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Kobelco SK260LC-8 (HS Engine) HYDRAULIC EXCAVATOR Service Repair Manual.pdf
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.S5LQ0017E03 0-1 SK250-8 SK260LC-8 (HS Engine) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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 © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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 © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
5.
0-5 Index No. Title Book Code No. Distribution
Year–Month S5LQ0217E01 2007-05 S5YN0118E01 2007-05 S5LQ0317E01 2007-05 S5LQ1114E01 2007-05 S5LQ1217E01 2007-05 S5LQ1314E01 2007-05 S5LQ2117E02 2008-10 S5LQ2217E01 2007-05 S5LQ2317E01 2007-05 S5LQ2417E02 2008-10 S5LQ2517E01 2007-05 S5YN3118E01 2007-05 _ _ S5LQ3214E01 2007-05 S5LQ3317E01 2007-05 _ S5YN4718E01 2007-05 S5YN4818E01 2007-05 _ S5LQ5117E03 2010-07 _ LQ12-06001~ LL12-05001~ S5LQ3417E01 2007-05 S5LQ4617E01 2007-05 STANDARD MAINTENANCE TIME SCHEDULE MAINTENANCE STANDARD AND TEST PROCEDURE MECHATRO CONTROL SYSTEM DISASSEMBLING & ASSEMBLING 2 1 3 11 12 13 21 22 23 24 25 31 32 33 34 46 47 48 51 OUTLINE SPECIFICATIONS ATTACHMENT DIMENSIONS TOOLS HYDRAULIC SYSTEM ELECTRIC SYSTEM COMPONENTS SYSTEM AIR-CONDITIONER SYSTEM ATTACHMENT UPPER STRUCTURE TRAVEL SYSTEM BY ERROR CODES BY TROUBLE TROUBLEDIAGNOSISMODE ENGINE APPLICABLE MACHINES SPECIFICATIONS MAINTENANCE SYSTEM DISASSEMBLING TROUBLESHOOTING E / G INDEX SK250-8 SK260LC-8 ASIA(HS Engine) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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 © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
7.
1-1 1 Book Code No.
S5YN0118E01 1. OUTLINE TABLE OF CONTENTS 1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3 1.1.1 PREPARATION BEFORE DISASSEMBLING..........................................................1-3 1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-3 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-3 1.1.4 ELECTRICAL EQUIPMENT .....................................................................................1-4 1.1.5 HYDRAULIC PARTS ................................................................................................1-5 1.1.6 WELD REPAIR .........................................................................................................1-5 1.1.7 ENVIRONMENTAL ISSUES.....................................................................................1-5 1.2 INTERNATIONAL UNIT SYSTEM .....................................................................................1-6 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
8.
1. OUTLINE 1-2 Issue Date
of Issue Applicable Machines Remarks First edition July, 2006 SK330-8 : LC10-07001~ SK350LC-8 : YC10-03501~ S5YN0118E01 (ASIA, OCE) K August, 2006 SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~ (ASIA, OCE) K October, 2006 SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~ (ASIA, OCE) K December, 2006 SK850LC: LY01-00101~ K February, 2007 E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~ (NHK) K SK235SRLC-2 : YU05-02001~ (North America) K March, 2007 E215B : YN11-45001~ E215BLC : YQ11-06001~ (NHK Russia) K April, 2007 SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~ (OCE) K SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~ ASIA (HS Engine) K May, 2007 SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~ ASIA (HS Engine) K June, 2007 E205BSR : YB05-03001~ E205BSRLC : LA05-02001~ (NHK) K Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
9.
1. OUTLINE 1-3 1.1 GENERAL
PRECAUTIONS FOR MAKING REPAIRS 1.1.1 PREPARATION BEFORE DISASSEMBLING (1) Knowledge of operating procedure Read Operator’s Manual carefully to understand the operating procedure. (2) 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. (3) 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. (4) Recording Record the following items to keep contact and prevent malfunction from recurring. 1) Inspecting date, place 2) Model name, Serial number and Record on hour meter 3) Trouble condition, place, cause 4) Visible oil leak, water leak and damage 5) Clogging of filters, oil level, oil quality, oil contamination and looseness. 6) Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour meter. (5) Arrangement and cleaning in service shop 1) Tools required for repair work. 2) Prepare the places to put the disassembled parts. 3) Prepare oil pans for leaking oil, etc. 1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING (1) Safety 1) Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves. 2) Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work. 3) Before starting inspection and maintenance stop the engine. 4) 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. 5) Choose a hard, lever and safe place, and put attachment on the ground without fail. 6) Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more). 7) Use proper tools, and change or repair defective tools. 8) Machine and attachment required to work in the lifting condition should be supported with supports or blocks securely. 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT (1) Removing hydraulic equipment assy 1) 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. 2) Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground. 3) Pipes with plugs or caps to prevent oil leaking, entry of dust, etc. 4) Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on working bench. (2) Disassembling hydraulic equipment 1) 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. 2) If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. 3) Make match mark on parts for reassembling. 4) Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not. Read Operator's Manual before disassembling WARNING Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
10.
1. OUTLINE 1-4 5) For
parts which are required to use jig and tools, don’t fail to use the specified jig and tools. 6) For parts which can not be removed in the specified procedure, never force removal. First check for the cause. 7) The removed parts should be put in order and tagged so as to install on proper places without confusion. 8) For common parts, pay attention to the quantity and places. (3) Inspecting parts 1) Check that the disassembled parts are free from adherence, interference and uneven working face. 2) Measure the wear of parts and clearance, and record the measured values. 3) If an abnormality is detected, repair or replace the parts. (4) Reassembling hydraulic equipment 1) During the parts cleaning, ventilate the room. 2) Before assembly, clean parts roughly first, and then completely. 3) Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. 4) Replace the removed O-ring, back-up rings and oil seal with new ones, and apply grease oil on them before assembling. 5) Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them. 6) Before assembling, remove rust preventives on new parts. 7) Use special tools to fit bearings, bushing and oil seal. 8) Assemble parts matching to the marks. 9) After completion, check that there is no omission of parts. (5) Installing hydraulic equipment 1) Confirm hydraulic oil and lubrication oil. 2) Air release is required in the following cases ; 1. Change of hydraulic oil 2. Replacement of parts on suction pipe side 3. Removing and attaching hydraulic pump 4. Removing and attaching swing motor 5. Removing and attaching travel motor 6. Removing and attaching hydraulic cylinder If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. 3) 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. 4) 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. For cylinder, don’t move it to the stroke end at beginning. 5) Air in pilot circuit can be bleed out by only operating digging, swing and traveling motions thoroughly. 6) 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 1.1.4 ELECTRICAL EQUIPMENT (1) The disassembly of electrical equipment is not allowed. (2) Handle equipment with care so as not to drop it or bump it. (3) Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire. (4) Check that connector is connected and locked completely. (5) Engine key off before removing and connecting connector. LEVEL GAUGE Oil level of hydraulic oil tank. If the indicator is within level marks, the oil quantity is acceptable. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
11.
1. OUTLINE 1-5 (6) Engine
key off before touching terminals of starter and alternator. (7) Remove battery grounding terminal before beginning work close to battery and battery relay with tools. (8) Wash machine with care so as not to splash water on electrical equipment and connector. (9) 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. 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 milk or water. • When it has adhered on clothes ; Wash it immediately. 1.1.5 HYDRAULIC PARTS (1) 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. (2) 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. 1.1.6 WELD REPAIR (1) 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. (2) Remove parts which may cause fire due to the entry of spark beforehand. (3) 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. 1.1.7 ENVIRONMENTAL ISSUES (1) Engine should be started and operated in the place where air can be sufficiently ventilated. (2) Waste disposal The following parts follows the regulation. Waste oil, waste container and battery (3) 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. (4) Others For spare parts, grease and oil, use KOBELCO genuine ones. Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
12.
1. OUTLINE 1-6 1.2 INTERNATIONAL
UNIT SYSTEM 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 (1) Basic Units (2) Supplementary Units (3) Derived Units of Basic Units (4) Derived Units bearing Peculiar Designations (5) Prefixes of SI 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 QUANTITIES DESIGNATION SIGN Plain angle Solid angle Radian Steradian rad sr Table1-3 QUANTITIES DESIGNATION SIGN 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 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 Table1-4 QUANTITY UNIT SYMBOL FORMULA Frequency hertz Hz 1Hz=1/s Force newton N kg • m/s 2 Pressure and Stress pascal Pa N/m2 Energy, Work and Quantity of heat joule J N•m Power watt W J/s Quantity of electricity coulomb C A•s Electric potential difference, Voltage, and Electromotive force volt V W/A Quantity of static electricity and Electric capacitance farad F C/V Electric resistance ohm V/A Celcius temperature celcius degree or degree °C (t+273.15)K Illuminance lux lx l m/m2 Table1-5 PREFIX POWER DESIGNATION SIGN Giga G 109 Mega M 106 Kilo k 103 Hecto h 102 Deca da 10 Deci d 10–1 Centi c 10–2 Milli m 10–3 Micro 10–6 Nano n 10–9 Pico p 10–12 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
13.
1. OUTLINE 1-7 (6) Unit
Conversion Table QUANTITIES JIS SI REMARKS Mass kg kg Force kgf N 1kgf=9.807N Torque kgf•m N•m 1kgf•m=9.807N•m Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa Motive power PS kW 1PS=0.7355kW Revolution r.p.m min–1 1r.p.m=1min–1 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
14.
33. UPPER STRUCTURE 33-45 33.1.18
SWING MOTOR UNIT 33.1.18.1 PREPARATION FOR REMOVING 33.1.18.2 REMOVAL (1) Park machine on firm level ground and place attachment on ground. (2) Remove the guard (6). (See 33.1.4 GUARD) (3) Operate the switch on gauge cluster and select the pressure release mode, and then release the inner pressure in circuit by operating control lever. (See 22.11 HYDRAULIC SYSTEM PRESSURE DRAINING(RELEASING) CIRCUIT) (4) Bleed air from the hydraulic oil tank and attach to each hose a tag showing port name and other information. (1) Remove hose. 1) Remove hose (7) from the connector in the makeup port M. : 36 mm 2) Remove 2 hoses (4), (5) from the Tee in the drain port Dr. : 27 mm 3) Remove hose (A2) from the elbow of the PG port (For swing parking brake) (See Fig. 33-77) : 19 mm 4) Remove 2 hoses (A4), (A7) from the connectors of the A, B port. : 36 mm Put in plugs PF3/4, PF1/2, and PF1/4 into the removed ports. Fig. 33-76 Removing swing unit piping Fig. 33-77 Removing swing unit A B As C/V Bs C/V M C/V H/D TANK MU Dr S/J E 7 4 5 A7 A4 13 14 PG 2 2 1 1 A2 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
15.
33. UPPER STRUCTURE 33-46 33.1.18.3
PREPARATION FOR INSTALL (1) Clean mating surfaces of swing motor unit and upper frame. Tools : spatula, wash oil (2) Apply Loctite #515 on entire mounting surface of swing motor unit. 33.1.18.4 INSTALLATION 33.1.18.5 PREPARATION FOR DRIVE (1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient. Amount of oil : 7L (1.8gal) (2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leak and noise. (2) Removing the swing unit Remove 14 capscrews (1) M2065. : 30 mm 1) Remove two plastic caps (2) M12 at the top of the swing motor and install eye bolts. : Flat-blade screwdriver 2) Put a wire sling in the eye bolts and remove the swing motor unit. Weight of swing motor unit ; Approx. 274kg (604 lbs) (Include reduction assy) Install the swing motor unit in the reverse order of disassembly, confirming the orientation of the swing motor unit. (1) Tighten 14 capscrews (1) M2065. : 30 mm Tightening torque : 539N•m (400 lbf•ft) Apply Loctite #262 (2) Fill inside from motor drain port to casing with hydraulic oil before piping for drain Fig. 33-78 Installing swing motor unit 1 LEVEL GAUGE FILLING PORT 1 Coat all the mounting surface of the swing motor with Loctite #515 equivalent. Apply Loctite #262 equivalent. Tightening torque 539N.m (400 lbf.ft) Put sealing tape on the both sides of thread portion of filling tube. Tightening torque 108 N.m (80 lbf.ft) Put sealing tape on the thread portion of tube for level gauge. Tightening torque 69.1 N.m (51 lbf.ft) Detail of swing motor unit assy mount Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
16.
33. UPPER STRUCTURE 33-47 33.1.19
SWIVEL JOINT 33.1.19.1 PREPARATION FOR REMOVING Remove boom piping hose 33.1.19.2 REMOVAL Fig. 33-79 Removing piping (lower side) (1) Remove travel motor hose and tube 1) Remove 2 hoses (A16). (E port : PF1/2) : 27 mm, Tightening torque : 78.5 N•m (58 lbf•ft) 2) Remove tubes (A1), (A2). (C, D port : PF1) : 41 mm, Tightening torque : 275 N•m (203 lbf•ft) 3) Remove tubes (A3), (A4). (A, B port : PF1) : 41 mm, Tightening torque : 275 N•m (203 lbf•ft) 4) Remove 2 hoses (A7). (F port : PF1/4) : 19 mm, Tightening torque : 29.4 N•m (22 lbf•ft) A3 A1 A16 A16 A7 A7 A2 B2 T=36.3 (26.8) A4 T=255 (188) T=255 (188) T=108 (80) T=108 (80) SWIVEL JOINT T : Tightening torque of connector N.m (lbf.ft) (LH) (RH) VB (LOWER) REVERSE VA (UPPER) FORWARD (TRAVEL MOTOR) FORWARD VA (LOWER) REVERSE VB (UPPER) (TRAVEL MOTOR) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
17.
33. UPPER STRUCTURE 33-48 (2)
Disconnecting the hoses on the top part of swivel joint 1) Remove drain hose (4). (E port : PF1/2) : 27 mm Tightening torque : 78 N•m (58 lbf•ft) 2) Remove hoses (A8), (A6). (A, CÉ|Å[Ég : 1-3/16-12UN) : 36 mm Tightening torque : 177 N•m (130 lbf•ft) 3) Remove hoses (A9), (A25). (B, D port : 1-3/16-12UN) : 36 mm Tightening torque : 177 N•m (130 lbf•ft) 4) Remove hose (A7). (Travel 2-speed change over port : PF1/4) : 19 mm Tightening torque : 29 N•m (21 lbf•ft) Fig. 33-80 Disconnecting the hoses on the top part of swivel joint (3) Remove whirl-stop of swivel joint. 1) Loosen the nut (19) M24. 2) Remove a capscrew (18) M124130. : 36 mm Fig. 33-81 Removing whirl-stop nut the capscrew (4) Remove joint for piping (See Fig. 33-79,Fig. 33-80) 1) Remove 2 connectors (B2). (F port) 2) Remove connector (14) (F port) for travel 2- speed change over. (PF1/4) : 19 mm (5) Remove seal (B3) 1) Remove 6 capscrews (B6) M1025. : 17 mm 2) Remove clip (B5). : Flat-blade screwdriver 3) Remove seal (B3). Fig. 33-82 Removing seal (B3) A25 4 A9 A8 A6 14 A7 19 18 Tightening torque 157N.m (116 lbf.ft) 13mm At assembling, this distance should be 13mm (0.512in). Tightening torque 6.8N.m (5 lbf.ft) Tightening torque 14.7N.m (11 lbf.ft) To prevent from entering water, apply Loctite 572 or 577 around this plate (B4). Before mounting the seal (B3), apply adhesive to the adhering surface of S/J and the upper frame. B5 B6 B4 B3 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
18.
33. UPPER STRUCTURE 33-49 33.1.19.3
INSTALLATION (1) Installing is done in the reverse order of removing. Piping tightening torque (2) Check for oil leak and the hydraulic oil level. (3) Check for operating. (6) Remove capscrew for installation Attach eye bolt, lift it up temporarily, and remove 3 capscrews (C2) M1225. : 19 mm (See 11.7 SPECIAL TOOLS No.9 Plug) Fig. 33-83 Removing capscrew for installation (7) Slinging the swivel joint Weight : Approx. 24kg (53 lbs) ! #$! $ % '$ O-ring type Connector Hydraulic hose Tightening torque N.m (lbf.ft) Tool. HEX Size PF 1/4 3/8 1/2 3/4 1 1-3/16-12UN 19 22 27 36 41 36 36 (27) 74 (54) 108 (80) 162 (120) 255 (180) - 29 (22) 49 (36) 78 (58) 118 (87) 137 (100) 177 (130) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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33. UPPER STRUCTURE 33-50 33.1.20
UPPER FRAME 33.1.20.1 PREPARATION FOR REMOVING 33.1.20.2 REMOVAL (1) Remove attachment (See chapter 32) (2) Remove cab (See 33.1.2 CAB) (3) Remove guard (See 33.1.4 GUARD) (4) Remove counterweight (See 33.1.11 COUNTERWEIGHT) (5) Remove swivel joint (See 33.1.19 SWIVEL JOINT) Fig. 33-84 Temporarily lift upper frame (1) Lifting up upper frame temporarily Lift the upper frame temporarily by after mentioned three points using lifting tool (Refer to the chapter of the tool). Use the near 2 holes of the boom foot pin and the rear of the upper frame at this work. (2) Marking match marks on swing bearing Put match marks on upper frame and swing bearing. Fig. 33-85 Matching mark on swing bearing and upper frame (3) Removing upper frame attaching bolts Remove 32 capscrews (9) M20115 and a reamer bolt (10) used to install swing bearing and upper frame. : 30 mm (4) Slinging upper frame Sling according to Fig. 33-84, and remove upper frame and put it on a stand. Weight : Approx. 5ton (11,000lbs) Fig. 33-86 Removing upper frame attaching bolts Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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33. UPPER STRUCTURE 33-51 33.1.20.3
INSTALLATION (1) Installing is done in the reverse order of removing. (2) Cleaning mating surfaces of upper frame and swing bearing. (3) Apply Loctite #515 to the inside of the capscrews on the contact surface. (4) Slinging upper frame Match marks and install it with a reamer bolt (10) and a washer (11) temporarily. Confirm the reamer bolt positions referring to Fig. 33- 88. : 30 mm Apply Loctite #262 Tightening torque : 490 N•m (360 lbf•ft) Apply Loctite #262 (5) Install swing bearing Install 32 capscrews (9) M20115. : 30 mm Apply Loctite #262 Tightening torque : 490 N•m (360lbf•ft) Install a reamer bolt (10). : 30 mm Tightening torque : 490 N•m (360lbf•ft) Fig. 33-87 Bearing mount Fig. 33-88 Reamer bolt position (*) Apply Loctite to shaded area Apply Loctite #515 to the race surface over the whole circumference (shaded area) on the inside of capscrew. Apply Loctite #262 equivalent. T=490N.m (360 lbf.ft) 10,11 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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33. UPPER STRUCTURE 33-52 33.2
DISASSEMBLING AND ASSEMBLING 33.2.1 HYDRAULIC PUMP • REGULATOR 33.2.1.1 HYDRAULIC PUMP 33.2.1.1.1 Structural exploded view (1) Main pump Fig. 33-89 Structural exploded view of main pump 04 824 127 127 113 806 953 886 535 789 732 W B X Z Y A 534 792 702 532 728 468 271 717 490 251 401 407 325 312 546 901 490 886 C D E F D E 727 467 725 466 885 886 710 116 414 05 326 261 774 710 724 111 885 212 214 211 153 156 157 141 717 314 124 727 546 725 B 717 313 124 406 981 983 531 . 548 123 151 . 152 A C F 954 808 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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33. UPPER STRUCTURE 33-53 Marks
in Fig. 33-108 show the position where regulator is installed. No. 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313 Shaft(F) Shaft(R) 1st gear Roller bearing Needle bearing Bearing spacer Cylinder block Piston Shoe Retainer Spherical bushing Cylinder spring Shoe plate Swash plate Tilting bushing Swash plate support Seal cover (F) Pump casing Valve block Valve plate (R) Valve plate (L) Sensor block Cover Socket bolt ; M20X210 Socket bolt ; M8X20 Socket bolt ; M6X55 Socket bolt ; M10X20 VP plug ; PF1/4 VP plug ; PF3/8 VP plug ; PF3/4 Plug ; NPTF1/16 Tilt pin ; M24X2 Servo piston ; M24X2 Stopper (L) Stopper (S) Spacer Feed back pin O-ring ; 1B G35 O-ring ; 1B G95 O-ring ; 1B G145 O-ring ; 1B P8 O-ring ; 1B P11 O-ring ; 1B P14 O-ring ; 1B P24 O-ring ; 1B P18 Oil seal Backup ring P18 Backup ring G35 Nut ; M16 Nut ; M20 Stop ring Valve plate pin Spring pin Eye bolt ; M10 Socket screw ; M16X30 Set screw ; M20 Gear pump PTO gear case (OPT.) Name Name Name Q'ty 1 1 1 2 2 3 2 18 18 2 2 18 2 2 2 2 1 2 1 1 No. 314 325 326 401 406 407 414 466 467 468 490 531 532 534 535 546 548 702 710 717 Q'ty 1 1 1 8 4 3 4 2 2 4 32 2 2 2 2 2 2 2 2 4 No. 724 725 727 728 732 774 789 792 806 808 824 885 886 901 953 954 04 05 No. 16 9 3 4 2 1 2 2 2 2 2 2 4 2 2 2 1 1 The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible. No. 401 406 407 414 466 467 468 490 531,532 806 808 Thread size M20 M8 M6 M10 PF 1/4 PF 3/8 PF 3/4 NPTF1/16 M24X2 M16 M20 Tightening torque N.m (lbf.ft) 430 (317) 29 (21) 12 (8.9) 57 (42) 36 (27) 74 (55) 170 (125) 8.8 (6.5) 240 (177) 130 (95) 240 (177) Tightening torque of bolt, plug, nut and servo piston Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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33. UPPER STRUCTURE 33-54 (2)
Gear pump (For pilot) Fig. 33-90 No. Parts Q’ty No. Parts Q’ty 307 Poppet 1 361 Front case 1 308 Seat 1 433 Flange socket; M840 2 309 Ring 1 434 Flange socket; M855 2 310 Spring 1 435 Flange socket; M820 4 311 Adjust screw 1 466 VP plug ; PF1/4 1 312 Lock nut ; M141.5 1 700 Ring 1 351 Gear case 1 710 O-ring ; 1B G95 1 353 Drive gear 1 725 O-ring ; 1B P11 1 354 Driven gear 1 732 O-ring ; 1B P16 1 355 Filter 1 850 Locking ring 1 433 353 351 354 700 Suction port : PF3/4 Tightening torque : 73.5N.m 434 Delivery port : PF1/2 Tightening torque : 53N.m (39.1 lbf.ft) 311 312 850 307 732 355 309 434 466 725 310 308 Drain port : PF3/8 Tightening torque : 34.3N.m (25.3 lbf.ft) 435 361 710 (54.2 lbf.ft) Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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33. UPPER STRUCTURE 33-55 33.2.1.1.2
Disassembly and assembly of main pump (1) Tools The right list shows the tools required for remove and install. (2) Disassembling procedure 1) Selecting a place for disassembly. • Choose a clean place. • Spread rubber sheet or cloth on work bench to protect parts from damaging. 2) Cleaning Remove dust and rust, etc. on pump surface with wash oil. 3) Drain oil Drain out the oil in the pump casing by removing drain port plug (466), (468). : 19 mm, 36 mm • Drain out oil from the plug of the front pump and the rear pump. 4) Removing regulator and PTO gear casing (OPT.) Remove the socket bolts [412, 413, 414 (See Fig. 33-89, Fig. 33-108)]. Then remove the regulator and the PTO cover (326). : 6 mm, 8 mm • Regarding the disassembly of the regulator, refer to article of Regulator. 5) Remove gear pump Remove the socket bolts (435). Then remove the gear pump (04). : 6 mm 6) Remove socket bolt (401) Loosen socket bolts (401) that fasten swash plate support (251), pump casing (271) and valve block (312). : 17 mm Fig. 33-91 Remove socket bolt (401) ! ! # # $% ' ( )*+ , - . , ) / 0 + 1* 2 * , 3 ! +2 2 3, , 44 3 - REGULATOR Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
25.
33. UPPER STRUCTURE 33-56 6)
Disassembling the pump casing and the valve block Place the pump level on a work bench with its mounting surface of the regulator facing down. Then separate pump casing (271) and valve block (312). • When facing the mounting surface of the regulator down, place a rubber sheet on a work bench so as not to score the mounting surface. • When the pump casing has been separated from the valve block, draw out the 1st gear (116) at the same time. Fig. 33-92 Disassembling the pump casing (271) and the valve block (312) 7) Drawing out the cylinder assy Draw out cylinder (141) out of pump casing (271) in parallel to shaft (111). At the same time draw out piston (151), plate (153), spherical bushing (156) and cylinder spring (157). • Use care so as not to score the sliding surface of the cylinder, spherical bushing, shoe and the swash plate. Fig. 33-93 Drawing out the cylinder assy 8) Remove seal cover (F) Remove socket bolt (406) M8 and seal cover F (261). : 6 mm • The seal cover (F) may be drawn out with ease if it is taken out by tightening bolts in the tapped holes (M6 tap) of the seal cover (F). • An oil seal is fitted to seal cover (F). Therefore, use care so as not to score the oil seal. Fig. 33-94 Removing seal cover F (261) 312 271 % ##% #$ #! 261 406 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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27.
33. UPPER STRUCTURE 33-57 9)
Separating the swash plate support and the pump casing Knock lightly on the mounting flange of swash plate support (251) from the pump casing (271) side and separate the swash plate support from the pump casing. Fig. 33-95 Separating the swash plate (251) support and the pump casing (271) 10) Remove shoe plate and swash plate Draw out shoe plate (211) and swash plate (212) from pump casing (271). Fig. 33-96 Removing shoe (211) and swash plate (212) 11) Drawing out the shaft Tap lightly the shaft end (111, 113) by means of a plastic hammer and draw out the shaft from the swash plate support. Fig. 33-97 Drawing out the shaft (111), (113) # % % # ! Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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33. UPPER STRUCTURE 33-58 12)
Remove valve plate Remove valve plate (313, 314) from valve block (312). • The valve plate may come off during the operation under 6). Fig. 33-98 Removing valve plates (313), (314) 13) Remove other parts If necessary, remove stopper (L) (534), stopper (S) (535), servo piston (532) and tilting pin (531) from pump casing (271), and remove needle bearing (124) from valve block (312). • When removing the tilting pin, use care so as not to score the head of the tilting pin, using a jig. • It is hard to separate the tilting pin from the servo piston in some cases as Loctite is coated on the mating part between them. Use care so as not to score the servo piston by applying undue force. • Do not draw out needle bearings except when their service life has ended. • Do not loosen hex nuts (806),(808) of valve block (312) and swash plate support (251). A set flow rate changes. Fig. 33-99 Removing other parts 314 (313 : Opposite Side) 312 531 534 535 806 532 808 124 312 271 251 Copyright © 2015 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LQ0017E03] [0811CsCshWbYs]
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