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Kobelco sk500 lc 10 (anz 2019) hydraulic excavator service repair manual
1.
SHOP MANUAL model INDEX HYDRAULIC EXCAVATOR SPECIFICATIONS MAINTENANCE SYSTEM DISASSEMBLING TROUBLESHOOTING E / G OPT. 1 2 3 4 5 6 7 SPECIFICATIONS
SECTION MAINTENANCE SECTION SYSTEM SECTION DISASSEMBLY SECTION TROUBLESHOOTING ENGINE SECTION PROCEDURE OF INSTALLING OPTIONS SECTION Book Code No.S5LS0028E03 0-1 SK500LC-10 Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
2.
0-2 GENERAL SAFETY INFORMATION Do
not operate or perform any maintenance on this machine until all instructions found in the OPERA- TOR’S MANUAL and this MANUAL have been thor- oughly read and understood. Improper operation or maintenance of this machine may cause accidents and could result in serious in- jury or death. Always keep the manual in storage. If it is missing or damaged, place an order with an authorized our Distributor for a replacement. If you have any questions, please consult an autho- rized our Distributor. (1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safe- ty rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the man- ual and on the machine should be read and under- stood by all personnel before starting any work with or on the machine. (2) Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in the manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. (3) Messages of safety appear in the manual and on the machine : All messages of safety are identified by either word of "DANGER", "WARNING" and "CAUTION". 1) DANGER- Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows: 2) WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows: 3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in mi- nor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as fol- lows: (4) It is very difficult to forecast every danger that may occur during operation. However, safety can be en- sured by fully understanding proper operating pro- cedures for this machine according to methods recommended by Manufacturer. (5) While operating the machine, be sure to perform work with great care, so as not to damage the ma- chine, or allow accidents to occur. (6) Continue studying the manual until all Safety, Oper- ation and Maintenance procedures are completely understood by all persons working with the ma- chine. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
3.
0-3 SAFETY PRECAUTIONS The proper
and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR’S MANUAL for the machine. Improper performance of lubrication or mainte- nance procedures are dangerous and could result in injury or death. Read and understand the MAN- UAL before performing any lubrication or mainte- nance. The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is im- portant before the removal or disassembly of any com- ponent. Because of the size of some of the machine compo- nents, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting proce- dures when removing any components. Weight of com- ponents table is shown in the section ; SPECIFICATIONS. The following is a list of basic precautions that must al- ways be observed. (1) Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine. (2) Always wear protective glasses and protective shoes when working around machines. In particu- lar, wear protective glasses when using hammers, punches or drifts on any part of the machine or at- tachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fit- ting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery. (3) Disconnect the battery and hang a "Do Not Oper- ate" tag in the Operators Compartment. Remove ig- nition keys. (4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine so it does not roll while working on or under the ma- chine. Hang a "Do Not Operate" tag in the Opera- tors Compartment. (5) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands, capable of supporting the machine, before performing any disassembly. Do not operate this machine unless you have read and understand the instructions in the OP- ERATOR’S MANUAL. Improper machine opera- tion is dangerous and could result in injury or death. (6) Relieve all pressure in air, oil or water systems be- fore any lines, fittings or related items are discon- nected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. (7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the ma- chine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correct- ly to prevent it from dropping unexpectedly. (8) Use steps and grab handles when mounting or dis- mounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face to the machine when using steps, lad- ders and walkways. When it is not possible to use the designed access system, provide ladders, scaf- folds, or work platforms to perform safe repair oper- ations. (9) To avoid back injury, use a hoist when lifting com- ponents which weigh 20kg (45lbs) or more. Make sure all chains, hooks, slings, etc., are in good con- dition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. (10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments. (11)Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pres- sure, before removing the last two capscrews or nuts completely. (12)Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liq- uids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
4.
0-4 (13)Always use the
proper tools that are in good condi- tion and that are suited for the job at hand. Be sure you understand how to use them before performing any service work. (14)Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary. (15)Repairs which require welding should be per- formed only with the benefit of the appropriate ref- erence information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to dis- connect battery before any welding procedures are attempted. (16)Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line contain- ing fluid. (17)Be sure all protective devices including guards and shields are properly installed and functioning cor- rectly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed. (18)The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t fail to lower the attach- ment and place the bucket to the ground before starting the work. (19)Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. (20)Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are in- stalled correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot ex- haust components in event of a line, tube or seal failure must be installed correctly. (21)Do not operate a machine if any rotating part is damaged or contacts any other part during opera- tion. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. (22)Be careful when servicing or separating the tracks (crawlers). Chips can fly when removing or install- ing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets. Block the ma- chine to prevent it from moving. The copyright of this manual belongs to KOBELCO CONSTRUCTION MACHINERY CO., LTD. Copy, reproduction, distribution, and delivery (including these actions on the Internet) of all or part of this manual are prohibited without permission of KOBELCO CONSTRUCTION MACHINERY CO., LTD. This manual is intended to provide instructions for repair, maintenance, and adjustment of the machine, sold directly or indirectly by KOBELCO CONSTRUCTION MACHINERY CO., LTD. or KOBELCO authorized dealer, and any use other than that purpose will not be allowed. Also, all or part of this manual cannot be transferred, sold, or lent to a third person without permission of KOBELCO CONSTRUCTION MACHINERY CO., LTD. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
5.
0-5 17 18 12 10 11 13 14 15 16 9 Index No. Title Distribution Year–Month _ _ _ _ _ _ YS14-05001~ YS14010001~ STANDARD MAINTENANCE TIME
SCHEDULE MAINTENANCE STANDARD AND TEST PROCEDURE MECHATRO CONTROL SYSTEM DISASSEMBLING & ASSEMBLING OUTLINE SPECIFICATIONS ATTACHMENT DIMENSIONS TOOLS HYDRAULIC SYSTEM ELECTRIC SYSTEM COMPONENTS SYSTEM AIR-CONDITIONER SYSTEM ATTACHMENT UPPER STRUCTURE TRAVEL SYSTEM BY ERROR CODES BY TROUBLE ENGINE APPLICABLE MACHINES SPECIFICATIONS MAINTENANCE SYSTEM DISASSEMBLING TROUBLESHOOTING E / G INDEX SK500LC-10 ANZ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 _ _ 2017-11 2019-02 2017-11 2017-11 2017-11 2019-02 2019-02 2017-11 2018-04 2019-02 2017-11 2017-11 2017-11 2017-11 2017-11 2019-02 2017-11 2017-11 Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0627CsCshWbYs]
6.
0-6 NOTE: This Manual is
prepared as a technical material in which the information necessary for the maintenance and repairing services of our hydraulic excavators are collected, and is categorized into 7 Chapters, Specifica- tion, Maintenance, System, Disassembly, Trouble- shooting, Engine, and Installation Procedures for Optional Attachment. • The Chapter "Specification" describes the specifi- cations for entire machine and material, which are instructive for replacement and repairing of attach- ments. • The Chapter "Maintenance" describes the material, which is helpful for maintenance service and adjust- ments for entire machine. • The Chapter "System" describes the operating sys- tem like hydraulic system, electric system, compo- nents, and so on. • The Chapter "Disassembly" describes the removal and installing of assembly mounted on the upper structure and undercarriage, and the assembling and disassembling of the associated hydraulic equipment. • The Chapter "Troubleshooting" describes how to find the fault equipment. • The Chapter "Engine" describes the engines mak- ing use of the "Maintenance Manual" provided by the suppliers. • The Chapter "Installation Procedures for Optional Attachment" describes the supplements added on request as required. This Manual may be properly revised due to the im- provement of products, modification of specifications, etc. And there are cases where the system on actual machine and a part of the contents of this manual may differ due to the variations of specification by countries. For the section in which the description is hardly under- stood, contact our distributor. The number is assigned to every part handled in this Manual on account of the description, but the parts, which cannot be supplied as service parts are con- tained. Therefore, the order must be placed with re- spective formal number with due confirmation on the Parts Manual for applicable machine. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
7.
1 [1. OUTLINE] 1-1 1. OUTLINE 1.1
ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................1-3 1.2 GENERAL PRECAUTIONS FOR MAKING REPAIRS .................................................................1-4 1.2.1 PREPARATION BEFORE DISASSEMBLING ..........................................................................1-4 1.2.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING .........................................................1-4 1.2.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .........................................1-5 1.2.4 ELECTRICAL EQUIPMENT....................................................................................................1-7 1.2.5 HYDRAULIC PARTS..............................................................................................................1-7 1.2.6 WELD REPAIR ......................................................................................................................1-8 1.2.7 ENVIRONMENTAL ISSUES ...................................................................................................1-8 1.3 INTERNATIONAL UNIT SYSTEM..............................................................................................1-9 Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
8.
[1. OUTLINE] 1 1-3 1.1 ABOUT
THE COPYRIGHT OF THIS SHOP MANUAL The copyright of this manual belongs to KOBELCO CONSTRUCTION MACHINERY CO., LTD. Copy, reproduction, distribution, and delivery (including these actions on the Internet) of all or part of this manual are prohibited without permission of KOBELCO CONSTRUCTION MACHINERY CO., LTD. This manual is intended to provide instructions for repair, maintenance, and adjustment of the machine, sold directly or indirectly by KOBELCO CONSTRUCTION MACHINERY CO., LTD. or KOBELCO autorized dealer, and any use other than that purpose will not be allowed. Also, all or part of this manual cannot be transferred, sold, or lent to a third person without permission of KOBELCO CONSTRUCTION MACHINERY CO., LTD. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
9.
1-4 [1. OUTLINE] 1.2 GENERAL
PRECAUTIONS FOR MAKING REPAIRS 1.2.1 PREPARATION BEFORE DISASSEMBLING Read Operator's Manual before disassembling Knowledge of operating procedure Read Operator's Manual carefully to understand the operating procedure. Cleaning machines Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled machine into the service shop, causes making less efficient work and damage of parts. Inspecting machines Confirm the disassembling section before starting work, determine the disassembly procedure taking the conditions in work shop into account, and request to procure necessary parts in advance. Recording Record the following items to keep contact and prevent malfunction from recurring. • Inspecting date, place • Model name, Serial number and Record on hour meter • Trouble condition, place, cause • Visible oil leak, water leak and damage • Clogging of filters, oil level, oil quality, oil contamination and looseness. • Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour meter. Arrangement and cleaning in service shop • Tools required for repair work. • Prepare the places to put the disassembled parts. • Prepare oil pans for leaking oil, etc. 1.2.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING WARNING Safety • Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves. • Attach "Don't operate" tag to control lever, and begin a meeting before starting the work. • Before starting inspection and maintenance stop the engine. • Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure and ambulance to prepare for accidents and fire. • Choose a hard, level and safe place, and put attachment on the ground without fail. • Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more). • Use proper tools, and change or repair defective tools. • Machine and attachment required to work in the lifting condition should be supported with supports or blocks securely. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
10.
[1. OUTLINE] 1 1-5 1.2.3 DISASSEMBLING
AND ASSEMBLING HYDRAULIC EQUIPMENT Removing hydraulic equipment assy • Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and take out the filter. • Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground. • Pipes with plugs or caps to prevent oil leaking, entry of dust, etc. • Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on working bench. Disassembling hydraulic equipment • Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture's side, disassembly, assembly and modification without permission are strictly prohibited. • If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. • Make match mark on parts for reassembling. • Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not. • For parts which are required to use jig and tools, don't fail to use the specified jig and tools. • For parts which can not be removed in the specified procedure, never force removal. First check for the cause. • The removed parts should be put in order and tagged so as to install on proper places without confusion. • For common parts, pay attention to the quantity and places. Inspecting parts • Check that the disassembled parts are free from adherence, interference and uneven working face. • Measure the wear of parts and clearance, and record the measured values. • If an abnormality is detected, repair or replace the parts. Reassembling hydraulic equipment • During the parts cleaning, ventilate the room. • Before assembly, clean parts roughly first, and then completely. • Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. • Replace the removed O-ring, back-up rings and oil seal with new ones, and apply grease oil on them before assembling. • Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them. • Before assembling, remove rust preventives on new parts. • Use special tools to fit bearings, bushing and oil seal. • Assemble parts matching to the marks. • After completion, check that there is no omission of parts. Installing hydraulic equipment • Confirm hydraulic oil and lubrication oil. • Air release is required in the following cases ; – Change of hydraulic oil – Replacement of parts on suction pipe side – Removing and attaching hydraulic pump Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
11.
1-6 [1. OUTLINE] – Removing
and attaching swing motor – Removing and attaching travel motor – Removing and attaching hydraulic cylinder • For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely. • For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed. • Air in pilot circuit can be bleed out by only operating digging, swing and traveling motions thoroughly. • Check hydraulic oil level. Move attachments to hydraulic oil check position, and check hydraulic oil level of tank. Refill oil if the oil level is lower than the specified level. How to check oil level of hydraulic oil tank LEVEL GAUGE Oil level of hydraulic oil tank. If the indicator is within level marks, the oil quantity is acceptable. I m p o r t a n t i m f o r m a t i o n Checking method for oil level of hydraulic oil tank WHEN AIR BLEEDING IS REQUIRED If hydraulic oil and lubricating oil are not filled and also air bleeding is not performed, the hydraulic equipment may be damaged. WHEN AIR IS BLED FROM HYDRUALIC CYLIDNER For cylinder, don't move it to the stroke end at beginning. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
12.
14 14-73 [14. UPPER SLEWING
STRUCTURE] 14.4.1.1.2 DISASSEMBLING AND ASSEMBLING MAIN PUMP TOOL B The tools necessary to disassemble/reassemble K5V212DPH pump are shown in the following list. The size of bolts and plugs depend on the pump type. Tool name and size ○: Necessary Tool Part name Pump model Names B K5V212DPH Hexagon socket head cap screw ROH plug VP plug (Parallel thread) Hexagon socket head set screw Allen wrench 2 ― ― M4 2.5 ― ― M5 3 ― ― M6 4 M5 ― M8 5 ○ M6 PF1/8 M10 6 ○ M8 PF1/4 M12, M14 8 ○ M10 PF3/8 M16, M18 10 ○ M12 PF1/2 M20 14 M16, M18 PF3/4 ― 17 ○ M20, M22 PF1 M30 19 M24, M27 ― ― 21 ― ― ― 22 M30 ― ― Adjustable angle wrench ― ○ Medium size 1set Screwdriver ― ○ Flat-blade screwdriver (medium size) 2pieces Hammer ― ○ Plastic hammer 1piece Plier ― ○ TSR-160 and TSR–200 for stop ring (retaining ring/internal snap ring) Torque wrench ― ○ Capable of tightening with the specified torques Resin cover ― ○ For Needle bearing Torx Plus 30 IP ○ Exclusive tool of MH plug M7 x 0.75 Disassembling Procedures 1. Selection of a place for disassembling • Select a clean place. • Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged. • Fix pump casing (271) by using the thread 2-M10-L16 in disassembling. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
13.
14-74 [14. UPPER SLEWING
STRUCTURE] 2. Cleaning Remove dust, and rust, etc., from the pump surfaces with cleaning oil or so on. 3. Draining oil Remove drain port plugs and let the oil out from pump casings (271) Tools: Spanner: 36 mm 4. Removing regulator Remove socket bolts (415) (See Figures "Structural exploded view of main pump" and "Structural exploded view of regulator") and remove the regulator. Tools: Allen wrench: 8 mm • Refer to Paragraph "REGULATOR" for dissembling the regulator. 5. Removing PTO unit and PTO cover (236) Place the pump horizontally on a workbench with its regulator-fitting surface up, and remove the PTO unit by removing flange socket (413). • Check the PTO unit maintenance manual for disassembling or assembling the PTO unit. In case the pump is not equipped with the PTO unit, remove cover (263). 6. Removing gear pump (04) Remove flange sockets (435) and then gear pump (04) and booster (132). 7. Removing socket bolts (410) Loosen socket bolts (410) and (411) and (412) valve cover (312). Tools: Allen wrench: 17mm • Remove the regulator (002) gear pump (04) and PTO (05) first before performing this work. Separating pump casings (271) and valve block (312) 8. Separating pump casings (271) and valve block (312) Place pump horizontally on workbench and separate pump casing (271) and valve cover (312). • Crane valve cover (312) at this work because it is heavy (about 60kg (132 lbs)). • Remove valve cover (312) with respect to drive shaft (111) and driven shaft (113) horizontally. (Needle bearing might be damaged.) When the guide bolt is used, posture is steady. (Refer to attached dwg.) • In removing valve cover (312), take care not to damage fitting surfaces between pump casing (271) and valve cover (312). • In removing valve cover (312), take care to not to drop valve plates (313) and (314), check valve subassembly (541) and (543) and (545), O-rings (724) and (725) and seat packing (752) because it they tend to come off. 9. Removing needle bearing If necessary, remove needle bearings (123) and (124) from valve cover (312). • Do not remove needle bearings (123) and (124) as far as possible, except when it is considered to be out of its life span. • Do not loosen hexagon nut (807) of the valve cover. If loosened, flow setting will be changed. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
14.
14 14-75 [14. UPPER SLEWING
STRUCTURE] Pulling out cylinder assembly 10. Pulling out cylinder assembly Pull cylinders (141) out of pump casing (271) straightly over drive shaft (111) and driven shaft (113). Pull out also piston subassembly (151) and (152), set plate (153), spherical bush (156) and cylinder springs (157) simultaneously. • Take care not to damage sliding surfaces of cylinder (141), spherical bush (156), shoes (152), swash plate (212), and so on. Removing shoe plate (211) and swash plate (212) 11. Removing shoe plate (211) and swash plate (212) Remove shoe plate (211) and swash plate (212) from pump casing (271). • Remove swash plate/shoe plate subassembly from pump casing (271), and remove shoe plate (211) from swash plate (212) by using flat-blade screwdriver. Removing front cover (261) 12. Removing front cover (261) Remove snap ring (827) and front cover (261) from front casing (171). • Fix and work. In fixing, take care not to damage fitting surfaces. • A groove is provided on the outer circumference of front cover (261) straight with respect to drive shaft (111) by placing a flat-blade screwdriver in the groove. • Since oil seal (774) is fitted on front cover (261), take care not to damage lip part of oil seal in removing. 13. Loosen hexagon socket head cap screws (408) which tighten front casing (171). • Fix and work. In fixing, take care not to damage fitting surfaces. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
15.
14-76 [14. UPPER SLEWING
STRUCTURE] Separating front casing (171) 14. Separating front casing (171) Separate front casing (171) and pump casing (271). • Take care of front casing (171) not to fall because it is heavy (about 28kg (62 lbs)). • Remove front casing (171) with respect to drive shaft (111) horizontally. When the guide bolt is used, posture is steady. (Refer to attached dwg.) In addition, take care not to damage oil seal sliding surfaces of drive shaft (111) in removing front casing. In removing front casing (171), seat packing (752) might adhere to front casing (171). Remove it taking care. • Take care not to damage fitting surfaces between front casing (171) and pump casing (271). Removing drive gear (191) 15. Removing drive gear (191) Remove snap rings (824) and (825), bearing spacers (126) and (127), drive gear (191), and driven gear (192). Pulling out drive shaft (111) 16. Pulling out drive shaft (111) If necessary, remove snap rings (828) and (829) and bearing spacers (129) and (131). Then remove drive shaft (111) and driven shaft (113) from pump casing (271) tapping back end of shaft lightly with a plastic hammer etc. • Take care in removing driven shaft (113), because there is the turn stop pin (887) in roller bearing (122) part of driven side 17. Removing roller bearings (121) and (122) If necessary, remove snap rings (824) and (826), bearing spacers (128) and (130), and roller bearings (121) and (122) from drive shaft (111) and driven shaft (113). • Do not remove roller bearings (121) and (122) as far as possible, except when it is considered to be out of its life span. Use a specified jig in removing because roller bearing is shrinkage fitted to shaft. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
16.
14 14-77 [14. UPPER SLEWING
STRUCTURE] Removing swash plate supports (251) and (252) 18. Removing swash plate supports (251) and (252) Loosen hexagon socket head cap screws (405) which tighten swash plate supports (251) and (252) and pump casing (271). Remove swash plate supports (251) and (252) from pump casing (271). • Adhesive (No.1305N of Threebond make) is applied to hexagon socket head cap screws (405). 19. Removing other parts If necessary, remove stopper (L) (534), stopper (S) (535), servo piston (532), tilting pin (531) and servo cover (536) from pump casing (271). • In removing tilting pin (531), use a protector to prevent pin head from being damaged. • Since adhesive (No.1305N of Threebond make) is applied to fitting areas of tilting pin (531) and servo piston (532), take care not to damage servo piston (532). • Do not loosen hexagon nut (806) on servo cover (536). If loosened, flow setting will be changed. Assembling Procedures 1. Precautions of assembling Perform assembling procedures in the reverse order of disassembling procedures by taking care of the following items. • Be sure to repair the parts damaged during disassembling, and repair replacement parts in advance. • Clean each part fully with cleaning oil and dry it with compressed air. • Be sure to apply clean hydraulic oil to the sliding portions and the bearings, etc. before assembling them. • Always replace the sealing parts, such as the O-ring and the oil seal, in general. • Prepare a torque wrench for mounting socket bolts or plugs at each part and tighten them with the specified torques shown in "Tightening torque for hydraulic pump". • In case of parallel type pump, rotating directions of drive shaft and driven shaft are different. Take care not to mix up parts of the drive shaft side with those of the driven shaft side. • In order to avoid mixing up regulator of drive side with that of driven side, mark each of them. 2. Installing servo piston (532) Place pump casing (271) horizontally. Fit servo piston (532), tilting pin (531), stopper (L) (534), and stopper (S) (535) to pump casing. Then fit servo cover (536) to pump casing and fix them with hexagon socket head cap screws (406). • In tightening servo piston (532) and tilting pin (531), use a protector to prevent tilting pin head and feedback pin (548) from being damaged. In addition, apply adhesive (No.1305N of Threebond make) to their threaded sections. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
17.
14-78 [14. UPPER SLEWING
STRUCTURE] Installing swash plate supports (251) 3. Installing swash plate supports (251) Fit swash plate supports (251) and (252) to pump casing (271) and fix them with hexagon socket head cap screws (405). • There are O-rings (724) on the matching surface in contact with pump casing (271). Fix them with grease so they do not come off. • Because positioning pin (888) is placed on the pump casing (271) side, adjust it so it enters the groove of swash plate supports (251) and (252) and fix it. • Fit swash plate supports (251) and (252) so it enters straight, while tapping it lightly. Installing drive shaft (111) 4. Installing drive shaft (111) Set roller bearing (121), bearing spacer (128), and snap ring (824) to drive shaft (111). And fit them to pump casing (271). Then fix them with bearing spacer (129) and snap rings (828). • Direct the sharp edge side of snap rings (824) to the outside. • Do not tap drive shaft (111) with hammer or so on. • Assemble them into pump casing, tapping outer race of bearing (121) lightly with plastic hammer. Fit them fully, using steel bar or so on. • Direct the sharp edge side of snap ring (828) to the outside. Installing driven shaft (113) 5. Installing driven shaft (113) Set roller bearing (122), bearing spacer (130), and snap ring (826) to driven shaft (113). Match the groove of roller bearing (122) and pump casing (271), and fit them to pump casing (271). Then install turn stop pin (887), and fix them with bearing spacer (131) and snap ring (829). • Direct the sharp edge side of snap ring (826) to the outside. • Do not tap driven shaft (113) with hammer or so on. • Assemble them into pump casing, tapping outer race of bearing (122) lightly with plastic hammer. Fit them fully, using steel bar or so on. • Direct the sharp edge side of snap ring (829) to the outside. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
18.
14 14-79 [14. UPPER SLEWING
STRUCTURE] Installing drive gear (191) 6. Installing drive gear (191) Fit drive gear (191), driven gear (192), and bearing spacers (126) and (127) to drive shaft (111) and driven shaft (113). Then fix them with snap rings (824) and (825). • Confirm the attaching direction of drive gear (191) and driven gear (192) before fitting. • Direct the sharp edge of snap rings (824) and (825) to the outside. Installing front casing (171) 7. Installing front casing (171) Fit front casing (171) to pump casing (271) and fix them with hexagon socket head cap screws (408). • Take care of front casing (171) not to fall because it is heavy (about 28kg (62 lbs)). • Fit front casing (171) with respect to drive shaft (111) horizontally. When the guide bolt is used, posture is steady. (Refer to attached dwg.) In addition, take care not to damage oil seal sliding surfaces of drive shaft (111) in fitting front casing. • Take care not to damage fitting surfaces between front casing (171) and pump casing (271). • There is the seat packing (752) between front casing (171) and pump casing (271). Apply grease to seat packing (752) because it tends to come off. Installing front cover (261) 8. Installing front cover (261) Fit front cover (261) to front casing (171) and fix them with snap ring (827). • In assembling oil seal (774), take full care not to damage lip part of it. • Direct the sharp edge of snap ring (827) to the outside. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
19.
14-80 [14. UPPER SLEWING
STRUCTURE] Installing swash plate (212) 9. Installing swash plate (212) Fit tilting bush (214) of swash plate (212) to tilting pin (531) and fit swash plate to swash plate supports (251) and (252) correctly. • Take care not to mix up parts of drive shaft (111) side with those of driven shaft (113) side. • Even after fitting, swash plate (212) comes off from swash plate supports (251) and (252), in some cases. They do not come off easily if grease is applied to the sliding surfaces. • Confirm with fingers of both hands that swash plate (212) can be moved smoothly. Installing piston cylinder subassembly 10. Installing piston cylinder subassembly Assemble piston cylinder subassembly [cylinder (141), piston subassembly (151) and (152), set plate (153), spherical bush (156), cylinder spring (157)]. Fit spline phases of spherical bush (156) and cylinder (141), and insert piston cylinder subassembly into pump casing (271) with respect to drive shaft (111) and driven shaft (113) straightly. • Take care not to mix up parts of drive shaft (111) side with those of driven shaft (113) side. • Confirm that swash plate (212) is not off from swash plate supports (251) and (252) and from tilting pin (531), before inserting them. Installing valve plates (313) and (314) 11. Installing valve plates (313) and (314) Fit valve plates (313) and (314) to valve cover (312), entering valve plate pin (885) into pin hole. • Take care not to mistake suction /delivery directions of valve plates (313) and (314). (Drive side : clockwise viewed from shaft end Driven side : c.clockwise viewed from shaft end) • Apply grease to matching surface in contact with valve cover (312) because valve plates (313) and (314) tend to come off. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
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14 14-81 [14. UPPER SLEWING
STRUCTURE] Installing check valve subassembly (541) and (543) and (545) 12. Installing check valve subassembly (541) and (543) and (545) Insert check valve subassembly (541) and (543) and (545) and needle bearings (123) and (124) to valve cover (312). • Insert check valve subassembly (541) and (543) and (545) into valve cover (312) in correct order. • Since check valve subassembly (541) and (543) and (545) tends to come off, apply grease to matching part of valve cover (312). Installing O-rings (724) and (725) and seat packing (752) 13. Installing O-rings (724) and (725) and seat packing (752) Fit O-rings (724) and (725) and seat packing (752) to the matching surface of pump casing (271) in contact with valve cover (312). • Since O-rings (724) and (725) and seat packing (752) tend to come off, apply grease to matching surface. Fitting resin cover 14. Fitting resin cover Before fitting valve cover (312) to pump casing (271), fit guide bolt to valve cover (312), and fit resin cover to drive shaft (111) and driven shaft (113). • Fit guide bolt and resin cover in fitting valve cover (312), because needle bearings (123) and (124) might be damaged. Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
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14-82 [14. UPPER SLEWING
STRUCTURE] Installing valve cover 15. Installing valve cover Fit valve cover (312) to pump casing (271), and tighten them with hexagon socket head cap screws (410) and (411) and (412). • Crane valve cover (312) at this work because it is heavy (about 60kg (132 lbs)). When the guide bolt is used, posture is steady. (Refer to attached dwg.) • Confirm that swash plate (212) is not off from swash plate supports (251) and (252) and tilting pin (531) before fitting. • Needle bearings (123) and (124) are located on valve cover (312) side, place valve cover with care. • In fitting valve cover (312), take care as valve plates (313) and (314), check valve subassembly (541) and (543) and (545), O-rings (724) and (725) and seat packing (752) may come off in some cases. • Take care not to damage fitting surfaces of valve cover (312) and pump casing (271). 16. Installing gear pump (04) and booster (132) Fit gear pump (04), booster (132) and tighten hexagon socket head cap screws. • Take care that the tightening torque of the flange socket (bolt with the seat) is different from same size hexagon socket head cap screws because gear pump (04) is an aluminum casing. Installing regulator 17. Installing regulator Putting feedback pin (548) of tilting pin (531) into feedback lever of regulator (002) (regulator: 611), fit regulators and tighten hexagon socket head cap screws (regulator: 415). 18. Installing PTO When there is PTO (05), fit it and tighten hexagon socket head cap screws (PTO: 416). Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0028E03] [0329CsCshWbYs]
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