DOWNLOAD PDF : Daewoo Doosan Excavator Solar 030 PLUS and 035 engines Operators Manual (1)

INTRODUCTION A Message to Daewoo Excavator Operators •

This manual has been prepared to inform you about the operation and maintenance of your new excavator. You are urged to read this manual carefully and to follow the instructions, safety rules and relevant laws and regulations before operating the excavator.

•

For Solar 030 PLUS and 035 engines, please see the Operator's and Maintenance Manual for Isuzu Diesel Engines (SOLAR 035 : 3LD1, SOLAR 030 PLUS : 3LD1)

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Do not operate, inspect or service the excavator until you are thoroughly familiar with its' design and controls. This manual must be left in the cab so that it is always available to others.

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If you have any questions concerning the excavator, please supply the MODEL NO and SERIAL (PI)NO. These numbers are stamped on a name plate, which is attached to the front part of the main frame.

The information, specifications and illustrations included in this manual are based on the information available at the time it was published. Daewoo reserves the right to make improvements and changes in specifications or design without prior notice and without incurring obligation. Please check with your authorized Daewoo dealer for information on possible updates or revisions.

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The safety symbols and other safety information contained in this manual and on the excavator can not cover every possible dangerous situation that may result from operation, inspection and maintenance of this excavator. In addition, operation, inspection or maintenance of the machine, in a manner not specified in this manual, could be dangerous and is the sole responsibility of the operator or technician.

August. 2001

TABLE OF CONTENTS 1. SAFETY ...................................................................................................................... 1 1.1. Safety Information 1.2. Safety Messages

1.3. Safe Operation 1.4 Locatoion of Safety Labels

2. GENERAL INFORMATION ....................................................................................... 23 2.1. Excavator Major Components 2.2. Excavator External View and Operating Space 2.3. Specification 2.4. Weight of Major Attachments and Components

2.5.

2.6.

2.7.

2.8.

2.9.

Excavator Identification Number Grease Supply Points and Locations Recommended Oils and Lubricants Inspection and Maintenance Hydraulic Line Diagram

3. WORKING ATTACHMENTS ..................................................................................... 40 3.1. Maintenance Standards

3.2. Inspection and Correction

4. ENGINE ..................................................................................................................... 47 4.1. Engine Specifications 4.2. Engine Performance Curve

4.3. Emgine Number Location 4.4. Engine RPM Standards

5. MAIN PUMP .............................................................................................................. 50 5.1. External Views 5.2. Construction

5.3. Pump Removal and Installation 5.4. Hydraulic Pump Performance Test

6. HYDRAULIC OIL FILTER ......................................................................................... 57 6.1. Piping Diagram 6.2. Hydraulic Oil Filter

6.3. Maintenance Procedure

7. CONTROL VALVE .................................................................................................... 63 7.1. Specifications 7.2. Construction 7.3. Disassembly and Reassembly

7.4. Construction of Each Valve 7.5. Cautions when Handlings

8. SWING MOTOR ........................................................................................................ 76 8.1. Specifications 8.2. Construction 8.3. Principles of Operation

8.4. Inspection and Adjustment 8.5. Maintenance Standards

9. TRAVEL MOTOR ...................................................................................................... 85 9.1. Specifications 9.2. Construction 9.3. Principles of Operation

9.4. Care 9.5. Running Speed

10. HYDRAULIC CYLINDER .......................................................................................... 98 10.1. Construction 10.2. Disassembly

10.3. Assembly

11. SWIVEL JOINT ....................................................................................................... 105 11.1. Specifications 11.2. Construction, Disassembly, and Reassembly

12. JOY STICK ............................................................................................................. 109 12.1. Specifications 12.2. Principles of Operation

12.3. Constrction

13. SOLENOID VALVE ................................................................................................. 113 13.1. Specifications 13.2. Construction

13.3. Operation 13.4. Construction

14. CRAWLERS ............................................................................................................ 118 14.1. Specifications and Construction 14.2. Disassembly and Reassembly

14.3. Maintenance Standards

15. IDLER .......................................................................................................................124 15.1. Construction 15.2. Disassembly and Reassembly

15.3. Maintenance Standards

16. TRACK TENSION ADJUSTING CYLINDER .......................................................... 127 16.1. Construction 16.2. Spring Specifications

16.3. Disassembly and Reassembly

17. TRACK ROLLER .................................................................................................... 130 17.2. Disassembly and Reassembly

18. SPROCKET ............................................................................................................ 133 18.1. Disassembly and Reassembly

18.2. Maintenance Standards

19. CRAWLER REPLACEMENT PROCEDURE .......................................................... 135 19.1. Steel Crawler Mounting Procedure 19.2. Replacement of Steel Crawlers with Rubber Crawlers

20. ELECTRICAL DEVICE ........................................................................................... 137 20.1. Electrical Circuit Diagram

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20.2. Troubleshooting

ENGINE ................................................................................................................... E-1

1.1. SAFETY INFORMATION

1. SAFETY 1.1. SAFETY INFORMATION 1)

Safety Information Location Basic safety information and rules are compiled in this section (Section 1) of the manual. Throughout the rest of the manual, safety information is identified by three levels of hazard: DANGER, WARNING, and CAUTION. These hazard levels are explained below, under "1.2 SAFETY MESSAGES". Safety information is also included on safety labels on the machine. Read and understand all safety precautions both in the manual and on the machine.

2)

Heavy Equipment Operation Make sure that operators are qualified and that they hold a heavy equipment operator's license, if required.

1.2. SAFETY MESSAGES 1)

Safety Hazard Levels The following information defines each hazard level.

DANGER :

This message indicates an extreme hazard that can result in serious personal injury or death to you or other persons if the machine is handled improperly or proper precautions are not taken.

WARNING :

This message indicates a hazard that can result in se rious personal injury or death to you or other persons, or cause minor injury or material damage if the machine is handled improperly or proper precautions are not taken.

CAUTION :

This message identifies a hazard that is not likely to cause personal injury but may cause property loss or result in machine damage if the machine is handled improperly or proper precautions are not taken.

IMPORTANT : This message is used when the machine may be damaged or its service life

may be shortened if the machine is handled improperly.

–1–

1. SAFETY

1.3. SAFE OPERATION editor's note: all numbers shift down one from here to end of section.

1)

General precautions Carefully read and understand the safety symbols and messages placed in this manual and on the machine.

• Keep safety labels clean at all times.

• If safety labels are damaged or lost, order new ones from your Daewoo dealer.

• Make sure all operators are qualified , as required by law.

• Keep correct operating techniques in mind at all times.

• Operate the machine in a normal manner at all times.

• Do not modify your machine without permission from the manufacturer: Unauthorized modifications can cause injury, machine malfunctions or reduction in machine service life.

• This Safety Section explains basic safety rules. Use extreme caution whenever operating, inspecting or servicing this machine, whether a specific potential hazard is mentioned or not.

2)

Per-operation inspection • Check for damage and problems that require maintenance before operation.

Always repair defective equipment before operation. Failure to inspect and repair the machine may result in failure of major components or systems such as the hydraulic system.

3)

Use handrail and steps whenever you get on or off the machine.

• Guard against falling when getting on or off the machine.

• Always face the machine squarely when getting on or off the machine.

• Always use the handrail and steps and keep three points of contact at all times.

• Be careful not to get caught on a control by mistake.

• Never jump on or off the machine, even when it is stationary. Never get on or off the machine when it is in operation.

• Always wipe up any oil, water or other slippery or foreign material from platform, steps, and handrail immediately.

–2–

1.3. SAFE OPERATION

4)

Adjust seat If the driver's seat is not adjusted correctly, the operator may become easily fatigued and injury and/or damage could result.

• Be sure to adjust the driver's seat at the beginning of each work period.

• Adjust driver's seat so that the operator can easily reach the pedals while his back is firmly against the lumbar support of the seat.

5)

Use seat belts(optional equipment) Fasten seat belts securely to reduce injuries from tip -over, etc, during operation. If a machine starts to tip over, do not jump, stay in seat with seat belt fastened.

• Check seat belt buckles, belts and accessories for damage and repair before using .

• Replace seat belts every 3 years, regardless of their condition.

6)

Stay in seat while starting, operating and stopping machine.

• •

Start engine only when seated in normal operating position in operator's seat.

Do not short the starting circuit to start the engine: it is dangerous and may cause injury and/or damage to the machine.

–3–

1. SAFETY

7)

Watch for safety and traffic signals when travelling.

Check for hazards in the work area before starting and moving.

• Use horn or other signal to warn others when you start and move the machine.

• Use a signal man whenever the operator's vision is obstructed in any way. Make sure the signal man is in sight of the operator at all times.

• Agree on signals before operation.

• Keep bystanders and obstacles out of work area.

• Keep work areas well lighted at night.

8)

Travel Precautions Always check for hazards when traveling the machine. Avoid traveling on slopes • Always keep a firm grip on control levers and keep the travel route in mind at all times.

• Raise bucket when encountering small obstacles.

• Keep bucket 20-30 cm (8-12") off ground when driving on slopes.

• Do not operate on grades in excess of those specified by the manufacturer.

• If machine slips, lower bucket to ground and stop immediately.

• When traveling on level ground, bring front attachment in and raise bucket 4050 cm (15-20") with teeth facing up.

A

A

–4–

1.3. SAFE OPERATION

9)

How to prevent machine from moving unintentionally and how to park machine.

Jumping onto or attempting to hold on to a moving machine, with or without an operator on board , can result in serious injury.

To prevent the machine from moving unintentionally, follow the procedures below: (1)Park on level ground and lower all attachments such as the bucket , blade, etc.

(2) Place throttle control at lowest setting.

(3) Turn ignition switch to OFF and remove key.

(4) If machine must be left on an incline, line it up in the direction of the incline, chock both tracks and drive the point of the bucket into the ground.

•

Non-slip support

Park machine so that there is enough clearance from other machines.

Non-slip support

10) Precautions for turning and traveling in reverse.

Turning and backing up are potentially dangerous because of restricted visibility.

Use a signal man when turning or backing up.

• Watch for people nearby.

•

Use horn or other signal to warn people nearby.

•

Keep windows, mirrors and head lights clean and in good repair at all times.

•

Slow down when visibility is poor due to dust, heavy rain, fog, or other conditions.

–5–

1. SAFETY

11) To prevent accidents.

The operator and supervisors or owners in charge of the equipment or worksite are responsible for avoiding hazardous working conditions.

• To prevent tip-over and to avoid surfaces with poor support, check terrain in advance and keep records of conditions.

• When operating on slopes, use a signal man • Keep people clear when working, swinging or travelling.

• Be sure that overhead guards are in place whenever there is a danger of falling objects.

• Tamp down soft ground before operation.

• Use special care on ground that is frozen or thawing: it is slippery.

12) Never carry people in or on the machine.

• •

Never transport other persons in or on the machine.

Riders restrict visibility, reduce concentration and may cause and/or be subject to injury.

–6–

1.3. SAFE OPERATION

13) Be careful of underground utilities Identify locations of underground cables, gas lines, water piping, etc. before beginning operation.

14) Be aware of buildings, fences and other structures while operating.

15) Tip-over Use care to avoid tip-over when operating on a slope or when handling a heavy load.

• Lower bucket and pull it back in toward machine when operating on an incline.

• Line up tracks in the direction of the incline to reduce the chance of tip- over or serious injury.

• Slow down, when swinging the bucket, to reduce danger of tip-over.

–7–

1. SAFETY

16) Be careful of power cables.

You can be struck by electricity even without touching a high voltage power cable. Never bring your machine closer than the minimum clearances shown in the table below.

Cable Voltage (Kv) Minimum Clearance m

• •

6.6

3(10)

33.0

4(13)

66.0

5(17)

154.0

8(27)

275.0

10(33)

A

Check with local power companies about the voltage of power cables in your area.

Carry out the following precautions: (1) Erect a fence to keep the machine and all personnel a safe distance away from the power cable.

(2) Install insulating material around power cable.

(3) Wear rubber or leather boots.

17) Never use machine for lifting.

• •

The excavator is designed for excavating and loading only.

The excavator is not equipped for lifting and does not have safety devices for lifting.

–8–

1.3. SAFE OPERATION

18) Safe Loading, Unloading and Transport Follow all local laws that apply to your machine. Use proper equipment and use care when loading, unloading and transporting the machine.

• Make sure ground is level and solid.

• Use a loading ramp.

• Never push down on pedal to shift gears while loading or unloading.

• Never turn on the loading ramp. To adjust direction of travel, go back to the ground or to the platform/bed of the hauling vehicle.

• Use extreme caution when crossing the point where the loading ramp is attached to the hauling vehicle: it may cause a shift in the machine's center of gravity.

• Fasten machine securely to chassis of hauling vehicle using wire cable.

19) Handle fuel and oil carefully (Do not allow any source of sparks, heat or flame near the machine) Fuel, oil and antifreeze are highly flammable and dangerous. Handle carefully.

(1) Keep sparks, heat and flame away from machine when refueling. Never smoke while refueling.

(2) Stop engine when refueling.

(3) Refuel in an open area.

• Store flammable liquids and material in a well ventilated area.

• Keep machine clean and free of grease and other foreign material.

• Do not store shop cloths that have

flammable substances on them: they can catch fire easily and "spontaneously".

–9–

1. SAFETY

20) Keep first-aid kits and fire extinguishers available •

•

Make sure that you know how to operate the fire extinguisher and are familiar with the contents of the first aid kit.

Know the location of emergency services such as hospitals, ambulance and fire stations.

21) Keep the inside and outside of the machine clean.

•

•

After operation, allow engine to idle and cool down to prevent the engine compartment from overheating and possibly causing a fire.

To reduce fire hazard, keep the engine compartment, radiator, batteries, hydraulic lines, fuel tank and operator's seat clean and free of any foreign material.

22) Wear proper clothing Wear proper safety protection and clothing such as hard hats.

• Never wear loose clothes or accessories such as watches and jewelry, since they can get caught on control levers or other parts of the machine.

• Concentrate on operation:do not listen to the radio or use headphones, which could distract you from safe operation.

– 10 –

1.3. SAFE OPERATION

23) Protect yourself from flying or falling objects.

Wear safety glasses when operating in dusty or sandy conditions or when rock fragments could be thrown up by operation. Also wear protection when carrying out maintenance such as removing or installing the bucket pin, etc.

24) Be careful of exhaust gases when operating in enclosed spaces.

Engine exhaust gases are deadly. Use the following precautions: (1) Open doors and windows to ventilate the work area.

(2) Use an extension on the exhaust pipe so that exhaust gas is piped outdoors.

– 11 –

1. SAFETY

25) Safe Inspection and Safe Maintenance •

Before inspecting or serving the machine, check with fellow workers and plan all procedures.

• • •

Park the machine safely (see Number 9).

Keep surroundings clean.

Place service warning tags on cab doors , on the operator's seat, and in other places where they are easy to see.

Wait for engine and hydraulic oil to cool down to a safe temperature before doing maintenance.

When it is necessary to check or service the machine with the engine running, always have a second person present to work the controls, shut down the engine, etc.

Never inspect or service the machine when it is in motion.

Avoid inspecting or carrying out service under a machine that is jacked up.

When inspecting or performing service under a machine that is jacked up, keep boom at a 90°-100°angle to the arm and chock tracks securely.

Care for and service the machine so that it functions correctly at all times.

Repair or replace worn or damaged parts immediately.

Remove grease, oil, loose paint and any foreign material from the machine immediately.

Disconnect negative battery terminal when making adjustments or welding.

•

•

• • •

• • •

•

– 12 –

1.3. SAFE OPERATION

26) Inspection and Service Cautions Use extreme care that machine does not move unintentionally.

• Place service warning tags on cab doors, on the operator's seat, and in other places where they are easy to see.

• Wait for all fluids (coolant, engine oil, gear oil and hydraulic oil) to cool down before checking or servicing the machine. Fluids are hot and/or under high pressure and will burn you or cause other serious injury.

27) Keep machine clean at all times • •

Keep machine free of oil and grease at all times.

Water will damage the electrical system.

Never use water or steam on the inside of the cab, in the engine compartment or in any location where it may reach sensors, connectors or other electrical components.

28) Block up machine securely •

Never inspect or service a machine that is unstable.

(1) Lower all working attachments to the ground.

(2) When it is necessary to work either with the machine or with working attachments raised, chock machine with wooden blocks(never concrete) or jack securely.

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1. SAFETY

29) Never touch moving parts Avoid becoming caught by moving parts.

30) Be careful with hydraulic oil under pressure (1) Whenever possible, release all hydraulic pressure before working on hydraulic components or lines. When pressure testing the hydraulic system, make sure all lines and connections are tight.

(2) Check for leaks of pressurized oil using cardboard or wood. Carefully avoid having pressurized oil hit your skin.

(3) If pressurized oil penetrates your skin, get help from a doctor immediately. It must be removed within a short time or it will cause serious injury.

– 14 –

1.3. SAFE OPERATION

31) Fire prevention (1) Hoses and piping • Check hoses, lines and connections for leaks, which can cause a fire.

• Check for loose or missing plugs, and frayed or kinked hoses and piping.

(2) Electric cable and wiring • Check daily for loose, kinked, hardened or frayed electric cables or lines. Electrical wiring with a short can cause a fire.

32) Prevention of battery explosion Batteries emit hydrogen gas, which can explode. Take the following precautions when handling batteries: (1) Never bring sparks, lighted cigarettes , any source of intense heat or flame near the battery.

(2) Never check battery by shorting positive terminal with a metal object. Use a voltmeter and a hydrometer.

(3) Never recharge frozen batteries. An explosion may result. Heat frozen batteries slowly up to 16°C (60°F) before recharging.

33) Burn Prevention (1) Be careful not to get burned by hot coolant or steam.

• Coolant in the engine, radiator and heater lines is very hot or is turned to steam during operation. It is also under high pressure. Stop the engine and allow the radiator to cool down before inspection or service.

• After radiator is cool, remove radiator cap slowly to release pressure slowly.

– 15 –

1. SAFETY

(2) Do not allow hot engine, gear or hydraulic oil to contact your skin.

• Allow all systems to cool down before inspecting and servicing the machine.

• The hydraulic oil tank is under pressure. Stop engine, wait for hydraulic oil to cool, then partly loosen cap to release internal pressure.

34) Remove coating before welding or heating (1) Protect yourself from noxious smoke or dust • Welding, soldering or heating with a welding torch directly on a coated surface can produce noxious gases.

Perform these operations in an open or well-ventilated area.

(2) Remove coatings from surface before welding or heating.

• When removing coating with a grinder, wear a welder's helmet to prevent inhaling the dust.

• When using a welding flux, wipe the face of the weld with soapy or clear water.

• Do not store a welding flux near flame. Wait 15 minutes or more after removing coating before welding or heating.

35) Do not heat hydraulic system and piping.

(1) Heating hydraulic components, piping or nearby areas can produce flammable steam or gas. Take the following precautions: 1. Clean flammable liquids out of piping using a nonflammable solvent before welding.

2. Never weld, solder or use a welding torch on hydraulic components or nearby areas.

3. Piping with hydraulic oil under pressure or rubber hoses can burst if heated directly. Be sure to use fireproof shields.

– 16 –

1.3. SAFE OPERATION

36) Store attachments safely • •

Store attachments such as the bucket, blade and breaker in a secure manner.

Do not allow access to storage area by children or unauthorized personnel.

37) Disposal of liquid and material waste • • •

Drain used liquids into approved containers.

Dispose of waste liquid according to current regulations.

Follow all regulations when disposing of oil, fuel, coolant, brake fluid, solvent, filters, batteries and other toxic material.

38) Be careful of asbestos dust •

•

There may be asbestos in brake pads, bands, linings , clutch plates and gaskets.

Asbestos is injected into these parts as a resin or by methods which do not usually allow dust to be released When handling parts that may contain asbestos, take steps to avoid inhaling asbestos dust- it can cause serious lung damage or death.

39) How to avoid inhaling asbestos dust.

• • • • • •

Do not use compressed air to clean parts.

Do not use a grinder.

Wear breathing apparatus (respirator) that you are sure will prevent breathing in asbestos dust.

Use a vacuum cleaner, if possible.

Wet down parts with oil or water.

Do not allow other personnel into the work area.

– 17 –

1. SAFETY

1.4. LOCATION OF SAFETY LABELS

5

6

2

1 7

(CABIN TYPE)

4

3

AHI0041L

Always keep these labels clean. If they are lost or damaged, replace them with a new label. It is the responsibility of the equipment owner and crew to provide essential safety information in the immediate vicinity of hazards.

Safety labels may be available in languages other than English, or labels providing a warning for other hazards than those that follow may be available. Contact your Daewoo distributor to find out what labels are available.

– 18 –

1.4. LOCATION OF SAFETY LABELS

1.

WARNING FOR OPERATION, INSPECTION AND MAINTENANCE (2190 - 2627, 190 - 00092)

CAUTION! •

•

•

•

2.

Read manual and labels before operation and maintenance. Follow instructions and warnings in manual and on labels on the machine.

Never get in under the machine while it is being jacked up with boom and arm.

Sound the horn to alert the people nearby before operating, and make sure all persons are clear of area.

ACO1360L Always make sure when leaving operator's seat to: - Lower bucket or other working tools to the ground.

- Turn key switch OFF. Remove key from switch.

- If hydraulic components and units are ABNORMAL, consult nearst DEAWOO dealer or authorized service shop. Do not attempt to make an overhaul.

WARNING TAG (2190-2549, 190 - 00098)

CAUTION! Don’t touch when performing inspection or maintenance.

ACO1450L

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1. SAFETY

3.

WARNING FOR BATTERY MAINTENANCE (2190 - 2533, 190 - 00100)

WARNING! •

•

•

•

4.

Battery fumes can explode. Keep sparks and flames away from batteries.

Always avoid storing metals like tools or inflammable materials around or on the batteries. explosion or fire can be caused by short circuiting batteries.

Sulfuric acid in battery is poisonous.

It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed in eyes.

If you spill acid on yourself: 1.

Flush your skin with water.

2.

Apply baking soda or lime to help neutralize the acid.

3.

Flush your eyes with water for 10-15 minutes.

Get medical attention immediately.

ACO1400L

WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (2190 - 2529, 190 - 00097)

CAUTION! HYDRAULIC OIL To prevent hot oil from spurting out: • Turn engine “OFF”.

• Allow oil to cool.

• Slowly loosen cap to relieve pressure before removing.

ACO1410L

– 20 –

1.4. LOCATION OF SAFETY LABELS

5.

WARNING WHEN OPENING ENGINE HOOD (2190-2640, 190 - 00095)

CAUTION! Before opening bonnet, stop engine.

ACO1420L

6.

KEEP OFF OF THE SWING AREA ( 2190 - 2590, 190 - 00163)

CAUTION! KEEP OFF OF SWING AREA

ACO1430L

– 21 –

1. SAFETY

7.

WARNING WHEN OPENING FRONT WINDOW ( 2190 - 2526, 190 - 00093) (IF EQUIPPED WITH CAB)

CAUTION! When raising window, lock it in place with lock pins on both sides.

Falling window can cause injury.

ACO1360L

– 22 –

2.1. EXCAVATOR MAJOR COMPONENTS

2. GENERAL INFORMATION 2.1 EXCAVATOR MAJOR COMPONENTS

26

ANO0010L

1. Boom

10. Engine hood

19. Travel motor

2. Boom cylinder

11. Fuel tank

20. Lower roller

3. Arm cylinder

12. Hydraulic oil tank

21. Idler

4. Arm

13. Canopy

22. Track spring

5. Bucket cylinder

14. Counterweight

23. Swing bracket

6. Bucket linkage

15. Seat

24. Swing cylinder

7. (Dump) linkage

16. Rubber crawler

25. Attachment control levers

8. Bucket

17. Blade

26. Air breather

9. Swing frame

18. Blade cylinder

- 23 -

2. GENERAL INFORMATION

2.2 EXCAVATOR EXTERNAL VIEWS AND OPERATING SPACE • SOLAR 035/SOLAR 030 Plus Excavators(with canopy)

90 (80 350

(280)290

(2450)2460

50

(585)650

(465)510

)

G.L.

(1440)1650 300 (1470)1500

(1350)1400

(3045)3610 (4395)5010

(1150)1200 (1470)1525

* Dimensions in ( ) indicate the specifications for SOLAR 030 Plus.

- 24 -

2.2 EXCAVATOR EXTERNAL VIEWS AND OPERATING SPACE

• SOLAR 035/SOLAR 030 Plus Excavators(with cabin)

350

280

(2330)2340

50

(585)640

(465)510

80

G.L.

300 (1470)1500

(1440)1650 (1350)1400

(3045)3610 (4395)5010

(1150)1200 (1470)1525

* Dimensions in ( ) indicate the specifications for SOLAR 030 Plus.

- 25 -

2. GENERAL INFORMATION

• SOLAR 035/SOLAR 030 Plus Excavator Operating Space

(1350)1400

(330)365

(2865)3465

(4200)4950

(1370)1585

(330)325

(1665)2300

(2590)3125

G.L.

(4460)5120

* Dimensions in ( ) indicate the specifications for SOLAR 030 Plus.

- 26 -

2.3. SPECIFICATIONS

2.3. SPECIFICATIONS SOLAR 030 Plus

SOLAR 035

Rubber shoe

2,740kg

3,140kg

Steel shoe

2,780kg

3,184kg

Rubber shoe

2,860kg

3,240kg

Steel shoe

2,900kg

3,284kg

Bucket capacity(full load in bulk)

0.07m3

0.09m3

Bucket width

445mm

525mm

ISUZU 3LD1

ISUZU 3LD1

1,496 cc

1,496cc

Rated engine power

24.5ps/1950 rpm

24.5ps/1950 rpm

Max digging depth

2,590mm

3,125mm

Vertical digging depth

1,665mm

2,300mm

Max digging height

4,200mm

4,950mm

Max dump height

2,865mm

3,465mm

Max digging radius

4,460mm

5,120mm

Min turning radius

Front:1,800mm/Rear:1,350mm

Front:2,060mm/Rear:1,400mm

Roof

80°(left), 50°(right)

90°(left), 50°(right)

Cabin

80°(left), 50°(right)

80°(left), 50°(right)

Rubber shoe

(Lo/Hi) 2.2/3.8 km/h

2.7/4.2 km/h

Steel shoe

(Lo/Hi) 2.4/3.9 km/h

2.6/3.9 km/h

Swing speed

8.3 rpm

9.4 rpm

Gradeability

30 degrees

30 degrees

Max digging force

2,110kg

2,300kg

Overall length

4,395mm

5,010mm

Overall width

1,470mm

1,525mm

Roof

2,450mm

2,460mm

Cabin

2,330mm

2,340mm

Width x height

1,470 x 350mm

1,525 x 340mm

Amount of movement

upper: 330, lower: 330

upper: 365, lower: 325

Ground clearance

280mm

290mm

Operating space

Engine

Gross weight

Items Roof

Cabin

Manufacturer and Model name Displacement

Main data

Performance

B/Swing angle Travel speed

Overall height

Blade

- 27 -

2. GENERAL INFORMATION

Ground pressure

Travel system

Items

SOLAR 030 Plus

SOLAR 035

Rubber shoe

0.30kg/cm2

0.30kg/cm2

Steel shoe

0.30kg/cm2

0.30kg/cm2

Rubber shoe

0.31kg/cm2

0.31kg/cm2

Steel shoe

0.31kg/cm2

0.31kg/cm2

Piston motor

Piston motor

Type(STD/OPT)

Rubber/Double grouser

Rubber/Double grouser

Method of adjustment

Grease cylinder method

Grease cylinder method

Variable piston pump

Variable piston pump

Roof

Cabin

Type of travel motor

Others

Hydraulic system

Shoe Type of pump Main pressure(kg/m2) Oil flow(L/min)

P1

P2

P3

P4

P1

P2

P3

P4

200

200

165

30

200

200

175

30

17.5

9

25.3

9.7

33.1

37

Capa. of oil tank

60 L

70 L

Capa. of engine oil

6.3 L

6.3 L

Capa. of fuel tank

40 L

40 L

Capa. of coolant

7L

7L

- 28 -

2.4 WEIGHTS OF MAJOR ATTACHMENTS AND COMPONENTS

2.4. WEIGHTS OF MAJOR ATTACHMENTS AND COMPONENTS Weight

Part Name

Weight

Part Name

SOLAR 030 Plus SOLAR 035

SOLAR 030 Plus SOLAR 035

Boom

105

178

Idler

19 x 2

19 x 2

Arm

58

74

Idler yoke

4

4

Bucket

43

85

Track cylinder

18 x 2

18 x 2

Dump linkage

11

21

Lower roller

7x6

7x8

Bucket linkage

3.1 x 2

3.6 x 2

Sprocket

9x2

7.6 x 2

Boom joint pin

2.0

3.0

Swing motor

23

31

Arm joint pin

1.0

2.3

Travel motor

36 x 2

44 x 2

Bucket pin

1.7

2.2

Joy stick

4x2

4x2

Swing bracket

71

87

Seat box

17

17

Swing boss pin

3.4 x 2

6.7 x 2

Seat

10

10

Swing frame

328

410

Stand(left)

5.6

5.6

Hydraulic oil tank

41

43

Stand(right)

5.6

5.6

Fuel tank

24

24

Engine

139

141

Engine hood(A)

54

54

Radiator

10.2

10.2

Engine hood(B)

16

16

Storage battery

20

20

Counterweight

160

200

Battery cover

1.9

1.9

Cabin

172

172

Floor plate

5.4

5.4

Boom cylinder

24

28

Center joint

21

23

Arm cylinder

22

30

Control valve

24

24

Bucket cylinder

17

21

Solenoid valve

7

7

Swing cylinder

18

27

Oil cooler

3.0

3.0

Blade cylinder

17

20

Tank cover

1.3

1.3

Swing bearing

39

4.2

Roof

13

13

Track frame

286

333

Roof post

12 x 2

12 x 2

Blade

126

158

Roof bracket

2

2

Steel crawler

135 x 2

150 x 2

Handle(A)

4

4

Rubber crawler

118 x 2

130 x 2

Handle(B)

4

4

- 29 -

2. GENERAL INFORMATION

2.5. EXCAVATOR IDENTIFICATION NUMBER

Manufacture Number(impressioned)

• Location of Manufacture Number Plate

Manufacture number plate

Type Serial No.

- 30 -

N

2.6. GREASE SUPPLY POINTS AND LOCATIONS

2.6. GREASE SUPPLY POINTS AND LOCATIONS Arm cylinder rod Boom/Arm joint

Arm cylinder head pin

Bucket cylinder head pin

Fuel oil Hydraulic oil tank

Boom cylinder rod pin Bucket linkage pin Bucket cylinder rod pin

Arch

Bucket pin Swing cylinder rod pin Boom joint pin Boom cylinder head pin Blade joint pin Dozer cylinder head pin

Swing bracket pin

Swing cylinder head pin

Swing bearing Swing gear Lower roller Travel motor

Dozer cylinder rod pin Track spring Front idler

- 31 -

2. GENERAL INFORMATION

2.7. RECOMMENDED OILS AND LUBRICANTS The Warranty does not apply to any defects caused by using unauthorized, non-genuine oils and lubricants.

Lubricant Manufacturer

Hydraulic Oil

Engine Oil

Caltex

Caltex HD 32

Caltex RPM Delo 300

Multifac EP

Multi-Purpose EP90

Exxon/Esso

NUTO (anti-wear) HD 32 or 46 or Teresstic (anti-rust)

Exxon XD-3

Ronex MP #2

straight Weight or

or cold temps use

15W40

Ronex MP #1

Spartan EP 220 or Exxon GX 80W90

Idemitsu Kosan

Daphne Kosan 46WR

Aporoil motire S300

Daphne corrone #2

Aporoil Gear HE90

Mobil

Mobil DTE13M

Delvac 1300 Super 15W40 or Delvac 1 or

Mobil FAW #2

Mobilube HD 80W90

(all-temp) or

DTE 24 (summer)

Lubricant Grease

Gear Oil

or cold temps use

Mobil FAW #1

straight Weight

Nippon Seikiyu

Supper Highland S26 or 32

High D. S3

Shell

Tellus 32

Total

Lipanoc grease

Niseki SP90 or EP90

Rotella T 15W40 or T30 (winter) or T40 (summer)

Alvania EP #2

Spirax HD 80W90 or DONAX TD

Total

Total Multris EP #2

straight Weight

Total Equivis ZS46

(transmission)

Total DA80W90

CAUTION: It is recommended to continuously use the same brand oils when replenishing or changing.

•

To prevent freezing of the cooling system in extremely cold places, be sure to add a specified amount of antifreeze to coolant.

•

Mix ratio of antifreeze Temperature,

-5°C

-10°C

-15°C

-20°C

-25°C

-30°C

Antifreeze(L)

1.6

2.0

2.4

2.9

3.3

3.7

- 32 -

2.8. INSPECTION AND MAINTENANCE

2.8. INSPECTION AND MAINTENANCE The amount of wear to each part varies according to whether or not the periodic maintenance is carried out, machine operating skill, working conditions, quality of lubricants in service, working environment, and amount of excavation. Operators are required to determine service intervals for their excavators based on engine conditions, hourmeter readings, extent of wear of each component, hydraulic system condition, and their own experience and related data.

2.8.1. How to perform inspection and maintenance Service intervals(hours) Check points

Engine oil pan

7 hours

50 hours

Check & Replenish

First oil change

Change oil

First replacement

Replace

Engine oil filter

100 hours 250 hours 500 hours 1,000hours

Check & Clean

Fuel filter Intake/Exhaust valve clearance

Clean

Replace

Check & Correct

Check & Adjust

Fuel tank

Drain

Replace filter

Coolant (Reservoir tank)

Check & Clean

Coolant (Radiator)

Check

Fan belt clearance

Check & Adjust

Check & Clean

Air cleaner element Hydraulic oil tank

Check & Replenish

Replace Replace filter

Drain

Return filter (hydraulic oil)

First replacement

Replace

Hydraulic oil suction filter

First replacement

Replace

Check & Grease

Swivel bearing (grease) Crawler tension adjustment

Check & Adjust Check

Storage battery Bolt looseness

Replace

Check & Correct First change

Reduction gear oil Electric devices

Check

Leaks

Check - 33 -

Change

2. GENERAL INFORMATION

2.8.2 Pre-operation inspection Check points

Check items

Remarks

Engine oil pan

Check oil level.

Check before start-up.

Fuel tank

Check fuel level.

Ensure that oil level should be above the center of the level gauge.

Radiator

Check coolant level.

Check to see if coolant in the reservoir tank is up to the specified level.

Each grease point

Grease

See 2.6.

Check for looseness or damage of each part.

Looseness, missing, oil leaks, coolant leaks

Working levers and gauges

Check for operation.

Check to see if levers work properly.

Hydraulic oil tank

Check oil level.

Add if required.

(Be careful of position of the machine.)

Bucket teeth and others

Wear

Check to determine if the teeth should be replaced with new ones.

Electric wiring

Looseness or damage

Check terminals for looseness, missing, or damage.

Fan belt

Check and adjust.

A firm push with the thumb at a point midway between the two pulleys should depress the belt 10~12mm.

2.8.3. Post-operation inspection Check points

Check items

Remarks

Each part of main body

Oil leaks, coolant leaks, looseness, damage, etc.

Fuel tank

Replenish fuel, if required.

Coolant

Check

Remove mud, foreign matters, etc. sticking to the main body.

Drain the coolant if freezing is expected.

- 34 -

2.8. INSPECTION AND MAINTENANCE

2.8.4. 50-hour services Check points

Check items

Remarks

Engine oil pan

Change oil and filter.

First change. Every 250 hours thereafter.

Intake/Exhaust valve clearance

Check, and adjust if required.

First check. Every 500 hours thereafter.

Coolant

Drain out foreign matters and sediment.

Drain the coolant through the drain plug located at the bottom.

Clean strainer.

Clean with light oil.

Radiator

Clean the core.

Dirts sticking to the core causes poor cooling efficiency

Swing bearing

Check and grease.

Always grease after underwater operation.

Check

Green: normal, Transparent: replace, Black: recharge

Clean

Keep clean each part, and apply grease to terminal area.

Storage battery

Each grease point

Add oil or grease.

2.8.5. 100-hour services Check points

Check items

Remarks

Fuel filter

Clean element.

After cleaning, loosen and remove the cap to bleed air.

Air cleaner

Clean dust cover, clean or replace the element if required.

Also check hose band for looseness.

Hydraulic oil return filter

Replace cartridge.

First replacement. Every 500 hours thereafter.

Hydraulic oil suction filter

Clean the element.

First cleaning. Every 500 hours thereafter.

2.8.6. 250-hour services Check points

Check items

Remarks

Engine oil pan

Change oil.

Every 250 hours thereafter.

Engine oil filter

Change cartridge.

Every 500 hours thereafter.

Hydraulic oil tank

Drain out foreign matters and condensates.

Drain the coolant through the drain plug located at the bottom.

Reduction gear lubricating oil

Change lubricating oil.

First change. Every 1,000 hours thereafter.

- 35 -

2. GENERAL INFORMATION

2.8.7. 500-hour services Check points

Check items

Remarks

Fuel filter

Replace the element.

Also clean the inside of the tank.

Intake/Exhaust valve clearance

Check clearance.

First check. Every 500 hours thereafter.

Radiator

Replace coolant.

Check to see that the reservoir tank indicates a normal coolant level.

Air cleaner

Replace the element.

Hydraulic oil return filter

Replace cartridge.

Hydraulic oil suction filter

Clean the element.

First 100 hours.

2.8.8. 1,000-hour services Check points

Check items

Remarks

Engine oil pan

Clean

Tighten the drain plug at the bottom of the tank before changing oil.

Hydraulic oil tank

Change hydraulic oil, and clean the inside of the tank.

Clean the inside of the hydraulic oil tank(every 1,000 hours).

Swing gear and reduction Change lubricating oil gear oil

2.8.9. 2,000-hour services Check points Lower roller

Check items

Remarks

Replace

2.8.10. Grease points list Check points

Designated oil

Grease volume

Reduction gear

API Class

1,200cc

Every 1,000 hours

Lower roller

CD Grade

100cc

Every 1,000 hours

Front idler

SAE30

80cc

Every 1,000 hours

- 36 -

Intervals

2.8. INSPECTION AND MAINTENANCE

2.8.11. Standard tightening torque • Bolt and nut tightening torque table Types of bolts and nuts

4T

7T

9T

SS41

S40C, S45C

SCr4

M6

0.80~0.95 (7.8~9.3)

1.00~1.15 (9.8~11.3)

1.25~1.45 (12.3~14.2)

M8

1.80~2.10 (17.7~20.6)

2.40~2.80 (23.5~27.5)

3.00~3.50 (29.4~34.3)

M10

4.00~4.60 (39.2~45.1)

4.90~5.70 (48.0~55.9)

6.20~7.20 (60.8~70.6)

M12

6.40~7.40 (62.8~72.6)

7.90~9.20 (77.5~90.2)

10.50~12.00 (103.0~117.7)

M14

11.00~12.80 (107.9~125.5)

12.60~15.00 (123.6~147.1)

17.00~20.00 (166.7~196.1)

M16

17.00~19.50 (166.7~191.2)

20.00~23.00 (196.1~225.6)

26.50~31.00 (259.9~304.0)

M18

25.00~29.00 (245.2~284.4)

28.00~32.50 (274.6~318.7)

35.00~41.00 (343.2~402.1)

M20

34.00~40.00 (333.4~392.2)

37.50~44.00 (367.7~431.5)

50.00~58.00 (490.3~568.8

Nominal designation

• Adaptor tightening torque Nominal designation

Tightening torque(kg•m)

Nominal designation

Tightening torque(kg•m)

PT1/4

3.5~4.5

PT1/4

PT3/8

4.5~5.5

PT3/8

PT1/2

6.5~7.5

PT1/2

PT3/4

8.5~9.5

PT3/4

9~11

PT1

12~14

6~8

NOTE: Torque represents the force required to tighten a bolt, e.g., if you grip a 1m long spanner and turn its handle with a force of 12kg, you will obtain 12kg• m(1m x 12kg). To produce a torque of 12kg• m using a 25cm long spanner, a force of 48kg is necessary as follows: 0.25 x (X kg) = 12kg• m 12 x 1/0.25= 48kg

- 37 -

2. GENERAL INFORMATION

2.9. HYDRAULIC LINE DIAGRAM • SOLAR 030 Plus

- 38 -

P1

B A

B A

ENGINE 24.5Ps / 2,000rpm

P2

B A

P3

- 39 4

P

PA1

S/RIGHT

PA8 1

LEFT

2

PB1

S/LEFT A/DUMP

T

3

4

P

PB5

PA4 1

RIGHT

2

PA5

T

3

PB4

A/CWD BKT/CWD BKT/DUM BOOM/DN BOOM/UP PB8

2.9. HYDRAULIC LINE DIAGRAM

• SOLAR 035

3. WORKING ATTACHMENTS

3. WORKING ATTACHMENTS 3.1. MAINTENANCE STANDARDS 3.1.1. Working attachments

ANS0020L

- 40 -

a

b

a

b

3.1. MAINTENANCE STANDARDS

B A 2. Swing cylinder rod

1. Swing cylinder head

a

a

b

b

C

D

4. Boom joint a b

F

3. Swing post bracket 5. Boom cylinder head

a a

a

b

b

b H G

I

6. Boom cylinder rod

7. Arm cylinder head

8. Arm cylinder rod

a

a

a

b

b

b

J

9. Boom/Arm joint

L

K

10. Bucket cylinder head

- 41 -

M

11. Bucket cylinder rod

N

3. WORKING ATTACHMENTS

a

a

b

b

P

O

12. Bucket/Dump linkages joint

a b

Q

S

R

13. Arm/Bucket linkages joint

14. Arm/Bucket rod

a

a

a

b

b

b

T

15. Dozer joint

U

16. Dozer cylinder rod

- 42 -

V

17. Dozer cylinder head

3.1. MAINTENANCE STANDARDS

• Clearance between pin and bush of each portion(SOLAR 030 Plus)

Portion

Basic Allowable Portion value clearance

Parts

Basic Allowable value clearance

Parts

A

Swing cylinder head pin

Ø35

1.0

L

Bucket cylinder head and arm

Ø35

1.0

B

Swing cylinder rod pin

Ø35

1.0

M

Bucket cylinder rod pin and dump linkage Ø35

1.0

C

Swing post pin and bush

Ø60

1.0

N

Bucket cylinder rod pin and bucket linkage Ø35

1.0

D

Boom joint pin and bush

Ø40

1.0

O

Bucket pin and bush

Ø35

1.0

E

Boom joint pin and swing post

Ø40

1.0

P

Bucket linkage pin and dump linkage Ø35

1.0

F

Boom cylinder head pin and swing post Ø40

1.0

Q

Bucket linkage pin and bush

Ø35

1.0

G

Boom cylinder rod pin and boom

Ø40

1.0

R

Bucket linkage pin and bucket linkage Ø35

1.0

H

Arm cylinder head pin and boom

Ø35

1.0

S

Dozer joint pin and frame

Ø35

1.0

I

Arm cylinder head pin and arm

Ø35

1.0

T

Dozer joint pin and dozer

Ø35

1.0

J

Boom/Arm joint pin and bush

Ø35

1.0

U

Dozer cylinder rod pin and frame

Ø35

1.0

K

Boom/Arm joint pin and boom

Ø35

1.0

V

Dozer cylinder head pin and dozer

Ø35

1.0

• Clearance of each portion(SOLAR 030 Plus) Criteria Portion

Parts

a

b

Basic clearance

1

Swing cylinder head and head bracket

50

53

2.0~3.5

2

Swing cylinder rod and swing post

52

50

2.0~3.5

3

Swing post and frame

265.5

264

0.1~1.6

4

Boom and swing post

175

174

0.5~2.5

5

Boom cylinder head and swing post

52

50

1.5~2.0

6

Boom cylinder rod and boom

52

50

1.0~2.5

7

Arm cylinder head and boom

52

50

1.0~2.5

8

Arm cylinder rod and arm

52

50

1.0~2.5

9

Boom and arm

130

129

0.5~1.7

10

Bucket cylinder head and arm

52

50

1.5~2.5

11

Bucket cylinder rod and dump linkage

52.5

50

1.0~2.5

12

Dump linkage and bucket

135

134.5

0~2.0

13

Arm and bucket linkages

135

134.5

0.3~1.7

14

Arm and bucket

135

134.5

0.3~1.7

15

Dozer and frame

32

31

0.5~2.0

16

Dozer cylinder rod and frame

52

50

0.5~2.5

17

Dozer cylinder head and dozer

52

50

0.5~2.5

- 43 -

3. WORKING ATTACHMENTS

• Clearance between pin and bush of each portion(SOLAR 035 Plus)

Portion

Basic Allowable Portion value clearance

Parts

Basic Allowable value clearance

Parts

A

Swing cylinder head pin

Ø35

1.0

L

Bucket cylinder head and arm

Ø35

1.0

B

Swing cylinder rod pin

Ø35

1.0

M

Bucket cylinder rod pin and dump linkage Ø35

1.0

C

Swing post pin and bush

Ø60

1.0

N

Bucket cylinder rod pin and bucket linkage Ø35

1.0

D

Boom joint pin and bush

Ø40

1.0

O

Bucket pin and bush

Ø40

1.0

E

Boom joint pin and swing post

Ø40

1.0

P

Bucket linkage pin and dump linkage Ø40

1.0

F

Boom cylinder head pin and swing post Ø40

1.0

Q

Bucket linkage pin and bush

Ø35

1.0

G

Boom cylinder rod pin and boom

Ø40

1.0

R

Bucket linkage pin and bucket linkage Ø35

1.0

H

Arm cylinder head pin and boom

Ø35

1.0

S

Dozer joint pin and frame

Ø35

1.0

I

Arm cylinder head pin and arm

Ø35

1.0

T

Dozer joint pin and dozer

Ø35

1.0

J

Boom/Arm joint pin and bush

Ø40

1.0

U

Dozer cylinder rod pin and frame

Ø40

1.0

K

Boom/Arm joint pin and boom

Ø40

1.0

V

Dozer cylinder head pin and dozer

Ø40

1.0

• Clearance of each portion(SOLAR 030 Plus) Criteria Portion

Parts

a

b

Basic clearance

1

Swing cylinder head and head bracket

50

53

2.0~3.5

2

Swing cylinder rod and swing post

52

50

2.0~3.5

3

Swing post and frame

265

264

0.1~1.6

4

Boom and swing post

195

194.5

0.5~2.5

5

Boom cylinder head and swing post

52

50

1.5~2.0

6

Boom cylinder rod and boom

52

50

1.0~2.5

7

Arm cylinder head and boom

52

50

1.0~2.5

8

Arm cylinder rod and arm

52

50

1.0~2.5

9

Boom and arm

150

149.5

0.5~1.7

10

Bucket cylinder head and arm

52

50

1.5~2.5

11

Bucket cylinder rod and dump linkage

52

50

1.0~2.5

12

Dump linkage and bucket

135

134.5

0~2.0

13

Arm and bucket linkages

135

134.5

0.3~1.7

E

Arm and bucket

135

134.5

0.3~1.7

15

Dozer and frame

53

50

0.5~2.0

16

Dozer cylinder rod and frame

57

55

0.5~2.5

17

Dozer cylinder head and dozer

57

55

0.5~2.5

- 44 -

3.2. INSPECTION AND CORRECTION

3.2. INSPECTION AND CORRECTION 3.2.1 Spontaneous settlement measurement •

Positioning the machine -

•

Apply basic load to the bucket, and extend the boom cylinder up to a maximum and the dozer cylinder up to a maximum shaft length within the maximum excavation radius as shown below.

Stop the engine and wait 5 minutes, then measure the amount of displacement of boom cylinder, arm cylinder, and bucket cylinder.

Basic value Item

Basic value

Allowable limit

Boom cylinder

8mm

20mm

Arm cylinder

12mm

24mm

Bucket cylinder

6mm

12mm

Dozer cylinder

4mm

8mm

•

Oil temperature: 50±50C

•

Applied load -

SOLAR 030 Plus:130kg SOLAR 035:160kg

Arm cylinder Bucket cylinder Boom joint portion

Dozer cylinder

Boom cylinder Arm/Bucket joint portion indicates cylinders' moving direction.

- 45 -

3. WORKING ATTACHMENTS

3.2.2. Speed measurement (Oil temperature: 50°C±5°C), Engine RPM: Maximum at un-load) Basic value Item

Measuring conditions

Unit Solar 030 Plus Solar 035

UP

SEC

2.3±0.4

2.7±0.4

DOWN

SEC

2.1±0.4

2.2±0.4

Crowd

SEC

3.2±0.4

3.2±0.4

Dump

SEC

2.6±0.4

2.9±0.4

Crowd

SEC

3.5±0.4

3.2±0.4

Dump

SEC

2.4±0.4

2.3±0.4

UP

SEC

1.6±0.4

1.0±0.4

DOWN

SEC

1.9±0.4

1.2±0.4

Left

SEC

5.7±0.4

7.5±0.4

Right

SEC

4.1±0.4

5.7±0.4

Boom

Arm

Bucket

Dozer

Boom swing

- 46 -

4.1. NE SPECIFICATION

4. ENGINE 4.1. ENGINE SPECIFICATIONS

Specifications Item

Unit

SOLAR 030 Plus / 035

Model name

3LDI

Type

Vertical 3-cylinder 4-cycle

No. of cylinders-bore x stroke

mm

3-83.1 x 92

Piston displacement

cc

1496

Firing order

1-3-2

Overall length

mm

670

Overall width

mm

471

Overall height

mm

744

Rated power

ps/rpm

24.5/1950

Maximum torque

kg•m/rpm

9.5/1700

Maximum rpm at no-load

rpm

2100

Minimum rpm at no-load

rpm

1250

Fuel consumption

g/ps•h

195

Engine dry weight

kg

141

Fuel

Light oil

Injection pump

Poppet type

Governor

Centrifugal all speed control

Alternator

12V-35A 12V-1.2kW

- 47 -

4. ENGINE

4.2. ENGINE PERFORMANCE CURVE • SOLAR 030 Plus / 035

93.2N·m (9.5kgf·m)/1700min-1(rpm) 10 9 8 30

7

Power N·m(kgf·m)

Torque

Power 20

220

10 Fuel consumption

200 180 265gr/kw·h (196gr/ps·h) 160 2100±50min (rpm) -1

0

1000

1500

2000 RPM(min-1)

- 48 -

2500

3000

Fuel consumption gr/kw·h (gr/ps·h)

Power kW(PS)

18kW(24.5PS)/1950min-1(rpm)

4. ENGINE

4.3. ENGINE NUMBER LOCATION

Engine number Engine type

4.4. ENGINE RPM STANDARDS(FOR A NEW VEHICLE) Engine rpm Conditions

SOLAR 030 Plus / 035

Maximum rpm at no-load

2100±50 rpm

At P1 relief

2050±50 rpm

At P2 relief

2050±50 rpm

- 49 -

5. MAIN PUMP

5. MAIN PUMP 5.1. EXTERNAL VIEWS • SOLAR 030 Plus

Piston pump Pump type

P1, P2

P3

P4

cc/rev

17

9.5

4.5

Maximum pressure kg/cm2

200

165

30

Quantity of delivery

- 50 -

5.1. EXTERNAL VIEWS

413 368

45

Outlet port P2 P2 PF1/2

101.5

101.6

109.5

Oil feed port (PF1/2)

Outlet port P4 P4 PF1/2

146 172

161 263.5

Outlet portP1 P1 PF1/2

Outlet port P3 P3 PF1/2

23.5

11.5

M10Thread M10 depth

21.8

342

24 37 Inlet port S3 141

PF3/4

263.5 S1 SAF.T5185- 1/4

Piston pump Pump type

P1, P2

P3

P4

cc/rev

19

13

5

Maximum pressure kg/cm2

200

175

40

Quantity of delivery

- 51 -

5. MAIN PUMP

5.2. CONSTRUCTION • SOLAR 030 Plus

1. Body S

14. Spring C

31. Needle bearing

59. O-ring

2. Body H

15. Spring T1

32. Oil seal

60. Hex. socket set screw

3. Shaft

16. Spring T2

33. Sliding shaft

61. Hex. nut

4. Cylinder barrel

17. Sleeve

34 & 35 & 36. Snap ring

62. Seal washer

5. Valve plate

18. Spring holder

37 & 38 & 39 & 41. O-ring 65. Gear pump

6. Piston

19. Spring guide

44 & 45. Hex. socket bolt

66. Coupling

7. Shoe

20. Rod P

47. Parallel pin

67. Collar

8. Shoe holder

21. Rod G

48. Conical small screw

68. Hex. bolt

9. Barrel holder

23. Control piston

49 & 50. Hex. socket plug 69. O-ring

10. Swash plate

24. Retainer

51. Plug

70. Washer

11. Neddle

25.Thrust bush

52. Spring washer

71 & 72. O-ring

12. Seal holder

28 & 29. Choke

55 & 56. Spring pin

13. Packing

30. Ball bearing

58. Bolt ass’y

- 52 -

5.2. CONSTRUCTION

• SOLAR 035

1, 23

6

11

30

14

35

19

36

29 5 7

25 22

2

20 21 26

17

18

32

24

13

28

4

3

15

16

27

1. Pump assembly

15. Spring pin

25. Oil seal

2. Ball bearing

16. Hold assembly

26. O-ring

3. Roller bearing

17. Set screw

27. O-ring

4. Bush

18. Nut

28. O-ring

5. Snap ring

19. Pump assembly

29. O-ring

6. Snap ring

20. Coupling

30. O-ring

7. Snap ring

21. Collar

32. Seal washer

11. Plug

22. Washer

33. O-ring

13. Plug

23. Packing assembly

34. O-ring

14. Spring pin

24. Packing

35. O-ring

- 53 -

33

34

5. MAIN PUMP

5.3. PUMP REMOVAL AND INSTALLATION 5.3.1. Pump removal 1. Remove nipples, fittings, and hoses from the pump, and cover both ends of each hose in order to prevent dust and other foreign matters from entering the hoses.

2. Remove the pump mounting bolt and spring washer(1,2).

3. Remove the pump flange(3) from the engine.

5.3.2. Pump installation 1. Install the pump to the pump flange(3).

At this time, ensure that the pump shaft spline should be correctly installed into the coupling boss.

•

Pump installation precautions - Ensure that the coupling (5) should not be warped when installing the coupling boss 4.

- Make sure that the coupling boss spline has not been deformed.

Item No.

Part name

Tightening torque

6

Bolt (M10 x 30L)

5.2 kg·m

7

Bolt (M10 x 25L)

6.5 kg·m

8

Nut (M10)

6.5 kg·m

5 8

6

6

4 3 7 2 1

- 54 -

5.4. HYDRAULIC PUMP PERFORMANCE TEST

5.4. HYDRAULIC PUMP PERFORMANCE TEST 5.4.1. Measuring instrument Flow(l/min.)

7~200(l/min.)

Pressure(kg/cm2)

0~350(kg/cm2)

Temperature(0°C)

0~150(°C)

Tester Port size

PF 1, O-ring type

Pressure gauge,

500kg/cm2, 50kg/cm2

Tachometer

Diesel engine tachometer

Test hose

Rated pressure: 210kg/cm2 or equivalent

• Preparation -

Park the machine on a level ground and stop the engine.

Operate the left/right attachment control levers and left/right direction control levers to release the pressure remaining in the lines.

5.4.2. Connection of testers 1. Disconnect the hose at the pump outlet side.

2. Connect the removed hose to the tester outlet port.

3. Connect the hose at the tester inlet port to the pump outlet port.

Pressure testing port

Pressure gauge Test hose

Outlet port

Throttle valve

Inlet port

Close Open

Test hose

P1

P2 P3

Control valve

Solenoid

- 55 -

5. MAIN PUMP

5.4.3. Measuring procedure Open the orifice valve of the tester, and start the engine.

Measure the pressure at P1 and P2 through the pressure gauge, and take the engine rpm and pump delivery simultaneously.

5.4.4. Pump performance curve(P-Q Curve) • SOLAR 030 Plus Pressure of P3 kgf/cm2

P3=25(kgf/cm2)

Flow(Q) ; (L/min)

P3=165 P3=25

Discharge pressure (P1+P2) kgf/cm2 • SOLAR 035 20 19

Quantity of delivery q1+q2(cc/rev)

P3=25(kgf/cm2)

15

10

P3=175(kgf/cm2)

5.7 5

0

0

85 100

300 330

190 200

400

Discharge pressure P1+P2(kgf/cm ) 2

- 56 -

6.1. PIPING DIAGRAM

6. HYDRAULIC OIL FILTER 6.1. PIPING DIAGRAM

Return filter

Hydraulic oil tank

A B C

Suction filter

Pilot line filter

C B A

ANS0050L

- 57 -

6. HYDRAULIC OIL FILTER

6.2. HYDRAULIC OIL FILTER 6.2.1. Suction filter(Y-3794)

Grain size

105 µ

Filtering ability

120 L/min

Pressure resistance

1 kg/cm2

Oil temperature

-20°C~120°C

6.2.1. Return filter(SP10) 2-PT 11/4

Grain size

105 µ

Filtering ability

120 L/min

BY-PASS

Open pressure: 1.05kg/cm2

Pressure resistance

15 kg/cm2

Oil temperature

-20°C~120°C

Tightening torque : 2kgf·m

- 58 -

6.2. HYDRAULIC OIL FILTER

6.2.3. Pilot line filter(for joy stick)

37 3.5 6.5

+0.25 -0

3

9

15 12

Quantity of flow

6 L/min

Rated pressure

40 kg/cm2

Filtering ability

40 µ

Filtering area

0.332 cm2

Oil temperature

-20°C~120°C

∅11.2

∅5.5 30 o +0.5 ∅12.5±0.2 0

C0.5

PF 1/4

12S

PF 3/8

PRESSURE LOSS. ∆P (kg/cm2 )

FLOW Q (l/min) ANS0060L

- 59 -

6. HYDRAULIC OIL FILTER

6.3. MAINTENANCE PROCEDURE WARNING • Always allow the hydraulic oil to cool down enough before replacing the filters, as at the operating temperature, the hydraulic oil is at high temperature and may cause personal injury.

• Loosen the hydraulic oil port cap tightening bolt slowly to release the air from the tank.

Oil port cap

6.3.1. Return filter(SP10) replacement 1. With a filter wrench, remove the filter cartridge1.

2. Coat clean hydraulic oil on the gasket surface of a new filter cartridge.

3. When installing the cartridge, bring the seal face into contact with the gasket and then turn the cartridge 1/2 turn by hand to tighten it.

4. Use a filter wrench to secure the cartridge in place.

Do not apply an unreasonable force.

1

1

6.3.2. Pilot line filter replacement 1. Remove the floor plate.

2. Unscrew the plug 1 with a spanner(27mm) to remove the element.

3. Clean the element thoroughly and remove dust and dirt, then install the plug 1.

WARNING : Always allow the hydraulic oil to cool down enough before replacing the filters, as at the operating temperature, the hydraulic oil is at high temperature and may cause personal injury.

- 60 -

6.3. MAINTENANCE PROCEDURE

6.3.3. Suction filter replacement 1.

2.

3.

4.

Remove the oil port cap from the hydraulic oil tank.

Take out the suction filter 1 from the tank.

Wash out foreign matters sticking to the element.

After cleaning the element, use compressed air to flush the strainer from the inside to the outside.

5. If the element is found damaged, replace with a new one.

When cleaning the element, be sure to check the hydraulic oil tank. If sediments or condensates are found in the tank, change the hydraulic oil.

6. Prepare a container to receive the drained oil. Drain the hydraulic oil through the oil port using the oil feeder pump.

7. Loosen the drain plug 2 located at the bottom of the hydraulic oil tank to drain out the hydraulic oil.

8. Install the filter 1 in the tank.

When installing the filter, be sure to keep the suction filter upright and push it down so that it can be secured to the pipe.

9. Remove and clean the drain plug 2, and secure it to its original position.

10. Inject hydraulic oil through the oil feed port located on top of the tank. During oil injection, keep checking the oil surface on the level gauge installed on the side of the tank.

1

2 1 MAX

Tank capacity : SOLAR 030 Plus: 60l SOLAR 035: 70l 11. Fit the oil port cap in place. In doing so, clean the top side of the flange and O-ring groove thoroughly to prevent oil leaks, and coat a sufficient amount of grease on the O-ring groove to secure the O-ring in place.

12. Bleed out air from the hydraulic lines.

• Rotate the engine at low speed.

• Operate each cylinder 4~5 times up to 5mm before end stroke.

• Operate each cylinder 3~4 times up to end stroke.

- 61 -

2

6. HYDRAULIC OIL FILTER

13. Correct position of machine for oil level check • machine on a level ground and stop the engine as shown.

• Check oil level with the level gauge for the hydraulic oil tank.

• If the oil surface is above the center line on the level gauge, it is normal.

14. If the oil surface is below the center line on the level gauge, add oil.

15. Hydraulic oil tank pressurizing procedure • Open the oil port cap on the hydraulic oil tank and operate each cylinder slowly up to the end stroke.

• Reinstall the oil port cap onto the tank. Tighten the bolt with the spring secured properly with the tab of the oil port cap.

• In this condition, operating the cylinder up to the maximum shaft length will pressurize the tank.

• Check for leaky portions.

- 62 -

7.1. SPECIFICATIONS

7. CONTROL VALVE 7.1. SPECIFICATIONS

A9 B9 A8 B8 L3

B7 B6 A5 B5 A4 B4 A6 R3 R4 A7

A3 B3 A2 B2A1 A2 L2

P1

P3

T1

T2

R1

R2

L1

L4 P2

PA8

PA5 PA4

PA1

PTO

A9

A8

T1

A6

A5

A4

A3

A7

P1

A2

A1 T2

P2

P3

B7 B9

B8

B6

B5

B4

B3

B2

PB1

PB5 PB4

PB8

B1

Port

Size

Port

Size

P1, P2, P3, T1, T2

PF1/2

PA1, PA4, PA5, PA8

PF1/4

A1~A9, B1~B9

PF3/8

PB1, PB4, PB5, PB8

PF1/4

Locations

SOLAR 030 Plus

SOLAR 035

P1 main relief pressure

200 kg/cm2

200 kg/cm2

P2 main relief pressure

200 kg/cm2

200 kg/cm2

P3 main relief pressure

165 kg/cm2

175 kg/cm2

A4 main relief pressure

235 kg/cm2

270 kg/cm2

B4,B5,A8,B8 main relief pressure

215 kg/cm2

250 kg/cm2

- 63 -

7. CONTROL VALVE

• Construction of blocks (SOLAR 030 Plus / SOLAR 035)

1 30 33

13 15

27

18 16

12 28 29

15 16 15

11 15

30

16

20

15

15

15

14

21

15

16

19

31 22

23

9 18 20

15

19

15

16

8

15 24

16 15

15

10

7 15

16

16

26 25 15 21 23 22

15

6

21 22

5 15

23

16 15

3 21 15 2 15

16

16

23

22

15

15

15

17

15

4 18 30

20

19 32

33

1. Control valve

9. Boom block

18. Main relief valve

27. Suction check valve

10. Pump block (P2)

19. O-ring

28. O-ring

2. Pump block (P1)

11. Swing block

20. O-ring

29. O-ring

3. Travel block(LH)

12. Dozer block

21. Conflex valve block

30. Plug

4. Spare block

13. Swing block

22. O-ring

31. Plug

5. Arm block

14. Pump block (P3)

23. O-ring

32. Tie rod

6. P.T.O. block

15. O-ring

24. Port relief valve

33. Nut

7. Travel block(RH)

16. O-ring

25. O-ring

8. Bucket block

17. O-ring

26. O-ring

assembly

- 64 -

7.1. SPECIFICATIONS

• Detail construction of blocks(SOLAR 030 Plus / SOLAR 035) Drive 9 9

1

10

10

2 3 4

11

Swing, Dozer

12

4

3

Arm, Boom, Bucket, Swivel 5 6

14

5 7 13

2 8 15

Arm 9 21

10 11 12

22 24

23

16 18,17

Arm 19 16 20 15

13 14

1. Screw

9. Plug

17. Spring

2. Seal holder

10. O-ring

18. Spring

3. Backup ring

11. Spring

19. Spring

4. O-ring

12. Poppet

20. Spool end

5. Spring holder

13. Cover

21. Spool end

6. Spring

14. Bolt

22. O-ring

7. Socket bolt

15. O-ring

23. Spring

8. Spring cover

16. Spring holder

24. Piston

- 65 -

1

7. CONTROL VALVE

7.2. CONSTRUCTION 7.2.1. Arrangement

Main relief valve(200K)

T1

P1

P1 block B9

A9

B8

A8

Travel(LH)

PA8

PB8

Arm Combination valve PTO

Combination valve

A7

B7 B6

A6

B5

A5

B4

A4

Travel(RH) PA5

PB5

PB4

Bucket PA4

Boom Combination valve

Combination valve

P2 block P2

Port relief(250K)

B3

A3

B2

A2

B1

A1

Boom swing PA1

PB1

Main relief valve(175K)

Dozer

P3

Swivel

T2

P3 P3 block

- 66 -

7.2. CONSTRUCTION

7.2.2. Principle of main spool's switchover function Principle of main spool's switchover function Neutral position Close

T P T

Oil flows from P to T.

Operating the joy stick valve generates pilot pressure. This pilot pressure generated at PA port will act on the right section of the main spool, which overrides, in turn, the springs(A)(B) and moves to the left side.

Then, if the oil flowing through the port P is shut off from the port T, oil pressure starts rising and the pressurized oil push up the load check valve to allow the oil to flow from the port P through port A to the cylinder rod. The return oil flows into the port B, passing through the main spool orifice A. If the joy stick valve which passes through line hole A to the tank circuit is turned to the neutral position, the pilot pressure is removed, which in turn, causes the spool to return to the neutral position from the springs(A) and (B) to the right side.

Hydraulic cylinder

Joy stick valve Pilot pressure Port A

Port B

Port PA Spring(A)

Oil line hole A

Spring (B)

Orifice A

Valve

Load check valve

- 67 -

Main spool

7. CONTROL VALVE

7.2.3. Principle of relief valve operation 1. Main relief valve The primary pressure passes through the poppet, valve seat, and orifice, presses the needle valve to the left side, and at the same time, acts on the inside of the poppet to push it to the right side. (The oil in the secondary pressure chamber does this.)

As the primary pressure rises higher and higher, it pushes out the spring in the rear of the needle valve, which in turn is forced to move to the left side. Then, since the oil pressure in the secondary pressure chamber returns to the oil tank and the force pushing the poppet in the closed direction(force pushing the poppet to the right side) disappears, the poppet is pushed and opened by the primary pressure, causing the oil to return to the tank.

As a decrease in the primary pressure makes the secondary pressure decrease, the poppet is closed by the spring force and the secondary pressure rises again to push the poppet to the right side, with the result that the relief condition is stopped.

Valve seat Main relief valve

Tank Primary pressure

Spring

Needle valve

Poppet

Secondary pressure chamber

- 68 -

7.2. CONSTRUCTION

2. Combination valve

Poppet Combination valve

Line pressure

Tank pressure

If the line pressure exceeds the set pressure, the poppet is pushed to the right side to make the line pressure flow to the tank.

Combination valve

Line pressure

Tank pressure

The suction pressure activates the line pressure to make the seat move to the left side, and oil flows in the line from the tank. If the oil flows into the line to release the exhaust pressure, the seat moves to the right side again and is separated from the tank.

- 69 -

7. CONTROL VALVE

3. Port relief valve

Poppet

Port relief valve Spring

Line pressure

Tank pressure

In general, the poppet is pushed to the left side by the spring force to shut off the line pressure and tank pressure.

Poppet

Port relief valve Spring

Line pressure

Tank pressure

If the line pressure exceeds the set value, the poppet is pushed to the right side to make the line pressure flow to the tank.

If the line pressure goes below the set value, the poppet is pushed to the left side again by the spring force and shut off the line pressure and tank pressure.

- 70 -

7.2. CONSTRUCTION

7.2.4. Arm regeneration circuit Spool

PB

PA

Piston

•

At arm crowd If the pressure(PB) of the arm cylinder rod side is higher than the pressure(PA) of the cylinder head side, the pressure of the rod side flows toward the head past the line holes(A)(B) in order for (PA<PB) to actuate the piston(A) to the right side at the pressure(PB) of the rod side.

(The amount of oil corresponding only to that in the orifice(C) is bypassed to the tank.)

Line

•

T

Line hole(A)

Orifice(C)

Piston(A)

At arm crowd If the pressure at the arm cylinder rod side is lower than that at the head side(PA>PB), the piston(A) is seated in the left side by the pressure at the head and accordingly the return oil flows straightly in the tank port.

When no regeneration of arm crowd is done = At excavation, etc.

- 71 -

7. CONTROL VALVE

7.3. DISASSEMBLY AND REASSEMBLY 7.3.1. To replace the O-ring on the mating surface and block assembly 1. Disconnect the tie rod.

2. Remove each block. Take care not to damage the mating surface for each block.

3. At disassembly, replace the O-ring on the mating surface if possible.

4. Clean the mating surface to remove dust or dirt at reassembly and install a new O-ring, then assemble them by reversing the sequence as described above. (When installing the O-ring, always coat it with grease.)

5. Tighten the tie rod nut. (Tightening torque: 2.4kg• m) (When tightening the nut, ensure that the spool of each block should operate properly.)

Block

O-ring

Tie rod

Nut

- 72 -

7.3. DISASSEMBLY AND REASSEMBLY

7.3.2. Replacement of O-ring on the spool 1. Replacement of lever • Remove the O-ring holding bolt 1 from the block.

• Remove the wiper 2 and O-ring 3.

• When assembling the wiper, take care not to damage the O-ring.

2. Replacement of cap • Loosen the cap holding bolt 4 to remove the cap 5.

• Remove the spool 6 and replace the O-ring 7.

• Clean the spool, and then assemble it to the block body.

• When assembling the spring cap, take care not to damage the O-ring.

- Cap holding bolt tightening torque: 1.1kg• m - Replace the spool and block as an assembly.

1 23

7 6

5 4

7.3.3. Removal of load check valve • •

Remove the load check spring and load check valve from the valve block.

Thoroughly clean them before reassembling them.

7.3.4. Replacement of relief valve and O-ring • • • • •

Remove the suction assembly relief valve.

If necessary, replace the O-ring or relief valve.

Coat the O-ring with grease at installation.

When loosening the cap nut and hexagon head nut on the relief set adjusting screw, always use a pressure gauge to check for the relief setting pressure.

When removing the relief valve assembly, take care so that the center hole of the relief piston may not be blocked by foreign matters. Relief valve tightening torque: 7.0kg• m

- 73 -

7. CONTROL VALVE

7.4. CONSTRUCTION OF EACH VALVE 7.4.1. Main relief valve 1

2 3 4

1.

2.

3.

4.

5.

5

6 7

8

9 10 11 12 13 14

Cap nut Set screw Gasket ring Spring Housing

6. O-ring 7. Needle valve 8. Wire 9. O-ring 10. Valve seat

Location

Tightening torque

Cap nut tightening torque

1.5~2.0kg• m

Relief valve fixing torque

3.0~3.5kg• m

11. Spring 12. Poppet 13. O-ring 14. Sleeve

7.4.2. Complex valve 1

2

1.

2.

3.

4.

3

4

5

6

7 8

Cap nut Set screw Gasket ring Spring

9 10

5.

6.

7.

8.

Relief valve Poppet O-ring Seat

Location

Tightening torque

Cap nut tightening torque

1.5~2.0kg• m

Relief valve fixing torque

3.0~3.5kg• m

9. O-ring 10. Clip

7.4.3. Port relief valve 1

2

3

4

1. Plug 2. O-ring 3. Body

5 6 7 8

9

4. Spring 5. O-ring 6. O-ring - 74 -

Location

Tightening torque

Relief valve fixing torque

3.0 kg• m

7. Backup ring 8. Poppet 9. O-ring

7.5. CAUTIONS WHEN HANDLING

7.5. CAUTIONS WHEN HANDLING 7.5.1. Handling 1. When handling or transporting the valve, take care not to drop it so that it may not give impact to the spool tip and cap area.

2. When storing the valve for an extended time, tighten plugs to each portion to prevent the entry of dust or water.

7.5.2. Installation 1. When assembling valve fittings, use the specified tightening torque.

(Take care so that the pipe may not give unnecessary stress over the valve.)

2. Install the control linkage so that the spool moves correctly in the axial direction.

3. When welding near the valve, take care so that excessive heat and welding sputter may not damage the O-ring and dust seal.

4. In painting, prevent paint from being contacted with the spool.

5. Do not leave plug unscrewed until doing piping works so that dust or water may not enter each port.

7.5.3. Operation 1. Before operation, check to see that the hydraulic pipes and hydraulic oil are clean.

2. Hydraulic oil for use should be at -20°C~80°C. If the oil temperature is below 0°C, warm up the engine.

3. Do not raise the set pressure for the main relief valve and port relief valve above the specified one.

How to adjust the pressure for the main relief • Install a pressure gauge between the pump at a portion to be measured and the control valve.

(Use a pressure gauge fitting if available.)

• Raise the oil temperature up to 50°C~60°C to obtain the rated engine rpm.

• Operate the control lever and check the pressure when the cylinder reaches the end stroke.

• When raising the pressure, use a hexagon socket wrench to turn the suction port-to-relief valve adjusting nut counterclockwise.

- Main relief valve: 100kg/cm2 per turn - Port relief valve: 100kgcm2 per turn • After adjusting to the specified pressure, tighten it securely.

- 75 -

Pressure up

8. SWING MOTOR

8. SWING MOTOR 8.1. SPECIFICATIONS SOLAR 030 Plus

Av,Bv port 2-PF3/8 O-ring port 45

101

63

14

45

292

64

125h7

•

48

PF3/8 O-ring port 162

Tank port

T Pilot port

Bv

Av

Type

Specifications

Diaplacement

244cc/rev

Maximum rpm

69.7 rpm

Rated flow rate

19 l/min

Relief set pressure

130kg/cm2

- 76 -

45

8.1. SPECIFICATIONS

• SOLAR 035

218 2-M16 13H7 0 35

2-15

150 h8

50

2-

2- 50

G1/4

10

48

6- 17

0

2-G3/8 A,B port G3/8 T-port

10

325.5

0

21

D PC

RED.

A T B

Item

Reduction gear

Type

Specifications

Output torque

72kg• m

Output rpm

66 rpm

Deceleration ratio

19.3

Displacement

18.1cc/rev

Maximum rpm

1286 rpm

Rated flow rate

24 L/min

Relief set pressure

160kg/cm2

Motor

- 77 -

8. SWING MOTOR

8.2. CONSTRUCTION • SOLAR 030 Plus

1

10

13 9

12

7

8 5 6

3 4 2

1. Swing motor assembly

5. Rear bearing

9. Plug

2. Plug

6. Snap ring

10. Bolt

3. Front bearing

7. O-ring

12. Bolt

4. Snap ring

8. Spring washer

13. Relief valve block

- 78 -

8.2. CONSTRUCTION

• Internal structure(SOLAR 035)

1. Swing motor assembly 2. Relief valve assembly 3. O-ring 4. O-ring 5. O-ring 6. O-ring 7. O-ring 8. O-ring 9. O-ring 10. Carrier gear assembly(2) 11. Carrier gear assembly(1) 12. Pinion gear assembly 13. Bolt 14. Bearing 15. Spring pin 16. Snap ring 17. Bolt 18. Parallel pin 19. Bearing 20. Filter 21. S2 gear 22. Thrust collar 23. Snap ring(S) 24. Spring pin 25. Snap ring(SA)

- 79 -

8. SWING MOTOR

8.3. PRINCIPLES OF OPERATION 8.3.1. Principles of operation (SOLAR 030 Plus) The pressurized oil flowing in the motor flows past the disc valve to the Z-Rotor, the star of which does planetary motion to rotate the main drive. At this time, the disc valve is driven by the valve drive.

Inlet

Outlet

Right-hand turn

Tape roller bearing Main drive Z-Rotor Valve drive Valve plate port(7 No.) Check valve(2 No.)

External drain clamping plug Disc valve (with 12 ports)

- 80 -

8.3. PRINCIPLES OF OPERATION

• Motor principle(SOLAR 035) 1. Hydraulic motor functions The hydraulic motor is of a axial piston motor type, and converts the pump-fed hydraulic energy to rotational motion.

2. Motor construction and principle of operation The pressurized oil flowing in through the hydraulic valve is delivered to the valve plate. The pressurized oil delivered to the port A is fed to the cylinder port, in the cylinder barrel, corresponding to the port A and pushes out the piston. This pushing force is converted to rotational force by means of the swash plate.

The return oil within the cylinder port flows out through the port B of the valve plate.

In the case of reverse rotation, the pressurized oil flows in from the port B and the return oil flows out to the tank through the port A.

Piston

Shaft

Cylinder barrel

Valve plate

Swash plate Port A

Port B

- 81 -

8. SWING MOTOR

8.3.2. Shockless relief valve functions The hydraulic motor, even at stationary, would continue to rotate by inertia force although the port A shuts off hydraulic pressure. Then, pressure generated within the port B pushes the relief valve poppet open at the primary pressure P1.

Also, pressurized oil is induced at the piston section by means of the poppet check, and as a result, the piston moves to the right side. This motion increases the spring load to generate the secondary pressure P and to control the pressure within the port B in the manner as shown, and accordingly the hydraulic motor come to a stop smoothly.

Suction check valve

Port B

Port A

Suction check valve

Piston To upper side

P1

Shockless relief valve

Check

- 82 -

Poppet

Shockless relief valve

8.4. INSPECTION AND ADJUSTMENT

8.4. INSPECTION AND ADJUSTMENT 8.4.1. Swivel's spontaneous settlement measurement 1. Machine position • Part the machine on an incline with a swash angle of 12° with the hydraulic oil temperature at 50°C±5°C. • Fully extend the arm cylinder, position the boom cylinder parallel to the surface of the incline, and then stop the engine.

2. Measurement Check the amount of oil leak for 3 minutes. (Measure the travel of the swing bearing outer race.)

Model

Standard

Limit

Weight(kg)

SOLAR 030 Plus 100mm or less 200mm or less

130kg

SOLAR 035 100mm or less 200mm or less

160kg

8.4.2. Amount of drag when swinging is stopped Position the machine on a level ground with high engine rpm, oil temperature at 50°C±5°C, and at maximum operating radius as shown, and align the boom joint 1 parallel to the arm bucket coupling pin 2.

Apply a weight to the bucket tip, and measure the moving length with the bucket tip as a basis after making a turn.

• Bucket load : S030 Plus:130kg, S035: 160kg • Standard : 90mm or less

- 83 -

(1)

(2) (W)

8. SWING MOTOR

8.5. MAINTENANCE STANDARDS 8.5.1. Swing motor removal 1. Remove the pipes connected to the swing motor, and do not allow the fittings to be contaminated.

2. Remove the swing motor clamping bolt.

3. Install the eye bolt into the swing motor removing thread to remove the swing motor.

After applying LOCTITE to the threaded portion, tighten to the specified torque.

M12 x 1.75 x 601 Tightening torque : 11.5kg·m

M12 x 1.75 x 701 Tightening torque : 11.5kg·m

M16 x 2.0 x 451 Tightening torque : 27.5kg·m

8.5.2. Swing bearing seal replacement If the seal is found cracked or scored, replace the inner and outer race seals with new ones.

• How to replace 1. Remove the old seal and eliminate gasket materials remaining in the inner and outer race grooves.

2. Use thinner to eliminate the gasket material marks and dry them up.

3. Apply adhesive such as nitrile rubber around the circumference of the seal.

Apply adhesive to the cut sections and align them with each other to press the seal in the seal groove.

If the seal is circular, the cut sections do not require any special treatment, but the seal should be made longer than its overall length before being pressed in the circumference evenly. Do not leave any part of seal unused.

- 84 -

Cut section

To cut 45° to make the contact area wider.

9.1. SPECIFICATIONS

9. TRAVEL MOTOR 9.1. SPECIFICATIONS • SOLAR 030 Plus

G1/4 Travel second-speed

ANS0160L

Item

Reduction gear

Type

Specifications

Maximum output torque

266kg• m

Maximum output rpm

41.2/68.1 rpm

Deceleration ratio

1/45.2

Amount of delivery

21.5/12.9cc/rev

Maximum service pressure

200kg/cm2

Maximum amount of flow

40.9 l/min

2-speed switchover pressure

15kg/cm2

Hydraulic motor

- 85 -

9. TRAVEL MOTOR

• SOLAR 035

2-G1/4 (Dr) 2-G1/2 (A,B) G1/4 Travel secons-speed G1/4

56

51

165 h8 192 214

255 232 210 h8 204

297.5 70

12-M12

107 147 160

9-M12

Dr

RED

A B

RP

Item

Reduction gear

Hydraulic motor

Type

Specifications

Maximum output torque

272kg• m

Maximum output rpm

38.2/56.9 rpm

Deceleration ratio

40.6

Amount of delivery

23.6/15.7cc/rev

Maximum service pressure

210kg/cm2

Maximum output rpm

1553/2311 rpm

Maximum amount of flow

37 l/min

2-speed switchover pressure

15kg/cm2

- 86 -

9.2. CONSTRUCTION

9.2. CONSTRUCTION • SOLAR 030 Plus

- 87 -

9. TRAVEL MOTOR

101. Body 102. Cover 104. Carrier 2 106. B1 gear 107. B2 gear 108. S1 gear 109. S2 gear 110. Ring 111. B2 pin 113. Snap ring 115. Thrust color 116. Slide ring 117. Floating seat 118. O-ring 119. Bearing 120. Needle 121. Needle 122. Thrust whasher 123 & 128. Snap ring 124. Snap ring 125 - 126. Snap ring 127. Spring pin 129 - 131. O-ring 132 - 133. Plug 134. Hydraulic motor 137. Name plate

138. Plug 139. O-ring 140 - 141. Thrust washer 202. Body 2 203. Shaft 204. Cylinder barrel 205. Valve plate 206. Piston 207. Shoe 208. Shoe holder 210. Swash plate 211. Control piston 212. Pin 213. Spring 214. Retainer 215. Bearing 216. Bearing 217 - 218. O-ring 219. Oil seal 220. Ball 221. Snap ring 222. Screw 223. Spring pin 224. Pin 228. Bearing 301. Body 1

- 88 -

302. Spool 303. Check valve 304. Spring guide 305. Spool 306. Shuttle spool 307. Spring V1 308. Spring V2 309. Spring V3 310 - 312. Plug 313. Choke 314. ring 315. Plug 317 - 320. O-ring 321. Choke 324. Screw 401. Body 403. O-ring 404. Plug 501. Retainer 502. Poppet 503. Spring guide 504. Spring 505. Adjuster kit 506 - 508. O-ring

9.2. CONSTRUCTION

• SOLAR 035

1. Travel motor assembly 2. Roller bearing 3. Pin(b2) 4. Pin(b1) 5. O-ring 6. Gear(b1) 7. Gear(b2) 8. O-ring 9. O-ring 10. O-ring 11. O-ring 12. O-ring

13. O-ring 14. O-ring 15. Oil seal 16. Backup ring 17. Piston seal 18. Piston seal 19. Roller bearing 20. O-ring 21. O-ring 22. O-ring 23. Relief valve assembly 24. Relief cartridge 25. Plug

26. Bolt 27. Bolt 28. Plug 29. Parallel pin 30. Spring pin 31. Ball bearing 32. Snap ring(H) 33. Ball bearing 34. Floating seal 35. Ball bearing 36. Plug 37. Carrier(1) 38. Gear(S1) 39. Thrust washer

- 89 -

40. Snap ring(S) 41. Carrier(2) 42. Thrust collar 43. Slide ring 44. Thrust washer 45. Snap ring 46. Snap ring 47. Plug 48. O-ring 49. Plug 50. O-ring 51. O-ring

9. TRAVEL MOTOR

9.3. PRINCIPLES OF OPERATION • SOLAR 030 Plus

Carrier 1 a1 Stationary part

a2

Moving part b p1 b1

1

b2

s1 s2

s p2

p4

Carrier 2 Hydraulic motor

p3

Simple planetary reduction gear (2 shift levels)

Counterbalance valve ANS0170L

The hydraulic motor output shaft is connected to the s2 gear by the spline as shown above, and the rotation of the s2 gear is reduced preliminarily by the s2, b2, and a2 gear.

The rotation reduced at the first level is reduced further by the s1, b1, a1 gear connected to the carrier 2 by the spline, and this rotation reduced finally at the second level is transferred to the rotor body through the a1, a2 internal gear to produce driving force.

- 90 -

9.3. PRINCIPLES OF OPERATION

• SOLAR 035

Carrier 1

Stationary part

a1

a2

Moving part b p1 b1

1

b2

Dr s1 A B

s2

s p2

p4

PP

Carrier 2

Hydraulic motor

p3

Simple planetary reduction gear (2 shift levels)

Shockless overload relief valve Counterbalance valve

The s2 gear is installed over the hydraulic motor output shaft by the spline as shown above, and the rotation of the s2 gear is reduced preliminarily by s2, b2, and a2 gears.

The rotation reduced at the first level is reduced further by s1, b1, and a1 gears connected with the carrier 2 by the spline, and this rotation reduced finally at the second level is transferred to the rotor body through the a1 and a2 internal gears to produce driving force.

- 91 -

9. TRAVEL MOTOR

9.3.2. Explanation about operation The travel motor composed of the hydraulic motor and reduction gear.

Carrier 1 a1 - a 2

• Reduction gear 1. Operation The reduction gear consists of a planetary gear(with 2 shift levels). This gear allows the hydraulic motor to reduce its high speed to increase the torque at a low speed and rotate the case.

2. Principle of operation The s2 gear is placed over the hydraulic motor output shaft as shown, and the rotation of the s2 gear is reduced preliminarily by the s2, b2, and a2 gears.

The rotation reduced at the first level is reduced further by the s1, b1, and a1 gears connected to the carrier 2 by the spline, and this rotation reduced finally at the second level is transferred to the rotor body through the a1 and a2 internal gears to produce driving force.

The deceleration ratio for the simple planetary gear(with 2 shift levels) is calculated generally as follows: R =

Zs1 Zs2 • Zs1+Za1 Zs2+Za2

Here: Zs1, s2: No. of teeth of s2 gear Za1, a2: No. of teeth of a2 gear In case of hydraulic motor, the deceleration ratio of the main body's rotor is calculated as follows: R' =

1 1-1/R

- 92 -

b1

b2

s1 s2

Carrier 2

9.3. PRINCIPLES OF OPERATION

• Hydraulic motor 1. Hydraulic motor operation The hydraulic motor is of a axial piston type, and converts the hydraulic pressure energy fed from the pump into rotational motion.

2. Construction and operation principle of hydraulic motor

Piston

Shaft

Cylinder valve

Valve plate

Swash plate Port A

Port B

The pressurized oil flowing from the hydraulic valve is fed to the valve plate. When the pressurized oil is delivered to the port A, it flows in the cylinder port, in the cylinder barrel, corresponding to the port A to push out the cylinder. This pushing force is converted to rotational force by means of the swash plate.

The return oil within the cylinder port flows into the tank through the port B of the valve plate.

In the case of reverse rotation, the pressurized oil flows in from the port B and the return oil flows into the tank through the port A.

- 93 -

9. TRAVEL MOTOR

3. Principle of second-speed motor operation

Piston Face B

Control Seal

Shoe

Shoe Ball

Ball

Spring Face 1 Control ring

Cylinder barrel Stop ring

Face 1 Hydraulic pressure

The swash plate has 2 faces of A and B on the opposite side of the sliding face for the shoe and is clamped by two balls fixed on the body(2).

As these balls are installed eccentrically from the center shaft, both the hydraulic force acting on the piston and the spring in the cylinder barrel in the first speed condition are combined to fix a swash angle to α, from which a large capacity results.

If depressing the second accelerator pedal, hydraulic pressure produced by the stopper ring and control ring together by means of the second-speed spool is guided to the control seal and goes forward until it contacts the swash plate body to fix the swash plate at an angle β, from which a small capacity results.

If the engine is started, the control seal gets connected to the tank port. As a result, the spring force makes the swash plate return to the first-speed condition.

- 94 -

9.3. PRINCIPLES OF OPERATION

4. Counterbalance valve operation

2 C 4

3

A

Dr

PP

B

Dr

D

A

B

1

E

When the pressurized oil is fed from the port A, it forces the check valve(3) open to flow into the inlet port (A)'. Then, it enters the chamber(D) through the check hole(C), overcomes the spring(4) force, and allows the spool valve(2) to slide in the right direction. As a result, the return oil in the hydraulic motor flows from the port(B)', past the body(1) and the opening(E) of spool valve(2), to the port (B) to rotate the hydraulic motor.

If the pressurized oil is fed from the port (B), each component operates in a reverse way, resulting in reverse rotation of the hydraulic motor.

If the hydraulic pressure of the port(A) is not supplied in a pressurized condition, the spool valve(2) which is operating in the right side would turn to the left side by the spring(4) force. At this time, the oil in the chamber(D) would flow out to the port(A) through the check hole(C), but it controls the speed of spool valve(2) which would return to the left side, using the orifice effect of the check hole(C). Also, the hydraulic motor would continue to turn by inertia force although the pressurized oil of the port(A) is not supplied. Then, the shifting speed of the spool valve(2) and notch phenomenon combines to reduce the return oil speed, and therefore the hydraulic motor is stopped smoothly.

In addition, the drain oil of the hydraulic motor flows from the oil gallery(F), through the port Dr, to both ports Dr.

- 95 -

9. TRAVEL MOTOR

9.4. CARE •

•

Always allow the hydraulic oil to cool down enough before making an inspection, as at the operating temperature the hydraulic oil is at high temperature.

Oil pressure remaining still in the case may make oil and plug pop out.

Loosen the plug slowly to release the pressure in the case.

1. There are 3 plugs on the cover 1 of the travel motor.

Use these plugs for oil feeding, drain, and oil level check.

2. Use a hexagon socket wrench to remove the oil feed plug and drain plug 2 located on top of the tank and drain out old oil.

3. After draining the oil, clean the oil feed, drain, and oil level check plugs, then wind a seal tape on them.

4. Tighten the plug over the drain port before injecting oil into the feed port. Overfill the tank to obtain the normal oil level(600cc).

5. Tighten each plug.

• Use recommended lubricants(gear oil).

• Never mix different type of oils together.

• Tightening torque • Feed port plug and drain plug 2 : 4.7~5.2kg• m • Oil level check plug 3 : 1.2~1.3kg• m

2. Oil feel port

1

3. Oil level check hole SOLAR 035

SOLAR 030 Plus 2. Drain port PF3/8

ANS0080L

- 96 -

9.4. CARE

9.5. RUNNING SPEED Check your machine's running speed with the engine at maximum rpm and oil temperature at 50±5°C. 1. At attachment operating mode(3 rotations) Steel shoe

Rubber shoe

Low speed

High speed

Low speed

High speed

SOLAR 030 Plus

18.5±2

11.5±2

18.5±2

11.5±2

SOLAR 035

18±2

12±2

18±2

12±2

2. When running 20m on level ground Steel shoe

Rubber shoe

Low speed

High speed

Low speed

High speed

SOLAR 030 Plus

32±2

20±2

31±2

19±2

SOLAR 035

25±2

19±2

26±2

17±2

9.6. INSPECTION AND ADJUSTMENT Travel deviation measurement(Engine maximum rpm, no load, oil temperature: 50±5°C)

Running distance

Amount of travel deviation

SOLAR 030 Plus

11 mm

less than 500mm

SOLAR 035

10 mm

less than 500mm

Running distance

Amount of travel deviation

- 97 -

10. HYDRAULIC CYLINDER

10. HYDRAULIC CYLINDER 10.1. CONSTRUCTION • SOLAR 030 Plus

K

C

D

B

A

H, L

F E J

D

I

C

B

A

H, L

F E

G1

G2

K

Cylinder

Item

Unit

Boom

Arm

Bucket

Boom swing

Dozer

A

Rod pin diameter

mm

ø40

ø35

ø35

ø35

ø35

B

Head pin diameter

mm

ø40

ø35

ø35

ø35

ø35

C

Rod diameter

mm

ø40

ø40

ø35

ø35

ø40

D

Cylinder bore

mm

ø70

ø70

ø70

ø60

ø75

Maximum extended length

mm

1432

1315

1105

1552

595

Minimum closed length

mm

865

805

680

925

470

F

Stroke

mm

567

510

425

627

125

G1

Width

mm

50

50

50

50

50

G2

Width

mm

50

50

50

50

50

kg

24

22

17

18

17

E

Weight

- 98 -

10.1. CONSTRUCTION

• SOLAR 035

I, J

C

D

B

A

H, K

F

G2

G1

E

Cylinder

Item

Unit

Boom

Arm

Bucket

Boom swing

Dozer

A

Rod pin diameter

mm

ø40

ø35

ø35

ø35

ø40

B

Head pin diameter

mm

ø40

ø35

ø35

ø35

ø40

C

Rod diameter

mm

ø40

ø45

ø40

ø45

ø50

D

Cylinder bore

mm

ø70

ø75

ø70

ø80

ø90

Maximum extended length

mm

1545

1520

1295

1609

595

Minimum closed length

mm

920

920

795

957

470

F

Stroke

mm

625

600

500

652

125

G1

Width

mm

50

50

50

50

55

G2

Width

mm

50

50

50

50

55

kg

28

30

21

27

20

E

Weight

- 99 -

10. HYDRAULIC CYLINDER

• Internal construction(SOLAR030 Plus)

1. Cylinder assembly

9. O-ring

17. O-ring

2. Cylinder tube assembly

10. O-ring

18. Set screw

3. Piston rod assembly

11. Backup ring

19. Bush

4. Rod cover

12. Backup ring

20. Grease nipple

5. Bush

13. Piston

21. Grease nipple

6. Rod packing

14. Piston packing

22. Dust seal

7. Dust seal

15. Wear ring

8. Snap ring

16. Cushion plunger

- 100 -

10.1. CONSTRUCTION

• Internal construction(SOLAR035)

1. Cylinder assembly

9. Cushion ring

17. Retainer ring

2. Cylinder tube assembly

10. Cushion guide

18. O-ring

3. Bush

11. Nut

19. Backup ring

4. Rod assembly

12. Rod cover

20. O-ring

5. Bush

13. Bush

21. Grease nipple

6. Piston

14. Packing

22. Grease seal

7. Seal

15. Backup ring

8. Wear ring

16. Dust wiper

- 101 -

10. HYDRAULIC CYLINDER

10.2. DISASSEMBLY 10.2.1. Disassembly procedures 1. Clamp the cylinder tube in a vise enough to avoid its deformation. Supply compressed air into the ports A and B to actuate the cylinder rod in order to drain out the old oil in the cylinder.

Extract the cylinder rod about 1/3.

Vise A

Wood block

B

2. Using a driver, make the rod cover stopping capacity even.

3. With a rack wrench, turn the rod cover counterclockwise from the cylinder tube to loosen it.

Counterclockwise

Rubber 4. Piston rod assembly disassembly Slowly turn the cylinder rod assembly to disconnect it from the tube.

After disassembling the piston rod, take care not to damage it.

5. Piston assembly disassembly Install a wood block on the inside of the vise as shown so that the piston rod may not be damaged.

Make the surface of the surface table parallel with the piston rod. Otherwise, the piston rod may be damaged.

- 102 -

Wood block

10.2. DISASSEMBLY

10.2.2. Internal component disassembly procedure 1. Piston removal With a special tool or spanner, remove the piston nut from the piston rod assembly by turning the nut slowly counterclockwise.

Counterclockwise

2. Mount the piston rod assembly on the work bench.

Remove the rod cover by moving it back and forth.

Use a tool to remove the backup ring and then O-ring.

*

Packing case

When attempting to use the rod cover again, do not damage it.

3. Packing assembly disassembly Exercise care not to damage the cover or piston groove.

4. As the piston rod and cylinder tube assembly removing bush is pressed fit in the rod head, use a press to remove the bush.

In case of ball bearing, remove the snap ring.

- 103 -

Socket

orth

nd f

ing

Mov

ka bac

Press(cylinder rod side)

10. HYDRAULIC CYLINDER

10.3. ASSEMBLY 10.3.1. ASSEMBLY PROCEDURE 1. Assemble the components by reversing the disassembly sequence.

2. Before assembling, check each component for metal chips or other foreign matters.

3. Apply hydraulic oil to each component before assembling them.

4. Semi-assemble each component before final assembly.

10.3.2. Inspection 1. Clean disassembled parts except for packings with light oil thoroughly.

2. Clean packings with hydraulic oil.

3. Do not use a mixture of different type oils. Service life of parts may be shortened.

4. Expecially, clean the sliding surfaces, oil holes, and packing grooves thoroughly.

5. If parts are not to be used immediately after cleaning, dip them in a suitable rust preventive compound.

(Coating with hydraulic oil has some rust-proofing effect.)

- Ensure that all the major parts are not damaged, deformed, rusted, or scored.

- Check each part for metal chips and other foreign matters.

- Check the piston rod and sliding surfaces for signs of damage, fretting, or discoloration.

- Replace packings and seals with new ones.

If parts are to be reused, ensure that they are not damaged and have no foreign matters.

10.3.3. Cautions to be taken at assembly 1. Before starting assembly, be sure to replace packings with new ones.

2. For retainer ring and seal ring, note the installing direction.

3. Replace set pin with a new one.

After assembling and fitting the set pin, secure it by punching 2 places on the circumference so that it may not be missed.

4. Strictly follow the specified tightening torque when tightening the rod cover, piston, nut etc.

5. Check sufficiently prior to assembly.

Note cushion bearing installation direction

Seal ring To punch

Secure by punching

- 104 -

11.1. SPECIFICATIONS

11. SWIVEL JOINT 11.1. SPECIFICATIONS • SOLAR 030 Plus

Dr

2 kg/cm2

A~F.P

210 kg/cm2

A,B,P,Dr

PF 1/4

C~F

PF 1/2

Service pressure

Port size, Service rpm

10 rpm

Left travel

100 124

Right travel

175 199 Right travel

Left travel

78

110

B: Dozer Down

332

A: Dozer Up D: Right travel Forward

C: Left travel Forward

F: Right travel Reverse

44

E: Left travel Reverse

Dr: Drain

- 105 -

11. SWIVEL JOINT

• SOLAR 035 Dr

2 kg/cm2

A~F.P

210 kg/cm2

A,B,P,Dr

PF 1/4

C~F

PF 1/2

Service pressure

Port size, Service rpm

14 rpm

Right travel

Left travel Travel second-speed(left)

100 125

Travel second-speed(P)

Travel second-speed(right)

175 200 Left travel

Right travel

88

A: Dozer Up

D: Right travel Forward

321

B: Dozer Down C: Left travel Forward E: Left travel Reverse

Dr: Drain

78

F: Right travel Reverse Dr: Drain 122 150

- 106 -

11.2. CONSTRUCTION, DISASSEMBLY, AND REASSEMBLY

11.2. CONSTRUCTION, DISASSEMBLY, AND REASSEMBLY 11.2.1. SOLAR 030 Plus • Construction

1. Center joint assembly 2. Body 3. Slipper seal 4. O-ring 5. Dust wiper 6. Spindle 7. Hexagon head plug 8. Thrust plate 9. Hexagon head bolt 10. O-ring 11. Cover 12. Hexagon head bolt 13. Spring washer 14. Pin

• Disassembly 1. Remove the bolt(12) and spring washer(13).

2. Remove the spindle(6) from the body(2) in the upper direction. * To prevent damage of the O-ring, turn the spindle at disassembly.

• Reassembly 1. Check the O-ring and sliding surfaces of the assembly for damage or break.

2. Assemble parts by reversing the disassembly sequence.

When assembling the O-ring, be sure to apply hydraulic oil and grease to it.

- 107 -

11. SWIVEL JOINT

11.2.2. SOLAR 035 • Construction

1

1. Swivel joint assembly 14

2. Slipper seal 15

3. Cover 4. Hub 5

5. Spindle 6. Spacer 7. Hexagon socket head cap bolt 4

8. Snap ring

9

9. Dust seal 10. 11.12. O-ring

13

13. Backup ring 10

14. Plug

6

15. Pin 12

8 2 11

3

7

• Disassembly 1. Remove the bolt(7).

2. Remove the spindle(5) from the housing hub in the upper direction. * To remove the O-ring and backup ring, lightly tap the case with a copper hammer.

• Reassembly 1. Check the O-ring and sliding surfaces of the assembly for damage or break.

2. Assemble parts by reversing the disassembly sequence.

When assembling the O-ring, be sure to apply hydraulic oil and grease to it.

- 108 -

12.1. SPECIFICATIONS

12. JOY STICK 12.1. SPECIFICATIONS 100 kg/cm2

Permissible exhaust pressure

3 kg/cm2

Rated flow

15L

O

1.3 = 19 2.4 = 23

o

SINGLE

OUBLE

28 D

(364.5)

O

(247.5)

Maximum primary pressure

T

90

4.5

Over 350

17.5

P

1

3

2

HYDRAULIC SYMBOL

∅113

71

45

o

(131)

6-PF1/4 O-ring port

4-∅7 Hole 27

71 98

ANS0090L

- 109 -

4 ANS0100L

12. JOY STICK

• Secondary pressure characteristics and control torque

40 37.7

Operating Torque 25.1±2 19.5±1.5 (11.6) 7.7±1

5±0.75

Secondary Pressure

0

OPERATING TORQUE (kgf cm )

SECONDARY PRESSURE (kgf/cm2 )

PORT 1, 3

7

1.1±0.5

6.5±0.5

PUSH-ROD STROKE (mm) ANS0110L

40

39.7

Operating Torque

26.9±2

19.5±1.5

(11.6) 7.7±1

5±0.75

OPERATING TORQUE (kgf cm )

SECONDARY PRESSURE (kgf/cm2 )

PORT 2, 4

9 8.5±0.5

0 1.1±0.5 PUSH-ROD STROKE (mm)

ANS0120L

- 110 -

12.2. PRINCIPLES OF OPERATION

12.2. PRINCIPLES OF OPERATION The pilot valve operation principle is explained according to the operation diagram as given below. The diagram below explains about a typical pilot valve.

12.2.1. Neutral The force of spring 2 setting up the output pressure of the pilot valve does not act on the spool 1.

Accordingly, the spool is pushed upward by the spring 8 to reach the location of port B in the diagram As a result, it indexes with the tank port T only and the output port pressure becomes equal to tank pressure.

12.2.2. If the lever is forced inclined The spool moves downward according to the push rod 3 stroke. Also, the port P is indexes with the port A so that the oil fed from the pilot pump flows out to the port A to produce pressure. If the pressure of port A increases up to that corresponding to the spring force set by inclining the lever, the hydraulic pressure and spring force becomes in a balanced state. Furthermore, if the pressure of port A exceeds the set pressure, the port A and P are closes, while A and T are opened; if the pressure of port A goes down below the set pressure, the port A and P are opened, while A and T are closed. This principle of operation maintains the secondary pressure stable.

Port T

Port P Port A

- 111 -

Port B

12. JOY STICK

12.3. CONSTRUCTION

ANS0140L

1. Body

12. Push rod

23. Connector

2. Plug

13. Push rod

24. Nut

3. O-ring

14. Plug

25. Boot (LH), (RH)

4. Spring

15. O-ring

26. Nut

5. Spring seat

16. Rod seal

27. Switch ass’y

6. Spring seat

17. Plate (A)

28. Insert

7. Stopper

18. Busing

29. Handle ass’y

8. Spring

19. Machine screw

30. Screw (Tapping)

9. Spring

20. Joint ass’y

31. Plate (B)

10. Spring seat

21. Swash plate

32. Boot

11. Spool

22. Hex. nut

- 112 -

13.1. SPECIFICATION

13. SOLENOID VALVE 13.1. SPECIFICATIONS

T

P

X

Y

X

A

Y

B G

X-X Section

SOL2

SOL1 P Y-Y Section T

A

ANS0180L

B

- 113 -

13. SOLENOID VALVE

13.2. CONSTRUCTION 1

14 14 5

5 17 4

17 4

11 7 15 11

19 9

3 12

15

2

2

6

3 12 16

16

16

18 8

13

ANS0190L

1. Solenoid valve assembly

8. Body

15. Washer

2. Shim

9. Spring

16. Scale ball

3. Spring

10. Spool

17. O-ring

4. Sleeve

11. Spool

18. O-ring

5. Solenoid

12. Stopper

19. O-ring

6. Plunger

13. Plug

7. Stopper

14. Bolt

- 114 -

13.3. OPERATION

13.3. OPERATION The solenoid valve is a valve designed to control the joy stick pilot pressure and travel second-speed pilot pressure.

SOL2

SOL1

P XG

T Right-hand travel motor

Right-hand joy stick

Left-hand travel motor

Left-hand joy stick ANS0200L

SOL1 : Limit switch(cutoff) attached to the right control stand SOL2 : Limit switch for travel second-speed control

- 115 -

13. SOLENOID VALVE

13.4. CONSTRUCTION The solenoid valve consists of a relief valve, a un-load valve, a lever lock, and a travel second-speed valve.

1. Relief valve If the pressure of the port P increases to reach a set pressure, the poppet is pushed to the right side to make the port P indexed with the port T, with the result that the pressure is relieved.

Poppet

Spring T

P

<Relief state> Poppet

Spring T

P

2. Lever lock solenoid If the lever lock solenoid(A) is OFF, the spool does not allow the oil in the port P to flow to the port A. If the lever lock solenoid(A) is ON, the spool moves downward to permit the passage for the port P and A to be opened.

SOL(A)

SOL(B)

T A

B

P

Spool (B) ANS0210L

- 116 -

13. SOLENOID VALVE

13.4. CONSTRUCTION

3. Travel motor high/low speed shifting solenoid If the travel motor speed shifting solenoid(B) is OFF, the oil discharged from the port P is shut off from the port B by the spool(B), with the result that the pilot pressure does not flow in the port B. If the travel motor speed shifting solenoid(B) is ON, the spool(B) moves to allow the ports P and A to be opened.

SOL(A)

SOL(B)

T A

B

P

Spool (B) ANS0220L

- 117 -

14. CRAWLERS

14. CRAWLERS 14.1. SPECIFICATIONS AND CONSTRUCTION

SOLAR 035 300mm

SOLAR 030 300mm

14.1.1. Steel crawlers

101.6mm

Shoe

Pin

14.1.2. Track frame

Idler Track frame

Guide

Track Spring roller

- 118 -

14.2. DISASSEMBLY AND REASSEMBLY

14.2. DISASSEMBLY AND REASSEMBLY 14.2.1. Crawler removal • •

Crawler removal operation may very dangerous as it should be done with the machine inclined. Never move the machine during removal operation so that the machine may not be tipped over.

When loosening the cartridge valve, do not bring your face near the grease nipple because the inside of the track tension adjusting cylinder is in a high pressure state and allow highly pressurized grease to splash, with the result that the grease nipple may pop out.

1. Crawler loosening • Loosening the cartridge valve of the tension adjusting cylinder drains the grease to loosen the crawlers. Loosen the cartridge valve slowly. * The maximum amount of loosening can be obtained if 1/2 turn is made.

•

When removing the crawlers, position the machine as shown and install non-slip supports under the frames. * If the grease would not be drained out easily, turn the crawlers a little in the position as shown.

•

After completing the tension adjustment, tighten the valve securely. * Cartridge tightening torque: 6~9kg• m

1

2. Crawler removal • Lift the machine in one side using the front and install wood block under the machine.

•

Steel crawlers Remove the master pin(1) from the linkage by turning it to the idler side, and then remove the crawler(2).

1 2

•

Rubber crawlers Slide in the idler all the way, and remove the rubber crawler from the idler using a steel bar.

- 119 -

14. CRAWLERS

14.2.2. Crawler installation •

Crawler installation operation may very dangerous as it should be done with the machine inclined.

Never move the machine during removal operation so that the machine may not be tipped over.

1. Crawler installation • Lift the machine in one side using the front and install wood block under the machine.

• Index the crawler(1) with the sprocket teeth and then install it on top of the idler.

• For steel crawlers, insert the the master pin(2).

For rubber crawlers, install the crawler over the idler.

2 1

2. Track tension adjustment • With a grease gun, inject grease into the grease nipple.

•

Check Measure the distance between the rolling surface of the track roller and the contact surface of the crawler.

Gap

a. For steel crawlers It is accepted if the distance between the rolling surface of the track roller and the contact surface of the crawler is 10~15mm.

- 120 -

Track roller 10~15mm

14.3. MAINTENANCE STANDARDS

b. For rubber crawlers It is accepted if the distance between the rolling surface of the track roller and the contact surface of the crawler is 10~15mm.

•

Make sure that the tension is properly adjusted.

•

If tension is proper, tighten the cartridge valve.

Tightening torque: 6~9kg• m

•

If tension is difficult to adjust although grease was injected, it indicates that the pin and bush have been severely worn. The bush must be replaced.

For rubber crawlers, check the track tension adjusting cylinder seal and replace the seal, if required.

Track roller 10~15mm

14.3. MAINTENANCE STANDARDS 14.3.1. Steel crawlers

2

5

1

3

4

No

Item

Standards

Limits

Remarks

1

Link pitch

101.6 mm

104 mm

When measuring 5 links

2

Link height

60 mm

57.5 mm

Build up or replace

3

Crawler height

6.5±1.5 mm

7 mm

Build up or replace

4

Pin clearance

0.33 mm

2 mm

Replace

5

Bush thickness

32.2 mm

29 mm

Replace

- 121 -

14. CRAWLERS

3

14.3.2. Track frame spring

4

2

1

Unit: mm No.

Item

Remarks

Criteria Limit

1

2

3

4

Deformed frame

Gap between upper and lower sides of idler guide Gap between left and right of idler guide Track spring (Free length)

Bending

5(Overall length of track frame

Distorted

10(Distortion between left and right crawler frames)

Widened idler

5

Bent

Standards

Limits

Track frame

126

131

Idler frame

124

119

Track frame

166

171

Idler support

162±1.0

157

Standards

Limits

286.5

203.5

- 122 -

Build up or replace

Build up or replace Replace

14.3. MAINTENANCE STANDARDS

14.3.3. Rubber crawler features Amount of friction

Limit of use

20

rfa

ce

15

te

su

rd

a

St

Co n

cre

10

a nd

rth

Ea

5

0

500

1000

2000

1500

2500

3000

Operating hours(H)

20

23 21.5

25

31.5

The amount of friction of the rubber crawler sets the limit of use. However, it is subject to change depending upon the work condition and environment.

300

(Unit:mm) 52.5mm SOLAR 035 SOLAR 030 Plus

Item Distance between centers of crawlers

4,410±12

3,990±10

Scale cord

Rigid

800 kg

800 kg

Scale cord

No. of coils

40±4 coils

40±4 coils

Range of temperature of use

-25°C~55°C

-25°C~55°C

Width x Pitch

300 x 52.5

300 x 52.5

- 123 -

15. IDLER

15. IDLER 15.1. CONSTRUCTION

8 7 6

1 5 4 2 3 4 5

6

8

7

1. Front idler assembly

5. C-type stopper ring

2. Idler

6. Oil seal(QLF 35, 72, 12, 19.5)

3. Shaft

7. Guide

4. Bearing(BL-207),

8. Spring pin (ø10x60L)

15.2. DISASSEMBLY AND REASSEMBLY 15.2.1. Disassembly procedures • • • • •

Refer to "Crawler Disassembly" to remove the crawlers and then idler assembly.

Remove the spring pin(8) from the guide(7).

Remove the guide(7) from the shaft(3).

Remove the oil seal(6) using a screw driver. * Once removed, the oil seal should not be reused.

Remove the C-type stopper ring(5), bearing(4), and shaft(3).

15.2.2. Reassembly procedures For reassembly, reverse the disassembly procedures.

• Clean segregated parts.

• Coat clean gear oil or engine oil(80cc) before assembling the oil seal(6).

• Refer "Crawler Installation" for crawler reassembly.

- 124 -

15.3. MAINTENANCE STANDARDS

15.3. MAINTENANCE STANDARDS

5

1

2

15.3.1. Idler(for steel crawlers)

3 4

No

Item

Unit

Standard

Limits

Remarks

1

Outside diameter

mm

ø295

ø291

Build up or replace

2

Contact outside diameter

mm

ø269

ø265

Build up or replace

3

tab width

mm

25

21

Build up or replace

4

Overall width

mm

65

60

Build up or replace

5

Contact width

mm

20

24

Build up or replace

6

Lubricant volume

cc

80

80

Gear oil

- 125 -

15. IDLER

5

2

1

15.3.2. Idler(for rubber crawlers)

3 4

No

Item

Unit

Standard

Limits

Remarks

1

Outside diameter

mm

ø311

ø287

Build up or replace

2

Contact outside diameter

mm

ø269

ø265

Build up or replace

3

tab width

mm

26.2

22

Build up or replace

4

Overall width

mm

65

60

Build up or replace

5

Contact width

mm

19.4

24

Build up or replace

6

Lubricant volume

cc

80

80

Gear oil

- 126 -

16.1. CONSTRUCTION

16. TRACK TENSION ADJUSTING CYLINDER 16.1. CONSTRUCTION

1 13 12 2

5 6 7 8 94

3

10 11

1. Plate

6. Backup ring(T2-P40)

11. Grease nipple(PT1/8-A)

2. Cylinder

7. Dust seal(DKR-40)

12. Castle nut

3. Spring

8. Spacer

13. Split pin

4. Rod

9. Snap ring(H-52)

5. O-ring(IB-P40)

10. Cartridge valve

16.2. SPRING SPECIFICATIONS

I.D

O.D P.C.D

d

L L1 L0

Designation

Dimensions

Designation

Dimensions

No. of active coils

7.5

Minimum closed length

195.1

Total No. of coils

9

Outside diameter

107

Spring constant(kg/mm)

50.9

Mean diameter

85

Set load(kg)

2698

Inside diameter

63

Compressive load(kg)

4650

Wire diameter

22

Free length(mm):L0

286.5

Set length

233.5

- 127 -

16. TRACK TENSION ADJUSTING CYLINDER

16.3. DISASSEMBLY AND REASSEMBLY • •

Be sure to use a special tool when removing the spring.

Take care as the spring may pop out.

2

3 1 13

12 4

14 6

5

7

8

10

9

11

1. Plate

6. Backup ring

11. Grease nipple

2. Cylinder

7. Dust seal

12. Castle nut

3. Spring

8. Spacer

13. Split pin

4. Rod

9. Snap ring

14. Yoke

5. O-ring

10. Cartridge valve

16.3.1. Disassembly and reassembly procedures 1. Disassembly procedure • Remove the crawlers and idlers.

• Remove the idler yoke(14).

• Use a press to relieve the spring force.

• Remove the split pin(14) and castle nut(12).

• Remove the spring(3) from the tension cylinder tube(2).

• Remove the cartridge valve(10) and grease nipple(11) together from the tension cylinder rod(4).

• Remove the cylinder rod(4) from the tension cylinder tube(2).

• Remove the snap ring(9), and then remove the spacer(8), dust seal(7), backup ring(6), and O-ring(5).

- 128 -

16.3. DISASSEMBLY AND REASSEMBLY

2. Reassembly procedure Reverse the disassembly sequence for reassembly operation.

• Install the O-ring(5), backup ring(6), Dust seal(7), and spacer(8) to the cylinder tube(2).

To prevent damage, coat great to the O-ring and dust seal at assembly.

•

Assemble the cylinder(4) to the cylinder tube(2).

First, inject great into the cylinder tube.

Install the cartridge valve(10) into the tension adjusting cylinder rod until two threaded portions contact the threaded hole, and then assemble the cylinder rod.

At this time, ensure that grease is drained from the grease drain port, and then tighten the cartridge valve. * Cartridge valve tightening torque: 6~9 kg• m

•

Use a special tool to install the spring(3) to the cylinder tube(2) and secure the spring in place with a castle nut(12).

•

After adjusting the spring set length, bend the split pin(13) completely. * Spring set length: 233.5mm

CAUTION : • Release air from the cylinder tube completely before assembly.

• Be sure to apply grease to the piston area on the cylinder tube rod before assembly.

- 129 -

17. TRACK ROLLER

17. TRACK ROLLER 17.1. CONSTRUCTION

11 9 10 8

7

6

1 5

4 2 3 4 5

6

7

89

11 10

1. Track roller assembly

7. Spacer

2. Track roller

8. C-type stopper ring(S-35)

3. Shaft

9. Washer

4. Bearing(6207)

10. Spring washer

5. C-type stopper ring(H-72)

11. Nut(M20)

6. Oil seal(QLF35, 72.12, 19.5)

17.2. DISASSEMBLY AND REASSEMBLY 1. Disassembly procedure • Remove the crawler.

• Loosen the nut(11) and remove the track roller from the track frame.

• Remove the nut(11), spring washer(10), and washer (9), and then remove the C-type stopper ring(8) and spacer(7).

• Use a screw driver to take out the oil seal(6). * Once removed, the oil seal should not be reused.

• Remove the C-type stopper ring(5) and disconnect the bearing(4) and shaft(3).

2. Reassembly procedure • Clean segregated parts with cleansing oil.

• Inject clean gear oil or engine oil(100cc) before assembling the oil seal(6).

• Refer to "Crawler Installation" to assemble the crawlers.

- 130 -

17.3. MAINTENANCE STANDARDS

17.3. MAINTENANCE STANDARDS 17.3.1. Track roller(for steel crawler)

4 3

5

7

1

2

6

8

No

Item

Unit

Standard

Limits

Remarks

1

Outside diameter

mm

ø115

–

Build up or replace

2

Contact outside diameter

mm

ø95

ø92

Build up or replace

3

tab width

mm

24

21

Build up or replace

4

Overall width

mm

108

–

Build up or replace

5

Contact width

mm

42

–

Build up or replace

6

Side clearance

mm

0.2±0.1

1.5

Replace bush

Tightening torque

kg·m

34.5

- 131 -

17. TRACK ROLLER

17.3.2. Track roller(for rubber crawler)

4 3

5

7

1

2

6

No

Item

Unit

Standard

Limits

Remarks

1

Outside diameter

mm

ø135

–

Build up or replace

2

Contact outside diameter

mm

ø95

ø92

Build up or replace

3

tab width

mm

26.2

23

Build up or replace

4

Overall width

mm

108

–

Build up or replace

5

Contact width

mm

41

–

Build up or replace

6

Side clearance

mm

0.2±0.1

1.5

Replace bush

Tightening torque

kg·m

34.5

- 132 -

18.1. DISASSEMBLY AND REASSEMBLY

18. SPROCKET 18.1. DISASSEMBLY AND REASSEMBLY 1. Disassembly procedure • Remove the crawler.

• Remove the sprocket clamping bolt(1) and remove the sprocket(2) from the travel motor.

2. Reassembly procedure • Install the sprocket to the travel motor and tighten the clamping bolt. * Tightening torque: 11.5kg• m • Assembly the crawler.

- 133 -

1

2

18. SPROCKET

18.2. MAINTENANCE STANDARDS

2

5

1

4 3

No

Item

Unit

Standard

Limits

Remarks

1

Sprocket tooth width

mm

25

19

Build up or replace

2

Sprocket deddendum diameter

mm

ø312.8

ø305

Build up or replace

3

Mounting bolt tightening torque

kg·m

11.5

M12 x 1.75

4

Motor mounting bolt tightening torque

kg·m

11.5

M12 x 1.75

ø190

SOLAR 030

5

Travel motor mounting hole

mm ø210

SOLAR 035

- 134 -

19.1. STEEL CRAWLER MOUNTING PROCEDURE

19. CRAWLER REPLACEMENT PROCEDURE 19.1. STEEL CRAWLER MOUNTING PROCEDURE 1. Remove the crawlers and idlers.

2. Loosen the track roller mounting bolt to remove the track roller.

3. Mount the track roller for steel crawler.

Then, be sure to install a washer for steel crawler.

Washer for steel crawler

4. Install the guide plate.

Tightening torque: 4.3.kg·m Guide plate 5. Assemble the idler for steel crawler.

6. After installing the crawlers, adjust their tension.

- 135 -

19. CRAWLER REPLACEMENT PROCEDURE

19.2. REPLACEMENT OF STEEL CRAWLERS WITH RUBBER CRAWLERS 1. Remove the steel crawlers and track rollers for steel crawler.

2. Remove the idlers for steel crawler.

3. Mount the track roller for rubber crawler.

Nut tightening torque: 34.5kg·m

Washer for steel crawler

4. Remove the guide plate.

5. Install the idlers for rubber crawler.

Guide plate

6. After assembling the rubber crawlers, adjust their tension.

- 136 -

M

EHM

RL Or

Or Br

Or GY

GH SPEED SWITCH

CRO SWITCH (R.H)

CRO SWITCH (L.H)

FUEL SENSOR

HORN

WORK LAMP

L

L

L

L

L

L

L

M

FUEL

ILLUMINATION

M

WTM

HARZARD SWITCH

B BR

RL

YR B YW

RW BR

WR YG R WG YW L R GR RL R WG

B

B

LW

SOLENOID ASS'Y

Y

RW

RY

BM

B

R

R2

BR

BR B

HORN SWITCH

HARNESS STARTER SWITCH GND

B

R

WR Or G L Br

C ACC

B Br RG

FUSE BOX

START

ON

OFF

TML PST

YL

WL

WB

RW

W

BR

ACC

RIGHT RELAY (SRM-12C NORMAL OPEN)

LW

R2

C

PREHEAT RELAY

QOS CONTROLLER

KEY SWITCH CONNECTION

B

BR

SP

SPEAKER

R

S B B

GROW PLUG INDICATOR ALTERNATOR STARTER MOTOR

SERVO SERVO UNIT SENSOR OIL SW

Y

B R LW L

B Or R

B RY RB

RIGHT SWITCH

Or Y B W WL

WR

W

M

BL

M

B

OPTION

RL LB

RADIO

RG BY

M

W

WR

HEATER

R YW

HEATER ROOM SWITCH LAMP

B

STARTER RELAY

FUSIBLE LINK(0.3W) SAFETY UNIT

M

E/G STOP MOTOR

E/G GND

G BW

BW LW

B

YW

B

YB

YG

RG B LW

Br

B L Br

FUSIBLE LINK(0.85R)

BATTERY

B

FUEL PUMP

BY

WASHER MOTOR

BY BR

WIPER SWITCH

L

BL Br B LB GR RG

Br Or Or Y B W Or Y B W

WB Or Or RY RG RB RY R BY Or

GAUGE PANEL

B GY

YG YL

L LW R RY

B

- 137 10A 10A 15A 10A 15A 3A 10A 10A

BW YB

WIPER MOTOR

20.1. ELECTRICAL CIRCUIT DIAGRAM

20. ELECTRICAL DEVICE

20.1. ELECTRICAL CIRCUIT DIAGRAM(SOLAR 030 PLUS/035)

RY

20. ELECTRICAL DEVICE

20.2. TROUBLESHOOTING 20.2.1. STARTER Complaints

Causes

Corrections

Open wiring, bad contact of battery with switch terminal Spline which is engaged with the armature shaft pinion had been worn causing the pinion to fail to operate.

Plunger of magnetic switch malfunction, or coil short or open.

Correct

Tighten or replace

• •

Open cable which connects the battery and magnetic switch Improper connection of connecting wires which connect the magnetic switch and motor terminal Improper engagement of pinion with ring gear Excessive wear of brush, and contact of brush with spring Commutator contaminated Armature and field coil defective Improper tightening of field coil and brush contact surface Contractor improperly contacted Contractor contact surface not smooth

Pinion rotates at high speed before engaging with the ring gear.

•

Plunger cap improperly adjusted

Adjust

Pinion gear is engaged with ring gear and the starter rotates, but the engine does not rotate.

•

Overrun clutch defective

Replace

Starter would not stop although the switch is turned to OFF after starting.

• •

Inside of switch short Connector missing

Replace switch.

Replace

Pinion would not slide out if the starter switch is ON.

• •

•

Pinion engages with ring gear, but starter does not rotate.

• •

• • • • •

- 138 -

Correct spline.

Correct• Replace

Tighten or replace

Correct teeth.

Correct• Replace Correct Correct• Replace Correct Correct Correct

20.2 TROUBLESHOOTING

20.2.2. Regulator Complaints

Causes

Corrections

Hard to charge

• • • • •

Each wiring open Each connector improperly contacted Low-speed side point improperly contacted No-load voltage lower than rated Rotor-press fit resistor open

Repair Repair Repair Adjust Replace

Battery overcharged

• • •

Repair• Replace Repair• Replace Replace

• •

Low-speed side point deposited High-speed side point contact improper Voltage regulator volt coil open and resistor open Unloaded set voltage higher than rated Circuits for terminal I and terminal F short

Pilot lamp lights.

• • • • •

Each connector loosely connected Field relay and coil open Field relay and point contact improperly Unloaded voltage higher than rated Pilot lamp circuit short

Repair Replace Correct Adjust Repair

Fuse broken

•

Set voltage higher than rated

Adjust

- 139 -

Adjust Repair• Replace

20. ELECTRICAL DEVICE

20.2.3. Alternator Complaints

Causes

Corrections Correct

• • • • •

Cords between each terminal open or connector improperly contacted Improper grounding Improper contact between brush and spring Start coil open or lost Rotor coil open or lost Diode lost

Insufficiently charged

• • • • • •

Cords between each terminal loosened V-belt slipped Improper contact between brush and spring Rotor coil short Start coil open or short Bad diode

Correct Correct Sleeve ring worn Correct• Replace Correct• Replace Replace

Overcharged

•

Circuits for terminal A and F short

Correct

Received current unstable

• • • • • •

Cords between each terminal loosened V-belt loosened Brush contact improper Rotor coil open or short Start coil open or short Start coil and diode loosely contacted

Correct Correct Correct • Replace Correct • Replace Correct • Replace Correct

Joints

• • • • • •

Bad joining face V-belt defective Bearing unacceptable Diode defective Start cord unacceptable Correct

Replace Replace Replace Correct • Replace

Fuse open

• •

+/- sides of diode improper Insufficient capacity

Replace Replace

Fails to charge

•

- 140 -

Correct Correct• Replace Correct• Replace Correct• Replace Replace