Daewoo Doosan Solar 300LL Excavator Operation & Maintenance Manual – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Solar 300LL Excavator Operation & Maintenance Manual – PDF DOWNLOAD
Solar 300LL
Operation and Maintenance Manual
022-00060E
Serial Number 1001 and Up
January 2004
022-00060E
Serial Number 1001 and Up
January 2004
- Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
- It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package.
- Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item.
GENERAL HAZARD INFORMATION:
SAFETY RULES:
- Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
- Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems. These problems will interfere with your sense of judgement in emergencies and may cause accidents.
- When working with another operator or with a person on work site traffic duty, be sure that all personnel know the nature of the work and understand all hand signals that are to be used. Always observe strictly any other rules related to safety.
SAFETY FEATURES
- Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as safety lock lever and the seat belt, and use them properly.
- Never remove any safety features. Always keep them in good operating condition. Failure to use safety features according to the instructions in the Operation and Maintenance Manual could
TABLE OF CONTENTS:
Daewoo Doosan Solar 300LL Excavator Operation & Maintenance Manual – PDF DOWNLOAD
Safety.......................................................................................................... 7 To the Operator of a Daewoo Excavator....................................................................... 7 Learn the Signal Words Used with the Safety Alert Symbol................................................ 9 Location of Safety Labels................................................................................... 10 1. Warnings for Operation, Inspection and Maintenance (19000688, 19000092)............................ 11 2. Warnings for High Voltage (19000689, 19000096)..................................................... 11 3. Warnings When Opening a Front Window (21903388)..................................................... 11 4. Warnings When Adjusting Track Tension (21903386A, 19000521)........................................ 12 5. Warnings for Leaving Operator's Seat (19000693, 19000094).......................................... 12 6. Warnings for Batteries Maintenance (21902533A, 19000100)........................................... 13 7. Warnings for High Temperature Hydraulic Oil (19000691, 19000097)................................... 13 8. Warnings for Hot Coolant (19000692, 19000097)...................................................... 14 9. Warnings for Handling an Accumulator (19000703, 19000099).......................................... 14 10. Warnings for Rotating Parts (19000694, 19000095, 19000557)....................................... 14 11. Warning Tag Used When Inspection and Maintenance (19000695, 19000098)........................... 15 12. Warning for a Hot Surface (19000648A).............................................................. 15 13. Caution for Hood (19000522)........................................................................ 15 14. Keep Out of the Swing Area (21903379, 19000090)................................................... 16 15. warning for Intrusion Hazard (21903444)............................................................ 16 16. Warning for Power Lines (2190 3450A).............................................................. 16 17. Warning for Tilt Cab (2190 3446).................................................................. 17 18. Warnings for a Highpressure Cylinder (19000122)................................................... 17 19. Warnings for Front Attachments (19000652).......................................................... 17 Summary of Safety Precautions for Lifting in Digging Mode................................................... 18 Unauthorized Modifications.................................................................................. 19 General Hazard Information.................................................................................. 19 Safety Rules............................................................................................ 19 Safety Features......................................................................................... 19 Inside Operator's Compartment........................................................................... 20 Clothing and Personal Protective Items.................................................................. 20 Breathing Masks, Ear Protection May Be Required......................................................... 21 Vibration Level Information............................................................................. 21 Mounting and Dismounting................................................................................ 21 Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 22 Precautions When Handling Fluids at High Temperature.................................................... 22 Asbestos Dust Hazard Prevention......................................................................... 23 Injury from Work Equipment.............................................................................. 23 Fire Extinguisher and First Aid Kit..................................................................... 24 Protection from Falling or Flying Objects............................................................... 24 Attachment Precautions.................................................................................. 25 Accumulator............................................................................................. 25 Indoor Ventilation...................................................................................... 26 Emergency Exit.......................................................................................... 26 Before Starting Engine...................................................................................... 27 Work Site Precautions................................................................................... 27 Checks Before Starting Engine........................................................................... 28 Engine Starting......................................................................................... 29 Before Operating Machine................................................................................ 29 Machine Operation........................................................................................... 30 When Swinging or Changing Direction of Travel........................................................... 30 Travel Precautions...................................................................................... 30 Traveling on Slopes..................................................................................... 31 Prohibited Operations................................................................................... 32 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.............................................................. 39 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 Hydraulic Cylinders, Pins and Bushings.................................................................. 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 Excavator Rated Lift Capacity Tables........................................................................ 47 Lifting Capacities...................................................................................... 50 Operating Controls.............................................................................................. 51 Component Locations......................................................................................... 52 Operator's Area............................................................................................. 54 Operational Controls and Panels............................................................................. 55 1. Starter Switch....................................................................................... 56 2. Engine Speed Control Dial............................................................................ 56 3. light Switch......................................................................................... 57 4. Wiper Switch......................................................................................... 57 5. Windshield Washer Switch............................................................................. 58 6. Travel Speed Selector Switch......................................................................... 58 7. Stereo OnOff Switch................................................................................. 59 8. Cab Work Light Switch................................................................................ 59 9. Travel Alarm Switch.................................................................................. 59 10. Blank (Empty Switch Socket)......................................................................... 59 11. Blank (Empty Switch Socket)......................................................................... 60 12. Heater and Air Conditioner Control Panel............................................................ 60 13. Cigar Lighter....................................................................................... 60 14. Power Socket for 12 Volt............................................................................ 60 15. Lefthand Work Lever (Joystick) with Horn, Grapple Motor and Grapple Cylinder Switches)............. 61 16. Righthand Work Lever (Joystick) with Power Booster, Grapple Motor and Grapple Cylinder Switches.... 61 17. Instrument Panel.................................................................................... 61 18. Safety Lever........................................................................................ 62 Instrument Panel............................................................................................ 63 Functional check........................................................................................ 64 1. Engine Coolant Temperature Gauge..................................................................... 64 2. Fuel Gauge........................................................................................... 64 3. Multifunction Gauge and Graphic Information Area..................................................... 65 4. Digital Clock........................................................................................ 65 5. Hour Meter........................................................................................... 65 6. Battery Warning Light................................................................................ 66 7. Engine Oil Pressure Warning Light.................................................................... 66 8. Engine Coolant Temperature Warning Light............................................................. 66 9. Preheat Indicator Light.............................................................................. 67 10. Work Light Indicator Light.......................................................................... 67 11. Overload Warning Light (Optional)................................................................... 67 Multifunction Gauge and Graphic Information................................................................. 68 Communication Indicator................................................................................. 68 Communication Error Warning............................................................................. 69 1. Engine Speed......................................................................................... 69 2. Battery Voltage...................................................................................... 69 3. Front Hydraulic Pump Pressure........................................................................ 70 4. Rear Hydraulic Pump Pressure......................................................................... 70 5. Abnormal State Warning of Filters.................................................................... 71 Mode Selector Buttons....................................................................................... 72 1. Power Mode Selector Button........................................................................... 72 2. Work Mode Selector Button............................................................................ 73 3. Auto Idle Selector Button............................................................................ 73 4. Display Selector Button.............................................................................. 74 Setting Method for Main Menu................................................................................ 75 Main Menu............................................................................................... 75 Language................................................................................................ 76 Set Clock............................................................................................... 76 Filter / Oil Info....................................................................................... 77 Heater and Air Conditioner Control Panel.................................................................... 79 Location of Controls and Vents.......................................................................... 79 Operation Panel......................................................................................... 80 1. Fan and Air Conditioner Switch....................................................................... 80 2. Fan Speed Selector Switches.......................................................................... 81 3. Temperature Control Switch........................................................................... 81 4. Air Outlet Selector Switch........................................................................... 82 5. Ventilation Selector Switch.......................................................................... 83 Memory Function of Used Mode............................................................................ 83 Additional Operating Instructions....................................................................... 83 Stereo...................................................................................................... 84 Security and Area Code Setting.......................................................................... 84 Order to Set Up Security and Area Code.................................................................. 84 Front Panel............................................................................................. 85 1. Power/Volume Control Knob............................................................................ 85 2. Sound Mode Selector Button........................................................................... 85 3. Band Selector Switch................................................................................. 86 4. Tuning Up/Down....................................................................................... 86 5 & 6. Auto Memory and Preset Scan Button / Preset Station Button....................................... 87 7. Tape Slot............................................................................................ 87 8. Tape Ejection Button................................................................................. 87 9. Cassette and Program Buttons......................................................................... 88 10. Security Warning LED................................................................................ 88 11. Scan................................................................................................ 88 12. LCD................................................................................................. 89 Care of Stereo.......................................................................................... 89 Fuse Boxes.................................................................................................. 91 Miscellaneous Electrical Devices............................................................................ 92 1. Cab Light............................................................................................ 92 2. Pilot Cutoff Switch.................................................................................. 92 3. Circuit Breaker...................................................................................... 92 4. Fusible Link......................................................................................... 93 Seat Adjustment............................................................................................. 94 1. Forward / Backward Adjustment (Figure 80)............................................................ 94 2. Adjusting the Seat's Tilt and Seat Height (Figure 80)................................................ 94 3. Weight Adjustment (Figure 80)........................................................................ 94 4. Adjusting Reclining (Figure 80)...................................................................... 94 5. Moving the Whole Seat Setting Forward/Backward (Figure 80)........................................... 95 6. Angle Adjustment of Armrest (Figure 81).............................................................. 95 7. Headrest (Figure 81)................................................................................. 95 Recommendations for Limiting Vibrations................................................................. 95 Seat Belt................................................................................................... 96 Seat Belt Locking and Unlocking......................................................................... 96 Ceiling Cover............................................................................................... 97 Opening the Ceiling Cover............................................................................... 97 Closing the Ceiling Cover............................................................................... 97 Front Windows............................................................................................... 98 Front Upper Window...................................................................................... 98 Front Bottom Window.....................................................................................100 Doors and Access Covers.....................................................................................101 Door Side Latch.........................................................................................101 Cabin Riser Access Door.................................................................................101 Tilt Cab....................................................................................................102 Miscellaneous Access Covers and Doors.......................................................................103 Side Door...............................................................................................103 Battery Box Door........................................................................................103 Engine Cover............................................................................................103 Cab Storage Compartments....................................................................................104 Ashtray.....................................................................................................104 Window Glass Breaking Tool..................................................................................105 Operation.......................................................................................................107 To Handle a New Excavator...................................................................................107 Lubrication and Filters.................................................................................107 Starting and Stopping the Engine............................................................................108 Inspection Before Starting Engine.......................................................................108 Operational Checks Before Starting Engine...............................................................108 Engine Start............................................................................................110 Cold Weather Starting...................................................................................112 Starting Engine With a Booster Cable....................................................................114 Hydraulic System Warmup................................................................................116 Hydraulic System Warmup – Cold Weather.................................................................117 Engine Shut Down........................................................................................118 Check and Confirmation After Stopping Engine............................................................119 Safety Lever................................................................................................120 Travel......................................................................................................121 Automatic Travel Speed Control..........................................................................121 General Travel Instructions.............................................................................122 Travel Control Lever Operation..........................................................................124 Operating Instructions......................................................................................126 Engine Speed Control....................................................................................126 Mode Selection..........................................................................................128 Work Levers (Joysticks) (ISO Style).....................................................................130 Operating Precautions.......................................................................................131 ALWAYS OBSERVE THESE PRECAUTIONS........................................................................135 Working in Water........................................................................................135 Parking Excavator...........................................................................................136 Towing Procedure............................................................................................137 Operating Techniques........................................................................................138 Lifting.................................................................................................138 Operation Under Unusual Conditions..........................................................................140 Operation In Extreme Cold...............................................................................140 Operation In Extreme Heat...............................................................................140 Operation In Dusty or Sandy Areas.......................................................................141 Operation In Rainy or Humid Conditions..................................................................142 Operation In Salt Water Areas...........................................................................142 Operation at High Altitudes.............................................................................142 Inspection, Maintenance and Adjustment..........................................................................143 Preventive Maintenance......................................................................................143 Serial Numbers..........................................................................................144 Safety Precautions......................................................................................144 Preliminary Work Machine Setup for Maintenance..............................................................145 Table of Recommended Lubricants.............................................................................147 Fluid Capacities............................................................................................149 Lubrication and Service Chart...............................................................................149 Maintenance Intervals.......................................................................................153 10 Hour / Daily Service.................................................................................153 50 Hour / Weekly Service................................................................................153 250 Hour / Monthly Service..............................................................................153 500 Hour / 3 Month Service..............................................................................154 1,000 Hour / 6 Month service............................................................................154 2,000 Hour / Yearly Service.............................................................................154 4,000 Hour / Biennial Service...........................................................................154 12,000 Hour / Six Year Service..........................................................................154 10 Hour / Daily Service.....................................................................................155 Grease Boom, Stick and Grapple Pins (for first 100 hours)...............................................155 Check Engine Oil Level..................................................................................155 Check Level of Hydraulic Oil Tank.......................................................................156 Check for Leaks in Hydraulic System.....................................................................157 Check Fuel Level........................................................................................158 Check for Leaks in Fuel System..........................................................................158 Check Water Separator and Drain Water As Required.......................................................159 Check Oil Level of Swing Reduction Device...............................................................160 Clean Dust Net in Front of Oil Cooler...................................................................161 Check Cooling System and Refill As Required.............................................................161 Check Level of Window Washer Liquid.....................................................................162 Inspect Engine Fan Blade................................................................................162 Check Air Intake System.................................................................................163 Inspect Seat Belt for Proper Operation..................................................................163 Inspect the Structure for Cracks and Faulty Welds.......................................................163 Check the Operation of All Switches.....................................................................163 Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......163 Start Engine, Check Starting Ability, and Observe Exhaust Color at Startup and at Normal Operati.......164 Check Operation of All Controls.........................................................................164 50 Hour / Weekly Service....................................................................................165 Perform All Daily Service Checks........................................................................165 Grease Boom, Stick and Grapple Pins.....................................................................165 Grease Swing Bearing....................................................................................170 Drain Water and Sediment from Fuel Filter...............................................................170 Drain Water and Sediment from Fuel Tank.................................................................170 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours).......................170 Change Engine Oil and Filter (After First 50 Hours).....................................................170 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, R.......171 250 Hour / Monthly Service..................................................................................172 Perform All Daily and 50 Hour Service Checks............................................................172 Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours)..............................172 Clean Outer Filter of Two Stage Air Cleaner.............................................................172 Check Engine Fan Belt Tension...........................................................................173 Check Engine Fan Belt Wear..............................................................................173 Change Engine Oil and Filter............................................................................175 Check Oil Level In Travel Reduction Device (One on Each Side of Unit)...................................176 Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 250 Hours)................176 Replace Full Flow Hydraulic Oil Filter (After First 250 Hours)..........................................176 Change Pilot Filter (After First 250 Hours).............................................................176 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear................................176 Check Fluid Levels in Batteries and Battery Charge Levels...............................................176 Inspect for Any Loose or Missing Nuts and Bolts.........................................................176 Inspect Fuel System Hose Clamps.........................................................................176 500 Hour / 3 Month Service..................................................................................177 Perform All Daily, 50, and 250 Hour Service Checks......................................................177 Grease Swing Gear and Pinion............................................................................177 Replace Full Flow Hydraulic Oil Filter..................................................................178 Change Pilot Filter.....................................................................................179 Clean Airconditioning Filter...........................................................................180 Clean Radiator, Oil Cooler, Intercooler and Air Conditioner Condenser Core..............................181 Replace Outer and Inner Air Cleaner Filters.............................................................182 Change Fuel Filter......................................................................................183 1,000 Hour / 6 Month Service................................................................................185 Perform All Daily, 50, 250 and 500 Hour Service Checks..................................................185 Grease Swing Reduction Device...........................................................................185 Change Swing Reduction Device Oil.......................................................................185 Change Oil in Travel Reduction Device (One on Each Side of Unit)........................................186 Clean Fuel Injection Priming Pump Strainer..............................................................187 Check Air Conditioner Refrigerant.......................................................................188 Check and Adjust Engine **..............................................................................189 Change Air Conditioner Filter...........................................................................189 2,000 Hour / Yearly Service.................................................................................190 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks...........................................190 Check Alternator and Starter**..........................................................................190 Check All Rubber Antivibration Shock Mounts.............................................................190 Perform and Record the Results of the Cycle Time Tests..................................................190 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.........................190 Check, Adjust Valve Clearance **........................................................................190 Check Head Bolt Torques.................................................................................190 Change Radiator Coolant (Propylene Glycol Extended Life Antifreeze)...................................190 Hydraulic Oil Exchange and Suction Strainer Cleaning....................................................192 4,000 Hour / Biennial Service...............................................................................195 Major Parts Periodic Replacement......................................................................195 12,000 Hour / Six Year Service..............................................................................196 Hose Inservice Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................196 Airconditioning System.....................................................................................197 Check Control Panel.....................................................................................197 Check Air Conditioner Hoses.............................................................................197 Check Condenser.........................................................................................197 Check Magnetic Clutch...................................................................................197 Check Belt Tension......................................................................................197 Bolt and Nut Inspection.....................................................................................198 Electrical System...........................................................................................200 Battery.................................................................................................200 Fuses...................................................................................................202 Engine Cooling System.......................................................................................204 General.................................................................................................204 Antifreeze Concentration Tables.........................................................................205 Fuel Transfer Pump (Option).................................................................................206 Handling of Accumulator.....................................................................................208 Long Term Storage...........................................................................................209 Maintenance in Special Conditions...........................................................................210 Track Tension...............................................................................................211 Venting and Priming Hydraulic System........................................................................213 Main System Pump........................................................................................213 Hydraulic Cylinders.....................................................................................213 Swing Motor.............................................................................................214 Air Release of Travel Motor.............................................................................214 General Venting.........................................................................................214 Transportation..................................................................................................215 Loading and Unloading.......................................................................................215 Lifting With Sling..........................................................................................220 Troubleshooting.................................................................................................221 Electrical System...........................................................................................221 Engine......................................................................................................222 Hydraulic System............................................................................................223 Swing System................................................................................................224 Travel System...............................................................................................225 Specification...................................................................................................227 Standard Specification......................................................................................227 Working Range...............................................................................................230 Approximate Weight of Workload Materials....................................................................231 Index...........................................................................................................233
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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