Kobelco SK520XDLC-10 HYDRAULIC EXCAVATOR Service Repair Manual (Book Code No.S5LS0031E01).pdf

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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.S5LS0031E01
0-1
SK520XDLC-10
Copyright©2018 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0031E01]

0-5
17
18
12
10
11
13
14
15
16
9
Index
No.
Title
Distribution Year–Month
_
_
_
_
_
_
YS14-B0001~
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 SK520XDLC-10
India (KCEI)
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
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
2018-07
Copyright©2018 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5LS0031E01] [0809CsCsspWbYs]

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.

14-144
［14. UPPER SLEWING STRUCTURE］
14.4.4.2 DISASSEMBLING PILOT VALVE (ATT)
1. Plug each port of pilot valve, and clean it with kerosine.
P port: PF1/4
1 to 4 and T port: PF3/8
501
Removing cover (501)
2. Fix the pilot valve to a vise and remove cover (501).
312
302
Removing adjusting nut (312)
3. Remove adjusting nut (312) applying spanners to
adjusting nut (312) and circular plate (302).
Tools: Spanner: 22 mm, 32 mm
302
Removing circular plate (302)
4. Remove circular plate (302)
Tools: Spanner: 32 mm

14
14-145
Circular plate is removed
Installing Jig A
5. Turn joint (301) in counterclockwise with Jig A to
remove.
Jig (A): See Paragraph "JIG FOR PILOT VALVE
(ATT)".
301
Removing joint (301)
When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in jumping out
of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with two fingers.

14-146
6. Removing plate (151)
151
Removing plate (151)
• When the force of return springs (221) are strong,
press plate to let it come up slowly.
211
Removing plug (211)
• When the force of return springs (221) are weak, plug
(211) is left in casing (101) due to sliding resistance of
O-ring (214).
Tools: Pull plug (211) out with a driver.
To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring (221) force is
completely released.
221
101
212
211
Removing push rod, plug, pressure reducing valve
and spring
7. Remove push rod (212), plug (211), pressure
reducing valve assy (spool), return springs (221)
from casing (101).

14
14-147
Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.
201-1
201-2
216-1
216-2
Removing spool (201)
8. Push springs (241-1), (241-2) in the range of 7 mm
(0.28 inch) that the movement of spring seats (216-
1), (216-2) and shift the seats (216) in a side
direction, and remove spools (201-1), (201-2)
through the larger hole of seat.
Never push down spring seat (216-1) in 7 mm (0.28 inch) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.37 inch) or more. (For port 2,4)
201-1
201-2
241-1
241-2
216-1
216-2
217
Disassembling pressure reducing valve
9. Remove spool (201-1), (201-2), spring seats (216-
1), (216-2), spring (241-1), (241-2) and washer
(217).
211
212
214
246-1
246-2
218
218
Disassembling push rod
10. Remove spring (246-1), (246-2), spring seat (218),
from push rod (212).

14-148
212
Removing push rod (212)
11. Pull out push rod (212) from plug (211).
12. Remove O-ring (214) from plug (211).
213
Removing seal (213)
13. Remove inside seal (213) from plug (211) with small
driver.
14.4.4.3 WASHING OF PILOT VALVE (ATT) PARTS
1. Clean parts with wash oil roughly.
2. Clean parts with wash oil completely.
3. Dry parts by swabbing clean rag.
4. Apply rust preventives on parts.

14
14-149
14.4.4.4 ASSEMBLING PILOT VALVE (ATT)
217
201-1
201-2
201-1
201-2
241-1
241-2
216-1
216-2
Assembling pressure reducing valve
1. Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2).
216-1
216-2
201-1
201-2
Installing spools (201-1), (201-2)
2. Push spring seat (216-1) within 7mm (0.28 inch) and
insert the head of spool (201-1) through the larger
hole of the spring seat to assemble it.
(See Fig. "Removing spool (201)")
In case of spring seat (216-2), push it within 9.4 mm
(0.37 inch) to assemble spool (201-2).
Never push down spring seat (216-1) in 7 mm (0.28 inch) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.37 inch) or more. (For port 2,4)
101
221
PRESSURE REDUCING
VALVE ASSY
Installing pressure reducing valve assy
3. Place spring (221) into ports 1,3 of casing (101),
and then install pressure reducing valve assy in it.
Place springs (221) into ports 2,4 of casing (101),
and install it.

14-150
For the assembling
direction of seal (213).
SEAL (213)
PUSH ROD
(212)
PLUG (211)
-RING (214)
Apply hydraulic oil
213
211
214
Installing O-ring (214) and seal (213)
4. Fit O-ring (214) and seal (213) into plug (211).
• Apply hydraulic oil on surface of push rod.
212 211
246-1
246-2 218
Assembling push rod, spring (246-1), (246-2) and
seat (218)
5. Insert push rod (212) in plug (211) and install spring
(246-1) and spring seat (218) to push rod (212) on
port 1,3 side.
Insert push rod (212) in plug (211) and install spring
(246-2) and spring seat (218) to push rod (212) on
port 2, 4 side.

14
14-151
6. Fit plug (211) assy to casing (101).
101 211
Installing plug assy
1) When the force of spring (211) is weak, it stops at
the position where it is pushed in by the sliding
resistance of O-ring (214).
151
301
Installing plug assy and plate (151)
2) When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at the
same time, and tighten joint (301) temporarily.
• Install spool (201) straight and evenly into the hole of casing (101).
• Take care so that plug (211) and plate (151) do not jump out of casing (101).
A
101
Installing joint (301)
7. Install joint (301) on casing (101) with jig A securely.
Jig (A): See Paragraph "JIG FOR PILOT VALVE
(ATT)".
Tightening torque : 47.1N·m (34.7 lbf·ft)

14-152
302
312
Installing circular plate (302)
8. Install circular plate (302) to joint (301)
9. Screw adjusting nut (312) in until it touches circular plate (302), and tighten it applying spanner to stop circular
plate returning.
Tools: Socket: 22 mm
• Apply Loctite #277 to threads of joint.
Tightening torque: 68.6N·m (51 lbf·ft)
– Screw it in until it comes in contact with 4 push rods (212) equally.
– The exceeding of screw in may cause malfunction of machine.
GREASE
301
212
Applying grease to joint section and push rod
10. Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
11. Cover it with boots.
12. Spray rust preventives through each port and attach plug respectively.

14
14-153
14.4.4.5 MAINTENANCE STANDARD OF PILOT VALVE (ATT)
Check item Standard Remarks
Leakage
When leakage quantity reaches to 1000 cc/min.
(61 cu·in/min) or more where handle is set in
neutral position, or to 2000 cc/min. (122 cu·in/
min) or more in operation, replace spool with new
one.
If leaked, even if the spool is replaced, replace
pilot valve assy with new one.
Conditions
Primary pressure 2.94 MPa (426 psi)
Hydraulic oil viscosity 23 cSt
Spool
When the wear of sliding section is 10 μm
(0.0004 inch) more than the that of non sliding
section, replace it with new one.
This condition may be the same as the above.
Push rod When the wear of top is 1 mm (0.04 inch) or more, replace it with new one.
Looseness of control
section
When looseness of 2 mm (0.08 inch) or more on
circular plate (302) on control section and joint
section (301) due to wear is pro-duced, replace
them with new ones.
In case of the looseness due to the loosening on
tightening section, adjust it.
Stability of operation
In case abnormal noise, hunting, or decrease of
the primary pressure occurs during operation
and it cannot be returned to a normal condition
even though measures in
"TROUBLESHOOTING OF PILOT VALVE (ATT)"
are taken, replace the pilot valve assembly.
-
• O-ring, etc. should be replaced with new one at every disassembling.
• If socket bolt (125) was loosened, seal washer (121) should be replaced.
14.4.4.6 TROUBLESHOOTING OF PILOT VALVE (ATT)
It is very difficult to find defective section. The following table explains the several estimated causes. For repair,
refer to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required.
The following table does not cover causes and corrective actions for all the troubles. So it may be necessary to
perform further investigation of troubles and causes.
Phenomenon Possible Cause Corrective action
Secondary pressure
does not rise.
Primary pressure is insufficient. Secure primary pressure.
Secondary pressure springs (241) are broken or fatigued. Replace with new ones.
Clearance between spool (201) and cas-ing (101) is
abnormally large.
Replace spool (201).
Handle has a looseness. Disassembly and reassembly or
replace handle section.
Secondary pressure is
unstable.
Sliding parts are caught. Repair the unsmoothed section.
Tank line pressure varies. Bring pressure directly to oil tank.
Air has mixed into pipeline. Bleed air by operating it several
times.
Secondary pressure is
high.
Tank line pressure is high. Bring pressure directly to oil tank.
Sliding parts are caught. Correct.

14-154
14.4.4.7 JIG FOR PILOT VALVE (ATT)
Jig for removing and installing joint (301)
(1.14”)
(1.04”)
(0.93”)
(0.75”)
(0.51”)
(2.72”)
(2.13”)
(1.97”)
(1.81”)
(0.98”)
(0.67”)
(0.91”)
(1.06”)
(1.22”)
(0.63”)
(
0
.
5
1
”
)
(
0
.
2
3
”
)
(0.18”)
(0.49”)
(0.02”)
(0.61”)
(0.46”)
(0.26”)
(0.02”)
(0.02”)
(0.37”)
(1)
Material ; SCM415 (N)
Carburizing and Quenching
(2)
Material ; S45C
BUSHING
A A
SECTION AA
* (1) and (2) are tight fitted
Material ; SCM415 (N)
Carburizing and Quenching
Q'ty ; 2
Installing condition on joint
Sectional drawing of jig
Detail of bushing

14
14-155
14.4.5 PILOT VALVE (FOR TRAVEL)
14.4.5.1 CONSTRUCTION OF PILOT VALVE (TRAVEL)
271
201
412
412
412
203
210
202
212
203
210
202
212
214
214
224
337
336
218
225
203
210
202
212
214
224
337
224
337
336
336
218
220
220
105
102
225
218
225
203
210
202
212
214
224
337
336
218
225
213
311
335
324
313
301
101
194
192
163
153
194
192
163
153
217
213
213
311
311
335
335
324
324
313
313
301
211
211
301
217
217
213
311
335
324
313
301
217
413
413
171
171
204
420
423
501
501
423
420
271
471
472
471
472
471
472
471 201
472
Exploded view of pilot valve

14-156
No. Parts Q'ty No. Parts Q'ty
101 Casing 1 218 Seat 4
102 Casing 1 220 Socket bolt 2
105 Plug 1 224 Piston 4
153 Plug 2 225 Ball 12
163 O-ring 2 271 Socket bolt 2
171 Socket bolt 2 301 Spool 4
191 Seat 1 2 311 Spring seat 4
192 Seat 2 2 313 Washer 4
194 Ball 2 324 Spring 4
201 Cover 2 335 Spring 4
202 Plug 4 336 Spring 4
203 Collar 4 337 Spring 4
204 Cover 1 412 Bushing 4
210 Packing 4 413 Shaft 2
211 O-ring 2 420 Cam 2
212 O-ring 4 423 Setscrew 2
213 O-ring 4 471 Setscrew 4
214 Push rod 4 472 Lock nut 4
217 Washer 4 501 Berrows 2

14
14-157
14.4.5.2 JIGS FOR DISASSEMBLING AND ASSEMBLING PILOT VALVE (TRAVEL)
Special jig 1 (for removing bush)
32 (1.26)
Unit : mm (inch)
20 (0.79) 2
(0.079)
12
dia
.
(0.47
dia
.
)
-0.25
-0.40
-0.010
-0.016
10
dia
.
(0.39
dia
.
)
-0.20
-0.25
-0.008
-0.010
Special jig {Allen wrench and socket with width across flats of 7 mm (0.28 inch) (special)}
7
7

14-158
14.4.5.3 DISASSEMBLING PILOT VALVE (TRAVEL)
General precautions for works
1. Prepare a work bench that is strong and large enough to place the components without rattling, and does not
allow the components to fall or move.
2. Prepare the tools and the materials.
3. Use extreme caution when handling each part because it is made very precisely and avoid it from hitting with
each other or falling.
4. Hitting or prying stiff parts forcibly can cause burrs or breakage, making the parts impossible to install, or
causing oil leakage or decreased performance. So use extreme caution to avoid it and work patiently.
5. If the component is left disassembled or left during disassembling, rust can occur because of humidity or
foreign materials. So pay attention to prevent rust and dust when stopping the work unavoidably.
Disassembly procedure
1. Wash the remote control valve with white kerosene.
Plug each port before the work.
2. Fix the remote control valve to a vise through buffer
plates.
Remove rubber boot (501) upward.
3. Loosen hex head socket set screw (423) with the
Allen wrench.
Tools: Allen wrench: 3 mm
Be careful about loosening the screws because Locktite #241 is applied and the loosening torque is large.

14
14-159
(0LS 4)
4. Push and pull out cam shaft (413) with the Allen
wrench (0LS4 or 0LS3) or others from the inside
face of two tandem parts.
5. Remove cam (420) with set screws (471) and lock
nuts (472) installed as an assembly.
• Record the relation of positions between the cams and covers (201).
• When removing the cam, push rods (214) may pop out, so be careful about it.
6. Loosen and remove socket bolt (271) with the Allen
wrench.
7. Then remove cover (201).

14-160
• Record the relation of positions between the covers and damper casing (102).
• When removing the cover, push rods (214) or plugs (202) may pop out because of damping springs (336) and
(337), so be careful about it. {The plugs remain in the casing because of only the sliding friction of O-rings (212).}
8. Pull out push rod (214) from plug (202).
• Record the relation of positions between the plugs and the push rods.
• Be careful not to damage the surface of the push rods.
• When removing the push rod, the plug may pop out, so be careful about it.
9. Remove plug (202) with collar (203) and NHU
packing (210) attached.
• Record the relation of positions between the plugs and the casing.
• When removing the plug, the piston may pop out because of damping spring, so be careful about it.

14
14-161
10. Remove piston (224) from the casing.
Record the relation of positions between the pistons and the casing.
11. Remove damping springs (336) and (337) from the
casing.
Record the relation of positions between the damping springs and the casing holes.
12. Remove spring seat (218) from the casing.
Record the relation of positions between the spring seats and the casing holes.

14-162
13. Remove steel balls (225) by using a magnet.
Do not lose the steel balls.
14. Loosen and remove socket bolts (171) with the Allen
wrench and then remove cover (204).
Parallel Parallel
15. Loosen and remove socket bolts (220) with the Allen
wrench.
Evenly loosen two socket bolts (220) with damper casing (102) in a parallel condition.

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14-163
16. Remove damper casing (102).
• Record the relation of positions between the damper casing and casing (101).
• When removing the damper casing, the pressure reducing valve assembly may pop out because of return
springs (335), so be careful about it.
17. Remove O-rings (211) and (213) from the casing.
18. Remove the pressure reducing valve assembly from
the casing.
Record the relation of positions between the removed parts and the casing holes.

14-164
19. Remove return spring (335) from the casing.
Record the relation of positions between the removed parts and the casing holes.
20. Place cover (201) sideways on a level work bench
and apply special jig 1 to bushing (412) and tap it
lightly with a hammer to take out the bushing.
21. Fix the cam assembly to the vise, loosen lock nut
(472) with a wrench, and remove the lock nut and
set screw (471).
Tools: Wrench: 17 mm
The set screws need to be adjusted to the neutral position at installation. So if the set screws do not need to be
replaced, hereinafter they shall be dealt as the cam assembly.

14
14-165
22. When disassembling the pressure reducing valve
assembly, place the end of spool (301) vertically on
the level work bench. Push and slide spring seat
(311) sideways while pressing secondary pressure
setting spring (324) and then remove spring seat
(311) from spool (301) through the bigger hole.
• Be careful not to damage the surface of the spool.
• Do not push down the spring seat for 4 mm or more.
23. Disassemble spool (301), secondary pressure
setting spring (324), and washer (217), and washer
(313).
• Handle the parts as an assembly until reassembly.
• Washers (217) are used for preset adjustment of the secondary pressure setting springs and each thickness of
them is different for each spool assembly. Also, sometimes the washer is not used.
24. Remove collar (203) from plug (202).
25. Remove NHU packing (210) from the plug. Remove
it using a plastic spatula or others.
Be careful not to damage the inner surface of the plug.

Kobelco SK520XDLC-10 HYDRAULIC EXCAVATOR Service Repair Manual (Book Code No.S5LS0031E01).pdf

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Kobelco SK520XDLC-10 HYDRAULIC EXCAVATOR Service Repair Manual (Book Code No.S5LS0031E01).pdf