Hydraulic Excavator Shop Manual Index and Sections Guide

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.S5LS0025E03
0-1
SK500LC-10
Copyright©2019 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0025E03] [0329CsCshWbYs]

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.

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.

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 Construction
Machinery U.S.A Inc. 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.

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
APPLICABLE MACHINES
SPECIFICATIONS
MAINTENANCE
SYSTEM
DISASSEMBLING
TROUBLESHOOTING
INDEX SK500LC-10
North America
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
ENGINE
E/G
2016-08
2019-02
2016-08
2016-08
2016-08
2019-02
2019-02
2016-08
2018-04
2019-02
2016-08
2016-08
2016-08
2016-08
2016-08
2019-02
2016-08
2016-08

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.

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

［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 Construction Machinery
U.S.A Inc. 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.

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.

［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

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.

［1. OUTLINE］
1
1-7
1.2.4 ELECTRICAL EQUIPMENT
BATTERY FLUID IS DANGEROUS.
The battery fluid is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes, skin and clothes.
When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical
advice.
• When it has adhered on skin; Wash with soap and water.
• When it has got in eyes; Wash in water for 10 minutes or more immediately.
• When it has spilled out in large quantity; Use sodium bicarbonate to neutralize, or wash away with water.
• When it was swallowed; Drink a lot of water.
• When it has adhered on clothes; Wash it immediately.
• The disassembly of electrical equipment is not allowed.
• Handle equipment with care so as not to drop it or bump it.
• Connector should be removed by unlocking while holding the connector.
Never stress in tension to the caulked section by pulling wire.
• Check that connector is connected and locked completely.
• Engine key off before removing and connecting connector.
• Engine key off before touching terminals of starter and alternator.
• Remove battery grounding terminal before beginning work close to battery and battery relay with tools.
• Wash machine with care so as not to splash water on electrical equipment and connector.
• When water has entered in the waterproofed connector, the removing of water is not easy. So check the
removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it
completely before connecting.
1.2.5 HYDRAULIC PARTS
O-ring
• Check that O-ring is free from flaw and has elasticity before fitting.
• Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections, the rubber
hardness also differs according to the pressure force, and also the quality differs depending on the materials to
be seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and bend.
• Floating seal should be put in pairs.
Flexible hose (F hose)
• Even if the connector and length of hose are the same, the parts differ according to the withstanding pressure.
Use proper parts.
• Tighten it to the specified torque, and check that it is free from twist, over tension, interference, and oil leak.

1-8
［1. OUTLINE］
1.2.6 WELD REPAIR
• The weld repair should be carried out by qualified personnel in the specified procedure after disconnecting the
grounding cable of battery. If the grounding cable is not disconnected, the electrical equipment may be
damaged.
• Remove parts which may cause fire due to the entry of spark beforehand.
• Repair attachments which are damaged, giving particular attention to the plated section of piston rod to protect it
from sparks, and don't fail to cover the section with flame-proof clothes.
1.2.7 ENVIRONMENTAL ISSUES
• Engine should be started and operated in the place where air can be sufficiently ventilated.
• Waste disposal
The following parts follows the regulation.
– Waste oil and waste container
– Battery
• Precautions for handling hydraulic oil
Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
– When it has got in eyes ;Wash eyes with water until the stimulus is gone.
– When it was swallowed ;Don't force him to vomit it, but immediately receive medical treatment.
– When it has adhered on skin ;Wash with soap and water.
• Others
For spare parts, grease and oil, use KOBELCO genuine ones.

［1. OUTLINE］
1
1-9
1.3 INTERNATIONAL UNIT SYSTEM
SI unit
system
Prefixes of SI
(n-th power of 10, where n is an integer)
Table 1- 5
SI units
Base units
Table 1-1
Supplemen
tary units
Table 1-2
Derived units
of base units
Table 1-3
Derived units
bearing peculiar
designations
Table 1-4
Derived
units
(1) Basic Units
(2) Supplementary Units
(3) Derived Units of Basic Units
Table1-1
QUANTITIES DESIGNATION SIGN
Length
Mass
Time
Current
Thermodynamic
temperature
Gram molecule
Luminous intensity
Meter
Kilogram
Second
Ampere
Kelvin
Mol
Candela
m
kg
s
A
K
mol
cd
Table1-2
Plain angle
Solid angle
Radian
Steradian
rad
sr
Table1-3
Area
Volume
Velocity
Acceleration
Density
Square meter
Cubic meter
Meter per second
Meter per second / second
Kilogram per cubic meter
m2
m3
m/s
m/s2
kg/m3
(4) Derived Units bearing Peculiar Designations
Table1-4
QUANTITY UNIT SYMBOL FORMULA
Frequency
Force
Pressure and
Stress
Energy, Work
and Quantity of
heat
Power
Quantity of
electricity
Electric
potential
difference,
Voltage, and
Electromotive
force
Quantity of
static electricity
and Electric
capacitance
Electric
resistance
Celcius
temperature
Illuminance
hertz
newton
pascal
joule
watt
coulomb
volt
farad
ohm
celcius
degree or
degree
lux
Hz
N
Pa
J
W
C
V
F
°C
lx
1Hz=1/s
kg.m/s2
N/m2
N.m
J/s
A.s
W/A
C/V
V/A
(t+273.15)K
l m/m2
(5) Prefixes of SI
Table1-5
PREFIX
POWER
DESIGNATION SIGN
Giga
Mega
Kilo
Hecto
Deca
Deci
Centi
Milli
Micro
Nano
Pico
G
M
k
h
da
d
c
m
µ
n
p
109
106
103
102
10
10-1
10-2
10-3
10-6
10-9
10-12
(6) Unit Conversion Table
QUANTITIES JIS SI REMARKS
Mass
Force
Torque
Pressure
Motive power
Revolution
kg
kgf
kgf.m
kgf/cm2
PS
r.p.m
kg
N
N.m
MPA
kW
min-1
1kgf=9.8 07N
1kgf.m=9.8 07N.m
1kgf/cm 2
=0.098MPa
1PS=0.7355kW
1r.p.m=1min-1
Table1-6
Introduction
Although this manual uses the SI units system. Outline
of SI units system is described here.
Given hereinunder are an excerpt of the units that are
related to this manual :
1. Etymology of SI Units
English : International System of units
2. Construction of SI Unit System

14
14-75
［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.

14-76
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.

14
14-77
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.

14-78
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
• Remove front casing (171) with respect to drive shaft
(111) horizontally.
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.

14
14-79
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.

14-80
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.

14
14-81
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
• Fit front casing (171) with respect to drive shaft (111)
horizontally.
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.

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14-82
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.

14
14-83
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.

14-84
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
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).

Hydraulic Excavator Shop Manual Index and Sections Guide

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Hydraulic Excavator Shop Manual Index and Sections Guide