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Daewoo Excavator Solar 300LL Shop Manual 023-00079E – PDF
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Description
Daewoo Excavator Solar 300LL Shop Manual 023-00079E – PDF DOWNLOAD
FILE DETAILS:
Daewoo Excavator Solar 300LL Shop Manual 023-00079E – PDF DOWNLOAD
Language : English
Pages : 696
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Daewoo Excavator Solar 300LL Shop Manual 023-00079E – PDF DOWNLOAD
Publication Request for Proposed Revision................................................. 7 Safety.................................................................................... 9 Track Excavator Safety S0102015K...................................................... 11 To the Operator of a Daewoo Excavator............................................. 13 Learn the Signal Words Used with the Safety Alert Symbol...................... 15 General Safety Essentials......................................................... 16 Accessory Applications........................................................ 16 Lifting Capacity Rating Configuration......................................... 16 Location of Safety Labels......................................................... 16 Summary of Safety Precautions for Lifting in Digging Mode......................... 17 Unauthorized Modifications........................................................ 18 General Hazard Information........................................................ 18 Safety Rules.................................................................. 18 Safety Features............................................................... 18 Inside Operator's Compartment................................................. 19 Clothing and Personal Protective Items........................................ 19 Breathing Masks, Ear Protection May Be Required............................... 20 Vibration Level Information................................................... 20 Mounting and Dismounting...................................................... 20 Fuel, Oil and Hydraulic Fluid Fire Hazards.................................... 21 Precautions When Handling Fluids at High Temperature.......................... 21 Asbestos Dust Hazard Prevention............................................... 22 Injury from Work Equipment.................................................... 22 Fire Extinguisher and First Aid Kit........................................... 23 Protection from Falling or Flying Objects..................................... 23 Attachment Precautions........................................................ 24 Accumulator................................................................... 24 Indoor Ventilation............................................................ 25 Emergency Exit................................................................ 25 Before Starting Engine............................................................ 26 Work Site Precautions......................................................... 26 Checks Before Starting Engine................................................. 27 Engine Starting............................................................... 28 Before Operating Machine...................................................... 28 Machine Operation................................................................. 29 When Swinging or Changing Direction of Travel................................. 29 Travel Precautions............................................................ 30 Traveling on Slopes........................................................... 31 Prohibited Operations......................................................... 31 Precautions for Operation..................................................... 32 Avoid High Voltage Cables..................................................... 33 Operate Carefully on Snow, Ice and in Very Cold Temperatures.................. 33 Operations on Slopes.......................................................... 34 Parking Machine............................................................... 34 Never Let Anyone Ride on Attachment........................................... 34 Maintenance....................................................................... 35 Warning Tag................................................................... 35 Clean Before Inspection or Maintenance........................................ 35 Proper Tools.................................................................. 36 Use of Lighting............................................................... 36 Fire Prevention and Explosion Prevention...................................... 36 Burn Prevention............................................................... 37 Welding Repairs............................................................... 38 Warning for Counterweight and Front Attachment Removal........................ 38 Precautions for Removal, Installation, and Storage of Attachments............. 39 Precautions When Working on Machine........................................... 39 Lock Inspection Covers........................................................ 39 Crushing Prevention and Cutting Prevention.................................... 40 Track Tension Adjustments Require Caution..................................... 40 Supports and Blocking for Work Equipment...................................... 40 Action When Abnormally Is Found During Inspection............................. 41 Precautions with Highpressure Line, Tubes and Hoses.......................... 41 Waste Materials............................................................... 42 Battery........................................................................... 43 Battery Hazard Prevention..................................................... 43 Boost Starting or Charging Engine Batteries................................... 44 Towing............................................................................ 45 Precautions When Towing....................................................... 45 Shipping and Transportation....................................................... 46 Obey State and Local OvertheRoad Regulations................................ 46 Lifting With Sling................................................................ 46 Specifications............................................................................ 47 Specifications for Solar 300LL S0202160K.............................................. 49 General Description............................................................... 51 General Dimensions................................................................ 54 Dimensions and Working Range...................................................... 56 General Specifications............................................................ 57 Engine Performance Curves (Per DIN6270 Standard)................................. 58 Approximate Weight of Workload Materials.......................................... 60 Performance Tests................................................................. 63 Excavator Performance Standards................................................... 64 Test Conditions............................................................... 64 Travel Speed and Travel Motor Balance (Steering Deviation) Tests.............. 64 Cylinder Performance Tests.................................................... 67 General Maintenance....................................................................... 69 General Maintenance Procedures S0302000............................................... 71 Welding Precautions and Guidelines................................................ 73 Hydraulic System General Precautions............................................ 74 Maintenance Service and Repair Procedure.......................................... 75 General Precautions........................................................... 75 Hydraulic System Cleanliness and Oil Leaks........................................ 76 Maintenance Precautions for Hydraulic System Service.......................... 76 Oil Leakage Precautions....................................................... 76 Cleaning and Inspection........................................................... 77 General Guidelines............................................................ 77 Bearing inspection............................................................ 78 Standard Torques S0309000............................................................. 85 Torque Values for Standard Metric Fasteners....................................... 87 Torque Values for Standard U.S. Fasteners......................................... 88 Type 8 Phosphate Coated Hardware.................................................. 90 Torque Values for Hose Clamps..................................................... 91 Torque Values for Split Flanges................................................... 92 Torque Wrench Extension Tools..................................................... 93 Torque Multiplication......................................................... 93 Other Uses for Torque Wrench Extension Tools.................................. 94 Tightening Torque Specifications (Metric)..................................... 94 Upper Structure........................................................................... 97 Cab S0402040K......................................................................... 99 Removal...........................................................................101 Installation......................................................................104 Counterweight S0403000................................................................107 General...........................................................................109 Removal...........................................................................111 Installation......................................................................113 Fuel Tank \S0405050...................................................................115 General Description...............................................................117 Parts List....................................................................118 Specifications................................................................119 Removal...........................................................................120 Installation......................................................................124 Startup Procedures...............................................................126 Fuel Transfer Pump S0405500...........................................................127 General Description...............................................................129 Theory of Operation...........................................................129 Troubleshooting...................................................................130 Replacement of Rotor and Vane.....................................................130 Replacement of Rear Cover.........................................................131 Replacement of Armature...........................................................132 Swing Bearing S0407000................................................................133 Swing Bearing Maintenance.........................................................135 Operating Recommendation......................................................135 Measuring Swing Bearing Axial Play............................................135 Measuring Bearing Lateral Play................................................135 Swing Bearing Basic Operation.................................................136 Rebuilding Swing Bearing......................................................136 Swing Reduction Gear S0408070K........................................................139 General Description...............................................................141 Theory of Operation...........................................................141 Parts List....................................................................142 Specifications................................................................143 Special Tools and Materials.......................................................144 Special Tools.................................................................144 Troubleshooting, Testing and Adjustment...........................................147 Removal...........................................................................148 Disassembly.......................................................................150 Cleaning and Inspection (Wear Limits and Tolerances)..............................154 Reassembly........................................................................155 Installation......................................................................160 Startup Procedures...............................................................161 Lower Structure and Chassis...............................................................163 Track Assembly S0505010...............................................................165 General Description...............................................................167 Track Tension.....................................................................167 Cleaning and Inspection (Wear Limits and Tolerances)..............................169 Track Shoes and Links.............................................................172 Track Removal.................................................................172 Track Installation............................................................173 Front Idler Roller................................................................174 Parts List....................................................................174 Front Idler Roller Disassembly................................................175 Front Idler Roller Reassembly.................................................177 Lower/Upper Roller................................................................178 Parts List....................................................................178 Lower Roller Removal..........................................................179 Lower Roller Disassembly......................................................179 Lower Roller Reassembly.......................................................180 Lower Roller Installation.....................................................181 Upper Roller Removal/Installation.............................................181 Track Spring and Track Adjusting Cylinder.........................................182 Parts List....................................................................182 Engine and Drive Train....................................................................185 Air Conditioner S0605060K.............................................................187 General Description...............................................................189 Refrigerant Circulation...........................................................191 Control Panel.....................................................................193 Control Specifications............................................................194 Temperature Level Control and Display.............................................195 Air Discharge According to Path Selection.........................................196 Airconditioning System Circuit Diagram...........................................198 Troubleshooting...................................................................200 Weight of R134a Gas Used In Machines..............................................202 Refrigerant System Repairs........................................................204 Refrigerant Safe Handling Procedures..........................................204 Repair and Replacement Procedure..............................................205 Refrigerant Recovery..........................................................207 Vacuuming Refrigerant System..................................................207 Leakage Check.................................................................209 Refrigerant Charging..........................................................209 Inspecting System for Leakage.................................................211 Drive Coupling (Main Pump) S0609010K..................................................213 Drive Coupling....................................................................215 Special Tools.....................................................................218 Drive Coupling Installation.......................................................220 Installation Procedure........................................................222 Hydraulics................................................................................223 Hydraulic System Troubleshooting, Testing and Adjustment S0702170K....................225 Hydraulic System General Notes..................................................228 Hydraulic Schematic...............................................................229 General Notes.................................................................229 Operation of Working Components...................................................230 Boom Operating Circuit........................................................230 Boom Up Circuit...............................................................230 Boom Down Circuit.............................................................230 Arm Operating Circuit.........................................................231 Arm Crowd Circuit.............................................................231 Arm Dump Circuit..............................................................231 Bucket Operating Circuit......................................................232 Bucket Crowd Circuit..........................................................232 Bucket Dump Circuit...........................................................232 Swing Operating Circuit.......................................................232 Right Swing Operating Circuit.................................................233 Left Swing Operating Circuit..................................................233 Swing Relief Valve and Makeup Valve...........................................233 Travel Operating Circuit......................................................233 Forward Travel Circuit........................................................234 Reverse Travel Circuit........................................................234 Procedural Troubleshooting Baseline Recommendations...............................234 Initial Checks and Tests to Establish Operating Condition of the Excavator....234 Pilot Pressure....................................................................236 Adjustment and Testing........................................................236 Power Mode Valve..................................................................238 Current Signal and Hydraulic Pressure Adjustments.............................238 Swing Priority Valve..............................................................240 Control Valve Pressure and Current Adjustments................................240 Pressure Up Valve.................................................................241 Checks and Adjustments........................................................241 Pump Input Power Control..........................................................243 Pump Regulator Adjustment.....................................................243 Flow Meter and Flow Meter Kit Installation and Testing............................248 Swing System Troubleshooting......................................................250 Precautions/Initial Checks....................................................250 Swing Relief Valve Checking and Adjustment....................................250 Troubleshooting – Swing Gearbox...................................................252 Troubleshooting – Hydraulic Problems..............................................254 Troubleshooting – Control Valve...................................................256 Troubleshooting – Travel Control Valve............................................258 Troubleshooting – Joystick Control Valve..........................................259 Accumulator S0703010K.................................................................261 General Description...............................................................263 Specifications................................................................264 Center Joint (Swivel) S0704080K.......................................................267 General Description...............................................................269 Parts List....................................................................270 Troubleshooting, Testing and Adjustment...........................................271 Inspection....................................................................271 Testing.......................................................................271 Disassembly.......................................................................272 Reassembly........................................................................273 Cylinders S0705000....................................................................275 General Description...............................................................277 Theory of Operation...........................................................277 Parts List....................................................................278 Special Tools and Materials.......................................................280 Piston Nut....................................................................280 Piston Jig....................................................................284 Steel Bushing Jig.............................................................288 Dust Wiper Jig................................................................292 Slipper Seal Jig..............................................................298 Slipper Seal Straightening Jig................................................302 Disassembly.......................................................................305 Assembly..........................................................................311 Swing Motor (Toshiba MFC200) S0707270K................................................315 General Description...............................................................318 Theory of Operation...........................................................318 Parts List....................................................................326 Specifications................................................................328 Special Tools and Materials.......................................................329 Special Tools.................................................................329 Troubleshooting, Testing and Adjustment...........................................330 Removal...........................................................................332 Disassembly.......................................................................333 Disassembly of Lining Plates and Plates.......................................336 Disassembly of Cylinder Assembly..............................................336 Disassembly of Taper Roller Bearing Outer Race................................336 Disassembly of Cylinder Assembly..............................................337 Cleaning and Inspection (Wear Limits and Tolerances)..............................338 Reassembly........................................................................338 General.......................................................................338 Reassembly of Cylinder Assembly...............................................339 Reassembly of Oil Seal........................................................340 Reassembly of Taper Roller Bearing Outer Race.................................341 Reassembly of Cylinder Assembly...............................................341 Reassembly of Lining Plate and Plate..........................................342 Reassembly of Oring..........................................................342 Reassembly of Brake Piston....................................................342 Reassembly of Spring..........................................................342 Reassembly of Balance Plate...................................................343 Reassembly of Inner Race......................................................343 Reassembly of Oring..........................................................343 Applying Liquid Packing.......................................................344 Reassembly of Cover...........................................................344 Tightening of Bolt (Tightening of Cover (19) and Housing (28))................344 Reassembly of Relief Valve Assembly, Etc......................................345 Confirming of Reassembly......................................................345 Installation......................................................................345 Startup Procedures...............................................................346 Hydraulic Oil.................................................................346 Preliminary Operation.........................................................346 Relief Valve..................................................................346 Travel Motor (with Gearbox) S0707315K.................................................347 General Description...............................................................350 Theory of Operation...........................................................351 Parts List....................................................................358 Specifications................................................................361 Special Tools and Materials.......................................................362 Special Tools.................................................................362 Troubleshooting, Testing and Adjustment...........................................369 Hydraulic Motor...............................................................369 Travel Reduction Gear.........................................................371 Disassembly.......................................................................372 General Caution Matters.......................................................372 Reduction Gear Part...........................................................372 Hydraulic Motor Part..........................................................375 Cleaning and Inspection (Wear Limits and Tolerances)..............................380 Maintenance Standard..........................................................380 Reassembly........................................................................384 General Caution Matters.......................................................384 Motor Part....................................................................384 Reduction Gear................................................................390 Installation......................................................................397 Check.........................................................................397 Fitting.......................................................................397 Piping........................................................................397 Gear Oil......................................................................398 General Caution Matters.......................................................398 Grapple Rotate Motor S0707400.........................................................399 General Description...............................................................401 General Notes.................................................................401 Torqmotor™ Features...........................................................402 Parts List....................................................................404 Special Tools and Materials.......................................................405 Special Tools.................................................................405 Tools and Materials Required for Servicing....................................406 Torque Chart..................................................................407 Troubleshooting, Testing and Adjustment...........................................408 Preliminary Checks............................................................408 Hydraulic Components..........................................................408 Disassembly and Inspection (Preparation Before Disassembly)...................409 Disassembly.......................................................................411 Reassembly........................................................................420 One Piece Stator Reassembly...................................................432 Two Piece Stator Reassembly...................................................433 Startup Procedures...............................................................435 Hydraulic Fluid...............................................................435 Main Pump (Kawasaki) S0708315K........................................................437 Swash Plate Type K5V Series Axial Piston Pump.....................................440 Type Designation..............................................................440 Specifications................................................................441 Construction and Function.....................................................442 Cautions for Operation........................................................444 Troubleshooting...............................................................447 Construction of Tandem Type Duplex Pump.......................................450 Tools.........................................................................452 Axial Piston Pump Disassembling...............................................454 Axial Piston Pump Reassembling................................................458 Axial Pump Maintenance Criteria...............................................461 Tightening Torques............................................................462 Regulator for K5V, K3V Series of Kawasaki Swash Plate Type Axial Piston Pump......463 Type Description..............................................................463 Construction of Regulator.....................................................464 Outline.......................................................................466 Specifications................................................................467 Functional Explanations.......................................................468 Adjustment of Maximum and Minimum Flows.......................................473 Fault Finding and Remedies on Regulator.......................................474 Preparation for Disassembly...................................................476 Tools.........................................................................476 Regulator Disassembly.........................................................477 Regulator Reassembly..........................................................480 Tightening Torque.............................................................483 Main Control Valve S0709400...........................................................485 Control Valve Operation...........................................................488 Swing Priority Circuit........................................................488 Arm Priority Circuit..........................................................489 Bucket (Junction) Circuit.....................................................490 Straight Traveling Circuit....................................................491 Plunger Replacement...........................................................493 Main Relief Valve.............................................................494 Overload Relief Valve.........................................................495 Arm Load Holding Valve........................................................497 Boom Load Holding Valve.......................................................500 Arm Regeneration..............................................................502 Boom Regeneration.............................................................504 Foot Relief Valve.............................................................505 Parts List....................................................................506 Specifications................................................................516 Control Valve Drawing and Hydraulic Circuit.......................................517 Disassembly and Reassembly........................................................522 General Disassembly...........................................................522 General Reassembly............................................................522 Main Plunger Element Disassembly and Assembly...............................523 Tool..........................................................................523 Main Relief Valve.............................................................526 Main Relief Valve Adjustment..................................................527 Overload Relief Valve.........................................................529 Arm Load Holding Valve........................................................531 Boom Load Holding Valve.......................................................534 Arm Regeneration Valve........................................................536 Bucket Unity Check............................................................537 Foot Relief Valve.............................................................538 Center Bypass Valve (CB Valve)................................................539 Boom Parallel Switch Valve....................................................540 Tool..........................................................................540 Swing Priority Valve..........................................................542 Boom Unity Check Valve........................................................544 Straight Travel Selector Valve................................................545 Check Valve Locations.......................................................546 Check Valve...................................................................547 Pilot Control Valve (Work Lever / Joystick) S0709450..................................553 General Description...............................................................555 Theory of Operation...........................................................555 Parts List....................................................................556 Specifications................................................................557 Hydraulic Specifications......................................................558 Special Tools.....................................................................559 Disassembly.......................................................................560 Reassembly........................................................................565 Travel Control Valve (With Damper) S0709820K..........................................571 General Description...............................................................573 Theory of Operation...........................................................573 Parts List....................................................................576 Specification.................................................................577 Torque........................................................................577 Troubleshooting, Testing and Adjustment...........................................578 Removal...........................................................................579 Disassembly.......................................................................581 Cleaning and Inspection (Wear Limits and Tolerances)..............................587 assembly..........................................................................588 Installation......................................................................593 Startup Procedures...............................................................594 Hydraulic Schematic (Solar 300LL) S0792035K...........................................595 General Description...............................................................597 Solar 300LL.......................................................................598 General Notes.................................................................600 Electrical System.........................................................................601 Electrical System S0802220K...........................................................603 Troubleshooting Electrical System...............................................607 Overview..........................................................................608 Electric Supply System............................................................609 Engine Starting Circuit...........................................................610 Operation During Start Process................................................610 Operation After Start Process.................................................611 Engine Preheating and After Start Heating System..................................612 Engine Stop System................................................................614 Charging System...................................................................617 Monitoring System.................................................................618 Instrument Panel..............................................................619 Monitoring System Schematic...................................................620 Operation.........................................................................622 Instruments...................................................................622 Warning and Indicator Lights......................................................624 Initial Operation.................................................................626 Mode Selector Switch..............................................................627 Graphic Information Area Display..................................................628 Overview......................................................................628 Main Menus for the Graphic Display Area.......................................629 Menu Selector Buttons.........................................................629 Main Menu.........................................................................630 Language Setting..............................................................630 Time Setting..................................................................630 Filter/Oil Information........................................................631 Special Menu......................................................................632 Entering/Accessing and Exiting/Escaping Menus.................................632 Special Menu Selections.......................................................633 Electronic Hydraulic Control System (eEPOS)......................................646 Control System Schematic......................................................646 Power Mode Control................................................................648 Operation.....................................................................649 Power Mode Control Circuit Diagram..............................................652 Work Mode Control.................................................................654 Operation.....................................................................655 Work Mode Control Circuit Diagram...............................................656 Engine Control System.............................................................657 Engine Control Motor..............................................................659 Engine Control Dial...............................................................660 Engine Control Circuit Diagram....................................................662 Automatic Deceleration Control (Auto Idle Control)................................663 Engine Overheat Protection System.................................................664 Power Boost Mode..................................................................665 Operation.....................................................................665 Power Boost Control Circuit Diagram.........................................666 Automatic Travel Speed Control....................................................667 Automatic Travel Speed Control Circuit Diagram..............................668 Engine Control Device Adjustment................................................669 Selfdiagnostic Function..........................................................673 eEPOS Controller.............................................................673 Engine Throttle Controller........................................................675 Wiper System......................................................................676 Wiper Circuit.................................................................676 Wiper Operation...............................................................676 Window Washer Operation.......................................................677 Lighting System...................................................................678 Lighting System Circuit Diagram...............................................678 Kind of Light.................................................................679 Operation.....................................................................679 Overload Warning Device...........................................................680 Overload Warning Device Circuit Diagram.......................................680 Electrical Schematic (Solar 300LL) S0892035K..........................................681 General Description...............................................................683 Solar 300LL.......................................................................684 Attachments...............................................................................687 Boom and Stick S0902140K..............................................................689 Front Attachment Specifications...................................................691 Pin Specifications............................................................691 Size and Weight Specifications................................................691 Front Attachment Removal and Installation.......................................692 Stick Removal Procedure.......................................................692 Boom Removal Procedure........................................................694 Installation......................................................................695 Stick Installation Procedure..................................................695 Boom Installation Procedure...................................................695 Startup Procedures...............................................................696
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