securely support the
weight of the arm and arm cylinder.
CAUTION!
To make sure that the polished surfaces of cylinder rod ends will not suffer accidental damage
during disassembly or removal procedures, wrap exposed rod surfaces (especially those of
boom cylinders) with a protective covering material. Immediately following disassembly and
removal, cylinder rods should always be fully retracted. This eases handling problems and also
avoids possible damage.
Remove retainers on the end of the mounting pin for the arm cylinder rod end. Use the assist crane to
relieve the weight load and withdraw the pin. Lower the arm down to the blocking support for any continued
disassembly procedures.

Page 5
BOOM REMOVAL PROCEDURE
NOTE: Boom removal may be simplified if the shell of the operator's cab is taken off the turntable
deck first. Refer to the Operator's Cab Removal procedure before continuing, if both
components are to be removed from the excavator.
After the bucket, arm and arm cylinder have been removed, lower the end of the boom to a stable, secure
blocking support.
Attach the assist crane sling to the body of either boom cylinder, break the mounting pin connection to the
boom by tapping through the pin from the same side of the boom and repeat for the opposite cylinder.
Release hydraulic pressure and disconnect line couplings as previously outlined in the Arm Removal
Procedure, observing the same precautions.
Disconnect wiring for work light assemblies and any other accessory lines or connections. Locate the sling
of the assist crane near the center of gravity, optimum lift point for the boom, and use the crane to take
pressure off the boom foot pin. Drive out the pin after disassembling retainers and carefully lift away the
boom.
WARNING!
Traveling the excavator, swinging the turntable or movement over bumps or sloping, uneven
surfaces could all produce loss of control and possible accidents or injuries, if the turntable
deck has been unbalanced by removal of weight from one end only.
To maintain stability, the counterweight should be removed whenever the front attachment is taken off the
machine.

Page 6
INSTALLATION
ARM INSTALLATION PROCEDURE
Reattach the base of the arm cylinder to the mounting point on top of the boom.
WARNING!
Before assembling the front attachment, make sure that the individual boom, arm and bucket
sections are all compatible and can be used safely for work intended. Refer to the General
Safety Pages, Lift Ratings, Working Range Diagrams and Weights of Materials sections in the
Operation and Maintenance Manual. Consult your dealer or Daewoo After Sales Service for more
information if you have any questions or require more information.
Begin with the arm securely supported on blocking in front of the excavator. Pregrease the mounting pin for
the rod end of the arm cylinder and push it through the ears on the end of the arm. Attach a sling around
that mounting pin and lift the arm with an assist crane until it is in position for the boom-arm pin connection
to be made.
Relieve hydraulic pressure from all points of the system before any hydraulic lines are opened, then
carefully assemble hydraulic connections to the arm cylinder.
Remove the sling from around the rod end arm cylinder pin, withdraw the pin and lift the body of the arm
cylinder to re-pin the mounting connection.
BOOM INSTALLATION PROCEDURE

Before reassembling the attachment, make sure to inspect all bushings and pivot points of each section. To
avoid damaging the seats, bushings should never be hammered or chiseled out of their seats.
Installation is otherwise a reversal of the removal procedures.

Page 7
START-UP PROCEDURES
Once the boom has been serviced, it should be lubricated as outlined in the initial start-up procedures of
the operation manual. Refer to the appropriate operation and maintenance manual for unit.

Page 8
S0904000
R4
1BUCKET
CAUTION!
BUCKET S0904000
Solar 015 PLUS 1001 thru 1157, 20001 thru 20065, 20066 and Up
Models continued on back of cover.

January 2004
Bucket S0904000
Page 1
TABLE OF CONTENTS
Bucket Tooth Inspection and Replacement .................................................... 3

Type 1...................................................................................................... 3
Type 2...................................................................................................... 4
Type 3...................................................................................................... 5
Bucket O-ring Replacement ........................................................................... 7
Type 1...................................................................................................... 7
Type 2...................................................................................................... 8
Bucket Shimming Procedures ...................................................................... 10
New Bucket Installation ......................................................................... 10
Type 1.................................................................................................... 10
Type 2.................................................................................................... 11
Bucket Attachment, Removal and Reversal ................................................. 12
Detaching the Bucket ............................................................................ 12
Attaching the bucket.............................................................................. 12
Reversing the Bucket ............................................................................ 13
S0904000 Bucket
Page 2
BUCKET TOOTH INSPECTION AND REPLACEMENT
There are several different types of attachment methods for replaceable bucket teeth. Some of the most
common types are shown in the following drawings.
Bucket teeth are usually replaced in sets but it may sometimes be necessary to replace individual teeth.
TYPE 1
Look for the following indications of wear or damage:
• Lock pins protrude unevenly on one side.
• Lock pins have been worn down so far that they no longer make full contact through the length
of the pin hole.
• Lock washers or pins show obvious damage or weakness.
• Wear points on the working surfaces of tooth points - pits, cracks, chips or craters - are larger
than 8 - 10 mm (1/3" - 1/2") across.
HAOC680L
Figure 1
1. On a routine basis, inspect the bucket

teeth to make sure that tooth wear or
breakage has not developed. Do not allow
the replaceable bucket teeth to wear down
to the point that the bucket adapter is
exposed. See Figure 7.
2. To replace a tooth (1, Figure 4), use a
hammer and punch to drive the locking pin
(2) and lock washer (3) out of the tooth
adapter (4).
3. Once the worn tooth has been removed,
use a putty knife to scrape the adapter as
Figure 2
clean as possible.
4. Slide the new tooth into position and insert
the lock washer.
5. Insert the locking pin into the tooth and
with a hammer, drive the pin in until the
lock washer seats in the locking groove.
Bucket S0904000
Page 3
TYPE 2
WARNING!
Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and
eye protection when changing bucket teeth.
Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground.
Shut the engine off and lock out the hydraulic controls before working on the bucket.
NOTE: These instructions are only for Daewoo OEM buckets. If you are using other
manufacturers buckets, refer to their specific instructions.
Figure 3
1. On a routine basis, inspect the bucket

teeth to make sure that tooth wear or
breakage has not developed. Do not allow
the replaceable bucket teeth to wear down
to the point that the bucket is exposed.
See Figure 3.
2. To replace a tooth, remove bolts, lock
washers and plain washers from seat.
Remove tooth and shim(s) from bucket.
See Figure 4.
use a putty knife to scrape bucket as clean
as possible. Figure 4
S0904000 Bucket
Page 4
4. Slide the new tooth into position and insert
shims. Shim tooth until gap is less than "X"
[0.5 mm (0.020 in)]. See Figure 5.
5. Secure tooth and shim into position with
seat, plain washers, lock washers and
bolts.
Figure 5
TYPE 3
WARNING!
Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and
eye protection when changing bucket teeth.
Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground.
Place wooden blocks under front of bucket. Shut the engine off and lock out the hydraulic
controls before working on the bucket.
Inspect locking pin assembly and replace it if the following conditions exist;
1. The locking pin is too short when both surfaces are aligned.
2. The rubber has been torn and bosses of the steel balls are liable to slip off.
3. Pressing steel ball causes the boss to go inside.
X 1/3T
X X
T
4 3
HAOE380L
Figure 6
Bucket S0904000
Page 5
HAOC680L
Figure 7
1. On a routine basis, inspect bucket teeth to

make sure that tooth wear or breakage has
not developed. Do not allow replaceable
bucket teeth to wear down to a point that 1
bucket adapter is exposed. See Figure 7.
2. To replace a tooth, use a hammer (1, 2
Figure 8) and punch (2) to drive locking pin
assembly out of tooth and tooth adapter.
use a putty knife to scrape adapter as
clean as possible.
HAOE370L
4. Slide new tooth into position and insert Figure 8
locking pin assembly.
S0904000 Bucket
Page 6
BUCKET O-RING REPLACEMENT
TYPE 1
WARNING!
Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye
protection when changing pins.
1. Inspect the bucket O-rings on a routine

basis. If worn or damaged, replacement is
necessary.
HAOH640I
Figure 9
2. Roll the old O-ring (1, Figure 10) onto the
boss (2) around the bucket pin (3).
1 4
Remove the bucket pin and move the arm 2
or bucket link (4) out of the way.
HAOC710L
Figure 10
3. Remove the old O-ring and temporarily
install the new O-ring (1, Figure 11) onto 4
the bucket boss (2). Make sure that the 1
2
O-ring groove on both the bucket link (4)
and boss have been cleaned.
4. Realign the arm or link with the bucket pin
hole and insert the bucket pin (3, Figure
10).
HAOC701L
Figure 11
Bucket S0904000
Page 7
5. Roll the new O-ring (1, Figure 12) into the
O-ring groove.
1
HAOC720L
Figure 12
TYPE 2
WARNING!
Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye
protection when changing pins.
1. Inspect the bucket O-rings on a routine

basis. If worn or damaged, replacement is
necessary.
HAOE360L
Figure 13
2. Roll the old O-ring (1, Figure 10) onto the
bushing (2) around the bucket pin (3).
1 4
Remove the bucket pin and move the arm 2
or bucket link (4) out of the way.
HAOC710L
Figure 14
S0904000 Bucket
Page 8
3. Remove the old O-ring and temporarily
install the new O-ring (1, Figure 11) onto
the bucket bushing (2). Make sure that the 1 3
2
O-ring groove on both the bucket link (3)
and bushing have been cleaned.
4. Realign the arm or link with the bucket pin
hole and insert the bucket pin (3, Figure
10).
HAOC700L
Figure 15
5. Roll the new O-ring (1, Figure 12) into the
O-ring groove.
1
HAOC720L
Figure 16
Bucket S0904000
Page 9
BUCKET SHIMMING PROCEDURES
NEW BUCKET INSTALLATION
1. If a new bucket is being installed on the excavator, measure the inside dimension between the bucket
ears and the outside dimension across the arm mounting boss.
2. Subtract the clearance on both sides from the difference of the two and shim accordingly, before
assembly.
WARNING!
To check end play (side-to-side) clearance at bucket attachment point, the bucket must be free to
move but at all other times lower it to the ground or use support blocks to immobilize this
assembly. Shut off engine and tag and lock out controls to prevent movement during this
procedure.
TYPE 1
Shimming Procedures for Installed Bucket

1. With bucket attached, curl bucket and arm outward and lower boom so that bucket teeth are pointing
away from excavator, just a few inches off ground. This position provides easy accessibility for
dimensional measurements.
2. Force bucket to one side and check for end
play (side-to-side) clearance under O-rings
at attachment point. Total clearance
should be 1 mm (0.04 in) between side
face of boss and inside edge of ear
bushing (Y, Figure 17). Too tight a fit (less
than 1 mm (0.04 in)) can cause excessive
wear while too much clearance may
produce excessive noise and potentially
hazardous slack control.
3. Recheck end play by forcing bucket
towards opposite side and repeating
clearance measurements.
4. If an adjustment is required, remove two
jam nuts (1, Figure 17) and bolt (2) from
pin (3). Add or remove shims (4) as
required. Use equal amount of shims on
each side. Install bolt (2) and two jam nuts
(1). Jam nuts must clear boss by 1 - 2 mm Figure 17
(0.04 - 0.08 in) at point (X).
S0904000 Bucket
Page 10
TYPE 2
Shimming Procedures for Installed Bucket

1. With bucket attached, curl bucket and arm outward and lower boom so that bucket teeth are pointing
away from excavator, just a few inches off ground. This position provides easy accessibility for
dimensional measurements.
2. Force bucket to one side and check for end
play (side-to-side) clearance under O-rings
at attachment point. Clearance should be
between 0.2 - 0.7 mm (0.0078 - 0.0275 in)
on each end of arm boss, between side
face of boss and inside edge of ear
bushing. Too tight a fit can cause
excessive wear while too much clearance
may produce excessive noise and
potentially hazardous slack control.
3. Recheck end play by forcing bucket
towards opposite side and repeating HAOE361L
clearance measurements. Figure 18
4. If an adjustment is required, remove bolt
(Figure 17) and pin. Add or remove shims
as required. Install pin and bolt. Torque
bolts to 42 Nm / 4.3 kg•m (31 ft lb).
Bucket S0904000
Page 11
BUCKET ATTACHMENT, REMOVAL AND REVERSAL
DETACHING THE BUCKET
Park the excavator away from obstructions on clear, flat, level ground. Lower the bucket carefully to
preassembled blocking on the ground. Brace the bucket so that there is no load weight on the pin
connecting the bucket and arm. Disassemble the fasteners on the end of the bucket pin and pull out the
pin.
If the pin sticks and resists normal withdrawal, there may be a load on it. Raise and lower the arm slightly
until the unstressed pin position is located.
CAUTION!
Use care pulling out the pin to avoid damaging the dust seals on either end of the arm.
When the pin has been withdrawn, move the operating joystick slightly to take weight off the remaining link
pin. Disassemble the link pin end retainers and pull out the pin.
Lift the arm away from the bucket so that the bucket can be carried away or another end attachment can be
put on the excavator.
ATTACHING THE BUCKET

Carefully inspect all parts before reassembling
the bucket linkage. Look for cracks or any other
evidence of physical damage and replace any
seal or O-ring that is not in like-new condition.
Prelube linkage pins before assembly.
Use an old cylinder rod, a long breaker bar or a
similar, relatively thin diameter support bar for
making the first (temporary) pin connection,
between the bucket and arm. If the support bar
is straight, the arm can be raised and the bucket
will hang level, allowing direct insertion of the
bucket ear-attachment linkage pin.
Figure 19
S0904000 Bucket
Page 12
When the link pin has been installed, withdraw
the temporary support rod from the bucket pin
holes, lower and raise the arm and boom and
install the bucket pin.
WARNING!
When making linkage alignments, never
insert fingers into pin holes. The
attachment or bucket could shift position
and cause a severe injury. Match holes by
visually lining them up. Use the sharp
tipped, soft point of a pencil or a similar
tool to check for high spots or
irregularities.
REVERSING THE BUCKET

Follow instructions for "Detaching the Bucket"
and remove both the bucket and link pins.
Rotate the bucket 180° to change bucket
configuration. This procedure is greatly
simplified if some type of rotating or swiveling
support can be used, on the ground underneath
the bucket. Follow instructions for "Bucket
Attachment" to replace pins.
Figure 20
WARNING!
Bucket curl and dump levers must be
used in opposite directions, after the
bucket has been reversed.
Bucket S0904000
Page 13

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What safety precautions should be taken when working with heavy equipment?

What safety precautions should be taken when working with heavy equipment?

What are the recommended procedures for attaching and detaching a bucket?

What are the recommended procedures for attaching and detaching a bucket?

Solar 75-V

023-00066AE Shop Manual

Lower Structure and Chassis

Engine and Drive Train

TRACK EXCAVATOR SAFETYS0102035K

MODEL SERIAL NUMBER RANGE

Copyright 2004 Daewoo

Track Excavator Safety S0102035K

To the Operator of a Daewoo Excavator ........................................................ 5

S0102035K Track Excavator Safety

Track Excavator Safety S0102035K

S0102035K Track Excavator Safety

Track Excavator Safety S0102035K

S0102035K Track Excavator Safety

Safety precautions are described in SAFETY from page -8 on.

Track Excavator Safety S0102035K

LIFTING CAPACITY RATING CONFIGURATION

LOCATION OF SAFETY LABELS

S0102035K Track Excavator Safety

Track Excavator Safety S0102035K

GENERAL HAZARD INFORMATION

S0102035K Track Excavator Safety

CLOTHING AND PERSONAL PROTECTIVE

Track Excavator Safety S0102035K

VIBRATION LEVEL INFORMATION

S0102035K Track Excavator Safety

Track Excavator Safety S0102035K

PRECAUTIONS WHEN HANDLING FLUIDS

S0102035K Track Excavator Safety

INJURY FROM WORK EQUIPMENT

Track Excavator Safety S0102035K

PROTECTION FROM FALLING OR FLYING OBJECTS

S0102035K Track Excavator Safety

Track Excavator Safety S0102035K

S0102035K Track Excavator Safety

Track Excavator Safety S0102035K

CHECKS BEFORE STARTING ENGINE

S0102035K Track Excavator Safety

BEFORE OPERATING MACHINE

Track Excavator Safety S0102035K

S0102035K Track Excavator Safety

TRAVEL POSTURE INCORRECT

Track Excavator Safety S0102035K

Do not travel on grass, fallen leaves, or wet steel

S0102035K Track Excavator Safety

PRECAUTIONS FOR OPERATION

Track Excavator Safety S0102035K

Voltage Minimum Safe Distance

6.6 kV 3 m (9' 10") AXO0130L

154.0 kV 8 m (26' 3")

275.0 kV 10 m (32' 10")

OPERATE CAREFULLY ON SNOW, ICE AND IN VERY COLD TEMPERATURES

S0102035K Track Excavator Safety

NEVER LET ANYONE RIDE ON

Track Excavator Safety S0102035K