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1SAFETY
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S0102000
R1

1TRACK EXCAVATOR
SAFETY

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

TRACK EXCAVATOR SAFETYS0102000

MODEL SERIAL NUMBER RANGE

Solar 130LC-V 0001 and Up
Solar 170LC-V 1001 and Up
Solar 220LC-V 0001 and Up
Solar 220N-V 1001 and Up
Solar 250LC-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
Solar 400LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2001 Daewoo

December 2001

Track Excavator Safety S0102000

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TABLE OF CONTENTS

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

General Safety Essentials .............................................................................. 5
Location of Safety Labels ............................................................................... 5
Summary of Safety Precautions for Lifting in Digging Mode .......................... 6
Work-site Precautions .................................................................................... 7
Operation........................................................................................................ 9
Equipment .................................................................................................... 14
Maintenance................................................................................................. 18
Shipping and Transportation......................................................................... 21
Lifting With Sling........................................................................................... 21

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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 5
2. “Location of Safety Labels” on page 5
3. “Summary of Safety Precautions for Lifting in Digging Mode” on page 6
4. “Work Site Precautions” on page 7
5. “Operation” on page 9
6. “Equipment” on page 14
7. “Maintenance” on page 18
8. “Shipping and Transportation” on page 21

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SAFETY ALERT SYMBOL

Be Prepared - Get To Know All Operating and Safety Instructions.
This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the
machine you should be alert to the potential for personal injury or accidents. Always observe
safety precautions and follow recommended procedures.

LEARN THE SIGNAL WORDS USED WITH THE SAFETY ALERT SYMBOL
The words "CAUTION," "WARNING" and "DANGER" used throughout this manual and on decals on the
machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety
is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which
signal word appears next to the "Exclamation Point" symbol.

CAUTION!
Indicates potential of a hazardous situation that, if not avoided, could result in minor or
moderate injury. It may also be used to alert against a generally unsafe practice.

WARNING!
Indicates potential of a hazardous situation that, if not avoided, could result in serious injury or
death. It may also be used to alert against a highly unsafe practice.

DANGER!
Indicates imminent hazard of a situation that, if not avoided, is very likely to cause death or
extremely serious injury. It may also be used to alert against equipment that may explode or
detonate if handled or treated carelessly.

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GENERAL SAFETY ESSENTIALS

ACCESSORY APPLICATIONS
The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for
other object handling, contact Daewoo for proper installation and application. Lifting-work applications
(unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated
capacity only, with no side-loading. DO NOT use the machine for activities for which it was not intended.
DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration.
Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other
hazardous operation may require installation of additional protective structures to safeguard the operator.

LIFTING CAPACITY RATING CONFIGURATION

Lifting capacity ratings that are printed at the end of this safety section are based on the machine being
level, on a firm supporting surface, with hooks and slings attached in approved configuration. Loads must
be balanced and supported evenly. Use taglines to keep the load steady if wind conditions and large
surface area are a problem. Work crew hand signals, individual tasks and safe procedures should all be
universally understood before the lift is made.

IMPORTANT
Before using the excavator to make lifts check municipal and regional regulations or statutes
that could apply. Governing ordinances may require that all heavy lifting be done with single
purpose equipment specifically designed for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that can be used for digging, loading,
grading or other work may be expressly forbidden by a regional injunction or other legal
prohibition. Always follow all of the other instructions, guidelines and restrictions for Safe
Lifting in the Operation and Maintenance Manuals.

LOCATION OF SAFETY LABELS

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

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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/hr (30 mi/h).
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.

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.

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WORK SITE PRECAUTIONS

ATTACHMENT PRECAUTIONS
Options 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.

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
HAOA230L
6.6 kV 3.0 m (9’ 10")
Figure 1
33.0 kV 4.0 m (13’ 1")
66.0 kV 5.0 m (16’ 5")
154.0 kV 8.0 m (26’ 3")
275.0 kV 10.0 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.

BEFORE STARTING TO DIG, CONTACT AUTHORITIES

Below ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know
what’s underneath the work site before starting to dig.

BE AWARE OF HEIGHT OBSTACLES

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.

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USE CARE ON LOOSE SUPPORT

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 balanced load may also be hazardous.
If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen
ground. Stay away from ditches, overhangs and all other weak support surfaces. Halt work and install
support mats or blocking if work is required in an area of poor track support.

USE SOLID SUPPORT BLOCKING

Never rely on lift jacks or other inadequate supports when work is being done. Block tracks fore and aft to
prevent any movement.

OVERHANGS ARE DANGEROUS

Digging the workface under an overhang - the work area beneath a cliff or under the edge of a ditch - is
dangerous. Know the height and reach limits of the excavator and plan ahead while working. Avoid
creating dangerous situations by moving around the work site while making excavations. Go onto another
digging area before steep overhangs are formed. Working around deep pits or along high walls or
trenching may require support blocks, especially after heavy rainfalls or during spring thaws. Park the
excavator away from overhangs before work shut down.

SLOPING TERRAIN REQUIRES CAUTION

Dig evenly around the work site whenever
possible, trying to gradually level any existing
slope. If it’s not possible to level the area or
avoid working on a slope, reducing the size and
cycling rate of the workload is recommended.
On sloping surfaces, use caution when
positioning the excavator before starting a work
cycle. Stay alert for instability situations to avoid
getting into them. For example, you should
always avoid working the bucket over downhill
HAOA210L
crawler tracks when parked perpendicular to the
Figure 2
slope. Slow all downhill swing movements and
avoid full extensions of the bucket in a downhill
direction. Lifting the bucket too high, too close to
the machine, while the excavator is turned uphill
can also be hazardous.

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STAY ALERT FOR PEOPLE MOVING

THROUGH THE WORK AREA
When loading a truck you should always know
where the driver is.
Avoid loading over the cab of a truck even if the
driver is in a safe spot. Someone else could
have gone inside, for any number of reasons.
Avoid working where unseen passersby might
be.
Slow down the work cycle and use slower travel
speeds in congested or populated areas. Use a HAOA170L
commonly understood signal so that other Figure 3
members of the work crew can warn the
operator to slow or halt work in an impending
hazard situation.

BE AWARE OF AND CONFORM TO LOCAL

REGULATIONS
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 guidelines,
standards or restrictions on equipment that may be used to perform certain kinds of work. Check and
follow all local requirements, which may also be related to below ground hazards and power lines.

OPERATION
OPERATE WHILE SEATED AT THE
OPERATOR’S STATION ONLY
Never reach in through a window to work a
control. Do not operate the excavator unless
you’re in the command position stay alert and
focused on your work at all times but DO NOT
twist out of the seat if job activity behind you (or
to the side) requires your attention.
Use a spotter or signal person if you cannot see
clearly and something is happening behind you.
Replace damaged safety labels and lost or HAOA150L
damaged owner’s manuals. Figure 4
Do not let anyone operate the machine unless
they’ve been fully and completely trained, in
safety and in the operation of the machine.

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BEFORE STARTING THE ENGINE

Do a "pre-start" safety check:
• 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, or people or property 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.

NEVER USE ETHER STARTING AIDS

An electric-grid type manifold heater is used for
cold starting. The glowing heater element can
cause ether or other starting fluid to detonate,
causing injury.

Figure 5
MOUNTING AND DISMOUNTING
NEVER get on or off a moving machine. Do not
jump on/off. The entry/egress path should be
clear of mud, oil and spills and mounting
hardware must be kept tight and secure.
Always use handholds, steps or track shoes and
maintain at least 3-point contact of hands and
feet. Never use controls as handholds.
NEVER get up from the operator’s seat or leave
the operator’s station and dismount the machine
if the engine is running.
Figure 6

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OBSERVE GENERAL SAFETY RULES

Only trained and authorized personnel, with a good knowledge and awareness of safe procedures, may be
allowed to operate or perform maintenance or service on the excavator.

,,,
All personnel at the work site should be aware of assigned individual responsibilities and tasks.
Communication and hand signals used should be understood by everyone.
Terrain and soil conditions at the work site, approaching traffic, weather-related hazards and any above or
below ground obstacles or hazards should be observed and monitored by all work crew members.

,,,
ENGINE VENTILATION
Engine exhaust gases can cause fatal
accidents, and unconsciousness, loss of
alertness, judgement and motor control and
serious injury.
Make sure of 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. HAOA070L
Figure 7
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your health if it is inhaled.
If you handle materials containing asbestos fibers, follow these guidelines as given below:
• Never use compressed air for cleaning.
• Use water for cleaning to keep down the dust.
• Work on the machine or component with the wind at your back whenever possible.
• Use an approved respirator with proper filtration.

TAKE TIME TO PROVIDE GOOD VISIBILITY

Halt work if visibility is poor. Strong rains, snow, fog and extremely dusty conditions can all obscure
visibility so badly that it is best to wait for weather to change or dust to settle before continuing operation.
Night work in areas of limited visibility should be halted if installation of extra work lights on the machine (or
work area) is necessary.
Keep dirt and dust off of windows and off the lens surfaces of work lights. Stop working if lights, windows or
mirrors need cleaning or adjustment.

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FUEL, OIL AND HYDRAULIC FLUID FIRE

HAZARDS
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
HAOA120L
at the fuel filling nozzle. In very cold, dry
Figure 8
weather or other conditions that could produce
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.

BOOST STARTING OR CHARGING ENGINE

BATTERIES
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 machine or
vehicle do not allow the two machines to touch.
Wear safety glasses or goggles while required
parallel battery connections - positive to positive
and negative to negative - are made.
HAOA310L
24 volt battery units consisting of two series- Figure 9
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 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.

TRAVEL CONTROLS MAY PRODUCE REVERSED OPERATIONS

Before starting the machine you should always check to see which end of the track frame is under the
operator’s cab. In the normal travel configuration, track frame travel motors are at the rear of the machine,
under the engine and counterweight. If the operator swings the cab 180˚, travel motors will be underneath
the operator’s cab, toward the front of the track frame and operating travel will be reversed.
When traveling the excavator always keep lights on; make sure that you are in compliance with all state
and local regulations concerning warning flags and signs and keep the operator’s cab positioned over the

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idler end of the track frame. That will keep travel controls in their intended configuration and at the same
time, maintain the proper orientation of lights on the machine and posted flags and signs.

KEEP "PINCH POINT" AREAS CLEAR - USE

CAUTION IN REVERSE AND SWING
Use a signal person in high traffic areas and
whenever the operator’s view is not clear, such
as when traveling in reverse. Make sure that no
one comes inside the swing radius of the
machine.
Anyone standing near the track frames, or
working assemblies of the attachment, is at risk
of being caught between moving parts of the
machine.
HAOA190L
Never allow anyone to ride on any part of the Figure 10
machine or attachment, including any part of the
turntable or operator’s cab.

TRAVEL PRECAUTIONS
Attachment control levers should not be operated while traveling.
Do not change selected travel mode (FAST/SLOW) while traveling.
Fold in work equipment so that the outer end of the boom is as close to the machine as possible, and is
200 mm - 300 mm (8" - 12") above ground.
Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope
or obstacle that causes 10 degrees tilt, or more.

OPERATE CAREFULLY ON SNOW AND ICE AND IN VERY COLD TEMPERATURES

In icy cold weather avoid sudden travel movements and stay away from even very 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.

PARKING THE MACHINE

Avoid making sudden stops, or parking the machine wherever it happens to be at the end of the work day.
Plan ahead so that the excavator will be on a firm, level surface away from traffic and away from high
walls, cliff edges and any area of potential water accumulation or runoff. If parking on inclines is
unavoidable, block the crawler tracks to prevent movement. Lower the bucket or other working attachment
completely to the ground, or to an overnight support saddle. There should be no possibility of unintended
or accidental movement.

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SHUTDOWN CONTROL FUNCTIONS

After the machine has been lowered to the overnight storage position and all switches and operating
controls are in the "OFF" position, the control stand lock lever must be engaged. Release the left console
to disable all pilot circuit control functions.
Insert the swing lock pin and engage all brakes and lock-down security equipment that may have been
installed on the machine.

IMPORTANT
When hydraulic system maintenance or service work must be performed, you should be aware
that an accumulator in the system stores fluid under pressure after system lock down, even after
the control stand is raised. Release this energy by working controls with the engine off, until
pressure in the pilot circuit has been completely bled away.

EQUIPMENT
ROUGH OPERATION MAY REQUIRE USE OF
CERTIFIED SAFETY EQUIPMENT
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 FOG / Falling Object
Guard or windows guards.

HAOA110L
Figure 11
Any reinforcement system that is installed on
the machine must pass safety and certification
standards and carry appropriate labeling and
rating information. For example, the most often
added type of reinforcement system, FOG, must
meet or exceed International Standard
ISO10262, Laboratory Tests and Performance
Requirements Earth-Moving Machinery.
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 HAOA100L
system requires a complete integrity Figure 12
reevaluation. Reinstallation, recertification and/
or replacement of the system may be
necessary.

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INSTALL ADDITIONAL SAFETY EQUIPMENT IF CONDITIONS REQUIRE

When working with a breaker or in some shear work applications, a front guard over the windshield may be
required. The windshield guard may or may not be OPS/certified, depending upon the specific application
and working situation.
Laminate glass protection for the front, side or rear windows may also be recommended depending upon
particular site conditions.
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 other work site crew
members are kept well away from the excavator and safe from potential hazards.

MOVEMENT ALARMS
If the excavator is equipped with an audible travel movement alarm or visible swing movement alarm
(strobe light), test the alarm on a daily basis. The audible alarm should sound as soon as the travel system
is engaged. The strobe light should begin to flash as soon as the swing system is engaged.

SEAT BELTS SHOULD BE USED AT ALL

TIMES
Whenever the engine is running, the operator
should be seated at the control station with the
seat belt properly engaged.

Figure 13
WINDOW GLASS BREAKING TOOL
This excavator is equipped with a glass
breaking tool. It is behind the operator seat in
the upper right corner of the cab. This tool can
be used in case of an emergency situation
which 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 14
Protect your eyes when breaking the
glass.

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KEEP A FIRE EXTINGUISHER AT HAND

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 extinguisher at regular
intervals and make sure that all work site crew
members are adequately trained in its use.

MAINTAIN STANDARD SAFETY EQUIPMENT

IN GOOD CONDITION
Machinery guards and body panel covers must HAOA080L
be in place at all times. Keep well clear of Figure 15
rotating parts. Pinch point hazards such as
cooling fan and alternator drive belts could
catch hair, jewelry or oversize or very loose
clothing.
Safety labels must be replaced if they are damaged or become unreadable. The information on labels
gives work crew members an important safety reminder exactly where it will do the most good. Part
numbers for each label and required mounting locations are shown in Operation and Maintenance Manual.

SAFETY-CRITICAL PARTS MUST BE REPLACED PERIODICALLY

Replace the following fire-related components as soon as they begin to show any sign of wear, or at
regular periodic intervals, whether or not deterioration is visible:
• Fuel system flexible hoses, the tank overflow drain hose and the fuel fill cap.
• Hydraulic system hoses, especially the pump outlet lines and front and rear pump branch
hoses.
• Keep mounting brackets and hose and cable routing straps tight. Hose routing should have
gradual bends.

HYDRAULIC CYLINDER SEALS REQUIRE PERIODIC REPLACEMENT

Check cylinder drift rate at regular intervals. Maximum allowable rates are included in the in this manual.
Overhaul seal kits are available through Daewoo.

HIGH PRESSURE HYDRAULIC LINES CAN STORE A GREAT DEAL OF ENERGY

Exposed hydraulic hoses on the arm or boom could react with explosive force if struck by a falling rock,
overhead obstacle or other work site hazard. Extra safety guards may be required. NEVER allow hoses to
be hit, bent or interfered with during operation.

THE OPERATOR’S CAB AND TURNTABLE DECK SHOULD BE KEPT CLEAN

Cleaning off accumulations of grease and dirt helps extend equipment service life. Cleaning also provides
an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems
result.
Keep the cab floor and consoles free of tools and personal items.

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WEAR EYE PROTECTION AND SAFETY

CLOTHING
Full eye protection, a hard hat, safety shoes and
gloves may be required at the work site.
While working on the machine, never use
inadequate tools. They could break or slip,
causing injury, or they may not adequately
perform intended functions.

BREATHING MASKS, EAR PROTECTION

MAY BE REQUIRED HAOA020L
Figure 16
Don’t 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.

BATTERY ELECTROLYTE AND EXPLOSIVE

GASES CAN BE LETHAL
Flush eyes with water for 10-15 minutes if acid
is splashed in the face. Anyone who swallows
acid must have immediate medical aid. Call the
Poison Control listing in the front cover of the
telephone directory. Water, a popsicle or ice
cream are likely better than old remedies that try
to induce vomiting (which would expose tissue
to damage twice).
Explosive battery gas can be set off by sparks HAOA440L
from incidental contact or static discharge. Turn
Figure 17
off all switches and the engine when working on
batteries. Keep battery terminals tight. Contact
between a loose terminal and post can create
an explosive spark.

DISCONNECT BATTERIES FOR ELECTRICAL SERVICE BEFORE ELECTRICAL WELDING

Remove cable to negative terminal first, when disconnecting cable. Connect positive terminal cables
first when installing a battery.

USE LOW HEAT PORTABLE LIGHTING

Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.

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MAINTENANCE
USE WARNING TAG CONTROL LOCKOUT
PROCEDURES DURING SERVICE
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 lockout WARNING
can be made with any OSHA certified lockout
device and a length of chain or cable to keep the
left-hand control console in the fully raised, non-
active position.
Warning tags for controls are available from HAOC920L
Daewoo distributors.
Figure 18

DO NOT RUN THE ENGINE IF REPAIRS OR

WORK IS BEING PERFORMED ALONE
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.

ALWAYS USE ADEQUATE EQUIPMENT SUPPORTS AND BLOCKING

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.

DO NOT WORK ON HOT ENGINES OR HOT COOLING OR HYDRAULIC SYSTEMS

Wait for the engine to cool off after normal operation. Park the excavator on a firm, level surface and lower
all equipment before shutting down and switching off controls. When engine lube oil, gearbox lubricant or
other fluids require change, wait for fluid temperatures to decrease to a moderate level before removing
drain plugs.
NOTE: Oil will drain more quickly and completely if it is warm. Do not drain fluids at 95˚C (203˚F)
temperatures but don’t allow full cool-down.

S0102000 Track Excavator Safety

Page 18
 Return to Master Table of Contents

COOL-DOWN IS REQUIRED PRIOR TO

RADIATOR OR RESERVOIR CHECKS
Stop the engine and allow heat to dissipate
before performing service on the engine radiator
or hydraulic fluid reservoir. Both assemblies
have air vent levers at or near the fill cap for
venting built-up air pressure. Release the levers
before trying to take off fill caps and LOOSEN
CAPS SLOWLY, before removal.

PRESSURIZED HYDRAULIC OIL FLUID

HAOA060L
LEAKS CAN BE DANGEROUS
Figure 19
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.

X X O

HAOA420L
Figure 20

OBTAIN IMMEDIATE MEDICAL ATTENTION IF PRESSURIZED OIL PIERCES THE SKIN

WARNING!
Failure to obtain prompt medical assistance could result in gangrene or other serious damage to
tissue.

USE CORRECT REPLACEMENT FASTENERS TIGHTENED TO PROPER TORQUE

Refer to the "General Maintenance" section of this manual for information on tightening torques and
recommended assembly compounds and always use the correct part.
Poor or incorrect fastener connections can dangerously weaken assemblies.

Track Excavator Safety S0102000

Page 19
 Return to Master Table of Contents

DISPOSE OF ALL PETROLEUM-BASED OILS

AND FLUIDS PROPERLY
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. Never drain any petroleum-
based product on the ground or dispose of old
oil in municipal waste collection containers, or in
metropolitan sewer systems or rural landfills. HAOA470L
Check state and local regulations for other Figure 21
requirements.

TRACK TENSION ADJUSTMENTS REQUIRE CAUTION

NEVER turn out the track tension grease fitting nut. To release pressure from the crawler frame track
tension assembly, you should NEVER attempt to disassemble the track adjuster or attempt to remove the
grease fitting or valve assembly.
Keep your face and body away from the valve. Refer to the track adjustment procedure in the Operation
and Maintenance Manual or this manual.

S0102000 Track Excavator Safety

Page 20
 Return to Master Table of Contents

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 this manual for information on partial disassembly.
Refer to the Transportation and Shipping section of the Operation and Maintenance Manual for information
on loading, unloading and towing.

LIFTING WITH SLING

WARNING!
Improper lifting can allow load to shift and
cause injury or damage.

1. Refer to Specification section of Operation

and Maintenance Manual for information
on weight and dimensions.
2. Use properly rated cables and slings for
lifting.
3. Position machine for a level lift.
4. Lifting cables should have a long enough
length to prevent contact with the machine.
Spreader bars may be required. Figure 22
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.

Track Excavator Safety S0102000

Page 21
 Return to Master Table of Contents

S0102000 Track Excavator Safety

Page 22
Return to Master Table of Contents

1SPECIFICATIONS
 S0202090K

1SPECIFICATIONS FOR
SOLAR 470LC-V

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 470LC-V

MODEL SERIAL NUMBER RANGE
Solar 470LC-V 1001 and UP

Copyright 2001 Daewoo

November 2001

Specifications for Solar 470LC-V S0202090K

Page 1
TABLE OF CONTENTS

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

Component Locations .................................................................................... 4
General Dimensions....................................................................................... 7
Working Range............................................................................................... 8
General Specifications ................................................................................. 10
Engine Performance Curves (Per Ks-r1004 Standard) ................................ 12
Approximate Weight Of Workload Materials................................................. 14
Performance Tests........................................................................................ 17
Excavator Performance Standards............................................................... 18
Test Conditions...................................................................................... 18
Travel Speed and Travel Motor Balance (Steering Deviation) Tests ...... 18
Cylinder Performance Tests .................................................................. 21

S0202090K Specifications for Solar 470LC-V

Page 2
GENERAL DESCRIPTION
The excavator has three main component sections:
• The Upper Turntable
• The Lower Undercarriage and Track Frames
• The Excavator Front-end Attachment
The following illustration identifies main components and their locations. (See Figure 1 on page -4.)

Specifications for Solar 470LC-V S0202090K

Page 3
COMPONENT LOCATIONS

1 2 3 4 5 6

9
35

11 10
12

13

34
29
33
30 14

15
16
32 17
28 18 19
31
27

26

25 24 23 22 21 20
ASO0010L
Figure 1

S0202090K Specifications for Solar 470LC-V

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

Specifications for Solar 470LC-V S0202090K

Page 5
S0202090K Specifications for Solar 470LC-V
Page 6
GENERAL DIMENSIONS

H A

B C
I J

G
O

F
N
M
K D
L E

ASO0420L
Figure 2

DIMENSION 7.1 M (23.3 FT) BOOM

2.9 M (9.5 FT) ARM 3.35 M (11.0 FT) ARM 4.0 M (13.1 FT) ARM

A 12,200 mm (40' 0'') 12,110 mm (39' 9'') 10,700 mm (35' 1'')

B 3,660 mm (12' 0'')

C 8,535 mm (28' - 0'') 8,445 mm (27' 8'') 8,510 mm (27' 11'')

D 4,470 mm (14' 8'')

E 5,465 mm (17' 11'')

F 1,460 mm (4' 9'')

G 3,905 mm (12' - 10'') 3,705 mm (12' 1'') 3,940 mm (12' 11'')

H 2,990 mm (9' 10'')

CAT Walk 3,278 mm (10' 9'')
I 1,500 mm (4' 11'')
CAT Walk 1,788 mm (5' 10'')

J 1,490 mm (4' 10'')

K 3,300 mm (10' 10'')

L 3,900 mm (12' 10'')

M 600 mm (2' 0'')

N 761 mm (2' 6'')

O 3,350 mm (10' 11'')

Specifications for Solar 470LC-V S0202090K

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.

G
G.L

.
.
.

ASS1170L
Figure 3

S0202090K Specifications for Solar 470LC-V

Page 8
 Boom Type One Piece 7.1 m (23.3 ft)
2.9 m 3.35 m 4.0 m
Arm Type
Dim. (10.17 ft) (8.2 ft) (12.3 ft)
2.39 m3 2.15 m3 1.8 m3
Bucket Type (PCSA)
(3.12 yd3) (2.80 yd3) (2.35 yd3)
11,700 mm 12,100 mm 12,650 mm
A Max. Digging Reach
(38' 5'') (39' 8'') (41' 6'')
Max. Digging Reach 11,850 mm 12,410 mm
B 11,440 mm (37' 6'')
(Ground) (38' 11'') (40' 9'')
7,340 mm 7,790 mm 8,420 mm
C Max. Digging Depth
(24' 1'') (25' 7'') (27' 8'')
7,760 mm 7,900 mm 8,070 mm
D Max. Loading Height
(25' 6'') (25' 11'') (26' 6'')
10,940 mm 11,810 mm 11,230 mm
F Max. Digging Height
(35' 11'') (36' 4'') (36' 10'')
9,560 mm 9,705 mm 9,865 mm
G Max. Bucket Pin Height
(31' 4'') (31' 10'') (32' 4'')
4,050 mm 4,370 mm 4,930 mm
H Max. Vertical Wall
(13' 3'') (14' 4'') (16' 2'')
9,960 mm 10,230 mm 9,700 mm
I Max. Radius Vertical
(32' 8'') (33' 7'') (31' 10'')
7,180 mm 7,660 mm 8,290 mm
J Max. Depth to 8 ft Line
(23' 7'') (25' 2'') (27' 2'')
3,935 mm 3,935 mm 3,935 mm
K Min. Radius 8 ft Line
(12' 11'') (12' 11'') (12' 11'')
2,095 mm 925 mm 120 mm
L Min. Digging Reach
(6' 11'') (3' 0'') ( 0' 5'')
5,195 mm 5,170 mm 5,135 mm
M Min. Swing Radius
(17' 1'') (16' 12'') (16' 10'')

Specifications for Solar 470LC-V S0202090K

Page 9
GENERAL SPECIFICATIONS
Shipping Weight 46.9 metric tons (103,400 lb), includes 10% fuel, boom, 3,350
mm (11’ 0") arm, 1,681 mm (5’ 6") backhoe bucket and standard
shoes
Operating Weight Add weight of full fuel tank and operator.
Shipping Weights With Optional Add 700 kg (1,540 lb) for 750 mm (30") shoes
Track Shoes Add 1,000 kg (2,204 lb) for 800 mm (32") shoes
Add 1,500 kg (3,310 lb) for 900 mm (35") shoes
Major Component Weights Standard Boom 3,700 kg (8,160 lb)
2,900 mm (9’ 6") Arm 1,440 kg (3,170 lb)
3,350 mm (11’ 0") Arm 1,560 kg (3,440 lb)
4,000 mm (13’ 5") Arm 1,780 kg (3,260 lb)
Boom Cylinders 430 kg (948 lb) each
Arm Cylinder 660 kg (1,460 lb)
Bucket Cylinder 380 kg (838 lb)
Counterweight 8,500 kg (18,700 lb)
Upper Turntable 9,995 kg (22,000 lb)
Lower - below Swing Bearing 18,195 kg (40,100 lb)
Digging Forces:
Bucket Cylinder 267 KN or 18,100 kg (39,900 lb) - (with 3,350 mm [11’ 0"]
standard arm)
Arm Cylinder 131 KN or 27,200 kg (59,900 lb) with 4,000 mm (13’ 11")
standard arm
Fuel Tank Capacity 620 liters (164 U.S. gal)
Hydraulic System Capacity 500 liters (132 U.S. gal)
Hydraulic Reservoir Capacity 265 liters (70 U.S. gal)
Bucket Heaped Capacity Range PCSA 1.27 - 2.86 m3 (1.66 - 3.73 yd3)
IMPORTANT: Refer to the Load Weight, Bucket and Arm Length
Compatibility Table for information on which bucket sizes may be
used safely with which arm length, for load material weights.
Shoe Type Triple Grouser
Shoe Width and Optional Sizes 600 mm (23.5") - standard
750 mm (30") - optional
800 mm (32") - optional
700 mm (35") - optional
Ground Pressure Ratings:
Standard 600 mm (23.6") 0.81 kg/cm2 (11.5 psi)
shoe -
Optional 750 mm (30.0") 0.66 kg/cm2 (9.4 psi)
shoe -
Optional 800 mm (32.0") 0.62 kg/cm2 (8.8 psi)
shoe -
Optional 900 mm (35.0") 0.56 kg/cm2 (7.9 psi)
shoe -

S0202090K Specifications for Solar 470LC-V

Page 10
 Transport Dimensions
Overall Shipping Length 12,110 mm (39’ 9'')
(standard boom and arm)
Overall Shipping Width 3,900 mm (12’ 9")
(standard shoes)
Overall Shipping Height (to 3,705 mm (12’ 1'')
top of cylinder hose)
Track Shipping Length 5,465 mm (17’ 11")
Transport Trailer Capacity 47 tons , minimum load capacity
Transport Loading Ramp 15˚ angle CAUTION: Refer to Transport Maximum Procedure for
Allowable Slope Safe Shipping Instructions.

Specifications for Solar 470LC-V S0202090K

Page 11
ENGINE PERFORMANCE CURVES (PER KS-R1004
STANDARD)

TORUE (m)
OER OUTUT (p)

UEL ONUTION (p)

REVOLUTION(rpm)

ASS1190L
Figure 4

S0202090K Specifications for Solar 470LC-V

Page 12
 Condition Specification
Engine Model DE12TIS
Barometic Pressure 760 mmHg (20°C)
Cooling Fan 813 mm, SUCKER
Alternator 24V x 50A
Air Cleaner Installed
Muffler Installed

Performance Standard KS-R1004

Power 316 ps / 2,000 rpm
Max. Torque 133 kg.m / 1,400 rpm
Fuel Consumption (Min. Rated) 165 g / ps.h

Specifications for Solar 470LC-V S0202090K

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

LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR

DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS

Charcoal 401 kg/m3

--------------------- ---------------------
(695 lb/yd3)

Coke, blast furnace 433 kg/m3

size --------------------- ---------------------
(729 lb/yd3)

Coke, foundry size 449 kg/m3

--------------------- ---------------------
(756 lb/yd3)

Coal, bituminous slack, 801 kg/m3

piled --------------------- ---------------------
(1,350 lb/yd3)

Coal, bituminous r. of 881 kg/m3

m., piled --------------------- ---------------------
(1,485 lb/yd3)

Coal, anthracite 897 kg/m3

--------------------- ---------------------
(1,512 lb/yd3)

Clay, DRY, in broken 1,009 kg/m3

lumps --------------------- ---------------------
(1,701 lb/yd3)

Clay, DAMP, natural 1,746 kg/m3

bed --------------------- ---------------------
(2,943 lb/yd3)

Cement, Portland, DRY 1,506 kg/m3

granular --------------------- ---------------------
(2,583 lb/yd3)

Cement, Portland, DRY 1,362 kg/m3

clinkers --------------------- ---------------------
(2,295 lb/yd3)

Dolomite, crushed 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)

Earth, loamy, DRY, 1,202 kg/m3

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

S0202090K Specifications for Solar 470LC-V

Page 14
 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS

Earth, DRY, packed 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)

Earth, WET, muddy 1,762 kg/m3

--------------------- ---------------------
(2,970 lb/yd3)

Gypsum, calcined, 961 kg/m3

(heated, powder) --------------------- ---------------------
(1,620 lb/yd3)

Gypsum, crushed to 3 1,522 kg/m3

inch size --------------------- ---------------------
(2,565 lb/yd3)

Gravel, DRY, packed 1,810 kg/m3

fragments --------------------- ---------------------
(3,051 lb/yd3)

Gravel, WET, packed 1,922 kg/m3

fragments --------------------- ---------------------
(3,240 lb/yd3)

Limestone, graded 1,282 kg/m3

above 2 --------------------- ---------------------
(2,160 lb/yd3)

Limestone, graded 1,362 kg/m3

1-1/2 or 2 --------------------- ---------------------
(2,295 lb/yd3)

Limestone, crushed 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)

Limestone, fine 1,602 kg/m3

--------------------- ---------------------
(2,705 lb/yd3)
Phosphate, rock 1,282 kg/m3
--------------------- ---------------------
(2,160 lb/yd3)

Salt 929 kg/m3

--------------------- ---------------------
(1,566 lb/yd3)

Snow, light density 529 kg/m3

--------------------- ---------------------
(891 lb/yd3)

Sand, DRY, loose 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)

Sand, WET, packed 1,922 kg/m3

--------------------- ---------------------
(3,240 lb/yd3)

Specifications for Solar 470LC-V S0202090K

Page 15
 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS

Shale, broken 1,362 kg/m3

--------------------- ---------------------
(2,295 lb/yd3)

Sulphur, broken 529 kg/m3

--------------------- ---------------------
(1,620 lb/yd3)

S0202090K Specifications for Solar 470LC-V

Page 16
PERFORMANCE TESTS
1. Main Relief Pressure

normal operation: 320 kg/cm3 (4,641 psi)

with "Pressure Up": 350 kg/cm3 (4,970 psi)

2. Actuator Speeds

Operation Unit Power Mode II Power Mode III

Boom Up sec. 4.6 ±0.4 4.3 ±0.4
Down sec. 3.2 ±0.3 3.0 ±0.3
Arm Dump sec. 3.8 ±0.4 3.6 ±0.4
Crowd sec. 5.1 ±0.4 4.8 ±0.4
Bucket Dump sec. 3.2 ±0.3 3.0 ±0.4
Crowd sec. 3.3 ±0.3 3.1 ±0.4
Swing (3 Revolutions) sec. 18.0 ±1.5 17.5 ±1.5
Jack-Up Speed (3 High sec. 24.0 ±1.5 23.5 ±1.5
Turns) Low sec. 38.5 ±2.0 38.0 ±2.0
Travel Speed 20 m High sec. 15.0 ±1.0 14.5 ±1.0
(65.62 ft) Low sec. 24.0 ±1.5 23.5 ±1.5
Travel Deviation 20 m High mm (in) 150 (5.91) 150 (5.91)
(65.62 ft) Low mm (in) 150 (5.91) 150 (5.91)

Specifications for Solar 470LC-V S0202090K

Page 17
EXCAVATOR PERFORMANCE STANDARDS
Evaluation of equipment performance and operating condition can be made by running the excavator
through a series of different tests, and recording results with a stop watch and tape measure.
Compare results of performance tests against the specifications and standards that follow, which are for
equipment in new or renewed condition.

TEST CONDITIONS
1. All tests should be performed on a flat, level, firmly supporting ground surface.
2. All recommended, applicable maintenance and adjustment service should be completed prior to
testing.
3. Hydraulic fluid and engine oil should be of appropriate viscosity for ambient weather conditions.
Warm up hydraulic oil to standard operating temperature, between 45° - 55°C (112° - 135°F).
4. Run all tests with the engine speed control set to maximum RPM.
5. Repeat tests with Power Mode engine control settings at both Power Mode II (standard work mode)
and Power Mode III (high speed mode). Travel speed tests should also be repeated at both high and
low speed.

TRAVEL SPEED AND TRAVEL MOTOR BALANCE (STEERING DEVIATION) TESTS

Speed Test
Prepare the excavator for travel speed tests by extending all hydraulic cylinders - boom, arm and bucket -
to the fully extended position, shown in Figure 5.

0.3 M - 0.5 M (1' - 2')

ARS1480L
Figure 5

The lowest part of the bucket linkage should be 0.3 - 0.5 m (1' - 2') off the ground.
Mark off a 20 m (65' 7-1/2") test distance, with a 3 - 5 m (10' - 15') run-up area, and a 3 - 5 m (10' - 15', or
longer) speed run-off distance.
Travel the excavator back and forth to be sure steering is centered and side frames are perfectly parallel
with the test course.
Operate both travel levers at the fully engaged position and measure the time it takes to cross 20 m (65' 7-
1/2"). Compare measured results against the standard for new machines:

S0202090K Specifications for Solar 470LC-V

Page 18
 TIME
RATE OF TRAVEL
MODE II MODE III
High Speed 15 ±1.0 seconds 14.5 ±1.0 seconds
Low Speed 24 ±1.5 seconds 23.5 ±1.5 seconds

Rotate the turntable 180°. Both tests should be repeated three times. Average all results to obtain a final
value.

20 M (65' 7-1/2")
3M - 5M 3M - 5M
(10' - 15') (10' - 15')
ARS1500L
Figure 6

Travel Deviation
To check steering deviation (travel motor balance), use a long tape or rope, or the edge of an undeviating
straight road curb or other marker to verify side-to-side travel motor uniformity.
Deviation distance should always be measured at the 20 m (65' 7-1/2") "finish line." Repeat the test in
reverse to measure in both directions, with starting point becoming the finish line, and vice versa. (Figure
6)
A greater amount of deviation is allowed with the travel control set for high speed.

RATE OF TRAVEL MAX. DISTANCE

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

Specifications for Solar 470LC-V S0202090K

Page 19
Swing Speed Test

1.5 m

ARS1490L
Figure 7

Extend the bucket cylinder completely and retract the arm cylinder, as shown in Figure 7, to test swing
speed. The lowest point of the bucket will be approximately 1.5 m (3') off the ground.
Use paint marks at the same point on the turntable and undercarriage, or select alternate measuring
locations and use a stopwatch to time 3 full 360° rotations. The time required for 3 revolutions should be
between 16.5 and 19.5 seconds in Power Mode II, 16.0 and 19.0 seconds in Power Mode III.

Swing Force Test

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

Reference
Description
1
HJA7007L
Number
1 Start Swing Figure 8
2 90˚ Swing
3 Swing Force
4 Swing Stop

S0202090K Specifications for Solar 470LC-V

Page 20
CYLINDER PERFORMANCE TESTS
NOTE: All tests are performed with standard boom, arm and bucket configuration. The bucket
should be empty.

Boom Cylinders Test

The starting points for the test are with the boom and arm extended away from the excavator, and the
bucket curled inward. The arm cylinder should be fully retracted; boom and bucket cylinders must be
extended. Test movement in both directions, several times, and average results for both Power Mode II and
Power Mode III.

Arm Cylinder Test

Start with the boom up and the arm cylinder fully retracted. Test movement in both directions several times,
between the "crowd" and "dump" positions, and average the results of both tests, in both standard and
extra-duty power modes.

Bucket Cylinder Test

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

OPERATION MODE II MODE III

Boom Up 4.2 - 5.0 seconds 3.9 - 4.7 seconds
Boom Down 2.9 - 3.5 seconds 2.7 - 3.3 seconds
Arm Dump 3.4 - 4.2 seconds 3.2 - 4.0 seconds
Arm Crowd 4.7 - 5.5 seconds 4.4 - 5.2 seconds
Bucket Dump 2.9 - 3.5 seconds 2.7 - 3.3 seconds
Bucket Crowd 3.0 - 3.6 seconds 2.8 - 3.4 seconds

Hydraulic Cylinder Natural Drop Test

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

Travel Motor Jack-up Test

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

OPERATION MODE II MODE III

High Speed 22.5 - 25.5 seconds 22.0 - 25.0 seconds
Low Speed 36.5 - 40.5 seconds 36.0 - 40.0 seconds

Specifications for Solar 470LC-V S0202090K

Page 21
S0202090K Specifications for Solar 470LC-V
Page 22
Return to Master Table of Contents

1GENERAL MAINTENANCE
 Return to Master Table of Contents

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 2000 Daewoo

December 2000

General Maintenance Procedures S0302000

Page 1
 Return to Master Table of Contents

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

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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.

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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.

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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.

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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, non-combustible, 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.

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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

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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 matter. 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.

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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

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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

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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

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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

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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

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S0302000 General Maintenance Procedures

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S0309000

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 2000 Daewoo

December 2000

Standard Torques S0309000

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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

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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

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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

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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 NON-LUBRICATED
(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
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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
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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 ±5 in lb (0.1 kg•m)

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) 0.6 - 0.7 55 - 65 ------- ------

Worm Drive - 1-3/4 in 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50

Open Diameter and Under

Worm Drive - Over 1-3/4 in 0.5 - 0.6 40 - 50 ------- ------

Open Diameter

Worm Drive - All "Ultra- 1.1 - 1.2 95 - 105 0.5 - 0.6 40 - 50

Tite"

Standard Torques S0309000

Page 7
 Return to Master Table of Contents

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
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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
 Return to Master Table of Contents

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
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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/non-clog" formula for high-
4 Hours (or 1/2 hour
pressure hydraulic systems. Over-
545 Purple Hand tools with Locquic "T"
application will not restrict or foul system
Primer)
components.
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 non-rigid assemblies Purple faster (1/4 - 2 hours) setup.
subject to shock, vibration or deflection. Unprimed setup 1 - 12 hours.

Standard Torques S0309000

Page 11
 Return to Master Table of Contents

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
Return to Master Table of Contents

1UPPER STRUCTURE
 S0402040K

1CAB

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.

CAB
MODEL SERIAL NUMBER RANGE
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

Copyright 2001 Daewoo

December 2001

Cab S0402040K
Page 1
TABLE OF CONTENTS

Removal ......................................................................................................... 3
Installation ...................................................................................................... 6

S0402040K Cab
Page 2
REMOVAL

CAUTION!
Avoid disassembling cab if there are strong wind gusts, which could catch large surface area of
cab shell and push it sideways during lift.

1. Park on firm and level ground.

2. Lower bucket to ground.
3. Shut engine down and remove key from
starter switch.

WARNING!
If engine must be run while
performing maintenance, use
extreme care. Always have one
person in the cab at all times. Never Figure 1
leave the cab with the engine
running.

4. Set safety lever on "LOCK" position.

5. Hang maintenance warning tag on
controls.
6. Disconnect negative (-) battery cable
leading to frame from battery.
7. Prepare cab shell for removal by disconnecting wiring connectors for:
A. Cab interior lighting.
B. External light wiring.
C. Radio antenna and connections.
D. Wiper/washer connections.
NOTE: Control console wiring harnesses and hydraulic piping lines that pass through the floor of
the cab do not need to be disassembled.
NOTE: If unit is equipped with a cab protective structure (for forestry, or hazardous working
conditions), it must be removed.

Cab S0402040K
Page 3
8. Remove floor mat.
9. Remove operator’s seat (1, Figure 2). 1
NOTE: Be careful not to damage seat
4 5
covering.
10. Remove duct covers (2, 3 and 4, Figure 2). 6
When removing cover (2) disconnect hour
meter connector and cigar lighter
connector. Disconnect main harness
connector before removing cover (4).
11. Removing pocket (5, Figure 2) before
removing side panel (6, Figure 2). 2 7

3
ARS1510L
Figure 2
12. Remove air duct (1, 2 and 3, Figure 2)
located at right side of cab. Disconnect
duct wiring connector before removing
3
duct (2).
13. Disconnect washer hose located at floor
plate bottom.

2
ARS1520L
Figure 3
14. Remove cover (5, Figure 4) on left side
dash cover (3) and bolts (1, Figure 5).
NOTE: When removing cover
disconnect speaker wire. 2 1 2

15. Remove two rubber stops (2, Figure 4) 3

used in storing the front lower glass.
Remove bolts (1) from the rear left and 4
5
right dash covers. Remove left side cover
(3).
16. Lift right side dash cover (4, Figure 4) and
disconnect speaker wire. Remove cover. ARS1530L
Figure 4

S0402040K Cab
Page 4
17. Remove three bolts (2, Figure 5) after
disconnect speaker wire and antenna wire.
Remove stereo assembly.
18. Disconnect cab lamp wiring connector. 2

19. Disconnect cabin ground cable (7, Figure

2).
1

ARS1540L
Figure 5
20. Remove four mounting nuts from four
corners of cabin floor (2, Figure 6). 1
21. Remove four hex bolts (3, Figure 6) from
door side of cabin floor.
22. Remove two hex bolts (1, Figure 6) from 2
right side of cabin floor and one bolt (4)
under front window of cab floor. 4
Quantity Description
4 16 mm hex nuts at each
corner of the cab
4 10 mm x 1.5 hex bolts at
the door side of the cab 3
3 10 mm x 1.5 mm hex HAOF270L
head bolts, 2 on the right Figure 6
side of the cab and 1
under the front window.

23. Using a suitable lifting device, attach slings

to four lift points on top of cab (Figure 7).
NOTE: Cab weighs approximately 290
kg (639 lb).
24. Lift cab from 25 - 50 mm (1" - 2") above
deck height. Check that all electrical
connections have been disconnected and
all other items unbolted.
25. Continue lifting with the assist crane to
remove the cab shell. Lower the shell to a
pre-prepared safe blocking support.
Figure 7

Cab S0402040K
Page 5
INSTALLATION
1. Using a suitable lifting device, attach slings
to four lift points on top of cab (Figure 7).
NOTE: Cab weighs approximately 290
kg (639 lb).
2. Lower cab into position on cab floor

Figure 8
3. Install four mounting nuts on four corners
of cabin floor (2, Figure 9). 1
NOTE: Mounting nut torque 20.2 kg•m
(146 ft lb)
4. Install four hex bolts (3, Figure 9) in door 2
side of cabin floor.
5. Install two hex bolts (1, Figure 9) in right 4
side of cabin floor and one bolt (4) under
front window of cab floor.

Quantity Description
4 16 mm hex nuts at each
corner of the cab 3
HAOF270L
4 10 mm x 1.5 hex bolts at
the door side of the cab Figure 9
3 10 mm x 1.5 mm hex
head bolts, 2 on the right
side of the cab and 1
under the front window.

6. Once cab is mounted to floor, unhook

lifting device
7. Connect cabin ground cable (7, Figure 2).
8. Connect cab light wiring connector.

S0402040K Cab
Page 6
9. Install stereo assembly with bolts (2,
Figure 10) after connect speaker wire and
antenna wire.
2

ARS1540L
Figure 10
10. Lift right side dash cover (4, Figure 11)
with bolts (1, Figure 10). Install two
rubbers (2, Figure 11).
11. Install left side dash cover (3, Figure 11) 2 1 2
with bolts (1, Figure 10). Install two
3
rubbers (2, Figure 11).
12. Install cover (5, Figure 11) on left side 4
5
dash cover (3).
NOTE: Connect speaker wire before
installing cover.
ARS1530L
13. Connect washer hose located at floor plate
bottom. Figure 11

14. Install air duct (3, 2 and 1, Figure 12)

located at right side of cab.
NOTE: Connect wire connector of duct 3
(2).
15. Install side panel (6, Figure 12) and pocket
(5).

2
ARS1520L
Figure 12

Cab S0402040K
Page 7
16. Install cover (4, Figure 13) and connect
main harness. Install cover (3, Figure 13).
Connect hour meter connector and cigar 1
lighter connect of cover (2, Figure 13).
4 5
17. Install cover (2).
18. Install operator’s seat (1, Figure 13). 6

NOTE: Be careful not to damage seat

covering.
19. Install floor mat.
20. Disconnect negative (-) battery cable 7
2
leading to frame from battery.

3
ARS1510L
Figure 13

S0402040K Cab
Page 8
 S0403050K

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
MODEL SERIAL NUMBER RANGE
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

Copyright 2001 Daewoo

December 2001

Counterweight S0403050K
Page 1
TABLE OF CONTENTS

General........................................................................................................... 3
Removal ......................................................................................................... 5
Installation ...................................................................................................... 6

S0403050K Counterweight
Page 2
GENERAL
Before any attempt is made to begin removal or installation of the counterweight, the excavator must be
parked on a firm and level supporting surface, with no sloping surfaces or soft or muddy ground in the area
where the assist lift crane will be working. Position all accessories in the overnight storage position.

WARNING!
The weight of counterweight is given in the following table. Use only rated and approved slings
and hardware when removal or installation lifts are being made. Lifting slings, shackles and all
other hardware must be rigged safely. An assist crane that is rated above weight capacity is
required.

MODEL WEIGHT OF COUNTERWEIGHT

Solar 300LC-V 4,900 kg (10,803 lb)
Solar 300LL 6,300 kg (13,890 lb)
Solar 340LC-V 6,500 kg (14,330 lb)
Solar 420LC-V 8,200 kg (18,078 lb)
Solar 470LC-V 8,500 kg (18,740 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.

To maintain stability the counterweight should

be removed whenever the front attachment is
taken off the machine.

90 ~ 110

15
HDO4002I
Figure 1

Counterweight S0403050K
Page 3
When loading an excavator (either track or
wheeled type) on a trailer for transport after the
front attachment has been removed, secure the
swing lock (if equipped) to hold the deck in place
and always go backwards up the loading ramp.
The counterweight end of the deck has to get on
the trailer first, while the cab is still going up the
ramp (Figure 1).

15

HDO4003I
Figure 2

S0403050K Counterweight
Page 4
REMOVAL
1. Park on firm and level ground.
2. Lower bucket to ground.
3. Shut engine down and remove key from
starter switch.

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

4. Set safety lever on "LOCK" position.

5. Hang maintenance warning tag on
controls.
6. Disconnect negative (-) battery cable
leading to frame from battery.
7. Raise engine compartment cover.
8. Remove two caps (1, Figure 4) from
counterweight (2). 3
1
9. Install two lifting eyes in lifting holes (3,
Figure 4).
3
Model Lifting Eye Size
2
Solar 300LC-V
Solar 300LL
Solar 340LC-V M48x5.0
Solar 420LC-V
Solar 470LC-V

10. Using a suitable lifting device capable of

handling load, partially support
counterweight (2, Figure 4) before
beginning to loosen four bolts (4). Stop
lifting with assist crane as soon as lifting
slings are taut.
11. Remove four bolts (4, Figure 4) and 6
washers (5) from counterweight (2).
5
NOTE: Heat bolts if necessary, to free
them. 4

12. When bolts (4, Figure 4) and washers (5) ARS1650L

have been removed, lift counterweight (2) Figure 4

Counterweight S0403050K
Page 5
 a very short distance above support frame (6) and stop. Check slings and make sure counterweight
is being supported evenly.

INSTALLATION
1. Raise engine compartment cover.
3
2. Using suitable lifting device capable of 1
handling load, raise counterweight (2,
Figure 5) into position just above support
frame (6) leaving counterweight 3
suspended. Verify that counterweight is
2
level and even.
NOTE: Leave counterweight (2, Figure
5) suspended 3 mm (0.125")
above support frame (6) until all
four mounting bolts (4) are
started in counterweight
mounting holes.
3. Slide washers (5, Figure 5) onto bolts (4).
Apply Loctite #242 to mounting bolt
threads.
4. Install four bolts (4, Figure 5) with washers
(5) into counterweight until washers 6
contact support frame. Fully lower
counterweight onto support frame and 5
finish tightening bolts. 4
NOTE: Tighten bolts (4, Figure 5) to ARS1650L
values shown in following table.
Figure 5

Model Bolt Torque

Solar 300LC-V
Solar 300LL
250 kg•m
Solar 340LC-V
(1,807 ft lb)
Solar 420LC-V
Solar 470LC-V

5. Remove lifting device and lifting eyes from counterweight lifting holes (3, Figure 5).
6. Install two caps (1, Figure 5) in lifting holes (3).
7. Connect negative (-) battery cable to battery.

S0403050K Counterweight
Page 6
 S0405120K

1FUEL TANK

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 TANK
MODEL SERIAL NUMBER RANGE
Solar 470LC-V 1001 and Up

Copyright 2002 Daewoo

January 2002

Fuel Tank S0405120K

Page 1
TABLE OF CONTENTS

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

Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Removal ......................................................................................................... 6
Installation ...................................................................................................... 9
Start-up Procedures ..................................................................................... 11

S0405120K Fuel Tank

Page 2
GENERAL DESCRIPTION

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

Fuel Tank S0405120K

Page 3
PARTS LIST

12

11

FR
ON
T
1

13

16

26
14

35
33 19

20

35
33

10

23

6
7
5
ASS1180L

Figure 1

S0405120K Fuel Tank

Page 4
 Reference Reference
Description Description
Number Number
1 Fuel Tank 12 Cap
3 O-ring 13 Plug
4 Cover 14 Level Gauge
5 Bolt (M10x1.5x25) 16 O-ring
6 Spring Washer 19 O-ring
7 Drain Cock 20 Plug
8 Bolt (M16x2.6x60) 23 Spacer
9 Shim 26 Bolt (M12x1.75x16)
10 Shim 33 Bolt (M8x1.25x12)
11 Fuel Filter 35 Clip

SPECIFICATIONS
Fuel tank capacity is 620 liters (164 U.S. gal).

Fuel Tank S0405120K

Page 5
REMOVAL
1. Look at fuel level display (Figure 2) on
instrument panel in operator’s cab to see
what it displays. The display is divided into GREEN
ten separated segments, each F
representing 10 percent of total fuel
supply. Also look at level gauge on side of RED
tank to estimate volume of fuel left in tank.
NOTE: If possible, work excavator until
available fuel supply in tank has E
been run down as far as
possible.
ARO0150L
Figure 2
2. Park on firm and level ground and swing
turntable to approximately a 90˚ with
respect to tracks. See Figure 3.

ARS1550L
Figure 3
3. Lower bucket to ground.
4. Shut engine down and remove key from
starter switch.

WARNING!
If engine must be run while
performing maintenance, use
extreme care. Always have one
person in the cab at all times. Never
leave the cab with the engine
Figure 4
running.

5. Set safety lever on "LOCK" position.

6. Hang maintenance warning tag on
controls.
7. Disconnect negative (-) battery cable
leading to frame from battery.

S0405120K Fuel Tank

Page 6
8. Clean area around fuel tank fill cap (1,
Figure 5). Open fuel cap.

Figure 5
9. Place a large enough container under fuel
tank to collect remaining fuel. Open drain
valve (Figure 6) at bottom of tank and
drain.
NOTE: Fuel tank capacity is 620 liters
(164 U.S. gal).

Figure 6
10. Tag and disconnect fuel supply line (1,
Figure 7) and fuel return line (2) from Fuel
tank (3) and carefully drain remaining fuel
from lines.
11. Remove clamp (4, Figure 7) holding fuel 3
return line (2) to tank (3).

1 2
ASS1200L
Figure 7
12. Tag and disconnect wires leading to fuel
sensor (1, Figure 8) on side of fuel tank
(2).
3
13. If equipped, remove components from fuel
filler pump port (3, Figure 8) on side of fuel 2
tank (2).

ASS1210L
Figure 8

Fuel Tank S0405120K

Page 7
14. Remove four bolts (1 and 2, Figure 9),
clamp (6) and stay (3) from fuel tank and
frame.
Remove four bolts (4) and cover (5) from
fuel tank.

1 2
6

5
4

ASS1220L
Figure 9
15. Install two 12 mm eye bolts in threaded
holes (1 and 2, Figure 10). Using a 1
suitable lifting device, sling eye bolts.
16. Remove six bolts and washers (4 , Figure
10) holding tank (3) to frame. Lift tank 25 3
mm (1 in) and make sure it is balanced. 2
Make sure that there are no other
electrical wires or hoses connected to
tank. Completely remove tank after
inspection.
NOTE: The clear level gauge on the
side of the tank is easily 5
damaged. Be careful of
obstacles and wind gusts. 4
ASS1230L
17. Remove shims (5, Figure 10). Figure 10
NOTE: If tank is to be reused note
position and amount of shims
used for each mounting bolt
location.

S0405120K Fuel Tank

Page 8
INSTALLATION
1. Install two 12 mm eye bolts in threaded
holes (1 and 2, Figure 11). Using a 1
suitable lifting device, sling eye bolts.
2. Set fuel tank (3, Figure 11) into position.
Install six bolts and washers (4) finger 3
tight, to secure tank to frame. 2

NOTE: The clear level gauge on the

side of the tank is easily
damaged. Be careful of
obstacles and wind gusts.
3. Install shims (5, Figure 11) as needed to 5
prevent tank (3) from rocking or stress
from mounting bolts (4). 4
ASS1230L
4. Tighten mounting bolts (4, Figure 11) after
shims are installed. Figure 11
NOTE: Bolt torque is 27 kg•m
5. Install four bolts (4, Figure 12) and cover
(5) on fuel tank.
Install four bolts (1 and 2), clamp (6) and
stay (3) on fuel tank and frame.

1 2
6

5
4

ASS1220L
Figure 12

Fuel Tank S0405120K

Page 9
6. Connect wires as tagged to fuel sensor (1,
Figure 13) on side of fuel tank (2).
7. If equipped, connect components to the
3
fuel filter pump port (3, Figure 13) on side
of fuel tank (2). 2

ASS1210L
Figure 13
8. Connect as tagged, fuel supply line (1,
Figure 14) and fuel return line (2) to fuel
tank (3).
9. Install clamp (4, Figure 14) to hold fuel
return line (2) to tank (3). 3

1 2
ASS1200L
Figure 14
10. Make sure fuel tank drain valve (Figure 15)
on bottom of tank is closed.
11. Fill fuel tank and check for signs of leaks.
Correct any problems found.
12. Connect negative (-) battery cable to
battery.

Figure 15

S0405120K Fuel Tank

Page 10
START-UP PROCEDURES
If engine does not start, the fuel system may
need priming. Prime the fuel system using the
following procedure;
1. Loosen plug (Figure 16) on top of fuel filter
head.

Figure 16
2. Unscrew and pump hand operated primer
pump (Figure 17) by fuel injection pump.
Pump primer until fuel is present at plug
hole in fuel filter head.
3. Tighten plug in fuel filter head.
4. Continue to pump primer pump until a
strong resistance is felt. Screw primer
pump knob back into housing.
5. Start engine and look for signs of leaks.
6. Repeat procedure if necessary.
Figure 17

Fuel Tank S0405120K

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S0405120K Fuel Tank
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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 1001 and Up
Mega 250-III 1001 and Up
Mega 250-V 1001 and Up
Mega 300-V 1001 and Up
Mega 400-III PLUS 1001 and Up
Mega 400-V 1001 and Up
Mega 500-V 1001 thru 2000
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Solar 170LC-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 220LC-V 0001 and Up
Solar 220LL 1001 and Up
Solar 220N-V 1001 and Up
Solar 250LC-V 1001 and Up

Models continued on back of cover.

Copyright 2001 Daewoo

December 2001

Fuel Transfer Pump S0405500

Page 1
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MODEL SERIAL NUMBER RANGE

Solar 290LC-V 0001 and Up
Solar 290LL 1001 and Up
Solar 300LC-V 1001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 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

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

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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

Fuel pump consists of motor, pump, switch and

hose assembly.

Figure 2

Fuel Transfer Pump S0405500

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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 pump
during operation, it can become lodged between
the rotor and/or vanes and generate heat which
can cause 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 a new ones.

Figure 5 WITHOUT TOGGLE SWITCH

S0405500 Fuel Transfer Pump

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Insert vane, with the circled edge of vane facing

in the counterclockwise direction. (Detail A)
Insert O-ring again at reassembly of 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.
Loosen the switch cover and screw (M5 x L95)
from the rear cover.
Remove cover.
At reassembly of rear cover, widen the space of
brush and insert it to the armature. Then fit the Figure 7
hole of screw in the housing.
Be careful when installing screw. The cover
screw may be attracted by the motor magnet.

Fuel Transfer Pump S0405500

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

S0405500 Fuel Transfer Pump

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S0407000
R1

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 S0407000

MODEL SERIAL NUMBER RANGE
Solar 130LC-V 0001 and Up
Solar 170LC-V 1001 and Up
Solar 220LC-V 0001 and Up
Solar 220LL 1001 and Up
Solar 250LC-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

Copyright 2001 Daewoo

December 2001

Swing Bearing S0407000

Page 1
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TABLE OF CONTENTS

Swing Bearing Maintenance .......................................................................... 3

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

S0407000 Swing Bearing

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

Swing Bearing S0407000

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SWING BEARING BASIC OPERATION

The swing bearing, which connects the upper
structure with the lower structure, consists of a
inner ring, outer ring and ball bearings. During
swing movement, power from the swing motor is
transferred to the pinion by planetary gears
connected to gears on the inner ring, which is
fixed in the undercarriage. Ball bearings turn the
outer ring.

Reference
Description
Number
1 Ball
2 Seal A
3 Seal B
4 Retainer
5 Retainer
6 Outer Ring
7 Inner Ring
8 Tapered Pin
9 Plug

Figure 2
REBUILDING SWING BEARING
1. Remove tip of tapered pin (1, Figure 3)
using grinder and tap lightly to remove
debris.

Figure 3
2. Remove plug (1, Figure 4) using a M10 x
1.25 bolt (2).

Figure 4

S0407000 Swing Bearing

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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 S0407000

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S0407000 Swing Bearing

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S0408060

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 GEARBOXS0408060

MODEL SERIAL NUMBER RANGE
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2002 Daewoo

January 2002

Swing Reduction Gearbox S0408060

Page 1
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TABLE OF CONTENTS

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

Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Special Tools and Materials............................................................................ 6
Special Tools ........................................................................................... 6
Troubleshooting, Testing and Adjustment....................................................... 8
Removal ......................................................................................................... 9
Disassembly ................................................................................................. 11
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 14
Reassembly.................................................................................................. 16
Installation .................................................................................................... 21

S0408060 Swing Reduction Gearbox

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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 S0408060

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PARTS LIST

24
32

19

30
9

33 23
25 22
29 6

20

18
17 14
13
16 10
31 12
11
8
2 15
7

27

1
28
34 27

4 3
35 5
36
38 37 39
26

HAAA4260

Figure 1

S0408060 Swing Reduction Gearbox

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Reference Reference
Description Description
Number Number
1 Casing 21 -------------
2 Drive Shaft 22 No. 1 Planet Gear
3 Plate 23 No. 1 Pin Assembly
4 Roller Bearing 24 Socket Bolt
5 Cover Plate 25 No. 1 Sun Gear
6 Thrust Washer No. 1 26 Spacer
7 Oil Seal 27 Plug
8 Roller Bearing 28 Plug
9 No. 1 Ring Gear 29 Level Gauge Pipe
10 No. 2 Carrier 30 Level Gauge
11 Thrust Washer No. 2 31 Double Tab Washer
12 Planet Gear No. 2 32 Pipe
13 No. 2 Bushing 33 Snap Ring
14 No. 2 Pin 34 Pinion
15 Spring Pin 35 Cover
16 Bolt 36 Spring Washer
17 No. 3 Thrust Washer 37 Bolt
18 No. 2 Sun Gear 38 Wire
19 Knock Pin 39 Bolt
20 No. 1 Carrier

SPECIFICATIONS

Swing Reduction Gearbox Specification

Drive Type Two Stage Planetary Gear
Reduction Ratio 19.64
Maximum Output Speed 74.3 rpm
Maximum Output Torque 1,176.8 kg•m (8,512 ft lb)
Weight 170 kg (375 lb)

Pinion Gear Specification

Type Stub Gear
Gear P.C.D. 180 mm (7.09 in)
No. of Teeth 15
Module 12

Swing Reduction Gearbox S0408060

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SPECIAL TOOLS AND MATERIALS

SPECIAL TOOLS

Drive Shaft Front Bearing Jig

Dimension Measurement
A 130.0 mm (5.1181 in) Dia.
B 100.0 mm (3.9370 in) Dia,
C 83.0 mm (3.2677 in)

HAAC8850
Figure 2
Oil Seal Insert Jig

Dimension Measurement
A 10.0 mm (0.3937 in)
B 20.0 mm (0.7874 in)
C 99.0 mm (3.8976 in) Dia.
D 123.0 mm (4.8425 in) Dia.
E 40.0 mm (1.5748 in) Dia.
F 100.0 mm (3.9370 in)

HAAC8860
Figure 3
Spring Pin Insert Jig

Dimension Measurement
A 9.50 mm (0.3740 in) Dia.
B 15.0 mm (0.5906 in)
C 5.50 mm (0.2165 in) Dia.

HAAC8870
Figure 4

S0408060 Swing Reduction Gearbox

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Swage Jig

Dimension Measurement
A 18.0 mm (0.7087 in) Dia.
B 26.0 mm (1.0236 in) Dia.
C 40.0 mm (1.5748 in) Dia.
D 10.0 mm (0.3937 in)
E 1.0 mm (0.0394 in) Radius
F 2.0 mm (0.0787 in) Radius

HAAC8880
Figure 5
Roller Bearing insert Jig

Dimension Measurement
A 90.10 - 90.20 mm
(3.5472 - 3.5512 in)
Dia.
B 159.70 - 159.8 mm
(6.2874 - 6.2913 in)
Dia.
C 50.0 mm (1.9685 in)

HAAC8890
Figure 6

Swing Reduction Gearbox S0408060

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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

S0408060 Swing Reduction Gearbox

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REMOVAL
1. Lower bucket to ground.
2. Shut engine down and remove key from
starter switch.

WARNING!
If engine must be run while
performing maintenance, use
extreme care. Always have one
person in the cab at all times. Never
leave the cab with the engine
Figure 7
running.

3. Fully stroke work levers (joysticks) in all

directions to relieve pressure from
accumulators.
4. Set safety lever on "LOCK" position.
5. Hang maintenance warning tag on
controls.
6. Disconnect negative (-) battery cable
leading to frame from battery.
7. Tag and disconnect hoses from swing
motor (1, Figure 8). Plug and cap hoses
and ports to prevent contamination from
entering hydraulic system or component.
8. Disconnect tube (2, Figure 8) from drain
cock (3).
9. Disconnect grease lubrication line (not
shown) from reduction gearbox (5, Figure
8).
10. Remove twenty-two bolts and washers (4,
Figure 8) holding swing reduction gearbox
(5) to frame.
11. Using a suitable lifting device, sling swing
motor (1, Figure 8) and remove swing
motor and reduction gearbox (5) as an
assembly from unit.
Figure 8
NOTE: A drain cock (3, Figure 8) and
tube are on side of gearbox. Be
careful not to damage valve or
tube.
NOTE: There are two alignment pins
(6, Figure 8), on reduction
gearbox flange.

Swing Reduction Gearbox S0408060

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S0408060 Swing Reduction Gearbox

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DISASSEMBLY
NOTE: Prior to disassembly match mark swing motor (2, Figure 9), No. 1 ring gear (9, Figure 10)
and casing (1).
1. Remove oil level dipstick, dipstick tube and
adaptor (1, Figure 9) from swing motor (2).
2. Remove breather pipe (3, Figure 9) and
adaptor (4) from swing motor (2).
3. Remove breather (5, Figure 9) from
breather pipe (3) if replacement is
necessary.
4. Remove drain cock (6, Figure 9) and
reducer (7) to drain gear oil from gearbox
(8).

IMPORTANT
Use a clean, dry container (with at
least 11 liters, or 2.9 gallons capacity)
to catch gear oil. A clean container
allows an evaluation to be made of
the used oil. The presence or relative
lack of metal wear shavings in the
used oil or obvious deterioration or
contamination of the oil can provide
a useful indicator of the motor’s
general condition.

5. Cut lock wire (9, Figure 9) and remove it

from drilled head bolts (10). Figure 9
6. Remove four drilled head bolts and lock
washers (10, Figure 9), lock plate (11),
pinion gear (12) and spacer ring (13) from
drive shaft (14).
NOTE: Loctite is spread on the spacer ring (13, Figure 9) when it is originally installed at factory.
Heat may be required for disassembly.
7. Unbolt the sixteen socket head bolts (15, Figure 9) and separate swing motor (2) from gearbox (8).
NOTE: Ring gear (9, Figure 1) may come loose with swing motor (2, Figure 9).

Swing Reduction Gearbox S0408060

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19

33 23
25 22
6

20

18
17 14
13

10
12
11
8
15
7

27
16
31
1
28
2 27

3
5

39

HAAA4261
Figure 10

S0408060 Swing Reduction Gearbox

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8. Snap ring (1, Figure 10) will remain on swing motor shaft. Remove snap ring only if replacement is
necessary.
9. Remove No. 1 sun gear (25, Figure 10) from No. 1 carrier (20) and from end of No. 2 sun gear (18).
10. Remove No. 1 carrier (20, Figure 10) with three No. 1 planetary gears (22) still installed.
NOTE: When removing carrier (20, Figure 10), No. 2 sun gear (18) may come out with it.
11. Remove pin (23, Figure 10), No. 1 planet gear (22) and No. 1 thrust washer (6) from No. 1 carrier
(20). Repeat procedure for remaining planetary gear assemblies.
NOTE: Discard pin (23, Figure 10) and use a new one at reassembly.
NOTE: Keep all components together in proper orientation so that wear patterns match during
assembly. Do not mix previously used parts.
12. Remove No. 1 ring gear (9, Figure 10) from casing (1).
NOTE: Remove knock pin (19, Figure 10) from No. 1 ring gear (9) if replacement is necessary.
13. Remove No. 2 sun gear (18, Figure 10) from on top of No. 3 thrust washer (17).
14. Bend tabs on double tab washer (31, Figure 10) away from head of bolt (16). Remove bolt (16),
double tab washer (31) and No. 3 thrust washer (17) securing No. 2 carrier (10) to drive shaft (2).
NOTE: Discard double tab washer (23, Figure 10) and use a new one at reassembly.
15. Remove No. 2 carrier (10, Figure 10) from drive shaft (2).
16. Disassemble No. 2 carrier (10, Figure 10).
A. Remove spring pin (15, Figure 10) from No. 2 carrier (10) and No. 2 pin (14).
B. Remove No. 2 pin (14, Figure 10), No. 2 thrust washer (11), No. 2 planet gear (12) and No. 2
bushing (13).
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.
17. Remove eight bolts (39, Figure 10) and cover plate (5) from casing (1).
18. Remove plate (3, Figure 10) from cover plate (5).
19. Press drive shaft (2, Figure 10) and roller bearing (4) from casing (1).
NOTE: Press on carrier end of drive shaft (2, Figure 10). Be careful not to damaged threaded
hole.
20. Press drive shaft (2, Figure 10) out of roller bearing (4).
21. Using a suitable puller, remove roller bearing (8, Figure 10) from casing (1).
22. Remove oil seal (7, Figure 10) from casing (1).
23. Remove two plugs (27, Figure 10) and plug (28) from front casing (1), if replacement is necessary.

Swing Reduction Gearbox S0408060

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CLEANING AND INSPECTION (WEAR LIMITS AND

TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
Inspect all components in the assembly. Pay particular attention to oil seals, lock and spring pins and
fastener bolts. Using new replacement parts for these components is recommended whenever there is any
doubt at all about the condition or serviceability of original parts.

S0408060 Swing Reduction Gearbox

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Swing Reduction Gearbox S0408060

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REASSEMBLY

19

33 23
25 22
6

20

18
17 14
13

10
12
11
8
15
7

27
16
31
1
28
2 27

3
5

39

HAAA4261
Figure 11

S0408060 Swing Reduction Gearbox

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1. Install two plugs (27, Figure 11) and plug (28) in front casing (1), if replacement was necessary.
NOTE: Use Loctite #592 Pipe Sealant on plugs.
2. Press oil seal (7, Figure 11) into casing (1).
NOTE: Use Loctite #277 on O.D. of seal. Be careful not to get sealant on lips of seal.
3. Press roller bearing (8, Figure 11) into casing (1).
NOTE: Press only on outer bearing race.
4. Press roller bearing (4, Figure 11) on drive shaft (2).
NOTE: Press only on inner bearing race.
5. Press drive shaft (2, Figure 11) and roller bearing (4) into casing (1).
NOTE: Press on outer race of bearing (4, Figure 11) and pinion gear end of shaft (2) at the same
time. Be careful not to damage threaded holes in end of shaft.
NOTE: Make sure that bearing (8, Figure 11) remains seated on shoulder.
6. Hand pack bearing (4, Figure 11) and grease cavity with grease. Rotate drive shaft to ensure that
bearing is coated with grease.
7. Install plate (3, Figure 11) in cover plate (5).
8. Secure cover plate (5, Figure 11) to casing (1) with eight bolts (39, Figure 11).
NOTE: Apply Loctite #262 to bolt threads.
NOTE: Tighten bolts to 700 - 740 kg•cm (51- 54 ft lb).
9. Assemble No. 2 carrier (10, Figure 11).
A. Position No. 2 bushing (13, Figure 11) in No. 2 planet gear (12). Position gear and bushing, No.
2 thrust washer (11) and No. 2 pin (14) in No.2 carrier (10).
B. Align spring pin hole in No. 2 pin (14,
Figure 11) with hole in No. 2 carrier
(10).
NOTE: Figure 12, shows how end of
holes in pin (14, Figure 11)
should be turned, in relation to
the drive shaft.
C. Press spring pin (15, Figure 11) into
No. 2 carrier (10) and No. 2 pin (14).

Figure 12

Swing Reduction Gearbox S0408060

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19

33 23
25 22
6

20

18
17 14
13

10
12
11
8
15
7

27
16
31
1
28
2 27

3
5

39

HAAA4261
Figure 13

S0408060 Swing Reduction Gearbox

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D. As shown in Figure 14, use a punch

to stake spring pins (15, Figure 13)
(inserted in the previous step) into
place.
E. Repeat procedure for remaining
planetary gear assemblies.
10. Position No. 2 carrier (10, Figure 13) on
drive shaft (2).
11. Secure No. 2 carrier (10, Figure 13) to
drive shaft (2) with No. 3 thrust washer
(17), new double tab washer (31) and bolt
(16). Figure 14
NOTE: Tighten bolt to 3,000 - 3,070
kg•cm (217 - 222 ft lb).
NOTE: Bend tabs on washer to hold bolt into position.
12. Position No. 1 ring gear (9, Figure 13) on casing (1).
NOTE: Install knock pin (19, Figure 13) in No. 1 ring gear (9) if replacement was necessary.
NOTE: Coat mating faces of casing and ring gear with Loctite #609.
13. Attach No. 1 thrust washer (6, Figure 13), No. 1 planet gear (22) and new pin (23) to No. 1 carrier
(20),. 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.
14. Install No. 2 sun gear (18, Figure 13) on top of No. 3 thrust washer (17).
15. Position No. 1 carrier (20, Figure 13) into No. 1 ring gear (9) and engage No.2 sun gear (18).
16. Set No. 1 sun gear (25, Figure 13) into No. 1 carrier (20) and on end of No. 2 sun gear (18).
17. Install snap ring (1, Figure 13) on swing motor shaft, if replacement was necessary.

Swing Reduction Gearbox S0408060

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18. Align match marks and position swing

motor (2, Figure 15) on gearbox (8). Install
twelve socket head bolts (15) to secure
swing motor to gearbox.
NOTE: Coat mating faces of swing
motor (2, Figure 15) and ring
gear (3, Figure 11) with Loctite
#609.
NOTE: Apply Loctite #262 to bolt
threads.
NOTE: Tighten bolts to 1,440 - 1,500
kg•cm (104 - 108 ft lb).
19. Coat I.D. of spacer ring (13, Figure 15)
with Loctite #609. Slide spacer into
position on drive shaft (14).
NOTE: Make sure that Loctite does not
come into contact with oil seal
(33, Figure 11) or an leak failure
may occur.
20. Install lock plate (11, Figure 15), four lock
washers and drilled head bolts (10) on
drive shaft (14).
NOTE: Apply Loctite #262 to bolt
threads. Figure 15
NOTE: Tighten bolts to 27 kg•m (195 ft
lb).
21. Use lock wire (9, Figure 15) to secure drilled head bolts (10) into position.
22. Install reducer (7, Figure 15) and drain cock (6, Figure 15) in gearbox (8).
23. Install breather (5, Figure 15) on breather pipe (3) if remove during disassembly.
24. Install adaptor (4, Figure 15) and breather pipe (3, Figure 15) in swing motor (2).
25. Install dipstick tube (1, Figure 15) and oil level dipstick on swing motor (2).

S0408060 Swing Reduction Gearbox

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INSTALLATION
1. Coat pinion gear with grease. Refer to
operation manual for specifications.
2. Make sure two alignment pins (6, Figure
16) are installed in flange of swing
reduction gearbox (5).
3. Using a suitable lifting device, sling swing
motor (1, Figure 16) and position swing
motor and reduction gearbox (5) as an
assembly on unit.
4. Install twenty-two bolts and washers (4,
Figure 16) to secure swing reduction
gearbox (5) to frame.
NOTE: Apply Loctite #262 to bolt
threads.
5. Connect tube (2, Figure 16) to drain cock
(3).
Figure 16
6. Connect grease lubrication line (not
shown) from reduction gearbox (5, Figure
16).
7. Connect hoses as tagged during removal
to swing motor (1, Figure 16).
8. Fill swing reduction gearbox with oil. Refer
to operation manual for specifications.

Swing Reduction Gearbox S0408060

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S0408060 Swing Reduction Gearbox

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1LOWER STRUCTURE AND CHASSIS

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S0505120

1TRACK ASSEMBLY

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

TRACK ASSEMBLY S0505120

MODEL SERIAL NUMBER RANGE
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2002 Daewoo

January 2002

Track Assembly S0505120

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TABLE OF CONTENTS
General Description ....................................................................................... 3
Track Tension.................................................................................................. 3
Cleaning and Inspection (Wear Limits and Tolerances) ................................. 5
Track Shoes and Links ................................................................................... 9
Parts List ................................................................................................. 9
Track Removal....................................................................................... 10
Track Installation ................................................................................... 11
Front Idler Roller........................................................................................... 12
Parts List ............................................................................................... 12
Front Idler Roller........................................................................................... 13
Parts List ............................................................................................... 13
Front Idler Roller Disassembly .............................................................. 14
Front Idler Roller Reassembly............................................................... 16
Lower Roller ................................................................................................. 17
Lower Roller ................................................................................................. 18
Parts List ............................................................................................... 18
Lower Roller Removal ........................................................................... 19
Lower Roller Disassembly..................................................................... 19
Lower Roller Reassembly ..................................................................... 20
Lower Roller Installation........................................................................ 21
Upper Roller ................................................................................................. 22
Parts List ............................................................................................... 22
Upper Roller ................................................................................................. 24
Parts List ............................................................................................... 24
Upper Roller Removal ........................................................................... 25
Upper Roller Disassembly..................................................................... 25
Upper Roller Reassembly ..................................................................... 27
Track Spring and Track Adjusting Cylinder ................................................... 29
Parts List ............................................................................................... 29
Track Spring and Track Adjusting Cylinder ................................................... 30
Parts List ............................................................................................... 30

S0505120 Track Assembly

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GENERAL DESCRIPTION
The track assembly is composed of the following major components:
1. Track
2. Front Idler Roller
3. Upper Roller
4. Lower Roller
5. Track Spring and Track Adjustment Cylinder

TRACK TENSION

WARNING!
Safely measuring track tension requires two people. One person must be in the operator's seat,
running the controls to keep one side frame in the air, while the other person makes dimensional
checks. Take all necessary precautions to make sure the machine won’t move or shift position
during service. Warm up the engine to prevent stalls, travel the excavator to an area that
provides level, uniform ground support and/or use support blocks when necessary.
The track adjusting mechanism is under very high pressure. NEVER release pressure too
suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from
the fully snugged down position. Bleed off pressure slowly and keep your body away from the
valve at all times.

Track shoe link pins and bushings wear with normal usage, reducing track tension. Periodic adjustment is
necessary to compensate for wear and it may also be required by working conditions.
1. Track tension is checked by jacking up one
side of the excavator. See Figure 1. Place
blocking under frame while taking
measurement.

HAOC740L
Figure 1

Track Assembly S0505120

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2. Measuring the distance (A, Figure 2)

between the bottom of the side frame and
the top of the lowest crawler shoe.
Recommended tension for operation over
most types of terrain is 320 - 340 mm
(12.60 - 13.38 in)
NOTE: This measurement can be
thrown off if there is too much
mud or dirt or other material in
the track assembly. Clean off
the tracks before checking
clearance.
Figure 2
3. Too little sag in the crawler track (less than
320 mm (12.60 in) clearance) can cause
excessive component wear. The recommended adjustment can also be too tight causing accelerated
stress and wear if ground conditions are wet, marshy or muddy, or if the ground is hard and full of
rocks or gravel.
4. The increased clearance recommended for muddy ground conditions is between 340 - 380 mm
(13.38 - 14.96 in). The clearance should be approximately 380 mm (14.96 in) for operation over
gravel, rocky terrain, or over sand or snow. 410.0 mm (16.14 in)

Terrain Type Distance "A"

Normal 340 - 370 mm (13.39 - 14.57 in)
Muddy 370 - 410 mm (14.57 - 16.14 in)
Gravel, Rocky, Sand or Snow 380 mm (14.96 in)

WARNING!
The track adjusting mechanism is under very high pressure. NEVER release pressure too
suddenly. The grease cylinder valve should never be backed off more than 1 complete turn
from the fully snugged down position. Bleed off pressure slowly and keep your body away
from the valve at all times.

5. Track tension adjustments are made

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

S0505120 Track Assembly

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CLEANING AND INSPECTION (WEAR LIMITS AND

TOLERANCES)

CAUTION!
Refer to the "Welding Precautions and Guidelines" information in "General Maintenance
Procedures" section for general recommendations and specific safety precautions, before
starting any lower travel frame component rebuilding procedure.

The tables that follow provide factory-specified dimensional limits (as-new condition, recommended
service and replacement limit) for lower travel frame components.
Recommended maintenance to renew most listed components requires welding on additional material and
grinding off excess. Some components must be replaced before the service limit is exceeded. No
maintenance or renewal is possible.
Compare the values in the tables with dimensions and profiles shown in the adjacent figures.

Normal Recommended Limit for Use

Component / Reference Dimensions Reference (New) Limit for (Repair - P or
Dimension Maintenance Replace - R)
Standard 600 mm (23.62 in) Shoe 24 mm
A
(0.94 in)
18 mm
D B
A B (0.71 in)
C
36 mm 32 mm 30 mm [P]
C
(1.42 in) (1.26 in) (1.18 in)

HBOJ060I
247 mm
Figure 4 D
(9.72 in)

Track link, master link 129 mm 126 mm 122 mm [P]

A
(5.08 in) (4.96 in) (4.80 in)
62 mm 56 mm 50 mm [P]
B
A (2.44 in) (2.20 in) (1.97 in)
B 215.9 mm 220 mm 222 mm [R]
C*
C (8.50 in) (8.66 in) (8.74 in)
HDA7013L
*Check and record the pitch of at least 5 links. Use average of
Figure 5
all measurements to assess required service or action. Master
links must be replaced, they cannot be renewed or rebuilt.

Track Assembly S0505120

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Normal Recommended Limit for Use

Component / Reference Dimensions Reference (New) Limit for (Repair - P or
Dimension Maintenance Replace - R)
Track link, master pin bushing, 71 mm 68 mm 66 mm [R]
A
master bushing (2.80 in) (2.68 in) (2.60 in)
47 mm 49 mm 50 mm [R]
B
(1.85 in) (1.93 in) (1.97 in)
B A
47 mm 45 mm 44 mm [R]
C
(1.85 in) (1.77 in) (1.73 in)
D 46.83 mm 44.83 mm 43.83 mm
D*
C (1.84 in) (1.76 in) (1.73 in)
HDA7014L
Figure 6 * Master pin

B
A
HDA7015L
Figure 7

85 mm 84.5 mm 84.2 mm [R]

Lower roller, axle A
(3.35 in) (3.33 in) (3.31 in)
85 mm 85.5 mm 86 mm [R]
Lower roller, bushing A
(3.35 in) (3.37 in) (3.39 in)
0.39 mm 0.51 mm
Axle-bushing, clearance
(0.0154 in) (0.0201 in)
Gap between bushing and side
1 mm 1.8 mm
collar. (Total amount for both B
(0.039 in) (0.071 in)
sides.)
5 mm 4.5 mm 4.2 mm
Flange thickness B
(0.20 in) (0.18 in) (0.17 in)

Lower roller dimensions 278 mm

A
A
(10.94 in)
209.2 mm 228 mm 242 mm [P]
B B
(8.24 in) (8.98 in) (9.53 in)
200 mm 194 mm 190 mm [P]
C
(7.87 in) (7.64 in) (7.48 in)
250 mm 234 mm 227 mm [P]
D
D (9.84 in) (9.21 in) (8.94 in)
C

HBOJ130I
Figure 8

S0505120 Track Assembly

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Normal Recommended Limit for Use

Component / Reference Dimensions Reference (New) Limit for (Repair - P or
Dimension Maintenance Replace - R)

Figure 9

60 mm 59.5 mm 59.2 mm [R]

Upper roller, axle A
(2.36 in) (2.34 in) (2.33 in)
60 mm 60.5 mm 61 mm [R]
Upper roller, bushing A
(2.36 in) (2.38 in) (2.40 in)
1 mm 1.8 mm [R]
Axle-bushing, clearance
(0.039 in) (0.07 in)
1 mm 1.5 mm
Upper roller, axle B
(0.039 in) (0.06 in)
8 mm 5.5 mm 5 mm [R]
Upper roller, bushing B
(0.31 in) (0.22 in) (0.20 in)

Upper roller 190 mm

A
(7.48 in)
A
B 95 mm
B
(3.74 in)

C
180 mm 171 mm 165 mm [P]
HBOJ070I C
(7.09 in) (6.73 in) (6.50 in)
Figure 10

Track Assembly S0505120

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Normal Recommended Limit for Use

Component / Reference Dimensions Reference (New) Limit for (Repair - P or
Dimension Maintenance Replace - R)

B A HDA7018L
Figure 11
Front idler, axle 85 mm 84.5 mm 84.2 mm [R]
A
(3.35 in) (3.33 in) (3.31 in)
85.5 mm 86 mm [R]
Front idler, bushing A
(3.37 in) (3.39 in)

1 mm 1.8 mm
Axle-bushing, clearance
(0.039 in) (0.071 in)
Gap between bushing and side
1 mm 1.5 mm
collar. (Total amount for both B
(0.039 in) (0.06 in)
sides.)
8 mm 7 mm 6.6 mm [R]
Bushing flange thickness B
(0.315 in) (0.276 in) (0.26 in)

Front idler 200 mm 192 mm 188 mm [P]

A
(7.87 in) (7.56 in) (7.40 in)
99 mm 95 mm 93 mm [P]
B
(3.90 in) (3.74 in) (3.66 in)
B A
600 mm 590 mm 585 mm [P]
C
(23.62 in) (23.23 in) (23.03 in)
C 25 mm 30 mm 32.50 mm [P]
D D
(0.98 in) (1.18 in) (1.28 in)
HDA7021L
Figure 12

S0505120 Track Assembly

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TRACK SHOES AND LINKS

PARTS LIST

Figure 13

Reference Reference
Description Description
Number Number
1 Track Link Assembly 8 Pin; Lock
2 Link; Track (R.H.) 9 Bushing
3 Link; Track (L.H.) 10 Bushing; Master
4 Link; Master (R.H.) 11 Pin; Master
5 Link; Master (L.H.) 12 Shoe 600 mm (23.62 in)
6 Pin 13 Bolt
7 Spacer 14 Nut

Track Assembly S0505120

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

HAOV100L
Figure 15
8. Rotate upper structure to 90˚ from track.
Use bucket and boom to raise track frame
off track.
9. Position blocking under frame.

HAOC741L
Figure 16

S0505120 Track Assembly

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TRACK INSTALLATION
1. Lay rebuilt or new track into position under
track frame. End of track should be
positioned under front idler roller.
2. With upper structure at 90˚ to track frame.
Use bucket and boom to raise track frame
off blocking.
3. With blocking removed, lower track frame
onto track. Make sure all rollers are
properly positioned on track.
HAOC741L
Figure 17
4. Move unit backwards while feeding track
up over front idler roller. Continue to pull
track back until it engages drive sprocket.
5. Align master links and install master pin.
6. Insert new lock pin in master pin. Bend
end of pin over so it is pointing in opposite
direction of other end as shown.
7. Apply track tension. Refer to "Track
Tension" in this section for procedure.

HAOV101L
Figure 18

Track Assembly S0505120

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FRONT IDLER ROLLER

PARTS LIST

Figure 19

Part No. Part Quantity Part No. Part Quantity

1 Bearing 2 5 Axle 1
2 Plug 1 6 Group Seal 2
3 Pin 2 7 Idler 1
4 O-ring 2 8 Bushing 2

S0505120 Track Assembly

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FRONT IDLER ROLLER

PARTS LIST

Figure 20

Reference Reference
Description Description
Number Number
1 Bearing 5 Axle
2 Plug 6 Group Seal
3 Pin 7 Idler
4 O-ring 8 Bushing

Track Assembly S0505120

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FRONT IDLER ROLLER DISASSEMBLY

1. Remove plug (2, Figure 21) and drain oil
from roller assembly (1).

Figure 21
2. Separate the pin (3, Figure 22) from the
bearing (1).

Figure 22
3. Use a press to remove the bearing from
the axle. Separate the O-ring (4, Figure
23) from the axle and insert it into the
bearing.

Figure 23

S0505120 Track Assembly

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4. Detach the group seal (6, Figure 24) from

the idler (7) and bearing (1).

Figure 24
5. Use a press to separate the axle (5, Figure
25), O-ring (4) and bearing (1).

Figure 25
6. Remove bushing (8, Figure 26) with the
press and special tool (ST-1909).

Figure 26

Track Assembly S0505120

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FRONT IDLER ROLLER REASSEMBLY

1. Degrease, clean and dry all parts before
reassembly. Insert bushing (8, Figure 27)
into the idler (7).
2. Grease O-ring (4, Figure 27) and insert it
into the axle.
3. Align the bearing (1, Figure 27) and axle
(5) holes and pin (3) them together.

Figure 27
4. Install group seal (6, Figure 28) inside the
idler (7) and bearing (1).
NOTE: Apply clean engine oil to the
joint side of the group seal.
Apply grease to the group seal
O-ring.

Figure 28
5. Install idler (7, Figure 29) on the axle.
6. Install bearing (1, Figure 29) and pin (3) to
the axle.
NOTE: Fill the idler assembly with new
engine oil with approximately
300 cc (10 fluid ounces).

Figure 29

S0505120 Track Assembly

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LOWER ROLLER
Heat treatment of the lower rollers provides improved wear resistance and hardness. High quality bushings
and seals will ensure long service life if lubricant is replaced at recommended intervals.
NOTE: An exploded view of the lower roller is shown in Figure 30.
Parts List.

Figure 30

Part No. Part Quantity Part No. Part Quantity

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

Track Assembly S0505120

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LOWER ROLLER
PARTS LIST

Figure 31

Reference Reference
Description Description
Number Number
1 Pin 6 Group Seal
2 O-ring 7 Bushing
3 Collar 8 Plug
4 Axle 9 Spring Washer
5 Roller 10 Bolt

S0505120 Track Assembly

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LOWER ROLLER REMOVAL

1. Relieve track tension. Refer to "Track
Tension" in this section for procedure.
2. Swing upper structure at 90˚ to frame.
3. Using bucket raise track off ground and
place blocking under frame.
4. Remove four bolts and lower roller
assembly from track frame. There is an
alignment pin on each end of lower roller
assembly.
HAOC740L
NOTE: To gain access to some rollers Figure 32
the link guard may have to be
removed. Remove four spring
washers and bolts to remove
guard.
NOTE: If additional track clearance is
required, remove upper rollers
before raising track.

LOWER ROLLER DISASSEMBLY

1. Remove plug from the collar and drain oil.
2. Pull the pin (1, Figure 33) from the collar.

Figure 33
3. Separate the collar (3, Figure 34) from the
axle, using a press.

Figure 34

Track Assembly S0505120

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4. Detach O-rings (2, Figure 35) from the

axle.
5. Separate group seals (6, Figure 35) from
the collar and roller (5).
6. Detach collar (3, Figure 35) and O-rings
(2) from the axle, using a press.

Figure 35
LOWER ROLLER REASSEMBLY
1. Degrease, clean and dry all parts before
reassembly. Insert bushing (7, Figure 36)
into roller.
2. Apply grease to the O-rings (2, Figure 36)
and insert into axle.

Figure 36
3. Align collar (3, Figure 37) and axle (4) pin
holes and pin (1) the collar.

Figure 37

S0505120 Track Assembly

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4. Insert group seals (6, Figure 38) into the

roller (5) and collar (3).
NOTE: Apply clean engine oil to the
joint side of the group seal.
Apply grease to the group seal
O-ring.
5. Slide the axle inside the roller.

Figure 38
6. Install the collar (3, Figure 39), O-ring (2),
and pin (1) on the remaining side.
7. Fill with clean engine oil with
approximately 300 cc (10.1 fluid ounces).

Figure 39
LOWER ROLLER INSTALLATION
1. Install four bolts to hold lower roller
assembly to track frame.
NOTE: To gain access to some rollers
a link guard may have to be
removed. Remove four spring
washers and bolts to remove
guard.

HAOC740L
Figure 40

Track Assembly S0505120

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UPPER ROLLER
NOTE: An exploded view of the upper roller is shown in Figure 41.

PARTS LIST

Figure 41

S0505120 Track Assembly

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Part No. Part Quantity Part No. Part Quantity

1 Washer 1 8 Plug 1
2 Cover 1 9 Bushing 1
3 Bolt 6 10 Floating Seal 1
4 Spring Washer 6 11 O-ring 1
5 O-ring 1 12 Thrust Ring 1
6 Body 1 13 Spacer 1
7 Bushing 1 14 Shaft 1

Track Assembly S0505120

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UPPER ROLLER
PARTS LIST

Figure 42

Reference Reference
Description Description
Number Number
1 Plug 7 Axle
2 Bolt 8 Group Seal
3 Cover 9 Bracket
4 Bolt 10 Bushing
5 Washer 11 O-ring
6 Roller 12 Lock Washer

S0505120 Track Assembly

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UPPER ROLLER REMOVAL

1. Relieve track tension. See This will allow
track to be raised so that links clear top of
roller.
2. Position a bottle jack on top of track frame
and apply pressure to track shoe.
3. Remove mounting hardware holding upper
roller assembly to track frame.

Figure 43
UPPER ROLLER DISASSEMBLY
1. Remove the plug (1, Figure 44) from the
cover and drain oil.

Figure 44
2. Remove the bolts and cover (3, Figure 45).
Detach bolts (4) and washer (5).

Figure 45
3. Separate the roller (6, Figure 46) from the
axle (7).

Figure 46

Track Assembly S0505120

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4. Separate the group seal (8, Figure 47)

from the roller and bracket (9).

Figure 47

5. Separate the bushing (10, Figure 48) from

the roller with a press and special tool (ST-
1919).

Figure 48

S0505120 Track Assembly

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UPPER ROLLER REASSEMBLY

1. Degrease, clean and dry all parts before
reassembly. Insert bushing (10, Figure 49)
into the roller (6).

Figure 49
2. Insert group seal (8, Figure 50) into the
roller (6) and bushing.
NOTE: Apply clean engine oil to the
joint side of the group seal.
Apply grease to the group seal
O-ring.

Figure 50
3. Install the axle, washer (5, Figure 51) and
bolt (4).
4. Attach group seal (8, Figure 42) to the
roller (6, Figure 51) and cover (3).
5. Insert the O-ring (11, Figure 51) to the
cover. Attach cover (3) and bolt (2) to the
roller.
6. Fill with 200 cc (6.8 fluid ounces) of engine
oil.

Figure 51

Track Assembly S0505120

Page 27
 Return to Master Table of Contents

7. Tighten plug (1, Figure 52).

Figure 52

S0505120 Track Assembly

Page 28
 Return to Master Table of Contents

TRACK SPRING AND TRACK ADJUSTING CYLINDER

PARTS LIST

Figure 53

Part No. Part Quantity Part No. Part Quantity

1 Tube 1 6 Nut 1
2 Piston Rod 1 7 Track Spring 1
3 Dust Seal 1 8 Bracket 1
4 U-packing 1 (2) 9 Nut 1
5 Backup Ring 1 (2) 10 Bolt (M10 x 1.25) 1

Track Assembly S0505120

Page 29
 Return to Master Table of Contents

TRACK SPRING AND TRACK ADJUSTING CYLINDER

PARTS LIST

Figure 54

Reference Reference
Description Description
Number Number
1 Piston Rod 11 Flange
2 Piston Ring 12 Nut
3 Backup Ring 13 Valve
4 Packing 14 Bolt
5 Retaining Ring 15 Plate
6 Rod 16 Yoke
7 O-ring 17 Socket Bolt
8 Cylinder 18 Flange
9 Spring 19 O-ring
10 Spacer

S0505120 Track Assembly

Page 30
 Return to Master Table of Contents

1ENGINE AND DRIVE TRAIN

 S0605060K

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

MODEL SERIAL NUMBER RANGE

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

Copyright 2001 Daewoo

October 2001

Air-Conditioner S0605060K
Page 1
TABLE OF CONTENTS

Refrigerant Circulation ................................................................................... 3

Control Panel.................................................................................................. 5
Control Specifications..................................................................................... 6
Temperature Level Control and Display ......................................................... 7
Air Discharge According to Path Selection..................................................... 8
Air-conditioning System Circuit Diagram...................................................... 10
Troubleshooting ............................................................................................ 12
Refrigerant System Repairs ......................................................................... 15
Refrigerant Safe Handling Procedures ................................................. 15
Repair and Replacement Procedure..................................................... 16
Refrigerant Recovery ............................................................................ 18
Vacuuming Refrigerant System............................................................. 18
Leakage Check ..................................................................................... 19
Refrigerant Charging............................................................................. 20
Inspecting System For Leakage............................................................ 22

S0605060K Air-Conditioner
Page 2
REFRIGERANT CIRCULATION

3 HDA6046L
Figure 1

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

Air-Conditioner S0605060K
Page 3
 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/sq cm (213 psi) within the
compressor.
• The compressed refrigerant flows into the condenser at high temperature (approximately 80°C
(176˚F)).
• The refrigerant in the condenser is cooled to approximately 60° by the condenser fan. At this
time the refrigerant changes from the gas to the liquid state, even though the temperature has
only been reduced 20°C (68˚F). (From 80° - 60°C (176˚ - 140˚F)).
• The refrigerant in its liquid form is injected into the evaporator through the expansion valve. At
this time the pressure is reduced by approximately 2.0 kg/sq cm (28 psi) and the temperature is
also reduced. As a result, the refrigerant absorbs the heat from the air surrounding the
evaporator creating a cooling effect and changes from the gas to the liquid state.
• The refrigerant once again flows into the compressor in the gaseous state and the process is
repeated.

WARNING!
Refrigerant gas is pressurized and sealed in the air conditioning system. Special
precautions are required for the proper recharging or release of refrigerant. Release of
refrigerant into the atmosphere is strictly regulated by law. Make sure that you are in
compliance with all mandated federal, state and municipality requirements, before starting
any service or repair of the air conditioner. Refrigerant gas used in the system must meet or
exceed specifications for R134a refrigerant, or any subsequently issued environmentally-
mandated standard.

S0605060K Air-Conditioner
Page 4
CONTROL PANEL

ARO0501L
Figure 2

INPUT CONTROL OUTPUT

PANEL

DISPLAY
TEMPERATURE
SENSOR
LOW SPEED RELAY

OFF SW MID SPEED RELAY BLOWER

MOTOR
A / C SW
VENT SW HIGH SPEED RELAY
DEF. SW
HEAT SW A/C TEMP. CONTROL
ACTUATOR MIX DOOR
FRE SW CONTROL
REC SW PANEL VENT ACTUATOR VENT CONTROL
LOW SW
MID SW DEF. ACTUATOR FOOT / DEF.
HI SW
COOL SW INTAKE RECYCLE/FRESH
ACTUATOR AIR CONTROL
WARM SW
TEMPERATURE COMP. RELAY COMPRESSOR
CONTROL ACTUATOR
CONDENSER CONDENSER
FAN RELAY FAN

HDA6048L
Figure 3

Air-Conditioner S0605060K
Page 5
CONTROL SPECIFICATIONS

Control Item Control Switch Control Specifications

Temperature ‘COOL’ Switch
MAX COOL
Control
‘WARM’ Switch 100%

50%

MAX HOT
0%

HDA6049L
Figure 4

Temperature control switch consists of a 24 step

variable selector. The display uses 7, Green / Red two-
color LEDs to display the selected temperature.
Blower Fan ‘OFF’ Switch
Speed Control
‘LOW’ Switch
‘MID’ Switch HI RELAY
‘HI’ Switch MID RELAY
LOW RELAY

OFF LOW MID HI

HDA6050L
Figure 5

Compressor Temperature Sensor

Control
COMP ON

COMP OFF

1.5 C 4.0 C

HDA6051L
Figure 6

S0605060K Air-Conditioner
Page 6
TEMPERATURE LEVEL CONTROL AND DISPLAY
Position
Step LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Sensor Remark
Voltage
0 Green Green Green Green Green Green Green 4.50 V ± 0.2 MAX. COOL
1 Green Green Green Green Green Green Green 4.33 V ± 0.2
2 Green Green Green Green Green Green Green 4.15 V ± 0.2
3 Red Green Green Green Green Green Green 3.98 V ± 0.2
4 Red Green Green Green Green Green Green 3.80 V ± 0.2
5 Red Green Green Green Green Green Green 3.63 V ± 0.2
6 Red Red Green Green Green Green Green 3.46 V ± 0.2
7 Red Red Green Green Green Green Green 3.28 V ± 0.2
8 Red Red Green Green Green Green Green 3.11 V ± 0.2
9 Red Red Red Green Green Green Green 2.93 V ± 0.2
10 Red Red Red Green Green Green Green 2.76 V ± 0.2
11 Red Red Red Green Green Green Green 2.59 V ± 0.2
12 Red Red Red Red Green Green Green 2.41 V ± 0.2
13 Red Red Red Red Green Green Green 2.24 V ± 0.2
14 Red Red Red Red Green Green Green 2.07 V ± 0.2
15 Red Red Red Red Red Green Green 1.89 V ± 0.2
16 Red Red Red Red Red Green Green 1.72 V ± 0.2
17 Red Red Red Red Red Green Green 1.54 V ± 0.2
18 Red Red Red Red Red Red Green 1.37 V ± 0.2
19 Red Red Red Red Red Red Green 1.20 V ± 0.2
20 Red Red Red Red Red Red Green 1.02 V ± 0.2
21 Red Red Red Red Red Red Red 0.85 V ± 0.2
22 Red Red Red Red Red Red Red 0.67 V ± 0.2
23 Red Red Red Red Red Red Red 0.50 V ± 0.2 MAX. HOT

Air-Conditioner S0605060K
Page 7
AIR DISCHARGE ACCORDING TO PATH SELECTION
Face, Rear, and Defroster

ARS1280L
Figure 7

Foot

ARS1290L
Figure 8

S0605060K Air-Conditioner
Page 8
Face and Defroster

ARS1300L
Figure 9

Air-Conditioner S0605060K
Page 9
AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM

3 2
5
B A

10A 20A 30A

BR
4 E
6 1
0
6 I 2

3 II
10 9
15
15-1 15-2
+ -
M
14

22
15-3 15-4 15-5
11 13

7
8 87a
30
3
5
11
12
HIGH
MID
- + 87
M 8 13 LOW
85 86 18 9 REC
19 10 FRE

10 M
15-6
MODE SELECT
23 7 VENT
9 AIR MODE
RECIRCLE/FRESH
21
20
17
8
DEF
FOOT 15-7
87a
BLOWER SPEED
30
M
87 TEMP. CONTROL

85 86 14 3
15 2 (COOL) M

9
2
16
4
5
15-8
4 1

DEF 2 7 1 6

10 M FOOT
3 6
26 16
15-9
CN6 HRS 26P
CN5 AMP MIC 13P + 250 4P
14
11 15
HR 3P

13
12
(CN6) (CN5)
ARS1310L
Figure 10

S0605060K Air-Conditioner
Page 10
 Reference Reference
Description Description
Number Number
1 Battery 13 Compressor
2 Battery Relay 14 A/C Control Panel
3 Fusible Link 15 A/C Unit
4 Circuit Breaker 15-1 Blower Motor
5 Fuse 15-2 Resister
6 Lamp Switch 15-3 High Speed Relay
7 Condenser Fan Relay 15-4 Mid Speed Relay
8 Condenser Fan Motor 15-5 Low Speed Relay
9 Compressor Relay 15-6 Recirculate / Fresh Air
10 Foot / Defrost Control Control Actuator
Actuator 15-7 Vent Actuator
11 Receiver Dryer (Low / High 15-8 Temperature Control
Pressure Cut Off Switch) Actuator
12 Diode 15-9 Temperature Sensor
(Evaporator)

Air-Conditioner S0605060K
Page 11
TROUBLESHOOTING
Refrigerant Pressure Check

LO HI

HDA6074L
Figure 11

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 (36 - 43 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.

S0605060K Air-Conditioner
Page 12
 High Pressure: Approximately 20 - 25 kg/cm2 (285 - 356 psi)
3
Low Pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.

High Pressure: Over 6 kg/cm2 (85 psi)

4
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 10
1 minutes.
5. Recheck high / low pressure readings. Contaminated system, replace
expansion valve.
High Pressure: 13.0 - 19.0 kg/cm2 (185 - 270 No
(Replace evaporator core
psi) assembly.)
Low Pressure: 1.5 - 3.3 kg/cm2 (21.3 - 46.9 psi)

High Pressure: Over 6 - 18 kg/cm2 (85 - 256 psi)

5
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.

Air-Conditioner S0605060K
Page 13
 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.

S0605060K Air-Conditioner
Page 14
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 12

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.

Air-Conditioner S0605060K
Page 15
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.

S0605060K Air-Conditioner
Page 16
 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 13

Air-Conditioner S0605060K
Page 17
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 14
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 15
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.

S0605060K Air-Conditioner
Page 18
2. Check system for vacuum leak.
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
If the system is holding the pressure and it
has not changed for 10 minutes, vacuum
out the system for an additional 20
minutes. HDA6069L
Figure 16
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 1
Description
Number
1 Handle
2 Hose Connection
3 Mounting Disk 2

A. Before mounting valve on the 3

container, make sure the handle is in
the counter clockwise most position,
with the puncture pin retracted and HDA6070L
the mounting disk is in the raised Figure 17
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 psi) and close the
high side valve.

Air-Conditioner S0605060K
Page 19
3. Using a refrigerant leak detector or soapy
water check each joint for leakage.
1
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 HDA6071L
charging process. Figure 18

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 100g (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 19
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)

S0605060K Air-Conditioner
Page 20
 Engine Speed: 1,300 - 1,500 RPM

WARNING!
When charging refrigerant system with the engine running;
• Always keep refrigerant supply container in the upright position.
• Never open the high side pressure valve.

4. Open the manifold gauge low side valve and charge system to standard capacity.

Gauge Dial Standard Reading

High Side Gauge 13 - 20 kg/cm2

(185 - 285 psi)

Low Side Gauge 1.5 - 3.5 kg/cm2

(22 - 50 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.

Air-Conditioner S0605060K
Page 21
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 2
from the high pressure side. 1
NOTE: When the refrigerant circulation
has been stopped the high
pressure will start to decrease
and the low pressure will start 3
to increase until they are
equalized. Starting the
4
inspection from the high side HDA6073L
will result in a accurate test. Figure 20

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 matter inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds
minimum.)
NOTE: When inspecting leakage from the air-conditioning unit, perform the inspection in a well
ventilated area.

S0605060K Air-Conditioner
Page 22
 S0609010K

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)

MODEL SERIAL NUMBER RANGE
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

Copyright 2001 Daewoo

December 2001

Drive Coupling (Main Pump) S0609010K

Page 1
TABLE OF CONTENTS

Drive Coupling................................................................................................ 3
Special Tools .................................................................................................. 4
Drive Coupling Installation.............................................................................. 6
Installation Procedure ............................................................................. 9

S0609010K 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 2, show typical drive coupling installations.

ARS1710L

Figure 1 KAWASAKI

ARS1720L

Figure 2 REXROTH

Drive Coupling (Main Pump) S0609010K

Page 3
SPECIAL TOOLS
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 3 and
Figure 5). This distance will be referred to as
"Measurement H" in the installation instructions
that follow.
NOTE: In manufacturing drawings
(Figure 4), dimension "A" and
"B" equal the "Measurement H."
The two tools shown are
designed to be used on various
models of equipment. Only one
end of the tool is used for a
specific model of equipment.

Figure 3

A C
B

D
E
G
F

RELIEF H
RELIEF
KNURL
HAAA8350
Figure 4

S0609010K Drive Coupling (Main Pump)

Page 4
 Dimensional Details for Figure 4
Dimension Measurement Models
A 6 ±0.1 mm
S300LC-V, S300LL
(0.2362 ±0.0039 in.)
B 7 ±0.1 mm
S340LC-V, S420LC-V, S470LC-V
(0.2756 ±0.0039 in.)
C 20.0 mm (0.787 in.)
D 7.0 mm (0.275 in.)
E 18.0 mm (0.708 in.) Radius
F 22.0 mm (0.866 in.) Radius
G 30.0 mm (1.181 in.) Radius
H 1.0 mm (0.039 in.) x 45˚
Chamfer

Drive Coupling (Main Pump) S0609010K

Page 5
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 5 DRIVE COUPLING INSTALLATION

S0609010K Drive Coupling (Main Pump)

Page 6
 Table 1 Parts Information and Torque for Figure 5
Reference Description Qty. Torque
Number (See Table 2)
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) S0609010K

Page 7
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 5)

Coupling Part Torque Value for Torque Value for
Model "Measurement H"
Number "Ta" "Tb"
S300LC-V 5.5 - 6.5 mm 44 - 49 kg•m 20 - 22 kg•m
414-00040
S300LL (0.216 - 0.256 in.) (318 - 354 ft lb) (145 - 159 ft lb)
S340LC-V
6.5 - 7.5 mm 44 - 49 kg•m 20 - 22 kg•m
S420LC-V 414-00041
(0.256 - 0.295 in.) (318 - 354 ft lb) (145 - 159 ft lb)
S470LC-V

S0609010K Drive Coupling (Main Pump)

Page 8
INSTALLATION PROCEDURE
NOTE: Refer to Figure 5 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. (S300LC-V, S340LC-V only.)
4. Slide hub (7) into place on pump shaft (9)
as specified in the "Table 2" 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 6 DRIVE COUPLING INSTALLATION
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 non-resistant 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.
4. Misalignment between pump and engine should be controlled to less than 0.6 mm
(0.023 in.).

S0609010K Drive Coupling (Main Pump)

Page 9
S0609010K Drive Coupling (Main Pump)
Page 10
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1HYDRAULICS
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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

MODEL SERIAL NUMBER RANGE
Solar 420LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2001 Daewoo

November 2001

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TABLE OF CONTENTS
Hydraulic System - General Notes ................................................................. 4
Hydraulic Schematic....................................................................................... 5
General Notes ......................................................................................... 5
Operation of Working Components ................................................................ 6
Boom Operating Circuit........................................................................... 6
Boom Up Circuit ...................................................................................... 6
Boom Down Circuit ................................................................................. 6
Arm Operating Circuit ............................................................................. 7
Arm Crowd Circuit ................................................................................... 7
Arm Dump Circuit.................................................................................... 7
Bucket Operating Circuit ......................................................................... 8
Bucket Crowd Circuit............................................................................... 8
Bucket Dump Circuit ............................................................................... 8
Swing Operating Circuit .......................................................................... 8
Right Swing Operating Circuit ................................................................. 9
Left Swing Operating Circuit ................................................................... 9
Swing Relief Valve and Make-up Valve ................................................... 9
Travel Operating Circuit........................................................................... 9
Forward Travel Circuit............................................................................ 10
Reverse Travel Circuit............................................................................ 10
Procedural Troubleshooting Baseline Recommendations ............................ 11
Initial Checks and Tests to Establish Operating Condition of the Excavator
11
Pilot Pressure ............................................................................................... 12
Adjustment and Testing ......................................................................... 12
Power Mode Valve ........................................................................................ 13
Current Signal and Hydraulic Pressure Adjustments ............................ 13
Boom/Front Priority Valve ............................................................................. 14
Control Valve Pressure and Current Adjustments................................. 14
Pressure Up Valve........................................................................................ 15
Checks and Adjustments ...................................................................... 15
Pump Input Power Control ........................................................................... 17

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Pump Regulator Adjustment ................................................................. 17

Flow Meter and Flow Meter Kit Installation and Testing ............................... 20
Swing System Troubleshooting .................................................................... 22
Precautions/Initial Checks..................................................................... 22
Swing Relief Valve Checking and Adjustment....................................... 22
Troubleshooting - Swing Gearbox ................................................................ 24
Troubleshooting - Hydraulic Problems.......................................................... 25
Troubleshooting - Control Valve.................................................................... 27
Troubleshooting - Travel Control Valve.......................................................... 28
Troubleshooting - Joystick Control Valve ...................................................... 29

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HYDRAULIC SYSTEM - GENERAL NOTES

3

HAOF420L
Figure 1 Pattern of Drawing (Solar 470LC-V)
The hydraulic system has several improvements over conventional hydraulic systems - including cross-
sensing total horsepower control - to maximize output efficiency.
The system features an electronically controlled output optimization system, which allows the operator to
choose between three, distinctly different power modes: high-output/rapid cycling maximum-speed power
mode, low fuel consumption/low-noise light duty power mode, and a standard power mode for most types
of general operation offering some of the advantages of each of the other two power modes.
Electronic management of hydraulic control valves assists in optimizing the application speed and overall
operator control of hydraulic actuators and functions.

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HYDRAULIC SCHEMATIC
The hydraulic schematic(s) is available in the "Hydraulic and Electrcial Schematic Shop Manual." This
manual is a collection of diagrams and schematics for a number of models.

GENERAL NOTES
When refering to the schematic, refer to the following items:
• As shown in the schematic, the main pump assembly is driven by the engine. Mechanical
energy is converted to hydraulic power, generating the required hydraulic flow which drives the
system. Two main pumps (a right side pump and a left side pump) make up the main pump
assembly.
• Hydraulic output from the right side pump is transmitted to the right side of the control valve.
Output from the left side pump is transmitted to the valve spools on the left side of the control
valve. Hydraulic output from the pilot pump is used to control the pump and to operate pilot and
solenoid valves.
• The right half of the hydraulic control valve, supplied by the right pump in the pump assembly,
operates valve spools for right travel, swing, boom2, and arm1 functions. The amount of oil flow
to the actuators at the output end of each of those circuits is regulated through the movement of
each individual valve spool.
• The left half of the hydraulic control valve, fed by the left pump in the pump assembly, has
control spools for left travel, bucket, boom1 and arm2 operation.
• Two-stage operation is a feature of boom and arm function. All of these circuits can be operated
using the output of only one half of the hydraulic pump assembly (one pump or the other), or –
since both halves of the control valve have a spool and available circuit for these functions – the
output of both pumps can be combined, allowing higher speed operation. Boom up, arm crowd
and dumping functions can operate in any one of the two available power modes – the standard
or general duty mode, the high speed/rapid cycling mode.
• Whenever the right travel or left travel control spools are shifted, output from the main pump
assembly passes through the center joint to one or both of the axial piston motors driving the
side frame crawler tracks. A pilot valve connected to the swash plate of each travel motor
changes motor capacity (and output) in direct proportion to the position of the travel switch
selected by the operator.
• The hydraulic reservoir return line and the pilot circuit both have 10 micron full flow filters. The
disposable elements in these two canister-type filters trap and remove impurities from the oil in
the system. An 80 mesh, 177 micron reservoir intake strainer also helps maintain system
cleanliness and should be cleaned each time hydraulic fluid is drained and replaced. An oil
cooler in the hydraulic system helps maintain the operating temperature of the system at
approximately 50°C (122°F).
• The arm cylinder operating circuit includes anti-vacuum valves which protect the hydraulic
system from vacuum that could result from external shocks or other unusual conditions. Boom,
Arm, and Bucket cylinder circuit are also protected by overload relief valves. Whenever high
pressure is generated as a result of a shock or overload, excess pressure is dumped to the
reservoir return circuit through the relief valve.
• A selection valve in the travel circuit can be used to provide constant high torque/low speed
travel, or variable speed/variable torque output for travel. To prevent sliding during simultaneous
travel and boom/arm/bucket operation, select the high torque/low speed travel position.

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OPERATION OF WORKING COMPONENTS

BOOM OPERATING CIRCUIT
The boom operating circuit includes the right and left main hydraulic pumps (both halves of the main pump
assembly), both sides of the control valve and the boom cylinder. The circuit operates in boom down mode
through the first shift position and through the second shift position in boom up mode. Overload relief
valves set at 360 kg/cm2. (5,112 psi) protect the hydraulic system from damage as a result of overloads or
shocks to the boom. Additional protection - to prevent cavitation of the cylinder - is provided by a make-up
valve and reservoir return circuit, which ensures that the volume of oil going to the cylinder will not exceed
the volume of oil coming out.

BOOM UP CIRCUIT
When you pull the boom control lever backward,
the right side pilot valve generates secondary BOOM
boom up pilot pressure that is transmitted to the CYLINDER
BOOM1 and BOOM2 spools of the control valve
simultaneously. When secondary pilot pressure
reaches 7 - 10 kg/cm2 (100 - 142 psi), boom
spools open and oil from both pumps goes to BOOM1 BOOM2
the boom cylinder. BOOM UP
PILOT

PUMP(L) PUMP(R)
ATS0750L
Figure 2
BOOM DOWN CIRCUIT
When the boom control lever is pushed forward,
the right side pilot valve generates secondary BOOM
boom down pilot pressure that is transmitted CYLINDER
only to BOOM1 spool of the valve. When
secondary pilot pressure reaches 7 - 10 kg/cm2
(100 - 142 psi), the BOOM1 spool opens so that
oil from only one pump (PUMP(L)) assembly BOOM1 BOOM2
goes to the boom cylinder for boom lowering. BOOM DOWN
PILOT

PUMP(L) PUMP(R)
ATS0760L
Figure 3

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ARM OPERATING CIRCUIT

The arm operating circuit includes both the right and left hydraulic main pumps, the both sides of the
control valve, arm regen. valve, and the arm cylinder. The circuit can be operated in the two-stage speed
control mode which works through both halves of the control valve and doubles the volume of oil flowing to
the cylinder.

Overload relief valves set at 360 kg/cm2 (5,112 psi) have been installed at the crowd and dump cylinder
ports on ARM1 side of the control valve to protect the circuit and system components from possible
damage caused by shocks or overload pressure. additional protection - to prevent cavitation of the cylinder
- is provided by a make-up valve and reservoir return circuit, which ensures that the volume of oil going to
the cylinder will not exceed the volume of oil coming out.

ARM CROWD CIRCUIT

When the arm control lever is put in the crowd
mode, the left side pilot valve generates ARM
secondary pressure that is transmitted to the CYLINDER
ARM1 and ARM2 of the control valve
simultaneously.
When secondary pilot pressure reaches 7 - 10
kg/cm2 (100 - 142 psi), the arm control valve ARM2 ARM1
ARM CROWD
spool on the ARM1 and ARM2 spools open.
PILOT
Output flow from both pumps are directed to the
arm cylinder.
REGEN V/V
When working in the arm crowd mode, under
certain conditions, arm cylinder could be forced
out by the weight of the arm and bucket itself. At
this time insufficient oil flow to the cylinder could PUMP(L) PUMP(R)
lead to cavitation in the cylinder head and/or ATS0770L
surging or irregular movement. This is prevented Figure 4
by a regeneration valve attached to the control
valve which maintains the balance between oil
flowing into the cylinder and oil flowing out.

ARM DUMP CIRCUIT

When the arm control lever is put in "dump"
mode, the left side pilot valve generates ARM
secondary pilot pressure that goes to both CYLINDER
ARM1 and ARM2 the control valve
simultaneously.

When pilot pressure reaches 7 - 10 kg/cm2 (100

- 142 psi), the control spools open allowing oil
from PUMP(L) and PUMP(R) to flow to the arm
cylinder. ARM DUMP
ARM2 ARM1
PILOT

PUMP(L) PUMP(R)
ATS0780L
Figure 5

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BUCKET OPERATING CIRCUIT

The bucket operating circuit includes the right and left main pumps, the both sides of the control valve and
the bucket cylinder. 360 kg/cm2 (5,112 psi) overload relief valves located at crowd and dump cylinder ports
on BUCKET of the control valve protect the circuit and its components from damage.

BUCKET CROWD CIRCUIT

When the bucket control lever is placed in the
crowd position, the right side pilot valve BUCKET
generates secondary bucket crowd pilot CYLINDER
pressure that is transmitted to BUCKET and BC
spool of the control valve. When secondary pilot
pressure reaches 7 - 10 kg/cm2 (100 - 142 psi),
the BUCKET and BC spools open so that oil
BUCKET
from both pumps goes to the bucket cylinder. BUCKET
CROWD BC
PILOT

PUMP(L) PUMP(R)
ATS0790L
Figure 6
BUCKET DUMP CIRCUIT
When the bucket control lever is put in the dump
mode, the right side pilot valve generates BUCKET
secondary bucket dump pilot pressure that is CYLINDER
transmitted to BUCKET spool of the control
valve. When secondary pilot pressure reaches 7
- 10 kg/cm2 (100 - 142 psi), the bucket spool
opens so that oil form PUMP(L) goes to the
BUCKET BUCKET
bucket cylinder.
DUMP
PILOT

PUMP(L) PUMP(R)
ATS0800L
Figure 7
SWING OPERATING CIRCUIT
The swing operating circuit consists of the right main pump in the pump assembly, the right half of the
control valve and the swing motor. To keep the upper works from coasting when the swing control is in
neutral, an electrical sensor in the control circuit activates a valve to automatically engage a mechanical
brake.

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RIGHT SWING OPERATING CIRCUIT

SWING MOTOR
When the swing control lever is pushed to the
right swing position, pilot pressure from the left
side pilot valve is directed to SWING spool of
the control valve. Output flow from PUMP(R) is
goes to the swing motor.
SWING
SWING
RIGHT
PILOT

PUMP(L) PUMP(R)
ATS0810L
Figure 8
LEFT SWING OPERATING CIRCUIT
SWING MOTOR
When the swing control lever is pushed to the
left swing position, pilot pressure from the left
side pilot valve is directed to SWING spool of
the control valve moves in the opposite direction
and output flow from the PUMP(R) is goes to the SWING SWING
swing motor. LEFT
PILOT

PUMP(L) PUMP(R)
ATS0820L
Figure 9

SWING RELIEF VALVE AND MAKE-UP VALVE

Whenever the spool is shifted to the neutral mode during swing operation, the possibility exists that surge
pressure in the circuit - caused by inertial momentum of the upper works and correspondingly reduced
pressure at the opposite motor port - could produce cavitation in the circuit. To keep that from happening, a
relief valve is installed in the swing motor and a large-capacity make-up valve is connected to the entrance
port of the hydraulic reservoir, helping maintain acceptable pressures on both sides of the circuit.
NOTE: Relief Valve Setting Pressure:
S420LC-V : 270.0 kg/cm2 (3,840 psi)
S470LC-V : 280.0 kg/cm2 (3,980 psi)

TRAVEL OPERATING CIRCUIT

Output flow from both halves of the pump assembly is directed to the right and left travel motors through
the right and left sides of the control valve, and the upper works center joint.

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FORWARD TRAVEL CIRCUIT

TRAVEL TRAVEL
When the right and left travel control levers are MOTOR(L) MOTOR(R)
pushed forward, output from both of the main
pumps is directed through the TRAVEL (R) and
TRAVEL (L) spools on the control valve, through
CENTER JOINT
the upper works center joint, to the travel motors
on each side of the machine.
TRAVEL(L) TRAVEL(R)
L.TRAVEL R.TRAVEL
FORWARD FORWARD
PILOT PILOT

PUMP(L) PUMP(R)
ATS0830L
Figure 10
REVERSE TRAVEL CIRCUIT
TRAVEL TRAVEL
When the right and left travel control levers are MOTOR(L) MOTOR(R)
pushed backward, output from both main pumps
is directed through the TRAVEL (R) and
TRAVEL (L) spools on the control valve, through
the upper works center joint, to the travel CENTER JOINT
motors.

TRAVEL(L) TRAVEL(R)
L.TRAVEL R.TRAVEL
BACKWARD BACKWARD
PILOT PILOT

PUMP(L) PUMP(R)
ATS0840L
Figure 11

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PROCEDURAL TROUBLESHOOTING BASELINE

RECOMMENDATIONS
INITIAL CHECKS AND TESTS TO ESTABLISH OPERATING CONDITION OF THE EXCAVATOR

Triage Summary
An excavator that fails to deliver designed performance should be checked for the following:
• Hydraulic flow, first, and
• Hydraulic pressure, afterwards, in a specified order of priority through different points of the
system.
To verify adequate available hydraulic flow, before any other tests are performed through the circuit:
Check engine operation -
• at 2,150 RPM with no load
• at 2,000 RPM stall load
If engine RPM drops excessively with a load or fails to surpass rated speed (1,900 RPM), performance
problems may be due to inadequate hydraulic flow caused by lagging rotational speed.
NOTE: Verify actual flow on the excavator against rated performance, with a flow meter.
If engine tests meet specifications and adequate torque and horsepower are available at the pump drive
flex coupling, pull out the electrical tray under the operator’s seat to inspect the self-diagnostic display.
If the EPOS trouble code display is clear, check hydraulic functions in the following sequence:
• Pilot pressure
• Negacon, negative control pressure
• Main relief pressure (front and rear pump)
• Swing pressure
• Port relief pressure (individual control functions; crowd, bucket, boom, travel)
• Power boost circuit
• Standard performance tests; cylinder speed, hydraulic motor (travel and swing) speed, cylinder
oil-tightness "permissible drift" test
NOTE: System specification performance tests of individual activator function are determined by
flow rate through the component or circuit, not the control pressure or system pressure
available to the actuator. Poor flow through the individual circuit may indicate that the
component is worn beyond tolerance limits, while all other hydraulic functions are
adequate.

IMPORTANT
It is suggested that the troubleshooter maintain the testing sequence of the preceding list.
Checks and adjustments nearer the middle or the end of the list may depend on adequate
functioning of systems tested nearer the top of the list.

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PILOT PRESSURE
ADJUSTMENT AND TESTING

WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.

Vent hydraulic pressure from the reservoir before breaking the seal on fittings to install two in-line "t-style"
adapters and test gauges (60 bar/1,000 psi) at the gear pump outlet port, and at the joystick control valve
pilot line.
Start the engine and turn the engine speed control dial to the maximum setting. After the excavator has
been operated long enough to reach normal operating temperature, back off the engine control dial to
minimum rated RPM speed. With all controls in neutral, make sure the left console control stand is locked
in the down (operating) position and check pressure at the gear pump outlet port and at the joystick.
If gear pump pressure is outside the tolerance specified in the table, adjust gear pump relief pressure by
loosening the lock nut and turning the set screw in (clockwise) to increase pressure, or turning it out to
decrease it.
NOTE: Be aware that serial number changes and variation in the joystick assemblies used on
different excavators could produce slight change in actual performance characteristics.
Comparison of part numbers to serial numbers stamped on your assembly may be
required, if questions or doubt exists.

IMPORTANT
Top off the hydraulic fluid reservoir if there is any measurable loss of hydraulic oil during test
gauge and adapter fitting installation.

Engine RPM Pilot Pressure @ Pump Pilot Pressure - Joystick

Minimum Speed Setting (full left) on 40 ±5 bar 40 ±5 bar
Speed Control Dial (580 ±73 psi) (580 ±73 psi)

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POWER MODE VALVE

CURRENT SIGNAL AND HYDRAULIC PRESSURE ADJUSTMENTS

WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.

The electromagnetic pressure proportioning control (EPPR) "power mode" valve is located on the
underside of the pumps (not visible in the harness connections drawing, because it is underneath the
assembly), near the engine/pump flexible coupling, adjacent to the pump return line. To test and adjust
power shift current and pressure through the power mode valve a multi-lead jumper harness is required.
The jumper harness (which is available through Daewoo After Sales Service, or could be spliced together
from commonly available, purchased parts) has extra leads so that a VOM meter can be connected to the
circuit.
To set up the testing equipment, turn off the engine and disconnect the single electrical lead from the
power mode valve. Attach the jumper harness to the terminal on the valve, connect the test leads of the
multimeter to the extra leads on the harness and reconnect the valve electrical lead.
Vent the lever on top of the hydraulic tank to relieve pressure and connect an in-line "t-style" adapter to the
valve pressure port. Install a 60 bar/870 psi (1,000 psi) test gauge in the adapter.
Restart the engine and increase engine RPM by turning the speed control to the maximum speed setting.
Warm up the engine and hydraulic system until hydraulic oil temperature is at least 45°C (113°F). Select
Power Mode on the Instrument Panel. Check current readings (in milliamps) on the VOM meter and
hydraulic pressure gauge readings and make sure both conform to the values in the table below.
NOTE: If recorded values do not conform to the specified current or pressure in the table, back off
the lock nut on the end of the valve, turn the adjusting screw 1/4 turn and re-check current
and pressure. Repeat adjustment as required to obtain specified performance and
retighten the valve lock nut.

Mode Engine RPM Current Pressure

1.5 bar
Power Mode High Idle: 2,150 RPM 600 ±20 mA
(22 psi)
Standard Mode High Idle 2,150 RPM 0 mA 18 bar (261 psi)

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BOOM/FRONT PRIORITY VALVE

CONTROL VALVE PRESSURE AND CURRENT ADJUSTMENTS

WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.

The front priority control valves are located inside the compartment behind the cabin.
The same jumper harness used for testing the power mode (EPOS) control valve is used to test these two
valves. Turn off the engine, disconnect either of the electrical leads and connect the test equipment to that
side of the valve. An in-line "t-style" gauge adapter can be used to connect a 60 bar/870 psi (1,000 psi) test
gauge to the outlet (pressure) side of the valve. Set the engine control speed dial to maximum and warm
up the engine to at least 45°C (113°F) before making any tests.
NOTE: Vent air from the hydraulic system before installing test equipment. Use the lever on the
reservoir, while the engine is running. Pour clean replacement fluid back into the system if
excessive fluid was lost.
Operate the swing and boom simultaneously. Measure signal current and hydraulic pressure through the
valve and record the highest and lowest values. Reset the work mode control to "digging" mode, and then
to "trenching" mode and repeat the same tests.

DIGGING MODE TRENCHING MODE

VALVE FUNCTION
HAOB730L HAOB740L

VOLTAGE PRESSURE VOLTAGE PRESSURE

40 bar 0 bar
Front Priority 0V 20 - 30 V
(580 psi) (0 psi)

NOTE: If recorded values do not conform to the specified current or pressure in the table, readjust
as required.

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PRESSURE UP VALVE
CHECKS AND ADJUSTMENTS

WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.

Vent hydraulic pressure from the reservoir to install an in-line "t-style" adapter and test gauge (60 bar/1,000
psi) at the pilot pump signal port relief valve outlet.
Start the engine and turn the engine speed dial to maximum. When normal operating temperature is
reached,
• Check pilot pressure and readjust it, if required;
• Select the Instrument Panel rear pump "pressure display";
• Select Power Mode;
• Stall the boom cylinder (towards the extend side);
• Read rear pump pressure on the Instrument Panel display.
Repeat all tests with and without "pressure up" selected through the console rocker switch and joystick
button.
If the 2-stage main relief valve was not set correctly and main relief high-stage pressure ("pressure up") is
outside the tolerance range, begin valve adjustment by loosening the outside (widest diameter) lock nut on
the relief valve. Turn the adjusting screw clockwise to increase pressure, or counterclockwise to decrease
it. Pressure must be 350 bars (5075 psi), or up to 10 bars (145 psi) higher.
Because one adjustment can affect the other, check low-stage main relief pressure by repeating the
cylinder stall test without "pressure up." Readjust standard relief pressure by turning the inner-most
(smallest diameter) screw clockwise to increase the setting, or counterclockwise to decrease it. Pressure
should be at least 320 bars (4,641 psi), but less than 325 bars (4,714 psi).

IMPORTANT
Pressure adjustments and checks cannot be made if pilot pressure is outside the specified
range. Refer to the pilot pump adjustment procedure if required, then proceed with any
necessary adjustments to main relief pressure settings.

Main Pressure and Pilot Pressure and

Power Mode Operation
Tolerance Tolerance
20 - 40 bar 30 bar + 10 bar
Mode Neutral, No Operation
(290 - 580 psi) (435 psi + 145 psi)
320 bar + 5 bar 30 bar + 10 bar
Mode Cylinder Stall
(4,641 psi + 75 psi) (435 psi + 145 psi)
Mode W/ 350 bar + 10 bar 30 bar + 10 bar
Cylinder Stall
pressure Up 5,075 psi + 145 psi (435 psi + 145 psi)

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NOTE: The electrical pressure up (power boost) solenoid valve located alongside the swing
priority solenoid and arm speed control solenoid, in compartment rear of the operator’s
cab, must be operating correctly, or pressure tests and further adjustments cannot be
made.

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PUMP INPUT POWER CONTROL

PUMP REGULATOR ADJUSTMENT

WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.

To perform these adjustments accurately the use of a flow meter is strongly recommended, as is consulting
the factory (before starting work) to validate the need for making regulator adjustments. Vent hydraulic
pressure from the reservoir before breaking the seal on fittings to install the flow meter kit. (Refer to the
"Flow meter Installation and Testing" procedure.)

IMPORTANT
Before starting this procedure or going on to make any changes of adjustment settings,
• Verify engine output to the rated speed - 2,150 ±50 RPM.
• Permanently mark setscrew positions at the current regulator control setting.

Use a scribe or other permanent marker to identify a reference point on adjusting screws with a
corresponding reference on the body of the valve. The adjustment process affects a complex balance and
could require some time to complete. If adjustment has to be interrupted or postponed, reference marks at
the adjustment point allow immediate restoration of original performance.
This adjustment procedure is normally performed:
• If the engine is being consistently overloaded (and engine troubleshooting shows engine
performance to be at or above rated output);
• If reduced cylinder speed and diminished work performance provide an indication that rated,
maximum pump flow may not be available (and all other troubleshooting gives no indication of
other flaws or hydraulic system defects);
• If pump output is out of balance and one pump is failing to keep up with the output flow of the
other.
To check pump imbalance without a flow meter, travel the excavator forward on flat, level terrain. If the
machine veers off despite neutral control input and even, balanced track adjustment, the pump which
supplies output to the track frame toward which the excavator is veering is weak.

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2
2

1
1 ASS0320L

Figure 12

Refer to the illustration of the pump regulator control valve (Figure 12) for the location of adjustment screws
(1, 2 and 3). There are three different adjustments, Qmax, Pd-Q, adjustment screws (1, 2 and 3). Each one
of the adjustment procedures could affect the setting of the others.
Check and record the arm dump speed performance test before and after input power adjustment, whether
or not a flow meter is used.
NOTE: Regulator adjustments affect total cumulative horsepower, since each regulator
compensates for the output of the other. It is not necessary to adjust both regulators at the
same time, but after checking or adjusting one of them, the remaining unit should also be
checked.

Hydraulic System Troubleshooting, Testing and

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Start the engine and turn the engine speed dial

to maximum. When normal operating
temperature is reached, adjust screw 2
Q
clockwise to shft the Pi-Q control valve curve
decrease componsating control pressure.
1/2 turn on the adjusting screw is equal to
approximately -0.7 kgf/cm2 of Pi.
NOTE: For each full turn of adjustment
on the screw (2), the square-
tipped adjusting screw should
be turned in the opposite Pi
ATS0850L
direction turns to avoid Figure 13
changing inner spring
adjustment.
Pump input power adjustments are normally
made in small increments, 1/4 turn (90°) or less,
each time. Q
Turning the screw (3) clockwise shift Pd-Q
curves right and increase input horse power. 1/2
turn on the screw (3) is equal to approximately
+33 kgf/cm2 of Pd.

Pd
ATS0870L
Figure 14
The adjusting screw (1) affects the delivery rate
(Q) of the pump. Turning the adjusting screw
shift the maximum cut flow (as shown in Figure
Q
15).
Balance both pumps for equal output.

P
ATS0860L
Figure 15

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FLOW METER AND FLOW METER KIT INSTALLATION

AND TESTING
Checking regulator and pump output, to assess the output balance between the front and rear pumps and
to verify operating adjustment of each regulator, will require installation of a flow meter.
The After Sales Service department of the nearest local Daewoo dealer can assist you with these tests or,
if you prefer carrying out your own testing, they should be able to help in putting together a hose and fitting
kit (or the required dimensions and specifications for hoses and fittings) to allow you to install a flow meter
downstream from the main pump assembly.

Installation and Testing Procedure

• Turn off the engine and operate controls to release hydraulic pressure from the accumulator.
• Vent the reservoir to release all pressure from the hydraulic system.
• Remove guard panels from around the main pump assembly.
• Disconnect the main pump discharge output line. Install the input flange of the flow meter on the
pump end of the output line.
• Cap off the unused (input) end of the pump discharge line with a blocking flange.
• Bolt up a pre-measured length of hydraulic hose, between the output end of the flow meter
assembly and the top of the reservoir. Use appropriate fittings and adapter flanges to guarantee
a pressure tight seal.
NOTE: Be sure to maintain even tightening torque on all flange fittings. Use Loctite brand "PST
545" (or an alternate manufacturer’s hydraulic system joint seal) if required, to give an
airtight seal.
• An assistant - who must remain at the operator’s control station at all times - should restart the
engine and run it long enough (at minimum RPM) to de-aerate the system and warm up the
engine and hydraulic system to operating temperature.
Record the values of all test results in three columns, comparing 1) pump pressure (from the instrument
panel display) with 2) measured flow, in gallons or liters per minute, from the installed flow.
meter. The third column of test results should provide a record of engine RPM measured during each of the
following tests - with the engine speed control dial set at maximum, the power mode selector at Power
Mode III and the work mode selector at digging mode:
• Unloaded maximum engine speed baseline test (all controls in neutral).
• Front pump test - operate "travel right" lever. Record values at all specified pressures.
• Rear pump test - operate "travel left" lever. Record values at all specified pressures.
Record the values for each of the three tests (neutral, travel right and travel left) at the following pump
pressure levels, with travel speed control set at "high speed."

Engine RPM Pressure Flow

100 kg/sq cm (1,422 psi)
135 kg/sq cm (1,930 psi)
180 kg/sq cm (2,560 psi)
240 kg/sq cm (3,413 psi)
320 kg/sq cm (4,550 psi)*
*See Note, below

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Compare recorded values with output shown in the P-Q curve in the specifications section of this book.
If test results do not measure up to specified values, pump output tests can be repeated using different
control levers. Recheck front pump operation while stroking the bucket cylinder out lever, and the rear
pump by actuating the swing control lever.

NOTE: When testing bucket and swing functions, read maximum flow tests at 320 kg/cm2 (4,550
psi), not 350.0 kg/cm2 (4,978 psi).

Hydraulic System Troubleshooting, Testing and

Adjustment Page 21
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SWING SYSTEM TROUBLESHOOTING

PRECAUTIONS/INITIAL CHECKS
1. Stop work. Release all weight or any type of load safely before proceeding. Avoid risking injury or
adding to damage.
2. Turn off engine and disengage control functions until initial tests are ready to be made.

WARNING
Prevent possible injury and/or loss of operating control. Stop work and park the excavator at the
first indication of:
1. Equipment breakdown
2. Inadequate control response
3. Erratic performance

Stop the machine, put the boom and arm in the inoperative (overnight park) position and begin by making
the fastest, simplest checks first:
• Check oil level.
• Check for overheating, oil leaks, external oil cooler clogging or broken fan belt. Consult service
record for prior repair/service work.
• Drain some tank oil to a clean, clear container. Look for metal shavings/grit, cloudiness/water or
foam/air bubbles in the oil.
• Check for wobble through the engine/pump flex coupling. Run engine with the pump input
hydraulic power control nut turned to the lowest power to check the engine.
• Investigate unusual operating noises or vibration. Check for loose bolts, connections.

SWING RELIEF VALVE CHECKING AND ADJUSTMENT

Make a check of operating pressures through the swing relief valve if:
• The swing motor fails to turn.
• Swings in one direction only.
• Swings but continues to coast.
• There is drifting on a slope.
1. Check operation by connecting:
A. Two 600 bar (8,700 psi) pressure gauges to the inlet and outlet measuring ports on top of the
swing motor.
Pressure should be between 270 - 280 bar (3,916 - 4,061 psi), with both swing locks engaged.
With swing locks released, during full acceleration and deceleration, pressure should approach
250 bar (3,625 psi) in each direction.
B. Connect a 60 bar (870 psi) pressure gauge at the "SH" port of the hydraulic brake.
Pressure should always stay at or above 4 bar (58 psi) when operating swing, boom or arm.
C. Connect a 10 bar (145 psi) gauge at the motor makeup valve.

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Pressure should stay consistently above 2.5 bar (36 psi). If pressure falls below the
recommended minimum level, forceful acceleration of the swing motor could lead to cavitation
of the circuit and stalling, slowed rotation, noise and possible damage.
2. If main inlet and outlet pressures were off in the preceding tests in Step 1, adjust swing relief valve
pressure.
Following adjustment, repeat the operating pressure tests (with gauges connected to the inlet and
outlet test ports on top of the swing motor) and check pressures with the swing locks engaged and
released.
If pressure adjustment fails to restore adequate performance, proceed to the Troubleshooting - Swing
table.
3. If pressure tests were at recommended levels through the main inlet and outlet ports, and through the
"SH" port of the swing brake, the causes of poor swing performance could include a faulty swing
motor, drive train overloading or gearbox defect, or a problem in the brake assembly or swing control
valve. Proceed to the troubleshooting information in the next procedure.
If pressure through the "SH" port was tested below the minimum 4 bar (58 psi) level, check the shuttle
valve in the rear compartment behind cabin. When pressure through the port is at the recommended
level, the brake release valve should disengage the swing brake, allowing the swing motor to rotate
the excavator. If pressure adjustment to the valve has been restored but the brake still fails to release,
the brake piston or friction plate may be frozen, requiring disassembly of the motor and parts repair/
replacement.
4. If pressure tested at the motor makeup valve falls below recommended minimum level, and
consequent problems with cavitation, stalling and surging are observed, check the restriction valve. If
pressure adjustment to the valve has been restored but if problems with cavitation continues,
disassemble the upper swing motor housing and clean or replace assembly components as required.
NOTE: If all tested pressures are at or above recommended levels, and there are no mechanical
problems in the drive train or in the motor/brake assembly, the problem will require further
hydraulic troubleshooting. It’s also possible that a defective joystick, an intermittent short in
an electrical control circuit or a problem in the e-EPOS circuit is causing diminished swing
performance. Pull out the e-EPOS indicator panel from underneath the operator’s seat
and perform the self-diagnosis test. If the display panel reads code "0.2," it is reporting
that the swing priority proportional valve is not functioning, except in the minimum "fail-
safe" mode. Refer to the Electrical section of this book for more information.

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TROUBLESHOOTING - SWING GEARBOX

Problem Possible Causes Remedies
Swing motor fails to operate and:
Three pressure tests at motor, Swing relief valve defective Adjust pressure to
brake or makeup valve show low Brake release valve defective recommended range in affected
reading(s). Motor makeup valve defective. valve.
OR
Disassemble and clean valve
assembly. Replace all valve
components that show damage.
All three pressure checks are If swing and left travel are
Exchange front and rear pump
OK but left travel also fails to restored but right travel stops
inlet and outlet hoses to test
run. working, replace or repair P1
pump function.
pump.
All three pressure tests are OK, Brake assembly or motor friction Check for binding. Disassemble
but machine fails to swing at all. plate failing to release. and repair.
Disassemble / Repair pilot
Pilot (control) pressure low or
pressure swing spool (305) and /
swing control valve stuck.
or swing control valve.
Test motor drain rate. Replace /
Swing motor defective.
Repair motor.
Refer to "Swing Gear
Gear train defective.
Troubleshooting" procedure.
Swing functions but only at Check above list; then replace
Causes listed above could also
reduced RPM. oil, test motor drain rate and
produce dragging swing, OR hot
check for "02" reading (e-EPOS
or wrong oil OR worn-out parts.
self-test).
Left travel speed is also Low output at P1 pump or
Clean and repair piping or repair
reduced. external pilot piping leaks/is
or replace pump P1.
clogged.
Swing control movement is
Inlet / outlet piping reversed. Reset controls or reverse piping.
reversed.
Machine swings but continues Swing control valve spool not Replace return spring; clean/
coasting on past stopping point. centered. repair valve piston and spool.
Pilot pressure may be outside Disassemble, clean or replace
range. pilot relief valve or pilot valve.
Swing relief valve may be faulty. Repair/Replace swing relief
valve.

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Problem Possible Causes Remedies

Swing movement is in one If pilot pressure is unequal,
Check to see that pilot pressure
direction only. clean or repair piping or repair/
is the same right and left.
replace valve.
Swing control valve spool may Repair/Replace the swing
be stuck. control valve.
Repair/Replace the swing relief
Swing relief valve may be faulty.
valve.
No rotation and:
Pressure at swing motor inlet Swing brake not releasing. Check brake engagement and
increases. disengagement; check release
pressure.
Internal damage to gearbox Replace broken gears and drive
drive train. train assemblies.
Overload. Reduce load weight.
Pressure at swing motor inlet Swing motor drive shaft
Replace swing motor.
shows no increase, and the damage.
swing motor is making irregular Internal damage to gearbox Repair/Replace broken or faulty
noises. drive train. assemblies.
Pressure at swing motor inlet
shown no increase, but without Hydraulic pump or valve
Troubleshoot hydraulic system.
irregular noises from the swing problem.
motor.
Oil Leakage:
From drive shaft From bolted Oil seal damaged Assembly Replace oil seal Disassemble
connections or other assembled compound (joint sealer) old and and check mating surfaces.
surfaces. not sealing, bolt not tight or Reapply Loctite; torque bolts to
flange warped. specifications.
Excess heat:
Gearbox casing becomes Replace oil; refill to specified
Low oil level.
excessively hot, with or without level.
irregular noises, during Bearings or gears worn but not
operation. Repair or replace gearbox.
completely inoperative.

TROUBLESHOOTING - HYDRAULIC PROBLEMS

Problem Possible Causes Remedies
Attachment cylinders, swing and Main pump(s) malfunction Repair or replace
travel motors are all inoperable. Low oil level in hydraulic system Refill
Loud noises are heard from
Main pump inlet (oil supply)
main pump assembly. Repair or replace
piping or hose damaged
Attachment cylinders, swing and Pilot pump malfunction Repair or replace
travel motors are all inoperable. Pilot cutoff solenoid stuck Repair or replace
No usual or loud noises can be
Pilot cutoff switch faulty Repair or replace
heard.
Engine/pump flex coupling
Replace flex coupling
damaged

Hydraulic System Troubleshooting, Testing and

Adjustment Page 25
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Problem Possible Causes Remedies

Sluggish performance of all Main pump(s) damaged or worn Repair or replace
hydraulic functions - attachment, Main relief valve pressure off Readjust pressure
swing and travel.
Low oil level in hydraulic system Refill
Hydraulic reservoir intake
Clean
strainer clogged
Pump inlet (supply side) piping
or hose allowing air into Tighten connection
hydraulic system
Oil temperature abnormally Oil cooler clogged or air
Clean
high. circulation to cooler blocked
Cooling fan belt tension too
Readjust belt tension
loose
Relief valve set too low Readjust valve
Reduce or slow work load or
Relief valve in constant use
cycling rate
Hydraulic oil severely neglected
Replace oil
or incorrect for application
One circuit in hydraulic system Overload relief valve malfunction Readjust or replace
inoperable. Oil leak at make-up valve Clean, repair
Control valve spool damaged Repair or replace
Dirt in control valve spool Clean or replace
Actuator (joystick, foot pedal)
Repair or replace
damaged or worn
Internal seal leak in cylinder Repair or replace
Cylinder rod damaged Repair or replace
Pilot valve or piping malfunction Repair or replace
Mechanical linkage frozen,
Repair or replace
loose or damaged
Travel motors inoperable. Center joint damaged. Repair or replace.
Parking brake not releasing. Repair or replace.
Travel motor worn or damaged. Repair or replace.
Travel motor pilot piping
Repair or replace.
damaged.
Travel motors operate very Track tension poorly adjusted
Readjust tension Refill.
slowly. Low oil in idlers or rollers.
Travel brake dragging. Repair
Track frame out of alignment,
Repair
deformed or twisted.
Swing motor inoperable. Swing brake not releasing. Repair or replace
Relief valve malfunction. Repair or replace
Pilot piping damaged. Repair or replace

Hydraulic System Troubleshooting, Testing and

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Problem Possible Causes Remedies

Swing motor operates unevenly. Swing gear, bearing or mounting
Repair or replace
loose or worn.
Lubricant worn away,
Grease
inadequate.
Repair/Replace the swing relief
Swing relief valve may be faulty.
valve.

TROUBLESHOOTING - CONTROL VALVE

Check control valve problems only after other hydraulic circuit operational tests have been made. Refer to
the "Troubleshooting Baseline Recommendations" procedure. Pump flow, pilot pressure, Negacon
pressure, main relief pressure, and port relief pressure should all be checked before starting to work on the
control valve. Make sure the hydraulic system is topped up to the required level and free of oil leaks or air
in the system that could cause cavitation problems.

Problem Possible Causes Remedies

Main Relief Valve Disassemble, clean main
Particulate contamination.
poppet.
Broken or damaged spring. Replace
Adjusting screw loose. Readjust
Main poppet sticking. Repair/replace
Clogged orifice in pilot passage
Clean/replace
to control valve.
Cylinder goes down in spool Excessive clearance between
Replace spool or casing.
neutral. casing and spool.
Spool does not return to neutral/
Check secondary pilot pressure.
sticking spool.
Spool does not return to neutral
because of dirt or other Clean
contaminants.
Broken or damaged spring. Replace
Main relief or port relief not
See above
operating properly.
Impurities in pilot circuit. Clean
Cylinder drops before start at Rod check valve damaged or
Clean/replace
boom up operation clogged.
Poppet sticking. Clean/replace
Broken or damaged spring Replace
Slow operation or response Excessive clearance between Check pilot pressure and/or
spool or casing. replace spool or casing.
Sticking spool. Clean/replace
Broken or damaged spring. Replace
Main or port relief valve
Check pressure/replace
damaged.

Hydraulic System Troubleshooting, Testing and

Adjustment Page 27
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Problem Possible Causes Remedies

Swing priority not operating Sticking spool. Clean/replace
correctly Solenoid valve faulty. Replace
Boom and arm cylinders do not Priority valve faulty or spool
Check pilot pressure.
perform normally in combined sticking.
operation Broken or deformed spring. Replace
Excess clearance between right
Clean/replace
and left casing and valve spool.
Clogged spool passage. Clean/replace, replace filter.
Relief valve malfunctions:
Pressure does not increase at Main poppet or pilot poppet
Clean/replace
all. stuck open.
Irregular or uneven pressure. Poppet seat damaged or pilot
Clean/replace
piston sticking to main poppet.
Loose lock nut and adjusting
Readjust
screw.
Components worn out, past
Replace
wear limits.

TROUBLESHOOTING - TRAVEL CONTROL VALVE

Problem Possible Causes Remedies
Secondary pressure does not Low primary pressure. Check primary pressure.
increase. Broken spring. Replace spring.
Spool sticking. Clean, repair or replace.
Excess spool to casing
Replace spool casing.
clearance.
Worn or loose universal joint Repair or replace U-joint
(handle) subassembly. subassembly.
Secondary pressure too high. Dirt, other interference between
Clean, repair or replace.
valve parts.
Return line pressure too high. Redirect return line.
Secondary pressure does not Dirt, other interference between
hold steady. valve parts, or worn spool Clean, repair or replace.
sticking intermittently.
Interference or binding on spool
Clean, repair or replace.
return spring.
Interference, restriction or
Repair or re-route tank return
unsteady pressure in tank return
line.
line.
Air bubbles in piping (temporary)
Vent air, or repair leak.
or air leak.
NOTE: Look for evidence of leaking oil.

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TROUBLESHOOTING - JOYSTICK CONTROL VALVE

Problem Possible Causes Remedies
Secondary pressure does not Low primary pressure Check primary pressure
increase Broken spring Replace spring
Spool sticking Clean, repair or replace
Excess spool to casing Replace spool casing
clearance
Worn or loose handle Repair or replace handle
subassembly subassembly
Secondary pressure too high Dirt, other interference between Clean, repair or replace
valve parts
Return line pressure too high Redirect return line
Secondary pressure does not Dirt, other interference between Clean, repair or replace
hold steady valve parts, or worn spool
sticking intermittently
Interference or binding on spool Clean, repair or replace
return spring
Unsteady pressure in tank Redirect return line
return line
Air bubbles in piping (temporary) Vent air, or repair leak
or air leak
NOTE: Look for evidence of leaking oil to help locate damaged seals or gaskets that could be
the cause of air leaks.

Hydraulic System Troubleshooting, Testing and

Adjustment Page 29
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Hydraulic System Troubleshooting, Testing and

Page 30 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
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

Models continued on back of cover.

Copyright 2001 Daewoo

November 2001

Accumulator S0703010K
Page 1
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

Accumulator
Model Nitrogen Charge Volume
Solar 300LC-V
Solar 300LL
Solar 340LC-V 10 kg/cm2 (142 psi) 320 cc (19.5 in3)
Solar 420LC-V
Solar 470LC-V

S0703010K Accumulator
Page 4
 S0704090K

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)

MODEL SERIAL NUMBER RANGE
Solar 470LC-V 1001 and Up

Copyright 2001 Daewoo

November 2001

Center Joint (Swivel) S0704090K

Page 1
TABLE OF CONTENTS

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

Parts List ................................................................................................. 4
Troubleshooting, Testing and Adjustment....................................................... 5
Inspection................................................................................................ 5
Testing..................................................................................................... 5
Disassembly ................................................................................................... 6
Reassembly.................................................................................................... 6

S0704090K 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) S0704090K

Page 3
PARTS LIST

Figure 1

Reference Reference
Description Description
Number Number
10A Center Joint Body 10G Hex Bolt
10B Spindle 10H Spring Washer
10C O-ring 10I Plug
10D Slipper Seal 10J Plug
10E O-ring 25 Spring Washer
10F Cover 31 Bolt

S0704090K Center Joint (Swivel)

Page 4
TROUBLESHOOTING, TESTING AND ADJUSTMENT
INSPECTION
The center joint should be checked for evidence of external oil leakage every 2,000 hour of operation.
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 change over 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).

Center Joint (Swivel) S0704090K

Page 5
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. Unbolt the three 8 mm fasteners holding the cover. Use a vise or v-block to hold the assembly in
place.
4. Remove the cover, withdraw the spindle.
5. If the spindle doesn’t separate easily when cover and fastener bolts are removed, use a wooden
block and hammer to drive it out of the housing.
6. O-rings and seals should be replaced whenever the assembly is being overhauled or rebuilt. For
repair procedures or emergency teardown, 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.
NOTE: The O-ring (10E) shown in the assembly drawing (above the swivel joint stem lower seals)
should not be overlooked. It is tucked behind the top slip ring, doubled up inside the same
groove in the body of the Center Joint.
7. Before reassembling the center swivel, visually inspect ball bearing surfaces for visible signs of wear,
damage or discoloration and replace any worn component.
Check clearance between the spindle and thrust plate. Replace any component that shows more
than 0.5 mm (0.020") of visible wear.
Clearance between the spindle 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.

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

CAUTION!
Apply a very light film of white grease or petroleum jelly to the lower rim of the spindle and
inner surface of the center swivel body. Apply slow, even-handed pressure, using both
hands, to slowly push the spindle into the body. Seals may be damaged if the spindle is
pushed in too quickly.

2. Thoroughly clean all other component surfaces of dirt or grease prior to reassembly.
3. Reverse disassembly steps for reassembly.

S0704090K Center Joint (Swivel)

Page 6
4. Clean threads of fasteners before pre-applying Loctite #243 to the threads, and before torquing the
cover bolts.
5. Pre-fill the center swivel with clean hydraulic fluid prior to 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.

Center Joint (Swivel) S0704090K

Page 7
S0704090K Center Joint (Swivel)
Page 8
 Return to Master Table of Contents

S0705000
R3

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 170LC-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 220LC-V 0001 and Up
Solar 250LC-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
Solar 400LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2001 Daewoo

December 2001

Cylinders S0705000
Page 1
 Return to Master Table of Contents

TABLE OF CONTENTS

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

Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 4
Special Tools and Materials............................................................................ 6
Piston Nut................................................................................................ 6
Piston Jig................................................................................................. 8
Disassembly ................................................................................................. 10
Reassembly.................................................................................................. 16

S0705000 Cylinders
Page 2
 Return to Master Table of Contents

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

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
P = circuit oil pressure and the inside diameter
of the cylinder is expressed by B (Figure 1).
Figure 1
F1 = P x πB2
4

(P: Pressure, π = 3.14, B: Cylinder Inside

Diameter)

1. Cylinder Inside Diameter - B

2. Oil Path A
3. Oil Path B
4. Rod Diameter

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 Figure 2
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
 Return to Master Table of Contents

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
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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
Page 6
G

S0705000
PISTON NUT

C
E (C3 ~ C5)
A

D
B

R (R15 ~ R20)
SPECIAL TOOLS AND MATERIALS
Return to Master Table of Contents

HBOJ040I

Figure 6
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quence

Cylinders
 MODEL CYLINDER A B C D E F G MODEL (CYLINDER)

Cylinders
110.0 mm 69.0 mm 9.0 mm 4.5 mm 30.0 mm 300.0 mm 15.0 mm
S55-V ARM S55-V (BOOM, BUCKET)
(4.33 in) (2.72 in) (0.35 in) (0.18 in) (1.18 in) (11.81 in) (0.59 in)
S130W-V (ARM)
S170LC-V (BUCKET)
130.0 mm 90.0 mm 11.0 mm 4.5 mm 35.0 mm 350.0 mm 15.0 mm
ARM S170W-V (BOOM)
(5.12 in) (3.54 in) (0.43 in) (0.18 in) (1.38 in) (13.78 in) (0.59 in)
S200W-V (BOOM)
S130-V S200LC-V (BOOM)
120.0 mm 85.0 mm 11.0 mm 4.5 mm 30.0 mm 300.0 mm 15.0 mm S130W-V (BOOM)
BOOM
(4.72 in) (3.35 in) (0.43 in) (0.18 in) (1.18 in) (11.81 in) (0.59 in) S170W-V (BUCKET)
115.0 mm 75.0 mm 11.0 mm 4.5 mm 30.0 mm 300.0 mm 15.0 mm
BUCKET S130W-V (BUCKET)
(4.53 in) (2.95 in) (0.43 in) (0.18 in) (1.18 in) (11.81 in) (0.59 in)
S170LC-V (ARM)
S200W-V (ARM)
140.0 mm 102.0 mm 11.0 mm 4.5 mm 35.0 mm 350.0 mm 15.0 mm
ARM S250LC-V (BOOM, ARM,
(5.51 in) (4.02 in) (0.43 in) (0.18 in) (1.38 in) (13.78 in) (0.59 in)
S220LC-V BUCKET)
S290LC-V (BOOM)
125.0 mm 102.0 mm 11.0 mm 4.5 mm 35.0 mm 350.0 mm 15.0 mm S170LC-V (BOOM)
BUCKET
(4.92 in) (4.02 in) (0.43 in) (0.18 in) (1.38 in) (13.78 in) (0.59 in) S200W-V (BUCKET)
S290LC-V (ARM)
S360-V (ARM)
140.0 mm 107.0 mm 11.0 mm 4.5 mm 35.0 mm 350.0 mm 15.0 mm S400LC-V (BOOM,
Return to Master Table of Contents

ARM
(5.51 in) (4.21 in) (0.43 in) (0.18 in) (1.38 in) (13.78 in) (0.59 in) BUCKET)
S330-V S450LC-V (BOOM,
BUCKET)
140.0 mm 105.0 mm 11.0 mm 4.5 mm 35.0 mm 350.0 mm 15.0 mm S360-V (BUCKET)
BOOM
(5.51 in) (4.13 in) (0.43 in) (0.18 in) (1.38 in) (13.78 in) (0.59 in) S400LC-V (BUCKET)
140.0 mm 115.0 mm 11.0 mm 4.5 mm 35.0 mm 350.0 mm 15.0 mm
S400LC-V ARM
(5.51 in) (4.53 in) (0.43 in) (0.18 in) (1.38 in) (13.78 in) (0.59 in)
S170W-V (DOZER,
130.0 mm 92.0 mm 11.0 mm 4.5 mm 35.0 mm 350.0 mm 15.0 mm
S200W-V DOZER OUTRIGGER)
(5.12 in) (3.62 in) (0.43 in) (0.18 in) (1.38 in) (13.78 in) (0.59 in)
S200W-V (OUTRIGGER)
130.0 mm 98.0 mm 11.0 mm 4.5 mm 35.0 mm 350.0 mm 15.0 mm
S170W-V ARM
(5.12 in) (3.86 in) (0.43 in) (0.18 in) (1.38 in) (13.78 in) (0.59 in)

Page 7
S0705000
Page 8
S0705000
PISTON JIG

(2) B H

R = F/2

E
A
D
F
C R (R15 ~ 20)
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I
G

HBOJ050I

Figure 7
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quence

Cylinders
 Cylinders
MODEL CYLINDER A B C D E F G H I MODEL (CYLINDER)
63.0 mm 12.0 mm 15.0 mm 22.0 mm 50.0 mm 30.0 mm 320.0 mm 15.0 mm 12.0 mm
ARM S55-V (BUCKET)
(2.48 in) (0.47 in) (0.59 in) (0.87 in) (1.97 in) (1.18 in) (12.60 in) (0.59 in) (0.47 in)
S55-V
80.0 mm 12.0 mm 16.0 mm 25.0 mm 55.0 mm 30.0 mm 320.0 mm 15.0 mm 15.0 mm
BOOM
(3.15 in) (0.47 in) (0.63 in) (0.98 in) (2.17 in) (1.18 in) (12.60 in) (0.59 in) (0.59 in)
80.0 mm 12.0 mm 15.0 mm 29.0 mm 55.0 mm 30.0 mm 320.0 mm 15.0 mm 15.0 mm S130W-V (ARM)
ARM
(3.15 in) (0.47 in) (0.59 in) (1.14 in) (2.17 in) (1.18 in) (12.60 in) (0.59 in) (0.59 in) S170LC-V (BUCKET)
75.0 mm 12.0 mm 15.0 mm 27.0 mm 55.0 mm 30.0 mm 320.0 mm 15.0 mm 14.0 mm
S130-V BOOM S130W-V (BOOM)
(2.95 in) (0.47 in) (0.59 in) (1.06 in) (2.17 in) (1.18 in) (12.60 in) (0.59 in) (0.55 in)
70.0 mm 12.0 mm 16.0 mm 25.0 mm 65.0 mm 30.0 mm 300.0 mm 15.0 mm 12.0 mm
BUCKET S130W-V (BUCKET)
(2.76 in) (0.47 in) (0.63 in) (0.98 in) (2.56 in) (1.18 in) (11.81 in) (0.59 in) (0.47 in)
S170LC-V (ARM)
S200W-V (ARM)
110.0 mm 14.0 mm 17.0 mm 40.0 mm 75.0 mm 32.0 mm 350.0 mm 15.0 mm 15.0 mm S250LC-V (BOOM, ARM,
ARM
(4.33 in) (0.55 in) (0.67 in) (1.57 in) (2.95 in) (1.26 in) (13.78 in) (0.59 in) (0.59 in) BUCKET)
S220LC-V S290LC-V (BOOM,
BUCKET)
S170LC-V (BOOM)
50.0 mm 14.0 mm 16.0 mm 33.0 mm 65.0 mm 32.0 mm 350.0 mm 15.0 mm 15.0 mm
BUCKET S200W-V (BUCKET)
(1.97 in) (0.55 in) (0.63 in) (1.30 in) (2.56 in) (1.26 in) (13.78 in) (0.59 in) (0.59 in)
S200LC-V (BUCKET)
S170W-V (DOZER,
96.0 mm 14.0 mm 17.0 mm 35.0 mm 65.0 mm 30.0 mm 350.0 mm 15.0 mm 15.0 mm
S200W-V OUTRIGGER OUTRIGGER)
(3.78 in) (0.55 in) (0.67 in) (1.38 in) (2.56 in) (1.18 in) (13.78 in) (0.59 in) (0.59 in)
S200W-V (DOZER)
S330-V (BOOM,
120.0 mm 14.0 mm 18.0 mm 46.0 mm 80.0 mm 35.0 mm 350.0 mm 15.0 mm 15.0 mm BUCKET)
S290LC-V ARM
(4.72 in) (0.55 in) (0.71 in) (1.81 in) (3.15 in) (1.38 in) (13.78 in) (0.59 in) (0.59 in) S360-V (BOOM,
BUCKET)
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S360-V (ARM)
S400LC-V (ARM)
130.0 mm 14.0 mm 20.0 mm 50.0 mm 90.0 mm 35.0 mm 350.0 mm 15.0 mm 20.0 mm S400LC-V (BOOM)
S330LC-V ARM
(5.12 in) (0.55 in) (0.79 in) (1.97 in) (3.54 in) (1.38 in) (13.78 in) (0.59 in) (0.79 in) S400LC-V (BUCKET)
S450LC-V (BOOM,
BUCKET)

Page 9
S0705000
 Return to Master Table of Contents

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 8
2. Position piston rod so that it is extended
approximately one half meter (20").

Figure 9
3. Loosen 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 10

S0705000 Cylinders
Page 10
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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 11
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 12
6. Lower piston rod to support blocks and
detach wear ring (outer surface) (18) from
end of rod.

Figure 13

Cylinders S0705000
Page 11
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7. Immobilize piston rod by inserting a

wooden or other non-scoring, non-metallic
support through end of rod.

Figure 14
8. Loosen set screw by using a socket
wrench.

HAOF340L
Figure 15

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 16

S0705000 Cylinders
Page 12
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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 17

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 18
12. Use a dull, rounded-tip tool to pry off O-
ring (11) and backup ring (12).

HAOF37OL
Figure 19

Cylinders S0705000
Page 13
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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 20
14. Pull off O-ring (20) and backup ring (21)
from cylinder head.

HAOF38OS
Figure 21
15. During disassembly of cylinder head, be
careful not to damage buffer seal (5) and
U-packing (4).

HAOF39OL

Figure 22

S0705000 Cylinders
Page 14
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16. Disassemble retaining ring (3) and dust

wiper (2). Separate retaining ring (8) and
rod bushing (6).

Figure 23
17. Force out pin bushing (1) from body of
cylinder.

Figure 24

Cylinders S0705000
Page 15
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REASSEMBLY
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 reassembly 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 reassembly procedure.

NOTE: Reassemble the

subassemblies of the cylinder
in the following order:
1. Body of the cylinder
2. Piston rod
3. Piston assembly
4. Cylinder head assembly
1. Reassemble pin bushing (1) to piston rod
(13) and body of cylinder (14).

Figure 25
2. Following reassembly of rod cover
components, install the dust wiper (2) and
rod bushing (6) to the rod cover (9). Insert
retaining rings (3 and 8).

Figure 26

S0705000 Cylinders
Page 16
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3. Pre-lubricate O-rings and seals before

reassembly (Figure 27).

Figure 27
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 28
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 29

Cylinders S0705000
Page 17
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6. Assemble cushion ring (15) and attach

piston assembly to piston rod.

Figure 30

7. Use specially fabricate or factory-sourced

tool to tighten piston nut (22).

Figure 31
8. Assemble wear ring (18), slide ring (17)
and set screw (23) to piston assembly.

Reference
Description
Number
1 Set Screw

Figure 32
9. Immobilize body of cylinder before
reassembly.

Figure 33

S0705000 Cylinders
Page 18
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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 34

Cylinders S0705000
Page 19
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S0705000 Cylinders
Page 20
 S0707260

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 S0707260

MODEL SERIAL NUMBER RANGE
Solar 170LC-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2002 Daewoo

January 2002

Swing Motor S0707260

Page 1
TABLE OF CONTENTS

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

Theory of Operation ................................................................................ 3
Swing Motor Anti-cavitation Make-up Valve ............................................ 4
Relief Valve ............................................................................................. 5
Swing Brake Operation ........................................................................... 5
Parts List ................................................................................................. 8
Specifications ........................................................................................ 10
Special Tools ................................................................................................ 11
Disassembly ................................................................................................. 12
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 19
Reassembly.................................................................................................. 21

S0707260 Swing Motor

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION

Figure 1

Reference Reference
Description Description
Number Number
1 Valve Plate 4. Cylinder Block
2. Shoe 5. Piston
3. Swash Plate

The cross sectional views of the swing motor, show most of the main components of an axial-piston type
hydraulic motor. Arrows indicating direction of flow and other graphic symbols provide a general guide for
understanding basic operation (Figure 1).
When high-pressure oil enters the cylinder through the inlet port of the valve plate (1, Figure 1), the sliding
piston inside the cylinder is driven back, generating force "F" against the shoe behind the piston (2).
Force "F" acts in two different directions, as indicated by the arrows (Figure 1). Force F1 exerts pressure
directly on the swash plate (Item 3) to generate oil flow through the motor, while force F2 pushes laterally -
at a right angle - against the drive shaft, providing the rotational energy to turn the cylinder block around
the drive shaft.
All nine pistons in the cylinder block have equal width bore, length and volume. They are configured in a
concentric layout around the drive shaft, as shown in the cross section end-view. As oil is forced through
the inlet port, pistons rotating past the pressurized (supply) side of the motor (indicated as the shaded
cylinders) transmit drive torque - one after the next, each in turn - to the swash plate (through F1, direct
output force) and to the cylinder block (F2, lateral force to keep the block rotating).

Swing Motor S0707260

Page 3
If oil flow to the motor is directed to the opposite port (so that the supply side becomes the exhaust side
and vice versa), the rotation of the motor is reversed.
Trench mode allows the operator to "prioritize" hydraulic oil flow between swing function and boom and
arm function. Turning "ON" the trench mode boosts oil flow to swing circuit components, increasing swing
speed, as boom up/arm dump speed is reduced. If trench mode is turned "OFF" - diminishing the size of
the opening through the swing priority valve - boom/arm speed increases as slew rate falls off.
Connected through the EPOS-V controller, the switch of the trench mode changes the voltage of the
electronic signal sent to the solenoid valve.

IMPORTANT
The trench mode setting only has a noticeable effect if both functions are used at the same time,
when the right and the left joysticks are each engaged simultaneously, to control swing and
boom/arm functions.

When the trench mode is engaged, an engaged voltage signal to the solenoid valve shifts the "swing
priority" spool valve to increase oil flow through the swing motor. With trench mode "OFF," voltage is
disengaged while current flow is reduced, shifting the spool in the priority valve for increased oil flow to the
boom/arm side of the circuit.

SWING MOTOR ANTI-CAVITATION MAKE-UP VALVE

Unlike those designs for hydraulic swing motor application which incorporate a separate, external
counterbalance valve, the problem of motor rotational speed overtaking or surpassing oil flow rate at the
motor’s supply-side inlet is answered with pressure-control valving that is incorporated in the motor casing.
An anti-cavitation "make-up" valve is incorporated into each relief valve (Figure 2) to prevent oil starvation
on whichever side of the motor is serving as the supply side by allowing greater oil flow through one side of
the circuit. There is one valve for each side of the motor. When swing motor case drain pressure increases
past the set value of the make-up valves, oil flow is increased through that side of the motor circuit.

S0707260 Swing Motor

Page 4
RELIEF VALVE
The relief valve is one in a set of two, and is
Item "51" of the swing motor assembly.
Return line pressure (the normal pressurization
of the hydraulic reservoir, also referred to as
"tank pressure") pushes the valve piston to open
ports "R" and "P" at the end of the valve
whenever the hydraulic system is operating.
This valve initially reacts to the engagement of
hydraulic function (and pressurization of the
tank) by opening momentarily, so that there is
no pressure developed through the valve at all.
Tank pressure at "pressurized area A2" is set Figure 2
against spring pressure inside the valve,
opening the relief valve until pressure at the
spring chamber ("g") momentarily reduces "g"
chamber pressure "Pg." "Pg" subsequently
increases until the piston reaches the end of
travel inside the valve bore at "h."
After the piston reaches "h" and its normally
closed, pressurized operating position, pressure
through the valve can be continually increased
up to the relief valve maximum pressure ("Ps").

= ---------------------
1 – 2

Where Fsp: Spring Force

SWING BRAKE OPERATION

The swing brake is normally held in the applied position - preventing the upper deck revolving
superstructure from rotating - whenever the hydraulic system is not operated (pressurized). The brake
system is automatically released whenever the swing controls are engaged to swing in one direction or the
other.

Swing Motor S0707260

Page 5
 Figure 3

The swing brake is applied when the brake spring (Item 712, Figure 3) locks up the friction plate (742), split
plate (743) and swing motor casing (301), preventing the motor drive shaft from turning. When hydraulic
pressure is forced to the back side of the brake piston, the friction plate and swing motor casing are
separated, releasing the brake.

IMPORTANT
Along with the swing brake, a 2-position positive swing lock has also been provided. It should
be secured whenever the upper deck revolving superstructure must be locked down and
positively kept from rotating - including maintenance and/or repair intervals. (Do not rely on the
swing brake alone to hold the superstructure in position for repairs, transport, maintenance or
normal storage.

S0707260 Swing Motor

Page 6
Swing Motor S0707260
Page 7
PARTS LIST

841
401

468
487
111

303
52
116 117
51 113
351
355
488 123
469 433
121
444 122
124
472
464
485 301
712
993
994
31
702

707

706
451
131
101
743

742
432
743 106

742 443
743 106
432
491
438 304
106 471
114 437

118
HAAA4340
Figure 4

S0707260 Swing Motor

Page 8
 Reference Reference
Description Description
Number Number
31 Brake Valve 401 Socket Bolt
31-1 O-ring 432 Snap Ring
31-2 O-ring 433 Snap Ring
51 Relief Valve 437 Snap Ring
51-1 O-ring 438 Snap Ring
51-2 Backup Ring 443 Roller Bearing
52 Reactionless Swing Valve 444 Roller Bearing
52-1 O-ring 451 Spring Pin
101 Drive Shaft 464 VP Plug
106 Spacer 468 VP Plug
111 Cylinder Block 469 RO Plug
113 Spherical Bushing 471 O-ring
114 Cylinder Spring 472 O-ring
116 Push Rod 485 O-ring
117 Front Spacer 487 O-ring
118 Rear Spacer 488 O-ring
* Piston Assembly 491 Oil Seal
121 Piston 702 Brake Piston
122 Shoe 706 O-ring
123 Retainer 707 O-ring
124 Shoe Plate 712 Brake Spring
131 Valve Plate 742 Friction Plate
301 Casing 743 Separation Plate
303 Valve Casing 993 PT Plug
304 Front Cover 994 PT Plug
351 Plunger 841 Socket Bolt
355 Spring

Swing Motor S0707260

Page 9
SPECIFICATIONS

Item Specification
Solar 170W-V Solar 170LC-V
Solar 220LC-V
Solar 220LL
Type Axial Piston Axial Piston
Displacement 121.6 cc/rev 128.0 cc/rev
(18.85 in3/rev.) (7.81 in3/rev.)
Crossover Relief Valve 280 kg/cm2 280 kg/cm2
Setting (3,980 psi) (3,980 psi)
Maximum Supply Flow Rate 227 lpm 210 lpm
@ 2000 rpm (60 gpm) (55 gpm)
Max. Motor Shaft Speed 1,867 rpm 1640 rpm
Rated Motor Shaft Torque 54.2 kg•m 57 kg•m
(392 ft lb) (412 ft lb)
Weight 56.5 kg 62 kg
(125 lb) (137 lb)

S0707260 Swing Motor

Page 10
SPECIAL TOOLS

Figure 5

Swing Motor S0707260

Page 11
DISASSEMBLY
1. The area where the motor is going to be rebuilt should be well lighted, clean and protected from dust
and/or wind gusts that could carry grit or dust. Use a rubber mat or other protective overlay on
workbench area to prevent damaging or scratching any precision machined components.

IMPORTANT
Clean all of the exterior surfaces of the motor before disassembly. There should not be any
visible dirt, grease, or other type of accumulation on the outside of the casing. Clean off or
blow dry all traces of cleaner or solvent before starting work and cap off or use other types
of protective seals, plugs or wrapping on temporarily disconnected hoses, piping or ports.

2. Open drain plug and drain all oil from motor casing.
NOTE: Swing Motor component parts (numbered in parentheses) are keyed to Figure 4.

IMPORTANT
Use a clean, dry container to catch gear oil. A clean container allows an evaluation to be
made of the used oil. The presence or lack of metal wear shavings in the used oil or
obvious deterioration or contamination of the oil can provide a useful indicator of the
motor’s general condition.

NOTE: Used oil is an environmental

contaminant and should be
disposed of promptly at
approved recycling facilities.
Prolonged physical contact with
used oil has been thought by
some to pose a health risk.
Clean oil residue from hands
and clothing promptly, and don’t
allow used oil containers to
accumulate.
Figure 6
3. After oil has been drained completely,
motor should be positioned so that
exposed end of drive shaft faces
downwards.

Figure 7

S0707260 Swing Motor

Page 12
4. Make two permanent marks on exterior of
motor to indicate assembly position of
motor casing (301) and upper valve casing
(303).

Figure 8
5. Disassemble brake valve (31) from side of
casing.

Figure 9
6. Loosen and remove relief valve
assemblies (51) from upper valve casing
(303).

Figure 10
7. Remove RO plug (469) from upper valve
casing (303). That will allow subsequent
separation of spring (355) and plunger
(351).

IMPORTANT
Use extra care to avoid damaging the
plunger seat.

Figure 11

Swing Motor S0707260

Page 13
8. Loosen and remove all four socket head
bolts (401) and separate upper valve
casing (303) from lower casing (301).
NOTE: Valve plate (131) inside upper
valve casing (303) must be
separated from assembly but
take extra care to make sure
that it is not scratched or
damaged by an accidental fall,
after cover is removed.

Figure 12
9. Remove all twenty brake springs.
NOTE: If brake springs are to be
reused and not replaced, check
and record spring free height. If
a test stand is available, check
height of all twenty springs
under consistent loading.
Replace all springs that show
excessive variation or
weakness.

Figure 13
10. Disassemble brake piston assembly using
special tool and corresponding piston bolt
hole.
NOTE: See "Special Tools" portion of
this section for manufacturing
details of special tool.

Figure 14

S0707260 Swing Motor

Page 14
11. Reposition motor so that end of drive shaft
faces out to one side. Pull out cylinder
block (111) and disassemble pistons (121),
retainer plate (123), spherical bushing
(113), front spacer (117) and shoe plate
(124). Be careful not to make any
scratches or leave nicks on reciprocating
parts.
NOTE: Record or mark piston position
or store them in order in which
they were removed so that they
Figure 15
can be returned to same
cylinder bores they were taken
out of. Service life could be
extended incrementally by
maintaining previous wear-
pattern relationships by
avoiding new ones.
12. Pull out friction plates (742) and separator
plates (743) from area behind cylinder
block.

Figure 16
13. Remove lock ring (437) from around drive
shaft. Use a large enough pair of snap-ring
pliers to properly tension ring and pull it
away from locking groove.
Use extra caution in pulling off front cover
(304) behind snap ring. Drive shaft oil seal
(491) underneath cover must be replaced
if it is damaged during disassembly. Use a
little bit of extra caution (and a very large
set of channel locks, a puller or extra wide
adjustable wrench) to carefully withdraw
Figure 17
cover straight back off drive shaft.

Swing Motor S0707260

Page 15
14. Separate casing and drive shaft (101). Tap
upper end of drive shaft with a soft-faced,
plastic hammer. To avoid damaging drive
shaft, do not use excessive force.

Figure 18
15. Tap bearing race out of casing.

Figure 19
16. Disassembly of motor has now been
completed, unless there is any reason to
suppose that drive shaft bearing has
become excessively worn.
If it is necessary, replace bearing by
pulling away stop ring (432) and spacer
(106). Put drive shaft in a press to
separate bearing cage from drive shaft.

Reference
Description
Number
1 Press
2 Drive Shaft Figure 20
3 Roller Bearing
4 Base of Press

S0707260 Swing Motor

Page 16
 NOTE: Final disassembly of individual
components may also require:
A. Disassemble oil seal from the front
cover if they were not separated
during removal. Apply force (2,
Figure 21) and use a plug (1) to
hammer through drive shaft opening
in cover.

Reference
Description
Number
1 Plug
2 Applied Force Figure 21

Figure 22
B. If upper bearing is going to be
replaced, whether as a general
precaution as part of normal
rebuilding or because of
unmistakable wear, separate bearing
from cover.

Figure 23

Swing Motor S0707260

Page 17
 C. Relief valves can be replaced in sets
by ordering one part number through
your authorized Daewoo dealer/parts
distributor. To disassemble relief
valves, pull out plug (201, Figure 4),
disassemble bushing (343), spring
(322) and spring seat (331) from rod
(303). Position valve housing facing
down and separate piston (302), rod
(303), spring (321), spring seat (331)
and plunger (301).
Figure 24
IMPORTANT
Do not touch the adjusting
screw and lock nut. Replace the
valve as a complete unit if any
parts have been damaged.

S0707260 Swing Motor

Page 18
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
Inspect all components and precision surfaces, to confirm that they haven’t been worn beyond service
limits. Refer to table below for dimensional specifications.
All parts should be cleaned, air-dried and re-lubricated with clean, approved-type hydraulic fluid, before
final reassembly or as the final step after the unit has been put back together.
Replacement of all O-rings and oil seals with new parts is generally recommended, unless motor has had
minimal use. Inspect O-rings and oil seals very carefully for cuts, nicks, brittleness or softness, or any other
type of damage or distortion, before final reassembly.
NOTE: When parts exceed the standard, replace them. When there is conspicuous surface
damage, it is always safer to replace parts, whether standards are exceeded or not.

2
1

d D

5
4
3
H
h
a
t

HBOA230L
Figure 25

NOTE: Spherical bushing and push plate must always be replaced as a set. If either one requires
replacement, replace the other
1. Clearance Between Piston and Cylinder Bore (D-d)
2. Spring Free Length (L)
3. Thickness of Shoe (t)
4. Piston Ball - Shoe Socket Clearance (a)
5. Height Between Round Bushing and Push Plate (H-h)

Swing Motor S0707260

Page 19
Service Standards for Replacing Worn Parts
NOTE: When parts exceed the standard, replace them. When there is conspicuous surface
damage, it is always safer to replace parts, whether standards are exceeded or not.

Standard Value Replacement

Item Remedy
mm (In) Limit mm (In)
Clearance between cylinder 0.028 mm 0.058 mm Replace piston or
bore and piston (D-d) (0.0011 in) (0.0023 in) cylinder
Clearance between piston 0 mm 0.30 mm Replace piston, shoe
and shoe socket (0 in) (0.0118 in) assembly parts
5.5 mm 5.30 mm Replace piston, shoe
Thickness of shoe (t)
(0.2166 in) (0.2087 in) assembly parts
Height of push plate, round 6.5 mm 6.0 mm Replace set; spherical
bushing assembly (H-h) (0.256 in) (0.236 in) bushing and retainer
4.0 mm 3.6 mm
Thickness of friction plate Replace
(0.157 in) (0.142 in)

Inspect O-rings and oil seals very carefully for cuts, nicks, brittleness, softness or any other type of
damage or distortion, before final reassembly if any must be reused.

S0707260 Swing Motor

Page 20
REASSEMBLY
Reassembly of the motor is basically accomplished by reversing disassembly steps.
Use a torque wrench to make sure that assembly fasteners are tightened to specified values. Always begin
a bolt tightening sequence from the innermost part of the assembly, working outward toward the ends in
careful, even rotation.
1. Position motor casing face down (Figure
26).

Figure 26
2. If drive shaft roller bearings were not
disassembled, go onto next phase of
assembly. Bearing reassembly begins with
replacement of stop ring (432) (Figure 4
and its accompanying Parts List) and
spacer (106) on drive shaft (101).

Figure 27
Make sure that bearing raceways (collars)
are facing right direction. The drawing
shows one side of the bearing collar (1,
Figure 28), marked "R," which should be
assembled next to spacer (2) on lower end
of drive shaft.
A. Both bearing cages (inner roller
assemblies) will probably require
heating in oil before reassembly.
Heat bearings to cause sufficient
expansion of their inner diameters to
allow reassembly on drive shaft.
Figure 28

Swing Motor S0707260

Page 21
3. Reassemble drive shaft (101, Figure 4),
roller bearing (443) and lower casing
(301). Pay attention to bearing alignment
inside bore of case. Make sure it is fully
seated.

Figure 29
4. There is a "right side" and "wrong side" on
oil seal. Be careful that you install seal
inside cover with correct side facing in.

Figure 30
5. Before replacing O-ring (471) in lower
casing (301), grease O-ring (and/or inside
of groove) very lightly, to facilitate
assembly and to help protect O-ring from
accidental damage.

Figure 31
6. Put a little grease on lip of front cover oil
seal before replacing front cover and
tapping it lightly into place with plastic
hammer.

Figure 32

S0707260 Swing Motor

Page 22
7. Use snap-ring pliers to replace lock ring
(437) into lower casing (301).

Figure 33
8. Turn motor sideways and assemble shoe
plate (124), placing it in motor housing in
same position it was in before removal.
Using grease on assembled side can help
keep individual components in place.

Figure 34
9. Carefully examine cylinder block for any
evidence of damage around rotating parts.
Put push rods (116) and front spacer (117)
back into cylinder block and replace
spherical bushing (113).

Figure 35
10. Using reference notes or marks made
earlier, replace all of the pistons and shoes
(121, 122) back in their original cylinder
bores.

Figure 36

Swing Motor S0707260

Page 23
11. Put cylinder block (111) and retainer plate
(123) back in motor. Spherical bushing and
grooves of cylinder block splines should fit
together without undue difficulty. (Do not
try to force or pound parts together.)

Figure 37
12. Turn motor so that front cover side (304) is
down. Put separator plates (743) and
friction plates (742) back in same order in
which they were removed. There are three
separator plates (743) and two friction
plates (742), which should be positioned
as shown in drawing below, with clearance
towards side of casing with brake valve (1,
Figure 38).

Reference
Description
Number
1 Brake Valve
Figure 38 \
13. Very lightly grease larger O-rings (706 and
707, Figure 4) before replacing them in
casing (301).

Figure 39
14. Position brake piston (1, Figure 40) in
casing. The diagram shows position of four
piston grooves (2) in relation to valve-
connected side (3), and two 8 mm bolts
which should be tightened in an even,
progressive rotation.

Reference
Description
Number
1 Brake Piston
2 Groove
3 Valve-connected Side
Figure 40

S0707260 Swing Motor

Page 24
15. Reinstall brake springs, making sure that
each gets fully seated on piston.

Figure 41
16. Tap roller bearing (444) race back into
upper valve casing (303), using hammer
and copper rod specified in tool list.

Figure 42
17. Assemble valve plate (131), O-ring and
upper valve casing (303). Refer to
assembly that shows "R" part (2, Figure
43) of the valve plate turned away from
mounting flanges (1) on side of valve plate.
Lightly grease O-ring to help keep it in
place during assembly.

Reference
Description
Number
1 Flange Side
2 R Port
Figure 43
18. Bolt up two halves of motor casing (301
and 303, Figure 4). Be careful not to lose
or damage O-ring. Tighten four 20 mm
socket head bolts using a progressive,
even rotation. Make sure that all brake
springs are fully seated and that valve
casing inlet and output ports are correctly
matched.

Figure 44

Swing Motor S0707260

Page 25
19. Put plungers (351), springs (355), O-rings
(488), and RO plugs (469) back in casing.
Make sure that both plungers are free to
move back and forth.

Figure 45
20. Reassemble relief valves (51) by putting
rod, spring, stop and piston back together,
then turning plunger side of valve up to
reassemble valve body and all
components of piston: spring seat, spring,
bushing, retainer, O-ring and plug.

Figure 46

IMPORTANT
Be careful not to damage the plunger
and spring seat.

Figure 47
21. Before replacing relief valves (51) in upper
valve casing (303), install backup rings
and O-rings.

Figure 48

S0707260 Swing Motor

Page 26
22. Replace the VP plugs (464, 468) and O-
rings (485, 487) on each of the three
plugs. Reinstall the brake cutoff valve (31).

Figure 49

Swing Motor S0707260

Page 27
S0707260 Swing Motor
Page 28
 S0707365

1TRAVEL MOTOR (WITH

GEARBOX) (A6V160HD)

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 (WITH GEARBOX) (A6V160HD)S0707365

MODEL SERIAL NUMBER RANGE
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2002 Daewoo

January 2002

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 1
TABLE OF CONTENTS

General Description ....................................................................................... 4

Theory of Operation ................................................................................ 4
Reduction Gearbox Operation ................................................................ 5
Parts List ................................................................................................. 7
Specifications ........................................................................................ 15
Tightening Torques................................................................................ 16
Travel Motor Disassembly ............................................................................ 18
Sectional View....................................................................................... 18
Seal Kits and Component Groups......................................................... 19
Sealing Drive Shaft ............................................................................... 22
Sealing Control Parts ............................................................................ 23
Sealing Relief Valve .............................................................................. 24
Disassembly Port Plate ......................................................................... 24
Exchanging Rotary Group..................................................................... 29
Travel Motor Speed Reduction Gearbox Disassembly ................................. 32
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 41
Travel Motor Speed Reduction Gearbox Reassembly.................................. 42
Travel Motor Reassembly ............................................................................. 52
Rotary Group Assembly ........................................................................ 52
Rotary Group Adjustment (See Serve Information) .............................. 53
Assembly of Port Plate.......................................................................... 55
Safety Regulations ................................................................................ 56

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
Refer to the assembly cross-section at the end. Travel motor consists of the hydraulic motor and reduction
gearbox.
Hydraulic motor consists of the rotary part, cross relief valve, negative brake, counter balance valve and
tilting parts. The reduction gearbox consists of a 3-speed planetary gearbox. The next figure shows the
motor as a symbol.

Figure 1

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 3
HYDRAULIC MOTOR OPERATION

1. Hydraulic Motor operation.

Figure 2

The high pressure oil from the hydraulic pump goes to the cylinder block (104) through the rear
flange (101) of the motor and the brake valve device and the timing plate (109). This high
pressure oil acts only on the single side of the line Y1-Y2 which connects the bottom dead
center and the top dead center of the piston (105) stroke. The oil, after flowing into the side of
the cylinder block (104), exerts force on each piston (4 or S pieces) and generates force F (p kg/
cm x A cm2 ). The force F is exerted on the swash plate (103): as the swash plate (103) is tilted
with respect to the driving shaft (102) by a degrees, the force F is divided into two resultant
forces F2 and F3. Among these forces, radial force F3 develops torque T (F3 x ri) with respect
to each Yl-Y2 line. The combined torque T(Z(F3 x ri)), which is a rotation force, rotates the
cylinder block through pistons (105). The cylinder block is coupled with the driving shaft by a
spline, and the driving torque is transferred to the shaft.

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 4
2. Brake Valve
A. During Travel.

Figure 3

If the pressure oil is supplied from port A, this oil opens the valve (130), flows into the inlet port
C of the hydraulic motor, and turns the hydraulic motor.
At the same time, the oil, which flows from a small hole of the spool (126) to the chamber b
through passage a, exerts pressure on the spool section, and moves the spool to the left over
spring (128) force.
As the spool moves, port D at the return side of the motor and part B at the tank are connected
together by a hole in the spool, and the motor turns as the return oil from motor flows into the
tank.
By the movement of spool (126), the pressure oil goes into port P and S. In port P, the pressure
oil releases the parking brake force and moves the piston of parking brake.
In port S. the pressure oil goes into chamber t, presses the stopper (157) of the inner surface of
the main body, prevents the spool (137) from moving, and closes port C during driving. If the
pressure oil is supplied from port B, the spool (120) and the valve (130) operate in reverse, and
rotate in the opposite direction.

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 5
 B. When Stopping by Deceleration.

Figure 4

If the pressure oil supplied by the port A is cut off during drive. there will be no hydraulic force.
Then, the spool (126) returns to the right (neutral position) through the stopper (125) by the
spring (128).
The hydraulic oil in chamber b goes through passage a into port A, and back pressure, which is
generated by throttling of passage a controls the return speed of spool (126).
At the same time, the hydraulic motor rotates by inertia force even without the pressure oil.
So the return oil from port D returns to port B through a gap between the spool hole and the rear
flange.
If the spool returns to the neutral position, hydraulic motor stops because all passages are
closed completely.
Like this, the spool’s returning speed controls the return oil from motor gradually according to
the spool’s shape, and stops the hydraulic motor.
As the hydraulic motor rotates because of inertia force, it tries to absorb the hydraulic oil. But
hydraulic oil cannot be supplied because the oil is blocked. So the hydraulic motor will be
damaged by cavitation. But, at the same time, the pressure at port D rises because the return
oil from the hydraulic motor is closed.
By this pressure, the spool (137) slides to the left, the ports D, C are connected. And, by this,
cavitation and pressure rising is prevented.
(Function of the surge cut valve and anti-cavitation valve)
The valve (127) is operated by a little secondary pressure, opens the oil passage between the
port A and the motor suction part, and it prevents the hydraulic motor from cavitation.

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 6
3. Parking Brake
C. During Travel.
If the pressure oil is supplied by the
brake valve, the brake valve spool of
the hydraulic motor part is operated,
and the passage into the parking
brake is opened.
So the pressure oil flows into the
cylinder a which consists of a spindle
and a piston.
If the pressure rises above 11 kg/cm2,
it over comes the spring force, and
the piston (112) moves.
By the movement of the piston, the
force exerted by the piston (112) on
the separator plate (116) and the
friction plate (115) is released, and
the friction plate (115) can move
freely. So the brake force acting on
the hydraulic motor’s cylinders is
released.
If the pressure rises above 45 kg/cm2,
the pressure is reduced by the and Figure 5
the pressure at the chamber a is fixed
at 45 kg/cm2. A safety valve which is
set up at 100 kg/cm2 as a limit is
installed to the reduction valve.

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 7
 D. During Braking.
If the pressure of the cylinder drops
below 11 kg/cm2 because the
pressure oil of the brake valve is
blocked, the piston (112) returns by
the spring (113) force.
If the piston (112) is pushed by the
spring force, the separator plate (116)
and the friction plate (115) are pushed
to the spindle of the reduction device.
The friction force generated by this
push generates braking torque (49.3
kg•m) to hydraulic motor shaft by
removing turning force of the cylinder.
It operates smoothly because of
proper oil paths.

Figure 6

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 8
4. High and Low Speed Switching Device
E. At low speed (If the pilot pressure is lower than 10 kg/cm2 )

Figure 7

If pilot pressure is not applied from port A (If the pressure is lower than 10 kg/cm2), the valve
(163) is pushed to the left by the spring (I66) force, the pressure oil from the supply port B is
blocked, and the oil of the chamber C flows through the valve (l63) into the motor case. So it
rotates at low speed because the swash plate (103) is tilted to the maximum angle, and the
piston stroke volume is maximized.

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 9
 F. At high speed (If the pilot pressure is higher than 20 kg/cm2 )

Figure 8

If pilot pressure is supplied from port A (If the pressure is higher than 20 kg/cm2), the valve (163)
is pushed to the right bv the spring (166) force, the pressure oil from the supply port B goes
through valve (163) into the chamber C. So the piston (161) is fixed because the swash plate
(103) is pushed to the plate b of the spindle. At this time, it rotates at high speed because the
slope of the swash plate (103) becomes minimum and the piston’s displacement volume
becomes minimized (c: 20 kg/cm2 ).

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 10
REDUCTION GEARBOX OPERATION
This reduction gear is a combined system of planetary gear and differential gear, It reduces rotational
speed, while increasing output torque of the hydraulic motor, and rotates the gear case.
1. Planetary gear
(R)
If the sun gear (S) connected to the input
shaft rotates, the planetary gear (P) turns (P1) (P2)
around the teeth of the ring gear (R) while
the shaft rotates. The planetary gear device Input Output
transmits torque to the carrier (K) by
transmitting this rotation. (S)
(K)

HJA4011L
Figure 9
2. Differential gear (D)
If the carrier combined to the input shaft (R)
rotates, the planetary gears (Pl, P2) turn. If
the gear ratios between (R) and (P1), (Pl) (P1) (P2)
and (P2) are properly different, the co-axial
gears (P1) and (P2) transmit torque by Input Output
generating different rotation with the gear
(D).
(K)

= ---------------------------
2 ⋅ 2
– -----------------
⋅ 1
HJA4012L
Figure 10
3. Combined device of planetary and (D)
differential dvice.
(R)
If the sun gear (S and R), and (P1), and the
carrier rotates by the planetary motion of (P1) (P2)
the gear (P1).And the rotation of the carrier
causes the differential motion between Input Output
gears (R) and (P1), and between (P2) and
(D), and causes the rotation ofthe ring gear, (S)
and so torque is transmitted.

= 1 × 2

HJA4013L
Figure 11

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 11
PARTS LIST

Travel Motor

HTS6331
Figure 12

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 12
 Reference Reference
Description Qty. Description Qty.
Number Number
6315-- Travel Motor 2 11 Back Up Plate 1
1 Rotary Group 1 12 O-ring 1
2 Control 1 13 Rocking Screw 1
5 Housing 1 17 Threaded Pin 2
9 Retaining Ring 1 18 Seal Lock Nut 2
10 Shaft Seal Ring 1

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 13
Travel Motor - Rotary Group

HTS6321
Figure 13

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 14
 Reference Reference
Description Qty. Description Qty.
Number Number
6325-- Rotary Group 1 1h Retaining Plate 1
1 Rotary 1 1i Screw 14
1a Cylinder 1 2 Drive Shaft 1
1b Control Lens 1 3 Shim 1
1c Center Pin 1 6 Back Up Plate 1
1d Piston 7 7 Retaining Ring 1
1e Steel Sealing Ring 14 10 Tapered Roller 1
1f Adjustment Shim 1 Bearing
1g Pressure Spring 1 11 Tapered Roller 1
Bearing

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 15
Travel Motor - Control

HTS6331
Figure 14

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 16
 Reference Reference
Description Qty. Description Qty.
Number Number
6335-- Control 1 15 Bush 1
10 Brake Valve 1 20 Socket - Head 2
11 Throttle Pin 1 Screw
12 Valve 2 21 Socket - Head 2
Screw
49 Pressure Control 1
Valve 22 Socket - Head 4
Screw
50 Pressure Relief 2
Valve 23 Cylinder Pin 2
1 Port Plate 1 24 Rocking Screw 3
2 Positioning Piston 1 25 Rocking Screw 2
3 Positioning 1 26 O-ring 1
Trunnion 27 O-ring 1
4 Control Bush 1 28 Double Break-Off 5
5 Control Piston 1 Pin
6 Pressure Spring 1 29 Ball 1
7 Rocking Screw 1 6335-- Control 1
8 Throttle Screw 1 30 Rocking Screw 1
9 Throttle Screw 1 31 Double Break-Off 2
Pin
13 Rocking Screw 1
32 Rocking Screw 1
14 Valve Screw 1

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 17
Travel Motor Speed Reduction Gearbox Assembly

3033
Figure 15

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 18
 Reference Description Qty. Reference Description Qty.
Number Number
1 Washer 2 19 Brake Shaft 1
2 Breather Plug 2 20 O-ring 1
3 Screw 16 21 Disc 7
4 Cover Set 1 22 Ring, Steel 6
5 O-ring 1 23 Ring, Backup 1
6 Pad 1 24 O-ring 1
7 Sun Gear 1 25 O-ring 1
8 1st Red Ass’y 1 26 Ring, Spiral 1
9 Sun Gear 1 27 Piston 1
10 2nd Red Gear 1 28 Spring 21
Ass’y 29 Spacer 1
11 Screw, Uni 5931 4 30 Circlip 1
12 3rd Red Gear 1 31 Brake Ass’y 1
Ass’y
32 Flange 1
13 Bushing 4
33 O-ring 1
14 Sun Gear 1
34 Screw 2
15 Bearing Ass’y 1
36 Plug 1
16 Gasket, Lifetime 1
37 Screw 8
17 Hub 1
38 O-ring 1
18 Spacer 1

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 19
SPECIFICATIONS
Name Plate Identification

A6VE 160 HZ3 / 63W - V Z L - 220B - S

1
2
3
4
5
6
7
8
9
10

Reference
Description
Number
1 Unit With CBV, Brake Release Valve & Relief Valves Incooporated
2 Beginning of Regulation At Max Displacement
3 2 hole Flange
4 Drive Shaft 45 mm Diameter
5 Viton Seals
6 Alternating Direction of Rotation
7 Series
8 Two-point Control
9 Max Displacement 160 cc/rev
10 Beat Axis Plug-in Type Motor

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 20
Component specifications are shown in following table.

Item Unit Specification

Rated Torque kg•m 81.5
Max Rotation Rate rpm 3680@99 cc/rev
Max Output/rev cc/rev 160
Operating Rotation rpm 2900
Max Output Pressure kg/cm2 320
2 Speed Switching Pressure kg/cm2 Auto. Switching
Parking Brake Torque kg•m 11.140 kg•m
Parking Brake Releasing Pressure kg/cm2 12.5 kg/cm2

TIGHTENING TORQUES

Tightening Torques For Shat Bolts

(Metric ISO Standard Thread)
Strength Classes
The valve for tightening torques Thread 8.8 10.9 12.9 8.8 10.9 12.9
shown in the table are valid only Size Tightening Torques (Ib.ft) Tightening Torques
for shaft bolts with metric ISO- (Nm)
standard threads and head M3 0.8 1.2 1.4 1.1 1.6 1.9
support surface dimensions in M4 2.1 3.0 3.6 2.9 4.1 4.9
accordance with DIN 912, DIN M5 4.4 6.3 7.4 6 8.5 10
931 and DIN 933. These values M6 7.4 10.3 12.5 10 14 17
are also valid only for light or M8 18.4 25.8 30.2 25 96 41
unoiled, untreated surface and for M10 36.1 50.9 61.2 49 69 83
use only with torque-indicating M12 63.4 88.4 106.9 86 120 145
wrenches and force limiting tools. M14 99.5 140.0 169.5 135 190 230
M16 154.8 217.4 261.6 210 295 355
M18 213.7 298.5 357.4 290 405 485
M20 302.2 427.5 508.5 410 580 690
M22 405.4 574.9 685.4 550 780 930
M24 523.5 737.0 884.4 710 1000 1200
M27 773.9 1105.5 1326.6 1050 1500 1800
M30 1068.7 1474.0 1768.8 1450 2000 2400

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 21
 Tightening Torques For Locking Screws Vsti
(Metric ISO Fine Thread)
Thread Size Designation Tightening Torques Tightening Torques
(Ib.ft) (Nm)
M8 x1 VSTI 8x1 -ED/SA =4 =5
M 10 x 1 VSTI 10x1 -ED =7 =10
M 12 x 1,5 VSTI 12x1,5 -ED =15 =20
M 14 x 1,5 VSTI 14x1,5 -ED =22 =30
M 16 x 1,5 VSTI 16x1,5 -ED/SA =22 =30
M 18 x 1,5 VSTI 18x1,5 -ED/SA =29 =40
M 20 x 1,5 VSTI 20x1,5 -ED/SA =37 =50
M 22 x 1,5 VSTI 22x1,5 -ED =44 =60
M 26 x 1,5 VSTI 16x1,5 -ED/SA =51 =70
M 27 x 2 VSTI 27x2 -ED =66 =90
M 30 x 1,5 VSTI 30x1,5 -ED/SA =74 =100
M 33 x 2 VSTI 33x2 -ED/SA =88 =120
M 42 x 2 VSTI 42x2 -ED/SA =147 =200
M 48 x 2 VSTI 48x2 -ED =220 =300

Tightening torques for seal-lock nuts

(Metric ISO Standard Thread)
Strength Classes
The values for tightening torques Thread 8.8 10.9 12.9 8.8 10.9 12.9
shown in the table are valid only for Size Tightening Torques Tightening Torques
seal-lock nuts of the strength class (Ib.ft) (Nm)
8.8 and with metric ISO-standard M6 7,4 10
thread. M8 16,2 22
M10 29,5 40
M12 50,9 69
M14 81,1 110
M16 125,3 170

Tightening Torques For Cross-slotted Lens Head Screws

Din 7985
(Metric ISO Standard Thread)
Strength Classes
The values for tightening torques Thread 8.8 10.9 12.9 8.8 10.9 12.9
shown in the table are valid only Size Tightening Torques Tightening Torques
for cross-slotted lens head screws (Ib.ft) (Nm)
DIN 7985 of the strength class 8.8 M3 0,8 1.1
and with metric ISO-standard M4 2,1 2.9
thread. M5 4,4 6
M6 7,4 10
M8 18,4 25
M10 36,1 49

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 22
TRAVEL MOTOR DISASSEMBLY
SECTIONAL VIEW

HTS063S
Figure 16

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 23
SEAL KITS AND COMPONENT GROUPS
NOTE: Observe the following notices
when carrying out repair work
at hydraulic aggregates!

HTS001S
Figure 17
1. Close all points of the hydaulic
aggregates.

HTS002S
Figure 18
2. Replace all seals.
NOTE: Use only original Hydromatik
spare parts.

HTS003S
Figure 19
3. Check all seal and sliding surfaces for w
ear.
NOTE: Rework of sealing area f. ex.
with crocus cloth can dammage
surface.

HTS004S
Figure 20

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 24
4. Full up hydaulic aggregates with hydraulic
oil before start-up.

HTS005S
Figure 21
5. Seal kit for drive shaft.

HTS006S
Figure 22
6. External seal kit.

HTS007S
Figure 23
7. Housing.

HTS008S
Figure 24

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 25
8. Complete rotary group.

HTS009S
Figure 25
9. Port plate with control piston and counter-
balance valve.

HTS010S
Figure 26
10. Relief valve / Make up check valve.

HTS011S
Figure 27
11. Replace seal nut.
NOTE: First measure and record
setting height.

HTS012S
Figure 28

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 26
12. When tightening, counter hold setting
screw, then check setting height.

HTS013S
SEALING DRIVE SHAFT Figure 29

HTS014S
Figure 30

1. Protecting the drive shaft.

2. Remove retaining ring and shim.

HTS015S
Figure 31

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 27
3. Screw in sheet metal screw into the holes
fitted with rubber.
4. Pull out seal with pliers.

HTS016S
Figure 32
5. Press in shaft seal and shim with bush to
stop.
NOTE: Pay attention to pressing depth!
* Mark for pressing depth.
Assemble retaining ring.

HTS017S
Figure 33
SEALING CONTROL PARTS
1. H-Z- Controler.
NOTE: Inspect O-ring, O-ring groove,
housing.

HTS019S
Figure 34
SEALING RELIEF VALVE
1. Remove relief valve.

HTS020S
Figure 35

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 28
2. Inspect O-ring.

HTS021S
Figure 36
DISASSEMBLY PORT PLATE
1. Note dimension X.
2. Remove Qmin-screw.

HTS023S
Figure 37

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 29
3. For disassembly of the port plate, swivel
always rotary group to zero position.
4. Piston rings to hang out the cylinder boring.
Swivel rotary group to zero position with
screw Q max.

HTS024S
Figure 38

5. Port plate.
A. Mark position.
B. Loosen screws.
C. Remove.

HTS025S
Figure 39
6. Ceck O-ring.
NOTE: Coat new O-ring with some
grease. Do not swivel rotary
group. Piston rings to hang out
from the cylinder boring.

HTS026S
Figure 40

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 30
7. Braking valve.

HTS027S
Figure 41
8. Throttle pin.

HTS028S
Figure 42
9. Valve.

HTS029S
Figure 43
10. Pressure control valve.

HTS030S
Figure 44

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 31
11. Pressure relief valve.

HTS031S
Figure 45
12. Positioning piston.

HTS032S
Figure 46
13. H-Z- control.

HTS033S
Figure 47
14. Check valve.

HTS034S
Figure 48

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 32
 HTS035S
Figure 49

HTS036S
Figure 50

15. Screw in threaded pin into center pin.

16. Fix the cylinder with disc and locknut.

HTS037S
Figure 51

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 33
17. Press out rotary group.
NOTE: If the bearings are used again
do not hit on the drive shaft.

HTS038S
Figure 52
EXCHANGING ROTARY GROUP
1. Complete rotary group.
NOTE: Setting of hydraulic part
necessary.

HTS039S
Figure 53
2. Rotary group.
• Mechanical part; Adjust drive shaft
with bearing.
• Hydraulic part; Adjustment necessary.

HTS040S
Figure 54
3. Remove fixing screw (cylinder).
4. Remove cylinder.

HTS041S
Figure 55

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 34
5. Disassemble retaining plate.
NOTE: screws are glued . Use Torx-
tools.

HTS042S
Figure 56
6. Free of corrosion, erosion or fretting; No
damage to splines or keyways.

HTS043S
Figure 57
7. Pistons; No scoring and no pittings.

HTS044S
Figure 58
8. Center pin; No scoring and no pittings.

HTS045S
Figure 59

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 35
9. Retaining plate; No scoring and no
evidence of wear.

HTS046S
Figure 60
10. Cylinder block / control lens;
Bores free of scoring, no evidence of wear.
Faces smooth and even, free of cracks and
scoring.

HTS047S
Figure 61
11. Control housing; Sliding surface and side
guides free of scoring and no wear.

HTS048S
Figure 62
12. Visual check; Bearing areas free of scoring
and no evidence of wear.

HTS049S
Figure 63

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 36
TRAVEL MOTOR SPEED REDUCTION GEARBOX
DISASSEMBLY
1. Drain gear oil and remove travel motor and
O-ring.
2. Remove motor flange (8 socket bolts, M16
x 35 ). Figure 64.

3034
Figure 64
3. Remove O-ring from motor flange. Figure
65.

3035
Figure 65
4. Remove O-ring from hub groove. Figure 66.

3036
Figure 66

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 37
5. Attach disc (B, Figure 67) to spring retainer;
fasten pusher (A) to hub and install screw
rod (C).

3037
Figure 67
6. Remove circlip from hub groove using
pliers. Figure 68.

3038
Figure 68
7. Remove jig and circlip. Figure 69.

3039
Figure 69

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 38
8. Remove spring retainer. Figure 70.

3040
Figure 70
9. Pull spring from groove. Figure 71.

3041
Figure 71
10. Blow air into brake port hole and remove
brake piston using pliers. Figure 72.

3042
Figure 72
11. Remove brake shaft. Figure 73.

3043
Figure 73

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 39
12. Remove disc. Figure 74.

3044
Figure 74
13. Remove O-ring and backup ring. Figure 75.

3045
Figure 75
14. Turn reduction gear assembly over and
remove 2 plugs (M22 x 1.5). Figure 76.

3046
Figure 76
15. Remove 16 socket bolts (M14 x 40). Figure
77.

3047
Figure 77

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 40
16. Remove end cover, using puller. Figure 78.

3048
Figure 78
17. Remove O-ring from end cover groove.
Figure 79.

3049
Figure 79
18. Remove first sun gear. Figure 80.

3050
Figure 80
19. Remove first planetary gear assembly.
Figure 81.

3051
Figure 81

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 41
20. Remove second sun gear. Figure 82.

3052
Figure 82
21. Remove second planetary gear assembly.
Figure 83.

3053
Figure 83
22. Remove third sun gear. Figure 84.

3054
Figure 84
23. Loosen bolts (4, M 30 x 150) from third
planetary gear assembly. Figure 85.

3055
Figure 85

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 42
24. Remove bolts. Figure 86.

3056
Figure 86
25. Seperate hub from reduction gear housing,
using press and stopper. Figure 87.
NOTE: Do not remove main ball
bearing.

3057
Figure 87
26. Remove third shift assembly from hub.
Figure 88.

3058
Figure 88

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 43
27. Remove bushing from hub using a jig.
Figure 89.

H
H 3059

Figure 89
28. Remove bearing inner race and spacer
from hub, using puller. Figure 90.

3060
Figure 90

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 44
29. Remove gasket. Figure 91.

3061
Figure 91

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 45
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
Gearbox Inspection
1. If a gear is damaged, replace the damaged gear and the interlocking gear next to it. If one planetary
gear is damaged, replace the entire planetary gear assembly.
2. Replace O-rings.
3. Apply grease to assembly side of O-rings to make assembly easier.

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 46
TRAVEL MOTOR SPEED REDUCTION GEARBOX
REASSEMBLY
1. Install seal to jig. Figure 92.

HTS3062S

3062
Figure 92
2. Install jig to housing. Figure 93.

3063
Figure 93
3. Clean seal surface. Figure 94.

3064
Figure 94

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 47
4. Install seal to hub using jig used in Step 1.
Figure 95.

3065
Figure 95
5. Apply lubricant to seal surface. Figure 96.

3066
Figure 96
6. Support ball bearing housing with spacers
(1 and 2, Figure 97) and install bearing into
housing. Install spacer between balls,
noting diameter shown in illustration.

30

3067
Figure 97
7. Install upper balls and upper housing.
Figure 98.

3068
Figure 98

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 48
8. Install hub to housing. Figure 99.

3069
Figure 99

9. Press hub into housing using a press and a

stopper. Figure 100.

3070
Figure 100
10. Install four bushings using a press. Figure
101.

3071
Figure 101
11. Assemble planetary gear assembly. Figure
102.

3072
Figure 102

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 49
12. Install four planetary gear assemblies,
using press. Figure 103.

3073
Figure 103
13. Tighten gear box of planetary gear
assembly to 150 Nm (110.7 ft lb). Figure
104.

3074
Figure 104
14. Assemble third shift sun gear. Figure 105.

3075
Figure 105
15. Assemble the second shift reduction
assembly. Figure 106.

3076
Figure 106

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 50
16. Place planetary gear carrier on hub. Figure
107.

3077
Figure 107
17. Press planetary gear carrier into hub.
Figure 108.

3078
Figure 108
18. Apply loctite to planetary gear carrier
fastening bolts.
19. Install and tighten bolts. Figure 109.
NOTE: In next step, the O-ring and
backup rings are different. Be
careful not to switch them.

3079
Figure 109
20. Install O-ring to end cover. Figure 110.

3080
Figure 110

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 51
21. Install end cover to housing.
NOTE: Apply Loctite 243 to bolts and
torque to 10 Nm (7.38 ft lb).
Figure 111

3081
Figure 111
22. Tighten plugs to 6 - 8 Nm (4.42 - 5.90 ft lb).
Figure 112.

3082
Figure 112
23. Turn housing over and install second shift
sun gear. Figure 113.

3083
Figure 113
24. Install first shift planetary gear assembly.
Figure 114.

3084
Figure 114

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 52
25. Install first shift sun gear. Figure 115.

3085
Figure 115
26. Install O-ring (1, Figure 116) and backup
ring (2) into hub groove.
NOTE: The O-ring and backup rings are
different. Be careful not to switch
them.

3086
Figure 116

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 53
27. Install brake shaft while turning the
reduction gear assembly. Figure 117.

3087

Figure 117
28. Install brake disc assembly, starting with a
copper disc (seven pieces) and alternating
with steel discs (six pieces). Figure 118 and
Figure 119.

3088
Figure 118

3089
Figure 119
29. Install jig to hub and insert spring retainer
disc under left side of circlip. Figure 120.

3090
Figure 120

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 54
30. Install circlip using circlip pliers. Figure 121.

3091
Figure 121
31. Install O-ring to hub groove. Figure 122.

3092
Figure 122
32. Place brake piston inside hub being careful
not to damage seal. Figure 123.

3093
Figure 123
33. Insert springs into brake piston holes.
Figure 124.

3094
Figure 124

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 55
34. Install retainer disc. Figure 125.

3095
Figure 125
35. Install O-ring to motor flange groove. Figure
126.

3096
Figure 126
36. Tighten motor flange to hub. Figure 127.

3097
Figure 127

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 56
TRAVEL MOTOR REASSEMBLY
ROTARY GROUP ASSEMBLY
1. Rotary group completely assembled ready for
assembly.

Figure 128
2. Place assembly sleeve.

HTS051S

Figure 129

3. Warm up housing to 80˚C (176˚F).

HTS052S

Figure 130

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 57
4. Insert rotary group into housing to seat
position.

HTS053S
Figure 131

5. Fix zero position of cylinder with Qmax-

screw.
6. Disassemble cylinder fixing screw.
7. Insert O-ring.

HTS054S
Figure 132

ROTARY GROUP ADJUSTMENT (SEE SERVE

INFORMATION)
1. Determine cylinder swivel range to max.
angle with screw.

HTS055S
Figure 133

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 58
2. Disc.

HTS056S
Figure 134
3. Place centering disc.

HTS057S
Figure 135
4. Mount measuring device.

HTS058S
Figure 136
5. Check dimention X.

HTS059S
Figure 137

Travel Motor (With Gearbox) (A6V160HD) S0707365

Page 59
ASSEMBLY OF PORT PLATE
1. Stick control lens in sliding surface with
grease.
2. Assemble in reversal order.
3. Mount port plate.

HTS060S
Figure 138
4. Assemble port plate.
NOTE: Take care of assembly design!
Tighten fixing screws with
torque.
5. Set Qmin-screw to dimention (*).
6. Assemble plug.
7. Remove assembly sleeve.

HTS061S
Figure 139
8. Assemble shaft seal, disc and safety ring.
Press-in with assembly sleeve.
NOTE: Take care of press-in depth.

HTS062S
Figure 140

S0707365 Travel Motor (With Gearbox) (A6V160HD)

Page 60
 S0708325K

1MAIN PUMP
(REXROTH)

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 (REXROTH)

MODEL SERIAL NUMBER RANGE
Solar 420LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2001 Daewoo

November 2001

Main Pump (Rexroth) S0708325K

Page 1
TABLE OF CONTENTS

Sectional View ................................................................................................ 3

A8VO200LA1KH1/63 .............................................................................. 3
General Repair Guidelines ............................................................................. 5
Seal Kits and Sub-assemblies........................................................................ 6
Sealing The Drive Shaft................................................................................ 11
Gear Pump Sealing ...................................................................................... 13
Remove The Control Housing ...................................................................... 14
Control Module ............................................................................................. 18
Control Module LR ................................................................................ 18
Control Module H .................................................................................. 19
Removing The Controller.............................................................................. 20
Valve Plate With Valves ................................................................................ 22
Remove The Rotary Groups......................................................................... 23
Remove The Intermediate Wheel ................................................................. 26
Remove Auxiliary Drive ................................................................................ 28
Inspection Hints............................................................................................ 30
Re-fitting The Rotary Group ......................................................................... 35
Pump Assembly ........................................................................................... 36
Hydraulic Component - Measurement "D" ................................................... 39
Measuring Device - Hydraulic Component 452 269.............................. 39
Mounting Position.................................................................................. 40
Measuring Procedure............................................................................ 42
Fit Control Housing....................................................................................... 44
Assembly of The Intermediate Wheel........................................................... 47
Fit The Gear Pump ....................................................................................... 48
Fit The Cover / Auxiliary Drive ...................................................................... 49
Assembly Guidelines for Tightening Torques ............................................... 50
Bolts (to N 08.001) ................................................................................ 50
Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)......... 51
Seal-lock - Sealing Nuts (to N 02.100).................................................. 51

S0708325K Main Pump (Rexroth)

Page 2
Main Pump (Rexroth) S0708325K
Page 3
SECTIONAL VIEW
A8VO200LA1KH1/63

ASS0010L

Figure 1

S0708325K Main Pump (Rexroth)

Page 4
 ASS0020L

Figure 2

Main Pump (Rexroth) S0708325K

Page 5
GENERAL REPAIR GUIDELINES
NOTE: Observe the following notices
when carrying out repairs on
hydraulic units.

ASS1140L
Figure 3
1. Close off all openings of the hydraulic unit.

ASS0030L
Figure 4
2. Replace all of the seals.
Use only original HYDROMATIK spare
parts.

ASS0040L
Figure 5

S0708325K Main Pump (Rexroth)

Page 6
3. Check all sealing and sliding surfaces for
wear.
NOTE: Re-work of the sliding surfaces
by using, for example with
crocus cloth, can damage the
surface.

ASS0050L
Figure 6
4. Fill the hydraulic unit with hydraulic oil
before commissioning.

ASS0060L
Figure 7

SEAL KITS AND SUB-ASSEMBLIES

1. Seal kit for drive shaft.

ASS0070L
Figure 8

Main Pump (Rexroth) S0708325K

Page 7
2. Peripheral seal kit.

ASS0080L
Figure 9
3. Rotary group 1, ready to install.

ASS0090L
Figure 10
4. Rotary group 2, ready to install.

ASS0100L
Figure 11
5. Rotary group, hydraulic component (order
rotary groups 1 and 2 separately).
NOTE: Adjustment is necessary.
Pay attention to the direction of
rotation.

ASS0110L
Figure 12

S0708325K Main Pump (Rexroth)

Page 8
6. Rotary group 1, mechanical section, ready
to install.

ASS0120L
Figure 13
7. Rotary group 2, mechanical section, ready
to install.

ASS0130L
Figure 14
8. Control, pre-adjusted.

ASS0140L

Figure 15

Main Pump (Rexroth) S0708325K

Page 9
9. Gear pump, complete.

ASS0150L
Figure 16
10. Intermediate gear

ASS0160L
Figure 17
11. Auxiliary drive

ASS0170L
Figure 18
12. Valve plate with valves

ASS0180L
Figure 19

S0708325K Main Pump (Rexroth)

Page 10
13. Pipe, complete with fittings.

ASS0190L
Figure 20

Main Pump (Rexroth) S0708325K

Page 11
SEALING THE DRIVE SHAFT

ASS0200L
Figure 21

1. Protect drive shaft. (e.g. tape).

ASS0210L
Figure 22
2. Remove retaining ring and shim.

ASS0220L
Figure 23

S0708325K Main Pump (Rexroth)

Page 12
3. Screw in sheet metal screw into the holes
fitted with rubber.
Pull out seal with pliers.

ASS0230L
Figure 24
4. Press in shaft seal ring and shim with bush
to stop.
NOTE: Take note of press-in depth.
Install mark for press-in depth
of safety ring.

ASS0240L
Figure 25

Main Pump (Rexroth) S0708325K

Page 13
GEAR PUMP SEALING

ASS0250L
Figure 26

Remove gear pump.

Visual check:
1. O-ring (1, Figure 27).

1 ASS0260L
Figure 27

S0708325K Main Pump (Rexroth)

Page 14
2. Sealing surface of the housing (2, Figure
27).

ASS0270L
Figure 28

REMOVE THE CONTROL HOUSING

ASS0280L
Figure 29

Main Pump (Rexroth) S0708325K

Page 15
1. Place the pump into a disassembly /
assembly device with a crane and fix it.

ASS0290L
Figure 30
2. Loosen fixing screws of port plate and
remove the port plate.
Lift the port plate away with a crane.
NOTE: Mark installation position.
NOTE: Control lenses can fall down.

ASS0300L

Figure 31

S0708325K Main Pump (Rexroth)

Page 16
3. Remove paper seal, clean sealing surface.

ASS0310L
Figure 32

2
2

1
1 ASS0320L
Figure 33

Number Description
1 Setting Screw : Qmax
2 Setting Screw : Hydraulic Stroke Limitation
3 Setting Screw : Power Characteristic (Begin of Regulation)

Main Pump (Rexroth) S0708325K

Page 17
 NOTE: Before carrying out a setting or
disassembly of the regulator,
measure the measurement X
and note of the setting screw.

X
ASS0330L
Figure 34

S0708325K Main Pump (Rexroth)

Page 18
CONTROL MODULE
CONTROL MODULE LR

ASS0340L
Figure 35

* Remove and disassemble control module LR.

* *

ASS0350L
Figure 36

Main Pump (Rexroth) S0708325K

Page 19
CONTROL MODULE H

ASS0360L

Figure 37
* Remove and disassemble control module H.

ASS0370L
Figure 38

S0708325K Main Pump (Rexroth)

Page 20
REMOVING THE CONTROLLER

(1)
ASS0380L

Figure 39

1. Remove cover.
NOTE: Do not change the setting
screw (1, Figure 39).

ASS0390L
Figure 40

Main Pump (Rexroth) S0708325K

Page 21
2. Loosen fixing screws.
NOTE: Fit control lens - torque support.

ASS0400L
Figure 41
3. Remove locking screw and replace with a
new locking screw.
NOTE: Loosen adhesive with a "gentle"
flame (approx. 120°C).

ASS0410L

Figure 42

ASS0420L

Figure 43
4. Loosen swivel pin and then remove it.

ASS0430L
Figure 44

S0708325K Main Pump (Rexroth)

Page 22
VALVE PLATE WITH VALVES

ASS0440L
Figure 45

1. Pressure relief valve

2. Electro- proportional pressure reducing valve (EPPR).

Main Pump (Rexroth) S0708325K

Page 23
REMOVE THE ROTARY GROUPS

ASS0450L
Figure 46

1. Keep the cylinder with a device (Remove it

completely with the drive shaft).

ASS0460L
Figure 47
2. Remove cylinder (Take out the drive shaft
without cylinder).

ASS0470L
Figure 48

S0708325K Main Pump (Rexroth)

Page 24
3. Remove cup springs 1 and spring cup 2.

ASS0480L
Figure 49
4. New disassembly position: (1, 2 and 3,
Figure 50). 3

2
Rotary Group 2

Rotary Group 1

ASS0490L

Figure 50
5. Press out hydraulically or mechanically
rotary group with a tool device.

2
1

ASS0500L
Figure 51

Main Pump (Rexroth) S0708325K

Page 25
 Fixing screws are glued

A Adjustment of measurement D

*
1. Holding device

Drive shaft 2

Drive shaft 1

1. Holding device
*
A
Adjustment of measurement D

Fixing screws are glued

ASS0510L
Figure 52

NOTE: Position * Drive shafts with bearing set are the smallest assembly group.
The assembly group is adjusted to measurement A.
The tapered roller bearings are adjusted to the spezified through-torque.
NOTE: Fixing screw - Retaining device.
Loosen of the screws is only possible if the drive shaft is warmed up at a temperature of
approx. 120°C 1/2 hour in an oil bath or heat air furnace.
Screw out the screw quickly.

S0708325K Main Pump (Rexroth)

Page 26
REMOVE THE INTERMEDIATE WHEEL
1. * Press in bolt into the gear wheel. (Fixed
pressing fit).
NOTE: Can only be disassembled with
a hydraulic press. *

ASS0520L

Figure 53
2. Install sleeve.
NOTE: Press out bolt with a hydraulic
manual press.

ASS0530L
Figure 54

Main Pump (Rexroth) S0708325K

Page 27
3. Remove gear wheel through side drive
opening.

ASS0540L
Figure 55
4. Remove bearing with extraction device.

ASS0550L
Figure 56

S0708325K Main Pump (Rexroth)

Page 28
REMOVE AUXILIARY DRIVE

ASS0560L

Figure 57

1. Remove fixing screws - auxiliary drive.

ASS0570L
Figure 58
2. Press off bearing cap.

ASS0580L
Figure 59

Main Pump (Rexroth) S0708325K

Page 29
3. In the event of leakage, visual check of O-
ring, housing and groove.

ASS0590L
Figure 60
4. Fit extractor device.

ASS0600L
Figure 61
5. Pull out output pinion.

ASS0610L
Figure 62
6. Fit bearing extractor device.

ASS0620L
Figure 63

S0708325K Main Pump (Rexroth)

Page 30
7. Completely mount device and pull out
bearing.

ASS0630L
Figure 64
8. Pull out pinion bearing.

ASS0640L
Figure 65

INSPECTION HINTS

1. Check to see that the bearing area is free

of scores and that there is no evidence of
wear.

ASS0650L

Figure 66

Main Pump (Rexroth) S0708325K

Page 31
2. Visual check:
To ensure that the bearing seats are free
of scores.

ASS0660L

Figure 67
3. Visual check:
Check to see that the bearing area is free
of scores and that there is no evidence of
wear.

ASS0670L

Figure 68
4. Axial piston play.
(Checked with the retaining plate fitted)

ASS0680L
Figure 69
5. Drive shafts
Check to ensure that the cups are free of
scores and that there are no pittings (1.
Figure 70).
Check to see that there is no evidence of
corrosion and wear steps (2, Figure 70).

ASS0690L
Figure 70

S0708325K Main Pump (Rexroth)

Page 32
6. Piston
Check to ensure that they are free of
scores and that there are no pittings.

ASS0700L
Figure 71
7. Central pin
Check to ensure that it is free of scores
and that there are no pittings.

ASS071L

Figure 72
8. Retaining plate
Check to ensure that it is free of scores
and that there is no evidence of wear.

ASS0720L
Figure 73
9. Cylinder block / control lens
Check to ensure that:
The bores (1, Figure 74) are free of
scores, no evidence of wear.
The faces (2, Figure 74) are even, that
there are no cracks, no scores.
The side guides (3, Figure 74) show no
evidence of wear, free of scores.

ASS0730L
Figure 74

Main Pump (Rexroth) S0708325K

Page 33
10. Check
Control land (1, Figure 75), internal control
drilling (2, Figure 75), pin cups (3, Figure
75).

ASS0740L
Figure 75
11. Check
That sliding surfaces (1, Figure 76) are
free of scores, seal (2, Figure 76).

ASS0750L
Figure 76

12. Complete rotary group

NOTE: Adjustment of the hydraulic component is necessary.
Mechanical component: drive shaft is adjusted with the bearing (1, Figure 77).
Hydraulic component (2, Figure 77) : Adjustment is necessary * (Figure 77).

2
1

1
ASS0760L
Figure 77

S0708325K Main Pump (Rexroth)

Page 34
13. Rotary group: All of the components.
* Adjustment (Figure 78).
For adjustment values, torque values, see service information.

*
*

*
*

ASS0770L
Figure 78

Main Pump (Rexroth) S0708325K

Page 35
RE-FITTING THE ROTARY GROUP
1. The threads must be free of oil, grease,
dust or any other contaminants which may
impair the locking of the screws.

ASS0780L
Figure 79
2. Fit the retaining plate with pistons and
centre pin into place. Use screws that have
a Precote coating. * For tightening torques,
see service information.

ASS0790L
Figure 80
3. Fit the spring plate (1, Figure 81) and cup
springs (2, Figure 81) into their correct
position (and orientation) using grease to
hold them into place.

ASS0800L
Figure 81

S0708325K Main Pump (Rexroth)

Page 36
4. Ensure that all of the parts are assembled
in correct order and orientation.

ASS0810L
Figure 82
5. Insert pistons into the cylinder. Using a
soft surface as a support to prevent the
sliding surfaces from being damaged. Pre-
assemble both of the rotary groups in this
manor.

ASS0820L
Figure 83

PUMP ASSEMBLY
1. Warm up the housing to approx. 80°C.

ASS0830L
Figure 84

Main Pump (Rexroth) S0708325K

Page 37
2. Insert the pre-assembled rotary group 2,
taking into account gear tooth markers.

ASS0840L
Figure 85
3. Insert rotary group 1. Align the marked
gear teeth.

ASS0850L
Figure 86
4. The gear tooth markers must coincide.

ASS0860L
Figure 87

S0708325K Main Pump (Rexroth)

Page 38
5. Adjustment of measurement D.
NOTE: Control hydraulic part.

Stop
D
A

A
D
Stop

ASS0870L

Figure 88

NOTE: Drive shafts with bearing set

The assembly group is adjusted to dimension (A). The tapered roller bearings are
adjusted to the stipulated breakaway torque.

Assembly guideline
Retaining force:
After the rotary group has been fitted into the housing, it has to be pressed in until the end stop is reached.
Allow the housing to cool down from its assembly temperature (approx.80°C) to room temperature.

Main Pump (Rexroth) S0708325K

Page 39
Adjustment of the hydraulic component of the rotary group
The adjustment of dimension D is carried out using spring plates of differing thickness, so that the correct
clearance is achieved between the rotary group which is fitted in the housing and the centre pinand spring
plates.
NOTE: Dimension (D) = 0,4 ± 0,1 mm
After assembly of the complete unit the breakaway torque of the rotary group has to be checked with the
torque wrench.

HYDRAULIC COMPONENT - MEASUREMENT "D"

MEASURING DEVICE - HYDRAULIC COMPONENT 452 269

Size 80-107 Size 140 - 200

ASS0880L
Figure 89

Measuring Centering Intermediate Intermediate

Size Shim (5) S.H.C.S (6)
Device (*) Device (1) ring (4) plate (7)
1x 2x 2x 2x 2x
80 9452269 9452019 9452014 9083277 9083105
107 9452269 9452022 9452014 9083277 9083105
140 9452269 9452026 9452015 9083279 9083134 2775186
200 9452269 9452025 9452015 9083279 9083134 2775187

S0708325K Main Pump (Rexroth)

Page 40
MOUNTING POSITION
Ensure that the correct mounting position
is used. The numbers on the top of the
measuring device (*, Figure 89) refer to the
piston diameter.

ASS0900L
Figure 90
Size Mounting Position
80 22
107 25
140 28
200 28

ASS0890L
Figure 91
1. Fit the intermediate ring or plates onto the
housing.
A. Size 80 - 107 (Figure 92)

ASS0910L
Figure 92

Main Pump (Rexroth) S0708325K

Page 41
 B. Only Size 140 - 200(Figure 93)

ASS0920L
Figure 93
2. Zero adjustment - measuring device
Turn using the hand wheel until the stop is
reached. - Set dial gauge to zero -.
A. Size 80 - 107 (Figure 94)

Figure 94
B. Size 140 - 200 (Figure 95)

Figure 95

S0708325K Main Pump (Rexroth)

Page 42
MEASURING PROCEDURE
1. Turn down by 4 turns on the dial gauge.
Check: 2 mm clearance, set dial gauge to
"Zero."
NOTE: Clearance: Size 28 - 160 0,4
mm ± 0,1
A. Size 82 - 107 (Figure 96)

ASS0950L
Figure 96
B. Size 140 - 200 (Figure 97)

ASS0960L
Figure 97
2. Turn down, using the hand wheel, until
resistance is met. Read the measured
value.
NOTE: Don't use excessive force.
A. Size 82 - 107 (Figure 98)

Figure 98

Main Pump (Rexroth) S0708325K

Page 43
 B. Size 140 - 200 (Figure 99)

Figure 99

S0708325K Main Pump (Rexroth)

Page 44
FIT CONTROL HOUSING

ASS0990L
Figure 100

1. Fit the swivel pin into correct position and

orientation. Take the hardening time and
tightening torque into account.
NOTE: Tightening Torques (*):
M6 = 8.5 Nm
M8 = 14 Nm
M10 = 35 Nm
M12 = 69 Nm

* ASS1000L

Figure 101

Main Pump (Rexroth) S0708325K

Page 45
2. Push on the piston ring by hand. Fix
adjustment piston. Take the tightening
torques into account.

ASS1010L
Figure 102
3. Fit control housing.

ASS1020L
Figure 103
4. Fit the control lens in its correct position
using grease to hold it in place. Direction of rotation Direction of rotation
anti-clockwise clockwise

Pressure Pressure
side side

Suction side
ASS1030L

Figure 104

S0708325K Main Pump (Rexroth)

Page 46
 ASS1040L
Figure 105
5. Fit seal and controller.

ASS1050L
Figure 106

Main Pump (Rexroth) S0708325K

Page 47
ASSEMBLY OF THE INTERMEDIATE WHEEL
1. Press in bearing (1, Figure 107) into
housing. 1
2. Install and align the intermediate wheel (2, New Assembly
Figure 107) through side drive opening. Position 3
3. Cool down the bolt (3, Figure 107) with
nitrogen and place it.
4. Press in bearing (4, Figure 107). 1

2
ASS1060L
Figure 107
5. Press in the bearing into the housing.

ASS1070L

Figure 108

S0708325K Main Pump (Rexroth)

Page 48
FIT THE GEAR PUMP

ASS1080L

Figure 109

Assemble shaft seal, disc and safety ring.

Press-in with assemble sleeve.
NOTE: Take care of press-in depth!

ASS1090L
Figure 110

Main Pump (Rexroth) S0708325K

Page 49
FIT THE COVER / AUXILIARY DRIVE

ASS1100L
Figure 111

S0708325K Main Pump (Rexroth)

Page 50
ASSEMBLY GUIDELINES FOR TIGHTENING TORQUES
BOLTS (TO N 08.001)
The values stated are valid for bolts with
metric ISO threads to DIN 13 part 13, as
well as head areas to DIN 912 socked
head cap screws, DIN 931 hexagon bolt or
DIN 933 hexagon bolts with threads up to
the head.

ASS1110L
Figure 112

Tensile Strength Class

Thread 8.8 10.9 12.9
Tightening Torque M A In Nm
M3 1.1 1.6 1.9
M4 3.1 4.5 5.3
M5 6.1 8.9 10.4
M6 10.4 15.5 18
M8 25 37 43
M 10 51 75 87
M 12 87 130 150
M 14 140 205 240
M 16 215 310 370
M 18 300 430 510
M 20 430 620 720
M 22 480 830 970
M 24 740 1060 1240

Main Pump (Rexroth) S0708325K

Page 51
PLUGS WITH INTERNAL HEXAGON AND
PROFILE SEAL RING (TO N 02.009).

G
Seal
ASS1120L
Figure 113

Thread Tightening Torque M A In Nm Thread Tightening Torque M A In Nm

M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1.5 20 G 3/8 A 35
M14 x 1.5 30 G 1/2 A 60
M16 x 1.5 35 G 3/4 A 90
M18 x 1.5 40 G1A 140
M20 x 1.5 50 G 1 1/4 A 240
M22 x 1.5 60 G 1 1/2 A 300
M26 x 1.5 70
M27 x 2 90
M30 x 1.5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

SEAL-LOCK - SEALING NUTS (TO N 02.100)

Tightening Torque M A In
Thread
Nm
M6 10
M6 x 0.5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
ASS1130L
M12 69
Figure 114
M12 x 1.5 72
M14 110
M14 x 1.5 120
M16 170
M16 x 1.5 180

S0708325K Main Pump (Rexroth)

Page 52
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S0709402K

1MAIN CONTROL VALVE

(KAYABA)

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 VALVE (KAYABA)S0709402K

MODEL SERIAL NUMBER RANGE
Solar 420LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2001 Daewoo

December 2001

Main Control Valve (Kayaba) S0709402K

Page 1
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TABLE OF CONTENTS

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

Theory of Operation ................................................................................ 3
Parts List ............................................................................................... 23
Specifications ........................................................................................ 33
Troubleshooting, Testing and Adjustment..................................................... 34
General ................................................................................................. 34
Relief Valve ........................................................................................... 35
Hydraulic System .................................................................................. 35
Adjustment of Relief Valve .................................................................... 35
Disassembly ................................................................................................. 37
General Instructions for Disassembly ................................................... 37
Disassembly Procedure ........................................................................ 37
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 42
Cleaning ................................................................................................ 42
Inspection.............................................................................................. 42
Reassembly.................................................................................................. 43
Subassembly......................................................................................... 43
Reassembly of Control Valve ................................................................ 44
Installation .................................................................................................... 49
Start-up Procedures ..................................................................................... 49

S0709402K Main Control Valve (Kayaba)

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GENERAL DESCRIPTION
THEORY OF OPERATION

When All Spools Are In Neutral

1. Neutral Passage
The oil supplied from the port (P1, Figure 1 and Figure 2) passes through the neutral passage (R1) to the
low pressure relief valve throttle (Rc1), flows into the tank passage (Ta), and returned to the ports (T1 and
T3).
The oil supplied from the port(P2) passes through the neutral passage(R1) to the low pressure relief valve
throttle (Rc1), flows into the tank passage (Ta), and returned to the ports (T1 and T3).
The pressures of the low pressure relief valve chambers (L2 and R2) reach through the port (Ps1 and Ps2)
to the pump and control the displacements of the pumps (P1 and P2).
If too much oil flows into the neutral passages, the low pressure relief valves activate and prevent the ports
(P1 and P2) from raising the pressures.

Main Control Valve (Kayaba) S0709402K

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Figure 1

2. Signal Passage
The oil supplied from the port (PP, Figure 2) is, after passing through the throttle (Lc3), divided into two
flows, one of which flows to the port (pt), and the other of which passes through the land (Lc4) and the
passage (5) to the land (Rc3) and flows into the tank passage (Ta).
The some oil supplied from the port (PP), after passing through the throttle (Lc5), flows partly to the port
(PA) and passes partly through the passages (L4), (8) and (R4) to the boom 1 spool land (Rc4) and flows
into the tank passage (Ta).
The oil passed through the throttle (Lc6) flows partly from the land (Lc7) to the tank passage (Ta) and
passes partly through the passage (4) to the travel spool land (Rc5) and flows into the tank passage (Ta).

S0709402K Main Control Valve (Kayaba)

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Figure 2

Main Control Valve (Kayaba) S0709402K

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Single Operation
1. Travel Spool Shifting
When shifting the travel spool by increasing the pressure of the travel (section1, Figure 3) pilot port
(Pb1(Pa1)), the oil supplied from the port (P1) passes through the neutral passage (L1) to the spool
and flows to the port (B1(A1)). The return oil passes through the port (A1(B1)) to the spool and return
to the tank passage (Ta). When shifting the travel spool by increasing the pressure of the travel
(section6) pilot port (Pb6(Pa6)), the oil supplied from the port (P2) passes through the neutral
passage (R1) and the spool to the passage (S6-1) and flows to the port (B6(A6)). At this time the
poppet (S6-2) is not opened because the parallel passage pressure is the same as the passage
pressure (S6-1). The return oil passes through the port (A6(b6)) to the spool and return to the tank
passage (Ta).
When shifting either one of the spools (section1 or 6), the land (Lc4) or (Rc3) is closed. The oil
supplied from the port (PP) flows through the tank passage and then is closed so that the port (PT)
pressure is increased.

Figure 3

S0709402K Main Control Valve (Kayaba)

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2. Swing Spool Shifting

When shifting the swing spool by increasing the pressure of the swing (section2) pilot port
(Pb2(Pa2)), the neutral port (L1) is closed. The oil supplied from the port (P1) flows through the
parallel passage (L3), the load check valve (S2-1) and the spool to the port (B2(A2)). The return oil
passes through the port (A2(B2)) to the spool and returned to the tank passage (Ta).

Figure 4

Main Control Valve (Kayaba) S0709402K

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3. Boom Spool Shifting

A. Neutral
This valve has the anti drift valve which is installed on the cylinder bottom side of the boom 1.
When neutral, the poppet (AD1, Figure 5) is closed by the port (A7) pressure which is sent
through the passage (AD2), the spool (AD3), and the passage (AD4) to the poppet (AD1).

Figure 5 Neutral Condition

S0709402K Main Control Valve (Kayaba)

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B. Boom Up (2 Speed Junction)

When the boom 1(section 7, Figure 6) spool is shifted by increasing the pressure of the boom 1
pilot port (Pa7), the neutral passage (R1) is closed. The oil supplied from the port (P2) passes
through the parallel passage (R3) and the load check valve (S7-1) to the spool and flows into
the port (A7). When the boom 2 (section 3) spool is shifted by increasing the pressure of the
boom 2 pilot port (Pa3) also, the neutral passage (L1) is closed. The oil supplied from the port
(P1) passes through the parallel passage (L3), the load check valve (S3-1), and the spool to the
passage (6) and joins at the port (A7). The return oil flows from the port (B7) to the spool and
returned to the tank passage (Ta).

Figure 6 Boom Up

Main Control Valve (Kayaba) S0709402K

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C. Boom Down (Regeneration)

When the boom 1(section 7, Figure 7) spool is shifted by increasing the pressure of the boom 1
pilot port (Pb7), the neutral passage (R1) is closed. The oil supplied from the port (P2) passes
through the parallel passage (R3) and the load check valve (S7-1) to the spool and flows into
the port (B7). When the spool (AD3) of the anti drift valve is shifted by increasing the pressure of
the port (pc2) also, the poppet (AD1) is opened by the decreasing of the pressure of the spring
chamber (AD5), and the return oil from the port (B7) returned to the tank passage. Some of the
return oil open the poppet (S7-3) in the boom 1 spool, passes through the passage (S7-2), join
with the port (B7), and prevent the cavitation of the cylinder rod side.

Figure 7 Boom Down

S0709402K Main Control Valve (Kayaba)

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4. Spare Spool Shifting

When the spare spool is shifted by increasing the pressure of the spare (section4, Figure 8) pilot port
(Pb4(Pa4)), the neutral passage (L1) is closed. The oil supplied from the port (P1) flows through the
parallel passage (L3), the load check valve (S4-1), the passage (S4-2) and the spool into the port
(B4(A4)). When the neutral cut spool (R) is shifted by increasing the pressure of the port (pa10,
Figure 1) also, the oil supplied from the port (P2) passes through the passage (11) and the poppet
(S4-3) and join with the passage (S4-2). The return oil returns through the port (A4(B4)) and the
spool to the tank passage (Ta).
5. Bucket Spool Shifting
When the bucket spool is shifted by increasing the pressure of the bucket (section8, Figure 8) pilot
port (Pb8(Pa8)), the neutral passage (R1) is closed.The oil supplied from the port (P2) flows through
the parallel passage (R3), the load check valve (S8-1), the passage (S8-2) and the spool into the port
(B8(A8)). When the neutral cut spool (L) is shifted by increasing the pressure of the port
(pa10)(Figure 1) also, the oil supplied from the port (P1) passes through the passage (7) and the
poppet (S8-3) and join with the passage(S8-2). The return oil returns through the port (A8(B8)) and
the spool to the tank passage (Ta).

Figure 8

Main Control Valve (Kayaba) S0709402K

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6. Arm Spool Shifting

A. Arm Dump (2 Speed Junction)
When the arm 1 spool is shifted by increasing the pressure of the arm 1(section5, Figure 9) pilot
port (Pb5), the oil supplied from the port (P1) flows through the neutral passage (L1), the load
check valve (S5-1), the passage (S5-2) and the spool into the port (B5). When the arm 2 spool
is shifted by increasing the pressure of the arm 2 (section9) pilot port (pb9) also, the oil supplied
from the port (P2) passes through the neutral passage (R1), the load check valve (S9-1), the
passage (S9-2), the spool and the passage (10) and join with the port (B5). The return oil
returns through the port (A5) and the spool to the tank passage (Ta).

Figure 9 Dump

S0709402K Main Control Valve (Kayaba)

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B. Arm Crowd (2 Speed Junction)

When the arm 1 spool is shifted by increasing the pressure of the arm 1(section5, Figure 10)
pilot port (Pa5), the oil supplied from the port (P1) flows through the neutral passage (L1), the
load check valve (S5-1), the passage (S5- 2) and the spool into the port (A5). When the arm 2
spool is shifted by increasing the pressure of the arm 2 (section9) pilot port (pa9) also, the oil
supplied from the port (P2) passes through the neutral passage (R1), the load check valve (S9-
1), the passage (S9-2), the spool and the passage (9) and join with the port (A5). When the
spool (AD3) of the anti drift valve is shifted by increasing the pressure of the port (pc1) also, the
poppet (AD1) is opened by the decreasing of the pressure of the spring chamber (AD5), and the
return oil from the port (B5) returned through the spool, the passage (S5-3) and the arm
variable regeneration throttle (Lc8) to the tank passage (Ta). Some of the return oil open the
poppet (S5-4) in the boom 1 spool, passes through the passage (S5-2), join with the port (B7),
increases the cylinder speed, and then prevent the cavitation of the cylinder bottom side.
C. Variable Regeneration (When Crowding)
When crowding arm, the spool (S5-6) is stroked according to the pressure of the passage (S5-
2, Figure 10) connected to the passage (S5-5), and the opening size of the arm variable
regeneration throttle(Lc8) varies. When the pressure of the passage (S5-2) is high, the stroke of
the spool (S5-6) is increased, so that the opening size of the throttle (Lc8) is increased. On the
contrary, when the pressure of the passage (S5-2) is low, the stroke of the spool (S5-6) is
decreased, so that the opening size of the throttle (Lc8) is decreased. Therefore the
regeneration flow varies according to the pressure of the bottom of the arm cylinder.

Figure 10

S0709402K Main Control Valve (Kayaba)

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7. Neutral Cut Spool Shifting

This valve has the neutral cut spool which is installed at the lowest flow side (the upper flow side of
the low pressure relief valve). When the spool (L(R)) is shifted by increasing the pressure of the port
(pa10 (pa11), Figure 11), the neutral passage (L1(R1)) is closed. The oil supplied from the port (P1)
passes through the passage (7) and the poppet (S8-3) (Figure 8) and join with the bucket (section8)
passage (S8-2). The oil supplied from the port (P2) passes through the passage (12) and the poppet
(S4-3) (Figure 8) and join with the spare (section4) passage (S4-2) also.
8. Parallel Throttle for Arm
The throttle, which is installed in the parallel circuit for the arm of this valve, in each of the
arm1(section5, Figure 11) and the arm2 (section9) prevents the arm speed from increasing when
combined operation. The parallel circuit of the arm 2 (section9), after narrowing at the throttle (Rc6) of
the poppet (S9-3) from the parallel passage (R3), joins with the passage (S9-2) (Figure 10).The
parallel circuit of the arm 1(section5), after narrowing at the throttle (Lc9) of the poppet (S9-3) from
the parallel passage (L3), joins with the passage (S5-2) (Figure 10).

Figure 11

S0709402K Main Control Valve (Kayaba)

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9. Relief Valve
A. Main Relief Valve
The oil supplied from the port (P1, Figure 12) passes through the poppet (LP), the oil supplied
from the port (P2) passes through the poppet (RP) and the passage (3) also, and join with the
main relief valve. The highest pressure of the pump (P1) and (P2) is controlled by actuating of
main relief valve.
B. Over Load Relief Valve
The over load relief valve, which is installed in each cylinder port of the boom1, arm1 and
bucket, prevent the pressure of the actuator from increasing extremely high by the foreign
pressure. This relief valve, when the pressure of the cylinder port is a negative pressure, has the
function to prevent the cavitation by sucking the oil from the tank also.

Figure 12

Main Control Valve (Kayaba) S0709402K

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Combined Operation
1. Travel Combined Operation
When applying simultaneously the operation except travel while travel left and right simultaneous
operating (while forward traveling, backward traveling, or pivot turning) or when applying travel left
and right simultaneous operating while applying the operation except travel, the oil supplied from the
port (PP) is disconnected with the tank passage (Ta) at the signal land part of the section of the
exception of travel shifted with the land (Lc4) (Lc7) (Rc3) (Rc), and the pressure of the signal
passage increases up to the relief setting pressure of the pressure source for signal. By increasing of
the signal pressure, the travel straight spool is shifted and the pressures of the ports (PT) (PA)
increase. When the travel straight spool is shifted, the oil supplied from the port (P1) flows from the
neutral passage (L1) to the travel (section1), and simultaneously flows through the passage (2), the
travel straight spool and the passage (1) into the travel (section6). The oil supplied from the port (P2)
flows through the travel straight spool and the passage(1) into the parallel passage (L3).
If the section load pressure except the travel is higher than the travel (section6) load pressure, some
of the oil supplied from the port (P2) opens the poppet (S6-1) and joins through the throttle of the
head of the poppet with the passage (S6-1). Because the travel (section1 and 6) is activated by the
oil supplied from the port (P1) and the implement except the travel is activated by the oil supplied
from the port (P2), when applying the combined operation with the travel left and right simultaneous
operation and the implement operation except the travel, the travel is prevented from veering.

Figure 13

S0709402K Main Control Valve (Kayaba)

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2. Swing Combined Operation

When applying the combined operation with the swing and the other implement, the poppet (S2-1) is
fixed increasing the port (pc6) pressure, the poppet (S2-3) is opened, and the pressure supplied to
the port (L-3) increased through the throttle (S2-4). Accordingly, even in the case that the swing load
pressure is low, the simultaneous operation character with the other implement can be secured.

Figure 14

Main Control Valve (Kayaba) S0709402K

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Anti drift Valve

The anti drift valve is installed in the cylinder
port of the arm rod (boom bottom) side to
prevent the arm (boom) cylinder from natural
lowering. At neutral condition (Figure 15), the
cylinder port pressure is sent through the
passage (AD2), the spool (AD3), and the
passage (AD4) to the spring chamber r(AD5).
The poppet (AD1) is completely closed by the
spring strength or the pressure difference by the
difference of the poppet sizes.

Figure 15 Neutral Condition

When arm dumping (boom up)(Figure 16), the
oil supplied from the pump opened the
poppet(AD1) and flows to the cylinder port.

Figure 16 Arm Dump (Boom Up)

When arm crowding (boom down), the
spool(AD3) is shifted by increasing the pressure
of the port(pc1(pc2)), and the oil of the spring
chamber(AD5) flows through the passage(AD6)
to the drain port(DR1'(DR2')), so that the poppet
(AD1) is opened and the return oil flows into the
tank passage (Ta).

Figure 17 Arm Crowd (Boom Down)

S0709402K Main Control Valve (Kayaba)

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Main Relief Valve

1. The main relief valve is located between
the neutral oil passage (HP, Figure 18) and
the low pressure oil passage (LP). The
pressure oil in the neutral oil passage (HP)
flows through the throttle hole in the main
poppet (C) to fill the internal cavity (D).
Owing to the difference between (A) and
(B) in area on which the hydraulic pressure
acts, the main poppet (C) closely seats to
the sleeve (E).

Figure 18
2. When the pressure in the neutral oil
passage (HP) rises and exceeds the relief
valve setting, the pilot poppet (F) opens.
The pressure oil flows from the pilot
poppet (F) into the low pressure oil
passage (LP), passing through the hole
(G).

Figure 19
3. As the pilot poppet (F) opens, the pressure
in the internal cavity (D) lowers to move
the main poppet (C) so that the pressure
oil in the neutral oil passage (HP) flows
directly into the low pressure oil passage
(LP).

Figure 20

Main Control Valve (Kayaba) S0709402K

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4. Pressure up operation
When the pressure at the pilot port (Pi) is
increased, the piston (H) moves to the
setting position of plug (I) so that the
strength of spring increase and the
pressure at the neutral oil passage (HP)
increase.

Figure 21
Overload Relief Valve
1. The overload relief valve is located
between the cylinder port (HP) and the low
pressure oil passage (LP). The pressure
oil at the cylinder port (HP) flows through
the throttle hole in the piston (C) to fill the
internal cavity (G). Owing to the difference
between (A) and (B) in area on which the
hydraulic pressure acts, the main poppet
(D) closely seats to the sleeve (K).

Figure 22
2. When the pressure in the cylinder port
(HP) rises and exceeds the relief valve
setting, the pilot poppet (E) opens. The
pressure oil flows from the pilot poppet (E)
into the low pressure oil passage (LP),
passing through the hole (H).

Figure 23

S0709402K Main Control Valve (Kayaba)

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3. As the pilot poppet (E) opens, the pressure

oil flows through the throttle hole (I) so that
the pressure at the back of the piston (C)
lowers to move the piston (C). As a result,
the piston (C) closely seats to the pilot
poppet (E).

Figure 24
4. The pressure oil in the passage (HP) flows
through the throttle hole (F) in the piston
(C) so that the pressure at the back of the
main poppet (D) lowers to move the main
poppet (D). The pressure oil in the
passage (HP) flows directly into the direct
passage (LP).

Figure 25
5. Sucking operation
The anti void unit is installed in the cylinder
port (HP) against the development of
cavitation. If the pressure at the cylinder
port (HP) becomes lower than that at the
low pressure oil passage (LP), the sleeve
(K) moves depending upon the difference
between (A) and (B) in area so that oil is
supplied from the low pressure oil passage
(LP) to the cylinder port(HP) to eliminate
the cavitation.

Figure 26

Main Control Valve (Kayaba) S0709402K

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Low Pressure Relief Valve

1. When oil does not pass

Figure 27
2. When spool is in neutral
The oil in the neutral oil passage (HP)
flows through the signal orifice (A) into the
low pressure oil passage (LP). The
pressure of the signal port (4Ps (5Ps))
increases by the negacon signal orifice
(A).

Figure 28
3. Low pressure relief valve operation
When the excessive quantities of oil in the
neutral oil passage (HP) flows, the
pressure in the neutral oil passage (HP)
exceeds the spring setting pressure (C) so
that the poppet (B) opens. The oil flows
from the neutral oil passage (HP) into the
low pressure oil passage (LP) so that the
development of abnormal pressure is
prevented.

Figure 29

S0709402K Main Control Valve (Kayaba)

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PARTS LIST

Figure 30

Main Control Valve (Kayaba) S0709402K

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Figure 31

S0709402K Main Control Valve (Kayaba)

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Figure 32

Main Control Valve (Kayaba) S0709402K

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Reference Reference
Description Description
Number Number
1 Valve Housing 41 Back-up Ring
2 Valve Housing 42 Body
3 Spool Assembly (Arm-2) 43 Piston
4 Spool Assembly (Bucket) 44 Flange
5 Spool Assembly (Boom 1) 45 O-ring
6 Spool Assembly (Travel) 46 Poppet
7 Spool Assembly (Straight Travel) 47 Body Assembly
8 Spool Assembly (Arm-1) 48 Relief Valve Assembly
9 Spool Assembly (Service) 49 Relief Valve Assembly
10 Spool Assembly (Boom 2) 50 Relief Valve Assembly
11 Spool Assembly (Swing) 51 Plug Assembly
12 Cap 52 Poppet
13 Cap 53 Spring
14 O-ring 54 Plug
15 Poppet 55 O-ring
16 Spring 56 Flange
17 Spacer 57 O-ring
18 O-ring 58 Plug Assembly
19 Back-up Ring 59 Plug Assembly
20 Spool Assembly 60 Plug Assembly
21 Spring Seat (A) 61 Plug Assembly
22 Spring 62 Plug Assembly
23 Plug 63 Socket-Head Bolt
24 Spool Assembly 64 Socket-Head Bolt
25 Spring 65 Socket-Head Bolt
26 O-ring 66 Name Plate
27 Plug 67 Drive Screw
28 Poppet 68 Socket-Head Bolt
29 Spring 69 O-ring
30 Poppet 70 O-ring
31 Poppet 71 O-ring
32 Poppet 72 O-ring
33 Spring 73 Cap
34 Flange 74 Cap
35 O-ring 75 Steel Ball
36 Poppet Assembly 76 Flange Cap
37 Spring 77 Socket-Head Bolt
38 Sleeve 78 O-ring
39 Piston 79 Poppet
40 O-ring

S0709402K Main Control Valve (Kayaba)

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Spool Assembly (4, Bucket)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 33
Spool Assembly (5, Boom)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
6 Poppet
7 Spring
8 Plug Figure 34
9 O-ring
10 Back-up Ring

Spool Assembly (6, Travel)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 35

Main Control Valve (Kayaba) S0709402K

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Spool Assembly (7, Straight Travel)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 36
Spool Assembly (8, Arm1)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
6 Poppet
7 Spring
8 Plug Figure 37
9 O-ring
10 Back-up Ring

Spool Assembly (9, Service)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 38

S0709402K Main Control Valve (Kayaba)

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Spool Assembly (10, Boom 2)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 39
Spool Assembly (11, Swing)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 40
Spool Assembly (3, Arm 2)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 41

Main Control Valve (Kayaba) S0709402K

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Spool Assembly (20, Arm Regeneration

Release Valvle)

Reference
Description
Number
1 Spool
2 Sleeve
3 Sleeve
4 Piston
5 O-ring
6 Back-up Ring
7 O-ring Figure 42
8 Back-up Ring

Spool Assembly (24)

Reference
Description
Number
1 Spool
2 Spool End

Figure 43

S0709402K Main Control Valve (Kayaba)

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Poppet Assembly (36)

Reference
Description
Number
1 Poppet
2 Poppet
3 Spring
4 Plug

Figure 44
Plug Assembly (51)

Reference
Description
Number
1 Plug
2 O-ring
3 O-ring
4 O-ring

Figure 45
Plug Assembly (58)

Reference
Description
Number
1 Plug
2 O-ring
3 O-ring
4 Back-up Ring

Figure 46

Main Control Valve (Kayaba) S0709402K

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Relief Valve Assembly (48)

Figure 47

Item Specification
Hi: 34.3 ± 0.5 MPa
Relief Valve Pressure
Low: 31.4 ± 0.5 MPa
Flow 250 liter/min.

Relief Valve Assembly (49)

Reference
Description
Number
1 O-ring
2 O-ring
3 O-ring
4 Back-up Ring
5 O-ring
6 Back-up Ring
7 O-ring
Figure 48
Item Specification
Relief Valve Pressure 35.3 ± 0.5 MPa
Flow 20 liter/min.

S0709402K Main Control Valve (Kayaba)

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Relief Valve Assembly (50)

Reference
Description
Number
1 Plug
2 Spring
3 Poppet
4 Sleeve
5 O-ring
6 O-ring

Figure 49

SPECIFICATIONS

Component Name Specification

Rated Flow 400 liter/min.
500 liter.min at Neutral
Max. Pressure 31.9 MPa
Allowable Back Pressure Peak Pressure: Below 1.5 MPa
Normal Pressure: Below 0.5 MPa
Allowable Working Temperature Range -20 ~ 90°C

Main Control Valve (Kayaba) S0709402K

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TROUBLESHOOTING, TESTING AND ADJUSTMENT

GENERAL

Problem Possible Cause Remedy

Spool does not stroke. Hydraulic oil excessively hot. Remove blockage in oil piping.

Hydraulic oil contaminated. Change oil and clean oil

passages.
Overtightened piping port fittings. Check torque.

Valve housing deformed when Loosen assembling bolts and

assembling. check.
Pressure too high. Check pump port pressure and
cylinder port pressure with
pressure gauge.
Spool bent. Replace valve assembly.

Return spring damaged. Replace damaged parts.

Spring or cap crisscrossed. Remove and center cap.

Valve temperature uneven. Warm up entire system.

Dirt in valve. Clean valve.

Lack of pilot pressure. Check pilot valve and pilot relief

pressure.
Fails to bear load Leaky cylinder. Check seal parts of cylinder.

Leaky spool. Check spool.

Leaky overload relief valve. Clean valve housing and relief

valve seat parts.
Leaky anti draft valve. Remove anti draft valve and clean
every seat parts.
If seat parts are damaged,
replace poppet or lap poppet and
seat parts. If draft valve is out of
order, replace spool and sleeve at
the same time.
Load drops when changing Dirt in load check valve. Remove and clean check valve.
the spool from neutral to up.
Poppet or seat parts in check valve Remove poppet or lap poppet and
damaged. seat parts.

S0709402K Main Control Valve (Kayaba)

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RELIEF VALVE

Problem Possible Cause Remedy

Pressure does not rise. Pressure does not rise. Replace relief valve.

Pressure unstable Pressure unstable

Relief pressure is incorrect. Seat parts worn due to dirt.

Lock nut and adjuster deformed. Reset pressure and tighten lock
nut in rated torque.
Oil leaks Relief valve seat parts damaged. Replace relief valve.

Every parts stuck due to dirt.

O-ring worn. Replace adjuster or O-ring.

HYDRAULIC SYSTEM

Problem Possible Cause Remedy

Hydraulic system is poor or Hydraulic pump failed. Check pressure or replace pump.
none of the controls function
Relief valve failed. Replace pump.

Some kinds of cylinders failed. Repair or replace.

Pump load pressure too high. Check circuit pressure.

Valve cracked. Replace valve assembly.

Spool does not fully stroke. Check spool operation.

Hydraulic oil level in tank too low. Add hydraulic oil.

Filter in circuit plugged. Clean or replace filter.

Circuit piping snarled. Check piping.

ADJUSTMENT OF RELIEF VALVE

Main Relief Valve

1. Connect a pressure gauge to inlet port.
2. Start the engine and maintain the rated pump speed.
3. Shift the control valve spool and read the pressure gauge from the stroke end of the cylinder.
NOTE: Shift the spool of the actuator of which the setting pressure of the over load relief valve is
higher than the pressure of the main relief valve
4. High pressure adjustment (See Figure 50 on page -40).
4-1 Loosen lock nut (5) and tighten plug (6) until piston contacts the end(* mark) of plug (4). Plug (6)
should be torqued below 19.9 Nm. While plug (6) is tightened, plug (4) should not be turned. The
distance A (See Figure 18 on page -19) should be above 15 mm. Tighten lock nut (5).

Main Control Valve (Kayaba) S0709402K

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4-2 Loosen lock nut (3) and turn adjusting plug (4) clockwise to raise relief pressure at the state of 4-1.
Turn adjusting plug (4) counterclockwise to lower relief pressure. One turn varies 25.7 MPa. Tighten
lock nut (3) after pressure has been adjusted.
5. Low pressure adjustment
Loosen lock nut (5) and turn adjusting plug (6) counterclockwise to lower relief pressure at the state
of 4. One turn varies 21.3 MPa.Tighten lock nut (5) after pressure has been adjusted.
6. Recheck the setting pressure by raising pressure.

Over Load Relief Valve

IMPORTANT
If the pressure of the main relief valve is higher than the setting pressure of it, change it to the
set main relief valve assembly without adjusting the over load relief valve.

1. Shift the control valve spool and read the pressure gauge from the stroke end of the cylinder.
2. Loosen lock nut (3) and turn adjusting plug clockwise to raise pressure. One turn varies 21.2 MPa.
3. Tighten lock nut(3) after pressure has been adjusted. Lock nut (3) should be torqued to 27.5-31.4
Nm.
4. Recheck the setting pressure by raising pressure.

S0709402K Main Control Valve (Kayaba)

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DISASSEMBLY
GENERAL INSTRUCTIONS FOR DISASSEMBLY
1. Stop engine at low actuator pressure.

WARNING!
If valve parts are replaced or valve is disassembled in high actuator pressure, serious
accident may occur by accidental squirting out of pressurized oil or popping out of parts.
Before disassembling, ground bucket and release pressure.

2. Vent pressurized air in tank.

3. Clean all of the exterior surfaces of the valve prior to disassembly and protect it from dirt and foreign
materials.
4. Mark the disassembled parts to know reassembling position.
5. Replace all sealing parts such as O-ring and back-up ring with a new ones.
6. Do not replace spool as it is engaged with valve housing and sleeve.

DISASSEMBLY PROCEDURE
The further part numbers of an assembly part are shown as (assembly part number - further part number).

Disassembly of Main Spool (3) - (11)

1. Remove socket head bolt (63, Width across flats : 10 mm) and long cap (12,73). Remove O-ring(14)
from valve housing.

2. Remove every spool subassembly from valve housing.

WARNING!
When removing spool, perpendicularly pull out spool not to damage. Scratched spool may
damage body hole and so it can not be reassembled. If it is reassembled, it may
malfunction. Tag and label each component so that all parts can be reassembled in the
proper order. If it is reassembled wrong, serious accident may occur by malfunctioning of
actuator.

3. Remove socket head bolts (63) and short cap (13,74). Remove O-ring from valve housing.
4. Remove spool end (further part number-5, Width across flats : 22 mm) of spool (3,4,6,7,9 -11), spring
seat (further part number-2) and spring (further part number-3,4).
5. Remove spool end (5-5, Width across flats : 22 mm) of spool (5), spring seat (5-2) and spring (5-3,4).
Remove plug (5-8:groove width; 3mm), O-ring (5-9) and back-up ring (5-10).
6. Remove spool end (8-5, Width across flats : 22 mm) of spool (8), spring seat (8-2) and spring (8-3,4).
Remove plug (8-8:groove width; 3mm), spring (8-7) and poppet (8-6).

Main Control Valve (Kayaba) S0709402K

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WARNING!
When disassembling spool, grip spool in vise with wood not to scratch. At this time, grip
end of spool as much as possible not to bend by torque. Spool end is secured with Loctite.
To prevent damage of thread, heat spool end prior to loosen it (Heating temperature : 200 -
250°C). Pay attention to overheating of spring that can be deformed by heat. Wear proper
safety protection and clothing and be careful not to get burned by hot material.

Disassembly of Subspool (24)

1. Remove plug (27, Width across flats : 36 mm), spring (25), spring seat (21), and spool (24). Remove
the other spool in a same way.
2. Remove O-ring (26) from plug.
3. Spool (24-1) and spool end (24-2) are secured with Loctite. Heat spool end to loosen it (Heating
temperature : 200 - 250°C) to prevent damage of thread.

Disassembly of Subspool (20)

1. Remove plug (23, Width across flats : 32 mm) and O-ring (72).
2. Remove spring (22), spring seat (21) and spool(20-1).
3. Pull off sleeve (20-2,3) and piston (20-4).

Disassembly of Anti drift Valve of Boom and Arm

1. Loosen socket head bolt (63) and remove body assembly (47) and O-ring (35,70).

WARNING!
When removing this part of control valve from machine, it may accidentally popped out by
the internal pressure. Loosen socket head bolt (63) slightly to allow the pressurized oil to
release. After the pressure has been released, it is safe to remove this valve from machine.

2. Remove spring (33) and poppet (46).

3. Grip body assembly (47, Width across flats : 8 mm) in vise not to scratch the surface that has O-ring
(35,70).
4. Remove plug (47-5) and O-ring (47-10).
5. Remove spring (47-4), spool (47-2) and O-ring (47-3).
6. Remove plug assembly (47-7, Width across flats : 6 mm) and O-ring.

IMPORTANT
The filter of plug assembly is fixed in plug assembly (47-7) and so it is impossible to
separate it from plug assembly. When it is needed to replace filter, replace a new plug
assembly.

S0709402K Main Control Valve (Kayaba)

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7. Remove plug (47-8, Width across flats : 8 mm) and O-ring.

8. Remove plug (47-9, Width across flats : 5 mm) and O-ring. It is impossible to remove steel ball due to
pressure fit.

Disassembly of Swing Load Check

1. Remove socket head bolt (68, Width across flats : 10 mm) and flange (44).
2. Remove body (42), piston (43) and O-ring (45).
3. Pull off sleeve (38) and remove spring (37) and piston (39).
4. Remove O-ring (40,35) and backup ring (41).
5. Remove poppet assembly (36).
6. Grip plug (36-4, Width across flats : 12 mm) in vise and remove poppet (36-1), spring (36-3) and
poppet (36-2).

Disassembly of Load Check

1. Remove travel semi parallel check of P2 port. Remove plug (54, Width across flats : 27 mm). Remove
O-ring (54) from plug. Remove spring (53) and poppet (52).

WARNING!
At this time, be careful not to drop spring in passage. If valve is operated with dropped
spring, spool is stuck by broken piece penetrated in main spool sliding surface and serious
accident may occur by runaway or incapability of stop.

2. Remove travel load check of P1 port. Loosen socket head bolt (63, Width across flats : 10 mm) and
remove flange (34). Remove poppet (32), spring (33) and O-ring (35).
3. Remove the remaining load check. Loosen socket head bolt (63, Width across flats : 10 mm) and
remove flange (34). Remove poppet (31), spring (33) and O-ring (35).

Disassembly of The Other Check Valves

1. Remove two common check valves of main relief valve. Loosen socket head bolt (64, Width across
flats : 8 mm) and remove flange (56). Pull off collar of spacer (17). Remove O-ring (18) and backup
ring (19). Remove spring (16) and poppet (15).
2. Remove parallel check valve of spare junction, bucket junction and arm one. Remove plug (61, Width
across flats : 10 mm) and O-ring.
Remove spring(29) and poppet(28).
3. Remove semi parallel check valve of arm two. Remove plug (61, Width across flats : 10 mm) and O-
ring. Remove spring (29) and poppet (30).

Disassembly of Flange
1. Remove flange of spare port. Loosen socket head bolt (77, Width across flats : 10 mm) and remove
flange (76) and O-ring (78).
2. Remove flange of boom two. Loosen socket head bolt (64, Width across flats : 8 mm) and remove
flange (56) and O-ring (57).

Main Control Valve (Kayaba) S0709402K

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Disassembly of Relief Valve

1. Remove eight overload relief valves (49, (8 places, Width across flats : 32 mm)).
2. Remove main relief valve (48, Width across flats : 41 mm).
3. Remove two negacon relief valves (50, Width across flats : 46 mm).

Disassembly of The Other Flange

1. Remove plug assembly (60 (5 places, Width across flats : 6 mm)) and O-ring.
2. Remove plug assembly (61 (17 places, Width across flats : 10 mm)) and O-ring.
3. Remove plug assembly (62 (6 places, Width across flats : 12 mm)) and O-ring.
4. Remove plug assembly (58 (1 places, Width across flats : 24 mm)) and O-ring.
5. Remove plug assembly (52, Width across flats : 27 mm) and O-ring.
6. Remove plug assembly (59, Width across flats : 8 mm) and O-ring.
NOTE: Valve housings (1, 2) should not be disassembled because O-rings and housings can be
deformed and joint surfaces can be crisscrossed when reassembling them.
Steel ball (75) should not be disassembled due to pressure fit.

Disassembly of Main Relief Valve

This unit should be replaced by assembly. When replacing it, loosen cap (8, Width across Flats : 41) and
O-ring (1, Figure 50). If oil leaks from the nut (3), loosen nut (3) and plug (4) and replace O-ring and
backup ring.

Figure 50

S0709402K Main Control Valve (Kayaba)

Page 40
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Disassembly of Overload Relief Valve

This unit should be replaced by assembly. When replacing it, loosen cap (1, Width across Flats : 31.75
mm) and O-ring (2). If oil leaks from the nut (3), loosen adjusting kit and replace O-ring (4).
NOTE: When disassembling adjusting kit, be careful not to spring components by spring or to lose
poppet.

Figure 51

Disassembly of Low Pressure Relief Valve

This unit has the press fit portion (D) so that it
should be replaced by assembly.

Figure 52

Main Control Valve (Kayaba) S0709402K

Page 41
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CLEANING AND INSPECTION (WEAR LIMITS AND

TOLERANCES)
CLEANING
Clean all parts thoroughly using a suitable cleaning fluid and dry them with moisture free compressed air.
Put them on a clean paper or a vinyl for inspection.

INSPECTION
Inspect all parts for scratches, notches and the other defects.
1. Inspect load check seat surface of valve housing for scratches, scores, dirt, notches and corrosion.
Remove small scratches with oilstone.
2. Inspect exterior surface of spool for scratches and notches. Remove small scratches with oilstone.
3. Inspect all grooves and passages of sliding parts for foreign materials.
4. Replace any springs that are damaged, heavy deformed or worn.
5. If relief valve malfunction, inspect it by relief valve procedure (see page).
6. Replace all O-rings and backup rings with new ones.
7. After disassembling cap or plug, check whether there are paint chips around body hole or plug. If
paint chips penetrate into valve, they can cause malfunction or leak of valve.

S0709402K Main Control Valve (Kayaba)

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REASSEMBLY
NOTE: Before reassembling, confirm number of components, reassembling position, tools and
etc.

SUBASSEMBLY
Before reassembling valve housing, subassembly parts needed.

Main Spool (3) - (11)

1. Apply Loctite to threads of spools (3,4,6,7,9-11). Assemble spring seat (above parts numbers-2),
spring (above parts numbers-3,4) and spool end (above parts numbers-5), and assemble spool end
in spool that is gripped in vise with wood. Torque is 24 - 26 Nm.

IMPORTANT
When applying a quantity of Loctite to spool, be careful not to leak out. When assembling
spool with vise, grip end of spool as much as possible not to bend by torque.

2. After assembling poppet (above parts numbers-6) and spring (above parts numbers-7) in the middle
hole of spool (5), apply Loctite to thread of spool. Grip spool in vise with wood. Assemble plug (5-8)
into which O-ring (5-9) and back up ring (5-10) are inserted. Torque is 24 - 26 Nm. Assemble spring
seat (5-2), spring (5-3,4) and spool end (5-5) and tighten spool end. Torque is 24 - 26 Nm.
3. Assemble poppet (8-6) and spring(8-7) in the middle hole of spool (8). Apply Loctite to thread of spool
and assemble plug (8-8). Torque is 24 - 26 Nm. Apply Loctite to thread of spool. Grip spool in vise
with wood. Assemble spring seat (8-2), spring (8-3,4) and spool end (8-5) and tighten spool end.
Torque is 24 -26 Nm.

Subspool (20)
1. Assemble backup ring (20-8) and O-ring (20-7) in sleeve (20-3). Assemble backup ring (20-6) and O-
ring (20-5) in sleeve (20-2).
2. Assemble piston (20-4) in sleeve (20-3) with O-ring.
3. Assemble piston in sleeve (20-2).

Subspool (24)

1. Apply Loctite to thread of spool (24-1).

IMPORTANT
When applying a quantity of Loctite to spool, be careful not to leak out. If Loctite penetrates
small hole of spool (24-1), it can malfunction. When assembling spool with vise, grip end of
spool as much as possible not to bend by torque.

2. Tighten spool end (24-2) in spool (24-1). Torque is 19 - 22 Nm.

Main Control Valve (Kayaba) S0709402K

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Boom, Arm Anti draft Valve

1. Grip body in vise not to scratch the surface with O-ring (35,70) of body (47-1).
2. Insert spring seat (47-3) in spool (47-2), and insert spool in body (47-1) hole.
3. Assemble spring (47-4).
4. Tighten plug (47-5) with O-ring (47-10) to body (47-1). Torque is 28 - 30 Nm.
5. Tighten plug (47-9) with O-ring to body(47-1). Torques 14 - 17 Nm. Tighten plug (47-8) with O-ring to
body(47-1). Torque is 28 - 30 Nm.
6. Tighten plug (47-7) with O-ring and filter to body (47-1). Torque is 28 - 30 Nm.

Swing Load Check

1. Insert poppet (36-2) and spring (36-3) in poppet (36-1), and tighten plug (36-4) to poppet. Torque is
39 - 43 Nm.

IMPORTANT
Insert spring into poppet and the large end of spring should be faced to poppet. If spring is
misinserted, it can braked.

REASSEMBLY OF CONTROL VALVE

Reassembly of Load Check Valve

1. Assembly of travel semi parallel check of P2 port.
Assemble poppet (52) and spring (53), and fasten plug (54) with O-ring (55). Torque is 103 - 113 Nm.
2. Assembly of travel load check of P1 port.
Assemble poppet (32), spring (33) and O-ring (35), and fasten flange (34) with socket head bolt (63).
Torque is 103 - 113 Nm.

IMPORTANT
When fastening flange, spring (33) should be inserted into flange. If it is not completely
inserted, spring can be braked. When tightening socket head bolts, four bolts should be
equally tightened.

3. Assembly of the remaining load check.

Assemble poppet (31), spring (33) and O-ring, and fasten flange (34) with socket head bolts (63).
Torque is 103 - 113 Nm.

Reassembly of Swing Load Check

1. Install O-ring (40) and backup ring (41) on sleeve (38).
2. Install piston (39), spring (37) and poppet assembly (36) in sleeve (38).
3. Install sleeve assembly to body. Install O-ring (35) on body.
4. Install piston (43) and O-ring (45)in body (42).

S0709402K Main Control Valve (Kayaba)

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5. Install body assembly to sleeve (38).

6. Fasten flange (44) and body (42) with socket head bolt (68). Torque is 106 - 113 Nm.

Reassembly of The Other Check Valve

1. Assembly of two common check valves of main relief valve.
Install poppet (15) and spring (16). Insert spacer (17) with O-ring (18) and backup ring (19). Fasten
flange (56) with socket head bolts (64). Torque is 58 - 64 Nm.

IMPORTANT
Be careful of installing position of O-ring and backup ring. If they are reversed, O-ring can
be braked and oil leak can be caused.

2. Assembly of parallel check valve of spare junction, bucket junction and arm one.
Install poppet (28) and spring (29), and tighten plug (61) with O-ring. Torque is 116 - 128 Nm.
3. Assembly of arm two semi parallel check valve.
Install poppet (28) and spring (29), and tighten plug (61) with O- ring. Torque is 116 - 128 Nm.

Reassembly of Flange
1. Assembly of flange of spare port.
Install O-ring (78) on flange (76), and fasten flange with socket head bolts (77). Torque is 103 - 113
Nm.
2. Assembly of flange of boom two.
Install O-ring (57) on valve housing, and fasten flange (56) with socket head bolt (64). At this time the
good surface of flange should be faced to O-ring side. Torque is 58 - 64 Nm.

Reassembly of Boom and Arm Anti drift Valve

1. Install poppet (46) and spring (57), and fasten body assembly (47) with socket head bolt (63). Torque
is 103 - 113 Nm.

IMPORTANT
When installing body assembly (47), spring (33) should be completely installed in spring
position of body assembly.

Reassembly of Relief Valve

1. Tighten eight over load relief valves (49). Torque is 78 - 88 Nm.
2. Tighten main load relief valve (48). Torque is 93 - 108 Nm.
3. Tighten negacon relief valve (50). Torque is 103 - 113 Nm.

Reassembly of Subspool (24)

1. Install spool (24) in the previously assembled position.
2. Install spring seat (24) and spring (25).

Main Control Valve (Kayaba) S0709402K

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3. Tighten plug (27) with O-ring. Torque is 93 -108 Nm.

IMPORTANT
Insert spool in hole perpendicularly. Make sure that spool is in correct position. If it is not in
correct position, malfunction can occur.

Reassembly of Subspool (20)

1. Install spool assembly in the previously assembled position.
2. Install spring seat (21) and spring (22).
3. Tighten plug (23) with O-ring (72). Torque is 93 -108 Nm.

Reassembly of Mainspool (3) - (11)

1. Install O-ring on valve housing (1,2).
2. Fasten short cap (74) with socket head bolt (63) for travel straight spool (7). Fasten short cap (13)
with socket head bolt (63) for the other travel straight spools. Torque is 103 - 113 Nm.
3. Install spools (3 - 11) in the previously assembled position.
4. Fasten long cap (73) with socket head bolt (63) for travel straight spool (7). Fasten long cap (12) with
socket head bolt (63) for the other travel straight spools. Torque is 103 - 113 Nm.

IMPORTANT
When assembling, be careful not to drop O-ring from contact surface.

Reassembly of The Other Plugs

1. Tighten plug assembly (60) with O-ring. Torque is 31 - 42 Nm.
2. Tighten plug assembly (61) with O-ring. Torque is 116 - 128 Nm.
3. Tighten plug assembly (62) with O-ring. Torque is 73 - 79 Nm.
4. Tighten plug assembly (58) with O-ring and backup ring. Torque is 78 - 88 Nm.
5. Tighten plug assembly (51) with O-ring. Torque is 103 - 113 Nm.

6. Tighten plug assembly (59) with O-ring. Torque is 73 - 79 Nm.

IMPORTANT
After reassembling is completed, recheck tightening torque of all reassembled
components. If they are not completely tightened, oil leak can occur. The torque values are
based on the use of lubricated threads.

S0709402K Main Control Valve (Kayaba)

Page 46
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Reassembly of Main Relief Valve

Check whether there are dirt and paint chips around plug (2, Figure 53), (4) and nut (3) and reassemble
with a new one. Clean the installing part of relief valve and install it. Tighten cap (8:Width across Flats 41).
Torque is 93 - 108 Nm.
When adjusting the position of (Pi) port, adjust it before adjusting pressure and tighten plug (2, Width
across Flats 41 mm) after adjusting plug (2) which is loosened to slightly move cap (7, Width across Flats
54 mm). Torque is78- 88 Nm. If plugs are disassembled, Adjust pressure by referring “Main Relief Valve” on
page -35.
NOTE: The torque values are based on the use of lubricated threads.

Figure 53

Main Control Valve (Kayaba) S0709402K

Page 47
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Reassembly of Overload Relief Valve

Check whether there are dirt and paint chips around cap (1, Width across Flats : 31.75 mm) and
reassemble with a new one. Clean the installing part of relief valve and install it. Tighten cap (1). Torque is
78 - 88 Nm.
If adjusting kit is disassembled, Clean around threads and adjust pressure by referring “Over Load Relief
Valve” on page -36.
NOTE: The torque values are based on the use of lubricated threads.

Figure 54

Reassembly of Low Pressure Relief Valve

Check whether there are dirt and paint chips
around plug (1, Width across Flats : 46 mm) and
reassemble it with new O-rings, (3) and (4).
NOTE: The torque values are based on
the use of lubricated threads.

Figure 55

S0709402K Main Control Valve (Kayaba)

Page 48
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INSTALLATION
1. Be careful not to work other foreign strength to control valve by pipe laying.
2. Tighten the assembling bolts alternately and evenly to the specified torque.
3. If welding procedures are being performed near control valve that could be damaged by weld spatters
and heat, be careful and use adequate shielding protection in front of valve.
Clean the installing part of relief valve and install it. Tighten plug (1). Torque: 103 - 113 Nm.
4. Valve ports should be covered with caps, plugs or tape to protect the disconnected openings from
dust and other foreign materials until pipe laying work is started.

START-UP PROCEDURES
1. Before operating machine, make sure that oil passages and hydraulic oil are clean.
2. Hydraulic oil of which annealing point is 82-113°C should be used for hydraulic system.
3. Relief valve pressure should not be raised above setting pressure.
4. The difference between main relief valve setting pressure and over load relief valve setting pressure
should not be set over 2.0 MPa.
5. Before operating machine, hydraulic system should be fully warmed up. If machine is operated with
cold hydraulic oil and valve, be careful of the followings for preventing from sticking by heat shock of
spool.
NOTE: Do not operate main relief valve or over load relief valve suddenly and continuously. Cycle
oil through all actuators and warmed up cold hydraulic oil in the lines and components
uniformly.
NOTE: Slight or compound work should not be suddenly operated at cold weather because heat
is developed partly at all the throttles.

Main Control Valve (Kayaba) S0709402K

Page 49
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S0709402K Main Control Valve (Kayaba)

Page 50
 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)

MODEL SERIAL NUMBER RANGE
Solar 420LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2001 Daewoo

November 2001

Pilot Control Valve (Work Lever / Joystick)

Page 1
TABLE OF CONTENTS
General Description ....................................................................................... 3
Theory of Operation ................................................................................ 3
Structure .......................................................................................... 3
Function ........................................................................................... 3
Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Torques ............................................................................................ 5
Performance..................................................................................... 6
Removal ......................................................................................................... 6
Disassembly ................................................................................................... 8
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 12
Reassembly.................................................................................................. 13
Installation .................................................................................................... 18
Start-up Procedures ..................................................................................... 18

Pilot Control Valve (Work Lever / Joystick)

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION

Structure
The remote control valve contains four push rods, spring holders, spools and return springs, which are
located in the valve casing. The valve works as a pressure reduction valve.
The housing has six ports, which include input port P, tank port T, and four secondary pressure ports.
The electric horn switch is installed in the valve handle. Gear pump pressure is used for operating control
spools.

Function
1. Neutral Mode
When the lever is in neutral mode, the spool is thrust upward by return spring, and the force of
balancing spring, which determines the secondary discharge pressure, is not transmitted to the
spool. The input port is closed and the pressure of the output port is the same as the pressure of the
tank port T.
2. Control Mode
When push rod is pushed, the balance spring begins to compress, and spring force is conveyed to
the spool. Ports P and T are then connected together and the pilot pressure is conveyed to the area.
Output pressure works on the bottom of the spool, thrusting the spool upward until it is balanced with
the power of the balance spring. The secondary pressure (output pressure), therefore, changes in
proportion to the compression force of the balance spring.

Pilot Control Valve (Work Lever / Joystick)

Page 3
PARTS LIST

25

24
23

21
22

18 20

19 15

14
13
17
12
16

11
26
8

10

27 9

28
29
30 7

6
1
2 3 5 4

ASS1240L
Figure 1

Pilot Control Valve (Work Lever / Joystick)

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

SPECIFICATIONS

Component Name Specification

Type Pilot Control
Pressure / Stroke 28 kg/cm2 @ 6.5 mm stroke (398 psi @ 0.256 in Stroke)
Weight 4.8 kg (10.58 lbs)

Torques
Reference
Bolt Size Tool Torque
Number
2 PT 1/8 5 mm (0.197 in.) L-Wrench 150 kg•cm (10.9 ft lbs)
3 PF 3/8 8 mm (0.315 in.) L-Wrench 500 kg•cm (36.2 ft lbs)
19 M14 27 mm (1.063 in.) Spanner 1,660 kg•cm (12.0 ft lbs)
20 M14 22 mm (0.866 in.) Spanner 1,240 kg•cm (89.7 ft lbs)
22 M14 22 mm (0.866 in.) Spanner 1,240 kg•cm (89.7 ft lbs)

Pilot Control Valve (Work Lever / Joystick)

Page 5
Performance

40 40

(31.1)
28±1.5
25.8±4
Operating Torque (22)

TORQUE (kgf.cm)
PRESSURE (kgf/cm2)

lex
) 18.4±3
mp
(Co
gle)
(Sin
9.6±2.5
6.8±2
5±1 SECONDARY PRESSURE

1.1±0.3 6.5±0.5
0 2 4 6 7
PUSH-ROD STROKE(mm)
ASS1250L
Figure 2

REMOVAL
1. Lower bucket to ground.
2. Shut engine down and remove key from
starter switch.

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

Pilot Control Valve (Work Lever / Joystick)

Page 6
3. Fully stroke work levers (joystick) in all
directions to relieve pressure from
3
accumulators.
4
4. Set safety lever on "Lock" position.
5 2
5. Hang maintenance warning tag on
controls.
6. Disconnect negative (-) battery cable 1
leading to frame from battery.
7. Remove left and right control stand case (1
and 2, Figure 4).
ATS0880L
8. Remove four socket bolts (3, Figure 4) Figure 4
holding joystick (5, Figure 4) to stand
bracket.
9. Remove plate (4, Figure 4).
10. Using hand, lift joystick (5, Figure 4).
11. Tag and disconnect hoses from joystick
valve (1, Figure 5). T
1 P 2
12. Remove six fittings (3, Figure 5) and O- 1 2
rings (2, Figure 5). 3
1 3
2
4
T

ATS0890L
Figure 5

Pilot Control Valve (Work Lever / Joystick)

Page 7
DISASSEMBLY
1. Lift up the boot (23) and pull the switch
cord through the hole in the case (1).

Figure 6
2. Loosen nut (22) from hex nut (20) and
remove handle assembly (25).

Figure 7
3. Remove hex nut (20) and swash plate
(19).

Figure 8

Pilot Control Valve (Work Lever / Joystick)

Page 8
4. Remove boot (17).

Figure 9
5. Remove joint assembly (18) from case (1).

Figure 10
6. Remove plate (16).

Figure 11
7. Press spring (10) and remove plug (12).

Figure 12

Pilot Control Valve (Work Lever / Joystick)

Page 9
8. Remove pressure reduction valve (6, 7, 8,
9, 11) and spring (10).

IMPORTANT
Mark valve disassembling position
(port).

Figure 13
9. Remove plug (3).

Figure 14
10. Remove stopper (11) from pressure
reduction valve (6, 7, 8, 9, 11).

Figure 15
11. Remove spool (6), spring seat (9), spring
(8) and shim (7).

Figure 16

Pilot Control Valve (Work Lever / Joystick)

Page 10
12. Remove push rod (15) and plug (12).

Figure 17
13. Remove O-ring (13) from plug (12).

Figure 18
14. Remove seal (14) from plug (12).

Figure 19

Pilot Control Valve (Work Lever / Joystick)

Page 11
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section.
Clean all parts and dry them with compressed air. Keep all parts free from dust. Lubricate all moving parts.

Pilot Control Valve (Work Lever / Joystick)

Page 12
REASSEMBLY
1. Tighten plug (3) slowly.
NOTE: Torque: 350 kg•cm (25.3 ft lbs).

Figure 20
2. Install shim (7), spring (8), spring seat (9),
and spool (6).

Figure 21
3. Press spring (10) and install stopper (11).

Figure 22

Pilot Control Valve (Work Lever / Joystick)

Page 13
4. Install spring (10) in case (1) and pressure
reducing valve assembly (6, 7, 8, 9, 11).

Figure 23
5. Install seal (14) on plug (12).

Figure 24
6. Install O-ring (13) on plug (12).

Figure 25
7. Install push rod (15) on plug (12).

Figure 26

Pilot Control Valve (Work Lever / Joystick)

Page 14
8. Install plug (12) in case (1).

Figure 27
9. Install plate (16).

Figure 28
10. Tighten joint assembly (18).

Figure 29
11. Install swash plate (19) on joint (18).

Figure 30

Pilot Control Valve (Work Lever / Joystick)

Page 15
12. Install hex nut (20) and tighten swash plate
(24).

Figure 31
13. Grease joint (18), swash plate (19) and
push rod (15).

Figure 32
14. Install the boot (17).
NOTE: Apply gease onto the fitting
surface swash plate and push
rod.

Figure 33
15. Align the direction of handle (25) and
tighten hex nut (20) and nut (22).

Figure 34

Pilot Control Valve (Work Lever / Joystick)

Page 16
16. Push the switch cord through the hole in
the case (1).

Figure 35
17. Install boot (23).

Figure 36

Pilot Control Valve (Work Lever / Joystick)

Page 17
INSTALLATION
1. Install six fittings (3, Figure 37) and O-
rings (2, Figure 37). T
1 P 2
2. Connect hoses to joystick valve (1, Figure 1 2
37). 3
1 3
2
4
T

ATS0890L
Figure 37
3. Install plate and four socket bolts top
secure joystick (5, Figure 38) valve to
3
control stand bracket.
4
4. Install left and right control stand case (1
and 2, Figure 38). 5 2

ATS0880L
Figure 38

START-UP PROCEDURES
1. Start engine and set throttle at "LOW
IDLE".
2. Set safety lever on "UNLOCK" position.

HAOB290L
Figure 39

Pilot Control Valve (Work Lever / Joystick)

Page 18
3. Slowly cycle boom, arm, bucket cylinders
and swing motor about five times without a
load to vent air from pilot lines. Do this for
5 minutes.

ARO0470L
Figure 40

Pilot Control Valve (Work Lever / Joystick)

Page 19
 Pilot Control Valve (Work Lever / Joystick)
Page 20
 S0709820K

1TRAVEL CONTROL
VALVE (WITH DAMPER)

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 CONTROL VALVE (WITH DAMPER)S0709820K

MODEL SERIAL NUMBER RANGE
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

Copyright 2001 Daewoo

December 2001

Travel Control Valve (With Damper) S0709820K

Page 1
TABLE OF CONTENTS

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

Theory of Operation ................................................................................ 3
Pressure Reducing Valve................................................................. 3
Operating Theory of Damper Mechanism........................................ 5
Parts List ................................................................................................. 6
Specification............................................................................................ 7
Torque ..................................................................................................... 7
Troubleshooting, Testing and Adjustment....................................................... 8
Removal ......................................................................................................... 9
Disassembly ................................................................................................. 11
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 17
Reassembly.................................................................................................. 18
Installation .................................................................................................... 23
Start-up Procedures ..................................................................................... 24

S0709820K Travel Control Valve (With Damper)

Page 2
GENERAL DESCRIPTION
THEORY OF OPERATION
The damper valve is divided into two areas of operation. There is the pressure reducing valve (a) and the
damper mechanism (b). The following hydraulic circuit is an example of a remotely located control valve.

5
6

4
2

ARS1810L
Figure 1

Reference Reference
Description Description
Number Number
1 Remote Control Valve 4 Control Valve
2 Pilot Pump 5 Hydraulic Motor
3 Main Pump 6 Hydraulic Cylinder

Pressure Reducing Valve

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

Travel Control Valve (With Damper) S0709820K

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

40 160
SECONDARY PRESSURE (kgf/cm2)

OPERATING TORQUE (kgf.cm)

117.6
27±1.5
Operating Torque 100.5

49.5

5.5±1
Secondary Pressure

0 1±0.5 4.8±0.5 5.5

PUSH-ROD STROKE (mm)

ARS1840L

Figure 2

S0709820K Travel Control Valve (With Damper)

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

pushing push rod and spool presses

cylinder, return spring and hydraulic oil in
cylinder is compressed, piston coming
down with push rod compresses vibration
prevention chamber of lower part, oil of
vibration prevention chamber of lower part
is flowed through orifice to oil pressure
vibration prevention chamber of upper part
of low pressure, at this time, ball check
valve becomes closing condition because
high pressure operates to vibration
prevention chamber of lower part.

ARS1820L
Figure 3
2. Operation When Operating Lever In
Neutral Condition
Climbing restoring force acting on push 1
rod, raises piston in oil pressure prevention
2
chamber and compresses upper oil
3
pressure prevention chamber. This
4
compression operation of upper oil
pressure prevention chamber prevents the
push rod from quickly rising by restoring
spring, and the damping force is
Upper vibration
generated. prevention chamber

Lower vibration
prevention chamber

ARS1830L
Figure 4

Travel Control Valve (With Damper) S0709820K

Page 5
PARTS LIST

19 20 30 29 28 33

32
25

24 26

23 3

22 36

16 14

15
21
17
13
18
12
19
11
20
9
6
5
7
4
10

3 8

37 1 35 34 2
ARS1850L
Figure 5

P T

1 2 3 4 ARS1860L

Figure 6

S0709820K Travel Control Valve (With Damper)

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

SPECIFICATION

Travel Control Valve Specification

Pilot Control
Type
(With Damper)

Pressure / Stroke 27 kg/cm2 @ 4.8 mm Stroke

(384 psi @ 1.890 in. Stroke)
7.8 kg
Weight
(17.2 lb)

TORQUE

Part Reference
Bolt Size Tool Tightening Torque
Number
88 kg•cm
26 M6 5 mm L-Wrench
(6.37 ft lb)
100 kg•cm
30 M8 4 mm L-Wrench
(7.23 ft lb)
440 kg•cm
32 M10 17 mm Spanner
(31.8 ft lb)
440 kg•cm
37 M10 8 mm L-Wrench
(31.8 ft lb)

Travel Control Valve (With Damper) S0709820K

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

Problem Possible Cause Remedy

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

S0709820K Travel Control Valve (With Damper)

Page 8
REMOVAL
1. Lower bucket to ground.
2. Shut engine down and remove key from
starter switch.

WARNING!
If engine must be run while
performing maintenance, use
extreme care. Always have one
person in the cab at all times. Never
leave the cab with the engine
Figure 7
running.

3. Fully stroke work levers (joysticks) in all

directions to relieve pressure from
accumulators.
4. Set safety lever on "LOCK" position.
5. Hang maintenance warning tag on
controls.
6. Disconnect negative (-) battery cable
leading to frame from battery.
7. Remove cabin under cover by loosening
bolts.
2
8. Tag and disconnect hoses from pedal
valve (1, Figure 8). Plug and cap hoses
and ports to prevent contamination from 1
entering hydraulic system or component.

ARS2940L
Figure 8
9. Remove rubber boots (1, Figure 9).
10. Remove four bolts and washers (2, Figure
9), pedal brackets (3), and levers (4). 4 1

2
1

3
3

ARS2950L
Figure 9

Travel Control Valve (With Damper) S0709820K

Page 9
11. Remove four bolts and washers (2, Figure
10), and pedal valve (1).
2

ARS2940L
Figure 10

S0709820K Travel Control Valve (With Damper)

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

1. Remove bellows (33).

Figure 11
2. Remove set screw (30) by using L wrench.

Figure 12

Travel Control Valve (With Damper) S0709820K

Page 11
3. Remove cam shaft (29) and bushing (28)
from cam (27).

Figure 13

Figure 14
4. Remove cam (27) from cover (25).

Figure 15
5. Loosen wrench bolt (26) by using tool.

Figure 16

S0709820K Travel Control Valve (With Damper)

Page 12
6. Remove cover (25) from body (1 and 2).

Figure 17
7. Remove plug assembly (21 - 24) with push
rod assembly (14 - 20).

Figure 18
8. Remove snap ring (13).

IMPORTANT
Be careful not to spring rod guide
(11).

Figure 19
9. Remove rod guide (11).

Figure 20

Travel Control Valve (With Damper) S0709820K

Page 13
10. Remove spool assembly (5 - 9).

Figure 21
11. Remove spring (10).

Figure 22
12. Remove stopper (9), spring (6) and spring
seat (7) from spool assembly (5 - 9).

Figure 23

Figure 24

S0709820K Travel Control Valve (With Damper)

Page 14
13. Remove plug assembly (21 - 24) from
push rod assembly (14 - 20).

Figure 25
14. Remove seal (23 and 24) from plug (21).

Figure 26
15. Remove O-ring (22) from plug (21).

Figure 27
16. Remove seal (16) from push rod (14).

Figure 28

Travel Control Valve (With Damper) S0709820K

Page 15
17. Remove snap ring (20) from push rod (14).

Figure 29
18. Remove plate (19) from push rod (14).

Figure 30
19. Remove spring (18) from push rod (14).

Figure 31
20. Remove steel ball (17) from push rod (14).

Figure 32

S0709820K Travel Control Valve (With Damper)

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

Travel Control Valve (With Damper) S0709820K

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

1. Clean body (1 and 2) and all parts.

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

Figure 33

S0709820K Travel Control Valve (With Damper)

Page 18
3. Clean plug (21) with thinner, inspect burrs
and install rod seal (23) and dust seal (24)
on both sides of plug by using tool.

Figure 34
4. Install O-ring (22) on outside diameter of
plug (21) and check plug whether it is
abnormal.

Figure 35
5. Install spring seat (7), spring (6) and
spring seat (5) on spool (8).

Figure 36
6. Install O-ring (12) on rod guide (11).

Figure 37

Travel Control Valve (With Damper) S0709820K

Page 19
7. Install steel ball (17), spring (18), plate (19)
and spring pin (15) on push rod (14).

Figure 38
8. Install snap ring (20) on push rod
assembly (14 - 19).

Figure 39
9. Install seal (16) on push rod (14).

Figure 40
10. After installing spool assembly (5 - 9) on
body (1 and 2), insert rod guide (11) and
install snap ring (13).

Figure 41

S0709820K Travel Control Valve (With Damper)

Page 20
11. Install plug assembly (21 - 24) with push
rod assembly (14 - 20) on body (1 and 2).

Figure 42
12. Install cover (25) on the upside of body (1
and 2).

Figure 43
13. Tighten wrench bolt (26).
NOTE: Tightening torque: 88 kg•cm
(6.37 ft lb).

Figure 44
14. Put cam (27) on cover (25) and install cam
shaft (29).

IMPORTANT
Check whether there is a play of cam.

Figure 45

Travel Control Valve (With Damper) S0709820K

Page 21
15. Tighten set screw (30) on center of cam
(27) not to loose cam (27) and cam shaft
(29) by using wrench.
NOTE: Tightening torque: 88 kg•cm
(6.37 ft lb).

Figure 46
16. One side holds L wrench and the other
side holds spanner and tighten set screw
(31) and hex nut (32) attached to cam (27)
not to loose.

IMPORTANT
Check whether there is a play of cam.

NOTE: Tightening torque: 440 kg•cm

(31.8 ft lb).
Figure 47
17. Install bellows.

Figure 48

S0709820K Travel Control Valve (With Damper)

Page 22
INSTALLATION
1. Position pedal valve (1, Figure 49) on
cabin floor plate and install four bolts and
washers (2). 2

ARS2940L
Figure 49
2. Install pedal brackets (3) and levers (4,
Figure 50) on pedal valve and install four
bolts and washers (2).
4 1
3. Install rubber boots (1, Figure 50).
2
1

3
3

ARS2950L
Figure 50
4. Connect hoses as tagged during removal
to pedal valve (1, Figure 51).
2
5. Install cabin under cover by tightening
bolts.
1

ARS2940L
Figure 51

Travel Control Valve (With Damper) S0709820K

Page 23
START-UP PROCEDURES
1. Start engine and set throttle at "LOW
IDLE".
2. Set safety lever on "UNLOCK" position.

HAOB290L
Figure 52
3. Slowly push and pull both travel lever
about five times without a load to vent air
from pilot lines.

HAOB903L
Figure 53

S0709820K Travel Control Valve (With Damper)

Page 24
 S0792170K

3HYDRAULIC
SCHEMATIC
(S470LC-V)

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 (S470LC-V)

MODEL SERIAL NUMBER RANGE

Solar 470LC-V 1001 and Up

Copyright 2001 Daewoo

December 2001

Hydraulic Schematic (S470LC-V) S0792170K

Page 1
TABLE OF CONTENTS

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

Solar 470LC-V................................................................................................ 4

S0792170K Hydraulic Schematic (S470LC-V)

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

Figure 1

Hydraulic Schematic (S470LC-V) S0792170K

Page 3
SOLAR 470LC-V

Figure 2

S0792170K Hydraulic Schematic (S470LC-V)

Page 4
Hydraulic Schematic (S470LC-V) S0792170K
Page 5
S0792170K Hydraulic Schematic (S470LC-V)
Page 6
Return to Master Table of Contents

1ELECTRICAL SYSTEM
 S0802220K

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 SYSTEM
MODEL SERIAL NUMBER RANGE
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

Copyright 2001 Daewoo

October 2001

Electrical System S0802220K

Page 1
TABLE OF CONTENTS
Troubleshooting - Electrical System ............................................................... 4
Overview ........................................................................................................ 5
Electric Supply System .................................................................................. 6
Engine Starting Circuit ................................................................................... 7
Operation During Start Process .............................................................. 7
Operation After Start Process ................................................................. 8
Engine Preheating System............................................................................. 9
Engine Stop System..................................................................................... 10
Charging System.......................................................................................... 13
Monitoring System ....................................................................................... 14
Instrument Panel ................................................................................... 15
Monitoring System Schematic .............................................................. 16
Operation...................................................................................................... 18
Instruments ........................................................................................... 18
Warning and Indicator Lights........................................................................ 20
Initial Operation ............................................................................................ 22
Mode Select Switch...................................................................................... 23
Graphic Information Area Display ................................................................ 24
Overview ............................................................................................... 24
Main Menus for the Graphic Display Area............................................. 25
Menu Selection Buttons ........................................................................ 25
Main Menu.................................................................................................... 26
Language setting................................................................................... 26
Time Setting .......................................................................................... 26
Filter/Oil information .............................................................................. 27
Special Menu................................................................................................ 28
Entering/Accessing and Exiting/Escaping Menus ................................. 28
Special Menu Selections....................................................................... 29
Electronic Hydraulic Control System (e-EPOS) ........................................... 42
Control System Schematic.................................................................... 42
Power Mode Control..................................................................................... 44

S0802220K Electrical System

Page 2
 Operation .............................................................................................. 45
Power Mode Control - Circuit Diagram ......................................................... 48
Trenching Mode Control ............................................................................... 50
Operation .............................................................................................. 51
Trenching Mode Control - Circuit Diagram ................................................... 52
Engine Control System................................................................................. 53
Engine Control Motor ................................................................................... 54
Engine Control Dial ...................................................................................... 55
Engine Control Circuit Diagram.................................................................... 57
Automatic Deceleration Control (Auto Idle Control)...................................... 58
Engine Overheat Protection System ............................................................ 59
Power Boost Mode ....................................................................................... 60
Operation .............................................................................................. 60
Power Boost Control - Circuit Diagram ................................................. 61
Automatic Travel Speed Control ................................................................... 62
Automatic Travel Speed Control - Circuit Diagram ................................ 63
Engine Control Device - Adjustment ............................................................ 64
Self-diagnostic Function ............................................................................... 67
e-EPOS Controller ................................................................................ 67
Engine Throttle Controller ............................................................................ 69
Wiper System ............................................................................................... 70
Wiper Circuit.......................................................................................... 70
Wiper Operation .................................................................................... 70
Window Washer Operation ................................................................... 71
Lighting System............................................................................................ 72
Lighting System Circuit Diagram........................................................... 72
Kind of Light .......................................................................................... 73
Operation .............................................................................................. 73
Overload Warning Device............................................................................. 74
Overload Warning Device Circuit Diagram............................................ 74

Electrical System S0802220K

Page 3
TROUBLESHOOTING - ELECTRICAL SYSTEM

Problem Possible Causes Remedies

Battery will not stay Internal battery short. Replace battery.
charged. Short in other part of circuit. Repair wiring or replace component.
Battery does not Battery worn out or defective. Replace battery.
charge. Defective alternator or belt. Repair or replace.
Cable connection loose or severely Repair or replace.
corroded. Circuit ground corroded or
weak.
Engine rpm not Engine speed potentiometer or dial Repair or replace.
controllable. defective.
Engine control cable broken or loose. Repair or replace.
Engine control motor defective or not Repair connection or replace
connected. component.
Engine throttle controller defective or Repair connection or replace
not connected. component.
Blown fuse. Replace fuse. Check connections
and circuit components for shorts or
other damage.
Wiring harness or connector Repair or replace.
defective or damaged.
Power mode selection Blown fuse. Replace fuse. Check connections
does not change. and circuit components for shorts or
other damage.
Instrument Panel switch broken. Repair or replace.
Wiring harness or connector Repair or replace.
defective or damaged.
e-EPOS controller defective. Replace.
Speed sensor defective. Replace.
Work mode selection Blown fuse. Replace fuse. Check connections
does not change. and circuit components for shorts or
other damage.
Instrument Panel switch broken. Repair or replace.
Wiring harness or connector Repair or replace.
defective or damaged.
e-EPOS controller defective. Replace.
Solenoid valve defective. Replace.

S0802220K Electrical System

Page 4
OVERVIEW
The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24
volts with the exception of the car stereo and the air-conditioning control actuator. The system contains two
12 volt batteries connected in series 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 electrical
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 S0802220K

Page 5
ELECTRIC SUPPLY SYSTEM
The electric power circuit supplies electric current to each electric component. It consists of a battery,
battery relay, starter switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle body.
Even when the starter switch (5) is in the "OFF" position, electric current is supplied to the following
components through battery (1) → fusible link (3) → fuse (6).
1. Cabin light, fuel pump switch, No. 1 terminal of DC-DC converter (backup for car stereo memory)
2. "B" terminal of starter switch and No. 22 terminal of air conditioner control panel.
3. No. 17 terminal of instrument panel (back up for instrument panel).
4. Power terminal "B" of engine stop motor.
When the starter switch (5) is in the preheat, on and start positions, the current flows from the battery (1)
→ fusible link (3) → fuse (6) → starter switch (5) "B" terminal/starter switch (5) "BR" terminal → battery
relay (2) "BR" terminal which activates the coil of the battery relay and the electric supply system is
energized.
When the battery relay’s contacts are connected, all electric devices can be operated.
While the engine is not running, the electric power for all electric devices are supplied by the battery. Once
the engine is started the power is supplied from the alternator (7).

ACC C
B
R2
5
BR
0.5G
R1

6
3
8
4 2
B A

BR
E

- + - +
12V 150AH 12V 150AH
R(I) B(B+)
1
PST TML B BR R1 R2 C ACC
OFF
PREHEAT 7
ON
R
START F
E

E
ARS0010L
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM

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 8 Diode

S0802220K Electrical System

Page 6
ENGINE STARTING CIRCUIT
OPERATION DURING START PROCESS
When the starter switch is turned to the start position, the "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 flow from the
battery (1, Figure 2) → fusible link (3) → "B" terminal of the starter switch (5) → "C" terminal of the starter
switch (5) → "C" terminal of the 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 (9) is
pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter
are connected.
The current flows from the battery (1) → "A" terminal of the battery relay (2) → "B" terminal of the battery
relay (2, Figure 2) → "B" terminal of the starter (9). The starter motor is rotated and the engine is started.

7 8
N S D PP C
P B
B E
11
9
A

ACC C
B
R2
BR
5 R1
3

6
2
4
B A

BR
E

R(I) P(R)

PST TML B BR R1 R2 C ACC

OFF SG
- + - +
PREHEAT 10
ON R
START
F 1
E

E
ARS0020L
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING

Reference Reference
Description Description
Number Number
1 Battery 7 Starter Controller
2 Battery Relay 8 Starter Relay
3 Fusible Link 9 Starter
4 Circuit Breaker 10 Alternator
5 Starter Switch 11 Diode
6 Fuse Box

Electrical System S0802220K

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

Operation of the Start Circuit (2) - Immediately After Start

7 8
N S D PP C
P B B
B E
11
9
A

ACC C
B
R2
BR
5 R1
3

6
2
4
B A

BR
E
11
R(I) B( P(R)

PST TML B BR R1 R2 C ACC

OFF
PREHEAT - + - +
10
ON
R
START F 1
E

ARS0030L
Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START

Reference Reference
Description Description
Number Number
1 Battery 7 Starter Controller
2 Battery Relay 8 Starter Relay
3 Fusible Link 9 Starter
4 Circuit Breaker 10 Alternator
5 Starter Switch 11 Diode
6 Fuse Box

S0802220K Electrical System

Page 8
ENGINE PREHEATING SYSTEM
An air heater (8) device is installed in the intake manifold of the engine.
When the starter switch (5) is turned to the "Preheat" position, the current flows from the battery (1) →
fusible link (3) → "B" terminal of starter switch (5) → "R1" terminal of starter switch (5) → "C" terminal of
preheat relay (7) → ground and the contact points of the preheat relay are closed.
When the contact points of the preheat relay (7) are closed, the heating coils of the air heating device are
heated by current flowing from the battery (1) → battery relay (2) → preheat relay (7) → air heater (8) →
ground.
The preheat time is approximately 19 seconds. A built-in timer in the instrument panel will activate an
indicator light approximately 19 seconds after the preheat process has been selected.
Even after the starter switch (5) has been moved to the start position the current will continue to flow
through the "R2" terminal of the starter switch (5) to the coil of the preheat relay (7) without disruption of
the preheat process.

6
9 4
CN7-9 2
ACC C B A
PREHEAT CN7-6
L4 B 5
R2 BR

R1 BR E
10

C B
10 - + - +

7
1
H

STARTER SWITCH CONNECTION

PST TML B BR R1 R2 C ACC

OFF
8
PREHEAT
ON
START
ARS0040L

Figure 4 ENGINE PREHEAT CIRCUIT

Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Preheat Relay
3 Fusible Link 8 Air Heater
4 Circuit Breaker 9 Indicator Lamp
5 Starter Switch 10 Diode

Electrical System S0802220K

Page 9
ENGINE STOP SYSTEM
The engine stop circuit consists of a starter switch (5), engine stop motor (9) and engine stop relay (8).
There are two modes of operation - engine running and engine stop.
The worm gear built into the motor reduces the engine stop motor’s speed and changes motor’s revolution
to reciprocation. The fuel shut off lever is pushed or pulled by this change.
When the start switch is in the "ON" position, the engine stop motor rotates 180° and comes to a stop due
to the cam switch. When the start switch is in the "OFF" position, the engine stop motor moves 180° from
the running mode position and is stopped by the cam switch.

A STARTER SWITCH CONNECTION

P1 87a TML
PST B BR R1 R2 C ACC
30
P2 87 OFF
A 85 86 PREHEAT
B
ON
E
START

8
9
0.5G

6
3
ACC C
B
R2
5
BR
4 2
R1 B A

BR
E
7

- + - +

1
ARS0050L

Figure 5 ENGINE STOP CIRCUIT

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

S0802220K Electrical System

Page 10
Operation In Engine Running Mode
When the starter switch (3) is turned to the "ON" position, the contact points "30" and "87" of the engine
stop relay (5) are closed due to current flowing from the battery (1) → fusible link (2) → "B" terminal of
starter switch (3) → "ACC" terminal of starter switch (3) → "86" terminal of engine stop relay (5) → "85"
terminal of engine stop relay (5) → ground.
As a result, the engine stop motor (6) is rotated by the current flow from the battery (1) → fusible link (2) →
"B" terminal of the engine stop motor (6) → "P2" terminal of engine stop motor (6) → "87" terminal of
engine stop relay (5) → "30" terminal of the engine stop relay (5) → "A" terminal of engine stop motor (6) →
"E" terminal of engine stop motor (6) → ground. The engine stop motor opens (pushes) the fuel shut off
lever of the fuel injection pump and the system is in the running mode. The engine stop motor rotates 180°
and comes to a stop due to the cam switch which shuts off the current to the motor.
When the starter switch is in the "ON" position, the internal components of the engine stop motor‘s cam
switch is in running mode position.

A STARTER SWITCH CONNECTION

P1 87a TML
PST B BR R1 R2 C ACC
30
P2 87 OFF
A 85 86 PREHEAT
B
ON
E
START

5
6
0.5G

4
2
ACC C
B
R2
3
A BR
R1 - + - +
P1

P2 1
A B

ENGINE RUNNING MODE

ARS0060L
Figure 6 ENGINE STOP CIRCUIT - RUNNING MODE

Reference Reference
Description Description
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor

Electrical System S0802220K

Page 11
Operation In Engine Stop Mode
When the starter switch (3) is in the "OFF" position, the electric current flow to the coil of the engine stop
relay (5) is shut off.
As a result, the "30" and "87a" contact point of the engine stop relay are connected and current is supplied
to the engine stop motor from the battery (1) → fusible link (2) → "B" terminal of engine stop motor (6) →
"P1" terminal of engine stop motor (6) → "87a" terminal of engine stop relay (5) → "30" terminal of engine
stop relay (5) → "A" terminal of engine stop motor (6) → "E" terminal of engine stop motor (6) → ground
and the motor is rotated.
The shut off lever of the fuel injection pump, linked to the engine stop motor by a cable, is moved to the
close (pull) position and the engine is stopped. The engine stop motor moves 180° from the running mode
position and is stopped by the internal cam switch which cuts off the current to the motor.
When the starter switch is in the "OFF" position, the internal components of the engine stop motor‘s cam
switch is in the stop mode position.

A STARTER SWITCH CONNECTION

P1 87a TML
PST B BR R1 R2 C ACC
30
P2 87 OFF
A 85 86 PREHEAT
B
ON
E
START

5
6
0.5G

4
2
ACC C
B
R2
3
A BR
R1 - + - +
P1

P2 1
A B

ENGINE STOP MODE

ARS0070L

Figure 7 ENGINE STOP CIRCUIT - STOP MODE

Reference Reference
Description Description
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor

S0802220K Electrical System

Page 12
CHARGING SYSTEM
When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of
the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this
condition the alternator (7) starts charging. The current flows from the "B" terminal of alternator (7) →
circuit breaker (4) → battery relay (2) → battery (1).
The alternator also supplies electric current to other electrical components. When the alternator (7) starts
to operate, a current flows from the "R(I)" terminal of alternator → diode (8) → battery relay (2) coil
securing a path for the charging current to the battery (1). Thus preventing the possibility of a high voltage
build up and possible damage to the electric system.

ACC C
B
R2
5
BR
0.5G
R1

6
3
8
4 2
B A

BR
E

- + - +
R(I) B(B+) P(R) 12V 150AH 12V 150AH
STARTER SWITCH CONNECTION
1
PST TML B BR R1 R2 C ACC
OFF SG
PREHEAT 7
ON
R
START F
E

ARS0080L
Figure 8 CHARGING CIRCUIT

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 8 Diode

Electrical System S0802220K

Page 13
MONITORING SYSTEM

ARS0090L
Figure 9

Reference Reference
Description Description
Number Number
1 Instrument Panel Pump Discharge Pressure
9
2 Battery Sensor
3 Engine Speed Sensor Engine Coolant
10
Temperature Sensor
4 Return Filter Switch
11 Fuel Sensor
5 Pilot Filter Switch
12 Air Cleaner Indicator
6 e-EPOS Controller
13 Engine Oil Pressure Switch
7 Alternator
14 Light Switch
8 Warning Buzzer

The monitoring system displays the various data and warning signals onto the instrument panel by
processing the information gathered from the e-EPOS controller. It displays information selected by the
operator.

S0802220K Electrical System

Page 14
INSTRUMENT PANEL

ARO0100L
Figure 10

Gauges Warning Lights Mode Select Switches

1. Engine Coolant Temp. 6. Charge Warning Light 12. Power Mode Select Switch
Gauge (Up Arrow Button)
7. Engine Oil Pressure
2. Fuel Gauge Warning Light 13. Trenching Mode Select
Switch (Down Arrow
3. Multi-function Gauge & 8. Coolant Temp. Warning
Button)
Graphic Information Area Light
14. Auto Idle Switch
4. Digital Clock 9. Preheat Completion Light
(Enter Button)
5. Service Hour Meter 10. Work Light Indicator Light
15. Display Select Switch
11. Overload Warning Light (Escape Button)

When the engine starter switch is turned to the "I" (ON) position, all bands of gauges, indicator lights of
switches/buttons and indicator/warning lights will turn "ON" and the alarm buzzer will sound for about 2
seconds.
During this time, a moving excavator will appear on the digital clock and graphic information area (3 and 4,
Figure 10).

Electrical System S0802220K

Page 15
MONITORING SYSTEM SCHEMATIC

1
21
9
10

+
2
8 - 3
11
L1 L2 L3 L4 L5 L6

6 4
R1 B
19
17
18
ILLUMINATION B
16 BR
+
EL SIG CN4-1 E
19 5 - CN4-2
20
A
+
SIG CN4-3
6 CN4-4
WARNING LAMP -
L1 : BATTERY CHARGE 20
L2 : ENG. OIL PRESS CN4-5 17
L3 : WATER TEMP.
L4 : PREHEAT 7 CN4-6
L5 : WORK LAMP
L6 : OVER LOAD
CN4-7
8 CN4-8
LCD DISPLAY PANEL
WATER TEMPERATURE
FUEL LEVEL CN4-16
9 CN4-17
GRAPHIC DISPLAY

CN3-4
CN3-5
10
22
CN3-9 TxD CN3-1
CN3-10 TxD CN3-2
RS-422
POWER DISPLAY
CN3-11 RxD CN3-3
ESC 5 CN3-12
RxD
3 CN3-8

R(I) CN2-1

CN2-11
15 11
CN2-12
12
CN2-13
13
CN2-14
14
ARS0110L

Figure 11

S0802220K Electrical System

Page 16
 Reference Reference
Description Description
Number Number
1 Instrument Panel 11 Engine Oil Pressure Switch
2 Pilot Buzzer 12 Air Cleaner Indicator
3 Light Switch 13 Return Filter Switch
4 Start Switch 14 Pilot Filter Switch
5 Front Pump Pressure 15 Alternator
Sensor 16 e-EPOS Controller
6 Rear Pump Pressure 17 Battery
Sensor
18 Battery Relay
7 Engine Coolant
19 Circuit Breaker
Temperature Sensor
20 Fusible Link
8 Fuel Gauge
21 Fuse Box
9 Engine Speed Sensor
22 Check Connector
10 Hydraulic Oil Temp. Sensor

Electrical System S0802220K

Page 17
OPERATION
INSTRUMENTS

Sensor Specification
Function Display Input
Input Specification
Terminal
RED 41°C (106°F) → 1,372
H ohms
GREEN
61°C (142°F) → 855 ohms
Engine WHITE CN4-5
107°C 102°C (216°F)→ 160 ohms
Coolant
Temperature 105°C
CN4-6 105˚C (221˚F) → 147
C ohms
61°C 107˚C (225˚F) → 128
41°C ARS0780L ohms

GREEN
F
RED 1/10 LCD Blinking → over
CN4-7
Fuel Level 5K ohms
CN4-8
E FULL → under 525 ohms

1/10 ARS0790L

N = 146 f / 60 (S300LC-V)
N = 146 f / 60 (S300LL)
02/05 [MO] 11:30A
N = 152 f / 60 (S340LC-V)
ENG SPEED CN4-16 N = 152 f / 60 (S420LC-V)
Tachometer
CN4-17 N = 152 f / 60 (S470LC-V)
1950 RPM N = Engine speed (rpm)
ARO0160L F = Frequency of engine
speed sensor (Hz)

02/05 [MO] 11:30A

BATTERY CN7-9
Voltmeter 0 - 32 VDC
CN7-19

28.5 VOLT
ARO0180L

S0802220K Electrical System

Page 18
 Sensor Specification
Function Display Input
Input Specification
Terminal

02/05 [MO] 11:30A

Main pump
discharge FRONT PUMP CN4-1
pressure CN4-2
(front pump)
320 BAR V = 0.00816 x P + 1.0

ARO0190L V: Sensor output voltage

(V)
P: Displayed pressure
02/05 [MO] 11:30A (Bar)
Main pump
discharge
REAR PUMP CN4-3
pressure
(rear pump) CN4-4

313 BAR
ARO0200L

Electrical System S0802220K

Page 19
WARNING AND INDICATOR LIGHTS
Input
Description Symbol Operation Remarks
Terminal

Lights up when not

charging [R(I)
Lights up before
terminal output
engine start up and
Charge CN2 - 1 drops below 12±1V]
shut off once engine
and over charging
is running.
[R(I) terminal output
HAOA610L increase over 33 V].

Lights up when After starting

engine oil pressure engine, if engine oil
Engine Oil switch is turned pressure is
CN2 - 11 "ON" (Oil pressure
Pressure insufficient after 8
drops below 0.7 kg/ seconds, a warning
HAOA620L
cm2 (10 psi). buzzer will sound.

Lights up when the

resistance of
Engine CN4 - 5 engine coolant
Coolant
CN 4 - 6 temperature sensor
Temperature
drops below 128
HAOD350L
ohms.

Lights up when
preheat process is
Preheat CN7 - 6 completed.
(Approximately 19
seconds from start)
HAOA639L

Lights up when
Work Light CN2 - 7 work light switch is
turned "ON."

S0802220K Electrical System

Page 20
 Input
Description Symbol Operation Remarks
Terminal
Lights up when Warning buzzer will
lifting load exceeds sound.
limit. (When the 2.80 V (S300LC-V)
CN1 - 3 over load warning
Overload 2.80 V (S300LL)
switch is turned
(Optional) CN1 - 4 "ON," output 2.80 V (S340LC-V)
voltage increases
ARO0220L
over reading in 2.88 V (S420LC-V)
remarks.) 2.80 V (S470LC-V)
Graphic Information Area

02/05 [MO] 11:30A

2059 RPM Lights up when air

Air Cleaner CN2 - 12 Symbol is blinking.
Air Cleaner cleaner is clogged
CLOGGED!!
ARO0210L

02/05 [MO] 11:30A Lights up when

2059 RPM return filter
Return Filter CN2 - 13 pressure increases Symbol is blinking.
Return Filter
over 1.5 kg/cm2 (21
CLOGGED!!
psi).
ARO0230L

02/05 [MO] 11:30A

Lights up when pilot
2059 RPM filter pressure
Pilot Filter CN2 - 14 increases over 1.0 Symbol is blinking.
Pilot Filter
CLOGGED!! kg/cm2 (14 psi).
ARO0240L

Electrical System S0802220K

Page 21
INITIAL OPERATION
Item Input (Terminal) Output (Operation and initial setting mode)
Initial When battery voltage is input • All LCD, LED and warning lights are turned on
Operation to CN7 - 9 (starter switch is and turned off after about 2 seconds.
turned from "OFF" to "ON"
• Warning buzzer is activated and turned off
position).
after about 2 seconds.
• Power mode: Previous setting mode.
• Work Mode: Previous setting mode.
• Auto Idle: High Output (Activation).
• Numerical display: Engine speed.
• Clock: Current time display.

NOTE: Refer to the clock setting method of operation manual for time setting.

S0802220K Electrical System

Page 22
MODE SELECT SWITCH
Power Mode / Trenching Mode Switch

e-EPOS Output
Output Check
(Operation Pump Discharge
Operation Mode Volume Control Swing Priority 7-Segment
mode display
LED) Valve Current Solenoid Valve Display
(mA)
Power Power Mode ON Variable Output - 9x
Mode Standard Mode OFF 0 - 7x
Work Mode Trenching Mode ON - ON x2
Digging Mode OFF - OFF x0

Auto Idle Switch

Output Check (Operation e-EPOS Output (CN1 - 7
Operation Mode
mode display LED) Terminal)
Auto Idle Activation ON H (11 ±1.5V)
Cancellation OFF L (0 - 1V)

Electrical System S0802220K

Page 23
GRAPHIC INFORMATION AREA DISPLAY
OVERVIEW
Many kinds of condition of machine are displayed on the letter information display department. The
information display department is divided into two menus. One is main menu for user and the other is
special menu for specialist. These menus can be moved from normal display mode by the combination of
select buttons.

02/05 [MO] 11:30A

ENG SPEED
5
2059 RPM

POWER DISPLAY
AUTO

ESC

1 2 3 4

ARS0800L
Figure 12

Selection Buttons Graphic Display Area

1. Up Arrow Button 5. Letter Information Display Department
2. Down Arrow Button
3. Enter Button
4. Escape Button

S0802220K Electrical System

Page 24
MAIN MENUS FOR THE GRAPHIC DISPLAY AREA
1. Main menu: Language setting, Time setting, Filter/Oil information
2. Special menu: Information of machine status, failure information, Information of machine operation.

MENU SELECTION BUTTONS

1. Up Arrow Button ( , 1 on Figure 12): Move the cursor to up, left and previous screen.
2. Down Arrow Button ( , 2 on Figure 12): Move the cursor to down, right and next screen.
3. Enter Button ( , 3 on Figure 12): Move the menu to selected mode. When setting the menu, this
button is used to function as the select button.
4. Escape Button (ESC, 4 on Figure 12): Move a screen to previous menu or main menu.

Electrical System S0802220K

Page 25
MAIN MENU
When the "ESC" button is pressed for more than
3 seconds, the main menu screen is displayed.
Main menu offers three sub-menus (language
setting, time setting, or filter/oil information) to
MAIN MENU
the operator.
Language 1
Refer to the "Operation and Maintenance
Manual" for details. Set Clock
Filter / Oil Info
ARO0330L
Figure 13
LANGUAGE SETTING
This mode is used for setting desired language.
LANGUAGE
Francais
Deutsch 4
Set : English
ARO0341L
Figure 14
TIME SETTING
This mode is used for setting time on the digital
clock.
SET CLOCK
02 : 30 P
2001 02 / 15
:+ : :MOVE
ARO0380L
Figure 15

S0802220K Electrical System

Page 26
FILTER/OIL INFORMATION
This mode displays total operating hours of
filters and oils.
After changing the filter and oil, reset the
operating hour and then the operating hours
until the next service interval can be easily
checked.
1.Fuel Filter
Hrs: 0232 Reset:
ARO0400L
Figure 16

Menu Display Order and Icon Explanation

1 2 3 4 5 6 7 8

1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Return Filter

8. Coolant Water 7. Hydraulic Oil 6. Engine Oil 5. Pilot Filter

ARO0410L

Figure 17

Electrical System S0802220K

Page 27
SPECIAL MENU
In this menu, many types of operating conditions and functions can be accessed and disp[layed, including
the e-EPOS controller. This menu is mainly used for machine testing and failure diagnostics.
The special menu offers three sub-menus;
1. Machine status.
2. Failure information.
3. Information on machine operation

ENTERING/ACCESSING AND EXITING/ESCAPING MENUS

Entering/Accessing Menus

1 2 3 4

ARO0250L
Figure 18

When normal mode screen is displayed, if the enter button ( , 3) and escape button (ESC, 4) are
pressed simultaneously for more than 3 seconds, normal mode screen (Figure 19) will be changed to
special menu screen (Figure 20).
Normal Mode Screen
NOTE: Normal mode screen can
display many kinds of display 02/05 [MO] 11:30A
mode by selecting, for example,
engine revolution (RPM),
battery voltage (V), front pump ENG SPEED
pressure (BAR), rear pump

1950 RPM
pressure (BAR) and so on by
selecting.

ARO0160L
Figure 19

S0802220K Electrical System

Page 28
Special Menu Screen
NOTE: Displayed language on the
special menu screen consists
of Korean and English.
SPECIAL MENU
If any language except for achine Info 1
Korean is selected during
language selection mode of
main menu, only English will be
Failure Info
displayed on special menu
screen.
Operating Hrs
ARS0850L
Figure 20

Exiting/Escaping Menus
1. If escape button (ESC, 4 on Figure 18) is pressed for more than 1 second, the special menu screen
will be returned to the normal mode screen.
2. If this special menu is "ON" without any activity, for more than 20 seconds, it will turn to the normal
mode screen.
3. After the turning starter switch to the "OFF" position, turn it back to the "ON" position, and the normal
mode screen displayed once again.

SPECIAL MENU SELECTIONS

Sub-menu Selection Method
Various sub-menus can be selected by pressing
"Up ( , 1 on Figure 18)" and "Down ( , 2 on SPECIAL MENU
Figure 18)" button.
Move the cursor to desired menu and a selected achine Info 1
menu will be inverse displayed.
When the selected menu is inverse displayed, Failure Info
press the "Enter ( , 3 on Figure 18)" button for
menu selection.
Operating Hrs
ARS0850L
Figure 21
Information of Machine Status
1. Entering Sub-menus: When cursor is
located on "Machine Info" of special menu
screen, press "Enter ( , 3 on Figure 18)"
MACHINE INFO
button and the "Machine Info Sub-menu"
will be displayed.
EPPR Current 1
2. Exiting Sub-menus: If escape button (ESC,
4 on Figure 18) is pressed for more than 1
Dial Voltage
second, display will be turned to previous
sub-menu.
TPS Voltage
ARS0820L
Figure 22

Electrical System S0802220K

Page 29
Contents of Machine Status

Display Item of Machine State Information Display Remarks

1. EPPR Current "mA" EPPR valve current
2. Dial Voltage "mV" Dial voltage
3. TPS Voltage "mV" TPS voltage
1. Alternator 8. Pressure (Px) Input status delivered from
2. Power Max 9. E/G Oil Press. switches and sensors to e-
3. Work/Travel EPOS controller is displayed as
10. Air Cleaner on or off.
Sel.
4. Input State On or Off
4. Hi Speed Sel. 11. Return Filter * Number 3 (Work/Travel sel.) is
5. Auto Travel 12. Pilot Filter used only wheel type machine.
6. Work Lamp 13. OWD Select * Number 13 (OWD Select) is
7. Pressure (Py) optional part.
1. Relief Press Up 4. Spare Out 1 Output status delivered from e-
5. Output
2. High Speed 5. Spare Out 2 On or Off EPOS controller to solenoid
State
3. Swing Priority valves is displayed as on or off.
6. Hydraulic Oil Temp ˚C (˚F) Hydraulic oil temperature.
On machine with overload
7. Boom Pressure (Opt) BAR warning device, it displays
cylinder pressure.
At this machine, it is always
8. T/M Pressure (Wheel Type) BAR
displayed as "O."

Sub-menu Selections

EPPPR Current Input State

Dial Voltage Output State
TPS Voltage Hyd. Oil Temp.

Boom Press
T/M Press

ARS0860L
Figure 23

S0802220K Electrical System

Page 30
Display Example: Machine Status Information
1. EPPR Valve Current

EPPR CURRENT

598 mA
ARS0870L
Figure 24
2. Dial Voltage

DIAL VOLTAGE

2089 mV
ARS0880L
Figure 25
3. TPS Voltage
Output voltage of potentiometer built into
engine control motor.
TPS VOLTAGE

2095 mV
ARS0890L
Figure 26

Electrical System S0802220K

Page 31
4. Input Status
"YES" or "NO" for alternator’s generation
(Generation: "ON"/ Non-generation:
"OFF"), selection status of select switch
M AC H I N E I N F O
(Selection: "ON"/ Non-selection: "OFF")
and the other statuses of on/off type Input State 4
sensors.
Output State
Hyd. Oil Temp
ARS1780L
Figure 27

1. Alternator : OFF 4. Hi Speed Sel. : OFF

2. Power Max. : ON 5. Auto Travel : ON
3. Work/Travel Sel. : OFF 6. Work Lamp : OFF

13. OWD Select : OFF 7. Pressure (Py) : OFF

8. Pressure (Px) : ON
9. E/G Oil Pres. : OFF

10. Air Cleaner : OFF

11. Return Filter : ON
12. Pilot Filter : OFF
ARS0900L
Figure 28

S0802220K Electrical System

Page 32
5. Output Status: Output status of solenoid valves and spare valves are displayed. (Output: "ON"/ Non-
output: "OFF")

1. Relief Pess Up : OFF 4. Spare Out 1 : OFF

2. High Speed : ON 5. Spare Out 2 : ON
3. Swing Priority : OFF
ARS0920L
Figure 29

6. Hydraulic Oil Temperature

HYD. OIL TEMP

LOW HIGH

ARS0870L
Figure 30
• Display Specification

Sensor Input
BAR Graph Display Input Terminal Remarks
Specification
Below 30˚C
1/6 BAR Lit Over 1,510 Ω
(Below 86˚F)
31 ~ 50˚C
1/6 ~ 2/6 BAR Lit 745 ~ 1,510 Ω
(87 - 122˚F)
51 ~ 75˚C
1/6 ~ 3/6 BAR Lit CN 3 - 4 332 ~ 745 Ω
(123 - 167˚F)
CN 3 - 5 76 ~ 85˚C
1/6 ~ 4/6 BAR Lit 244 ~ 332 Ω
(168 - 185˚F)
86 ~ 95˚C
1/6 ~ 5/6 BAR Lit 181 ~ 244 Ω
(186 - 203˚F)
Over 96˚C
1/6 ~ 6/6 BAR Lit Under 181 Ω
(Over 204˚F)

Electrical System S0802220K

Page 33
7. Boom Pressure (Optional)
On machine with OWD (Overload Warning
Device), detected pressure from boom
cylinder is displayed with numeric values
BOOM PRESSURE
(Unit: Bar).
The relative equation between the, output
voltage of pressure sensor, and the
pressure of boom cylinder, is as follows. 205 BAR
• V = 0.00816P + 1
V: Output voltage of pressure sensor (V). ARS0940L
P: Displayed pressure (Bar).
Figure 31
NOTE: At standard machine, "0 BAR"
is always displayed.

Failure Information
1. Entering Sub-menus: When a cursor is
located in "Failure Info" of special menu
screen press enter button ( , 3 on
Figure 18) and "Failure Info" screen is SPECIAL MENU
displayed.
2. Exiting Sub-menus: If escape button (ESC,
Machine Info 1
4 on Figure 18) is pressed for more than 1
second, this information screen will be ailure Info 2
returned to previous screen.
Operating Info 3
ARS0930L
Figure 32
* Real-time Failure:
Current status of failure is
displayed.
* Failure Log:
FA I L U R E I N F O
Memorized record of past
failure is displayed. Realtime Fail
* Delete Fail Log:
This mode is used to delete all
Failure Log
of the memorized record of past
failure.
Delete Fail Log
ARS0950L
Figure 33

S0802220K Electrical System

Page 34
 A. Current failure information
Current status of failure is displayed
(Failure code, failure contents).
REALTIME FAIL
When a number of failures are
produced, failure information can be
checked by using "PRV" ( , 1 on
C OD E :1 2
Figure 18) or "NXT" ( , 2 on Figure Press up s/v open
18) button.
* CODE: 12: Unique code of failure PRV: NXT: 01/02
information.
ARS0960L
* 01/02: A serial number of current Figure 34
failure/ total quantity of failure.
This example shows one of two
failures.
B. Past failure information
Memorized record of past failure is
displayed (Failure code, failure
contents).
FAILURE LOG
When a number of failures are
produced, failure information can be
CODE:12 N:001 0075 Hr
checked by using "PRV" ( , 1 on Press up s/v open
Figure 18) or "NXT" ( , 2 on Figure
18) button. PRV: NXT: 01/01
NOTE: " N: xxx " : "xxx" means that the
ARS0980L
totally counted number of the
same failure. Figure 35

" xxxx Hr " : It will display the

operation hour until the failure is
generated. (Above example
screen shows that breaking of a
wire of pressure solenoid valve
is generated at 75Hr.)

Electrical System S0802220K

Page 35
 C. Failure record deletion
This mode is used to delete the
memorized record of past failure. If
this mode is selected, all records will
FA I L U R E L O G
be deleted.
When "YES" ( , 3 on Figure 18)
All Fail Log
button is pressed, the memorized will be DELETE.
record will be deleted.
At this time, deletion signal will be YES: NO: ESC
displayed and the screen will move to
previous menu after deletion. ARS0970L
This screen will be displayed during 3 Figure 36
seconds.
When "NO" (ESC, 4 on Figure 18)
button is pressed, the screen will
recover to previous menu without
deletion.
Code Description of Failure Information

Code State
0x Short Circuit
1x Open circuit
2x Output error
3x Output error
8x Communication

S0802220K Electrical System

Page 36
Display Contents of Failure Information Code

Reset
Code Contents Cause Operation
Procedure
Communication error
Automatic reset
between e-EPOS
82 Communication Err!!
controller and instrument
* Note when problem is
corrected
panel
01 EPPR v/v short Short Circuit After correcting
problem, turn
02 Press Up s/v short Short Circuit Cut off output
start switch
current (0 mA)
from "OFF" to
03 Swing pri. s/v short Short Circuit
"ON."

Electrical System S0802220K

Page 37
 Reset
Code Contents Cause Operation
Procedure
11 EPPR v/v open Open Circuit -
12 Press Up s/v open Open Circuit -
13 Swing pri. s/v open Open Circuit -
Output voltage Over
21 Dial Voltage Err (H)
4.6±0.2 V
-

Output voltage Over

22 Dial Voltage Err (L)
0.4±0.2 V
-

Output voltage Over Cut off EPPR v/

23 TPS Voltage Err (H)
4.6±0.2 V v current (0 mA)
Output voltage Over Cut off EPPR v/
24 TPS Voltage Err (L)
0.4±0.2 V v current (0 mA)
Output voltage Over
25 Fpump Sensor Err (H)
4.6±0.2 V
-

Output voltage Over

26 Fpump Sensor Err (L)
0.4±0.2 V
-

Output voltage Over

27 Rpump Sensor Err (H)
4.6±0.2 V
-

Output voltage Over Automatic reset

28 Rpump Sensor Err (L)
0.4±0.2 V
- when problem is
corrected
Under 1067±20Hz (On
condition that alternator
29 Speed Sensor Err
output exceeds over
-
12±1V)
Sensor’s resistance -
31 Fuel shot to GND between two terminals is
under 150±100Ω
Sensor’s resistance -
32 Fuel Sensor open between two terminals is
under 6.5±0.5 kΩ
Output voltage of -
33 Alternator too high alternator exceeds 33 V
for more than 3 seconds
When the output voltage -
is maintained under
18±1 for more than 3
34 Alternator too low
seconds (On condition
that speed sensor output
exceeds over 1,067Hz)

NOTE:
1. If a communication error is generated during operation, the power mode, work mode and auto
idle mode will be maintained at the last mode setting before the failure took place until the unit is
shutdown.
2. When start switch is turned to the "ON" position during a period of a communication error, the
e-EPOS controller will operate in the following modes.
• Power mode: Standard mode

S0802220K Electrical System

Page 38
 • Work mode: Digging mode
• Auto idle: "ON"(Selection state)
3. The above mentioned two statuses are applicable to normal condition of an e-EPOS controller.
4. Under the abnormal condition of an e-EPOS controller, communication cable or instrument
panel failure, "Failure code: 82" can be generated.

Information of Machine Operation

Accumulated operation hour of each mode and status is displayed.
1. Operating Hour Information
A. Entering Sub-menus: When a cursor
is located in "Operating Info" of
special menu screen (Figure 37)
SPECIAL MENU
press enter button( , 3 on Figure
18) and "Operating Info" screen will
Machine Info 1
be displayed (Figure 38).
Failure Info 2
Operating Info 3
ARS0990L
Figure 37
B. Information screen of machine
operation (Figure 38).

OPERATING INFO
Operating Hrs
Reset Hrs

ARS1000L
Figure 38
C. Operation Hour Screen
D. Exiting Sub-menus: If escape button
(ESC, 4 on Figure 18) is pressed for
more than 1 second, this information
OPERATING HRS
screen will be returned to previous
screen. 1. Power : 0345 Hr
2. Trenching : 0190 Hr
3. Auto Idle : 0227 Hr
ARS1330L
Figure 39

Electrical System S0802220K

Page 39
 Information contents of operation hour

Item Information Contents Detection Method

Operation hours used power mode Power mode switch (Instrument panel) -
Power Mode
are displayed. "ON" status & Alternator signal (CN2-1)
Trenching mode switch (Instrument
Trenching Operation hours used trenching
panel) - "ON" status & Alternator signal
Mode mode are displayed.
(CN2-1)
Operation hours used auto idle Auto idle switch (Instrument panel) - "ON"
Auto Idle
status are displayed. status & Alternator signal (CN2-1)
Low speed: High speed s/v "OFF" status
& travel pressure switch "Py" (control
Travel Speed:
Operation hours used low speed valve) - "ON" status
- Low speed and high speed are displayed High speed: High speed s/v & travel
- High speed
pressure switch "Py" (control valve) -
"ON" status
Temperature of hydraulic oil is
classified 6 steps. And operation
hours of each step are displayed The resistance delivered from
Hydraulic Oil
Under 30˚C (87˚F) temperature sensor of hydraulic oil is
Temperature
31 ~ 50˚C (88 - 123˚F) classified 6 steps. And operation hours of
Distribution
51 ~ 75˚C (124 - 168˚F) each step are displayed. (Alternator
(˚C (˚F))
76 ~ 85˚C (169 - 186˚F) output)
86 ~ 95˚C (187 - 203˚F)
Over 96˚C (204˚F)
Temperature of coolant is classified
6 steps. And operation hours of
each step are displayed
Coolant The resistance delivered from coolant
Temperature Under 40˚C (105˚F) sensor is classified 6 steps. And
Distribution 41 ~ 60˚C (106 - 141˚F) operation hours of each step are
(˚C (˚F)) 61 ~ 85˚C (142 - 186˚F) displayed. (Alternator output)
86 ~ 95˚C (187 - 204˚F)
96 ~ 105˚C (205 - 222˚F)
Over 106˚C (223˚F)

S0802220K Electrical System

Page 40
Menu Selection of Operation Hour Information

1. Power : 0345 Hr 4. Travel Speed

2. Trenching : 0190 Hr High : 0012 Hr
3. Auto Idle : 0227 Hr Low : 0059 Hr

6. Coolant Temp (°C) 5. Hyd. Oil Temp (°C)

40 ↓ : 0030 Hr 30 ↓ : 0030 Hr
41 ~ 60 : 0045 Hr 31 ~ 50 : 0045 Hr
ARS1010L
Figure 40

2. Operation hour reset

A. Entering Sub-menus: When cursor is
located in "Reset Hrs" of information
screen of operation hour press enter
OPERATING INFO
button ( , 3 on Figure 18) and
"Reset Hrs" screen will be displayed.
Operating Hrs
Reset Hrs

ARS1001L
Figure 41
B. Reset screen of operation hour
C. Exiting Sub-menus: If escape button
(ESC, 4 on Figure 18) is pressed for
more than 1 second, this information
RESET HRS
screen will be returned to previous
screen. All Operating Hours
NOTE: When "YES" ( , 3 on Figure will be DELETE.
18) button is pressed, operation
hours will reset. YES: NO: ESC
At this time, resetting signal will
be displayed and the screen will ARS1020L
move to previous menu after Figure 42
resetting.
NOTE: When "NO" (ESC, 4) button is
pressed, the screen will recover
to previous menu without
resetting.

Electrical System S0802220K

Page 41
ELECTRONIC HYDRAULIC CONTROL SYSTEM
(E-EPOS)
CONTROL SYSTEM SCHEMATIC

7
11
12
3
(Wheel)

P
13
4 5
N

9
19
10
(Pump control signal)
(Potentiometer signal)

(Engine speed sensor signal) (Switch signal)

(Drive signal)

(Throttle signal)

(Engine throttle control signal)

15 17
Hi

(Throttle command)
Lo 1
(Coolant water temp. signal)
(Mode select signal)
(Auto idle signal)
(Machine information)
Sensors

18
30L
Figure 43

S0802220K Electrical System

Page 42
 Reference Reference
Description Description
Number Number
1 Instrument Panel Solenoid Valve (Pressure
11
2 Engine Control Motor Up)
3 Engine Solenoid Valve (Swing
12
Priority)
4 Main Hydraulic Pump
Solenoid Valve (High
5 Control Pump 13
Speed)
6 Control Valve
14 Travel Motor
7 Pressure Switch
15 Engine Throttle Control
8 Pump Pressure Sensor
16 Engine Control Dial
9 Engine Speed Sensor
17 e-EPOS Controller
Electro-magnetic
18 Auto Travel Select Switch
Proportional Pressure
10 Boost Switch (Right Work
Reducing Valve (E.P.P.R. 19
Valve) Lever)

Electrical System S0802220K

Page 43
POWER MODE CONTROL

6 6
3
(Wheel type)

P
4 5
N

10
1 (Pump control signal)
g
(Potentiometer signal)

(Drive signal)

(Engine speed sensor signal)

17
(Throttle Position signal)

(Engine throttle control signal)

15
Hi
20
(Throttle signal) Low 16
(Power mode switch signal)

ARS1040L

Figure 44

Reference Reference
Description Description
Number Number
Instrument Panel (Power 9 Engine Speed Sensor
1
Mode Selection Switch) 10 E.P.P.R. Valve
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial
4 Main Hydraulic Pump 17 e-EPOS Controller
5 Control Pump Work / Travel Selection
20
6 Control Valve Switch (Wheel Type)

The power mode switch permits the selection of the appropriate engine power depending on the working
condition. One of the two, Power Mode or Standard Mode, setting can be selected. When the engine start
switch is turned "ON," the last setting before "OFF" will be maintained. The desired mode can be selected
by pressing the select button on the instrument panel. When the power mode is selected, the indicator
lamp will turn "ON" to display the selected mode.

S0802220K Electrical System

Page 44
The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by
the operator. The pump output in each mode is determined by the mode selection and is listed in the
following table

Mode Standard Mode Power Mode

Output (%) Approximately 85% 100%

OPERATION

1. Power Mode
This mode should be selected for high
speed work. In this mode the engine
output is most efficiently utilized due to the
discharged oil volume being controlled
based on the equivalent horsepower curve
at various loaded pressures. The e-EPOS
controller compares the target engine
speed with the actual engine speed and
controls the signal to the E.P.P.R. (Electric
Proportional Pressure Reducing) valve
which in turn varies the pump output
quantity. ARO0260L
If the load increases, the engine speed will Figure 45
fall below the rated speed. When this
occurs, the controller senses this decrease
and immediately reduces the pump
discharge volume to maintain the engine
speed at the rated level.
On the other hand, if the load is decreased the controller increases the discharge volume of the pump
to maintain the engine speed at the rated level.
By repeating these control operations, the engine speed is maintained at the rated speed so that
maximum power can be generated.
In Power Mode, the controller receives engine speed signals from the engine speed sensor and the
throttle position sensor (sensor is built into engine control motor) and converts it to an operating
signal current and is then transferred to the pump’s E.P.P.R valve. At this time the E.P.P.R. valve
converts the electric signal to the corresponding control pressure and sends it to the two pumps,
adjusting the pump discharge volume to the desired level.

Electrical System S0802220K

Page 45
 A C

B D
HDA6020L
Figure 46

Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) D Pump Discharge Pressure
B Engine Speed (rpm) (kg/cm2)
C Pump Discharge Volume
(lpm)

2. Standard Mode
Standard Mode is used for general work. When this mode is selected it will reduce noise and fuel
consumption in comparison with Power Mode. The current to the E.P.P.R. valve is shut off and pump
discharge volume is controlled by pump regulator.

A C

B D
ARS1050L

Figure 47

S0802220K Electrical System

Page 46
 Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) D Pump Discharge Pressure
B Engine Speed (rpm) (kg/cm2)
C Pump Discharge Volume
(lpm)

Electrical System S0802220K

Page 47
POWER MODE CONTROL - CIRCUIT DIAGRAM

10A 10A 3 20A 2

5 4
9
10
CN1-1
CN1-2 1
19 CN1-8
20 CN4-16 CN1-9

6 CN4-17

RxD 1 CN3-9 TxD

2
RxD TxD RS-422
4 CN3-11
TxD RxD
5 CN3-12
TxD RxD
3 CN3-8
CN7

CN1-10
9
CN1-19
10
15 S-MODE CN1-5
4 4
16 A/I MODE CN1-7

M CN4-10
5 5 7 CN4-11

3 8 1 1
(+ (+) CW LOW
2
2
1
7
6
(-) (-)
3
12
2
3
HIGH
9
8 CN2

CN4-12
CN4-13
CN4
CN1 CN2 CN3

TERMINAL NO
8 7 6 5 4 2 1 5 4 3
10 9 8 7 6 5 4 3 2 1
18 17 14 13 10 9 12 11 10 9 8 6

(CN4) (CN3)
(CN7)

6 4 3 2 1 10 9 8 7 6 5 4 1

16 15 11 10 9 21 19 18 17 16 15 14 11

(CN2) (CN1)

ARS1060L

Figure 48

S0802220K Electrical System

Page 48
 Reference Reference
Description Description
Number Number
1 Battery 6 Engine Speed Sensor
2 Battery Relay 7 Engine Throttle Controller
3 Fuse 8 Engine Control Motor
4 e-EPOS Controller 9 Engine Control Dial
5 Instrument Panel

Electrical System S0802220K

Page 49
TRENCHING MODE CONTROL

6 Main Relief v/v 6

12
3
(Wheel)

1 4
(Potentiometer signal)

(Drive signal)

17
15 (Engine throttle control signal)

Hi

(Throttle signal) Lo
16
(Trenching mode switch signal)

ARS1070L

Figure 49

Reference Reference
Description Description
Number Number
Instrument Panel (Trenching 6 Control Valve
1
Mode Select Switch) 12 Solenoid Valve
2 Engine Control Motor 15 Engine Throttle Control
3 Engine 16 Engine Control Dial
4 Main Hydraulic Pump 17 e-EPOS Controller
5 Control Pump

Depending on the working condition, one of two work modes, "DIGGING" or "TRENCHING" can be
selected from the instrument panel.
When the engine start switch is turned "ON," the last setting before "OFF" will be maintained.
Depending on the trenching mode selected, the control valve solenoid adjusts the assignment of hydraulic
oil flow to each device on the equipment.

S0802220K Electrical System

Page 50
OPERATION

1. Digging Mode
This mode is used for general digging work, loading work and ground leveling work requiring quick
stops. The current to the solenoid valve for swing priority is shut off.

2. Trenching Mode
This mode is used for heavy duty ditch
digging work or for loading work requiring
big swing angles. The voltage is assigned
to the swing priority control valve activating
the swing control valve restricting the flow
of oil to the boom and the arm.

ARO0270L
Figure 50

Electrical System S0802220K

Page 51
TRENCHING MODE CONTROL - CIRCUIT DIAGRAM

10A 3 20A
2
5
9
10
4 1
CN1-1
19
CN1-2
20

CN1-8
CN1-9

1
2
CN3-9
CN3-10
TxD CN1-14 6
RxD TxD RS-422
CN3-11 RxD
5 CN3-12
TxD RxD
3 CN3-8
CN7

CN4

CN1 CN2 CN3

TERMINAL NO
6 5 3 2 1 5 4 2 1
10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 12 11 10 12 11 10 7 6 14 13

(CN4) (CN3)
(CN7)

8 7 6 5 4 3 10 9 7 6 5 4 3 2 1

17 16 14 13 12 11 9 21 18 17 16 15 13 12 11

(CN2) (CN1)

ARS1080L

Figure 51

Reference Reference
Description Description
Number Number
1 Battery 4 e-EPOS Controller
2 Battery Relay 5 Instrument Panel
3 Fuse Solenoid Valve (Swing
6
Priority)

S0802220K Electrical System

Page 52
ENGINE CONTROL SYSTEM

(Feedback Signal)

15 3
16
(Command Signal) (Drive Signal)

10A
BATT. RELAY
9
10 AUTO IDLE COMMAND
5 4

17 OVER HEAT e-EPOS CONTROLLER

M
5 5 BATTERY
RETRACT 3 8 (+) 5V 1 1
5V (+) CW LOW
2
1 6
(-) (-)
3
12
3 16
2
15
ARS1090L

Figure 52

Reference Reference
Description Description
Number Number
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial

When the engine control dial is moved the output voltage changes according to the dial position. This
signal is input to the engine throttle controller. The engine throttle controller then compares the input
voltage from the engine speed dial with the feedback signal from the throttle position sensor built into the
engine control motor and drives the motor to the position set by the control dial. When the command signal
and the potentiometer feed back signals are the same the engine controller shuts off the current to the
control motor. The engine control motor cable is a solid type and is connected to the engine fuel injection
control lever. The engine speed is controlled by the movement of the fuel injection lever which is directly
linked with the rotation of the control motor.

Electrical System S0802220K

Page 53
ENGINE CONTROL MOTOR

1
2 3

CIRCUIT DIAGRAM
P4
(GREEN)

P1(Gr) P2(P) P3(L) M

P5
(YELLOW)

(RETRACT) (GRAY) P1
ACCEL

(PINK) P2
P4(G) P5(Y) + Vs
-
(5.0V)
(BLUE) P3 Vp
DECEL
(EXTEND)
ARS1100L

Figure 53

Reference
Description
Number
1 Motor Assembly
2 Cable
3 Spring Assembly

The engine control motor uses a D.C. motor with a built in potentiometer to sense the position of the control
cable. If an abnormal load (worn or kinked control cable) is sensed in the control motor, the engine
controller cuts off the electric current flowing to the engine control motor to protect the system. In such a
case, the engine control motor will not operate even though the engine control dial is moved.
The starter switch should be turned off and the cause of abnormal load should be repaired and the starter
switch can be turned on again. The engine control dial can once again be used to control the engine
speed.

IMPORTANT
When the engine control motor has been replaced or repaired refer to Adjusting the
Engine Control Device for correct adjustment of the engine control system. The engine
will not perform to its maximum efficiency if it is not adjusted properly.

S0802220K Electrical System

Page 54
ENGINE CONTROL DIAL

1st STEP 7th STEP 13th STEP

CCW ( 10 ) ( 10 ) CW
MECHANICAL MECHANICAL
STOP STOP

(V)

5
4.0V
4

3 2.5V

2
2 1.0V
1

0 SETUP
1ST 2nd 7th 12th 13th
CCW CW
STOP STOP

VIEW ( POTENTIOMETER BOTTOM)

1 2 3

HDA6033L
Figure 54

Reference
Description
Number
1 Knob
2 Potentiometer (Variable
Resistor)

Electrical System S0802220K

Page 55
The engine control dial has a built in potentiometer. When the control knob is moved the output voltage
(through terminals 2 and 3) will vary from the 5 V supplied from the throttle controller as shown in the
graph.

S0802220K Electrical System

Page 56
ENGINE CONTROL CIRCUIT DIAGRAM

ARS1110L
Figure 55

Reference Reference
Description Description
Number Number
1 Battery 7 Engine Throttle Controller
2 Battery Relay 8 Engine Control Motor
3 Fuse 9 Engine Control Dial
4 e-EPOS Controller 10 Pressure Switch (Py Port)
5 Instrument Panel 11 Pressure Switch (Px Port)
6 Engine Speed Sensor

Electrical System S0802220K

Page 57
AUTOMATIC DECELERATION CONTROL (AUTO IDLE
CONTROL)

(Feedback Signal)

16 15 2 3
M

(Command Signal) (Drive Signal)

7 1
17

7 Auto deceleration Switch Signal

ARS1120L

Figure 56

Reference Reference
Description Description
Number Number
1 Instrument Panel 15 Engine Throttle Controller
2 Engine Control Motor 16 Engine Control Dial
3 Engine 17 e-EPOS Controller
7 Pressure Switch

If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed
is automatically lowered. Once the controls are operated and work is being started the machine will be
restored to the previous settings. As a result, noise and fuel consumption will be reduced. This function can
be selected or cancelled through the Auto Idle Select Switch on the instrument panel.
The initial setting at start-up is with this switch in the select position. Approximately 4 seconds after this
function is selected, if all work levers are in the neutral position, the e-EPOS controller sends an automatic
reduction signal to the throttle controller. When the engine throttle controller receives this signal, it is
compared with the signal set by the engine control dial. The lower of the two signals is selected and the
engine control motor is adjusted to this engine speed.
The neutral status of the machine is detected by the two pressure switches in the control valve. When the
work levers are in the neutral position, the switch is in the off position.

S0802220K Electrical System

Page 58
ENGINE OVERHEAT PROTECTION SYSTEM

1
21
(Pump control signal)
10
(Potentiometer signal)

(Drive signal)

15 17

Engine overheat signal

Engine overheat signal
ARS1130L

Figure 57

Reference Reference
Description Description
Number Number
1 Instrument Panel 10 E.P.P.R. Valve
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 17 e-EPOS Controller
4 Main Pump 21 Warning Buzzer
5 Control Pump

When the engine coolant temperature increases to over 107°C (225˚F), the sensor mounted in the coolant
line will send a signal to the instrument panel. A overheat signal is also sent to the e-EPOS controller and
the overheat warning buzzer will sound. The e-EPOS controller will send a signal to the engine throttle
controller and the engine speed is adjusted to standard mode. The engine throttle controller will signal the
engine control motor to decrease the engine speed.
When the coolant is overheated, the warning buzzer will sound, standard mode is selected and low engine
speed will be selected.
When the coolant temperature falls below 95°C (203˚F), normal operation will resume.

Electrical System S0802220K

Page 59
POWER BOOST MODE
OPERATION

Main Relief v/v

4
5
17
19

(Button Signal)

ARS1140L

Figure 58

Reference Reference
Description Description
Number Number
3 Engine 11 Solenoid Valve
4 Main Pump 17 e-EPOS Controller
5 Control Pump Power Boost Switch (Top of
19
6 Control Valve Right Work Lever)

The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation
ability. When the switch button on top of the right work lever is pressed during work, the e-EPOS controller
will activate the power boost solenoid valve and increase the relief valve pressure from 330 - 350 kg/cm2
(4,700 - 5,000 psi). The excavation ability is increased by approximately 6%.
NOTE: Do not use this switch for more than 10 seconds.

S0802220K Electrical System

Page 60
POWER BOOST CONTROL - CIRCUIT DIAGRAM

10A 3 20A
2
5
9
10

1
19
20
4
CN1-1
CN1-2

CN1-8
CN1-9

6
RxD 1 CN3-9 TxD CN1-13
2 CN3-10
RxD TxD RS-422
4 CN3-11
TxD RxD
5 CN3-12
TxD RxD
3 CN3-8
CN7

7
CN2-3

CN4

CN1

TERMINAL NO
8 1 3
10 9 8 7 6 5 1
18 17 14 13 11 9 11 10 9 8 7 6 20 17 16 11

(CN4) (CN3)
(CN7)

7 6 4 3 2 1 10 9 8 7 6 4 3 2 1

16 15 12 10 9 21 20 17 14 13 12 11

(CN2) (CN1)
ARS1150L

Figure 59

Reference Reference
Description Description
Number Number
1 Battery 5 Instrument Panel
2 Battery Relay 6 Solenoid Valve (Pressure Up)
3 Fuse Power Boost Switch (Top of
7
4 e-EPOS Controller Right Work Lever)

Electrical System S0802220K

Page 61
AUTOMATIC TRAVEL SPEED CONTROL

6 6

3
8 8
14
13
5

17
16
Hi

Low

ARS1160L

Figure 60

Reference Reference
Description Description
Number Number
3 Engine 13 Solenoid Valve (High speed)
4 Main Pump 14 Travel Motor
6 Control Valve 16 Engine Control Dial
7 Pressure Switch (Py) 17 e-EPOS Controller
8 Pump Pressure Sensor Selection Switch For
20
Automatic Travel

If the automatic travel speed control switch is set to the "OFF" position, the travel motor will run in the I-
speed (low speed) range. If the selection switch is set to the "I" position, the travel motor will run in the II-
speed (high speed) range. If the selection switch is set to the "II" position, the e-EPOS controller will
monitor the main pump discharge pressure and automatically select the "ON" - "OFF" status of the II -
speed travel solenoid valve based on the travel load. The travel speed is changed between the I-speed and
the II-speed mode.
The travel load is monitored by the two pressure sensors in the discharge lines of the front (upper) and rear
(lower) pumps. When the travel load is high (pressure over 300 kg/cm2 (4,300 psi) the solenoid valve is
turned "OFF" and I-speed (low) is selected. In the case when the travel load is low (pressure under 160 kg/
cm2 (2,280 psi), the solenoid valve will be turned "ON" and the II-speed will be selected. But, if the engine
speed control switch dial is set below approximately 1400 rpm, the travel speed will be set to I-speed
mode.

S0802220K Electrical System

Page 62
AUTOMATIC TRAVEL SPEED CONTROL - CIRCUIT DIAGRAM

10A 10A 3 20A 2

1
+

5 SIG 4
- CN1-1
CN4-1 CN1-2
CN4-2
+
CN4-3
6 SIG
-
CN4-4
CN1-8
CN1-9

7 6
9
10 CN1-12
4 15
16
17
14
5 CN4-10
CN4-11
8 1 1
(+) (+) LOW
2
7
6
(-) (-)
12
2
3
HIGH
9 8
0
CN2 CN2-5 (MANUAL) 6 I 2
CN2-6 (AUTO) 3 II
10 9

CN4

CN1 CN2 CN3

TERMINAL NO
8 7 6 5 4 2 1 5 4 3 2 1

18 17 16 14 13 10 9 12 11 10 9 8 7 6

(CN4) (CN3)

6 5 3 10 8 7 6 5 4 3 2 1

16 15 11 10 21 18 17 15 14 13 12 11

(CN2) (CN1) ARS1170L

Figure 61

Reference Reference
Description Description
Number Number
1 Battery 6 Pressure Sensor (Rear Pump)
2 Battery Relay 7 Engine Throttle Controller
3 Fuse 8 Automatic Travel Select Switch
4 e-EPOS Controller 9 Engine Control Dial
5 Pressure Sensor (Front Pump) 10 Solenoid Valve (High Speed)

Electrical System S0802220K

Page 63
ENGINE CONTROL DEVICE - ADJUSTMENT
Engine speed adjustment should be made by following the procedures listed below. (Under no load
conditions)
1. Adjusting The High Idle Speed
1. Turn the starter switch to the "ON" position. Select Power Mode from the instrument panel. Turn
the Engine Speed Control dial to the "MAX" position to reduce the (3) motor cable to the
shortest length.
2. Adjust the (3) motor cable linked with the (2) bracket so that the engine governor lever touches
the maximum position of the stopper.
2. Adjusting The Low Idle Speed
1. Turn the engine speed control dial to the "MIN" position so that the (3) motor cable is extended
to the maximum length. (The maximum stroke range for the lever and cable is 37.0 mm (1.46
in).)
2. Check that the engine governor is at the minimum stopper position and the cable slack is
acceptable.
3. A. If the lever is not in the minimum position and touching the stopper, move the (3) cable to
one hole lower on the lever. If the cable slack is excessive, move the (3) cable to one hole above
the original hole on the lever. Repeat above steps 1 and 2.
B. Shorten the (3) motor cable 1 - 1.25 mm (0.0394 - 0.0591 in) by turning the cable
adjustment nut for motor cable (3), 2/3 - 1 turn in the high idle position.
3. Adjusting The Automatic Deceleration System and Power Mode (First perform Adjustments 1
and 2 before performing this adjustment.)
1. Set the following switches to the "ON" position as shown in the following table. Adjust the engine
speed by slowly turning the variable resister screw. (VR1)

Variable
Mode Dial Position and Mode Setting Engine Speed Setting
Resistor
Automatic VR1 S300LC-V - 1400 ±50 rpm
Deceleration
S300LL - 1400 ±50 rpm
(Auto Idle)
S340LC-V - 1200 ±50 rpm

ENGINE SPEED ARS1180L

S420LC-V - 1200 ±50 rpm
S470LC-V - 1200 ±50 rpm

S0802220K Electrical System

Page 64
 1 2

ARS1440L

Figure 63

Reference
Description
Number
1 VR1 (Automatic Deceleration Adjusting
Variable Resister)
2 Name Plate

Electrical System S0802220K

Page 65
 Figure 64

Reference Reference
Description Description
Number Number
1 Engine - Fuel Control Lever 3 Engine Speed Control Cable
Area 4 To Engine Control Motor
2 Control Motor Cable Bracket

S0802220K Electrical System

Page 66
SELF-DIAGNOSTIC FUNCTION
E-EPOS CONTROLLER
The system operation status and malfunction codes can be checked through the display on top of the e-
EPOS controller box in the drawer under the operator’s seat.

1 2
5

4 3
ARS1190L
Figure 65

Reference Reference
Description Description
Number Number
1 Upper Digit Power Monitor (Stays On
2 Lower Digit 4 While Power Is In Normal
Range,)
Engine Speed Monitor LED
3 (Flash Interval Increases With 5 Communication Monitor LED
Engine Speed.) 6 (Flash when normal condition)

1. Power Monitor
This LED is turned off when the input voltage to the e-EPOS controller is below 18.5 ±1 V or above
32.5 ±1 V. Stays on while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine speed. The flashing interval is proportional to the
engine speed.
3. Communication Monitor
These LED lamps flash when normal state of communication between main controller and instrument
panel.

Electrical System S0802220K

Page 67
4. Normal Operation Display Readout

Display Readout
Mode Selection Operation Status
Upper Digit Lower Digit

Normal Operation
Power Mode
Power Mode
HAOH340L

Power Mode

Normal Operation
Standard Mode
Standard Mode
HAOH350L

Normal Operation
Digging
Digging Mode
HAOH370L

Work Mode

Normal Operation
Trenching
Trenching Mode
HAOH380L

5. Malfunction Display and Reset Procedure

The malfunction codes displayed on the top of the e-EPOS controller and reset procedure are the
same with failure information codes a part of failure information.
Refer to the failure information part of letter information display for details.

S0802220K Electrical System

Page 68
ENGINE THROTTLE CONTROLLER
Under the rubber cap on the surface of the engine controller, there are three LEDs. Based on the
equipment status the following LEDs will turn "ON."

LED Status Voltage At

Throttle Controller
Status Control Motor
Input Signal Red Green Yellow Terminal
Dial Voltage < Motor While Control Motor Is Approximately
X ∆ O
Potentiometer Voltage Operating (Increasing rpm) +24 V
Dial Voltage > Motor While Control Motor Is Approximately -
Potentiometer Voltage Operating (Decreasing ∆ X O 24 V
rpm)
Dial Voltage = Motor
Control Motor Stopped O O O 0V
Potentiometer Voltage
Motor Overload (Cut Off
X X O 0V
Motor Current)
Abnormal Controller Power
X X X 0V
Voltage (Low Or No Input)

∆ O X
Brightly Lit ON OFF

NOTE: 1. Control Motor Voltage is Measured at throttle controller 4 (+) and 5 (-) terminals.
2. Yellow LED indicates power status (ON, OFF).
3. To protect the control motor from overloads, the control motor automatically cuts off
supply voltage to the motor when there is a heavy load on the motor and the
possibility of motor damage or burn out exists.
4. After the malfunction is corrected, turn the starter switch from "OFF" to the "ON"
position and normal operation will resume.

Electrical System S0802220K

Page 69
WIPER SYSTEM
WIPER CIRCUIT

3
10A 10A

7 2
6 4
B 1 0
+ S 4 2 6 I 2

M
- E
5
3
6
3
10
II
9
1

5
0
1
5 I
10 9
+

8 P
-

ARS1200L

Figure 66

Reference Reference
Description Description
Number Number
1 Battery 5 Washer Switch
2 Battery Relay 6 Wiper Timer
3 Fuse 7 Wiper Motor
4 Wiper Switch 8 Window Washer

WIPER OPERATION

Intermittent Operation (I - position)

When the wiper switch (4) is turned "I" position, the current flows from the fuse (3) → "B" terminal of wiper
motor (7) → "L" terminal of wiper motor (7) → "5" terminal of wiper timer (6) → "6" terminal of wiper timer
(6) → ground and the wiper motor operates intermittently by the timer built in wiper timer. (On:
approximately 1 second, Off: approximately 5 seconds)

Continuous Operation (II - Position)

When the wiper switch (4) is turned "I" position, the current flows from the fuse (3) → "B" terminal of wiper
motor (7) → "L" terminal of wiper motor (7) → No. 5 terminal of wiper timer (6) → No. 6 terminal of wiper
timer (6) → ground and the contact points No. 5 and No. 6 of wiper timer (6) are connected continuously,
the wiper motor operates continuously.

S0802220K Electrical System

Page 70
When the wiper switch (4) is turned "OFF," the current flows from the fuse (3) → "B" terminal of wiper
motor (7) → "L" terminal of wiper motor (7) → No. 5 terminal of wiper timer (6) → No. 4 terminal of wiper
timer (6) → "S" terminal of wiper motor (7) → "B" terminal of wiper motor (7) and the wiper motor is
stopped at the auto stop position.

WINDOW WASHER OPERATION

When the window washer switch is turned "ON," the current flows from the fuse (3) → No. 1 terminal of
washer switch (5) → No. 5 terminal of washer switch (5) → "+" terminal of window washer (8) → ground
and windshield washer fluid is sprayed.

Electrical System S0802220K

Page 71
LIGHTING SYSTEM
LIGHTING SYSTEM CIRCUIT DIAGRAM

(FR) (RR)
87a

(FML) 87
30
19 *
* (RL)

18 (FMR)
85 86

10 *
(FL)

87a

87
30 6 *
0
* (FR)
85 86 6 2

17 3
10
II
9
3
(FL)

9 * 30A

(RH)
*
16 20A
(LH)

8 2
87a * 5*
87
30
13 7 0
5 10A
(RH)
85 86
1
10
I
9 1
15
(LH)

87a
7 4
30
87 0
6 I 2
(RH) 85 86 3 II
10 9
14 10A
(LH)

12 11
10A
CN7-9
CN2-7

CN3-9 CN7-1 L5
CN3-10
CN3-11
CN3-12
CN3-8

ARS1210L

Figure 67

S0802220K Electrical System

Page 72
 Reference Reference
Description Description
Number Number
1 Battery *10 Rear Cabin Light Relay
2 Battery Relay 11 Instrument Panel
3 Fuse Box 12 e-EPOS Controller
4 Light Switch *13 Rotating Warning Light
*5 Warning Light Switch 14 Headlight (2 ea.)
6 Cabin Light Switch 15 Work Light (2 ea.)
7 Headlight Relay (Work Light *16 Additional Work Light (2 ea.)
Indicate Light) *17 Front Cabin Light (2 ea.)
8 Work Light Relay *18 Front Cabin Light (4 ea.)
*9 Front Cabin Light Relay *19 Rear Cabin Light (2 ea.)

NOTE: The "*" mark (5, 9, 10, 13, 16, 17, 18, 19) are optional parts.

KIND OF LIGHT
The lighting system is consists of headlights, work lights, cabin lights (optional), rotating warning light
(optional), relays and switches.

OPERATION

Connected
Switch Position Activated Relay Lit Light
Terminal of switch
1 2-6 Terminal - Illumination Light of Switch
2-6 Terminal - Illumination Light of Switch
Headlight Relay Headlight (2 Ea.)
Light Switch Work Light (2 Ea.),
2
2-3 Terminal Additional Work Light (2 Ea.)
Work Relay
Indicator Light of Work Light
(L5)
Front Cabin Light Front Cabin Light (2 Ea.) or
1 2-6 Terminal
Relay Front Cabin Light (4 Ea.)
Cabin Light Front Cabin Light Front Cabin Light (2 Ea.) or
2-6 Terminal
Switch Relay Front Cabin Light (4 Ea.)
2
Rear Cabin Light
2-3 Terminal Rear Cabin Light (2 Ea.)
Relay
Warning
- 5-1 Terminal - Rotating Warning Light
Light Switch

Electrical System S0802220K

Page 73
OVERLOAD WARNING DEVICE
OVERLOAD WARNING DEVICE CIRCUIT DIAGRAM

4 1
5

ARS1260L

Figure 68

Reference Reference
Description Description
Number Number
1 Battery 4 e-EPOS Controller
2 Battery Relay 5 OWD Select Switch
3 Fuse Box 6 Pressure Sensor

S0802220K Electrical System

Page 74
 S0892170K

1ELECTRICAL
SCHEMATIC
(S470LC-V)

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 (S470LC-V)

MODEL SERIAL NUMBER RANGE

Solar 470LC-V 1001 and Up

Copyright 2001 Daewoo

December 2001

Electrical Schematic (S470LC-V) S0892170K

Page 1
TABLE OF CONTENTS

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

Solar 470LC-V................................................................................................ 4

S0892170K Electrical Schematic (S470LC-V)

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

Figure 1

Electrical Schematic (S470LC-V) S0892170K

Page 3
SOLAR 470LC-V

6-LAMP ASS'Y (OPTION)

0.85RG 1.25RG 0.85RG 0.85RG
(FR) 0.85B 0.85B (RR) (RH) 0.85B
B
(FRONT) 87a
0.85RG 30 (REAR) + S
1.25RL 0.85RG 0.85RG
(FML) 0.85B 1.25RG 87
(RL) (LH) L
CABIN LAMP 0.85B 0.85B M
(534-00077 )2 0.85RG 85 86 0.5RG
ROTATING BEACON (OPT)
0.5B 1.25B - E
(FMR) CABIN LAMP
0.85B WORING LAMP ROTATING
(534-00077 )2 (534-00064 )2 BEACON SWITCH
0.85RG (2549-9098 )
(FL) CABIN LAMP RELAY 2 WORING LAMP 87a +(2190-2036D10)
0.85B WIPER MOTOR
2B (534-00064 )2 30 2RY ROTATING BEACON
(2544-9033 ) (538-00009 )
0.85RG 2RG 87 (534-00062) 7 0
5 0.85RG
CABIN LAMP SWITCH (RH) 0.85B 85 86 0.5RG
0.85Or 1 I FUEL PUMP (OPT)
87a 0.5B
(2549-9109 ) 0.85B 0.5B 10 9 0.5WR
30 2RL FUEL PUMP
+(2190-2584D14)
0.85RG 2RG 87 (401-00238) (2
0.85RG
(FR) 0
0.85B 1.25B 1.25WL
0.5B 85 86 0.5WR 0.5WR 6 I 2 0.5RL (LH) 0.85B WORING LAMP RELAY P
(FRONT) (2544-9033 )
0.85RG 0.5RG 3 II LAMP SWITCH
(FL) 0.5B 10 9 0.5WR (2549-9109 ) CIGAR LIGHTER
0.85B
CABIN LAMP RELAY 1 HEAD LAMP 87a +(2190-2036D24) (545-00001)
2B (2544-9033 ) (534-00063 )2 30 1.25R
CABIN LAMP 0
2RL 0.85RW 1.25RW 87
(2534-1127 )2 0.5WR 6 I 2 0.5R
(RH) 1.25B
0.85B 0.5B 85 86 0.5RG 0.5RG 3 II
0.5B 10 9 0.5WR
1.25W
0.85RW
(LH) HEAD LAMP RELAY 1.25R
0.85B (2544-9033 )
LCD GAUGE PANEL 2RY
(539-00048 ) 0.5RG
2RL 2RL
0.5WR 0.5WR
9 0.5R 0.85R 0.85R
10 0.5R PILOT BUZZER 87a
(2516-1116 )
+
BREAER/ 2-WAY OPTION PARTS 87
30 0.85RB
0.5R 0.85RY 0.85RY
8 0.5WB 0.5WB HORN 1
- H.F 0.85B
0.85BrY 0.85BrY (516-00014 ) 0.5G 85 86 0.5RB
1 1 1
0.85BrW 0.85BrW 0.85BrW
2 2 2
BREAER 2-WAY 0.85BrR
3 3 3 0.85RY
0.85B 0.85B HORN 2
L1 L2 L3 L4 L5 L6 4 4 4 L.F 0.85B HORN RELAY
(516-00015 )
(2544-9033 )
BREAER 0.85B
SOLENOID VALVE DIODE 9A
19 0.5B DIODE 9 DIODE 9B
OYSTIC LEVER SWITCH
20 0.5B
0.85BrW (420-000 )
PEDAL BREAER 1 (ON OYSTIC L.H)
BREAER 2 (HORN) 0.5B 3 1 0.5G
PRESS SW 0.85BrR
3 (L)
BREAER 0.85B 0.85BrY 0.85BrR
4 (OPT VALVE) 4 2
SOLENOID VALVE DIODE 9
(R)
0.85BrR
17 0.5RW 0.5RW
ILLUMINATION 0.5BW OYSTIC LEVER SWITCH
6 0.5BW
(420-000 )
11 0.5WR 0.5WR (ON OYSTIC R.H)
(BREAER) 0.85BrW 3 1 0.85BrR 0.85BrR
EL OVER LOAD WARNING (OPT)
(L)
OVER LOAD 0.85R (C) 0.5BrL (POWER MAXIMIZING) 0.5BrL 4 2 0.5RL 2
CN2-3 0.85R
WARNING SWITCH + DC/DC
(2549-9098 ) CN2-7 0.5RG (R) 12V POWER CONVERTER
+(2190-2036D25) 0.5RL SOCET (2531-1003 )
- 0.85B 3
WARNING LAMP (527-00006)
7 0
L1 BATTERY CHARGE 5 0.5BrY 0.5BrY CN2-15 EPOS CONTROLLER CN1-15 0.5LB
0.5B 1 I (543-00052 )
L2 ENG. OIL PRESS 0.5RW 0.85RB
L3 WATER TEMP. 10 9 0.5WR
0.5B 0.5BW 0.5BW
L4 PREHEAT
L5 WOR LAMP 0.5WR 0.85RG
0.85R
L6 OVER LOAD + 1.25RL 1.25RL
PRESSURE SENSOR 0.5BrW 0.5BrW CN1-3
SIG CN2-1 0.5RW 0.5RW 0.5RW
(OWD)
0.5W 0.5W CN1-4
(2547-9045 ) -
LCD DISPLAY PANEL
WATER TEMPERATURE HIGH SPEED SWITCH 0.5RW
FUEL LEVEL 0.85R (2549-9109 )
+ +(2190-2036D13)
PRESSURE SENSOR(A) 0.85GR 0.5GR CN4-1
SIG
GRAPHIC DISPLAY (FRONT PUMP) 0
0.85W 0.5W CN4-2
(2547-9045 ) - CN2-5 0.5WR (MANUAL) 0.5WR 6 I 2 0.5RL
CN2-6 0.5BrW (AUTO) 0.5BrW 3 II
+ 0.85R 0.5B 10 9 0.5WR
PRESSURE SENSOR(B) CN1-8 0.85B
SIG 0.85GY 0.5GY CN4-3 0.5WR 0
(REAR PUMP)
AMP MIC 21P

0.85WL 0.5WL CN4-4 CN1-9 0.85B

(2547-9045 ) -
SOL-VALVE ASS'Y
CN1-1 0.85RL (426-00163 ) CONDENSER FAN RELAY
AMP 070 18P

CN4-5 (2544-9033 )
AVX 0.85YL CN1-2 0.85RL 0.85RL CONDENSER FAN
WATER TEMP SENSOR (C1) 87a
AVX 0.85BL CN4-6 (2520-6004 )
CN1

(2547-9038B) HIGH 30 1.
DIODE 10 - + 1.25L 87
CN1-12 0.85Gr SPEED
M
0.85RL 0.5YB 85 86
CN4

(C2) 0.
0.85YR CN4-7
FUEL SENSOR RELIEF 1.25B
0.85BR CN4-8 DIODE 11
(2547-9035 ) CN1-13 0.85GrW PRESS UP

0.85RL (C3)
0.85GrL 0.5GrL CN4-16 SWING
ENG SPEED SENSOR DIODE 12 PRIORITY
(2547-1015) 0.85GrR 0.5GrR CN4-17 CN1-14 0.85Lg
(TRENCHING)
AMP 070 12P

COMPRESSOR RELAY
(2544-9033 )
87a
AVX 0.85LgR CN3-4 CN1-10 0.85Or 30
OIL TEMP SENSOR
AVX 0.85LgW CN3-5 PUMP 0.85BW 87
(2547-9038B)
CN3

CN1-19 0.85OrB PROPORTIONAL V/V

0.5RB 85 86
1 0.5Y 0.5Y CN3-9
RD TD
2 0.5YB 0.5YB CN3-10
RD TD
DISPLAY
4 RS-422
POWER
0.5YL 0.5YL CN3-11
AUTO
TD RD
MENU 5 0.5YW 0.5YW CN3-12
TD RD
3 SHIELD WIRE SHIELD WIRE CN3-8 FOOT/DEF
CN7 AMP 040 20P DEF 2
ACTUATOR
CHEC CONN FOOT 3
(2213-9002 ) M
0.5GL CN3-1
A TD
0.5GW CN3-2
B RD RS-232C
0.5RG CN3-3
C GND
2 bar 32 bar
P4 0.85GW 4 0.85BW
10 0.5WG 0.5WG 0.5P
CN1-7 A/I
17 0.5LG 0.5LG CN1-17 LOW PRESS HIGH PRES
O/H P
M CN2-9 19bar AUTO IDLE (1) CUT OFF SW CUT OFF S
THROTTLE 0.85P 0.85B
/ TRAVEL SW RECEIVER DRIER
P5 5 CONTROLLER 0.5G CN4-10 (2549-9112 )
0.85Y P (2204-6039A)
(2543-1036) 0.5GB CN4-11 19bar
CN2-10 0.85V 0.85B AUTO IDLE (2) SW
RETRACT P3 0.85L 8 1 0.5GR (2549-9112 )
(+) (+) 1 LOW
CW
P2 0.85Or 7 2 0.5G 2 AVX
TRAVEL/SWING A
0.7bar
6 3 0.5GB CN2-11 0.85BY ENG OIL PRESS SWITCH
P1 0.85Gr (-) (-) 3
AMP MIC 17P

HIGH (66.27441-7005)
0.85RB 9 12 0.85B
AMP MIC 17P
ENG COTROL ENG CONTROL DIAL INDICATOR 87a
CN2 CN2-12 0.85BW 0.85B
MOTOR (2552-1004 ) 0.85RG 30
(170-00004)
(523-00006 ) 87
0.5Or 0.5Or CN4-12 CN2-13 0.85RB 0.85B RETURN FILTER SWITCH (OPTION)
CN2

0.5Gr 0.5Gr CN4-13 0.5RG 86 85 0.5W 2

1.3bar (2549-1135D10)
CN2-14 0.85BG 0.85B PILOT FILTER SWITCH
(471-00075) 0.5WR 9
ALARM RELAY
(2544-9033 ) ALA
0.85RB 0.85RB
(254
+(2190

Figure 2

S0892170K Electrical Schematic (S470LC-V)

Page 4
 SPEAER
0.85L 0.85L ANTENNA (2541-9020 )2
WIPER SWITCH (LH) (RH)
WIPER TIMER (2549-9109 )
(2537-9008 ) +(2190-2036D11)
B 0.85L 1 0.5L 0.5B 11 7 0.5GrR + - + -
0
+ S 0.85Y 4 2 0.5LR 6 I 2 0.5L 17 0.5BY
CAR STEREO
3 0.5LY 3 II 0.5WR 3 2 0.5GrL
M L 0.85LW 5 (541-00014 )
(OPT) 6 0.85B 0.5B 10 9 0.5WR 0.85LW 4 10 0.5BW
- E 0.85B
ROTATING 0.85B 14 0.85BR
BEACON SWITCH 5 0.85L
2549-9098 )
0
90-2036D10) WIPER MOTOR 1 0.85LY
(538-00009 ) 0.85LB 0.85LB 5 I
0 WINDOW WASHER 87a 3
5 0.85RG (2554-9005A) 0.5B 10 9 0.5WR DC / DC
I FUEL PUMP (OPT) + 30 0.85L 0.85L 2
CONVERTER

DIODE 7
0.85LW 87
9 0.5WR P 0.85WR 1 (2531-1003 )
FUEL PUMP PUMP SW WASHER SWITCH
(401-00238) (2549-9096 ) - (2549-9110 ) 0.5W 86 85 0.5B
0.85B 0.5B +(2190-2036D12)
1.25B 1.25WL 1.25WR A
P 0.85L
PILOT CUT-OFF SWITCH STEREO RELAY ENG STOP RELAY 0.85LY P1
H
PILOT CUT OFF (549-00046 ) (2544-9033 )
CIGAR LIGHTER (2544-9033 )
SOLENOID VALVE 0.85YG 0.85YG 3 4 0.85Y 87a 0.85LR B
(545-00001)
(2426-9039A) 0.85L 30
1 2
0 7 87 P2 A
0.5Y 5 0.85LW
2 0.5R DIODE 8
1.25B I 1 0.5W
0.5LR 86 85 0.5B 0.85B E
0.85B 0.5WR 9 10 0.5B
9 0.5WR
1.25W CAR STEREO SWITCH ENG STOP MOTOR
(2549-9098 ) 0.85LR (2523-9016 )
+(2190-2036D23 )
STARTER
0.85RG CONTROLLER STARTER RELAY
(2543-9015 ) (2544-1022)
0.5B E 10W B 0.5WR
N S 0.85BW D PP AVX 3Y
0.5WR
0.85R ROOM LAMP
(2534-9063 ) C B 3W

DIODE 5
87a
30 0.85RB 0.85RB E B P STARTER
87 0.85LR 0.85B 0.85BY (65.26201-7058A)
0.85RY 0.85RY

1.25WG
50 24V 6.6W
0.85B 85 86 0.85LR
0.5G 0.5RB
0.85RG

0.85LR
0.85LY
0.85RB

0.85R

0.85Y
0.85L

0.85RY
1.25WR
1.25W
1.25R
2RY
2RL

0.85B HORN RELAY

(2544-9033 )
9 10 11 12 13 14 1 2 3 4 5 6 7 8 1.25WR 15R 30
C LEVER SWITCH 30A 20A 15A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A

1.25WG
1.25WR
0.85LR

0.85BY
1.25WR 2WR
420-000 )
17 18 15 16
OYSTIC L.H)
3 1 0.5G 5W 5W ACC C
FUSE BOX 2 FUSE BOX 1 A
(L) 5W 5W
(2510-1010 ) (2510-1010 ) B
4 2 0.85BrR BR 0.85Br
(R) 15 16 2WR 17 18 1.25WR R2 31
0.85BrR 85B
10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 15A 15A 15A 15A R1 85R
C LEVER SWITCH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 STARTER SWITCH
420-000 ) FUSIBLE LIN
0.85BW
0.85BG

(2549-1152)
0.85LR

0.85WR
0.85BrR

(2527-1023A)
0.85RG

OYSTIC R.H)
0.85RB

0.5RW

1.25RL
2LR
0.85WR

3 1 0.85BrR 0.85BrR 0.85Br

2WR 2WR 2WR 2R
(L)
4 2 0.5RL 0.85R 2 0.85WR 0.5G
+ DC/DC 0.5WR
(R) 12V POWER 1
CONVERTER 2 DIODE 1 CIRCUIT BREAER BATTERY RELAY
SOCET (2531-1003 ) 0.5RL (2544-9024 ) 2R
- 0.85B 3 (2527-9004 )
(527-00006)
0.5LB
B
8W 8W 8W A
0.85RB
0.5BW 0.5BW 1.25BrW
1.25BrW BR
0.85RG 0.5WR 1
0.85BW
0.5RW 3 HOUR METER E
1.25RL
HOUR DIODE 3 1.25B
2 (2528-9040 )
0.5RW 0.5RW 0.5B
DIODE 2 85R

0.5RW 0.5RW 0.5RW 85B 85R

0.85BG

0.5RW
BLOWER AFTER HEAT RELAY
15 (2544-9033 ) - + - +
1.25LR 2LR + -
M 87a
0.85LR 14 12V 150AH 12V 150AH
30
22 87 0.5BG BATTERY
0.5RL
0.5WR 0.5WR 11 13 1.25LR (2506-6008 )2
86 85 0.5LB
LED 112 0.5RL
CONDENSER FAN RELAY
(2544-9033 )
CONDENSER FAN 87a 3 0.5LB 11 HIGH
(2520-6004 ) 30 1.25LR 5 0.5LY 12 MID AVX
- + 1.25L 87 15R 8W
M 8 0.5LW 13 LOW
0.85BG AVX 1.25WG
0.5YB 85 86 0.5LR 18 0.5GrG 9 REC C B AVX 2RW
A/C CONTROL PANEL
1.25B 19 10 FRE
(543-00049 ) 0.5GrY INTAE 0.85BG
200A

ACTUATOR
10 M
0.5YB DIODE 4 PREHEAT RELAY P(R) B(B+) R(I)
MODE SELECT
(544-00007 )
23 0.5OrR 7 VENT 0.85B
COMPRESSOR RELAY AIR MODE
21 0.5OrB 17 DEF
(2544-9033 ) RECIRCLE/FRESH D H
87a 20 0.5OrW 8 FOOT SG
VENT 0.85B
BLOWER SPEED
30 0.85LR ACTUATOR 15L
M
0.85BW 87 TEMP. CONTROL

0.5RB 85 86 14 0.5LgW 3 (WARM)

0.5LR R
15 0.5LgB 2 (COOL) AIR HEATER F
M
2 0.5YR 4 MIX E
0.5RB 9 16 0.5YW 5 ACTUATOR
E ALTERNATOR 50A
4 0.5YG 1
8B (2502-9009 )
1 0.5B 6 15B
FOOT/DEF DEF 2 0.5G 7 0.85B
ACTUATOR THERMISTOR
FOOT 3 0.5GW 6
(2213-9002 ) M ALTERNATOR 80A(OPTION)
26 1.25B 2B 16 (502-00003)
CN6 HRS 26P
CN5 AMP MIC 13P + 250 4P NOTE.

2 bar 32 bar AVX MAGNET AIRCON UNIT 1. DIODE PART NO.

0.85BW 0.85LW CLUTCH
(920-00020A)
COMPRESSOR DIODE 2 . 548-00003A
LOW PRESS HIGH PRESS (2208-6013B) DIODE 1 3 12 2548-1027
DIODE 6

CUT OFF SW CUT OFF SW

STARTER SWITCH CONNECTION
RECEIVER DRIER
(2204-6039A) AVX 0.85B
PST TML B BR R1 R2 C ACC
0.85B
TERMINAL NO OFF

TRAVEL/SWING ALARM ASS'Y (OPT) PREHEAT

ON
AMP 070 18P AMP 070 12P HRS NO.GT7A-26PD-DS 26P AMP 040 20P START
8 7 6 5 4 3 2 1 5 4 3 2 1
87a 0.85RY
13 12 11 2 1 10 9 8 7 6 5 4 3 2 1
0.85RG 30 ALARM BUZZER 10 9 8 7 6 5 4 3
0.85B 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6 20 19 18 17 16 15 14 13 12 11
87 (516-00011 ) 26 25 24 23 22 21 20 19 18 17 16 15 14
0 (CN4) (CN3)
0.5RG 86 85 0.5W 2 0.5P (CN6) (CN7)
I 6
II 3 0.85V 0.85B AMP MIC 13P AMP MIC 17P AMP MIC 21P
0.5WR 9 10 6 5 4 3 2 1 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
0.5B 4bar
ALARM RELAY
SWING PRESS SW 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
(2544-9033 ) ALARM SWITCH (2549-9407 )

SOLAR 470LC-V
(2549-9109 ) (CN1)
ONLY SWING (OPT) (CN5) (CN2)
+(2190-2584D13)

ASS1150L

Electrical Schematic (S470LC-V) S0892170K

Page 5
S0892170K Electrical Schematic (S470LC-V)
Page 6
Return to Master Table of Contents

1ATTACHMENTS
 S0902110
R1

1BOOM AND ARM

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.

BOOM AND ARM S0902110

MODEL SERIAL NUMBER RANGE
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up

Copyright 2002 Daewoo

January 2002

Boom and Arm S0902110

Page 1
TABLE OF CONTENTS

Front Attachment Pin Specifications .............................................................. 3

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

S0902110 Boom and Arm

Page 2
FRONT ATTACHMENT PIN SPECIFICATIONS
The table below has a complete listing of dimensional specifications for all mounting pins used on the front
attachment.
NOTE: Some mounting pins must be drilled and tapped for lubrication fittings and piping, or may
have other required specifications. Consult Daewoo After Sales Service for information on
wear tolerances and replacement limits for mounting pins.

Mounting Pin Diameter, mm (Inches) Length, mm (Inches)

A 125.0 mm (4.92 in) 1,140.0 mm (44.88 in)
B 120.0 mm (4.72 in) 1,119.0 mm (44.06 in)
C 120.0 mm (4.72 in) 307.0 mm (12.09 in)
D 125.0 mm (4.92 in) 681.0 mm (26.81 in)
E 110.0 mm (4.33 in) 295.0 mm (11.61 in)
F 110.0 mm (4.33 in) 295.0 mm (11.61 in)
G 110.0 mm (4.33 in) 653.0 mm (25.71 in)
H 110.0 mm (4.33 in) 655.0 mm (25.79 in)
I 100.0 mm (3.94 in) 568.0 mm (22.36 in)
J 110.0 mm (4.33 in) 568.0 mm (22.36 in)
K 110.0 mm (4.33 in) 289.0 mm (11.38 in)

A B
C

D E

K J I H G F

HAOF300L
Figure 1

Boom and Arm S0902110

Page 3
FRONT ATTACHMENT - REMOVAL AND
INSTALLATION

DANGER!
Daewoo warns any user, that the removal of
the counterweight from the machine, front
attachment or any other part, may affect
X
the stability of the machine. This could
cause unexpected movement, resulting in
death or serious injuries. Daewoo is not
liable for any misuse.
Never remove the counterweight or front
attachment unless the upper structure is X
in-line with the lower structure.
Never rotate the upper structure once the
counterweight or front attachment has
been removed.
HAAD4060
Figure 2

IMPORTANT
Always break down the front attachment by removing outermost sections first - the bucket
before the arm, the arm before the boom. Reinstallation of the attachment should begin with the
boom and end with the bucket.

Refer to the appropriate Bucket section for its removal and installation procedure before going onto the
initial step of the front attachment removal or installation procedure.

ARM REMOVAL PROCEDURE

WARNING!
This procedure is only intended for routine removal or replacement of the attachment, while
working under normal, safe operating conditions. In the event of a major structural collapse of
some part of the attachment, an accident or complete loss of attachment hydraulic function, DO
NOT proceed with attachment disassembly unless you are completely sure of what you are
doing. Please call your local Daewoo distributor or Daewoo After Sales Service for assistance.
DO NOT allow personnel to stand underneath a weakened or only partially supported
attachment section. Keep clear of hydraulic lines that may have fluid escaping at high pressure -
it can cause severe or even fatal injuries.

Complete the bucket end removal procedure by pulling out the two bucket linkage pins and the bucket
cylinder mounting pin, on the arm. Use an assist crane or hoist to lift the cylinder and relieve weight on
mounting pins.

S0902110 Boom and Arm

Page 4
Park the excavator away from obstructions and all traffic on clear, flat, level ground. Extend the arm
cylinder and crowd the arm into the boom. Partially retract the boom cylinder so that the boom is stretched
out in front of the excavator, as low to the ground as possible, with the arm crowded under the boom.
The tip of the arm point should be lowered to secure blocking that will safely support the weight of the arm.
Place the blocking directly in front of the excavator and make sure that it will not be unbalanced with an
initial weight load that is all to one end, under the arm point.
Shut off the engine and release hydraulic system pressure - move any of the control levers with the engine
off to release pressure built up in the accumulator. Manually vent residual hydraulic pressure in the tank by
moving the lever near the cap, on top of the reservoir.

WARNING!
Secure the swing lock and tag and lock out controls in the operator’s cab to keep anyone from
moving or inadvertently starting the engine. Restrict access to the work site while sections of
the attachment are in the air, or while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must exceed the weight of the heaviest
section of the attachment, the boom (approximately 2,000 kg [4,400 lb], not including the weight
of accessories or fixtures).

Before beginning the disassembly of attachment mounting pins, disconnect the arm cylinder hydraulic
hose couplings and put a clean plug in the end of each one. Use any and all reasonable precautions
necessary to avoid introducing dirt or other contaminants into the hydraulic system. Wipe down coupling
points before disconnecting hydraulic lines and use evaporative-type solvent spray cleaner. Tag and mark
hoses for reassembly, if necessary.
Place a sling under the arm cylinder (the cylinder used to extend and retract the attachment arm, pinned to
the top of the boom). Lift the sling so that the weight load on the rod end of the arm cylinder (pinned to the
ears on the inner end of the arm) is released. Prepare blocking under the arm that will securely support the
weight of the arm and arm cylinder.

CAUTION!
To make sure that the polished surfaces of cylinder rod ends will not suffer accidental damage
during disassembly or removal procedures, wrap exposed rod surfaces (especially those of
boom cylinders) with a protective covering material. Immediately following disassembly and
removal, cylinder rods should always be fully retracted. This eases handling problems and also
avoids possible damage.

Remove retainers on the end of the mounting pin for the arm cylinder rod end. Use the assist crane to
relieve the weight load and withdraw the pin. Lower the arm down to the blocking support for any continued
disassembly procedures.

Boom and Arm S0902110

Page 5
BOOM REMOVAL PROCEDURE
NOTE: Boom removal may be simplified if the shell of the operator’s cab is taken off the turntable
deck first. Refer to the Operator’s Cab Removal procedure before continuing, if both
components are to be removed from the excavator.
After the bucket, arm and arm cylinder have been removed, lower the end of the boom to a stable, secure
blocking support.
Attach the assist crane sling to the body of either boom cylinder, break the mounting pin connection to the
boom by tapping through the pin from the same side of the boom and repeat for the opposite cylinder.
Release hydraulic pressure and disconnect line couplings as previously outlined in the Arm Removal
Procedure, observing the same precautions.
Disconnect wiring for work light assemblies and any other accessory lines or connections. Locate the sling
of the assist crane near the center of gravity, optimum lift point for the boom, and use the crane to take
pressure off the boom foot pin. Drive out the pin after disassembling retainers and carefully lift away the
boom.

WARNING!
Traveling the excavator, swinging the turntable or movement over bumps or sloping, uneven
surfaces could all produce loss of control and possible accidents or injuries, if the turntable
deck has been unbalanced by removal of weight from one end only.

To maintain stability, the counterweight should be removed whenever the front attachment is taken off the
machine.

S0902110 Boom and Arm

Page 6
INSTALLATION
ARM INSTALLATION PROCEDURE
Re-attach the base of the arm cylinder to the mounting point on top of the boom.

WARNING!
Before assembling the front attachment, make sure that the individual boom, arm and bucket
sections are all compatible and can be used safely for work intended. Refer to the General
Safety Pages, Lift Ratings, Working Range Diagrams and Weights of Materials sections in the
Operation and Maintenance Manual. Consult your dealer or Daewoo After Sales Service for more
information if you have any questions or require more information.

Begin with the arm securely supported on blocking in front of the excavator. Pre-grease the mounting pin
for the rod end of the arm cylinder and push it through the ears on the end of the arm. Attach a sling
around that mounting pin and lift the arm with an assist crane until it is in position for the boom-arm pin
connection to be made.
Relieve hydraulic pressure from all points of the system before any hydraulic lines are opened, then
carefully assemble hydraulic connections to the arm cylinder.
Remove the sling from around the rod end arm cylinder pin, withdraw the pin and lift the body of the arm
cylinder to re-pin the mounting connection.

BOOM INSTALLATION PROCEDURE

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

Boom and Arm S0902110

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

S0902110 Boom and Arm

Page 8
 S0904005K

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
MODEL SERIAL NUMBER RANGE
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

Copyright 2001 Daewoo

November 2001

Bucket
Page 1
TABLE OF CONTENTS

Bucket Tooth Inspection and Replacement .................................................... 3

Type 1...................................................................................................... 3
Type 2...................................................................................................... 4
Bucket O-ring Replacement ........................................................................... 6
Bucket Shimming Procedures ........................................................................ 8
New Bucket Installation ........................................................................... 8
Bucket Attachment, Removal and Reversal ................................................... 9
Detaching the Bucket .............................................................................. 9
Attaching The bucket............................................................................... 9
Reversing the Bucket ............................................................................ 10

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 mm to 10 mm (1/3" to 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 4.
2. To replace a tooth (1, Figure 2), 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
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.
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 3

HAOC680L
Figure 4

Bucket
Page 4
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 4.
2. To replace a tooth, use a hammer (1, 2
Figure 5) 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 5
locking pin assembly.

Bucket
Page 5
BUCKET O-RING REPLACEMENT

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.

ARO1350L
Figure 6
2. Roll the old O-ring (1, Figure 7) 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.

ARO1390L
Figure 7
3. Remove the old O-ring and temporarily
install the new O-ring (1, Figure 8) onto the 1
bucket boss (2). Make sure that the O-ring
4
2
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 7).

ARO1391L
Figure 8

Bucket
Page 6
5. Roll the new O-ring (1, Figure 9) into the
O-ring groove.
1

ARO1392L
Figure 9

Bucket
Page 7
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, prior to
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.

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 "Y" 1
boss and inside edge of ear bushing (Y, "X"
Figure 10). 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
3. Recheck end play by forcing bucket
towards opposite side and repeating 4 2
clearance measurements.
4. If an adjustment is required, remove two
jam nuts (1, Figure 10) 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 ARO1710L
(0.04 - 0.08 in.) at point (X). Figure 10

Bucket
Page 8
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 an 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 reassembly.
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 11

Bucket
Page 9
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 12
WARNING!
Bucket curl and dump levers must be used
in opposite directions, after the bucket
has been reversed.

Bucket
Page 10