Solar 55W-V Plus

Shop Manual
023-00067E
Serial Number 1001 and Up

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.

023-00067E Shop Manual

 Pub.No. 023-00067E
Serial Number 1001 and Up
Solar 55W-V Plus
Product Label

Instructions

Trim Out The Label Along

The Lines And Insert Into
Pocket On The Binder Spine

Pub. No. 023-00067E

 1TABLE OF CONTENTS
Safety
Wheel Excavator Safety ........................................................................S0102050

Specifications
Specifications for Solar 55W-V PLUS....................................................S0202120

General Maintenance
General Maintenance Procedures .........................................................S0302000
Standard Torques ..................................................................................S0309000

Upper Structure
Counterweight........................................................................................S0403060
Fuel Transfer Pump ...............................................................................S0405500
Swing Bearing........................................................................................S0407010
Swing Reduction Gearbox .....................................................................S0408080

Lower Structure and Chassis

Ram Lock Valve Operation....................................................................S0503000

Engine and Drive Train

Drive Axle (Clark-Hurth).........................................................................S0602220
Air Conditioner .......................................................................................S0605070
Transmission (Spicer Clark-Hurth) ........................................................S0607130
Drive Coupling (Main Pump)..................................................................S0609000

Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ................S0702200
Accumulator........................................................................................ S0703010K
Center Joint (Swivel)..............................................................................S0704100
Cylinders................................................................................................S0705000

Table of Contents
Page I
 Travel Motor........................................................................................ S0707351K
Swing Motor...........................................................................................S0707380
Main Pump.............................................................................................S0708520
Main Control Valve ................................................................................S0709417
Pilot Control Valve (Work Lever / Joystick)............................................S0709454
Hydraulic Schematic (Solar 55W-V PLUS)............................................S0792200

Electrical System
Electrical System ...................................................................................S0802230
Electrical Schematic (Solar 55W-V PLUS) ............................................S0892200

Attachments
Bucket....................................................................................................S0904000

Publication Request for Proposed Revision

Table of Contents
Page II
1SAFETY
 S0102050

1WHEEL 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.

WHEEL EXCAVATOR SAFETYS0102050

MODEL SERIAL NUMBER RANGE

Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Wheel Excavator Safety S0102050

Page 1
TABLE OF CONTENTS

To the Operator of a Daewoo Excavator ........................................................ 3

General Safety Essentials .............................................................................. 6
Location of Safety Labels ............................................................................... 6
Summary of Safety Precautions for Lifting in Digging Mode .......................... 7
Unauthorized Modifications ............................................................................ 8
General Hazard Information ........................................................................... 8
Before Starting Engine ................................................................................. 16
Machine Operation ....................................................................................... 19
Maintenance................................................................................................. 24
Battery.......................................................................................................... 32
Towing .......................................................................................................... 34
Shipping and Transportation ........................................................................ 35
Lifting With Sling........................................................................................... 35

S0102050 Wheel Excavator Safety

Page 2
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 6
2. “Location of Safety Labels” on page 6
3. “Summary of Safety Precautions for Lifting in Digging Mode” on page 7
4. “Unauthorized Modifications” on page 8
5. “General Hazard Information” on page 8
6. “Before Starting Engine” on page 16
7. “Machine Operation” on page 19
8. “Maintenance” on page 24
9. “Battery” on page 32
10. “Towing” on page 34
11. “Shipping and Transportation” on page 35
12. “Lifting With Sling” on page 35

Wheel Excavator Safety S0102050

Page 3
 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.

S0102050 Wheel Excavator Safety

Page 4
 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!
This word is used on safety messages and safety labels and 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!
This word is used on safety messages and safety labels and 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!
This word is used on safety messages and safety labels and indicates an 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 -6 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.

Wheel Excavator Safety S0102050

Page 5
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.

LOCATION OF SAFETY LABELS

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 (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.

S0102050 Wheel Excavator Safety

Page 6
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.

Wheel Excavator Safety S0102050

Page 7
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.

S0102050 Wheel Excavator Safety

Page 8
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.

Wheel Excavator Safety S0102050

Page 9
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.

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.

MOUNTING AND DISMOUNTING

Before getting on or off the machine, if there is any oil, grease, or mud on the handrails or steps, 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 chassis 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.

Figure 2

S0102050 Wheel Excavator Safety

Page 10
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.

ARO1760L
Figure 5

Wheel Excavator Safety S0102050

Page 11
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

S0102050 Wheel Excavator Safety

Page 12
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

Wheel Excavator Safety S0102050

Page 13
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.

S0102050 Wheel Excavator Safety

Page 14
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
rear center 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!
Figure 12
Protect your eyes when breaking the
glass.

Wheel Excavator Safety S0102050

Page 15
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
serious personal injury or death.
Water lines, gas lines, phone lines and high-
Figure 13
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

S0102050 Wheel Excavator Safety

Page 16
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.
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
Figure 15
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.

Wheel Excavator Safety S0102050

Page 17
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 the steering axle to the front under the cab and the rigid axle to the rear. When the
undercarriage is in the reversed position, the travel controls must be operated in opposite
directions.

S0102050 Wheel Excavator Safety

Page 18
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
area.
• Check that there is no one in the area HGB1014L
around the machine. There are blind Figure 16
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.

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.
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 axles.
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.

Wheel Excavator Safety S0102050

Page 19
 INCORRECT TRAVEL POSTURE

BNO1180L
Figure 17

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 200mm~300mm
(8"-12")
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.

200mm~300mm
(8"-12")

BNO0330L
Figure 18
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 19

S0102050 Wheel Excavator Safety

Page 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.

Figure 20
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
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. BNO1210L
When using the machine, to prevent accidents Figure 21
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 22
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.

Wheel Excavator Safety S0102050

Page 21
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.

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'') BNO0340L

Figure 23
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.

S0102050 Wheel Excavator Safety

Page 22
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 BNO1220L
machine as horizontal as possible. Figure 24
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 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 wheels 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 25

Wheel Excavator Safety S0102050

Page 23
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 26
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 27). If
water gets into the electrical system, there is danger that it will cause defective operation and
malfunction.

Figure 27

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.

S0102050 Wheel Excavator Safety

Page 24
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 28
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 29
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.

Wheel Excavator Safety S0102050

Page 25
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 30

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.

S0102050 Wheel Excavator Safety

Page 26
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.
BCO0890L
Figure 31

Wheel Excavator Safety S0102050

Page 27
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 32

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 33
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.

S0102050 Wheel Excavator Safety

Page 28
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.

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 34

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.

Wheel Excavator Safety S0102050

Page 29
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 the Operation and Maintenance Manual, for additional European regulations.

X X O

HAOA420L
Figure 35

S0102050 Wheel Excavator Safety

Page 30
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 36
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.

Wheel Excavator Safety S0102050

Page 31
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 37

S0102050 Wheel Excavator Safety

Page 32
BOOST STARTING OR CHARGING ENGINE
BATTERIES
If any mistake is made in the method of
connecting the booster cables, it may cause an
explosion or fire. Always do the following;
• Turn off all electrical equipment
before connecting leads to the
battery. This includes electrical
switches on the battery charger or
boost starting equipment.
• When boost-starting from another HAOA310L
machine or vehicle do not allow the Figure 38
two machines to touch. Wear safety
glasses or goggles while required
battery connections are made.
• 24 volt battery units consisting of two series-connected twelve volt batteries have a cable
connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the
other battery. Booster or charger cable connections must be made between the non series-
connected positive terminals and between the negative terminal of the booster battery and the
metal frame of the machine being boosted or charged. Refer to the procedure and illustration in
"Starting Engine With a Booster Cable" in the Operation and Maintenance Manual.
• Connect positive cable first when installing cables and disconnect the negative cable first when
removing them. The final cable connection, at the metal frame of the machine being charged or
boost-started, should be as far away from the batteries as possible.

Wheel Excavator Safety S0102050

Page 33
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 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 and follow these signals correctly.
• If the engine on the problem machine will not start or there is a failure in the brake system.
always contact your Daewoo distributor.
• 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.

S0102050 Wheel Excavator Safety

Page 34
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.
NOTE: 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.

Wheel Excavator Safety S0102050

Page 35
S0102050 Wheel Excavator Safety
Page 36
1SPECIFICATIONS
 S0202120

1SPECIFICATIONS FOR
SOLAR 55W-V PLUS

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.

SPECIFICATIONS FOR SOLAR 55W-V PLUSS0202120

MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Specifications for Solar 55W-V PLUS S0202120

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Component Locations .................................................................................... 4
General Dimensions....................................................................................... 6
Working Range............................................................................................... 8
General Specifications ................................................................................. 10
Weight Table................................................................................................. 12
Working Attachments ................................................................................... 14
Pin and Bushing Wear Limits ................................................................ 14
Measuring Cylinder Drift ....................................................................... 16
Measuring Speed .................................................................................. 17

S0202120 Specifications for Solar 55W-V PLUS

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.)

Specifications for Solar 55W-V PLUS S0202120

Page 3
COMPONENT LOCATIONS

4 5 6 7 8 9
3
2 10
1
11

12
13

b10
a10

b9
a9

b8
a8

b7
a7

P1
pp

P2

b6
a6

A10

B8 B9 B10

b5
a5

A8 A9

b4
a4

A7

B7
P3
A6

B6
A5

B4 B5

b3
a3

A4

b2
a2

B3
A3

B2
A2
a1

b1
BI
AI
15 14
16
32
31 33
17
30

29
18
28
27 19

26 25 24 23 22 21 20

BNO0360L
Figure 1

S0202120 Specifications for Solar 55W-V PLUS

Page 4
 Reference Reference
Description Description
Number Number
1 Center Joint 17 Pre-Cleaner
2 Battery Cover 18 Dozer Blade
3 Swing Motor 19 Dozer Cylinder
4 Fuel Tank 20 Rear Axle and Tires
5 Fuel Tank Fill Cap 21 Swing Bearing
Hydraulic Oil Tank Fill 22 Transmission
6
Cover 23 Drive Shafts
7 Hydraulic Oil Tank 24 Travel Motor
8 Engine Radiator 25 Front Axle and Tires
9 Counterweight 26 Ram Cylinder
10 Hydraulic Oil Cooler 27 Bucket
11 Air Cleaner 28 Link
12 Engine 29 Bucket Cylinder
13 Muffler 30 Arm
14 Pump 31 Arm Cylinder
15 Control Valve 32 Boom
16 Cab 33 Boom Cylinder

Specifications for Solar 55W-V PLUS S0202120

Page 5
GENERAL DIMENSIONS

A I
E
D
C

P 21W

2a02
01
RR 02
00

P 21W
21/5W
E13 SI
P9158
COBO
02.808

02.808
COBO
P9158
E13 SI
21/5W
P 21W

RR 02
2a02

P 21W
00
01
H
G

F
K
B J

BNS0010L
Figure 2

S0202120 Specifications for Solar 55W-V PLUS

Page 6
 General Dimensions
Reference Description Dimension
A Shipping Length 6,187 mm
(20’ 4")
B Shipping Width 1,920 mm
(6’ 4")
2,856 mm
C Shipping Height (Cabin)
(9’ 4")
2,856 mm
D Height Over Cab
(9’ 4")
1,650 mm
E Counter Weight Swing Clearance
(5’ 5")
280 mm
F Ground Clearance
(0’ 11")
980 mm
G Frame Clearance
(3’ 3")
1,944 mm
H Engine Cover Height
(6’ 5")
1,820 mm
I Upper Housing Width
(5’ 6")
2,100 mm
J Wheel Base
(6’ 11")
1,600 mm
K, L Tread Width
(5’ 3")
M Boom Swing (Left) 80°
N Boom Swing (Right) 50°

Specifications for Solar 55W-V PLUS S0202120

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.
C

A
B

BNS0020L
Figure 3

S0202120 Specifications for Solar 55W-V PLUS

Page 8
 Reference Description Dimension
3,000 mm
Boom
(9’ 10")
1,600 mm
Arm
(5’ 3")
0.174 m3 (SAE)
Bucket
(0.23 yd3)
6,010 mm
A Maximum Digging Radius
(19’ 9")
3,405 mm
B Maximum Digging Depth
(11’ 2")
5,715 mm
C Maximum Digging Height
(18’ 9")
4,303 mm
D Maximum Dump Height
(14’ 1")

Specifications for Solar 55W-V PLUS S0202120

Page 9
GENERAL SPECIFICATIONS
Solar 55W-V PLUS
Weight 5,550 kg (12,240 lb)
0.174 m3 / 0.15 m3
Bucket Capacity (PCSA/CECE)
(0.23 yd3 / 0.20 yd3)
Bucket Width 700 mm (27.56 in)
Manufacturer and Model No. DAEWOO 4TNV94L
Displacement 3,054 cc (186.37 in3)
Engine 54.9 ps @ 2,400 rpm
Rated Output
(54.15 hp @ 2,400 rpm)
19.3 kg•m @ 1,600 rpm
Torque
(139.6 ft lb @ 1,600 rpm)
3,405 mm
Maximum Digging Depth
(11’ 2")
5,715 mm
Maximum Digging Height
(18’ 9")
4,303 mm
Working Maximum Dump Height
(14’ 1")
Range
6,010 mm
Maximum Digging Radius
(19’ 9")
5,000 mm
Minimum Turning Radius
(16' 5'')
Boom Swing Angle 80° (left), 50° (right)
25 km/h (20 km/h)
Travel Speed
(15.54 MPH (12.43 MPH))
Swing Speed 9.1 rpm
Performance
Gradeability 30°
2,800 kg
Tractive Effort
(6,170 lb)
5,406 mm
Overall Length
(17' 9'')
1,920 mm
Overall Width
(6' 4'')
3,795 mm
Main Data Overall Height
(12' 5'')
Width X Height 1,920 mm x 412 mm
(Option) (75.59 in x 16.22 in)
Blade
Lowest Road 280.0 mm
Clearance (11.02 in)

S0202120 Specifications for Solar 55W-V PLUS

Page 10
 Solar 55W-V PLUS
Pump type Variable piston pump + gear pump
P1 P2 P3 P3
Main pressure; kg/cm2 (psi) 230 230 210 100
Hydraulic (3,300) (3,300) (3,000) (1420 psi)
Pressure 60.0 60.0 38.9 21.4
Delivery; liter/min (gpm)
(15.84) (15.84) (10.27) (5.65)
72 liters
Hydraulic Oil Capacity
(19 U.S. gal.)
Minimum 5.7 liters (1.5 U.S. gal.)
Engine Oil Capacity
Maximum 9.2 liters (2.4 U.S. gal.)
Others
Fuel Tank Capacity 120 liters (32 U.S. gal.)
Coolant Capacity 11.5 liters (3.0 U.S. gal.)

Specifications for Solar 55W-V PLUS S0202120

Page 11
WEIGHT TABLE
Weight Weight
Part Name Part Name
Solar 55W-V PLUS Solar 55W-V PLUS
Boom 284.0 kg (630 lb) (Dump)
15.20 kg (34 lb)
Bucket 120.0 kg (265 lb) Linkage
Bucket Boom Joint Pin 2.0 kg (4.41 lb)
6.2X7.4 kg
Linkage Bucket Pin 1.70 kg (3.75 lb)
Arm Joint Pin 1.0 kg (2.20 lb) Hydraulic Oil
65.50 kg (144 lb)
Swing Frame 559.0 kg (1,230 lb) Tank
Fuel Tank 59.0 kg (130 lb) Engine Hood
33.0 kg (73 lb)
(A)
Cabin 220.0 kg (490 lb)
Counterweight 234.0 kg (520 lb)
Arm Cylinder 54.0 kg (119 lb)
Boom Cylinder 61.0 kg (134 lb)
Swing Cylinder 49.0 kg (108 lb)
Bucket
Blade Cylinder 36.40 kg (80 lb) 35.60 kg (78 lb)
Cylinder
Blade 195.0 kg (430 lb)
Swivel Bearing 91.50 kg (202 lb)
Travel Motor 48.50 kg (107 lb)
Chassis Frame 525.0 kg (1,160 lb)
Seat Box 32.0 kg (71 lb)
Swing Motor 76.0 kg (168 lb)
Stand (Left) 5.60 kg (12.3 lb)
Seat 15.0 kg (33 lb)
Engine 260.0 kg (570 lb)
Stand (Right) 5.60 kg (12.3 lb)
Battery 24.40 kg (54 lb)
Joystick 4.0 kg (8.82 lb)
Floor Plate 5.40 kg (11.9 lb)
Battery Cover 7.80 kg (17.2 lb)
Control Valve 39.50 kg (87 lb)
Radiator 59.0 kg (130 lb)
Tank Cover 1.30 kg (2.87 lb)
Center Joint 36.40 kg (80 lb)
Front Axle 271.50 kg (600 lb)
Transmission 67.0 kg (148 lb)
Chocking
12.20 kg (27 lb) Rear Axle 205.0 kg (450 lb)
Cylinder
Boom Swing
Tire 54.0 kg (119 lb) 118.50 kg (261 lb)
Bracket
Arm 122.0 kg (269 lb)

* The weight of each unitized part is subject to change without prior notice.

S0202120 Specifications for Solar 55W-V PLUS

Page 12
Specifications for Solar 55W-V PLUS S0202120
Page 13
WORKING ATTACHMENTS
PIN AND BUSHING WEAR LIMITS

16 1

b10
a10

b9
a9

A10

B7 B8 B9 B10

b8
a8

A8 A9

b7
a7

P2 P1
pp

A7

b6
a6

A6

b5
a5

B6
A5

b4
B4 B5
a4

P3A4

b3
a3

B3
A3

b2
a2

B2
A2
a1

b1
BI
AI
7 6 5 4 3 2

9 10 11 12 13 14 15

BNS0040L

Figure 4

• Pins for Each Component and Bush Clearance (Solar 55W-V PLUS)

S0202120 Specifications for Solar 55W-V PLUS

Page 14
 Reference Diameter Allowable
Number Components Reference Clearance
(Figure 4) Value
80 mm 0.20 mm
1 Swing Post
(3.15 in) (0.0079 in)
55 mm 0.30 mm
2 Boom Joint Pin and Push
(2.17 in) (0.0118 in)
50 mm 0.10 mm
3 Boom Cylinder Head Pin and Swing Post
(1.97 in) (0.0039 in)
50 mm 0.180 mm
4 Boom Cylinder Rod Pin and Boom
(1.97 in) (0.0071 in)
50 mm 0.180 mm
5 Arm Cylinder Head Pin and Boom
(1.97 in) (0.0071 in)
50 mm 0.360 mm
6 Boom and Arm Joint Pin and Bush
(1.97 in) (0.0142 in)
50 mm 0.180 mm
7 Arm Cylinder Rod Pin and Arm
(1.97 in) (0.0071 in)
50 mm 0.180 mm
8 Bucket Cylinder Head and Arm
(1.97 in) (0.0071 in)
45 mm 0.180 mm
9 Bucket Dump Linkage Pin
(1.77 in) (0.0071 in)
50 mm 0.1090 mm
10 Bucket Cylinder Rod Pin and Dump Linkage
(1.97 in) (0.0043 in)
45 mm 0.1090 mm
11 Bucket Pin
(1.77 in) (0.0043 in)
45 mm 0.170 mm
12 Bucket Pin and Bush
(1.77 in) (0.0067 in)
65 mm 0.30 mm
13 Blade Cylinder Head Pin
(2.56 in) (0.0118 in)
50 mm 0.40 mm
14 Dozer Joint Pin and Frame
(1.97 in) (0.0157 in)
65 mm 0.30 mm
15 Blade Cylinder Rod Pin
(2.56 in) (0.0118 in)
50 mm 0.180 mm
16 Boom Swing Cylinder Rod Pin
(1.97 in) (0.0071 in)

Specifications for Solar 55W-V PLUS S0202120

Page 15
MEASURING CYLINDER DRIFT
• Positioning the machine
• Apply standard load to bucket, then extend boom cylinder fully and crowd dozer cylinder
fully at the maximum excavating radius as shown in Fig. below.
• Shut down engine, then wait for 5 minutes and measure the variation of boom, arm, and
bucket cylinders.
• Reference value table

Components Reference Value Tolerances

Boom Cylinder 5 mm (0.20 in) 10 mm (0.39 in)
Arm Cylinder 12 mm (0.47 in) 24 mm (0.94 in)
Bucket Cylinder 6 mm (0.24 in) 12 mm (0.47 in)
Dozer Cylinder 4 mm (0.16 in) 8 mm (0.31 in)

• Oil temperature: 50 ±5°C (113° - 131°F)

• Load applied: 160 kg (353 lb)

2 3

BNS0050L
Figure 5

Arm and bucket joint, Bucket cylinder, Arm cylinder, Boom joint,
→ Indicates the direction of cylinder movement.

S0202120 Specifications for Solar 55W-V PLUS

Page 16
MEASURING SPEED
(Oil temperature: 50 ±5°C (113° - 131°F), Engine revolutions: full, no-load)

Reference
Value
Cylinder Measuring Conditions Unit
Based On New
Machine
UP SEC 2.5 ±0.3
DOWN SEC 2.8 ±0.3

Boom

BNS0060L

CROWD SEC 3.8 ±0.3

DUMP SEC 3.0 ±0.3

Arm

BNS0070L

CROWD SEC 3.3 ±.0.3

DUMP SEC 2.1 ±0.3

Bucket

BNS0080L

Specifications for Solar 55W-V PLUS S0202120

Page 17
 Reference
Value
Cylinder Measuring Conditions Unit
Based On New
Machine
UP SEC 3.1±0.3
DOWN SEC 2.8±0.3

Dozer

BNS0090L

LEFT SEC 9.1±0.5

RIGHT SEC 7.1±0.5

Boom
Swing

BNS0100L

S0202120 Specifications for Solar 55W-V PLUS

Page 18
1GENERAL MAINTENANCE
 S0302000
R1

1GENERAL
MAINTENANCE
PROCEDURES
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.

GENERAL MAINTENANCE PROCEDURESS0302000

MODEL SERIAL NUMBER RANGE

ALL MODELS ALL RANGES

Copyright 2002 Daewoo

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.

General Maintenance Procedures S0302000

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 pre-filling 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 pre-lube) or has been contaminated by dirt or by
questionable oils, flushing and pre-filling 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 pre-start 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.

S0302000 General Maintenance Procedures

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 pre-clean any exterior surface of the system before it is exposed
to air. For example, the reservoir filler 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 filter elements 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 pre-fill the
assembly before bolting together the drain line piping connections. Run the system at low rpm.

General Maintenance Procedures S0302000

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.

S0302000 General Maintenance Procedures

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 snap 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

General Maintenance Procedures S0302000

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.

S0302000 General Maintenance Procedures

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

General Maintenance Procedures S0302000

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

S0302000 General Maintenance Procedures

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

General Maintenance Procedures S0302000

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

S0302000 General Maintenance Procedures

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

General Maintenance Procedures S0302000

Page 13
S0302000 General Maintenance Procedures
Page 14
 S0309000
R1

1STANDARD TORQUES

CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.

STANDARD TORQUESS0309000
MODEL SERIAL NUMBER RANGE
ALL MODELS ALL RANGES

Copyright 2002 Daewoo

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
Pitch (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)

Standard Torques S0309000

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.

S0309000 Standard Torques

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
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
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.

Standard Torques S0309000

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
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2 522.8 3780

S0309000 Standard Torques

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 "Ultra- 0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50

Tite"

Standard Torques S0309000

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.

S0309000 Standard Torques

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.

Standard Torques S0309000

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.

S0309000 Standard Torques

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
504 compound. Fills gaps to 0.0012 mm (0.030"), Orange faster (1/2 - 4 hours) setup.
cures to rigid seal. Unprimed setup 4 - 24 hours.
General purpose, fast setup, flexible-cure Use Locquic "N" primer for
515 gasket eliminator. For nonrigid assemblies Purple faster (1/4 - 2 hours) setup.
subject to shock, vibration or deflection. Unprimed setup 1 - 12 hours.

Standard Torques S0309000

Page 11
IV. "Loctite" retaining compounds

Product Application Color Notes

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

Product Application Color Notes

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.

S0309000 Standard Torques

Page 12
1UPPER STRUCTURE
 S0403060

1COUNTERWEIGHT

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.

COUNTERWEIGHT S0403060
MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Counterweight S0403060
Page 1
TABLE OF CONTENTS

General........................................................................................................... 3
Removal ......................................................................................................... 5
Installation ...................................................................................................... 7

S0403060 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 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
in-line with the lower structure.
X
Never rotate the upper structure once the
counterweight or front attachment has
been removed.
BCS0830L
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 weigh 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 55W-V PLUS 234 kg (520 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.

Counterweight S0403060
Page 3
To maintain stability the counterweight should
be removed whenever the front attachment is
taken off the machine.

BNO0550L
Figure 1
When loading an excavator 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).

15
BNO0560L
Figure 2

S0403060 Counterweight
Page 4
REMOVAL
1. Park on firm and level ground.
2. Lower front attachment (bucket) to the
ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch "ON."

WARNING!
If engine must be run while Figure 3
performing maintenance, use
extreme care. Always have one
person in the cab at all times. Never
leave the cab with the engine
running.

6. Fully stroke work levers (joysticks) in all

directions to relieve pressure from
accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "OFF" position and remove
from starter switch.
9. Hang maintenance warning tag on
controls.
10. Disconnect negative (-) battery cable
leading to frame from battery.
11. Raise engine compartment cover.
12. Tag and disconnect wiring harnesses from
tail lights (1 and 2, Figure 4).
NOTE: Make sure that all harnesses
and mounting hardware are
removed from counterweight (3,
Figure 4).

Figure 4

Counterweight S0403060
Page 5
13. Using a suitable lifting device capable of
handling load partially support
counterweight (1) before beginning to
loosen three bolts (2). Stop lifting with
1 2
assist crane as soon as lifting slings are
taut. 3
14. Remove three bolts (2, Figure 5) and 5
washers (3) that secure counterweight (1)
to support frame (4).
NOTE: Heat bolts if necessary, to free
them. 4
15. When bolts (2, Figure 5) and washers (3)
have been removed, lift counterweight (1)
a very short distance above support frame
(4) and stop. Check slings and make sure
counterweight is being supported evenly.
Once checked, continue to remove
counterweight.
16. Remove shims (5) from support frame (4),
if used.

BNS3050L
Figure 5

S0403060 Counterweight
Page 6
INSTALLATION
1. Raise engine compartment cover.
2. Using suitable lifting device capable of
handling load raise counterweight (1,
Figure 6) into position just above support 1 2
frame (4) leaving counterweight
suspended. Verify that counterweight is 3
level and even. 5
NOTE: Leave counterweight (1, Figure
6) suspended 3 mm (0.125")
above support frame (4) until all
three mounting bolts (2) are 4
started in counterweight
mounting holes.
3. Install three bolts (2, Figure 6) with
washers (3) into counterweight mounting
holes. Tighten bolts until washers contact
counterweight. Fully lower counterweight
onto support frame.
4. Using a feeler gauge, check for a gap
between counterweight (1, Figure 6) and
support frame (4). Use an appropriate
amount of shims (5) for each bolt location.
5. Remove three bolts (2, Figure 6) and BNS3050L
washers (3). Figure 6
6. Raise counterweight (1, Figure 6) so that
shims (5) can be set into position on
support frame (4).
7. Lower counterweight (1, Figure 6) until it is 3 mm (0.125") above the shims (5) and install three bolts
and washers. Apply Loctite #242 to mounting bolt threads.
8. Fully lower counterweight (1, Figure 6) onto shims (5), and support frame (4). Finish tightening bolts
(2).
NOTE: Tighten bolts (2, Figure 6) to values shown in following table.

Model Bolt Torque

Solar 55W-V PLUS 55 kg•m (400 ft lb)

9. Remove lifting device and lifting hooks from counterweight (1, Figure 6).

Counterweight S0403060
Page 7
10. Connect wiring harnesses as tagged to tail
lights (1 and 2, Figure 7).
NOTE: Make sure that all harnesses
and mounting hardware are
secured to counterweight (3,
Figure 7), if removed during
removal procedures.
11. Connect negative (-) battery cable to
battery.

Figure 7

S0403060 Counterweight
Page 8
 S0405500

1FUEL TRANSFER PUMP

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.

FUEL TRANSFER PUMPS0405500

MODEL SERIAL NUMBER RANGE
Mega 130 0001 and Up
Mega 160 0001 and Up
Mega 200-III 1001 and Up
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-III 1001 and Up
Mega 250-V (Tier I) 1001 thru 2000
Mega 250-V (Tier II) 2001 and Up
Mega 300-V (Tier I) 1001 thru 2000
Mega 300-V (Tier II) 2001 and Up
Mega 400-III PLUS 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Mega 500-V (Tier II) 2001 and Up
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 170LC-V 1001 and Up
Solar 170W-V 1001 and Up

Models continued on back of cover.

Copyright 2003 Daewoo

August 2003

Fuel Transfer Pump S0405500

Page 1
 MODEL SERIAL NUMBER RANGE
Solar 175LC-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 210W-V 1001 and Up
Solar 220LC-V 0001 and Up
Solar 220LL 1001 and Up
Solar 220N-V 1001 and Up
Solar 225LC-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 250LC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 290LC-V 0001 and Up
Solar 290LL 1001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 1001 and Up
Solar 330LC-V 1001 and Up
Solar 340LC-V 1001 and Up
Solar 400LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up
Solar 55W-V PLUS 1001 and Up

TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Troubleshooting .............................................................................................. 4
Replacement of Rotor and Vane .................................................................... 4
Replacement of Rear Cover ........................................................................... 5
Replacement of Armature .............................................................................. 6

S0405500 Fuel Transfer Pump

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION

Figure 1

Reference Reference
Description Description
Number Number
1 Motor 3 Inlet Hose
2 Pump 4 Outlet Hose
2-1 Pump Cover 5 Check Valve
2-2 Rotor and Vane 6 Strainer Cap

The fuel pump consists of a motor, pump,

switch, and hose assembly.

Figure 2

Fuel Transfer Pump S0405500

Page 3
TROUBLESHOOTING
On some pumps the ON-OFF switch is installed separately at a remote location.
A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it
from damage.
NOTE: OPEN TEMP: 150 ±5°C (302 ±41°F). After circuit is automatically shut off due to
overheating the pump will stop running. When temperature drops below 143°C (289°F) the
circuit will reactivate allowing the pump to restart.

Figure 3 WITH TOGGLE SWITCH Figure 4 WITHOUT TOGGLE SWITCH

Check resistance at connectors "A." If reading is zero, or very close to zero, the motor is bad and must be
replaced.
On units equipped with a toggle switch, check the resistance through the toggle switch, while the switch is
in the "ON" position. If continuity is not present, the switch is bad. Be sure to check resistance through the
motor.

REPLACEMENT OF ROTOR AND VANE

If dirt or other foreign materials enter the pump
during operation, it can become lodged between
the rotor and/or vanes and generate heat which
can cause the pump damage.
Remove the pump cover and check the rotor
and vane. If any pump parts or components
become lost, damaged or inoperable,
immediately replace them with new ones.

Figure 5 WITHOUT TOGGLE SWITCH

S0405500 Fuel Transfer Pump

Page 4
Insert vane, with the circled edge of vane facing
in the counterclockwise direction. (Detail A)
Insert a new O-ring again at reassembly of the
pump cover.

Figure 6

REPLACEMENT OF
REAR COVER
Brush assembly and a thermal limiter are
installed in the rear cover. If you find any
damage, replace them with new ones.
Remove the switch cover and screw (M5 x L95)
from the rear cover.
Remove cover.
At reassembly of rear cover, widen the space of
the brush and insert it to the armature. Then fit Figure 7
the hole of screw in the housing.
Be careful when installing the screw. The cover
screw may be attracted by the motor magnet.

Fuel Transfer Pump S0405500

Page 5
REPLACEMENT OF
ARMATURE
You can replace only the armature in case the
motor was damaged by a short circuit.
Remove the switch cover and rear cover, than
remove the armature from the housing.
Remove the pump cover and remove the rotor
and vane.
Insert a new armature into the housing.
Figure 8
Refer to “Replacement of Rear Cover” on page
5, for installation of the rear cover.
Fit the rotor into the shaft flute of the armature.
Insert vane to the rotor being careful of the
direction. Refer to “Replacement of Rotor and
Vane” on page 4.

S0405500 Fuel Transfer Pump

Page 6
 S0407010
R2

1SWING BEARING

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.

SWING BEARING S0407010

MODEL SERIAL NUMBER RANGE
Solar 130W-V 0001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 210W-V 1001 and Up
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Swing Bearing S0407010

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

S0407010 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, 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
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 Figure 1
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.

Swing Bearing S0407010

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 / 1.5 bolt (2).

Figure 4

S0407010 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 steel ball, retainer
(A) and retainer (B) to bearing; if gap is too
wide, adjust by moving steel balls or by
replacing one of the retainers.

Figure 8

Swing Bearing S0407010

Page 5
S0407010 Swing Bearing
Page 6
 S0408080

1SWING REDUCTION
GEARBOX

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.

SWING REDUCTION GEARBOXS0408080

MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Swing Reduction Gearbox S0408080

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 4
Special Tools and Materials............................................................................ 6
Special Tools ........................................................................................... 6
Troubleshooting, Testing and Adjustment....................................................... 7
Removal ......................................................................................................... 8
Disassembly ................................................................................................. 10
Reassembly.................................................................................................. 11
Installation .................................................................................................... 13

S0408080 Swing Reduction Gearbox

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
The swing motor final drive is a two-step planetary gearbox with two planet gears, two sun gears and two-
step output reduction. The planetary gear engages with the ring gear. The pinion gear is connected with
the output shaft and spline.
The final drive reduces swing motor rpm to increase swing motor output torque. The available maximum
swing speed provides a fast turning rate for efficient, rapid work cycling with more than adequate power for
good acceleration.

Swing Reduction Gearbox S0408080

Page 3
PARTS LIST

16

18

13
10 14-4
14-3
15
14-5 14-2 14 11

14-1 14-1 ~ 14-5 11-1 ~ 11-6

12 11-2

11-3
11-1
11-4
9
11-5
8 11-6
7
6

5
17
6

BNS3060L
Figure 1

S0408080 Swing Reduction Gearbox

Page 4
 Reference Reference
Description Description
Number Number
1 Shaft (Pinion Gear) 11-5 No. 2 Thrust Plate
2 Collar 11-6 No. 2 Spring Pin
3 Plate 12 No. 2 Sun Gear
4 Taper Bearing 13 Ring Gear
5 Gear Case 14 No. 1 Carrier Assembly
6 Plug 14-1 No. 1 Carrier
7 Oil Seal 14-2 No. 1 Planetary Gear
8 Taper Bearing 14-3 No. 1 Shaft Assembly
9 Collar (Two-piece) 14-4 No. 1 Thrust Plate
10 Pin (Locating) 14-5 No. 1 Thrust Plate
11 No. 2 Carrier Assembly 15 No. 1 Sun Gear
11-1 No. 2 Carrier 16 Socket Bolt
11-2 No. 2 Shaft 17 Plug
11-3 No. 2 Bushing 18 Gasket
11-4 No. 2 Planetary Gear

NOTE: The inner and outer cylinder roller bearing must be changed at the same time.

Swing Reduction Gearbox S0408080

Page 5
SPECIAL TOOLS AND MATERIALS
SPECIAL TOOLS

O 93

125

118
138

O 10

8
12
O
O 140

O 74

HIA3012L

Figure 2 Pattern of Drawing

S0408080 Swing Reduction Gearbox

Page 6
TROUBLESHOOTING, TESTING AND ADJUSTMENT

Symptoms Possible Causes Remedies

1. No rotation and –
a. Pressure at swing motor inlet Swing brake not releasing Check brake engagement
increases and disengagement,
check release pressure
Internal damage to gearbox Replace broken gears,
drive train drive train assemblies
Overload Reduce load weight
b. Pressure at swing motor inlet Swing motor drive shaft damage Replace swing motor
shows no increase, and the swing
motor is making irregular noises Internal damage to gearbox Repair/replace broken or
drive train faulty assemblies
c. Pressure at swing motor inlet shows Hydraulic pump or valve broken Troubleshoot hydraulic
no increase, but without irregular system
noises from the swing motor
2. Oil leakage
a. From drive shaft Oil seal damaged Replace oil seal
b. From bolted connections or other Assembly compound (joint sealer) Disassemble and check
assembled surfaces old and not sealing, bolt not tight mating surfaces. Reapply
or flange warped Loctite, torque bolts to
specifications
3. Excess heat
Gearbox casing becomes excessively Low oil level Replace oil, refill to
hot, with or without irregular noise(s) specified level
during operation
Bearings or gear worn but not Repair or replace
completely inoperative gearbox
HAOE960L

Swing Reduction Gearbox S0408080

Page 7
REMOVAL
1. Park on firm and level ground.
2. Lower front attachment (bucket) to the
ground.
3. Stop the engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch "ON."

WARNING!
If engine must be run while Figure 3
performing maintenance, use
extreme care. Always have one
person in the cab at all times. Never
leave the cab with the engine
running.

6. Fully stroke work levers (joysticks) in all

directions to relieve pressure from
accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "OFF" position and remove
from starter switch.
9. Hang maintenance warning tag on
controls.
10. Disconnect negative (-) battery cable
leading to frame from battery.

S0408080 Swing Reduction Gearbox

Page 8
11. Tag and disconnect hoses from swing
motor (1, Figure 4). Plug and cap hoses
and port to prevent contamination from
entering hydraulic system or component.
12. Disconnect tube (2, Figure 4) from drain
valve (3)
13. Remove eleven bolts and washers (4,
Figure 4) holding swing reduction gearbox
(5) to frame.
14. Using a suitable lifting device, sling swing
motor (1, Figure 4) and remove swing
motor and reduction gearbox (5) as an
assembly from unit.
NOTE: A drain valve (3, Figure 4) and
tube are on side of gearbox. Be
careful not to damage valve or
tube.
NOTE: There is one alignment pin (6,
Figure 4), on side of reduction
gearbox flange.

Figure 4

Swing Reduction Gearbox S0408080

Page 9
DISASSEMBLY
1. Remove mounting bolts (16, Figure 1). Remove motor and gasket (18) from ring gear (13).
2. Remove No. 1 sun gear (15, Figure 1) and No. 1 thrust plate (14-5).
3. Remove No. 1 carrier assembly (14, Figure 1).
NOTE: When removing carrier (14, Figure 1), No. 2 sun gear (12) may come out with it.
4. Disassemble No. 1 carrier assembly (14, Figure 1).
NOTE: If there are no visible defects after inspection, do not disassemble the No. 1 carrier
assembly.
A. Remove pin (14-4, Figure 1), No. 1 planet gear (14-3) and No. 1 thrust washer (14-2) from No. 1
carrier (14-1).
NOTE: Discard pin (14-4, Figure 1) and use a new one at reassembly.
B. Repeat procedure for remaining planetary gear assemblies.
NOTE: Keep all components together in proper orientation so that wear patterns match during
assembly. Do not mix previously used parts.
5. Remove No. 2 sun gear (12, Figure 1).
6. Remove No. 2 carrier assembly (11, Figure 1).
NOTE: Collar (9, Figure 1) is made from two halves that are held in place by the No. 2 carrier (11-
1). Be careful not to dislodge the collar or the pinion shaft (1) may come out of gear case
(5).
7. Disassemble No. 2 carrier assembly (11, Figure 1).
NOTE: If there are no visible defects after inspection, do not disassemble the No. 2 carrier
assembly.
A. Remove spring pin (11-6, Figure 1) from No. 2 carrier (11-1) and No. 2 shaft (11-2).
B. Remove No. 2 shaft (11-2, Figure 1), No. 2 thrust washer (11-5), No. 2 planet gear (11-4) and
No. 2 bushing (11-3).
C. Repeat procedure for remaining planetary gear assemblies.
NOTE: Keep all components together in proper orientation so that wear patterns match during
assembly. Do not mix previously used parts.
8. Position the swing reduction gear case (5, Figure 1) so that pinion shaft (1) is pointing down. Remove
two-piece collar (9) from pinion shaft. Press shaft out of bearing cone (8) in gear case.
NOTE: Bearing cone (4, Figure 1), plate (3) and collar (2) will come out with pinion gear shaft (1).
9. Using special tool, press on bearing cone (4, Figure 1) to remove collar (2), plate (3) and bearing
cone (4).from pinion shaft (1).
10. Remove oil seal (7, Figure 1) from gear case (5).
11. Remove ring gear (13, Figure 1) from gear case (5).
NOTE: Remove locating pin (10, Figure 1) from No. 1 ring gear (13) if replacement is necessary.
12. Using a suitable puller, remove bearing cups (4 and 8, Figure 1) from gear case (5).

S0408080 Swing Reduction Gearbox

Page 10
REASSEMBLY
1. Press bearing cups (4 and 8, Figure 1) into
gear case (5), if removed during
disassembly.
2. Coat O.D. of oil seal (7, Figure 1) with
Loctite #277, and press into gear case (5).
Be careful not to get sealant on lips of
seal.
3. Make sure that seal lip is facing up (Figure
5) when pressing seal into case. Coat lip of
seal with clean oil.

Figure 5
4. Position collar (2, Figure 1) on pinion gear
shaft (1). Set plate (3) on collar (2). Press
bearing cone (4) onto pinion gear shaft.
Make sure that collar, plate and cone are
properly seated. Pack bearing cone with
grease.
5. With end of pinion gear shaft (1, Figure 1)
pointing up, lower gear case (5) onto shaft
seating bearing cone and cup (4) together.
Be careful not to damage oil seal (7) with
splines on pinion gear shaft.
6. Press bearing cone (8, Figure 1) onto
pinion gear shaft. (1) Rotate gear case (5)
back and forth to ensure that bearings are
properly seated. Insert two-piece collar (9)
into groove of pinion bearing shaft. There Figure 6
must be a 0.00 - 0.05 mm (0.000 - 0.002
in) clearance between the collar and
bearing cone (8).
7. Attach No. 1 thrust washer (14-2, Figure
1), No. 1 planet gear (14-3) and new pin
(14-4) to No. 1 carrier (14-1),. Repeat
procedure for remaining planetary gear
assemblies.
NOTE: Keep all components together
in proper orientation so that
wear patterns match during
assembly. Do not mix
previously used parts.

Swing Reduction Gearbox S0408080

Page 11
8. Assemble No. 2 carrier (11, Figure 1).
A. Position No. 2 bushing (11-3, Figure
1) in No. 2 planet gear (11-4).
Position gear and bushing, No. 2
thrust washer (11-5) and No. 2 shaft
(11-2) in No.2 carrier (11-1).
B. Align spring pin hole in No. 2 shaft
(11-2, Figure 1) with hole in No. 2
carrier (11-1).
NOTE: Figure 7, shows how end of
holes in shaft (11-2, Figure 1)
should be turned, in relation to Figure 7
carrier.
C. Press spring pin (11-6, Figure 1) into
No. 2 carrier (11-1) and No. 2 shaft
(11-2).
D. As shown in Figure 8, use a punch to
stake spring pins (11-6, Figure 1)
(inserted in the previous step) into
place.
E. Repeat procedure for remaining
planetary gear assemblies.
9. Position No. 1 ring gear (13, Figure 1) on
gear case (5).
NOTE: Install locator pin (10, Figure 1)
in No. 1 ring gear (13) if
replacement was necessary.
Figure 8
NOTE: Coat mating faces of casing
and ring gear with Loctite #609.
10. Align splines and install No. 2 carrier
assembly (14, Figure 1) on to end of pinion
gear shaft (1). Make sure that two-piece
collar (9) is properly seated.
11. Install No. 2 sun gear (12, Figure 1) into
No. 2 carrier assembly (14). Make sure
that splines on end of gear that engage
No, 1 carrier (14) are facing up.
12. Install No. 1 carrier assembly (14, Figure
1), No.1 thrust plate (14-5), and No.1 sun
gear (15).
13. Install gasket (18, Figure 1), swing motor
and bolts (16).

S0408080 Swing Reduction Gearbox

Page 12
INSTALLATION
1. Coat pinion gear with grease. Refer to
operation manual for specifications.
2. Make sure alignment pin (6) is installed in
flange of swing reduction gearbox (5).
3. Using a suitable lifting device, sling swing
motor (1, Figure 9) and position swing
motor and reduction gearbox (5) as an
assembly on unit.
4. Install eleven bolts and washers (4, Figure
9) to secure swing reduction gearbox (5) to
frame.
NOTE: Apply Loctite #262 to bolt
threads.
5. Connect tube (2) to drain valve (3)
6. Connect hoses as tagged during removal
to swing motor (1, Figure 9).
7. Fill swing reduction gearbox with oil. Refer
to operation manual for specifications.

Figure 9

Swing Reduction Gearbox S0408080

Page 13
S0408080 Swing Reduction Gearbox
Page 14
1LOWER STRUCTURE AND CHASSIS
 S0503000
R1

1RAM LOCK VALVE

OPERATION

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.

RAM LOCK VALVE OPERATIONS0503000

MODEL SERIAL NUMBER RANGE
Solar 130W-V 0001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 210W-V 1001 and Up
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Ram Lock Valve Operation S0503000

Page 1
TABLE OF CONTENTS

Theory of Operation ....................................................................................... 3

S0503000 Ram Lock Valve Operation

Page 2
THEORY OF OPERATION
The ram lock valve absorbs vibration of the front axle and helps adjust the front axle, according to the type
of work being done. When the ram lock solenoid valve is off, port P’s pressure is the same as the tank
pressure and spring pressure moves the check valve to the left and blocks passage between the ram
cylinders. When the ram lock solenoid valve is on, pressurized oil flows into port P, pushes the spool,
moves the check valve to the right and opens the passage between the ram cylinders. The stroke is
adjusted according to the load applied to the ram cylinder.

Figure 1

Ram Lock Valve Operation S0503000

Page 3
S0503000 Ram Lock Valve Operation
Page 4
1ENGINE AND DRIVE TRAIN
 S0602220

1DRIVE AXLE
(CLARK-HURTH)

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.

DRIVE AXLE (CLARK-HURTH)S0602220

MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Drive Axle (Clark-Hurth) S0602220

Page 1
TABLE OF CONTENTS

Introduction..................................................................................................... 3
Introductory Statement............................................................................ 3
Special Tool .................................................................................................... 4
Trouble Shooting .......................................................................................... 13
Clark-Hurth Axle Identification...................................................................... 16
Data Plate ............................................................................................. 16
Maintenance Points ...................................................................................... 17
Maintenance Intervals .................................................................................. 17
Conversion Tables ........................................................................................ 18
Tightening Torques....................................................................................... 18
Brakes .......................................................................................................... 19
Safety Brake ................................................................................................. 22
Adjustment ............................................................................................ 25
Wheel Hub.................................................................................................... 27
Wheel Hub onto Axle Housing ..................................................................... 29
Epicycloidal Reduction 4.25 ......................................................................... 31
Epicycloidal Reduction 5.25 ......................................................................... 33
Articulation 271-278 ..................................................................................... 35
Steering Cylinder.......................................................................................... 40
Disassembly - Assembly (T11 bis A, B, C - (See page -9)) .................. 41
Bevel Pinion Support.................................................................................... 43
Adjustments of Bevel Gear Set .................................................................... 50
Taper Roller Bearings of Differential............................................................. 52
Disassembling of Differential ........................................................................ 55
Assembling of the Differential....................................................................... 57
Self Locking Differential................................................................................ 59
NoSpin.......................................................................................................... 61
Hydraulic Differential Lock............................................................................ 63

S0602220 Drive Axle (Clark-Hurth)

Page 2
INTRODUCTION
The efficiency and continued operation of mechanical units depends on constant and correct maintenance
and also on efficient repair work should there be a break-down or malfunctioning.
The instructions in this manual have been made based on a complete overhaul of the unit. However the
mechanic must decide whether or not it is necessary to dismantle the individual components when only
localized repair work is needed.
The manual provides a quick and sure guide which, with the use of photographs and diagram illustrating
the various phases of the operations, allows accurate work to take place. Therefore all the information
needed for correct disassembly, the relative checks and assembly of each individual component, have
been written down.

IMPORTANT
Throughout the phases of repair or maintenance work it is advisable to use purpose-built
equipment such as: trestles, or supporting benches, plastic or copper hammers, appropriate
levers, extractors and specific spanners or wrenches, so that the work is facilitated, the working
surfaces and the operators themselves are safeguarded.
Before going on to disassemble the parts it would be opportune to thoroughly clean the unit,
removing any encrusted or accumulated greases and then drain the oil through the oil-draining
plugs.

INTRODUCTORY STATEMENT
All the disassembled mechanical units should be thoroughly cleaned with appropriate products and
restored or replaced if damage, wear, cracking or seizing have occurred.
In particular, thoroughly check the condition of all moving parts (bearings, gears, crown wheel and pinion,
shafts) and sealing parts (O-rings, oil shields) which are subject to major stress and wear. In any case, it is
advisable to replace the seals every time a component is overhauled or repaired. During assembly, the
sealing rings must be lubricated on the sealing edge. In the case of the crown wheel and pinion,
replacement of one component requires the replacement of the other one. During assembly, the prescribed
pre-loading, backlash and torque of parts must be maintained.

Drive Axle (Clark-Hurth) S0602220

Page 3
SPECIAL TOOL

Figure 1

Figure 2

S0602220 Drive Axle (Clark-Hurth)

Page 4
 Figure 3

Figure 4

Drive Axle (Clark-Hurth) S0602220

Page 5
 Figure 5

S0602220 Drive Axle (Clark-Hurth)

Page 6
 Figure 6

Figure 7

Drive Axle (Clark-Hurth) S0602220

Page 7
 Figure 8

S0602220 Drive Axle (Clark-Hurth)

Page 8
 Figure 9

Drive Axle (Clark-Hurth) S0602220

Page 9
 Figure 10

S0602220 Drive Axle (Clark-Hurth)

Page 10
 Figure 11

Drive Axle (Clark-Hurth) S0602220

Page 11
 Figure 12

S0602220 Drive Axle (Clark-Hurth)

Page 12
TROUBLE SHOOTING
Problem Cause Correction
Loss of brakes 1. Incorrect adjustment Inspect disc thickness (See page -19)
and if discs are usable readjust brakes
to the specifications in the vehicle’s
manual.
2. Brake discs worn out Inspect disc thickness (See page -19)
and replace if needed.
3. Incorrect brake fluid If incorrect fluid leaked into axle oil,
seals and O-rings in axle must be
replaced.
4. Loss of brake fluid If leak is to the inside replace above
O-rings and brake piston O-rings.
5. Overheated axle causing brake See "Overheating" problem.
fluid to vaporize (brake return
when axle cools).
Soft brake pedal 6. Air in brake fluid Bleed brakes as described in the
vehicle’s service manual.
Ineffective safety 7. One or both overrides are Check override bolts and adjust if
brake engaged needed (See page -25)
8. Incorrect adjustment See correction N. 1.
9. Brake disc worn out See correction N. 2.
Overheating 10. Oil level wrong Drain, flush and refill oil to proper
level.
11. Too small of a brake gap Readjust brakes to the specifications
in the vehicle’s service manual.
12. Park brake dragging Unlock the brake and adjust the
correct gap.
13. Incorrect brake fluid in system See correction N. 3
14. No free-pedal at master cylinder Readjust brake pedal as described in
the vehicle’s service manual
15. Restriction in brake lines Inspect for and replace damage lines.
Inspect for and replace damaged
return line.
16. Restriction in return line of brake Inspect for and remove any filter, tee’d
Servo system in line or any other source of back
pressure from the return line.
17. Incorrect oil Drain, flush and refill to the proper
level with oil recommended in the
vehicle’s service manual.

Drive Axle (Clark-Hurth) S0602220

Page 13
 Problem Cause Correction
Diff-lock inoperative 18. If manual, loss or misadjusted Inspect and correct linkage and
linkage readjust as indicated in vehicle’s
service manual.
19. If hydraulic, problems in the Refer to the service manual for the
hydraulic or electrical circuits of vehicle.
the vehicle.
20. If hydraulic, problems in the Rebuilt cylinder as described (See
hydraulic or electrical circuits of page -63)
the vehicle
21. If with self locking differential, Replace discs as described (See
worn discs. page -59)
Oil coming out of 22. Hydraulic leak in brake system See corrections N. 2 & 3
breather
23. Hydraulic leak In diff-lock See corrections N. 20
activating cylinder.
Nospin indexing 24. Unequal tire pressure from one Inflate tires to the recommended
noise when driven side to the other pressure in the service manual or until
straight the rolling radius is equal.
25. Different style, size or brand of Change tires to make the rolling
tires from one side to the other radius equal.
Vary the tire pressure within the
specifications until the rolling radius
equal.
Noise during coast 26. Wheel bearings Replace and adjust as described (See
and under power the page -27)
same
Noise under power 27. Low oil level Refill oil to proper level
greater than during 28. Incorrect oil See correction N. 17.
coast
29. RIng and pinion worn Inspect through rear cover. Replace
and adjust as described (See page
-43)
30. Worn ring and pinion bearings Replace and adjust as described (See
page -43)
31. Worn planetary gears or Replace as described (See page -27)
bearings
Noise during coast 32. Loosen pinion nut Inspect ring, pinion and pinion
greater than under bearings. If undamaged, retighten nut
power as described (See page -43)
33. Only one pinion bearing See correction N. 30
damaged
Noise during turn 34. Worn spider and/or side gears Replace as described (See page -55)
(without Nospin)

S0602220 Drive Axle (Clark-Hurth)

Page 14
 Problem Cause Correction
"Stick slip" noise 35. Worn or damaged u-joint on Inspect and replace as described in
when going from drive shaft vehicle’s service manual
forward to reverse 36. Loosen wheel Inspect for wheel and wheel stud
damage. Replace if needed and
retorque nuts.
37. Worn or damaged u-joint at Inspect and replace as described
steering knuckle (See page -35)
38. Spider pins loosen in carrier Inspect through rear cover. Replace
as described (See page -55)
39. Damaged or missing spider and/ See correction N. 34.
or side gear washers

Drive Axle (Clark-Hurth) S0602220

Page 15
CLARK-HURTH AXLE IDENTIFICATION

Figure 13

DATA PLATE

Reference
Description
Number
1 Type of Unit
2 Type of Flanged Unit
3 Model of Unit
4 Serial Number
5 Year of Construction
6 Lubricant

Figure 14

S0602220 Drive Axle (Clark-Hurth)

Page 16
MAINTENANCE POINTS

Figure 15

MAINTENANCE INTERVALS
Operation Frequency Lubricants
• Check levels: Differential Monthly • SAE85W90 (API GL4 - MIL L-2105)
Planetary Every 400 hours With additives for oil immersed disc
reduction brakes.
• Oil change: Differential Every 1500 hours * • SAE85W90 (API GL5 - MIL 2105-B)
For execution with hypoid bevel gear
Planetary Every 1500 hours * set and/or with limited slip differential;
reduction with additives for oil immersed disc
• Greasing: Under Monthly brakes.
normal use
• Grease: Multipurpose lithium base
Under heavy Weekly
duty use
• Adjustment of the safety Every 1500 hours *
brake
• Screw/bolt tightening Every 200 hours

Drive Axle (Clark-Hurth) S0602220

Page 17
 • Service brake circuit • Only for mineral oil use e.g. ATF
Dexron II. Make sure that master
cylinder seals are suitable for mineral
oil.

* Initially at 100 operating hours

CONVERSION TABLES
1 Atm §ô1 bar§ô 105 Pa §ô14.4 Psi

Nm daNm KNm kg•m lb-in

1Nm 1 0.1 0.001 0.102 8.854
1 daNm 10 1 0.01 1.02 88.54
1 KNm 1000 100 1 102 8854
1 kg•m 9.81 0.981 0.00981 1 86.8
1 lb-in 0.1129 0.01129 0.0001129 0.01152 1
1 kg•cm 0.0981 0.00981 0.0000981 0.01 0.868

N daN KN Kg lb
1N 1 0.1 0.001 0.102 0.225
1 daN 10 1 0.01 1.02 2.25
1 KN 1000 100 1 102 225
1 Kg 9.81 0.981 0.00981 1 2.205
1 Lb 4.44 0.444 0.00444 0.4536 1

TIGHTENING TORQUES
Size of
8G/8.8 10K/10.9 12K/12.9
Bolt
M4 2.9 4.1
M6 10.0 14.0
M8 25.0 35.0
M 10 49.0 69.0
M 10x1.25 73.0
M 12 86.0 120.0
M 14 135.0 190.0
M 14x1.5 250.0
M 16 210.0 295.0
A 18 325.0

S0602220 Drive Axle (Clark-Hurth)

Page 18
BRAKES
1. Wear check and replacement of brake
discs: Use until minimum thickness of s =
4.5 mm (0.18 in).

Figure 16
2. Loosen fixing nuts and horizontally remove
the axle housing.

Figure 17
NOTE: If the brake discs do not need
replaced, remove the complete
pack without changing the
position of the discs.

Figure 18

Drive Axle (Clark-Hurth) S0602220

Page 19
3. For assembly reverse the disassembly
procedure.
Align lubrication holes.

Figure 19
4. Adjustment of brake discs gap.
Turn adjusting bolts counterclockwise and
then turn them a half turn clockwise. This
corresponds to a gap of 0.5 mm (0.02 in)
between the brake discs.

Figure 20
5. Remove brake pistons using air pressure
at 3 - 5 bar (45 - 70 psi).

Figure 21
6. Install O-rings and brake pistons.
NOTE: Observe that neither the
pistons nor the cylinders have
scratches or incrustations.

Figure 22

S0602220 Drive Axle (Clark-Hurth)

Page 20
7. Apply compressed air to brake
assemblies, at 0.5 - 1 bar (7 - 14 psi) for 10
minutes on each side.

Figure 23

Figure 24

Drive Axle (Clark-Hurth) S0602220

Page 21
SAFETY BRAKE
1. Apply 15 - 20 bar (220 - 290 psi) of
pressure into the hydraulic circuit, then
remove the axle housing.

Figure 25
2. Loosen the four assembling stud bolts and
disassemble intermediate covers.

Figure 26
3. Disassembling of spring applied safety
brake pistons. Reassemble the
components in reverse order.

Figure 27

S0602220 Drive Axle (Clark-Hurth)

Page 22
 Figure 28
4. Take measurement of cover.

Figure 29
5. Remove brake discs.

Figure 30
6. When assembling, align lubrication holes
of brake discs.

Figure 31

Drive Axle (Clark-Hurth) S0602220

Page 23
7. Remove pinion and ring gear.

Figure 32
8. Assemble internal lever mechanism.

Figure 33
9. Apply 15 - 20 bar (220 - 290 psi) pressure
in the hydraulic circuit and assemble the
axle.

Figure 34

S0602220 Drive Axle (Clark-Hurth)

Page 24
 Figure 35

ADJUSTMENT
1. Apply 15 - 20 bar (220 - 290 psi) of
pressure in the hydraulic circuit.
Remove bolt and locking plate.

Figure 36

Drive Axle (Clark-Hurth) S0602220

Page 25
 2. Turn the pinion with 8 Nm (5.9 ft lb) of
torque, counterclockwise until it
stops. Adjust the gap between the
brake discs by turning 3 complete
revolutions clockwise.

Figure 37
3. Adjust the bolts to unlock the safety
brake at 37 mm (1.45 in) and lock the
counter nut.

Figure 38

Figure 39

S0602220 Drive Axle (Clark-Hurth)

Page 26
WHEEL HUB
1. Disassembling and Assembling
Disassembling of wheel hub, seal and
center ring.

Figure 40

Figure 41

Figure 42

Drive Axle (Clark-Hurth) S0602220

Page 27
2. Assembling of wheel hub

Reference
Description
Number
1 Fitting of wheel studs
2 Installation of outer
races of taper roller
bearings
3 Assembling of
bearings
4 Fitting of seal
Figure 43

Figure 44

S0602220 Drive Axle (Clark-Hurth)

Page 28
WHEEL HUB ONTO AXLE HOUSING
1. Assembling of wheel hub, seal and center
ring.

Figure 45

Figure 46

Figure 47

Drive Axle (Clark-Hurth) S0602220

Page 29
 Figure 48
2. Torque of new bearings with seal: from 7 -
20 Nm (5.2 - 14.8 ft lb).

Figure 49

S0602220 Drive Axle (Clark-Hurth)

Page 30
EPICYCLOIDAL REDUCTION 4.25
1. Disassembling of planet carrier.

Figure 50

Figure 51

Figure 52

Drive Axle (Clark-Hurth) S0602220

Page 31
2. Assembling of planet carrier. Align trust
washer with holes of planet gear and
planet carrier.

Figure 53
3. To punch after assembling of the retaining
ring.

Figure 54

S0602220 Drive Axle (Clark-Hurth)

Page 32
EPICYCLOIDAL REDUCTION 5.25
1. Disassembling of planet carrier.

Figure 55

Figure 56

Figure 57

Drive Axle (Clark-Hurth) S0602220

Page 33
2. Assembling of planet carrier. Align trust
washer with holes of planet gear and
planet carrier.

Figure 58
3. To punch after assembling of the retaining
ring. Assemble trust plug with Arexons
Sealing Compound.

Figure 59

S0602220 Drive Axle (Clark-Hurth)

Page 34
ARTICULATION 271-278
1. Disassembling of articulation.

Figure 60

Figure 61

Figure 62

Drive Axle (Clark-Hurth) S0602220

Page 35
 Figure 63
2. Disassembling of external races of taper
roller bearing.

Figure 64
3. Removal of double cardan joint.
NOTE: Lock the brake discs before
removing the joint

Figure 65

Figure 66

S0602220 Drive Axle (Clark-Hurth)

Page 36
 Figure 67
4. Disassembling of seal, retaining ring and
needle bearing.

Figure 68
5. Check that the seats of the taper roller
bearings are not deformed.

Figure 69
6. Assembling of wheel hub onto the steering
housing.

Figure 70

Drive Axle (Clark-Hurth) S0602220

Page 37
 Figure 71

Figure 72
7. Determination of preloading of taper roller
bearings. Check of rotating torque: from 7 -
9 Nm (5.2 - 6.6 ft lb) for articulation type
271, from 10 - 12 Nm (7.4 - 8.9 ft lb) for
articulation type 278.

Figure 73

Figure 74

S0602220 Drive Axle (Clark-Hurth)

Page 38
 Figure 75

Drive Axle (Clark-Hurth) S0602220

Page 39
 STEERING CYLINDER
1. Check that the piston rod of the steering
cylinder is at half stroke. Check on both
sides with a caliper. Check parallelism
between both wheel hubs at approximately
500 mm (19.69 in) from the hub center
(front and rear)

Figure 76

Figure 77
2. Close security clip.

Figure 78

S0602220 Drive Axle (Clark-Hurth)

Page 40
3. Determination of steering angle.

Figure 79

Figure 80

Figure 81

DISASSEMBLY - ASSEMBLY (T11 BIS A, B, C - (SEE PAGE -9))

1. Remove snap ring AL 65 with retaining ring pliers
2. Retract gland until snap ring 78x2.5 is exposed
3. Slide snap ring 78x2.5 towards the inside of the cylinder on the tapered section of the oil connection
to bring it out of its seat, then remove
4. Remove snap ring with a deburred screw driver

Drive Axle (Clark-Hurth) S0602220

Page 41
5. Retract piston rod assembled out of the cylinder body
6. Take off gland from piston rod
7. Remove wipers 45/53x4/7, seal rings 45x53x8 backup rings 45/52.9x1.5 wear rings 70/75x5.5 and
Glyd-ring 75x64x4.2 with deburred marking tool. Seal ring housing must not be damaged! Assembly
in reversed order. At mounting of the glands it has to be regarded, that the O-rings not damaged by
the connecting hole.
Extend piston rod both sides and test with internal stop pressure 210 bar (3000 psi). No leakage should
occur. Cylinder is for ready for use.

Figure 82

S0602220 Drive Axle (Clark-Hurth)

Page 42
BEVEL PINION SUPPORT
1. Disassembling of bevel pinion support.

Figure 83

Figure 84

Figure 85

Drive Axle (Clark-Hurth) S0602220

Page 43
2. Assembling of external races of taper roller
bearings.

Figure 86
3. Control of dimension "A" of cover.

Figure 87
4. X = Value to add in order to obtain the
correct preload of the taper roller bearings.

Figure 88

Figure 89

S0602220 Drive Axle (Clark-Hurth)

Page 44
5. Assembling of bevel pinion support and
seal.

Figure 90

Figure 91
6. Ring nut tighten and torque checking.

Figure 92

Drive Axle (Clark-Hurth) S0602220

Page 45
 Figure 93

S0602220 Drive Axle (Clark-Hurth)

Page 46
7. Disassembling of bevel pinion support.

Figure 94

Figure 95
8. Determination of shim pack S2 for
adjustment of bevel pinion position.
Assembling of outer races without shims.
Insert tool and verify after having set to
zero the gauge on a surface plate. The
difference is S2. Remove outer race of
taper roller bearing, insert shims and
reassemble the outer race definitively.

Figure 96

Figure 97

Drive Axle (Clark-Hurth) S0602220

Page 47
9. Assembling of outer races of taper roller
bearings.

Figure 98
10. Determination of shim pack S1 for the
preload of taper roller bearings:
S1 = B, C + X
X = Value to add in order to obtain the
correct preload of the taper roller bearings
(See

Figure 99

Figure 100
11. Assembling of bevel pinion support and
tighten of flange nut.

Figure 101

S0602220 Drive Axle (Clark-Hurth)

Page 48
 Figure 102
12. For checking of torque.

Figure 103

Drive Axle (Clark-Hurth) S0602220

Page 49
ADJUSTMENTS OF BEVEL GEAR SET
1. Determination of shim pack S2 for
adjustment of bevel pinion position:
S2 = (l + A) - (D + r)

Figure 104

Figure 105
2. Assembling of bevel pinion support with
shim pack S2.

Figure 106

S0602220 Drive Axle (Clark-Hurth)

Page 50
3. Assembling of central axle housing.
NOTE: Be careful not to damage the
tight surfaces of the O-rings
while installing the differential
case into the central axle
housing.

Figure 107

Figure 108

Drive Axle (Clark-Hurth) S0602220

Page 51
TAPER ROLLER BEARINGS OF DIFFERENTIAL
1. Screw in the adjusting nuts to obtain
approximately 0.15 - 0.18 mm (0.0059 -
0.0071 in) backlash between the teeth of
bevel gear set. without preloading the
taper roller bearings.
Check the rotating torque of pinion and
differential. Tighten nut on opposite site to
the crown wheel to obtain A 35 - 45 Ncm
(3 - 4 in lb) higher rotating torque on the
pinion.

Figure 109

Figure 110
2. Mark both ring nuts. To adjust the backlash
move ring nuts only. Loosen the one on
bevel crown wheel side and tighten the
opposite one an equal amount if the
backlash is too high.

Figure 111

S0602220 Drive Axle (Clark-Hurth)

Page 52
3. Fit security sheets in the best position and
bend tabs with a punch.

Figure 112
4. Assemble the axle and check parallelism
between axle housing.

Figure 113

Drive Axle (Clark-Hurth) S0602220

Page 53
 Figure 114

Figure 115

S0602220 Drive Axle (Clark-Hurth)

Page 54
DISASSEMBLING OF DIFFERENTIAL
1. Disassembling of the differential from the
axle.

Figure 116

Figure 117
NOTE: Replace the fitting bolts of the
crown wheel every time that
they have to be removed.

Figure 118

Drive Axle (Clark-Hurth) S0602220

Page 55
 Figure 119

Figure 120

S0602220 Drive Axle (Clark-Hurth)

Page 56
ASSEMBLING OF THE DIFFERENTIAL
NOTE: Tighten all bolts with torque
wrench.
Bolt M 10x1.25-10K torque 73 -
76 Nm (53.8 - 56.0 ft lb).
Bolt M 10x25-10K torque 69 -
72 Nm (50.9 - 53.1 ft lb).

Figure 121

Figure 122

Figure 123

Drive Axle (Clark-Hurth) S0602220

Page 57
 Figure 124

S0602220 Drive Axle (Clark-Hurth)

Page 58
SELF LOCKING DIFFERENTIAL
1. Check the disc pack to determine the
shims. The total thickness of the disc with
eventual shims must be 17.5 ±0.1 mm
(0.689 ±0.004 in)

Figure 125

Figure 126

Figure 127

Drive Axle (Clark-Hurth) S0602220

Page 59
 Figure 128

S0602220 Drive Axle (Clark-Hurth)

Page 60
NOSPIN
1. Disassembling

Figure 129
2. Assembling
NOTE: Observe pairing number on
semi-cases. Tighten the fixing
bolts of the semi-cases and
remove mounting bolt.
Bolt M8X65-10K torque 35 - 37
Nm (25.8 - 27.3 ft lb).

Figure 130

Figure 131

Drive Axle (Clark-Hurth) S0602220

Page 61
 Figure 132

S0602220 Drive Axle (Clark-Hurth)

Page 62
HYDRAULIC DIFFERENTIAL LOCK
1. Disassembling

Figure 133

Figure 134
2. Assembling and check of position of
cylinder.

Figure 135

Drive Axle (Clark-Hurth) S0602220

Page 63
 Figure 136

Figure 137

S0602220 Drive Axle (Clark-Hurth)

Page 64
 Figure 138

Drive Axle (Clark-Hurth) S0602220

Page 65
S0602220 Drive Axle (Clark-Hurth)
Page 66
 S0605070

1AIR CONDITIONER

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.

AIR CONDITIONER S0605070

MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Air Conditioner S0605070

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
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

S0605070 Air Conditioner

Page 2
GENERAL DESCRIPTION
The heater and air conditioner are installed in
the below of the operator’s seat. If necessary,
the operator can control inner temperature using
the temperature control dial installed in the left-
hand control stand.

Air-conditioner

Heater
Defroster

AXO0340L

Figure 1

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.

Air Conditioner S0605070

Page 3
REFRIGERANT CIRCULATION

4
7

3
HBOI020L

Figure 1

Reference Reference
Description Description
Number Number
1 Evaporator 5 Compressor
2 Expansion Valve 6 Blower Fan
3 Condenser 7 Receiver Dryer
4 Engine Cooling Fan

S0605070 Air Conditioner

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 15.0 kg/cm2 (213.35 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 engine cooling 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 2.0 kg/cm2 (28.45 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.

Air Conditioner S0605070

Page 5
AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM

3
4
10 15A

OFF 1
5 11
2 7 1
E
12 8 2
L
3 9 3
CW
1
10 DEF
2
5
11 DUCT
M
12 A
6 B
4

7 BR
E L M H 4 32bar 2bar E
OFF 5

9 1 1
HIGH PRESS
CUT OFF SWITCH
LOW PRESS
CUT OFF SWITCH
2 2
13
3 3

+ -
M - + 1
6

BNS2960L
Figure 2

Reference Reference
Description Description
Number Number
1 Battery 8 Compressor
2 Battery Relay 9 A/C Blower Switch
3 Circuit Breaker 10 Foot/Defrost Select Switch
4 Fuse 11 Temp. Control Dial
5 A/C Controller 12 Foot/Defrost Actuator
6 A/C Unit 13 Diode
7 Receiver Dryer (Low/high)
Pressure Cutoff Switch

S0605070 Air Conditioner

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: 8.0 - 10.0 kg/cm2 (114 - 142 psi)

1
Low Pressure: Approximately 1.0 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 - 3.0 kg/cm2 (35.56 - 42.67 psi)
Possible Cause: Overcharge, Frost on condenser
Step Inspection Item Remedy
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.

Air Conditioner S0605070

Page 7
 High Pressure: Approximately 20 - 25 kg/cm2 (284.47 - 355.58 psi)
3
Low Pressure: Approximately 2.5 - 3.5 kg/cm2 (35.56 - 49.78 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
Step Inspection Item Remedy
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
1 10 minutes.
5. Recheck high / low pressure readings. Contaminated system, replace
expansion valve.
High Pressure: 13.0 - 19.0 kg/cm2 No
(Replace evaporator core
(185 - 270 psi) 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 22.0 - 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.
Step Inspection Item Remedy
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.

S0605070 Air Conditioner

Page 8
 High Pressure: Over 7.0 - 11.0 kg/cm2 (100 - 156 psi)
7
Low Pressure: 4.0 - 6.0 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression
Inspect and replace compressor if necessary.

Air Conditioner S0605070

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 170LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 170W-III 1100 ±20 grams (38 ±0.7 oz.)
Solar 175LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 180W-V 850 ±20 grams (30 ±0.7 oz.)
Solar 200W-III 1100 ±20 grams (38 ±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 220LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 220LL 850 ±20 grams (30 ±0.7 oz.)
Solar 225LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 225NLC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 250LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 255LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 280LC-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 290LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 290LL 850 ±20 grams (30 ±0.7 oz.)
Solar 300LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 300LL 850 ±20 grams (30 ±0.7 oz.)

S0605070 Air Conditioner

Page 10
 Model Weight of Gas
Solar 330-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 330LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 340LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 400LC-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 400LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 420LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 450LC-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 450LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 470LC-V 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 70-III 800 ±20 grams (28 ±0.7 oz.)
Solar 75-V 750 ±20 grams (26 ±0.7 oz.)

Air Conditioner S0605070

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.

S0605070 Air Conditioner

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.

Air Conditioner S0605070

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

S0605070 Air Conditioner

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
3 High 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.

Air Conditioner S0605070

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.

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 (14.22 psi) and close
the high side valve.

S0605070 Air Conditioner

Page 16
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.

Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low Pressure Side
3 High 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).

Air Conditioner S0605070

Page 17
 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

(184.90 - 284.47 psi)

Low Side Gauge 1.5 - 3.5 kg/cm2

(21.34 - 49.78 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.

6. Shut off engine and close refrigerant supply container adapter valve. Disconnect manifold gauge
hoses from vehicle.

S0605070 Air Conditioner

Page 18
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.

Air Conditioner S0605070

Page 19
S0605070 Air Conditioner
Page 20
 S0607130

1TRANSMISSION
(SPICER
CLARK-HURTH)
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.

TRANSMISSION (SPICER CLARK-HURTH)S0607130

MODEL SERIAL NUMBER RANGE
Solar 55W-V Plus 1001 and Up

Copyright 2003 Daewoo

August 2003

Transmission (Spicer Clark-Hurth) S0607130

Page 1
TABLE OF CONTENTS

Introduction..................................................................................................... 3
Introductory Remarks.............................................................................. 3
Maintenance and Lubricant ............................................................................ 4
Maintenance Points................................................................................. 4
Data Plate ............................................................................................... 4
Maintenance Intervals ............................................................................. 5
Conversion Tables................................................................................... 5
Tightening Torques.................................................................................. 5
Diagrams of Reduction Unit and Exploded Views .......................................... 6
Diagram................................................................................................... 6
Reduction Gear ....................................................................................... 7
First Gear ................................................................................................ 8
Second Gear ........................................................................................... 9
Disassembly of Directly Flanged Reduction Gear 357................................. 10
Removal of Hydraulic Gear Control.............................................................. 11
Disassembly of Directly Flanged Reduction Gear 357................................. 13
Assembly of Directly Flanged Reduction Gear 357...................................... 23
Installation of Hydraulic Gear Control........................................................... 35

S0607130 Transmission (Spicer Clark-Hurth)

Page 2
INTRODUCTION
The efficiency and continued operation of mechanical units depend on constant, correct maintenance and
also on efficient repair work, should there be a break-down or malfunction. The instructions contained in
this manual have been based on a complete overhaul of the unit.
However, it is up to the mechanic to decide whether or not it is necessary to assemble only individual
components, when partial repair work is needed. The manual provides a quick and sure guide which, with
the use of photographs and diagrams illustrating the various phases of the operations, allows accurate
work to be performed.
All the information needed for correct disassembly, checks and assembly of each individual component is
set out below. In order to remove the differential unit from the vehicle, the manuals provided by the vehicle
manufacturer should be consulted. In describing the following operations it is presumed that the unit has
already been removed from the vehicle.

IMPORTANT
In order to facilitate work and protect both working surfaces and operators, it is advisable to use
proper equipment such as: trestles or supporting benches, plastic or copper hammers,
appropriate levers, pullers and specific spanners or wrenches.
Before going on to disassemble the parts and drain the oil, it is best to thoroughly clean the unit,
removing any encrusted or accumulated grease.

INTRODUCTORY REMARKS
All the disassembled mechanical units should be thoroughly cleaned with appropriate products and
restored or replaced if damage, wear, cracking or seizing have occurred.
In particular, thoroughly check the condition of all moving parts (bearings, gears, crown wheel and pinion,
shafts) and sealing parts (O-rings, oil shields) which are subject to major stress and wear. In any case, it is
advisable to replace the seals every time a component is overhauled or repaired. During assembly, the
sealing rings must be lubricated on the sealing edge. In the case of the crown wheel and pinion,
replacement of one component requires the replacement of the other one. During assembly, the prescribed
pre-loading, backlash and torque of parts must be maintained.

Transmission (Spicer Clark-Hurth) S0607130

Page 3
MAINTENANCE AND LUBRICANT
MAINTENANCE POINTS

Figure 1

Reference
Description
Number
1 Oil Fill and Level Plug
2 Oil Drain Plug

DATA PLATE

Reference
Description
Number
1 Type and Model Unit
2 Serial Number
3 Lubricant

Figure 2

S0607130 Transmission (Spicer Clark-Hurth)

Page 4
MAINTENANCE INTERVALS

Operation Frequency Lubricants

• Check levels: Monthly • SAE85W90 API GL3
• Oil change: Every 1000 hours *

* Initially after 100 working hours

CONVERSION TABLES

1 Atm§ô1 bar§ô105 PA§ô14.4 Psi

Pa

N daN kN kg lb
1N 1 0.1 0.001 0.102 0.225
1daN 10 1 0.01 1.02 2.25
1kN 1000 100 1 102 225
1kg 9.81 0.981 0.00981 1 2.205

Nm daNm kNm kg•m lb in

1Nm 1 0.1 0.001 0.102 8.854
1daNm 10 1 0.01 1.02 88.54
1kNm 1000 100 1 102 8854
1kg•m 9.81 0.981 0.00981 1 86.8
1 lb in 0.1129 0.01129 0.0001129 0.01152 1

TIGHTENING TORQUES

Type of Bolt
Size of bolt 8G/8.8 Nm 10k/10.9 Nm 12k/10.9 Nm
M4 2.9 4.1
M6 10.0 14.0
M8 25.0 35.0
M10 49.0 69.0
M10x1.25 52.0 73.0 88.0
M12 86.0 120.0
M14 135.0 190.0
M14x1.5 150.0 210.0 250.0
M16 210.0 295.0
M18x1.5 325.0 460.0 550.0
A22 550

Transmission (Spicer Clark-Hurth) S0607130

Page 5
DIAGRAMS OF REDUCTION UNIT AND EXPLODED
VIEWS
DIAGRAM

Figure 3

Technical Data
A - Connector for hydraulic gear control - Pressure required 15 - 30 bar (220 - 435 psi).

S0607130 Transmission (Spicer Clark-Hurth)

Page 6
REDUCTION GEAR

Figure 4

Transmission (Spicer Clark-Hurth) S0607130

Page 7
FIRST GEAR

Figure 5

S0607130 Transmission (Spicer Clark-Hurth)

Page 8
SECOND GEAR

Figure 6

Transmission (Spicer Clark-Hurth) S0607130

Page 9
DISASSEMBLY OF DIRECTLY FLANGED REDUCTION
GEAR 357
1. Reduction gear directly flanged in the axle
with mechanic gear control.

Figure 7
2. Reduction gear flanged on the axle with
hydraulic gear control.

Figure 8
3. Reduction gear directly flanged on the axle
with or without revolution indicator.

Figure 9

S0607130 Transmission (Spicer Clark-Hurth)

Page 10
REMOVAL OF HYDRAULIC GEAR CONTROL
1. Remove the gear control rod.

Figure 10
2. Pull out the control rod.

Figure 11
3. Remove screws on the gear control
cylinder.

Figure 12

Transmission (Spicer Clark-Hurth) S0607130

Page 11
4. Remove the gear control cylinder.

Figure 13
5. Pull out the gear control cylinder. Note the
position of the O-rings. Remove the
protection plate.

Figure 14
6. Re-assembly arrangement of gear control
cylinder parts.

Figure 15

S0607130 Transmission (Spicer Clark-Hurth)

Page 12
DISASSEMBLY OF DIRECTLY FLANGED REDUCTION
GEAR 357
1. Remove fastening screws from the
reduction unit.

Figure 16
2. Separate the entire reduction unit from the
axle and place it on a bench.

Figure 17
3. Remove the sealing cover with the relative
washer or the revolution indicator.

Figure 18

Transmission (Spicer Clark-Hurth) S0607130

Page 13
4. Remove gear-in position switch, O-ring
and washer.

Figure 19
5. Remove screw, spring, with gear-and
neutral position spindle (mechanical
version).

Figure 20
6. Remove screw, spring and neutral position
ball (hydraulic version).

Figure 21
7. Remove screws from the motion input
cover.

Figure 22

S0607130 Transmission (Spicer Clark-Hurth)

Page 14
8. Remove the motion entrance cover.

Figure 23
9. Remove the nut from the flange.

Figure 24
10. Remove the O-ring and pull out the flange.

Figure 25
11. Remove screws from the cover.

Figure 26

Transmission (Spicer Clark-Hurth) S0607130

Page 15
12. Remove the cover.

Figure 27
13. Remove the cover and spacers.
NOTE: Pay attention to the orientation
of the notch, cast into the back
of the cover. It must be facing
upwards during assembly.

Figure 28
14. Remove screws.

Figure 29
15. Remove the cover. Take care not to
damage mating surfaces.

Figure 30

S0607130 Transmission (Spicer Clark-Hurth)

Page 16
16. When cover has been removed note the
position of the pins.

Figure 31
17. Remove gear, needle bearings and spacer
from the gearbox.

Figure 32
18. Remove the bearing if it needs replacing.

Figure 33
19. Install new bearing into gearbox.

Figure 34

Transmission (Spicer Clark-Hurth) S0607130

Page 17
20. Remove the oil shield plate only if
necessary.
NOTE: The oil inlet must be facing
upwards.

Figure 35
21. Install new oil shield plate with oil inlet
facing upwards.
NOTE: Apply Loctite #510 on the
outside.

Figure 36
22. Fit the oil shield plate into position 5 - 5.5
mm (0.197 - 0.216 in) below gearbox
surface.
NOTE: Oil inlet notch must be facing up
for proper lubrication during
operation.

Figure 37
23. Remove the check screws from the flow
regulator plate.

Figure 38

S0607130 Transmission (Spicer Clark-Hurth)

Page 18
24. Remove the plate and pull out coupling
and fork at the same time.

Figure 39
25. Check: sliding blocks, pin, and sliding
coupling. Replace if worn.

Figure 40
26. Remove the lower shaft.

Figure 41
27. Remove the entire shaft and the flow
regulator plate.

Figure 42

Transmission (Spicer Clark-Hurth) S0607130

Page 19
28. Disassembly of the entire lower shaft.

Figure 43
29. Progressive arrangement of parts fitted
onto the lower shaft.

Figure 44
30. Assembly of lower shaft.

Figure 45
31. Removal of upper shaft. (In case of
replacement, the shaft is supplied already
assembled).

Figure 46

S0607130 Transmission (Spicer Clark-Hurth)

Page 20
32. Pull out the sealing ring.

Figure 47
33. Install a new sealing ring.

Figure 48
34. Pull out the sealing ring from the cover.

Figure 49
35. Install a new sealing ring.

Figure 50

Transmission (Spicer Clark-Hurth) S0607130

Page 21
36. Pull out the sealing ring from the motion
input cover.

Figure 51
37. Remove the bearing from the cover of the
reduction unit.

Figure 52

S0607130 Transmission (Spicer Clark-Hurth)

Page 22
ASSEMBLY OF DIRECTLY FLANGED REDUCTION
GEAR 357
1. Install the bearing in the cover of the
reduction unit using a suitable driver.

Figure 53
2. Install a new sealing ring in the motion
input cover.

Figure 54
3. Assemble the cover.
NOTE: Use Loctite #510 on mating
surfaces and screws.

Figure 55

Transmission (Spicer Clark-Hurth) S0607130

Page 23
4. Tighten screws using a torque wrench
setting of 49 - 51 Nm (26 - 38 ft lb).

Figure 56
5. Lubricate the lip of the sealing ring with
grease.

Figure 57
6. Assemble the motion upper shaft.

Figure 58
7. Assemble the full lower shaft and the flow
regulator plate.

Figure 59

S0607130 Transmission (Spicer Clark-Hurth)

Page 24
8. Position the shaft so that the bearing
protrudes out approximately 5.0 mm
(0.197 in) from the cover of the reduction
unit.

Figure 60
9. Temporarily assemble the cover with
screws. (Be sure that the notch faces
upwards).

Figure 61
10. Simultaneously insert: fork and sliding
blocks, coupling and flow regulator plate.

Figure 62
11. Install screws and tighten.

Figure 63

Transmission (Spicer Clark-Hurth) S0607130

Page 25
12. Tighten screws using a torque wrench
setting of 25 - 26 Nm (18 - 19 ft lb).

Figure 64
13. Assemble needle bearings, gear and
spacer.

Figure 65
14. Check the insertion of pins.

Figure 66
15. Spread Loctite #510 on the surface and
assemble the cover.

Figure 67

S0607130 Transmission (Spicer Clark-Hurth)

Page 26
16. Fasten the cover.

Figure 68
17. Tighten screw using a torque wrench
setting of 49 - 51 Nm (26 - 38 ft lb).
NOTE: Tighten using the crossed
method.

Figure 69
18. Grease components and install spindle,
spring and screw (mechanical version).
NOTE: Tighten using a max. torque
wrench setting of 80 - 100 Nm
(59 - 74 ft lb).

Figure 70
19. Grease components and install ball, spring
and screw (hydraulic version).
NOTE: Tighten using a max. torque
wrench setting of 80 - 100 Nm
(59 - 74 ft lb).

Figure 71

Transmission (Spicer Clark-Hurth) S0607130

Page 27
20. Install the gear-in position switch with
washer and O-ring.
NOTE: Tighten with torque wrench
setting of max. 54.2 Nm (40 ft
lb).

Figure 72
21. Assemble the sealing cover with washer
and revolution indicator.
NOTE: Tighten using a torque wrench
setting of max. 25 Nm (18 ft lb).

Figure 73
22. Apply Loctite #510 on the mating surfaces,
and install the reduction unit onto the axle.

Figure 74
23. Fasten the support surfaces (turn flange to
assist assembly).

Figure 75

S0607130 Transmission (Spicer Clark-Hurth)

Page 28
24. Install screws.
NOTE: Coat screws with Loctite #510.

Figure 76
25. Place the reduction unit in a vertical
position in relation to the axel and tighten
screws.

Figure 77
26. Tighten screws using a torque wrench
setting of 49 - 51 Nm (26 - 38 ft lb).

Figure 78
27. Remove screws and the temporarily
assembled cover.

Figure 79

Transmission (Spicer Clark-Hurth) S0607130

Page 29
28. Install bearing using a suitable driver.

Figure 80
29. Measure dimension "A" between the
bearing and the gearbox mounting surface
using a depth gauge (if original parts are
not replaced, use disassembled spacers).

Figure 81
30. Measure dimension "B" on the cover,
between the bearing and bearing support.
Calculate the dimension of the thickness of
spacers required:
Dimension "B" - Dimension "A" = "S" -
Backlash (0.2 - 0.3 mm) = Spacer
Required.

Dimension B 5.2 mm (0.2047 in)

Dimension A - 4.6 mm (0.1811 in)
S =0.6 mm (0.0236 in)
Backlash - 0.2 - 0.3 mm Figure 82
(0.0079 - 0.0118 in)
Spacer =0.4 - 0.3 mm
Required (0.0157 - 0.0118 in)

S0607130 Transmission (Spicer Clark-Hurth)

Page 30
31. Apply Loctite #510 on the surface,
lubricate the sealing ring, insert the spacer
and assemble the cover with notch facing
upwards.

Figure 83
32. Install screws after applying Loctite #510.

Figure 84
33. Tighten screws using a torque wrench
setting of 49 - 51 Nm (26 - 38 ft lb).

Figure 85
34. Assemble flange, O-ring and nut using
Loctite #242.

Figure 86

Transmission (Spicer Clark-Hurth) S0607130

Page 31
35. Screw down the nut on the flange.

Figure 87
36. Tighten the nut using a torque wrench
setting of 260 - 280 Nm (192 - 206 ft lb).

Figure 88
37. Install the protection plate after applying
Loctite #510.

Figure 89
38. Completed flanged reduction gear 357
with mechanical gear control.

Figure 90

S0607130 Transmission (Spicer Clark-Hurth)

Page 32
39. Assemble all the parts of the gear control
cylinder, according to the arrangement
shown in, Figure 91.

Figure 91
40. Install the protection plate after applying
Loctite #510 on it.

Figure 92
41. Install the gear control cylinder into place
with its O-ring.

Figure 93
42. Install screws.

Figure 94

Transmission (Spicer Clark-Hurth) S0607130

Page 33
43. Install the gear control rod after applying
Loctite #242 on it.

Figure 95

S0607130 Transmission (Spicer Clark-Hurth)

Page 34
INSTALLATION OF HYDRAULIC GEAR CONTROL
1. Tighten the gear control rod using a torque
wrench setting of 25 - 26 Nm (18 - 19 ft lb).

Figure 96
2. Tighten gear control cylinder screws using
a torque wrench setting of 49 - 51 Nm (26 -
38 ft lb).

Figure 97

Transmission (Spicer Clark-Hurth) S0607130

Page 35
S0607130 Transmission (Spicer Clark-Hurth)
Page 36
 S0609000

DRIVE COUPLING
(MAIN PUMP)

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.

DRIVE COUPLING (MAIN PUMP)S0609000

MODEL SERIAL NUMBER RANGE
DD80L 0001 and Up
Solar 130LC-III 0001 and Up
Solar 130LC-V 0001 and Up
Solar 130W-III 0001 and Up
Solar 130W-V 0001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 170LC-III 0001 and Up
Solar 170LC-V 1001 and Up
Solar 170W-III 0001 and Up
Solar 170W-V 1001 and Up
Solar 200W-III 0001 and Up
Solar 200W-V 0001 and Up
Solar 210W-V 1001 and Up
Solar 220LC-III 0001 and Up
Solar 220LC-V 0001 and Up
Solar 220LL 1001 and Up
Solar 220N-V 1001 and Up
Solar 225LC-V 1001 and Up

Models continued on back of cover.

Copyright 2003 Daewoo

August 2003

Drive Coupling (Main Pump) S0609000

Page 1
 MODEL SERIAL NUMBER RANGE
Solar 225NLC-V 1001 and Up
Solar 250LC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 280LC-III 0001 and Up
Solar 290LC-V 0001 and Up
Solar 290LL 1001 and Up
Solar 330LC-III 0001 and Up
Solar 330LC-V 1001 and Up
Solar 400LC-III 0001 and Up
Solar 400LC-V 1001 and Up
Solar 450-III 0001 and Up
Solar 450LC-V 0001 and Up
Solar 55W-V PLUS 1001 and Up

TABLE OF CONTENTS

Drive Coupling................................................................................................ 3
Special Tools .................................................................................................. 4
Kawasaki / Tong Myung Pump Tool ........................................................ 4
Uchida Pump Tool ................................................................................... 7
Drive Coupling Installation.............................................................................. 9
Installation Procedure ........................................................................... 14

S0609000 Drive Coupling (Main Pump)

Page 2
DRIVE COUPLING
When installing the main pump on the engine, it is very important to properly adjust clearance between the
face of the coupling hub and end of pump drive shaft ("Measurement H" shown in the following procedure)
to a specific value.
Figure 1 thru Figure 3, show typical drive coupling installations.

Figure 1 KAWASAKI (OR TONG MYUNG)

Figure 2 UCHIDA

Figure 3 SAUER SUNDSTRAND

Drive Coupling (Main Pump) S0609000

Page 3
SPECIAL TOOLS
KAWASAKI / TONG MYUNG PUMP TOOL
NOTE: This tool is also used for the
Sauer Sundstrand Pump for the
DD80L.
This tool is used to control the distance between
the end of the pump drive shaft and the front
face of the drive coupling hub (Figure 4 and
Figure 9). This distance will be referred to as
"Measurement H" in the installation instructions
that follow.
NOTE: In manufacturing drawings
(Figure 5 and Figure 6),
dimension "A" and "B" equal
the "Measurement H." The two
tools shown are designed to be Figure 4
used on various models of
equipment. Only one end of the
tool is used for a specific model
of equipment.

S0609000 Drive Coupling (Main Pump)

Page 4
 A C
B

D
E
G
F

RELIEF H
RELIEF
KNURL
HAAA8350
Figure 5

Dimensional Details for Figure 5

Dimension Measurement Models
A 18 ±0.1 mm DD80L
(0.7087 ±0.0039 in)
B 5.5 ±0.1 mm S330LC-III, S330LC-V, S400LC-III, S400LC-V,
(0.2165 ±0.0039 in) S450LC-V
C 20.0 mm (0.787 in)
D 7.0 mm (0.275 in)
E 11.0 mm (0.433 in) Radius
F 18.0 mm (0.708 in) Radius
G 30.0 mm (1.181 in) Radius
H 1.0 mm (0.039 in) x 45° Chamfer

Drive Coupling (Main Pump) S0609000

Page 5
 A C
B

D
E G
F

H
RELIEF RELIEF
KNURL
HAAA8360

Figure 6

Dimensional Details for Figure 6

Dimension Measurement Models
S170LC-III, S200W-V, S220LC-III, S220LC-V,
10.5 ±0.1 mm
S220LL, S220N-V, S225LC-V, S225NLC-V,
(0.4134 ±0.0039 in)
S250LC-V, S255LC-V
A 2.0 ±0.1 mm
S170LC-V, S170W-V
(0.0787 ±0.0039 in)
1.0 ±0.1 mm
S140W-V, S160W-V
(0.0394 ±0.0039 in)
5.0 ±0.1 mm
B S280LC-III, S290LC-V, S290LL
(0.1969 ±0.0039 in)
C 20.0 mm (0.787 in)
D 7.0 mm (0.275 in)
E 12.0 mm (0.472 in) Radius
F 14.50 mm (0.570 in) Radius
G 25.0 mm (0.984 in) Radius
H 1.0 mm (0.039 in) x 45° Chamfer

S0609000 Drive Coupling (Main Pump)

Page 6
UCHIDA PUMP TOOL
This tool is used to control the distance between
the shoulder on the pump drive shaft and the
rear face of the drive coupling hub (Figure 7 and
Figure 10). This distance will be referred to as
"Measurement H" in the installation instructions
that follow.
NOTE: In manufacturing drawing
(Figure 8), dimension "A"
equals "Measurement H."

Figure 7

Drive Coupling (Main Pump) S0609000

Page 7
 C
G D
A

B
H

E G
F

G
HAAA8370
Figure 8

Dimensional Details for Figure 8

Dimension Measurement Models
16.0 ±0.1 mm
S130W-III, S130W-V
(0.6299 ±0.0039 in)
A
5.0 ±0.1 mm *
S55W-V
(0.1969 ±0.0039 in)
B 8.0 mm (0.315 in)
C 60.0 mm (2.362 in)
D 40.0 mm (1.575 in)
E 55.0 mm (2.165 in)
F 40.0 mm (1.575 in)
G 5.0 mm (0.196 in) Radius
H TAP M10X1.5
* Do not use dimension "H."

S0609000 Drive Coupling (Main Pump)

Page 8
DRIVE COUPLING INSTALLATION
Whenever the drive coupling for main pump is installed, the following mounting dimensions and installation
procedures must be observed.
NOTE: If these procedures are not followed, noise will occur and/or the service life of drive
coupling or main pump will be reduced.

Figure 9 DRIVE COUPLING INSTALLATION (KAWASAKI / TONG MYUNG PUMP)

Drive Coupling (Main Pump) S0609000

Page 9
 Figure 10 DRIVE COUPLING INSTALLATION (UCHIDA PUMP)

S0609000 Drive Coupling (Main Pump)

Page 10
 Table 1 Parts Information and Torque for Figure 9 and Figure 10
Reference Torque
Description Qty.
Number (See Table 2 and 3)
1 Spring Pin 4
2 Insert 4
3 Bolt 4 Ta
4 Flywheel 1
5 Spring Pin 8
6 Insert 4
7 Hub 1
8 Bolt 4 Ta
9 Pump Shaft 1
10 Clamping Screw 2 Tb
11 Element 1

Drive Coupling (Main Pump) S0609000

Page 11
Specification for "Measurement H," from front hub face to pump shaft end, and TIGHTENING TORQUE of
bolts and screws written in the "Table 2" must be observed.

Table 2 Specification for "Measurement H" and Torque (Refer to Figure 9)

Coupling Part Torque Value for Torque Value for
Model "Measurement H"
Number "Ta" "Tb"
17.5 - 18.5 mm 21 - 23 kg•m 10 - 12 kg•m
DD80L 2414-9009A
(0.689 - 0.728 in) (152 - 166 ft lb) (72 - 87 ft lb)
S130LC-III 21 - 23 kg•m 10 - 12 kg•m
2414-9009A Note 1
S130LC-V (152 - 166 ft lb) (72 - 87 ft lb)
S130W-III
See Table 3.
S130W-V
S140W-V 0.5 - 1.5 mm 21 - 23 kg•m 12 kg•m
2414-9042
S160W-V (0.020 - 0.059 in) (152 - 166 ft lb) (87 ft lb)
10.0 - 11.0 mm 21 - 23 kg•m 10 - 12 kg•m
S170LC-III 2414-9008A
(0.394 - 0.433 in) (152 - 166 ft lb) (72 - 87 ft lb)
2.5 - 3.5 mm 21 - 23 kg•m 10 - 12 kg•m
S170LC-V 2414-9042
(0.098 - 0.138 in) (152 - 166 ft lb) (72 - 87 ft lb)
S170W-III 21 - 23 kg•m 10 - 12 kg•m
2414-9025 Note 2
S200W-III (152 - 166 ft lb) (72 - 87 ft lb)
S220LC-III
S220LC-V
S220N-V 10.0 - 11.0 mm 21 - 23 kg•m 10 - 12 kg•m
2414-9008A
S220LL (0.394 - 0.433 in) (152 - 166 ft lb) (72 - 87 ft lb)
S225LC-V
S225NLC-V
S200W-V
S210W-V 10.0 - 11.0 mm 21 - 23 kg•m 10 - 12 kg•m
2414-9041
S250LC-V (0.394 - 0.433 in) (152 - 166 ft lb) (72 - 87 ft lb)
S255LC-V
S280LC-III
4.5 - 5.5 mm 44 - 49 kg•m 20 - 22 kg•m
S290LC-V 2414-9034
(0.177 - 0.216 in) (318 - 354 ft lb) (145 - 159 ft lb)
S290LL
S330LC-III
S330LC-V 5.0 - 6.0 mm 44 - 49 kg•m 20 - 22 kg•m
2414-9040
S400LC-III (0.196 - 0.236 in) (318 - 354 ft lb) (145 - 159 ft lb)
S400LC-V
S450-III 44 - 49 kg•m 20 - 22 kg•m
2414-9040 Note 2
S450LC-V (318 - 354 ft lb) (145 - 159 ft lb)
NOTE: 1) S130LC-III and S130LC-V has reverse dimension, that is, pump shaft must protrude
outwards by 5.5 - 6.5 mm (0.216 - 0.255 in)
NOTE: 2) Push the hub toward the pump until it stops on S170W-III, S200W-III and S450-III.

S0609000 Drive Coupling (Main Pump)

Page 12
 Table 3 Specification for "Measurement H" for Wheel Excavator (Refer to Figure 10)
Coupling Part Torque Value for Torque Value for
Model "Measurement H"
Number "Ta" "Tb"
S130W-III 15.5 - 16.5 mm 21 - 23 kg•m 10 - 12 kg•m
2414-9021
S130W-V (0.610 - 0.650 in) (152 - 166 ft lb) (72 - 87 ft lb)
5 mm 13 - 15 kg•m 10 - 12 kg•m
S55W-V PLUS 414-00045A
(0.197 in) (94 - 108 ft lb) (72 - 87 ft lb)

Drive Coupling (Main Pump) S0609000

Page 13
INSTALLATION PROCEDURE
NOTE: Refer to Figure 9 and Figure 10
while using following procedure.
1. Install spring pin (1) and attach insert (2)
with bolt (3) to engine flywheel (4).
NOTE: Tighten bolts to value "Ta" in
the tables.
2. Install two spring pins (5) and attach insert
(6) to hub (7) bolts (8).
NOTE: Tighten bolts to value "Ta" in
the tables.
3. Attach flywheel cover to the main pump
with bolts. (Kawasaki pump only.)
4. Slide hub (7) into place on pump shaft (9)
as specified in the "Table 2" or "Table 3" for
"Measurement H" and secure it in position
with clamping screws (10).
NOTE: Tighten clamping screws to
value "Tb" in the tables.
NOTE: Coat clamping screws (10) with
Loctite #262. Figure 11 DRIVE COUPLING INSTALLA-
TION (KAWASAKI / TONG MYUNG PUMP)
5. Install element (11) between inserts (2) on
engine flywheel (4).
6. Install main pump and hub (7) by pushing
it softly into element (11).
7. Attach flywheel cover / pump housing to
flywheel housing with bolts.

CAUTION!
1. Bolts (3 and 8) are coated against
loosening with a bonding compound.
Do not use any additional bonding
compounds, oils or cleaning solvents
on them.
2. Element (11) is nonresistant to
bonding compounds, oil or grease.
Be careful not to expose it to them.
3. Remove oil or dirt from flywheel
cover and pump shaft before
assembly.
Figure 12 DRIVE COUPLING INSTALLA-
4. Misalignment between pump and TION (UCHIDA PUMP)
engine should be controlled to less
than 0.6 mm (0.023 in).

S0609000 Drive Coupling (Main Pump)

Page 14
1HYDRAULICS
 S0702200

1HYDRAULIC SYSTEM
TROUBLESHOOTING,
TESTING AND
ADJUSTMENT
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.

HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENT

S0702200
MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Hydraulic System Troubleshooting, Testing and S0702200

Adjustment Page 1
TABLE OF CONTENTS

Hydraulic System ........................................................................................... 3

Outline..................................................................................................... 3
Major Components.................................................................................. 4
Hydraulic Schematic (Solar 55W-V PLUS) ............................................. 6
Control Valve Operation .......................................................................... 8
Circuit Operation ..................................................................................... 9

S0702200 Hydraulic System Troubleshooting, Testing and

Page 2 Adjustment
HYDRAULIC SYSTEM
OUTLINE
The hydraulic system consists of the engine, variable displacement piston pumps, gear pump, control
valve, boom cylinder, arm cylinder, bucket cylinder, boom swing cylinder, blade cylinder, swing motor,
swivel joint, travel motor, oil cooler, and hydraulic oil tank.
The oil discharged from the variable displacement piston pumps and the gear pump flows to the actuators
through the control valve.
The hydraulic pilot operation system comprises the pilot pump mounted on the main hydraulic pump, cut-
off valve and two pilot valves. The oil discharged from the pilot pump, passing through the cut-off valve and
the pilot valve, flows into the pilot port of the control valve to control the valve spool movement in proportion
to the pressure in the pilot port.
The variable displacement piston pumps, the gear pump, and the pilot pump are linked to the flywheel of
the engine through the coupling. The number of revolutions of each hydraulic pump is identical to the
engines speed. The displacement of each piston pump is 25 cu.cm/rev., that of the gear pump P3 is 16.2
cu.cm/rev and that of the pilot pump P4 is 8.9 cu.cm/rev. Each pump receives oil from the hydraulic oil tank
via the intake strainer.
The oil discharged from the pumps P1 and P2 flows to the control valve ports P1 and P2 and returns from
the ports T1 and T2 to the hydraulic oil tank through the return filter.
The oil discharged from the gear pump P3 flows into the port P1 of the steering valve to move the steering
cylinder in the front axle. When the steering valve is not operated, the oil from the gear pump P3 flows
through the port P1 and EF of the steering valve to the port P3 of the control valve.
The oil from the pilot pump P4 flows through the cut-off valve and the pilot valves and returns to the
hydraulic oil tank.
The system relief valves R1 and R2 of the control valve control the discharge pressure of the pumps.
The bypass valve in the return filter opens with a differential pressure of 147 kpa (21 psi).

Hydraulic System Troubleshooting, Testing and S0702200

Adjustment Page 3
MAJOR COMPONENTS

3
2
1
4

C2
C1

C21
C16

C19
PS

C5
C13

C17
b10
a10

b9
a9
R L

b8
a8
EF

b7
a7

P1
pp

P2

b6
a6

A10

B8 B9 B10

b5
a5

A8 A9

b4
a4

A7

B7
P3
A6

B6
A5

B4 B5

b3
a3

A4

b2
a2

B3
A3

B2
A2
a1

b1
BI
AI
5
9
8 7 6
10

14

11

13

12

BNS2520L
Figure 1

Reference Reference
Description Description
Number Number
1 Boom Swing Cylinder 8 Steering Valve
2 Swing Motor 9 Swivel Joint
3 Hydraulic Oil Tank 10 Boom Cylinder
4 Pilot Supply Valve 11 Dozer Blade Cylinder
5 Hydraulic Pump 12 Travel Motor
6 Pilot Valve (Joystick Valve) 13 Bucket Cylinder
7 Control Valve 14 Arm Cylinder

S0702200 Hydraulic System Troubleshooting, Testing and

Page 4 Adjustment
Hydraulic System Troubleshooting, Testing and S0702200
Adjustment Page 5
HYDRAULIC SCHEMATIC (SOLAR 55W-V PLUS)

T2
HYDRAULIC PUMP
DOUBLE SINGLE P1 : 1.53 cu.in/rev.(25 cu.cm/rev)
ACTION ACTION A10 Pb10 P2 : 1.53 cu.in/rev.(25 cu.cm/rev)
P3 : 0.99 cu.in/rev.(16.2 cu.cm/rev)
B10 P.T.O.
P4 : 0.54 cu.in/rev.(8.9 cu.cm/rev)
Pa10 3k
A
P
ENGINE
B
SWITCH VALVE YANMAR 4TNV94L
A9 Pb9 54.9PS/2400RPM
19.3KgM/1600RPM
BKO BKI
BUCKET
B9
OIL COOLER
Pa9
250K
CR DP
BUCKET
A8
4.5k RETURN
BD 250K Pb8 FILTER
B8 BOOM1
Pa8
250K UP DN
BOOM BU
A7

C2 B7
TRAVEL1
E Pb7 Pa7
LOCK VALVE 2
B F
1
P1
T V2 Pil
R1 T
Pp
P2
230K
P3 T3 T2
HORN
P2
PILOT VALVE(RH) P T PILOT VALVE(LH)
Pb6 B F Pa6
TRAVEL2
B6

A6
BOOM
BUCKET SWING

Pb9 3 1 2 4 3
ARM
Pb5 CROWD Pa9 UP RIGHT LE
ARM DUMP (Pb4,Pb8)
Pa5
AO AI B5 250K 250K CR DP

A5 Pb4 SHUTTLE V/V

SWING LEFT CHANGE
Pa2 a2 a1
UP BR Pa4
(Pb5) CROWD b2
BOOM2
b1 BOOM SWING
SWING MOTOR B4 E (Pb1)
c2 c1 LEFT
SWING RIGHT
A4 Pb2
-RG-

SH T1 DOWN d2
Pa8 BOOM SWIN
T1 210K d1 (Pa1)
PG P3 RIGHT
R2
AIR VENT PORT

Pb3 UP DN Pa3
BLADE
A3
-GB-

-GA-

B3
T
RH LH Pa2
B(R) A(L) Pb2
SWING
B2

A2
Pb1
LH RH BOOM SWING

B1 Pa1

BSL BSR
A1

BOOM SWING

BLADE CYLINDER

BLD BLU

Figure 2

S0702200 Hydraulic System Troubleshooting, Testing and

Page 6 Adjustment
 STEERING VALVE

)(

)(
HYDRAULIC PUMP
P1
P1 : 1.53 cu.in/rev.(25 cu.cm/rev)
P2 : 1.53 cu.in/rev.(25 cu.cm/rev) OSPC

)(

)(
P3 : 0.99 cu.in/rev.(16.2 cu.cm/rev) 160LS
P4 : 0.54 cu.in/rev.(8.9 cu.cm/rev) EF
3k R1 P1 P2 P3 P4 100k
T
ENGINE 150k
YANMAR 4TNV94L PILOT PUMP P4

54.9PS/2400RPM R
19.3KgM/1600RPM
60k
L
OIL COOLER

GEAR PUMP P3 PSD GBR

S1
A2
PISTON PUMP P1,P2 C20 0.32 25
C15 RB L
P C1 40 C13
4.5k RETURN STRAINER
FILTER C14 FB
PILOT FILTER 0.32 25
+2 +2 70 A1 L
33 -2 22 -2 100
85
C2 C21 C16 C17
T
Po C19
C18

GPS AC2
0.32 15
L
AC1 C3
0.32 15 PARK
L SAFETY
CUT OFF
SP EMERGENCY C10
T PULL 15k
1.1 SW
C4
P2 P PS

P3 T3 T2 P1 T1 PAR FORWARD
HORN PILOT VALVE(DOZER)
PILOT VALVE(RH) P T PILOT VALVE(LH) P T T P
C6 CHOCK
C5

REVERSE C8

BOOM (DOZER)
BUCKET SWING ARM C7 PILOT
1 DOWN(Pa3) 2 PBR SUPPLY
Pb9 3 1 2 4 3 1 2 4
VALVE
CROWD Pa9 UP RIGHT LEFT DUMP CROWD
UP(Pb3) TS TR CH PK
DUMP (Pb4,Pb8)
(Pa5)

1 2

SHUTTLE V/V SAFETY

SWING LEFT T P
a2 a1 CHANGE VALVE CUT OFF
Pa2 (Pa10)
C 1 C1 3
5) CROWD b2 PA
b1 BOOM SWING OA T1
E TRAVEL MODULATION
(Pb1) T2 PB
C2
c2 c1 LEFT
RIGHT D
DOWN d2 2 T
BOOM SWING OB O
Pa8 d1 (Pa1) (Pb10) P
RIGHT (Pa4)

BRAKE

DIG LATCH

50k T1
BR1

P1
BL1
1 2 9 8 10 3 4 5 7 0 11 6
SWIVEL JOINT

4.8K

TRAVEL MOTOR MB B A

HI
LO 250k
T2
BR2
BL
BLADE CYLINDER P2
TB Y
BL2 BRAKE VALVE
PL 50 BAR
T MA
BLD BLU
BR

PK

Solar 55W-V Plus

BNS2801L

Hydraulic System Troubleshooting, Testing and S0702200

Adjustment Page 7
CONTROL VALVE OPERATION
The oil from the piston pump P1 is fed to the travel motor, the boom cylinder, the bucket cylinder, and PTO
The oil from the piston pump P2 flows to the travel motor, the arm and boom cylinders, through parallel
passages to be actuated simultaneously.
The oil from the gear pump P3 is fed to the blade cylinder, the swing motor and boom swing cylinder,
through parallel passages to be actuated simultaneously.
The boom cylinder and travel motor are actuated by the combined oil flow which consists of oil from the
piston pump P1 and P2.
A lock valve is installed on the boom cylinder to prevent the boom from drifting, when hoses are ruptured.
In addition, a swing motor brake release pilot circuit is installed to release the brake of the swing motor with
the pressure of the oil from the pilot pump P4.

S0702200 Hydraulic System Troubleshooting, Testing and

Page 8 Adjustment
CIRCUIT OPERATION

Boom
The lock valve is installed on the bottom end circuit of the boom cylinder to prevent the boom from drifting
when hoses are ruptured.
When the boom control lever is pulled back to raise the boom, the oil from the pilot pump P4 flows through
the cut-off valve and the port 2 of the pilot valve (RH) to the ports Pb4 and Pb8 of the control valve to move
the boom spool.
The oil discharged from the piston pump P1 flows through the port P1 of control valve, parallel-flow divider
and parallel passage to the boom1 spool.
The oil discharged from the piston pump P2 flows, passing through the port P2 of control valve, parallel-
flow divider and parallel passage to the boom2 spool.
The oil from the boom1 spool and the boom2 spool is combined at the external line, and flows the port V2
of the lock valve attached on the port BU of the boom cylinder, to extend its cylinder rod.
The return oil from BD of the boom cylinder flows back to the hydraulic oil tank through the ports A8, T1
and T2 of the control valve and the return filter.
When the boom control lever is pushed forward to lower the boom, the oil from the pilot pump P4 flows to
the port Pa8 of the control valve through the cut-off valve, the port 4 of the pilot valve (RH) and the port d2
of the shuttle valve to move the boom spool. The pilot oil from the port d2 of the shuttle valve also flows to
the port Pi1 of the lock valve and opens the poppet of the lock valve, and accordingly, the oil in the lock
valve flows out to the port T to open the valve.
The oil from the piston pump P1 flows through the ports P1 and A8 of the control valve to BD of the boom
cylinder to retract its cylinder rod. The return oil from BU of the boom cylinder flows back to the hydraulic oil
tank through the opened lock valve, the port B8 of the control valve, the ports T1 and T2 of the control
valve and the return filter.

Arm
When the arm control lever is pulled back to retract the arm (i.e., to extend the cylinder rod), the oil from the
pilot pump P4 flows through the cut-off valve, the port 4 of and the pilot valve (LH) and the port b2 of the
shuttle valve to the port Pb5 of the control valve to move the arm spool.
The oil from the piston pump P2 flows through the ports P2 of the control valve, the port B5 of the control
valve to AI of the arm cylinder to extend its cylinder rod.
The return oil from AO of the arm cylinder flows back to the hydraulic oil tank through the ports A5, T1 and
T2 of the control valve, and the return filter.
When the arm control lever is pushed forward to extend the arm, the oil from the pilot pump P4 flows
through the cut-off valve and the port 2 of the pilot valve (LH) to the port Pa5 of the control valve to move
the arm spool.
In this operation, the oil from the piston pump P2 flows in the opposite direction to the oil flow in the Arm
Retract operation.

Bucket
When the bucket control lever is moved to the left to curl the bucket, the oil from the pilot pump P4 flows
through the cut-off valve and the port 3 of the pilot valve (RH) to the port Pb9 of the control valve to move
the bucket spool.
The oil from the piston pump P1 flows through the ports P1 and B9 of the control valve to BKI of the bucket
cylinder to extend its cylinder rod.

Hydraulic System Troubleshooting, Testing and S0702200

Adjustment Page 9
The return oil from BKO of the bucket cylinder flows back to the hydraulic oil tank through the ports A9, T1
and T2 of the control valve and the return filter.
When the bucket control lever is moved to the right to dump the bucket, the oil from the pilot pump P4 flows
through the cut-off valve and the port 1 of the pilot valve (RH) to the port Pa9 of the control valve to move
the bucket spool.
The oil from the piston pump P1 flows through the ports P1 and A9 of the control valve to BKO of the
bucket cylinder to retract its cylinder rod.
The return oil from BKI of the bucket cylinder flows back to the hydraulic oil tank through the ports B9, T1
and T2 of the control valve and the return filter.

Swing
Mechanical Brake Operation
A. During the engine stop, no pressurized oil flows to the brake release port PG in the swing motor.
Therefore, the mechanical brake of the swing motor operates and the pinion gear of the swing motor
is locked so they do not to rotate the upper structure.
B. Even though the engine is started, if the safety cut-off valve is off, no pressurized oil flows through the
port SP of the pilot supply valve to the brake release port PG in the swing motor. Therefore, the
mechanical brake of the swing motor operates and the pinion gear of the swing motor is locked so
they do not to rotate the upper structure.
C. When the engine is started and the safety cut-off valve is on and the swing control lever is moved, the
pressurized oil flows through port 1 or 3 of the swing control lever and the port C or D of the change
valve and the port E of the shuttle valve to the port SH of the swing motor to move the spool in the
swing motor, so that the pinion gear of the swing motor is released.
When the swing control lever is moved to the right, the oil from the pilot pump P4 flows through the
cut-off valve, the port 3 of the pilot valve (LH), the port D of the change valve, and the port C2 of the
shuttle valve to the port Pb2 of the control valve to move the swing spool.
The oil from the gear pump P3 flows through the port EF of the steering valve and the ports P3 and
B2 of the control valve to the port B(R) of the swing motor.
The return oil from the motor flows back to the hydraulic oil tank through the port A(L) of the swing
motor, the ports A2, T1 and T2 of the control valve and the return filter.
When the swing control lever is released (i.e., returned to the neutral position), the oil from the gear
pump P3 is blocked and the pressures of the ports A(L) and B(R) of the swing motor become equal.
However, the upper structure continues to swing for a short time due to its inertia. This causes the
motor to act like a pump and increases the pressure at port A(L). The increased pressure opens the
relief valve to let the oil escape to the port B(R), so that the shock due to the inertia is absorbed. A
check valve is also installed to prevent cavitation of port A(L). The port T of the swing motor draws oil
from the port T2 of the control valve in order to provide a draining function and prevent the motor from
cavitation.
When the swing control lever is moved to the left, the oil from the pilot pump P4 flows through the cut-
off valve and the port 1 of the pilot valve (LH) to the port Pa2 of the control valve to move the swing
spool.
The oil from the gear pump P3 to the motor flows in the opposite direction to the oil flow in the right
swing operation.

Boom Swing
To swing the boom to the right, the button at the top of the swing control lever (LH) has to be pressed once
before the swing control lever is moved to the right or the left.

S0702200 Hydraulic System Troubleshooting, Testing and

Page 10 Adjustment
When the button at the top of the swing control lever is pressed once, the solenoid valve in the change
valve turns on. At the same time, the boom swing indicator light on the console box will turn on.
When the button is pressed again, boom swing will be deactivated and boom swing indicator light turns off.
When the solenoid valve turns on and the swing control lever is moved to the right, the oil from the pilot
pump P4 flows through the cut-off valve and the port 3 of the pilot valve (LH) and the port OB of the change
valve to the port Pa1 of control valve to move the boom swing spool.
The oil from the gear pump P3 flows through the port EF of the steering valve and the ports P3 and A1 of
the control valve to BSR of the boom swing cylinder to retract its cylinder rod.
The return oil from BSL of the boom swing cylinder flows back to the hydraulic tank through the port B1, T1
and T2 of the control valve, and the return filter.
When the solenoid valve turns on and the swing control lever is moved to the left, the oil from the pilot
pump P4 flows through the cut-off valve and the port 1 of the pilot valve (LH) and the port OA of the change
valve to the port Pb1 of control valve to move the boom swing spool.
In this operation, the oil from the gear pump P3 flows in the opposite direction to the oil in the BOOM
SWING RIGHT operation.

Blade
The blade control lever is pushed forward to lower the blade. The oil from the pilot pump P4 flows through
the cut-off valve and the port 1 of the pilot valve (DOZER) to the port Pa3 of the control valve to move the
blade spool.
The oil from the pump P3 flows through the port EF of the steering valve, the ports P3 and A3 of the control
valve and the port 9 of the swivel joint, to BLD of the blade cylinder to extend its cylinder rod.
The return of from BLU of the blade cylinder flows back to the hydraulic oil tank through the port 8 of the
swivel joint, the ports B3, T1 and T2 of the control valve and the return filter.
When the blade control lever is pulled back to raise the blade, the oil flows in the opposite direction to the
oil flow in the blade lower operation.

Travel
When the forward valve in the pilot supply valve turns on and the travel modulation valve is pressed by foot,
the oil from the pilot pump P4 flows through the port PAR of the pilot supply valve to the port Pa6 and Pa7
of the control valve.
The oil discharged from the piston pump P1 flows, passing through the port P1 of control valve, parallel-
flow divider to the TRAVEL1 spool.
The oil discharged from the piston pump P2 flows, passing through the port P2 of control valve, parallel-
flow divider to the TRAVEL2 spool.
The oil from the travel 1 spool and the travel 2 spool flows through the port A6 and A7, and is combined at
the swivel joint and flows to the port B of the travel motor to move the machine forward.
The return oil from the port A of the travel motor flows back to the hydraulic oil tank through the swivel joint,
the ports B6, B7, T1 and T2 of the control valve and the return filter.
When the reverse valve in the pilot supply valve turns on and the travel modulation valve is pressed by foot,
the oil from the pilot pump P4 flows through the port PBR of the pilot supply valve to the port Pb6 and Pb7
of the control valve.
The oil discharged from the piston pump P1 and the piston pump P2 flows in the opposite direction to the
oil flow in the FORWARD TRAVEL operation.

Hydraulic System Troubleshooting, Testing and S0702200

Adjustment Page 11
Simultaneous Operation of Boom Up and Arm Retract
When the boom control lever is pulled back to raise the boom, the oil from the pilot pump P4 flows through
the cut-off valve and the port 2 of the pilot valve (RH) to the ports Pb4 and Pb8 of the control valve to move
the boom valve spool.
If the arm control lever is pulled back to retract the arm while the boom is rising, the oil from the pilot pump
P4 flows through the cut-off valve and the port 4 of the pilot valve (LH) to the ports Pb5 of the control valve
to move the arm valve spool.
The oil discharged from the piston pump P1 flows through the ports P1 and B8 of the control valve to BU of
the boom cylinder to extend its cylinder rod.
The return oil from BD of the boom cylinder flows through the ports A8, T1 and T2 of the control valve and
the return filter, then back to the hydraulic oil tank.
The oil from the piston pump P2 flows to the ports P2 of the control valve, and the oil flows through the port
B5 of the control valve to AI of the arm cylinder to extend its cylinder rod.
The return oil from AO of the arm cylinder flows through the ports A5, T1 and T2 of the control valve and
the return filter, then back to the hydraulic oil tank.

Simultaneous Operation of Boom Up and Bucket

When the boom control lever is pulled back to raise the boom, the oil from the pilot pump P4 flows through
the cut-off valve and the port 2 of the pilot valve (RH) to the ports Pb4 and Pb8 of the control valve to move
the boom valve spool.
The oil from the piston pump P1 and P2 flow to the ports P1 and P2 of the control valve, respectively, and
are combined in the boom section, and the combined oil flows through the port B8 of the control valve to
BU of the boom cylinder to extend its cylinder rod.
The return oil from BD of the boom cylinder flows through the ports A8, T1 and T2 of the control valve and
the return filter, the back to the hydraulic oil tank.
If the bucket control lever is moved to the left to curl the bucket while the boom is rising, the oil from the
pilot pump P4 flows through the cut-off valve and the port 3 of the pilot valve (RH) to the port Pb9 of the
control valve to move the bucket valve spool.
The oil from the piston pump P1 flows through the ports P1 of the control valve, the boom section, and the
oil flows through the port B9 of the control valve to BKI of the bucket cylinder to extend its cylinder rod.
The return oil from BKO of the bucket cylinder flows through the ports A9, T1 and T2 of the control valve
and the return filter, then back to the hydraulic oil tank.
When the bucket control lever is moved to the right to dump the bucket, the oil from each pump flows in the
opposite direction to the bucket curl operation.
A check valve with an orifice (Boom priority orifice) is installed in the parallel passage before the bucket
section so as for oil to easily flow to the boom section when the boom receives heavier load than the bucket
in the simultaneous operation of boom-up and bucket.

PTO
When the PTO left switch on the pilot valve (RH) is pushed, the oil from the piston pump P1 flows through
the ports P1 of the control valve, to the port B10 of the control valve.
The return oil from the PTO flows back to the hydraulic oil tank through the ports A10, T1 and T2 of the
control valve and the return filter.
The oil flows in the opposite direction when the PTO right switch on the pilot valve (RH) is pushed.

S0702200 Hydraulic System Troubleshooting, Testing and

Page 12 Adjustment
 S0703010K

1ACCUMULATOR

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.

ACCUMULATOR S0703010K
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier II) 2001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 175LC-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 210W-V 1001 and Up
Solar 225LC-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 1001 and Up
Solar 340LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 470LC-V 1001 and Up
Solar 55 0001 and Up
Solar 55-V PLUS 1001 and Up
Solar 55W-V PLUS 1001 and Up

Models continued on back of cover.

Copyright 2003 Daewoo

August 2003

Accumulator S0703010K
Page 1
 MODEL SERIAL NUMBER RANGE
Solar 75-V 1001 and Up

TABLE OF CONTENTS

General Description........................................................................................ 3
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 pre-charging or expelling gas from the
compressible, pre-charged 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 pre-pressure 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

Accumulator S0703010K
Page 3
 NOTE: Pre-charge 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 pre-charge 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 counter-pressure
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 pre-charge 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 pre-charge 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 pre-charge
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)
Solar 140W-V 30 kg/cm2 750 cc
S/N 1000 and Up Brake System
/160W-V (427 psi) (45.77 in3)
Solar 140W-V 15 kg/cm2 320 cc
S/N 1000 and Up Pilot
/160W-V (213 psi) (19.53 in3)

S0703010K Accumulator
Page 4
 Charge
Model Serial Number System Volume
Pressure
Solar 140W-V 8 kg/cm2 750 cc
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
Solar 210W-V S/N 0001 and Up Brake System
(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
Solar 225LC-V S/N 1001 and Up Pilot / Travel
(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
Solar 255LC-V S/N 1001 thru 1002 Pilot / Travel
(142 psi)) (19.53 in3)
10 kg/cm2 750 cc
Solar 255LC-V S/N 1003 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm2 320 cc
Solar 300LC-V S/N 1001 thru 1099 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
Solar 300LC-V S/N 1100 and Up Pilot / Travel
(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
Solar 340LC-V S/N 1001 thru 1059 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
Solar 340LC-V S/N 1060 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm2 320 cc
Solar 420LC-V S/N 1001 thru 1029 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
Solar 420LC-V S/N 1030 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm2 320 cc
Solar 470LC-V S/N 1001 thru 1049 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm2 750 cc
Solar 470LC-V S/N 1050 and Up Pilot / Travel
(142 psi)) (45.77 in3)

Accumulator S0703010K
Page 5
 Charge
Model Serial Number System Volume
Pressure
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
Solar 55W-V S/N 1001 and Up Brake System
(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)

S0703010K Accumulator
Page 6
 S0704100

1CENTER JOINT
(SWIVEL)

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.

CENTER JOINT (SWIVEL)S0704100

MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Center Joint (Swivel) S0704100

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Parts List ................................................................................................. 4
Troubleshooting, Testing and Adjustment....................................................... 6
Inspection................................................................................................ 6
Testing..................................................................................................... 6
Disassembly ................................................................................................... 7
Reassembly.................................................................................................... 8

S0704100 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.

Center Joint (Swivel) S0704100

Page 3
PARTS LIST

6
3

10

11
13
13
12
11 13 12 12
BNS2930L
Figure 1

S0704100 Center Joint (Swivel)

Page 4
 Reference Reference
Description Description
Number Number
1 Center Joint 8 O-ring
2 Sleeper Seal 9 O-ring
3 Cover 10 O-ring
4 Hub 11 Plug, Hex Socket
5 Spindle 12 Plug, Hex Socket
6 Spring Washer 13 Plug, Hex Socket
7 Bolt, Hex

Center Joint (Swivel) S0704100

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 change- Changeover Valve

over 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).

S0704100 Center Joint (Swivel)

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 the 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 the cover (3), withdraw O-ring (8), O-ring (9), and O-ring (10).
NOTE: For removal of O-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. O-rings and seals should be replaced whenever the assembly is being overhauled or rebuilt. 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 reassembling 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.

Center Joint (Swivel) S0704100

Page 7
REASSEMBLY

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. Pre-lubricate O-rings with hydraulic oil, white grease or petroleum jelly.

2. Thoroughly clean all other component surfaces of dirt or grease before reassembly.
3. Assemble in reverse order of disassembly.
4. Clean threads of fasteners before pre-applying Loctite #243 to the threads, and before torquing cover
bolts.
5. Pre-fill the center swivel with clean hydraulic fluid before reassembly of high-pressure and drain line
piping. Clean and pre-fill 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.

S0704100 Center Joint (Swivel)

Page 8
 S0705000
R5

1CYLINDERS

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.

CYLINDERS S0705000
MODEL SERIAL NUMBER RANGE
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 170LC-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 175LC-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 210W-V 1001 and Up
Solar 220LC-V 0001 and Up
Solar 225LC-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 250LC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 290LC-V 0001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 1001 and Up
Solar 330LC-V 1001 and Up
Solar 340LC-V 1001 and Up

Copyright 2003 Daewoo

August 2003

Cylinders S0705000
Page 1
 MODEL SERIAL NUMBER RANGE
Solar 400LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up
Solar 55 0001 and Up
Solar 55-V PLUS 1001 and Up
Solar 55W-V PLUS 1001 and Up
Solar 75-V 1001 and Up

TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 4
Special Tools and Materials............................................................................ 6
Piston Nut................................................................................................ 6
Piston Jig............................................................................................... 10
Steel bush 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
Description Description
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))
S140W-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)
S130W-V (NEW BOOM)
S130LC-V (SHORT ARM)
S140W-V (ARM)
S140W-V (BOOM)
S140W-V (OUTRIGGER)
125 mm 85 mm 12 mm 5 mm
BOOM (OP) S160W-V (BOOM)
(4.92 in) (3.35 in) (0.47 in) (0.20 in)
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
 MODEL CYLINDER øA øB C D MODEL (CYLINDER)
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)
S450LC-V (BOOM, BUCKET)
S470LC-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
(4.92 in) (4.02 in) (0.43 in) (0.18 in) S200W-V (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)
S390LL (BOOM, 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
 MODEL CYLINDER øA øB C D MODEL (CYLINDER)
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
BOOM S130LC-V (DOZER)
(4.72 in) (3.11 in) (0.39 in) (0.20 in)
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)
S255LC-V (BOOM, BUCKET)
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))
(3.15 in) (0.43 in) (1.77 in) (4.33 in) S55W-V (BOOM)
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)
70 mm 11 mm 53 mm 95 mm S130LC-V (DOZER)
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)
S290LC-V (BOOM, BUCKET)
S300LC-V (BOOM, BUCKET)
S70-III (BOOM)
S75-V (SWING)
S80W-II (BOOM)
S220LC-V S130W-V (ARM (EURO))
S130LC-V (S/ARM, BOOM
(OP), ARM)
S160W-V (ARM)
90 mm 11 mm 63 mm 115 mm S170LC-V (BOOM)
BUCKET
(3.54 in) (0.43 in) (2.48 in) (4.53 in) 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)
S330LC-V (BOOM, BUCKET)
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))
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)
S450LC-V (BOOM, BUCKET)
S470LC-V (BOOM, BUCKET)

Cylinders S0705000
Page 11
 MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER)
150 mm 13 mm 103 mm 180 mm
S450LC-V ARM S470LC-V (ARM)
(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
(2.48 in) (0.43 in) (1.69 in) (3.54 in) S55W-V (BUCKET)
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)
75 mm 11 mm 53 mm 100 mm S75-V (BOOM)
S130W-V BOOM
(2.95 in) (0.43 in) (2.09 in) (3.94 in) S130LC-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 BUSH 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
-0.15
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)
S75-V (ARM, BOOM,
S130LC-V SWING)
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
 MODEL CYLINDER øA -0.05
-0.15
øB (±0.1) E F +0.05
0
Part MODEL (CYLINDER)
S210W-V (ARM)
S290LC-V (S/ARM, ARM)
S290LL (BOOM, BUCKET)
S300LC-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-III (BUCKET)
MEGA 200 (BUCKET)
MEGA 300 (BUCKET)
MEGA 300-V (LIFT)
65 mm 80 mm 35 mm 6.5 mm
BUCKET S210W-V (BUCKET)
(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)
S330LC-V (ARM, BOOM,
BUCKET)
S340LC-V (ARM, BOOM,
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
 MODEL CYLINDER øA -0.05
-0.15
øB (±0.1) E F +0.05
0
Part MODEL (CYLINDER)
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
71 mm 86 mm 40 mm 6.5 mm (OP))
BOOM
(2.80 in) (3.39 in) (1.58 in) (0.26 in) S140W-V (BOOM)
S160W-V (BOOM)

S130W-V S130W-V (ARM)

S130LC-V (S/ARM, 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
-0.3 øB -0.2
-0.3 C 0
-0.1
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)
70 mm 84 mm 5.5 mm 6 mm S130W-V (BOOM)
BOOM
(2.76 in) (3.31 in) (0.22 in) (0.24 in) S130LC-V (BOOM)
MEGA 160-III (BUCKET)
S55-V (ARM, BOOM, BOOM (OP),
BUCKET)
S55-V PLUS (BUCKET, SWING)
55 mm 69 mm 5 mm 6 mm
BUCKET S55W-V (ARM)
S70-III (2.17 in) (2.72 in) (0.20 in) (0.24 in)
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 S140W-V (DOZER)
DOZER
(2.36 in) (2.91 in) (0.20 in) (0.24 in) S160W-V (DOZER)
MEGA 130-III (BUCKET)
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)
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))
S225NLC-V (BOOM (OP))
S130LC-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)

Cylinders S0705000
Page 19
 MODEL CYLINDER øA -0.2
-0.3 øB -0.2
-0.3 C 0
-0.1
D MODEL (CYLINDER)
S210W-V (ARM)
S220N-V (ARM (OP))
95 mm 109 mm 6 mm 7 mm S225LC-V (ARM)
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)
S470LC-V (BOOM, BUCKET)
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)
S450LC-V (BOOM, BUCKET)
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, BUCKET
S250LC-V (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)
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)

S0705000 Cylinders
Page 20
 MODEL CYLINDER øA -0.2
-0.3 øB -0.2
-0.3 C 0
-0.1
D MODEL (CYLINDER)
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)
BUCKET 100 mm 114 mm 6 mm 7 mm
(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)
BUCKET 100 mm 114 mm 6 mm 7 mm
(OP) (3.94 in) (4.49 in) (0.24 in) (2.28 in)
120 mm 136 mm 9 mm 7 mm S420LC-V (ARM)
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
BUCKET S420LC-V (BUCKET)
(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)
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)

Cylinders S0705000
Page 21
 MODEL CYLINDER øA -0.2
-0.3 øB -0.2
-0.3 C 0
-0.1
D MODEL (CYLINDER)
S130W-V (S/ARM)
S130LC-V (BOOM (OP))
S140W-V (ARM)
75 mm 89 mm 6 mm 7 mm S140W-V (BOOM)
ARM
(2.95 in) (3.50 in) (0.24 in) (2.28 in) S160W-V (BOOM)
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
(2.56 in) (3.11 in) (0.24 in) (2.28 in) S160W-V (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 S250LC-V (BOOM, BUCKET)
ARM
(3.54 in) (4.10 in) (0.24 in) (2.28 in) S255LC-V (BOOM, BUCKET)
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
BUCKET S180W-V (BUCKET)
(2.95 in) (3.50 in) (0.24 in) (2.28 in)
85 mm 99 mm 6 mm 7 mm S210W-V (BOOM)
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)
S210W-V (BUCKET)
115 mm 28.5 mm
S130LC-V ARM S220LC-V (BUCKET)
(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)
S220LL (BOOM (HOIST))
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)
S470LC-V (BOOM, BUCKET)

Cylinders S0705000
Page 25
 MODEL CYLINDER øA +0.2
+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
BUCKET S420LC-V (BUCKET)
(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)
S130LC-V (BOOM (OP))
S140W-V (ARM)
110 mm 28.5 mm
ARM S140W-V (BOOM)
(4.33 in) (1.12 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 28.5 mm
BOOM S130W-V (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)
S225NLC-V (ARM (OP))
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
 MODEL CYLINDER øA +0.2
+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)
S210W-V (BUCKET)
115 mm
S130LC-V ARM S220LC-V (BUCKET)
(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)
S220LL (BOOM (HOIST))
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
 MODEL CYLINDER øA +0.2
+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
BUCKET S420LC-V (BUCKET)
(6.30 in)
190 mm
S450LC-V ARM S470LC-V (ARM)
(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)
S225NLC-V (ARM (OP))
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. Pre-lubricate 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. Pre-apply 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
S0705000 Cylinders
Page 40
 S0707351K

1TRAVEL MOTOR

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.

TRAVEL MOTOR S0707351K

MODEL SERIAL NUMBER RANGE
Solar 180W-V 1001 and Up
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Travel Motor S0707351K

Page 1
TABLE OF CONTENTS

Sectional View................................................................................................ 4
Seal Kits and Component Groups.................................................................. 5
Seal Kits and Component groups / Replace Seal Nut.................................... 8
Sealing the Drive Shaft................................................................................. 10
Sealing of the Control Parts ......................................................................... 12
Sealing of the Relief Valve / Counter-Balance Valve.................................... 15
Spare Parts List Counter-Balance Valve ...................................................... 16
Spare Parts list Brake Release Valve (Pos. 50) ........................................... 17
Shuttle Valve (Pos. 25) .......................................................................... 18
Disassembly of the Port Plate ...................................................................... 19
Remove of the Positioning Piston................................................................. 21
Remove Rotary Group ................................................................................. 23
Exchanging of the rotary group .................................................................... 25
Complete Rotary Group ........................................................................ 25
Rotary Group ........................................................................................ 25
Inspection Notes........................................................................................... 27
Rotary Group Assembly ............................................................................... 30
Rotary Group Adjustment (see service information) .................................... 33
Assembly of the Port Plate ........................................................................... 35
Tightening Torques....................................................................................... 37
Safety Regulations ....................................................................................... 39
General Advice...................................................................................... 39
Before starting....................................................................................... 39
Start ...................................................................................................... 39
Hydraulic Equipment ............................................................................. 40

S0707351K Travel Motor

Page 2
 Figure 1

Specifications, descriptions and illustrative material shown herein were as accurate as known at the time
this publication was approved for printing.
BRUENINGHAUS HYDROMATIK reserves the right to discontinue models or options at any time or to
change specifications, materials, or design without notice and without incurring obligation.
Optional equipment and accessories may add cost to the basic unit, and some options are available only in
combination with certain models or other options.
For the available combinations refer to the relevant data sheet for the basic unit and the desired option.
Adjustment and tests have to be carried out on the test bench under operating temperatures.
Protection of personnel and property has to be guaranteed by appropriate measures.
Expert knowledge, the precondition of any service work, can be obtained in our training courses.

Travel Motor S0707351K

Page 3
SECTIONAL VIEW

Figure 2

S0707351K Travel Motor

Page 4
SEAL KITS AND COMPONENT GROUPS
Close all ports of the hydraulic aggregates.

Figure 3
Replace all seals. Use only original Hydromatik
spare parts.

Figure 4
Check all seal and sliding surfaces for wear.
NOTE: Rework of sealing area f. ex. with
abrasive paper can damage
surface.

Figure 5

Travel Motor S0707351K

Page 5
Fill up hydraulic aggregates with hydraulic oil
before start-up.

Figure 6
Seal kit for drive shaft.

Figure 7
External seal kit.

Figure 8
Housing

Figure 9

S0707351K Travel Motor

Page 6
Complete rotary group

Figure 10
Port plate with control piston

Figure 11

Travel Motor S0707351K

Page 7
SEAL KITS AND COMPONENT GROUPS / REPLACE
SEAL NUT
Counter-balance valve

Figure 12
Relief valve / Make up check valve

Figure 13
Replace seal nut. First measure and record
setting height.

Figure 14

S0707351K Travel Motor

Page 8
When tightening, counter hold setting screw, then
check setting height.

Figure 15

Travel Motor S0707351K

Page 9
SEALING THE DRIVE SHAFT

Figure 16

Protecting the drive shaft.

Remove retaining ring and shim.

Figure 17
Screw in sheet metal screw into the holes fitted
with rubber.
Pull out seal with pliers.

Figure 18

S0707351K Travel Motor

Page 10
Press in shaft seal and shim with bush to stop.
NOTE: Pay attention to pressing depth!
* Mark for pressing depth.
Assemble retaining ring.

Figure 19

Travel Motor S0707351K

Page 11
SEALING OF THE CONTROL PARTS

Figure 20

Disassembly position: Remove cover pos 1.

Figure 21
Reference
Description
Number
1 O-ring
2 Input Flow of Oil Control
3 Throttle Pin

NOTE: Installation position differs

according to the control
components

Figure 22

S0707351K Travel Motor

Page 12
 Reference
Description
Number
1 Input Flow Of Oil Control
2 High Pressure / Low
Pressure
3 High Pressure / Low
Pressure
4 Leakage Oil
5 Control Piston

Figure 23

Figure 24

Disassembly position: Remove cover pos. 2.

NOTE: Attention! Spring load.
Dimension x: Note dimension
(begin of regulation).

Figure 25

Travel Motor S0707351K

Page 13
 Reference
Description
Number
1 Check of O-ring

Figure 26
Reference
Description
Number
1 O-ring / High Pressure -
Small Control Piston Side
2 O-ring / Control Pressure
3 O-ring / High Pressure -
Check Valve
4 O-ring / High Pressure -
Check Valve

Figure 27

S0707351K Travel Motor

Page 14
SEALING OF THE RELIEF VALVE / COUNTER-
BALANCE VALVE
Remove relief valve.

Figure 28
Inspect!
O-ring

Figure 29

Figure 30

Remove counter-balance valve

Inspect!
O-ring

Travel Motor S0707351K

Page 15
SPARE PARTS LIST COUNTER-BALANCE VALVE

Figure 31 Size 16 and 20

Reference Reference
Description Description
Number Number
1 Housing 15 Valve Seat
2 Screw Plug 16 Sleeve
3 Spring 18 O-ring
4 Spring Retainer 19 O-ring
5 Snap Ring 20 O-ring
6 Spool 24 Thrust Ring
7 Screw Plug *25 Shuttle Valve
8 Spring 26 Screw Plug
9 Cone 30 Screw Plug
10 O-ring 31 Screw Plug
11 Spring 32 S. H. C. S.
12 Cone 40 identification Plate
13 Screw Plug 41 Round-head Grooved Pin
14 Throttle Element *50 Brake Release Valve

S0707351K Travel Motor

Page 16
SPARE PARTS LIST BRAKE RELEASE VALVE (POS.
50)

Figure 32

Reference Reference
Description Description
Number Number
2 Guide 7 O-ring
3 Sleeve 8 O-ring
4 Spool 9 O-ring
5 Screw Plug 10 Thrust Ring
6 Spring

These parts are not available separately

Travel Motor S0707351K

Page 17
SHUTTLE VALVE (POS. 25)

Figure 33

Reference
Description
Number
10 Valve Seat
11 Valve Seat
12 Ball

These parts are not available separately

S0707351K Travel Motor

Page 18
DISASSEMBLY OF THE PORT PLATE

Figure 34

Note dimension x.
Remove Qmin-screw.
Swivel rotary group to zero p
NOTE: For disassembly of the port plate, swivel always rotary group to zero position.
Piston rings to hang out of the cylinder boring.

Travel Motor S0707351K

Page 19
Port plate
Mark position. Loosen screws.
Removal

Figure 35
Check O-ring
NOTE: Stick new O-ring with some
grease.
Do not swivel rotary group.
Piston rings to hang out from the
cylinder boring.

Figure 36

S0707351K Travel Motor

Page 20
REMOVE OF THE POSITIONING PISTON

Figure 37

Loosen fixing screw.

Use only socket wrench.

Figure 38

Travel Motor S0707351K

Page 21
Remove piston with piston ring.

Figure 39
Warm up fixation screw * for positioning plug via
boring (screw glued - to turn out).
NOTE: Use new screw.
Pre cote coating.
Note tightening torque!

Figure 40
NOTE: Stick control lens in sliding
surface with grease.
Assembly in reversal order.
Mount port plate.
NOTE: Rotary group vertical

Figure 41

S0707351K Travel Motor

Page 22
REMOVE ROTARY GROUP

Figure 42

Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.

Size
28 M4 x 58 mm
55 M5 x 71 mm
80 M6 x 82 mm
107 M6 x 92 mm
140 M8 x 105 mm
160 M8 x 105 mm
200 M8 x 109 mm

Figure 43

Travel Motor S0707351K

Page 23
Press out rotary group!
NOTE: If the bearings are used again do
not hit on the drive shaft.

Figure 44

S0707351K Travel Motor

Page 24
EXCHANGING OF THE ROTARY GROUP
COMPLETE ROTARY GROUP
NOTE: Setting of hydraulic part necessary.

Figure 45

ROTARY GROUP
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part: Adjustment necessary*

Figure 46

Travel Motor S0707351K

Page 25
Remove fixing screw (cylinder).
Remove cylinder.

Figure 47
Disassemble retaining plate.
NOTE: Screws are glued.
Use Torx-tools.

Figure 48

S0707351K Travel Motor

Page 26
INSPECTION NOTES
Free of corrosion, erosion or fretting; no damage
to splines or keyways.

Figure 49
Pistons
No scoring and no pitting.

Figure 50
Center pin
No scoring and no pitting.

Figure 51

Travel Motor S0707351K

Page 27
Retaining plate
No scoring and no evidence of wear

Figure 52
Cylinder block / control lens
1. Bores free of scoring, no evidence of wear.
2. Faces smooth and even, free of cracks and
scoring.

Figure 53
Control housing
Sliding surface and side guides free of scoring
and no wear.

Figure 54

S0707351K Travel Motor

Page 28
Visual check: Bearing areas free of scoring and
no evidence of wear.

Figure 55

Travel Motor S0707351K

Page 29
ROTARY GROUP ASSEMBLY

Figure 56

S0707351K Travel Motor

Page 30
 Reference
Description
Number
1 Rotary group completely assembled
ready for assembly.
2 Place assembly sleeve.
3 Warm up housing to 80°C

Figure 57

Insert rotary group into housing to seat position.

Travel Motor S0707351K

Page 31
 Figure 58

Reference
Description
Number
1 Disassemble cylinder fixing screw.
2 Insert O-ring

S0707351K Travel Motor

Page 32
ROTARY GROUP ADJUSTMENT (SEE SERVICE
INFORMATION)
Determine cylinder swivel range to max. angle
with screw.

Figure 59
*Disc

Figure 60
Place centering disc.

Figure 61

Travel Motor S0707351K

Page 33
Mount measuring device.

Figure 62
Check dimension X.

Figure 63

S0707351K Travel Motor

Page 34
ASSEMBLY OF THE PORT PLATE

Figure 64

1. Assemble port plate.

NOTE: Take care of assembly design!
Tighten fixing screws with torque.
2. Set Qmin-screw to dimension*.
3. Assemble plug.
4. Remove assembly sleeve.
Assemble control components.
Assemble cover.

Figure 65

Travel Motor S0707351K

Page 35
Assemble cover

Figure 66
Assemble shaft seal, disc and safety ring.
Press-in with assembly sleeve.
NOTE: Take care of press-in depth.

Figure 67

Figure 68

Assemble counter-balance valve

S0707351K Travel Motor

Page 36
TIGHTENING TORQUES
Tightening torques for shaft bolts (Metric ISO Standard Thread)
The values for tightening torques shown in the table are valid only for shaft bolts with metric ISO-standard
threads and head support surface dimensions in accordance with DIN 912, DIN 931 and DIN 933. These
values are also valid only for light or unoiled, untreated surface as well as for use only with torque-
indicating wrenches and force limiting tools.

Strength Classes
Tread Size 8.8 10.9 12.9 8.8 10.9 12.9
Tightening Torque (Nm) Tightening Torque (lb. ft)
M3 1.1 1.6 1.9 0.8 1.2 1.4
M4 2.9 4.1 4.9 2.1 3.0 3.6
M5 6 8.5 10 4.4 6.3 7.4
M6 10 14 17 7.4 10.3 12.5
M8 25 36 41 18.4 25.8 30.2
M 10 49 69 83 36.1 50.9 61.2
M 12 86 120 145 63.4 88.4 106.9
M 14 135 190 230 99.5 140.0 169.5
M 16 210 295 355 154.8 217.4 261.6
M 18 290 405 485 213.7 298.5 357.4
M 20 410 580 690 302.2 427.5 508.5
M 22 550 780 930 405.4 574.9 685.4
M 24 710 1000 1200 523.5 737.0 884.4
M 27 1050 1500 1800 773.9 1105.5 1326.6
M 30 1450 2000 2400 1068.7 1474.0 1768.8

Tightening Torques for Locking Screws VSTI (Metric ISO fine thread)

Tightening Tightening
Thread Size Designation
Torques (Nm) Torque (lb. ft)
M8x1 VSTI 8 x 1 -ED/SA =5 =4
M 10 x 1 VSTI 10 x 1 -ED = 10 =7
M 12 x 1.5 VSTI 12 x 1.5 -ED = 20 = 15
M 14 x 1.5 VSTI 14 x 1.5 -ED = 30 = 22
M 16 x 1.5 VSTI 16 x 1.5 -ED/SA = 40 = 22
M 18 x 1.5 VSTI 18 x 1.5 -ED/SA = 50 = 29
M 20 x 1.5 VSTI 20 x 1.5 -ED/SA = 60 = 37
M 22 x 1.5 VSTI 22 x 1.5 -ED = 70 = 44
M 26 x 1.5 VSTI 26 x 1.5 -ED/SA = 80 = 51
M 27 x 2 VSTI 27 x 2 -ED = 90 = 66
M 30 x 1.5 VSTI 30 x 1.5 -ED/SA = 100 = 74
M 33 x 2 VSTI 33 x 2 -ED/SA = 120 = 88
M 42 x 2 VSTI 42 x 2 -ED/SA = 200 = 147
M 48x 2 VSTI 48 x 2 -ED = 300 = 220

Travel Motor S0707351K

Page 37
Tightening Torques for Seal-lock Nuts (Metric ISO-Standard Thread)
The values for tightening torques shown in the table are valid only for seal-lock nuts of the strength class
8.8 and with metric ISO-standard thread.

Strength Classes
Tread
8.8 10.9 12.9 8.8 10.9 12.9
Size
Tightening Torque (Nm) Tightening Torque (lb. ft)
M6 10 7.4
M8 22 16.2
M 10 40 29.5
M 12 69 50.9
M 14 110 81.1
M 16 170 125.3

Tightening Torques for Cross-slotted Lens Head Screws DIN 7985 (Metric ISO-Standard Thread)
The values for tightening torques shown in the table are valid only for cross-slotted lens head screws DIN
7985 of the strength class 8.8 and with metric ISO-standard thread.

Strength Classes
Tread
8.8 10.9 12.9 8.8 10.9 12.9
Size
Tightening Torque (Nm) Tightening Torque (lb. ft)
M3 1.1 0.8
M4 2.9 2.1
M5 6 4.4
M6 10 7.4
M8 25 18.4
M 10 49 36.1

S0707351K Travel Motor

Page 38
SAFETY REGULATIONS
GENERAL ADVICE
• Make yourself familiar with the equipment of the machine.
• Only operate the machine if your are completely familiar with the operating and control elements
as well as the functioning of the machine.
• Use your safety equipment like helmet, safety shoes and hearing protection.
• Make yourself familiar with your working field.
• Only operate the machine for its intended purpose.
NOTE: Please observe the guidelines of the Professional Association and the machine
manufacturer.

BEFORE STARTING
• observe the operating instructions before starting.
• Check the machine for remarkable faults.
• Do not operate the machine with defective instruments, warning lights or control elements.
• All safety devices must be in a secure position.
• Do not carry with you movable objects or secure them to the machine.
• Keep oily and inflammable material away from the machine.
• Before entering the driver’s cabin, check if persons or obstacles are beside of beneath the
machine.
• Be careful when entering the driver’s cabin, use stairs and handles.
• Adjust your seat before starting.

START
• When starting all operating levers must be in "neutral position".
• Only start the machine from the driver’s seat
• Check the indicating instruments after start to assure that all functions are in order.
• Do not leave the machine unobserved when the motor is running.
• When starting with battery connection cables connect plus with plus and minus with minus.
Always connect mass cable (minus) at last and cut off at first.

CAUTION!
Exhaust gas is dangerous. Assure sufficient fresh air when starting in closed
rooms!

Travel Motor S0707351K

Page 39
HYDRAULIC EQUIPMENT
1. Hydraulic equipment is standing under high pressure.

CAUTION!
High pressure fluids (fuel, hydraulic oil) which escape under high pressure
can penetrate the skin and cause heavy injuries. Therefore immediately
consult a doctor as otherwise heavy infections can be caused.

2.When searching leakages use appropriate auxiliary devices because of the danger of accidents.
3.Before working at the hydraulic equipment, lower pressure to zero and lower working arms of the
machine.
4.When working at the hydraulic equipment, absolutely stop motor and secure tractor against rolling away
(parking brake, shim)!
5. When connecting hydraulic cylinders and motor pay attention to correct connection of hydraulic flexible
hoses.
6. In case of exchanging the ports, the functions are vice versa (f. ex. lift-up/lower) - danger of accidents!
7. Check hydraulic flexible hoses regularly and replace them in case of damage or wear! The new hose
pipes must comply with the technical requirements of the machine manufacturer!
NOTE: Orderly disposal or recycling of oil, fuel and filters!

S0707351K Travel Motor

Page 40
 Return to Master Table of Contents

S0707380

1SWING MOTOR

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.

SWING MOTOR S0707380

MODEL SERIAL NUMBER RANGE
Solar 55 0001 and Up
Solar 55-V PLUS 1001 and Up
Solar 55W-V 1001 and Up
Solar 55W-V PLUS 1001 and Up
Solar 75-V 1001 and Up

Copyright 2003 Daewoo

August 2002

Swing Motor S0707380

Page 1
 Return to Master Table of Contents

TABLE OF CONTENTS

Swing Motor ................................................................................................... 3

Motor ....................................................................................................... 3
Valve Casing ........................................................................................... 4
Relief Valve ............................................................................................. 4
Troubleshooting .............................................................................................. 6

S0707380 Swing Motor

Page 2
 Return to Master Table of Contents

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

Swing Motor S0707380

Page 3
 Return to Master Table of Contents

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

S0707380 Swing Motor

Page 4
 Return to Master Table of Contents

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

Swing Motor S0707380

Page 5
 Return to Master Table of Contents

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.

S0707380 Swing Motor

Page 6
 S0708520

1MAIN PUMP

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.

MAIN PUMP S0708520

MODEL SERIAL NUMBER RANGE
Solar 55W-V 1001 and Up
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Main Pump S0708520

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Description of Ports................................................................................. 4
Operation Principle and Function of Components.......................................... 5
Components of the Pump ....................................................................... 5
Operation Principle.................................................................................. 6
Adjustment ..................................................................................................... 8
Installation ...................................................................................................... 9
Driving ............................................................................................................ 9
Hydraulic Oil ................................................................................................... 9
Procedures for Test Operation........................................................................ 9
Maintenance and Protection......................................................................... 11
Checking Filters............................................................................................ 11
Filter Replacement ....................................................................................... 11
Replacement of Hydraulic Oil....................................................................... 12
Hydraulic Fluid Leakage Check.................................................................... 12
Diagnosis of Troubles and Actions to be Taken............................................ 13
Diagnosis of Troubles with the Pump .................................................... 13
Disassembling and Reassembling hydraulic pump ...................................... 15
Necessary Tools and Jigs ..................................................................... 15
Reminders for Disassembly and Assembly........................................... 15
Disassembling Procedure ..................................................................... 16
Standard Values for Maintenance ......................................................... 25
Reassembly Procedure......................................................................... 27

S0708520 Main Pump

Page 2
GENERAL DESCRIPTION
This is a capacity-adjusting piston pump where two ports discharge oil to a single cylinder block. Although
this is a double pump, it has a simple structure like a single pump. This pump is a swash plate type and its
tilt angle is like that of two pumps. The tilt angle of the pump changes the total pressure, P1 + P2. That is,
as the output is controlled by a constant value, the relation between discharge pressure and flow rate, Q
remains constant ((P1 + P2) x Q). Pump No. 3 and the pilot pump are connected on the same axle using a
coupling.

Figure 1

Main Pump S0708520

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DESCRIPTION OF PORTS

Figure 2

Port Names Size/Standard

S1 Intake Port SAE 2 1/2 (Standard)
A1, A2 Discharge Port G 1/2 (JIS B2351 O-TYPE)
A3 Discharge Port G 1/2 (JIS B2351 O-TYPE)
A4 Discharge Port G 1/2 (JIS B2351 O-TYPE)
A1G, A2G Gauge Port G 1/4 (JIS B2351 O-TYPE)
R1 Air Discharge Port M10 x 1 (With Bleeder Valve)

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OPERATION PRINCIPLE AND FUNCTION OF
COMPONENTS
COMPONENTS OF THE PUMP
• This is a capacity-adjusting double piston pump which discharges oil into two ports from a
single cylinder block. This being a single rotary group, it has a single intake port. Actuation oil is
divided into two points by the control plate on the cover, where it is discharged into two
discharge ports.
• Discharge pressure is determined by the control valve and the tilting plate by restoration
strength of the spring. The quantity of discharged flow may vary because piston strokes are
changed according to the tilt angle.
• At the same time, a method is adopted to control a constant output of the tilt angle.
• Pump No. 3 and the pilot pump are connected on the same axle using a coupling.

Figure 3

Reference Reference
Description Description
Number Number
1 Driving Axle 5 Control Spring
2 Tilting Plate 6 Control Piston
3 Rotary Group 7 Gear Pump
4 Cover 8 Housing

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OPERATION PRINCIPLE
1. Function of Pump
• The cylinder block is joined together by a key groove and rotates along with driving axle.
• The piston is assembled inside cylinder which operates in a reciprocal action along with surface
of tilting plate.
• The piston moves towards direction in which quantity of discharged oil increases, from lower
tilting point toward upper tilting point (suction process).
• While piston strokes are going on from upper tilting point toward lower tilting point, piston moves
towards direction in which quantity of discharged oil decreases. The actuator oil is discharged
into discharge port (discharge process).
• The quantity of discharged oil changes according to change in tilt angle of tilting plate (tilting
plate).
• Actuator oil that came into ports of cylinder block is discharged into discharge port of valve
plate.
• The actuator oil that came into outer ports of cylinder block is discharged into discharge port of
outer side of valve plate.

Figure 4

S0708520 Main Pump

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2. Control Function
• Exhaust pressure P1 and P2 are determined by movement of tilting plate and piston.
• Spring works in direction against discharge pressure.
• The set load of spring A (outer spring) decreases and tilting plate becomes fixed at maximum tilt position,
when hydraulic pressure is applied to piston.
• The tilting plate begins to incline when hydraulic pressure is applied to piston and spring A exceeds its set
load, and keeps its tilting face at point where hydraulic pressure is in equilibrium with strength of spring.
(Refer to "A" in middle part of Figure 5).
• Tilt angle begins to decrease when hydraulic pressure is applied to piston, and then spring B that so far
has not worked begins to operate.
• The two springs become to revive their spring tension when hydraulic pressure reaches highest lower
tilting point. (Refer to (A + B) domain in middle part of Figure 5).
• The control changeover curve begins to change when hydraulic pressure P3 that presses piston is applied.

Spring B
Spring A

X X
P2
Tilting Plate
Exhaust Pressure

P3 Changeover P3
A+B
A
Piston
P1

Changeover Plate X-X

Qmax
Quantity of Discharge

BNS2940L
Figure 5

Main Pump S0708520

Page 7
3. Control / Adjustment Procedure
A. Loosen hexagon nuts.
B. Tighten or release adjusting nuts for adjustment of the power change curve.

Figure 6

Reference Reference
Description Description
Number Number
1 Spring Seat 6 Release
2 Cover 7 Total Pressure
3 Adjusting Nut 8 Tighten
4 Hexagon Nut 9 Release
5 Tighten 10 Quantity of Oil

ADJUSTMENT
Fine adjustment of the hydraulic pump is made possible by the input power and control. Re-adjustment of
any and all adjusting parts may result in depriving them of control function and placing the pump off the
certified specifications. Do not adjust adjusting nuts at your disposal.

S0708520 Main Pump

Page 8
INSTALLATION
1. Install pump and place input axle horizontally.
2. Install pump lower than lowest level of actuator oil to ensure that actuator oil will continue to flow into
tank.
3. Use a flexible hose after installation of pump on diesel engine. Install an intake pipe, be careful not to
allow air to flow into pump.
4. Use a high-pressure flexible hose for discharge ports P1 and P2.
5. Fully charge pump with hydraulic oil following its installation.

DRIVING
1. Use a flexible coupling when you connect it to the motor.
2. Insert couplings near input axle. Do not give strong impact to couplings while inserting.
3. While viewing axle from end, rotate input axle clockwise.

HYDRAULIC OIL
1. Make sure that hydraulic oil is either general kerosene-based hydraulic oil or anti-corrosive actuator
oil (ISO 3448, VG32 - 56 or equivalent)
2. The range of an optimum viscosity shall be:
• Maximum allowable viscosity: 1000 ß ±/s.
• Minimum allowable viscosity: 10 ß ±/s.
• The range of recommended viscosity: 15 - 150 ß ±/s.

PROCEDURES FOR TEST OPERATION

Make sure that the following shall be done before operating the engine:
1. Check whether or not actuator oil tank is clean.
2. Check whether or not pipe lines are well arranged and pump is installed to prevent tension.
3. Check whether or not pipe lines are tightly secured, according to pipe line diagram.
4. Check whether or not connecting parts and flanges are secured.
5. Check whether or not connecting parts between pump and motor are securely installed.
6. Check whether or not revolutionary direction of motor coincides with that of pump.
7. Check whether or not refined hydraulic oil is supplied from filter, and hydraulic oil is refilled up to
gauge measuring point.
8. Check whether or not filer is capable of fine filtering (10 micron or below).
9. Check whether or not filter is correctly installed in same direction as that of the oil road.

Main Pump S0708520

Page 9
10. Check whether or not pump case is filled with hydraulic oil.
11. Check whether or not control valve is adjusted to location of bypass.
12. Operate the motor. Drive it at a warm temperature at a low speed.
13. Check whether or not system remains on "no load" condition when actuator gallery operates it
correctly.
14. Check operating condition of actuator gallery while load is applied, when motor reaches an operation
speed.
15. Check by use of monitors or built-in measuring devices.
16. Check noise level.
17. Check oil level of actuator oil tank. Refill if necessary.
18. Apply load to actuator gallery and set control valve pressure.
19. Check weather or not there are any parts having a oil leak.
20. Stop operating the motor.
21. Tighten again all bolts and plugs where oil leakage took place. (Make sure that all remaining pressure
of circuit is removed before re-tightening.)
22. Check oil level of actuator oil tank.
23. Check whether or not pump and actuator gallery are operating properly.
24. Any irregular operation of actuator gallery indicates that air is still contained in the circuit. When all air
is removed from circuit, then all parts will operate smoothly without any irregular motion and no foam
will arise in actuator oil tank any longer.
25. Check temperature of actuator oil.
26. Stop operating the motor.
27. Check filter to insure that element is freed from any contamination.
28. Clean circuit if element is contaminated.

CAUTION!
Be careful not to cause any damage to pump. Keep in mind the following while pump is in
operation after air has come into pipe line and actuator gallery (If necessary, repair or replace
actuator gallery or hydraulic oil).
1. Fill pump housing with hydraulic oil after supplying actuator oil.
2. Operate pump at a speed of 1,000 rpm or below. Make sure that oil quantity shall not fall
below specified level.
3. Maintain motor speed at 1,000 rpm or below when air is discharged from hydraulic circuit.
Otherwise, operate actuator galleries at a cycle exceeding that, and then operate motor at
idle for 5 minutes or more.

S0708520 Main Pump

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MAINTENANCE AND PROTECTION
Need for maintenance of a hydraulic pump is limited to case where the actuator oil tank, especially actuator
oil is replaced. Maintenance intervals may vary according to the operation hours and operation condition,
and needs special interest of the operator.

CHECKING FILTERS
1. Check filters every day during the initial time of operation.
2. Check them once a week until operation has become stabilized.
3. Check them once a month after operation time exceeds 100 hours.

CAUTION!
Check at the time of beginning operating whether or not filters are new after any part of the
hydraulic system has been changed (for instance, an additional component has been installed
or pipelines have been replaced or repaired).

FILTER REPLACEMENT
1. Replace after beginning operating.
2. Replace after a lapse of 500 hours of operation.
3. Afterwards, hydraulic oil will change its property or quality hour by hour, largely on every 500 hours of
operation. Check for any unusual contamination of the filter every day until the first filter has been
replaced after beginning operation.

CAUTION!
If the filter is a paper element replace complete assembly, as paper material cannot be washed.

Main Pump S0708520

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REPLACEMENT OF HYDRAULIC OIL
1. After 2000 hours of operation.
2. The replacement time period of every 2,000 hours or at other regular intervals may be shorten
according to the degree of contamination and temperatures depending on the load condition of
hydraulic oil.
When hydraulic oil level is low or needs replacement, keep in mind the following:
• Be sure to note the lowest and the highest operating temperature ratings of the hydraulic fluids
when the equipment is being operated in the summer and winter seasons.
• Replace all hydraulic fluid.
• Be careful not to allow any foreign objects to enter the hydraulic system.
• Keep the inside of the actuator oil tank clean.
• Refill oil through the filter.

HYDRAULIC FLUID LEAKAGE CHECK

1. Check every day after starting operation.
2. When the viscosity is below the operating range, due to the low hydraulic fluid temperature, warm up
the motor by operating the motor at approximately half the maximum engine speed. After that,
operate the actuators at no load for a short period of time. When the oil temperature is lower than the
outside temperature, the hydraulic oil tank must be preheated before operating the motor.
3. Be careful not to allow the hydraulic oil temperature to exceed 90°C (194°F).

S0708520 Main Pump

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DIAGNOSIS OF TROUBLES AND ACTIONS TO BE
TAKEN
When a malfunction occurs, refer to the following table for the symptoms and perform the suggested
actions to resolve the problem.

DIAGNOSIS OF TROUBLES WITH THE PUMP

Symptoms Causes Check Remedies

Abnormal Air seeping into system due to Hydraulic oil level Refill hydraulic fluid
Noises low fluid level
Loss of intake pressure due to Check filters Clean / replace filter
increases in filter resistance element
Loss of intake pressure due to Check temperature and Increase oil
increase in oil viscosity at low condition of hydraulic oil temperature or change
temperatures to suitable oil.
Input axle rpm is higher than Check input axle rpm. Adjust rotation speed
the specified limit
• Check pressure in
overload condition
• Check for
contaminants
• Check for water in
hydraulic fluid
Mechanical damage (bearing, Check all major components Replace damaged parts
etc.) or replace pump
• Adjust rpm.
• Clean circuit
• Replace oil
Insufficient Input axle rpm is low Check input axle rpm. Adjust rotation speed
Outflow Abnormally high hydraulic oil Check oil temperature Stop operation and
Rate temperature check after oil
temperature has cooled
Increasing oil leakage in Carefully examine control Replace control valve
control valve and actuator valve and actuator and actuator
gallery
Below optimum pump level Carefully examine pump for Replace pump
problems
Output control valve loose Check lock nuts Adjust and tighten
Air seeping into system due to Check hydraulic oil level Refill hydraulic fluid
low fluid level
Loss of intake pressure due to Check filter element Wash or replace
clogged filter element
viscosity is increased and check temperature and raise oil temperature or
suction pressure is reduced condition of oil replace oil
due to low temperature

Main Pump S0708520

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Symptoms Causes Check Remedies
Pressure The relief valve set Check circuit oil pressure Adjust relief valve
Does Not pressure is low
Increase Oil Leaking from control Check the function of the Replace control valve and
valve and actuator actuators and return line pipes actuator
for overheating
Poor pump efficiency Examine if problem originates Replace pump
from the pump
Overload Increase in pump output Check motor sound and speed Compare and verify
At Normal adjustment sound of motor and adjust
Load output
Control system Failure Check movement of control Repair or replace
system and presence of foreign damaged parts
objects
Mechanical damage Check bearing for cause of Repair or replace
(bearing etc.) abnormal heat and noise damaged parts
Decreased Maximum pressure in Check circuit for cause of Replace relief valve.
Revolution relief valve circuit abnormal vibration
• Remove
Speed At
• Check pilot line for foreign objects
Varying
foreign objects
Load • Repair or
• Check slipping of replace
the control valve due damaged parts
to foreign objects
Poor control valve
performance
Abnormally Increasing pump leakage Measure the actuator speed Replace pump
High Heat Mechanical damage Check the source of noise and Replace damaged parts
(bearing etc.) heat
Damaged rubbing Check the source of abnormal Replace damaged parts
surfaces heat
Oil Damaged O-rings and Check area around leak and for Replace seal
Leakage packings abnormal pressure
Damaged oil seals Check for damage caused by Replace seal
Worn input axle seal foreign objects and for Replace input axle, seal
abnormal pressure and pump
Loose plug Check area around leak Tighten and replace seal

S0708520 Main Pump

Page 14
DISASSEMBLING AND REASSEMBLING HYDRAULIC
PUMP
NECESSARY TOOLS AND JIGS
Disassembling and reassembling hydraulic pump needs the following tools and jigs as shown below:

Tools

Names of Tools Quantity Size

Hexagonal Wrench 1 Each 3, 6, 8, 12, 6, L=20
Spanner 1 17, 22
Plastic Hammer 1 Medium Size
Snap Ring Pliers 1 Internal
Snap Ring Pliers 1 External
Screw Driver 2 Medium Size
Torque Wrench - -
Grease As Needed -
Adhesive Compound As Needed Loctite #270

Jigs
Stand for disassembling and assembling is a
plate on which the pump can be placed to face
downward.
Rectangular blocks may be used in place of jig
as long as end of axle does not touch the work
bench.

REMINDERS FOR DISASSEMBLY AND

ASSEMBLY
Reminders for Disassembly
1. Do not remove adjusting screws or nuts Figure 7
unless it is absolutely necessary.
Unnecessary adjustments will affect
operation and performance of equipment.
2. Be careful not to strike or drop any parts
during disassembly.
Reminders for Assembly
1. Thoroughly clean all parts.
2. Be very careful not to damage any parts or allow any foreign objects to come into the parts being
assembled.
3. As a rule, do not reuse O-ring and oil seal, Daewoo recommends to use new O-rings and oil seals.
4. During assembly, always use a torque wrench to tighten all bolts and nuts to specified limits.

Main Pump S0708520

Page 15
DISASSEMBLING PROCEDURE

Gear Pump Disassembly

1. Remove hexagon socket bolts (M10 x 25,
2 each) by using a 8 mm allen key.
NOTE: Be careful not to damage O-
rings on the gear pump.

Figure 8
2. Remove couplings.

Figure 9
3. Remove bushing.

Figure 10

S0708520 Main Pump

Page 16
Main Pump Disassembly
1. Remove cover.
2. Remove allen head bolts: (M14 x 40, 2
Each), (M14 x 65, 2 Each) and (M14 x 75,
2 Each).
NOTE: Use allen-wrench (12 mm)

Figure 11
3. Remove cover while keeping horizontal
balance. There may be some resistance,
while removing cover, so lightly tap cover
with a plastic hammer.

Figure 12
4. Remove gasket.

Figure 13
5. Remove components from housing.
6. Remove two springs and spring seats.
7. Remove parallel piston from housing.

Figure 14

Main Pump S0708520

Page 17
Rotary Group Removal
1. Lay pump on its side, and remove rotary
group from the axle.

Figure 15
Axle Removal
1. Remove snap ring (C-type) (80) using an
internal snap ring pliers.

Figure 16
2. Remove oil seal case and O-ring by using
two screw drivers.

Figure 17
3. Tilting plate disassembly
4. Using an allen-wrench (6 mm), remove
hexagon socket bolts (M8 x 22, 4 Each)
and plate.

Figure 18

S0708520 Main Pump

Page 18
5. Remove O-ring, seal, and bearing (outside
wheel).

Figure 19
6. Bearing (inside wheel) disassembly.
Use a brass drift (10) and tap the
underside of the bearing and remove.

Figure 20
7. Remove tilting plate.

Figure 21
8. Bearing (outside ring) disassembly.
NOTE: Perform this disassembly only
when necessary.

Figure 22

Main Pump S0708520

Page 19
Cover Disassembly
1. Disassemble and remove control plate.

Figure 23
2. Remove two plugs (GIA).

Figure 24
3. Control piston disassembly
4. Remove two spring seats, two springs and
two parallel pins.
5. Two conic plate spring and spring are
between the two slotted taps and the
piston. Mark the right and the left for
differentiation, and place them on the right
side.

Figure 25
6. Disassembling the two pistons.
7. Mark the right and the left for
differentiation.

Figure 26

S0708520 Main Pump

Page 20
Disassembling Cylinder
1. Using an allen-wrench (8 mm), remove
allen head bolts (M10 x 30, 2 Each).
NOTE: Bolts are coated with Loctite
#270. Disassemble them only
when necessary.

Figure 27
2. Disassemble the control spring.
NOTE: Disassemble hexagon nuts only
when necessary. Disengage
hexagon bolts (M10 x 30, 2
Each) and remove cover by
using an allen-wrench (8 mm).

Figure 28
3. Disassemble spring seat.

Figure 29
Gear Pump Disassembly
1. Using an allen-wrench (6 mm), remove
allen head bolts (M8 x 45, 4 each).

Figure 30

Main Pump S0708520

Page 21
2. Remove side plate, backup ring, oblong
cylindrical ring and gear.

Figure 31
3. Remove idle gear.

Figure 32
4. Gear pump (GSP2) disassembly
5. Using a wrench (6 mm), remove hexagon
socket bolts (M10 x 90, 4 each).
6. Remove O-rings and filters assembled into
the gear pump housing.

Figure 33
7. Remove front cover.

Figure 34

S0708520 Main Pump

Page 22
8. Disassemble the middle body.

Figure 35
9. Remove molded O-rings.

Figure 36
10. Disassemble plate, guide and O-ring.

Figure 37
11. Remove plate.

Figure 38

Main Pump S0708520

Page 23
12. Disassemble drive gear, idle gear and side
plate.

Figure 39

S0708520 Main Pump

Page 24
STANDARD VALUES FOR MAINTENANCE
Wash and dry all parts thoroughly before inspection. Inspect the critical parts carefully and replace those
which are found to have abnormal abrasion or damaged by impact beyond their tolerance with new ones.
Replace seals, if they are found to have noticeable deformation or damage.
1. Piston Assembly and Cylinder Block
• Inspect their appearance to insure
that they have no damage
(particularly to the moving areas),
corrosion and abnormal abrasions.
• Measure the gap between the
outside diameter of the piston and
the inside diameter of the cylinder
block and verify that they are within
acceptable limits.
Gap Limit: D - d = 0.050 mm (0.0197")
Figure 40
Reference
Description
Number
1 Piston Assembly
2 Cylinder Block

2. Piston Shoe and Piston

• Check gap between the piston and
the piston shoe axle.
Gap Limit: E = 0.2 mm (0.0079")

Reference
Description
Number
1 Shoe
2 Piston

Figure 41
3. Axle
• Check surface condition of the
mating area of the oil seal to the axle
shaft.
Wear Limit: A = 0.025 mm (0.0010")

Reference
Description
Number
1 Oil Seal Seat Area

Figure 42

Main Pump S0708520

Page 25
4. Control Plate
• Check for any surface damage and
replace if necessary

Figure 43
5. Guide and Retainer
• Check for any corrosion or uneven
wear. If unsure, replace both guide
and retainer as a set.
• Minor corrosion or damage can be
removed by lapping. Wash the
surface after lapping.

Reference
Description
Number
1 Guide
2 Retainer Figure 44

S0708520 Main Pump

Page 26
REASSEMBLY PROCEDURE

Assembling Tilting Plate

1. Install bearings (outside wheel) into
housing.

Figure 45
2. Coat backside of the plate with grease,
and install tilting plate.

Figure 46
Reference
Description
Number
1 Shiny Surface
2 Front Face
3 Rear Face

Figure 47
3. Install tilting plate into housing.

Figure 48

Main Pump S0708520

Page 27
4. Install bearings (both inside and outside
wheels).

Figure 49
5. Install seal and O-rings.

Figure 50
6. Using an allen-wrench (8 mm), install allen
head socket bolts (M8 x 22, 4 each) to
mount the plate.
NOTE: Tightening Torque 28 - 35 N•m
(2.9 - 3.6 kg•m) (21 - 26 ft lb)

Figure 51
Assembling the Drive Axle
1. Install axle into housing. Use a plastic
hammer and tap key groove to position the
bearing near the end of the housing.

Figure 52

S0708520 Main Pump

Page 28
2. Lightly coat the O-rings with grease and
install into housing.

Figure 53
3. Place oil seal flat to the housing surface.
Prepare oil seal by coating with grease in
advance.

Figure 54
4. Install snap rings to hold axle in place.

Figure 55
5. Coat three parallel pins with grease and
insert them into cylinder block.

Figure 56

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6. Assembling Rotary Group
7. Install ten pistons into retainer.

Figure 57
8. Coat inside of the guides with grease.
9. Install guides between retainer and
cylinder block and then insert pistons into
cylinder block.

Figure 58
10. Install rotary group assembly into spool
axle.
NOTE: While assembling, coat the
slipping face of the piston shoe
and the contact points of the
control plate cylinder block with
grease.

Figure 59
Assembling Control Spring
1. Coat control spring bores with grease
before assembling.

Figure 60

S0708520 Main Pump

Page 30
2. Install two springs (both internal and
external).

Figure 61
3. Install spring seat and insert control
spring.

Figure 62
4. Install cover with allen head bolts.
NOTE: Tightening Torque 55 - 69 N•m
(5.6 - 7.0 kg•m) 40.5 - 50.5 ft lb)

Figure 63
5. Install allen head bolts (M10 x 30, 2 each)
to mount cylinder.
NOTE: Coat bolts with Loctite #270
before tightening.
NOTE: Tightening Torque 55 - 69 N•m
(5.6 - 7.0 kg•m) 40.5 - 50.5 ft lb)

Figure 64

Main Pump S0708520

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6. Install pistons.

Figure 65
7. Engage a spring and a cone-type plate
spring (2 units).

Figure 66
Reference
Description
Number
1 Assembling Direction
Cone-type Plate
2
Spring

Figure 67
8. Install two plugs (GIA).
NOTE: Tightening Torque 350 - 470
N•m (36 - 48 kg•m) (260 - 347 ft
lb)

Figure 68

S0708520 Main Pump

Page 32
9. Coat parallel pins with grease and insert
into cylinder.

Figure 69
10. Coat rear side of control plate with grease
and align plate with key groove in cover
and install onto block.

Figure 70

Assembling Relief Valve

1. Assembling of pickings.
2. Place gasket on the housing surface and
assemble the upper and lower halves of
the pump together.
NOTE: Be careful not to let aligning
pins drop while assembling.

Figure 71

Main Pump S0708520

Page 33
3. Install cover.
(M14 x 40, 2 each) (M14 x 75, 1 each)
NOTE: Torque 150 - 180 N•m (15 - 18
kg•m) 108.50 - 130 ft lb).

Figure 72
4. Install O-rings in cover.

Figure 73
5. Install bushings.

Figure 74
6. Install couplings at the end of the main
pump axle.

Figure 75

S0708520 Main Pump

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7. Assemble main pump and gear pump.

Figure 76
8. Using an allen-wrench, install hexagon
bolts to hold the gear pump.
NOTE: Torque 55 - 69 N•m (5.6 - 7.0
kg•m) (40.50 - 50.63 ft lb)

Figure 77
Assembling of the Gear Pump
1. Gear pump (GSP2)
Install square rings on the side.

Reference
Description
Number
1 Intake Side
2 Discharge Side
Direction of Inserting
3
Square Rings

Figure 78
NOTE: Be careful not to reverse the
directions of intake and exhaust
sides.

Figure 79

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2. Install drive axle and idle gear on the side
plate.

Figure 80
3. Install drive axle, idle gear and side plate.

Figure 81
4. Engage O-ring in guide, and then insert
them into plate.

Figure 82
Reference
Description
Number
1 Face With Large
Radius
2 Guide

Figure 83

S0708520 Main Pump

Page 36
5. Assemble plate, guide and O-ring.

Figure 84
6. Assemble two plates. Be careful not to
reverse the directions of the intake and
exhaust sides.

Figure 85
Reference
Description
Number
1 Intake Side
2 Discharge Side

Figure 86
7. Install square ring.

Figure 87

Main Pump S0708520

Page 37
8. Insert two alignment pins into front cover.

Figure 88
9. Install front cover.

Figure 89
Assembling Gear Pump (G1)
1. Insert drive gear into housing.

Figure 90
2. Insert idle gear.

Figure 91

S0708520 Main Pump

Page 38
3. Coat square rings with grease. Assemble
making certain the backup ring is in place.

Figure 92
4. Install side plate (assembled in step 12),
into housing.

Figure 93
5. Install two aligning pins in the middle
housing.

Figure 94
6. Install O-ring into middle housing.

Figure 95

Main Pump S0708520

Page 39
7. Assemble the two middle housings.

Figure 96
8. Install socket head bolts to secure
housing.
NOTE: Tightening Torque 29 N•m (3
kg•m) (21.70 ft lb).

Figure 97
9. Insert aligning pins into the middle
housing.

Figure 98
10. Place the Gear Pump (GSP2) on its side
and install coupling to the end of axle.

Figure 99

S0708520 Main Pump

Page 40
11. Assemble two Gear Pumps (GSP2 and
G1).

Figure 100
12. Install allen head bolts to secure the two
gear pumps (GSP2 and G1).
NOTE: Tightening Torque 59 N•m (6
kg•m) (43.40 ft lb)

Figure 101
13. Install O-ring and filter in the front housing.

Figure 102

Main Pump S0708520

Page 41
S0708520 Main Pump
Page 42
 S0709417

1MAIN CONTROL VALVE

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.

MAIN CONTROL VALVES0709417

MODEL SERIAL NUMBER RANGE
Solar 55W-V Plus 1001 and Up

Copyright 2003 Daewoo

August 2003

Main Control Valve S0709417

Page 1
TABLE OF CONTENTS

Specifications ................................................................................................. 4
Internal Construction ...................................................................................... 8
Construction of Relief and makeup Valves................................................... 10
Relief Valve ........................................................................................... 10
Makeup Valve........................................................................................ 11
Overload Relief Valve............................................................................ 11
Operation...................................................................................................... 12
Operation in Neutral Position ................................................................ 12
Operation for Travel ............................................................................... 14
Boom Operation .................................................................................... 18
Bucket Operation .................................................................................. 24
Arm Operation....................................................................................... 28
Boom Swing Operation ......................................................................... 32
Swing Operation.................................................................................... 34
Combined Operation (Actuation of Inlet (P1, P2) Valve) ....................... 36
Actuation of Relief Valve (MRV) ............................................................ 38
Actuation of Overload Relief Valve (ORV)............................................. 39
Function and Operation of Makeup Valve ............................................. 40
Detail Views of Major Components ....................................................... 40
Disassembly ................................................................................................. 51
Valve Handling Guide............................................................................ 51
Disassembly of Relief Valve (MRV), Overload Relief Valve (ORV),
and Anti-cavitation Valve (ACV) ............................................................ 52
Check Valve Disassembly ..................................................................... 53
Pressure Relief Load Check Valve Disassembly .................................. 53
Anti-cavitation Valve Disassembly......................................................... 53
Relief Valve Disassembly ...................................................................... 54
Overload Relief Valve Disassembly ...................................................... 54
Other Components Disassembly .......................................................... 54
Joint Body Disassembly ........................................................................ 54
Disassembly Precautions...................................................................... 55

S0709417 Main Control Valve

Page 2
 Assembly...................................................................................................... 56
Assembly Precautions.......................................................................... 56
Guide for Assembly of Each Part .......................................................... 56
Criteria for Maintenance ............................................................................... 58
Inspection of Spare Parts...................................................................... 58
Troubleshooting and Remedies............................................................. 59
Control Valve......................................................................................... 59
Relief Valve ........................................................................................... 60

Main Control Valve S0709417

Page 3
SPECIFICATIONS

14

BOOM SWING
A1 13
22
B1 1
b1 a1
A2 25
SWING
B2
b2 a2
2
A3
BLADE
B3 3
b3 a3

12
20 P3 MR2
A4 T1

BOOM 2 B4
4
b4 a4
15
26
A5
ARM B5
16
b5 a5

5
A6
TRAVEL 2
B6 24
b6 a6

11 6
P2
MR1
P.P 27
28 P1
7
b7 a7
B7 8 23
TRAVEL 1
A7
9
b8 a8
B8
BOOM 1 18
A8

10
b9 a9
17 B9
BUCKET 19
A9

b10 a10 30
P.T.O. B10
A10
29
T2 21
BNS3000L
Figure 1

S0709417 Main Control Valve

Page 4
 Reference Reference
Description Description
Number Number
1 Boom Swing Spool 19 B9 Overload Relief Valve
2 Swing Spool 20 Bypass Gallery
3 Blade Spool (P2 Pump Line)
4 Boom 2-speed 21 Bypass Gallery
(P1 Pump Line)
5 Arm Spool
22 Bypass Gallery
6 Travel 2 Spool
(P3 Pump Line)
7 Inlet (P1, P2) Spool
23 Parallel Gallery
8 Travel 1 Spool (P1 Pump Line)
9 Boom 1-speed Spool 24 Parallel Gallery
10 Bucket Spool (P2 Pump Line)
11 P1/P2 Relief Valves 25 Parallel Line
12 P3 Relief Valve (P3 Pump Line)
13 A1 Overload Relief Valve 26 Pilot Gallery
14 B1 Anti-cavitation Valve 27 Tank Gallery
15 A5 Overload Relief Valve 28 External Piping for Boom
Confluence
16 B5 Overload Relief Valve
29 PTO Spool
17 A8 Overload Relief Valve
30 A9 Anti-cavitation Valve
18 B8 Overload Relief Valve

Main Control Valve S0709417

Page 5
 A1 A2
B1 B2
b1

a1
A3
B3

a2
b2

B4 B5

A4 A5 P3A6
b3

a3
B6
B7

STROKE
A7

a4
b4

B8 B9 B10

A8 A9 A10
8 mm (0.31 in.)
b5

a5
7 mm (0.28 in.)
b6

a6
6 mm (0.24 in.)
P2

5 mm (0.20 in.)
pp
P1

4 mm (0.16 in.)
a7
b7

3 mm (0.12 in.)
b8

a8

2 mm (0.08 in.)
1.5 mm (0.06 in.)
a9
b9

1 mm (0.04 in.)
a10
b10

PILOT Pr.
2.8 kg/sq cm (39.83 psi)

6 kg/sq cm (85.34 psi)

10 kg/sq cm (142.23 psi)

20 kg/sq cm (284.47 psi)

BNS3010L
Figure 2

Main Relief Valve Setting Pressure- MR1: 230+5 kg/cm2 (P1, P2)

MR2: 210+5 kg/cm2 (P3)

Overload Relief Valve Setting Pressure- 245+5 kg/cm2 (A5, B5, A8, B8, B9)

S0709417 Main Control Valve

Page 6
Main Control Valve S0709417
Page 7
 Main Control Valve
BNS3020L
a1 a2 a3 a4 a5 a6 pp a7 a8 a9
a10

19
19
18

17
A1 A2 A3 A4 A5 P3A6 A7 A8 A9 A10
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

15
P2 P1
1
INTERNAL CONSTRUCTION

b1 b2 b3 b4 b5 b6 b7 b8 b9 b10
2

10

11

12

13

14

S0709417
Figure 3

Page 8
 Reference Reference
Description Description
Number Number
1 End Cover 11 Boom 1 Speed
2 Boom Swing 12 Bucket
3 Swing 13 P. T. O
4 Blade 14 End Cover
5 Inlet (P3) 15 O-ring
6 Boom 2-speed 16 O-ring
7 Arm 17 Bolt
8 Travel 2 18 Bolt
9 Inlet (P1, P2) 19 Hexagon Nut
10 Travel 1

Main Control Valve S0709417

Page 9
CONSTRUCTION OF RELIEF AND MAKEUP VALVES
RELIEF VALVE

Figure 4

Reference Reference
Description Description
Number Number
1 Main Poppet 10 O-ring
2 Pressure Control Valve 11 Backup Ring
3 Piston 12 Valve Seat
4 Housing 13 O-ring
5 Poppet 14 O-ring
6 Adjustment Screw 15 O-ring
7 Lock Nut (M14) 16 O-ring
8 Spring 17 Backup Ring
9 Spring

S0709417 Main Control Valve

Page 10
MAKEUP VALVE

Figure 5

Reference Reference
Description Description
Number Number
1 Makeup Poppet 4 Spring
2 Housing 5 Backup Ring
3 Plug 6,7,8 O-ring

OVERLOAD RELIEF VALVE

Figure 6

Reference Reference
Description Description
Number Number
1 Main Poppet 8 Lock Nut (M14)
2 Pressure Adjusting Valve 9,10 Spring
3 Spring Seat 11,12,13 O-ring
4,5 Housing 14 Backup Ring
6 Poppet 15 O-ring
7 Adjustment Screw

Main Control Valve S0709417

Page 11
OPERATION
OPERATION IN NEUTRAL POSITION
P1: Hydraulic oil under pressure delivered from hydraulic pump flows into control valve past port P1 and
then enters travel spool through forward travel valve.
With valve in NEUTRAL position, if bypass gallery is not shut off, pressurized oil passes through
bypass gallery (travel 1 → boom 1 → bucket → PTO Spool), pass the tank gallery, then flows into
ports T1 and T2.
P2: Pressurized oil delivered from hydraulic pump flows into control valve through port P2 and then
enters travel spool through forward travel valve. With valve in NEUTRAL position, if bypass gallery is
not shut off, pressurized oil passes through the bypass gallery (travel 2 → arm →boom 2 spool), pass
the tank gallery, then flows into ports T1 and T2.
P3: Pressurized oil delivered from hydraulic pump flows into control valve through port P3 and then
enters valve area. With valve in NEUTRAL position, if bypass gallery is not shut off, pressurized oil
passes through bypass gallery (blade → swing → boom swing valve), past tank gallery, then flows
into ports T1 and T2.
Pp: Pressurized oil delivered from hydraulic pump flows into control valve through port Pp and then
enters pilot gallery through orifice gallery set on pressure relief area (inlet (P1, P2) valve). When the
valve is in neutral, oil flows to the tank gallery through the orifice gallery set on each valve of both the
travel spool, and boom 2/breaker. When the pressure in pilot gallery becomes equal to the tank
pressure, hydraulic pressure from inlet (P1, P2) valve is changed into tank pressure, so that inlet (P1,
P2) valve is not moved over. The tank gallery always remains open, and pressurized oil flowing into
tank gallery, flows pass the entire spool gallery and is passed on through ports T1 and T2.

(See Figure 7)

Reference Reference
Description Description
Number Number
1 Boom 2-speed Tank Path 11 Bypass Gallery
Gallery 12 Travel 1
2 Boom Swing 13 Boom 1
3 Swing 14 Bucket
4 Dozer 15 Travel Spool Tank Gallery
5 Signal Line Path 16 Bypass Gallery
6 Boom 2 17 Bypass Gallery
7 Arm 18 Bypass Gallery
8 Travel 2 19 Tank Gallery
9 Orifice 20 PTO
10 Inlet (P1, P2)

S0709417 Main Control Valve

Page 12
 Figure 7 DIAGRAM OF HYDRAULIC OIL CIRCUIT IN NEUTRAL

Main Control Valve S0709417

Page 13
OPERATION FOR TRAVEL
1. Forward Travel Operation (Figure 8)
When the forward valve in the pilot supply valve is activated and the travel modulation valve is
pressed by foot, the oil from the pilot pump P4 flows through the port PAR of the pilot supply valve to
the ports a6 and a7 of the control valve.
The travel spool is moved to the left.
The oil from the piston pumps P1 and P2 flows through the bypass gallery to the actuator ports A6
and A7.
The oil returned from the ports B6 and B7 flows back to the hydraulic oil tank through the return (tank
gallery) passage.
The spool is returned to the neutral position by the return spring.

S0709417 Main Control Valve

Page 14
 Figure 8 ACTUATION WHEN OPERATING FOR TRAVEL (FORWARD)

Reference Reference
Description Description
Number Number
1 Bypass Gallery 4 Tank Gallery
2 Travel Spool 5 Orifice Gallery
3 Flow Out to Boom 1 Spool,
Bucket, Arm, and Boom 2
Spool

Main Control Valve S0709417

Page 15
2. Reverse Travel Operation (Figure 9)
When the reverse valve in the pilot supply valve is activated and the travel modulation valve is
pressed by foot, the oil from the pilot pump P4 flows through the port PBR of the pilot supply valve to
ports b6 and b7 of the control valve.
The travel spool is moved to the right.
The oil from the piston pumps P1 and P2, flows through the bypass gallery to the actuator ports B6
and B7.
The oil returned from the ports A6 and A7 flows back to the hydraulic oil tank through the return (tank
gallery) passage.
The spool is returned to the neutral position by the return spring.

S0709417 Main Control Valve

Page 16
 Figure 9 ACTUATION WHEN OPERATING FOR TRAVEL (REVERSE)

Reference Reference
Description Description
Number Number
1 Bypass Gallery 4 Orifice Gallery
2 Tank Gallery 5 Flowing Out to Boom 1-
3 Travel Spool speed, Bucket, Arm, and
Boom 2-speed

Main Control Valve S0709417

Page 17
BOOM OPERATION
1. Boom Up Operation (Figure 10)
Actuating boom to raise forces secondary pressure of remote valve to be transmitted to port b8,
moving boom 1-speed valve. Once the valve moves, boom 1-speed valve shuts off the bypass
gallery. Pressurized oil flowing into port P1 enters parallel gallery through a check valve installed
downstream of the travel valve bypass gallery. Boom 1-speed valve moves to open actuator gallery of
port b8. Pressurized oil flowing into the parallel gallery enters port b8, past load check valve on boom
1-speed change over area, through actuator gallery, and then joins into the delivery side of the boom
cylinder.
Pressurized oil from the cylinder rod side flows into port A8, and then enters tank gallery with spool
forced open by valve movement, with a result that the boom rises. Pressurized oil flowing into port Pp
passes through orifice gallery installed on inlet (P1, P2) valve, then enters bypass gallery. As a result,
pilot gallery pressure becomes equal to tank pressure and inlet (P1, P2) valve cannot be moved over.

S0709417 Main Control Valve

Page 18
 Figure 10 OPERATION FOR BOOM UP

Reference Reference
Description Description
Number Number
1 Travel Tank Gallery at P1 7 Tank Gallery
Side 8 External Piping for
2 Orifice Gallery Confluence
3 Pilot Gallery 9 Parallel Gallery
4 Travel Tank Gallery 10 Load Check Valve
5 Load Check Valve 11 Tank Gallery
6 Actuator Gallery 12 Boom 1-speed Spool
Bypass Closed.

Main Control Valve S0709417

Page 19
2. Boom Down Operation (Figure 11)
Actuating the boom to lower forces secondary pressure of remote valve to flow into port b8, moving
boom 1-speed valve. Once valve moves, boom 1-speed valve shuts off bypass gallery, and
pressurized oil flows into port P1, forcing open check valve installed downstream of travel valve
bypass gallery to flow into bypass valve.
Boom 1-speed valve moves to open actuator gallery of port A8. Then, pressurized oil flows into the
parallel gallery and joins at delivery side of boom cylinder. Pressurized oil flowing to cylinder delivery
side enters port B8, then flows out to tank gallery with spool opened by valve movement.
The boom cylinder moves in direction of crowd to descend boom. Pressurized oil flowing into port Pp
flows in same way as when operating for boom up operation as described in “Boom Up Operation
(Figure 10)” on Page 18.

S0709417 Main Control Valve

Page 20
 Figure 11 OPERATION FOR BOOM DOWN

Reference Reference
Description Description
Number Number
1 Travel Tank Gallery At P1 6 Load Check Valve
Side 7 External Piping For
2 Orifice Gallery Confluence
3 Travel Tank Gallery 8 Parallel Gallery
4 Load Check Valve 9 Boom 1-speed Spool
5 Actuator Gallery Bypass Closed.
10 Load Check Valve

Main Control Valve S0709417

Page 21
3. Boom Up Confluence Operation (Figure 12)
When the boom is actuated to lower as described in “Boom Down Operation (Figure 11)” on Page 20,
pilot pressure of remote valve is applied to boom 2-speed spool, which causes oil flow in port P1 to
join that in port P2 to make for a faster boom lowering speed.
Operating boom confluence forces pressurized oil to flow into port b4 for secondary pressure of
remote valve and then to move boom 2-speed valve. This valve movement allows the bypass gallery
to connect with boom 2-speed valve, and part of pressurized oil flowing into port P1 forces open the
check valve installed downstream of the travel valve bypass gallery until it exits to the tank gallery
through boom 2-speed valve bypass gallery. The actuator gallery of port B4 is opened by movement
of boom 2-speed valve, and pressurized oil flowing into parallel gallery enters port B4, past load
check valve of boom 2-speed changeover area, through actuator gallery. Then, it forces open
confluence gallery (external piping) and travels in line of port B8 on boom 1-speed spool.
Consequently, oil flow of port P1 joins that of port P2, making faster boom lowering speed.

(See Figure 12)

Reference Reference
Description Description
Number Number
1 Load Check Valve 7 Boom 1 Spool Bypass
2 Actuator Gallery Closed.
3 Travel Tank Path 8 Load Check Valve
4 Travel Tank Path 9 Parallel Gallery
5 Boom 1 Block 10 Boom 2 Spool Bypass
Closed.
6 External Piping For
Confluence 11 Boom 2 Block

S0709417 Main Control Valve

Page 22
 Figure 12 OPERATION FOR BOOM UP CONFLUENCE

Main Control Valve S0709417

Page 23
BUCKET OPERATION
1. Bucket Crowd Operation (Figure 13)
Actuating bucket for excavating operation forces secondary pressure of remote valve to be
transmitted to port b9, moving bucket spool. Once the valve moves, the bypass gallery is shut off, and
pressurized oil flowing into port P1 forces open the check valve installed downstream of the travel
valve pilot gallery, then enters parallel gallery. Bucket valve movement causes actuator gallery of port
B9 to be opened, and pressurized oil flowing into parallel gallery enters port B9, past check valve,
through actuator gallery and finally is fed to bucket cylinder piston area.
Pressurized oil that has been forced out of the cylinder rod area, flows into port A9, which moves
valve to open tank gallery. Consequently, bucket cylinder operates in direction of extension and
bucket begins excavating operation.
Pressurized oil flowing into port Pp, enters pilot gallery through the orifice gallery installed on the inlet
(P1, P2) valve. The oil that has flowed into the pilot gallery then enters the tank gallery of travel spool,
which equalizes pilot pressure with tank pressure. As a result, inlet (P1, P2) valve does not shift.

S0709417 Main Control Valve

Page 24
 5

6
B9 A9

b9 a9

7
BNS3140L
Figure 13 OPERATION FOR BUCKET CROWD

Reference Reference
Description Description
Number Number
1 P1 Side Travel Spool Tank 6 Actuator Gallery
Path 7 Tank Path
2 Orifice Path 8 Parallel Path
3 Pilot Gallery 9 Bucket Spool Bypass
4 Travel Tank Path Closed
5 Load Check Valve 10 Load Check Valve

Main Control Valve S0709417

Page 25
2. Bucket Dump Operation (Figure 14)
Actuating bucket for dump operation forces secondary pressure of remote valve to be transmitted to
port a9, moving bucket spool.
Once valve moves, bypass gallery is shut off, and pressurized oil flowing into port P1 forces open
check valve installed downstream of travel valve pilot gallery, it then enters the parallel gallery. Bucket
valve movement causes port A9 to open actuator gallery, and pressurized oil flows into port B9
through actuator gallery and finally joins at cylinder rod area. Consequently, bucket cylinder operates
in direction of extension and pressurized oil flow into port Pp actuates bucket in same way as
described in “Bucket Crowd Operation (Figure 13)” on Page 24).

S0709417 Main Control Valve

Page 26
 3

B9 A9 4

b9 a9

BNS3150L
Figure 14 OPERATION FOR BUCKET DUMP

Reference Reference
Description Description
Number Number
1 P1 Side Travel Spool Tank 5 Parallel Path
Path 6 Bucket Spool Bypass
2 Orifice Path Closed
3 Load Check Valve 7 Load Check Valve
4 Actuator Gallery 8 Travel Tank Path

Main Control Valve S0709417

Page 27
ARM OPERATION
1. Arm Dump Operation (Figure 16)
When the arm is actuated to descend, pilot pressure from the remote valve is applied to the arm
spool.
Operating arm confluence forces pressurized oil to flow into port a5 for secondary pressure of remote
valve and then to move arm valve. This valve movement allows the bypass gallery to connect with
arm valve, and part of pressurized oil flowing into port P2 forces open check valve installed
downstream of travel valve bypass gallery until it exits to tank gallery through arm valve bypass
gallery.
Arm valve movement causes port A5 to open actuator gallery, and pressurized oil flows into port B5
through actuator gallery and finally joins at cylinder rod area.
Consequently, arm cylinder moves in direction of dump to ascend the arm.
Pressurized oil flowing into port Pp enters pilot gallery through orifice gallery installed on inlet (P1,
P2) valve.
The oil that has flowed into pilot gallery enters tank gallery of travel spool, which equalizes pilot
pressure with tank pressure. As a result, inlet (P1, P2) valve does not shift.

S0709417 Main Control Valve

Page 28
 1

2
B5 A5

b5 a5

10 11
7
9
8

BNS3170L
Figure 15 ARM DUMP OPERATION

Reference Reference
Description Description
Number Number
1 Load Check Valve 7 Tank Path
2 Actuator Gallery 8 Parallel Line
3 Orifice Path 9 Arm Spool Bypass Path
4 P2 Side Travel Spool Tank Closed
Path 10 Arm Spool
5 Pilot Gallery 11 Regeneration Valve
6 Load Check Valve

Main Control Valve S0709417

Page 29
2. Arm Crowd Operation (Figure 16)
When the arm is actuated to descend, pilot pressure from the remote valve is applied to the arm
spool.
Operating arm confluence forces pressurized oil to flow into port b5 for secondary pressure of remote
valve and then to move arm valve. This valve movement allows the bypass gallery to connect with
arm valve, and part of the pressurized oil flowing into port P2, forces open check valve installed
downstream of travel valve bypass gallery until it exits to tank gallery through arm valve bypass
gallery.
Arm valve movement causes port B5 to open actuator gallery, and pressurized oil flows into port A5
through actuator gallery and finally joins at cylinder rod area.
Consequently, arm cylinder moves in direction of dump to ascend arm.
Pressurized oil flowing into port Pp, enters pilot gallery through orifice gallery installed on inlet (P1,
P2) valve.
The oil that has flowed into the pilot gallery, enters tank gallery of travel spool, which equalizes the
pilot pressure with tank pressure. As a result, inlet (P1, P2) valve does not shift.

S0709417 Main Control Valve

Page 30
 1

B5 A5
2

b5 a5

10 7 11
8
9

BNS3160L
Figure 16 OPERATION FOR ARM CROWD

Reference Reference
Description Description
Number Number
1 Load Check Valve 7 Tank Path
2 Actuator Gallery 8 Parallel Line
3 Orifice Path 9 Arm Spool Bypass Path
4 P2 Side Travel Spool Tank Closed
Path 10 Arm Spool
5 Pilot Gallery 11 Arm Regeneration Valve
6 Load Check Valve

Main Control Valve S0709417

Page 31
BOOM SWING OPERATION
1. Boom Swing Operation (Left and Right) (Figure 17)
Actuating swing moves boom swing valve for desired boom swing direction.
Valve movement shuts off bypass gallery, and pressurized oil flowing into port P3 enters the parallel
port.
With actuator gallery of port B1 opened by boom/swing movement, pressurized oil flowing into
parallel gallery enters port B1, flows past load check valve on boom/swing changeover area, through
actuator gallery, and is then fed to the boom/swing cylinder.
Pressurized oil fed to cylinder delivery side enters port A1 and flows out with tank gallery opened by
valve movement.
Consequently, boom/swing cylinder operates in direction of extension to actuate boom in left or right
direction.
Load check valve, actuator gallery, tank gallery, boom/swing spool bypass gallery is shut off.

S0709417 Main Control Valve

Page 32
 1

2
B1 A1

b1
a1

BNS3180L

Figure 17 BOOM SWING OPERATION (LEFT AND RIGHT)

Reference Reference
Description Description
Number Number
1 Load Check Valve 4 Boom Sw Spool Bypass
2 Actuator Path Path Closed
3 Tank Path 5 Parallel Path

Main Control Valve S0709417

Page 33
SWING OPERATION
1. Swing Operation (Left and Right) (Figure 18)
Actuating swing moves swing valve in direction of take-in.
Valve movement shuts off bypass gallery, and pressurized oil flowing into port P3 enters parallel
gallery.
With actuator gallery of port A2 opened by swing movement. pressurized oil flowing into parallel
gallery, enters port A2, flows past load check valve on swing changeover area, through actuator
gallery, and then is fed to swing motor left side. Again, this oil fed to swing motor enters port B2 and
flows out with tank gallery opened by valve movement.
Load check valve, actuator gallery, tank gallery, swing spool bypass gallery is shut off.

S0709417 Main Control Valve

Page 34
 Figure 18 SWING OPERATION (LEFT AND RIGHT)

Reference Reference
Description Description
Number Number
1 Load Check Valve 4 Boom Sw Spool Bypass
2 Actuator Path Path Closed
3 Tank Path 5 Parallel Path

Main Control Valve S0709417

Page 35
COMBINED OPERATION (ACTUATION OF INLET (P1, P2) VALVE)
• If placed in neutral position, pilot gallery for inlet (P1, P2) valve change over signal is connected
to 3 tank galleries on travel spool boom 2-speed spool. When feed pressure for valve becomes
equal to tank pressure, inlet (P1, P2) valve is switched over. If inlet (P1, P2) travel spool is
switched over, pilot gallery is connected to tank galleries, but it is shut off by boom 2-speed
spool. Pilot gallery is shut off together with boom 2-speed spool tank gallery, which causes
change over of inlet (P1, P2) valve.
• With travel spool switched over, attachment changeover spool moves in sequence of boom 1-
speed → bucket → arm → boom 2-speed, causing tank gallery to be shut off and consequently
switching over inlet (P1, P2) valve.
• Pressurized oil fed to ports P1 and P2 by change over of inlet (P1, P2) valve flows to travel
spool via a small path installed on outside of inlet (P1, P2) valve, while part of it is distributed to
orifice in inlet (P1, P2) valve.
• Consequently, when travel and attachment spools are switched over simultaneously,
pressurized oil fed to P1 and P2 is always distributed constantly to enable inlet (P1, P2).

S0709417 Main Control Valve

Page 36
 Figure 19 ACTUATION OF INLET (P1, P2) VALVE

Reference Reference
Description Description
Number Number
1 To P1 and P2 Parallel and 5 Each Parallel Gallery For
Attachment Galleries Port P2
2 Orifice 6 Each Parallel Gallery For
3 Travel Spool Tank Closed. Port P1
4 Tank of Each of Boom 7 To Travel Spool
1-speed, Bucket, Arm, and
Boom 2-speed Spools Is
Closed.

Main Control Valve S0709417

Page 37
ACTUATION OF RELIEF VALVE (MRV)
1. Pressurized oil flows into pressure relief
valve and then fills chamber A, past inside
of piston, through orifice B. Chamber A is
closed by main poppet.

Reference
Description
Number
1 Sleeve
2 T Channel
3 Orifice B
4 Poppet
5 Chamber A
Figure 20
6 Piston
7 Main Poppet

2. When spring (2) reaches setting pressure,

pressurized oil in port P pushes poppet
and forces main poppet open. This
pressurized oil passes through inside of
piston orifice (1) Chamber and gallery (3)
and flows out through tank gallery.

Reference
Description
Number
1 Orifice D
2 Spring C
3 Path E
Figure 21
3. If adjust valve is opened, pressure in
Chamber A is reduced and pressurized oil
in main poppet port P flows directly
through tank gallery via return hole (1).

Reference
Description
Number
1 Return Path F

4. As pressure in port P is reduced and

setting pressure of spring C is reduced,
seat of poppet is closed by force of spring
C and pressure in chamber A becomes
Figure 22
equal to that in port P, consequently main
poppet is closed to return to its original
condition.

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Page 38
ACTUATION OF OVERLOAD RELIEF VALVE (ORV)
1. Pressurized oil passes through internal
gallery orifice B of piston on main poppet
and then fills chamber A. Chamber A is
closed by main poppet and plunger
change over seat.

Reference
Description
Number
1 Orifice B
2 Piston
6 Seat
5 Plunger
Figure 23
4 Main Poppet
3 Chamber A
7 Poppet

2. When pressurized oil in port P reaches

setting pressure of spring (3), it presses in
piston, then poppet is opened. Pressurized
oil passes through inside of piston orifice
(1) through chamber → orifice D →
Return hole E in sequence and flows out
to tank gallery through outside of plunger.

Reference
Description
Number
1 Orifice D
2 Return Gallery
3 Spring C Figure 24

3) Main poppet has been opened and

pressure of chamber A is reduced.
Pressurized oil in main poppet port P
passes through return hole and flows out
directly to tank gallery.
4) When decrease in pressure of port P
reduces pressure of spring C below setting
pressure, adjusted pressure is increased
above force of spring C and applies
pressure to plunger. Then, pressure of
chamber A becomes equal to pressure of
port P, which presses seat area of main
poppet and flows in its original state. Figure 25

Reference
Description
Number
1 Return Gallery F

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Page 39
FUNCTION AND OPERATION OF MAKEUP
VALVE
1. Pressurized oil is fed to tank port when
cavitation is generated at port P.
2. If pressure of tank gallery is greater than
port P pressure, former forces plunger
open. Seat is opened in between plunger,
and pressurized oil of tank gallery flows to
port P to prevent cavitation from being
generated.

DETAIL VIEWS OF MAJOR COMPONENTS Figure 26

1. Boom Swing Changeover Assembly
15 14 13 12 17 16
18

11
8
6 5 4 9 372 1
10 BNS3080L
Figure 27

Reference Reference
Description Description
Number Number
1 Work Block 10 P. Washer
2 Spool (Boom Swing) 11 Pilot Cap-B1
3 Spring Seat 12 Poppet Check
4 Spring Pilot 13 Spring Check
5 Spacer Bolt 14 O-ring
6 Spring Seat 15 Plug 1 Check
7 O-ring 16 O-ring
8 Pilot Cap-A 17 Plug
9 Wrench Bolt 18 Anti-Void Valve

S0709417 Main Control Valve

Page 40
2. Swing Changeover Assembly

Figure 28

Reference Reference
Description Description
Number Number
1 Block 10 Plane Washer
2 Spool (Swing) 11 Spool Cap
3 Spring Seat 12 Load Check Valve
4 Spring Load Check Valve
13
Bolt 0.4 -0.5 kg•m Spring
5
(3 - 4 ft lb) 14 O-ring
6 Spring Seat Load Check Valve
7 O-ring 15 Cap 3.5 - 4.0 kg•m
(25 - 29 ft lb)
8 Spring Cap
16 O-ring
Bolt 1.0 - 1.1 kg•m
9 17 Plug
(7 - 8 ft lb)

Main Control Valve S0709417

Page 41
3. Dozer Changeover Assembly

Figure 29

Reference Reference
Description Description
Number Number
1 Block 11 Spool Cap
2 Spool (Dozer) 12 Load Check
3 Spring Seat Load Check Valve
13
4 Spring Spring
Bolt 0.4 -0.5 kg•m 14 O-ring
5
(3 - 4 ft lb) Load Check Valve
6 Spring Seat Cap
15
3.5 - 4.0 kg•m
7 O-ring
(25 - 29 ft lb)
8 Spring Cap
16 O-ring
Bolt 1.0 - 1.1 kg•m
9 17 Plug
(7 - 8 ft lb)
10 Plane Washer

4. Pressure Relief Assembly

Reference
Description
Number
1. Relief Valve Block
2. O-ring
3. Plug (PF3/4)
4. O-ring
5. Plug (PF1/2)
Relief Valve Setting:
180 kg2
6. (397 lb.) Figure 30
6.0 - 7.0 kg•m
(43 - 51 ft lb)

S0709417 Main Control Valve

Page 42
5. Boom 2-speed Changeover Assembly

Figure 31

Reference Reference
Description Description
Number Number
1 Block 9 Bolt
Spool 10 Plane Washer
2 (Boom 2-speed/ 11 Spool Cap
breaker)
12 Load Check
3 Spring Seat
Load Check Valve
4 Spring 13
Spring
Bolt 0.4 - 0.5 kg•m 14 O-ring
5
(3 - 4 ft lb)
Load Check Valve
6 Spring Seat 15
Cap
7 O-ring 16 O-ring
8 Spring Cap 17 Plug

Main Control Valve S0709417

Page 43
6. Arm Changeover Assembly
9 16 11 10 20 15 18 17 16

8 12,13 7 6 2 3 1 4 5 19 14
AXS1600L
Figure 32

Reference Reference
Description Description
Number Number
1 Block 13 Plain Washer
2 Spool (Arm) 14 Spool Cap
Regeneration Valve 15 Load Check
3
Check Overload Relief Valve
Regeneration Valve
4 16 250 kg/sq cm (3,555.84 psi)
Stopper at 5 /min (1.32 U.S. gal.)
( T=4 kg•m (28.93 ft lbs) )
5 O-ring
6 Spring Seat 17 O-ring
7 Spring Load Check Valve
Cap
Bolt 0.4 - 0.5 kg•m 18
8 3.5 - 4.0 kg•m
(3 - 4 ft lb)
(25 - 29 ft lb)
9 Spring Seat
19 Hexagon Head Bolt
10 O-ring
Load Check Valve
11 Spring Cap 20
Spring
12 Bolt

S0709417 Main Control Valve

Page 44
7. Travel Changeover Assembly
14 15 13 12

8 11

6 5 4 9 372 1
10 BNS3040L
Figure 33

Reference Reference
Description Description
Number Number
1 Block 9 Wrench Bolt
2 Spool (Travel) 10 P. Washer
3 Spring Seal 11 Pilot Cap-B1
4 Spring Pilot 12 Poppet-Check
5 Spacer Bolt 13 Spring-Check
6 Spring Seal 14 O-ring
7 O-ring 15 Plug 1-Check
8 Pilot Cap-A

Main Control Valve S0709417

Page 45
8. Relief Area Assembly

Figure 34

Reference Reference
Description Description
Number Number
1 Block 14 Load Check Valve
2 Travel Straight Spool Main Relief Valve
Bolt 0.5 ±0.6 kg•m 15 210 +50 kg/sq cm (2,986.90 +50 psi)
3
(3 - 4 ft lb) at 50 /min (13.20 U.S. gal.)
(T=6~7 kg•m (43.40 ~ 50.63 ft lbs))

4 O-ring
16 O-ring
5 Filter Case
Load Check Valve
6 O-ring
Cap
7 Filter 17
4.0 - 5.0 kg•m
8 Cap (29 - 36 ft lb)
9 Bolt Plug 4.0 - 5.0 kg•m
18
10 Plain Washer (29 - 36 ft lb)
11 Spring Seat Plug 1.0 - 1.2 kg•m
19
(7 - 8 ft lb)
12 Spring
20 Spring
13 Cap

S0709417 Main Control Valve

Page 46
9. Travel Changeover Assembly
14 15 13 12

8 11

6 5 4 9 372 1
10 BNS3040L
Figure 35

Reference Reference
Description Description
Number Number
1 Block 9 Wrench Bolt
2 Spool (Travel) 10 P. Washer
3 Spring Seal 11 Pilot Cap-B1
4 Spring Pilot 12 Poppet-Check
5 Spacer Bolt 13 Spring-Check
6 Spring Seal 14 O-ring
7 O-ring 15 Plug 1-Check
8 Pilot Cap-A

Main Control Valve S0709417

Page 47
10. Boom 1-speed Changeover Assembly

Figure 36

Reference Reference
Description Description
Number Number
1 Block 11 Plain Washer
2 Spool (Boom 1- 12 Cap
speed) 13 Load Check Valve
3 Plug 1 - 1.2 kg•m 14 Spring
(7 - 9 ft lb)
15 O-ring
4 Spring Seat
16 Load Check Plug
5 Spring 3.5 - 4.0 kg•m
6 Bolt 0.4 - 0.5 kg•m (25 - 29 ft lb)
(3 - 4 ft lb) Overload Relief Valve
7 Spring Seat
17 250 kg/sq cm (3,555.84 psi)
8 O-ring at 5 /min (1.32 U.S. gal.)
( T=4 kg•m (28.93 ft lbs) )
9 Cap
10 Bolt 1.0 - 1.1 kg•m
(7 - 8 ft lb)

S0709417 Main Control Valve

Page 48
11. Bucket Changeover Assembly
15 14 13 12 18
17
16

8 11

6 5 4 9 372 1
10 AXS1610L
Figure 37

Reference Reference
Description Description
Number Number
1 Block 12 Load Check Valve
2 Spool (Bucket) 13 Spring
3 Spring Seat 14 O-ring
4 Spring 15 Load Check Plug
5 Bolt 0.4 - 0.5 kg•m 3.5 - 4.0 kg•m
(3 - 4 ft lb) (25 - 29 ft lb)
6 Spring Seat 16 Overload relief valve
7 O-ring 250 kg/sq cm (3,555.84 psi)
at 5 /min (1.32 U.S. gal.)
( T=4 kg•m (28.93 ft lbs) )
8 Cap
9 Bolt 17 Anti-cavitation Valve
10 Plain Washer 4.0 kg•m (29 ft lb)
11 Cap 18 Orifice Plug

Main Control Valve S0709417

Page 49
12. PTO Changeover Assembly
14 15 13
12 16 17
11

8 6 9,10 5 4 3 7 2 1
AXS1620L
Figure 38

Reference Reference
Description Description
Number Number
1 Block 10 Washer
2 Spool (Arm 2) 11 Pilot Cap
3 Spring Seat 12 Poppet
4 Spring 13 Spring
5 Spacer Bolt 14 O-ring
6 Spring Seat 15 Plug
7 O-ring 16 O-ring
8 Pilot Cap 17 Plug
9 Bolt

S0709417 Main Control Valve

Page 50
DISASSEMBLY
Figures in ( ) in contents below are matched to those parts shown in Figure 3.

VALVE HANDLING GUIDE

Place cylinder on work bench with port facing upward.
1. For pilot pressurized oil change over type
A. Handling guide is provided below
taking swing valve as an example.
B. Using 5 mm hexagon socket wrench,
unscrew two bolts (2) and remove
washer (3). Then, disconnect spool
cap (1). When the spring is exposed
from swing valve, pull out spring
slowly in horizontal direction (parallel
with valve hole) and disconnect spool
assembly.
C. Pilot valve can be disconnected in Figure 39
the same way. Then, ensure that pilot
take-off plunger and O-ring (6) are
removed from the body.
2. For override type
A. Handling guide is provided below
taking boom swing valve as an
example.
B. Using 5 mm hexagon socket wrench,
unscrew 2 hexagon head bolts (9)
and remove spring (1) exposed from
valve. When spring assembly is
exposed from swing valve, pull out
spring slowly in horizontal direction
(parallel with valve hole) and
disconnect spool assembly.
Figure 40
C. Override valve can be removed in
same way. Used O-ring must not be
reused.

Main Control Valve S0709417

Page 51
3. For forward travel valve
A. Using 5 mm hexagon socket wrench,
unscrew two bolts (3) and remove
plane washer (9).
B. Remove spool cap (1). Remove
spring (2) exposed from valve. After
removing spring, if a section of
forward travel valve is exposed, hold
exposed section and take it out in
horizontal direction (parallel with
valve hole) slowly.
C. Then, pull out O-ring (6) on low Figure 41
pressure area so that pilot cap can
be easily removed from body.
Remove opposite bolt (3) with 5 mm
hexagon socket wrench, then
disassemble pilot cap and filter cap
assembly (4 - 5).

CAUTION!
Be sure to remove relief valve
assembly to spring side. (Do not
disassemble it from spool cap side,
or spring seat (11) may fall in valve.)

4. Spool replacement precaution.

NOTE: Spool must be replaced in an
assembled state.

DISASSEMBLY OF RELIEF VALVE (MRV), OVERLOAD RELIEF VALVE (ORV),

AND ANTI-CAVITATION VALVE (ACV)
1. Hold body so that it may not move. Then, with a 30 mm hexagon socket wrench, remove MRV, ORV,
and ACV must be removed with a 22 mm hexagon socket wrench. Then, remove MRV and ORV with
a 19 mm hexagon socket wrench. At disassembly, take care that the setting pressure for MRV and
ORV is not changed, and mark position for assembly.
NOTE: At disassembly, do not damage seat the area of MRV, ORV, and ACV.
2. As MRV and ORV are critical components from a viewpoint of performance and safety, do not reset
pressure. If problem occurs at disassembly, replace them in an assembled state.

S0709417 Main Control Valve

Page 52
CHECK VALVE DISASSEMBLY
1. Hold on body so that it does not move.
2. Using 8 mm hexagon socket wrench,
remove check valve (15) on upper center.
3. Pull out plug O-ring (14) with a tool. Do not
apply excess force, or oil may leak out.
With tweezers, take out load check valve
spring (13) and load check valve (12) from
hole which load check valve has been
removed.

Figure 42 LOAD CHECK VALVE

Figure 43 LOAD CHECK

PRESSURE RELIEF LOAD CHECK VALVE
DISASSEMBLY
1. Hold on valve body so that it does not
move.
2. Remove 21 mm bolt from load check valve
(17) on upper center of pressure relief
area.
3. Do not apply excess force when pulling O-
ring (16) from groove. With tweezers or
magnet, take out load check valve spring
(15) and load check valve (14) from hole
which plug has been removed. Figure 44 PRESSURE RELIEF CHECK

ANTI-CAVITATION VALVE DISASSEMBLY

1. As anti-cavitation is a critical component from viewpoint of performance and safety, if damaged,
replace in assembled state.
2. Gently hold hexagon part (width across flat: 22 mm) of anti-cavitation valve (2) with a vise. Using 8
mm hexagon socket wrench, remove plug (3). Pull out spring (4) and remove anti-cavitation valve (1)
to seat side, taking care that seat may not be damaged. Remove O-ring (6) and backup ring (5) off
plug (3), taking care that each part of body (2) may not be damaged.

Main Control Valve S0709417

Page 53
RELIEF VALVE DISASSEMBLY
1. Relief valve is a critical component from viewpoint of performance and safety. Do not reset pressure.
If unusual wear occurs, replace in assembled state.
2. Gently hold hexagon part (width across flat: 30) of relief valve body (4) with a vise. Using 19 mm
hexagon socket wrench, remove nut M14 (7). Pull out adjust nut (6) with 4 mm hexagon socket
wrench. Spring (8) and poppet (5) must be removed using tweezers, etc. Hold upper and lower sides
of relief valve body (4).
3. Separate socket (1) by inserting a bar through its hole and disassemble remaining parts
simultaneously. Remove poppet seat (12), piston (13), spring (9), and main poppet (2) in sequence.

OVERLOAD RELIEF VALVE DISASSEMBLY

1. Overload relief valve is a critical component from viewpoint of performance and safety. Do not reset
pressure. If unusual wear occurs, replace in assembled state.
2. Hold hexagon part (width across flat: 22 mm) of body (5) with a vise. Using 19 mm hexagon socket
wrench, remove nut M14 (8). Pull out adjust nut (7) with 4 mm hexagon socket wrench. Spring (9) and
poppet (6) must be removed using tweezers, etc. Remove remaining parts simultaneously. Then,
arrange socket (1), piston (3), spring (10), and poppet (2) in sequence.

OTHER COMPONENTS DISASSEMBLY

NOTE: Other components which have not been removed can be disassembled as follows:
1. Hydraulic pilot type change over pilot cap (Figure 40)
Unscrew two hexagon head bolts (2) with 5 mm hexagon socket wrench. Place pilot cap (4)
horizontally. At this time, ensure that O-ring (5) on pilot cap support flange has been removed.
2. Override type valve seal (Figure 41)
Unscrew two hexagon head bolts (9) with 5 mm hexagon socket wrench. At the same time, remove
seal (3), dust seal (5), and O-ring (4).

CAUTION!
Do not reuse used O-ring. If reusing it, exercise extreme care when disassembling. Take
care that valve seal change over body on valve hole body side may not be damaged. Using
a small screw driver, remove seal (O-ring) (8) and dust seal (4).

JOINT BODY DISASSEMBLY

1. Unscrew eight M8 hexagon nuts (4 x 2), which assemble joint body on valve side, using 13 mm
socket or 13 mm wrench to remove each change over body.
2. At this time, take care that each O-ring installed on contact surface of each change over body does
not slip or become damaged.
3. There are a few plugs mounted on change over body. These plugs are installed to block holes.
Therefore, remove them only if necessary.

S0709417 Main Control Valve

Page 54
DISASSEMBLY PRECAUTIONS
1. Store and transport each of disassembled parts with care. When conducting other operation with
these parts disassembled, take care when storing or transporting that foreign material does not enter
holes from which they have been removed. If foreign material enters, clean thoroughly.

Main Control Valve S0709417

Page 55
ASSEMBLY
ASSEMBLY PRECAUTIONS
1. For disassembly procedures, refer to Figures contained in this manual.
2. Seal assembly precautions
• Damaged seals must be replaced with new at assembly.
• Check for defects on shape of seal, if any, replaced with new.
• Apply a sufficient amount of grease or hydraulic oil to seal and seating face.
• Do not use any seals which have a permanent deformation.
• Take care when you insert O-ring into a moving part. Inserting an O-ring of different size will
cause oil leaks.
3. Refer to construction view for assembly operation. Each part must be reassembled after checks. Take
care not to assemble wrong parts.
4. Tighten each fitting port or nut to specified torque. Tightening above specified torque will cause
damage.
5. Clean and degrease coating face before coating double with LOCTITE.

GUIDE FOR ASSEMBLY OF EACH PART

1. Install change over body, with its sealing port facing up, according to number shown in control valve
specifications in “Table 1” on Page 57.
2. Ensure that mating face of change over body has been inserted properly to accommodate O-ring.

CAUTION!
Insert four assembling port (20), (21) at both sides, and tighten eight M8 nuts to specified
torque using a 13 mm socket wrench or spanner. Do not tighten these nuts to less than
specified torque, or oil leaks may result. Tighten nuts in several stages to obtain equal
tightening torque.
Strike each change over body with a plastic hammer and then tighten them equally.

S0709417 Main Control Valve

Page 56
3. Check valve assembly
A. Change over portions other than travel change over portion
Place valve on a work bench with cylinder port facing up. Insert check valve (12) into hole on
valve center and then ensure that it has been inserted into valve center.
Install check valve spring (13) which is a guide for check valve. Insert check valve guide into
guide for check valve housing (15) and install check valve spring on check valve housing guide
so that spring is against check valve housing.
When spring goes into check valve housing guide to some extent, tighten it to specified torque
with a hexagon socket head spanner.
B. Travel change over portion
Insert check valve (12) into hole on valve center, and then ensure that it has been inserted into
valve center.
Apply grease to check valve spring (13) and insert it into guide portion for check valve housing
(15).
In this state, ensure that check valve has not slipped off and insert guide, which is mounted on
change over body, into guide for check valve housing. Insert check valve manually with care.
When guide goes into check valve housing guide to some extent, tighten it to specified torque
with a hexagon socket head spanner. Pay attention to two types of check valves when
assembling.

Table 1

Names Symbols
End cover HD
Boom/Swing change over BB
Swivel change over BB
Dozer change over QB1
Pressure regulator (P3) GZ
Boom 2-speed change over BG
Arm 1 - speed change over BF
Travel (Left-hand) change over DC
Pressure regulator (P1, P2) FC
Travel (Right-hand) change over CC
Boom 1-speed change over AD
Arm 2 - speed change over AN
Bucket change over AL
End cover HC Tank port

NOTE: Symbols are marked on upper part of change over body

4. MRV•ORV
Tighten MRV and ORV to specified torque. When installing MRV and ORV, pay attention to marks
made at disassembly so that set pressure may not be changed.
5. Assemble complete valve assembly
NOTE: Tighten tie rod nuts to 2 ±0.1 kg•m (14 ±1 ft lb).

Main Control Valve S0709417

Page 57
CRITERIA FOR MAINTENANCE
INSPECTION OF SPARE PARTS
Criterion for Determination
Spare Parts Inspection Items
and Actions to Be Taken
Change over body Whether or not there is any damage, 1) Replace any of following, if
rust or corrosion. damaged:
• Components of
spools, particularly,
actuation parts where
pressure is applied.
• Seal pockets into
which spools are
inserted or flange
areas.
• Seals of ports with
which O-rings are
contacted.
• Overload relief, anti-
cavitation ports, etc.
• Other parts that fail to
perform their normal
function.
Spool Whether or not there is any damage, Replace parts if damaged.
rust or corrosion.
Insert spools in holes of change over Replace spool if it does not
body and rotate them. operate smoothly.
Check valve Check valve and check valve damage Correct or replace seat it is
unstable.
Around springs Damage caused by rust, corrosion, Replace if conspicuously
deformation of, and shock to, springs, damaged.
spring seats, plug and cover.
Around seals of valves Outward oil leakage Replace.
Rust, corrosion and deformation of Correct or replace.
front lip of oil seal.
MIRV-ORV Outside rust Replace.
Contact areas of valve seats Replace if damaged.
Damage (including deformation, Replace.
friction, etc.) to springs
O-rings, backup rings, etc. Replace all.

S0709417 Main Control Valve

Page 58
TROUBLESHOOTING AND REMEDIES
1. When any abnormality takes place, failure of control valves may lead to trouble with circuit
encompassing pump, cylinder motor, etc. To prevent this, it is required to measure pilot pressure,
pump exhaust pressure, load pressure, etc. For partial check through disassembling, refer to
procedures for disassembly and assembly.
2. Be careful to prevent occurrence of any failure of hydraulic system as it may be very dangerous. For
partial disassembling, do work after sealing. Handle operating parts with care.
3. Correct with fine sandpaper or replace it if even minor damage is found. Thoroughly clean parts when
you repair or replace. Any damage here may cause oil leakage.

CONTROL VALVE

Criterions for Determination

Symptoms Inspection Items
and Actions to Be Taken
Attachments do not Defective operation of relief valves Pressure measurement of
operate, or do not work relief valve
• Foreign materials between
properly with abnormality.
adjusting valve and seat • Replace assembly.
(power deficiency).
• Adhesion of relief valves • Replace assembly.
• Breakage of springs • Replace assembly.
• Clogging of piston orifice • Replace assembly.
• Loose adjusting nuts/ • Readjust adjusting
nuts and tighten lock
nuts to specified
torque.
Natural descent is big Large aperture between a control valve Replace spool.
when spool is in a neutral and a spool
position. Foreign materials are incorporated or Measure 2nd pressure of pilot.
adhere between a control valve and a
• Disassemble and
spool when latter is not in neutral
clean spool.
position.
• Replace spring.
• When spring is damaged.
Defective operation of RV ORV/ Measure RV ORV pressure.
A descent takes place due Defective operation of load check valve
to defective air sealing
• Foreign materials are • Disassemble and
when ascent manipulation
incorporated between check clean. Replace when
is being tried.
valve and control valve. found severely
damaged.
• Adhesion of check valves
• Replace check valve.
• Damage to or breakage of
spring valves • Replace spring.

Main Control Valve S0709417

Page 59
RELIEF VALVE
Relief valve being one of most critical items for performance and safety of equipment, never fail to replace
assembly when any abnormality takes place as shown on following table while resetting pressures.

Criterions for Determination

Symptom Inspection Items
and Actions to be Taken
Pressure does not rise Any abnormality of pressure adjusting Check if any foreign object is
valve of every relief valve, adhesion of incorporated into valves. Check
pistons, and incorporation of foreign if every part is moving freely.
objects into valve seats.
Relief pressure is unstable. Damaged pressure adjusting valve of Replace damaged parts if any.
every relief valve and sticking of
Clean all parts completely.
pressure adjusting valves of pistons
Clear any surface damage.
Relief pressure appears Abrasion by foreign objects. Replace assembly.
abnormal Loosen adjusting nut of load check Adjust pressure.
• Broken spring • Replace assembly.
Defective operation of RV ORV Measure pressure of RV
• ORV
Oil leakage Damage to all seats Abrasion O-ring Replace damaged and
abraded parts. Check if all
parts are operating smoothly,
and then reassemble.
Adhesion of parts by foreign objects Assemble while attending to
avoid incorporation of any
foreign object.

S0709417 Main Control Valve

Page 60
 S0709454

1PILOT CONTROL
VALVE (WORK LEVER /
JOYSTICK)
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.

PILOT CONTROL VALVE (WORK LEVER / JOYSTICK)S0709454

MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Pilot Control Valve (Work Lever / Joystick) S0709454

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 4
Specifications .......................................................................................... 6
Hydraulic Specifications .......................................................................... 6
Special Tools .................................................................................................. 7
Disassembly ................................................................................................... 8
Reassembly.................................................................................................. 13

S0709454 Pilot Control Valve (Work Lever / Joystick)

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
The pilot control valve contains four push rods, a spring holder and return spring, which are 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 switch is installed in the valve handle. Gear pump pressure is used for operating control
spools.

Neutral Mode
When the lever is in neutral mode, the spool (8) is thrust upward by return spring (17), and the force of
balance spring (16), 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.

Control Mode
When push rod (10) is pushed, the balance spring (16) begins to compress, and spring force is conveyed
to spool (8). 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 (8), thrusting the spool upward until it is balanced with
the power of the balance spring (16). The secondary pressure (output pressure), therefore, changes in
proportion to the compression force of the balance spring.

Pilot Control Valve (Work Lever / Joystick) S0709454

Page 3
PARTS LIST

Figure 1

S0709454 Pilot Control Valve (Work Lever / Joystick)

Page 4
 Reference Reference
Description Description
Number Number
1 Casing 17 Spring
2 Plate, Port 18 Joint
3 Washer, Seal 19 Disc
4 O-ring 20 Nut, Adjustment
5 Bolt, Socket M8 x 1.25 x30L 21 Boot
6 Bushing 22 Bar, Handle
7 Plate 23 Nut, M12 x 1.25
8 Spool 24 Insert
9 Plug 25 Pin, Spring D5 x 10L
10 Rod, Push 26 Switch Assembly
11 U-seal 27 Screw, M4 x 0.7 x 14
12 O-ring 28 Nut, Lock M14 x 2.0 (H3)
13 Washer 29* Handle Assembly
14 Seat, Spring 30 Bushing
15 Washer 31 Cap, Dust
16 Spring

NOTE: * On some models the handle assembly (29) may contain other switches for operation of
specialized components (grapples, scrap handlers, etc.). Basic construction of valve is the
same.

Pilot Control Valve (Work Lever / Joystick) S0709454

Page 5
SPECIFICATIONS

Performance

30 30
SECONDARY PRESSURE (kgf/cm2)

21.7

OPERATION TORQUE (kg.cm)

20 20
19.5 +
_ 1.5
18.3

OPERATING TORQUE

13.0

10 10

6.8
SECONDARY PRESSURE
5+
_1 4.8

0 1.1 2 4 6 6.5 7

PUSH - ROD STROKE (mm) BNS2510L

Figure 2

HYDRAULIC SPECIFICATIONS

Implement Control Valve Type: Pilot Control

Pressure/Stroke: 30 kg/cm2 (427 psi) @ 6.5 mm (0.256") stroke
Weight: 4.8 kg (10.6 lb)

S0709454 Pilot Control Valve (Work Lever / Joystick)

Page 6
SPECIAL TOOLS
Tool Size
Spanner 22.0 mm
Spanner 27.0 mm
Socket Wrench 6.0 mm
Phillips Screwdriver
Slotted Screwdriver
Special Tool

Pilot Control Valve (Work Lever / Joystick) S0709454

Page 7
DISASSEMBLY
1. Lift up boot and pull switch cord through
hole in housing.

Figure 3

Figure 4
2. Loosen nut (4) from hex nut and detach
handle assembly.
NOTE: Handle assembly may vary
from model to model depending
upon front attachments.
(Example; breakers, scrap
grapples, logging grapples,
etc.)

Figure 5

S0709454 Pilot Control Valve (Work Lever / Joystick)

Page 8
3. Remove hex nut and plate.

Figure 6
4. Detach joint using special tool.

Figure 7

Figure 8
5. Remove plate.

Figure 9

Pilot Control Valve (Work Lever / Joystick) S0709454

Page 9
 CAUTION!
Plug (8) may fly out due to spring (11)
being compressed.

6. While pressing down spring, remove plug.

Figure 10

IMPORTANT
Tag or label valve position so that
each valve can be install into its
original position.

7. Remove pressure reduction valve

assembly and spring.

Figure 11
8. Remove plug.

Figure 12
9. Remove stopper from pressure reduction
valve assembly using a screwdriver.

Figure 13

S0709454 Pilot Control Valve (Work Lever / Joystick)

Page 10
10. Detach spool, spring seat, spring and
shim.

Figure 14
11. Detach plug (8) from push rod.

Figure 15
12. Remove O-ring (20) and seal, from plug.

Figure 16

Figure 17

Pilot Control Valve (Work Lever / Joystick) S0709454

Page 11
13. Remove boot and nut from handle
assembly.

Figure 18

S0709454 Pilot Control Valve (Work Lever / Joystick)

Page 12
REASSEMBLY
1. Clean all parts and dry them with
compressed air. Keep all parts and tools
free from dust. Lubricate all moving parts.
2. Tighten plug slowly and diagonally.

Figure 19
3. Assemble shim, spring and spring seat.

Figure 20
4. While pressing down spring seat, insert
stopper.

Figure 21

Pilot Control Valve (Work Lever / Joystick) S0709454

Page 13
5. After attaching spring to housing, install
pressure reduction valve assembly.

Figure 22
6. Insert O-ring into plug.

Figure 23
7. Attach seal to plug.

Figure 24
8. Insert push rod into plug.

Figure 25

S0709454 Pilot Control Valve (Work Lever / Joystick)

Page 14
9. Install plug in housing. Coat parts with
clean hydraulic oil.

Figure 26

Reference
Description
Number
1 Seal
2 Plug
3 Hydraulic Oil

Figure 27
10. Assemble plate. Tighten joint to housing
using special tool.

Figure 28
11. Attach swatch plate to joint.

Figure 29

Pilot Control Valve (Work Lever / Joystick) S0709454

Page 15
12. After attaching hex nut, tighten plate.

Figure 30
13. Attach boot and nut to handle assembly.

Figure 31
14. Pull cord and tube out through hole in hex
nut.

Figure 32
15. Adjust direction of handle so that bent part
of handle faces seat,. Tighten hex nut and
outer nut.

Figure 33

S0709454 Pilot Control Valve (Work Lever / Joystick)

Page 16
16. Lubricate joint, plate and push rod.

Figure 34
17. Install boot.
18. Apply evaporative, anti-seize compound to
ports.

Figure 35

Pilot Control Valve (Work Lever / Joystick) S0709454

Page 17
S0709454 Pilot Control Valve (Work Lever / Joystick)
Page 18
 S0792200

2HYDRAULIC
SCHEMATIC
(SOLAR 55W-V PLUS)
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.

HYDRAULIC SCHEMATIC (SOLAR 55W-V PLUS)S0792200

MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Hydraulic Schematic (Solar 55W-V PLUS) S0792200

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Solar 55W-V PLUS......................................................................................... 4

S0792200 Hydraulic Schematic (Solar 55W-V PLUS)

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

Hydraulic Schematic (Solar 55W-V PLUS) S0792200

Page 3
SOLAR 55W-V PLUS

T2
HYDRAULIC PUMP
DOUBLE SINGLE P1 : 1.53 cu.in/rev.(25 cu.cm/rev)
ACTION ACTION A10 Pb10 P2 : 1.53 cu.in/rev.(25 cu.cm/rev)
P3 : 0.99 cu.in/rev.(16.2 cu.cm/rev)
B10 P.T.O.
P4 : 0.54 cu.in/rev.(8.9 cu.cm/rev)
Pa10 3k
A
P
ENGINE
B
SWITCH VALVE YANMAR 4TNV94L
A9 Pb9 54.9PS/2400RPM
19.3KgM/1600RPM
BKO BKI
BUCKET
B9
OIL COOLER
Pa9
250K
CR DP
BUCKET
A8
4.5k RETURN
BD 250K Pb8 FILTER
B8 BOOM1
Pa8
250K UP DN
BOOM BU
A7

C2 B7
TRAVEL1
E Pb7 Pa7
LOCK VALVE 2
B F
1
P1
T V2 Pil
R1 T
Pp
P2
230K
P3 T3 T2
HORN
P2
PILOT VALVE(RH) P T PILOT VALVE(LH)
Pb6 B F Pa6
TRAVEL2
B6

A6
BOOM
BUCKET SWING

Pb9 3 1 2 4 3
ARM
Pb5 CROWD Pa9 UP RIGHT LE
ARM DUMP (Pb4,Pb8)
Pa5
AO AI B5 250K 250K CR DP

A5 Pb4 SHUTTLE V/V

SWING LEFT CHANGE
Pa2 a2 a1
UP BR Pa4
(Pb5) CROWD b2
BOOM2
b1 BOOM SWING
SWING MOTOR B4 E (Pb1)
c2 c1 LEFT
SWING RIGHT
A4 Pb2
-RG-

SH T1 DOWN d2
Pa8 BOOM SWIN
T1 210K d1 (Pa1)
PG P3 RIGHT
R2
AIR VENT PORT

Pb3 UP DN Pa3
BLADE
A3
-GB-

-GA-

B3
T
RH LH Pa2
B(R) A(L) Pb2
SWING
B2

A2
Pb1
LH RH BOOM SWING

B1 Pa1

BSL BSR
A1

BOOM SWING

BLADE CYLINDER

BLD BLU

Figure 2

S0792200 Hydraulic Schematic (Solar 55W-V PLUS)

Page 4
 STEERING VALVE

)(

)(
HYDRAULIC PUMP
P1
P1 : 1.53 cu.in/rev.(25 cu.cm/rev)
P2 : 1.53 cu.in/rev.(25 cu.cm/rev) OSPC

)(

)(
P3 : 0.99 cu.in/rev.(16.2 cu.cm/rev) 160LS
P4 : 0.54 cu.in/rev.(8.9 cu.cm/rev) EF
3k R1 P1 P2 P3 P4 100k
T
ENGINE 150k
YANMAR 4TNV94L PILOT PUMP P4

54.9PS/2400RPM R
19.3KgM/1600RPM
60k
L
OIL COOLER

GEAR PUMP P3 PSD GBR

S1
A2
PISTON PUMP P1,P2 C20 0.32 25
C15 RB L
P C1 40 C13
4.5k RETURN STRAINER
FILTER C14 FB
PILOT FILTER 0.32 25
+2 +2 70 A1 L
33 -2 22 -2 100
85
C2 C21 C16 C17
T
Po C19
C18

GPS AC2
0.32 15
L
AC1 C3
0.32 15 PARK
L SAFETY
CUT OFF
SP EMERGENCY C10
T PULL 15k
1.1 SW
C4
P2 P PS

P3 T3 T2 P1 T1 PAR FORWARD
HORN PILOT VALVE(DOZER)
PILOT VALVE(RH) P T PILOT VALVE(LH) P T T P
C6 CHOCK
C5

REVERSE C8

BOOM (DOZER)
BUCKET SWING ARM C7 PILOT
1 DOWN(Pa3) 2 PBR SUPPLY
Pb9 3 1 2 4 3 1 2 4
VALVE
CROWD Pa9 UP RIGHT LEFT DUMP CROWD
UP(Pb3) TS TR CH PK
DUMP (Pb4,Pb8)
(Pa5)

1 2

SHUTTLE V/V SAFETY

WING LEFT T P
a2 a1 CHANGE VALVE CUT OFF
Pa2 (Pa10)
C 1 C1 3
CROWD b2 PA
b1 BOOM SWING OA T1
E TRAVEL MODULATION
(Pb1) T2 PB
C2
c2 c1 LEFT
GHT D
DOWN d2 2 T
BOOM SWING OB O
Pa8 d1 (Pa1) (Pb10) P
RIGHT (Pa4)

BRAKE

DIG LATCH

50k T1
BR1

P1
BL1
1 2 9 8 10 3 4 5 7 0 11 6
SWIVEL JOINT

4.8K

TRAVEL MOTOR MB B A

HI
LO 250k
T2
BR2
BL
BLADE CYLINDER P2
TB Y
BL2 BRAKE VALVE
PL 50 BAR
T MA
BLD BLU
BR

PK

Solar 55W-V Plus

BNS2801L

Hydraulic Schematic (Solar 55W-V PLUS) S0792200

Page 5
The hydraulic system consists of the engine, variable displacement piston pumps, gear pump, control
valve, boom cylinder, arm cylinder, bucket cylinder, boom swing cylinder, blade cylinder, swing motor,
swivel joint, travel motor, oil cooler, and hydraulic oil tank.
The oil discharged from the variable displacement piston pumps and the gear pump flows to the actuators
through the control valve.
The hydraulic pilot operation system comprises the pilot pump mounted on the main hydraulic pump, cut-
off valve and two pilot valves. The oil discharged from the pilot pump, passing through the cut-off valve and
the pilot valve, flows into the pilot port of the control valve to control the valve spool movement in proportion
to the pressure in the pilot port.
The variable displacement piston pumps, the gear pump, and the pilot pump are linked to the flywheel of
the engine through the coupling. The number of revolutions of each hydraulic pump is identical to the
engines speed. The displacement of each piston pump is 25 cu.cm/rev., that of the gear pump P3 is 16.2
cu.cm/rev and that of the pilot pump P4 is 8.9 cu.cm/rev. Each pump receives oil from the hydraulic oil tank
via the intake strainer.
The oil discharged from the pumps P1 and P2 flows to the control valve ports P1 and P2 and returns from
the ports T1 and T2 to the hydraulic oil tank through the return filter.
The oil discharged from the gear pump P3 flows into the port P1 of the steering valve to move the steering
cylinder in the front axle. When the steering valve is not operated, the oil from the gear pump P3 flows
through the port P1 and EF of the steering valve to the port P3 of the control valve.
The oil from the pilot pump P4 flows through the cut-off valve and the pilot valves and returns to the
hydraulic oil tank.
The system relief valves R1 and R2 of the control valve control the discharge pressure of the pumps.
The bypass valve in the return filter opens with a differential pressure of 147 kpa (21 psi).

S0792200 Hydraulic Schematic (Solar 55W-V PLUS)

Page 6
1ELECTRICAL SYSTEM
 S0802230

1ELECTRICAL SYSTEM

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.

ELECTRICAL SYSTEMS0802230
MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Electrical System S0802230

Page 1
TABLE OF CONTENTS

Overview ........................................................................................................ 3
Electric Supply System .................................................................................. 4
Engine Starting Circuit ................................................................................... 6
Operation During Starting Process ......................................................... 6
Operation After Start Process ................................................................. 8
Engine Preheating System........................................................................... 10
Engine Stop System..................................................................................... 12
Charging System.......................................................................................... 14
Instrument System ....................................................................................... 16
Instrument Panel ................................................................................... 17
Function Check ..................................................................................... 17
Operation .............................................................................................. 18
Circuit Diagram of Instrument Panel ..................................................... 20
Circuit Diagram of Control Unit ............................................................. 22
Control Unit ........................................................................................... 23

S0802230 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 volts 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

Electrical System S0802230

Page 3
ELECTRIC SUPPLY SYSTEM
The electric power circuit supplies electric current to each electric component. It consists of a battery,
battery relay, start 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. Cab light, fuel pump switch, No. 5 terminal of car stereo for back up.
2. "B" terminal of start switch.
3. "B" terminal of engine stop relay
4. Headlight, turn signal light, illumination light and hazard switch.
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 → "BR" terminal of battery
relay (2) → "B" 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 all 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).

S0802230 Electrical System

Page 4
 6

4 2

BNS2840L
Figure 1

Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker

Electrical System S0802230

Page 5
ENGINE STARTING CIRCUIT
OPERATION DURING STARTING PROCESS
When the starter switch (5) is turned to the start position, then "S" and "E" terminals of the starter controller
(7) are connected. At this time, the contacts in the starter relay (8) are closed by the current flowing from
the battery (1) → fusible link (3) → fuse box (9) → "B" terminal of starter switch (5) → "C" terminal of the
starter switch (5) → "C" terminal of starter relay (8) → "D" terminal of starter relay (8) → "S" terminal of
starter controller (7) → "E" terminal of the starter controller (7) → ground.
The contact point "B" and "PP" of starter relay (8) are connected, the pinion gear of the starter (4) 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 battery relay (2) → "B" terminal of battery relay (2)
→ "B" terminal of starter (4). The starter motor is rotated and the engine is started.
If the forward or reverse travel signal is inputted to the "N" terminal of starter controller (7), the starter will
not be started. The starter is only started when the travel signal is in the neutral state.

S0802230 Electrical System

Page 6
Operation of The Starter Circuit (1) - During Start Process

7 8
From
Combination Switch
4

9 3

STARTER SWITCH CONNECTION

PST TML B BR R1 R2 C ACC
OFF
PREHEAT
ON
START

BNS2850L
Figure 2

Reference Reference
Description Description
Number Number
1 Battery 6 Alternator
2 Battery Relay 7 Starter Controller
3 Fusible Link 8 Starter Relay
4 Starter 9 Fuse Box
5 Starter Switch

Electrical System S0802230

Page 7
OPERATION AFTER START PROCESS
Once the engine has been started, the belt driven alternator (6) generates a current.
The output generated by the alternator (6) 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 (7) monitors the frequency of the output. Once the frequency equivalent to 500 rpm is
sensed the connection between "S" and "E" terminals of starter controller (7) as well as the connection
between "B" and "PP" terminals of starter relay (8) are opened.
As a result the rotation of the starter (4) is stopped.
Once the engine is running, the starter (4) will not operate even if the starter switch (5) is moved to the start
position, preventing possible damage to the starter.

S0802230 Electrical System

Page 8
Operation Of The Starting Circuit (2) - Immediately After Start

7 8
From
Combination Switch
4

9
3

STARTER SWITCH CONNECTION

PST TML B BR R1 R2 C ACC
OFF
PREHEAT
ON
START

BNS2860L
Figure 3

Reference Reference
Description Description
Number Number
1 Battery 6 Alternator
2 Battery Relay 7 Starter Controller
3 Fusible Link 8 Starter Relay
4 Starter 9 Fuse Box
5 Starter Switch

Electrical System S0802230

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 (4) is turned to the "Preheat" position, the current flows from the battery (1) →
fusible link (3) → fuse box (12) → "B" terminal of starter switch (4) → "R1" terminal of starter switch (4) →
diode (7) → "C" terminal of preheat relay (8) → "D" terminal of preheat relay (8) → ground.
The contact points of preheat relay (8) are closed. At this time, preheat timer (6) counts preheat time.
When the contact points of preheat relay (8) are closed, the heating coils of air heater, are heated by
current flowing from the battery (1) → battery relay (2) → preheat relay (8) → air heater (9) → 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.
The preheating will be continued even if the starter switch (4) is turned to the start position by current
flowing form the "R2" terminal of starter switch.

S0802230 Electrical System

Page 10
 3

12 4 12 5 2

7
10 11

1
6
8

STARTER SWITCH CONNECTION

PST TML B BR R1 R2 C ACC
OFF
PREHEAT
ON
START

BNS2870L
Figure 4

Reference Reference
Description Description
Number Number
1 Battery 7 Diode (1)
2 Battery Relay 8 Preheat Relay
3 Fusible Link 9 Air Heater
4 Starter Switch 10 Instrument Panel
5 Circuit Breaker 11 Diode (2)
6 Preheat Timer 12 Fuse Box

Electrical System S0802230

Page 11
ENGINE STOP SYSTEM
There are two modes of operation - engine running and engine stop.
When the starter switch (5) is turned to "ON" position, the current flows from battery (1) to "4" terminal of
engine stop timer (6) and "A" terminal of engine stop solenoid (8). At this time, "1" and "3" terminals of
engine stop timer (6) are closed then "B" and "PP" terminals of engine stop relay (7) are closed for about 1
second.
The contact points of engine stop relay (7) are closed. At this time, the pull coil of engine stop solenoid (8)
is energized and the system is in the running mode.
Once the engine is in running mode, the hold coil of engine stop solenoid (8) will pull the plunger of engine
stop solenoid to sustain the running mode.
When the starter switch (5) is turned to "OFF" position, the hold coil of engine stop solenoid (8) is de-
energized and the system is in the stop mode.

S0802230 Electrical System

Page 12
 6 7 8
1 D PP B PULL
4
2 C B A HOLD

3 C

9
3

2
ACC A
C
B
4 5 B BR

BR
R2
E
R1

STARTER SWITCH CONNECTION

PST TML B BR R1 R2 C ACC

OFF
PREHEAT - + 1
ON
START

BNS2830L
Figure 5

Reference Reference
Description Description
Number Number
1 Battery 6 Engine Stop Timer
2 Battery Relay 7 Engine Stop Relay
3 Fusible Link 8 Engine Stop Solenoid
4 Fuse Box 9 Diode
5 Starter Switch

Electrical System S0802230

Page 13
CHARGING SYSTEM
When the start switch (4) is turned to the "ON" position, an initial excited current flows to the field coil of the
alternator (6) through the battery relay (2) and circuit breaker (5). When the engine is started from this
condition the alternator (6) starts charging. The current flows from the "B" terminal of alternator (6) →
circuit breaker (5) → battery relay (2) →battery (1).
The alternator (6) also supplies electric current to other electrical components through fuse box (7).

7
3

5 2

STARTER SWITCH CONNECTION

PST TML B BR R1 R2 C ACC
OFF
PREHEAT
ON
START
1

BNS2880L
Figure 6

S0802230 Electrical System

Page 14
 Reference Reference
Description Description
Number Number
1 Battery 5 Circuit Breaker
2 Battery Relay 6 Alternator
3 Fusible Link 7 Fuse Box
4 Starter Switch

Electrical System S0802230

Page 15
INSTRUMENT SYSTEM

AXS0260L
Figure 7

Reference Reference
Description Description
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 Fuel Sensor 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.

S0802230 Electrical System

Page 16
INSTRUMENT PANEL

AXS0270L

Reference Reference
Description Description
Number Number
1 Coolant Temperature Gauge 6 Engine Overheat Warning
2 Fuel Gauge Light
3 Hour Meter 7 Air Cleaner Clogged
Warning Light
4 Engine Oil Pressure
Warning Light 8 Fuel Warning Light
5 Charging Warning Light 9 Preheat Completion
Indicator

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.

Electrical System S0802230

Page 17
OPERATION

Gauge

Sensor Specification
Function Display
Input Terminal Input Specification

Engine Coolant Red

CN6 50°C - Over 188.2Ω
White
Temperature
67°C - 102Ω
105°C - 32Ω
125°C - below 19.8Ω

AXO0280L

Fuel Quantity CN12 Empty - Over 90Ω

Red White
1/2 - 38Ω
Full - below 10Ω

AXO0290L

Operation Hour CN1 "I" terminal of alternator

1
10

HA0O2012

S0802230 Electrical System

Page 18
Warning Lights

Input
Function Display Operation Remarks
Terminal
CN7 Lights up when oil After starting
pressure drops below engine, if engine oil
0.5 kg/cm2. pressure is
Engine Oil insufficient after 8
Pressure seconds, a warning
buzzer will sound.
HAOA620L

CN8 Lights up when not Under normal

charging. ("L" terminal condition, it will light
output of alternator up before engine
Charging drops below 5V) start up and shut off
once engine is
running.
HAOA610L

CN11 Lights up when

coolant temperature
Engine increase over 100°C.
Coolant
Temperature

HAOD350L

CN5 Lights up when air

cleaner is clogged.

Air Cleaner

HAOA660L

CN2 Lights up when fuel

remains about 13 liter.

Fuel

AXO0300L

CN9 Lights up when

preheat process is
completed.
Preheat (Approximately 15
seconds from start)

HAOH280L

Electrical System S0802230

Page 19
CIRCUIT DIAGRAM OF INSTRUMENT PANEL

1
10

U 6
26
W/T GAUGE +
W -
25
U 12 (1) (3)
FUEL GAUGE +
F - (2)
ILLUMINATION 3

L7 L8
4
24
(2)
23
HOUR METER
H
+ (1) 21
(3) L

22 20
AIR CLEANER 5
L4 3
1
PREHEAT 9 4
L6

FUEL 2 2
L5 7
CHARGE 8 2 1
L2

3
ENG OIL PRESS
L1
7 9
19
11 4 11
WATER TEMP
L3
AMP MIC 13P 5 8 -
1
CN4
6 + 18
17
7 12
6
13 AMP MIC 13P 10

2
CN4
87a
15
30
BEAM 11 87
L2
85 86
16
9 TURN SIGNAL(L) 10 B BR E
L1

TURN SIGNAL(R) 12
L3
13
8 87a

87
30
5
TRAVEL
L4
13
14
PARKING BRAKE 1
9 85 86 A
4
L5

SPARE 2
L6
10
BRAKE OIL PRESS 3
L7
11 12 3
WORKING LAMP 4
L8
- +
AMP MIC 13P
CN4 5

BNS2810L
Figure 8

S0802230 Electrical System

Page 20
 Reference Reference
Description Description
Number Number
1 Instrument Panel 14 Travel/Work/Park Select
2 Console Box Switch
3 Battery 15 Lamp Relay
4 Battery Relay 16 Headlight Switch (II Step)
5 Fusible Link 17 Headlight Switch (I Step)
6 Circuit Breaker 18 Pilot Buzzer
7 Control Unit 19 Combination Switch (Travel)
8 Combination Switch 20 Preheat Timer
9 Pressure Switch 21 Alternator
10 Pressure Switch 22 Air Cleaner Indicator
11 Diode 23 Water Temp. Switch
12 Work Light Switch 24 Pressure Switch
13 Travel Relay 25 Fuel Sensor
26 Water Temp. Sensor

Electrical System S0802230

Page 21
CIRCUIT DIAGRAM OF CONTROL UNIT

6
10

U 6
W/T GAUGE +
W -

U 12
FUEL GAUGE +
F -

ILLUMINATION 3

L7 L8
4
11
HOUR METER (2)
H 12
+ (1)
8
(3) L

AIR CLEANER 5
L4

PREHEAT 9
L6

FUEL 2
L5 5
CHARGE 8 2 1
L2

ENG OIL PRESS

L1
7 3 9
13
11 4 11
WATER TEMP
L3
AMP MIC 13P 5 8 -
1
CN4
6 + 14
15
7 12 4
13 AMP MIC 13P 10
CN4
7
BEAM 11
L2

9 TURN SIGNAL(L) 10 B BR E
L1

TURN SIGNAL(R) 12
L3

TRAVEL 13
3
L4
9 A
PARKING BRAKE
L5
1 2
SPARE 2
L6

BRAKE OIL PRESS 3

10
L7
1
WORKING LAMP 4
L8
- +
AMP MIC 13P
CN4 5

BNS2820L
Figure 9

Reference Reference
Description Description
Number Number
1 Battery 9 Parking Pressure Switch
2 Battery Relay 10 Brake Oil Pressure Switch
3 Fusible Link 11 Engine Oil Pressure Switch
4 Circuit Breaker 12 Coolant Temperature Switch
5 Control Unit 13 Forward/reverse Travel
6 Instrument Panel Select Switch
7 Console Box 14 Pilot Buzzer
8 Alternator 15 Headlight Switch (I Step)

S0802230 Electrical System

Page 22
CONTROL UNIT

Performance Specification

No. Input Output

1 Starter switch "ON." All warning lights will turn "ON" and
pilot buzzer will sound for about 2
seconds.

2 Alternator output voltage 6.5 ±1V Below "L2" turned on (Instrument Panel)
("L" terminal)
3 6.5 ±1V Over "L2" turned off (Instrument Panel)

4 Alternator output voltage Engine oil pressure Pilot buzzer will sound after
6.5 ±1V Over state and switch: ON approximately 8 seconds.
starter switch "ON"
5 Coolant temperature Pilot buzzer will sound immediately.
switch: ON

6 Brake oil pressure

switch: ON

7 Parking pressure switch

& Forward/Reverse
travel select switch: ON

8 Starter switch: OFF Headlight switch (I step)

Electrical System S0802230

Page 23
S0802230 Electrical System
Page 24
 S0892200

1ELECTRICAL
SCHEMATIC
(SOLAR 55W-V PLUS)

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.

ELECTRICAL SCHEMATIC (SOLAR 55W-V PLUS)S0892200

MODEL SERIAL NUMBER RANGE
Solar 55W-V PLUS 1001 and Up

Copyright 2003 Daewoo

August 2003

Electrical Schematic (Solar 55W-V PLUS) S0892200

Page 1
TABLE OF CONTENTS

General Description........................................................................................ 3
Solar 55W-V PLUS......................................................................................... 4

S0892200 Electrical Schematic (Solar 55W-V PLUS)

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

Electrical Schematic (Solar 55W-V PLUS) S0892200

Page 3
SOLAR 55W-V PLUS

GAUGE PANEL FOOT/DEF

(539-00036) SWITCH 1.25LR
(549-00044)
+(132-00022) 0.85BW
10 0.85Or
OFF 1
U 6 0.85L AVX 0.85L 2
+ WATER TEMP SENDER 0.85LR 0.85BW 7 0.5P 1 TEMP.
W/T GAUGE (2547-6028 ) E
W - CONTROL DIAL
0.85RG 0.85RG 12 8 0.5Or 2 (552-00004)
L
U 12 0.85YR 0.85YR (1) (3) 0.85B FUEL SENDER +(132-00022)
FUEL GAUGE + 0.85LR 3 9 0.5BL 3
F - (547-00015 ) CW
0.85Y (2) AIR CON
0.85LW 1
CONTROLLER 10 0.85GW
ILLUMINATION 3 0.5WR DEF FOOT/DEF
0.85YG 5 (543-00042) ACTUATOR
E/G OIL PRESS SWITCH 11 0.85G FOOT
L7 L8 M

0.85LW
AVX 0.85BY 0.85B (2213-9002)

1.25LR

0.85LY

1.25LB
(124250-39450 ) 0.85YG 6
4 0.5B
4
0.85B RECEIVER DRYER
HOUR METER (2) WATER TEMP SWITCH (2204-6032 )
0.5B AVX 0.85YB 0.85B
H (121250-44901 ) E L M H 0.85YG 4 32bar 2bar
+ (1) 0.5Or
OFF 0.85YG 5

(3) 0.5RW HIGH PRESS LOW PRESS

1 0.85LW 1
CUT OFF SWITCH CUT OFF SWITCH
2 0.85LY 2
5 0.5GW INDICATOR DIODE 6
AIR CLEANER 0.85GW 0.85B
L4 (2170-1003 ) 3 0.85LB 3 AVX 0.85LW

PREHEAT 9 0.5LB BLOWER SWITCH 1.25B

L6 1.25LB + -
(549-00043) M
FUEL 2 0.5Y +(132-00022)
L5 AIR HANDLING UNIT
(920-00047) 0
CHARGE 8 0.85RB 0.85RB 2 1 0.85Or
L2

3 COMPRESSOR
ENG OIL PRESS 7 0.5BY 0.5BY 9 0.85RW
L1 (2208-6012B)

11 0.5YB 0.5YB 4 12 0.85WR WORKING LAMP RELAY

WATER TEMP
L3 (2544-9032)
AMP MIC 13P 0.5G 5 CONTROL UNIT 11 0.85BW WORKING LAMP 87a
1 0.85BW 30
CN4 (543-00080 ) (534-00029 ) 0.85LB
0.5GL 6 0.85RG 87
8 0.85BY -
PILOT BUZZER 55W 0.85B 85 86
0.85BW 7 0.85LB
0.85Y + (2516-1104)
7 0 5 0.85LR
13 AMP MIC 13P 10 1 I
CONSOLE ASS'Y CN4 9
(539-00054 ) 0.85B 10 0.85WR
0.85B
TURN SIGNAL(R) 12 0.5GR WORKING LAMP SW
L3 (2549-9115)+(2190-2036D5)
0.85LR
9 TURN SIGNAL(L) 10 0.5GL
L1
0.85B
BEAM 11 0.5R
L2 2Y
PARKING PRESS SW TRAVEL RELAY
(2549-1135D8) (2544-9032) 1.25WR
0.5G 0.85B 87a
30 0.85RY
TRAVEL 13 0.5LR 15bar 0.5LR 87 0.85B
L4 30 87a
85 86 E L M 1.25Y
PARKING BRAKE 1 0.5G 87 1.25WY
L5 0.85B OFF
2 0.85WR 0.85RY 86 85
SPARE 1
L6 BRAKE OIL PRESS SWITCH 0.85BrB 0.85B
(2549-9093) 2
BRAKE OIL PRESS 3 0.85GL 0.85GL 0.85B LAMP SWITCH LAMP RELAY
L7
(2549-1132D12) (2544-9032)
WORKING LAMP 4 0.85YR 65bar 0.85YR 0.85LR
L8

AMP MIC 13P DIODE 11

0.85BrB

CN4 5 0.85BW
0.5LB
6 0.85Or 0.85R
0.85R

0.85RW
BRAKE SELECT SW.
PILOT CUT OFF SOL. VALVE (2549-9099 ) PILOT CUT OFF SW
DIODE 10 (2549-9139) 0.85LR
0.85RG 4
NC 0.85Or
1 5 0.85YG NO
COM

0.85B DIODE 9 3 2 6
0.85WG
0.85WR
PILOT RELAY
(2544-9032) 0.5L 0.85BW
87a
30 0.85GR
PILOT CUT OFF S/V
0.85RY 87
0.85GL
(C4)
85 86 0.85WR 0.85Or 0.85R
0.85B 0.85B FRONT COMBI
FRON
LAMP (LH)
LAMP
1 2 KICK SIDE T/S LAMP (534-00098 ) (534-00
0.85RY
CN3-7

PARKING BRAKE S/V F N R (534-00030 )

BACK BUZZER STEP STEP DOWN 21W 3.4W 60/55W 60/55W
(516-00011 ) 5W
FORWARD RELAY 15(49a)
(C10)
0.85B (2544-9032) 0.85LR CN3-1
15(53a)
87a
30 CN3-4
0.85RY 0.85B 53b D E C A B B A
87 0.85GL

0.85Or
FOWARD SOLENOID 0.85BY

0.85GW

0.85GW
53

0.85R

0.85R
86 OPTION

0.85GL
85 0.85YB

0.85B
0.85YB CN3-2
(C6) F ARM LAMP

(clearanc)
0.85B 0.85LR (534-00055A)
0.85B CN3-3
R

(high)

(high)
87a
(turn sig)
0.85YB

(low)

(low)
0.85LR

30 CN3-8
0.85RY KD 5W
0.85Lg 87
REVERSE SOLENOID T/M SELECT SWITCH (RH)
0.85Or
DIODE 7

DIODE 8

85 86 (2549-9118 )2/2
(C7) 0.85LR 0.85LR
0.85B
0.85B 0.85BW
REVERSE RELAY 2-WAY RELAY (1)
(2544-9032) (2544-9032)
RAM LOCK S/V 0.85G
87a
30
(C8) 0.85LR 0.85LR
0.85RY 0.85BrW 87
0.85B 0.85G
85 86
RAM LOCK SW. 0.85Lg 5 2 0.85LR
(2549-9096)
(R)

0.85LR
PILOT SUPPLY VALVE
0.85OrR
0.85BrW 0.85G

0.85GR
ROTATING BEACON (OPTION)
0.85LR

6 3 0.85LR
0.85GL

0.85Or

87a
0.85G

30 0.85G
(C)
5 0 7
0.85BrL 0.85BrL 87 4 1 0.85LR 0.85LR

(back up)
(turn sig)
(clearanc)
(turn sig)

1 0.85R
(clearanc)

(L) I
(back up)

86
0.85WR

85
(stop)

(stop)

0.85RY 0.85WR 9 10 0.5B

JOYSTICK LEVER SWITCH 0.85B
(ON JOYSTICK R.H)
0.85B 0.85B ROTATING C D A B B A D C
2-WAY RELAY (2) ROTATING BEACON 0.85B
(2544-9032) BEACON SWITCH 0.85B
(2RL006846-001)
(2549-9115)
HELLA
2-WAY SOL. VALVE +(2190-2036D10)
21W 21W 21/5W 5W 5/21W 21W 2
REAR COMB. LAMP(L) LICENCE LAMP REAR COMB. L
7 0 5 (2534-1174B) (2534-1176B) (2534-1175B)
0.85LR
0.85LB 1 I
9 0.85WR 0.85WR
10
0.85B BOOM SWING SOL. VALVE
0.85B
QUICK CLAMP SWITCH 0.85GW
(549-00027)+(2190-2584D19)
TERMINAL NO LAMP NO. 87a
QUICK CLAMP (OPTION) FOR GAUGE PANEL 30
AMP 9PR 1-480672-0 87 (1) 0.85B
AMP MIC 13P AMP 9PT 1-480673
6 5 4 3 2 1 L1 WATER 0.85B
TEMP 85 86 0.85GW
L2 0.85GW
3 2 1 1 2 3

5 5
L3 FUEL
6 4 4 6
L4
9 8 7 7 8 9 HOUR
13 12 11 10 9 8 7 L5 METER BOOM SWING RELAY 0.85B
(CN4) (CN1) (2)
(CN2) (CN3) L6 (2544-9032)

Figure 2

S0892200 Electrical Schematic (Solar 55W-V PLUS)

Page 4
 RESISTOR
(545-00007)
1.25LR 1.25LB 0.85WL (1) 0.85WG

0.85BW (2) 0.85WG

(3) 0.85W (4)

7 0.5P 1 TEMP.
M
CONTROL DIAL 0.85B
8 0.5Or 2 (552-00004) HEATER
+(132-00022) E L M H (920-00119) SPEAKER
9 0.5BL 3 (2541-9020)*2 (LH) (RH)
CON CW OFF ANTENNA E/G STOP
OLLER 10 0.85GW 1 E/G STOP TIMER E/G STOP RELAY SOLENOID
DEF FOOT/DEF (1119233-77932)
042) 0.85WR 3 (129211-77920) (2544-1023 )
ACTUATOR 2
11 0.85G FOOT - + - + PULL
0.85RG 5 18 0.85BY 1 0.85Y D PP 5RW 5RW B
M (2213-9002) 3
CAR
4 HEATER BLOWER SWITCH 0.85LB 4 8 0.85LR 4
0.85GrR
0.85B RECEIVER DRYER STEREO
(549-00043) 2 0.85RW C B 5RL 0.85LR A HOLD
1.25LR
(2204-6032 ) 0.85B 11 (541-00014) 9 0.85BW
+(132-00022)
32bar 2bar 14 1 0.85GrL 3 C
FUEL PUMP (OPTION) 0.85LR
(2401-1276A)
HIGH PRESS LOW PRESS 5RL 2B
CUT OFF SWITCH CUT OFF SWITCH DIODE 12
CIGAR LIGHTER 0.85LR
2B - + 2RG CLOCK
DIODE 6 P (545-00002)
(528-00039)
AVX 0.85LW
STARTER
- 1.25B CONTROLLER STARTER RELAY
0.85WR
M 4 2 3 1 (2523-9005 ) (2544-1023 )
1.25B
N S D PP 5Y

0.5WR
NG UNIT

0.5RG
0.85BW 0.85Br AVX 5Y

0.5RY
0.5B
ROOM LAMP
47) 0.85B
(534-00051 )

1.25RY
0.85R C B 5W
COMPRESSOR 10W

DIODE 1
0.85B E B 0.85RG
(2208-6012B) 0.85B E B P

0.85WG
0.85LR
WORKING LAMP RELAY
(2544-9032)
87a
30
0.85LB
87 C

86 B
85 0.85LB 0.85LR

5 0.85LR

0.85LR
9

0.85R
0.85WR
ACC
P SW
C A
6D5) BR
0.85WR B 0.85Br
STARTER
(129900-77010 )
0.85BG R2 12V 2.3kW
2Y R1

5WR

0.85BW
0.85YR

0.85LR

1.25LR

1.25LB
1.25RY
0.85Or

0.85R

1.25L

85RY DIODE 2

30 87a 1 2 3 4 5 6 7 8
1.25Y
87 AIR HEATER

DIODE 3
1.25WY 10A 10A 10A 10A 15A 15A 15A 15A 0.85BG C PP 5W
5W (129915-77050 )
0.85RY 86 85 FUSE BOX
15 16
1.25RL
0.85B (570-00001) 0.85B D B 5L AVX 5L
2RL
LAMP RELAY PREHEAT RELAY
2Y
1.25WR

1.25WY
0.85YR

1.25WR
0.85R

0.85LR

1.25L
0.85Or

(2544-9032) 30R
(2544-1023 )
17 18 19 20 0.5G
20A 15A 10A 30A 10A 10A 5RL 5R

9 10 11 12 13 14
0.5LB FUSIBLE LINK
2RG

(2527-1023A)
2Y

0.85OrR
0.85W

1.25WR

0.85R
0.85Or

0.85RW 8W 8WR 8WR A

B
0.85LR
CIRCUIT BREAKER 0.85Br
0.85Or (2527-9004)
0.85W BR

1.25WR E
0.85B
0.85Or 0.85Or 1 PREHEAT 3 0.85BW BATTERY RELAY
0.5LB 0.5LB 4 TIMER (2544-9025) 30R
(537-00010)
0.85RW 2
0.85B 30B
AVX 1.25WG

FRONT COMBI
FRONT COMBI - +
LAMP (LH) SIDE T/S
LAMP (RH) 12V 100AH
S LAMP (534-00098 ) 0.85W AVX 8W
(534-00099 ) LAMP
30 ) (534-00030 ) B BATTERY
21W 3.4W 60/55W 60/55W 3.4W 21W
1 (2506-1104)
AVX 1.25WG

5W 5W
5
AVX 0.85W

0.85GY L
AVX 2RW
0.85WR

7 BLINK UNIT
0.85RL
0.85RL

(2525-1012)
0.85GY

2
D E C A B B A C E D 6 E
0.85B
0.85WR

8
0.85GL 0.85GR
0.85Or

0.85OrR

IG L P B(BATT)
0.85GW

0.85GW
0.85R

0.85R

OPTION OPTION 0.85B 10 9

0.85GR
0.85GL

0.85B

0.85B

AMP ARM LAMP

DIODE 5

DIODE 4
(clearanc)

55A) (534-00055A)
1.25WY

HAZARD SWITCH
(clearanc)

1.25Y
(high)

(high)
(turn sig)

(turn sig)

(549-00007 )
(low)

(low)

5W 5W SW TURN SIGNAL HEAD LAMP

+(2190-2036D2) IG
0.85GR

N
0.85GL

TML
0.85Or 0.85OrR 0.85GY CN1-8
49a
0.85GR 0.85GR CN1-4 R
L
0.85GL 0.85GL CN1-1
L
1.25WY CN1-5 F
56 E
0.85GW 0.85GW CN1-6
56b
0.85R 0.85R CN1-7 E
56a ALTERNATOR
0.85LR 0.85LR 1.25Y CN1-9 AVX 8B
3bar 15/1
0.85G 0.85G 0.85YR 0.85L CN2-6
15(53a)
0.85G CN1-2
H
STOP LAMP SWITCH HORN RELAY
0.85LR

0.85LB CN2-8
(549-00010 ) (2544-9032) 53c
0.85OrR

0.85GR
0.85LR

0.85GL

CN2-7
0.85Or

0.85LR
0.85G

0.85G

87a J
30 0.85WR CN2-3
0.85L 53b
0.85GR 87 CN2-1
(back up)
(turn sig)
(clearanc)

53
(turn sig)

(clearanc)

HORN
(back up)

0.85B NOTE
0.85WR
(stop)

(stop)

(516-00021) 85 86 0.85G 31b

1. DIODE PART NO : 2548 - 1027
TML J 0 I II OFF ON OFF ON
C D A B B A D C 0.85B
0.85B SW WIPER WASHER HORN
0.85B 0.85B COMBINATION SWITCH (LH) STARTER SWITCH CONNECTION
0.85WR
0.85LR
0.85LB

(2549-9118 )1/2
21W 21W 21/5W 5W 5/21W 21W 21W PST TML B BR R1 R2 C ACC
REAR COMB. LAMP(L) LICENCE LAMP REAR COMB. LAMP(R) 0.85G
OFF
(2534-1174B) (2534-1176B) (2534-1175B)
0.85L PREHEAT
WINDOW WASHER
I
0.85Y (2916-9002A) ON
WIPER TIMER
BOOM SWING SOL. VALVE II (537-00070 ) 0.85LB + - START
I II
S 0.85LW 4
P
1 0.85L
0.85GW 0.85LB 0.85B
M STOP 5 2 0.85LR
- RUN B DIODE 13
30 E 6 3 0.85WR
(1) 0.85B 0.85B 0.85B

86 0.85GW WIPER MOTOR A 0.85WG 3 1 0.85B

0.85GW (538-00006) 0.85GW B
(L)
4 2 0.85B
(R)
ELAY (2)
0.85B
(ON JOYSTICK L.H)
JOYSTICK LEVER SWITCH

Solar 55W-V Plus

BNS3071L

Electrical Schematic (Solar 55W-V PLUS) S0892200

Page 5
S0892200 Electrical Schematic (Solar 55W-V PLUS)
Page 6
1ATTACHMENTS
 S0904000
R4

1BUCKET

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.

BUCKET S0904000
MODEL SERIAL NUMBER RANGE
Solar 015 0001 and Up
Solar 015 PLUS 1001 and Up
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 170LC-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 210W-V 1001 and Up
Solar 220LC-V 0001 and Up
Solar 225NLC-V 1001 and Up
Solar 250LC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 290LC-V 0001 and Up
Solar 330LC-V 1001 and Up
Solar 400LC-V 1001 and Up
Solar 450LC-V 1001 and Up

Models continued on back of cover.

Copyright 2003 Daewoo

August 2003

Bucket S0904000
Page 1
 MODEL SERIAL NUMBER RANGE
Solar 55 0001 and Up
Solar 55-V PLUS 1001 and Up
Solar 55W-V PLUS 1001 and Up
Solar 75-V 1001 and Up

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.
3. Once the worn tooth has been removed,
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.
3. Once the worn tooth has been removed,
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 O- 1
2
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 N•m / 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 pre-
assembled 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.
Pre-lube 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
S0904000 Bucket
Page 14
 1PUBLICATION REQUEST FOR
PROPOSED REVISION
In Daewoo’s continuing effort to provide the best customer satisfaction, we invite you to help us improve the
manuals that you work with on a daily basis. This form is provided to give you a means of feedback to the
publication department.

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