PC 180 WV
PC 180 WV
Shop Manual
023-00068E
Serial Number 1001 and Up
February 2003
Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine’s package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Instructions
Specifications
Specifications for Solar 180W-V ......................................................... S0202065K
General Maintenance
General Maintenance Procedures .........................................................S0302000
Standard Torques ..................................................................................S0309000
Upper Structure
Cab ..................................................................................................... S0402040K
Counterweight..................................................................................... S0403015K
Fuel Tank............................................................................................ S0405105K
Fuel Transfer Pump ...............................................................................S0405500
Swing Bearing........................................................................................S0407010
Swing Reduction Gearbox .....................................................................S0408050
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............. S0702155K
Table of Contents
Page I
Accumulator........................................................................................ S0703010K
Center Joint (Swivel)..............................................................................S0704070
Cylinders................................................................................................S0705000
Swing Motor...........................................................................................S0707260
Travel Motor........................................................................................ S0707351K
Main Pump.......................................................................................... S0708307K
Brake Supply Valve ...............................................................................S0709220
Counterbalance Valve ...........................................................................S0709300
Main Control Valve (Toshiba DX28) ......................................................S0709440
Pilot Control Valve (Work Lever / Joystick)......................................... S0709451K
Steering Valve .......................................................................................S0709710
Dozer Control Valve............................................................................ S0709905K
Hydraulic Schematic (SOLAR 180W-V) ............................................. S0792142K
Electrical System
Electrical System ................................................................................ S0802125K
Electrical Schematic (Solar 180W-V).................................................. S0892145K
Attachments
Boom and Arm.......................................................................................S0902120
Bucket....................................................................................................S0904000
Table of Contents
Page II
1SAFETY
S0102025K
1WHEEL EXCAVATOR
SAFETY
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
DANGER!
Unsafe use of the excavator could lead to serious injury or death. Operating procedures,
maintenance and equipment practices or traveling or shipping methods that do not follow the
safety guidelines on the following pages could cause serious, potentially fatal injuries or
extensive damage to the machine or nearby property.
Please respect the importance of taking responsibility for your own safety, and that of other people who
may be affected by your actions.
The safety information on the following pages is organized into the following sections:
1. “General Safety Essentials” on page 6
2. “Location of Safety Labels” on page 6
3. “Summary of Safety Precautions for Lifting in Digging Mode” on page 7
4. “Unauthorized Modifications” on page 8
5. “General Hazard Information” on page 8
6. “Before Starting Engine” on page 17
7. “Machine Operation” on page 20
8. “Maintenance” on page 25
9. “Battery” on page 33
10. “Towing” on page 35
11. “Shipping and Transportation” on page 36
12. “Lifting With Sling” on page 36
LEARN THE SIGNAL WORDS USED WITH THE SAFETY ALERT SYMBOL
The words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on decals on the
machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety
is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which
signal word appears next to the "Exclamation Point" symbol.
CAUTION!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert
against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and indicates potential of a hazardous
situation that, if not avoided, could result in serious injury or death. It may also be used to alert
against a highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and indicates an imminent hazard of a
situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also
be used to alert against equipment that may explode or detonate if handled or treated carelessly.
IMPORTANT
Before using the excavator to make lifts check municipal and regional regulations or statutes
that could apply. Governing ordinances may require that all heavy lifting be done with single
purpose equipment specifically designed for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that can be used for digging, loading,
grading or other work may be expressly forbidden by a regional injunction or other legal
prohibition. Always follow all of the other instructions, guidelines and restrictions for Safe
Lifting in the Operation and Maintenance Manuals.
Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and
Maintenance Manual, and parts manual for your unit.
Always replace damaged or faded decals.
DANGER!
Unsafe use of the excavator while making rated lifts could cause serious, potentially fatal
injuries or extensive damage to the machine or nearby property. Do not let anyone operate the
machine unless they’ve been properly trained and understand the information in the Operation
and Maintenance Manual.
To lift safely while in Digging Mode, the following items must be evaluated by the operator and the work site
crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Taglines on opposite sides of the load can be very helpful in keeping a suspended load secure, if they are
anchored safely to control points on the ground.
WARNING!
NEVER wrap a tagline around your hands or body.
NEVER rely on taglines or make rated lifts when wind gusts are more than 48.3 km/h (30 MPH).
Be prepared for any type of wind gust when working with loads that have a large surface area.
Always engage the "Digging Mode" control on the Instrument Panel before using the excavator for lifting
work.
WARNING!
If you need more information or have any questions or concerns about safe operating
procedures or working the excavator correctly in a particular application or in the specific
conditions of your individual operating environment, please consult your local Daewoo
representative.
SAFETY FEATURES
Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety features such as safety lock lever and the seat
belt, and use them properly.
Never remove any safety features. Always keep them in good operating condition.
Failure to use safety features according to the instructions in the Operation and Maintenance Manual could
result in serious bodily injury.
Figure 2
ARO1760L
Figure 5
HAOA110L
Figure 9
ATTACHMENT PRECAUTIONS
Option kits are available through your dealer. Contact Daewoo for information on available one-way (single-
acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because Daewoo cannot
anticipate, identify or test all of the attachments that owners may wish to install on their machines, please
contact Daewoo for authorization and approval of attachments, and their compatibility with options kits.
ACCUMULATOR
The pilot control system is equipped with an accumulator. For a brief period of time after the engine has
been shut down, the accumulator will store a pressure charge that may enable hydraulic controls to be
activated. Activation of any controls may enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the hydraulic pressure in the system must be
released as describe in "Handling of Accumulator" in the Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas, so it is extremely dangerous if it is handled in
the wrong way. Always observe the following precautions;
• Do not drill or make any holes in the accumulator or expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching anything to it.
• When carrying out disassembly or maintenance of the accumulator, or when disposing of the
accumulator, the charged gas must be properly released. Contact your Daewoo distributor.
• Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious injuries.
WARNING!
Figure 12
Protect your eyes when breaking the
glass.
Figure 14
TRAVEL PRECAUTIONS
Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops
when the machine is traveling. It will be impossible to operate the steering.
Attachment control levers should not be operated while traveling.
Do not change selected travel mode (FAST/SLOW) while traveling.
Fold in work equipment so that the outer end of the boom is as close to the machine as possible.
Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope or
obstacle that causes the machine to tilt 10 degrees or more to the right or left, or 30 degrees or more from
front to rear.
Do not operate the steering suddenly. The work equipment may hit the ground and cause the machine to
lose its balance, and this may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.
Always keep to the permissible water depth. Permissible water depth is to the centerline of the axles.
When traveling over bridges or structures on private land, check first that the bridge or structure can
withstand the weight of the machine. When traveling on public roads, check with the local authorities and
follow their instructions.
TWB
BCO0580L
Figure 17
TRAVELING ON SLOPES
Never jump onto a machine that is running away
to stop it. There is danger of serious injury.
Traveling on slopes could result in the machine
tipping over or slipping.
200mm-300mm
On hills, banks or slopes, carry the bucket (8"-12")
approximately 20 - 30 cm (8 - 12 in) above the
ground. In case of an emergency, quickly lower
the bucket to the ground to help stop the
machine.
200mm-300mm
(8"-12")
BCO0700L
Figure 18
Do not travel on grass, fallen leaves, or wet steel
plates. Even slight slopes may cause the
machine to slip to the side, so travel at low
speed and make sure that the machine is
always traveling directly up or down the slope.
Avoid changing the direction of travel on a slope.
This could result in tipping or side slipping of the
machine.
When possible, operate the machine up slopes
and down slopes. Avoid operating the machine
across the slope, when possible.
Figure 19
Figure 20
Do not carry out deep digging under the front of
the machine. The ground under the machine
may collapse and cause the machine to fall.
Working heavy loads over loose, soft ground or
uneven, broken terrain can cause dangerous
side load conditions and possible tipover and
injury. Travel without a load or a balanced load
may also be hazardous.
Never relay on lift jacks or other inadequate
supports when work is being done. Block tracks
fore and aft to prevent any movement. BCO0620L
When using the machine, to prevent accidents Figure 21
caused by damage to the work equipment and
overturning because of an excessive load, do
not use the machine in excess of its ability (in
terms of the maximum load and stability
determined by the structure of the machine).
Use these minimum distances as a guideline only. Depending upon the voltage in the line and atmospheric
conditions, strong current shocks can occur with the boom or bucket as far away as 4 - 6 m (13 - 20 ft) from
the power line. Very high voltage and rainy weather could further decrease that safety margin.
NOTE: Before starting any type of operation near power lines (either above ground or buried
cable-type), you should always contact the power utility directly and work out a safety plan
with them.
PARKING MACHINE
Avoid making sudden stops, or parking the machine wherever it happens to be at the end of the work day.
Plan ahead so that the excavator will be on firm, level ground away from traffic and away from high walls,
cliff edges and any area of potential water accumulation or runoff. If parking on inclines is unavoidable,
block the wheels to prevent movement. Lower the bucket or other working attachment completely to the
ground, or to an overnight support saddle. There should be no possibility of unintended or accidental
movement.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs
to ensure that passing traffic can see the machine clearly, and park the machine so that the machine, flags,
and fences do not obstruct traffic.
After the front attachment has been lowered to an overnight storage position and all switches and
operating controls are in the "OFF" position, the safety lock lever must be set to the "LOCKED" position.
This will disable all pilot circuit control functions.
Always close the door of the operator’s compartment.
ARO1310L
Figure 25
keep the left hand control console in the fully when performing inspection
raised, non active position. or maintenance
Daewoo distributors.
ARO1320L
Figure 26
CLEAN BEFORE INSPECTION OR
MAINTENANCE
Clean the machine before carrying out inspection and maintenance. This prevents dirt from getting into the
machine and also ensures safety during maintenance.
If inspection and maintenance are carried out when the machine is dirty, it will become more difficult to
locate the problems, and also there is danger that you may get dirt or mud in your eyes or that you may slip
and injure yourself.
When washing the machine, do the following;
• Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places.
• Wear safety glasses and protective clothing when washing the machine with high-pressure
steam.
• Take action to prevent touching high-pressure water and cutting your skin or having mud fly into
your eyes.
• Do not spray water directly on electrical components (sensors, connector) (1, Figure 27). If
water gets into the electrical system, there is danger that it will cause defective operation and
malfunction.
Figure 27
Pick up any tools or hammers that are laying in the work place, wipe up any grease or oil or any other
slippery substances, and clean the area to make it possible to carry out the operation in safety. If the work
place is left untidy, you may trip or slip and suffer injury.
HDO1037L
Figure 28
USE OF LIGHTING
When checking fuel, oil, battery electrolyte, or
window washing fluid, always use lighting with
anti-explosion specifications. If such lighting
equipment is not used, there is danger of
explosion.
If work is carried out in dark places without
using lighting, it may lead to injury, so always
use proper lighting.
Even if the place is dark, never use a lighter or
flame instead of lighting. There is danger of fire. HDO1040L
There is also danger that the battery gas may Figure 29
catch fire and cause and explosion.
ARO1360L
Figure 30
If the coolant level in the coolant recovery tank is below the lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Allow cooling system components to cool before you drain the cooling system.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact
the skin.
Remove the hydraulic tank filter plug only after the engine has been stopped. Make sure that the hydraulic
tank filter plug is cool before you remove it with your bare hand. Remove the hydraulic tank filter plug slowly
to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel system, or in the cooling system before you
disconnect any lines, fittings, or related items.
Batteries give off flammable fumes that can explode.
Do not smoke while you are checking the battery electrolyte levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or
the eyes.
Always wear protective glasses when you work on batteries.
DANGER!
Daewoo warns any user, that the removal
of the counterweight from the machine,
front attachment or any other part, may
X
affect the stability of the machine. This
could cause unexpected movement,
resulting in death or serious injuries.
Daewoo is not liable for any misuse.
Never remove the counterweight or front
attachment unless the upper structure is X
in-line with the lower structure.
Never rotate the upper structure once the
counterweight or front attachment has
been removed.
BCO0890L
Figure 31
HDO1042L
Figure 34
X X O
HAOA420L
Figure 35
Figure 37
WARNING!
Improper lifting can allow load to shift and cause injury or damage.
1. Refer to Specification section of Operation and Maintenance Manual for information on weight and
dimensions.
2. Use properly rated cables and slings for lifting.
3. Position machine for a level lift.
4. Lifting cables should have a long enough length to prevent contact with the machine. Spreader bars
may be required.
NOTE: If spreader bars are used, be sure that cables are properly secured to them and that the
angle of the cables is factored into the lift strength.
1SPECIFICATIONS FOR
SOLAR 180W-V
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
1 2 3
10
8
7 6 5 4
17 18 19
15
16
13 14
12
11
25
24
30
31
36 20
35 21
29 26
34 32 33 27 22
28 23
BLS0010L
Figure 1
BLS0020L
Figure 2
General Dimensions
Reference Description Dimension
A Overall Length 8,595 mm (28' 2'')
B Overall Width 2,496 mm (8' 2'')
C Overall Height (Boom) 3,795 mm (12' 5'')
D Height Over Cab 3,103 mm (10' 2'')
E Counter Weight Swing Clearance 2,450 mm (8' 0'')
F Ground Clearance 340 mm (1’ 1")
G Frame Clearance 1,249 mm (4' 1'')
H Engine Cover Height 2,486 mm (8' 2'')
I Upper Housing Width 2,490 mm (8' 2'')
J Wheel Base 2,800 mm (9' 2'')
K, L Tread Width 1,914 mm (6' 3'')
WARNING!
The actual value for "Digging Reach," depends on the stability and support provided by
ground conditions. Digging too far underneath the excavator if soil conditions are wet, loose
or unstable can collapse ground support, which could cause injury and/or equipment
damage.
Mono Boom
BLS0030L
Figure 3
BLS0040L
Figure 4
HYDRAULIC CYLINDERS
Art.
Boom Arm Bucket Blade Stabilizer Chocking
Boom
Quantity 2 1 1 2 2 2
115 mm 125 mm 110 mm 130 mm 130 mm 100 mm 200 mm
Bore
(4.53 in.) (4.92 in.) (4.33 in.) (5.12 in.) (5.12 in.) (3.94 in.) (7.87 in.)
1,195 mm
Stroke (47.05 in.) 1,450 mm 1,025 mm 175 mm 391 mm 130 mm 639 mm
[*] [1,032 mm (57.09 in.) (40.35 in.) (6.89 in.) (15.39 in.) (5.12 in.) (25.16 in.)
(40.63 in.)]
80 mm 90 mm 75 mm 80 mm 80 mm 100 mm 130 mm
Rod Dia.
(3.15 in.) (3.54 in.) (2.95 in.) (3.15 in.) (3.15 in.) (3.94 in.) (5.12 in.)
1,695 mm
Closed (66.73 in.) 2,000 mm 1,525 mm 615 mm 858 mm 242 mm 1,155 mm
Length
[1,532 mm (78.74 in.) (60.04 in.) (24.21 in.) (33.78 in.) (9.53 in.) (45.47 in.)
[*]
(60.31 in.)]
Retract.
X O X X X X X
Cushion
Extend.
O O O X X X X
Cushion
Maker Dongyang Dongyang Dongyang Dongyang Dongyang Dongyang Dongyang
65
60
55
160
100
40 180
170
160
BLS1780L
Figure 5
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(756 lb/yd3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy --------------------- ---------------------
(2,970 lb/yd3)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulphur, broken --------------------- ---------------------
(1,620 lb/yd3)
TEST CONDITIONS
1. All tests should be performed on a flat, level, firmly supporting ground surface.
HBOJ160I
Figure 6
2. All recommended, applicable maintenance and adjustment service should be completed prior to
testing.
3. Hydraulic fluid and engine oil should be of appropriate viscosity for ambient weather conditions.
Warm up hydraulic oil to standard operating temperature, between 45° to 55°C (112° to 135°F).
4. Run all tests with the engine speed control set to maximum rpm.
5. Repeat tests with Power Mode engine control settings at both Power Mode S (standard work mode)
and Power Mode H (high speed mode). Travel speed tests should also be repeated at both high and
low speed.
Figure 7
Reference Reference
Description Description
Number Number
1 Travel Motor 4 Front Axle
2 Transmission 5 Center Joint
3 Propeller Shaft
HBOJ170I
Figure 8
1GENERAL
MAINTENANCE
PROCEDURES
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
WARNING!
Structural elements of the machine may be built from a variety of steels. These could contain
unique alloys or may have been heat treated to obtain particular strength characteristics. It is
extremely important that welding repairs on these types of steel are performed with the proper
procedures and equipment. If repairs are performed incorrectly, structural weakening or other
damage to the machine (that is not always readily visible) could be caused. Always consult
Daewoo After Sales Service before welding on integral components (loader arm, frames, car
body, track frames, turntable, attachment, etc.) of the machine. It is possible that some types of
structurally critical repairs may require Magnetic Particle or Liquid Penetrant testing, to make
sure there are no hidden cracks or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety equipment on hand. Adequate
ventilation and a dry work area are absolutely essential. Keep a fire extinguisher nearby and
always wear protective clothing and the recommended type of eye protection.
IMPORTANT
Make sure that cleaning solvents will be compatible with rubber materials used in the hydraulic
system. Many petroleum based compounds can cause swelling, softening, or other deterioration
of system sealing elements, such as O-rings, caps and other seals.
Figure 1
WARNING!
Care should be exercised to avoid inhalation of vapors, exposure to skin and creating fire
hazards when using solvent type cleaners.
1. Clean all metal parts thoroughly using a suitable cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down slowly until all oils, lubricants, and/or foreign
materials are dissolved and parts are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable cleaning fluid for a minute or two, then
remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified
particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation
until bearings are thoroughly clean. To dry bearings, use moisture-free compressed air. Be careful to
direct air stream across bearing to avoid spinning bearings that are not lubricated. DO NOT SPIN
BEARINGS WHEN DRYING; bearings may be rotated slowly by hand to facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for wear, chipping or nicks to determine
condition. Do not replace a bearing cone or cup individually without replacing mating cup or cone at
the same time. After inspection, dip bearings in light weight oil and wrap in clean lintless cloth or
paper to protect them until installation.
For those bearings that are to be inspected in place; inspect bearings for roughness of rotation,
scoring, pitting, cracked or chipped races. If any of these defects are found, replace bearings. Also
inspect defective bearing housing and/or shaft for grooved, galled or burred conditions that indicate
bearing has been turning in its housing or on its shaft.
4. It is more economical to replace oil seals, O-rings, sealing rings, gaskets and snap rings when unit is
disassembled than waiting for premature failures; refer to latest Micro Fiche and/or Parts Book for
replacement items. Be extremely careful when installing sealing members, to avoid cutting or
BEARING INSPECTION
The conditions of the bearing are vital to the smooth and efficient operation of the machinery. When any
component containing bearings is disassembled, always carefully examine the condition of the bearings
and all of its components for wear and damage.
Once the bearing is removed, clean all parts thoroughly using a suitable cleaning solution. If the bearing is
excessively dirty soak the bearing assembly in a light solution and move the bearing around until all
lubricants and or foreign materials are dissolved and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be used. Be careful not to direct the air in a
direction which will force the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully inspect all bearing rollers, cages and cups for
wear, chipping or nicks. If the bearing cannot be removed and is to be inspected in place, check foe
roughness of rotation, scoring, pitting, cracked or chipped races. If any of these defects are found replace
the whole bearing assembly. NEVER replace the bearing alone without replacing the mating cup or the
cone at the same time.
After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper
and protect them from moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that
indicate that the bearing has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for cracks that are not visible to the naked eye.
The following illustrations will aid in identifying and diagnosing some of the bearing related problems.
NOTE: The illustrations will only show tapered roller bearings, but the principles of identifying,
diagnosing and remedying the defects are common to all styles and types of bearings.
Figure 2
Bent Cage
Cage damage due to improper handling or tool
usage.
Replace bearing.
Figure 3
Figure 4
Galling
Metal smears on roller ends due to overheat,
lubricant failure or overload.
Replace bearing - check seals and check for
proper lubrication.
Figure 5
Figure 6
Etching
Bearing surfaces appear gray or grayish black
in color with related etching away of material
usually at roller spacing.
Replace bearings - check seals and check for
proper lubrication.
Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make
sure races are properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused
by hard particles of foreign materials.
Clean all parts and housings, check seals and
replace bearings if rough or noisy.
Figure 9
Figure 10
Brinelling
Surface indentations in raceway caused by
rollers either under impact loading or vibration
while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller
pockets caused by abrasive material and
inefficient lubrication.
Replace bearings - check seals.
Figure 12
Abrasive Roller Wear
Pattern on races and rollers caused by fine
abrasives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or noisy.
Figure 13
Figure 14
Smears
Smearing of metal due to slippage caused by
poor fitting, lubrication, overheating, overloads
or handling damage.
Replace bearings, clean related parts and check
for proper fit and lubrication.
Replace shaft if damaged.
Figure 15
Frettage
Corrosion set up by small relative movement of
parts with no lubrication.
Replace bearing. Clean all related parts. Check
seals and check for proper lubrication.
Figure 16
Stain Discoloration
Discoloration can range from light brown to
black caused by incorrect lubrication or
moisture.
if the stain can be removed by light polishing or
if no evidence of overheating is visible, the
bearing can be reused.
Check seals and other related parts for damage.
Figure 18
1STANDARD TORQUES
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
STANDARD TORQUESS0309000
MODEL SERIAL NUMBER RANGE
ALL MODELS ALL RANGES
Grade
Dia. x
Pitch (mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
Recommended torque, in foot pounds, for all Standard Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE-30 engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 when finished jam nuts are used.
0.70 when Molykote, white lead or similar mixtures are used as lubricants.
0.75 when parkerized bolts or nuts are used.
0.85 when cadmium plated bolts or nuts and zinc bolts w/waxed zinc nuts are used.
0.90 when hardened surfaces are used under the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use minimum torque values.
GRADE 5 GRADE 8
THREAD SIZE
(3 RADIAL DASHES ON HEAD) (6 RADIAL DASHES ON HEAD)
NEWTON
FOOT POUNDS FOOT POUNDS NEWTON METER
METER
(ft lb) (ft lb) (Nm)
(Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at values less than what the chart states, it is
recommended that the loose bolt and/or nut be replaced with a new one.
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2 522.8 3780
TORQUE
KILOGRAM KILOGRAM
INCH POUNDS INCH POUNDS
METER METER
(in lb) (in lb)
(kg•m) (kg•m)
BOLT TORQUE
FLANGE BOLT
SIZE (*) SIZE KILOGRAM METER FOOT POUNDS
(kg•m) (ft lb)
TORQUE MULTIPLICATION
A wrench extension tool can be used to
increase the tightening force on a high capacity
nut or bolt.
For example, doubling the distance between the
bolt and the back (handle) end of the torque
wrench doubles the tightening force on the bolt.
It also halves the indicated reading on the scale
or dial of the torque wrench. To accurately
adjust or convert indicated scale or dial
readings, use the following formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench Figure 1
scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque).
A = Length of the torque wrench (between the center of the nut or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque wrench, and the indicated torque on the dial
reads "150 ft lb," the real force applied to the bolt is 300 ft lb:
NOTE: The formula assumes that there is no added deflection or "give" in the joint between the
extension and torque wrench. Readings may also be inaccurate:
• If the extension itself absorbs some of the tightening force and starts to bend or bow out.
• If an extension has to be fabricated that is not perfectly straight (for example, an extension
made to go around an obstruction, to allow access to a difficult to tighten fastener), the
materials and methods used must be solid enough to transmit full tightening torque.
CAUTION!
Disassembly, overhaul and replacement of components on the machine, installation of new or
replacement parts and/or other service-related maintenance may require the use of thread or
flange sealing assembly compound.
Use the information on this page as a general guide in selecting specific formulas that will meet
the particular requirements of individual assembly installations. Daewoo does not specifically
endorse a specific manufacturer or brand name but the following table of "Loctite" applications
is included for which cross-references to other makers’ products should also be widely
available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of fastener adhesives, with Thread locker
sealers 222, 242/243, 262, 271, 272, or 277.
Break-away
Cure Strength
Product Application Color Removal
(in lb) of Sealer
Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
242 or Medium strength for 6 mm (1/4") and
Blue Hand tools 80
243 larger fasteners.
High strength for high grade Heat/260°C (500°F)
262 fasteners subject to shock, stress Red Remove HOT 160
and vibration. (NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
V. "Loctite" Adhesives
1CAB
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
CAB S0402040K
MODEL SERIAL NUMBER RANGE
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 175LC-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 210W-V 1001 and Up
Solar 225LC-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 1001 and Up
Solar 340LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 470LC-V 1001 and Up
Cab S0402040K
Page 1
TABLE OF CONTENTS
Removal ......................................................................................................... 3
Installation ...................................................................................................... 6
S0402040K Cab
Page 2
REMOVAL
CAUTION!
Avoid disassembling cab if there are strong wind gusts, which could catch large surface area of
cab shell and push it sideways during lift.
WARNING!
If engine must be running while Figure 1
performing maintenance, always use
extreme caution. Always have one
person in the cab at all times. Never
leave the cab with engine running.
Cab S0402040K
Page 3
12. Remove floor mat.
13. Remove operator’s seat (1, Figure 2).
1
NOTE: Be careful not to damage the
seat covering. 4 5
3
BCS0720L
Figure 2
16. Remove air duct (1, 2 and 3, Figure 3)
located at right side of cab. Disconnect
duct wiring connector before removing
duct (2). 3
2
ARS1520L
Figure 3
18. Remove cover (5, Figure 4) on left side
dash cover (3) and bolts (1, Figure 5).
NOTE: When removing the cover,
disconnect speaker wire. 2 1 2
S0402040K Cab
Page 4
21. Remove three bolts (2, Figure 5) after
disconnecting the speaker and antenna
wires. Remove stereo assembly.
22. Disconnect cab lamp wiring connector. 2
ARS1540L
Figure 5
24. Remove four mounting nuts from four
corners of cab floor (2, Figure 6). 1
25. Remove four hex bolts (3, Figure 6) from
door side of cab floor.
26. Remove two hex bolts (1, Figure 6) from 2
right side of cab floor and one bolt (4) from
front of cab floor. 4
Quantity Description
4 16 mm hex nuts at each
corner of the cab
4 10 mm x 1.5 hex bolts at
the door side of the cab 3
3 10 mm x 1.5 mm hex HAOF270L
head bolts, 2 on the right Figure 6
side of the cab and 1
under the front window.
Cab S0402040K
Page 5
INSTALLATION
1. Using a suitable lifting device, attach slings
to four lift points on top of cab (Figure 8).
NOTE: Cab weighs approximately 290
kg (640 lb).
2. Lower cab into position on cab floor
Figure 8
3. Install four mounting nuts on four corners
of cab floor (2, Figure 9). 1
NOTE: Mounting nut torque 20.2 kg•m
(146 ft lb)
4. Install four hex bolts (3, Figure 9) in door 2
side of cab floor.
5. Install two hex bolts (1, Figure 9) in right 4
side of cab floor and one bolt (4) in front of
cab floor.
Quantity Description
4 16 mm hex nuts at each
corner of the cab 3
HAOF270L
4 10 mm x 1.5 hex bolts at
the door side of the cab Figure 9
3 10 mm x 1.5 mm hex
head bolts, 2 on the right
side of the cab and 1
under the front window.
S0402040K Cab
Page 6
9. Install stereo assembly with bolts (2,
Figure 10) after connecting speaker and
antenna wires.
2
ARS1540L
Figure 10
10. Install right side dash cover (4, Figure 11)
with bolts (1, Figure 10).
11. Install left side dash cover (3, Figure 11)
with bolts (1, Figure 10). Install two rubber 2 1 2
stops (2, Figure 11).
3
12. Install cover (5, Figure 11) on left side
dash cover (3). 4
5
NOTE: Connect speaker wire before
installing cover.
13. Connect washer hose located at floor plate
ARS1530L
bottom.
Figure 11
14. Install air duct (3, 2 and 1, Figure 12)
located at right side of cab.
NOTE: Connect wire connector of duct 3
(2, Figure 12).
1
2
ARS1520L
Figure 12
Cab S0402040K
Page 7
15. Install side panel (6, Figure 13) and pocket
(5).
1
16. Install cover (4, Figure 13) and connect the
main harness. Install cover (3). Connect 4 5
the hour meter connector and cigar lighter
connector of cover (2).
6
17. Install cover (2, Figure 13).
18. Install operator’s seat (1, Figure 13).
NOTE: Be careful not to damage the
seat covering.
2 7
19. Install the floor mat.
20. Connect negative (-) battery cable leading
3
to the frame from the battery.
BCS0720L
Figure 13
S0402040K Cab
Page 8
S0403015K
1COUNTERWEIGHT
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
COUNTERWEIGHT S0403015K
MODEL SERIAL NUMBER RANGE
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 210W-V 1001 and Up
Counterweight S0403015K
Page 1
TABLE OF CONTENTS
General........................................................................................................... 3
Removal ......................................................................................................... 5
Installation ...................................................................................................... 7
S0403015K Counterweight
Page 2
GENERAL
DANGER!
Daewoo warns any user, that the removal of
the counterweight from the machine, front
attachment or any other part, may affect X
the stability of the machine. This could
cause unexpected movement, resulting in
death or serious injuries. Daewoo is not
liable for any misuse.
Never remove the counterweight or front
attachment unless the upper structure is
in-line with the lower structure.
X
Never rotate the upper structure once the
counterweight or front attachment has
been removed.
BCS0830L
Figure 1
Before any attempt is made to begin removal or installation of the counterweight, the excavator must be
parked on a firm and level supporting surface, with no sloping surfaces or soft or muddy ground in the area
where the assist lift crane will be working. Position all accessories in the overnight storage position.
WARNING!
The weigh of counterweight is given in the following table. Use only rated and approved slings
and hardware when removal or installation lifts are being made. Lifting slings, shackles and all
other hardware must be rigged safely. An assist crane that is rated above weight capacity is
required.
Responsibility should be assigned to one person to be in charge of the lifting crew, and to verify that
required safe lifting precautions have been taken before each part of the procedure has been started.
All members of the working crew should know and understand the signals that will be used between the
lifting leader, the assist crane operator and the remainder of the work crew.
Counterweight S0403015K
Page 3
WARNING!
If the turntable deck has been unbalanced by removal of weight from one end only, traveling the
excavator, swinging the turntable, movement over bumps or sloping and uneven surfaces could
cause loss of control and possible accidents or injuries.
90 ~ 110
15 BCS0430L
Figure 1
When loading an excavator on a trailer for
transport after the front attachment has been
removed, secure the swing lock (if equipped) to
hold the deck in place and always go backwards
up the loading ramp. The counterweight end of
the deck has to get on the trailer first, while the
cab is still going up the ramp (Figure 1).
15
BCS0440L
Figure 2
S0403015K Counterweight
Page 4
REMOVAL
1. Park on firm and level ground.
2. Lower front attachment (bucket) to the
ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch "ON."
WARNING!
If engine must be run while Figure 3
performing maintenance, use
extreme care. Always have one
person in the cab at all times. Never
leave the cab with the engine
running.
Solar 140W-V
Solar 160W-V
M36x4.0
Solar 180W-V
Solar 210W-V
Counterweight S0403015K
Page 5
14. Using a suitable lifting device capable of
handling load partially support
counterweight (1) before beginning to
loosen four bolts (2). Stop lifting with assist
crane as soon as lifting slings are taut.
15. Remove four bolts (2, Figure 4) and
washers (3) from counterweight (1).
NOTE: Heat bolts if necessary, to free
them.
16. When bolts (2, Figure 4) and washers (3)
have been removed, lift counterweight (1)
a very short distance above support frame
(4) and stop. Check slings and make sure
counterweight is being supported evenly.
Once checked, continue to remove
counterweight.
17. Remove shims (5) from frame (4) if they
exist.
Figure 4
S0403015K Counterweight
Page 6
INSTALLATION
1. Raise engine compartment cover.
2. Using suitable lifting device capable of
handling load raise counterweight (1,
Figure 5) into position just above support
frame (4) leaving counterweight
suspended. Verify that counterweight is
level and even.
NOTE: Leave counterweight (1, Figure
5) suspended 3 mm (0.125")
above support frame (4) until all
four mounting bolts (2) are
started in counterweight
mounting holes.
3. Install four bolts (2, Figure 5) with washers
(3) into counterweight until washers
contact support frame. Fully lower
counterweight onto plates and support
frame.
4. Using a feeler gauge, check for a gap
between counterweight (1, Figure 5) and
frame (4). Use an appropriate amount of
shims (5) for each bolt location.
5. Remove four bolts (2, Figure 5) and
washers (3).
6. Raise counterweight (1, Figure 5) so that
shims (5) can be set into position on frame
(4).
7. Lower counterweight (1, Figure 5) until it is
3 mm (0.125") above the shims (5) and
install four bolts and washers. Apply
Loctite #242 to mounting bolt threads.
8. Fully lower counterweight (1, Figure 5)
onto shims (5), frame (4) and support
frame (4) and finish tightening bolts (2). Figure 5
NOTE: Tighten bolts (2, Figure 5) to
values shown in following table.
Solar 140W-V
115 kg•m (830 ft lb)
Solar 160W-V
Solar 180W-V
150 kg•m (1,080 ft lb)
Solar 210W-V
Counterweight S0403015K
Page 7
9. Remove lifting device and lifting hooks from counterweight (1, Figure 5).
10. Install two caps in lifting holes (A, 13, Figure 5).
11. Connect negative (-) battery cable to battery.
S0403015K Counterweight
Page 8
S0405105K
1FUEL TANK
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Removal ......................................................................................................... 6
Installation .................................................................................................... 11
Start-up Procedures ..................................................................................... 14
WARNING!
Engine fuel is highly flammable and potentially explosive. To prevent possible injury and/or
damage to equipment, extinguish or move to a safe distance all potential fire hazards.
Figure 1
SPECIFICATIONS
Fuel tank capacity is 280 liters (74 U.S. gal).
ARS1550L
Figure 3
WARNING!
If engine must be run while
performing maintenance, use
Figure 4
extreme care. Always have one
person in the cab at all times. Never
leave the cab with the engine
running.
Figure 5
Figure 6
14. Tag and disconnect fuel supply line (1,
Figure 7) and fuel return line (2) from Fuel
tank (3) and carefully drain remaining fuel
from lines.
15. Remove clamp (4, Figure 7) holding fuel
return line (2) to tank (3).
Figure 7
Figure 8
18. Remove four bolts (1 and 2, Figure 9),
clamp (6) and stay (3) from fuel tank and T
ON
FR
frame.
3
Remove four bolts (4) and cover (5) from
frame.
2
6
4
5
ARS1750L
Figure 9
6
4
5
ARS1750L
Figure 12
Figure 13
8. Connect as tagged, fuel supply line (1,
Figure 14) and fuel return line (2) to fuel
tank (3).
9. Install clamp (4, Figure 14) to hold fuel
return line (2) to tank (3).
Figure 14
Figure 15
Figure 16
2. Unscrew and pump hand operated primer
pump (Figure 17) by fuel injection pump.
Pump primer until fuel is present at plug
hole in fuel filter head.
3. Tighten plug in fuel filter head.
4. Continue to pump primer pump until a
strong resistance is felt. Screw primer
pump knob back into housing.
5. Start engine and look for signs of leaks.
6. Repeat procedure if necessary.
Figure 17
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Troubleshooting .............................................................................................. 4
Replacement of Rotor and Vane .................................................................... 4
Replacement of Rear Cover ........................................................................... 5
Replacement of Armature .............................................................................. 6
Figure 1
Reference Reference
Description Description
Number Number
1 Motor 3 Inlet Hose
2 Pump 4 Outlet Hose
2-1 Pump Cover 5 Check Valve
2-2 Rotor and Vane 6 Strainer Cap
Figure 2
Check resistance at connectors "A." If reading is zero, or very close to zero, the motor is bad and must be
replaced.
On units equipped with a toggle switch, check the resistance through the toggle switch, while the switch is
in the "ON" position. If continuity is not present, the switch is bad. Be sure to check resistance through the
motor.
Figure 6
REPLACEMENT OF
REAR COVER
Brush assembly and a thermal limiter are
installed in the rear cover. If you find any
damage, replace them with new ones.
Remove the switch cover and screw (M5 x L95)
from the rear cover.
Remove cover.
At reassembly of rear cover, widen the space of
the brush and insert it to the armature. Then fit Figure 7
the hole of screw in the housing.
Be careful when installing the screw. The cover
screw may be attracted by the motor magnet.
1SWING BEARING
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Reference
Description
Number
1 Ball
2 Seal A
3 Seal B
4 Retainer
5 Retainer
6 Outer Ring
7 Inner Ring
8 Tapered Pin
9 Plug
Figure 2
REBUILDING SWING BEARING
1. Remove tip of tapered pin (1, Figure 3)
using grinder and tap lightly to remove
debris.
Figure 3
2. Remove plug (1, Figure 4) using a M10 x
1.25 bolt (2).
Figure 4
Figure 5
4. Turn inner ring and use magnet bar (1,
Figure 6) to remove steel balls (2).
Figure 6
5. Turn inner ring and use wire (1, Figure 7)
to remove retainers (2).
Figure 7
6. Assemble in reverse order of disassembly
and then adjust the gap between the steel
balls and retainers using the following
guidelines: Assemble steel ball, retainer
(A) and retainer (B) to bearing; if gap is too
wide, adjust by moving steel balls or by
replacing one of the retainers.
Figure 8
S0408050
1SWING REDUCTION
GEARBOX
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
TABLE OF CONTENTS
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Special Tools and Materials............................................................................ 6
Special Tools ........................................................................................... 6
Troubleshooting, Testing and Adjustment....................................................... 8
Removal ......................................................................................................... 9
Disassembly ................................................................................................. 11
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 14
Reassembly.................................................................................................. 16
Installation .................................................................................................... 21
GENERAL DESCRIPTION
THEORY OF OPERATION
The swing motor final drive is a two-step planetary gearbox with two planet gears, two sun gears, and two
step output reduction. The planetary gear engages with the ring gear. The pinion gear is connected with
the output shaft and spline.
The final drive reduces swing motor rpm to increase swing motor output torque. The available maximum
swing speed provides a fast turning rate for efficient, rapid work cycling with more than adequate power for
good acceleration.
PARTS LIST
24
32
19
30
9
33 23
25 22
29 6
20
18
17 14
13
16 10
31 12
11
8
2 15
7
27
1
28
34 27
4 3
35 5
36
38 37 39
26
HAAA4260
Figure 1
Reference Reference
Description Description
Number Number
1 Casing 21 -------------
2 Drive Shaft 22 No. 1 Planet Gear
3 Plate 23 No. 1 Pin Assembly
4 Roller Bearing 24 Socket Bolt
5 Cover Plate 25 No. 1 Sun Gear
6 Thrust Washer No. 1 26 Spacer
7 Oil Seal 27 Plug
8 Roller Bearing 28 Plug
9 No. 1 Ring Gear 29 Level Gauge Pipe
10 No. 2 Carrier 30 Level Gauge
11 Thrust Washer No. 2 31 Double Tab Washer
12 Planet Gear No. 2 32 Pipe
13 No. 2 Bushing 33 Snap Ring
14 No. 2 Pin 34 Pinion
15 Spring Pin 35 Cover
16 Bolt 36 Spring Washer
17 No. 3 Thrust Washer 37 Bolt
18 No. 2 Sun Gear 38 Wire
19 Knock Pin 39 Bolt
20 No. 1 Carrier
SPECIFICATIONS
Dimension Measurement
A 130.0 mm (5.1181 in) Dia.
B 100.0 mm (3.9370 in) Dia,
C 83.0 mm (3.2677 in)
HAAC8850
Figure 2
Oil Seal Insert Jig
Dimension Measurement
A 10.0 mm (0.3937 in)
B 20.0 mm (0.7874 in)
C 99.0 mm (3.8976 in) Dia.
D 123.0 mm (4.8425 in) Dia.
E 40.0 mm (1.5748 in) Dia.
F 100.0 mm (3.9370 in)
HAAC8860
Figure 3
Spring Pin Insert Jig
Dimension Measurement
A 9.50 mm (0.3740 in) Dia.
B 15.0 mm (0.5906 in)
C 5.50 mm (0.2165 in) Dia.
HAAC8870
Figure 4
Swage Jig
Dimension Measurement
A 18.0 mm (0.7087 in) Dia.
B 26.0 mm (1.0236 in) Dia.
C 40.0 mm (1.5748 in) Dia.
D 10.0 mm (0.3937 in)
E 1.0 mm (0.0394 in) Radius
F 2.0 mm (0.0787 in) Radius
HAAC8880
Figure 5
Roller Bearing insert Jig
Dimension Measurement
A 90.10 - 90.20 mm
(3.5472 - 3.5512 in)
Dia.
B 159.70 - 159.8 mm
(6.2874 - 6.2913 in)
Dia.
C 50.0 mm (1.9685 in)
HAAC8890
Figure 6
REMOVAL
1. Park on firm and level ground.
2. Lower the front attachment (bucket) to the
ground.
3. Shut down the engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch "ON."
WARNING!
If engine must be running while Figure 7
performing maintenance, always use
extreme caution. Always have one
person in the cab at all times. Never
leave the cab with engine running.
DISASSEMBLY
NOTE: Prior to disassembly match mark swing motor (2, Figure 9), No. 1 ring gear (9, Figure 10)
and casing (1).
1. Remove oil level dipstick, dipstick tube and
adaptor (1, Figure 9) from swing motor (2).
2. Remove breather pipe (3, Figure 9) and
adaptor (4) from swing motor (2).
3. Remove breather (5, Figure 9) from
breather pipe (3) if replacement is
necessary.
4. Remove drain valve (6, Figure 9) and
reducer (7) to drain gear oil from gearbox
(8).
IMPORTANT
Use a clean, dry container (with at
least 11 liters, or 3 gallons capacity)
to catch gear oil. A clean container
allows an evaluation to be made of
the used oil. The presence or relative
lack of metal wear shavings in the
used oil or obvious deterioration or
contamination of the oil can provide
a useful indicator of the motor’s
general condition.
19
33 23
25 22
6
20
18
17 14
13
10
12
11
8
15
7
27
16
31
1
28
2 27
3
5
39
HAAA4261
Figure 10
8. Snap ring (1, Figure 10) will remain on swing motor shaft. Remove snap ring only if replacement is
necessary.
9. Remove No. 1 sun gear (25, Figure 10) from No. 1 carrier (20) and from end of No. 2 sun gear (18).
10. Remove No. 1 carrier (20, Figure 10) with three No. 1 planetary gears (22) still installed.
NOTE: When removing carrier (20, Figure 10), No. 2 sun gear (18) may come out with it.
11. Remove pin (23, Figure 10), No. 1 planet gear (22) and No. 1 thrust washer (6) from No. 1 carrier
(20). Repeat procedure for remaining planetary gear assemblies.
NOTE: Discard pin (23, Figure 10) and use a new one at reassembly.
NOTE: Keep all components together in proper orientation so that wear patterns match during
assembly. Do not mix previously used parts.
12. Remove No. 1 ring gear (9, Figure 10) from casing (1).
NOTE: Remove knock pin (19, Figure 10) from No. 1 ring gear (9) if replacement is necessary.
13. Remove No. 2 sun gear (18, Figure 10) from on top of No. 3 thrust washer (17).
14. Bend tabs on double tab washer (31, Figure 10) away from head of bolt (16). Remove bolt (16),
double tab washer (31) and No. 3 thrust washer (17) securing No. 2 carrier (10) to drive shaft (2).
NOTE: Discard double tab washer (23, Figure 10) and use a new one at reassembly.
15. Remove No. 2 carrier (10, Figure 10) from drive shaft (2).
16. Disassemble No. 2 carrier (10, Figure 10).
A. Remove spring pin (15, Figure 10) from No. 2 carrier (10) and No. 2 pin (14).
B. Remove No. 2 pin (14, Figure 10), No. 2 thrust washer (11), No. 2 planet gear (12) and No. 2
bushing (13).
C. Repeat procedure for remaining planetary gear assemblies.
NOTE: Keep all components together in proper orientation so that wear patterns match during
assembly. Do not mix previously used parts.
17. Remove eight bolts (39, Figure 10) and cover plate (5) from casing (1).
18. Remove plate (3, Figure 10) from cover plate (5).
19. Press drive shaft (2, Figure 10) and roller bearing (4) from casing (1).
NOTE: Press on carrier end of drive shaft (2, Figure 10). Be careful not to damaged threaded
hole.
20. Press drive shaft (2, Figure 10) out of roller bearing (4).
21. Using a suitable puller, remove roller bearing (8, Figure 10) from casing (1).
22. Remove oil seal (7, Figure 10) from casing (1).
23. Remove two plugs (27, Figure 10) and plug (28) from front casing (1), if replacement is necessary.
REASSEMBLY
19
33 23
25 22
6
20
18
17 14
13
10
12
11
8
15
7
27
16
31
1
28
2 27
3
5
39
HAAA4261
Figure 11
1. Install two plugs (27, Figure 11) and plug (28) in front casing (1), if replacement was necessary.
NOTE: Use Loctite #592 Pipe Sealant on plugs.
2. Press oil seal (7, Figure 11) into casing (1).
NOTE: Use Loctite #277 on O.D. of seal. Be careful not to get sealant on lips of seal.
3. Press roller bearing (8, Figure 11) into casing (1).
NOTE: Press only on outer bearing race.
4. Press roller bearing (4, Figure 11) on drive shaft (2).
NOTE: Press only on inner bearing race.
5. Press drive shaft (2, Figure 11) and roller bearing (4) into casing (1).
NOTE: Press on outer race of bearing (4, Figure 11) and pinion gear end of shaft (2) at the same
time. Be careful not to damage threaded holes in end of shaft.
NOTE: Make sure that bearing (8, Figure 11) remains seated on shoulder.
6. Hand pack bearing (4, Figure 11) and grease cavity with grease. Rotate drive shaft to ensure that
bearing is coated with grease.
7. Install plate (3, Figure 11) in cover plate (5).
8. Secure cover plate (5, Figure 11) to casing (1) with eight bolts (39, Figure 11).
NOTE: Apply Loctite #262 to bolt threads.
NOTE: Tighten bolts to 700 - 740 kg•cm (51- 54 ft lb).
9. Assemble No. 2 carrier (10, Figure 11).
A. Position No. 2 bushing (13, Figure 11) in No. 2 planet gear (12). Position gear and bushing, No.
2 thrust washer (11) and No. 2 pin (14) in No.2 carrier (10).
B. Align spring pin hole in No. 2 pin (14,
Figure 11) with hole in No. 2 carrier
(10).
NOTE: Figure 12, shows how end of
holes in pin (14, Figure 11)
should be turned, in relation to
the drive shaft.
C. Press spring pin (15, Figure 11) into
No. 2 carrier (10) and No. 2 pin (14).
Figure 12
19
33 23
25 22
6
20
18
17 14
13
10
12
11
8
15
7
27
16
31
1
28
2 27
3
5
39
HAAA4261
Figure 13
INSTALLATION
1. Coat pinion gear with grease. Refer to
operation manual for specifications.
2. Make sure alignment pin (6, Figure 16) is
installed in flange of swing reduction
gearbox (5).
3. Using a suitable lifting device, sling swing
motor (1, Figure 16) and position swing
motor and reduction gearbox (5) as an
assembly on unit.
4. Install eleven bolts and washers (4, Figure
16) to secure swing reduction gearbox (5)
to frame.
NOTE: Apply Loctite #262 to bolt
threads.
5. Connect tube (2, Figure 16) to drain valve
(3).
Figure 16
6. Connect grease lubrication line (not
shown) from reduction gearbox (5, Figure
16).
7. Connect hoses as tagged during removal
to swing motor (1, Figure 16).
8. Fill swing reduction gearbox with oil. Refer
to operation manual for specifications.
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Figure 1
1FRONT AXLE
(ZF-AXLE)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
APL-B755 ....................................................................................................... 6
Inscriptions On the Model Identification Plate (For ZF-Axles) ........................ 7
Examples of Gear-tooth Contact Patterns
for the Gleason Gear-tooth System................................................................ 8
Lubrication and Maintenance Instructions.................................................... 11
Oil Quality.............................................................................................. 11
Oil Change ............................................................................................ 11
Oil Drain - Final Drive..................................................................... 11
Oil Filling - Final Drive.................................................................... 11
Oil Drain ......................................................................................... 12
Oil Filling ........................................................................................ 12
Oil Level Check .............................................................................. 12
Oil Change Intervals ...................................................................... 12
Grease Lubrication ........................................................................ 12
List of Lubricants TE-ML 05 ......................................................................... 14
Brake Lining - Wear Test On ZF-Axles of the
Series AP (L) - B 700 ............................................................................ 15
Carry Out Wear Test ............................................................................. 15
Dimension "X" - Dimension "Y" = Actual
Value (Piston Stroke + Wear)................................................................ 16
Special Tools ................................................................................................ 17
Final Drive - Disassembly............................................................................. 25
Planetary Carrier................................................................................... 25
Internal Gear ......................................................................................... 27
Two-piece Internal Gear (Piston Reset By
Means of Return Springs) - Version "A"......................................... 29
One-piece Internal Gear (Piston Reset By
Means of Compression Springs) - Version "B" and "C" ................. 30
Hub........................................................................................................ 31
Steering Knuckle Hull............................................................................ 32
Steering Knuckle Bearing - Version "A" ......................................... 32
Steering Knuckle Bearing - Version "B" ......................................... 33
Figure 1
Figure 3
Drive side (convex).
Figure 4
Pinion distance must be increased.
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
OIL QUALITY
Gearbox oil with limited slip additives.
API GL-5, MIL-L-2105 D.
Precondition for a correct oil filling of all axles and axle components is a horizontal installation level in
every sense.
In case of exceptions, please contact ZF.
For greasing points, a multipurpose grease with the following properties has to be used: Lithium soap
grease, dropping point over 170°C (338°F), NLGI-Grade 2.
The grease must be anticorrosive, water resistant and resistant to flexing.
OIL CHANGE
Place the vehicle in a horizontal position.
Clean all lubricating points carefully before opening them.
Drain oil immediately ONLY after a long drive.
Figure 11
Oil Filling
Axle housing (Figure 12). Fill oil up to the
overflow (arrow) on the fill plug hole, resp.
level plug (3).
Grease Lubrication
Regreasing on the pressure grease fittings monthly.
IMPORTANT
Oil level check monthly, however, especially before a vehicle with new or repaired axles, resp.
axle components is put into service.
Technical Data and Adjustment values for ZF-Planetary steering axle APL-B 755
NOTE: * Binding is an oil level up to the marks of the filler and control plug.
When using multigrade gear oils, the base oil must not contain more than 2% by weight of dissolved
additives (VI improver, pour point depressant etc.) in addition to EP additives.
At greasing points, use a multipurpose grease with the following properties:
Lithium soap, drop point above 170°C (338°F), NLGI Class 2.
The grease must be anti-corrosive, water-resistant and walk stable.
Note to lubricant suppliers: Please inform ZF immediately of any changes to the composition of trade
names of approved products, and of differences between Germany and other countries.
This list can be obtained through any ZF After Sales Service point. Zahnradfabrik Passau GmbH
Postflight 26 40
D-8390 Passau 1
Telephone (08 51) 494-0
Telex 5 78 49 zp d
Telefax (08 51) 45 340
Limit Value for Piston Stroke with Max, Wear Condition Piston Stroke - New
2.50 - 2.90 mm
AP(L)-B755 (4 Plates)... 5.0 mm (0.1969 in)
(0.0984 - 0.1142 in)
3.10 - 3.50 mm
AP(L)-B755 (5 Plates)... 5.0 mm (0.1969 in)
(0.1220 - 0.1378 in)
Figure 13
Figure 14
5. Loosen the brake, adjust subsequently
measuring screw to the stop and tighten it
to a torque limit of 1 kg•m (7 ft lb) (the plate
pack is going to be compressed)
6. Determine Dimension "Y" (Screw head /
Spotfacing / Planetary carrier).
7. Determine the difference of the two
dimensions.
ATTENTION!
If the permitted limit value - see Chart / See page 15 - is exceeded, the lining plates must be
replaced on both final drive sides.
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
2. Drain oil from the axle housing.
Figure 24
PLANETARY CARRIER
1. Screw out screw plug carefully.
2. Swivel planetary carrier through 180° and
drain oil.
NOTE: Pay attention to the position of
the screw plug - 12-o’clock
position while opening.
Figure 25
Figure 26
4. Separate planetary carrier from the hub.
Figure 27
5. Squeeze out the retaining ring.
(S) External snap ring pliers -
5870 900 015
Figure 28
6. Pull off planetary gears.
7. If required, remove the thrust washer (for
the sun-gear shaft).
(S) Two-leg puller - 5870 970 002
Figure 29
Figure 30
INTERNAL GEAR
1. Squeeze out the retaining ring.
(S) External snap ring pliers -
5870 900 015
Figure 31
2. Remove the plate carrier and the thrust
washer installed behind it.
Figure 32
3. Squeeze out the retaining ring.
(S) Clamping pliers - 5870 900 021
Figure 33
Figure 34
5. Squeeze out the retaining ring (slotted
nut).
(S) Set of snap ring pliers -
5870 900 013
Figure 35
6. Assemble the spacing ring (3) (required
only for APL-B 755) and centering disk (2)
upon hook spanner (4), position and fix
them using the retaining ring.
DANGER!
Pay attention to exact engagement of
the retaining ring (circlip).
Figure 37
8. Screw off the slotted nut and separate
complete internal gear from the hub
carrier.
Figure 38
9. Remove the hook spanner.
10. Lift the slotted nut, angle ring and O-ring
out of the internal gear.
Figure 39
Two-piece Internal Gear (Piston Reset By
Means of Return Springs) - Version "A"
NOTE: Figure 40 thru Figure 41.
1. Unhook return springs.
(S) Spring hook - 5870 281 029
Figure 40
Figure 41
One-piece Internal Gear (Piston Reset By
Means of Compression Springs) - Version
"B" and "C"
NOTE: Figure 42 thru Figure 44.
1. Tap piston loose and drive it out of the
internal gear.
NOTE: Grooved rings and backup rings
will be damaged in course of
the piston removal. Use new
grooved rings and backup
rings.
Figure 42
2. Loosen the lock nuts.
Figure 43
3. Loosen all hex. head screws, resp. socket
head screws.
4. Remove compression springs, spring
cages and the released supporting disk.
Figure 44
Figure 45
HUB
1. Pull hub from steering knuckle hull.
2. Pay attention to the released inner bearing
race and the spacing ring.
3. Take O-ring out of the hub.
(S) Two-leg puller - 5870 970 006
(S) Side bar - 5870 654 025
(S) Pressure piece - 5870 100 019
Figure 46
4. Pry out the sealing ring and remove the
inner bearing race.
5. If necessary, drive the two outer bearing
races out of the hub.
NOTE: If the inner bearing race
remains on the neck of the
steering knuckle hull, this one
must be disassembled as
described under Figure 48.
(S) Adjusting device - 5870 400 001
Figure 47
6. Pull the inner bearing race from the neck
of the steering knuckle hull and pry off the
shaft seal.
(S) rab sleeve "Super" - 5870 029 005
(S) Two-leg puller - 5870 970 006
Figure 48
Figure 49
3. Loosen tie rod from the steering knuckle
hull, using ejection tool.
4. Now, screw off the castle nut and unhook
the tie-rod.
(S) Ejection Tool - 5870 000 077
(S) Yoke - 5870 000 079
Figure 50
5. Loosen hex. head screws and tighten
back-off screws.
(S) Back-off screws (M8) - 5870 204 008
Figure 51
Steering Knuckle Bearing - Version "A"
NOTE: Figure 52 thru Figure 54.
1. Remove the two bearing pins.
NOTE: Pay attention to the released
shim on the upper bearing pin.
Figure 52
Figure 53
3. Remove the sealing caps and the inner
bearing races.
Figure 54
Steering Knuckle Bearing - Version "B"
NOTE: Figure 55 thru Figure 57.
1. Remove the two bearing pins.
NOTE: Pay attention to the released
shim on the upper bearing pin.
Figure 55
2. If necessary, press the inner bearing race
from the bearing pin, using the parting
tool.
(S) Parting tool - 5870 300 024
Figure 56
Figure 57
4. Pull the sealing elements and the sleeve
installed behind them out of the steering
knuckle hull, using the internal puller.
NOTE: Expand the internal puller (S)
max. to the sleeve outer
diameter.
(S) Internal puller - 5870 300 007
(S) Backup tool - 5870 300 003
Figure 58
DOUBLE JOINT SHAFT
1. Take the double joint shaft out of the axle
housing.
Figure 59
2. Expand the retaining ring and pull the sun-
gear shaft out of the double-joint shaft.
Figure 60
Figure 61
AXLE HOUSING
1. Pull outer bearing race out of the steering
knuckle bores.
(S) Internal puller - 5870 300 019
(S) Backup tool - 5870 300 020
Figure 62
2. Pull the shaft seal and the sleeve installed
behind it out of the bore.
(S) Internal puller - 5870 300 019
(S) Backup tool - 5870 300 020
Figure 63
3. In case of versions - with traversing
steering knuckle bore, if necessary, drive
the cover out of the steering knuckle bore.
Figure 64
Reference
Description
Number
1 Axle Housing
2 Sleeve
3 Lubricating Groove
Sectional position vertical.
Figure 65
1. Drive in the sleeve- inner lubricating
groove (3) showing downward towards the
axle center- until is flush (Also see Figure
65).
(S) Driver (II) with Ring (III) -
5870 055 090
(S) Handle (I) (See Figure 67) -
5870 260 002
Figure 66
Reference
Description
Number
I Handle 5870 260 002
II Driver 5870 055 090
III Ring
IV Sleeve
Figure 67
Figure 68
2. Cover shaft seal on the outer diameter with
Loctite #574 and insert it until contact is
obtained.
NOTE: Pay attention to the installation
position. Sealing lip must face
the oil chamber (See Figure
68). Grease shaft seal in the
zone of the dust lip and sealing
lip.
(S) Driver - 5870 055 090
(S) Handle - 5870 260 002
Figure 69
Reference
Description
Number
1 Handle -
5870 260 002
2 Driver -
5870 055 090
3 Shaft Seal
Figure 70
3. If necessary, according to the version,
inset the cover in the steering knuckle bore
until contact is obtained.
(S) Driver - 5870 057 010
(S) Handle - 5870 260 002
Figure 71
Figure 72
5. Insert the retaining ring (Arrow 1),
assemble the stub shaft into the double
joint until the retaining ring engages in the
annular groove. (2).
Figure 73
6. Insert the retaining ring (Arrow 1).
7. Assemble the sun gear shaft until the
retaining ring engages in the annular
groove (Arrow 2).
(S) External snap ring pliers -
5870 900 015
Figure 74
8. Introduce the complete double joint shaft
into the axle housing until the stub shaft
splines are received in the differential.
NOTE: Pay attention to the sealing
elements.
Figure 75
Figure 77
2. Cover the shaft seal on the outer diameter
with Loctite #574 and install it until contact
is obtained.
NOTE: Pay attention to the installation
position, see Figure 79. Grease
the shaft seal in the zone of the
dust lip and the sealing lip.
(S) Driver - 5870 055 090
(S) Handle - 5870 260 002
Figure 78
Reference
Description
Number
1 Steering Knuckle Hull
2 Shaft Seal
3 Sleeve
4 Double-joint Shaft
5 Screw Plug
Sectional position vertical.
Figure 79
Figure 80
ADJUSTING STEERING KNUCKLE BEARING
Figure 82
Figure 83
4. Fix the steering knuckle hull by mean of
bearing pins.
5. Install the shim (Arrow) on the upper
bearing pin.
NOTE: Pay attention to the installation
position of the bearing pins.
Grease fitting must face the
axle center.
Figure 84
Steering Knuckle Bearing - Version "B"
NOTE: Figure 85 thru Figure 88.
1. Position the steering knuckle hull on the
axle housing.
Figure 85
2. Grease the O-ring and insert it in the
annular groove of the bearing pin (Arrow
1).
3. Assemble the sealing cap and install
subsequently inner bearing race until
contact is obtained.
4. Cover the collar of the bearing pin (Arrow
2) with an anti-corrosive agent (Never
Seez).
Figure 86
Figure 87
7. Insert shim (e.g. s = 0.80 mm (0.0315 in))
on the upper bearing pin.
Figure 88
8. Tighten the hex. head screws.
9. At the same time, tilt the steering knuckle
hull several times.
NOTE: Torque limit (M16/10.9)
28.55 kg•m (207 ft lb).
Figure 89
Figure 91
2. Insert the two undercooled outer bearing
races in the hub and place them against
shoulder.
NOTE: Do not support the hub on the
wheel studs.
(S) Driver - 5870 050 007
(S) Handle - 5870 260 004
Figure 92
Figure 93
2. Pressurize tapered roller bearing with 15 -
18 metric tons (17 - 20 tons).
3. Make several full revolutions of the hub.
NOTE: To obtain a correct measuring
result, the inner bearing races
should rest flatly and with the
full circumference upon the
support.
Figure 94
4. Check the rolling movement of the wheel
bearing, resp. the traction force (F) using a
spring scale.
NOTE: Rolling moment - T = 0.82 -
1.22 kg•m (6 - 9 ft lb)
NOTE: In case of deviations from the
required rolling moment, correct
using corresponding spacing
ring (Figure 93).
(S) Spring Scale - 5870 230 006
Figure 95
Determination of the Spacing Ring (Mount
Hub Provisionally On the Axle Housing) -
Version "B"
NOTE: Figure 96 thru Figure 101.
1. Place the heated bearing inner against the
steering knuckle hull until contact is
obtained.
2. Reset after the cooling down period.
NOTE: Pay attention to the different
sizes of the two inner bearing
races.
Figure 96
Figure 97
4. Assemble the hub (without the shaft seal)
and fix it using the heated inner bearing
race.
Figure 98
5. Assemble the internal gear (without
sealing elements).
Figure 102
Mount Hub
1. Insert heated inner bearing race.
NOTE: Pay attention to the different
bearing inner ring sizes. To avoid
an excessive cooling down of the
inner bearing race, the reassembly
of the inner bearing race, the
reassembly of the shaft seal, resp.,
and the assembling of the hub
must be carried out immediately
after the insertion of the inner
bearing race.
Figure 103
Figure 104
NOTE: By using the prescribed driver,
the exact installation depth is
obtained (See Figure 105).
Reference
Description
Number
1 Shaft Seal
2 Hub
3 Steering Knuckle Hull
Figure 105
3. Assemble pre-assembled hub and
determined spacing ring (e.g. s =
14.50 mm (0.5709 in)).
Figure 106
4. Fix the hub using the heated inner bearing
race.
Figure 107
Figure 108
2. Heat the two backup rings (2) as far as
they can be inserted in the recesses of
piston (1).
3. Install the grooved ring (3), with the sealing
lip facing the pressure chamber, see
Figure 109.
NOTE: Oil backup rings and grooved
rings. Use W-10 oils.
Reference
Description
Number
1 Piston
Figure 109
2 Backup Ring
3 Grooved Ring
4 Roll Pins (5x22 / 3x22)
5 Snap Ring
Figure 110
Figure 111
6. Press the piston using a hand press
carefully into the internal gear carrier until
contact is obtained.
7. Remove installer.
Figure 112
8. Insert all return springs with wire ring into
the internal gear carrier.
NOTE: If the return springs are
replaced, install them in sets
(per final drive side) only.
Figure 113
9. Clamp the internal gear carrier in a vise
and engage the return springs on the
piston side at the wire ring.
NOTE: Do not overstretch the return
springs.
(S) Spring hook - 5870 281 029
Figure 114
Figure 115
11. Secure snap ring, see Figure 109.
12. Drive double-roll pins (2 pieces each)
(5x22) and (3x22) into the bores (4x) of the
internal gear carrier firmly against
shoulder and caulk them.
NOTE: Internal gear and internal gear
carrier can no longer be
dismantled.
Figure 116
One-piece Internal Gear, Piston Reset / Hex.
Head Screws - Version "B"
NOTE: See Illustrated Table 1, See
Figure 180 on page -71.
NOTE: If the assembly help, required
the following Reassembly
(Figure 117 thru Figure 130) is
not at hand, an already pre-
assembled internal gear (with
piston) can be ordered from ZF.
Order No. for the complete
internal gear, see
Figure 117
corresponding Spare Parts List.
1. Close the bores (Arrows) using screw
plugs.
(S) Lever riveting tongs - 5870 320 016
Figure 118
3. Assemble spring cage (2) and
compression spring (3) upon hex. head
screw (1) and screw it into the piston.
Figure 119
4. Install hex. head screws into the piston as
far as the Dimension "X" = 1.0 - 1.5 mm
(0.0394 - 0.0591 in) is obtained (See draft
99).
Figure 120
Reference
Description
Number
1.0 - 1.5 mm
Dimension "X"
(0.0394 - 0.0591 in)
1 Piston
2 Backup Ring
3 Grooved Ring
Figure 121
Figure 122
6. Heat the two backup rings in an oil bath
and insert them into the piston recesses.
Install grooved rings.
NOTE: Pay attention to the installation
position, see Figure 123.
Reference
Description
Number
1 Piston
2 Backup Rings
3 Grooved Rings
4 Pressure Chamber Figure 123
Figure 124
Reference
Description
Number
1 Assembly Help Part I
2 Assembly Help Part II
3 Piston
Figure 125
8. Insert pre-assembled piston (3) into the
assembly help / Part II.
Figure 126
9. Mount assembly help / Part II and press
piston into the assembly help / Part I until
contact is obtained.
Figure 127
10. Remove assembly help / Part II.
NOTE: Oil sealing surfaces in the
internal gear. Use W-10 Oils.
Figure 128
Figure 129
12. Press piston carefully against shoulder.
13. Now, remove assembly help / Part I.
NOTE: To avoid shearing off, resp.
tipping of the grooved rings,
install the piston with utmost
care (using a hand press).
Figure 131
Reference
Description
Number
1 Piston
2 Backup Rings
3 Grooved Rings
4 Pressure Chamber Figure 132
Figure 133
5. After the cooling down, oil the backup ring
and the grooved ring. (Use W-10 oils.)
Reference
Description
Number
1 Assembly Help / Part I
2 Assembly Help / Part II
3 Piston
Figure 134
Figure 135
7. Place assembly help / Part II upon Part I
and press piston through.
Figure 136
8. Take off assembly help / Part II.
Figure 137
9. Insert the supporting disk into the piston.
Figure 138
Figure 139
11. Assemble the assembly help / Part I (with
the inserted piston) in the internal gear.
NOTE: Pay attention to the radial
installation position of the
piston.
Figure 140
12. Press piston carefully against shoulder.
13. Now, take the assembly help / Part I out of
the internal gear.
NOTE: To avoid the shearing off, resp.
tipping of the grooved rings,
install the piston with utmost
care (using a hand press).
Figure 141
14. Adjust Dimension "X" = 3.750 thru
4.250 mm (0.1476 thru 0.1673 in), Bearing
contract / Internal gear to the screw head.
see Figure 143.
NOTE: Pay attention to the exact
position of the piston contact in
the internal gear.
Figure 142
Figure 144
Mount Internal Gear on the Steering Knuckle
Hull
1. Oil O-ring and insert it in the annular
groove of the steering knuckle hull (Arrow).
Figure 145
Figure 146
3. Place internal gear using slotted nut over
the O-ring until contact on the inner
bearing race is obtained.
4. Now, remove the slotted nut again.
(S) Hook Spanner - 5870 401 085
(S) Spacing Ring - 5870 912 017
(S) Centering Ring - 5870 912 009
Figure 147
5. Insert O-ring evenly in the gap of the
steering knuckle hull and the internal gear.
6. Install subsequently angle ring and pull it
using slotted nut against shoulder.
NOTE: Cover O-ring and angle ring
amply with grease. Pay
attention to the installation
position, (See Figure 149).
Figure 148
7. Unscrew slotted nut again and check O-
ring (if damaged), resp. angle ring seat.
Reference
Description
Number
1 Angle Ring
2 O-ring
3 O-ring
4 Slotted Nut
5 Steering Knuckle
Gear
6 Internal Gear Figure 149
MULTIDISK BRAKE
Figure 153
5. Determine Dimension "III" (thickness of
the backing plate).
NOTE: Dimension "III" e.g. 9.0 mm
(0.3543 in).
Figure 154
EXAMPLE "A"
Dimension "I" 81.00 mm (3.1890 in)
Dimension "II" - 42.70 mm (1.6811 in)
Difference 38.30 mm (1.5079 in)
Dimension "III" - 9.00 mm (0.3543 in)
Gives Dimension "X" 29.30 mm (1.1535 in)
Figure 155
7. The inner plates have a constant thickness
of s = 3.50 mm (0.1378 in).
Figure 156
EXAMPLE "A"
Dimension "X" 29.30 mm (1.1535 in)
Dimension "Y" - 26.50 mm (1.0433 in)
Difference = Piston travel = 2.80 mm (0.1102 in)
NOTE: If the required piston travel is not obtained, correct using corresponding outer plate(s). (s =
2.0 mm (0.0787 in), 2.50 mm (0.0984 in), 3.0 mm (0.1181 in))
Figure 157
2. Engage in the retaining ring and place it
against the outer face of the recess
(direction of Arrow) against shoulder.
3. Measure Dimension "II" from the end face /
internal gear to the inner of the retaining
ring.
NOTE: Dimension "II" - 45.40 mm
(1.7874 in).
4. Now, remove the retaining ring again.
Figure 158
5. Determine Dimension "III" (thickness of
the backing plate).
NOTE: Dimension "III" e.g. - 9.0 mm
(0.3543 in).
Figure 159
EXAMPLE "A"
Dimension "I" 89.70 mm (3.5315 in)
Dimension "II" - 45.40 mm (1.7874 in)
Difference 44.30 mm (1.7441 in)
Dimension "III" - 9.00 mm (0.3543 in)
Gives Dimension "X" 35.30 mm (1.3898 in)
Figure 160
7. The inner plates have a constant thickness
of s = 3.50 mm (0.1378 in).
Figure 161
EXAMPLE "B"
Dimension "X" 35.30 mm (1.3898 in)
Dimension "Y" - 32.00 mm (1.2598 in)
Difference = Piston travel = 3.30 mm (0.1299 in)
NOTE: If the required piston travel is not obtained, correct using corresponding outer plate(s). {s =
2.0 mm (0.0787 in), s = 2.50 mm (0.0984 in), s = 3.0 mm (0.1181 in)}
Figure 162
9. Engage the retaining ring in the plate
carrier.
(S) Set of internal snap ring pliers -
5870 900 013
Figure 163
10. Assemble the plate carrier upon the sun
gear shaft and fix it using the retaining
ring.
11. Now, place the sun-gear shaft along with
the plate carrier against shoulder (thrust
washer).
(S) Set of external snap ring pliers -
5870 900 015
Plate Arrangement
To assure a correct plate arrangement, the
Figure 164
undulated outer plates are marked by
suppression of several teeth.
Figure 165 thru Figure 166 show the correct arrangement of the outer plates.
Great tooth space (2 teeth missing) must be centrical in line.
Small tooth space (1 tooth missing, see arrows) lies alternating to the left (outer plate1, 3, 4, 5), resp. to the
right (outer plate 2, 4, 6 - only in case of 5-coated plate arrangement).
NOTE: There must be one coated (inner) plate installed between the two outer plates.
Figure 165
Plate arrangement 5 Coated Plates.
Figure 166
1. Install the plate pack according to the
prescribed arrangement and fix it using
backing plate and retaining ring.
NOTE: If outer plates of different
thickness are assembled, install
thinner plates externally in the
pack.
(S) Clamping pliers - 5870 900 021
Figure 167
Check Tightness of the Brake Hydraulic
System
1. Install the pressure port (1) and the
breather (2) (use new sealing rings).
(S) HP-Pump compl. - 5870 287 007
2. Bleed and test the brake system.
Figure 168
PLANETARY GEARS
1. Install the components, as illustrated in the
Figure 170, into the planetary gear.
NOTE: Make cylindrical rollers adhere
with grease on the inner
bearing races. Offset side
(small diameter) of the angle
rings so that they are always
facing the outside.
Figure 170
2. Heat the inner bearing race of the
preassembled planetary gear and place it
against shoulder.
NOTE: Large radius on the inner
bearing race should be facing
the planetary carrier
(downward).
Figure 171
Figure 172
Adjust End Play of the Sun-gear Shaft
NOTE: 0.30 - 0.60 mm (0.0118 -
0.0236 in).
1. Determine Dimension "I" from the Flange-
mounted surface / Planetary carrier to the
Locating face / Thrust washer.
NOTE: Dimension "I" e.g. (APL-B 755)
- 199.10 mm (7.8386 in).
(S) Depth gauge - 5870 200 052
(S) Straightedge - 5870 200 022
Figure 173
2. Slide sun-gear shaft, resp. plate carrier in
until contact is obtained.
3. Measure Dimension "II" from the end face /
sun gear shaft to the flange-mounted
surface / hub.
NOTE: Dimension "II" e.g. (APL-B 755)
- 196.60 mm (7.7402 in).
(S) Depth gauge - 5870 200 052
(S) Straightedge - 5870 200 022
Figure 174
Figure 175
5. According to the Version - press in thrust
washer - resp. in case of an unfavorable
tolerance disposition, caulk (4 points).
Figure 176
6. Grease the O-ring and insert it in the
annular groove of the hub.
Figure 177
7. Assemble the planetary carrier and fasten
it by mean of socket head screws.
NOTE: Torque limit (M10/8.8) DIN
6912 3.26 kg•m (24 ft lb).
NOTE: Torque limit (M12/8.8) DIN
6912 5.61 kg•m (41 ft lb).
Figure 178
Figure 179
Figure 180
DISASSEMBLE DIFFERENTIAL
1. Drain oil from the axle housing.
Figure 181
2. Remove cotter pin, loosen the castle nut
for some threads.
Figure 182
3. Loosen the tie rod using the ejection tool.
4. Now, screw off the castle nut and unhook
the tie rod.
(S) Ejection Tool - 5870 000 077
(S) Yoke - 5870 000 079
Figure 183
Figure 184
6. Loosen hex. head screws of the guide.
7. Displace the guide on the piston rod. See
arrows.
Figure 185
8. Loosen hex. head screws and reamed
bolt. See arrow.
NOTE: If a ground anchoring of the
assembly car is not possible,
the Axle housing part 1 must be
secured using a support (See
Figure 187).
Figure 186
9. Separate Axle housing Part II from Part I.
NOTE: In case of the Version with
100% lock, possibly pay
attention to the released shut
off slide.
Figure 187
Figure 188
Only for the Version - 100% Lock
NOTE: Figure 189 thru Figure 191.
1. Remove the piston and the four-lip rings
from the axle housing.
Figure 189
2. Remove the complete shut-off slide from
the differential case.
Figure 190
3. If necessary, remove the thrust bearing,
the compression spring, the washer and
the retaining ring from the shut-off slide.
Figure 191
Figure 192
DISASSEMBLE DIFFERENTIAL
1. Pull off the two tapered roller bearings.
(S) Grab sleeve "Super" - 5870 026 017
(S) Back-off insert - 5870 026 100
(S) Pressure piece - 5870 100 009
NOTE: Version 100% lock:
(S) Grab sleeve "Super" - 5870 027 009
(S) Basic set - 5870 027 000
(S) Pressure piece - 5870 506 104
Figure 193
2. Loosen socket head screws.
Figure 194
3. Take off Differential case half / Part II and
remove the released components.
Figure 195
Figure 196
5. Remove outer bearing race from Axle
housing / Part I.
NOTE: Pay attention to the released
shim.
(S) Striker - 5870 650 004
Figure 197
REMOVE DRIVE PINION
1. Remove lock plate.
Figure 198
2. Loosen hex. nut.
(S) Clamping yoke - 5870 240 025
Figure 199
Figure 200
4. Pry out shaft seal.
(S) Adjusting device (2x) - 5870 400 001
Figure 201
5. Remove drive pinion.
NOTE: If the pinion bearing should not
be replaced, pay attention that
during the driving out of the
drive pinion, the outer bearing
race is always held against
shoulder to avoid the damage
of bearing.
Figure 202
6. Remove spacing ring.
Figure 203
Figure 204
8. Drive the outer bearing race out of the
inner bearing bore.
NOTE: Pay attention to the released
spacing washer.
Figure 205
9. Pull the outer bearing race out of the outer
bearing bore.
(S) Internal puller - 5870 300 019
(S) Backup tool - 5870 300 020
Figure 206
Figure 207
Reference
Description
Number
1 Dimension "I’
2 Dimension "II" (Pinion
Dimension)
3 Dimension "III"
(Bearing Width)
4 Dimension "X"
5 Shim
6 Axle Housing
Figure 208
Figure 209
3. Determine Dimension "III" (Bearing width).
NOTE: Dimension "III" e.g. 32.05 mm
(1.26 in).
(S) Straightedge - 5870 200 022
(S) Gauge blocks - 5870 200 066
(S) Digital-depth gauge - 5870 200 072
Figure 210
EXAMPLE "A"
Dimension "II" 111.95 mm (4.4075 in)
Dimension "III" +32.05 mm (1.2618 in)
Gives Dimension "X" 144.00 mm (5.6693 in)
EXAMPLE "B"
Dimension "I" 145.05 mm (5.7106 in)
Dimension "X" -144.00 mm (5.6693 in)
Difference = Thickness of Shim s = 1.05 mm (0.0413 in)
Reference
Description
Number
1 Pinion Dimension and
Mating Number
2 (S) Measuring Shaft -
5870 500 001
3 (S) Adjusting Piece -
5870 500 013 Figure 211
4 Shim
5 (S) Gauge Ring -
5870 200 064
6 (S) Measuring Cover -
5870 200 034
7 (S) Centering Ring -
5870 200 042
Reference
Description
Number
1 Pinion Dimension and
Mating Number
2 (S) Measuring Shaft -
5870 500 001
3 (S) Adjusting Piece -
5870 500 013
4 Shim
5 (S) Gauge Ring -
5870 200 076
6 (S) Measuring Cover -
5870 200 077
Figure 212
2. Push centering ring upon Measuring cover
(6), place it against shoulder and fasten it
using hex. head screws.
3. Introduce Measuring shaft (2) into the bore
of the adjusting piece (3) until the location
is obtained.
(S) Measuring shaft - 5870 500 001
(S) Measuring cover - 5870 200 034
(S) Centering ring - 5870 200 042
Figure 213
4. Position gauge ring (5) on the locating face
of the outer inner bearing race against
shoulder.
5. Determine Dimension "A" from the Plane
surface of the gauge ring (5) to the center /
measuring shaft (2) (See Figure 211).
Figure 214
Figure 215
8. Determine Dimension "C" (bearing width).
NOTE: Dimension "C" e.g 32.05 mm
(1.2618 in).
(S) Straightedge - 5870 200 022
(S) Gauge blocks - 5870 200 066
(S) Digital-depth gauge - 5870 200 072
Figure 216
9. Read pinion dimension (1).
NOTE: Pinion dimension e.g. 112.0
-0.05 mm = 111.95 mm
(4.4094-0.0020 = 4.4074 in).
Figure 217
EXAMPLE
Dimension "A" 223.85 mm (8.8130 in)
Dimension "B" + Dimension "C" -110.85 mm (4.3642 in)
Gives 113.00 mm (4.4488 in)
Pinion dimension -111.95 mm (4.4075 in)
Difference = Shim Thickness s = 1.05 mm (0.0413 in)
Figure 218
2. Undercool and insert outer bearing race.
(S) Driver - 5870 058 083
(S) Handle - 5870 260 002
Figure 219
3. Undercool and insert the inner outer
bearing race.
Figure 220
4. Position the two outer bearing races
against shoulder, using special device.
(S) Assembly jig - 5870 345 049
(S) Pressure ring - 5870 345 056
Figure 221
Figure 222
ADJUST ROLLING MOMENT OF THE DRIVE
PINION BEARING
NOTE: 0.10 - 0.20 kg•m (1 - 2 ft lb)
(without shaft seal): (Figure 223
thru Figure 232)
1. Assemble gauge ring.
2. Shape and description of gauge ring, see
Figure 217.
(S) Gauge ring - 5870 340 030
Figure 223
Reference
Description
Number
1 Gauge Ring
2 Roll Pins (3x)
Figure 224
3. Insert pre-assembled drive pinion and
assemble the heated inner bearing race
until contact is obtained.
Figure 225
Figure 226
6. Check the rolling moment (aim at upper
value).
NOTE: Rolling moment 0.10 - 0.20
kg•m (1 - 2 ft lb)
(S) Torque spanner - 5870 203 019
Figure 227
7. Loosen hex. nut.
8. Pull off disk and drive flange.
Figure 228
9. Remove drive pinion again.
10. Remove gauge ring from drive pinion and
determine Dimension "X" (Also see Figure
224).
NOTE: Dimension "X" e.g. s = 11.45
mm (0.4508 in).
NOTE: Dimension "X" corresponds to
the thickness of the spacing
ring to be installed.
Figure 229
Figure 230
12. Install the pinion again.
13. Assemble the drive flange and disk and
tighten the hex. nut.
NOTE: Torque limit 43.85 kg•m (317 ft
lb)
NOTE: During the tightening, make
several full revolutions of the
drive pinion in both senses.
(S) Clamping yoke - 5870 240 025
Figure 231
NOTE: Check rolling moment again. If
the required rolling moment
(0.10 - 0.20 kg•m (1 - 2 ft lb)) is
not obtained, correct using a
corresponding spacing ring.
(S) Torque spanner - 5870 203 019
Figure 232
14. Loosen hex. nut.
15. Pull off drive flange.
Figure 233
Figure 235
18. Assemble the drive flange and disk and
fasten finally using hex. nut.
NOTE: Torque limit 43.85 kg•m (317 ft
lb)
NOTE: Carry out securing of hex. nut -
after the Contact pattern has
been taken.
(S) Clamping yoke - 5870 240 025
Figure 236
Figure 238
3. Insert thrust washer and side gear.
Figure 239
Figure 240
6. Replace second side gear.
Figure 241
7. Make thrust washer adhere with grease in
the Differential case half II.
8. Replace Differential case half II.
NOTE: Pay attention to the radial
installation position of the two
differential case halves. ZP-No.
(See arrow.) signifies assembly
marking at the same time.
Figure 242
9. Mount flat washers and tighten socket
head screws.
NOTE: Torque limit (M12x1,5/12.9)
14.79 kg•m (107 ft lb).
Figure 243
Figure 246
Figure 247
Reference
Description
Number
1 Outer Plate (Optional)
2 Thrust Plate
3 Roll Pins (3x)
4 Side Gear
Figure 248
4. Insert the pre-assembled side gear in the
differential case half II.
NOTE: Pay attention to the installation
position of the outer plates.
Insert the driving tails of the
outer plates in the radii of the
fixing holes.
Figure 249
5. Assemble differential bevel gears and
thrust washers on the differential spider
and insert them in the differential case half
I.
NOTE: Pay attention to the radial
installation position of the thrust
washers. Tongue shows
upward. See arrow.
Figure 250
Figure 251
7. Fix the differential case halves using two
socket head screws for the measuring of
the end play.
NOTE: Make several full rotations of
the side gear.
Figure 252
4.3.2.1 Check End play of the Plate Pack
NOTE: End play = 0.20 mm (0.0079 in)
(per plate pack).
NOTE: In case of deviations from the
prescribed end play, correct
using corresponding outer
plates (s = 1.20 - 1.40 mm
(0.0472 - 0.0551 in).
(S) Dial indicator - 5870 200 057
(S) Magnetic base - 5870 200 055
Figure 253
1. Separate the differential case halves after
the adjustment again and remove
components.
2. Thickness and arrangement of the plate
pack may not be modified.
Figure 254
Figure 255
6. Insert the preassembled differential spider.
NOTE: Tongues of shims are showing
upward.
Figure 256
7. Insert second plate pack with the same
arrangement and thickness in Differential
case half II.
NOTE: Pay attention to the installation
position of the outer plates.
Insert the driving tails of the
outer plate in the radii of the
fixing holes.
Figure 257
8. Replace the Differential case half II.
NOTE: Pay attention to the radial
installation position. ZP-No.
(See arrow.) signifies assembly
marking the same time.
Figure 258
Figure 259
10. Heat the two inner bearing races and
press them against shoulder until contact
is obtained.
NOTE: For pressing on the second
inner bearing race, support the
first inner bearing race using
the pressing mandrel.
(S) Pressing mandrel - 5870 506 103
Only for Version - 100% lock:
(S) Pressing mandrel - 5870 506 104
Figure 260
DETERMINE AND ADJUST BACKLASH OF
THE CROWN
NOTE: Wheel set and bearing preload
of the differential;
Backlash: 0.15 - 0.25 mm
(0.0059 - 0.0098 in).
Bearing rolling moment: 0.10 -
0.20 kg•m (1 - 2 ft lb).
1. Insert shim e.g. s = 170.0 mm (6.6929 in)
(empirical value) in the bearing bore (Axle
housing / Part I) and install subsequently
Figure 261
outer bearing race.
(S) Driver - 5870 058 061
(S) Handle - 5870 260 002
Figure 262
3. Insert differential in the axle housing and
install clamping segment into the stub
shaft bore of the differential.
(S) Clamping segment - 5870 654 026
Figure 263
4. Fix the differential using measuring cover.
(S) Measuring cover - 5870 200 034
(S) Centering ring - 5870 200 042
(S) Magnetic base - 5870 200 055
(S) Dial indicator - 5870 200 057
Only for Version - 100% Lock:
(S) Measuring cover - 5870 200 077
(S) Magnetic base - 5870 200 055
(S) Dial indicator - 5870 200 057
Figure 264
5. Fasten special device using hex. head
screws.
Figure 265
Figure 266
Check Backlash
1. Mount straightedge on the clamping
segment.
2. Apply dial indicator right-angled (position
= outer diameter / crown wheel) on the
straight-edge and check backlash.
NOTE: Backlash; 0.15 - 0.25 mm
(0.0059 - 0.0098 in).
Figure 267
3. After termination of the backlash
adjustment, remove the measuring device
again.
4. Determine Dimension "I" from the Flange
mounted surface to the Locating face /
outer bearing race.
NOTE: Dimension "I" e.g. 16.55 mm
(0.6516 in).
(S) Straightedge - 5870 200 022
(S) Gauge blocks - 5870 200 066
(S) Digital - depth gauge - 5870 200 072
Figure 268
5. Measure Dimension "II" from the Flange
mounted surface of the Axle housing / Part
II to the Locating face / outer bearing race.
NOTE: Dimension "II" e.g. 13.90 mm
(0.5472 in).
NOTE: With various axle types, the
Dimension "II" can be greater than
Dimension "I." Change the
example accordingly.
(S) Straightedge - 5870 200 022
(S) Gauge blocks - 5870 200 066
(S) Digital - depth gauge - 5870 200 072 Figure 269
NOTE: With a bearing preload of 0.10 mm (0.0039 in), the required rolling moment of 0.10 - 0.41
kg•m (1 - 3 ft lb) is obtained.
6. Insert the determined shim(s) e.g s =
2.750 mm (0.1083 in) into the axle housing
/ Part II and install subsequently the outer
bearing race until contact is obtained.
(S) Driver - 5870 058 061
(S) Handle - 5870 260 002
Only for Version - 100% Lock:
(S) Driver - 5870 058 056
(S) Handle - 5870 260 002
Figure 270
CHECK CONTACT PATTERN
1. Wet some tooth flanks of the crown wheel
with gear-mounting compound.
2. Screw in the two adjusting screws.
3. Fasten axle housing / Part II provisionally
using hex. head screws.
4. Roll the crown wheel several times to and
fro over the drive pinion.
(S) Adjusting screws (M18) -
5870 204 026
Figure 271
5. Remove differential.
6. Compare the obtained contact pattern with
the Examples of Contact Patterns, See
page 8.
NOTE: In case of greater Contact
pattern deviation, a measuring
error has been made during the
determination of the shim (See
page 84), which must be
corrected.
Figure 272
Figure 273
ONLY FOR VERSION - 100% LOCK INSTALL
SHUT OFF SLIDE AND PISTON
NOTE: Figure 274 thru Figure 278.
Reference
Description
Number
1 Axle Housing
2 Differential
3 Stub Shaft
4 Side Gear
5 Shut-off Slide
6 Compression Spring Figure 274
7 Disk
8 Retaining Ring
9 Thrust Bearing
10 Four-lip Rings
11 Piston
Figure 275
Figure 276
4. Grease four-lip rings (10) and insert them
in the recesses of the Axle Housing / Part
II.
Figure 277
5. Oil piston and insert it in the Axle housing /
Part II until contact is obtained.
Figure 278
AXLE BOLTING
1. Insert the new O-ring in the annular groove
(Arrow).
Figure 279
Figure 280
3. Fasten Axle housing / Part II using hex.
head screws (with washers).
NOTE: Pay attention to the installation
position of the reamed bolt (1x).
See arrow.
NOTE: Torque limit 41.81 kg•m (302 ft
lb).
Figure 281
Secure Drive Pinion Bolting
1. Drive lock plate upon the hex. nut.
(S) Driver - 5870 057 020
(S) Handle - 5870 260 002
Figure 282
2. Caulk lock plate.
Figure 283
Version "A"
1. Make inner bearing race adhere with
grease in the steering knuckle bores and
install subsequently sealing caps.
Figure 284
NOTE: In case of the Version - inner
bearing race (1x) with loose
cylindrical rollers; install inner
race into the lower steering
knuckle bore.
2. Make O-Ring adhere with grease in the
bearing pin.
3. Cover collar of bearing pin (arrow) with
anti-corrosive agent (Never Seez).
Figure 285
4. Assemble double-joint shaft in the
differential and position complete final
drive on the axle.
Figure 286
Figure 287
Version "B"
1. Fix final drive using two bearing pins.
NOTE: Insert shim (arrow) on the
upper-bearing pin. Cover collar
of bearing pin with anticorrosive
agent (Never Seez).
Figure 288
2. Fasten bearing pins using hex. head
screws.
NOTE: Torque limit 28.55 kg•m (207 ft
lb).
NOTE: Pay attention to the installation
position of the bearing pins.
Grease fitting is facing the axle
center.
Figure 289
Install Tie Rod
1. Engage tie rod in the steering knuckle hull.
2. Tighten the castle nut and secure it using
the cotter pin.
NOTE: Torque limit 30.59 kg•m (221 ft
lb).
Figure 290
Figure 291
Figure 292
Figure 293
Figure 294
Figure 295
REMOVE TIE ROD
1. Remove cotter pin, loosen castle nut for
some threads.
Figure 296
2. Loosen tie rod using ejection tool (S).
3. Now, unscrew castle nut and unhook tie
rod.
(S) Ejection tool - 5870 000 077
(S) Yoke - 5870 000 079
Figure 297
Figure 298
Version - Tie Rod "With" Stop Ring for
Steering Lock
NOTE: Figure 299 thru Figure 302.
1. Heat piston rod in the zone of the bolting
Piston rod / Thrust bearing.
(S) Hot-air blower - 220 V -
5870 221 500
(S) Hot-air blower - 110 V -
5870 221 501
Figure 299
2. Loosen bolting and separate the complete
tie rod from the piston rod.
3. Now, pull off stop ring.
Figure 300
4. Heat the second bolting of piston rod /
axial joint.
(S) Hot-air blower - 220 V -
5870 221 500
(S) Hot-air blower - 110 V -
5870 221 501
Figure 301
Figure 302
Version - Tie Rod "Without" Stop Ring for
Steering Lock
1. Heat bolting piston rod / axial joint.
2. Loosen bolting and remove complete tie
rod.
NOTE: Disasssemble second tie rod
accordingly.
(S) Hot-air blower - 220 V -
5870 221 500
(S) Hot-air blower - 110 V -
5870 221 501 Figure 303
Figure 304
Figure 305
4. Remove snap ring, retaining ring, and split
ring.
Figure 306
5. Remove piston and remaining
components.
Figure 307
6. Take scraper rings and sealing ring from
the piston.
Figure 308
Figure 309
9. Drive guide I out of the housing.
10. If necessary, remove sealing elements.
Figure 310
Reference
Description
Number
1 Guide
2 O-ring
3 Grooved Ring
4 Scraper Ring Figure 311
Figure 312
3. Grease O-ring (See arrows) and insert it in
the annular groove.
4. Introduce cylinder and reset it until contact
is obtained.
NOTE: Pay attention to the different
diameters of the O-rings.
Figure 313
Reference
Description
Number
1 Piston Rod
2 Snap Ring
3 Retaining Ring
4 Split Ring
5 Disk
6 O-ring
7 Piston Figure 314
8 Scraper Ring
9 Sealing Ring
Figure 315
8. Insert split ring (4) in the annular groove of
the piston rod (See arrow) and assemble
the piston.
Figure 316
Figure 317
10. Insert split ring (4), fix it using retaining
ring (3) and snap ring (2).
Figure 318
11. Assemble scraper ring (8) and sealing ring
(9) upon the piston.
12. Grease sealing elements.
Figure 319
13. Introduce complete piston rod into the
cylinder.
Figure 320
Reference
Description
Number
1 Scraper Ring
2 Grooved Ring
3 Guide
Figure 322
15. Slide cylinder in until contact is obtained
and measure Dimension "B" from the End
face / Cylinder to the Flange-mounted
surface / Axle housing.
NOTE: Dimension "B" e.g. 30.90 mm
(1.2165 in).
NOTE: Pay attention to the contact of
the guide and cylinder.
(S) Digital Depth gauge - 5870 200 072
Figure 323
EXAMPLE
Dimension "A" 32.05 mm (1.2618 in)
Dimension "B" - 30.90 mm (1.2165 in)
Difference = shim thickness s = 1.15 mm (0.0453 in)
Figure 324
18. Assemble pre-assembled guide upon
piston rod and fasten it using hex. head
screws.
NOTE: Torque limit (M14/10.9) 18.86
kg•m (137 ft lb).
Figure 325
ADJUST TRACK AND STEERING LOCK
Figure 327
5. Engage tie rod.
NOTE: Pay attention to the installation
position of the tie rod. Standard
Version - shoulder (See arrow)
is facing the axle housing.
Different versions are possible.
Figure 328
6. Tighten the castle nut and secure it using
the cotter pin.
NOTE: Torque limit 30.59 kg•m (221 ft
lb).
NOTE: Install the second tie rod
accordingly.
Figure 329
Track- Basic adjustment:
NOTE: Figure 330 thru Figure 335.
X = equal distance
NOTE: Locate tie rod to the center
position (Figure 330 thru Figure
335) (Centralize).
Figure 330
Figure 331
2. Check the track position "Zero Degrees."
3. Locate the measuring device (1) to the 0
degree position.
NOTE: Measuring device must be
parallel to the straightedge (2).
Figure 332
4. Loosen the clamp of the tie rod.
Figure 333
5. Turn axial joint until the parallel position of
the measuring device and the straightedge
(0°) is obtained.
NOTE: Pay attention to the exact
central position of the tie rod.
Figure 334
Figure 335
Adjust Stop Screw
NOTE: If a track adjustment (toe-in
resp. toe-out, see 6.2.3 / See
page 125) has to be carried out,
the following steps (adjust stop
screw, Figure 336 thru Figure
339) should be carried out only
after the track adjustment is
completed.
1. Screw stop screw (Without shim) into the
steering knuckle hull.
Figure 336
2. Tilt final drives until the stop ring has
contact on the guide (Arrow).
3. Place the stop screw (Figure 336) against
the axle housing contact is obtained.
Figure 337
4. Determine Dimension "X."
NOTE: Dimension: "X" = Shim
thickness.
Figure 338
Figure 339
Version "B" - Without Stop Ring
NOTE: Figure 340 thru Figure 352.
1. Take the max. steering lock from the
Indications of the Manufacturer of the
vehicle.
Adjust Steering Lock
1. Screw stop screw into the steering knuckle
hull (without shim).
Figure 340
2. Fasten the measuring device (1) on the
drive flange and the straightedge (2) on
the Hub / Wheel stud.
(S) Measuring Device - 5870 200 033
(S) Straightedge - 5870 200 029
Figure 341
3. Adjust required steering lock, e.g. 31°, on
the measuring device (1).Tilt the drive unit
until the straightedge (2) is parallel to the
measuring device (See arrows.).
4. Place stop screw (See Figure 340) against
the axle housing until contact is obtained.
Figure 342
Figure 343
6. Assemble the determined shim(s) and
tighten the stop screw.
NOTE: Torque limit 39.77 kg•m (288 ft
lb).
NOTE: Adjust steering lock on the
opposite knuckle hull
accordingly.
Figure 344
Track- Basic adjustment:
1. Cover threads of tie rod with Loctite #242
and screw it into the piston rod.
2. Tighten tie rod.
NOTE: Torque limit 35.69 kg•m (258 ft
lb).
Figure 345
3. Engage tie rod.
NOTE: Pay attention to the installation
position of the tie rod. Standard
version - shoulder (See arrow.)
is facing axle housing. Different
versions are possible.
Figure 346
Figure 347
5. Locate piston rod in the central position.
X = equal distance
NOTE: To obtain a correct track
adjustment, it is for the following
steps (Figure 348 thru Figure
352) absolutely necessary to
respect the central position of
the piston rod.
Figure 348
6. Check track position "Zero degrees (0°)."
7. Locate measuring device (1) to the 0°
position.
NOTE: Measuring device (1) must be
parallel to the straightedge (2).
(S) Measuring device - 5870 200 033
(S) Straightedge - 5870 200 029
Figure 349
8. Loosen the clamp of the tie rod.
Figure 350
Figure 351
10. After termination of the adjustment, tighten
the clamp again.
NOTE: Torque limit 7.14 - 8.16 kg•m
(52 - 59 ft lb)
Figure 352
Figure 353
Reference Reference
Description Description
Number Number
1 Straightedge Y Steering Lock
2 Marking Notch
1. Determine Dimension "A," starting from the marking notches of the straightedges.
2. Now, turn the two wheel hubs through 180° and determine Dimension "B."
3. Adjust the track, according to the Indications of the Manufacturer of the vehicle by axial displacement
of the tie rods.
NOTE: During the track adjustment, the distance of the straightedges (track) must be modified on
the two tie rods in the same way. Dimension "X" (See Figure 353) corresponds to the
distance "Wheel center to Rim Flange."
Figure 355
1REAR AXLE
(ZF-AXLE)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Figure 1
Drive side (convex).
Figure 2
Pinion Distance must be increased.
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
TECHNICAL DATA
Torque limit - Slotted Nut 158 - 214 kg•m (1,140 - 1550 ft lb)
End play - sun gear / planetary carrier 0 30 - 0.60 mm (0.0118 - 0.0236 in)
DRIVE UNIT/DIFFERENTIAL
Torque limit of the hex. nut on the drive pinion 43.85 kg•m (317 ft lb)
General
The brake lining wearing test gives a limited information about the overall condition of the brake plate pack-
without disassembly of the planetary carrier, resp. of the plates.
The wearing test has to be carried out in case of the following criteria:
• in the course of the oil change intervals (min. once a year).
• braking noises.
• reduced braking power.
• change of deceleration, of the brake fluid level and of the brake pressure.
• in case of a general change of the brake performance.
Carry out the wearing test on both final drive sides.
Permitted piston stoke max 5.0 mm (0.1969 in).
Piston stroke in new condition of the plate pack.
a) with 4 lining plates 2.50 - 2.90 mm (0.0984 - 0.1142 in).
b) with 5 lining plates 3.10 - 3.50 mm (0.1220 - 0.1378 in).
NOTE: The number of lining plates is indicated on the Model Identification Plate, e.g..../ 5L or can
be taken from the corresponding Spare Parts List.
Figure 12
3. Apply the brake (required brake pressure
min. 40.0 bar (580.16 psi).
4. Screw measuring screw (S) in until contact
is obtained and tighten it with a torque of
1.02 kg•m (7.38 ft lb).
5. Determine Dimension "X" according to
Figure 13.
(S) Measuring screw - 5870 204 051
6. Release the brake and equalize the plate
clearance by resetting the measuring
screw (S).
Figure 13
NOTE: Torque limit 1 kg•m (7 ft lb).
7. Determine Dimension "Y" according to the
Figure 14.
8. The difference of the two Dimensions (X -
Y) corresponds to the piston stroke (actual
state).
NOTE: If the max. permitted piston
stroke = 5.0 mm (0.1969 in) is
exceeded, the lining plates
must be replaced on both final
drive sides.
Figure 14
Figure 19
2. Loosen both socket head screws and
separate planetary carrier from the hub.
Figure 20
3. Squeeze the retaining ring out and pull off
planetary gears.
(S) Set of external snap ring pliers -
5870 900 015
(S) Two-leg puller - 5870 970 002
Figure 21
Figure 22
5. Pull sun-gear shaft along with inner plate
carrier from the stub shaft, resp. out of the
plate pack.
6. Remove the released thrust washer.
Figure 23
7. Squeeze the retaining ring out.
(S) Clamping pliers - 5870 900 021
Figure 24
8. Remove backing plate and plate pack.
Figure 25
Figure 26
LOOSEN SLOTTED NUT
1. Figure 27, shows the components of the
Special Tool for the loosening of the slotted
nut (Figure 28).
Reference
Description
Number
1 Hook Spanner -
5870 401 085
2 Spacer -
5870 912 017
Figure 27
3 Centering Disk
(Compl.) -
5870 912 009
Figure 28
Figure 29
CAUTION!
Because of the high torque limit of the
slotted nut (greater than 152.96 kg•m
(1,106 ft lb)), it is absolutely necessary to
back up the axle, resp. the assembly car
at the loosening of the slotted nut.
Therefore, we recommend the use of
a power-operated screwdriver, see
Figure 30.
Figure 30
(S) Power operated screwdriver -
5870 203 012
(S) Profile disk - 5870 510 033
(S) Hook spanner - 5870 401 125
(S) Spacer - 5870 912 017
(S) Centering disk (compl.) - 5870 912 009
5. Drive the piston uniformly out of the
cylinder bore.
Figure 31
Figure 32
7. Pull hub from the hub carrier end.
NOTE: Pay attention to the released
inner bearing race and spacer.
(S) Two-leg puller - 5870 970 006
Figure 33
8. Pry sealing ring out of the hub bore and
remove inner bearing race.
9. If necessary, drive both outer bearing
races out of the hub bore.
NOTE: If the inner bearing race and the
sealing ring remains on the hub
carrier, disassemble as
described under Figure 35 and
Figure 36.
(S) Crow bar - 5870 345 071
Figure 34
10. Pull tapered roller bearing from the end of
the hub carrier.
(S) Grab sleeve "Super" - 5870 028 012
(S) Two-leg puller - 5870 970 003
Figure 35
Figure 36
12. Pry supporting plate from the collar of the
hub carrier.
(S) Crow bar - 5870 245 071
Figure 37
13. Pull stub shaft out of the axle housing and
remove shaft seal (Arrow).
Figure 38
14. Loosen socket head screws and separate
hub carrier from the axle housing.
Figure 39
Figure 41
2. Loosen hex. head screws and reamed
bolt.
NOTE: Mark axle housing I with axle
housing II.
Figure 42
3. Separate the axle housing II from the axle
housing I by mans of lifting device.
NOTE: If necessary, pay attention to
the released differential.
(S) Lifting belt - 5870 281 026
Figure 43
Figure 44
DISMANTLE DIFFERENTIAL
1. Pull tapered roller bearing from differential
case.
(S) Grab sleeve "Super" - 5870 026 025
(S) Back-off insert - 5870 026 100
(S) Pressure piece - 5870 100 009
Figure 45
2. Loosen socket head screws and separate
differential case halves.
Figure 46
3. Remove components.
Figure 47
Figure 48
5. Press crown wheel from differential case.
Figure 49
6. Pull stub shaft (Arrow) out of the axle
housing (Figure 50).
7. Remove also second stub shaft.
Figure 50
8. Pull both outer bearing races (differential
bearing) out of the bearing bores of axle
housing I and II.
NOTE: Pay attention to the released
shims.
Figure 51
Figure 52
2. Loosen hex. nut.
(S) Clamping yoke - 5870 240 025
Figure 53
3. Pull off drive flange.
Figure 54
4. Remove drive pinion.
NOTE: If the pinion bearing must not
be replaced pay attention that
at the driving out of the drive
pinion, the outer inner bearing
race has always contact on the
outer bearing race. If this is not
the case, the bearing would be
damaged and must therefore
be replaced.
Figure 55
Figure 56
6. Remove the shaft seal and the released
tapered roller bearing.
(S) Pry bar - 5870 345 065
Figure 57
7. Drive outer bearing race out of the inner
bearing bore.
NOTE: Pay attention to the released
spacing washer.
Figure 58
8. Pull outer bearing race out of the outer
bearing bore.
(S) Internal puller - 5870 300 019
(S) Backup tool - 5870 300 020
Figure 59
DRIVE PINON
NOTE: If crown wheel or drive pinion are damaged, both parts must be replaced as a set. If a new
complete crown wheel set is installed, pay attention that the crown wheel and drive pinion
have the same mating numbers. If crown wheel set or axle housing are replaced, pay
attention to Figure 61.
Determine shim thickness to obtain a correct contact pattern (Figure 61... Example "H"):
NOTE: Carry out the following measuring operations with utmost care. Inexact measurements
result in a faulty contact pattern - another correction on the installed drive pinion becomes
necessary.
Reference
Description
Number
4 (S) Shim
5 (S) Gauge Ring - Figure 61
5870 200 064
Figure 62
Figure 63
12. Place gauge ring (5) on the machine plane
surface of the housing neck against
shoulder.
13. Determine Dimension "A," see Figure 61.
NOTE: Dimension "A" e.g. 208.80 mm
(8.2205 in).
(S) Gauge ring - 5870 200 064
Figure 64
14. Measure Dimension "B" from the plane
surface/ gauge ring (5) to the contact
surface of the inner outer bearing race,
see Figure 61.
NOTE: Dimension "B" e.g. 78.70 mm
(3.0984 in).
Figure 65
15. Determine Dimension "C" = bearing width.
NOTE: Dimension "C" e.g. 31.95 mm
(1.2579 in).
Figure 66
Figure 67
EXAMPLE "E"
EXAMPLE "F"
EXAMPLE "G"
EXAMPLE "H"
Figure 68
18. Undercool outer bearing race (Arrow) and
place it against shoulder, using special
device.
(S) Assembly jig - 5870 345 049
(S) Thrust rings - 5870 345 056
Figure 69
19. Undercool second outer bearing race and
insert it until contact is obtained.
Figure 70
20. Heat tapered roller bearing and place it
against shoulder.
NOTE: Reset the bearing after the
cooling down.
Figure 71
1 Ring
Figure 74
3. Install drive flange, assemble disk and
tighten hex. nut until the required rolling
moment of 0.10 - 0.20 kg•m (1 - 2 ft lb) is
obtained.
4. Check rolling moment again, see Figure
75.
NOTE: During the tightening, turn the
drive pinion several times
through in both directions.
Figure 75
Figure 76
6. Remove gauge ring and determine
Dimension "X" (Also see Figure 73).
NOTE: Dimension "X" e.g. 11.36 mm
(0.45 in).
NOTE: Dimension "X" corresponds to
the thickness of the spacer to
be installed.
Figure 77
7. Assemble the corresponding spacer (e.g.
11.36 mm (0.45 in)). See arrow.
Figure 78
8. Install pinion again and assemble the drive
flange.
9. Mount disk and tighten hex. nut.
NOTE: Torque limit 43.85 kg•m (317 ft
lb).
NOTE: During the tightening, turn the
drive pinion several times
through in both directions.
(S) Clamping Yoke - 5870 240 025
Figure 79
Figure 80
12. Install shaft seal.
NOTE: By application of the prescribed
driver, the exact installation
position is obtained. If the outer
diameter of the shaft seal is
rubber-coated, wet the sealing
surface with spirit. If not, use
sealing compound Loctite #586.
Fill cavity between sealing lip
and dust lip with grease.
(S) Driver - 5870 048 120
Figure 81
13. If necessary, insert hex. head screws into
the bores of the drive flange (according to
the version) and press the dust plate
against shoulder until contact is obtained.
Figure 82
14. Assemble drive flange and fasten it finally
using disk and hex. nut.
NOTE: Torque limit 43.85 kg•m (317 ft
lb).
(S) Clamping yoke - 5870 24 025
Figure 83
Figure 85
3. Install thrust washer and side gear.
Figure 86
4. Install the complete differential spider.
NOTE: Pay attention to the radial
installation position of the thrust
washers noses are showing
upwards.
Figure 87
Figure 88
7. Mount flat washers and tighten the socket
head screws.
NOTE: Torque limit (M12x1,5/12.9)
14.79 kg•m (107 ft lb)
Figure 89
8. Heat both inner bearing races and place
them against shoulder.
Figure 90
Figure 92
3. Insert the differential into the axle housing
and fix it using measuring cover.
Figure 93
Figure 94
5. Adjust the differential without play and
pressure by application of the threaded
spindle.
6. Now, fix the threaded spindle using locking
screw (Arrow).
Figure 95
7. Apply dial indicator through the oil drain
hole right-angled on the crown wheel tooth
flank and check the backlash.
NOTE: In case of a deviation from the
required backlash, correct
using corresponding shim
(Figure 91).
Figure 96
8. After the backlash adjustment, remove the
measuring device.
9. Remove outer bearing race.
10. Determine Dimension "I" from the flange
mounted surface to the contact surface/
outer bearing race.
NOTE: Dimension "I" e.g. 16.90 mm
(0.6654 in).
Figure 97
Figure 98
EXAMPLE "I":
NOTE: With a bearing preload of 0.10 mm (0.0039 in) the required bearing rolling moment 0.10 -
0.41 kg•m (1 - 3 ft lb) is obtained.
12. Insert determined shim(s) e.g. 3.0 mm
(0.1181 in) into the bearing bore of the
axle housing II and install subsequently
outer bearing race until contact is
obtained.
(S) Driver - 5870 058 061
(S) Handle - 5870 260 002
Figure 99
Figure 101
5. Introduce stub shaft into the inner plate
carrier until contact is obtained and install
the differential.
Figure 102
6. Insert O-ring (Arrow) into the annular
groove of axle housing II and grease it.
Figure 103
Figure 104
9. Fasten the axle housing II using disks and
hex. head screws.
NOTE: Pay attention to the installation
position of the reamed bolt. See
arrow.
NOTE: Torque limit (M18/10.9) 39.77
kg•m (288 ft lb).
Figure 105
10. Fix hex. nut using lock plate. Caulk lock
plate on the drive flange.
(S) Driver - 5870 057 020
(S) Handle - 5870 260 002
NOTE: Before the axle is put into
service, pay attention to the
Lubrication and Maintenance
Instructions, See page 7.
Figure 106
HUB CARRIER
1. Close bores (4x) using king plug. See
arrows. Insert O-ring (Arrow 1) into the
annular groove and grease it.
NOTE: Prior to installing the screw plugs,
clean the oil holes carefully from
residues (preserving agent).
(S) Lever riveting tongs - 5870 320 016
Figure 108
2. Fasten the hub carrier on the axle housing
using socket head screws.
NOTE: Torque limit (M16/10.9) 28.55
kg•m (207 ft lb).
(S) Adjusting screws (M16) - 5870 204 023
Figure 109
3. Install supporting plate.
NOTE: Only by application of the
prescribed driver, is the exact
installation position of
supporting plate obtained.
(S) Driver - 5870 048 129
(S) Pressure Piece - 5870 506 109
Figure 110
Figure 111
HUB
1. Install wheel studs.
(S) Wheel stud puller basic set -
5870 610 000
(S) Insert (M20 x 1,5) - 5870 610 003
Figure 112
2. Insert outer bearing races into both hub
bores until contact is obtained.
Figure 114
2. Place adjusting ring, e.g. 4.45 mm (0.1752
in) (empirical value) against the hub carrier
collar until contact is obtained.
NOTE: If the hub and both wheel
bearings have not been
replaced, we recommend to
install the existing spacer again.
Decisive however is the rolling
moment of the wheel bearing
(Figure 121).
Figure 115
3. Assemble hub (without shaft seal) and fix it
using heated inner bearing race.
NOTE: The installation of the shaft seal
is carried out after the
adjustment of the wheel
bearing.
Figure 116
Tighten Slotted Nut
1. Figure 117 shows the components of the
Special Tool.
(S) Hook spanner - 5870 401 085 (1)
(S) Spacer - 5870 912 017 (2)
(S) Centering disk (compl) -
5870 912 009 (3)
Figure 117
Figure 118
4. Tighten the slotted nut.
NOTE: Torque limit 158 - 214 kg•m
(1,140 - 1,550 ft lb).
NOTE: During the tightening, turn the
hub several times through in
both directions.
IMPORTANT
Because of the high torque limit, it is
absolutely necessary to back up the Figure 119
axle, resp. the assembly car at the
tightening of the slotted nut.
Therefore, we recommend the use of
a power-operated screwdriver, see
Figure 120.
Figure 120
Figure 121
Traction Force F
Traction Force F
NOTE: In case of new bearings, aim at the higher value. Pay attention to the different hub
diameters (according to the version). In case of deviations from the required rolling
moment, correct again with the corresponding adjusting ring (Figure 115), repeat
adjustment procedure (Figure 114 thru Figure 121).
6. Loosen the slotted nut again, remove
internal gear and hub.
7. Heat inner bearing race (about 300°C
(572°F)) and insert it.
NOTE: To avoid the cooling down of
the inner bearing race, the
reassembly of the shaft seal
and the assembling of the hub
(Figure 123 and Figure 124)
must be carried out
immediately after the insertion
of the heated inner bearing
race. Figure 122
Figure 123
9. Assemble hub until contact is obtained and
install determined adjusting ring.
Figure 124
10. Heat inner bearing race and assemble it
until contact is obtained.
Figure 125
INTERNAL GEAR
1. Close bores (4x, See arrows.) using the
king plug.
NOTE: Prior to installing the king plugs,
clean the oil holes carefully
from residues (preserving
agent).
(S) Lever riveting tongs - 5870 320 016
Figure 126
Figure 127
3. Fix the supporting disk provisionally using
compression springs, spring cage and
socket head screws.
4. Insert grooved rings and backup rings into
the annual grooves (Arrows).
5. Installation position, see Figure 129.
6. Now, oil grooved rings and backup rings
(use W-10 oil.).
Figure 128
Reference
Description
Number
1 Piston
2 Backup Ring
3 Grooved Ring
X Pressure Chamber
Figure 129
7. Introduce piston carefully and press it
against shoulder.
NOTE: To avoid the shearing off, resp.
the tipping of the grooved rings,
install the piston with utmost
care (using a hand press). Pay
attention to the radial
installation position.
Figure 130
Figure 131
Reference
Description
Number
1 Internal Gear
2 Piston
4 Spring Cage
5 Compression Spring
6 Supporting Disk
Figure 132
7 Lock Nut
IMPORTANT
Wet thread of lock nuts with Loctite
#242.
Only use of new lock nuts is
permitted.
Figure 133
Figure 134
11. Guide internal gear over the splines of the
hub carrier.
IMPORTANT
Pay attention to the radial installation
position- the exact alignment of the
two oil holes (hub carrier/ internal
gear) must be absolutely ensured.
Position the oil holes 1 and 2 on the
hub carrier see Figure 134.
Figure 135
12. For the present, pull internal gar against
shoulder, using slotted nut.
13. Now, remove slotted nut again.
(S) Hook spanner - 5870 401 085
Figure 136
14. Insert O-ring (1) uniformly into the gap of
the hub carrier and internal gear.
15. Install subsequently angle ring (2).
NOTE: Oil O-ring and angle ring. Pay
attention to the installation
position of the angle ring- install
stepped plane surface facing
the O-ring.
Figure 137
Figure 138
2. Cover thread of slotted nut with lubricant
(Molytoke 1000) and screw on by hand.
3. Position hook spanner and fix it using the
retaining ring.
Figure 139
4. For the present, tighten slotted nut to 158
kg•m (1,140 ft lb).
NOTE: During the tightening, turn the
hub several times through in
both directions.
Figure 140
Figure 141
5. Fix slotted nut using the retaining ring.
NOTE: The locking of the slotted nut is
permitted on one of the two
upper grooves, see Figure 143.
If necessary increase the
torque limit of the slotted nut
within the tolerance range.
NOTE: Torque limit 158 - 214 kg•m
(1,140 - 1,550 ft lb).
Figure 142
(S) Set of internal snap ring pliers -
5870 900 013
Figure 143
IMPORTANT
The following piston stroke adjustment is only valid for the installation of new plates.
Installation Instruction
We know from experience that the required piston stroke is obtained by installation of 5 outer plates with a
thickness of s = 2.50 mm (0.0984 in) and 1 outer plate with a thickness of s = 2.0 mm (0.0787 in).
In case of exceptions, however, a correction may become necessary.
For this case, there are outer plates with a thickness of s = 2.0, 2.5 and 3.0 mm (0.0787, 0.0984 and
0.1181 in) available.
The following measurement, resp. adjustment is therefore absolutely necessary.
In case of the version with 4 lining plates, the piston stroke is 2.50 - 2.90 mm (0.0984 - 0.1142 in).
The number of the lining plates is indicated on the Model Identification Plate (e.g........./ 5L), or can be
taken from the corresponding Spare Parts List.
1. Determine Dimension "I" from the end
face/ internal gear to the contact surface/
piston.
NOTE: Dimension "I" e.g 90.80 mm
(3.57 in).
(S) Depth gauge - 5870 200 052
Figure 144
2. Squeeze the retaining ring in and place it
on the outer surface of the recess
(direction of Arrow) against shoulder.
Measure Dimension "II" from the end face/
internal gear to the inner surface of the
retaining ring.
NOTE: Dimension "II" e.g 46.50 mm
(1.8307 in).
(S) Depth gauge - 5870 200 052
Figure 145
By installation of the following components the required installation dimension, resp. the piston stroke
is obtained.
Figure 147
4. Install the thrust washer.
NOTE: To ensure the exact contact,
align the two tongues of the
thrust washer with the free
grooves of the hub carrier.
Grease contact surface.
Figure 148
5. Squeeze the retaining ring into the recess
(Arrow) of the inner plate carrier.
6. Grease O-ring and insert it into the annular
groove of the inner plate carrier.
7. Now, assemble the sun-gear shaft until
contact is obtained.
(S) Set of internal snap ring pliers -
5870 900 013
Figure 149
8. Assemble pre-assembled plate carrier until
contact is obtained.
Figure 150
Figure 151
11. Fix plate pack using retaining ring.
(S) Retaining ring pliers - 5870 900 021
Figure 152
Check Tightness of Brake Hydraulic System
NOTE: Before starting the test, bleed
the brake and apply it a
minimum of ten times.
(S) HP-Pump - 5870 287 007
High pressure test:
1. Build up test pressure p = 120.0 bar (1,741
psi) and close stop valve of the HP-Pump.
2. During a test period of 5 minutes, a
pressure drop of max. 2% (p = 117.0 bar
(1,697 psi)) is permitted. Figure 153
Low pressure test:
1. Reduce the test pressure to p = 5.0 bar (73
psi).
2. Close the stop valve.
3. During a test period of 5 minutes, no
pressure drop is permitted.
Test Media:
1. Engine oils SAE 10-W, corresponds to
MIL-L 2104 C, MIL-L 45-152, API-CC, CD,
SC, SD, SE, AT-Oils Type A, Suffix A
Dexron II D.
Figure 154
2. Heat inner bearing race and assemble
planetary gear until contact is obtained.
NOTE: Install large radius of inner
bearing race facing the
planetary carrier (downwards).
Figure 155
3. Fix planetary gear using the retaining ring.
4. Install the remaining planetary gears
correspondingly.
(S) Set of external snap ring pliers -
5870 900 015
Figure 156
Adjust End Play of Sun-gear Shaft
NOTE: 0.30 - 0.60 mm (0.0118 -
0.0236 in) (Figure 157 thru
Figure 158).
1. Determine Dimension "I" from the flange
mounted surface to the contact surface of
the thrust washer.
NOTE: Dimension "I" e.g. 199.10 mm
(7.8386 in).
(S) Straightedge - 5870 200 022
(S) Depth gauge - 5870 200 052 Figure 157
Figure 158
EXAMPLE:
Figure 159
NOTE: If the thrust washer has only a
phosphatized surface, this
surface must be installed facing
the sun gear.
Figure 160
Figure 161
6. Assemble the planetary carrier and fasten
it using both socket head screws.
NOTE: Torque limit (M12/8.8, DIN
6912) 5.61 kg•m (41 ft lb).
NOTE: Before the unit is put into
service, pay attention to the
Lubrication and Maintenance
Instructions, See page 7.
Figure 162
1AIR-CONDITIONER
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
AIR-CONDITIONER S0605060K
MODEL SERIAL NUMBER RANGE
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 175LC-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 210W-V 1001 and Up
Solar 225LC-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 1001 and Up
Solar 340LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 470LC-V 1001 and Up
Air-Conditioner S0605060K
Page 1
TABLE OF CONTENTS
General Description........................................................................................ 3
Refrigerant Circulation.................................................................................... 5
Control Panel.................................................................................................. 7
Control Specifications..................................................................................... 8
Temperature Level Control and Display.......................................................... 9
Air Discharge According to Path Selection................................................... 10
Air-conditioning System Circuit Diagram...................................................... 12
Troubleshooting ............................................................................................ 14
Weight of R134a Gas Used In Machines ..................................................... 16
Refrigerant System Repairs ......................................................................... 18
Refrigerant Safe Handling Procedures ................................................. 18
Repair and Replacement Procedure..................................................... 19
Refrigerant Recovery ............................................................................ 21
Vacuuming Refrigerant System............................................................. 21
Leakage Check ..................................................................................... 22
Refrigerant Charging............................................................................. 23
Inspecting System For Leakage............................................................ 25
S0605060K Air-Conditioner
Page 2
GENERAL DESCRIPTION
ARO0550L
Figure 1
The heater and air-conditioner are combined into one unit in the rear cover behind the operator's seat. If
necessary, the operator can control inner temperature using the operation panel installed in the right hand
control stand.
The unit is equipped with an air filtration system which filters out dirt and dust particles from air being
circulated into operator’s cab. This filter should be cleaned out every 500 hours.
NOTE: In the event that the unit is being operated in a dusty environment, the cleaning and
replacement should be performed more frequently. If filter element is damaged, replace
damaged filter by a new one.
WARNING!
All service and inspection of air conditioning system should be performed with the starter
switch in the "O" (OFF) position.
Air-Conditioner S0605060K
Page 3
WARNING!
If using compressed air to clean the element, make sure that proper eye protection is worn.
NOTE: All right and left call outs are based on the operator being seated in the operator’s seat
facing towards the front.
1. Turn the key cylinder (1, Figure 2) to open
cover (2, Figure 2) behind the operator’s
seat.
2. Disconnect speaker harness.
3. Remove cover (2, Figure 2) from the rear 1
box.
2 3
4. Remove filter cover (3, Figure 2) from the
air conditioning unit.
HAAD3860
Figure 2
5. Remove filter element (1, Figure 3) and
inspect it for any damage.
6. Use compressed air to clean filter element. 1
If filter element is very dirty use a mild
soap or detergent and water to clean it.
NOTE: If water was used to clean the
filter, be certain it is completely
dry before installing it.
NOTE: When assembling the filter
again, install so that the arrow
on top of the filter is facing the
inside of the cab.
NOTE: Refer to appropriate Operation
and Maintenance Manual for HAOO790L
latest service intervals.
Figure 3
S0605060K Air-Conditioner
Page 4
REFRIGERANT CIRCULATION
3 HDA6046L
Figure 4
Reference Reference
Description Description
Number Number
1 Evaporator 5 Compressor
2 Expansion Valve 6 Blower Fan
3 Condenser 7 Receiver Dryer
4 Condenser Fan
Air-Conditioner S0605060K
Page 5
Shading Temperature Refrigerant State
• Refrigerant (R134a) is compressed to approximately 15 kg/cm2 (213 psi) within the compressor.
• The compressed refrigerant flows into the condenser at high temperature, approximately 80°C
(176°F).
• The refrigerant in the condenser is cooled to approximately 60°C (140°F) by the condenser fan.
At this time the refrigerant changes from a gas to a liquid state, even though the temperature
has only been reduced 20°C (68°F). From 80° to 60°C (176° to 140°F).
• The refrigerant in its liquid form is injected into the evaporator through the expansion valve. At
this time the pressure is reduced by approximately 2 kg/cm2 (28 psi) and the temperature is also
reduced. As a result, the refrigerant absorbs the heat from the air surrounding the evaporator
creating a cooling effect and changes from the gas to the liquid state.
• The refrigerant once again flows into the compressor in the gaseous state and the process is
repeated.
WARNING!
Refrigerant gas is pressurized and sealed in the air conditioning system. Special
precautions are required for the proper recharging or release of refrigerant. Release of
refrigerant into the atmosphere is strictly regulated by law. Make sure that you are in
compliance with all mandated federal, state and municipality requirements, before starting
any service or repair of the air conditioner. Refrigerant gas used in the system must meet or
exceed specifications for R134a refrigerant, or any subsequently issued environmentally
mandated standard.
S0605060K Air-Conditioner
Page 6
CONTROL PANEL
ARO0501L
Figure 5
DISPLAY
TEMPERATURE
SENSOR
LOW SPEED RELAY
HDA6048L
Figure 6
Air-Conditioner S0605060K
Page 7
CONTROL SPECIFICATIONS
50%
MAX HOT
0%
HDA6049L
Figure 7
LOW RELAY
HDA6050L
Figure 8
COMP OFF
1.5 C 4.0 C
HDA6051L
Figure 9
S0605060K Air-Conditioner
Page 8
TEMPERATURE LEVEL CONTROL AND DISPLAY
Position
Step LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Sensor Remark
Voltage
0 Green Green Green Green Green Green Green 4.50 V ±0.2 MAX. COOL
1 Green Green Green Green Green Green Green 4.33 V ±0.2
2 Green Green Green Green Green Green Green 4.15 V ±0.2
3 Red Green Green Green Green Green Green 3.98 V ±0.2
4 Red Green Green Green Green Green Green 3.80 V ±0.2
5 Red Green Green Green Green Green Green 3.63 V ±0.2
6 Red Red Green Green Green Green Green 3.46 V ±0.2
7 Red Red Green Green Green Green Green 3.28 V ±0.2
8 Red Red Green Green Green Green Green 3.11 V ±0.2
9 Red Red Red Green Green Green Green 2.93 V ±0.2
10 Red Red Red Green Green Green Green 2.76 V ±0.2
11 Red Red Red Green Green Green Green 2.59 V ±0.2
12 Red Red Red Red Green Green Green 2.41 V ±0.2
13 Red Red Red Red Green Green Green 2.24 V ±0.2
14 Red Red Red Red Green Green Green 2.07 V ±0.2
15 Red Red Red Red Red Green Green 1.89 V ±0.2
16 Red Red Red Red Red Green Green 1.72 V ±0.2
17 Red Red Red Red Red Green Green 1.54 V ±0.2
18 Red Red Red Red Red Red Green 1.37 V ±0.2
19 Red Red Red Red Red Red Green 1.20 V ±0.2
20 Red Red Red Red Red Red Green 1.02 V ±0.2
21 Red Red Red Red Red Red Red 0.85 V ±0.2
22 Red Red Red Red Red Red Red 0.67 V ±0.2
23 Red Red Red Red Red Red Red 0.50 V ±0.2 MAX. HOT
Air-Conditioner S0605060K
Page 9
AIR DISCHARGE ACCORDING TO PATH SELECTION
Face, Rear, and Defroster
ARS1280L
Figure 10
Foot
ARS1290L
Figure 11
S0605060K Air-Conditioner
Page 10
Face and Defroster
ARS1300L
Figure 12
Air-Conditioner S0605060K
Page 11
AIR-CONDITIONING SYSTEM CIRCUIT DIAGRAM
3 2
5
B A
3 II
10 9
15
15-1 15-2
+ -
M
14
22
15-3 15-4 15-5
11 13
LED 1~12
7
8 87a
30
3
5
11
12
HIGH
MID
- + 87
M 8 13 LOW
85 86 18 9 REC
19 10 FRE
10 M
15-6
MODE SELECT
23 7 VENT
9 AIR MODE
RECIRCLE/FRESH
21
20
17
8
DEF
FOOT 15-7
87a
BLOWER SPEED
30
M
87 TEMP. CONTROL
85 86 14 3 (WARM)
15 2 (COOL) M
9
2
16
4
5
15-8
4 1
DEF 2 7 1 6
10 M FOOT
3 6
26 16
15-9
CN6 HRS 26P
CN5 AMP MIC 13P + 250 4P
14
11 15
HRS NO.GT7A-26PD-DS 26P AMP MIC 13P
13 6 5 4 3 2 1
12 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7
(CN6) (CN5)
ARS1310L
Figure 13
S0605060K Air-Conditioner
Page 12
Reference Reference
Description Description
Number Number
1 Battery 13 Compressor
2 Battery Relay 14 A/C Control Panel
3 Fusible Link 15 A/C Unit
4 Circuit Breaker 15-1 Blower Motor
5 Fuse 15-2 Resister
6 Lamp Switch 15-3 High Speed Relay
7 Condenser Fan Relay 15-4 Mid Speed Relay
8 Condenser Fan Motor 15-5 Low Speed Relay
9 Compressor Relay 15-6 Recirculate / Fresh Air
10 Foot / Defrost Control Control Actuator
Actuator 15-7 Vent Actuator
11 Receiver Dryer (Low / High 15-8 Temperature Control
Pressure Cut Off Switch) Actuator
12 Diode 15-9 Temperature Sensor
(Evaporator)
Air-Conditioner S0605060K
Page 13
TROUBLESHOOTING
Refrigerant Pressure Check
LO HI
HDA6074L
Figure 14
S0605060K Air-Conditioner
Page 14
High Pressure: Approximately 20 - 25 kg/cm2 (285 - 356 psi)
3
Low Pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.
Air-Conditioner S0605060K
Page 15
High Pressure: Over 7 - 11 kg/cm2 (100 - 156 psi)
7
Low Pressure: 4 - 6 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression Inspect and replace
compressor if necessary.
S0605060K Air-Conditioner
Page 16
Model Weight of Gas
Solar 225LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 225NLC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 250LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 255LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 280LC-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 290LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 290LL 850 ±20 grams (30 ±0.7 oz.)
Solar 300LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 300LL 850 ±20 grams (30 ±0.7 oz.)
Solar 330-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 330LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 340LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 400LC-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 400LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 420LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 450LC-III 1250 ±20 grams (44 ±0.7 oz.)
Solar 450LC-V 850 ±20 grams (30 ±0.7 oz.)
Solar 470LC-V 850 ±20 grams (30 ±0.7 oz.)
Air-Conditioner S0605060K
Page 17
REFRIGERANT SYSTEM REPAIRS
WARNING!
Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in
contact with the skin or eyes, immediately flush with clean, running water and consult a
physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high pressure and should be stored below 40°C (104°F). Be
careful not to drop the container from a high location
The contents are under high pressure and should not be used with compressed air or near an
open flame.
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
HDA6066L
Figure 15
The following procedures should be observed for safe handling of refrigerant during vacuum and charging
process.
1. Use an approved recovery / charging device which can safely perform vacuum and charge work
simultaneously.
2. The new refrigerant has improved cooling characteristics than the old type and care should be used
not to overcharge the system.
3. Do not over tighten connections when working on refrigerant system.
4. The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to
use equipment use in servicing the old refrigerant system.
S0605060K Air-Conditioner
Page 18
5. The new refrigerant oil (PAG type) has a high moisture absorption characteristic. When the
refrigerant system vacuum seal has been broken, immediately plug up all openings to prevent
moisture from entering into the system.
6. When joining unions which use O-ring seals, lightly coat O-rings with refrigerant oil. Be careful not to
drip oil on the threads of the nut.
7. Be certain the O-rings are seated properly on the refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine running, do not open the high pressure valve
on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose.
10. When releasing the high pressure hose after completing the charging process, quickly disconnect the
hose to minimize refrigerant released to the air.
Air-Conditioner S0605060K
Page 19
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
RUN SYSTEM
S0605060K Air-Conditioner
Page 20
REFRIGERANT RECOVERY
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low Pressure Side
3 High Pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50 psi), slowly open the low pressure valve.
4. Open both the high and low pressure valves slowly until the manifold gauge dials indicates 0 kg/cm2
(0 psi).
Reference 2 3
Description
Number 1 4
1 To Compressor
2 Low Pressure Side
3 High Pressure Side
4 From Receiver
5 Vacuum Pump
1. Vacuuming Procedure 5
HDA6068L
NOTE: When the A/C system has been Figure 18
exposed to the air, it must be
vacuumed out. Perform vacuum
process for 30 minutes for
complete moisture and air
evacuation.
A. Attach the manifold gauges and vacuum pump to the refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low pressure gauge shows approximately 710 mmHg, close both valves and turn off
vacuum pump.
Air-Conditioner S0605060K
Page 21
2. Check system for vacuum leak.
Allow system to sit for 10 minutes and
check whether the system is holding the
pressure. If the pressure has dropped, it
must be repaired before proceeding to the
next step.
3. Vacuuming Procedure
If the system is holding the pressure and it
has not changed for 10 minutes, vacuum
out the system for an additional 20
minutes. HDA6069L
Figure 19
A. Turn on the vacuum pump and slowly
open both valves.
B. Allow vacuum pump to run for
additional 20 minutes until the low
pressure gauge dial reads
approximately 750 mmHg.
C. Close both valves and stop the
vacuum pump.
4. Installation of Refrigerant Container
Reference 1
Description
Number
1 Handle
2 Hose Connection
3 Mounting Disk 2
LEAKAGE CHECK
NOTE: Perform the leakage check after completing vacuuming process.
1. After attaching the manifold gauge, open the high side valve.
S0605060K Air-Conditioner
Page 22
2. Charge system until the low side gauge dial indicates a pressure of 1 kg/cm2 (14 psi) and close the
high side valve.
3. Using a refrigerant leak detector or soapy
water check each joint for leakage.
1
Reference
Description
Number
Refrigerant Leak
1
Detection Device
WARNING!
For accurate refrigerant leak
detection, perform leak detection
procedure in a well ventilated area.
REFRIGERANT CHARGING
1. Perform the vacuuming procedure, vacuum holding and leaking tests as described in the proceeding
headings.
NOTE: First charge the refrigerant system with 100g (3.5 ounces) of refrigerant with the engine
off. Then using the manifold gauges as a guide fully charge the system with the engine
running.
When exchanging refrigerant containers, press the manifold gauge low side valve to
eliminate air from the charging hose.
Air-Conditioner S0605060K
Page 23
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low Pressure Side
3 High Pressure Side
4 From Receiver
5 Refrigerant Supply
Container
WARNING!
When charging refrigerant system with the engine running;
• Always keep refrigerant supply container in the upright position.
• Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge system to standard capacity.
NOTE: These standards are for outside temperatures between 30° - 35°C (86° - 95°F). The
gauge readings may vary for extreme temperature conditions.
WARNING!
• When outside temperature is low, warm the refrigerant supply container with
warm water not exceeding 40°C (104°F). Do not allow water to come in contact
with the charging adapter valve handle.
• When outside temperature is high, cool off refrigerant supply container and
condenser to aid the refrigerant charging process.
S0605060K Air-Conditioner
Page 24
5. Close low pressure side valve.
6. Shut off engine and close refrigerant supply container adapter valve. Disconnect manifold gauge
hoses from vehicle.
Reference
Description
Number
1 Pressure
2 High Pressure
3 Low Pressure
4 Compressor Stop
Inspection Procedure
1. High Pressure Side
Compressor outlet → condenser inlet → receiver dryer inlet → air-conditioner unit inlet
2. Low pressure side
Compressor inlet → air-conditioner unit outlet
3. Compressor
Compressor shaft area, bolt hole area and magnetic clutch area.
4. Receiver dryer
Pressure switch and plug area.
5. Connection valve area
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds
minimum.)
NOTE: When inspecting leakage from the air-conditioning unit, perform the inspection in a well
ventilated area.
Air-Conditioner S0605060K
Page 25
S0605060K Air-Conditioner
Page 26
S0607050
TRANSMISSION
(ZF 2HL-100)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Figure 1
POWER FLOW
Reference Reference
Description Description
Number Number
a 1st Gear 5 Planetary Stage
b 2nd Gear 6 Manual Disconnect Clutch
c Braking 7 Inductive Speed Sensor for
1 Drive Housing with Integrated Electrohydraulic Overspeed
Shifting Valves Protection
2 Hydraulically Released Plate 8 Hydraulic Overspeed
Springs Protection
3 Multi disc Brake 9 Emergency Steering Pump
4 Multi disc Clutch 10 Direct Axle Housing
TRANSMISSION DESIGN
The 2 HL-100 and the 2 HL-110 are two-speed powershift transmissions of planetary design with helically
cut spur gear and dual countershaft construction. The powershift stage for the planetary drive is composed
of an integrated multi disc brake (3) and a rotating multi disc clutch (4). Both are actuated by plate springs
(2) and released hydraulically. In the closed condition, both brake and clutch block the planetary stage (5)
and function as an auxiliary and parking brake.
SHIFT CONTROL
The shift control is specifically matched to the machine requirements. For open hydraulic circuitry, shift
control is hydraulic. For closed loop circuitry, electrohydraulic shift control is used. Both shift controls are
designed with overspeed protection that prevents downshifting until the vehicle has reached a
predetermined velocity to prevent overspeed damage to the hydraulic motor.
The electrohydraulic version of the shift control can be fully automated for increased operator’s comfort and
safety. The shifting points are preselected, giving the highest possible drive system performance.
OIL CAPACITY
Gearbox vertically installed about 3.40 liters (0.90 U.S. gal.) (*)
Gearbox horizontally installed about 3.80 liters (1 U.S. gal.) (*)
ADMITTED OILS
For the gearbox according to the ZF-List of Lubricants TE-ML 07.
For the gearbox according to the ZF-List of Lubricants TE-ML 07 or
HLP-Hydraulic Oils according to DIN 51524 Part 2.
At the first starting, the cross country gear must be engaged with the running control pump for about 2
minutes to avoid a dry-running in the drive compartment. The same measure must also be taken in case of
a replacement of the gearbox or hydromotor.
Ventilation of the gearbox control system with running control pump.
Vent air using bleeder screw on the gearbox brake. For this case, carry out several gearshifting operations.
If the parking brake is applied it must be ensured that an actuation of the accelerator pedal has no effect
(Accelerator valve in NEUTRAL).
The same is valid in case of an undue control pressure drop (<24.0 bar (348 psi)).
First oil change after 100 operating hours on duty.
Every further oil change after 2000 operating hours on duty, however, at least once a year.
NOTE: Binding are the filler, resp. level plugs, see Installation View and Instructions for the Oil
Filling Procedure.
Reference
Description
Number
1 Oil Filling Drain
2 Oil Drain
3 Oil Filling (Axle Housing)
4 Oil Drain (Axle Housing)
5 Oil Filling, Check and Oil Drain
(Planetary Drive)
Separate installation.
Figure 2
Installation position vertical.
Separate installation.
Installation position horizontal.
Oil quality - gearbox - TE-ML 07
Oil quality - axle - TE-ML 05
Figure 3
Figure 4
Figure 6
Figure 7
Drive side (convex).
Figure 8
Pinion Distance must be increased.
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 15
3. Pull inner plate carrier (along with sun
gear) from the stub shaft, resp. out of the
plate pack.
Figure 16
4. Pull stub shaft out of the axle housing.
Figure 17
Figure 18
6. Loosen the screw plug and drain oil from
the axle housing.
7. Secure 2 HL-100 using hoist, loosen
screwed joint and separate complete
gearbox from axle housing.
Figure 19
REMOVE SHIFTING CLUTCHES
1. Fasten gearbox in the assembly car.
2. Loosen screw plug (Arrow) and drain oil.
(S) Assembly car compl. with tilting device
5870 350 000
(S) Support - 5870 350 055
Figure 20
3. Remove the two lines. See arrows.
Figure 21
Figure 22
5. Squeeze out snap ring (Arrow).
Figure 23
6. Loosen socket head screws evenly, install
two adjusting screws and separate drive
casing from the gearbox.
NOTE: Drive casing is spring-loaded.
(S) Adjusting screw (M12) - 5870 204 021
Figure 24
7. Remove the two cup springs.
Figure 25
Figure 26
9. Remove screw plug and breather (Arrows).
Figure 27
10. Remove seal ring and backup ring from
the ring groove of the housing (Arrow).
Figure 28
11. Squeeze out snap ring.
Figure 29
Figure 30
13. Remove O-ring (Arrow).
Figure 31
14. Remove plate pack and backing plate.
Figure 32
15. Squeeze out retaining ring (Arrow).
Figure 33
Figure 34
17. Fix sun gear axially using assembly jig.
squeeze out retaining ring and relax the
cup spring pack.
(S) Assembly jig - 5870 345 047
Figure 35
18. Remove released disk and sun gear.
Figure 36
19. Separate internal gear from drive shaft.
Figure 37
Figure 38
21. Remove plate pack.
Figure 39
22. Remove plate.
Figure 40
23. Pry inner plate carrier out of the piston.
Figure 41
Figure 42
25. Remove cup spring pack.
Figure 43
26. Remove seal ring and O-ring.
27. Remove disk (Arrow).
NOTE: Replace sealing compound at
any rate.
Figure 44
28. Squeeze out retaining ring.
Figure 45
Figure 46
30. Separate guide bush from drive shaft.
Figure 47
31. Squeeze out snap ring and remove shaft
seal (Arrow).
Figure 48
32. Squeeze out retaining ring and press
bearing from shaft.
Figure 49
Figure 50
REMOVE AND DISMANTLE PLANETARY
DRIVE
1. Squeeze out retaining ring (Arrow).
Figure 51
2. Tilt housing for 90°.
3. Separate and remove planetary carrier
from helical gear, using internal puller.
(S) Internal puller - 5870 300 007
(S) Backup tool - 5870 300 003
Figure 52
4. Squeeze out retaining ring.
Figure 53
Figure 54
7. Pull off inner bearing race.
(S) Two-leg puller - 5870 970 001
Figure 55
8. Squeeze out retaining ring and remove
ball bearing.
Figure 56
REMOVE AND DISMANTLE DECLUTCH UNIT
AND SPUR GEAR
1. Loosen hex. head screw (shift lever
locking) and remove sliding collar along
with sliding blocks.
Figure 57
Figure 58
3. Drive out roll pin (Arrow).
Figure 59
4. Pry shift lever out of the housing bore and
remove released shift fork.
(S) Pry bar - 5870 345 065
Figure 60
5. Remove suction line.
Figure 61
Figure 62
7. Pull rotor set from shaft and remove drive
ball (Arrow).
Figure 63
8. Pry pump cover out of the housing bore.
Figure 64
9. Squeeze out retaining ring.
Figure 65
Figure 66
11. Squeeze out retaining ring.
Figure 67
12. Pry off helical gear (Figure 68) and take it
out of the housing (Figure 69).
Figure 68
Figure 69
Figure 70
14. Remove shift dog and spacer.
NOTE: According to the design, with or
without spacer, see parts
manual.
Figure 71
15. Pull needle bearing out of the housing
bore, using internal puller.
(S) Internal puller - 5870 300 001
(S) Backup tool - 5870 300 003
Figure 72
16. Press helical gear from bearing cap.
Figure 73
Figure 74
18. Squeeze out retaining ring.
Figure 75
19. Pry off ball bearing from helical gear collar.
(S) Pry bar - 5870 345 065
Figure 76
DISMANTLE SHIFT LOCK
NOTE: If a trouble is noted in the area
of the lubricating oil pump (rotor
or valve body), the complete
shift lock has to be replaced.
1. Remove control spool.
Figure 77
Figure 78
3. Remove pilot spool.
Figure 79
4. Remove shuttle valves.
Figure 80
5. Remove shuttle valves.
NOTE: Use Special Tool (S) for the
removal of the sleeves, see
Figure 81.
(S) Internal puller - 5870 300 022
(S) Striker - 5870 650 001
Figure 81
Figure 82
DISASSEMBLE FINAL DRIVE, AXLE
CARRIER AND DIFFERENTIAL
Figure 83
2. Pry out shaft seal.
Figure 84
3. Tilt housing for 90°.
4. Loosen hex. head screws and separate
axle drive from the gearbox, using back-off
screws (3 pieces).
NOTE: Use two adjusting screws. Pay
attention to the released inner
bearing race and shim.
(S) Adjusting screw (M12) - 5870 204 039
Figure 85
Figure 86
6. Remove baffle plate.
Figure 87
7. Drive outer bearing race out of the housing
bore.
Figure 88
8. Pry shaft seal out of the housing bore.
Figure 89
Figure 90
11. Eliminate differential bearing preload by
loosening the adjusting nut.
Figure 91
12. Loosen hex. head screws and remove the
two bearing caps and adjusting nuts.
NOTE: Mark bearing caps and
installation position of the crown
wheel with axle carrier.
Figure 92
13. Lift differential assembly out of the axle
carrier.
Figure 93
Figure 94
15. Loosen socket head screws.
Figure 95
16. Separate differential case halves and
remove released components.
Figure 96
17. Press crown wheel from differential case.
Figure 97
Figure 98
19. Remove O-ring and bushing.
Figure 99
20. Pull tapered roller bearing from drive
pinion.
(S) Grab sleeve "Super" - 5870 026 001
(S) Basic set - 5870 026 000
Figure 100
21. Pull outer bearing race out of the housing
bore, using internal puller.
(S) Internal puller - 5870 300 019
(S) Backup tool - 5870 300 020
Figure 101
Figure 102
CAUTION!
If crown wheel or drive pinion are damaged, the two parts must be replaced as a set.
If a new complete crown wheel set is installed, pay attention that the crown wheel and drive
pinion have the same mating numbers.
If a complete crown wheel set or axle carrier is exchanged, pay attention to the part list.
Figure 104
EXAMPLE "A":
Dimension "A" (= measuring pin) 134.00 mm (5.2756 in)
Dimension "B" + 0.85 mm (0.0335 in)
Dimension "C" (1/2 φ measuring shaft) + 15.00 mm (0.5906 in)
Gives Dimension "X" 149.85 mm (5.8996 in)
Figure 105
Figure 106
EXAMPLE "B":
Bearing Width 36.50 mm (1.4370 in)
Pinion Dimension +111.85 mm (4.4035 in)
Gives Dimension "X1" 148.35 mm (5.8406 in)
EXAMPLE "C":
Dimension "X" 149.85 mm (5.8996 in)
Dimension "X1" -148.35 mm (5.8406 in)
Difference = shim thickness = 1.50 mm (0.0591 in)
Figure 107
Figure 108
3. Insert 2nd outer bearing race into the
housing bore until contact is obtained.
(S) Driver - 5870 058 073
(S) Handle - 5870 260 002
Figure 109
4. Insert adapter. See arrow.
NOTE: Install new sealing edge ring.
Use Loctite #586.
Figure 110
5. Install oil pipe (compl.) and fasten using
hex. head screws.
NOTE: Secure hex. head screws with
Loctite #586.
NOTE: Torque limit (M8/8.8) 2.35 kg•m
(16.96 ft lb).
Figure 111
Figure 112
7. Insert shaft seal firmly against shoulder.
8. Install O-ring. See arrow.
NOTE: Pay attention to the installation
position of the shaft seal (open
side above), see Figure 113.
Cover outer diameter of shaft
seal with a spirit-water mixture
(1:1) and grease sealing lip.
(S) Driver - 5870 055 089
(S) Handle - 5870 260 002
Figure 113
9. Insert output gear.
NOTE: Pay attention to the installation
position, see Figure 114.
Figure 114
10. Install two adjusting screws, assemble
housing and fasten using hex. head
screws.
NOTE: Torque limit (M12/8.8) 8.06
kg•m (58.27 ft lb).
NOTE: Pay attention to the installation
position, see Figure 115.
(S) Adjusting screw (M12) - 5870 204 039
Figure 115
Figure 116
12. Assemble bushing and insert O-ring into
the ring groove (Arrow).
NOTE: Grease O-ring.
Figure 117
13. Install drive pinion.
Figure 118
14. Fix drive pinion provisionally axially by
mean s of puller.
(S) Two-leg puller - 5870 970 006
Figure 119
Figure 120
Adjust Roller Moment of Drive Pinion Bearing
NOTE: Roller moment = 0.25 - 0.36
kg•m (2 - 3 ft lb).
1. Assemble shim e.g. s = 2.60 mm (0.1024
in).
NOTE: Shim s = 2.60 mm (0.1024 in) is
an empirical value. However, a
later check of the rolling
moment is inevitable.
Figure 121
2. Heat inner bearing race and assemble it
until contact is obtained.
Figure 122
3. Assemble output flange.
Figure 123
Figure 124
5. Check rolling moment of the drive pinion
bearing.
NOTE: In case of a deviation from the
required rolling resistance 0.25
- 0.36 kg•m (2 - 3 ft lb), correct
with corresponding shim
(Figure 121).
6. Now, remove the output flange again.
(S) Two-leg puller - 5870 970 003
(S) Driver - 5870 057 009
(S) Handle - 5870 260 002 Figure 125
7. Insert shaft seal.
NOTE: By application of the prescribed
driver (S), the exact installation
depth of (2.0 +1.0 mm (0.0787
+0.0394 in)) is obtained. Wet
outer diameter of shaft seal with
a spirit-water mixture (1:1) and
grease sealing lip.
(S) Driver - 5870 048 143
Figure 126
8. Insert hex. head screws in the output
flange and align radially (Figure 127) to
allow the later mounting of the dust shield
(Figure 128).
Figure 127
Figure 128
10. Assemble output flange and install O-ring.
See arrow.
NOTE: Grease O-ring before the
installation.
Figure 129
11. Fasten output flange finally using washer
and hex. head screws.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (34 ft lb)
(S) Clamping yoke - 5870 240 025
Figure 130
12. Fix hex. head screws using lock plate
(Arrow).
(S) Driver - 5870 057 009
(S) Handle - 5870 260 002
Figure 131
Figure 132
2. Press crown wheel upon roll pins until
contact is obtained.
Figure 133
3. Mount thrust washer.
Figure 134
4. Insert side gear.
Figure 135
Figure 136
6. Make thrust washer adhere with grease in
the differential case half II.
7. Replace differential case half.
NOTE: Pay attention to the radial
installation position, see
designation (ZP-No.).
Figure 137
8. Fix differential using press.
9. Replace segments and tighten socket
head screws.
NOTE: Torque limit (M15x1,5/12.9)
14.79 kg•m (107 ft lb).
Figure 138
10. Press both inner bearing races of the
differential bearing firmly against shoulder.
Figure 139
Figure 140
12. Figure 141 shows the installation position
of the crown wheel (differential) in the
arrangement as rear axle.
13. Direction of Arrow indicates "Forward
drive."
Figure 141
14. Screw the two adjusting nuts into the
bearing bores.
Figure 142
15. Drive straight pin into the bore of the two
bearing caps until contact is obtained.
NOTE: Use Loctite #242.
Figure 143
Figure 144
Adjust Backlash and Bearing Preload
1. Backlash- see value engraved on the
crown wheel.
2. Bearing preload: 0.10 - 0.41 kg•m (1 - 3 ft
lb).
3. Apply dial indicator right-angled on the
outer diameter of the tooth flank/crown
wheel.
4. Adjust crown wheel side adjusting nut until
the required backlash is obtained.
5. Screw in 2nd adjusting nut (opposite to the Figure 145
crown wheel side) until the differential
bearing is free of play.
6. Now, tighten the adjusting nut for 2
notches more to obtain the required
differential bearing preload.
7. Check backlash again and correct if
necessary.
NOTE: During this step, rotate the
differential several times.
8. Check installation dimension = 216.00
±0.05 mm (8.5039 ±0.0020 in) and correct
if required (repeat step of Figure 144 and
Figure 145).
Figure 146
Figure 147
11. Cover some crown wheel tooth flanks with
gear marking compound.
12. Roll crown wheel to and fro over drive
pinion.
13. Take contact pattern and compare with
“Examples of Gear-tooth-contact Patterns
for the Gleason Gear-tooth System” on
page 10.
NOTE: In case of greater contact
pattern deviation, a measuring
error has been made during the
determination of the shim Figure 148
(“Adjust Roller Moment of Drive
Pinion Bearing” on page 42),
which must be absolutely
correct.
14. Fix both adjusting nuts using straight pins.
Figure 149
Figure 150
2. Press ball bearing over the collar of the
helical gear until contact is obtained and
fix it using retaining ring.
Figure 151
3. Press bearing cover (ball bearing) firmly
against shoulder with the retaining ring
showing toward above.
(S) Pressing sleeve - 5870 506 044
Figure 152
4. Insert spacer and shift dog.
NOTE: According to the design with
our without spacer, see
corresponding Spare-Parts List.
Figure 153
Figure 154
6. Press needle bearing firmly against
shoulder.
NOTE: Pay attention to the installation
position designation showing
upward.
(S) Driver - 5870 058 023
(S) Handle - 5870 260 002
Figure 155
7. Insert pre-assembled helical gear into the
housing bore.
Figure 156
8. Fix bearing cover using retaining ring. See
arrow.
Figure 157
Figure 158
10. Squeeze in retaining ring (1) and install O-
ring (2).
Figure 159
11. Insert shift fork and sliding collar.
Figure 160
12. Introduce shift shaft until contact is
obtained.
Figure 161
Figure 162
14. Install screw plug.
NOTE: Torque limit (M22x1,5) 6.12
kg•m (44 ft lb).
NOTE: Mount new O-ring.
Figure 163
COMPLETE AND INSTALL PLANETARY
CARRIER
1. Pre-assemble planetary gear.
NOTE: Install cylindrical rollers with
grease.
Figure 164
2. Press pre-assembled planetary gears
firmly against shoulder.
Figure 165
Figure 166
4. Insert ball bearing firmly against shoulder
and fix with retaining ring.
Figure 167
5. Heat ball bearing and mount planetary
carrier until contact is obtained.
Figure 168
6. Fix planetary carrier with retaining ring
(Arrow).
Figure 169
Figure 170
2. Bring shift shaft by clockwise rotation to
the stop, using auxiliary screw (M8) and
jam shift lever using socket head screw
and flat washer.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (34 ft lb).
Figure 171
3. Now bring shift lever in "ON-Position"
(Arrow) and fasten using hex. head screw.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (34 ft lb).
Figure 172
PRE-ASSEMBLE AND INSTALL CLUTCH
(ROAD GEAR)
1. Press ball bearing firmly against shoulder
and fix it using retaining ring.
Figure 173
Figure 174
3. Install shaft seal.
NOTE: By application of the prescribed
driver, the exact installation
depth is given. Wet outer
diameter of shaft seal with
spirit. Grease the sealing lip.
(S) Driver - 5870 055 105
(S) Handle - 5870 260 002
Figure 175
4. Fix shaft seal using snap ring.
Figure 176
5. Grease the two rectangular rings, align
them centrically and press the drive shaft
into the guide sleeve until contact is
obtained.
Figure 177
Figure 178
7. Squeeze in retaining ring (Arrow) and
replace backup plate, with the offset plane
surface showing upwards.
NOTE: Only the installation of one new
retaining ring admitted.
Figure 179
Figure 180
Adjustment value B with 10 plate pairs = 10.60 +0.20 mm (0.4173 +0.0079 in)
Adjustment value B with 11 plate pairs = 7.80 +0.20 mm (0.3071 +0.0079 in)
9. Replace piston.
Figure 181
10. Assemble plate carrier (Figure 182) and
tap it against shoulder until contact is
obtained, see Figure 183.
Figure 182
Figure 184
12. Assemble alternating plate pack, starting
with one inner plate.
NOTE: Number of inner and outer
plates, see corresponding
Spare-Parts List. For the
moment, install the plate pack
without oil.
Figure 185
13. Determine Dimension "B" from end face of
the inner plate carrier to the outer plate.
NOTE: Dimension "B" e.g. 10.70 mm
(0.42 in).
NOTE: Carry our any corrections using
the corresponding outer plates
(s = 1.0, 1.2, 1.4 or 1.8 mm
(0.0394, 0.0472, 0.0551, or
0.0709 in).
Figure 186
Figure 187
16. Assemble shim s = 3.0 - 3.9 mm (0.1181 -
0.1535 in), see arrow), fix it using retaining
ring and check end play.
17. Now, squeeze out retaining ring again and
remove the components again, up to the
piston included.
Figure 188
18. Squeeze retaining ring into the ring groove
(Arrow) with the sealing lip facing the
pressure chamber (toward above).
NOTE: Use installer (S). Grease
sealing lip.
(S) Installer - 5870 651 052
Figure 189
19. Install O-ring. See arrow.
NOTE: Grease O-ring.
Figure 190
Figure 191
21. Assemble piston.
Figure 192
22. Install seal ring (Arrow) with the sealing lip
facing the pressure chamber (toward
below) and insert the inner plate carrier
against shoulder, until contact is obtained.
NOTE: Grease seal ring.
Figure 193
23. Mount plate.
Figure 194
Figure 195
25. Insert ball bearing into the centering disk
and fix it using retaining ring.
Figure 196
26. Insert centering disk into the internal gear
bore and fix it using retaining ring.
Figure 197
27. Align outer plates radially and assemble
internal gear until all plates are installed.
Figure 198
Figure 199
29. Mount determined shim (Figure 187 and
Figure 188).
Figure 200
30. Preload cup spring pack using assembly
jig (S) and squeeze retaining ring.
NOTE: Installation of a new retaining
ring admitted only.
(S) Assembly jig - 5870 345 047
Figure 201
Check Tightness and Function of the Clutch
NOTE: Figure 202 and Figure 203.
1. Install hydraulic connection (S).
(S) Hydraulic connection - 5870 508 006
Figure 202
Figure 204
5. Introduce pre-assembled clutch.
Figure 205
Figure 206
INSTALL BRAKE (CROSS-COUNTRY GEAR)
1. Insert backing plate.
Figure 207
2. Determine adjustment Dimension "A" =
1.40 +0.02 mm (0.0551 +0.0079 in) (Figure
208, Example E).
3. Assemble alternating plate pack, starting
with one outer plate.
NOTE: Number of outer and inner
plates, see corresponding
Spare Parts List. Oil the plates.
Figure 208
4. Insert piston firmly against shoulder.
Figure 209
Figure 210
6. Assemble measuring cover (S) and pull it
evenly against shoulder, using 4 socket
head screws.
NOTE: Torque limit (M12/8.8) 8.06
kg•m (58 ft lb).
(S) Measuring cover - 5870 200 070
Figure 211
7. Determine Dimension "I" from plane
surface of the measuring cover to the
plane surface, piston.
NOTE: Dimension "I" e.g. 32.60 mm
(1.2835 in).
Figure 212
EXAMPLE "D":
Dimension "I" 32.60 mm (1.2835 in)
Manufacturing dimension measuring cover - 20.00 mm (0.7874 in)
Difference = Dimension "X" = 12.60 mm (0.4961 in)
NOTE: The manufacturing dimension is stamped on the measuring cover and is principally
20.0 mm (0.7874 in).
Figure 213
EXAMPLE "E":
Dimension "X" 12.60 mm (0.4961 in)
Dimension "Y" - 11.10 mm (0.4370 in)
Difference = Adjustment value "A" = 1.50 mm (0.0591 in)
NOTE: Carry out possible corrections with corresponding outer plates 3.0, 3.2, and 3.5 mm
(0.1181, 0.1260, and 0.1378 in). Now take off the measuring cover and remove the piston
again.
9. Insert O-ring in the ring groove of the
housing. See arrow.
NOTE: Expand O-ring slightly before
the reassembly to ensure a
prefect contact in the recess.
Figure 214
Reference
Description
Number
1 Drive Casing
2 Clutch Disk Housing
3 and 4 Gasket (Backup and U-
section Ring)
5 Retaining Ring
6 O-ring Figure 215
7 Disk
8 and 9 Gasket (U-section and
Backup Ring)
10 Piston
11 Cup Springs
12 O-ring
Figure 216
13. Fix disk using snap ring.
Figure 217
Figure 218
Figure 219
16. Insert the two cup springs and align them
centrically.
NOTE: Pay attention to the installation
position, see Figure 215.
Figure 220
INSTALL DRIVE CASING
1. Insert O-ring (Arrow 1) in the
countersinking.
2. Insert the two O-rings in the ring grooves
of the guide sleeve. See arrows.
NOTE: Grease O-rings.
Figure 221
Figure 222
4. Align guide bush radially.
Figure 223
5. Assemble drive casing.
NOTE: Pay attention to a radial
installation position.
(S) Adjusting screw (M12) - 5870 204 021
Figure 224
6. Pull drive casing evenly against shoulder,
using socket head screws.
NOTE: Torque limit (M12/8.8) 8.06
kg•m (58 ft lb).
Figure 225
Figure 226
8. Fix guide bush radially using screw plug.
See arrow.
NOTE: Install new CU-Ring.
Figure 227
9. Insert gasket, composed of O-ring and
Turcon Ring into the ring groove of the
piston and grease.
NOTE: Heat Turcon-Ring in an oil bath
before the installation. Use
installer. Pay attention to the
installation position, see Figure
228.
(S) Installer - 5870 651 054
Figure 228
10. Insert pre-assembled piston and spring
into the housing bore and fix it with screw
plug.
NOTE: Employ new O-ring for screw
plug.
Figure 229
Figure 230
12. Install the two screw plugs (1) and shear-
off plugs (2).
Figure 231
2. Ventilate piston chamber by filling it several
times.
3. Build up test pressure p = 35.0 bar (508
psi) and close connection to HP-Pump
using shut-off valve.
NOTE: During a test of 3 minutes, no
pressure drop is admitted.
NOTE: Test medium according to ZF-
List of Lubricants TE-ML 07 or
TE-ML 12.
(S) HP-Pump - 5870 287 007
Figure 232
4. Remove hydraulic connection (S) and
install throttle valve.
NOTE: Install new O-rings (Arrows).
Figure 233
Figure 235
2. Install shuttle valves according to Figure
236.
NOTE: Pay attention to the installation
position of the spools, ZF-No.
4143 342 039 and 040, (See
Figure 236.). Employ new O-
rings for the screw plugs.
NOTE: Torque limit (M18x1,5)
5.10 kg•m (37 ft lb).
Figure 236
Figure 237
4. Install control spool and screw plug.
Reference
Description
Number
1 Shift Lock Housing
2 Spring
3 Shim S =
1.20 mm (0.0472 in)
(Empirical Value)
4 Control Spool
5 Screw Plug
6 Screw Plug Figure 238
NOTE: The lubricating pressure is determined with the shim s = 1.20 mm (0.0472 in). If during the
test run a deviation from the prescribed lubricating pressure of 2.80 +0.3 bar (41 +4 psi) is
noted, correct using a corresponding shim of s = 1.50 or 1.80 mm (0.0591 or 0.0709 in).
Employ new O-rings for screw plugs.
4. Install components.
NOTE: Install new O-ring. See arrow.
Figure 242
Figure 243
8. Install screw connection according to
Figure 244.
Figure 244
9. Install diaphragm (Arrow 1) and the O-ring
(Arrow 2).
NOTE: Insert diaphragm with Loctite
#270.
Figure 245
INSTALL LUBRICATING OIL PUMP
1. Oil rotor set with RENOLIN MR 10 Z and
insert it into the housing bore.
NOTE: Mate parts (valve body and
rotor set) with the same color
marking only.
Figure 246
Figure 247
3. Insert shaft seal into the pump cover bore
(Arrow 1).
4. Grease O-ring and insert it into the ring
groove (Arrow 2).
Figure 248
5. Pre-assemble the pump shaft.
Figure 249
6. Assemble pump shaft.
NOTE: Pay attention to the installation
position, drive ball bore above.
Figure 250
Figure 251
8. Install two adjusting screws and insert
pump cover into the housing bore until
contact is obtained.
NOTE: Pay attention to the radial
installation position.
(S) Adjusting screw (M8) - 5870 204 011
Figure 252
9. Insert drive ball into drive shaft. See arrow.
Figure 253
10. Assemble shift lock.
NOTE: Pay attention to the overlapping
of the drive ball with the groove
of the inner rotor.
Figure 254
Figure 255
MOUNT SCREW PLUGS AND OIL LINES
1. Instal screw plugs. See arrows.
NOTE: Install new O-rings.
NOTE: Torque limit (M10x1) 2.55 kg•m
(18 ft lb).
NOTE: Torque limit (M14x1,5) 3.57
kg•m (26 ft lb).
NOTE: Torque limit (M18x1,5) 5.10
kg•m (37 ft lb).
NOTE: Different position of screw plugs
Figure 256
according to the design, see
corresponding Spare-Parts List.
2. Mount suction pipe.
Figure 257
Figure 258
4. Install delivery lines.
Figure 259
5. Install screw plugs. See arrows.
NOTE: Torque limit (M26x1,5) 8.16
kg•m (59 ft lb).
NOTE: Before the transmission is put
into Service, pay attention to
page 6.
Figure 260
MOUNT GEARBOX ON THE ZF-AXLE
1. Cover flange mounted surface with Loctite
#573.
2. Install 2 adjusting screws, place gearbox
against the axle until contact is obtained
and fasten using locking screws.
NOTE: Torque limit 23.45 kg•m (170 ft
lb).
(S) Adjusting screw (M12) - 5870 204 039
Figure 261
Figure 262
4. Assemble thrust washer.
Figure 263
5. Assemble inner plate carrier (along with
sun gear) until contact is obtained.
Figure 264
6. Figure 265, shows the prescribed
arrangement of the inner and outer plates.
7. Assemble plate pack according to Figure
265 and fix it using backing plate and
retaining ring.
Figure 265
Figure 266
9. Assemble planetary carrier and fasten it
using socket head screws (2x).
NOTE: Torque limit (M12/8.8) 5.71
kg•m (41 ft lb).
NOTE: Before the unit is put into
Service, pay attention to page
6.
Figure 267
DISASSEMBLE FINAL DRIVE
Figure 268
2. Pry shaft seal out of the housing bore.
(S) Adjusting spanner - 5870 400 001
Figure 269
Figure 270
5. Remove shaft seal.
(S) Adjusting spanner - 5870 400 001
Figure 271
6. Loosen hex. head screws.
Figure 272
7. Separate output gear along with cover
from the gear case, using hoist.
(S) Set of eye bolts - 5870 204 002
Figure 273
Figure 274
9. Remove oil baffle plate.
Figure 275
10. Squeeze out retaining ring.
(S) Clamping pliers - 5870 900 021
Figure 276
11. Press ball bearing out of the bearing bore.
Figure 277
Figure 278
13. Drive ball bearing out of the bore.
Figure 279
INSTALL FINAL DRIVE
Figure 280
3. Insert baffle plate firmly against shoulder.
NOTE: Pay attention to the radial
installation position.
Figure 281
Figure 282
5. Fix ball bearing using retaining ring.
(S) Retaining ring pliers - 5870 900 021
Figure 283
6. Install oil baffle plate.
NOTE: Pay attention to the radial
installation position.
Figure 284
7. Press bearing cap upon the short side of
the output gear.
NOTE: To avoid damage to the ball
bearing, apply pressing sleeve
(Arrow) on the inner bearing
race.
Figure 285
Figure 286
9. Heat ball bearing (Figure 287), install two
adjusting screws and assemble bearing
cap until contact is obtained. (Figure 288)
(S) Hot-air blower - 220 V - 5870 221 500
(S) Hot-air blower - 110 V - 5870 2210 501
(S) Adjusting screws (M12) - 5870 204 021
Figure 287
Figure 288
10. Fasten bearing cap using hex. head
screws.
NOTE: Torque limit (M12/8.8) 8.06
kg•m (58 ft lb).
Figure 289
Figure 291
Assemble Output Flange
1. Grease O-ring and insert it in the gap of
output flange/ output gear.
Figure 292
2. Mount washer and fix output flange using
hex. head screws.
NOTE: Torque limit (M10/8.8) 4.69
kg•m (34 ft lb).
Figure 293
Figure 294
4. Tilt gear case 180°.
5. Install shaft seal.
NOTE: By application of the prescribed
driver (S), the exact installation
position is obtained. If the outer
diameter is rubber-coated, wet
the sealing surface with spirit.
Otherwise, use sealing
compound (Curil T). Fill cavity
between sealing lip and dust lip
with grease.
(S) Driver - 5870 043 143 Figure 295
Figure 296
DRIVE COUPLING
(MAIN PUMP)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Drive Coupling................................................................................................ 3
Special Tools .................................................................................................. 6
Drive Coupling Installation.............................................................................. 8
Installation Procedure ........................................................................... 10
ARS1710L
Figure 1 KAWASAKI
ARS1720L
Figure 2 REXROTH (S340LC-V ~ S470LC-V)
Figure 4
A C
B
D
E
G
F
RELIEF H
RELIEF
KNURL
HAAA8350
Figure 5
Specification for "Measurement H," from front hub face to pump shaft end, and TIGHTENING TORQUE of
bolts and screws written in the "Table 2" must be observed.
CAUTION!
1. Bolts (3 and 8) are coated against loosening with a bonding compound. Do not use
any additional bonding compounds, oils or cleaning solvents on them.
2. Element (11) is nonresistant to bonding compounds, oil or grease. Be careful not to
expose it to them.
3. Remove oil or dirt from flywheel cover and pump shaft before assembly.
4. Misalignment between pump and engine should be controlled to less than 0.6 mm
(0.023 in).
1HYDRAULIC SYSTEM
TROUBLESHOOTING,
TESTING AND
ADJUSTMENT
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
HAOF420L
Figure 1 Pattern of Drawing (Solar 470LC-V)
The hydraulic system has several improvements over conventional hydraulic systems - including cross
sensing total horsepower control - to maximize output efficiency.
The system features an electronically controlled output optimization system, which allows the operator to
choose between two, distinctly different power modes: high-output/rapid cycling maximum-speed power
mode, and a standard power mode for most types of general operation.
Electronic management of hydraulic control valves assists in optimizing the application speed and overall
operator control of hydraulic actuators and functions.
GENERAL NOTES
When referring to the schematic, refer to the following items:
• As shown in the schematic, the main pump assembly is driven by the engine. Mechanical
energy is converted to hydraulic power, generating the required hydraulic flow which drives the
system. Two main pumps (a right side pump and a left side pump) make up the main pump
assembly.
• Hydraulic output from the right side pump is transmitted to the right side of the control valve.
Output from the left side pump is transmitted to the valve spools on the left side of the control
valve. Hydraulic output from the pilot pump is used to control the pump and to operate pilot and
solenoid valves.
• The right half of the hydraulic control valve, supplied by the right pump in the pump assembly,
operates valve spools for right travel, swing, boom up and arm functions. The amount of oil flow
to the actuators at the output end of each of those circuits is regulated through the movement of
each individual valve spool.
• The left half of the hydraulic control valve, fed by the left pump in the pump assembly, has
control spools for left travel, bucket, boom and arm operation.
• Two-stage operation is a feature of boom and arm function. All of these circuits can be operated
using the output of only one half of the hydraulic pump assembly (one pump or the other), or –
since both halves of the control valve have a spool and available circuit for these functions – the
output of both pumps can be combined, allowing higher speed operation. Boom up, arm crowd
and dumping functions can operate in any one of the two available power modes – the standard
or general duty mode, the high speed/rapid cycling mode.
• Whenever the right travel or left travel control spools are shifted, output from the main pump
assembly flows through the center joint to one or both of the axial piston motors driving the side
frame crawler tracks. A pilot valve connected to the swash plate of each travel motor changes
motor capacity (and output) in direct proportion to the position of the travel switch selected by
the operator.
• The hydraulic reservoir return line and the pilot circuit both have 10 micron full flow filters. The
disposable elements in these two canister-type filters trap and remove impurities from the oil in
the system. An 80 mesh, 177 micron reservoir intake strainer also helps maintain system
cleanliness and should be cleaned each time hydraulic fluid is drained and replaced. An oil
cooler in the hydraulic system helps maintain the operating temperature of the system at
approximately 50°C (122°F).
• The arm cylinder operating circuit includes anti-vacuum valves which protect the hydraulic
system from vacuum that could result from external shocks or other unusual conditions. Boom,
Arm, and Bucket cylinder circuit are also protected by overload relief valves. Whenever high
pressure is generated as a result of a shock or overload, excess pressure is dumped to the
reservoir return circuit through the relief valve.
• A selection valve in the travel circuit can be used to provide constant high torque/low speed
travel, or variable speed/variable torque output for travel. To prevent sliding during simultaneous
travel and boom/arm/bucket operation, select the high torque/low speed travel position.
BOOM UP CIRCUIT
When you pull the boom control lever backward,
the right side pilot valve generates secondary BOOM
boom up pilot pressure that is transmitted to the CYLINDER
BOOM1 and BOOM2 spools of the control valve
simultaneously. When secondary pilot pressure
reaches 7 - 10 kg/cm2 (100 - 142 psi), boom
control valve spools open and oil from both BOOM1 BOOM2
pumps goes to the boom cylinder. BOOM UP
PILOT
PUMP(L) PUMP(R)
ATS0750L
Figure 2
BOOM DOWN CIRCUIT
When the boom control lever is pushed forward,
the right side pilot valve generates secondary BOOM
boom down pilot pressure that is transmitted CYLINDER
only to BOOM1 spool of the valve. When
secondary pilot pressure reaches 7 - 10 kg/cm2
(100 - 142 psi), the BOOM1 spool on the left
side of the control valve opens so that oil from BOOM1 BOOM2
only one pump (PUMP(L)) assembly goes to the BOOM DOWN
PILOT
boom cylinder for boom lowering.
PUMP(L) PUMP(R)
ATS0760L
Figure 3
Overload relief valves set at 360 kg/cm2 (5,112 psi) have been installed at the crowd and dump cylinder
ports on ARM1 side of the control valve to protect the circuit and system components from possible
damage caused by shocks and/or overload pressure. Additional protection - to prevent cavitation of the
cylinder - is provided by a make-up valve and reservoir return circuit, which ensures that the volume of oil
going to the cylinder will not exceed the volume of oil coming out.
PUMP(L) PUMP(R)
ATS0780L
Figure 5
PUMP(L) PUMP(R)
ATS0790L
Figure 6
BUCKET DUMP CIRCUIT
When the bucket control lever is put in the dump
mode, the right side pilot valve generates BUCKET
secondary bucket dump pilot pressure that is CYLINDER
transmitted to BUCKET spool of the control
valve. When secondary pilot pressure reaches 7
- 10 kg/cm2 (100 - 142 psi), the bucket spool
opens so that oil form PUMP(L) goes to the
BUCKET BUCKET
bucket cylinder.
DUMP
PILOT
PUMP(L) PUMP(R)
ATS0800L
Figure 7
SWING OPERATING CIRCUIT
The swing operating circuit consists of the right main pump in the pump assembly, the right half of the
control valve and the swing motor. To keep the upper works from coasting when the swing control is in
neutral, an electrical sensor in the control circuit activates a valve to automatically engage a mechanical
brake.
PUMP(L) PUMP(R)
ATS0810L
Figure 8
LEFT SWING OPERATING CIRCUIT
SWING MOTOR
When the swing control lever is pushed to the
left swing position, pilot pressure from the left
side pilot valve is directed to SWING spool of
the control valve moves in the opposite direction
and output flow from the PUMP(R) is goes to the SWING SWING
swing motor. LEFT
PILOT
PUMP(L) PUMP(R)
ATS0820L
Figure 9
PUMP(L) PUMP(R)
ATS0830L
Figure 10
REVERSE TRAVEL CIRCUIT
TRAVEL TRAVEL
When the right and left travel control levers are MOTOR(L) MOTOR(R)
pushed backward, output from both main pumps
is directed through the TRAVEL (R) and
TRAVEL (L) spools on the control valve, through
the upper works center joint, to the travel CENTER JOINT
motors.
TRAVEL(L) TRAVEL(R)
L.TRAVEL R.TRAVEL
BACKWARD BACKWARD
PILOT PILOT
PUMP(L) PUMP(R)
ATS0840L
Figure 11
Triage Summary
An excavator that fails to deliver designed performance should be checked for the following:
• Hydraulic flow, first, and
• Hydraulic pressure, afterwards, in a specified order of priority through different points of the
system.
To verify adequate available hydraulic flow, before any other tests are performed through the circuit:
Check engine operation -
• at 2,050 rpm with no load
• at 1,900 rpm stall load
If engine rpm drops excessively with a load or fails to surpass rated speed (1,800 rpm), performance
problems may be due to inadequate hydraulic flow caused by lagging rotational speed.
NOTE: Verify actual flow on the excavator against rated performance, with a flow meter.
If engine tests meet specifications and adequate torque and horsepower are available at the pump drive
flex coupling, pull out the electrical tray under the operator’s seat to inspect the self-diagnostic display.
If the EPOS trouble code display is clear, check hydraulic functions in the following sequence:
• Pilot pressure
• Negacon, negative control pressure
• Main relief pressure (front and rear pump)
• Swing pressure
• Port relief pressure (individual control functions; crowd, bucket, boom, travel)
• Power boost circuit
• Standard performance tests; cylinder speed, hydraulic motor (travel and swing) speed, cylinder
oil-tightness "permissible drift" test
NOTE: System specification performance tests of individual activator function are determined by
flow rate through the component or circuit, not the control pressure or system pressure
available to the actuator. Poor flow through the individual circuit may indicate that the
component is worn beyond tolerance limits, while all other hydraulic functions are
adequate.
IMPORTANT
It is suggested that the troubleshooter maintain the testing sequence of the preceding list.
Checks and adjustments nearer the middle or the end of the list may depend on adequate
functioning of systems tested nearer the top of the list.
WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.
Vent hydraulic pressure from the reservoir before breaking the seal on fittings to install two in-line "t-style"
adapters and test gauges (60 bar/1,000 psi) at the gear pump outlet port, and at the joystick control valve
pilot line.
Start the engine and turn the engine speed control dial to the maximum setting. After the excavator has
been operated long enough to reach normal operating temperature, back off the engine control dial to
minimum rated rpm speed. With all controls in neutral, make sure the left console control stand is locked in
the down (operating) position and check pressure at the gear pump outlet port and at the joystick.
If gear pump pressure is outside the tolerance specified in the table, adjust gear pump relief pressure by
loosening the lock nut and turning the set screw in (clockwise) to increase pressure, or turning it out to
decrease it.
NOTE: Be aware that serial number changes and variation in the joystick assemblies used on
different excavators could produce slight change in actual performance characteristics.
Comparison of part numbers to serial numbers stamped on your assembly may be
required, if questions or doubt exists.
IMPORTANT
Top off the hydraulic fluid reservoir if there is any measurable loss of hydraulic oil during test
gauge and adapter fitting installation.
WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.
The electromagnetic pressure proportioning control (EPPR) "power mode" valve is located on the
underside of the pumps (not visible in the harness connections drawing, because it is underneath the
assembly), near the engine/pump flexible coupling, adjacent to the pump return line. To test and adjust
power shift current and pressure through the power mode valve a multi-lead jumper harness is required.
The jumper harness (which is available through Daewoo After Sales Service, or could be spliced together
from commonly available, purchased parts) has extra leads so that a VOM meter can be connected to the
circuit.
To set up the testing equipment, turn off the engine and disconnect the single electrical lead from the
power mode valve. Attach the jumper harness to the terminal on the valve, connect the test leads of the
multimeter to the extra leads on the harness and reconnect the valve electrical lead.
Vent the lever on top of the hydraulic tank to relieve pressure and connect an in-line "t-style" adapter to the
valve pressure port. Install a 60 bar (1,000 psi) test gauge in the adapter.
Restart the engine and increase engine rpm by turning the speed control to the maximum speed setting.
Warm up the engine and hydraulic system until hydraulic oil temperature is at least 45°C (113°F). Select
Power Mode on the Instrument Panel. Check current readings (in milliamps) on the VOM meter and
hydraulic pressure gauge readings and make sure both conform to the values in the table below.
NOTE: If recorded values do not conform to the specified current or pressure in the table, back off
the lock nut on the end of the valve, turn the adjusting screw 1/4 turn and re-check current
and pressure. Repeat adjustment as required to obtain specified performance and
retighten the valve lock nut.
WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.
The front priority control valves are located inside the compartment behind the cabin.
The same jumper harness used for testing the power mode (EPOS) control valve is used to test these two
valves. Turn off the engine, disconnect either of the electrical leads and connect the test equipment to that
side of the valve. An in-line "t-style" gauge adapter can be used to connect a 60 bar/870 psi (1,000 psi) test
gauge to the outlet (pressure) side of the valve. Set the engine control speed dial to maximum and warm
up the engine to at least 45°C (113°F) before making any tests.
NOTE: Vent air from the hydraulic system before installing test equipment. Use the lever on the
reservoir, while the engine is running. Pour clean replacement fluid back into the system if
excessive fluid was lost.
Operate the swing and boom simultaneously. Measure signal current and hydraulic pressure through the
valve and record the highest and lowest values. Reset the work mode control to "digging" mode, and then
to "trenching" mode and repeat the same tests.
VALVE FUNCTION
HAOB730L HAOB740L
NOTE: If recorded values do not conform to the specified current or pressure in the table, readjust
as required.
WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.
Vent hydraulic pressure from the reservoir to install an in-line "t-style" adapter and test gauge (60 bar/1,000
psi) at the pilot pump signal port relief valve outlet.
Start the engine and turn the engine speed dial to maximum. When normal operating temperature is
reached,
• Check pilot pressure and readjust it, if required;
• Select the Instrument Panel rear pump "pressure display";
• Select Power Mode;
• Stall the boom cylinder (towards the extend side);
• Read rear pump pressure on the Instrument Panel display.
Repeat all tests with and without "pressure up" selected through the console rocker switch and joystick
button.
If the two-stage main relief valve was not set correctly and main relief high-stage pressure ("pressure up")
is outside the tolerance range, begin valve adjustment by loosening the outside (widest diameter) lock nut
on the relief valve. Turn the adjusting screw clockwise to increase pressure, or counterclockwise to
decrease it. Pressure must be 350 bars (5075 psi), or up to 10 bars (145 psi) higher.
Because one adjustment can affect the other, check low-stage main relief pressure by repeating the
cylinder stall test without "pressure up." Readjust standard relief pressure by turning the inner-most
(smallest diameter) screw clockwise to increase the setting, or counterclockwise to decrease it. Pressure
should be at least 320 bars (4,641 psi), but less than 325 bars (4,714 psi).
IMPORTANT
Pressure adjustments and checks cannot be made if pilot pressure is outside the specified
range. Refer to the pilot pump adjustment procedure if required, then proceed with any
necessary adjustments to main relief pressure settings.
WARNING!
This procedure should be done with two people. To reduce the chance of accident or unintended
start-up, one person should remain at the operator’s control stand while checks and
adjustments are made.
To perform these adjustments accurately the use of a flow meter is strongly recommended, as is consulting
the factory (before starting work) to validate the need for making regulator adjustments. Vent hydraulic
pressure from the reservoir before breaking the seal on fittings to install the flow meter kit. (Refer to the
"Flow meter Installation and Testing" procedure.)
IMPORTANT
Before starting this procedure or going on to make any changes of adjustment settings,
• Verify engine output to the rated speed - 2,050 ±50 rpm.
• Permanently mark setscrew positions at the current regulator control setting.
Use a scribe or other permanent marker to identify a reference point on adjusting screws with a
corresponding reference on the body of the valve. The adjustment process affects a complex balance and
could require some time to complete. If adjustment has to be interrupted or postponed, reference marks at
the adjustment point allow immediate restoration of original performance.
This adjustment procedure is normally performed:
• If the engine is being consistently overloaded (and engine troubleshooting shows engine
performance to be at or above rated output);
• If reduced cylinder speed and diminished work performance provide an indication that rated,
maximum pump flow may not be available (and all other troubleshooting gives no indication of
other flaws or hydraulic system defects);
• If pump output is out of balance and one pump is failing to keep up with the output flow of the
other.
To check pump imbalance without a flow meter, travel the excavator forward on flat, level terrain. If the
machine veers off despite neutral control input and even, balanced track adjustment, the pump which
supplies output to the track frame toward which the excavator is veering is weak.
1
1 ASS0320L
Figure 12
Refer to the illustration of the pump regulator control valve (Figure 12) for the location of adjustment screws
(1, 2 and 3). There are three different adjustments, Qmax, Pi-Q Pd-Q, adjustment screws (1, 2 and 3).
Each one of the adjustment procedures could affect the setting of the others.
Check and record the arm dump speed performance test before and after input power adjustment, whether
or not a flow meter is used.
NOTE: Regulator adjustments affect total cumulative horsepower, since each regulator
compensates for the output of the other. It is not necessary to adjust both regulators at the
same time, but after checking or adjusting one of them, the remaining unit should also be
checked.
Pd
ATS0870L
Figure 14
The adjusting screw (1) affects the delivery rate
(Q) of the pump. Turning the adjusting screw
shift the maximum cut flow (as shown in Figure
Q
15).
Balance both pumps for equal output.
P
ATS0860L
Figure 15
Compare recorded values with output shown in the P-Q curve in the specifications section of this book.
If test results do not measure up to specified values, pump output tests can be repeated using different
control levers. Recheck front pump operation while stroking the bucket cylinder out lever, and the rear
pump by actuating the swing control lever.
NOTE: When testing bucket and swing functions, read maximum flow tests at 320 kg/cm2 (4,550
psi), not 350.0 kg/cm2 (4,978 psi).
WARNING
Prevent possible injury and/or loss of operating control. Stop work and park the excavator at the
first indication of:
1. Equipment breakdown
2. Inadequate control response
3. Erratic performance
Stop the machine, put the boom and arm in the inoperative (overnight park) position and begin by making
the fastest, simplest checks first:
• Check oil level.
• Check for overheating, oil leaks, external oil cooler clogging or broken fan belt. Consult service
record for prior repair/service work.
• Drain some tank oil to a clean, clear container. Look for metal shavings/grit, cloudiness/water or
foam/air bubbles in the oil.
• Check for wobble through the engine/pump flex coupling. Run engine with the pump input
hydraulic power control nut turned to the lowest power to check the engine.
• Investigate unusual operating noises or vibration. Check for loose bolts, connections.
1ACCUMULATOR
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
ACCUMULATOR S0703010K
MODEL SERIAL NUMBER RANGE
Mega 200-V (Tier I & II) 1001 and Up
Mega 250-V (Tier II) 2001 and Up
Solar 55 0001 and Up
Solar 55-V Plus 1001 and Up
Solar 75-V 1001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 175LC-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 210W-V 1001 and Up
Solar 225LC-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 300LC-V 1001 and Up
Solar 300LL 1001 and Up
Solar 340LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 470LC-V 1001 and Up
Accumulator S0703010K
Page 1
TABLE OF CONTENTS
General Description........................................................................................ 3
Specifications .......................................................................................... 4
S0703010K Accumulator
Page 2
GENERAL DESCRIPTION
The accumulator is a gas-charged storage
device designed to hold a reserve quantity of 1
hydraulic fluid under pressure. Accumulators are
used in hydraulic circuits in much the same way 2
that condensers (or capacitors) are used to
collect, store and maintain electrical charge in a
circuit.
In a hydraulic circuit, minor variations or lags in
pump output that might otherwise cause
unsteady or irregular operation are made up
from the supply of pressurized oil in the 3
accumulator.
Reference
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
4
3 Diaphragm ARS1790L
4 Fluid Valve Figure 1
Accumulators are solidly constructed to resist the high operating pressures of the fluids they contain. There
are only three main moving parts: a plug at the top allows pre-charging or expelling gas from the
compressible, pre-charged upper chamber; a valve assembly at the bottom of the accumulator for passing
hydraulic fluid in and out, and an elastic diaphragm to separate the two chambers. The flexible diaphragm
changes shape to conform to the changing pressures and volumes of the two fluids in the upper and lower
chambers.
There are six possible positions the diaphragm
can be in and they are as follows: Pressure Fluid Nitrogen
Accumulator S0703010K
Page 3
NOTE: Pre-charge pressure is referred to as the "P1" pressure. The accumulator manufacturer’s
"P1" rated pressure should be stamped or marked on the accumulator’s rating plate.
Annual checks of actual pre-charge pressure should be made by tapping a hydraulic
pressure gauge (and 3-way adapter coupling) into the valve on the bottom of the
accumulator. When hydraulic fluid is pushed out the lower valve opening by the pressure
of the gas charge on the other side of the diaphragm - and there is no counter-pressure
from system oil - the valve button on the bottom of the diaphragm eventually seals off the
lower oil passage. Just after the needle on the gauge reaches its highest point (when there
is 0 bar (0 psi) resistance from hydraulic system pressure) pressure on the gauge will drop
sharply to zero, as the accumulator is completely emptied of oil and the diaphragm button
closes.
Record the highest gauge reading and compare to the "P1" rated pre-charge pressure on the
accumulator manufacturer’s data label. Repeat this test at least once a year to verify proper
functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator pre-charge pressure, the flexible diaphragm
begins to retract upward.
4. When system oil is at highest working pressure and the accumulator fills to maximum reserve
capacity, the flexible diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as the "P3" pressure and can also be
referenced on the manufacturer’s data label on the exterior of the accumulator.
5. If system oil pressure begins to fall off or is momentarily checked or interrupted, the energy stored on
the other side of the diaphragm, in the form of compressed gas, pushes oil back out of the lower
chamber, maintaining oil pressure of the circuit.
6. With minimal system pressure, an equilibrium point may be reached in which accumulator pre-charge
pressure and hydraulic system oil pressure achieve a rough balance. In this condition a minimal
amount of oil is stored in the accumulator.
SPECIFICATIONS
Charge
Model Serial Number System Volume
Pressure
Mega 200-V (Tier I 30 kg/cm² 750 cc
S/N 1001 and Up Brake System
& II) (427 psi) (45.77 in3)
Mega 200-V (Tier I 15 kg/cm² 320 cc
S/N 1001 and Up Pilot
& II) (213 psi) (19.53 in3)
30 kg/cm² 750 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Mega 250-V (Tier I) S/N 1001 thru 2000 Pilot
(213 psi) (19.53 in3)
30 kg/cm² 750 cc
Mega 250-V (Tier II) S/N 2001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Mega 250-V (Tier II) S/N 2001 and Up Pilot
(213 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 55-V S/N 0001 and Up Pilot
(142 psi) (19.53 in3)
10 kg/cm2 320 cc
Solar 55-V Plus S/N 1001 and Up Pilot
(142 psi) (19.53 in3)
S0703010K Accumulator
Page 4
Charge
Model Serial Number System Volume
Pressure
10 kg/cm2 320 cc
Solar 75-V S/N 1001 and Up Pilot
(142 psi) (19.53 in3)
Solar 140W-V 30 kg/cm² 750 cc
S/N 1000 and Up Brake System
/160W-V (427 psi) (45.77 in3)
Solar 140W-V 15 kg/cm² 320 cc
S/N 1000 and Up Pilot
/160W-V (213 psi) (19.53 in3)
Solar 140W-V 8 kg/cm² 750 cc
S/N 1000 and Up Transmission
/160W-V (114 psi) (45.77 in3)
10 kg/cm² 750 cc
Solar 175LC-V S/N 1001 thru 1099 Pilot / Travel
(142 psi) (45.77 in3)
30 kg/cm² 750 cc
Solar 180W-V S/N 1001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Solar 180W-V S/N 1001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm² 750 cc
Solar 180W-V S/N 1001 and Up Transmission
(114 psi) (45.77 in3)
30 kg/cm² 750 cc
Solar 210W-V S/N 0001 and Up Brake System
(427 psi) (45.77 in3)
15 kg/cm² 320 cc
Solar 210W-V S/N 0001 and Up Pilot
(213 psi) (19.53 in3)
8 kg/cm² 750 cc
Solar 210W-V S/N 0001 and Up Transmission
(114 psi) (45.77 in3)
10 kg/cm² 750 cc
Solar 225LC-V S/N 1001 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm² 750 cc
Solar 225NLC-V S/N 1001 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm² 320 cc
Solar 255LC-V S/N 1001 thru 1002 Pilot / Travel
(142 psi)) (19.53 in3)
10 kg/cm² 750 cc
Solar 255LC-V S/N 1003 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm² 320 cc
Solar 300LC-V S/N 1001 thru 1099 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm² 750 cc
Solar 300LC-V S/N 1100 and Up Pilot / Travel
(142 psi) (45.77 in3)
10 kg/cm² 750 cc
Solar 300LL S/N 1100 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm² 320 cc
Solar 340LC-V S/N 1001 thru 1059 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm² 750 cc
Solar 340LC-V S/N 1060 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm² 320 cc
Solar 420LC-V S/N 1001 thru 1029 Pilot / Travel
(142 psi) (19.53 in3)
Accumulator S0703010K
Page 5
Charge
Model Serial Number System Volume
Pressure
10 kg/cm² 750 cc
Solar 420LC-V S/N 1030 and Up Pilot / Travel
(142 psi)) (45.77 in3)
10 kg/cm² 320 cc
Solar 470LC-V S/N 1001 thru 1049 Pilot / Travel
(142 psi) (19.53 in3)
10 kg/cm² 750 cc
Solar 470LC-V S/N 1050 and Up Pilot / Travel
(142 psi)) (45.77 in3)
S0703010K Accumulator
Page 6
S0704070
1CENTER JOINT
(SWIVEL)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Parts List ................................................................................................. 4
Troubleshooting, Testing and Adjustment....................................................... 6
Inspection................................................................................................ 6
Testing..................................................................................................... 6
Disassembly ................................................................................................... 7
Reassembly.................................................................................................... 8
Figure 1
TESTING
To check pressure through the center joint, Pressure
Gauge
• A stop valve.
Manually-Operated
• A manually operated, in-line change- Changeover Valve
over valve.
Install the change over valve upstream from one Relief
Valve
of the stem high-pressure ports. Connect the (1.5x)
IMPORTANT
Do not unbolt the center joint from the lower car body until an adequate number of piping block-
off plates are available, for disconnected piping lines. Be sure that system pressure has been
vented - including the hydraulic accumulator and tank reserve pressure - before disassembly is
started.
1. Clean off the exterior of the swivel joint after it has been removed.
2. Scribe or otherwise mark a line across the cover and the body of the center joint, to allow reassembly
in the same configuration.
3. Unbolt the four 12 mm fasteners holding the cover. Use a vise or v-block to hold the assembly in
place.
4. Remove the cover, withdraw the O-ring and unbolt the fasteners holding the thrust plate, taking care
to support the stem (inner) assembly, so that it will not separate and fall out when bolts are
disconnected.
5. If the stem assembly doesn’t separate easily when the thrust plate and fastener bolts are removed,
use a wooden block and hammer to drive it out of the housing.
6. O-rings and seals should be replaced whenever the assembly is being overhauled or rebuilt. For
repair procedures or emergency tear down, use a thin but rounded-tip, smooth-edge scraper or
spatula to remove O-rings or seals, to avoid causing damage to those that must be reused.
NOTE: The "backup ring" shown in the assembly drawing (above the swivel joint stem lower
seals) should not be overlooked. It is tucked behind the top slip ring, doubled up inside the
same groove in the body of the stem.
7. Before reassembling the center swivel, inspect ball bearing surfaces for visible signs of wear, damage
or discoloration and replace any worn component.
Check clearance between the cover and thrust plate, and between the stem and thrust plate.
Replace any component that shows more than 0.5 mm (0.020") of visible wear.
Clearance between the stem and body of the center swivel must be tight. Replace or repair either
component if there is more than 0.1 mm (0.0039") of measurable wear.
CAUTION!
Apply a very light film of white grease or petroleum jelly to the lower rim of the stem and
inner surface of the center swivel body. Apply slow, even-handed pressure, using both
hands, to slowly push the stem into the body. Seals may be damaged if the stem is pushed
in too quickly.
2. Thoroughly clean all other component surfaces of dirt or grease before reassembly.
3. Reverse disassembly steps for reassembly.
4. Clean threads of fasteners before pre-applying Loctite #243 to the threads, and before torquing the
thrust plate and cover bolts.
5. Pre-fill the center swivel with clean hydraulic fluid before reassembly of high-pressure and drain line
piping. Clean and pre-fill piping line ends to reduce the amount of air in the system. Bleed air from the
hydraulic system and verify hydraulic tank fluid level before returning the excavator to service.
1CYLINDERS
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
CYLINDERS S0705000
MODEL SERIAL NUMBER RANGE
Solar 55 0001 and Up
Solar 55-V Plus 1001 and Up
Solar 75-V 1001 and Up
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 170LC-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 175LC-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 210W-V 1001 and Up
Solar 220LC-V 0001 and Up
Solar 225LC-V 1001 and Up
Solar 225NLC-V 1001 and Up
Solar 250LC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 290LC-V 0001 and Up
Solar 300LC-V 1001 and Up
Cylinders S0705000
Page 1
MODEL SERIAL NUMBER RANGE
Solar 300LL 1001 and Up
Solar 330LC-V 1001 and Up
Solar 340LC-V 1001 and Up
Solar 400LC-V 1001 and Up
Solar 420LC-V 1001 and Up
Solar 450LC-V 1001 and Up
Solar 470LC-V 1001 and Up
TABLE OF CONTENTS
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Parts List ................................................................................................. 4
Special Tools and Materials............................................................................ 6
Piston Nut................................................................................................ 6
Piston Jig............................................................................................... 10
Steel bush Jig........................................................................................ 14
Dust Wiper Jig....................................................................................... 18
Slipper Seal Jig ..................................................................................... 24
Slipper Seal Straightening Jig ............................................................... 28
Disassembly ................................................................................................. 31
Assembly...................................................................................................... 37
S0705000 Cylinders
Page 2
GENERAL DESCRIPTION
Two essentially similar types of hydraulic cylinders are used on the excavator. The cylinder that is used to
operate the excavator boom or bucket is equipped with a rod stopper, which acts as a cushion only when
the cylinder rod is fully retracted (and the bucket is pulled close to the arm). This type of cylinder is shown
in the lower drawing.
Arm cylinders have a cushion or stopper for operation in both directions. This type of cylinder is shown in
the upper drawing.
THEORY OF OPERATION
Reference
Description
Number
1 Piston
2 Oil Path A
3 Oil Path B
F1 = P x πB2
4
Reference
Description
Number
1 Cylinder Inside Diameter -
B
2 Oil Path A
3 Oil Path B
4 Rod Diameter
Figure 2
When the cylinder rod is retracted, oil flow
through the circuit from the pump to the front
side of the cylinder generates a force (F2) that
can be expressed by the formula in which the
diameter of the piston rod is expressed by R,
and the other two terms are the same as in the
preceding expression.
F2 = P x π(B2-R2)
4
Cylinders S0705000
Page 3
Because the volume of oil needed to lengthen
the cylinder rod (Q1) is greater than the volume
of oil required to retract the cylinder rod, it takes
more time to decrease cylinder stroke length
than it does to lengthen it.
Q1 = S x π(B2)
4
Figure 3
Q2 = S x π(B2-R2)
4
Q1 > Q2
PARTS LIST
The following parts list is a partial listing only; for full and complete parts list information, refer to the
Hydraulic Equipment Component Parts List
Cross section in Figure 4 shows an arm cylinder.
Cross section in Figure 5 shows a boom cylinder.
The bucket and boom cylinders are identical and differ only in the attached pipes.
Figure 4
Figure 5
S0705000 Cylinders
Page 4
Reference Reference
Description Description
Number Number
1 Bushing 16 Piston
2 Dust Wiper 17 Slide Ring
3 Retaining Ring 18 Wear Ring
4 U-Packing 19 Slipper Seal
5 Buffer Seal 20 O-ring
6 Rod Bushing 21 Backup Ring
7 Bolt 22 Piston Nut
8 Retaining Ring 23 Set Screw
9 Rod Cover 24 Cushion Plunger
10 O-ring 25 Bushing
11 O-ring 26 Check Valve
12 Backup Ring 27 Spring Support
13 Piston Rod 28 Spring
14 Cylinder Tube 29 Plug
15 Cushion Ring 30 Stop Ring
Cylinders S0705000
Page 5
SPECIAL TOOLS AND MATERIALS
PISTON NUT
( )
15
-0.1
-0.2
C
(C3~C5)
D +0.1
+0.2
A
35
B
∅8 Through Hole
5
0.
R
R(R15 ~ R20)
4-
350
ARS4730L
Figure 6
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
S0705000 Cylinders
Page 6
MODEL CYLINDER øA øB C D MODEL (CYLINDER)
S55-V (BOOM, BOOM {OPT})
110 mm 69 mm 12 mm 5 mm
ARM S55-V PLUS (SWING)
(4.33 in) (2.72 in) (0.47 in) (0.20 in)
S75-V (BUCKET)
100 mm 58 mm 12 mm 5 mm
S55-V SWING
(3.94 in) (2.23 in) (0.47 in) (0.20 in)
S55-V PLUS (BUCKET)
110 mm 69 mm 10 mm 5 mm
BUCKET S80W-II (DOZER)
(4.33 in) (2.72 in) (0.39 in) (0.20 in)
MEGA 400 (P/S)
S130W-V (ARM (EURO))
S140W-V (ARM (EURO))
S160W-V (ARM)
S170LC-V (BOOM)
S170W-V (BOOM)
S175LC-V (BOOM)
S180W-V (BOOM)
130 mm 90 mm 12 mm 5 mm
ARM S200W-V (BOOM)
(5.12 in) (3.54 in) (0.47 in) (0.20 in)
S200LC-V (BOOM)
S200N-V (BUCKET) (OPTION)
S210W-V (BOOM)
S220LC-V (BOOM)
S225LC-V (BOOM)
S225NLC-V (BOOM)
S225NLC-V (BUCKET) (OPTION)
S130LC-V
S130W-V (ARM)
S130W-V (NEW BOOM)
S130LC-V (SHORT ARM)
S140W-V (ARM)
S140W-V (BOOM)
S140W-V (OUTRIGGER)
125 mm 85 mm 12 mm 5 mm
BOOM (OP) S160W-V (BOOM)
(4.92 in) (3.35 in) (0.47 in) (0.20 in)
S160W-V (OUTRIGGER)
S170W-V (BUCKET)
S220LC-V (BUCKET)
S220LL (BUCKET)
S225LC-V (BUCKET)
S225NLC-V (BUCKET)
115 mm 75 mm 12 mm 5 mm S140W-V (BUCKET)
BUCKET
(4.53 in) (2.95 in) (0.47 in) (0.20 in) S160W-V (BUCKET)
Cylinders S0705000
Page 7
MODEL CYLINDER øA øB C D MODEL (CYLINDER)
S330LC-V (ARM)
S340LC-V (ARM)
S370LC-V (ARM)
147 mm 107 mm 12 mm 5 mm
ARM S400LC-V (BOOM, BUCKET)
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
S420LC-V (BOOM, BUCKET)
S450LC-V (BOOM, BUCKET)
S470LC-V (BOOM, BUCKET)
S200N-V (ARM (OP))
S225NLC-V (ARM (OP))
S220LL S210W-V (ARM)
142 mm 102 mm 12 mm 5 mm S220LC-V (ARM)
BOOM
(5.59 in) (4.02 in) (0.47 in) (0.20 in) S225LC-V (ARM)
S225NLC-V (ARM)
S290LC-V (BOOM)
S300LC-V (BOOM)
S170LC-V (BOOM)
125 mm 102 mm 11 mm 4.5 mm S175LC-V (BOOM)
BUCKET
(4.92 in) (4.02 in) (0.43 in) (0.18 in) S200W-V (BUCKET)
S210W-V (BUCKET)
S255LC-V (ARM)
S290LL (BOOM, BUCKET)
S330LC-V (BUCKET (OP),
BOOM, BUCKET)
145 mm 105 mm 12 mm 5 mm
S250LC-V ARM S340LC-V (BUCKET (OP),
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
BOOM, BUCKET)
S370LC-V (BUCKET (OP),
BUCKET)
S390LL (BOOM, BUCKET)
S290LC-V (ARM)
147 mm 107 mm 12 mm 5 mm
S290LC-V S/ARM S300LC-V (ARM, S/ARM)
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
S370LC-V (BOOM)
S140W-V (ARTI.)
155 mm 115 mm 12 mm 5 mm S160W-V (ARTI.)
S290LL ARM
(6.10 in) (4.53 in) (0.47 in) (0.20 in) S400LC-V (ARM)
S420LC-V (ARM)
170 mm 129 mm 12 mm 5 mm
S450LC-V ARM S470LC-V (ARM)
(6.69 in) (5.08 in) (0.47 in) (0.20 in)
106 mm 66 mm 12 mm 5 mm
ARM
(4.17 in) (2.60 in) (0.47 in) (0.20 in)
S55W-V
112 mm 72 mm 12 mm 5 mm S55-V PLUS (ARM, BOOM)
BOOM
(4.41 in) (2.84 in) (0.46 in) (0.20 in) S75-V (ARM, SWING)
S70-III (ARM)
S80W-II (BOOM)
120 mm 79 mm 10 mm 5 mm
ARM MEGA 130-III (LIFT)
(4.72 in) (3.11 in) (0.39 in) (0.20 in)
S140W-V (DOZER)
S160W-V (DOZER)
S70-III (BOOM, DOZER)
S80W-II
S75-V (DOZER)
120 mm 79 mm 10 mm 5 mm
BOOM S130LC-V (DOZER)
(4.72 in) (3.11 in) (0.39 in) (0.20 in)
MEGA 200-III TC (BUCKET)
MEGA 130-III (BUCKET)
110 mm 69 mm 10 mm 5 mm
BUCKET S70-III (BUCKET)
(4.33 in) (2.72 in) (0.39 in) (0.20 in)
120 mm 80 mm 12 mm 5 mm
S130W-V BOOM S75-V (BOOM)
(4.72 in) (3.15 in) (0.47 in) (0.20 in)
S0705000 Cylinders
Page 8
MODEL CYLINDER øA øB C D MODEL (CYLINDER)
S170LC-V (ARM)
S175LC-V (ARM)
S180W-V (ARM)
140 mm 98 mm 12 mm 5 mm
S170W-V ARM S250LC-V (BOOM, BUCKET)
(5.52 in) (3.86 in) (0.47 in) (0.20 in)
S255LC-V (BOOM, BUCKET)
S290LC-V (S/BUCKET, BUCKET)
S300LC-V (S/ BUCKET, BUCKET)
S180W-V (DOZER)
132 mm 92 mm 12 mm 5 mm
S210W-V DOZER S180W-V (OUTRIGGER)
(5.20 in) (3.62 in) (0.47 in) (0.20 in)
S210W-V (OUTRIGGER)
P/S: Power Steering
Cylinders S0705000
Page 9
PISTON JIG
( )
15
2-∅"B"
)
F/2
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C"
35
R(R15~20)
R5
4-
30
ARS4740L
Figure 7
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
S0705000 Cylinders
Page 10
MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER)
S55 BOOM 80.0 mm 11.0 mm 45.0 mm 110.0 mm S55 (BOOM (OP))
(3.15 in) (0.43 in) (1.77 in) (4.33 in) S55W-V (BOOM)
SWING 58.0 mm 11.0 mm 38.0 mm 80.0 mm MEGA 300 (P/S)
(2.28 in) (0.43 in) (1.50 in) (3.15 in)
S55-V ARM 65.0 mm 11.0 mm 49.0 mm 90.0 mm MEGA 130-III (LIFT)
PLUS (2.56 in) (0.43 in) (1.93 in) (3.54 in) MEGA 160TC (BUCKET)
MEGA 400 (P/S)
70 mm 11 mm 51 mm 95 mm
ARM S80W-II (ARM)
(2.76 in) (0.43 in) (2.01 in) (3.74 in)
60 mm 11 mm 43 mm 85 mm S80W-II (BUCKET, DOZER)
BUCKET
(2.36 in) (0.43 in) (1.69 in) (3.35 in) S75-V (BUCKET)
S70-III
S75-V (ARM, DOZER)
70 mm 11 mm 53 mm 95 mm S130LC-V (DOZER)
DOZER
(2.76 in) (0.43 in) (2.09 in) (3.74 in) S140W-V (DOZER)
S160W-V (DOZER)
S210W-V (ARM)
S220LC-V (BOOM)
S220N-V (ARM (OP))
S225NLC-V (BOOM)
110 mm 13 mm 76 mm 140 mm
ARM S225NLC-V (ARM (OP))
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
S250LC-V (ARM)
S255LC-V (ARM)
S290LC-V (BOOM, BUCKET)
S300LC-V (BOOM, BUCKET)
S70-III (BOOM)
S75-V (SWING)
S80W-II (BOOM)
S220LC-V S130W-V (ARM (EURO))
S130LC-V (S/ARM, BOOM
(OP), ARM)
S160W-V (ARM)
90 mm 11 mm 63 mm 115 mm S170LC-V (BOOM)
BUCKET
(3.54 in) (0.43 in) (2.48 in) (4.53 in) S170W-V (BUCKET, BOOM)
S175LC-V (BOOM)
S180W-V (BOOM)
S210W-V (BUCKET)
S220LC-V (BUCKET)
S225LC-V (BUCKET)
S225NLC-V (BUCKET)
MEGA 200-III (LIFT)
S290LL (BUCKET, BOOM)
S300LC-V (ARM, S/ARM)
S330LC-V (BOOM, BUCKET)
ARM 120 mm 13 mm 85 mm 150 mm
S290LC-V S340LC-V (BUCKET, BOOM,
S/ARM (4.72 in) (0.51 in) (3.35 in) (5.91 in)
BUCKET (OP))
S370LC-V (BUCKET, BUCKET
(OP))
S140W-V (ARTI)
S160W-V (ARTI)
S340LC-V (ARM)
130 mm 13 mm 93 mm 165 mm S400LC-V (ARM, BOOM)
S330LC-V ARM
(5.12 in) (0.51 in) (3.66 in) (6.50 in) S420LC-V (ARM, BOOM,
BUCKET)
S450LC-V (BOOM, BUCKET)
S470LC-V (BOOM, BUCKET)
Cylinders S0705000
Page 11
MODEL CYLINDER A (±0.1) øB øC øD MODEL (CYLINDER)
150 mm 13 mm 103 mm 180 mm
S450LC-V ARM S470LC-V (ARM)
(5.91 in) (0.51 in) (4.06 in) (7.09 in)
S55-V (ARM, BUCKET)
63 mm 11 mm 43 mm 90 mm
S55W-V ARM S55W-V (BUCKET)
(2.48 in) (0.43 in) (1.69 in) (3.54 in)
S55-V PLUS (BUCKET)
75 mm 11 mm 53 mm 100 mm S75-V (BOOM)
S130W-V BOOM
(2.95 in) (0.43 in) (2.09 in) (3.94 in) S130LC-V (BOOM)
70 mm 11 mm 46 mm 95 mm
S140W-V BUCKET S160W-V (BUCKET)
(2.76 in) (0.43 in) (1.81 in) (3.74 in)
S170LC-V (ARM)
S175LC-V (ARM)
S180W-V (ARM)
96 mm 13 mm 69 mm 130 mm S180W-V (O/R, DOZER)
ARM
(3.78 in) (0.51 in) (2.72 in) (5.12 in) S200W-V (O/R, DOZER)
S210W-V (O/R, DOZER)
S250LC-V (BUCKET, BOOM)
S255LC-V (BUCKET, BOOM)
S55-V PLUS (BOOM, SWING)
S170W-V S70-III (BOOM)
S80W-II (BOOM)
S130W-V (ARM)
S130LC-V (S/ARM, BOOM
80 mm 11 mm 58 mm 110 mm {OP})
BUCKET
(3.15 in) (0.43 in) (2.28 in) (4.33 in) S140W-V (ARM)
S140W-V (BOOM)
S140W-V (O/R)
S160W-V (ARM)
S160W-V (O/R)
S180W-V (BUCKET)
S220LC-V (BOOM)
S220N-V (BUCKET) (OP)
90 mm 13 mm 63 mm 115 mm
S200W-V BOOM S225LC-V (BOOM)
(3.54 in) (0.51 in) (2.48 in) (4.53 in)
S225NLC-V (BOOM)
S225NLC-V (BOOM) (OP)
P/S: Power Steering
O/R: Out Rigger
S0705000 Cylinders
Page 12
Cylinders S0705000
Page 13
STEEL BUSH JIG
(5)
"A" - 20
"B" + 40
∅"B"
∅"A"
(∅20)
15 F E
ARS4750L
Figure 8
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
S0705000 Cylinders
Page 14
MODEL CYLINDER øA -0.05
-0.15
øB (±0.1) E F +0.05
0
Part MODEL (CYLINDER)
50 mm 65 mm 30 mm S55W-V (BOOM)
BOOM -
(1.97 in) (2.56 in) (1.18 in) S55-V PLUS (SWING)
40 mm 50 mm 20 mm
S55-V SWING -
(1.58 in) (1.97 in) (0.79 in)
65 mm 70 mm 30 mm
DOZER -
(2.56 in) (2.76 in) (1.18 in)
50 mm 60 mm 40 mm
DOZER 0 S75-V (DOZER)
(1.97 in) (2.36 in) (1.58 in)
S55-V (ARM)
50 mm 60 mm 25 mm 5 mm S55- V PLUS (ARM,
S70-III BUCKET H/C
(1.97 in) (2.36 in) (0.98 in) (0.20 in) BOOM, BUCKET)
S75-V (BUCKET)
55 mm 68 mm 30 mm 5.5 mm
BUCKET K/C S80W-II BUCKET (K/C)
(2.17 in) (2.68 in) (1.18 in) (0.22 in)
60 mm 70 mm 30 mm S140W-V (DOZER)
DOZER -
(2.36 in) (2.76 in) (1.18 in) S160W-V (DOZER)
S70-III (ARM, BOOM)
S75-V (ARM, BOOM,
S130LC-V SWING)
65 mm 80 mm 30 mm 6 mm
BUCKET S140W-V (BUCKET)
(2.56 in) (3.15 in) (1.18 in) (0.24 in)
S160W-V (BUCKET)
MEGA 200-III (LIFT)
MEGA 200-III TC (H/C)
Cylinders S0705000
Page 15
MODEL CYLINDER øA -0.05
-0.15
øB (±0.1) E F +0.05
0
Part MODEL (CYLINDER)
S210W-V (ARM)
S290LC-V (S/ARM, ARM)
S290LL (BOOM, BUCKET)
S300LC-V (S/ARM, ARM)
90 mm 105 mm 40 mm 6.5 mm
ARM MEGA 250-III (BUCKET)
(3.54 in) (4.13 in) (1.58 in) (0.26 in)
MEGA 400 (LIFT (H/C),
BUCKET)
MEGA 400-V (LIFT (H/C))
MEGA 500-III
S180W-V (DOZER, O/R)
S200W-V (BOOM, DOZER,
O/R)
S210W-V (BOOM, DOZER,
O/R)
S220N-V (ARM (OP),
BUCKET (OP))
S220LL S220LC-V (ARM, BOOM,
BUCKET)
S225LC-V (ARM, BOOM,
80 mm 95 mm 35 mm 6.5 mm BUCKET)
BOOM
(3.15 in) (3.74 in) (1.38 in) (0.26 in) S225NLC-V (ARM (OP),
BUCKET (OP))
S225NLC-V (ARM, BOOM,
BUCKET)
S250LC-V (ARM, BUCKET)
S255LC-V (ARM, BUCKET)
MEGA 160 (BUCKET)
MEGA 200-III (BUCKET)
MEGA 200 (BUCKET)
MEGA 300 (BUCKET)
MEGA 300-V (LIFT)
65 mm 80 mm 35 mm 6.5 mm
BUCKET S210W-V (BUCKET)
(2.56 in) (3.15 in) (1.38 in) (0.26 in)
S255LC-V (BOOM)
S290LC-V (S/BUCKET,
90 mm 105 mm 40 mm 7 mm
S250LC-V BOOM BOOM, BUCKET)
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
S300LC-V (S/BUCKET,
BOOM, BUCKET)
ARM 100 mm 115 mm 70 mm 6.5 mm
S290LL
(STICK) (3.94 in) (4.53 in) (2.76 in) (0.26 in)
S330LC-V (ARM, BOOM,
BUCKET)
S340LC-V (ARM, BOOM,
BUCKET)
BUCKET 100 mm 115 mm 45 mm 7.5 mm
S330LC-V S370LC-V (ARM, BOOM,
(OP) (3.94 in) (4.53 in) (1.77 in) (0.30 in)
BUCKET)
MEGA 300-V (BUCKET)
MEGA 400-V (BUCKET)
MEGA 500-III (LIFT (H/C))
S0705000 Cylinders
Page 16
MODEL CYLINDER øA -0.05
-0.15
øB (±0.1) E F +0.05
0
Part MODEL (CYLINDER)
120 mm 140 m 75 mm 11 mm
ARM S470LC-V (ARM)
(4.72 in) (5.51 in) (2.95 in) (0.43 in)
S400LC-V (ARM, BOOM
(H/C), BUCKET)
S420LC-V (ARM, BOOM
110 mm 130 mm 70 mm 11 mm
S450LC-V BOOM H/C (H/C), BUCKET)
(4.33 in) (5.12 in) (2.76 in) (0.43 in)
S450LC-V (BUCKET)
S470LC-V (BOOM,
BUCKET)
120 mm 140 m 70 mm 11 mm S420LC-V (BOOM (K/C))
BOOM K/C
(4.72 in) (5.51 in) (2.76 in) (0.43 in) S400LC-V (BOOM (K/C))
50 mm 60 mm 30 mm S55-V (ARM, BOOM (OP),
BUCKET -
(1.97 in) (2.36 in) (1.18 in) BUCKET)
S55W-V
65 mm 75 mm 30 mm
DOZER - S55-V PLUS (DOZER)
(2.56 in) (2.95 in) (1.18 in)
50 mm 60 mm 25 mm 5.5 mm
S80W-II BUCKET H/C
(1.97 in) (2.36 in) (0.98 in) (0.22 in)
S130LC-V (BOOM, BOOM
71 mm 86 mm 40 mm 6.5 mm (OP))
BOOM
(2.80 in) (3.39 in) (1.58 in) (0.26 in) S140W-V (BOOM)
S160W-V (BOOM)
S130W-V S130W-V (ARM)
S130LC-V (S/ARM, ARM)
ARM 71 mm 86 mm 40 mm 7 mm S140W-V (ARM)
(EURO) (2.80 in) (3.39 in) (1.58 in) (0.28 in) S160W-V (ARM)
S180W-V (ARM, BOOM,
BUCKET)
60 mm 75 mm 30 mm 6.5 mm
S140W-V O/R S160W-V (O/R)
(2.36 in) (2.95 in) (1.18 in) (0.26 in)
90 mm 105 mm 40 mm 6 mm
S140W-V ARTI. S160W-V (ARTI.)
(3.54 in) (4.13 in) (1.58 in) (0.24 in)
S170W-V (BOOM,
71 mm 86 mm 50 mm 6 mm BUCKET)
S170W-V ARM
(2.80 in) (3.39 in) (1.97 in) (0.24 in) S170LC-V (ARM, BOOM)
S175LC-V (ARM, BOOM)
H/C: Head Cover
K/C: Knuckle Cover
Cylinders S0705000
Page 17
DUST WIPER JIG
1.5
3-C
R0.2
1
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 9
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
S0705000 Cylinders
Page 18
MODEL CYLINDER øA -0.2
-0.3 øB -0.2
-0.3 C 0
-0.1
D MODEL (CYLINDER)
35 mm 47 mm 6 mm
TILT 0
(1.38 in) (1.85 in) (0.24 in)
45 mm 57 mm 0.5 mm 6 mm
DD80L DOZER DD80L (ANGLE)
(1.77 in) (2.24 in) (0.02 in) (0.24 in)
45 mm 57 mm 0.5 mm 6 mm
ANGLE
(1.77 in) (2.24 in) (0.02 in) (0.24 in)
55 mm 69 mm 5 mm 6 mm
ARM
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
55 mm 69 mm 5 mm 6 mm
BOOM
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
55 mm 69 mm 5 mm 6 mm
BOOM (OP)
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
S55-V
55 mm 69 mm 5 mm 6 mm
BUCKET
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
40 mm 52 mm 3.5 mm 6 mm
SWING S55W-V (SWING)
(1.58 in) (2.05 in) (0.14 in) (0.24 in)
60 mm 74 mm 7 mm 6 mm
DOZER
(2.36 in) (2.91 in) (0.28 in) (0.24 in)
65 mm 79 mm 5.5 mm 6 mm
ARM S80W-III (ARM)
(2.56 in) (3.11 in) (0.22 in) (0.24 in)
S80W-III (BOOM)
70 mm 84 mm 5.5 mm 6 mm S130W-V (BOOM)
BOOM
(2.76 in) (3.31 in) (0.22 in) (0.24 in) S130LC-V (BOOM)
MEGA 160-III (BUCKET)
S55-V (ARM, BOOM, BOOM (OP),
BUCKET)
S55-V PLUS (BUCKET, SWING)
55 mm 69 mm 5 mm 6 mm
BUCKET S55W-V (ARM)
S70-III (2.17 in) (2.72 in) (0.20 in) (0.24 in)
S75-V (BUCKET)
S80W-III (BUCKET)
MEGA 130-III (LIFT)
S55W-V (BOOM)
S55-V PLUS (ARM, BOOM)
S75-V (ARM, SWING DOZER)
60 mm 74 mm 5 mm 6 mm S140W-V (DOZER)
DOZER
(2.36 in) (2.91 in) (0.20 in) (0.24 in) S160W-V (DOZER)
MEGA 130-III (BUCKET)
MEGA 160-III (LIFT)
MEGA 200-III TC (BUCKET)
70 mm 84 mm 5 mm 6 mm
S75-V BOOM
(2.76 in) (3.31 in) (0.20 in) (0.24 in)
S55-V (DOZER)
60 mm 74 mm 7 mm 6 mm
S80-III DOZER S55-V PLUS (DOZER)
(2.36 in) (2.91 in) (2.28 in) (0.24 in)
S55W-V (DOZER)
S160W-V (ARM)
80 mm 94 mm 6 mm 7 mm S170W-V (BOOM)
ARM
(3.15 in) (3.70 in) (0.24 in) (2.28 in) S220N-V (BOOM (OP))
S225NLC-V (BOOM (OP))
S130LC-V
70 mm 84 mm 6 mm 7 mm
BOOM
(2.76 in) (3.31 in) (0.24 in) (2.28 in)
75 mm 89 mm 6 mm 7 mm
BOOM (OP)
(2.95 in) (3.50 in) (0.24 in) (2.28 in)
Cylinders S0705000
Page 19
MODEL CYLINDER øA -0.2
-0.3 øB -0.2
-0.3 C 0
-0.1
D MODEL (CYLINDER)
S210W-V (ARM)
S220N-V (ARM (OP))
95 mm 109 mm 6 mm 7 mm S225LC-V (ARM)
ARM
(3.74 in) (4.29 in) (0.24 in) (2.28 in) S225NLC-V (ARM)
S290LC-V (BOOM)
S220LC-V S300LC-V (BOOM)
85 mm 99 mm 6 mm 7 mm S225LC-V (BOOM)
BOOM
(3.35 in) (3.90 in) (0.24 in) (2.28 in) S225NLC-V (BOOM)
S210W-V (BUCKET)
75 mm 89 mm 6 mm 7 mm
BUCKET S225LC-V (BUCKET)
(2.95 in) (3.50 in) (0.24 in) (2.28 in)
S225NLC-V (BUCKET)
S340LC-V (ARM)
S420LC-V (BOOM)
S470LC-V (BOOM, BUCKET)
115 mm 131 mm 6 mm 7 mm
ARM (STICK) S370LC-V (ARM)
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
S360LC-V (ARM)
S220LL S400LC-V (BOOM)
S450LC-V (BOOM, BUCKET)
BOOM 90 mm 104 mm 6 mm 7 mm
(HOIST) (3.54 in) (4.10 in) (0.24 in) (2.28 in)
BUCKET 75 mm 89 mm 6 mm 7 mm
(HEEL) (2.95 in) (3.50 in) (0.24 in) (2.28 in)
95 mm 109 mm 6 mm 7 mm
ARM (OP) S225NLC-V (ARM (OP))
(3.74 in) (4.29 in) (0.24 in) (2.28 in)
S220N-V
80 mm 94 mm 6 mm 7 mm
BOOM (OP) S225NLC-V (BOOM (OP))
(3.15 in) (3.70 in) (0.24 in) (2.28 in)
S255LC-V (ARM)
S360LC-V (BOOM, BUCKET,
BUCKET (OP))
S340LC-V (BOOM, BUCKET,
100 mm 114 mm 6 mm 7 mm
ARM BUCKET (OP))
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
S370LC-V (BUCKET, BUCKET
S250LC-V (OP))
S290LL (BOOM (HOIST), BUCKET
(HEEL))
90 mm 104 mm 6 mm 7 mm
BOOM
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
90 mm 104 mm 6 mm 7 mm
BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
S290LC-V (S/ARM)
105 mm 121 mm 6 mm 7 mm
ARM S300LC-V (ARM, S/ARM)
(4.13 in) (4.76 in) (0.24 in) (2.28 in)
S370LC-V (BOOM)
105 mm 121 mm 6 mm 7 mm
S/ARM
(4.13 in) (4.76 in) (0.24 in) (2.28 in)
S290LC-V 95 mm 109 mm 6 mm 7 mm
BOOM
(3.74 in) (4.29 in) (0.24 in) (2.28 in)
90 mm 104 mm 6 mm 7 mm
BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
90 mm 104 mm 6 mm 7 mm
S/BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
S0705000 Cylinders
Page 20
MODEL CYLINDER øA -0.2
-0.3 øB -0.2
-0.3 C 0
-0.1
D MODEL (CYLINDER)
120 mm 136 mm 9 mm 7 mm
ARM (STICK)
(4.72 in) (5.35 in) (0.35 in) (2.28 in)
BOOM 100 mm 114 mm 6 mm 7 mm
S290LL
(HOIST) (3.94 in) (4.49 in) (0.24 in) (2.28 in)
BUCKET 100 mm 114 mm 6 mm 7 mm
(HEEL) (3.94 in) (4.49 in) (0.24 in) (2.28 in)
115 mm 131 mm 6 mm 7 mm
ARM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
100 mm 114 mm 6 mm 7 mm
BOOM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
S360LC-V
100 mm 114 mm 6 mm 7 mm
BUCKET
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
BUCKET 100 mm 114 mm 6 mm 7 mm
(OP) (3.94 in) (4.49 in) (0.24 in) (2.28 in)
120 mm 136 mm 9 mm 7 mm S420LC-V (ARM)
ARM
(4.72 in) (5.35 in) (0.35 in) (2.28 in) S290LL (ARM (STICK))
115 mm 131 mm 6 mm 7 mm
S400LC-V BOOM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
110 mm 126 mm 6 mm 7 mm
BUCKET S420LC-V (BUCKET)
(4.33 in) (4.96 in) (0.24 in) (2.28 in)
130 mm 146 mm 6.5 mm 7 mm
ARM S470LC-V (ARM)
(5.12 in) (5.75 in) (0.26 in) (2.28 in)
115 mm 131 mm 6 mm 7 mm S140W-V (ARTI.)
S450LC-V BOOM
(4.53 in) (5.16 in) (0.24 in) (2.28 in) S160W-V (ARTI.)
115 mm 131 mm 6 mm 7 mm
BUCKET
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
55 mm 69 mm 5 mm 6 mm
ARMS
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
40 mm 52 mm 3.5 mm 6 mm
SWING
(1.58 in) (2.05 in) (0.14 in) (0.24 in)
60 mm 74 mm 5 mm 6 mm
S55W-V BOOM
(2.36 in) (2.91 in) (0.20 in) (0.24 in)
50 mm 62 mm 4.5 mm 6 mm
BUCKET
(1.97 in) (2.44 in) (0.18 in) (0.24 in)
60 mm 74 mm 5 mm 6 mm
DOZER
(2.36 in) (2.91 in) (0.20 in) (0.24 in)
65 mm 79 mm 5.5 mm 6 mm
ARM
(2.56 in) (3.11 in) (0.22 in) (0.24 in)
70 mm 84 mm 5.5 mm 6 mm
S80W-III BOOM
(2.76 in) (3.31 in) (0.22 in) (0.24 in)
55 mm 69 mm 5 mm 6 mm
BUCKET
(2.17 in) (2.72 in) (0.20 in) (0.24 in)
Cylinders S0705000
Page 21
MODEL CYLINDER øA -0.2
-0.3 øB -0.2
-0.3 C 0
-0.1
D MODEL (CYLINDER)
S130W-V (S/ARM)
S130LC-V (BOOM (OP))
S140W-V (ARM)
75 mm 89 mm 6 mm 7 mm S140W-V (BOOM)
ARM
(2.95 in) (3.50 in) (0.24 in) (2.28 in) S160W-V (BOOM)
S170W-V (BUCKET)
S220LC-V (BUCKET)
S130W-V S220LL (BUCKET (HEEL))
75 mm 89 mm 6 mm 7 mm
S/ARM
(2.95 in) (3.50 in) (0.24 in) (2.28 in)
70 mm 84 mm 6 mm 7 mm
BOOM
(2.76 in) (3.31 in) (0.24 in) (2.28 in)
65 mm 79 mm 6 mm 7 mm S140W-V (BUCKET)
BUCKET
(2.56 in) (3.11 in) (0.24 in) (2.28 in) S160W-V (BUCKET)
70 mm 84 mm 0.5 mm 6 mm
S140W-V OR S160W-V (O/R)
(2.76 in) (3.31 in) (0.02 in) (0.24 in)
S180W-V (ARM)
S220LL (BOOM (HOIST))
90 mm 104 mm 6 mm 7 mm S250LC-V (BOOM, BUCKET)
ARM
(3.54 in) (4.10 in) (0.24 in) (2.28 in) S255LC-V (BOOM, BUCKET)
S290LC-V (BUCKET, S/BUCKET)
S170W-V S300LC-V (BUCKET, S/BUCKET)
80 mm 94 mm 6 mm 7 mm
BOOM S180W-V (BOOM)
(3.15 in) (3.70 in) (0.24 in) (2.28 in)
75 mm 89 mm 6 mm 7 mm
BUCKET S180W-V (BUCKET)
(2.95 in) (3.50 in) (0.24 in) (2.28 in)
85 mm 99 mm 6 mm 7 mm S210W-V (BOOM)
S200W-V BOOM
(3.35 in) (3.90 in) (0.24 in) (2.28 in) S220LC-V (BOOM)
S0705000 Cylinders
Page 22
Cylinders S0705000
Page 23
SLIPPER SEAL JIG
0
R1
R1
∅(A+2)
∅A
∅(A-14)
10°
B
(B+40)
ARS4770L
Figure 10
S0705000 Cylinders
Page 24
MODEL CYLINDER øA +0.2
+0.1 B +0.2
+0.1
MODEL (CYLINDER)
85 mm 32 mm
ARM S55W-V (ARM)
(3.35 in) (1.26 in)
110 mm 21.5 mm S55-V (BOOM (OP))
BOOM
(4.33 in) (0.85 in) S55W-V (BOOM)
S55-V S55W-V (BUCKET, SWING)
80 mm 30 mm
SWING S55-V PLUS (BUCKET)
(3.15 in) (1.18 in)
MEGA 300-III (P/S)
100 mm 18 mm
DOZER S55W-V (DOZER)
(3.94 in) (0.71 in)
90 mm 27 mm
ARM
S55-V (3.54 in) (1.06 in)
PLUS 115 mm 20 mm
BOOM
(4.53 in) (0.79 in)
85 mm 28.5 mm S55-V (ARM)
S70-III BUCKET
(3.35 in) (1.12 in) S80W-II (BUCKET, DOZER)
115 mm 25 mm
BOOM
(4.53 in) (0.90 in)
95 mm 23.5 mm
ARM
(3.74 in) (0.92 in)
S75-V
85 mm 23 mm
BUCKET
(3.35 in) (0.90 in)
110 mm 31.5 mm
SWING
(4.33 in) (1.24 in)
S170W-V (BOOM)
S180W-V (BOOM)
S210W-V (BUCKET)
115 mm 28.5 mm
S130LC-V ARM S220LC-V (BUCKET)
(4.53 in) (1.12 in)
S220LL (BUCKET (HEEL))
S225LC-V (BUCKET)
S225NLC-V (BUCKET)
S220N-V (BUCKET (OP))
120 mm 28.5 mm S225LC-V (BOOM)
S220LC-V BOOM
(4.72 in) (1.12 in) S225NLC-V (BUCKET (OP))
S225NLC-V (BOOM)
165 mm 34.5 mm S400LC-V (BOOM)
S220LL ARM (STICK)
(6.50 in) (1.36 in) S420LC-V (BOOM)
S220LL (BOOM (HOIST))
140 mm 28.5 mm S255LC-V (ARM)
ARM
(5.51 in) (1.12 in) S290-V (BOOM, BUCKET, S/BUCKET)
S250LC-V S300LC-V (BOOM, BUCKET. S/BUCKET)
130 mm 28.5 mm S250LC-V (BUCKET)
BOOM
(5.12 in) (1.12 in) S255LC-V (BOOM, BUCKET)
S290LL (BOOM (HOIST), BUCKET (HEEL))
S290LC-V (S/ARM)
150 mm 28.5 mm S300LC-V (ARM, S/ARM)
S290LC-V ARM
(5.91 in) (1.12 in) S340LC-V (BOOM, BUCKET, BUCKET (OP))
S360LC-V (BOOM, BUCKET, BUCKET (OP))
S370LC-V (BOOM, BUCKET, BUCKET (OP))
S340LC-V (ARM)
170 mm 34.5 mm S370LC-V (ARM)
S360LC-V ARM
(6.69 in) (1.36 in) S450LC-V (BOOM, BUCKET)
S470LC-V (BOOM, BUCKET)
Cylinders S0705000
Page 25
MODEL CYLINDER øA +0.2
+0.1 B +0.2
+0.1
MODEL (CYLINDER)
S140W-V (ARTI.)
180 mm 41.5 mm S160W-V (ARTI.)
ARM
(7.09 in) (1.63 in) S290LL (ARM (STICK))
S400LC-V S420LC-V (ARM)
160 mm 34.5 mm
BUCKET S420LC-V (BUCKET)
(6.30 in) (1.36 in)
190 mm 41.5 mm
S450-V ARM S470LC-V (ARM)
(7.48 in) (1.63 in)
S55-V PLUS (SWING)
S70-III (BOOM)
S80W-III (BOOM)
S130W-V (S/ARM)
S130LC-V (BOOM (OP))
S140W-V (ARM)
110 mm 28.5 mm
ARM S140W-V (BOOM)
(4.33 in) (1.12 in)
S140W-V (O/R)
S160W-V (ARM)
S160W-V (BOOM)
S160W-V (O/R)
S130W-V S170W-V (BUCKET)
S180W-V (BUCKET)
S70-III (ARM, DOZER)
S75-V (DOZER)
S80W-III (ARM)
100 mm 28.5 mm
BOOM S130W-V (BOOM)
(3.94 in) (1.12 in)
S130LC-V (BOOM (OP))
S140W-V (DOZER)
S160W-V (DOZER)
95 mm 28.5 mm S140W-V (BUCKET)
BUCKET
(3.74 in) (1.12 in) S160W-V (BUCKET)
125 mm 28.5 mm
S170W-V ARM S1480W-V (ARM)
(4.92 in) (1.12 in)
S210W-V (ARM)
S210W-V (BOOM)
S220LC-V (ARM)
135 mm 28.5 mm
S200W-V BOOM S220N-V (ARM (OP))
(5.32 in) (1.12 in)
S225LC-V (ARM)
S225NLC-V (ARM)
S225NLC-V (ARM (OP))
P/S: Power Steering
S0705000 Cylinders
Page 26
Cylinders S0705000
Page 27
SLIPPER SEAL STRAIGHTENING JIG
1
2-C
R
2-5
∅(A+15)
∅A
1
2-R
100
25
50
ARS4780L
Figure 11
S0705000 Cylinders
Page 28
MODEL CYLINDER øA +0.2
+0.1
MODEL (CYLINDER)
85 mm
ARM S55W-V (ARM)
(3.35 in)
110 mm S55-V (BOOM (OP))
BOOM
(4.33 in) S55W-V (BOOM)
S55-V S55W-V (BUCKET, SWING)
80 mm
SWING S55-V PLUS (BUCKET)
(3.15 in)
MEGA 300-III P/S
100 mm S55W-V (DOZER)
DOZER
(3.94 in) S55-V PLUS (DOZER)
90 mm
ARM
(3.54 in)
S55-V PLUS
115 mm
BOOM
(4.53 in)
115 mm
BOOM
(4.53 in)
95 mm
ARM
(3.74 in)
S75-V
85 mm
BUCKET
(3.35 in)
110 mm
SWING
(4.33 in)
S55-V (ARM)
85 mm
S70-III BUCKET S80W-III (BUCKET)
(3.35 in)
S80-III (DOZER)
S170W-V (BOOM)
S180W-V (BOOM)
S210W-V (BUCKET)
115 mm
S130LC-V ARM S220LC-V (BUCKET)
(4.53 in)
S220LL (BUCKET (HEEL))
S225LC-V (BUCKET)
S225NLC-V (BUCKET)
S220N-V (BUCKET (OP))
120 mm S225LC-V (BUCKET (OP))
S220LC-V BOOM
(4.72 in) S225NLC-V (BUCKET (OP))
S225NLC-V (BOOM)
165 mm S400LC-V (BOOM)
S220LL ARM (STICK)
(6.50 in) S420LC-V (BOOM)
S220LL (BOOM (HOIST))
140 mm S255LC-V (ARM)
ARM
(5.51 in) S290-V (BOOM, BUCKET, S/BUCKET)
S250LC-V S300LC-V (BOOM, BUCKET, S/BUCKET)
130 mm S250LC-V (BUCKET)
BOOM
(5.12 in) S255LC-V (BOOM, BUCKET)
S300LC-V (ARM, S/ARM)
S340LC-V (BOOM, BUCKET. BUCKET (OP))
150 mm S370LC-V (BOOM, BUCKET, BUCKET (OP))
S290LC-V ARM
(5.91 in) S290-V (S/ARM)
S360-V (BOOM, BUCKET, BUCKET (OP))
S290LL (BOOM (HOIST), BUCKET (HEEL))
S340LC-V (ARM)
170 mm S370LC-V (ARM)
S360-V ARM
(6.69 in) S470LC-V (BOOM, BUCKET)
S450-V (BOOM, BUCKET)
Cylinders S0705000
Page 29
MODEL CYLINDER øA +0.2
+0.1
MODEL (CYLINDER)
S140W-V (ARTI.)
180 mm S160W-V (ARTI.)
ARM
(7.09 in) S420LC-V (ARM)
S400LC-V S290LL (ARM (STICK))
160 mm
BUCKET S420LC-V (BUCKET)
(6.30 in)
190 mm
S450LC-V ARM S470LC-V (ARM)
(7.48 in)
S55-V PLUS (SWING)
S70-III (BOOM)
S80W-III (BOOM)
S130W-V (S/ARM)
S130-V (BOOM (OP))
S140W-V (ARM)
110 mm
ARM S140W-V (BOOM)
(4.33 in)
S140W-V (O/R)
S160W-V (ARM)
S160W-V (BOOM)
S160W-V (O/R)
S130W-V S170W-V (BUCKET)
S180W-V (BUCKET)
S70-III (ARM, DOZER)
S75-V (DOZER)
S80W-III (ARM)
100 mm
BOOM S130W-V (BOOM)
(3.94 in)
S130-V (BOOM)
S140W-V (DOZER)
S160W-V (DOZER)
95 mm S140W-V (BUCKET)
BUCKET
(3.74 in) S160W-V (BUCKET)
125 mm
S170W-V ARM S180W-V (ARM)
(4.92 in)
S210W-V (ARM)
S210W-V (BOOM)
S220LC-V (ARM)
135 mm
S200W-V BOOM S220N-V (ARM (OP))
(5.32 in)
S225LC-V (ARM)
S225NLC-V (ARM)
S225NLC-V (ARM (OP))
P/S: Power Steering
S0705000 Cylinders
Page 30
DISASSEMBLY
CAUTION!
Vent air from the hydraulic system before disconnecting cylinder piping connections. Use the
lever on the reservoir, while the engine is running. Discharge the hydraulic accumulator and
vent residual tank pressure after the engine is shut off. Pour clean replacement fluid back into
the system if excessive fluid is lost.
Figure 12
2. Position piston rod so that it is extended
approximately one half meter (20").
Figure 13
3. Remove bolts (7) on the end of cylinder.
NOTE: Wrap a cloth or other protective
material around piston rod, to
avoid possibility of accidentally
scratching or scoring rod
surface while fasteners are
being loosened and removed.
Component parts (numbered in
parentheses) are keyed to
Figure 4.
Figure 14
Cylinders S0705000
Page 31
4. Tap two bolts into cover of cylinder head,
180° apart. Tighten them in a staggered,
even sequence, to back off piston rod end
cover from edge of cylinder wall. Look for
adequate clearance between cover and
end of cylinder wall before using a plastic
or other soft-faced hammer for final
disassembly.
Figure 15
5. Begin withdrawing piston rod assembly,
away from cylinder. Attach a lifting support
when final 1/3 of rod is still inside barrel of
cylinder. Prepare support blocks for piston
rod before it has been completely
withdrawn.
Figure 16
6. Lower piston rod to support blocks and
detach wear ring (outer surface) (18) from
end of rod.
Figure 17
S0705000 Cylinders
Page 32
7. Immobilize piston rod by inserting a
wooden or other nonscoring, nonmetallic
support through end of rod.
Figure 18
8. Remove set screw by using a socket
wrench.
HAOF340L
Figure 19
9. Fabricate or purchase a piston nut removal
wrench. (Dimensions are called off at
beginning of this procedure. This tool may
also be ordered through your local
Daewoo Parts distributor). Remove nut
from end of piston.
Figure 20
Cylinders S0705000
Page 33
10. Use second piston tool described at
beginning of this procedure to separate
piston. Detach cushion ring (15), taking
care not to damage cushion ring.
Figure 21
11. Use a plastic hammer to evenly pull off rod
cover (9) from end of piston rod. Be careful
not to damage rod bushing (6) and dust
wiper, U-packing and other seals.
Figure 22
12. Use a dull, rounded-tip tool to pry off
O-ring (11) and backup ring (12).
HAOF37OL
Figure 23
13. Find a screwdriver with an appropriate
width tip to facilitate removal of slipper seal
(19), wear ring (18) and slide ring (17)
from piston (16).
Figure 24
S0705000 Cylinders
Page 34
14. Pull off O-ring (20) and backup ring (21)
from cylinder head.
HAOF38OS
Figure 25
15. During disassembly of cylinder head, be
careful not to damage buffer seal (5) and
U-packing (4).
HAOF39OL
Figure 26
16. Disassemble retaining ring (3) and dust
wiper (2). Separate retaining ring (8) and
rod bushing (6).
Figure 27
Cylinders S0705000
Page 35
17. Force out pin bushing (1) from body of
cylinder.
Figure 28
S0705000 Cylinders
Page 36
ASSEMBLY
IMPORTANT
Replace any part that shows evidence of damage or excessive wear. Replacement of all O-rings
and flexible seals is strongly recommended. Before starting the cylinder assembly procedure, all
parts should be thoroughly cleaned and dried, and/or prelubricated with clean hydraulic fluid.
Prepare the work area beforehand to maintain cleanliness during the assembly procedure.
Figure 29
2. Following the assembly of rod cover
components, install dust wiper (2) and rod
bushing (6) to rod cover (9). Insert
retaining rings (3 and 8).
Figure 30
Cylinders S0705000
Page 37
3. Pre-lubricate O-rings and seals before
assembly (Figure 31).
Figure 31
4. Before starting to rebuild piston assembly,
heat slipper seal for 5 minutes in an oil
bath warmed to 150°-180°C (302°-356°F).
Use special slipper seal jig (third item in list
of specialized tools at the beginning of this
procedure) to attach seal. Cool seal by
pushing a retracting jig against seal for
several minutes. Apply a strip of clean,
see-through sealing tape around slipper
seal to keep it free of dust.
Figure 32
5. Immobilize piston rod on solid support
blocks. Assemble O-ring (20) and backup
ring (21). Prepare to attach rod cover
assembly to piston rod. Push rod cover by
tightening piston nut (22).
Figure 33
6. Assemble cushion ring (15) and attach
piston assembly to piston rod.
Figure 34
S0705000 Cylinders
Page 38
7. Use specially fabricate or factory-sourced
tool to tighten piston nut (22).
Figure 35
8. Assemble wear ring (18), slide ring (17)
and set screw (23) to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 36
9. Immobilize body of cylinder before
assembly.
Figure 37
10. Pre-apply fastener locking compound
(Loctite #242 or #243 or an alternate
manufacturer’s equivalent product) to all
end cover retaining bolts. Wrap a
protective cushion around end of rod while
tightening fasteners, to prevent possible
damage to polished surface of rod, should
a wrench slip during retightening.
Figure 38
Cylinders S0705000
Page 39
S0705000 Cylinders
Page 40
S0707260
1SWING MOTOR
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Swing Motor Anti-cavitation Make-up Valve ............................................ 4
Relief Valve ............................................................................................. 5
Swing Brake Operation ........................................................................... 6
Parts List (Solar 140W-V, 160W-V) ......................................................... 8
Parts List (Solar 170LC-V, 170W-V, 175LC-V, 180W-V,
450LC-V, 470LC-V) ............................................................................... 10
Specifications ........................................................................................ 12
Special Tools (Solar 140W-V, 160W-V) ........................................................ 13
Special Tools (Solar 170LC-V, 170W-V, 180W-V) ........................................ 14
Special Tools (Solar 450LC-V, 470LC-V) ..................................................... 15
Disassembly ................................................................................................. 16
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 23
Reassembly.................................................................................................. 25
Figure 1
Reference Reference
Description Description
Number Number
1 Valve Plate 4 Cylinder Block
2 Shoe 5 Piston
3 Swash Plate
The cross sectional views of the swing motor, show most of the main components of an axial-piston type
hydraulic motor. Arrows indicating direction of flow and other graphic symbols provide a general guide for
understanding basic operation (Figure 1).
When high-pressure oil enters the cylinder through the inlet port of the valve plate (1, Figure 1), the sliding
piston inside the cylinder is driven back, generating force "F" against the shoe behind the piston (2).
Force "F" acts in two different directions, as indicated by the arrows (Figure 1). Force F1 exerts pressure
directly on the swash plate (3) to generate oil flow through the motor, while force F2 pushes laterally - at a
right angle - against the drive shaft, providing the rotational energy to turn the cylinder block around the
drive shaft.
All nine pistons in the cylinder block have equal width bore, length and volume. They are configured in a
concentric layout around the drive shaft, as shown in the cross section end-view. As oil is forced through
the inlet port, pistons rotating past the pressurized (supply) side of the motor (indicated as the shaded
cylinders) transmit drive torque - one after the next, each in turn - to the swash plate (through F1, direct
output force) and to the cylinder block (F2, lateral force to keep the block rotating).
IMPORTANT
The trench mode setting only has a noticeable effect if both functions are used at the same time,
when the right and the left joysticks are each engaged simultaneously, to control swing and
boom/arm functions.
When the trench mode is engaged, an engaged voltage signal to the solenoid valve shifts the "swing
priority" spool valve to increase oil flow through the swing motor. With trench mode "OFF," voltage is
disengaged while current flow is reduced, shifting the spool in the priority valve for increased oil flow to the
boom/arm side of the circuit.
Figure 3
The swing brake is applied when the brake spring (712, Figure 3) locks up the friction plate (742), split
plate (743) and swing motor casing (301), preventing the motor drive shaft from turning. When hydraulic
pressure is forced to the back side of the brake piston, the friction plate and swing motor casing are
separated, releasing the brake.
IMPORTANT
Along with the swing brake, a 2-position positive swing lock has also been provided. It should be
secured whenever the upper deck revolving superstructure must be locked down and positively
kept from rotating - including maintenance and/or repair intervals. (Do not rely on the swing
brake alone to hold the superstructure in position for repairs, transport, maintenance or normal
storage.
841
401
468
487
111
303
52
116 117
51 113
351
355
488 123
469 433
121
444 122
124
472
464
485 301
712
993
994
31
702
707
706
451
131
101
743
742
432
743 106
742 443
743 106
432
491
438 304
106 471
114 437
118
HAAA4340
Figure 4
841
401
468
487
111
303
52
116 117
51 113
351
355
488 123
469 433
121
444 122
124
472
464
485 301
712
993
994
31
702
707
706
451
131
101
743
742
432
743 106
742 443
743 106
432
491
438 304
106 471
114 437
118
HAAA4340
Figure 5
Specification
Item Solar 170W-V
Solar 140W-V Solar 170LC-V Solar 450LC-V
Solar 220LC-V
Solar 160W-V Solar 175LC-V Solar 470LC-V
Solar 220L
Type Axial Piston
64 cc/rev 121.6 cc/rev 128.0 cc/rev 2 x 128.0 cc/rev
Displacement
(3.91 in3/rev.) (18.85 in3/rev.) (7.81 in3/rev.) (2 x 7.81 in3/rev.)
Crossover Relief Valve 270 kg/cm2 280 kg/cm2 280 kg/cm2 280 kg/cm2
Setting (3,840 psi) (3,980 psi) (3,980 psi) (3,980 psi)
Maximum Supply Flow 125 liter/pm 227 liter/pm 210 liter/pm 2 x 210 liter/pm
Rate @ 2000 rpm (33 gpm) (60 gpm) (55 gpm) (2 x 55 gpm)
Max. Motor Shaft 1,640 rpm
1,953 rpm 1,867 rpm 1,640 rpm
Speed
Rated Motor Shaft 27.5 kg•m 54.2 kg•m 57 kg•m 114 kg•m
Torque (199 ft lb) (392 ft lb) (412 ft lb) (825 ft lb)
29 kg 56.5 kg 62 kg 2 x 62 kg
Weight
(64 lb) (125 lb) (137 lb) (2 x 137 lb)
2X 9
40
40
100
11 250
M10
10
M10
150
210
HDA3061L
Figure 6
Figure 7
Figure 8
IMPORTANT
Clean all of the exterior surfaces of the motor before disassembly. There should not be any
visible dirt, grease, or other type of accumulation on the outside of the casing. Clean off or
blow dry all traces of cleaner or solvent before starting work and cap off or use other types
of protective seals, plugs or wrapping on temporarily disconnected hoses, piping or ports.
2. Open drain plug and drain all oil from motor casing.
NOTE: Swing Motor component parts (numbered in parentheses) are keyed to Figure 5.
IMPORTANT
Use a clean, dry container to catch gear oil. A clean container allows an evaluation to be
made of the used oil. The presence or lack of metal wear shavings in the used oil or
obvious deterioration or contamination of the oil can provide a useful indicator of the
motor’s general condition.
Figure 10
Figure 11
5. Disassemble brake valve (31) from side of
casing.
Figure 12
6. Remove relief valve assemblies (51) from
upper valve casing (303).
Figure 13
7. Remove RO plug (469) from upper valve
casing (303). That will allow subsequent
separation of spring (355) and plunger
(351).
IMPORTANT
Use extra care to avoid damaging the
plunger seat.
Figure 14
Figure 15
9. Remove all twenty brake springs.
NOTE: If brake springs are to be
reused and not replaced, check
and record spring free height. If
a test stand is available, check
height of all twenty springs
under consistent loading.
Replace all springs that show
excessive variation or
weakness.
Figure 16
10. Disassemble brake piston assembly using
special tool and corresponding piston bolt
hole.
NOTE: See "Special Tools (Solar
140W-V, 160W-V)" portion of
this section for manufacturing
details of special tool.
Figure 17
Figure 19
13. Remove lock ring (437) from around drive
shaft. Use a large enough pair of snap-ring
pliers to properly tension ring and pull it
away from locking groove.
Use extra caution in pulling off front cover
(304) behind snap ring. Drive shaft oil seal
(491) underneath cover must be replaced
if it is damaged during disassembly. Use a
little bit of extra caution (and a very large
set of channel locks, a puller or extra wide
adjustable wrench) to carefully withdraw
Figure 20
cover straight back off drive shaft.
Figure 21
15. Tap bearing race out of casing.
Figure 22
16. Disassembly of motor has now been
completed, unless there is any reason to 1
suppose that drive shaft bearing has 2
become excessively worn.
If it is necessary, replace bearing by pulling
away stop ring (432) and spacer (106). Put 3
drive shaft in a press to separate bearing
cage from drive shaft.
4
Reference
Description
Number
1 Press HDA3078L
2 Drive Shaft Figure 23
3 Roller Bearing
4 Base of Press
Reference
Description
Number
1 Plug HDA3079L
Figure 25
B. If upper bearing is going to be
replaced, whether as a general
precaution as part of normal
rebuilding or because of
unmistakable wear, separate bearing
from cover.
Figure 26
2
1
d D
5
4
3
H
h
a
t
HBOA230L
Figure 28
NOTE: Spherical bushing and push plate must always be replaced as a set. If either one requires
replacement, replace the other
1. Clearance Between Piston and Cylinder Bore (D-d)
2. Spring Free Length (L)
3. Thickness of Shoe (t)
4. Piston Ball - Shoe Socket Clearance (a)
5. Height Between Round Bushing and Push Plate (H-h)
Inspect O-rings and oil seals very carefully for cuts, nicks, brittleness, softness or any other type of damage
or distortion, before final reassembly if any must be reused.
Figure 29
2. If drive shaft roller bearings were not
disassembled, go onto next phase of
assembly. Bearing reassembly begins with
replacement of stop ring (432) (Figure 5
and its accompanying Parts List) and
spacer (106) on drive shaft (101).
Figure 30
Make sure that bearing raceways (collars)
are facing right direction. The drawing
shows one side of the bearing collar (1,
Figure 31), marked "R," which should be
assembled next to spacer (2) on lower end
of drive shaft.
A. Both bearing cages (inner roller
assemblies) will probably require
heating in oil before reassembly.
Heat bearings to cause sufficient
expansion of their inner diameters to
allow reassembly on drive shaft.
Figure 31
Figure 32
4. There is a "right side" and "wrong side" on
oil seal. Be careful that you install seal
inside cover with correct side facing in.
Figure 33
5. Before replacing O-ring (471) in lower
casing (301), grease O-ring (and/or inside
of groove) very lightly, to facilitate
assembly and to help protect O-ring from
accidental damage.
Figure 34
6. Put a little grease on lip of front cover oil
seal before replacing front cover and
tapping it lightly into place with plastic
hammer.
Figure 35
Figure 36
8. Turn motor sideways and assemble shoe
plate (124), placing it in motor housing in
same position it was in before removal.
Using grease on assembled side can help
keep individual components in place.
Figure 37
9. Carefully examine cylinder block for any
evidence of damage around rotating parts.
Put push rods (116) and front spacer (117)
back into cylinder block and replace
spherical bushing (113).
Figure 38
10. Using reference notes or marks made
earlier, replace all of the pistons and shoes
(121, 122) back in their original cylinder
bores.
Figure 39
Figure 40
12. Turn motor so that front cover side (304) is
down. Put separator plates (743) and
friction plates (742) back in same order in
which they were removed. There are three
separator plates (743) and two friction
plates (742), which should be positioned
as shown in drawing below, with clearance
towards side of casing with brake valve (1,
Figure 41).
Reference
Description
Number
1 Brake Valve
Figure 41 \
13. Very lightly grease larger O-rings (706 and
707, Figure 5) before replacing them in
casing (301).
Figure 42
14. Position brake piston (1, Figure 43) in
casing. The diagram shows position of four
piston grooves (2) in relation to valve
connected side (3), and two 8 mm bolts
which should be tightened in an even,
progressive rotation.
Reference
Description
Number
1 Brake Piston
2 Groove
3 Valve-connected Side
Figure 43
Figure 44
16. Tap roller bearing (444) race back into
upper valve casing (303), using hammer
and copper rod specified in tool list.
Figure 45
17. Assemble valve plate (131), O-ring and
upper valve casing (303). Refer to
assembly that shows "R" part (2, Figure
46) of the valve plate turned away from
mounting flanges (1) on side of valve plate.
Lightly grease O-ring to help keep it in
place during assembly.
Reference
Description
Number
1 Flange Side
2 R Port
Figure 46
18. Bolt up two halves of motor casing (301
and 303, Figure 5). Be careful not to lose
or damage O-ring. Tighten four 20 mm
socket head bolts using a progressive,
even rotation. Make sure that all brake
springs are fully seated and that valve
casing inlet and output ports are correctly
matched.
Figure 47
Figure 48
20. Reassemble relief valves (51) by putting
rod, spring, stop and piston back together,
then turning plunger side of valve up to
reassemble valve body and all
components of piston: spring seat, spring,
bushing, retainer, O-ring and plug.
Figure 49
IMPORTANT
Be careful not to damage the plunger
and spring seat.
Figure 50
21. Before replacing relief valves (51) in upper
valve casing (303), install backup rings
and O-rings.
Figure 51
Figure 52
1TRAVEL MOTOR
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Sectional View................................................................................................ 4
Seal Kits and Component Groups.................................................................. 5
Seal Kits and Component groups / Replace Seal Nut.................................... 8
Sealing the Drive Shaft................................................................................. 10
Sealing of the Control Parts ......................................................................... 12
Sealing of the Relief Valve / Counter-Balance Valve.................................... 15
Spare Parts List Counter-Balance Valve ...................................................... 16
Spare Parts list Brake Release Valve (Pos. 50) ........................................... 17
Shuttle Valve (Pos. 25) .......................................................................... 18
Disassembly of the Port Plate ...................................................................... 19
Remove of the Positioning Piston................................................................. 21
Remove Rotary Group ................................................................................. 23
Exchanging of the rotary group .................................................................... 25
Complete Rotary Group ........................................................................ 25
Rotary Group ........................................................................................ 25
Inspection Notes........................................................................................... 27
Rotary Group Assembly ............................................................................... 30
Rotary Group Adjustment (see service information) .................................... 33
Assembly of the Port Plate ........................................................................... 35
Tightening Torques....................................................................................... 37
Safety Regulations ....................................................................................... 39
General Advice...................................................................................... 39
Before starting....................................................................................... 39
Start ...................................................................................................... 39
Hydraulic Equipment ............................................................................. 40
Specifications, descriptions and illustrative material shown herein were as accurate as known at the time
this publication was approved for printing.
BRUENINGHAUS HYDROMATIK reserves the right to discontinue models or options at any time or to
change specifications, materials, or design without notice and without incurring obligation.
Optional equipment and accessories may add cost to the basic unit, and some options are available only in
combination with certain models or other options.
For the available combinations refer to the relevant data sheet for the basic unit and the desired option.
Adjustment and tests have to be carried out on the test bench under operating temperatures.
Protection of personnel and property has to be guaranteed by appropriate measures.
Expert knowledge, the precondition of any service work, can be obtained in our training courses.
Figure 2
Figure 3
Replace all seals. Use only original Hydromatik
spare parts.
Figure 4
Check all seal and sliding surfaces for wear.
NOTE: Rework of sealing area f. ex. with
abrasive paper can damage
surface.
Figure 5
Figure 6
Seal kit for drive shaft.
Figure 7
External seal kit.
Figure 8
Housing
Figure 9
Figure 10
Port plate with control piston
Figure 11
Figure 12
Relief valve / Make up check valve
Figure 13
Replace seal nut. First measure and record
setting height.
Figure 14
Figure 15
Figure 16
Figure 17
Screw in sheet metal screw into the holes fitted
with rubber.
Pull out seal with pliers.
Figure 18
Figure 19
Figure 20
Figure 21
Reference
Description
Number
1 O-ring
2 Input Flow of Oil Control
3 Throttle Pin
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Reference
Description
Number
1 O-ring / High Pressure -
Small Control Piston Side
2 O-ring / Control Pressure
3 O-ring / High Pressure -
Check Valve
4 O-ring / High Pressure -
Check Valve
Figure 27
Figure 28
Inspect!
O-ring
Figure 29
Figure 30
Reference Reference
Description Description
Number Number
1 Housing 15 Valve Seat
2 Screw Plug 16 Sleeve
3 Spring 18 O-ring
4 Spring Retainer 19 O-ring
5 Snap Ring 20 O-ring
6 Spool 24 Thrust Ring
7 Screw Plug *25 Shuttle Valve
8 Spring 26 Screw Plug
9 Cone 30 Screw Plug
10 O-ring 31 Screw Plug
11 Spring 32 S. H. C. S.
12 Cone 40 identification Plate
13 Screw Plug 41 Round-head Grooved Pin
14 Throttle Element *50 Brake Release Valve
Figure 32
Reference Reference
Description Description
Number Number
2 Guide 7 O-ring
3 Sleeve 8 O-ring
4 Spool 9 O-ring
5 Screw Plug 10 Thrust Ring
6 Spring
Figure 33
Reference
Description
Number
10 Valve Seat
11 Valve Seat
12 Ball
Figure 34
Note dimension x.
Remove Qmin-screw.
Swivel rotary group to zero p
NOTE: For disassembly of the port plate, swivel always rotary group to zero position.
Piston rings to hang out of the cylinder boring.
Figure 35
Check O-ring
NOTE: Stick new O-ring with some
grease.
Do not swivel rotary group.
Piston rings to hang out from the
cylinder boring.
Figure 36
Figure 37
Figure 38
Figure 39
Warm up fixation screw * for positioning plug via
boring (screw glued - to turn out).
NOTE: Use new screw.
Pre cote coating.
Note tightening torque!
Figure 40
NOTE: Stick control lens in sliding
surface with grease.
Assembly in reversal order.
Mount port plate.
NOTE: Rotary group vertical
Figure 41
Figure 42
Size
28 M4 x 58 mm
55 M5 x 71 mm
80 M6 x 82 mm
107 M6 x 92 mm
140 M8 x 105 mm
160 M8 x 105 mm
200 M8 x 109 mm
Figure 43
Figure 44
Figure 45
ROTARY GROUP
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part: Adjustment necessary*
Figure 46
Figure 47
Disassemble retaining plate.
NOTE: Screws are glued.
Use Torx-tools.
Figure 48
Figure 49
Pistons
No scoring and no pittings.
Figure 50
Center pin
No scoring and no pittings.
Figure 51
Figure 52
Cylinder block / control lens
1. Bores free of scoring, no evidence of wear.
2. Faces smooth and even, free of cracks and
scoring.
Figure 53
Control housing
Sliding surface and side guides free of scoring
and no wear.
Figure 54
Figure 55
Figure 56
Figure 57
Reference
Description
Number
1 Disassemble cylinder fixing screw.
2 Insert O-ring
Figure 59
*Disc
Figure 60
Place centering disc.
Figure 61
Figure 62
Check dimension X.
Figure 63
Figure 64
Figure 65
Figure 66
Assemble shaft seal, disc and safety ring.
Press-in with assembly sleeve.
NOTE: Take care of press-in depth.
Figure 67
Figure 68
Strength Classes
Tread Size 8.8 10.9 12.9 8.8 10.9 12.9
Tightening Torque (Nm) Tightening Torque (lb. ft)
M3 1.1 1.6 1.9 0.8 1.2 1.4
M4 2.9 4.1 4.9 2.1 3.0 3.6
M5 6 8.5 10 4.4 6.3 7.4
M6 10 14 17 7.4 10.3 12.5
M8 25 36 41 18.4 25.8 30.2
M 10 49 69 83 36.1 50.9 61.2
M 12 86 120 145 63.4 88.4 106.9
M 14 135 190 230 99.5 140.0 169.5
M 16 210 295 355 154.8 217.4 261.6
M 18 290 405 485 213.7 298.5 357.4
M 20 410 580 690 302.2 427.5 508.5
M 22 550 780 930 405.4 574.9 685.4
M 24 710 1000 1200 523.5 737.0 884.4
M 27 1050 1500 1800 773.9 1105.5 1326.6
M 30 1450 2000 2400 1068.7 1474.0 1768.8
Tightening Torques for Locking Screws VSTI (Metric ISO fine thread)
Tightening Tightening
Thread Size Designation
Torques (Nm) Torque (lb. ft)
M8x1 VSTI 8 x 1 -ED/SA =5 =4
M 10 x 1 VSTI 10 x 1 -ED = 10 =7
M 12 x 1.5 VSTI 12 x 1.5 -ED = 20 = 15
M 14 x 1.5 VSTI 14 x 1.5 -ED = 30 = 22
M 16 x 1.5 VSTI 16 x 1.5 -ED/SA = 40 = 22
M 18 x 1.5 VSTI 18 x 1.5 -ED/SA = 50 = 29
M 20 x 1.5 VSTI 20 x 1.5 -ED/SA = 60 = 37
M 22 x 1.5 VSTI 22 x 1.5 -ED = 70 = 44
M 26 x 1.5 VSTI 26 x 1.5 -ED/SA = 80 = 51
M 27 x 2 VSTI 27 x 2 -ED = 90 = 66
M 30 x 1.5 VSTI 30 x 1.5 -ED/SA = 100 = 74
M 33 x 2 VSTI 33 x 2 -ED/SA = 120 = 88
M 42 x 2 VSTI 42 x 2 -ED/SA = 200 = 147
M 48x 2 VSTI 48 x 2 -ED = 300 = 220
Strength Classes
Tread
8.8 10.9 12.9 8.8 10.9 12.9
Size
Tightening Torque (Nm) Tightening Torque (lb. ft)
M6 10 7.4
M8 22 16.2
M 10 40 29.5
M 12 69 50.9
M 14 110 81.1
M 16 170 125.3
Tightening Torques for Cross-slotted Lens Head Screws DIN 7985 (Metric ISO-Standard Thread)
The values for tightening torques shown in the table are valid only for cross-slotted lens head screws DIN
7985 of the strength class 8.8 and with metric ISO-standard thread.
Strength Classes
Tread
8.8 10.9 12.9 8.8 10.9 12.9
Size
Tightening Torque (Nm) Tightening Torque (lb. ft)
M3 1.1 0.8
M4 2.9 2.1
M5 6 4.4
M6 10 7.4
M8 25 18.4
M 10 49 36.1
BEFORE STARTING
• observe the operating instructions before starting.
• Check the machine for remarkable faults.
• Do not operate the machine with defective instruments, warning lights or control elements.
• All safety devices must be in a secure position.
• Do not carry with you movable objects or secure them to the machine.
• Keep oily and inflammable material away from the machine.
• Before entering the driver’s cabin, check if persons or obstacles are beside of beneath the
machine.
• Be careful when entering the driver’s cabin, use stairs and handles.
• Adjust your seat before starting.
START
• When starting all operating levers must be in "neutral position".
• Only start the machine from the driver’s seat
• Check the indicating instruments after start to assure that all functions are in order.
• Do not leave the machine unobserved when the motor is running.
• When starting with battery connection cables connect plus with plus and minus with minus.
Always connect mass cable (minus) at last and cut off at first.
CAUTION!
Exhaust gas is dangerous. Assure sufficient fresh air when starting in closed
rooms!
CAUTION!
High pressure fluids (fuel, hydraulic oil) which escape under high pressure
can penetrate the skin and cause heavy injuries. Therefore immediately
consult a doctor as otherwise heavy infections can be caused.
2.When searching leakages use appropriate auxiliary devices because of the danger of accidents.
3.Before working at the hydraulic equipment, lower pressure to zero and lower working arms of the
machine.
4.When working at the hydraulic equipment, absolutely stop motor and secure tractor against rolling away
(parking brake, shim)!
5. When connecting hydraulic cylinders and motor pay attention to correct connection of hydraulic flexible
hoses.
6. In case of exchanging the ports, the functions are vice versa (f. ex. lift-up/lower) - danger of accidents!
7. Check hydraulic flexible hoses regularly and replace them in case of damage or wear! The new hose
pipes must comply with the technical requirements of the machine manufacturer!
NOTE: Orderly disposal or recycling of oil, fuel and filters!
1MAIN PUMP
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Section ........................................................................................................... 4
General Repair Guidelines ............................................................................. 5
Seal Kits and Sub-assemblies........................................................................ 7
Sealing the Drive Shaft................................................................................. 11
Gear Pump Sealing ...................................................................................... 14
Remove the control housing......................................................................... 15
Control Module ............................................................................................. 18
Removing the Controller............................................................................... 20
Valve Plate with Valves................................................................................. 22
Remove the Rotary Groups.......................................................................... 23
Dismantling the Rotary Group...................................................................... 26
Remove the Intermediate Wheel.................................................................. 28
Remove Auxiliary Drive ................................................................................ 30
Inspection Hints............................................................................................ 33
Complete rotary group .......................................................................... 36
Re-fitting the rotary group ............................................................................ 38
Pump Assembly ........................................................................................... 40
Assembly guideline: .............................................................................. 42
Hydraulic Component - Measurement "D" ................................................... 43
Fit Control Housing....................................................................................... 47
Assembly of the intermediate wheel............................................................. 52
Fit the Gear Pump ........................................................................................ 54
Fit the Cover / Auxiliary Drive ....................................................................... 55
Tightening Torques....................................................................................... 56
Specifications, descriptions and illustrative material shown herein were as accurate as known at the time
this publication was approved for printing.
HYDROMATIK reserves the right to discontinue models or options at any time or to change specifications,
materials, or design without notice and without incurring obligation.
Optional equipment and accessories may add cost to the basic unit, and some options are available only in
combination with certain models or other options.
For the available combinations refer to the relevant data sheet for the basic unit and the desired option.
Adjustment and tests have to be carried out on the test bench under operating temperatures.
Protection of personnel and property has to be guaranteed by appropriate measures.
Expert knowledge, the precondition of any service work, can be obtained in our training courses.
Figure 2
Figure 3
Replace all of the seals. Use only original
BRUENINGHAUS HYDROMATIK spare parts.
Figure 4
Check all sealing and sliding surfaces for wear.
NOTE: Re-work of the sliding surfaces
by using, for example with
abrasive paper, can damage the
surface.
Figure 5
Figure 6
Figure 7
Peripheral seal kit.
Figure 8
Rotary group 1, ready to install.
Figure 9
Figure 10
Rotary group, hydraulic component (order rotary
groups 1 and 2 separately). Adjustment is
necessary!
NOTE: Direction of rotation.
Figure 11
Rotary group 1, mechanical section, ready to
install.
Figure 12
Rotary group 2, mechanical section, ready to
install.
Figure 13
Figure 14
Internal gear pump, complete.
Figure 15
Intermediate gear
Figure 16
Figure 17
Valve plate with valves
Figure 18
Pipe, complete with fittings
Figure 19
Figure 20
Remove retaining ring.
Figure 21
Press off cover ring.
Figure 22
Figure 23
Remove old shaft seal.
Figure 24
Press in shaft seal.
Figure 25
If the shaft is deeply scored, insert the shim
provided in front of the shaft seal.
Figure 26
Figure 27
Fit cover ring.
Figure 28
Fit retaining ring tapping home until it springs into
place, carry out visual check to ensure that the
retaining ring is correctly seated!
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Remove paper seal, clean sealing surface.
Figure 36
Reference
Description
Number
1 Setting Screw Qmax
2 Setting Screw Hydraulic Stroke Limitation
3 Setting Screw Power Characteristic
(Begin of Regulation)
NOTE: Before carrying out a setting or disassembly of the regulator, measure the measurement X
and note of the setting screw.
Figure 38
Figure 40
Remove cover.
NOTE: Do not change the setting screw (1).
Figure 41
Remove locking screw and replace with a new
locking screw.
NOTE: Loosen adhesive with a "gentle"
flame {approx. 120°C (248°F)}
Figure 42
Loosen swivel pin and then remove it.
Figure 43
Figure 44
Figure 45
Figure 46
Remove cup springs 1 and spring cup 2.
Figure 47
Reference
Description
Number
1 Remove
2 Remove
3 Remove
4 Rotary Group 1
5 Rotary Group 2
Figure 50
Reference Reference
Description Description
Number Number
1 Fixing screws are glued 4 Drive Shaft 1
2 Adjustment od 5 Grooved nut for torque
measurement D adjustment is glued
3 Holding Device 6 Drive Shaft 2
Figure 51
NOTE: * Press in bolt into the gear wheel. (Fixed pressing fit). Can only be disassembled with a
hydraulic press.
Reference
Description
Number
1 Remove Bearing
NOTE: Install sleeve. Press out bolt with a hydraulic manual press.
Reference
Description
Number
1 Remove gear wheel through side drive opening.
2 Remove bearing with extraction device.
Figure 53
Figure 54
Press off bearing cap.
Figure 55
Figure 56
Fit extractor device.
Pull out output pinion.
Figure57
Fit bearing extractor device.
Figure 58
Completely mount device and pull out bearing.
Figure 59
Figure 60
Figure 61
Check to see that the bearing area is free of
scores and that there is no evidence of wear.
Figure 62
Visual check: to ensure that the bearing seats are
free of scores.
Figure 63
Figure 64
Axial piston play. (Checked with the retaining
plate fitted)
Figure 65
Drive shafts
1. Check to ensure that the cups are free of
scores and that there are no pittings.
2. check to see that there is no evidence of
corrosion and wear.
Figure 66
Piston
Check to ensure that they are free of scores and
that there are no pittings.
Figure 67
Figure 68
Retaining plate
Check to ensure that it is free if scores and that
there is no evidence of wear.
Figure 69
Cylinder block / control lens
Check to ensure that:
The bores (1) are free of scores, no evidence of
wear.
The faces (2) are even, that there are no cracks,
no scores.
The side guides (3) show no evidence of wear,
free of scores.
Figure 70
Check
Control land 1, internal control drilling 2, pin cups
3.
Figure 71
Figure 72
Figure 73
Reference
Description
Number
1 Mechanical component: Drive shaft is adjusted with the bearing
2 Hydraulic component: Adjustment is necessary *
Figure 75
Fit the retaining plate with pistons and centre pin
into place.
Use screws that have a Precote coating.
* For tightening torques, see service information.
Figure 76
Fit the spring plate 1 and cup springs 2 into their
correct position (and orientation) using grease to
hold them into place.
Figure 77
Figure 78
Insert pistons into the cylinder. Using a soft
surface as a support to prevent the sliding
surfaces from being damaged. Pre-assemble
both of the rotary groups in this manor.
Figure 79
Figure 80
Insert the pre-assembled rotary group 1, taking
into account gear tooth markers.
Figure 81
Insert rotary group 2. Align the marked gear
teeth.
Figure 82
Figure 83
Figure 84
Retaining force
After the rotary group has been fitted into the housing, it has to be pressed in until the end stop is reached.
Allow the housing to cool down from its assembly temperature {approx. 80°C (176°F)} to room
temperature.
Figure 85 A8VO
Figure 86
Figure 87
Measuring Procedure
Turn down by 4 turns on the dial gauge.
Check: 2 mm clearance, set dial gauge to "Zero".
Clearance (Size 28 - 160): 0.4 ±0.1 mm (0.0157 ±0.0039 in)
Figure 89
Figure 90
Figure 91
Fit the swivel pin into correct position and orientation. Take the hardening time and tightening torque into
account.
* M6 = 8.5 Nm {0.87 kg•m (6 ft lb)}
M8 = 14 Nm {1.43 kg•m (10 ft lb)}
M10 = 35 Nm {3.57 kg•m (26 ft lb)}
M12 = 69 Nm {7.04 kg•m (51 ft lb)}
Figure 93
Push on the piston ring by hand. Fix adjustment piston. Take the tightening torques into account.
Fit the control lens in its correct position using grease to hold it in place.
Reference
Description
Number
A Direction of rotation counterclockwise
B Direction of rotation clockwise
1 Pressure side
2 Suction side
Figure 97
Reference
Description
Number
A New assembly position
Figure 98
Figure 99
Figure 100
Figure 101
Strength Classes
Tread Size 8.8 10.9 12.9 8.8 10.9 12.9
Tightening Torque (Nm) Tightening Torque (lb. ft)
M3 1.1 1.6 1.9 1 1 1
M4 2.9 4.1 4.9 2 3 4
M5 6 8.5 10 4 6 7
M6 10 14 17 7 10 13
M8 25 36 41 18 26 30
M 10 49 69 83 36 51 61
M 12 86 120 145 63 88 107
M 14 135 190 230 100 140 170
M 16 210 295 355 155 217 262
M 18 290 405 485 214 299 357
M 20 410 580 690 302 428 509
M 22 550 780 930 405 575 685
M 24 710 1000 1200 524 737 884
M 27 1050 1500 1800 774 1106 1327
M 30 1450 2000 2400 1069 1474 1769
Tightening Torques for Locking Screws VSTI (Metric ISO fine thread)
Tightening Tightening
Thread Size Designation
Torques (Nm) Torque (lb. ft)
M8x1 VSTI 8 x 1 -ED/SA 5 4
M 10 x 1 VSTI 10 x 1 -ED 10 7
M 12 x 1.5 VSTI 12 x 1.5 -ED 20 15
M 14 x 1.5 VSTI 14 x 1.5 -ED 30 22
M 16 x 1.5 VSTI 16 x 1.5 -ED/SA 40 22
M 18 x 1.5 VSTI 18 x 1.5 -ED/SA 50 29
M 20 x 1.5 VSTI 20 x 1.5 -ED/SA 60 37
M 22 x 1.5 VSTI 22 x 1.5 -ED 70 44
M 26 x 1.5 VSTI 26 x 1.5 -ED/SA 80 51
M 27 x 2 VSTI 27 x 2 -ED 90 66
M 30 x 1.5 VSTI 30 x 1.5 -ED/SA 100 74
Strength Classes
Tread
8.8 10.9 12.9 8.8 10.9 12.9
Size
Tightening Torque (Nm) Tightening Torque (lb. ft)
M6 10 7
M8 22 16
M 10 40 30
M 12 69 51
M 14 110 81
M 16 170 125
Tightening Torques for Cross-slotted Lens Head Screws DIN 7985 (Metric ISO-Standard Thread)
The values for tightening torques shown in the table are valid only for cross-slotted lens head screws DIN
7985 of the strength class 8.8 and with metric ISO-standard thread.
Strength Classes
Tread
8.8 10.9 12.9 8.8 10.9 12.9
Size
Tightening Torque (Nm) Tightening Torque (lb. ft)
M3 1.1 1
M4 2.9 2
M5 6 4
M6 10 7
M8 25 18
M 10 49 36
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
Figure 1
SPECIFICATIONS
Brake Supply Valve
Loading-Unloading Pressure 103 - 125 kg/cm2 (1,465 - 1,778 psi)
Low Pressure Warning
65 kg/cm2 (925 psi)
Pressure Relief Valve
160 kg/cm2 (2,276 psi)
COUNTERBALANCE
VALVE
1
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
COUNTERBALANCE VALVES0709300
MODEL SERIAL NUMBER RANGE
Solar 130W-V 0001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 180W-V 1001 and Up
Solar 210W-V 1001 and Up
General Description........................................................................................ 3
While Operating to Run Forward............................................................. 3
While Operating to Stop .......................................................................... 3
While Operating to Back ......................................................................... 3
Adjustment of Relief Valve ...................................................................... 4
Troubleshooting .............................................................................................. 5
Counterbalance Valve .................................................................................... 6
Recommended Tools .............................................................................. 6
Disassembly............................................................................................ 6
Order of Disassembly and Torque Values ............................................... 7
Reassembly ............................................................................................ 8
Figure 2
DISASSEMBLY
NOTE: Disassemble counterbalance valve in reverse order of assembly.
Figure 3
Figure 4
2. Apply Loctite #242 to plug (4) and install
into spool (2). Torque to 75.5 ±7 kg•m (548
±50 ft lb). Install plugs on other side
following steps 1 and 2.
Figure 5
3. Install small ball bearings (12) into body
(1).
Figure 6
4. Install guide (7) into body (1).
Figure 7
Figure 8
6. Apply Loctite #241 to orifice (17) and
install into body (1) (on both sides). Torque
to 70.16 ±0.2 kg•m (507 ±2 ft lb).
Figure 9
7. Apply Loctite #572 and wind seal tape
around plug (16), and install to body (1)
(both sides). Torque to 70.25 ±0.3 kg•m
(508 ±2 ft lb).
Figure 10
8. Install small ball bearings (11) and spring
(21) into body (1) (both sides).
Figure 11
Figure 12
10. Install O-ring (25) into body (1) (both
sides).
NOTE: It is recommended to replace
O-ring with new.
Figure 13
11. Install spool (2) into body (1).
Figure 14
12. Install spring (19) into body (1), then install
cover (6).
Figure 15
Figure 16
14. Install plunger (8) and spring (18), in that
order, into body (1).
Figure 17
15. Install plug (14) into body (1) (both sides)
and torque to 71.2 ±1.5 kg•m (505 ±10 ft
lb).
Figure 18
16. Install plug (33) into body (1) (both sides)
and torque to 71.9 ±2.3 kg•m (520 ±16 ft
lb).
Figure 19
Figure 20
18. Torque to 78 ±9 kg•m (564 ±65 ft lb).
Figure 21
19. Install O-rings (22) and (23) into body (1).
NOTE: It is recommended to replace
O-rings with new.
Figure 22
NOTE: Reassembled counterbalance
valve is shown.
Figure 23
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
HAAA7450
Figure 1
HAAA7460
Figure 2
Figure 3
C. When the oil pressure reaches the
set pressure of spring (C, Figure 3)
the pilot poppet (B) is opened and oil
flows to the tank through paths (4)
and (5).
Figure 4
D. During oil flow when pressure drops
in front and back of orifice (2, Figure
5) and pressure of chamber (1) d2 >
pressure of chamber (1) d1, main
poppet A will open and pressurized
oil flows to the tank.
Figure 5
Figure 6
OVERLOAD RELIEF VALVE
1. Operation of overload relief valve.
A. The pressurized oil from the cylinder
port enter into chamber (2, Figure 7)
through orifice (3) of piston (A). Main
poppet (B) is closed shut due to
d1>d2.
Figure 7
B. When the pressurized oil overcomes
the set pressure of spring (C, Figure
7) pilot poppet (D) opens and oil
flows to the tank through the
transverse hole (4) and path (5).
Figure 8
Figure 9
Figure 10
2. Operation of make-up valve.
A. The main poppet area d1 > d2
(Figure 11) and since the cylinder
port pressure is usually higher than
the tank pressure the main poppet
will be in place. When the cylinder
port pressure drops (approaches
pressure load), and cylinder port
pressure < tank pressure the main
poppet (B) opens due to the area
difference d1 and d2 and the tank
pressure and oil flows from the tank
to the cylinder port preventing Figure 11
cavitation.
Figure 12
A. Piston (A, Figure 12) and poppet (B) are in position blocking path (5 and 6). As oil flows from
chamber (1) to chamber (2), the pressure at orifice (4) is Pe. Since d1 > d2, check valve (D) is
seated completely blocking out chambers (2 and 3).
Figure 13
A. Arm Dump Operation (p1 > pc) (PaL pilot signal: "OFF")
Oil passes through path (4, Figure 13) and chamber (1) pressure becomes pressure (Pc). At
squeeze (2), poppet (D) opens and high pressure oil is supplied to rod side of the cylinder.
Figure 15
2. When plunger is operated.
A. Boom-up (Pv > Pc) (Pi pilot signal:
"OFF")
As the plunger is operated, high
pressure oil flows in through
chamber (3, Figure 16). Chamber (1)
and chamber (2) pressures are Pc
and equalized through squeeze (4).
Pv overcomes set spring pressure
and high pressure oil is supplied to
the cylinder head.
Figure 16
Figure 17
HAAA7480
Figure 18
1. If the arm plunger is operated to crowd side, the plunger moves to the right side and the center
bypass route is interrupted. The oil from pump opens check valve (C1, Figure 18) from parallel route
and flows to the cylinder head through the high pressure supply route.
HAAA7490
Figure 19
2. Oil returning from the rod side flows back to the tank through regeneration valve route (2, Figure 19)
to route (1).
3. When the pilot signal is supplied to port (XRE, Figure 20), piston (A) is moved to the left. Rod side
pressure is raised up due to spool (B) closing route (1) and check valve (C2) in plunger is opened, as
a result oil is regenerated to the head side through route (3) to route (4) of the plunger.
Figure 21
1. To operate boom cylinder downward, the plunger moves to the left and the center bypass route is
interrupted. Oil flowing from pump through the parallel route opens check valve (C1, Figure 21) and is
supplied to the cylinder rod through the high pressure supply route. The oil returned from the cylinder
head flows to the tank route however, as the return line pressure is raised up, check valve (C2) in the
plunger is opened up. The oil will be regenerated to the rod side through sleeve traverse hole route
(1) to route (2).
Figure 22
2. A large amount of fluid flow from delayed
pump response causes pressure (fp) to
overcome set spring pressure and the
poppet is opened, allowing oil to flow to the
tank operating as a relief valve.
Figure 23
Figure 24
Reference Reference
Description Description
Number Number
1 Plunger 11 Cap
2 Bolt With Hole 12 Backup Ring
3 Cover 13 O-ring
4 Plunger Cap 14 Sleeve
5 Spring 15 Backup Ring
6 Spring Guide 16 O-ring
7 Spacer 17 Check Valve
8 O-ring 18 Spring
9 O-ring 19 Spring
10 Retainer 20 Check Valve
Figure 25
Reference Reference
Description Description
Number Number
1 Adjusting Screw 10 Sleeve
2 Hexagonal Nut 11 Orifice
3 Adjusting Screw 12 Spring
4 Hexagonal Nut 13 O-ring
5 Cap 14 Pilot Sheet
6 Spring 15 Piston
7 Pilot Poppet 16 O-ring
8 O-ring 17 Backup Ring
9 Main Poppet 18 O-ring
Figure 26
Reference Reference
Description Description
Number Number
1 Hex Nut 11 Main Poppet
2 Cap 12 Piston
3 O-ring 13 O-ring
4 Sleeve 14 Pilot Sheet
5 Spring 15 Pilot Poppet
6 Spring 16 Spring
7 O-ring 17 O-ring
8 Backup Ring 18 Spring Tray
9 Backup Ring 19 Adjusting Screw
10 O-ring
Figure 27
Reference Reference
Description Description
Number Number
1 Spring 4 Backup Ring
2 Check 5 Cap
3 O-ring
Figure 28
Reference Reference
Description Description
Number Number
1 Cover 8 Spring Seat
2 Spool 9 Spring
3 Spring 10 Manifold
4 Cap 11 Poppet
5 O-ring 12 Bolt With Hole
6 Backup Ring 13 O-ring
7 O-ring 14 O-ring
Reference
Description
Number
1 Cap
2 O-ring
3 Stopper
4 Spring
5 Check
Figure 29
Reference
Description
Number
1 Cap
2 Piston
3 O-ring
4 Spool
5 Spring
6 Sleeve
Figure 30
Foot Relief Valve
Reference
Description
Number
1 Cap
2 Shim
3 Shim
4 Cap
5 Spring
6 Poppet
7 O-ring
Figure 31
Arm Priority Valve [AP Valve]
Reference
Description
Number
1 Spacer
2 Screw
3 Cap
4 O-ring
5 Spring
6 Check
7 AP Spool
8 O-ring
HAAA7670
9 Backup Ring
Figure 32
10 Retainer
11 Drill Head Bolt
Reference
Description
Number
1 Cap
2 Spacer
3 Backup Ring
4 O-ring
5 Spring
6 Nylon Chip
7 Check
Figure 33
Check Valve [Opt, Bkt, Bm-1, Bm-2, Am-1]
Reference
Description
Number
1 Cap
2 Spacer
3 Backup Ring
4 O-ring
5 Spring
6 Nylon Chip
7 Check
Figure 34
Check Valve
Reference
Description
Number
1 Cap
2 Backup Ring
3 O-ring
4 Spring
5 Nylon Chip
6 Check
Figure 35
Reference
Description
Number
1 Cap
2 Backup Ring
3 O-ring
4 Spring
5 Nylon Chip
6 Check
Figure 36
Cap
Reference
Description
Number
1 Cap
2 Backup Ring
3 O-ring
4 Nylon Chip
Figure 37
Cap
Reference
Description
Number
1 Cap
2 O-ring
3 Backup Ring
Figure 38
Reference
Description
Number
1 Cap
2 O-ring
3 Spring
4 Cb Spool
Figure 40
Reference
Description
Number
1 Poppet
2 Spring
3 O-ring
4 O-ring
5 O-ring
6 Cap
7 Piston
8 Backup Ring
9 O-ring Figure 41
10 Sleeve
11 Backup Ring
12 O-ring
13 Poppet
14 Spring
15 O-ring
16 Cap
17 Bolt With Hole
18 Cover
19 Cap
20 Spring
21 Check Figure 42
SPECIFICATIONS
Control Valve Relief Valves (Main): 320 kg/cm² (4,600 psi) - normal, travel
350 kg/cm² (5,000 psi)
Left Side Spools: (and Dozer: left 28 mm (1.1") diameter
spool diameter)
Swing: 28 mm (1.1") diameter
Boom-2: 28 mm (1.1") diameter
Arm-1: 28 mm (1.1") diameter
Right Side Spools: (and Travel: 28 mm (1.1") diameter
spool diameter)
Option: open 28 mm (1.1") diameter
Bucket: 28 mm (1.1") diameter
Boom-1: 28 mm (1.1") diameter
Arm-2: 28 mm (1.1") diameter
Overload Relief Pressure: 360 kg/cm² (5,100 psi)
A B B A
A B B A
C C C C
HAAA7510 HAAA7520
Figure 43 CONTROL VALVE TOP VIEW Figure 44 CONTROL VALVE BOTTOM VIEW
HAAA7530 HAAA7540
Figure 45 CONTROL VALVE LEFT VIEW A-A Figure 46 CONTROL VALVE RIGHT VIEW B-B
AP
HAAA7570
Figure 49 CONTROL VALVE HYDRAULIC CIRCUIT
HAAA7580
Figure 50
HAAA7590
Figure 51
14 12
HAAA7600
Figure 52
HAAA7630 HAAA7640
Figure 55 Figure 56
HAAA7940
Figure 57
GENERAL DISASSEMBLY
To disassemble control valve, remove bolts from left and right side of the control valve.
GENERAL REASSEMBLY
Stand control valve on flat surface and tighten bolts with correct torque.
15 kg•m
Socket Bolt Tightening Torque
(108 ft lb)
IMPORTANT
Be sure to use extreme care when assembling and disassembling control valve. All O-rings
should be replaced with new ones. Never reuse old O-rings.
HAAA7470
Figure 58
1. The plunger is selected and toothed into the housing; as a result it is a non serviceable part and
cannot be replaced on site.
A. If for some reason it needs to be replaced, please contact us with the following information;
Make and/or model number.
Identification color for selected teething as inscribed on the name plate.
B. Identification color is painted on the right or left edge of the machine body. It is visible from the
bottom if the paint has been removed.
IMPORTANT
When disassembling Main Plunger element tag and label each component so that all parts can
be reassembled in the proper order.
IMPORTANT
The hydraulic control valve used in the S200W-V uses 3 different plungers. Care should be taken
when disassembling and reassembling plunger assemblies.
TOOL
This holding tool is used to clamp and hold
plunger for further disassembly, without
damaging it. The holder is comprised of 2 halves
of a hexagonal rod made from soft brass, with
the appropriate size hole and outside
dimensions.
Inside Outside
Application
Diameter Diameter
28.20 mm 41.0 mm
Main Plunger
(1.1102 in) (1.6142 in)
Figure 59
100.0 mm
Length
(3.9370 in)
Figure 60
Reference
Part Description
Number
1 8 mm Hex Head Bolts
2 Plunger Cover
3 Plunger Cap Bolt
IMPORTANT
Do not force out plunger. Pull out
plunger slowly, to avoid damage.
Figure 61
3. Use the holder tool described above to
clamp plunger assembly and loosen
plunger cap bolt.
Reference
Description
Number
1 Plunger Holding Tool
2 Spring Guide
Plunger Cap Bolt
3 Tightening Torque:
6 kg•m (43 ft lb)
Figure 62
4. Remove plunger cap bolt (3, Figure 63),
upper spring guide (4), spring (5), spacer
(6) and lower spring guide (4).
IMPORTANT
Use caution when disassembling and
assembling plungers. The travel
straight plunger does not have a
spacer. In addition the spring and
plunger cap bolts are different.
Figure 63
Figure 64
BM-1: Remove cap (7, Figure 65), O-ring,
backup ring, sleeve (10), check valve
(11) and spring (12).
Figure 65
TS: Remove cap (7, Figure 66), O-ring and
backup ring.
Figure 66
Disassembly
Reference
Description Size
Number
1 Adjusting Screw 22 mm
2 Hexagonal Nut 30 mm
3 Hexagonal Nut 30 mm
4 Cap 30 mm
5 Pilot Sheet
6 Lower Sleeve Figure 67
7 Sleeve 27 mm
IMPORTANT
Further disassembly of pilot sheet
from the cap is not recommended, as
it is pressed in at the factory.
Reassembly
1. Insert piston (A) into sleeve (7). Assemble hex nut (2) onto adjust screw (1). Assemble adjust screw
(1) to sleeve (7), until piston (A) is seated.
2. Insert pilot poppet (B) into pressure adjust spring (C) and insert into sleeve (7). Assemble cap (4)
onto sleeve (7), making sure pilot poppet (B) is properly seated.
3. Insert orifice (10), spring (9) and piston (8) into lower sleeve (6).
4. Assemble lower sleeve (6) onto cap (4).
10 kg•m
Tightening Torque
(72 ft lb)
IMPORTANT
Improper relief valve pressure settings may cause severe damage to the hydraulic system.
Extreme caution should be taken when making pressure adjustments.
Figure 69
IMPORTANT
Inspect all O-ring gaskets for damage and replace as necessary. Never reuse damaged or
questionable O-rings.
IMPORTANT
The relief valve is extremely sensitive and sudden extreme changes should be avoided.
6 kg•m
Tightening torque
(43 ft lb)
6 kg•m
Tightening Torque
(43 ft lb)
IMPORTANT
When disassembling Overload Relief Valve, tag and label each component so that all parts can
be reassembled in the proper order.
IMPORTANT
Do not disassemble the pressure adjustment element. The pressure is factory set and cannot be
correctly adjusted on the vehicle.
IMPORTANT
Each Overload Relief Valve must be reinstalled into its original position.
Reference
Description
Number
1 Sleeve
2 Cap
Figure 70
2. Loosen cap (1) subassembly from sleeve
assembly and remove O-ring, spring (2)
and pilot poppet (3).
Reference
Description
Number
2 Cap
3 Spring
4 Poppet
Reference
Description
Number
1 Pilot seat
2 Outer spring
3 Inner spring
4 Piston
5 Main Poppet
Figure 72
Figure 73
IMPORTANT
When disassembling Arm Load Holding Valve, tag and label each component so that all parts
can be reassembled in the proper order.
Figure 74
IMPORTANT
When assembling cover, inspect O-rings for any damage and replace as necessary.
Figure 75
Reference
Description
Number
1 Cap
2 Spring
3 Check
4 Cap
5 Piston
6 Sleeve
7 Poppet
8 Spring Figure 76
9 Cap
Figure 77
Figure 78
IMPORTANT
Be careful not to damage the edges Figure 79
of the inner and outer surfaces of the
sleeve.
IMPORTANT
When disassembling Boom Load Holding Valve, tag and label each component so that all parts
can be reassembled in the proper order.
Figure 80
Reference Reference
Description Description
Number Number
1 Cover 5 Spring Tray
2 Spool 6 Allen Head Bolt
3 Spring 7 Spring
4 cap 8 Poppet
IMPORTANT
When assembling cover, inspect O-rings for any damage and replace as necessary.
Figure 81
3. Loosen cap (4) and remove spring (3) and
spool (2).
Figure 82
IMPORTANT
When disassembling Arm Regeneration Valve, tag and label each component so that all parts
can be reassembled in the proper order.
Reference
Description
Number
1 Cap
2 Piston
3 Spool
4 Spring
5 Sleeve
Figure 83
1. Loosen cap (1) and remove piston (2).
Figure 84
2. Remove spool (3), spring (4) and sleeve
(5) from housing.
Figure 85
IMPORTANT
When disassembling Arm Regeneration Valve, tag and label each component so that all parts
can be reassembled in the proper order.
Reference
Description
Number
1 Cap
2 Check
3 Spring
Figure 86
1. Loosen cap (1) and remove check (2) and
spring (3).
Figure 87
IMPORTANT
When disassembling foot relief valve, tag and label each component so that all parts can be
reassembled in the proper order.
Reference
Description
Number
1 Cap
2 Poppet
3 Cap
4 Shim
5 Spring
Figure 88
1. Loosen cap (1) and remove poppet (2).
Figure 89
2. Loosen cap (3) and remove shim (4) and
spring (5).
IMPORTANT
Shim is necessary for correct
pressure adjustment and must not be
left out.
Figure 90
IMPORTANT
When disassembling Center Bypass Valve, tag and label each component so that all parts can
be reassembled in the proper order.
Reference
Description
Number
1 Cap
2 Spring
3 Spool
Figure 91
1. Loosen cap (1) and remove spring (2) and
spool (3).
Figure 92
IMPORTANT
When disassembling Boom Parallel Switch Valve, tag and label each component so that all parts
can be reassembled in the proper order.
Special Tool
This holding tool is used to clamp and hold AP
Spool for further disassembly, without damaging
it. The holder is comprised of 2 halves of a
hexagonal rod made from soft brass, with the
appropriate size hole and outside dimensions.
Inside Outside
Application
Diameter Diameter
19.0 mm 32.0 mm
AP Spool
(0.7480 in) (1.2598 in)
100.0 mm Figure 93
Length
(3.9370 in)
Reference
Description
Number
1 Allen Head Bolt
2 Retainer
3 Spacer
4 Screw
5 Cap
6 Spring
7 Check
HAAA7680
1. Remove allen head bolts (1) and retainer
Figure 94
(2).
IMPORTANT
When assembling AP spool, inspect O-rings and backup rings for any damage and replace
as necessary.
HAAA7690
Figure 95
3. Using the special tool, clamp and hold the
spool in place. Remove cap (5), spring (6)
and check (7).
HAAA7700
Figure 96
IMPORTANT
When disassembling Boom Unity Check Valve, tag and label each component so that all parts
can be reassembled in the proper order.
IMPORTANT
When assembling components, inspect O-rings for any damage and replace as necessary.
Reference
Description
Number
1 Cap
2 Stopper
3 Spring
4 Check
Figure 97
1. Loosen cap (1), remove stopper (2), spring
(3) and check (4).
Figure 98
Valve
Location Description
Reference
A Main Relief Valve
B P2
C AM-2
D OPT, BKT, BM-1, BM-2,
AM-1
E TL
F SW
HAAA7650
Figure 99
HAAA7660
Figure 100
IMPORTANT
When disassembling Check Valves, tag and label each component so that all parts can be
reassembled in the proper order.
Reference
Description
Number
1 Cap
2 Spring
3 Check
Figure 101
B: Check Valve (P2)
Reference
Description
Number
1 Cap
2 Spring
3 Check
Figure 102
Reference
Description
Number
1 Cap
2 Spring
3 Check
Figure 103
D: Check Valve [OPT, BKT, BM-1, BM-2, AM-1]
IMPORTANT
Even though the valve caps look the
same, they are different, and cannot
be interchanged.
Reference
Description
Number
1 Cap
2 Spring
3 Check
Reference
Description 1
Number
1 Cap
2 Backup Ring 2
3 O-ring
HAAA7950
Figure 105
F: Check Valve [SW]
IMPORTANT
Even though the valve caps look the
same, they are different, and cannot
be interchanged.
Reference
Description
Number
1 Cap
2 Spring
3 Check
1PILOT CONTROL
VALVE (WORK LEVER /
JOYSTICK)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Theory of Operation ................................................................................ 3
Structure .......................................................................................... 3
Function ........................................................................................... 3
Parts List ................................................................................................. 4
Specifications .......................................................................................... 5
Torques ............................................................................................ 5
Performance..................................................................................... 6
Removal ......................................................................................................... 6
Disassembly ................................................................................................... 9
Cleaning and Inspection (Wear Limits and Tolerances) ............................... 13
Reassembly.................................................................................................. 14
Installation .................................................................................................... 19
Start-up Procedures ..................................................................................... 20
Structure
The remote control valve contains four push rods, spring holders, spools and return springs, which are
located in the valve casing. The valve works as a pressure reduction valve.
The housing has six ports, which include input port P, tank port T, and four secondary pressure ports.
The electric horn switch is installed in the valve handle. Gear pump pressure is used for operating control
spools.
Function
1. Neutral Mode
When the lever is in neutral mode, the spool is thrust upward by return spring, and the force of
balancing spring, which determines the secondary discharge pressure, is not transmitted to the
spool. The input port is closed and the pressure of the output port is the same as the pressure of the
tank port T.
2. Control Mode
When push rod is pushed, the balance spring begins to compress, and spring force is conveyed to
the spool. Ports P and T are then connected together and the pilot pressure is conveyed to the area.
Output pressure works on the bottom of the spool, thrusting the spool upward until it is balanced with
the power of the balance spring. The secondary pressure (output pressure), therefore, changes in
proportion to the compression force of the balance spring.
30
29
28
26
27
23 25
24 14
13 20
19
22
18
21
12
17
11
31
8
15
10
16
9
36
32
33
7
34
35 6
1 2 3 5 4
ARS2260L
Figure 1
SPECIFICATIONS
Torques
Reference
Bolt Size Tool Torque
Number
2 PT 1/8 5 mm L-Wrench 150 kg•cm (11 ft lb)
3 PF 3/8 8 mm L-Wrench 500 kg•cm (36 ft lb)
24 M14 24 mm Spanner 1,240 kg•cm (90 ft lb)
25 M14 22 mm Spanner 1,240 kg•cm (90 ft lb)
27 M14 22 mm Spanner 1,240 kg•cm (90 ft lb)
ARS2270L
Figure 2
REMOVAL
1. Park on firm and level ground.
2. Lower front attachment (bucket) to the
ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch "ON."
WARNING!
If engine must be run while Figure 3
performing maintenance, use
extreme care. Always have one
person in the cab at all times. Never
leave the cab with the engine
running.
6. Fully stroke work levers (joysticks) in all directions to relieve pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "OFF" position and remove from starter switch.
9. Hang maintenance warning tag on controls.
10. Disconnect negative (-) battery cable leading to frame from battery.
5
ARS2910L
Figure 4
14. Remove four bolts (3, Figure 5) and cover
(2), and pull remote control valve L.H. (1) 3
out.
15. Tag and disconnect hoses from remote 2
control valve L.H. (1, Figure 5). Plug and 1
cap hoses and ports to prevent
contamination from entering hydraulic
system or component.
ARS2920L
Figure 5
16. Remove four bolts and washer (2, Figure
6), and cover (2). 2
1
17. Pull cap (5, Figure 6) out and remove
screw, three bolts and washers (6) and
cover (3). 4
3
18. Remove two screws, two bolts and
washers (7 and 8, Figure 6) and cover (4).
6 7
5
8 ARS2930L
Figure 6
ARS2920L
Figure 7
Figure 8
Figure 9
2. Loosen nut (27) from hex nut (25) and
remove handle assembly (30).
Figure 10
Figure 11
4. Remove joint (23) from case (1).
Figure 12
5. Remove plate (21).
Figure 13
6. Press spring (10) and remove plug (18).
Figure 14
IMPORTANT
Mark valve disassembling position
(port).
Figure 15
8. Remove plug (3) and four plugs (2).
Figure 16
9. Remove stopper (11) from pressure
reduction valve (6, 7, 8, 9, 11).
Figure 17
10. Remove spool (6), spring seat (9), spring
(8) and shim (7).
Figure 18
Figure 19
12. Remove O-ring (19) from plug (18).
Figure 20
13. Remove seal (20) from plug (18).
Figure 21
Figure 22
2. Install shim (7), spring (8), spring seat (9),
and spool (6).
Figure 23
3. Press spring (9) and install stopper (11).
Figure 24
Figure 25
5. Install seal (20) on plug (18).
Figure 26
6. Install O-ring (19) on plug (18).
Figure 27
7. Install push rod (14) on plug (18).
Figure 28
Figure 29
9. Position stopper (12) and spring (13) on
pressure reducing valve.
Figure 30
10. Install plug (18) in case (1).
Figure 31
11. Install plate (21) and tighten joint (23).
Figure 32
Figure 33
13. Install hex nut (25) and tighten swash plate
(24).
NOTE: Tightening torque 1,240 kg•cm
(90 ft lb).
Figure 34
14. Pull cord and tube out through hole of hex
nut (25).
Figure 35
15. Align the direction of handle (30) and
tighten hex nut (25) and nut (27).
NOTE: Tightening torque 1,240 kg•cm
(90 ft lb).
Figure 36
Figure 37
17. Install boot (28).
Figure 38
ARS2920L
Figure 39
3. Install two screws, two bolts and washers
(7 and 8, Figure 40) and cover (4). 2
1
4. Install a screw, three bolts and washers (6,
Figure 40) and cover (3). Push cap (5) into
cover (3). 4
3
5. Install four bolts and washers (2, Figure
40) and cover (1).
6 7
5
8 ARS2930L
Figure 40
6. Connect hoses as tagged during removal
to remote control valve L.H. (1, Figure 41). 3
7. Position remote control valve L.H. (1,
Figure 41) on control stand and install four 2 1
bolts and washers (3), and cover (2).
ARS2920L
Figure 41
5
ARS2910L
Figure 42
START-UP PROCEDURES
1. Start engine and set throttle at "LOW
IDLE."
2. Set safety lever on "UNLOCK" position.
HAOB290L
Figure 43
3. Slowly cycle boom, arm, bucket cylinders
and swing motor about five times without a
load to vent air from pilot lines. Do this for
5 minutes.
ARO0470L
Figure 44
1STEERING VALVE
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Theory of Operation ................................................................................ 4
Parts List ................................................................................................. 6
Specifications .......................................................................................... 7
Special Tools and Materials............................................................................ 8
Special Tools ........................................................................................... 8
Disassembly ................................................................................................. 10
Reassembly.................................................................................................. 19
Figure 1
Reference Reference
Description Description
Number Number
1 Knuckle Arm 3 Steering Valve
2 Steering Cylinder
Figure 2
26 2
26
1
27
29
25
24 2
5
32
7
34
8
11
9
2
13
14
12
15
16 21
17 22
18
20
BCS0850L
Figure 3
SPECIFICATIONS
Figure 4
B. Assembly tool for O-ring and kin-ring. Code
no. SJ 150-9000-11.
Figure 5
Figure 6
D. Assembly tool for cardin shaft. Code no. 150-
9000-3.
Figure 7
E. Assembly tool for dust seal. Code no. SJ
150-9000-22.
Figure 8
Figure 9
2. Slide end cover to one side.
Figure 10
Figure 11
4. Remove cardan shaft.
Figure 12
5. Remove distributor plate.
Figure 13
Figure 14
7. Remove O-ring.
Figure 15
8. Shake out check valve ball, and suction
valve pins and balls.
Figure 16
Figure 17
10. Remove ring, bearing races and needle
bearing from sleeve and spool. Check that
outer, thin bearing race is not stuck in
housing.
Figure 18
11. Press out cross pin, using special screw
from end cover.
Figure 19
Figure 20
12. Carefully press spool out of sleeve.
Figure 21
13. Press neutral springs out of their slots in
spool.
Figure 22
Figure 23
15. Remove plugs from shock valves using a 6
mm hex socket spanner.
Figure 24
16. Remove two seal washers.
Figure 25
Figure 26
18. Shake two springs and valve balls out of
housing.
NOTE: Valve seats are bonded into
housing and cannot be
removed.
Figure 27
19. Dual Shock Valves are shown
disassembled.
Figure 28
Figure 29
21. Unscrew set screw using 8 mm hex socket
spanner.
Figure 30
22. Shake out spring and piston. (Note: valve
seat is bonded into housing and cannot be
removed).
Figure 31
Figure 32
Figure 33
2. Place two, flat, neutral position springs in
slot. Place curved springs between flat
springs and press into place.
Figure 34
3. Line up spring set.
Figure 35
Figure 36
5. Press springs together and push neutral
position springs into place in sleeve.
Figure 37
6. Line up springs and center them.
Figure 38
Figure 39
8. Fit cross pin into spool/sleeve.
Figure 40
9. Assemble bearing races and needle
bearing as shown in Figure 41 and Figure
42.
Figure 41
Figure 42
10. Turn unit until bore is horizontal. Guide
outer part of assembly tool into bore of
spool/ sleeve.
Figure 43
11. Grease O-ring and ring with oil and place
on tool.
Figure 44
Figure 45
13. Press and turn O-ring and ring into
position in housing.
Figure 46
14. Draw inner and outer parts of assembly
tool out of housing bore, leaving guide
from inner part inside.
Figure 47
Figure 48
16. Guide assembly tool to bottom of housing.
Figure 49
17. Press and turn lip seal into place in
housing.
Figure 50
Figure 51
NOTE: O-ring and ring are now in
position; spool set will push out
assembly tool guide.
Figure 52
19. Turn steering until bore is vertical. Place
check valve ball into hole shown in
illustration.
Figure 53
Figure 54
21. Place ball in two holes shown in
illustration.
Figure 55
22. Place pin in holes.
Figure 56
Figure 57
24. Grease O-ring with mineral oil (500 cst
viscosity at 20°C [68°F]).
Figure 58
25. Install distributor plate so that channel
holes match holes in housing.
Figure 59
Figure 60
27. Place cardan shaft so that it is held in
position by mounting fork.
Figure 61
28. Grease two O-rings with mineral oil (500
cst viscosity at 20°C [68°F]) and place in
grooves in rear rim. Fit gearwheel and rim
on cardan shaft.
Figure 62
Figure 63
30. Install spacer, if used.
Figure 64
31. Place end cover in position.
Figure 65
Figure 66
33. Fit six screws with washers and install.
Cross-tighten screws and roll pin to 30
N•m (22 ft lb)
Figure 67
34. Place dust seal ring in housing after
pressure relief valve and shock valves are
installed.
Figure 68
Figure 69
36. Press plastic plugs into connection ports,
by hand, DO NOT use hammer.
Figure 70
37. Install piston.
Figure 71
Figure 72
39. Screw in set screw using 8 mm hex socket
spanner and set pressure setting as
follows.
Figure 73
40. Screw plug with dust seal into housing
using 8 mm hex socket spanner. Tighten to
5 ±1 N•m (1.12 ±0.22 ft lb).
Figure 74
1DOZER CONTROL
VALVE
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
BLS0070L
Figure 1
Reference Reference
Description Description
Number Number
1 Body 13 Push Rod
2 Plug 14 Cover
3 O-ring 15 Wrench Bolt
4 Spring 16 Guide
5 Spring Seat 17 Pin
6 Spool 18 Socket Bolt
7 Spring Seat 19 Nut
8 Spring 20 Lever
9 Stopper 21 Spring Pin
10 Plug 22 Boot
11 Rod Seal 23 Bushing
12 O-ring 24 Snap Ring
2HYDRAULIC
SCHEMATIC
(SOLAR 180W-V)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Solar 180W-V with Standard Boom................................................................ 4
Solar 180W-V with Articulated Boom ............................................................. 6
Figure 1
Figure 2
Figure 3
1ELECTRICAL SYSTEM
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
ELECTRICAL SYSTEMS0802125K
MODEL SERIAL NUMBER RANGE
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 210W-V 1001 and Up
NOTE: 0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
R(I) B(B+)
1
PST TML B BR R1 R2 C ACC
OFF
PREHEAT 7
ON
R
START F
E
E
ARS0010L
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
7 8
N S D PP C
P B
B E
11
9
A
ACC C
B
R2
BR
5 R1
3
6
2
4
B A
BR
E
R(I) P(R)
E
ARS0020L
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING
Reference Reference
Description Description
Number Number
1 Battery 7 Starter Controller
2 Battery Relay 8 Starter Relay
3 Fusible Link 9 Starter
4 Circuit Breaker 10 Alternator
5 Starter Switch 11 Diode
6 Fuse Box
7 8
N S D PP C
P B B
B E
11
9
A
ACC C
B
R2
BR
5 R1
3
6
2
4
B A
BR
E
11
R(I) B( P(R)
ARS0030L
Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Description Description
Number Number
1 Battery 7 Starter Controller
2 Battery Relay 8 Starter Relay
3 Fusible Link 9 Starter
4 Circuit Breaker 10 Alternator
5 Starter Switch 11 Diode
6 Fuse Box
6
9 4
CN7-9 2
ACC C B A
PREHEAT CN7-6
L4 B 5
R2 BR
R1 BR E
10
C B
10 - + - +
7
1
H
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Preheat Relay
3 Fusible Link 8 Air Heater
4 Circuit Breaker 9 Indicator Lamp
5 Starter Switch 10 Diode
8
9
0.5G
6
3
ACC C
B
R2
5
BR
4 2
R1 B A
BR
E
7
- + - +
1
ARS0050L
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Fusible Link 8 Engine Stop Relay
4 Circuit Breaker 9 Engine Stop Motor
5 Starter Switch
5
6
0.5G
4
2
ACC C
B
R2
3
A BR
R1 - + - +
P1
P2 1
A B
Reference Reference
Description Description
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor
5
6
0.5G
4
2
ACC C
B
R2
3
A BR
R1 - + - +
P1
P2 1
A B
Reference Reference
Description Description
Number Number
1 Battery 4 Fuse Box
2 Fusible Link 5 Engine Stop Relay
3 Starter Switch 6 Engine Stop Motor
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
R(I) B(B+) P(R) 12V 150AH 12V 150AH
STARTER SWITCH CONNECTION
1
PST TML B BR R1 R2 C ACC
OFF SG
PREHEAT 7
ON
R
START F
E
ARS0080L
Figure 8 CHARGING CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
5
+ 7
-
2
4 R
3 9
1
10
6
02/05 [MO] 11:30A
ENG SPEED
2059 RPM
11
POWER DISPLAY
AUTO
ESC
14
12
13
15
16 21
22 UN
IT
-104
6
OL 25
43
TR
V
24
N
CO
.
NO
RT .
PA LT
VO T NO
LO OO
EW
DA
23 19
20
17 24 18
BLS0100L
Figure 9
The monitoring system displays the various data and warning signals onto the instrument panel by
processing the information gathered from the e-EPOS controller. It displays information selected by the
operator.
6 7 8 9 10 11
< CONNECTOR AND TERMINAL NO.>
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
(CN7)
1 2
5 1
10
12 13
02/05 [MO] 11:30A 4
ENG SPEED
3
2059 RPM
POWER DISPLAY
AUTO
ESC
14 15 16 17
18 19 20 21
BLS0110L
Figure 10
When the engine starter switch is turned to the "I" (ON) position, all bands of gauges, indicator lights of
switches/buttons and indicator/warning lights will turn "ON" and the alarm buzzer will sound for about 2
seconds.
During this time, a moving excavator will appear on the digital clock and graphic information area (3 and 4,
Figure 10).
23
26 27
TURN SIGNAL (R)
L2
30
TURN SIGNAL (L)
L1
31
BEAM
L3
32
35
TRAVEL
L4
33 34 36
PARKING (T / M)
L5
BRAKE OIL PRESS
L6 28
37
25 24
1 HOUR
29
2 21
3
L1 L2 L3 L4 L5 L6
4
19
ILLUMINATION 18
16
EL
5
6
WARNING LAMP
L1 : BATTERY CHARGE 20
L2 : ENG OIL PRESS
L3 : WATER TEMP
17
L4 : PREHEAT 7
L5 : WORK LAMP 22
L6 : OVER LOAD
8
LOD DISPLAY PANEL
WATER TEMPERATURE
FUEL LEVEL
9
GRAPHIC DISPLAY 11
10 12
13
14
POWE R DISPLA Y
AUTO
ES C
15
BCS0620L
Figure 11
Sensor Specification
Function Display Input
Input Specification
Terminal
RED 41°C (106°F) → 1,372
H ohms
GREEN
61°C (142°F) → 855 ohms
Engine WHITE CN4-5
107°C 102°C (216°F)→ 160 ohms
Coolant
Temperature 105°C
CN4-6 105°C (221°F) → 147
C ohms
61°C 107°C (225°F) → 128
41°C ARS0780L ohms
GREEN
F
RED 1/10 LCD Blinking → over
CN4-7
Fuel Level 5K ohms
CN4-8
E FULL → under 525 ohms
1/10 ARS0790L
ARO0160L
BATTERY CN7-9
Voltmeter 0 - 32 VDC
CN7-19
28.5 VOLT
ARO0180L
313 BAR
ARO0200L
Lights up when
preheat process is
Preheat CN7 - 6 completed.
(Approximately 19
seconds from start)
HAOA639L
Lights up when
Work Light CN2 - 7 work light switch is
turned "ON."
1 B
E
8 19
L
TURN SIGNAL (R) L2
2 11 87a
30
87
TURN SIGNAL (L)
L1
1 12
85 86
BEAM L3
3 13
9
7 3 4
TRAVEL
L4
4 1 2 14 15 5
5 8 13 +
PARKING (T/M) L5
6 4 9 S
BRAKE OIL PRESS
L6 17
12 5
|
8
7 6
20
11
10 R(1)
10
2 7
7
8
9
|
+
6
18
16
BCS0630L
Figure 12
Reference
Reference Description
Description Number
Number
11 Right Directional Indicator
1 Steering Console Light Switch
2 Instrument Panel 12 Left Directional Indicator
3 Starter Switch Light Switch
4 Forward Run Select Switch 13 High Beam Switch
5 Backward Run Select 14 Travel Select Switch
Switch 15 Parking Brake Switch
6 Fuse Box 16 Lamp Switch
7 Control Unit 17 Transmission Pressure
8 Blinker Unit Sensor
9 Warning Buzzer 18 Brake Oil Pressure Switch
10 Alternator 19 Pilot Relay
20 Zener Diode
Input
Description Symbol Operation Remarks
Terminal
Turns on and
flashes when the
Directional left turn signal
Indicator CN11-1 switch is selected
(Left) and the hazard
switch is turned
BCS0760L "ON"
Turns on and
flashes when the
Directional right turn signal
Indicator CN11-2 switch is selected
(Right) and the hazard
switch is turned
BCS0761L "ON"
BCS0770L
BCS0790L
NOTE: Refer to the clock setting method of operation manual for time setting.
POWER DISPLAY
AUTO
ESC
1 2 3 4
ARS0801L
Figure 13
1. Up Arrow Button ( , 1 on Figure 13): Move the cursor to up, left and previous screen.
2. Down Arrow Button ( , 2 on Figure 13): Move the cursor to down, right and next screen.
3. Enter Button ( , 3 on Figure 13): Move the menu to selected mode. When setting the menu, this
button is used to function as the select button.
4. Escape Button (ESC, 4 on Figure 13): Move a screen to previous menu or main menu.
1 2 3 4 5 6 7 8
Figure 18
Entering/Accessing Menus
1 2 3 4
ARO0250L
Figure 19
When normal mode screen is displayed, if the enter button ( , 3) and escape button (ESC, 4) are
pressed simultaneously for more than 3 seconds, normal mode screen (Figure 20) will be changed to
special menu screen (Figure 21).
Normal Mode Screen
NOTE: Normal mode screen can
display many kinds of display 02/05 [MO] 11:30A
mode by selecting, for example,
engine revolution (rpm), battery
voltage (V), front pump ENG SPEED
pressure (BAR), rear pump
1950 RPM
pressure (BAR) and so on by
selecting.
ARO0160L
Figure 20
Exiting/Escaping Menus
1. If escape button (ESC, 4 on Figure 19) is pressed for more than 1 second, the special menu screen
will be returned to the normal mode screen.
2. If this special menu is "ON" without any activity, for more than 20 seconds, it will turn to the normal
mode screen.
3. After the turning starter switch to the "OFF" position, turn it back to the "ON" position, and the normal
mode screen displayed once again.
Sub-menu Selections
Boom Press
T/M Press
ARS0860L
Figure 24
EPPR CURRENT
598 mA
ARS0870L
Figure 25
2. Dial Voltage
DIAL VOLTAGE
2089 mV
ARS0880L
Figure 26
3. TPS Voltage
Output voltage of throttle position sensor.
TPS VOLTAGE
2095 mV
ARS0890L
Figure 27
ARS0870L
Figure 31
• Display Specification
Sensor Input
BAR Graph Display Input Terminal Remarks
Specification
Below 30°C
1/6 BAR Lit Over 1,510 Ω
(Below 86°F)
31 - 50°C
1/6 - 2/6 BAR Lit 745 - 1,510 Ω
(87 - 122°F)
51 - 75°C
1/6 - 3/6 BAR Lit CN 3 - 4 332 - 745 Ω
(123 - 167°F)
CN 3 - 5 76 - 85°C
1/6 - 4/6 BAR Lit 244 - 332 Ω
(168 - 185°F)
86 - 95°C
1/6 - 5/6 BAR Lit 181 - 244 Ω
(186 - 203°F)
Over 96°C
1/6 - 6/6 BAR Lit Under 181 Ω
(Over 204°F)
Failure Information
1. Entering Sub-menus: When a cursor is
located in "Failure Info" of special menu
screen press enter button ( , 3 on
Figure 19) and "Failure Info" screen is SPECIAL MENU
displayed.
2. Exiting Sub-menus: If escape button (ESC,
Machine Info 1
4 on Figure 19) is pressed for more than 1
second, this information screen will be ailure Info 2
returned to previous screen.
Operating Info 3
ARS0930L
Figure 33
* Real-time Failure:
Current status of failure is
displayed.
* Failure Log:
FA I L U R E I N F O
Memorized record of past
failure is displayed. Realtime Fail
* Delete Fail Log:
This mode is used to delete all
Failure Log
of the memorized record of past
failure.
Delete Fail Log
ARS0950L
Figure 34
Code State
0x Short Circuit
1x Open circuit
2x Output error
3x Output error
8x Communication
Reset
Code Contents Cause Operation
Procedure
Communication error
Automatic reset
between e-EPOS
82 Communication Error
controller and instrument
* Note when problem is
corrected
panel
01 EPPR v/v short Short Circuit After correcting
problem, turn
02 Press Up s/v short Short Circuit Cut off output
start switch
current (0 mA)
from "OFF" to
03 Swing pri. s/v short Short Circuit
"ON."
NOTE:
1. If a communication error is generated during operation, the power mode, work mode and auto
idle mode will be maintained at the last mode setting before the failure took place until the unit is
shut down.
2. When start switch is turned to the "ON" position during a period of a communication error, the
e-EPOS controller will operate in the following modes.
• Power mode: Standard mode
OPERATING INFO
Operating Hrs
Reset Hrs
ARS1000L
Figure 39
C. Operation Hour Screen
D. Exiting Sub-menus: If escape button
(ESC, 4 on Figure 19) is pressed for
more than 1 second, this information
OPERATING HRS
screen will be returned to previous
screen. 1. Power : 0345 Hr
2. Trenching : 0190 Hr
3. Auto Idle : 0227 Hr
ARS1330L
Figure 40
ARS1001L
Figure 42
B. Reset screen of operation hour
C. Exiting Sub-menus: If escape button
(ESC, 4 on Figure 19) is pressed for
more than 1 second, this information
RESET HRS
screen will be returned to previous
screen. All Operating Hours
NOTE: When "YES" ( , 3 on Figure will be DELETE.
19) button is pressed, operation
hours will reset. At this time, YES: NO: ESC
resetting signal will be
displayed and the screen will ARS1020L
move to previous menu after Figure 43
resetting.
NOTE: When "NO" (ESC, 4) button is
pressed, the screen will recover
to previous menu without
resetting.
7
11
12
3
(Wheel)
P
13
4 5
N
9
19
10
(Pump control signal)
(Potentiometer signal)
(Throttle signal)
15 17
Hi
(Throttle command)
Lo 1
(Coolant water temp. signal)
(Mode select signal)
(Auto idle signal)
(Machine information)
Sensors
18
30L
Figure 44
6 6
3
(Wheel type)
P
4 5
N
10
1 (Pump control signal)
g
(Potentiometer signal)
(Drive signal)
ARS1040L
Figure 45
Reference Reference
Description Description
Number Number
Instrument Panel (Power 9 Engine Speed Sensor
1
Mode Selection Switch) 10 E.P.P.R. Valve
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial
4 Main Hydraulic Pump 17 e-EPOS Controller
5 Control Pump Work / Travel Selection
20
6 Control Valve Switch (Wheel Type)
The power mode switch permits the selection of the appropriate engine power depending on the working
condition. One of the two, Power Mode or Standard Mode, setting can be selected. When the engine start
switch is turned "ON," the power mode is automatically defaulted to standard mode. The desired mode can
be selected by pressing the select button on the instrument panel. When the power mode is selected, the
indicator lamp will turn "ON" to display the selected mode.
OPERATION
Power Mode
This mode should be selected for high speed
work. In this mode the engine output is most
efficiently utilized due to the discharged oil
volume being controlled based on the equivalent
horsepower curve at various loaded pressures.
The e-EPOS controller compares the target
engine speed with the actual engine speed and
controls the signal to the E.P.P.R. (Electric
Proportional Pressure Reducing) valve which in
turn varies the pump output quantity.
If the load increases, the engine speed will fall
below the rated speed. When this occurs, the ARO0260L
controller senses this decrease and immediately Figure 46
reduces the pump discharge volume to maintain
the engine speed at the rated level.
On the other hand, if the load is decreased the
controller increases the discharge volume of the
pump to maintain the engine speed at the rated
level.
By repeating these control operations, the engine speed is maintained at the rated speed so that maximum
power can be generated.
In Power Mode, the controller receives engine speed signals from the engine speed sensor and the throttle
position sensor (sensor is built into engine control motor) and converts it to an operating signal current and
is then transferred to the pump’s E.P.P.R valve. At this time the E.P.P.R. valve converts the electric signal to
the corresponding control pressure and sends it to the two pumps, adjusting the pump discharge volume to
the desired level.
B D
HDA6020L
Figure 47
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) D Pump Discharge Pressure
B Engine Speed (rpm) (kg/cm2)
C Pump Discharge Volume
(liter/min)
A C
B D
HDA6022L
Figure 48
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) D Pump Discharge Pressure
B Engine Speed (rpm) (kg/cm2)
C Pump Discharge Volume
(liter/min)
1
2
3
5V
4V 3.75 0.15V
3V
2V 1.49 0.05V
1.0 0.1V
1V
HAAA4421
Figure 49
Reference Reference
Description Description
Number Number
1 Ground (-) 3 5V INput (+)
2 Output
BCS0640L
Figure 50
12
3
(Wheel)
1 4
(Potentiometer signal)
(Drive signal)
17
15 (Engine throttle control signal)
Hi
(Throttle signal) Lo
16
(Trenching mode switch signal)
ARS1070L
Figure 51
Reference Reference
Description Description
Number Number
Instrument Panel (Trenching 6 Control Valve
1
Mode Select Switch) 12 Solenoid Valve
2 Engine Control Motor 15 Engine Throttle Control
3 Engine 16 Engine Control Dial
4 Main Hydraulic Pump 17 e-EPOS Controller
5 Control Pump
Depending on the working condition, one of two work modes, "DIGGING" or "TRENCHING" can be
selected from the instrument panel.
When the engine start switch is turned "ON," the work mode is automatically defaulted to digging mode.
Depending on the trenching mode selected, the control valve solenoid adjusts the assignment of hydraulic
oil flow to each device on the equipment.
Digging Mode
This mode is used for general digging work, loading work and ground leveling work requiring quick stops.
The current to the solenoid valve for swing priority is shut off.
Trenching Mode
This mode is used for heavy duty ditch digging
work or for loading work requiring big swing
angles. The voltage is assigned to the swing
priority control valve activating the swing control
valve restricting the flow of oil to the boom and
the arm.
ARO0270L
Figure 52
10A 3 20A
2
5
9
10
4 1
CN1-1
19
CN1-2
20
CN1-8
CN1-9
1
2
CN3-9
CN3-10
TxD CN1-14 6
RxD TxD RS-422
CN3-11 RxD
5 CN3-12
TxD RxD
3 CN3-8
CN7
CN4
TERMINAL NO
6 5 3 2 1 5 4 2 1
10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 12 11 10 12 11 10 7 6 14 13
(CN4) (CN3)
(CN7)
8 7 6 5 4 3 10 9 7 6 5 4 3 2 1
17 16 14 13 12 11 9 21 18 17 16 15 13 12 11
(CN2) (CN1)
ARS1080L
Figure 53
Reference Reference
Description Description
Number Number
1 Battery 4 e-EPOS Controller
2 Battery Relay 5 Instrument Panel
3 Fuse 6 Solenoid Valve (Swing Priority)
(Feedback Signal)
15 3
16
(Command Signal) (Drive Signal)
10A
BATT. RELAY
9
10 AUTO IDLE COMMAND
5 4
Figure 54
Reference Reference
Description Description
Number Number
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial
When the engine control dial is moved the output voltage changes according to the dial position. This
signal is input to the engine throttle controller. The engine throttle controller then compares the input
voltage from the engine speed dial with the feedback signal from the throttle position sensor built into the
engine control motor and drives the motor to the position set by the control dial. When the command signal
and the potentiometer feed back signals are the same the engine controller shuts off the current to the
control motor. The engine control motor cable is a solid type and is connected to the engine fuel injection
control lever. The engine speed is controlled by the movement of the fuel injection lever which is directly
linked with the rotation of the control motor.
1
2 3
CIRCUIT DIAGRAM
P4
(GREEN)
(RETRACT) (GRAY) P1
ACCEL
(PINK) P2
P4(G) P5(Y) + Vs
-
(5.0V)
(BLUE) P3 Vp
DECEL
(EXTEND)
ARS1100L
Figure 55
Reference
Description
Number
1 Motor Assembly
2 Cable
3 Spring Assembly
The engine control motor uses a D.C. motor with a built in potentiometer to sense the position of the control
cable. If an abnormal load (worn or kinked control cable) is sensed in the control motor, the engine
controller cuts off the electric current flowing to the engine control motor to protect the system. In such a
case, the engine control motor will not operate even though the engine control dial is moved.
The starter switch should be turned off and the cause of abnormal load should be repaired and the starter
switch can be turned on again. The engine control dial can once again be used to control the engine
speed.
IMPORTANT
When the engine control motor has been replaced or repaired refer to Adjusting the Engine
Control Device for correct adjustment of the engine control system. The engine will not perform
to its maximum efficiency if it is not adjusted properly.
CCW ( 10 ) ( 10 ) CW
MECHANICAL MECHANICAL
STOP STOP
(V)
5
4.0V
4
3 2.5V
2
2 1.0V
1
0 SETUP
1ST 2nd 7th 12th 13th
CCW CW
STOP STOP
HDA6033L
Figure 56
The engine control dial has a built in potentiometer. When the control knob is moved the output voltage
(through terminals 2 and 3) will vary from the 5 V supplied from the throttle controller as shown in the
graph.
BCS0650L
Figure 57
Reference Reference
Description Description
Number Number
1 Battery 8 Engine Control Motor
2 Battery Relay 9 Engine Control Dial
3 Fuse 10 Pressure Switch (Py Port)
4 e-EPOS Controller 11 Pressure Switch (Px Port)
5 Instrument Panel 12 E.P.P.R Valve
7 Engine Throttle Controller 13 Throttle Position Sensor
(Feedback Signal)
16 15 2 3
M
7 1
17
ARS1120L
Figure 58
Reference Reference
Description Description
Number Number
1 Instrument Panel 15 Engine Throttle Controller
2 Engine Control Motor 16 Engine Control Dial
3 Engine 17 e-EPOS Controller
7 Pressure Switch
If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed
is automatically lowered. Once the controls are operated and work is being started the machine will be
restored to the previous settings. As a result, noise and fuel consumption will be reduced. This function can
be selected or cancelled through the Auto Idle Select Switch on the instrument panel.
The initial setting at start-up is with this switch in the select position. Approximately 4 seconds after this
function is selected, if all work levers are in the neutral position, the e-EPOS controller sends an automatic
reduction signal to the throttle controller. When the engine throttle controller receives this signal, it is
compared with the signal set by the engine control dial. The lower of the two signals is selected and the
engine control motor is adjusted to this engine speed.
The neutral status of the machine is detected by the two pressure switches in the control valve. When the
work levers are in the neutral position, the switch is in the off position.
BCS0660L
Figure 59
Reference Reference
Description Description
Number Number
1 Battery 7 Engine Throttle Controller
2 Battery Relay 8 Engine Control Motor
3 Fuse 9 Engine Control Dial
4 e-EPOS Controller 10 Pressure Switch (Py port)
5 Instrument Panel 11 Pressure Switch (Px port)
NOTE: The auto idle function will be only operated when the pressure switch and the control
conditions are corresponded with each other.
1
21
(Pump control signal)
10
(Potentiometer signal)
(Drive signal)
15 17
Figure 60
Reference Reference
Description Description
Number Number
1 Instrument Panel 10 E.P.P.R. Valve
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 17 e-EPOS Controller
4 Main Pump 21 Warning Buzzer
5 Control Pump
When the engine coolant temperature increases to over 107°C (225°F), the sensor mounted in the coolant
line will send a signal to the instrument panel. A overheat signal is also sent to the e-EPOS controller and
the overheat warning buzzer will sound. The e-EPOS controller will send a signal to the engine throttle
controller and the engine speed is adjusted to standard mode. The engine throttle controller will signal the
engine control motor to decrease the engine speed.
When the coolant is overheated, the warning buzzer will sound, standard mode is selected and low engine
speed will be selected.
When the coolant temperature falls below 95°C (203°F), normal operation will resume.
BCS0670L
Figure 61
Reference Reference
Description Description
Number Number
3 Engine 11 Solenoid Valve
4 Main Pump 17 e-EPOS Controller
5 Control Pump 18 Travel Select Switch
6 Control Valve Power Boost Switch
19
7 Pressure Switch (Top of Right Work Lever)
The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation
ability. When the switch button on top of the right work lever is pressed during work, the e-EPOS controller
will activate the power boost solenoid valve and increase the relief valve pressure from 330 - 350 kg/cm2
(4,700 - 5,000 psi). The excavation ability is increased by approximately 6%.
The excavation ability is increased by approximately 6%.
BCS0680L
Figure 62
BCS0690L
Figure 63
Reference Reference
Description Description
Number Number
2 Engine Control Motor 15 e-EPOS Controller
3 Engine 16 Engine Speed Control Dial
4 Main Pump 17 Forward Run Solenoid Valve
5 Control Pump 18 Relay
6 Control Valve 19 Cruise Switch
13 Cruise Solenoid Valve 20 Brake Pedal
14 Travel Motor
Cruise control is used for the purpose of reducing operator’s fatigue during long travel distances.
I II
Switch
engine speed control dial is adjusted to desired R
CRUISE OPERATION
BCS0700L
Figure 66
Reference Reference
Description Description
Number Number
1 Battery 7 Cruise Relay (1)
2 Battery Relay 8 Forward/Reverse Lever Switch
3 Fuse 9 Brake Light Switch
4 Pilot Relay 10 Pressure Switch
5 Forward Run Relay 11 Forward Run Solenoid Valve
6 Cruise Relay (2) 12 Cruise Solenoid Valve
If the cruise switch is turned on during the forward run, the "15/1 (+)" and "49" terminals of the travel speed
control switch are connected. At this time the current flows from the battery (1) → battery relay (2) → fuse
box (3) → "15/1" (+) and "49" terminals of the travel speed control switch (8) → "86" and "85" terminals of
cruise relay 1(7) → pressure switch (10) → ground. The other side, the current flows from the fuse box (3)
→ "30" and "87a" terminals of pilot relay (4) → "30" and "87" terminals of forward run relay (5) → "30" and
"87" of cruise relay 1(7) → cruise solenoid valve (12) and the machine runs as a cruise state. Also the
cruise relay 1 (7) is activated by the current flows from the "87a" and "30" terminals of cruise relay 2 (6) →
diode (13) and it makes self - activated circuit.
F J
C
H
D
E G
BCS0590L
Figure 68
HGA5016I
Figure 69
Figure 70
Table 1
Model "A" rpm "B" rpm "C" rpm
S140W-V 1,900 ±50 1,250 ±50 1,750 ±50
S160W-V 1,900 ±50 1,250 ±50 1,750 ±50
S180W-V 2,050 ±50 1,400 ±50 1,950 ±50
S210W-V 2,150 ±50 1,400 ±50 2,050 ±50
POWER
POWER
BCS0740L
Figure 72
Reference
Description
Number
1 VR1 (Automatic Deceleration Adjusting Variable Resister)
2 VR2 (Standard Mode Adjusting Variable Resister)
3 Name Plate
4 VR4 (Power Mode Adjusting Variable Resister)
MULTI-TESTER
DCV
TPS
HGA5019I
Figure 73
BGS0050L
Figure 74
1150 (LOW RPM) ENGINE SPEED (RPM) 2050 (WORK MODE RPM) 2250 (TRAVEL MODE RPM)
BGS0060L
Figure 75
BGS0070L
Figure 76
1 2
5
4 3
ARS1190L
Figure 77
Reference Reference
Description Description
Number Number
1 Upper Digit Power Monitor (Stays On
2 Lower Digit 4 While Power Is In Normal
Range,)
Engine Speed Monitor LED
3 (Flash Interval Increases With 5 Communication Monitor LED
Engine Speed.) 6 (Flash when normal condition)
1. Power Monitor
This LED is turned off when the input voltage to the e-EPOS controller is below 18.5 ±1 V or above
32.5 ±1 V. Stays on while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine speed. The flashing interval is proportional to the
engine speed.
3. Communication Monitor
These LED lamps flash when normal state of communication between main controller and instrument
panel.
Display Readout
Mode Selection Operation Status
Upper Digit Lower Digit
Normal Operation
Power Mode
Power Mode
HAOH340L
Power Mode
Normal Operation
Standard Mode
Standard Mode
HAOH350L
Normal Operation
Digging
Digging Mode
HAOH370L
Work Mode
Normal Operation
Trenching
Trenching Mode
HAOH380L
Display
No. Fault Area Cause Action Reset Procedure
Readout
Pump
Cut Off After correcting
Discharge
Output problem, turn
1 Volume Control Short Circuit
Current starter switch from
Valve (E.P.P.R.
HAOH400L (0 mA) "OFF" to "ON."
Valve)
Arm
Automatic reset
Regeneration
10 Open Circuit when problem is
Control
corrected.
Solenoid Valve HAOH490L
Output Voltage:
over 4.6 ±0.2 V Automatic reset
Engine Speed
12 when problem is
Control Dial Abnormal: under corrected.
0.4 ±0.2 V HAOH510L
Output Voltage:
Engine Control over 4.6 ±0.2 V Automatic reset
13 Motor when problem is
(Potentiometer) Abnormal: under corrected.
0.4 ±0.2 V HAOH520L
Automatic reset
CN1 - 12 and CN1 when problem is
Mode Select
16 - 13 Terminals At corrected.
Signal Input
High Level (12 V)
HAOH550L
∆ O X
Brightly Lit ON OFF
NOTE: 1. Control Motor Voltage is Measured at throttle controller 4 (+) and 5 (-) terminals.
2. Yellow LED indicates power status (ON, OFF).
3. To protect the control motor from overloads, the control motor automatically cuts off
supply voltage to the motor when there is a heavy load on the motor and the
possibility of motor damage or burn out exists.
4. After the malfunction is corrected, turn the starter switch from "OFF" to the "ON"
position and normal operation will resume.
Figure 78
Reference
Description
Number
1 Red LED
2 Yellow LED
3 Green LED
4
3
BCS0820L
Figure 79
Reference Reference
Description Description
Number Number
1 Fuse Box 4 Wiper Motor
2 Combination Switch (Left) 5 Window Washer
3 Washer Timer
WIPER OPERATION
4 1
5
ARS1260L
Figure 80
Reference Reference
Description Description
Number Number
1 Battery 4 e-EPOS Controller
2 Battery Relay 5 OWD Select Switch
3 Fuse Box 6 Pressure Sensor
1ELECTRICAL
SCHEMATIC
(SOLAR 180W-V)
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
General Description........................................................................................ 3
Solar 180W-V ................................................................................................. 4
Figure 1
TERMINAL NO
0.5RG 0.5RG
AMP MIC 21P AMP MIC 17P AMP MIC 13P AMP MIC 9P AMP 070 18P AMP 070 12P 0.5WR
0.5WR
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
0.5GW 0.5GW
21 20 19 18 17 16 15 14 13 12 11 17 16 15 14 13 12 11 10 9 13 12 11 10 9 8 7 9 8 7 6 5 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6 0.5BrW 0.5BrW
0.5BrB 0.5BrB
(CN1) (CN2) (CN5) (CN11) (CN4) (CN3)
0.85YB PARKING BRAKE
(2549-9098 )
CONSOLE ASS'Y T/M & PILOT VALVE
+(2190-2036D16)
(303-00010 ) 0.5RG 0.85YB
(2549-9098 ) 0.85YB 7 0
TURN SIGNAL (R) 2 0.5GR 0.5GR (C3) DIODE 20 +(2190-2584D17)
L2 1 I
7 0 DIODE 27
PARKING 0.85B 5 0.85YB 10
TURN SIGNAL (L) 1 0.5GL 0.5GL BRAKE
L1 0.5B
0.85Y 1 I
BEAM 3 0.5R 0.5R 0.5B 10 9 0.5WR
L3 (C5) DIODE 21
9 0.85B
0.85R 7 3 0.5BrW 0.5BrW RAM LOCK 0.85B 0.85BrB 3 1
RAM LOCK SW DIODE 26
0.85YG 4 3 0.85Y 0.85Y 1 0
TRAVEL 4 0.5GL 0.5GL 1 2 0.5BrB
L4 1 7
(C8) DIODE 8 2
8 13 0.5R 0.5B
PARKING(T/M) 5 0.5RG 0.5RG 0.85R HI-LO RELAY
L5 + PILOT 0.85B PILOT CUT OFF SW (2544-9033) TRAVEL SW
9 T/M LOW PRESS. CUT OFF 87a
BRAKE OIL PRESS 6 0.85YL 0.5YL 4 0.5YG 0.85YG (549-00046 ) (549-00026 )
L6 SIG. SENSOR 30 0.85LY
CONTROL UNIT 87 COBO AF1
(547-00001)
0.5GW
0.5BrB
0.5WR
0.85W
0.5GR
12 5 0.5BL 0.85BL
0.5GL
0.5WR (543-00077) HI-LO
0.5R
8 0.5LR -
0.85B 85 86 0.5G
7 0.85R 6 DIODE 28 0.5BL (C4) DIODE 10
0.5B
10 0.5RW 87a
CN11 AMP MIC 9P 11 0.5YG 0.85B
0.5WB 87
AMP MIC 13P CN5 FORWARD 0.85BY
HOUR METER
(C10) REVERSE RELAY 85
(2528-9043) DIODE 22 (2544-9033 ) 0.5B
0.85LY
1 0.5WR 87a
0.85YL 0.85B BRAKE OIL PRESS SW 0.5RW 3
(2549-9093) HOUR 2 0.5B 0.85B 30
65bar 0.85RY 87
REVERSE 0.85RY FORWARD RELAY
85 86 0.5WB (2544-9033 )
(C11) DIODE 23
6-LAMP ASS'Y (OPTION) 0.5B
CRUISE RELAY(2)
0.85B (2544-9033 )
0.85YB 87a
CRUISE
(FRONT) (2534-1127 )x2
CABIN LAMP RELAY 1
(2544-9033 )
CABIN LAMP ASS'Y (OPT) 30 0.5B
87
87a (C12) DIODE 24
0.85RG 0.85BY
30 2RL 2RL 87a 86 0.5G
LCD GAUGE PANEL 0.85B 87 85
(FR) 2RG RELIEF 0.85B 30
(539-00048C) CN4 87
85 86 0.5WR PRESS UP 0.85RG
0.85RG 0.5B 0.5B
CABIN LAMP SWITCH (C15) 0.5P 85 86 0.5BrY
7 7 0.5LR (FL) 0.85B DIODE 11
(REAR) (2549-9109 ) 0.85GrW
8 8 0.5WB +(2190-2584D14)
0.85RG 0.85RG 87a 0.85WG
9 9 0.5R 30 0 DOZER STAB CRUISE RELAY(1)
(FMR) 0.85B (RH) (2544-9033 )
10 10 0.5R 0.85B 1.25RG 87 0.5WR 6 I 2 0.5RL (C6)
0.5GW
DIODE
0.5BrB
0.5RW
0.5GR
0.5YG
0.5GL
0.5BL
0.5R
0.85RG 0.85RG 85 86 3 25
0.5RG II
(OPT)
L1 (FML) 0.85B (LH) 0.85B 0.85B 1.25RL
19 12 0.5B 0.5B 10 9 0.5WR
L2 20 13 CABIN LAMP CABIN LAMP 0.5B 2RY
0.5B 2RY BLINKER
0.85G
(534-00077 )x4 (534-00077 )x2 CABIN LAMP RELAY 2
1.25RL
1.25RL 2RL 2RL/0.5RL (2525-101
L3 (2544-9033 )
0.85RG
L4 0.85R 9 10 11 12 13 14
WORKING LAMP RELAY OUT TRIGGER SW
0.5WB 0.5WR WORKING LAMP (2544-9033 ) (2549-9098 )
L5 87a 30A 20A 15A 15A 15A 15A
(534-00044 )x2 +(2190-2584D18)
- 30 2RY
L6 PILOT BUZZER 87 0 7 17 18
0.85RG 2RG 0.85RG 5
(2516-1116 ) FUSE BOX 2
0.85B 0.5RG 86 85 I 1 0.85WG (2510-1010 )
+
0.5RW 0.5WR 9 10 0.5B 15 16
0.85RG
17 17 0.5RW 0.5B
0.85B 10A 10A 10A 10A 10A 10A 10A 10A
6 6 0.5BW 7 0 0.85GrW
ILLUMINATION 5 0.5RY 1 2 3 4 5 6 7 8
11 11 0.5WR 0.5RG 1 I 0.85RY
0.85WR
0.85WL
0.85GR
0.85BrR
0.85RB
0.85R
0.85LB
0.5B 10 9 0.5WR 0.5P
OVER LOAD WARNING (OPT) 0.85R
OVER LOAD WORKING LAMP SWITCH 1.25RL
WARNING SWITCH (2549-9098 )
(2549-9098 ) 0.5WR +(2190-2036D5) 0.85GR
WARNING LAMP
+(2190-2036D25) 0.85R 0.85RB
L1 : CHARGE
L2 : ENG OIL PRESS 7 0 0.5RG 0.85BrR
5 0.5BrY
L3 : WATER TEMP 0.5B 1 I 0.5RW 0.5RW
L4 : PREHEAT 10 9 0.5WR 0.5BW 0.5BW
L5 : WORK LAMP 0.5B
CN2-1 0.5RW 0.5RW
L6 : OVER LOAD
0.85R CN2-7 CN4-14 0.5YG 0.85WR
+ EPOS-V
LCD DISPLAY PANEL PRESSURE SENSOR 0.85BrW CN1-3 CN4-15 0.5BL 0.5LB
SIG CONTROLLER
WATER TEMPERATURE (OWD)
AMP MIC 21P
- 0.85W CN1-2
(2547-9045 )
CN1-8 0.85B SWING PRIORITY
SOL-VALVE ASS'Y SIDE T/S
+ 0.85R CN1-9 0.85B 0.85RL SIDE T/S
D E C A B A B C E D
PRESSURE SENSOR(B) LAMP (LH) LAMP (RH)
0.85GY 0.85GL
0.85WL
CN4-3
0.85WR
0.85RW
0.85RW
(REAR PUMP) SIG DIODE 12 (2534-9069 ) (2534-9069 )
0.85R
0.85R
0.85B
CN4
POWER
AUTO
DISPLAY
ESC
0.85GR
0.85RB
0.85GL
0.5GR
0.85B 0.85B
0.85R
CN1-10 0.85Or
0.5P
0.85GR
1 1 PUMP
(turn sig)
0.5Y 0.5Y CN3-9
(turn sig)
(clearanc)
TxD (clearanc)
0.85GL
RxD PROPORTIONAL
2 2 0.5YB 0.5YB CN3-10 0.85WR
(high)
(high)
(low)
TxD V/V
(low)
RxD CN1-19 0.85OrB
4 4 0.5YL 0.5YL CN3-11 RS-422 0.5GR 0.5GR 0.85GR
TxD RxD
5 5 0.5YW 0.5YW CN3-12 0.5P 0.85GL 0.85GL 0.85GL
CN10 TxD RxD
3 3 SHIELD WIRE SHIELD WIRE CN3-8 0.85GR 0.85WL
AMP 040 20P
0.85GrL CN4-16 (1) 0.85RW
ENG SPEED SENSOR 0.85GR 0.85GW
0.85GrR CN4-17 0.85R 0.85R 0.85R
(2547-1015)
(2) 0.85WR 0.85WR 0.5WR
QUICK CLAMP PARTS W/TEMP SENSOR
0.85YL CN4-5 0.85GR 0.85GW 0.85GW 0.85GW
QUICK CLAMP SW (2547-9038B) 0.85BL CN4-6 0.85RY 0.85RY
STOP LAMP SWITCH
(turn sig)
(549-00024) (549-00010) x2
(clearanc)
(clearanc)
(back up)
(back up)
+(2190-2584D19) 0.85WR
(turn sig)
0.85GW
0.85GW
(stop)
(stop)
(stop)
(stop)
0.85GR
0.85WR
0.85RY
0.85RY
0.85GL
0.85WL
0.85GW
0.85GW
AMP 070 12P
Px
0.85RB
-
DIODE 19
LAMP SW (6) OIL TEMP SENSOR 19bar (2549-9112 ) 21W 21W 10W 12W 12W 5W 12W 12W 10W 21W 21W
(2547-9038B) 0.85LgW CN3-5 BACK BUZZER
0.7bar
DIODE 4
(516-00011 ) REAR COMBI LAMP (LH) LICENCE LAMP REAR COMBI LAMP (RH)
SOL-VALVE CN2-11 0.85BY ENG OIL PRESS SWITCH 0.85B (2534-1159C ) (2534-1139A ) (2534-1158C )
CHECK CONN (66.27441-7005) 0.5G 0.5G
0.5GL CN3-1 HORN 1
A TxD 0.85LB 0.85LB
AMP MIC 17P
CONTROLLER (OPTION)
(543-00074) 10 0.5WG CN1-7 1.0bar 3 0.5LY
A/I (2549-1135D2) M L 0.85LW 5
M CN1-17 0.85RY HORN RELAY
17 0.5LG CN2-14 0.85BG 0.85B 6 0.85B
O/H L.F (2544-9033 ) E 0.85B
P5 0.85Y 5 CN1-18 PILOT FILTER SWITCH 0.85B -
14 0.5YL
W/M (471-00075)
RETRACT P3 0.85L 8 1
(+) (+) HORN 2
P2 0.85Or 7 2 0.5G CN4-10 (516-00006 ) WIPER TIMER
CN2-3 0.5BrL 0.5BrL 0.5LB 0.85BR
6 3 CN4-11 (2537-9008 )
P1 0.85Gr (-) (-) 0.5GB
0.85RB 0.85BrR 0.85BrR WINDOW WASHER
9 12
AMP MIC 17P (2554-9005A)
ENG CONTROL CN2 0.5GR 1 BREAKER/ 2-WAY OPTION PARTS - +
MOTOR CW LOW 0.5G 3 1 0.5LB 0.85B P
(523-00006 ) 0.85B 0.5G 2
0.85BrY 0.85BrY (HORN) (L)
0.5GB 3 1 1 1
0.85BrW 0.85BrW 0.85BrW 0.85BrY 4 2 0.85BrR
HIGH 2 2 2
ENG CONTROL DIAL BREAKER 2-WAY 0.85BrR (OPT VALVE) (R)
0.85B
DIODE 7
(2552-1004 ) 3 3 3
0.85B 0.85B JOYSTICK LEVER SWITCH COMPRESSOR
0.85Or CN1-20 4 4 4
(420-000 ) (2208-6013B )
0.85Gr CN1-21 BREAKER 0.85B (ON JOYSTICK L.H)
TPS(E/G THROTTLE LEVER) SOLENOID VALVE DIODE 9A MAGNET
DIODE 9 DIODE 9B CLUTCH 0.85LW
(2552-9005 ) 0.85BrW 0.85BrW 3 1 0.85BrR
LOW CW 1 0.85WR CN4-9
+(5V) PEDAL BREAKER 1 (BREAKER) (L) HIGH PRESS
DIODE 6
2 0.85LY CN4-12
SIG BREAKER 2 0.5BrL 4 2 0.5LB CUT OFF SW
3 0.85WB CN4-13 GND PRESS SW 0.85BrR
HIGH 3 (POWER MAXIMIZING) (R) RECEIV
BREAKER 0.85B (2204-60
0.85RB 4 JOYSTICK LEVER SWITCH 0.85B 0.85B
SOLENOID VALVE DIODE 9 (420-000 )
(ON JOYSTICK R.H)
Figure 2
0.85WG
1.25WR
15/1(+) CAR STEREO SWITCH 0.85L 5
0.5BrW
0.85BR
0.5GW
0.85Or
0.5WR
85 86 0.5G 0.5G CN9-4 (2549-9098 ) 11 0.5B
0.5B LO 87a
87a +(2190-2036D23 ) 30
30 HI 0.85L
0.85LY 0 7 87 0.85LW 4
87 0.5YB CN9-2
F 0.5BR 5 0.85B
I 1 0.5W 86 85 0.5B
REVERSE RELAY 85 86 0.5YB CN9-3
(2544-9033 ) 0.5B R
0.85LY
5RY
0.5WB
FORWARD RELAY
0.5YB
DIODE 5
85 86 0.5BrY I 1
0.85BR
0.5WR 9 10 0.5B 0.85B E B P
0.85B 0.85BY
1.25WG
CRUISE RELAY(1)
0.5LR
(2544-9033 )
0.85RG 0.85LR 0.85LR
0.85G 0.85G 0.85L 0.85L A
1.25RL ENG STOP RELAY 0.85LY P1 3W 3Y STARTER
B (2544-9033 ) (65.26201-7044)
2RY BLINKER UNIT 0.85WR/0.5RW 87a 0.85LR B C
E 0.85B 24V 4.5KW
0.85G
0.85WG
0.85BR
0.85RL
0.85RG
0.85LR
1.25RL
0.85Or
2RL/0.5RL (2525-1011 ) 30
0.85G
87 0.85LW P2 A
10A 10A 10A 10A 10A 10A 10A 10A 8W 30A 20A 15A 15A 15A 15A 0.85BY
60B
1 2 3 4 5 6 7 8 9 10 11 12 13 14
0.5LR STARTER SWITCH
CIGAR LIGHTER 60R
0.85WR
(2549-1152 )
0.85WL
0.85GR
0.85BrR
0.85RB
0.85R
0.85LB
C
1.25W
(545-00001 )
0.85L
2LR
2RG
(2544-9024 )
0.85BG
0.5BW 0.5BW
(2527-9004 )
0.5RW 0.5RW B
8W 8W 8W A
0.85WR
0.5LB 0.5LB 0.85BrW
1.25BrW BR
0.85WY 0.85WY 0.85G 0.85BW
ARM POSITION
0.85GY 87a 0.85WR E
FRONT COMBI. LAMP(R)(OPT)
DIODE 3
0.85WR 60R
COBO AA1 86 0.5GrW
0.5B 85 0.85BG
0.5WR
75/70W 3W 12W 3 II
1
2 10 0.5B 1.25RW
0.5WR 9 0.5RW
0.85LY 3
60B 60R
SIDE T/S HEAD LAMP RELAY 0.85BG
A B C E D 4 LAMP SWITCH
LAMP (RH) 5 0.5WG (2544-9033 )
0.85WR
0.85RW
TML N 87 0.5BG
0.85WR 0.85GY CN7-8
(high)
(low)
49a BATTERY
0.85GR 0.85GR CN7-4 0.5RG 86 85 0.5LB
R (2506-1104 )x2
0.85GL 0.85GL CN7-1
L AVX 8W
0.85WL 0.85WY CN7-5
56 AVX 1.25WG
0.85RW 0.85RW CN7-6 COMBINATION
56b SWITCH (LH) 0.85BG AVX 2RW
0.85R 0.85R CN7-7
56a COBO N5 15R
CN7-9 0.85BG I(L) BAT R
0.5WR 0.85RG (549-00022)
30 15B 15B 0.5 uF
0.85L CN8-6 C B
15
- - B+
0.85L CN8-9
15/1
200A
(turn sig)
0.85BR CN8-8
53c I(L)
(clearanc)
(back up)
(stop)
0.85GR
0.85WR
0.85RY
0.85GW
16 0.5YW 5 ACTUATOR
2 0.5LB CUT OFF SW CUT OFF SW
0.5RB 9 4 0.5YG 1
RECEIVER DRIER
(2204-6039A ) 1 0.5B 0.85B 6
0.85B 0.85B
SWITCH 1.25B 26
CN6 HRS 26P THERMISTOR CN5 AMP MIC 13P + 250 4P
R.H)
SOLAR 180W-V
BLS1770L
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
B
C
A
D E
K J I H G
HBOK092L
Figure 1
DANGER!
Daewoo warns any user, that the removal of
the counterweight from the machine, front
attachment or any other part, may affect
X
the stability of the machine. This could
cause unexpected movement, resulting in
death or serious injuries. Daewoo is not
liable for any misuse.
Never remove the counterweight or front
attachment unless the upper structure is X
in-line with the lower structure.
Never rotate the upper structure once the
counterweight or front attachment has
been removed.
HAAD4060
Figure 2
IMPORTANT
Always break down the front attachment by removing outermost sections first - the bucket
before the arm, the arm before the boom. Reinstallation of the attachment should begin with the
boom and end with the bucket.
Refer to the appropriate Bucket section for its removal and installation procedure before going onto the
initial step of the front attachment removal or installation procedure.
WARNING!
This procedure is only intended for routine removal or replacement of the attachment, while
working under normal, safe operating conditions. In the event of a major structural collapse of
some part of the attachment, an accident or complete loss of attachment hydraulic function, DO
NOT proceed with attachment disassembly unless you are completely sure of what you are
doing. Please call your local Daewoo distributor or Daewoo After Sales Service for assistance.
DO NOT allow personnel to stand underneath a weakened or only partially supported
attachment section. Keep clear of hydraulic lines that may have fluid escaping at high pressure -
it can cause severe or even fatal injuries.
Complete the bucket end removal procedure by pulling out the two bucket linkage pins and the bucket
cylinder mounting pin, on the arm. Use an assist crane or hoist to lift the cylinder and relieve weight on
mounting pins.
WARNING!
Secure the swing lock and tag and lock out controls in the operator’s cab to keep anyone from
moving or inadvertently starting the engine. Restrict access to the work site while sections of
the attachment are in the air, or while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must exceed the weight of the heaviest
section of the attachment, the boom (approximately 2,000 kg [4,400 lb], not including the weight
of accessories or fixtures).
Before beginning the disassembly of attachment mounting pins, disconnect the arm cylinder hydraulic
hose couplings and put a clean plug in the end of each one. Use any and all reasonable precautions
necessary to avoid introducing dirt or other contaminants into the hydraulic system. Wipe down coupling
points before disconnecting hydraulic lines and use evaporative-type solvent spray cleaner. Tag and mark
hoses for reassembly, if necessary.
Place a sling under the arm cylinder (the cylinder used to extend and retract the attachment arm, pinned to
the top of the boom). Lift the sling so that the weight load on the rod end of the arm cylinder (pinned to the
ears on the inner end of the arm) is released. Prepare blocking under the arm that will securely support the
weight of the arm and arm cylinder.
CAUTION!
To make sure that the polished surfaces of cylinder rod ends will not suffer accidental damage
during disassembly or removal procedures, wrap exposed rod surfaces (especially those of
boom cylinders) with a protective covering material. Immediately following disassembly and
removal, cylinder rods should always be fully retracted. This eases handling problems and also
avoids possible damage.
Remove retainers on the end of the mounting pin for the arm cylinder rod end. Use the assist crane to
relieve the weight load and withdraw the pin. Lower the arm down to the blocking support for any continued
disassembly procedures.
WARNING!
Traveling the excavator, swinging the turntable or movement over bumps or sloping, uneven
surfaces could all produce loss of control and possible accidents or injuries, if the turntable
deck has been unbalanced by removal of weight from one end only.
To maintain stability, the counterweight should be removed whenever the front attachment is taken off the
machine.
WARNING!
Before assembling the front attachment, make sure that the individual boom, arm and bucket
sections are all compatible and can be used safely for work intended. Refer to the General
Safety Pages, Lift Ratings, Working Range Diagrams and Weights of Materials sections in the
Operation and Maintenance Manual. Consult your dealer or Daewoo After Sales Service for more
information if you have any questions or require more information.
Begin with the arm securely supported on blocking in front of the excavator. Pre-grease the mounting pin
for the rod end of the arm cylinder and push it through the ears on the end of the arm. Attach a sling
around that mounting pin and lift the arm with an assist crane until it is in position for the boom-arm pin
connection to be made.
Relieve hydraulic pressure from all points of the system before any hydraulic lines are opened, then
carefully assemble hydraulic connections to the arm cylinder.
Remove the sling from around the rod end arm cylinder pin, withdraw the pin and lift the body of the arm
cylinder to re-pin the mounting connection.
1BUCKET
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual
or those contained within this section.
Always use tools and equipment that is in good working order.
Use lifting and hoisting equipment capable of safely handling load.
Remember, that ultimately safety is your own personal responsibility.
BUCKET S0904000
MODEL SERIAL NUMBER RANGE
Solar 015 0001 and Up
Solar 015 PLUS 1001 and Up
Solar 55 0001 and Up
Solar 55-V Plus 1001 and Up
Solar 75-V 1001 and Up
Solar 130LC-V 0001 and Up
Solar 130W-V 0001 and Up
Solar 140W-V 1001 and Up
Solar 160W-V 1001 and Up
Solar 170LC-V 1001 and Up
Solar 170W-V 1001 and Up
Solar 180W-V 1001 and Up
Solar 200W-V 0001 and Up
Solar 210W-V 1001 and Up
Solar 220LC-V 0001 and Up
Solar 225NLC-V 1001 and Up
Solar 250LC-V 1001 and Up
Solar 255LC-V 1001 and Up
Solar 290LC-V 0001 and Up
Solar 330LC-V 1001 and Up
Solar 400LC-V 1001 and Up
Solar 450LC-V 1001 and Up
Copyright 2002 Daewoo
November 2002
Bucket S0904000
Page 1
TABLE OF CONTENTS
S0904000 Bucket
Page 2
BUCKET TOOTH INSPECTION AND REPLACEMENT
There are several different types of attachment methods for replaceable bucket teeth. Some of the most
common types are shown in the following drawings.
Bucket teeth are usually replaced in sets but it may sometimes be necessary to replace individual teeth.
TYPE 1
Look for the following indications of wear or damage:
• Lock pins protrude unevenly on one side.
• Lock pins have been worn down so far that they no longer make full contact through the length
of the pin hole.
• Lock washers or pins show obvious damage or weakness.
• Wear points on the working surfaces of tooth points - pits, cracks, chips or craters - are larger
than 8 - 10 mm (1/3" - 1/2") across.
HAOC680L
Figure 1
Bucket S0904000
Page 3
TYPE 2
WARNING!
Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and
eye protection when changing bucket teeth.
Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground.
Shut the engine off and lock out the hydraulic controls before working on the bucket.
NOTE: These instructions are only for Daewoo OEM buckets. If you are using other
manufacturers buckets, refer to their specific instructions.
Figure 3
S0904000 Bucket
Page 4
4. Slide the new tooth into position and insert
shims. Shim tooth until gap is less than "X"
[0.5 mm (0.020 in)]. See Figure 5.
5. Secure tooth and shim into position with
seat, plain washers, lock washers and
bolts.
Figure 5
TYPE 3
WARNING!
Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and
eye protection when changing bucket teeth.
Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground.
Place wooden blocks under front of bucket. Shut the engine off and lock out the hydraulic
controls before working on the bucket.
Inspect locking pin assembly and replace it if the following conditions exist;
1. The locking pin is too short when both surfaces are aligned.
2. The rubber has been torn and bosses of the steel balls are liable to slip off.
3. Pressing steel ball causes the boss to go inside.
X 1/3T
X X
T
4 3
HAOE380L
Figure 6
Bucket S0904000
Page 5
HAOC680L
Figure 7
S0904000 Bucket
Page 6
BUCKET O-RING REPLACEMENT
TYPE 1
WARNING!
Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye
protection when changing pins.
HAOH640I
Figure 9
2. Roll the old O-ring (1, Figure 10) onto the
boss (2) around the bucket pin (3).
1 4
Remove the bucket pin and move the arm 2
or bucket link (4) out of the way.
HAOC710L
Figure 10
3. Remove the old O-ring and temporarily
install the new O-ring (1, Figure 11) onto 4
the bucket boss (2). Make sure that the O- 1
2
ring groove on both the bucket link (4) and
boss have been cleaned.
4. Realign the arm or link with the bucket pin
hole and insert the bucket pin (3, Figure
10).
HAOC701L
Figure 11
Bucket S0904000
Page 7
5. Roll the new O-ring (1, Figure 12) into the
O-ring groove.
1
HAOC720L
Figure 12
TYPE 2
WARNING!
Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye
protection when changing pins.
HAOE360L
Figure 13
2. Roll the old O-ring (1, Figure 10) onto the
bushing (2) around the bucket pin (3).
1 4
Remove the bucket pin and move the arm 2
or bucket link (4) out of the way.
HAOC710L
Figure 14
S0904000 Bucket
Page 8
3. Remove the old O-ring and temporarily
install the new O-ring (1, Figure 11) onto
the bucket bushing (2). Make sure that the 1 3
2
O-ring groove on both the bucket link (3)
and bushing have been cleaned.
4. Realign the arm or link with the bucket pin
hole and insert the bucket pin (3, Figure
10).
HAOC700L
Figure 15
5. Roll the new O-ring (1, Figure 12) into the
O-ring groove.
1
HAOC720L
Figure 16
Bucket S0904000
Page 9
BUCKET SHIMMING PROCEDURES
NEW BUCKET INSTALLATION
1. If a new bucket is being installed on the excavator, measure the inside dimension between the bucket
ears and the outside dimension across the arm mounting boss.
2. Subtract the clearance on both sides from the difference of the two and shim accordingly, prior to
assembly.
WARNING!
To check end play (side-to-side) clearance at bucket attachment point, the bucket must be free
to move but at all other times lower it to the ground or use support blocks to immobilize this
assembly. Shut off engine and tag and lock out controls to prevent movement during this
procedure.
TYPE 1
S0904000 Bucket
Page 10
TYPE 2
Bucket S0904000
Page 11
BUCKET ATTACHMENT, REMOVAL AND REVERSAL
DETACHING THE BUCKET
Park the excavator away from obstructions on clear, flat, level ground. Lower the bucket carefully to pre-
assembled blocking on the ground. Brace the bucket so that there is no load weight on the pin connecting
the bucket and arm. Disassemble the fasteners on the end of the bucket pin and pull out the pin.
If the pin sticks and resists normal withdrawal, there may be a load on it. Raise and lower the arm slightly
until the unstressed pin position is located.
CAUTION!
Use care pulling out the pin to avoid damaging the dust seals on either end of the arm.
When the pin has been withdrawn, move the operating joystick slightly to take weight off the remaining link
pin. Disassemble the link pin end retainers and pull out the pin.
Lift the arm away from the bucket so that the bucket can be carried away or another end attachment can be
put on the excavator.
Figure 19
S0904000 Bucket
Page 12
When the link pin has been installed, withdraw
the temporary support rod from the bucket pin
holes, lower and raise the arm and boom and
install the bucket pin.
WARNING!
When making linkage alignments, never
insert fingers into pin holes. The
attachment or bucket could shift position
and cause a severe injury. Match holes by
visually lining them up. Use the sharp
tipped, soft point of a pencil or a similar
tool to check for high spots or
irregularities.
Figure 20
WARNING!
Bucket curl and dump levers must be
used in opposite directions, after the
bucket has been reversed.
Bucket S0904000
Page 13
S0904000 Bucket
Page 14
1PUBLICATION REQUEST FOR
PROPOSED REVISION
In Daewoo’s continuing effort to provide the best customer satisfaction, we invite you to help us improve the
manuals that you work with on a daily basis. This form is provided to give you a means of feedback to the
publication department.
MACHINE MODEL:
SERIAL NUMBER:
MANUAL NUMBER:
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PROPOSED DESCRIPTION OF CORRECTION AND/OR SUGGESTION:
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illustrations. If digital photos are available, e-mail them to Bill.Bernhardt@dhiac.com (If possible, use 1024 x 768
resolution.).
HAS THIS BEEN DISCUSSED WITH A DAEWOO SERVICE REPRESENTATIVE: YES NO
IF YES - WHO:
(It is advised to discuss this with a Daewoo service representative to ensure that the above correction is appropriate
and valid.)
Mail to:
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Attention: Publications