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GENERALSAFETYINFORMATION

Donotoperateorperformanymaintenanceonthis machineuntilallinstructionsfoundintheOPERATOR’SMANUALandthisMANUALhavebeenthoroughlyreadandunderstood.

Improperoperationormaintenanceofthismachine maycauseaccidentsandcouldresultinseriousinjuryordeath. Alwayskeepthemanualinstorage. Ifitismissingordamaged,placeanorderwithan authorizedDistributorforareplacement. Ifyouhaveanyquestions,pleaseconsultanauthorizedDistributor.

(1)Mostaccidents,whichoccurduringoperation,are duetoneglectofprecautionarymeasuresandsafetyrules.Sufficientcareshouldbetakentoavoid theseaccidents.Erroneousoperation,lubrication ormaintenanceservicesareverydangerousand maycauseinjuryordeathtopersonnel.Therefore allprecautionarymeasures,NOTES,DANGERS, WARNINGSandCAUTIONScontainedinthemanualandonthemachineshouldbereadandunderstoodbyallpersonnelbeforestartinganyworkwith oronthemachine.

(2)Operation,inspection,andmaintenanceshouldbe carefullycarriedout,andsafetymustbegiventhe firstpriority.Messagesofsafetyareindicatedwith marks.Thesafetyinformationcontainedinthe manualisintendedonlytosupplementsafety codes,insurancerequirements,locallaws,rules andregulations.

(3)Messagesofsafetyappearinthemanualandon themachine:Allmessagesofsafetyareidentified byoneofthefollowingwords:"DANGER","WARNING"and"CAUTION".

1)DANGER-Indicatesanimminentlyhazardous situationwhich,ifnotavoided,willresultin deathorseriousinjuryandisrepresentedas follows:

3)CAUTION-Indicatesapotentiallyhazardous situationwhich,ifnotavoided,mayresultinminorormoderateinjury.Itmayalsobeusedto alertagainstpossibledamagetothemachine anditscomponentsandisrepresentedasfollows:

(4)Itisverydifficulttoforecasteverydangerthatmay occurduringoperation.However,safetycanbeensuredbyfullyunderstandingproperoperatingproceduresforthismachineaccordingtomethods recommendedbytheManufacturer.

(5)Whileoperatingthemachine,besuretoperform workwithgreatcare,soasnottodamagethemachine,orallowaccidentstooccur.

(6)ContinuestudyingthemanualuntilallSafety,OperationandMaintenanceproceduresarecompletely understoodbyallpersonsworkingwiththemachine.

2)WARNING-Indicatesapotentiallyhazardous situationwhich,ifnotavoided,couldresultin deathorseriousinjuryandisrepresentedas follows:

SAFETYPRECAUTIONS

Theproperandsafelubricationandmaintenance forthismachine,recommendedbytheManufacturer,areoutlinedintheOPERATOR’SMANUALfor themachine.

Improperperformanceoflubricationormaintenanceproceduresaredangerousandcouldresult ininjuryordeath.ReadandunderstandtheMANUALbeforeperforminganylubricationormaintenance.

Theservicemanormechanicmaybeunfamiliarwith manyofthesystemsonthismachine.Thismakesit importanttousecautionwhenperformingservicework. Aknowledgeofthesystemand/orcomponentsisimportantbeforetheremovalordisassemblyofanycomponent.

Becauseofthesizeofsomeofthemachinecomponents,thetechnicianshouldchecktheweightsnotedin thismanual.Useproperliftingprocedureswhenremovinganycomponent.Theweightofcomponentstableis showninsection;SPECIFICATIONS.

Thefollowingisalistofbasicprecautionsthatmustalwaysbeobserved.

(1)ReadandunderstandallWarningplatesanddecalsonthemachinebeforeOperating,Maintaining orRepairingthismachine.

(2)Alwayswearprotectiveglassesandprotective shoeswhenworkingaroundmachines.Inparticular,wearprotectiveglasseswhenusinghammers, punchesordriftsonanypartofthemachineorattachments.Useweldersgloves,hood/goggles, apronandtheprotectiveclothingappropriatetothe weldingjobbeingperformed.Donotwearloosefittingortornclothing.Removeallringsfromfingers, loosejewelry,confinelonghairandlooseclothing beforeworkingonthismachine.

(3)Disconnectthebatteryandhanga"DoNotOperate"tagintheOperatorsCompartment.Removeignitionkeys.

(4)Ifpossible,makeallrepairswiththemachine parkedonafirmlevelsurface.Blockthemachine soitdoesnotrollwhileworkingonorunderthemachine.Hanga"DoNotOperate"tagintheOperatorsCompartment.

(5)Donotworkonanymachinethatissupportedonly byalift,jacksorahoist.Alwaysuseblocksorjack standscapableofsupportingthemachinebefore performinganydisassembly.

Donotoperatethismachineunlessyouhave readandunderstandtheinstructionsintheOPERATOR’SMANUAL.Impropermachineoperationisdangerousandcouldresultininjuryor death.

(6)Relieveallpressureinair,oilorwatersystemsbeforeanylines,fittingsorrelateditemsaredisconnectedorremoved.Alwaysmakesureallraised componentsareblockedcorrectlyandbealertfor possiblepressurewhendisconnectinganydevice fromasystemthatutilizespressure.

(7)Lowerthebucket,dozer,orotherattachmentsto thegroundbeforeperforminganyworkonthemachine.Ifthiscannotbedone,makesurethebucket, dozer,ripperorotherattachmentisblockedcorrectlytopreventitfromdroppingunexpectedly.

(8)Usestepsandgrabhandleswhenmountingordismountingamachine.Cleananymudordebrisfrom steps,walkwaysorworkplatformsbeforeusing.Alwaysfacethemachinewhenusingsteps,ladders andwalkways.Whenitisnotpossibletousethe designedaccesssystem,provideladders,scaffolds,orworkplatformstoperformsaferepairoperations.

(9)Toavoidbackinjury,useahoistwhenliftingcomponentswhichweigh20kg(45lbs)ormore.Make sureallchains,hooks,slings,etc.,areingoodconditionandarethecorrectcapacity.Besurehooks arepositionedcorrectly.Liftingeyesarenottobe sideloadedduringaliftingoperation.

(10)Toavoidburns,bealertforhotpartsonmachines whichhavejustbeenstoppedandhotfluidsin lines,tubesandcompartments.

(11)Becarefulwhenremovingcoverplates.Gradually backoffthelasttwocapscrewsornutslocatedat oppositeendsofthecoverordeviceandcarefully prycoverloosetorelieveanyspringorotherpressurebeforeremovingthelasttwocapscrewsor nutscompletely.

(12)Becarefulwhenremovingfillercaps,breathersand plugsonthemachine.Holdaragoverthecapor plugtopreventbeingsprayedorsplashedbyliquidsunderpressure.Thedangerisevengreaterif themachinehasjustbeenstoppedbecausefluids canbehot.

(13)Alwaysusethepropertoolsthatareingoodconditionandthataresuitedforthejobathand.Besure

youunderstandhowtousethembeforeperforming anyservicework.

(14)Reinstallallfastenerswiththesamepartnumber. Donotusealesserqualityfastenerifreplacements arenecessary.

(15)Repairswhichrequireweldingshouldbeperformedonlywiththebenefitoftheappropriatereferenceinformationandbypersonneladequately trainedandknowledgeableinweldingprocedures. Determinethetypeofmetalbeingweldedandselectthecorrectweldingprocedureandelectrodes, rodsorwiretoprovideaweldmetalstrengthequivalentatleasttothatoftheparentmetal.Makesure todisconnectbatterybeforeanyweldingproceduresareattempted.

(16)Donotdamagewiringduringremovaloperations. Reinstallthewiringsoitisnotdamagednorwillbe damagedinoperationofthemachinebycontacting sharpcorners,orbyrubbingagainstsomeobjector hotsurface.Donotconnectwiringtoahoseortube containingfluid.

(17)Besureallprotectivedevicesincludingguardsand shieldsareproperlyinstalledandfunctioningcorrectlybeforestartingarepair.Ifaguardorshield mustberemovedtoperformtherepairwork,use extracautionandreplacetheguardorshieldafter repairiscompleted.

(18)Themaintenanceandrepairworkwhileholdingthe bucketraisedisdangerousduetothepossibilityof afallingattachment.Don’tfailtolowertheattachmentandplacethebuckettothegroundbefore startingthework.

(19)Looseordamagedfuel,lubricantandhydraulic lines,tubesandhosescancausefires.Donotbend orstrikehighpressurelinesorinstalloneswhich havebeenbentordamaged.Inspectlines,tubes andhosescarefully.Donotcheckforleakswith yourhands.Verysmall(pinhole)leakscanresultin ahighvelocityoilstreamthatwillbeinvisibleclose tothehose.Thisoilcanpenetratetheskinand causepersonalinjury.Usecard-boardtolocatepinholeleaks.

(20)Tightenconnectionstothecorrecttorque.Make surethatallheatshields,clampsandguardsareinstalledcorrectlytoavoidexcessiveheat,vibration orrubbingagainstotherpartsduringoperation. Shieldsthatprotectagainstoilsprayontohotexhaustcomponentsineventofaline,tubeorseal failuremustbeinstalledcorrectly.

(21)Donotoperateamachineifanyrotatingpartis damagedorcontactsanyotherpartduringoperation.Anyhighspeedrotatingcomponentthathas

beendamagedoralteredshouldbecheckedfor balancebeforereusing.

(22)Becarefulwhenservicingorseparatingthetracks (crawlers).Chipscanflywhenremovingorinstallingatrack(crawlers)pin.Wearsafetyglassesand longsleeveprotectiveclothing.Tracks(crawlers) canunrollveryquicklywhenseparated.Keepaway fromfrontandrearofmachine.Themachinecan moveunexpectedlywhenbothtracks(crawlers) aredisengagedfromthesprockets.Blockthemachinetopreventitfrommoving.

NOTE:

ThisManualispreparedasatechnicalmaterialin whichtheinformationnecessaryforthemaintenance andrepairingservicesofourhydraulicexcavatorsare collected,andiscategorizedinto7Chapters,Specification,Maintenance,System,Disassembly,Troubleshooting,Engine,andInstallationProceduresfor OptionalAttachments.

•TheChapter"Specification"describesthespecificationsforentiremachineandmaterial,whichare instructiveforreplacementandrepairingofattachments.

•TheChapter"Maintenance"describesthematerial, whichishelpfulformaintenanceserviceandadjustmentsfortheentiremachine.

•TheChapter"System"describestheoperatingsystemlikehydraulicsystem,electricsystem,components,andsoon.

•TheChapter"Disassembly"describestheremoval andinstallingofassembliesmountedontheupper structureandundercarriage,andtheassembling anddisassemblingoftheassociatedhydraulic equipment.

•TheChapter"Troubleshooting"describeshowto findtheequipmentfault.

•TheChapter"Engine"describestheenginesmakinguseofthe"MaintenanceManual"providedby thesuppliers.

•TheChapter"InstallationProceduresforOptional Attachment"describesthesupplementsaddedon requestasrequired.

ThisManualmaybeproperlyrevisedduetotheimprovementofproducts,modificationofspecifications, etc.Andtherearecaseswherethesystemontheactualmachineandapartofthecontentsofthismanual maydifferduetothevariationsofspecificationsby countries.Forthesectioninwhichthedescriptionis hardlyunderstood,contactourdistributor.

AnumberisassignedtoeveryparthandledinthisManualonaccountofthedescription,butthepartscannot besuppliedasserviceparts.Therefore,theordermust beplacedwiththerespectiveformalnumberwithconfirmationfromthePartsManualfortheapplicablemachine.

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2.SPECIFICATIONS

2.2GENERALDIMENSIONS

2.2.1SK210-9[5.65m(18ft-6in)Boom+2.94m(9ft-8in)StandardArm+0.80m3(1.05cu-yd) Bucket]

Dimensionsmarked*donotincludetheheightoftheshoelug.

2.2.2SK210-9[5.65m(18ft-6in)Boom+2.4m(7ft-10in)ShortArm+0.93m3(1.22cu-yd) Bucket

2.2.3SK210-9[5.65m(18ft-6in)Boom+3.5m(11ft-6in)LongArm+0.70m3(0.92cu-yd) Bucket

Dimensionsmarked*donotincludetheheightoftheshoelug.

2.SPECIFICATIONS

2.3WEIGHTOFCOMPONENTS

Unit;kg(lb)

Item/ModelSK210-9

Fullyequippedweight21,700(47,840)

1.Upperframeassy(Assemblyoffollowing:)

1.1Upperframe

1.2Counterweight

1.3Cab

1.4Engine

1.5Hydraulicoiltank

1.6Fueltank

1.7Slewingmotor(includingreductionunit)

1.8Controlvalve

1.9Boomcylinder

1.10Pin(formountingboom)

1.11Pump

1.12Radiator(includingintercooler)

2.Lowerframeassy(Assemblyoffollowing:)

2.1Lowerframe

2.2Slewingbearing

2.3Travelmotor(includingreductionunit)

2.4Upperroller

2.5Lowerroller

2.6Frontidler

2.7Idleradjuster

2.8Sprocket

2.9Swiveljoint

2.10Tracklinkwith600mm(23.6in)shoesassy

Tracklinkwith700mm(27.5in)shoesassy

Tracklinkwith800mm(31.5in)shoeassy

2.10.1Tracklinkassy

3.Attachment(Assemblyoffollowing:)

{4.68m(15ft-4in)Boom+2.84m(9ft-7in)Arm+0.38m3(0.50cu-yd)Bucket}

3.1Bucketassy(STD)

3.2STDArmassy(Assemblyoffollowing:)

3.2.1STDArm

3.2.2Bucketcylinder

3.2.3Idlerlink

3.2.4Bucketlink

3.2.5Pin(2pcs.formountingbucketcylinder/2pcs.formountingbucket)

3.3Boomassy(Assemblyoffollowing:)

3.3.1Boom

3.3.2Armcylinder

3.3.3Pin(Mountingarm-Mountingarmcylinder)

9,500(21,000) 1,770(3,900)

4,640(10,230)

260(570)

*540(1,190)

*150(330)

*110(240)

*210(460)

*230(510)

*170(375)X2

70(150)

*130(290)

*90(200)

7,130(15,720) 2,420(5,340)

250(550) 260(570)X2 20(44)X2 30(66)X16 110(240)X2 100(220)X2 50(110)X2 *30(66) 1350(2,980)X2 1,560(3,440)X2 1,700(3,750)X2 540(1,190)X2

3,420(7,540) 640(1,410) 1,050(2,315)

660(1,455)

*140(310) 20(44)X2 90(198)

100(220)

1,730(3,815)

1,310(2,890)

*255(560) 80(180)

Unit;kg(lb)

Item/ModelSK210-9

4.Lubricantandwater(Assemblyoffollowing:)

4.1Hydraulicoil

4.2Engineoil

4.3Fuel

4.4Water

Marks*showdryweight.

550(1,210)

200(440) 20(44)

310(680) 20(44)

2.4TRANSPOTATION

2.4.1OVERALLDIMENSIONSOFMACHINEONATRAILER

(1)5.65m(18ft-6in)Boom+2.94m(9ft-8in)LongArm+0.80m3(1.05cu-yd)Bucket

Item/Shoetype800mm(31.5in)

Width:mm(ft-in)3,190(10'6")

Weight:kg(lbs)21,700kg(47,800lbs)

2.5SPECIFICATIONSANDPERFORMANCE

2.5.1SPEEDANDCLIMBINGCAPABILITY

Item/ModelSK210-9

Swingspeed:min-1{rpm}12.8{12.8}

Travelspeed(1-speed/2-speed):km/h (mile/h) 3.4/5.6(2.1/3.5)

Gradeability:%(degree)70(35)

2.5.2ENGINE

EnginemodelF4HFE613*A003

Type

Numberofcylinders-BoreXStroke

Water-cooled,4cycle6cylinderdirectinjectiontypedieselengine withintercoolerturbo-chargerelectriccommonrailTier4certified SCR

6-104dia.mmX132mm (4.02inX5.12in)

Totaldisplacement6.728L(410cu-in)

Ratedoutput/Enginespeed129kW(175PS)/2,000min-1

Maximumtorque/Enginespeed740N-m(545lbf-ft)/1,400min-1

Starter24V/4.0kW

Alternator24V/70A

2.5.3HYDRAULICCOMPONENTS

HydraulicpumpVariabledisplacementaxialpistonpumpX2+gearpumpX1

Hydraulicmotor(swing)AxialpistonmotorX1

Hydraulicmotor(travel)

VariabledisplacementaxialpistonmotorX2 (withcounterbalancevalve)

Controlvalve8-spoolcontrolvalveX1

Cylinder(Boom,Arm,Bucket)Doubleactioncylinder

OilcoolerAir-cooledtype

2.5.4WEIGHT

Fullyequippedweight21,700(47,800)

Upperstructure9,500(21,000)

Lowermachinery(600mmgrousershoe)7,130(15,720)

Attachment

5.65m(18ft-6in)Boom+2.94m(9ft-8in) Arm+0.80m3(1.05cu-yd)Bucket

3.420(7,540)

Unit:kg(lbs)

2.SPECIFICATIONS

2.6TYPEOFCRAWLER

ShapeShoeWidthmm(in)Overallwidthofcrawler mm(ft-in)

GroundPressuerkPa(psi)

GrouserShoe600(23.6)2,990(9’10”)43(6.24)

700(27.6)3,090(10’2”)38(5.51)

800(31.5)3,190(10’6”)33(4.9)

Use600mm(23.6")grousershoesonroughground(areascoveredwithrocksandgravel).Ifyoudriveorexcavate withothershoes,thismaycauseshoebending,shoeboltlooseness,andtrackassembly(link,roller,etc.)

2.7TYPEOFBUCKET

2.9ENGINESPECIFICATION

2.9.1SPECIFICATIONS

ApplicablemachineSK210-9

EnginemodelF4HFE613S*A003

Type

Water-cooled,4cycle4cylinderdirectinjectiontypediesel enginewithintercoolerturbo-chargerelectriccommonrail Tier4aCertifiedSCR

Numberof cylinderXBoreXStroke mm(in)6X104X132(4.09X5.20)

Totaldisplacementcc(cu-in)6,728(410)

Compressionratio18.0

RatedoutputwithFankW(PS)atmin-1 129(175)at2,000

MaximumtorquewithoutFanN-m(lb-ft)at min-1

740(545)at1,400

Highidlingmin-1 2,000±30

Lowidlingmin-1 1,000±20

InjectionstartingpressureMPa(psi)50(7,250)

Thermostataction

Start/Fullopen K(degreesF) 350(170)/363(194)

Firingorder1-3-4-2

StartercapacityVXkW24X4.0

Generatorcapacity(Alternator)VXA24X70

CoolingfandrivemethodCirculatingtypewithcentrifugalpump

EngineoilquantityL(gal)Total20(5.3)

Dryweightkg(lbs)580(1,280)

Fuelconsumptionratio (Atratedoutput)

g/kW-h(g/ps-h)217(160)

AllowableinclinationFront/RearandRight/Left:35degrees

Dimension(LXWXH)mm(in)1,063X725X995(3ft-5.86inX28.5inX39.2in)

RotatingdirectionCounterclockwiseseeingfromflywheelside

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Service Manual - Kobelco SK210-9 Tier 4 Hydraulic Excavator

GENERALSAFETYINFORMATION

SAFETYPRECAUTIONS

NOTE:

2.SPECIFICATIONS

TABLEOFCONTENTS

2.2GENERALDIMENSIONS

2.SPECIFICATIONS

2.SPECIFICATIONS

2.7TYPEOFBUCKET