Solar 030 Plus / 035

Solar 030 Plus / 035
Shop Manual
023-00046E
Serial Number 101 and Up
Serial Number 20001 and Up
Yanmar reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine’s package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
023-00046E Shop Manual

INTRODUCTION
A Message to Daewoo Excavator Operators
• This manual has been prepared to inform you about the operation and maintenance of your
new excavator. You are urged to read this manual carefully and to follow the instructions,
safety rules and relevant laws and regulations before operating the excavator.
• For Solar 030 PLUS and 035 engines, please see the Operator's and Maintenance Manual
for Isuzu Diesel Engines (SOLAR 035 : 3LD1, SOLAR 030 PLUS : 3LD1)
• Do not operate, inspect or service the excavator until you are thoroughly familiar with its'
design and controls. This manual must be left in the cab so that it is always available to
others.
• If you have any questions concerning the excavator, please supply the MODEL NO and
SERIAL (PI)NO. These numbers are stamped on a name plate, which is attached to the
front part of the main frame.
The information, specifications and illustrations included in this manual are based on the
information available at the time it was published. Daewoo reserves the right to make
improvements and changes in specifications or design without prior notice and without
incurring obligation. Please check with your authorized Daewoo dealer for information on
possible updates or revisions.
• The safety symbols and other safety information contained in this manual and on the
excavator can not cover every possible dangerous situation that may result from operation,
inspection and maintenance of this excavator. In addition, operation, inspection or
maintenance of the machine, in a manner not specified in this manual, could be dangerous
and is the sole responsibility of the operator or technician.
August. 2001
TABLE OF CONTENTS
1. SAFETY ...................................................................................................................... 1
1.1. Safety Information 1.3. Safe Operation
1.2. Safety Messages 1.4 Locatoion of Safety Labels
2. GENERAL INFORMATION ....................................................................................... 23

2.1. Excavator Major Components 2.5. Excavator Identification Number
2.2. Excavator External View and 2.6. Grease Supply Points and Locations
Operating Space 2.7. Recommended Oils and Lubricants
2.3. Specification 2.8. Inspection and Maintenance
2.4. Weight of Major Attachments and 2.9. Hydraulic Line Diagram
Components
3. WORKING ATTACHMENTS ..................................................................................... 40

3.1. Maintenance Standards 3.2. Inspection and Correction
4. ENGINE ..................................................................................................................... 47
4.1. Engine Specifications 4.3. Emgine Number Location
4.2. Engine Performance Curve 4.4. Engine RPM Standards
5. MAIN PUMP .............................................................................................................. 50

5.1. External Views 5.3. Pump Removal and Installation
5.2. Construction 5.4. Hydraulic Pump Performance Test
6. HYDRAULIC OIL FILTER ......................................................................................... 57

6.1. Piping Diagram 6.3. Maintenance Procedure
6.2. Hydraulic Oil Filter
7. CONTROL VALVE .................................................................................................... 63

7.1. Specifications 7.4. Construction of Each Valve
7.2. Construction 7.5. Cautions when Handlings
7.3. Disassembly and Reassembly
8. SWING MOTOR ........................................................................................................ 76

8.1. Specifications 8.4. Inspection and Adjustment
8.2. Construction 8.5. Maintenance Standards
8.3. Principles of Operation
9. TRAVEL MOTOR ...................................................................................................... 85

9.1. Specifications 9.4. Care
9.2. Construction 9.5. Running Speed
10. HYDRAULIC CYLINDER .......................................................................................... 98
10.1. Construction 10.3. Assembly
10.2. Disassembly
11. SWIVEL JOINT ....................................................................................................... 105

11.1. Specifications
11.2. Construction, Disassembly, and Reassembly
12. JOY STICK ............................................................................................................. 109

12.1. Specifications 12.3. Constrction
13. SOLENOID VALVE ................................................................................................. 113

13.1. Specifications 13.3. Operation
13.2. Construction 13.4. Construction
14. CRAWLERS ............................................................................................................ 118

14.1. Specifications and Construction 14.3. Maintenance Standards
15. IDLER .......................................................................................................................124

15.1. Construction 15.3. Maintenance Standards
16. TRACK TENSION ADJUSTING CYLINDER .......................................................... 127

16.1. Construction 16.3. Disassembly and Reassembly
16.2. Spring Specifications
17. TRACK ROLLER .................................................................................................... 130

18. SPROCKET ............................................................................................................ 133

18.1. Disassembly and Reassembly 18.2. Maintenance Standards
19. CRAWLER REPLACEMENT PROCEDURE .......................................................... 135

19.1. Steel Crawler Mounting Procedure
19.2. Replacement of Steel Crawlers with Rubber Crawlers
20. ELECTRICAL DEVICE ........................................................................................... 137

20.1. Electrical Circuit Diagram 20.2. Troubleshooting
• ENGINE ................................................................................................................... E-1

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

Make sure that operators are qualified and that they hold a heavy equipment operator's license, if
required.
1.2. SAFETY MESSAGES

1) Safety Hazard Levels
The following information defines each hazard level.
DANGER : This message indicates an

extreme hazard that can result
in serious personal injury or
death to you or other persons if
the machine is handled im-
properly or proper precautions
are not taken.
WARNING : This message indicates a

hazard that can result in se -
rious personal injury or death to
you or other persons, or cause
minor injury or material damage if the machine is handled improperly or proper
precautions are not taken.
CAUTION : This message identifies a hazard that is not likely to cause personal injury but may
cause property loss or result in machine damage if the machine is handled
improperly or proper precautions are not taken.
IMPORTANT : This message is used when the machine may be damaged or its service life
may be shortened if the machine is handled improperly.
–1–
1. SAFETY
1.3. SAFE OPERATION

editor's note: all numbers shift down one from here to end of section.
1) General precautions
Carefully read and understand the safety
symbols and messages placed in this manual
and on the machine.
• Keep safety labels clean at all times.
• If safety labels are damaged or lost, order
new ones from your Daewoo dealer.
• Make sure all operators are qualified , as
required by law.
• Keep correct operating techniques in
mind at all times.
• Operate the machine in a normal manner
at all times.
• Do not modify your machine without
permission from the manufacturer:
Unauthorized modifications can cause
injury, machine malfunctions or reduction
in machine service life.
• This Safety Section explains basic safety
rules. Use extreme caution whenever
operating, inspecting or servicing this
machine, whether a specific potential
hazard is mentioned or not.
2) Per-operation inspection
• Check for damage and problems that
require maintenance before operation.
Always repair defective equipment before
operation. Failure to inspect and repair
the machine may result in failure of major
components or systems such as the
hydraulic system.
3) Use handrail and steps whenever you get

on or off the machine.
• Guard against falling when getting on or
off the machine.
• Always face the machine squarely when
getting on or off the machine.
• Always use the handrail and steps and
keep three points of contact at all times.
• Be careful not to get caught on a control
by mistake.
• Never jump on or off the machine, even
when it is stationary. Never get on or off
the machine when it is in operation.
• Always wipe up any oil, water or other
slippery or foreign material from platform,
steps, and handrail immediately.
–2–
1.3. SAFE OPERATION
4) Adjust seat
If the driver's seat is not adjusted correctly,
the operator may become easily fatigued and
injury and/or damage could result.
• Be sure to adjust the driver's seat at the
beginning of each work period.
• Adjust driver's seat so that the operator
can easily reach the pedals while his
back is firmly against the lumbar support
of the seat.
5) Use seat belts(optional equipment)

Fasten seat belts securely to reduce injuries
from tip -over, etc, during operation. If a
machine starts to tip over, do not jump, stay
in seat with seat belt fastened.
• Check seat belt buckles, belts and
accessories for damage and repair before
using .
• Replace seat belts every 3 years,
regardless of their condition.
6) Stay in seat while starting, operating and

stopping machine.
• Start engine only when seated in normal
operating position in operator's seat.
• Do not short the starting circuit to start the
engine: it is dangerous and may cause
injury and/or damage to the machine.
–3–
1. SAFETY
7) Watch for safety and traffic signals when

travelling.
Check for hazards in the work area before
starting and moving.
• Use horn or other signal to warn others
when you start and move the machine.
• Use a signal man whenever the operator's
vision is obstructed in any way. Make
sure the signal man is in sight of the
operator at all times.
• Agree on signals before operation.
• Keep bystanders and obstacles out of
work area.
• Keep work areas well lighted at night.
8) Travel Precautions
Always check for hazards when traveling the
machine. Avoid traveling on slopes
• Always keep a firm grip on control levers
and keep the travel route in mind at all
times.
• Raise bucket when encountering small
obstacles.
• Keep bucket 20-30 cm (8-12") off ground
when driving on slopes. A
• Do not operate on grades in excess of
those specified by the manufacturer.
• If machine slips, lower bucket to ground
and stop immediately.
• When traveling on level ground, bring
front attachment in and raise bucket 40-
50 cm (15-20") with teeth facing up.
–4–
1.3. SAFE OPERATION
9) How to prevent machine from moving

unintentionally and how to park machine.
Jumping onto or attempting to hold on to a

moving machine, with or without an operator
on board , can result in serious injury.
To prevent the machine from moving
unintentionally, follow the procedures below:
(1)Park on level ground and lower all
attachments such as the bucket , blade,
etc.
(2) Place throttle control at lowest setting.
(3) Turn ignition switch to OFF and remove
key. Non-slip
(4) If machine must be left on an incline, line it support
up in the direction of the incline, chock
both tracks and drive the point of the
bucket into the ground.
• Park machine so that there is enough

clearance from other machines.
Non-slip
support
10) Precautions for turning and traveling in

reverse.
Turning and backing up are potentially
dangerous because of restricted visibility.
Use a signal man when turning or backing up.
• Watch for people nearby.
• Use horn or other signal to warn people
nearby.
• Keep windows, mirrors and head lights
clean and in good repair at all times.
• Slow down when visibility is poor due to
dust, heavy rain, fog, or other conditions.
–5–
1. SAFETY
11) To prevent accidents.

The operator and supervisors or owners in
charge of the equipment or worksite are
responsible for avoiding hazardous working
conditions.
• To prevent tip-over and to avoid surfaces
with poor support, check terrain in
advance and keep records of conditions.
• When operating on slopes, use a signal
man
• Keep people clear when working,
swinging or travelling.
• Be sure that overhead guards are in place
whenever there is a danger of falling
objects.
• Tamp down soft ground before operation.
• Use special care on ground that is frozen
or thawing: it is slippery.
12) Never carry people in or on the machine.

• Never transport other persons in or on
the machine.
• Riders restrict visibility, reduce conc-
entration and may cause and/or be
subject to injury.
–6–
1.3. SAFE OPERATION
13) Be careful of underground utilities

Identify locations of underground cables, gas
lines, water piping, etc. before beginning
operation.
14) Be aware of buildings, fences and other

structures while operating.
15) Tip-over
Use care to avoid tip-over when operating on
a slope or when handling a heavy load.
• Lower bucket and pull it back in toward
machine when operating on an incline.
• Line up tracks in the direction of the
incline to reduce the chance of tip- over or
serious injury.
• Slow down, when swinging the bucket, to
reduce danger of tip-over.
–7–
1. SAFETY
16) Be careful of power cables.

You can be struck by electricity even without
touching a high voltage power cable. Never
bring your machine closer than the minimum
clearances shown in the table below.
Cable Voltage (Kv) Minimum Clearance m A
6.6 3(10)
33.0 4(13)
66.0 5(17)
154.0 8(27)
275.0 10(33)
• Check with local power companies about

the voltage of power cables in your area.
• Carry out the following precautions:
(1) Erect a fence to keep the machine
and all personnel a safe distance
away from the power cable.
(2) Install insulating material around
power cable.
(3) Wear rubber or leather boots.
17) Never use machine for lifting.

• The excavator is designed for excavating
and loading only.
• The excavator is not equipped for lifting
and does not have safety devices for
lifting.
–8–
1.3. SAFE OPERATION
18) Safe Loading, Unloading and Transport

Follow all local laws that apply to your
machine. Use proper equipment and use care
when loading, unloading and transporting the
machine.
• Make sure ground is level and solid.
• Use a loading ramp.
• Never push down on pedal to shift gears
while loading or unloading.
• Never turn on the loading ramp. To adjust
direction of travel, go back to the ground
or to the platform/bed of the hauling
vehicle.
• Use extreme caution when crossing the
point where the loading ramp is attached
to the hauling vehicle: it may cause a shift
in the machine's center of gravity.
• Fasten machine securely to chassis of
hauling vehicle using wire cable.
19) Handle fuel and oil carefully (Do not allow

any source of sparks, heat or flame near
the machine)
Fuel, oil and antifreeze are highly flammable
and dangerous. Handle carefully.
(1) Keep sparks, heat and flame away from
machine when refueling. Never smoke
while refueling.
(2) Stop engine when refueling.
(3) Refuel in an open area.
• Store flammable liquids and material
in a well ventilated area.
• Keep machine clean and free of
grease and other foreign material.
• Do not store shop cloths that have
flammable substances on them:
they can catch fire easily and
"spontaneously".
–9–
1. SAFETY
20) Keep first-aid kits and fire extinguishers

available
• Make sure that you know how to operate
the fire extinguisher and are familiar with
the contents of the first aid kit.
• Know the location of emergency services
such as hospitals, ambulance and fire
stations.
21) Keep the inside and outside of the

machine clean.
• After operation, allow engine to idle and
cool down to prevent the engine compa-
rtment from overheating and possibly
causing a fire.
• To reduce fire hazard, keep the engine
compartment, radiator, batteries, hyd-
raulic lines, fuel tank and operator's seat
clean and free of any foreign material.
22) Wear proper clothing

Wear proper safety protection and clothing
such as hard hats.
• Never wear loose clothes or accessories
such as watches and jewelry, since they
can get caught on control levers or other
parts of the machine.
• Concentrate on operation:do not listen to
the radio or use headphones, which could
distract you from safe operation.
– 10 –
1.3. SAFE OPERATION
23) Protect yourself from flying or falling

objects.
Wear safety glasses when operating in dusty
or sandy conditions or when rock fragments
could be thrown up by operation. Also wear
protection when carrying out maintenance
such as removing or installing the bucket pin,
etc.
24) Be careful of exhaust gases when oper-

ating in enclosed spaces.
Engine exhaust gases are deadly. Use the
following precautions:
(1) Open doors and windows to ventilate the
work area.
(2) Use an extension on the exhaust pipe so
that exhaust gas is piped outdoors.
– 11 –
1. SAFETY
25) Safe Inspection and Safe Maintenance

• Before inspecting or serving the machine,
check with fellow workers and plan all
procedures.
• Park the machine safely (see Number 9).

• Keep surroundings clean.
• Place service warning tags on cab doors ,
on the operator's seat, and in other
places where they are easy to see.
• Wait for engine and hydraulic oil to cool
down to a safe temperature before doing
maintenance.
• When it is necessary to check or service
the machine with the engine running,
always have a second person present to
work the controls, shut down the engine,
etc.
• Never inspect or service the machine
when it is in motion.
• Avoid inspecting or carrying out service
under a machine that is jacked up.
• When inspecting or performing service
under a machine that is jacked up, keep
boom at a 90°-100°angle to the arm and
chock tracks securely.
• Care for and service the machine so that
it functions correctly at all times.
• Repair or replace worn or damaged parts
immediately.
• Remove grease, oil, loose paint and any
foreign material from the machine
immediately.
• Disconnect negative battery terminal
when making adjustments or welding.
– 12 –
1.3. SAFE OPERATION
26) Inspection and Service Cautions

Use extreme care that machine does not
move unintentionally.
• Place service warning tags on cab doors,
on the operator's seat, and in other
places where they are easy to see.
• Wait for all fluids (coolant, engine oil, gear
oil and hydraulic oil) to cool down before
checking or servicing the machine. Fluids
are hot and/or under high pressure and
will burn you or cause other serious
injury.
27) Keep machine clean at all times

• Keep machine free of oil and grease at all
times.
• Water will damage the electrical system.
Never use water or steam on the inside of
the cab, in the engine compartment or in
any location where it may reach sensors,
connectors or other electrical compo-
nents.
28) Block up machine securely

• Never inspect or service a machine that is
unstable.
(1) Lower all working attachments to the
ground.
(2) When it is necessary to work either
with the machine or with working
attachments raised, chock machine
with wooden blocks(never concrete)
or jack securely.
– 13 –
1. SAFETY
29) Never touch moving parts

Avoid becoming caught by moving parts.
30) Be careful with hydraulic oil under

pressure
(1) Whenever possible, release all hydraulic
pressure before working on hydraulic
components or lines. When pressure
testing the hydraulic system, make sure
all lines and connections are tight.
(2) Check for leaks of pressurized oil using
cardboard or wood. Carefully avoid
having pressurized oil hit your skin.
(3) If pressurized oil penetrates your skin, get
help from a doctor immediately. It must be
removed within a short time or it will
cause serious injury.
– 14 –
1.3. SAFE OPERATION
31) Fire prevention

(1) Hoses and piping
• Check hoses, lines and connections for leaks, which can cause a fire.
• Check for loose or missing plugs, and frayed or kinked hoses and piping.
(2) Electric cable and wiring

• Check daily for loose, kinked, hardened or frayed electric cables or lines. Electrical wiring with a
short can cause a fire.
32) Prevention of battery explosion

Batteries emit hydrogen gas, which can
explode. Take the following precautions when
handling batteries:
(1) Never bring sparks, lighted cigarettes ,
any source of intense heat or flame near
the battery.
(2) Never check battery by shorting positive
terminal with a metal object. Use a
voltmeter and a hydrometer.
(3) Never recharge frozen batteries. An
explosion may result. Heat frozen
batteries slowly up to 16°C (60°F) before
recharging.
33) Burn Prevention

(1) Be careful not to get burned by hot
coolant or steam.
• Coolant in the engine, radiator and
heater lines is very hot or is turned to
steam during operation. It is also
under high pressure. Stop the engine
and allow the radiator to cool down
before inspection or service.
• After radiator is cool, remove radiator
cap slowly to release pressure slowly.
– 15 –
1. SAFETY
(2) Do not allow hot engine, gear or hydraulic

oil to contact your skin.
• Allow all systems to cool down before
inspecting and servicing the machine.
• The hydraulic oil tank is under pres-
sure. Stop engine, wait for hydraulic
oil to cool, then partly loosen cap to
release internal pressure.
34) Remove coating before welding or heating

(1) Protect yourself from noxious smoke or
dust
• Welding, soldering or heating with a
welding torch directly on a coated
surface can produce noxious gases.
Perform these operations in an open
or well-ventilated area.
(2) Remove coatings from surface before
welding or heating.
• When removing coating with a
grinder, wear a welder's helmet to
prevent inhaling the dust.
• When using a welding flux, wipe the
face of the weld with soapy or clear
water.
• Do not store a welding flux near
flame. Wait 15 minutes or more after
removing coating before welding or
heating.
35) Do not heat hydraulic system and piping.

(1) Heating hydraulic components, piping or
nearby areas can produce flammable
steam or gas. Take the following precau-
tions:
1. Clean flammable liquids out of piping
using a nonflammable solvent before
welding.
2. Never weld, solder or use a welding
torch on hydraulic components or
nearby areas.
3. Piping with hydraulic oil under
pressure or rubber hoses can burst if
heated directly. Be sure to use fire-
proof shields.
– 16 –
1.3. SAFE OPERATION
36) Store attachments safely

• Store attachments such as the bucket,
blade and breaker in a secure manner.
• Do not allow access to storage area by
children or unauthorized personnel.
37) Disposal of liquid and material waste

• Drain used liquids into approved containers.
• Dispose of waste liquid according to
current regulations.
• Follow all regulations when disposing of
oil, fuel, coolant, brake fluid, solvent,
filters, batteries and other toxic material.
38) Be careful of asbestos dust

• There may be asbestos in brake pads,
bands, linings , clutch plates and gaskets.
Asbestos is injected into these parts as a
resin or by methods which do not usually
allow dust to be released
• When handling parts that may contain
asbestos, take steps to avoid inhaling
asbestos dust- it can cause serious lung
damage or death.
39) How to avoid inhaling asbestos dust.

• Do not use compressed air to clean parts.
• Do not use a grinder.
• Wear breathing apparatus (respirator) that you are sure will prevent breathing in asbestos dust.
• Use a vacuum cleaner, if possible.
• Wet down parts with oil or water.
• Do not allow other personnel into the work area.
– 17 –
1. SAFETY
1.4. LOCATION OF SAFETY LABELS
6
5
(CABIN TYPE)
AHI0041L
Always keep these labels clean. If they are lost or damaged, replace them with a new label. It is the
responsibility of the equipment owner and crew to provide essential safety information in the immediate
vicinity of hazards.
Safety labels may be available in languages other than English, or labels providing a warning for other
hazards than those that follow may be available. Contact your Daewoo distributor to find out what labels are
available.
– 18 –
1. WARNING FOR OPERATION, INSPECTION AND MAINTENANCE (2190 - 2627, 190 - 00092)
CAUTION!
• Read manual and labels before
operation and maintenance. Follow
instructions and warnings in manual
and on labels on the machine.
• Never get in under the machine while
it is being jacked up with boom and
arm.
• Sound the horn to alert the people
nearby before operating, and make
sure all persons are clear of area.
ACO1360L
• Always make sure when leaving
operator's seat to:
- Lower bucket or other working tools to the ground.
- Turn key switch OFF. Remove key from switch.
- If hydraulic components and units are ABNORMAL, consult nearst DEAWOO dealer or
authorized service shop. Do not attempt to make an overhaul.
2. WARNING TAG (2190-2549, 190 - 00098)
CAUTION!
Don’t touch when performing inspection or
maintenance.
ACO1450L
– 19 –
1. SAFETY
3. WARNING FOR BATTERY MAINTENANCE (2190 - 2533, 190 - 00100)
WARNING!
• Battery fumes can explode. Keep
sparks and flames away from
batteries.
• Always avoid storing metals like tools
or inflammable materials around or
on the batteries.
explosion or fire can be caused by
short circuiting batteries.
• Sulfuric acid in battery is poisonous.
It is strong enough to burn skin, eat
holes in clothing, and cause
blindness if splashed in eyes.
• If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to ACO1400L
help neutralize the acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
4. WARNING FOR HIGH TEMPERATURE HYDRAULIC OIL (2190 - 2529, 190 - 00097)
CAUTION!
HYDRAULIC OIL
To prevent hot oil from spurting out:
• Turn engine “OFF”.
• Allow oil to cool.
• Slowly loosen cap to relieve pressure
before removing.
ACO1410L
– 20 –
5. WARNING WHEN OPENING ENGINE HOOD (2190-2640, 190 - 00095)
CAUTION!
Before opening bonnet, stop engine.
ACO1420L
6. KEEP OFF OF THE SWING AREA ( 2190 - 2590, 190 - 00163)
CAUTION!
KEEP OFF OF SWING AREA
ACO1430L
– 21 –
1. SAFETY
7. WARNING WHEN OPENING FRONT WINDOW ( 2190 - 2526, 190 - 00093)

(IF EQUIPPED WITH CAB)
CAUTION!
When raising window, lock it in place with
lock pins on both sides.
Falling window can cause injury.
ACO1360L
– 22 –
2.1. EXCAVATOR MAJOR COMPONENTS
2. GENERAL INFORMATION
2.1 EXCAVATOR MAJOR COMPONENTS
26
ANO0010L
1. Boom 10. Engine hood 19. Travel motor

2. Boom cylinder 11. Fuel tank 20. Lower roller
3. Arm cylinder 12. Hydraulic oil tank 21. Idler
4. Arm 13. Canopy 22. Track spring
5. Bucket cylinder 14. Counterweight 23. Swing bracket
6. Bucket linkage 15. Seat 24. Swing cylinder
7. (Dump) linkage 16. Rubber crawler 25. Attachment control levers
8. Bucket 17. Blade 26. Air breather
9. Swing frame 18. Blade cylinder
- 23 -
2.2 EXCAVATOR EXTERNAL VIEWS AND OPERATING SPACE

• SOLAR 035/SOLAR 030 Plus Excavators(with canopy)
90
(80
)
(465)510
(585)650
50
(2450)2460
(280)290
350
G.L.
(1440)1650
300 (1350)1400 (3045)3610 (1150)1200
(1470)1500 (4395)5010 (1470)1525
* Dimensions in ( ) indicate the specifications for SOLAR 030 Plus.
- 24 -
2.2 EXCAVATOR EXTERNAL VIEWS AND OPERATING SPACE
• SOLAR 035/SOLAR 030 Plus Excavators(with cabin)
80
(465)510
(585)640
50
(2330)2340
350
280
G.L.
300 (1440)1650
(1470)1500
(1350)1400 (3045)3610 (1150)1200
(4395)5010 (1470)1525
- 25 -
• SOLAR 035/SOLAR 030 Plus Excavator Operating Space
(1370)1585 (1350)1400
(4200)4950
(2865)3465
(330)365
G.L.
(330)325
(1665)2300
(2590)3125
(4460)5120
- 26 -
2.3. SPECIFICATIONS
2.3. SPECIFICATIONS
Items SOLAR 030 Plus SOLAR 035

Rubber shoe 2,740kg 3,140kg
Gross weight
Roof
Steel shoe 2,780kg 3,184kg
Rubber shoe 2,860kg 3,240kg

Cabin
Steel shoe 2,900kg 3,284kg
Bucket capacity(full load in bulk) 0.07m3 0.09m3
Bucket width 445mm 525mm
Manufacturer and Model name ISUZU 3LD1 ISUZU 3LD1

Engine
Displacement 1,496 cc 1,496cc
Rated engine power 24.5ps/1950 rpm 24.5ps/1950 rpm
Max digging depth 2,590mm 3,125mm
Vertical digging depth 1,665mm 2,300mm

Operating space
Max digging height 4,200mm 4,950mm
Max dump height 2,865mm 3,465mm
Max digging radius 4,460mm 5,120mm
Min turning radius Front:1,800mm/Rear:1,350mm Front:2,060mm/Rear:1,400mm
Roof 80°(left), 50°(right) 90°(left), 50°(right)

B/Swing
angle 80°(left), 50°(right) 80°(left), 50°(right)
Cabin
Rubber shoe (Lo/Hi) 2.2/3.8 km/h 2.7/4.2 km/h
Travel
speed
Performance
Steel shoe (Lo/Hi) 2.4/3.9 km/h 2.6/3.9 km/h
Swing speed 8.3 rpm 9.4 rpm
Gradeability 30 degrees 30 degrees
Max digging force 2,110kg 2,300kg
Overall length 4,395mm 5,010mm
Overall width 1,470mm 1,525mm
Roof 2,450mm 2,460mm

Main data
Overall
height 2,330mm 2,340mm
Cabin
Width x height 1,470 x 350mm 1,525 x 340mm
Blade Amount of movement upper: 330, lower: 330 upper: 365, lower: 325
Ground clearance 280mm 290mm
- 27 -
Items SOLAR 030 Plus SOLAR 035

0.30kg/cm2 0.30kg/cm2
Ground pressure
Rubber shoe
Roof
Steel shoe 0.30kg/cm2 0.30kg/cm2
Travel system
Rubber shoe 0.31kg/cm2 0.31kg/cm2

Cabin
Steel shoe 0.31kg/cm2 0.31kg/cm2
Type of travel motor Piston motor Piston motor
Type(STD/OPT) Rubber/Double grouser Rubber/Double grouser

Shoe
Method of adjustment Grease cylinder method Grease cylinder method
Type of pump Variable piston pump Variable piston pump

Hydraulic system
P1 P2 P3 P4 P1 P2 P3 P4
Main pressure(kg/m2)
200 200 165 30 200 200 175 30
Oil flow(L/min) 33.1 17.5 9 37 25.3 9.7
Capa. of oil tank 60 L 70 L
Capa. of engine oil 6.3 L 6.3 L

Others
Capa. of fuel tank 40 L 40 L
Capa. of coolant 7L 7L
- 28 -
2.4 WEIGHTS OF MAJOR ATTACHMENTS AND COMPONENTS
2.4. WEIGHTS OF MAJOR ATTACHMENTS AND COMPONENTS
Weight Weight
Part Name Part Name
SOLAR 030 Plus SOLAR 035 SOLAR 030 Plus SOLAR 035
Boom 105 178 Idler 19 x 2 19 x 2
Arm 58 74 Idler yoke 4 4
Bucket 43 85 Track cylinder 18 x 2 18 x 2
Dump linkage 11 21 Lower roller 7x6 7x8
Bucket linkage 3.1 x 2 3.6 x 2 Sprocket 9x2 7.6 x 2
Boom joint pin 2.0 3.0 Swing motor 23 31
Arm joint pin 1.0 2.3 Travel motor 36 x 2 44 x 2
Bucket pin 1.7 2.2 Joy stick 4x2 4x2
Swing bracket 71 87 Seat box 17 17
Swing boss pin 3.4 x 2 6.7 x 2 Seat 10 10
Swing frame 328 410 Stand(left) 5.6 5.6
Hydraulic oil tank 41 43 Stand(right) 5.6 5.6
Fuel tank 24 24 Engine 139 141
Engine hood(A) 54 54 Radiator 10.2 10.2
Engine hood(B) 16 16 Storage battery 20 20
Counterweight 160 200 Battery cover 1.9 1.9
Cabin 172 172 Floor plate 5.4 5.4
Boom cylinder 24 28 Center joint 21 23
Arm cylinder 22 30 Control valve 24 24
Bucket cylinder 17 21 Solenoid valve 7 7
Swing cylinder 18 27 Oil cooler 3.0 3.0
Blade cylinder 17 20 Tank cover 1.3 1.3
Swing bearing 39 4.2 Roof 13 13
Track frame 286 333 Roof post 12 x 2 12 x 2
Blade 126 158 Roof bracket 2 2
Steel crawler 135 x 2 150 x 2 Handle(A) 4 4
Rubber crawler 118 x 2 130 x 2 Handle(B) 4 4
- 29 -
2.5. EXCAVATOR IDENTIFICATION NUMBER
Manufacture Number(impressioned)
• Location of Manufacture Number Plate
Manufacture number plate
Type
Serial No.
- 30 -
N 2.6. GREASE SUPPLY POINTS AND LOCATIONS
2.6. GREASE SUPPLY POINTS AND LOCATIONS
Arm cylinder rod

Boom/Arm joint Arm cylinder head pin
Bucket cylinder
Fuel oil
head pin
Hydraulic oil tank
Boom cylinder
rod pin
Bucket linkage pin
Bucket cylinder
Arch
rod pin
Bucket pin
Swing cylinder rod pin

Boom joint pin
Boom cylinder head pin
Blade joint pin
Dozer cylinder head pin
Swing bracket pin
Swing cylinder head pin
Swing bearing
Swing gear
Lower roller
Dozer cylinder rod pin Travel motor

Track spring
Front idler
- 31 -
2.7. RECOMMENDED OILS AND LUBRICANTS

The Warranty does not apply to any defects caused by using unauthorized, non-genuine oils and lubricants.
Lubricant Hydraulic Engine Lubricant Gear

Manufacturer Oil Oil Grease Oil
Caltex Caltex HD 32 Caltex RPM Multifac EP Multi-Purpose
Delo 300 EP90
Exxon/Esso NUTO (anti-wear) Exxon XD-3 Ronex MP #2 Spartan EP 220 or
HD 32 or 46 or straight Weight or or cold temps use Exxon GX
Teresstic (anti-rust) 15W40 Ronex MP #1 80W90
Idemitsu Kosan Daphne Kosan Aporoil Daphne Aporoil Gear
46WR motire S300 corrone #2 HE90
Mobil Mobil DTE13M Delvac 1300 Mobil FAW #2 Mobilube HD
(all-temp) or Super 15W40 or or cold temps use 80W90
DTE 24 (summer) Delvac 1 or Mobil FAW #1
straight Weight
Nippon Supper High D. S3 Lipanoc Niseki SP90 or

Seikiyu Highland straight Weight grease EP90
S26 or 32
Shell Tellus 32 Rotella T Alvania EP #2 Spirax HD
15W40 or 80W90 or
T30 (winter) or DONAX TD
T40 (summer) (transmission)
Total Total Equivis Total Total Multris Total

ZS46 EP #2 DA80W90
CAUTION: It is recommended to continuously use the same brand oils when replenishing or changing.
• To prevent freezing of the cooling system in extremely cold places, be sure to add a specified amount of
antifreeze to coolant.
• Mix ratio of antifreeze
Temperature, -5°C -10°C -15°C -20°C -25°C -30°C
Antifreeze(L) 1.6 2.0 2.4 2.9 3.3 3.7
- 32 -
2.8. INSPECTION AND MAINTENANCE

The amount of wear to each part varies according to whether or not the periodic maintenance is carried out,
machine operating skill, working conditions, quality of lubricants in service, working environment, and
amount of excavation. Operators are required to determine service intervals for their excavators based on
engine conditions, hourmeter readings, extent of wear of each component, hydraulic system condition, and
their own experience and related data.
2.8.1. How to perform inspection and maintenance
Service intervals(hours)
Check points
7 hours 50 hours 100 hours 250 hours 500 hours 1,000hours
Check & First oil Clean
Engine oil pan Change oil
Replenish change
Engine oil filter First Replace

replacement
Fuel filter Check &

Clean Replace
Intake/Exhaust valve Check & Check &

clearance Correct Adjust
Fan belt clearance Check &

Adjust
Replace
Fuel tank Drain filter
Check &
Coolant (Reservoir tank) Clean
Coolant (Radiator) Check
Check &
Air cleaner element Clean Replace
Check & Replace

Hydraulic oil tank Replenish Drain filter
First
Return filter (hydraulic oil) replacement Replace
First Replace
Hydraulic oil suction filter replacement
Check & Replace
Swivel bearing (grease) Grease
Check &
Crawler tension adjustment Adjust
Storage battery Check
Check &
Bolt looseness Correct
First Change
Reduction gear oil change
Electric devices Check
Leaks Check
- 33 -
2.8.2 Pre-operation inspection
Check points Check items Remarks

Engine oil pan Check oil level. Check before start-up.
Ensure that oil level should be above the center of

Fuel tank Check fuel level.
the level gauge.
Check to see if coolant in the reservoir tank is up

Radiator Check coolant level.
to the specified level.
Each grease point Grease See 2.6.
Check for looseness or Looseness, missing, oil

damage of each part. leaks, coolant leaks
Working levers and

Check for operation. Check to see if levers work properly.
gauges
Add if required.
Hydraulic oil tank Check oil level.
(Be careful of position of the machine.)
Check to determine if the teeth should be replaced

Bucket teeth and others Wear
with new ones.
Electric wiring Looseness or damage Check terminals for looseness, missing, or

damage.
Fan belt Check and adjust. A firm push with the thumb at a point midway
between the two pulleys should depress the belt
10~12mm.
2.8.3. Post-operation inspection
Oil leaks, coolant leaks, Remove mud, foreign matters, etc.

Each part of main body
looseness, damage, etc. sticking to the main body.
Fuel tank Replenish fuel, if required.

Coolant Check Drain the coolant if freezing is expected.
- 34 -
2.8.4. 50-hour services

Engine oil pan Change oil and filter. First change. Every 250 hours thereafter.
Intake/Exhaust Check, and adjust

First check. Every 500 hours thereafter.
valve clearance if required.
Drain out foreign Drain the coolant through the drain plug located at
Coolant matters and sediment. the bottom.
Clean strainer. Clean with light oil.
Radiator Clean the core. Dirts sticking to the core causes poor cooling efficiency
Swing bearing Check and grease. Always grease after underwater operation.
Check Green: normal, Transparent: replace, Black: recharge
Storage battery Keep clean each part, and apply grease to terminal
Clean
area.
Each grease point Add oil or grease.
After cleaning, loosen and remove the cap to bleed

Fuel filter Clean element.
air.
Clean dust cover,

Air cleaner clean or replace the Also check hose band for looseness.
element if required.
Hydraulic oil return filter Replace cartridge. First replacement. Every 500 hours thereafter.
Hydraulic oil suction filter Clean the element. First cleaning. Every 500 hours thereafter.

Engine oil pan Change oil. Every 250 hours thereafter.
Engine oil filter Change cartridge. Every 500 hours thereafter.
Drain out foreign matters Drain the coolant through the drain plug located at
Hydraulic oil tank
and condensates. the bottom.
Reduction gear
Change lubricating oil. First change. Every 1,000 hours thereafter.
lubricating oil
- 35 -

Fuel filter Replace the element. Also clean the inside of the tank.
Intake/Exhaust valve
Check clearance. First check. Every 500 hours thereafter.
clearance
Check to see that the reservoir tank indicates

Radiator Replace coolant.
a normal coolant level.
Air cleaner Replace the element.
Hydraulic oil return filter Replace cartridge. First 100 hours.
Hydraulic oil suction filter Clean the element.
2.8.8. 1,000-hour services
Tighten the drain plug at the bottom of

Engine oil pan Clean
the tank before changing oil.
Change hydraulic oil,

Clean the inside of the hydraulic oil
Hydraulic oil tank and clean the inside of
tank(every 1,000 hours).
the tank.
Swing gear and reduction

Change lubricating oil
gear oil
2.8.9. 2,000-hour services

Lower roller Replace
2.8.10. Grease points list
Check points Designated oil Grease volume Intervals

Reduction gear API Class 1,200cc Every 1,000 hours
Lower roller CD Grade 100cc Every 1,000 hours
Front idler SAE30 80cc Every 1,000 hours
- 36 -
2.8.11. Standard tightening torque

• Bolt and nut tightening torque table
Types of bolts
and nuts 4T 7T 9T
Nominal
SS41 S40C, S45C SCr4
designation
0.80~0.95 1.00~1.15 1.25~1.45

M6
(7.8~9.3) (9.8~11.3) (12.3~14.2)
1.80~2.10 2.40~2.80 3.00~3.50

M8
(17.7~20.6) (23.5~27.5) (29.4~34.3)
4.00~4.60 4.90~5.70 6.20~7.20

M10
(39.2~45.1) (48.0~55.9) (60.8~70.6)
6.40~7.40 7.90~9.20 10.50~12.00

M12
(62.8~72.6) (77.5~90.2) (103.0~117.7)
11.00~12.80 12.60~15.00 17.00~20.00

M14
(107.9~125.5) (123.6~147.1) (166.7~196.1)
17.00~19.50 20.00~23.00 26.50~31.00

M16
(166.7~191.2) (196.1~225.6) (259.9~304.0)
25.00~29.00 28.00~32.50 35.00~41.00

M18
(245.2~284.4) (274.6~318.7) (343.2~402.1)
34.00~40.00 37.50~44.00 50.00~58.00

M20
(333.4~392.2) (367.7~431.5) (490.3~568.8
• Adaptor tightening torque
Nominal designation Tightening torque(kg•m) Nominal designation Tightening torque(kg•m)

PT1/4 3.5~4.5 PT1/4
PT3/8 4.5~5.5 PT3/8 6~8
PT1/2 6.5~7.5 PT1/2
PT3/4 8.5~9.5 PT3/4 9~11
PT1 12~14
NOTE: Torque represents the force required to tighten a bolt, e.g., if you grip a 1m long spanner and turn
its handle with a force of 12kg, you will obtain 12kg• m(1m x 12kg). To produce a torque of 12kg• m
using a 25cm long spanner, a force of 48kg is necessary as follows:
0.25 x (X kg) = 12kg• m

12 x 1/0.25= 48kg
- 37 -
2.9. HYDRAULIC LINE DIAGRAM

• SOLAR 030 Plus
- 38 -
• SOLAR 035
B A B A
B A
P1 P3
- 39 -
S/RIGHT S/LEFT A/DUMP A/CWD BKT/CWD BKT/DUM BOOM/DN BOOM/UP
PA1 PB1 PA8 PB8 PB5 PA5 PA4 PB4

4 2 1 3 4 2 1 3
P2
P LEFT T P RIGHT T
MENGINE
24M.5Ps / 2,000rpm
2.9. HYDRAULIC LINE DIAGRAM
3. WORKING ATTACHMENTS
3.1. MAINTENANCE STANDARDS
3.1.1. Working attachments
ANS0020L
- 40 -
a
b
a
b
B
A
1. Swing cylinder head 2. Swing cylinder rod
a
b
b
C a
D
4. Boom joint
a
b
3. Swing post bracket

5. Boom cylinder head
a
a b a
b b
H
G
I
6. Boom cylinder rod 7. Arm cylinder head 8. Arm cylinder rod
a a a
b b b
L M N
J K
9. Boom/Arm joint 10. Bucket cylinder head 11. Bucket cylinder rod
- 41 -
a a
a
b b
b
P O Q R S
12. Bucket/Dump linkages joint 13. Arm/Bucket linkages joint 14. Arm/Bucket rod
a a a
b b b
T U V
15. Dozer joint 16. Dozer cylinder rod 17. Dozer cylinder head
- 42 -
• Clearance between pin and bush of each portion(SOLAR 030 Plus)
Portion Parts Basic Allowable Portion Parts Basic Allowable

value clearance value clearance
A Swing cylinder head pin Ø35 1.0 L Bucket cylinder head and arm Ø35 1.0
B Swing cylinder rod pin Ø35 1.0 M Bucket cylinder rod pin and dump linkage Ø35 1.0
C Swing post pin and bush Ø60 1.0 N Bucket cylinder rod pin and bucket linkage Ø35 1.0
D Boom joint pin and bush Ø40 1.0 O Bucket pin and bush Ø35 1.0
E Boom joint pin and swing post Ø40 1.0 P Bucket linkage pin and dump linkage Ø35 1.0
F Boom cylinder head pin and swing post Ø40 1.0 Q Bucket linkage pin and bush Ø35 1.0
G Boom cylinder rod pin and boom Ø40 1.0 R Bucket linkage pin and bucket linkage Ø35 1.0
H Arm cylinder head pin and boom Ø35 1.0 S Dozer joint pin and frame Ø35 1.0
I Arm cylinder head pin and arm Ø35 1.0 T Dozer joint pin and dozer Ø35 1.0
J Boom/Arm joint pin and bush Ø35 1.0 U Dozer cylinder rod pin and frame Ø35 1.0
K Boom/Arm joint pin and boom Ø35 1.0 V Dozer cylinder head pin and dozer Ø35 1.0
• Clearance of each portion(SOLAR 030 Plus)
Criteria
Portion Parts
a b Basic clearance
1 Swing cylinder head and head bracket 50 53 2.0~3.5
2 Swing cylinder rod and swing post 52 50 2.0~3.5
3 Swing post and frame 265.5 264 0.1~1.6
4 Boom and swing post 175 174 0.5~2.5
5 Boom cylinder head and swing post 52 50 1.5~2.0
6 Boom cylinder rod and boom 52 50 1.0~2.5
7 Arm cylinder head and boom 52 50 1.0~2.5
8 Arm cylinder rod and arm 52 50 1.0~2.5
9 Boom and arm 130 129 0.5~1.7
10 Bucket cylinder head and arm 52 50 1.5~2.5
11 Bucket cylinder rod and dump linkage 52.5 50 1.0~2.5
12 Dump linkage and bucket 135 134.5 0~2.0
13 Arm and bucket linkages 135 134.5 0.3~1.7
14 Arm and bucket 135 134.5 0.3~1.7
15 Dozer and frame 32 31 0.5~2.0
16 Dozer cylinder rod and frame 52 50 0.5~2.5
17 Dozer cylinder head and dozer 52 50 0.5~2.5
- 43 -
• Clearance between pin and bush of each portion(SOLAR 035 Plus)
Portion Parts Basic Allowable Portion Parts Basic Allowable

value clearance value clearance
A Swing cylinder head pin Ø35 1.0 L Bucket cylinder head and arm Ø35 1.0
B Swing cylinder rod pin Ø35 1.0 M Bucket cylinder rod pin and dump linkage Ø35 1.0
C Swing post pin and bush Ø60 1.0 N Bucket cylinder rod pin and bucket linkage Ø35 1.0
D Boom joint pin and bush Ø40 1.0 O Bucket pin and bush Ø40 1.0
E Boom joint pin and swing post Ø40 1.0 P Bucket linkage pin and dump linkage Ø40 1.0
F Boom cylinder head pin and swing post Ø40 1.0 Q Bucket linkage pin and bush Ø35 1.0
G Boom cylinder rod pin and boom Ø40 1.0 R Bucket linkage pin and bucket linkage Ø35 1.0
H Arm cylinder head pin and boom Ø35 1.0 S Dozer joint pin and frame Ø35 1.0
I Arm cylinder head pin and arm Ø35 1.0 T Dozer joint pin and dozer Ø35 1.0
J Boom/Arm joint pin and bush Ø40 1.0 U Dozer cylinder rod pin and frame Ø40 1.0
K Boom/Arm joint pin and boom Ø40 1.0 V Dozer cylinder head pin and dozer Ø40 1.0
• Clearance of each portion(SOLAR 030 Plus)
Criteria
Portion Parts
a b Basic clearance
1 Swing cylinder head and head bracket 50 53 2.0~3.5
2 Swing cylinder rod and swing post 52 50 2.0~3.5
3 Swing post and frame 265 264 0.1~1.6
4 Boom and swing post 195 194.5 0.5~2.5
5 Boom cylinder head and swing post 52 50 1.5~2.0
6 Boom cylinder rod and boom 52 50 1.0~2.5
7 Arm cylinder head and boom 52 50 1.0~2.5
8 Arm cylinder rod and arm 52 50 1.0~2.5
9 Boom and arm 150 149.5 0.5~1.7
10 Bucket cylinder head and arm 52 50 1.5~2.5
11 Bucket cylinder rod and dump linkage 52 50 1.0~2.5
12 Dump linkage and bucket 135 134.5 0~2.0
13 Arm and bucket linkages 135 134.5 0.3~1.7
E Arm and bucket 135 134.5 0.3~1.7
15 Dozer and frame 53 50 0.5~2.0
16 Dozer cylinder rod and frame 57 55 0.5~2.5
17 Dozer cylinder head and dozer 57 55 0.5~2.5
- 44 -
3.2. INSPECTION AND CORRECTION
3.2. INSPECTION AND CORRECTION

3.2.1 Spontaneous settlement measurement
• Positioning the machine
- Apply basic load to the bucket, and extend the boom cylinder up to a maximum and the dozer cylinder
up to a maximum shaft length within the maximum excavation radius as shown below.
- Stop the engine and wait 5 minutes, then measure the amount of displacement of boom cylinder, arm
cylinder, and bucket cylinder.
• Basic value
Item Basic value Allowable limit • Oil temperature: 50±50C

• Applied load
Boom cylinder 8mm 20mm
- SOLAR 030 Plus:130kg
Arm cylinder 12mm 24mm - SOLAR 035:160kg
Bucket cylinder 6mm 12mm
Dozer cylinder 4mm 8mm
Arm cylinder
Bucket cylinder
Boom joint portion Dozer cylinder
Boom cylinder
Arm/Bucket joint portion
indicates cylinders' moving direction.
- 45 -
3.2.2. Speed measurement

(Oil temperature: 50°C±5°C), Engine RPM: Maximum at un-load)
Basic value
Item Measuring conditions Unit
Solar 030 Plus Solar 035
UP SEC 2.3±0.4 2.7±0.4
Boom
DOWN SEC 2.1±0.4 2.2±0.4
Crowd SEC 3.2±0.4 3.2±0.4
Arm
Dump SEC 2.6±0.4 2.9±0.4
Crowd SEC 3.5±0.4 3.2±0.4
Bucket
Dump SEC 2.4±0.4 2.3±0.4
UP SEC 1.6±0.4 1.0±0.4
Dozer
DOWN SEC 1.9±0.4 1.2±0.4
Left SEC 5.7±0.4 7.5±0.4
Boom
swing
Right SEC 4.1±0.4 5.7±0.4
- 46 -
4.1. NE SPECIFICATION
4. ENGINE
4.1. ENGINE SPECIFICATIONS
Specifications
Item Unit
SOLAR 030 Plus / 035
Model name 3LDI

Type Vertical 3-cylinder 4-cycle
No. of cylinders-bore x stroke mm 3-83.1 x 92
Piston displacement cc 1496
Firing order 1-3-2
Overall length mm 670
Overall width mm 471
Overall height mm 744
Rated power ps/rpm 24.5/1950
Maximum torque kg•m/rpm 9.5/1700
Maximum rpm at no-load rpm 2100
Minimum rpm at no-load rpm 1250
Fuel consumption g/ps•h 195
Engine dry weight kg 141
Fuel Light oil
Injection pump Poppet type
Governor Centrifugal all speed control
Alternator 12V-35A
12V-1.2kW
- 47 -
4. ENGINE
4.2. ENGINE PERFORMANCE CURVE

• SOLAR 030 Plus / 035
93.2N·m (9.5kgf·m)/1700min-1(rpm)
10
Torque
Power N·m(kgf·m)
9
30 7
18kW(24.5PS)/1950min-1(rpm)
Power
Power kW(PS)
20
10 220
Fuel consumption
Fuel consumption gr/kw·h (gr/ps·h)
200
180
265gr/kw·h (196gr/ps·h)
160
2100±50min-1(rpm)
0 1000 1500 2000 2500 3000
RPM(min-1)
- 48 -
4. ENGINE
4.3. ENGINE NUMBER LOCATION
Engine number
Engine type
4.4. ENGINE RPM STANDARDS(FOR A NEW VEHICLE)
Engine rpm
Conditions
SOLAR 030 Plus / 035
Maximum rpm at no-load 2100±50 rpm
At P1 relief 2050±50 rpm
At P2 relief 2050±50 rpm
- 49 -
5. MAIN PUMP
5. MAIN PUMP
5.1. EXTERNAL VIEWS
• SOLAR 030 Plus
Piston pump
Pump type
P1, P2 P3 P4
Quantity of delivery cc/rev 17 9.5 4.5
Maximum pressure kg/cm2 200 165 30
- 50 -
5.1. EXTERNAL VIEWS
413
45 368
Oil feed port (PF1/2) Outlet port
P2 P2
109.5 PF1/2
101.6
101.5
Outlet port
P4 P4
PF1/2
Outlet portP1
P1
146 161 Outlet port
P3 P3
172 PF1/2
263.5 PF1/2
342
21.8
M10Thread
M10 depth 23.5
11.5
24
37
Inlet port S3
PF3/4 141
263.5
S1
SAF.T5185- 1/4
Piston pump
Pump type
P1, P2 P3 P4
Quantity of delivery cc/rev 19 13 5
Maximum pressure kg/cm2 200 175 40
- 51 -
5. MAIN PUMP
5.2. CONSTRUCTION
• SOLAR 030 Plus
1. Body S 14. Spring C 31. Needle bearing 59. O-ring

2. Body H 15. Spring T1 32. Oil seal 60. Hex. socket set screw
3. Shaft 16. Spring T2 33. Sliding shaft 61. Hex. nut
4. Cylinder barrel 17. Sleeve 34 & 35 & 36. Snap ring 62. Seal washer
5. Valve plate 18. Spring holder 37 & 38 & 39 & 41. O-ring 65. Gear pump
6. Piston 19. Spring guide 44 & 45. Hex. socket bolt 66. Coupling
7. Shoe 20. Rod P 47. Parallel pin 67. Collar
8. Shoe holder 21. Rod G 48. Conical small screw 68. Hex. bolt
9. Barrel holder 23. Control piston 49 & 50. Hex. socket plug 69. O-ring
10. Swash plate 24. Retainer 51. Plug 70. Washer
11. Neddle 25.Thrust bush 52. Spring washer 71 & 72. O-ring
12. Seal holder 28 & 29. Choke 55 & 56. Spring pin
13. Packing 30. Ball bearing 58. Bolt ass’y
- 52 -
5.2. CONSTRUCTION
• SOLAR 035
1, 23
6 14 30 19 35 36
11
29
5
25
2 22
20
21
26 17 18 32 24 13 28 4 3 15 27 16 33 34
1. Pump assembly 15. Spring pin 25. Oil seal

2. Ball bearing 16. Hold assembly 26. O-ring
3. Roller bearing 17. Set screw 27. O-ring
4. Bush 18. Nut 28. O-ring
5. Snap ring 19. Pump assembly 29. O-ring
6. Snap ring 20. Coupling 30. O-ring
7. Snap ring 21. Collar 32. Seal washer
11. Plug 22. Washer 33. O-ring
13. Plug 23. Packing assembly 34. O-ring
14. Spring pin 24. Packing 35. O-ring
- 53 -
5. MAIN PUMP
5.3. PUMP REMOVAL AND INSTALLATION

5.3.1. Pump removal
1. Remove nipples, fittings, and hoses from the pump, and cover both ends of each hose in order to prevent
dust and other foreign matters from entering the hoses.
2. Remove the pump mounting bolt and spring washer(1,2).
3. Remove the pump flange(3) from the engine.
5.3.2. Pump installation

1. Install the pump to the pump flange(3).
At this time, ensure that the pump shaft spline should be correctly installed into the coupling boss.
• Pump installation precautions

- Ensure that the coupling (5) should not be warped when installing the coupling boss 4.
- Make sure that the coupling boss spline has not been deformed.
Item No. Part name Tightening torque

6 Bolt (M10 x 30L) 5.2 kg·m
7 Bolt (M10 x 25L) 6.5 kg·m
8 Nut (M10) 6.5 kg·m
5
8
6
4
3
2
1
- 54 -
5.4. HYDRAULIC PUMP PERFORMANCE TEST
5.4. HYDRAULIC PUMP PERFORMANCE TEST

5.4.1. Measuring instrument
Flow(l/min.) 7~200(l/min.)
Pressure(kg/cm2) 0~350(kg/cm2)
Tester
Temperature(0°C) 0~150(°C)
Port size PF 1, O-ring type
Pressure gauge, 500kg/cm2, 50kg/cm2
Tachometer Diesel engine tachometer
Test hose Rated pressure: 210kg/cm2 or equivalent
• Preparation
- Park the machine on a level ground and stop the engine.
- Operate the left/right attachment control levers and left/right direction control levers to release the
pressure remaining in the lines.
5.4.2. Connection of testers

1. Disconnect the hose at the pump outlet side.
2. Connect the removed hose to the tester outlet port.
3. Connect the hose at the tester inlet port to the pump outlet port.
Pressure testing port
Pressure gauge
Test hose
Outlet port Throttle valve
Inlet port
Close
Open
Test hose
P1
P2
P3
Control valve Solenoid
- 55 -
5. MAIN PUMP
5.4.3. Measuring procedure

Open the orifice valve of the tester, and start the engine.
Measure the pressure at P1 and P2 through the pressure gauge, and take the engine rpm and pump
delivery simultaneously.
5.4.4. Pump performance curve(P-Q Curve)

• SOLAR 030 Plus
Pressure of P3 kgf/cm2 P3=25(kgf/cm2)
P3=165 P3=25
Flow(Q) ; (L/min)
Discharge pressure (P1+P2) kgf/cm2
• SOLAR 035
20
19
P3=25(kgf/cm2)
Quantity of delivery q1+q2(cc/rev)
15
10
P3=175(kgf/cm2)
5.7
5
0
0 85 100 190 200 300 330 400
Discharge pressure P1+P2(kgf/cm2)
- 56 -
6.1. PIPING DIAGRAM
6. HYDRAULIC OIL FILTER

6.1. PIPING DIAGRAM
Return filter
Hydraulic
oil tank
A
B
C
Suction filter
Pilot line filter
B
A
ANS0050L
- 57 -
6.2. HYDRAULIC OIL FILTER

6.2.1. Suction filter(Y-3794)
Grain size 105 µ

Filtering ability 120 L/min
Pressure resistance 1 kg/cm2
Oil temperature -20°C~120°C
6.2.1. Return filter(SP10)
2-PT 11/4
Grain size 105 µ

Filtering ability 120 L/min
BY-PASS Open pressure: 1.05kg/cm2
Pressure resistance 15 kg/cm2
Tightening torque : 2kgf·m
- 58 -
6.2. HYDRAULIC OIL FILTER
6.2.3. Pilot line filter(for joy stick)
37
3.5 6.5 +0.25
3
-0 9 15 Quantity of flow 6 L/min
12
Rated pressure 40 kg/cm2
C0.5
Filtering ability 40 µ
Filtering area 0.332 cm2
30 o +0.5 ∅12.5±0.2
∅11.2
∅5.5
0
12-
S
PF 1/4
PF 3/8
PRESSURE
LOSS.
∆P
(kg/cm2 )
FLOW Q (l/min)
ANS0060L
- 59 -
6.3. MAINTENANCE PROCEDURE
WARNING • Always allow the hydraulic oil to cool Oil port cap
down enough before replacing the
filters, as at the operating
temperature, the hydraulic oil is at
high temperature and may cause
personal injury.
• Loosen the hydraulic oil port cap
tightening bolt slowly to release the air
from the tank.
6.3.1. Return filter(SP10) replacement

1. With a filter wrench, remove the filter cartridge1.
2. Coat clean hydraulic oil on the gasket surface of a 1
new filter cartridge.
3. When installing the cartridge, bring the seal face into
contact with the gasket and then turn the cartridge
1/2 turn by hand to tighten it.
4. Use a filter wrench to secure the cartridge in place.
Do not apply an unreasonable force.
1
6.3.2. Pilot line filter replacement
1. Remove the floor plate.
2. Unscrew the plug 1 with a spanner(27mm) to remove
the element.
3. Clean the element thoroughly and remove dust and
dirt, then install the plug 1.
WARNING : Always allow the hydraulic oil to cool

down enough before replacing the
filters, as at the operating
temperature, the hydraulic oil is at
high temperature and may cause
personal injury.
- 60 -
6.3. MAINTENANCE PROCEDURE
6.3.3. Suction filter replacement

1. Remove the oil port cap from the hydraulic oil tank.
2. Take out the suction filter 1 from the tank. 1
3. Wash out foreign matters sticking to the element.
4. After cleaning the element, use compressed air to
flush the strainer from the inside to the outside.
5. If the element is found damaged, replace with a new
one.
When cleaning the element, be sure to check the
hydraulic oil tank. If sediments or condensates are
found in the tank, change the hydraulic oil.
6. Prepare a container to receive the drained oil. Drain
the hydraulic oil through the oil port using the oil
feeder pump.
7. Loosen the drain plug 2 located at the bottom of the
hydraulic oil tank to drain out the hydraulic oil.
8. Install the filter 1 in the tank.
When installing the filter, be sure to keep the suction
filter upright and push it down so that it can be
secured to the pipe.
9. Remove and clean the drain plug 2, and secure it to 2
its original position.
10. Inject hydraulic oil through the oil feed port located on 1
top of the tank. During oil injection, keep checking the
oil surface on the level gauge installed on the side of MAX
the tank.
Tank capacity : SOLAR 030 Plus: 60l

SOLAR 035: 70l
11. Fit the oil port cap in place. In doing so, clean the top
side of the flange and O-ring groove thoroughly to 2
prevent oil leaks, and coat a sufficient amount of
grease on the O-ring groove to secure the O-ring in
place.
12. Bleed out air from the hydraulic lines.
• Rotate the engine at low speed.
• Operate each cylinder 4~5 times up to 5mm before
end stroke.
• Operate each cylinder 3~4 times up to end stroke.
- 61 -
13. Correct position of machine for oil level check

• machine on a level ground and stop the engine as
shown.
• Check oil level with the level gauge for the
hydraulic oil tank.
• If the oil surface is above the center line on the
level gauge, it is normal.
14. If the oil surface is below the center line on the level
gauge, add oil.
15. Hydraulic oil tank pressurizing procedure

• Open the oil port cap on the hydraulic oil tank and
operate each cylinder slowly up to the end stroke.
• Reinstall the oil port cap onto the tank. Tighten the
bolt with the spring secured properly with the tab of
the oil port cap.
• In this condition, operating the cylinder up to the
maximum shaft length will pressurize the tank.
• Check for leaky portions.
- 62 -
7.1. SPECIFICATIONS
7. CONTROL VALVE
7.1. SPECIFICATIONS
A9 B9 A8 B8 B7 B6 A5 B5 A4 B4 A3 B3 A2 B2A1 A2
L3 A6 R4 R3 L2
A7
P1 P3
T1 T2
L1 R2 R1 L4
P2
PA8 PA5 PA4 PA1
PTO
A9 A8 A6 A5 A4 A3 A2 A1
T1 T2
A7 P2
P1 B7 P3
B9 B8 B6 B5 B4 B3 B2 B1
PB8 PB5 PB4 PB1
Port Size Port Size

P1, P2, P3, T1, T2 PF1/2 PA1, PA4, PA5, PA8 PF1/4
A1~A9, B1~B9 PF3/8 PB1, PB4, PB5, PB8 PF1/4
Locations SOLAR 030 Plus SOLAR 035

P1 main relief pressure 200 kg/cm2 200 kg/cm2
A4 main relief pressure 235 kg/cm2 270 kg/cm2
B4,B5,A8,B8 main relief pressure 215 kg/cm2 250 kg/cm2
- 63 -
7. CONTROL VALVE
• Construction of blocks (SOLAR 030 Plus / SOLAR 035)
30
13 33
18
27 15
16 20
15 19
12
28
29 15
16
15 15
11 16
15
15 14
30 16
15 21
31
22
23
9
18
20 15
19 16
15
15 8 24
16
15 15 26
25
16
15
10 7
21
15 23
16 22
15
6
21 5
22 15
23
16
15
3
21
15 23
16 22
2 15
15
16 15
15 17
15
18
20
30 19
32
33
1. Control valve 9. Boom block 18. Main relief valve 27. Suction check valve
assembly 10. Pump block (P2) 19. O-ring 28. O-ring
2. Pump block (P1) 11. Swing block 20. O-ring 29. O-ring
3. Travel block(LH) 12. Dozer block 21. Conflex valve block 30. Plug
4. Spare block 13. Swing block 22. O-ring 31. Plug
5. Arm block 14. Pump block (P3) 23. O-ring 32. Tie rod
6. P.T.O. block 15. O-ring 24. Port relief valve 33. Nut
7. Travel block(RH) 16. O-ring 25. O-ring
8. Bucket block 17. O-ring 26. O-ring
- 64 -
7.1. SPECIFICATIONS
• Detail construction of blocks(SOLAR 030 Plus / SOLAR 035)
Drive
9
1 9
10
10
2
3 11
4 Swing, Dozer
12
4
3
Arm, Boom, Bucket, Swivel

5
6
14
5
7
13 2
8
15 1
Arm
9
21 10
22 11
24
12
23
16
18,17 Arm
19
16
20
15 13
14
1. Screw 9. Plug 17. Spring

2. Seal holder 10. O-ring 18. Spring
3. Backup ring 11. Spring 19. Spring
4. O-ring 12. Poppet 20. Spool end
5. Spring holder 13. Cover 21. Spool end
6. Spring 14. Bolt 22. O-ring
7. Socket bolt 15. O-ring 23. Spring
8. Spring cover 16. Spring holder 24. Piston
- 65 -
7. CONTROL VALVE
7.2. CONSTRUCTION
7.2.1. Arrangement
Main relief valve(200K)

P1 T1
P1 block
B9 A9 Travel(LH)
PB8 PA8
B8 A8 Arm
Combination valve
PTO
Combination valve
B7 A7
B6 A6 Travel(RH)
PB5 PA5
B5 A5 Bucket
PB4 PA4
B4 A4 Boom
Combination valve
Combination valve
P2 block
P2
Port relief(250K)
B3 A3
Boom swing
B2 A2
Dozer
PB1 PA1
B1 A1 Swivel
Main relief valve(175K) P3 T2
P3
P3 block
- 66 -
7.2. CONSTRUCTION
7.2.2. Principle of main spool's switchover function

Principle of main spool's switchover function
Neutral position
Close
T P T
Oil flows from P to T.
Operating the joy stick valve generates pilot pressure. This pilot pressure generated at PA port will act on
the right section of the main spool, which overrides, in turn, the springs(A)(B) and moves to the left side.
Then, if the oil flowing through the port P is shut off from the port T, oil pressure starts rising and the
pressurized oil push up the load check valve to allow the oil to flow from the port P through port A to the
cylinder rod. The return oil flows into the port B, passing through the main spool orifice A. If the joy stick
valve which passes through line hole A to the tank circuit is turned to the neutral position, the pilot pressure
is removed, which in turn, causes the spool to return to the neutral position from the springs(A) and (B) to
the right side.
Hydraulic cylinder
Joy stick valve
Pilot pressure
Port B Port A
Port PA
Spring(A) Oil line hole A
Spring (B) Orifice A Valve

Load check valve Main spool
- 67 -
7. CONTROL VALVE
7.2.3. Principle of relief valve operation

1. Main relief valve
The primary pressure passes through the poppet, valve seat, and orifice, presses the needle valve to the
left side, and at the same time, acts on the inside of the poppet to push it to the right side. (The oil in the
secondary pressure chamber does this.)
As the primary pressure rises higher and higher, it pushes out the spring in the rear of the needle valve,
which in turn is forced to move to the left side. Then, since the oil pressure in the secondary pressure
chamber returns to the oil tank and the force pushing the poppet in the closed direction(force pushing the
poppet to the right side) disappears, the poppet is pushed and opened by the primary pressure, causing
the oil to return to the tank.
As a decrease in the primary pressure makes the secondary pressure decrease, the poppet is closed by
the spring force and the secondary pressure rises again to push the poppet to the right side, with the
result that the relief condition is stopped.
Valve seat
Main relief valve
Tank
Primary
pressure
Spring Needle valve Poppet

Secondary pressure chamber
- 68 -
7.2. CONSTRUCTION
2. Combination valve
Poppet
Combination valve
Line pressure Tank pressure
If the line pressure exceeds the set pressure, the poppet is pushed to the right side to make the line
pressure flow to the tank.
Combination valve
The suction pressure activates the line pressure to make the seat move to the left side, and oil flows in the
line from the tank. If the oil flows into the line to release the exhaust pressure, the seat moves to the right
side again and is separated from the tank.
- 69 -
7. CONTROL VALVE
3. Port relief valve
Poppet Port relief valve
Spring
In general, the poppet is pushed to the left side by the spring force to shut off the line pressure and tank
pressure.
Poppet Port relief valve
Spring
If the line pressure exceeds the set value, the poppet is pushed to the right side to make the line pressure
flow to the tank.
If the line pressure goes below the set value, the poppet is pushed to the left side again by the spring force
and shut off the line pressure and tank pressure.
- 70 -
7.2. CONSTRUCTION
7.2.4. Arm regeneration circuit
Spool PB
PA
T
Piston
• At arm crowd
If the pressure(PB) of the arm cylinder rod side is higher than the pressure(PA) of the cylinder head side,
the pressure of the rod side flows toward the head past the line holes(A)(B) in order for (PA<PB) to
actuate the piston(A) to the right side at the pressure(PB) of the rod side.
(The amount of oil corresponding only to that in the orifice(C) is bypassed to the tank.)
Line Line Orifice(C) Piston(A)

hole(A)
• At arm crowd
If the pressure at the arm cylinder rod side is lower than that at the head side(PA>PB), the piston(A) is
seated in the left side by the pressure at the head and accordingly the return oil flows straightly in the
tank port.
When no regeneration of arm crowd is done = At excavation, etc.
- 71 -
7. CONTROL VALVE
7.3. DISASSEMBLY AND REASSEMBLY

7.3.1. To replace the O-ring on the mating surface and block assembly
1. Disconnect the tie rod.
2. Remove each block. Take care not to damage the mating surface for each block.
3. At disassembly, replace the O-ring on the mating surface if possible.
4. Clean the mating surface to remove dust or dirt at reassembly and install a new O-ring, then assemble
them by reversing the sequence as described above. (When installing the O-ring, always coat it with
grease.)
5. Tighten the tie rod nut. (Tightening torque: 2.4kg• m)
(When tightening the nut, ensure that the spool of each block should operate properly.)
Block
O-ring
Tie rod
Nut
- 72 -
7.3.2. Replacement of O-ring on the spool

1. Replacement of lever
• Remove the O-ring holding bolt 1 from the block.
• Remove the wiper 2 and O-ring 3.
• When assembling the wiper, take care not to damage the O-ring.
2. Replacement of cap
• Loosen the cap holding bolt 4 to remove the cap 5.
• Remove the spool 6 and replace the O-ring 7.
• Clean the spool, and then assemble it to the block body.
• When assembling the spring cap, take care not to damage the O-ring.
- Cap holding bolt tightening torque: 1.1kg• m
- Replace the spool and block as an assembly.
1
23
5
4
7.3.3. Removal of load check valve

• Remove the load check spring and load check valve from the valve block.
• Thoroughly clean them before reassembling them.
7.3.4. Replacement of relief valve and O-ring

• Remove the suction assembly relief valve.
• If necessary, replace the O-ring or relief valve.
• Coat the O-ring with grease at installation.
• When loosening the cap nut and hexagon head nut on the relief set adjusting screw, always use a
pressure gauge to check for the relief setting pressure.
• When removing the relief valve assembly, take care so that the center hole of the relief piston may not
be blocked by foreign matters. Relief valve tightening torque: 7.0kg• m
- 73 -
7. CONTROL VALVE
7.4. CONSTRUCTION OF EACH VALVE

7.4.1. Main relief valve
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Location Tightening torque

Cap nut tightening torque 1.5~2.0kg• m
Relief valve fixing torque 3.0~3.5kg• m
1. Cap nut 6. O-ring 11. Spring

2. Set screw 7. Needle valve 12. Poppet
3. Gasket ring 8. Wire 13. O-ring
4. Spring 9. O-ring 14. Sleeve
5. Housing 10. Valve seat
7.4.2. Complex valve
1 2 3 4 5 6 7 8 9 10
Cap nut tightening torque 1.5~2.0kg• m
Relief valve fixing torque 3.0~3.5kg• m
1. Cap nut 5. Relief valve 9. O-ring

2. Set screw 6. Poppet 10. Clip
3. Gasket ring 7. O-ring
4. Spring 8. Seat
7.4.3. Port relief valve
1 2 3 4 5 6 7 8 9

Relief valve fixing torque 3.0 kg• m
1. Plug 4. Spring 7. Backup ring

2. O-ring 5. O-ring 8. Poppet
3. Body 6. O-ring 9. O-ring
- 74 -
7.5. CAUTIONS WHEN HANDLING
7.5. CAUTIONS WHEN HANDLING

7.5.1. Handling
1. When handling or transporting the valve, take care not to drop it so that it may not give impact to the
spool tip and cap area.
2. When storing the valve for an extended time, tighten plugs to each portion to prevent the entry of dust or
water.
7.5.2. Installation
1. When assembling valve fittings, use the specified tightening torque.
(Take care so that the pipe may not give unnecessary stress over the valve.)
2. Install the control linkage so that the spool moves correctly in the axial direction.
3. When welding near the valve, take care so that excessive heat and welding sputter may not damage the
O-ring and dust seal.
4. In painting, prevent paint from being contacted with the spool.
5. Do not leave plug unscrewed until doing piping works so that dust or water may not enter each port.
7.5.3. Operation
1. Before operation, check to see that the hydraulic pipes and hydraulic oil are clean.
2. Hydraulic oil for use should be at -20°C~80°C. If the oil temperature is below 0°C, warm up the engine.
3. Do not raise the set pressure for the main relief valve and port relief valve above the specified one.
How to adjust the pressure for the main relief

• Install a pressure gauge between the pump at a
portion to be measured and the control valve.
(Use a pressure gauge fitting if available.)
• Raise the oil temperature up to 50°C~60°C to
obtain the rated engine rpm.
• Operate the control lever and check the pressure
when the cylinder reaches the end stroke.
• When raising the pressure, use a hexagon socket
wrench to turn the suction port-to-relief valve
adjusting nut counterclockwise. Pressure up
- Main relief valve: 100kg/cm2 per turn
- Port relief valve: 100kgcm2 per turn
• After adjusting to the specified pressure, tighten it
securely.
- 75 -
8. SWING MOTOR
8. SWING MOTOR
8.1. SPECIFICATIONS
• SOLAR 030 Plus
Av,Bv port
2-PF3/8 O-ring port
292 45 101 45
45
14
63
125h7
64
48
PF3/8 O-ring port

162
Tank port
T
Pilot port
Av Bv
Type Specifications
Diaplacement 244cc/rev
Maximum rpm 69.7 rpm
Rated flow rate 19 l/min
Relief set pressure 130kg/cm2
- 76 -
8.1. SPECIFICATIONS
• SOLAR 035
218
2-M16
13H7
325.5 6 - 17
0
2-G3/8
10
48 50
G1/4
A,B port 2-
35
G3/8
T-port
0
10
2-15
2-50
150 h8
10
CD2
P
A
RED.
Item Type Specifications

Output torque 72kg• m
Reduction gear Output rpm 66 rpm
Deceleration ratio 19.3
Displacement 18.1cc/rev
Maximum rpm 1286 rpm
Motor
Rated flow rate 24 L/min
Relief set pressure 160kg/cm2
- 77 -
8. SWING MOTOR
8.2. CONSTRUCTION
• SOLAR 030 Plus
10
13
9
12
8
5
1. Swing motor assembly 5. Rear bearing 9. Plug

2. Plug 6. Snap ring 10. Bolt
3. Front bearing 7. O-ring 12. Bolt
4. Snap ring 8. Spring washer 13. Relief valve block
- 78 -
8.2. CONSTRUCTION
• Internal structure(SOLAR 035)
1. Swing motor assembly

2. Relief valve assembly
3. O-ring
4. O-ring
5. O-ring
6. O-ring
7. O-ring
8. O-ring
9. O-ring
10. Carrier gear assembly(2)
11. Carrier gear assembly(1)
12. Pinion gear assembly
13. Bolt
14. Bearing
15. Spring pin
16. Snap ring
17. Bolt
18. Parallel pin
19. Bearing
20. Filter
21. S2 gear
22. Thrust collar
23. Snap ring(S)
24. Spring pin
25. Snap ring(SA)
- 79 -
8. SWING MOTOR
8.3. PRINCIPLES OF OPERATION

8.3.1. Principles of operation (SOLAR 030 Plus)
The pressurized oil flowing in the motor flows past the disc valve to the Z-Rotor, the star of which does
planetary motion to rotate the main drive. At this time, the disc valve is driven by the valve drive.
Inlet Outlet
Right-hand turn
Tape roller
bearing
Main drive
Z-Rotor
Valve drive
Valve plate port(7 No.)
Disc valve External drain clamping plug

Check valve(2 No.)
(with 12 ports)
- 80 -
• Motor principle(SOLAR 035)

1. Hydraulic motor functions
The hydraulic motor is of a axial piston motor type, and converts the pump-fed hydraulic energy to
rotational motion.
2. Motor construction and principle of operation

The pressurized oil flowing in through the hydraulic valve is delivered to the valve plate. The pressurized
oil delivered to the port A is fed to the cylinder port, in the cylinder barrel, corresponding to the port A and
pushes out the piston. This pushing force is converted to rotational force by means of the swash plate.
The return oil within the cylinder port flows out through the port B of the valve plate.
In the case of reverse rotation, the pressurized oil flows in from the port B and the return oil flows out to
the tank through the port A.
Shaft Piston
Cylinder barrel
Valve plate
Swash plate
Port A
Port B
- 81 -
8. SWING MOTOR
8.3.2. Shockless relief valve functions

The hydraulic motor, even at stationary, would continue to rotate by inertia force although the port A
shuts off hydraulic pressure. Then, pressure generated within the port B pushes the relief valve poppet
open at the primary pressure P1.
Also, pressurized oil is induced at the piston section by means of the poppet check, and as a result, the
piston moves to the right side. This motion increases the spring load to generate the secondary pressure
P and to control the pressure within the port B in the manner as shown, and accordingly the hydraulic
motor come to a stop smoothly.
Port A Port B
Suction check valve
Suction check valve
Piston
To upper side
P1
Check Poppet Shockless relief valve

Shockless relief valve
- 82 -
8.4. INSPECTION AND ADJUSTMENT

8.4.1. Swivel's spontaneous settlement measurement
1. Machine position
• Part the machine on an incline with a swash angle
of 12° with the hydraulic oil temperature at
50°C±5°C.
• Fully extend the arm cylinder, position the boom
cylinder parallel to the surface of the incline, and
then stop the engine.
2. Measurement
Check the amount of oil leak for 3 minutes. (Measure
the travel of the swing bearing outer race.)
Model Standard Limit Weight(kg)

SOLAR 030 Plus 100mm or less 200mm or less 130kg
SOLAR 035 100mm or less 200mm or less 160kg
8.4.2. Amount of drag when swinging is stopped

Position the machine on a level ground with high
engine rpm, oil temperature at 50°C±5°C, and at
maximum operating radius as shown, and align the
(1)
boom joint 1 parallel to the arm bucket coupling pin 2.
Apply a weight to the bucket tip, and measure the
moving length with the bucket tip as a basis after
making a turn.
(2)
• Bucket load : S030 Plus:130kg, S035: 160kg
(W)
• Standard : 90mm or less
- 83 -
8. SWING MOTOR

8.5.1. Swing motor removal
1. Remove the pipes connected to the swing motor, and M12 x 1.75 x 601
Tightening torque : 11.5kg·m
do not allow the fittings to be contaminated.
2. Remove the swing motor clamping bolt.
3. Install the eye bolt into the swing motor removing
thread to remove the swing motor.
After applying LOCTITE to the threaded portion,
tighten to the specified torque.
M12 x 1.75 x 701

Tightening torque : 11.5kg·m
M16 x 2.0 x 451

Tightening torque :
27.5kg·m
8.5.2. Swing bearing seal replacement

If the seal is found cracked or scored, replace the
inner and outer race seals with new ones.
• How to replace
1. Remove the old seal and eliminate gasket materials
remaining in the inner and outer race grooves.
2. Use thinner to eliminate the gasket material marks Cut section
and dry them up.
3. Apply adhesive such as nitrile rubber around the
circumference of the seal.
To cut 45°
Apply adhesive to the cut sections and align them to make the contact
with each other to press the seal in the seal groove. area wider.
If the seal is circular, the cut sections do not require
any special treatment, but the seal should be made
longer than its overall length before being pressed in
the circumference evenly. Do not leave any part of
seal unused.
- 84 -
9.1. SPECIFICATIONS
9. TRAVEL MOTOR
9.1. SPECIFICATIONS
• SOLAR 030 Plus
G1/4 Travel second-speed
ANS0160L

Maximum output torque 266kg• m
Reduction gear Maximum output rpm 41.2/68.1 rpm
Deceleration ratio 1/45.2
Amount of delivery 21.5/12.9cc/rev
Maximum service pressure 200kg/cm2
Hydraulic motor
Maximum amount of flow 40.9 l/min
2-speed switchover pressure 15kg/cm2
- 85 -
9. TRAVEL MOTOR
• SOLAR 035
2-G1/4 (Dr)
2-G1/2 (A,B)
297.5 G1/4 Travel secons-speed
G1/4
70
210 h8
165 h8
51
214
232
192
255
204
56
12-M12 107
9-M12 147
160
Dr
A
RED
RP

Maximum output torque 272kg• m
Reduction gear Maximum output rpm 38.2/56.9 rpm
Deceleration ratio 40.6
Amount of delivery 23.6/15.7cc/rev
Maximum service pressure 210kg/cm2
Hydraulic motor Maximum output rpm 1553/2311 rpm
Maximum amount of flow 37 l/min
2-speed switchover pressure 15kg/cm2
- 86 -
9.2. CONSTRUCTION
9.2. CONSTRUCTION
• SOLAR 030 Plus
- 87 -
9. TRAVEL MOTOR
101. Body 138. Plug 302. Spool

102. Cover 139. O-ring 303. Check valve
104. Carrier 2 140 - 141. Thrust washer 304. Spring guide
106. B1 gear 202. Body 2 305. Spool
107. B2 gear 203. Shaft 306. Shuttle spool
108. S1 gear 204. Cylinder barrel 307. Spring V1
109. S2 gear 205. Valve plate 308. Spring V2
110. Ring 206. Piston 309. Spring V3
111. B2 pin 207. Shoe 310 - 312. Plug
113. Snap ring 208. Shoe holder 313. Choke
115. Thrust color 210. Swash plate 314. ring
116. Slide ring 211. Control piston 315. Plug
117. Floating seat 212. Pin 317 - 320. O-ring
118. O-ring 213. Spring 321. Choke
119. Bearing 214. Retainer 324. Screw
120. Needle 215. Bearing 401. Body
121. Needle 216. Bearing 403. O-ring
122. Thrust whasher 217 - 218. O-ring 404. Plug
123 & 128. Snap ring 219. Oil seal 501. Retainer
124. Snap ring 220. Ball 502. Poppet
125 - 126. Snap ring 221. Snap ring 503. Spring guide
127. Spring pin 222. Screw 504. Spring
129 - 131. O-ring 223. Spring pin 505. Adjuster kit
132 - 133. Plug 224. Pin 506 - 508. O-ring
134. Hydraulic motor 228. Bearing
137. Name plate 301. Body 1
- 88 -
9.2. CONSTRUCTION
• SOLAR 035
1. Travel motor 13. O-ring 26. Bolt 40. Snap ring(S)

assembly 14. O-ring 27. Bolt 41. Carrier(2)
2. Roller bearing 15. Oil seal 28. Plug 29. Parallel pin 42. Thrust collar
3. Pin(b2) 16. Backup ring 30. Spring pin 43. Slide ring
4. Pin(b1) 17. Piston seal 31. Ball bearing 44. Thrust washer
5. O-ring 18. Piston seal 32. Snap ring(H) 45. Snap ring
6. Gear(b1) 19. Roller bearing 33. Ball bearing 46. Snap ring
7. Gear(b2) 20. O-ring 34. Floating seal 47. Plug
8. O-ring 21. O-ring 35. Ball bearing 48. O-ring
9. O-ring 22. O-ring 36. Plug 49. Plug
10. O-ring 23. Relief valve assembly 37. Carrier(1) 50. O-ring
11. O-ring 24. Relief cartridge 38. Gear(S1) 51. O-ring
12. O-ring 25. Plug 39. Thrust washer
- 89 -
9. TRAVEL MOTOR

• SOLAR 030 Plus
Carrier 1
a1 a2
Stationary part Moving part

b
p1
1
b1 b2
s1
s
s2
p4 p2
Carrier 2 p3
Simple planetary reduction gear
Hydraulic motor (2 shift levels)
Counterbalance valve
ANS0170L
The hydraulic motor output shaft is connected to the s2 gear by the spline as shown above, and the rotation
of the s2 gear is reduced preliminarily by the s2, b2, and a2 gear.
The rotation reduced at the first level is reduced further by the s1, b1, a1 gear connected to the carrier 2 by
the spline, and this rotation reduced finally at the second level is transferred to the rotor body through the a1,
a2 internal gear to produce driving force.
- 90 -
• SOLAR 035
Carrier 1
a1 a2
Stationary part Moving part

b
p1
b1
ａ1
b2
Dr
s1
A s
B s2
p4 p2
PP
Carrier 2 p3
Simple planetary reduction gear
Hydraulic motor (2 shift levels)
Shockless overload relief valve
Counterbalance valve
The s2 gear is installed over the hydraulic motor output shaft by the spline as shown above, and the rotation
of the s2 gear is reduced preliminarily by s2, b2, and a2 gears.
The rotation reduced at the first level is reduced further by s1, b1, and a1 gears connected with the carrier 2
by the spline, and this rotation reduced finally at the second level is transferred to the rotor body through the
a1 and a2 internal gears to produce driving force.
- 91 -
9. TRAVEL MOTOR
9.3.2. Explanation about operation

The travel motor composed of the hydraulic motor
and reduction gear. Carrier 1
• Reduction gear a1 - a 2
1. Operation
The reduction gear consists of a planetary gear(with 2
shift levels). This gear allows the hydraulic motor to
b1 b2
reduce its high speed to increase the torque at a low
speed and rotate the case.
2. Principle of operation
The s2 gear is placed over the hydraulic motor output s1
shaft as shown, and the rotation of the s2 gear is
s2
reduced preliminarily by the s2, b2, and a2 gears.
The rotation reduced at the first level is reduced
further by the s1, b1, and a1 gears connected to the
carrier 2 by the spline, and this rotation reduced finally
at the second level is transferred to the rotor body
through the a1 and a2 internal gears to produce
driving force. Carrier 2
The deceleration ratio for the simple planetary

gear(with 2 shift levels) is calculated generally as
follows:
Zs1 Zs2
R = •
Zs1+Za1 Zs2+Za2
Here: Zs1, s2: No. of teeth of s2 gear

Za1, a2: No. of teeth of a2 gear
In case of hydraulic motor, the deceleration ratio of

the main body's rotor is calculated as follows:
1
R' =
1-1/R
- 92 -
• Hydraulic motor
1. Hydraulic motor operation
The hydraulic motor is of a axial piston type, and converts the hydraulic pressure energy fed from the
pump into rotational motion.
2. Construction and operation principle of hydraulic motor
Shaft Piston
Cylinder valve
Valve plate
Swash plate
Port A
Port B
The pressurized oil flowing from the hydraulic valve is fed to the valve plate. When the pressurized oil is
delivered to the port A, it flows in the cylinder port, in the cylinder barrel, corresponding to the port A to
push out the cylinder. This pushing force is converted to rotational force by means of the swash plate.
The return oil within the cylinder port flows into the tank through the port B of the valve plate.
In the case of reverse rotation, the pressurized oil flows in from the port B and the return oil flows into the
tank through the port A.
- 93 -
9. TRAVEL MOTOR
3. Principle of second-speed motor operation
Piston Control Seal

Face B Shoe
Shoe
Ball
Ball
Spring
Face 1
Cylinder barrel
Control ring Stop ring Face 1

Hydraulic pressure
The swash plate has 2 faces of A and B on the opposite side of the sliding face for the shoe and is
clamped by two balls fixed on the body(2).
As these balls are installed eccentrically from the center shaft, both the hydraulic force acting on the
piston and the spring in the cylinder barrel in the first speed condition are combined to fix a swash angle
to α, from which a large capacity results.
If depressing the second accelerator pedal, hydraulic pressure produced by the stopper ring and control
ring together by means of the second-speed spool is guided to the control seal and goes forward until it
contacts the swash plate body to fix the swash plate at an angle β, from which a small capacity results.
If the engine is started, the control seal gets connected to the tank port. As a result, the spring force
makes the swash plate return to the first-speed condition.
- 94 -
4. Counterbalance valve operation
3 4
A B
Dr PP Dr
D
A B
When the pressurized oil is fed from the port A, it forces the check valve(3) open to flow into the inlet port
(A)'. Then, it enters the chamber(D) through the check hole(C), overcomes the spring(4) force, and
allows the spool valve(2) to slide in the right direction. As a result, the return oil in the hydraulic motor
flows from the port(B)', past the body(1) and the opening(E) of spool valve(2), to the port (B) to rotate the
hydraulic motor.
If the pressurized oil is fed from the port (B), each component operates in a reverse way, resulting in
reverse rotation of the hydraulic motor.
If the hydraulic pressure of the port(A) is not supplied in a pressurized condition, the spool valve(2) which
is operating in the right side would turn to the left side by the spring(4) force. At this time, the oil in the
chamber(D) would flow out to the port(A) through the check hole(C), but it controls the speed of spool
valve(2) which would return to the left side, using the orifice effect of the check hole(C). Also, the
hydraulic motor would continue to turn by inertia force although the pressurized oil of the port(A) is not
supplied. Then, the shifting speed of the spool valve(2) and notch phenomenon combines to reduce the
return oil speed, and therefore the hydraulic motor is stopped smoothly.
In addition, the drain oil of the hydraulic motor flows from the oil gallery(F), through the port Dr, to both
ports Dr.
- 95 -
9. TRAVEL MOTOR
9.4. CARE
• Always allow the hydraulic oil to cool down enough
before making an inspection, as at the operating
temperature the hydraulic oil is at high temperature.
• Oil pressure remaining still in the case may make oil
and plug pop out.
Loosen the plug slowly to release the pressure in the
case.
1. There are 3 plugs on the cover 1 of the travel motor.

Use these plugs for oil feeding, drain, and oil level
check.
2. Use a hexagon socket wrench to remove the oil feed 2. Oil feel port
plug and drain plug 2 located on top of the tank and 1 3. Oil level check hole
drain out old oil.
SOLAR 035
3. After draining the oil, clean the oil feed, drain, and oil
level check plugs, then wind a seal tape on them.
4. Tighten the plug over the drain port before injecting oil
into the feed port. Overfill the tank to obtain the
normal oil level(600cc).
5. Tighten each plug.
SOLAR 030 Plus
• Use recommended lubricants(gear oil).
• Never mix different type of oils together.
2. Drain port PF3/8
• Tightening torque
• Feed port plug and drain plug 2 : 4.7~5.2kg• m
• Oil level check plug 3 : 1.2~1.3kg• m
ANS0080L
- 96 -
9.4. CARE
9.5. RUNNING SPEED

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

Low speed High speed Low speed High speed
SOLAR 030 Plus 18.5±2 11.5±2 18.5±2 11.5±2
SOLAR 035 18±2 12±2 18±2 12±2
2. When running 20m on level ground
Steel shoe Rubber shoe

Low speed High speed Low speed High speed
SOLAR 030 Plus 32±2 20±2 31±2 19±2
SOLAR 035 25±2 19±2 26±2 17±2

Travel deviation measurement(Engine maximum rpm, no
load, oil temperature: 50±5°C)
Running Amount of
Running distance
distance travel deviation
SOLAR 030 Plus 11 mm less than 500mm
SOLAR 035 10 mm less than 500mm
Amount of travel deviation
- 97 -
10. HYDRAULIC CYLINDER

10.1. CONSTRUCTION
• SOLAR 030 Plus
H, L K
A
C D
B
F
E
H, L J I
A
D C
B
F
K
E
G2
G1
Item Cylinder Unit Boom Arm Bucket Boom swing Dozer

A Rod pin diameter mm ø40 ø35 ø35 ø35 ø35
B Head pin diameter mm ø40 ø35 ø35 ø35 ø35
C Rod diameter mm ø40 ø40 ø35 ø35 ø40
D Cylinder bore mm ø70 ø70 ø70 ø60 ø75
Maximum extended length mm 1432 1315 1105 1552 595
E
Minimum closed length mm 865 805 680 925 470
F Stroke mm 567 510 425 627 125
G1 Width mm 50 50 50 50 50
G2 Width mm 50 50 50 50 50
Weight kg 24 22 17 18 17
- 98 -
10.1. CONSTRUCTION
• SOLAR 035
H, K I, J
A
C D
B
F
E
G1
G2
Item Cylinder Unit Boom Arm Bucket Boom swing Dozer
A Rod pin diameter mm ø40 ø35 ø35 ø35 ø40
B Head pin diameter mm ø40 ø35 ø35 ø35 ø40
C Rod diameter mm ø40 ø45 ø40 ø45 ø50
D Cylinder bore mm ø70 ø75 ø70 ø80 ø90
Maximum extended length mm 1545 1520 1295 1609 595
E
Minimum closed length mm 920 920 795 957 470
F Stroke mm 625 600 500 652 125
G1 Width mm 50 50 50 50 55
G2 Width mm 50 50 50 50 55
Weight kg 28 30 21 27 20
- 99 -
• Internal construction(SOLAR030 Plus)
1. Cylinder assembly 9. O-ring 17. O-ring

2. Cylinder tube assembly 10. O-ring 18. Set screw
3. Piston rod assembly 11. Backup ring 19. Bush
4. Rod cover 12. Backup ring 20. Grease nipple
5. Bush 13. Piston 21. Grease nipple
6. Rod packing 14. Piston packing 22. Dust seal
7. Dust seal 15. Wear ring
8. Snap ring 16. Cushion plunger
- 100 -
10.1. CONSTRUCTION
• Internal construction(SOLAR035)
1. Cylinder assembly 9. Cushion ring 17. Retainer ring

2. Cylinder tube assembly 10. Cushion guide 18. O-ring
3. Bush 11. Nut 19. Backup ring
4. Rod assembly 12. Rod cover 20. O-ring
5. Bush 13. Bush 21. Grease nipple
6. Piston 14. Packing 22. Grease seal
7. Seal 15. Backup ring
8. Wear ring 16. Dust wiper
- 101 -
10.2. DISASSEMBLY
10.2.1. Disassembly procedures
1. Clamp the cylinder tube in a vise enough to avoid its
Vise
deformation. Supply compressed air into the ports A A
and B to actuate the cylinder rod in order to drain out
Wood block
the old oil in the cylinder.
Extract the cylinder rod about 1/3.
B
2. Using a driver, make the rod cover stopping capacity
even.
3. With a rack wrench, turn the rod cover counter- Counterclockwise

clockwise from the cylinder tube to loosen it.
Rubber
4. Piston rod assembly disassembly
Slowly turn the cylinder rod assembly to disconnect it
from the tube.
After disassembling the piston rod, take care not to
damage it.
5. Piston assembly disassembly Wood block

Install a wood block on the inside of the vise as
shown so that the piston rod may not be damaged.
Make the surface of the surface table parallel with the
piston rod. Otherwise, the piston rod may be
damaged.
- 102 -
10.2. DISASSEMBLY
10.2.2. Internal component disassembly procedure

1. Piston removal
With a special tool or spanner, remove the piston nut
from the piston rod assembly by turning the nut slowly
counterclockwise.
Counter-
Socket
clockwise
2. Mount the piston rod assembly on the work bench.

Remove the rod cover by moving it back and forth.
Use a tool to remove the backup ring and then O-ring. Packing case
* When attempting to use the rod cover again, do

not damage it. forth
ck and
ba
ing
3. Packing assembly disassembly Mov
Exercise care not to damage the cover or piston

groove.
4. As the piston rod and cylinder tube assembly

Press(cylinder
removing bush is pressed fit in the rod head, use a rod side)
press to remove the bush.
In case of ball bearing, remove the snap ring.
- 103 -
10.3. ASSEMBLY
10.3.1. ASSEMBLY PROCEDURE
1. Assemble the components by reversing the disassembly sequence.
2. Before assembling, check each component for metal chips or other foreign matters.
3. Apply hydraulic oil to each component before assembling them.
4. Semi-assemble each component before final assembly.
10.3.2. Inspection
1. Clean disassembled parts except for packings with light oil thoroughly.
2. Clean packings with hydraulic oil.
3. Do not use a mixture of different type oils. Service life of parts may be shortened.
4. Expecially, clean the sliding surfaces, oil holes, and packing grooves thoroughly.
5. If parts are not to be used immediately after cleaning, dip them in a suitable rust preventive compound.
(Coating with hydraulic oil has some rust-proofing effect.)
- Ensure that all the major parts are not damaged, deformed, rusted, or scored.
- Check each part for metal chips and other foreign matters.
- Check the piston rod and sliding surfaces for signs of damage, fretting, or discoloration.
- Replace packings and seals with new ones.
If parts are to be reused, ensure that they are not damaged and have no foreign matters.
10.3.3. Cautions to be taken at assembly

1. Before starting assembly, be sure to replace packings with new ones.
2. For retainer ring and seal ring, note the installing direction.
3. Replace set pin with a new one.
After assembling and fitting the set pin, secure it by punching 2 places on the circumference so that it
may not be missed.
4. Strictly follow the specified tightening torque when tightening the rod cover, piston, nut etc.
5. Check sufficiently prior to assembly.
Note cushion bearing

installation direction
Seal ring
To punch
Secure by punching
- 104 -
11.1. SPECIFICATIONS
11. SWIVEL JOINT

• SOLAR 030 Plus
Dr 2 kg/cm2
Service pressure
A~F.P 210 kg/cm2
A,B,P,Dr PF 1/4
Port size,
C~F PF 1/2
Service rpm 10 rpm
Left travel Right travel
100
124
175
199
78
110
B: Dozer Down
A: Dozer Up
332
D: Right travel
Forward C: Left travel
Forward
F: Right travel
Reverse E: Left travel
Reverse
44
Dr: Drain
- 105 -
11. SWIVEL JOINT
• SOLAR 035
Dr 2 kg/cm2
Service pressure
A~F.P 210 kg/cm2
A,B,P,Dr PF 1/4
Port size,
C~F PF 1/2
Service rpm 14 rpm
Travel second-speed(left)
Travel second-speed(P)
125
100
Travel second-speed(right)
175
200
88
A: Dozer Up
B: Dozer Down
321
C: Left travel
Forward
D: Right travel
Forward
E: Left travel
Reverse
F: Right travel
Reverse
78
Dr: Drain Dr: Drain
122
150
- 106 -
11.2. CONSTRUCTION, DISASSEMBLY, AND REASSEMBLY
11.2. CONSTRUCTION, DISASSEMBLY, AND REASSEMBLY

11.2.1. SOLAR 030 Plus
• Construction
1. Center joint assembly

2. Body
3. Slipper seal
4. O-ring
5. Dust wiper
6. Spindle
7. Hexagon head plug
8. Thrust plate
9. Hexagon head bolt
10. O-ring
11. Cover
12. Hexagon head bolt
13. Spring washer
14. Pin
• Disassembly
1. Remove the bolt(12) and spring washer(13).
2. Remove the spindle(6) from the body(2) in the upper direction.
* To prevent damage of the O-ring, turn the spindle at disassembly.
• Reassembly
1. Check the O-ring and sliding surfaces of the assembly for damage or break.
2. Assemble parts by reversing the disassembly sequence.
When assembling the O-ring, be sure to apply hydraulic oil and grease to it.
- 107 -
11. SWIVEL JOINT
11.2.2. SOLAR 035

• Construction
1
1. Swivel joint assembly
14
2. Slipper seal
15
3. Cover
4. Hub
5 5. Spindle
6. Spacer
7. Hexagon socket head
cap bolt
4 8. Snap ring
9
9. Dust seal
13 10. 11.12. O-ring

13. Backup ring
10
6 14. Plug
15. Pin
12
2
11 3
• Disassembly
1. Remove the bolt(7).
2. Remove the spindle(5) from the housing hub in the upper direction.
* To remove the O-ring and backup ring, lightly tap the case with a copper hammer.
• Reassembly
1. Check the O-ring and sliding surfaces of the assembly for damage or break.
2. Assemble parts by reversing the disassembly sequence.
When assembling the O-ring, be sure to apply hydraulic oil and grease to it.
- 108 -
12. JOY STICK

Maximum primary pressure 100 kg/cm2

Permissible exhaust pressure 3 kg/cm2
Rated flow 15L
(247.5)
1.3 = 19
O
2.4 = 23
o
OUBLE SINGLE
28 D
(364.5)
P T
17.5
Over 350
4.5
90
1 3 2 4
HYDRAULIC SYMBOL
ANS0100L
∅113
(131)
o
45
71
6-PF1/4 O-ring port

4-∅7 Hole
27
71
98 ANS0090L
- 109 -
12. JOY STICK
• Secondary pressure characteristics and control torque
PORT 1, 3
SECONDARY PRESSURE (kgf/cm2 )

40
OPERATING TORQUE (kgf cm )

37.7
Operating Torque
25.1±2
19.5±1.5
(11.6)
7.7±1
5±0.75
Secondary Pressure
7
0 1.1±0.5 6.5±0.5
PUSH-ROD STROKE (mm)
ANS0110L
PORT 2, 4
40 39.7
SECONDARY PRESSURE (kgf/cm2 )
OPERATING TORQUE (kgf cm )
Operating Torque
26.9±2
19.5±1.5
(11.6)
7.7±1
5±0.75
9
0 1.1±0.5 8.5±0.5
PUSH-ROD STROKE (mm)

ANS0120L
- 110 -

The pilot valve operation principle is explained according to the operation diagram as given below. The
diagram below explains about a typical pilot valve.
12.2.1. Neutral
The force of spring 2 setting up the output pressure of the pilot valve does not act on the spool 1.
Accordingly, the spool is pushed upward by the spring 8 to reach the location of port B in the diagram As a
result, it indexes with the tank port T only and the output port pressure becomes equal to tank pressure.
12.2.2. If the lever is forced inclined

The spool moves downward according to the push rod 3 stroke. Also, the port P is indexes with the port A so
that the oil fed from the pilot pump flows out to the port A to produce pressure. If the pressure of port A
increases up to that corresponding to the spring force set by inclining the lever, the hydraulic pressure and
spring force becomes in a balanced state. Furthermore, if the pressure of port A exceeds the set pressure,
the port A and P are closes, while A and T are opened; if the pressure of port A goes down below the set
pressure, the port A and P are opened, while A and T are closed. This principle of operation maintains the
secondary pressure stable.
Port T
Port P
Port A Port B
- 111 -
12. JOY STICK
12.3. CONSTRUCTION
ANS0140L
1. Body 12. Push rod 23. Connector

2. Plug 13. Push rod 24. Nut
3. O-ring 14. Plug 25. Boot (LH), (RH)
4. Spring 15. O-ring 26. Nut
5. Spring seat 16. Rod seal 27. Switch ass’y
6. Spring seat 17. Plate (A) 28. Insert
7. Stopper 18. Busing 29. Handle ass’y
8. Spring 19. Machine screw 30. Screw (Tapping)
9. Spring 20. Joint ass’y 31. Plate (B)
10. Spring seat 21. Swash plate 32. Boot
11. Spool 22. Hex. nut
- 112 -
13.1. SPECIFICATION
13. SOLENOID VALVE

X X
Y A B Y
X-X Section
SOL2 SOL1
P
Y-Y Section
T ANS0180L
A B
- 113 -
13. SOLENOID VALVE
13.2. CONSTRUCTION
1
14
14
5
17
4
17
11
7
15 19
11
3 9
12 2
15 2
6
3
12
16 16
16
18
8 13 ANS0190L
1. Solenoid valve assembly 8. Body 15. Washer

2. Shim 9. Spring 16. Scale ball
3. Spring 10. Spool 17. O-ring
4. Sleeve 11. Spool 18. O-ring
5. Solenoid 12. Stopper 19. O-ring
6. Plunger 13. Plug
7. Stopper 14. Bolt
- 114 -
13.3. OPERATION
13.3. OPERATION
The solenoid valve is a valve designed to control the joy stick pilot pressure and travel second-speed pilot
pressure.
SOL2 SOL1
P
XG
Right-hand travel motor Right-hand joy stick
Left-hand travel motor Left-hand joy stick

ANS0200L
SOL1 : Limit switch(cutoff) attached to the right control stand

SOL2 : Limit switch for travel second-speed control
- 115 -
13. SOLENOID VALVE
13.4. CONSTRUCTION
The solenoid valve consists of a relief valve, a un-load valve, a lever lock, and a travel second-speed
valve.
1. Relief valve
If the pressure of the port P increases to reach a set Poppet Spring
T
pressure, the poppet is pushed to the right side to
make the port P indexed with the port T, with the
result that the pressure is relieved. P
<Relief state>
Poppet Spring
T
2. Lever lock solenoid

If the lever lock solenoid(A) is OFF, the spool does SOL(A) SOL(B)
not allow the oil in the port P to flow to the port A.
If the lever lock solenoid(A) is ON, the spool moves
downward to permit the passage for the port P and A
to be opened. T
A B
P
Spool (B)
ANS0210L
- 116 -
13. SOLENOID VALVE 13.4. CONSTRUCTION
3. Travel motor high/low speed shifting solenoid

If the travel motor speed shifting solenoid(B) is OFF, SOL(A) SOL(B)
the oil discharged from the port P is shut off from the
port B by the spool(B), with the result that the pilot
pressure does not flow in the port B.
If the travel motor speed shifting solenoid(B) is ON, T
the spool(B) moves to allow the ports P and A to be
A B
opened.
P
Spool (B)
ANS0220L
- 117 -
14. CRAWLERS
14. CRAWLERS
14.1. SPECIFICATIONS AND CONSTRUCTION
14.1.1. Steel crawlers
SOLAR 030
300mm
Shoe
SOLAR 035
300mm
101.6mm Pin
14.1.2. Track frame
Idler
Track
frame
Guide Track Spring

roller
- 118 -

14.2.1. Crawler removal
• Crawler removal operation may very dangerous as it should be done with the machine inclined. Never
move the machine during removal operation so that the machine may not be tipped over.
• When loosening the cartridge valve, do not bring your face near the grease nipple because the inside
of the track tension adjusting cylinder is in a high pressure state and allow highly pressurized grease
to splash, with the result that the grease nipple may pop out.
1. Crawler loosening
• Loosening the cartridge valve of the tension 1
adjusting cylinder drains the grease to loosen the
crawlers. Loosen the cartridge valve slowly.
* The maximum amount of loosening can be
obtained if 1/2 turn is made.
• When removing the crawlers, position the machine

as shown and install non-slip supports under the
frames.
* If the grease would not be drained out easily,
turn the crawlers a little in the position as
shown.
• After completing the tension adjustment, tighten

the valve securely.
* Cartridge tightening torque: 6~9kg• m
2. Crawler removal
• Lift the machine in one side using the front and
install wood block under the machine.
• Steel crawlers
Remove the master pin(1) from the linkage by
turning it to the idler side, and then remove the 1
crawler(2).
2
• Rubber crawlers
Slide in the idler all the way, and remove the
rubber crawler from the idler using a steel bar.
- 119 -
14. CRAWLERS
14.2.2. Crawler installation

• Crawler installation operation may very dangerous as it should be done with the machine inclined.
Never move the machine during removal operation so that the machine may not be tipped over.
1. Crawler installation
• Lift the machine in one side using the front and
install wood block under the machine.
• Index the crawler(1) with the sprocket teeth and
then install it on top of the idler.
• For steel crawlers, insert the the master pin(2).
2
For rubber crawlers, install the crawler over the
idler.
1
2. Track tension adjustment

• With a grease gun, inject grease into the grease
nipple.
• Check
Measure the distance between the rolling surface
of the track roller and the contact surface of the
crawler.
Gap
a. For steel crawlers

It is accepted if the distance between the rolling Track roller
surface of the track roller and the contact
surface of the crawler is 10~15mm. 10~15mm
- 120 -
b. For rubber crawlers

Track roller
It is accepted if the distance between the rolling
surface of the track roller and the contact
surface of the crawler is 10~15mm. 10~15mm
• Make sure that the tension is properly adjusted.
• If tension is proper, tighten the cartridge valve.

Tightening torque: 6~9kg• m
• If tension is difficult to adjust although grease was

injected, it indicates that the pin and bush have
been severely worn. The bush must be replaced.
For rubber crawlers, check the track tension
adjusting cylinder seal and replace the seal, if
required.

14.3.1. Steel crawlers
1
5
4
3
No Item Standards Limits Remarks

1 Link pitch 101.6 mm 104 mm When measuring 5 links
2 Link height 60 mm 57.5 mm Build up or replace
3 Crawler height 6.5±1.5 mm 7 mm Build up or replace
4 Pin clearance 0.33 mm 2 mm Replace
5 Bush thickness 32.2 mm 29 mm Replace
- 121 -
14. CRAWLERS
14.3.2. Track frame spring

3
4
1
2
Unit: mm
No. Item Criteria Remarks

Limit
Bending 5(Overall length of track frame
1 Deformed frame Bent
Distorted 10(Distortion between left and right crawler frames)
Widened idler 5
Gap between Standards Limits

Build up or
2 upper and lower Track frame 126 131
replace
sides of idler guide Idler frame 124 119
Gap between left and Track frame 166 171 Build up or

3
right of idler guide Idler support 162±1.0 157 replace
Track spring Standards Limits

4 Replace
(Free length) 286.5 203.5
- 122 -
14.3.3. Rubber crawler features
Amount of friction
Limit of use
2 0
1 5
ce
rfa
rd
su
nda
e
1 0 a
ret
St
rth
nc
Ea
Co
0 5 00 1 000 1 500 2 000 2 500 3 000
Operating hours(H)
The amount of friction of the rubber crawler sets the limit of use. However, it is subject to change depending
upon the work condition and environment.
20
23
21.5
31.5
25
300
(Unit:mm)
52.5mm
Item SOLAR 035 SOLAR 030 Plus
Distance between centers of crawlers 4,410±12 3,990±10
Scale cord Rigid 800 kg 800 kg
Scale cord No. of coils 40±4 coils 40±4 coils
Range of temperature of use -25°C~55°C -25°C~55°C
Width x Pitch 300 x 52.5 300 x 52.5
- 123 -
15. IDLER
15. IDLER
15.1. CONSTRUCTION
8
7 1
6
5
4
2
3
4
5
6
8
7
1. Front idler assembly 5. C-type stopper ring

2. Idler 6. Oil seal(QLF 35, 72, 12, 19.5)
3. Shaft 7. Guide
4. Bearing(BL-207), 8. Spring pin (ø10x60L)

15.2.1. Disassembly procedures
• Refer to "Crawler Disassembly" to remove the crawlers and then idler assembly.
• Remove the spring pin(8) from the guide(7).
• Remove the guide(7) from the shaft(3).
• Remove the oil seal(6) using a screw driver.
* Once removed, the oil seal should not be reused.
• Remove the C-type stopper ring(5), bearing(4), and shaft(3).
15.2.2. Reassembly procedures

For reassembly, reverse the disassembly procedures.
• Clean segregated parts.
• Coat clean gear oil or engine oil(80cc) before assembling the oil seal(6).
• Refer "Crawler Installation" for crawler reassembly.
- 124 -

15.3.1. Idler(for steel crawlers)
1
2
5 3
No Item Unit Standard Limits Remarks

1 Outside diameter mm ø295 ø291 Build up or replace
2 Contact outside diameter mm ø269 ø265 Build up or replace
3 tab width mm 25 21 Build up or replace
4 Overall width mm 65 60 Build up or replace
5 Contact width mm 20 24 Build up or replace
6 Lubricant volume cc 80 80 Gear oil
- 125 -
15. IDLER
15.3.2. Idler(for rubber crawlers)
1
2
5 3

1 Outside diameter mm ø311 ø287 Build up or replace
3 tab width mm 26.2 22 Build up or replace
4 Overall width mm 65 60 Build up or replace
5 Contact width mm 19.4 24 Build up or replace
6 Lubricant volume cc 80 80 Gear oil
- 126 -
16.1. CONSTRUCTION
16. TRACK TENSION ADJUSTING CYLINDER

16.1. CONSTRUCTION
1 13 12 2 3 5 6 7 8 94
10
11
1. Plate 6. Backup ring(T2-P40) 11. Grease nipple(PT1/8-A)

2. Cylinder 7. Dust seal(DKR-40) 12. Castle nut
3. Spring 8. Spacer 13. Split pin
4. Rod 9. Snap ring(H-52)
5. O-ring(IB-P40) 10. Cartridge valve
16.2. SPRING SPECIFICATIONS
d
O.D
P.C.D
I.D
L
L1
L0
Designation Dimensions Designation Dimensions

No. of active coils 7.5 Minimum closed length 195.1
Total No. of coils 9 Outside diameter 107
Spring constant(kg/mm) 50.9 Mean diameter 85
Set load(kg) 2698 Inside diameter 63
Compressive load(kg) 4650 Wire diameter 22
Free length(mm):L0 286.5 Set length 233.5
- 127 -
16. TRACK TENSION ADJUSTING CYLINDER

• Be sure to use a special tool when removing the spring.
• Take care as the spring may pop out.
1
12
13
4 10
14 11
9
8
7
5
6
1. Plate 6. Backup ring 11. Grease nipple

2. Cylinder 7. Dust seal 12. Castle nut
3. Spring 8. Spacer 13. Split pin
4. Rod 9. Snap ring 14. Yoke
5. O-ring 10. Cartridge valve
16.3.1. Disassembly and reassembly procedures

1. Disassembly procedure
• Remove the crawlers and idlers.
• Remove the idler yoke(14).
• Use a press to relieve the spring force.
• Remove the split pin(14) and castle nut(12).
• Remove the spring(3) from the tension cylinder tube(2).
• Remove the cartridge valve(10) and grease nipple(11) together from the tension cylinder rod(4).
• Remove the cylinder rod(4) from the tension cylinder tube(2).
• Remove the snap ring(9), and then remove the spacer(8), dust seal(7), backup ring(6), and O-ring(5).
- 128 -
2. Reassembly procedure
Reverse the disassembly sequence for reassembly operation.
• Install the O-ring(5), backup ring(6), Dust seal(7), and spacer(8) to the cylinder tube(2).
To prevent damage, coat great to the O-ring and dust seal at assembly.
• Assemble the cylinder(4) to the cylinder tube(2).

First, inject great into the cylinder tube.
Install the cartridge valve(10) into the tension adjusting cylinder rod until two threaded portions contact
the threaded hole, and then assemble the cylinder rod.
At this time, ensure that grease is drained from the grease drain port, and then tighten the cartridge
valve.
* Cartridge valve tightening torque: 6~9 kg• m
• Use a special tool to install the spring(3) to the cylinder tube(2) and secure the spring in place with a
castle nut(12).
• After adjusting the spring set length, bend the split pin(13) completely.
* Spring set length: 233.5mm
CAUTION : • Release air from the cylinder tube completely before assembly.
• Be sure to apply grease to the piston area on the cylinder tube rod before assembly.
- 129 -
17. TRACK ROLLER
17. TRACK ROLLER

17.1. CONSTRUCTION
11 9
10 8
7
6 1
5
4
2
3
4
5
6
7
89
11
10
1. Track roller assembly 7. Spacer

2. Track roller 8. C-type stopper ring(S-35)
3. Shaft 9. Washer
4. Bearing(6207) 10. Spring washer
5. C-type stopper ring(H-72) 11. Nut(M20)
6. Oil seal(QLF35, 72.12, 19.5)

• Remove the crawler.
• Loosen the nut(11) and remove the track roller from the track frame.
• Remove the nut(11), spring washer(10), and washer (9), and then remove the C-type stopper ring(8)
and spacer(7).
• Use a screw driver to take out the oil seal(6).
* Once removed, the oil seal should not be reused.
• Remove the C-type stopper ring(5) and disconnect the bearing(4) and shaft(3).
2. Reassembly procedure
• Clean segregated parts with cleansing oil.
• Inject clean gear oil or engine oil(100cc) before assembling the oil seal(6).
• Refer to "Crawler Installation" to assemble the crawlers.
- 130 -

17.3.1. Track roller(for steel crawler)
3 5
7
6
2

1 Outside diameter mm ø115 – Build up or replace
3 tab width mm 24 21 Build up or replace
4 Overall width mm 108 – Build up or replace
5 Contact width mm 42 – Build up or replace
6 Side clearance mm 0.2±0.1 1.5 Replace bush
Tightening torque kg·m 34.5
- 131 -
17. TRACK ROLLER
17.3.2. Track roller(for rubber crawler)
3 5
7
2 6

1 Outside diameter mm ø135 – Build up or replace
3 tab width mm 26.2 23 Build up or replace
4 Overall width mm 108 – Build up or replace
5 Contact width mm 41 – Build up or replace
6 Side clearance mm 0.2±0.1 1.5 Replace bush
Tightening torque kg·m 34.5
- 132 -
18. SPROCKET
• Remove the crawler.
• Remove the sprocket clamping bolt(1) and
remove the sprocket(2) from the travel
motor.
2. Reassembly procedure 1
• Install the sprocket to the travel motor and
tighten the clamping bolt.
* Tightening torque: 11.5kg• m 2
• Assembly the crawler.
- 133 -
18. SPROCKET
5
2
4
3

1 Sprocket tooth width mm 25 19 Build up or replace
2 Sprocket deddendum diameter mm ø312.8 ø305 Build up or replace
3 Mounting bolt tightening torque kg·m 11.5 M12 x 1.75
4 Motor mounting bolt tightening torque kg·m 11.5 M12 x 1.75
ø190 SOLAR 030
5 Travel motor mounting hole mm
ø210 SOLAR 035
- 134 -
19.1. STEEL CRAWLER MOUNTING PROCEDURE
19. CRAWLER REPLACEMENT PROCEDURE

19.1. STEEL CRAWLER MOUNTING PROCEDURE
1. Remove the crawlers and idlers.
2. Loosen the track roller mounting bolt to remove the

track roller.
3. Mount the track roller for steel crawler.

Then, be sure to install a washer for steel crawler. Washer for steel crawler
4. Install the guide plate.

Tightening torque: 4.3.kg·m
Guide plate
5. Assemble the idler for steel crawler.
6. After installing the crawlers, adjust their tension.
- 135 -
19. CRAWLER REPLACEMENT PROCEDURE
19.2. REPLACEMENT OF STEEL CRAWLERS WITH RUBBER CRAWLERS

1. Remove the steel crawlers and track rollers for steel
crawler.
2. Remove the idlers for steel crawler.
3. Mount the track roller for rubber crawler.

Nut tightening torque: 34.5kg·m Washer for steel crawler
4. Remove the guide plate.
5. Install the idlers for rubber crawler.

Guide plate
6. After assembling the rubber crawlers, adjust their

tension.
- 136 -
HEATER HEATER OPTION
WIPER WIPER WASHER ROOM SWITCH
MOTOR SWITCH MOTOR LAMP M RADIO GROW PLUG
INDICATOR ALTERNATOR STARTER
M M MOTOR
R
S B B
SPEAKER
B
Br
RG
Br
Or
WR
Y
B
Or
W
SP B
BR
B
R
B
R
LW
L
L
LW
R
RY
BW
SERVO SERVO
RL
B
BY
UNIT SENSOR OIL SW
YG
W
BATTERY
GAUGE PANEL
RW FUSIBLE
RIGHT
SWITCH LINK(0.85R)
RY
HARZARD
LW
BL
L
SWITCH
Y
B
Or
W
LW
WTM M
B
Or
R
FUEL M
E/G STOP MOTOR
EHM M B
Y
B
20. ELECTRICAL DEVICE
Or
W
L
Br M
B
RY
RB
ILLUMINATION L B
B
Br
FUSIBLE
LINK(0.3W)
L
SAFETY UNIT
RG
B
L WR LW
YG
L R YG
WG YB
YW
B
- 137 -
L L
R
YW
L GR
RL B
L R
WG STARTER RELAY
BW
LW
Y
WORK LAMP G
BW
RW
HORN BR
YR
Y
B
BL
Br
B
LB
GR
RG
LB
RG
BY
BR
YL
YB
YW
BY
B
RB
RY
R
BY
RY
WL
YL
WL
W
RW
W
R
BM
Or
G
L
Or
Or
RY
RG
Or
WR
Br
WR
WB
WB
YW
FUEL SENSOR
E/G GND
20.1. ELECTRICAL CIRCUIT DIAGRAM(SOLAR 030 PLUS/035)
BR
B
10A
10A
15A
10A
15A
3A
10A
10A
RL
GH SPEED Or
SWITCH
Or QOS CONTROLLER FUEL PUMP
CRO SWITCH
Br RIGHT RELAY PREHEAT RELAY
(R.H) C ACC
(SRM-12C
B BR NORMAL OPEN)
Or
CRO SWITCH GY R2
(L.H) FUSE BOX
RL
B
BR
B
GY
B
TML
HARNESS STARTER SWITCH
PST B BR ACC R2 C
GND
OFF
HORN SWITCH
ON
START
KEY SWITCH CONNECTION

SOLENOID ASS'Y
20.1. ELECTRICAL CIRCUIT DIAGRAM
20.2. TROUBLESHOOTING
20.2.1. STARTER
Complaints Causes Corrections
Pinion would not slide out • Open wiring, bad contact of battery with Correct
if the starter switch is ON. switch terminal
• Spline which is engaged with the armature Correct spline.
shaft pinion had been worn causing the
pinion to fail to operate.
• Plunger of magnetic switch malfunction, or Correct• Replace
coil short or open.
Pinion engages with ring • Open cable which connects the battery and Tighten or replace
gear, but starter does not magnetic switch
rotate. • Improper connection of connecting wires Tighten or replace
which connect the magnetic switch and motor
terminal
• Improper engagement of pinion with ring gear Correct teeth.
• Excessive wear of brush, and contact of Correct• Replace
brush with spring
• Commutator contaminated Correct
• Armature and field coil defective Correct• Replace
• Improper tightening of field coil and brush Correct
contact surface
• Contractor improperly contacted Correct
• Contractor contact surface not smooth Correct
Pinion rotates at high speed • Plunger cap improperly adjusted Adjust

before engaging with the
ring gear.
Pinion gear is engaged with • Overrun clutch defective Replace

ring gear and the starter
rotates, but the engine does
not rotate.
Starter would not stop • Inside of switch short Replace switch.

although the switch is turned • Connector missing Replace
to OFF after starting.
- 138 -
20.2 TROUBLESHOOTING
20.2.2. Regulator
Hard to charge • Each wiring open Repair

• Each connector improperly contacted Repair
• Low-speed side point improperly contacted Repair
• No-load voltage lower than rated Adjust
• Rotor-press fit resistor open Replace
Battery overcharged • Low-speed side point deposited Repair• Replace

• High-speed side point contact improper Repair• Replace
• Voltage regulator volt coil open and resistor Replace
open
• Unloaded set voltage higher than rated Adjust
• Circuits for terminal I and terminal F short Repair• Replace
Pilot lamp lights. • Each connector loosely connected Repair

• Field relay and coil open Replace
• Field relay and point contact improperly Correct
• Unloaded voltage higher than rated Adjust
• Pilot lamp circuit short Repair
Fuse broken • Set voltage higher than rated Adjust
- 139 -
20.2.3. Alternator
Fails to charge • Cords between each terminal open or Correct

connector improperly contacted
• Improper grounding Correct
• Improper contact between brush and spring Correct• Replace
• Start coil open or lost Correct• Replace
• Rotor coil open or lost Correct• Replace
• Diode lost Replace
Insufficiently charged • Cords between each terminal loosened Correct

• V-belt slipped Correct
• Improper contact between brush and spring Sleeve ring worn
• Rotor coil short Correct• Replace
• Start coil open or short Correct• Replace
• Bad diode Replace
Overcharged • Circuits for terminal A and F short Correct
Received current unstable • Cords between each terminal loosened Correct

• V-belt loosened Correct
• Brush contact improper Correct • Replace
• Rotor coil open or short Correct • Replace
• Start coil open or short Correct • Replace
• Start coil and diode loosely contacted Correct
Joints • Bad joining face Replace

• V-belt defective Replace
• Bearing unacceptable Replace
• Diode defective Correct • Replace
• Start cord unacceptable
• Correct
Fuse open • +/- sides of diode improper Replace

• Insufficient capacity Replace
- 140 -

Solar 030 Plus / 035

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023-00046E Shop Manual

2. GENERAL INFORMATION ....................................................................................... 23

3. WORKING ATTACHMENTS ..................................................................................... 40

5. MAIN PUMP .............................................................................................................. 50

6. HYDRAULIC OIL FILTER ......................................................................................... 57

7. CONTROL VALVE .................................................................................................... 63

8. SWING MOTOR ........................................................................................................ 76

9. TRAVEL MOTOR ...................................................................................................... 85

11. SWIVEL JOINT ....................................................................................................... 105

12. JOY STICK ............................................................................................................. 109

13. SOLENOID VALVE ................................................................................................. 113

14. CRAWLERS ............................................................................................................ 118

15. IDLER .......................................................................................................................124

16. TRACK TENSION ADJUSTING CYLINDER .......................................................... 127

17. TRACK ROLLER .................................................................................................... 130

18. SPROCKET ............................................................................................................ 133

19. CRAWLER REPLACEMENT PROCEDURE .......................................................... 135

20. ELECTRICAL DEVICE ........................................................................................... 137

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

2) Heavy Equipment Operation

1.2. SAFETY MESSAGES

DANGER : This message indicates an

WARNING : This message indicates a

1.3. SAFE OPERATION

3) Use handrail and steps whenever you get

5) Use seat belts(optional equipment)

6) Stay in seat while starting, operating and

7) Watch for safety and traffic signals when

9) How to prevent machine from moving

Jumping onto or attempting to hold on to a

• Park machine so that there is enough

10) Precautions for turning and traveling in

11) To prevent accidents.

12) Never carry people in or on the machine.

13) Be careful of underground utilities

14) Be aware of buildings, fences and other

16) Be careful of power cables.

Cable Voltage (Kv) Minimum Clearance m A

• Check with local power companies about

17) Never use machine for lifting.

18) Safe Loading, Unloading and Transport

19) Handle fuel and oil carefully (Do not allow

20) Keep first-aid kits and fire extinguishers

21) Keep the inside and outside of the

22) Wear proper clothing

23) Protect yourself from flying or falling

24) Be careful of exhaust gases when oper-

25) Safe Inspection and Safe Maintenance

• Park the machine safely (see Number 9).

26) Inspection and Service Cautions

27) Keep machine clean at all times

28) Block up machine securely

29) Never touch moving parts

30) Be careful with hydraulic oil under

31) Fire prevention

(2) Electric cable and wiring

32) Prevention of battery explosion

33) Burn Prevention

(2) Do not allow hot engine, gear or hydraulic

34) Remove coating before welding or heating

35) Do not heat hydraulic system and piping.

36) Store attachments safely