Daewoo Excavator Solar 290LL Shop Manual 2023-7132E – PDF

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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

S.S 06/24