Daewoo Excavator Solar 290LL Shop Manual 2023-7132E – PDF DOWNLOAD
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Daewoo Excavator Solar 290LL Shop Manual 2023-7132E – PDF DOWNLOAD
Language : English
Pages : 454
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Daewoo Excavator Solar 290LL Shop Manual 2023-7132E – PDF DOWNLOAD
Safety................................................................................................ 7 Track Excavator Safety S0102010................................................................... 9 To the Operator of a Daewoo Excavator......................................................... 11 Learn the Signal Words Used with the Safety Alert Symbol.................................. 11 General Safety Essentials..................................................................... 13 Accessory Applications.................................................................... 13 Lifting Capacity Rating Configuration..................................................... 13 Location of Safety Labels..................................................................... 13 Summary of Safety Precautions for Lifting in Digging Mode..................................... 14 Unauthorized Modifications................................................................ 14 Work-site Precautions......................................................................... 15 Attachment Precautions.................................................................... 15 Avoid High-voltage Cables................................................................. 15 Be Aware of Height Obstacles.............................................................. 15 Use Care on Loose Support................................................................. 15 Use Solid Support Blocking................................................................ 16 Overhangs Are Dangerous................................................................... 16 Sloping Terrain Requires Caution.......................................................... 16 Stay Alert for People Moving through the Work Area........................................ 16 Be Aware of and Conform to Local Regulations.............................................. 17 Operation..................................................................................... 17 Operate While Seated at the Operator’s Station ONLY....................................... 17 Before Starting the Engine................................................................ 17 Never Use Ether Starting Aids............................................................. 18 Mounting and Dismounting.................................................................. 18 Observe General Safety Rules.............................................................. 18 Engine Ventilation........................................................................ 18 Asbestos Dust Hazard Prevention........................................................... 18 Take Time to Provide Good Visibility...................................................... 19 Fuel, Oil and Hydraulic Fluid Fire Hazards................................................ 19 Boost Starting or Charging Engine Batteries............................................... 19 Travel Controls May Produce Reversed Operations........................................... 20 Keep "Pinch Point" Areas Clear - Use Caution in Reverse & Swing........................... 20 Travel Precautions........................................................................ 20 Operate Carefully on Snow and Ice and in Very Cold Temperatures........................... 20 Parking the Machine....................................................................... 21 Shutdown Control Functions................................................................ 21 Additional Operational Comments........................................................... 21 Equipment..................................................................................... 22 Rough Operation May Require Use of Certified Safety Equipment............................. 22 Install Additional Safety Equipment If Conditions Require................................. 22 Movement Alarms........................................................................... 22 Seat Belts Should Be Used at All Times.................................................... 23 Window Glass Breaking Tool................................................................ 23 Keep a Fire Extinguisher at Hand.......................................................... 23 Maintain Standard Safety Equipment in Good Condition...................................... 23 Safety - critical Parts Must Be Replaced Periodically..................................... 23 Hydraulic Cylinder Seals Require Periodic Replacement..................................... 24 High Pressure Hydraulic Lines Can Store a Great Deal of Energy............................ 24 The Operator’s Cab and Turntable Deck Should Be Kept Clean................................ 24 Wear Eye Protection and Safety Clothing................................................... 24 Breathing Masks, Ear Protection May Be Required........................................... 24 Battery Electrolyte and Explosive Gases Can Be Lethal..................................... 25 Disconnect Batteries for Electrical Service Before Electrical Welding..................... 25 Use Low Heat Portable Lighting............................................................ 25 Maintenance................................................................................... 26 Use Warning Tag Control Lockout Procedures During Service................................. 26 Do not Run the Engine If Repairs or Work Is Being Performed Alone......................... 26 Always Use Adequate Equipment Supports and Blocking....................................... 26 Do not Work on Hot Engines or Hot Cooling or Hydraulic Systems............................ 26 Cool-down Is Required Prior to Radiator or Reservoir Checks............................... 27 Pressurized Hydraulic Oil Fluid Leaks Can Be Dangerous.................................... 27 Obtain immediate medical attention if pressurized oil pierces the skin.................... 27 Use Correct Replacement Fasteners Tightened to Proper Torque.............................. 27 Dispose of All Petroleum-based Oils and Fluids Properly................................... 28 Track Tension Adjustments Require Caution................................................. 28 Do not attempt repairs you do not understand. There is no disgrace in asking for help..... 28 All Welding Should Be Performed By Qualified Welder....................................... 28 Cylinders................................................................................. 28 Hydraulic Cylinders, Pins and Bushings.................................................... 29 Shipping and Transportation................................................................... 30 Obey State and Local Over-the-Road Regulations............................................ 30 Lifting With Sling............................................................................ 30 Specifications........................................................................................ 31 Specifications for Solar 290LL S0202010........................................................... 33 General Description........................................................................... 35 General Dimensions............................................................................ 38 Dimensions And Working Range.................................................................. 40 General Specifications........................................................................ 41 Engine Performance Curve...................................................................... 42 Performance Tests............................................................................. 44 Excavator Performance Standards............................................................... 45 Test Conditions........................................................................... 45 Travel Speed and Travel Motor Balance (Steering Deviation) Tests.......................... 45 Cylinder Performance Tests................................................................ 48 General Maintenance................................................................................... 49 General Maintenance Procedures S0302000........................................................... 51 Welding Precautions and Guidelines............................................................ 53 Hydraulic System - General Precautions........................................................ 54 Maintenance Service and Repair Procedure...................................................... 55 General Precautions....................................................................... 55 Hydraulic System Cleanliness And Oil Leaks.................................................... 56 Maintenance Precautions for Hydraulic System Service...................................... 56 Oil Leakage Precautions................................................................... 56 Cleaning and Inspection....................................................................... 57 Genral Guidelines......................................................................... 57 Bearing inspection........................................................................ 58 Standard Torques S0309000......................................................................... 65 Torque Values for Standard Metric Fasteners................................................... 67 Torque Values for Standard U.S. Fasteners..................................................... 68 Type 8 Phosphate Coated Hardware.............................................................. 70 Torque Values for Hose Clamps................................................................. 71 Torque Values for Split Flanges............................................................... 72 Torque Wrench Extension Tools................................................................. 73 Torque Multiplication..................................................................... 73 Other Uses for Torque Wrench Extension Tools.............................................. 74 Tightening Torque Specifications (Metric)................................................. 74 Upper Structure....................................................................................... 77 Cab S0402000...................................................................................... 79 Removal....................................................................................... 81 Installation.................................................................................. 83 Window and Gasket Replacement................................................................. 86 Falling Object Protective Structures (F.O.P.S.)............................................... 87 Counterweight S0403000............................................................................ 89 General....................................................................................... 91 Removal....................................................................................... 92 Installation.................................................................................. 94 Fuel Tank S0405050................................................................................ 95 General Description........................................................................... 97 Parts List................................................................................ 98 Specifications............................................................................ 99 Removal.......................................................................................100 Installation..................................................................................104 Start-up Procedures...........................................................................106 Swing Bearing S0407000............................................................................107 Swing Bearing Maintenance.....................................................................109 Operating Recommendation..................................................................109 Measuring Swing Bearing Axial Play........................................................109 Measuring Bearing Lateral Play............................................................109 Swing Bearing Basic Operation.............................................................110 Rebuilding Swing Bearing..................................................................110 Swing Reduction Gearbox S0408000..................................................................113 General Description...........................................................................115 Theory of Operation.......................................................................115 Parts List................................................................................116 Specifications............................................................................117 Troubleshooting, Testing and Adjustment.......................................................118 Removal.......................................................................................119 Disassembly...................................................................................120 Cleaning and Inspection (Wear Limits and Tolerances)..........................................123 Reassembly....................................................................................124 Installation..................................................................................128 Lower Structure and Chassis...........................................................................129 Track Assembly S0505010...........................................................................131 General Description...........................................................................133 Track Tension.................................................................................133 Cleaning and Inspection (Wear Limits and Tolerances)..........................................135 Track Shoes and Links.........................................................................138 Track Removal.............................................................................138 Track Installation........................................................................139 Front Idler Roller............................................................................140 Parts List................................................................................140 Front Idler Roller Disassembly............................................................141 Front Idler Roller Reassembly.............................................................143 Lower/Upper Roller............................................................................144 Parts List................................................................................144 Lower Roller Removal......................................................................145 Lower Roller Disassembly..................................................................145 Lower Roller Reassembly...................................................................146 Lower Roller Installation.................................................................147 Upper Roller Removal/Installation.........................................................147 Track Spring And Track Adjusting Cylinder.....................................................148 Parts List................................................................................148 Engine and Drive Train................................................................................151 Air-Conditioner S0605010..........................................................................153 General Description...........................................................................155 Refrigerant Circulation.......................................................................156 Control Panel.................................................................................158 Control Specifications........................................................................159 Temperature Level Control and Display.........................................................160 Air Discharge According to Path Selection.....................................................161 Air-conditioning System Circuit Diagram.......................................................164 Troubleshooting...............................................................................166 Refrigerant System Repairs....................................................................169 Refrigerant Safe Handling Procedures......................................................169 Repair and Replacement Procedure..........................................................170 Refrigerant Recovery......................................................................172 Vacuuming Refrigerant System..............................................................172 Leakage Check.............................................................................173 Refrigerant Charging......................................................................174 Inspecting System For Leakage.............................................................176 Hydraulics............................................................................................177 Hydraulic System Troubleshooting, Testing and Adjustment S0702000.................................179 Hydraulic System - General Notes..............................................................182 Hydraulic Schematic...........................................................................183 General Notes.............................................................................183 Operation of Working Components...............................................................184 Boom Operating Circuit....................................................................184 Boom Up Circuit...........................................................................184 Boom Down Circuit.........................................................................184 Arm Operating Circuit.....................................................................184 Arm Crowd Circuit.........................................................................185 Arm Dump Circuit..........................................................................185 Bucket Operating Circuit..................................................................186 Bucket Crowd Circuit......................................................................186 Bucket Dump Circuit.......................................................................186 Swing Operating Circuit...................................................................186 Right Swing Operating Circuit.............................................................187 Left Swing Operating Circuit..............................................................187 Swing Relief Valve and Make-up Valve......................................................187 Travel Operating Circuit..................................................................187 Forward Travel Circuit....................................................................188 Reverse Travel Circuit....................................................................188 Procedural Troubleshooting Baseline Recommendations...........................................189 Initial Checks and Tests to Establish Operating Condition of the Excavator................189 Pilot Pressure................................................................................190 Adjustment and Testing....................................................................190 Power Mode Valve..............................................................................191 Current Signal and Hydraulic Pressure Adjustments.........................................191 Boom/Swing Priority Valve.....................................................................192 Control Valve Pressure and Current Adjustments............................................192 Pressure Up Valve.............................................................................193 Checks and Adjustments....................................................................193 Pump Input Power Control......................................................................195 Pump Regulator Adjustment.................................................................195 Flow Meter and Flow Meter Kit Installation and Testing........................................197 Swing System Troubleshooting..................................................................199 Precautions/Initial Checks................................................................199 Swing Relief Valve Checking and Adjustment................................................199 Troubleshooting – Swing Gearbox...............................................................201 Troubleshooting – Hydraulic Problems..........................................................202 Troubleshooting – Control Valve...............................................................203 Troubleshooting – Travel Control Valve........................................................205 Troubleshooting – Joystick Control Valve......................................................205 Accumulator S0703000..............................................................................207 General Description...........................................................................209 Specifications............................................................................210 Accumulator Charging..........................................................................211 Charging the Accumulator with Nitrogen....................................................211 Center Joint (Swivel) S0704000....................................................................213 General Description...........................................................................215 Parts List................................................................................216 Troubleshooting, Testing and Adjustment.......................................................217 Inspection................................................................................217 Testing...................................................................................217 Disassembly...................................................................................218 Reassembly....................................................................................218 Swing Motor S0707200..............................................................................221 General Description...........................................................................223 Theory of Operation.......................................................................223 Swing Motor Anti-cavitation Make-up Valve.................................................224 Relief Valve..............................................................................225 Swing Brake Operation.....................................................................225 Parts List................................................................................228 Specifications............................................................................229 Special Tools.................................................................................230 Disassembly...................................................................................231 Cleaning and Inspection (Wear Limits and Tolerances)..........................................238 Reassembly....................................................................................240 Travel Motor (With Gearbox) (Kawasaki DNB Series) S0707310........................................247 General Description...........................................................................249 Theory of Operation.......................................................................249 Travel Motor Parts List...................................................................258 Travel Reduction Gearbox Parts List.......................................................260 Specifications............................................................................261 Special Tools and Materials...................................................................264 Special Tools.............................................................................264 Troubleshooting, Testing and Adjustment.......................................................266 General Notice............................................................................266 Troubleshooting...........................................................................266 Disassembly...................................................................................270 General Notes for disassembly.............................................................270 Reduction Gearbox.........................................................................270 Hydraulic Motor...........................................................................274 Cleaning and Inspection (Wear Limits and Tolerances)..........................................280 General Inspection........................................................................280 Assembly..................................................................................280 Pipe laying...............................................................................281 Gear oil..................................................................................281 General Notice............................................................................282 Wear Limits...............................................................................282 Reassembly....................................................................................286 General Instructions for Reassembly.......................................................286 Hydraulic Motor...........................................................................286 Reduction Gearbox.........................................................................292 Main Pump (With Regulator) S0708300...............................................................299 General Description...........................................................................301 Gear (Pilot) Pump.........................................................................304 Relief Valve..............................................................................304 Pump Regulator Description................................................................304 Horsepower Control........................................................................304 Power Shift Control.......................................................................305 Negative Oil Discharge (Pump Bypass) Control..............................................305 Pump Regulator Operation..................................................................305 Pump Output Decrease......................................................................307 Pump Discharge Decrease...................................................................307 Pump Discharge Increase...................................................................307 Horsepower Control........................................................................307 Overload Protection.......................................................................308 Regulator Adjustment......................................................................308 Pump Input Power Control Adjustment.......................................................309 Parts List................................................................................310 Specifications............................................................................314 Hydraulic Pump Performance Characteristics................................................314 Troubleshooting, Testing and Adjustment.......................................................316 Main Pump.................................................................................316 Disassembly...................................................................................317 General Disassembly.......................................................................317 Main Pump Disassembly.....................................................................318 Pump Regulator Disassembly................................................................320 Cleaning and Inspection (Wear Limits and Tolerances)..........................................324 Reassembly....................................................................................326 Pump Regulator Reassembly.................................................................326 Main Pump Reassembly......................................................................330 Remote Control Valve (Work Lever / Joystick) S0709450.............................................333 General Description...........................................................................335 Theory of Operation.......................................................................335 Parts List................................................................................336 Specifications............................................................................337 Hydraulic Specifications..................................................................338 Special Tools.................................................................................339 Disassembly...................................................................................340 Reassembly....................................................................................345 Travel Control Valve (RCV8C4015A) S0709800........................................................351 General Description...........................................................................353 Theory of Operation.......................................................................353 Parts List................................................................................356 Specifications............................................................................357 Torque Table..............................................................................357 Special Tools and Materials...................................................................358 Special Tools.............................................................................358 Troubleshooting, Testing and Adjustment.......................................................360 Disassembly...................................................................................361 Cleaning and Inspection (Wear Limits and Tolerances)..........................................368 Reassembly....................................................................................369 Hydraulic Schematic (S290LL) S0792030.............................................................379 General Description...........................................................................381 Solar 290LL...................................................................................382 Electrical System.....................................................................................385 Electrical System S0802000........................................................................387 Troubleshooting - Electrical System...........................................................390 Wiring Harness Illustrations..................................................................391 Overview......................................................................................391 Electric Supply System........................................................................392 Engine Starting Circuit.......................................................................394 Operation During Start Process............................................................394 Operation After Start Process.............................................................395 Engine Preheating System......................................................................397 Engine Stop System............................................................................398 Charging System...............................................................................402 Monitoring System.............................................................................403 Instrument Panel..............................................................................404 Function Check................................................................................406 Monitoring System Schematic...............................................................406 Operation.....................................................................................408 Instruments...............................................................................408 Mode Select Switch............................................................................410 Pilot Lamp....................................................................................411 Initial Operation.............................................................................412 Electronic Hydraulic Control System (Epos - V)................................................414 Power Mode Control............................................................................416 Operation.................................................................................417 Power Mode Control - Circuit Diagram..........................................................422 Work Mode Control.............................................................................424 Operation.................................................................................425 Work Mode Control - Circuit Diagram...........................................................426 Engine Control System.........................................................................427 Engine Control Motor..........................................................................428 Engine Control Dial...........................................................................429 Engine Control Circuit Diagram................................................................431 Automatic Deceleration Control (Auto Idle Control)............................................432 Engine Overheat Protection System.............................................................433 Power Boost Mode..............................................................................434 Operation.................................................................................434 Power Boost Control - Circuit Diagram.....................................................435 Automatic Travel Speed Control................................................................436 Automatic Travel Speed Control - Circuit Diagram..........................................437 Engine Control Device - Adjustment............................................................438 Self-diagnostic Function......................................................................441 EPOS-V Controller.........................................................................441 Engine Throttle Controller....................................................................445 Electrical Schematic (S290LL) S0892030............................................................447 General Description...........................................................................449 Solar 290LL...................................................................................450 Attachments...........................................................................................453
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