Solar 030 Plus / 035
Solar 030 Plus / 035
Solar 030 Plus / 035
Shop Manual
023-00046E
Serial Number 101 and Up
Serial Number 20001 and Up
Yanmar 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.
• This manual has been prepared to inform you about the operation and maintenance of your
new excavator. You are urged to read this manual carefully and to follow the instructions,
safety rules and relevant laws and regulations before operating the excavator.
• For Solar 030 PLUS and 035 engines, please see the Operator's and Maintenance Manual
for Isuzu Diesel Engines (SOLAR 035 : 3LD1, SOLAR 030 PLUS : 3LD1)
• Do not operate, inspect or service the excavator until you are thoroughly familiar with its'
design and controls. This manual must be left in the cab so that it is always available to
others.
• If you have any questions concerning the excavator, please supply the MODEL NO and
SERIAL (PI)NO. These numbers are stamped on a name plate, which is attached to the
front part of the main frame.
The information, specifications and illustrations included in this manual are based on the
information available at the time it was published. Daewoo reserves the right to make
improvements and changes in specifications or design without prior notice and without
incurring obligation. Please check with your authorized Daewoo dealer for information on
possible updates or revisions.
• The safety symbols and other safety information contained in this manual and on the
excavator can not cover every possible dangerous situation that may result from operation,
inspection and maintenance of this excavator. In addition, operation, inspection or
maintenance of the machine, in a manner not specified in this manual, could be dangerous
and is the sole responsibility of the operator or technician.
August. 2001
TABLE OF CONTENTS
1. SAFETY ...................................................................................................................... 1
1.1. Safety Information 1.3. Safe Operation
1.2. Safety Messages 1.4 Locatoion of Safety Labels
4. ENGINE ..................................................................................................................... 47
4.1. Engine Specifications 4.3. Emgine Number Location
4.2. Engine Performance Curve 4.4. Engine RPM Standards
1. SAFETY
1.1. SAFETY INFORMATION
1) Safety Information Location
Basic safety information and rules are compiled in this section (Section 1) of the manual. Throughout
the rest of the manual, safety information is identified by three levels of hazard: DANGER, WARNING,
and CAUTION. These hazard levels are explained below, under "1.2 SAFETY MESSAGES". Safety
information is also included on safety labels on the machine. Read and understand all safety
precautions both in the manual and on the machine.
CAUTION : This message identifies a hazard that is not likely to cause personal injury but may
cause property loss or result in machine damage if the machine is handled
improperly or proper precautions are not taken.
IMPORTANT : This message is used when the machine may be damaged or its service life
may be shortened if the machine is handled improperly.
–1–
1. SAFETY
1) General precautions
Carefully read and understand the safety
symbols and messages placed in this manual
and on the machine.
• Keep safety labels clean at all times.
• If safety labels are damaged or lost, order
new ones from your Daewoo dealer.
• Make sure all operators are qualified , as
required by law.
• Keep correct operating techniques in
mind at all times.
• Operate the machine in a normal manner
at all times.
• Do not modify your machine without
permission from the manufacturer:
Unauthorized modifications can cause
injury, machine malfunctions or reduction
in machine service life.
• This Safety Section explains basic safety
rules. Use extreme caution whenever
operating, inspecting or servicing this
machine, whether a specific potential
hazard is mentioned or not.
2) Per-operation inspection
• Check for damage and problems that
require maintenance before operation.
Always repair defective equipment before
operation. Failure to inspect and repair
the machine may result in failure of major
components or systems such as the
hydraulic system.
–2–
1.3. SAFE OPERATION
4) Adjust seat
If the driver's seat is not adjusted correctly,
the operator may become easily fatigued and
injury and/or damage could result.
• Be sure to adjust the driver's seat at the
beginning of each work period.
• Adjust driver's seat so that the operator
can easily reach the pedals while his
back is firmly against the lumbar support
of the seat.
–3–
1. SAFETY
8) Travel Precautions
Always check for hazards when traveling the
machine. Avoid traveling on slopes
• Always keep a firm grip on control levers
and keep the travel route in mind at all
times.
• Raise bucket when encountering small
obstacles.
• Keep bucket 20-30 cm (8-12") off ground
when driving on slopes. A
• Do not operate on grades in excess of
those specified by the manufacturer.
• If machine slips, lower bucket to ground
and stop immediately.
• When traveling on level ground, bring
front attachment in and raise bucket 40-
50 cm (15-20") with teeth facing up.
–4–
1.3. SAFE OPERATION
Non-slip
support
–5–
1. SAFETY
–6–
1.3. SAFE OPERATION
15) Tip-over
Use care to avoid tip-over when operating on
a slope or when handling a heavy load.
• Lower bucket and pull it back in toward
machine when operating on an incline.
• Line up tracks in the direction of the
incline to reduce the chance of tip- over or
serious injury.
• Slow down, when swinging the bucket, to
reduce danger of tip-over.
–7–
1. SAFETY
6.6 3(10)
33.0 4(13)
66.0 5(17)
154.0 8(27)
275.0 10(33)
–8–
1.3. SAFE OPERATION
–9–
1. SAFETY
– 10 –
1.3. SAFE OPERATION
– 11 –
1. SAFETY
– 12 –
1.3. SAFE OPERATION
– 13 –
1. SAFETY
– 14 –
1.3. SAFE OPERATION
– 15 –
1. SAFETY
– 16 –
1.3. SAFE OPERATION
– 17 –
1. SAFETY
6
5
(CABIN TYPE)
AHI0041L
Always keep these labels clean. If they are lost or damaged, replace them with a new label. It is the
responsibility of the equipment owner and crew to provide essential safety information in the immediate
vicinity of hazards.
Safety labels may be available in languages other than English, or labels providing a warning for other
hazards than those that follow may be available. Contact your Daewoo distributor to find out what labels are
available.
– 18 –
1.4. LOCATION OF SAFETY LABELS
1. WARNING FOR OPERATION, INSPECTION AND MAINTENANCE (2190 - 2627, 190 - 00092)
CAUTION!
• Read manual and labels before
operation and maintenance. Follow
instructions and warnings in manual
and on labels on the machine.
• Never get in under the machine while
it is being jacked up with boom and
arm.
• Sound the horn to alert the people
nearby before operating, and make
sure all persons are clear of area.
ACO1360L
• Always make sure when leaving
operator's seat to:
- Lower bucket or other working tools to the ground.
- Turn key switch OFF. Remove key from switch.
- If hydraulic components and units are ABNORMAL, consult nearst DEAWOO dealer or
authorized service shop. Do not attempt to make an overhaul.
CAUTION!
Don’t touch when performing inspection or
maintenance.
ACO1450L
– 19 –
1. SAFETY
WARNING!
• Battery fumes can explode. Keep
sparks and flames away from
batteries.
• Always avoid storing metals like tools
or inflammable materials around or
on the batteries.
explosion or fire can be caused by
short circuiting batteries.
• Sulfuric acid in battery is poisonous.
It is strong enough to burn skin, eat
holes in clothing, and cause
blindness if splashed in eyes.
• If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to ACO1400L
help neutralize the acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
4. WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (2190 - 2529, 190 - 00097)
CAUTION!
HYDRAULIC OIL
To prevent hot oil from spurting out:
• Turn engine “OFF”.
• Allow oil to cool.
• Slowly loosen cap to relieve pressure
before removing.
ACO1410L
– 20 –
1.4. LOCATION OF SAFETY LABELS
CAUTION!
Before opening bonnet, stop engine.
ACO1420L
CAUTION!
KEEP OFF OF SWING AREA
ACO1430L
– 21 –
1. SAFETY
CAUTION!
When raising window, lock it in place with
lock pins on both sides.
Falling window can cause injury.
ACO1360L
– 22 –
2.1. EXCAVATOR MAJOR COMPONENTS
2. GENERAL INFORMATION
2.1 EXCAVATOR MAJOR COMPONENTS
26
ANO0010L
- 23 -
2. GENERAL INFORMATION
90
(80
)
(465)510
(585)650
50
(2450)2460
(280)290
350
G.L.
(1440)1650
300 (1350)1400 (3045)3610 (1150)1200
- 24 -
2.2 EXCAVATOR EXTERNAL VIEWS AND OPERATING SPACE
80
(465)510
(585)640
50
(2330)2340
350
280
G.L.
300 (1440)1650
(1470)1500
(1350)1400 (3045)3610 (1150)1200
(4395)5010 (1470)1525
- 25 -
2. GENERAL INFORMATION
(1370)1585 (1350)1400
(4200)4950
(2865)3465
(330)365
G.L.
(330)325
(1665)2300
(2590)3125
(4460)5120
- 26 -
2.3. SPECIFICATIONS
2.3. SPECIFICATIONS
Roof
Steel shoe 2,780kg 3,184kg
Overall
height 2,330mm 2,340mm
Cabin
Width x height 1,470 x 350mm 1,525 x 340mm
Blade Amount of movement upper: 330, lower: 330 upper: 365, lower: 325
- 27 -
2. GENERAL INFORMATION
Rubber shoe
Roof
Steel shoe 0.30kg/cm2 0.30kg/cm2
Travel system
P1 P2 P3 P4 P1 P2 P3 P4
Main pressure(kg/m2)
200 200 165 30 200 200 175 30
Capa. of coolant 7L 7L
- 28 -
2.4 WEIGHTS OF MAJOR ATTACHMENTS AND COMPONENTS
Weight Weight
Part Name Part Name
SOLAR 030 Plus SOLAR 035 SOLAR 030 Plus SOLAR 035
Boom 105 178 Idler 19 x 2 19 x 2
Arm 58 74 Idler yoke 4 4
Bucket 43 85 Track cylinder 18 x 2 18 x 2
Dump linkage 11 21 Lower roller 7x6 7x8
Bucket linkage 3.1 x 2 3.6 x 2 Sprocket 9x2 7.6 x 2
Boom joint pin 2.0 3.0 Swing motor 23 31
Arm joint pin 1.0 2.3 Travel motor 36 x 2 44 x 2
Bucket pin 1.7 2.2 Joy stick 4x2 4x2
Swing bracket 71 87 Seat box 17 17
Swing boss pin 3.4 x 2 6.7 x 2 Seat 10 10
Swing frame 328 410 Stand(left) 5.6 5.6
Hydraulic oil tank 41 43 Stand(right) 5.6 5.6
Fuel tank 24 24 Engine 139 141
Engine hood(A) 54 54 Radiator 10.2 10.2
Engine hood(B) 16 16 Storage battery 20 20
Counterweight 160 200 Battery cover 1.9 1.9
Cabin 172 172 Floor plate 5.4 5.4
Boom cylinder 24 28 Center joint 21 23
Arm cylinder 22 30 Control valve 24 24
Bucket cylinder 17 21 Solenoid valve 7 7
Swing cylinder 18 27 Oil cooler 3.0 3.0
Blade cylinder 17 20 Tank cover 1.3 1.3
Swing bearing 39 4.2 Roof 13 13
Track frame 286 333 Roof post 12 x 2 12 x 2
Blade 126 158 Roof bracket 2 2
Steel crawler 135 x 2 150 x 2 Handle(A) 4 4
Rubber crawler 118 x 2 130 x 2 Handle(B) 4 4
- 29 -
2. GENERAL INFORMATION
Manufacture Number(impressioned)
Type
Serial No.
- 30 -
N 2.6. GREASE SUPPLY POINTS AND LOCATIONS
Boom cylinder
rod pin
Bucket cylinder
Arch
rod pin
Bucket pin
Swing bearing
Swing gear
Lower roller
- 31 -
2. GENERAL INFORMATION
CAUTION: It is recommended to continuously use the same brand oils when replenishing or changing.
• To prevent freezing of the cooling system in extremely cold places, be sure to add a specified amount of
antifreeze to coolant.
- 32 -
2.8. INSPECTION AND MAINTENANCE
Service intervals(hours)
Check points
7 hours 50 hours 100 hours 250 hours 500 hours 1,000hours
Check & First oil Clean
Engine oil pan Change oil
Replenish change
Check &
Air cleaner element Clean Replace
First Replace
Hydraulic oil suction filter replacement
Check & Replace
Swivel bearing (grease) Grease
Check &
Crawler tension adjustment Adjust
Check &
Bolt looseness Correct
First Change
Reduction gear oil change
Leaks Check
- 33 -
2. GENERAL INFORMATION
Add if required.
Hydraulic oil tank Check oil level.
(Be careful of position of the machine.)
Fan belt Check and adjust. A firm push with the thumb at a point midway
between the two pulleys should depress the belt
10~12mm.
- 34 -
2.8. INSPECTION AND MAINTENANCE
Drain out foreign Drain the coolant through the drain plug located at
Coolant matters and sediment. the bottom.
Radiator Clean the core. Dirts sticking to the core causes poor cooling efficiency
Swing bearing Check and grease. Always grease after underwater operation.
Storage battery Keep clean each part, and apply grease to terminal
Clean
area.
Hydraulic oil return filter Replace cartridge. First replacement. Every 500 hours thereafter.
Hydraulic oil suction filter Clean the element. First cleaning. Every 500 hours thereafter.
Drain out foreign matters Drain the coolant through the drain plug located at
Hydraulic oil tank
and condensates. the bottom.
Reduction gear
Change lubricating oil. First change. Every 1,000 hours thereafter.
lubricating oil
- 35 -
2. GENERAL INFORMATION
Intake/Exhaust valve
Check clearance. First check. Every 500 hours thereafter.
clearance
- 36 -
2.8. INSPECTION AND MAINTENANCE
Types of bolts
and nuts 4T 7T 9T
Nominal
SS41 S40C, S45C SCr4
designation
NOTE: Torque represents the force required to tighten a bolt, e.g., if you grip a 1m long spanner and turn
its handle with a force of 12kg, you will obtain 12kg• m(1m x 12kg). To produce a torque of 12kg• m
using a 25cm long spanner, a force of 48kg is necessary as follows:
- 37 -
2. GENERAL INFORMATION
- 38 -
• SOLAR 035
B A B A
B A
P1 P3
- 39 -
S/RIGHT S/LEFT A/DUMP A/CWD BKT/CWD BKT/DUM BOOM/DN BOOM/UP
P LEFT T P RIGHT T
MENGINE
24M.5Ps / 2,000rpm
2.9. HYDRAULIC LINE DIAGRAM
3. WORKING ATTACHMENTS
3. WORKING ATTACHMENTS
3.1. MAINTENANCE STANDARDS
3.1.1. Working attachments
ANS0020L
- 40 -
3.1. MAINTENANCE STANDARDS
a
b
a
b
B
A
a
b
b
C a
D
4. Boom joint
a
b
H
G
I
a a a
b b b
L M N
J K
9. Boom/Arm joint 10. Bucket cylinder head 11. Bucket cylinder rod
- 41 -
3. WORKING ATTACHMENTS
a a
a
b b
b
P O Q R S
12. Bucket/Dump linkages joint 13. Arm/Bucket linkages joint 14. Arm/Bucket rod
a a a
b b b
T U V
15. Dozer joint 16. Dozer cylinder rod 17. Dozer cylinder head
- 42 -
3.1. MAINTENANCE STANDARDS
B Swing cylinder rod pin Ø35 1.0 M Bucket cylinder rod pin and dump linkage Ø35 1.0
C Swing post pin and bush Ø60 1.0 N Bucket cylinder rod pin and bucket linkage Ø35 1.0
D Boom joint pin and bush Ø40 1.0 O Bucket pin and bush Ø35 1.0
E Boom joint pin and swing post Ø40 1.0 P Bucket linkage pin and dump linkage Ø35 1.0
F Boom cylinder head pin and swing post Ø40 1.0 Q Bucket linkage pin and bush Ø35 1.0
G Boom cylinder rod pin and boom Ø40 1.0 R Bucket linkage pin and bucket linkage Ø35 1.0
H Arm cylinder head pin and boom Ø35 1.0 S Dozer joint pin and frame Ø35 1.0
I Arm cylinder head pin and arm Ø35 1.0 T Dozer joint pin and dozer Ø35 1.0
J Boom/Arm joint pin and bush Ø35 1.0 U Dozer cylinder rod pin and frame Ø35 1.0
K Boom/Arm joint pin and boom Ø35 1.0 V Dozer cylinder head pin and dozer Ø35 1.0
Criteria
Portion Parts
a b Basic clearance
1 Swing cylinder head and head bracket 50 53 2.0~3.5
- 43 -
3. WORKING ATTACHMENTS
B Swing cylinder rod pin Ø35 1.0 M Bucket cylinder rod pin and dump linkage Ø35 1.0
C Swing post pin and bush Ø60 1.0 N Bucket cylinder rod pin and bucket linkage Ø35 1.0
D Boom joint pin and bush Ø40 1.0 O Bucket pin and bush Ø40 1.0
E Boom joint pin and swing post Ø40 1.0 P Bucket linkage pin and dump linkage Ø40 1.0
F Boom cylinder head pin and swing post Ø40 1.0 Q Bucket linkage pin and bush Ø35 1.0
G Boom cylinder rod pin and boom Ø40 1.0 R Bucket linkage pin and bucket linkage Ø35 1.0
H Arm cylinder head pin and boom Ø35 1.0 S Dozer joint pin and frame Ø35 1.0
I Arm cylinder head pin and arm Ø35 1.0 T Dozer joint pin and dozer Ø35 1.0
J Boom/Arm joint pin and bush Ø40 1.0 U Dozer cylinder rod pin and frame Ø40 1.0
K Boom/Arm joint pin and boom Ø40 1.0 V Dozer cylinder head pin and dozer Ø40 1.0
Criteria
Portion Parts
a b Basic clearance
1 Swing cylinder head and head bracket 50 53 2.0~3.5
- 44 -
3.2. INSPECTION AND CORRECTION
• Basic value
Arm cylinder
Bucket cylinder
Boom joint portion Dozer cylinder
Boom cylinder
- 45 -
3. WORKING ATTACHMENTS
Basic value
Item Measuring conditions Unit
Solar 030 Plus Solar 035
Boom
Arm
Bucket
Dozer
Boom
swing
- 46 -
4.1. NE SPECIFICATION
4. ENGINE
4.1. ENGINE SPECIFICATIONS
Specifications
Item Unit
SOLAR 030 Plus / 035
- 47 -
4. ENGINE
93.2N·m (9.5kgf·m)/1700min-1(rpm)
10
Torque
Power N·m(kgf·m)
9
30 7
18kW(24.5PS)/1950min-1(rpm)
Power
Power kW(PS)
20
10 220
Fuel consumption
Fuel consumption gr/kw·h (gr/ps·h)
200
180
265gr/kw·h (196gr/ps·h)
160
2100±50min-1(rpm)
RPM(min-1)
- 48 -
4. ENGINE
Engine number
Engine type
Engine rpm
Conditions
SOLAR 030 Plus / 035
Maximum rpm at no-load 2100±50 rpm
At P1 relief 2050±50 rpm
At P2 relief 2050±50 rpm
- 49 -
5. MAIN PUMP
5. MAIN PUMP
5.1. EXTERNAL VIEWS
• SOLAR 030 Plus
Piston pump
Pump type
P1, P2 P3 P4
- 50 -
5.1. EXTERNAL VIEWS
413
45 368
Oil feed port (PF1/2) Outlet port
P2 P2
109.5 PF1/2
101.6
101.5
Outlet port
P4 P4
PF1/2
Outlet portP1
P1
146 161 Outlet port
P3 P3
172 PF1/2
263.5 PF1/2
342
21.8
M10Thread
M10 depth 23.5
11.5
24
37
Inlet port S3
PF3/4 141
263.5
S1
SAF.T5185- 1/4
Piston pump
Pump type
P1, P2 P3 P4
- 51 -
5. MAIN PUMP
5.2. CONSTRUCTION
- 52 -
5.2. CONSTRUCTION
• SOLAR 035
1, 23
6 14 30 19 35 36
11
29
5
25
2 22
20
21
26 17 18 32 24 13 28 4 3 15 27 16 33 34
- 53 -
5. MAIN PUMP
5
8
6
4
3
2
1
- 54 -
5.4. HYDRAULIC PUMP PERFORMANCE TEST
Flow(l/min.) 7~200(l/min.)
Pressure(kg/cm2) 0~350(kg/cm2)
Tester
Temperature(0°C) 0~150(°C)
Port size PF 1, O-ring type
Pressure gauge, 500kg/cm2, 50kg/cm2
Tachometer Diesel engine tachometer
Test hose Rated pressure: 210kg/cm2 or equivalent
• Preparation
- Park the machine on a level ground and stop the engine.
- Operate the left/right attachment control levers and left/right direction control levers to release the
pressure remaining in the lines.
Pressure gauge
Test hose
Outlet port Throttle valve
Inlet port
Close
Open
Test hose
P1
P2
P3
- 55 -
5. MAIN PUMP
P3=165 P3=25
Flow(Q) ; (L/min)
• SOLAR 035
20
19
P3=25(kgf/cm2)
Quantity of delivery q1+q2(cc/rev)
15
10
P3=175(kgf/cm2)
5.7
5
0
0 85 100 190 200 300 330 400
Discharge pressure P1+P2(kgf/cm2)
- 56 -
6.1. PIPING DIAGRAM
Return filter
Hydraulic
oil tank
A
B
C
Suction filter
B
A
ANS0050L
- 57 -
6. HYDRAULIC OIL FILTER
2-PT 11/4
- 58 -
6.2. HYDRAULIC OIL FILTER
37
3.5 6.5 +0.25
3
-0 9 15 Quantity of flow 6 L/min
12
Rated pressure 40 kg/cm2
C0.5
Filtering ability 40 µ
Filtering area 0.332 cm2
30 o +0.5 ∅12.5±0.2
∅11.2
∅5.5
Oil temperature -20°C~120°C
0
12-
S
PF 1/4
PF 3/8
PRESSURE
LOSS.
∆P
(kg/cm2 )
FLOW Q (l/min)
ANS0060L
- 59 -
6. HYDRAULIC OIL FILTER
WARNING • Always allow the hydraulic oil to cool Oil port cap
down enough before replacing the
filters, as at the operating
temperature, the hydraulic oil is at
high temperature and may cause
personal injury.
• Loosen the hydraulic oil port cap
tightening bolt slowly to release the air
from the tank.
1
6.3.2. Pilot line filter replacement
1. Remove the floor plate.
2. Unscrew the plug 1 with a spanner(27mm) to remove
the element.
3. Clean the element thoroughly and remove dust and
dirt, then install the plug 1.
- 60 -
6.3. MAINTENANCE PROCEDURE
11. Fit the oil port cap in place. In doing so, clean the top
side of the flange and O-ring groove thoroughly to 2
prevent oil leaks, and coat a sufficient amount of
grease on the O-ring groove to secure the O-ring in
place.
12. Bleed out air from the hydraulic lines.
• Rotate the engine at low speed.
• Operate each cylinder 4~5 times up to 5mm before
end stroke.
• Operate each cylinder 3~4 times up to end stroke.
- 61 -
6. HYDRAULIC OIL FILTER
- 62 -
7.1. SPECIFICATIONS
7. CONTROL VALVE
7.1. SPECIFICATIONS
A9 B9 A8 B8 B7 B6 A5 B5 A4 B4 A3 B3 A2 B2A1 A2
L3 A6 R4 R3 L2
A7
P1 P3
T1 T2
L1 R2 R1 L4
P2
PTO
A9 A8 A6 A5 A4 A3 A2 A1
T1 T2
A7 P2
P1 B7 P3
B9 B8 B6 B5 B4 B3 B2 B1
- 63 -
7. CONTROL VALVE
30
13 33
18
27 15
16 20
15 19
12
28
29 15
16
15 15
11 16
15
15 14
30 16
15 21
31
22
23
9
18
20 15
19 16
15
15 8 24
16
15 15 26
25
16
15
10 7
21
15 23
16 22
15
6
21 5
22 15
23
16
15
3
21
15 23
16 22
2 15
15
16 15
15 17
15
18
20
30 19
32
33
1. Control valve 9. Boom block 18. Main relief valve 27. Suction check valve
assembly 10. Pump block (P2) 19. O-ring 28. O-ring
2. Pump block (P1) 11. Swing block 20. O-ring 29. O-ring
3. Travel block(LH) 12. Dozer block 21. Conflex valve block 30. Plug
4. Spare block 13. Swing block 22. O-ring 31. Plug
5. Arm block 14. Pump block (P3) 23. O-ring 32. Tie rod
6. P.T.O. block 15. O-ring 24. Port relief valve 33. Nut
7. Travel block(RH) 16. O-ring 25. O-ring
8. Bucket block 17. O-ring 26. O-ring
- 64 -
7.1. SPECIFICATIONS
Drive
9
1 9
10
10
2
3 11
4 Swing, Dozer
12
4
3
23
16
18,17 Arm
19
16
20
15 13
14
- 65 -
7. CONTROL VALVE
7.2. CONSTRUCTION
7.2.1. Arrangement
B9 A9 Travel(LH)
PB8 PA8
B8 A8 Arm
Combination valve
PTO
Combination valve
B7 A7
B6 A6 Travel(RH)
PB5 PA5
B5 A5 Bucket
PB4 PA4
B4 A4 Boom
Combination valve
Combination valve
P2 block
P2
Port relief(250K)
B3 A3
Boom swing
B2 A2
Dozer
PB1 PA1
B1 A1 Swivel
Main relief valve(175K) P3 T2
P3
P3 block
- 66 -
7.2. CONSTRUCTION
T P T
Operating the joy stick valve generates pilot pressure. This pilot pressure generated at PA port will act on
the right section of the main spool, which overrides, in turn, the springs(A)(B) and moves to the left side.
Then, if the oil flowing through the port P is shut off from the port T, oil pressure starts rising and the
pressurized oil push up the load check valve to allow the oil to flow from the port P through port A to the
cylinder rod. The return oil flows into the port B, passing through the main spool orifice A. If the joy stick
valve which passes through line hole A to the tank circuit is turned to the neutral position, the pilot pressure
is removed, which in turn, causes the spool to return to the neutral position from the springs(A) and (B) to
the right side.
Hydraulic cylinder
Pilot pressure
Port B Port A
Port PA
- 67 -
7. CONTROL VALVE
As the primary pressure rises higher and higher, it pushes out the spring in the rear of the needle valve,
which in turn is forced to move to the left side. Then, since the oil pressure in the secondary pressure
chamber returns to the oil tank and the force pushing the poppet in the closed direction(force pushing the
poppet to the right side) disappears, the poppet is pushed and opened by the primary pressure, causing
the oil to return to the tank.
As a decrease in the primary pressure makes the secondary pressure decrease, the poppet is closed by
the spring force and the secondary pressure rises again to push the poppet to the right side, with the
result that the relief condition is stopped.
Valve seat
Main relief valve
Tank
Primary
pressure
- 68 -
7.2. CONSTRUCTION
2. Combination valve
Poppet
Combination valve
If the line pressure exceeds the set pressure, the poppet is pushed to the right side to make the line
pressure flow to the tank.
Combination valve
The suction pressure activates the line pressure to make the seat move to the left side, and oil flows in the
line from the tank. If the oil flows into the line to release the exhaust pressure, the seat moves to the right
side again and is separated from the tank.
- 69 -
7. CONTROL VALVE
Spring
In general, the poppet is pushed to the left side by the spring force to shut off the line pressure and tank
pressure.
Spring
If the line pressure exceeds the set value, the poppet is pushed to the right side to make the line pressure
flow to the tank.
If the line pressure goes below the set value, the poppet is pushed to the left side again by the spring force
and shut off the line pressure and tank pressure.
- 70 -
7.2. CONSTRUCTION
Spool PB
PA
T
Piston
• At arm crowd
If the pressure(PB) of the arm cylinder rod side is higher than the pressure(PA) of the cylinder head side,
the pressure of the rod side flows toward the head past the line holes(A)(B) in order for (PA<PB) to
actuate the piston(A) to the right side at the pressure(PB) of the rod side.
(The amount of oil corresponding only to that in the orifice(C) is bypassed to the tank.)
• At arm crowd
If the pressure at the arm cylinder rod side is lower than that at the head side(PA>PB), the piston(A) is
seated in the left side by the pressure at the head and accordingly the return oil flows straightly in the
tank port.
- 71 -
7. CONTROL VALVE
Block
O-ring
Tie rod
Nut
- 72 -
7.3. DISASSEMBLY AND REASSEMBLY
2. Replacement of cap
• Loosen the cap holding bolt 4 to remove the cap 5.
• Remove the spool 6 and replace the O-ring 7.
• Clean the spool, and then assemble it to the block body.
• When assembling the spring cap, take care not to damage the O-ring.
- Cap holding bolt tightening torque: 1.1kg• m
- Replace the spool and block as an assembly.
1
23
5
4
- 73 -
7. CONTROL VALVE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
Location Tightening torque
Cap nut tightening torque 1.5~2.0kg• m
Relief valve fixing torque 3.0~3.5kg• m
1 2 3 4 5 6 7 8 9
- 74 -
7.5. CAUTIONS WHEN HANDLING
7.5.2. Installation
1. When assembling valve fittings, use the specified tightening torque.
(Take care so that the pipe may not give unnecessary stress over the valve.)
2. Install the control linkage so that the spool moves correctly in the axial direction.
3. When welding near the valve, take care so that excessive heat and welding sputter may not damage the
O-ring and dust seal.
4. In painting, prevent paint from being contacted with the spool.
5. Do not leave plug unscrewed until doing piping works so that dust or water may not enter each port.
7.5.3. Operation
1. Before operation, check to see that the hydraulic pipes and hydraulic oil are clean.
2. Hydraulic oil for use should be at -20°C~80°C. If the oil temperature is below 0°C, warm up the engine.
3. Do not raise the set pressure for the main relief valve and port relief valve above the specified one.
- 75 -
8. SWING MOTOR
8. SWING MOTOR
8.1. SPECIFICATIONS
• SOLAR 030 Plus
Av,Bv port
2-PF3/8 O-ring port
292 45 101 45
45
14
63
125h7
64
48
T
Pilot port
Av Bv
Type Specifications
Diaplacement 244cc/rev
Maximum rpm 69.7 rpm
Rated flow rate 19 l/min
Relief set pressure 130kg/cm2
- 76 -
8.1. SPECIFICATIONS
• SOLAR 035
218
2-M16
13H7
325.5 6 - 17
0
2-G3/8
10
48 50
G1/4
A,B port 2-
35
G3/8
T-port
0
10
2-15
2-50
150 h8
10
CD2
P
A
RED.
- 77 -
8. SWING MOTOR
8.2. CONSTRUCTION
• SOLAR 030 Plus
10
13
9
12
8
5
- 78 -
8.2. CONSTRUCTION
- 79 -
8. SWING MOTOR
Inlet Outlet
Right-hand turn
Tape roller
bearing
Main drive
Z-Rotor
Valve drive
- 80 -
8.3. PRINCIPLES OF OPERATION
Shaft Piston
Cylinder barrel
Valve plate
Swash plate
Port A
Port B
- 81 -
8. SWING MOTOR
Port A Port B
Suction check valve
Suction check valve
Piston
To upper side
P1
- 82 -
8.4. INSPECTION AND ADJUSTMENT
2. Measurement
Check the amount of oil leak for 3 minutes. (Measure
the travel of the swing bearing outer race.)
- 83 -
8. SWING MOTOR
• How to replace
1. Remove the old seal and eliminate gasket materials
remaining in the inner and outer race grooves.
2. Use thinner to eliminate the gasket material marks Cut section
and dry them up.
3. Apply adhesive such as nitrile rubber around the
circumference of the seal.
To cut 45°
Apply adhesive to the cut sections and align them to make the contact
with each other to press the seal in the seal groove. area wider.
If the seal is circular, the cut sections do not require
any special treatment, but the seal should be made
longer than its overall length before being pressed in
the circumference evenly. Do not leave any part of
seal unused.
- 84 -
9.1. SPECIFICATIONS
9. TRAVEL MOTOR
9.1. SPECIFICATIONS
• SOLAR 030 Plus
ANS0160L
- 85 -
9. TRAVEL MOTOR
• SOLAR 035
2-G1/4 (Dr)
2-G1/2 (A,B)
297.5 G1/4 Travel secons-speed
G1/4
70
210 h8
165 h8
51
214
232
192
255
204
56
12-M12 107
9-M12 147
160
Dr
A
RED
RP
- 86 -
9.2. CONSTRUCTION
9.2. CONSTRUCTION
• SOLAR 030 Plus
- 87 -
9. TRAVEL MOTOR
- 88 -
9.2. CONSTRUCTION
• SOLAR 035
- 89 -
9. TRAVEL MOTOR
Carrier 1
a1 a2
s1
s
s2
p4 p2
Carrier 2 p3
Simple planetary reduction gear
Hydraulic motor (2 shift levels)
Counterbalance valve
ANS0170L
The hydraulic motor output shaft is connected to the s2 gear by the spline as shown above, and the rotation
of the s2 gear is reduced preliminarily by the s2, b2, and a2 gear.
The rotation reduced at the first level is reduced further by the s1, b1, a1 gear connected to the carrier 2 by
the spline, and this rotation reduced finally at the second level is transferred to the rotor body through the a1,
a2 internal gear to produce driving force.
- 90 -
9.3. PRINCIPLES OF OPERATION
• SOLAR 035
Carrier 1
a1 a2
Dr
s1
A s
B s2
p4 p2
PP
Carrier 2 p3
Simple planetary reduction gear
Hydraulic motor (2 shift levels)
Counterbalance valve
The s2 gear is installed over the hydraulic motor output shaft by the spline as shown above, and the rotation
of the s2 gear is reduced preliminarily by s2, b2, and a2 gears.
The rotation reduced at the first level is reduced further by s1, b1, and a1 gears connected with the carrier 2
by the spline, and this rotation reduced finally at the second level is transferred to the rotor body through the
a1 and a2 internal gears to produce driving force.
- 91 -
9. TRAVEL MOTOR
• Reduction gear a1 - a 2
1. Operation
The reduction gear consists of a planetary gear(with 2
shift levels). This gear allows the hydraulic motor to
b1 b2
reduce its high speed to increase the torque at a low
speed and rotate the case.
2. Principle of operation
The s2 gear is placed over the hydraulic motor output s1
shaft as shown, and the rotation of the s2 gear is
s2
reduced preliminarily by the s2, b2, and a2 gears.
The rotation reduced at the first level is reduced
further by the s1, b1, and a1 gears connected to the
carrier 2 by the spline, and this rotation reduced finally
at the second level is transferred to the rotor body
through the a1 and a2 internal gears to produce
driving force. Carrier 2
Zs1 Zs2
R = •
Zs1+Za1 Zs2+Za2
1
R' =
1-1/R
- 92 -
9.3. PRINCIPLES OF OPERATION
• Hydraulic motor
1. Hydraulic motor operation
The hydraulic motor is of a axial piston type, and converts the hydraulic pressure energy fed from the
pump into rotational motion.
Shaft Piston
Cylinder valve
Valve plate
Swash plate
Port A
Port B
The pressurized oil flowing from the hydraulic valve is fed to the valve plate. When the pressurized oil is
delivered to the port A, it flows in the cylinder port, in the cylinder barrel, corresponding to the port A to
push out the cylinder. This pushing force is converted to rotational force by means of the swash plate.
The return oil within the cylinder port flows into the tank through the port B of the valve plate.
In the case of reverse rotation, the pressurized oil flows in from the port B and the return oil flows into the
tank through the port A.
- 93 -
9. TRAVEL MOTOR
Ball
Ball
Spring
Face 1
Cylinder barrel
The swash plate has 2 faces of A and B on the opposite side of the sliding face for the shoe and is
clamped by two balls fixed on the body(2).
As these balls are installed eccentrically from the center shaft, both the hydraulic force acting on the
piston and the spring in the cylinder barrel in the first speed condition are combined to fix a swash angle
to α, from which a large capacity results.
If depressing the second accelerator pedal, hydraulic pressure produced by the stopper ring and control
ring together by means of the second-speed spool is guided to the control seal and goes forward until it
contacts the swash plate body to fix the swash plate at an angle β, from which a small capacity results.
If the engine is started, the control seal gets connected to the tank port. As a result, the spring force
makes the swash plate return to the first-speed condition.
- 94 -
9.3. PRINCIPLES OF OPERATION
3 4
A B
Dr PP Dr
D
A B
When the pressurized oil is fed from the port A, it forces the check valve(3) open to flow into the inlet port
(A)'. Then, it enters the chamber(D) through the check hole(C), overcomes the spring(4) force, and
allows the spool valve(2) to slide in the right direction. As a result, the return oil in the hydraulic motor
flows from the port(B)', past the body(1) and the opening(E) of spool valve(2), to the port (B) to rotate the
hydraulic motor.
If the pressurized oil is fed from the port (B), each component operates in a reverse way, resulting in
reverse rotation of the hydraulic motor.
If the hydraulic pressure of the port(A) is not supplied in a pressurized condition, the spool valve(2) which
is operating in the right side would turn to the left side by the spring(4) force. At this time, the oil in the
chamber(D) would flow out to the port(A) through the check hole(C), but it controls the speed of spool
valve(2) which would return to the left side, using the orifice effect of the check hole(C). Also, the
hydraulic motor would continue to turn by inertia force although the pressurized oil of the port(A) is not
supplied. Then, the shifting speed of the spool valve(2) and notch phenomenon combines to reduce the
return oil speed, and therefore the hydraulic motor is stopped smoothly.
In addition, the drain oil of the hydraulic motor flows from the oil gallery(F), through the port Dr, to both
ports Dr.
- 95 -
9. TRAVEL MOTOR
9.4. CARE
• Always allow the hydraulic oil to cool down enough
before making an inspection, as at the operating
temperature the hydraulic oil is at high temperature.
• Oil pressure remaining still in the case may make oil
and plug pop out.
Loosen the plug slowly to release the pressure in the
case.
plug and drain plug 2 located on top of the tank and 1 3. Oil level check hole
drain out old oil.
SOLAR 035
3. After draining the oil, clean the oil feed, drain, and oil
level check plugs, then wind a seal tape on them.
4. Tighten the plug over the drain port before injecting oil
into the feed port. Overfill the tank to obtain the
normal oil level(600cc).
5. Tighten each plug.
SOLAR 030 Plus
• Use recommended lubricants(gear oil).
• Never mix different type of oils together.
2. Drain port PF3/8
• Tightening torque
• Feed port plug and drain plug 2 : 4.7~5.2kg• m
• Oil level check plug 3 : 1.2~1.3kg• m
ANS0080L
- 96 -
9.4. CARE
Running Amount of
Running distance
distance travel deviation
SOLAR 030 Plus 11 mm less than 500mm
SOLAR 035 10 mm less than 500mm
- 97 -
10. HYDRAULIC CYLINDER
H, L K
A
C D
B
F
E
H, L J I
A
D C
B
F
K
E
G2
G1
G1 Width mm 50 50 50 50 50
G2 Width mm 50 50 50 50 50
Weight kg 24 22 17 18 17
- 98 -
10.1. CONSTRUCTION
• SOLAR 035
H, K I, J
A
C D
B
F
E
G1
G2
Item Cylinder Unit Boom Arm Bucket Boom swing Dozer
A Rod pin diameter mm ø40 ø35 ø35 ø35 ø40
B Head pin diameter mm ø40 ø35 ø35 ø35 ø40
C Rod diameter mm ø40 ø45 ø40 ø45 ø50
D Cylinder bore mm ø70 ø75 ø70 ø80 ø90
Maximum extended length mm 1545 1520 1295 1609 595
E
Minimum closed length mm 920 920 795 957 470
G1 Width mm 50 50 50 50 55
G2 Width mm 50 50 50 50 55
Weight kg 28 30 21 27 20
- 99 -
10. HYDRAULIC CYLINDER
- 100 -
10.1. CONSTRUCTION
• Internal construction(SOLAR035)
- 101 -
10. HYDRAULIC CYLINDER
10.2. DISASSEMBLY
10.2.1. Disassembly procedures
1. Clamp the cylinder tube in a vise enough to avoid its
Vise
deformation. Supply compressed air into the ports A A
and B to actuate the cylinder rod in order to drain out
Wood block
the old oil in the cylinder.
Extract the cylinder rod about 1/3.
B
2. Using a driver, make the rod cover stopping capacity
even.
Rubber
4. Piston rod assembly disassembly
Slowly turn the cylinder rod assembly to disconnect it
from the tube.
After disassembling the piston rod, take care not to
damage it.
- 102 -
10.2. DISASSEMBLY
Counter-
Socket
clockwise
- 103 -
10. HYDRAULIC CYLINDER
10.3. ASSEMBLY
10.3.1. ASSEMBLY PROCEDURE
1. Assemble the components by reversing the disassembly sequence.
2. Before assembling, check each component for metal chips or other foreign matters.
3. Apply hydraulic oil to each component before assembling them.
4. Semi-assemble each component before final assembly.
10.3.2. Inspection
1. Clean disassembled parts except for packings with light oil thoroughly.
2. Clean packings with hydraulic oil.
3. Do not use a mixture of different type oils. Service life of parts may be shortened.
4. Expecially, clean the sliding surfaces, oil holes, and packing grooves thoroughly.
5. If parts are not to be used immediately after cleaning, dip them in a suitable rust preventive compound.
(Coating with hydraulic oil has some rust-proofing effect.)
- Ensure that all the major parts are not damaged, deformed, rusted, or scored.
- Check each part for metal chips and other foreign matters.
- Check the piston rod and sliding surfaces for signs of damage, fretting, or discoloration.
- Replace packings and seals with new ones.
If parts are to be reused, ensure that they are not damaged and have no foreign matters.
To punch
Secure by punching
- 104 -
11.1. SPECIFICATIONS
Dr 2 kg/cm2
Service pressure
A~F.P 210 kg/cm2
A,B,P,Dr PF 1/4
Port size,
C~F PF 1/2
Service rpm 10 rpm
100
124
175
199
78
110
B: Dozer Down
A: Dozer Up
332
D: Right travel
Forward C: Left travel
Forward
F: Right travel
Reverse E: Left travel
Reverse
44
Dr: Drain
- 105 -
11. SWIVEL JOINT
• SOLAR 035
Dr 2 kg/cm2
Service pressure
A~F.P 210 kg/cm2
A,B,P,Dr PF 1/4
Port size,
C~F PF 1/2
Service rpm 14 rpm
Travel second-speed(left)
Travel second-speed(P)
125
100
Travel second-speed(right)
175
200
Left travel Right travel
88
A: Dozer Up
B: Dozer Down
321
C: Left travel
Forward
D: Right travel
Forward
E: Left travel
Reverse
F: Right travel
Reverse
78
122
150
- 106 -
11.2. CONSTRUCTION, DISASSEMBLY, AND REASSEMBLY
• Disassembly
1. Remove the bolt(12) and spring washer(13).
2. Remove the spindle(6) from the body(2) in the upper direction.
* To prevent damage of the O-ring, turn the spindle at disassembly.
• Reassembly
1. Check the O-ring and sliding surfaces of the assembly for damage or break.
2. Assemble parts by reversing the disassembly sequence.
When assembling the O-ring, be sure to apply hydraulic oil and grease to it.
- 107 -
11. SWIVEL JOINT
1
1. Swivel joint assembly
14
2. Slipper seal
15
3. Cover
4. Hub
5 5. Spindle
6. Spacer
7. Hexagon socket head
cap bolt
4 8. Snap ring
9
9. Dust seal
2
11 3
• Disassembly
1. Remove the bolt(7).
2. Remove the spindle(5) from the housing hub in the upper direction.
* To remove the O-ring and backup ring, lightly tap the case with a copper hammer.
• Reassembly
1. Check the O-ring and sliding surfaces of the assembly for damage or break.
2. Assemble parts by reversing the disassembly sequence.
When assembling the O-ring, be sure to apply hydraulic oil and grease to it.
- 108 -
12.1. SPECIFICATIONS
(247.5)
1.3 = 19
O
2.4 = 23
o
OUBLE SINGLE
28 D
(364.5)
P T
17.5
Over 350
4.5
90
1 3 2 4
HYDRAULIC SYMBOL
ANS0100L
∅113
(131)
o
45
71
27
71
98 ANS0090L
- 109 -
12. JOY STICK
PORT 1, 3
Operating Torque
25.1±2
19.5±1.5
(11.6)
7.7±1
5±0.75
Secondary Pressure
7
0 1.1±0.5 6.5±0.5
ANS0110L
PORT 2, 4
40 39.7
SECONDARY PRESSURE (kgf/cm2 )
Operating Torque
26.9±2
19.5±1.5
(11.6)
7.7±1
5±0.75
9
0 1.1±0.5 8.5±0.5
- 110 -
12.2. PRINCIPLES OF OPERATION
12.2.1. Neutral
The force of spring 2 setting up the output pressure of the pilot valve does not act on the spool 1.
Accordingly, the spool is pushed upward by the spring 8 to reach the location of port B in the diagram As a
result, it indexes with the tank port T only and the output port pressure becomes equal to tank pressure.
Port T
Port P
Port A Port B
- 111 -
12. JOY STICK
12.3. CONSTRUCTION
ANS0140L
- 112 -
13.1. SPECIFICATION
X X
Y A B Y
X-X Section
SOL2 SOL1
P
Y-Y Section
T ANS0180L
A B
- 113 -
13. SOLENOID VALVE
13.2. CONSTRUCTION
1
14
14
5
17
4
17
11
7
15 19
11
3 9
12 2
15 2
6
3
12
16 16
16
18
8 13 ANS0190L
- 114 -
13.3. OPERATION
13.3. OPERATION
The solenoid valve is a valve designed to control the joy stick pilot pressure and travel second-speed pilot
pressure.
SOL2 SOL1
P
XG
- 115 -
13. SOLENOID VALVE
13.4. CONSTRUCTION
The solenoid valve consists of a relief valve, a un-load valve, a lever lock, and a travel second-speed
valve.
1. Relief valve
If the pressure of the port P increases to reach a set Poppet Spring
T
pressure, the poppet is pushed to the right side to
make the port P indexed with the port T, with the
result that the pressure is relieved. P
<Relief state>
Poppet Spring
T
Spool (B)
ANS0210L
- 116 -
13. SOLENOID VALVE 13.4. CONSTRUCTION
Spool (B)
ANS0220L
- 117 -
14. CRAWLERS
14. CRAWLERS
14.1. SPECIFICATIONS AND CONSTRUCTION
14.1.1. Steel crawlers
SOLAR 030
300mm
Shoe
SOLAR 035
300mm
101.6mm Pin
Idler
Track
frame
- 118 -
14.2. DISASSEMBLY AND REASSEMBLY
1. Crawler loosening
• Loosening the cartridge valve of the tension 1
adjusting cylinder drains the grease to loosen the
crawlers. Loosen the cartridge valve slowly.
* The maximum amount of loosening can be
obtained if 1/2 turn is made.
2. Crawler removal
• Lift the machine in one side using the front and
install wood block under the machine.
• Steel crawlers
Remove the master pin(1) from the linkage by
turning it to the idler side, and then remove the 1
crawler(2).
2
• Rubber crawlers
Slide in the idler all the way, and remove the
rubber crawler from the idler using a steel bar.
- 119 -
14. CRAWLERS
1. Crawler installation
• Lift the machine in one side using the front and
install wood block under the machine.
• Index the crawler(1) with the sprocket teeth and
then install it on top of the idler.
• For steel crawlers, insert the the master pin(2).
2
For rubber crawlers, install the crawler over the
idler.
1
• Check
Measure the distance between the rolling surface
of the track roller and the contact surface of the
crawler.
Gap
- 120 -
14.3. MAINTENANCE STANDARDS
1
5
4
3
- 121 -
14. CRAWLERS
4
1
2
Unit: mm
- 122 -
14.3. MAINTENANCE STANDARDS
Amount of friction
Limit of use
2 0
1 5
ce
rfa
rd
su
nda
e
1 0 a
ret
St
rth
nc
Ea
Co
Operating hours(H)
The amount of friction of the rubber crawler sets the limit of use. However, it is subject to change depending
upon the work condition and environment.
20
23
21.5
31.5
25
300
(Unit:mm)
52.5mm
Item SOLAR 035 SOLAR 030 Plus
Distance between centers of crawlers 4,410±12 3,990±10
Scale cord Rigid 800 kg 800 kg
Scale cord No. of coils 40±4 coils 40±4 coils
Range of temperature of use -25°C~55°C -25°C~55°C
Width x Pitch 300 x 52.5 300 x 52.5
- 123 -
15. IDLER
15. IDLER
15.1. CONSTRUCTION
8
7 1
6
5
4
2
3
4
5
6
8
7
- 124 -
15.3. MAINTENANCE STANDARDS
1
2
5 3
- 125 -
15. IDLER
1
2
5 3
- 126 -
16.1. CONSTRUCTION
1 13 12 2 3 5 6 7 8 94
10
11
d
O.D
P.C.D
I.D
L
L1
L0
- 127 -
16. TRACK TENSION ADJUSTING CYLINDER
1
12
13
4 10
14 11
9
8
7
5
6
- 128 -
16.3. DISASSEMBLY AND REASSEMBLY
2. Reassembly procedure
Reverse the disassembly sequence for reassembly operation.
• Install the O-ring(5), backup ring(6), Dust seal(7), and spacer(8) to the cylinder tube(2).
To prevent damage, coat great to the O-ring and dust seal at assembly.
• After adjusting the spring set length, bend the split pin(13) completely.
* Spring set length: 233.5mm
CAUTION : • Release air from the cylinder tube completely before assembly.
• Be sure to apply grease to the piston area on the cylinder tube rod before assembly.
- 129 -
17. TRACK ROLLER
11 9
10 8
7
6 1
5
4
2
3
4
5
6
7
89
11
10
2. Reassembly procedure
• Clean segregated parts with cleansing oil.
• Inject clean gear oil or engine oil(100cc) before assembling the oil seal(6).
• Refer to "Crawler Installation" to assemble the crawlers.
- 130 -
17.3. MAINTENANCE STANDARDS
3 5
7
6
2
- 131 -
17. TRACK ROLLER
3 5
7
2 6
- 132 -
18.1. DISASSEMBLY AND REASSEMBLY
18. SPROCKET
18.1. DISASSEMBLY AND REASSEMBLY
1. Disassembly procedure
• Remove the crawler.
• Remove the sprocket clamping bolt(1) and
remove the sprocket(2) from the travel
motor.
2. Reassembly procedure 1
• Install the sprocket to the travel motor and
tighten the clamping bolt.
* Tightening torque: 11.5kg• m 2
• Assembly the crawler.
- 133 -
18. SPROCKET
5
2
4
3
- 134 -
19.1. STEEL CRAWLER MOUNTING PROCEDURE
- 135 -
19. CRAWLER REPLACEMENT PROCEDURE
- 136 -
HEATER HEATER OPTION
WIPER WIPER WASHER ROOM SWITCH
MOTOR SWITCH MOTOR LAMP M RADIO GROW PLUG
INDICATOR ALTERNATOR STARTER
M M MOTOR
R
S B B
SPEAKER
B
Br
RG
Br
Or
WR
Y
B
Or
W
SP B
BR
B
R
B
R
LW
L
L
LW
R
RY
BW
SERVO SERVO
RL
B
BY
UNIT SENSOR OIL SW
YG
W
BATTERY
GAUGE PANEL
RW FUSIBLE
RIGHT
SWITCH LINK(0.85R)
RY
HARZARD
LW
BL
L
SWITCH
Y
B
Or
W
LW
WTM M
B
Or
R
FUEL M
E/G STOP MOTOR
EHM M B
Y
B
20. ELECTRICAL DEVICE
Or
W
L
Br M
B
RY
RB
ILLUMINATION L B
B
Br
FUSIBLE
LINK(0.3W)
L
SAFETY UNIT
RG
B
L WR LW
YG
L R YG
WG YB
YW
B
- 137 -
L L
R
YW
L GR
RL B
L R
WG STARTER RELAY
BW
LW
Y
WORK LAMP G
BW
RW
HORN BR
YR
Y
B
BL
Br
B
LB
GR
RG
LB
RG
BY
BR
YL
YB
YW
BY
B
RB
RY
R
BY
RY
WL
YL
WL
W
RW
W
R
BM
Or
G
L
Or
Or
RY
RG
Or
WR
Br
WR
WB
WB
YW
FUEL SENSOR
E/G GND
20.1. ELECTRICAL CIRCUIT DIAGRAM(SOLAR 030 PLUS/035)
BR
B
10A
10A
15A
10A
15A
3A
10A
10A
RL
GH SPEED Or
SWITCH
Or QOS CONTROLLER FUEL PUMP
CRO SWITCH
Br RIGHT RELAY PREHEAT RELAY
(R.H) C ACC
(SRM-12C
B BR NORMAL OPEN)
Or
CRO SWITCH GY R2
(L.H) FUSE BOX
RL
B
BR
B
GY
B
TML
HARNESS STARTER SWITCH
PST B BR ACC R2 C
GND
OFF
HORN SWITCH
ON
START
20.2. TROUBLESHOOTING
20.2.1. STARTER
Pinion would not slide out • Open wiring, bad contact of battery with Correct
if the starter switch is ON. switch terminal
• Spline which is engaged with the armature Correct spline.
shaft pinion had been worn causing the
pinion to fail to operate.
• Plunger of magnetic switch malfunction, or Correct• Replace
coil short or open.
Pinion engages with ring • Open cable which connects the battery and Tighten or replace
gear, but starter does not magnetic switch
rotate. • Improper connection of connecting wires Tighten or replace
which connect the magnetic switch and motor
terminal
• Improper engagement of pinion with ring gear Correct teeth.
• Excessive wear of brush, and contact of Correct• Replace
brush with spring
• Commutator contaminated Correct
• Armature and field coil defective Correct• Replace
• Improper tightening of field coil and brush Correct
contact surface
• Contractor improperly contacted Correct
• Contractor contact surface not smooth Correct
- 138 -
20.2 TROUBLESHOOTING
20.2.2. Regulator
- 139 -
20. ELECTRICAL DEVICE
20.2.3. Alternator
- 140 -