Service Manual - Kobelco SK260-8 Tier 3 Hydraulic Excavator LL12-05001

1.1GENERALPRECAUTIONSFORMAKINGREPAIRS......................................................1-3

1.1.1PREPARATIONBEFOREDISASSEMBLING..........................................................1-3

1.1.2SAFETYWHENDISASSEMBLINGANDASSEMBLING.........................................1-3

1.1.3DISASSEMBLINGANDASSEMBLINGHYDRAULICEQUIPMENT.......................1-3

1.1.4ELECTRICALEQUIPMENT.....................................................................................1-4

1.1.5HYDRAULICPARTS................................................................................................1-5

1.1.6WELDREPAIR.........................................................................................................1-5

1.1.7ENVIRONMENTALISSUES.....................................................................................1-5 1.2INTERNATIONALUNITSYSTEM.....................................................................................1-6

2.1NAMEOFCOMPONENTS................................................................................................2-3

2.2GENERALDIMENSIONS..................................................................................................2-4

2.2.1SK260–8[6.02m(19ft-9in)Boom+2.98m(9ft-9in)StandardArm+1.0m3 (1.3cu•yd)BucketShoe]...........................................................................................2-4

2.2.2SK260–8[6.02m(19t-9in)Boom+3.66m(12ft-0in)LongArm+0.81m3 (1.06cu•yd)BucketShoe].........................................................................................2-4

2.3WEIGHTOFCOMPONENTS............................................................................................2-5

2.4TRANSPORTATION..........................................................................................................2-7

2.4.1OVERALLDIMENSIONSOFMACHINEONATRAILER........................................2-7

2.4.2DIMENSIONSOFATTACHMENT............................................................................2-8

2.5SPECIFICATIONSANDPERFORMANCE........................................................................2-10

2.5.1SPEEDANDCLIMBINGCAPABILITY.....................................................................2-10

2.5.2ENGINE....................................................................................................................2-10

2.5.3HYDRAULICCOMPONENTS..................................................................................2-10

2.5.4WEIGHT....................................................................................................................2-10

2.6TYPEOFCRAWLER.........................................................................................................2-11

2.7COMBINATIONSOFATTACHMENT................................................................................2-12

2.8ENGINESPECIFICATIONS..............................................................................................2-13

2.8.1SPECIFICATIONS....................................................................................................2-13

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3.1BOOM................................................................................................................................3-3

3.1.1BOOMDIMENSIONALDRAWING...........................................................................3-3

3.1.2BOOMMAINTENANCESTANDARD.......................................................................3-4

3.2ARM...................................................................................................................................3-6

3.2.1ARMDIMENSIONALDRAWING..............................................................................3-6

3.2.2ARMMAINTENANCESTANDARD..........................................................................3-7

3.3BUCKETANDPIN.............................................................................................................3-10

3.3.1BUCKETANDPINDIMENSIONALDRAWING........................................................3-10

3.3.2BUCKETANDPINDIMENSIONALTABLE..............................................................3-11

11.1STANDARDTORQUESPECIFICATIONSFORCAPSCREWSANDNUTS..................11-3 11.2SCREWSIZE...................................................................................................................11-5

11.2.1CAPSCREW(BOLT)..............................................................................................11-5

11.2.2CAPSCREW(SOCKETBOLT)...............................................................................11-5

11.2.3SOCKETSETSCREW...........................................................................................11-5

11.3TORQUESPECIFICATIONSFORHOSEANDFITTINGS.............................................11-6

11.4TORQUESPECIFICATIONSFORNUTSANDSLEEVES.............................................11-7 11.5PLUG...............................................................................................................................11-8

11.5.1PLUGFORHYDRAULICPIPEJOINT...................................................................11-8

11.5.2PLUGFORHYDRAULICEQUIPMENT.................................................................11-9

11.6SPECIALSPANNERFORTUBE....................................................................................11-11

11.7SPECIALTOOLS.............................................................................................................11-12

11.8APPLICATIONOFSCREWLOCKINGCOMPOUNDANDSEALINGCOMPOUND......11-14

11.9SUCTIONSTOPPER.......................................................................................................11-15

11.9.1COMPONENTS......................................................................................................11-15

11.9.2DIMENSION............................................................................................................11-15

11.9.3APPLICABLEMODEL............................................................................................11-15

11.10COUNTERWEIGHTLIFTINGJIG..................................................................................11-16

111.10UPPERFRAMELIFTINGJIG........................................................................................11-17

11.11ENGINETURNOVERSTAND.........................................................................................11-18

11.13TRACKSPRINGSETJIG................................................................................................11-19

13.1HOWTOUSETHEMAINTENANCESTANDARD..........................................................13-3

13.2PERFORMANCEINSPECTIONSTANDARDTABLE.....................................................13-4

13.3MEASUREMENTOFENGINESPEED...........................................................................13-6

13.3.1MEASUREMENTOFENGINESPEED..................................................................13-6

13.4MEASUREMENTOFHYDRAULICPRESSURE.............................................................13-7

13.4.1PREPARINGTOMEASUREHYDRAULICPRESSURE.......................................13-7

13.4.2PLACETOINSTALLPRESSUREGAUGE............................................................13-7

13.4.3PRESSUREADJUSTMENTPOSITION.................................................................13-8

13.4.4PROCEDUREFORADJUSTINGRELIEFVALVE.................................................13-10

13.5MEASURINGTRAVELPERFORMANCES.....................................................................13-12

13.5.1TRAVELSPEED.....................................................................................................13-12

13.5.2DEVIATIONOFTRAVEL........................................................................................13-12

13.5.3PERFORMANCESOFPARKINGBRAKE.............................................................13-13

13.5.4DRAINRATEOFTRAVELMOTOR.......................................................................13-14

13.6MEASURINGSWINGPERFORMANCES.......................................................................13-15

13.6.1SWINGSPEED.......................................................................................................13-15

13.6.2PERFORMANCEOFSWINGBRAKE....................................................................13-15

13.6.3PERFORMANCEOFSWINGPARKINGBRAKE..................................................13-16

13.6.4DRAINRATEOFSWINGMOTOR.........................................................................13-17

13.7MEASURINGATTACHMENTOPERATINGPERFORMANCES....................................13-18

13.7.1OPERATINGTIMEOFCYLINDERS......................................................................13-18

13.7.2CYLINDERLEAKCHECK......................................................................................13-19

13.8MEASURINGPERFORMANCESOFSWINGBEARING................................................13-20

13.9MECHATROCONTROLLER...........................................................................................13-21

13.9.1ENGINECONTROLINPUT/OUTPUT..................................................................13-21

13.9.2ENGINECONTROL................................................................................................13-22

13.9.3ADJUSTMENTOFMECHATROCONTROLLEROUTPUT (A-B-CADJUSTMENT)...........................................................................................13-24

13.9.4OPERATIONSINTHEEVENTOFAMECHATROCONTROLLERFAILURE......13-29

21.1SUMMARYOFMECHATROCONTROLSYSTEM.........................................................21-4

21.1.1MECHATROCONTROLSYSTEMINGENERAL..................................................21-4

21.1.2UNLOADVALVECONTROL..................................................................................21-6

21.1.3POSITIVECONTROL&P-QCONTROL...............................................................21-7

21.1.4BOOMUPCONFLUXCONTROL..........................................................................21-9

21.1.5ARMINRECIRCULATION&CONFLUXCONTROL.............................................21-10

21.1.6ARM-INANTI-CAVITATIONCONTROL.................................................................21-12

21.1.7ARM-OUTCONFLUXCONTROL..........................................................................21-13

21.1.8BUCKETDIGGING(DUMP)CONFLUXCONTROL..............................................21-14

21.1.9BUCKETDIGGINGANTI-CAVITATIONCONTROL..............................................21-15

21.1.10SWINGPRIORITYCONTROL...............................................................................21-17

21.1.11TRAVELSTRAIGHTCONTROL............................................................................21-18

21.1.12TRAVELINDEPENDENTCONTROL.....................................................................21-20

21.1.12PRESSURERELEASECONTROL........................................................................21-22

21.1.13N&BSWITCHCONTROL(OPTION)......................................................................21-23

21.1.14OPTIONCONFLUXCONTROL(OPTION)............................................................21-24

21.2MECHATROCONTROLLER...........................................................................................21-25

21.2.1SUMMARYOFMULTIDISPLAY............................................................................21-25

21.2.2SELFDIAGNOSISDISPLAY..................................................................................21-30

21.2.3SERVICEDIAGNOSISDISPLAYFUNCTION.......................................................21-31

21.2.4TROUBLEHISTORYDIAGNOSIS.........................................................................21-42

21.2.5TROUBLEDIAGNOSISMODE..............................................................................21-43

21.2.6SETPROCEDUREOFMAINTENANCESCHEDULE...........................................21-43

21.2.7ADJUSTINGPROCEDUREOFDISPLAY.............................................................21-44

21.2.8MECHATROCONTROLEQUIPMENT..................................................................21-47

22.1SUMMARY..............................................................................................................22-3

22.2HYDRAULICCIRCUITSANDCOMPONENTS......................................................22-4

22.3COLORCODINGSTANDARDFORHYDRAULICCIRCUITS...............................22-8

22.4NEUTRALCIRCUIT................................................................................................22-8

22.5TRAVELCIRCUIT..................................................................................................22-10

22.6BUCKETCIRCUIT..................................................................................................22-12

22.7BOOMCIRCUIT.....................................................................................................22-14

22.8SWINGCIRCUIT....................................................................................................22-18

22.9ARMCIRCUIT........................................................................................................22-20

22.10COMBINEDCIRCUIT.............................................................................................22-26

22.11PRESSUREDRAINING(RELEASING)CIRCUIT..................................................22-32

23.1ELECTRICCIRCUITDIAGRAM......................................................................................23-3

23.2ELECTRICALEQUIPMENTLIST....................................................................................23-8

23.3HARNESS........................................................................................................................23-10

23.3.1HARNESSLIST......................................................................................................23-10

23.3.2INSTRUMENTPANELASSY.................................................................................23-11

23.3.3TUNERINSTALL....................................................................................................23-12

23.3.4UPPERELECTRICASSY......................................................................................23-13

23.3.5UPPERFRAMEHARNESSASSY.........................................................................23-14

23.3.6UPPERFLOORPLATEHARNESSASSY.............................................................23-20

23.3.7CABHARNESSASSY............................................................................................23-25

23.3.8BOOMHARNESSASSY........................................................................................23-28

23.3.9INSTALLINGBOOMLIGHT...................................................................................23-28

23.3.10INSTALLINGDECKLIGHT....................................................................................23-29

23.3.11TRAVELALARMASSY..........................................................................................23-29

23.3.12FLASHERLAMPINSTALL.....................................................................................23-35

24.1HYDRAULICCOMPONENTS..........................................................................................24-3

24.1.1HYDRAULICPUMP,REGULATOR.......................................................................24-3

24.1.2CONTROLVALVE..................................................................................................24-21

24.1.3PILOTVALVE(ATT)...............................................................................................24-59

24.1.4PILOTVALVE(TRAVEL)........................................................................................24-63

24.1.5SWINGMOTOR.....................................................................................................24-65

24.1.6TRAVELMOTOR....................................................................................................24-76

24.1.7SWIVELJOINT.......................................................................................................24-93

24.1.8CYLINDER..............................................................................................................24-95

24.2ELECTRICEQUIPMENT.................................................................................................24-100

24.2.1ELECTRICEQUIPMENTLIST...............................................................................24-100

24.2.2SPECIFICATIONOFELECTRICEQUIPMENT.....................................................24-104

25.1BASICAIRCONDITIONERSYSTEM(HVACAIRCONDITIONER)...............................25-3

25.1.1AIRCYCLE......................................................................................................................25-3

25.1.2AUTOAIRCONDITIONERSYSTEMOUTLINE....................................................25-4

25.2COMPONENTANDCONSTRUCTION...........................................................................25-5

25.2.1COMPONENT.........................................................................................................25-5

25.2.2CONSTRUCTION...................................................................................................25-6

25.3PIPING.............................................................................................................................25-9

25.3.1AIRCONDITIONER................................................................................................25-9

25.3.2RECEIVERDRYERASSY.....................................................................................25-11

25.4FUNCTION.......................................................................................................................25-12

25.4.1MECHANISMOFCOOLINGCIRCUIT...................................................................25-12

25.4.2COOLINGCIRCUIT................................................................................................25-14

25.4.3COMPONENTPARTS............................................................................................25-15

25.5DISASSEMBLYANDASSEMBLY...................................................................................25-19

25.5.1PRECAUTIONSTOBEEXERCISEDINOPERATION..........................................25-19

25.5.2DISASSEMBLYANDASSEMBLYOFUNIT..........................................................25-20 25.6CHARGINGREFRIGERANT...........................................................................................25-24

25.6.1PRECAUTIONSTOBEEXERCISEDINOPERATION..........................................25-24

25.6.2OPERATINGPROCEDURE...................................................................................25-25

25.6.3CHARGINGPROCEDURE.....................................................................................25-26

25.7ELECTRICCIRCUIT........................................................................................................25-32

25.7.1WIRINGDIAGRAMANDCONNECTORS..............................................................25-32

25.7.2STRUCTUREANDOPERATIONOFEACHPARTANDINSPECTION................25-34

25.8TROUBLESHOOTING.....................................................................................................25-37

25.9SELFDIAGNOSISFUNCTIONONDISPLAYOFPANEL..............................................25-44

25.9.1POSITIONOFINDICATIONFORFAILURE..........................................................25-44

25.9.2EXPLANATIONOFINDICATIONFORFAILURE..................................................25-44

25.9.3EXPLANATIONOFMONITORMODE...................................................................25-46

33.1.2CAB.........................................................................................................................33-4

33.1.3BATTERY...............................................................................................................33-6

33.1.4GUARD...................................................................................................................33-7

33.1.5UNDERCOVER.....................................................................................................33-13

33.1.6FUELTANK............................................................................................................33-14

33.1.7HYDRAULICTANK.................................................................................................33-16

33.1.8HYDRAULICPUMP................................................................................................33-20

33.1.9AIRCLEANER........................................................................................................33-25

33.1.10MUFFLER...............................................................................................................33-26

33.1.11COUNTERWEIGHT................................................................................................33-28

33.1.12RADIATOR&OILCOOLER...................................................................................33-29

33.1.13ENGINE..................................................................................................................33-35

33.1.14CONSOLECOVER.................................................................................................33-38

33.1.15CONTROLVALVE..................................................................................................33-39

33.1.16PILOTVALVE(FORATT)......................................................................................33-42

33.1.17PILOTVALVE(FORTRAVEL)...............................................................................33-43

33.1.18SWINGMOTOR.....................................................................................................33-46

33.1.19SWIVELJOINT.......................................................................................................33-48

33.1.20UPPERFRAME......................................................................................................33-51

34.2.1CONSTRUCTIONOFTRAVELMOTOR................................................................34-38

0.SAFETY

GENERALSAFETYINFORMATION

Donotoperateorperformanymaintenanceonthis machineuntilallinstructionsfoundintheOPERATOR’SMANUALandthisMANUALhavebeenthoroughlyreadandunderstood.Improperoperationor maintenanceofthismachinemaycauseaccidents andcouldresultinseriousinjuryordeath. Alwayskeepthemanualinstorage.Ifitismissing ordamaged,placeanorderwithanauthorizedDistributorforareplacement.Ifyouhaveanyquestions,pleaseconsultanauthorizedDistributor.

(1)Mostaccidentsthatoccurduringoperationaredue toneglectofprecautionarymeasuresandsafety rules.Sufficientcareshouldbetakentoavoidthese accidents.Erroneousoperation,lubricationor maintenanceservicesareverydangerousandmay causeinjuryordeathofpersonnel.Thereforeall precautionarymeasures,NOTES,DANGERS, WARNINGSandCAUTIONScontainedinthemanualandonthemachineshouldbereadandunderstoodbyallpersonnelbeforestartinganyworkwith oronthemachine.

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

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

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

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

3)CAUTION-Indicatesapotentiallyhazardous situationwhich,ifnotavoided,mayresultin minorormoderateinjury.Itmayalsobeusedto alertforpossibledamagetothemachineand itscomponentsandisrepresentedasfollows:

(4)Itisverydifficulttoforecasteverydangerthatmay occurduringoperation.However,safetycanbeensuredbyfullyunderstandingproperoperatingproceduresforthismachineaccordingtomethods recommendedbyManufacturer.

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

(6)ContinuestudyingthemanualuntilallSafety,OperationandMaintenanceproceduresarecompletely understoodbyallpersonsworkingwiththemachine.

SAFETYPRECAUTIONS

Theproperandsafelubricationandmaintenance forthismachineareoutlinedintheOPERATOR’S MANUALforthemachine.Improperperformanceof lubricationormaintenanceproceduresaredangerousandcouldresultininjuryordeath.Readand understandtheMANUALbeforeperforminganylubricationormaintenance.

Theservicetechniciansmaybeunfamiliarwithmanyof thesystemsonthismachine.Thismakesitimportant tousecautionwhenperformingservicework.Aknowledgeofthesystemandorcomponentsisimportant beforetheremovalordisassemblyofanycomponent. Becauseofthesizeofsomeofthemachinecomponents,thetechnicianshouldchecktheweightsnotedin thismanual.Useproperliftingprocedureswhenremovinganycomponents.Weightofcomponentstableis showninthesection;SPECIFICATIONS.

Thefollowingisalistofbasicprecautionsthatmust alwaysbeobserved.

(1)ReadandunderstandallWarningplatesand decalsonthemachinebeforeOperating, MaintainingorRepairingthismachine.

(2)Alwayswearprotectiveglassesandprotective shoeswhenworkingaroundmachines.Inparticular,wearprotectiveglasseswhenusinghammers, punchesordriftsonanypartofthemachineorattachments.Usewelders’gloves,hood/goggles, apronandtheprotectiveclothingappropriatetothe weldingjobbeingperformed.Donotwearloose fittingortornclothing.Removeallringsfrom fingers,loosejewelry,confinelonghairandloose clothingbeforeworkingonthismachinery.

(3)Disconnectthebatteryandhanga"DoNotOperate"tagintheOperator’sCompartment.Remove ignitionkeys.

(4)Ifpossible,makeallrepairswiththemachine parkedonafirm,levelsurface.Blockthemachine soitdoesnotrollwhileworkingonorunderthe machine.Hanga"DoNotOperate"tagintheOperator’sCompartment.

(5)Donotworkonanymachinethatissupportedonly bylift,jacksorahoist.Alwaysuseblocksorjack stands,capableofsupportingthemachine,before performinganydisassembly.

Donotoperatethismachineunlessyouhave readandunderstandtheinstructionsinthe OPERATOR’SMANUAL.Impropermachine operationisdangerousandcouldresultin injuryordeath.

(6)Relieveallpressureinair,oilorwatersystems beforeanylines,fittingsorrelateditemsaredisconnectedorremoved.Alwaysmakesureallraised componentsareblockedcorrectlyandbealertfor possiblepressurewhendisconnectinganydevice fromasystemthatutilizespressure.

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

(8)Usestepsandgrabhandleswhenmountingordismountingamachine.Cleananymudordebrisfrom steps,walkwaysorworkplatformsbeforeusing. Alwaysfacetothemachinewhenusingsteps,laddersandwalkways.Whenitisnotpossibletouse thedesignedaccesssystem,provideladders,scaffolds,orworkplatformstoperformsaferepairoperations.

(9)Toavoidbackinjury,useahoistwhenlifting componentswhichweigh20kg(45lbs)ormore. Makesureallchains,hooks,slings,etc.,arein goodconditionandarethecorrectcapacity.Be surehooksarepositionedcorrectly.Liftingeyes arenottobeside-loadedduringaliftingoperation.

(10)Toavoidburns,bealertforhotpartsonmachines whichhavejustbeenstoppedandhotfluidsin lines,tubesandcompartments.

(11)Becarefulwhenremovingcoverplates.Gradually backoffthelasttwocapscrewsornutslocatedat oppositeendsofthecoverordeviceandcarefully prycoverloosetorelieveanyspringorotherpressure,beforeremovingthelasttwocapscrewsor nutscompletely.

(12)Becarefulwhenremovingfillercaps,breathersand plugsonthemachine.Holdaragoverthecapor plugtopreventbeingsprayedorsplashedby liquidsunderpressure.Thedangerisevengreater ifthemachinehasjustbeenstoppedbecausefluids canbehot.

(13)Alwaysusepropertoolsthatareingoodcondition andthataresuitedforthejobathand.Besureyou understandhowtousethembeforeperformingany servicework.

(14)Reinstallallfastenerswiththesamepartnumber. Donotusealesserqualityfastenerifreplacements arenecessary.

(15)Repairswhichrequireweldingshouldbeperformedonlywiththebenefitoftheappropriatereferenceinformationandbypersonneladequately trainedandknowledgeableinweldingprocedures. Determinetypeofmetalbeingweldedandselect correctweldingprocedureandelectrodes,rodsor wiretoprovideaweldmetalstrengthequivalentat leasttothatoftheparentmetal.Makesuretodisconnectbatterybeforeanyweldingproceduresare attempted.

(16)Donotdamagewiringduringremovaloperations. Reinstallthewiringsoitisnotdamagednorwillbe damagedinoperationofthemachinebycontacting sharpcorners,orbyrubbingagainstsomeobjector hotsurface.Donotconnectwiringtoalinecontainingfluid.

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

(18)Maintenanceandrepairworkwhileholdingthe bucketraisedisdangerousduetothepossibilityof afallingattachment.Fullylowertheattachmentand placethebuckettothegroundbeforestartingany work.

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

(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.Blockthe machinetopreventitfrommoving.

NOTE:

ThisManualcontainsinformationnecessaryforthe maintenanceandrepairingservicesofyourhydraulic excavator.Informationiscategorizedinto6Chapters: Specification,Maintenance,System,Disassembly, TroubleshootingandEngine.

•TheChapter,"Specification"describesthespecificationsfortheentiremachine,whichisinstructive forreplacementandrepairingofattachments.

•TheChapter,"Maintenance"providesmaterial whichishelpfulformaintenanceserviceandadjustmentsforentiremachine.

•TheChapter,"System"describestheoperating system,suchasthehydraulicsystem,electrical system,components,andsoon.

•TheChapter,"Disassembly"describestheremoval andinstallationofassembliesmountedonthe upperstructureandundercarriage,andthe assemblinganddisassemblingoftheassociated hydraulicequipment.

•TheChapter,"Troubleshooting"describeshowto findthefaultequipment.

•TheChapter,"Engine"describesenginerepairusingofthe"MaintenanceManual"providedbythe enginemanufacture.

KOBELCOreservestherighttomakeimprovementsin designorchangesinspecificationsatanytimewithout incurringanyobligationtoinstallthemonunitspreviouslysold.

This is the sample of the manual if you need complete manual Click Here to download

1.OUTLINE

TABLEOFCONTENTS

1.1GENERALPRECAUTIONSFORMAKINGREPAIRS......................................................1-3

1.1.1PREPARATIONBEFOREDISASSEMBLING..........................................................1-3

1.1.2SAFETYWHENDISASSEMBLINGANDASSEMBLING........................................1-3

1.1.3DISASSEMBLINGANDASSEMBLINGHYDRAULICEQUIPMENT.......................1-3

1.1.4ELECTRICALEQUIPMENT.....................................................................................1-4

1.1.5HYDRAULICPARTS................................................................................................1-5

1.1.6WELDREPAIR.........................................................................................................1-5

1.1.7ENVIRONMENTALISSUES.....................................................................................1-5

1.2INTERNATIONALUNITSYSTEM.....................................................................................1-6

IssueDateofIssueApplicableMachinesRemarks

FirsteditionMay,2007SK260–8:LL12-05001~S5YN0118E01

1.1GENERALPRECAUTIONSFOR MAKINGREPAIRS

1.1.1PREPARATIONBEFORE DISASSEMBLING

(1)Knowledgeofoperatingprocedure

ReadOperator’sManualcarefullytounderstand theoperatingprocedure.

(2)Cleaningmachines

Cleanmachinesofsoil,mud,anddustbefore carryingintotheserviceshop.

Carryingasoiledmachineintotheserviceshop causeslessefficientworkanddamageofparts.

(3)Inspectingmachines

Confirmthedisassemblingsectionbeforestarting work,determinethedisassemblyproceduretaking theconditionsinworkshopintoaccount,and requesttoprocurenecessarypartsinadvance.

(4)Recording

Recordthefollowingitemstokeepcontactand preventmalfunctionfromrecurring.

1)Inspectiondate,place

2)Modelname,SerialNumberandRecordon hourmeter

3)Troublecondition,place,cause

4)Visibleoilleak,waterleakanddamage

5)Cloggingoffilters,oillevel,oilquality,oil contaminationandlooseness.

6)Examinetheproblemsonthebasisofmonthly operationratewiththelastinspectiondateand recordsonhourmeter.

(5)Arrangementandcleaninginserviceshop

1)Toolsrequiredforrepairwork.

2)Preparetheplacestoputthedisassembled parts.

3)Prepareoilpansforleakingoil,etc.

1.1.2SAFETYWHENDISASSEMBLINGAND ASSEMBLING

3)Beforestartinginspectionandmaintenance, stoptheengine.

4)Confirmthepositionoffirst-aidkitandfire extinguisher,andalsowheretomakecontact foremergencymeasuresandambulanceto prepareforaccidentsandfire.

5)Chooseahard,levelandsafeplace.The attachmentmustbefullyontheground.

6)Usehoist,etc.toremoveheavyparts(23kg [50lb]ormore).

7)Usepropertools,andchangeorrepair defectivetools.

8)Machineandattachmentrequiredtobeservicedintheliftingpositionshouldbesupported withsupportsorblockedsecurely.

1.1.3DISASSEMBLINGANDASSEMBLING HYDRAULICEQUIPMENT

(1)Safety

1)Wearappropriateclothing,safetyshoes,safety helmet,goggles,andclotheswithlongsleeves.

2)Attach"Don’toperate"tagtocontrollever,and beginameetingbeforestartingthework.

(1)Removinghydraulicequipmentassembly

1)Beforeremovingpipes,releasethepressureof hydraulicsystem.

2)Draintheoilintheremovedpipesintopanto preventtheoilfromspillingontheground.

3)Installplugsorcapsinpipeendstopreventoil fromleaking,entryofdust,etc.

4)Cleantheoutsidesurfaceofthemachinearea tobeworkedonbeforedisassembling.Drain hydraulicoilandgearoilbeforeputtingpartson theworkingbench.

(2)Disassemblinghydraulicequipment

1)Makealignmentmarksonpartsforassembly.

2)Beforedisassembly,readtheinstructionsin advancetobesurethepartsareallowedtobe disassembled.

3)Forpartswhicharerequiredtouseajigand specialtools,usethespecifiedjigandtools.

4)Forpartswhichcannotberemovedinthe specifiedprocedure,neverforceremoval.First checkforthecause.

5)Removedpartsshouldbeplacedinorderand taggedforeaseofassembly.

6)Forcommonparts,notethequantityandfrom whereremoved.

(3)Inspectingparts

1)Checkthatthedisassembledpartsfordamage orheavywear.

2)Measurethewearofpartsandclearance,and recordthemeasuredvalues.

3)Ifaparthasdamageorheavywear,replacethe part.

(4)Assemblinghydraulicequipment

1)Duringthepartscleaning,ventilatetheroom.

2)Beforeassembly,thoroughlycleanallparts.

3)Applycleanhydraulicoilorgearoilpriorto assembly.

4)ReplacetheremovedO-ring,back-upringsand oilsealwithnewones,andapplygreaseoilon thembeforeassembling.

5)Fullycleanthesurfaceonwhichliquidsealants areapplied.

6)Beforeassembling,removerustpreventiveson newparts.

7)Usespecialtoolstofitbearings,bushingandoil seal.

8)Assemblepartsusingthealignmentmarks madeduringdisassembly.

(5)Installinghydraulicequipment

1)Usethecorrecthydraulicoilandlubricationoil.

2)Airremovalisrequiredinthefollowingcases:

1.Changeofhydraulicoil

2.Replacementofpartsonsuctionpipeside

3.Removingandinstallinghydraulicpump

4.Removingandinstallingswingmotor

5.Removingandinstallingtravelmotor

6.Removingandinstallinghydrauliccylinder

Ifhydraulicoilandlubricatingoilarenot filledandalsoairbleedisnotperformed, thehydraulicequipmentmaybedamaged.

3)Forairremovalinthehydraulicpumpand swingmotor,loosenbutdonotremovethe drainplugontheupperhousing,startengine, andruninlowidleuntilhydraulicfluidflows fromtheport.Tightentheplugsecurely.

4)Forairremovalfromthetravelmotorand hydrauliccylinder,startengineandoperatefor 10minutesormoreatno-loadandlowidle.

Forcylinder,don’tmoveittothestrokeend atbeginning.

5)Airinpilotcircuitscanberemovedbyonly operatingdigging,swingandtravelingmotions thoroughly.

6)Checkhydraulicoillevel. Moveattachmentstohydraulicoilcheck position,andcheckhydraulicoilleveloftank. Addoiliftheoillevelislowerthanthespecified level.

Howtocheckoillevelofhydraulicoiltank

1.1.4ELECTRICALEQUIPMENT

(1)Handleequipmentwithcaresoasnottodropor bumpit.

(2)Connectorshouldberemovedbyunlockingwhile holdingtheconnector. Neverstressintensiontothecaulkedsectionby pullingwire.

(3)Checkthatconnectorisconnectedandlocked completely.

(4)TurntheenginekeyOFFbeforedisconnectingand connectingconnectors.

(5)TurntheenginekeyOFFbeforetouchingterminals ofstarterandalternator.

(6)Removebatterygroundingterminalbefore beginningworkclosetobatteryandbatteryrelay withtools.

(7)Washmachinewithcaresoasnottosplashwater onelectricalequipmentandconnector.

(8)Beforeconnectingawaterproofconnector,check theconnectorendsformoisture.Ifmoistureis present,dryitcompletelybeforeconnecting.

Batteryfluidisdangerous.

Thebatteryfluidisdilutesulfuricacid,andcauses scaldandlossofeyesightwhenadheringoneyes, skinandclothes.Whenthefluidhasadheredon them,takeanemergencymeasureimmediatelyand seeadoctorformedicaladvice.

•Whenithasadheredonskin,washwithsoap andwater.

•Whenithasadheredoneyes,washinwaterfor 10minutesormoreimmediately.

•Whenithasspilledoutinlargequantity,use sodiumbicarbonatetoneutralizeorwashaway withwater.

•Whenitwasswallowed,drinkmilkorwater.

•Whenithasadheredonclothes,washit immediately.

1.1.5HYDRAULICPARTS

(1)O-ring

•CheckthatO-ringisfreefromflawandhas elasticitybeforefitting.

•EvenifthesizeofO-ringisequal,theusage differs,forexampleindynamicandstatic sections,therubberhardnessalsodiffers accordingtothepressureforce,andalsothe qualitydiffersdependingonthematerialstobe seated.So,chooseproperO-ring.

•FitO-ringsoastobefreefromdistortionand bend.

•Floatingsealshouldbeputinpairs.

(2)Flexiblehose(Fhose)

•Eveniftheconnectorandlengthofhosearethe same,thepartsdifferaccordingtothe withstandingpressure.Useproperparts.

•Tightenittothespecifiedtorque,andcheckthat itisfreefromtwist,overtension,interference, andoilleak.

1.1.6WELDREPAIR

(1)Theweldrepairshouldbecarriedoutbyqualified personnelinthespecifiedprocedureafter disconnectingthegroundingcableofbattery.Ifthe groundingcableisnotdisconnected,theelectrical equipmentmaybedamaged.

(2)Removepartswhichmaycausefireduetothe entryofsparkbeforehand.

(3)Repairattachmentswhicharedamaged,giving particularattentiontotheplatedsectionofpiston rodtoprotectitfromsparks,anddon’tfailtocover thesectionwithflame-proofclothes.

1.1.7ENVIRONMENTALISSUES

(1)Engineshouldbestartedandoperatedintheplace whereaircanbesufficientlyventilated.

(2)Wastedisposal

Thefollowingpartsfollowstheregulation.

Wasteoil,wastecontainerandbattery

(3)Precautionsforhandlinghydraulicoil

Hydraulicoilmaycauseinflammationofeyes. Weargogglestoprotecteyeswhenhandlingit.

•Whenithasgotineyes,washeyeswithwater untilthestimulusisgone.

•Whenitwasswallowed,don’tforcevomitingweekmedicaltreatmentimmediately.

•Whenithasadheredonskin,washwithsoap andwater.

(4)Others

Forspareparts,greaseandoil,useKOBELCO genuineones.

1.2INTERNATIONALUNITSYSTEM

Introduction

ThismanualusestheSIunitssystem.OutlineofSI unitssystemisdescribedhere. Givenhereinunderareanexcerptoftheunitsthatare relatedtothismanual:

1.EtymologyofSIUnits

English:InternationalSystemofunits

2.ConstructionofSIUnitSystem

(1)BasicUnits

Table1-1

(2)SupplementaryUnits

Table1-2

QUANTITIESDESIGNATIONSIGN

(3)DerivedUnitsofBasicUnits

Table1-3

QUANTITIESDESIGNATIONSIGN

(4)DerivedUnitsbearingPeculiarDesignations

Table1-4

QUANTITYUNITSYMBOLFORMULA

FrequencyhertzHz1Hz=1/s

ForcenewtonNkg•m/s2

Pressureand StresspascalPaN/m2

Energy,Work andQuantityof heat jouleJN•m

PowerwattWJ/s

Quantityof electricity coulombCA•s

Electric potential difference, Voltage,and

Electromotive force voltVW/A

Quantityof staticelectricity andElectric capacitance faradFC/V

Electric resistance ohmV/A

Celsius temperature celcius degreeor degree °C(t+273.15)K

Illuminanceluxlxlm/m2

(5)PrefixesofSI

Table1-5

PREFIX POWER DESIGNATIONSIGN

GigaG109

MegaM106

Kilok103

Hectoh102

Decada10

Decid10–1

Centic10–2

Millim10–3

Micro 10–6

Nanon10–9

Picop10–12

(6)UnitConversionTable

QUANTITIESJISSIREMARKS

Masskgkg

ForcekgfN1kgf=9.807N

Torquekgf•mN•m1kgf•m=9.807N•m

Pressurekgf/cm2MPa1kgf/cm2=0.098MPa

MotivepowerPSkW1PS=0.7355kW

Revolutionr.p.mmin–11r.p.m=1min–1

2.SPECIFICATIONS

TABLEOFCONTENTS

2.1NAMEOFCOMPONENTS................................................................................................2-3

2.2GENERALDIMENSIONS..................................................................................................2-4

2.2.1SK260–8

[6.02m(19ft-9in)Boom+2.98m(9ft-9in)StandardArm+1.0m3(1.3cu•yd)BucketShoe].......2-4

2.2.2SK260–8

[6.02m(19ft-9in)Boom+3.66m(12ft-0in)LongArm+0.81m3(1.06cu•yd)BucketShoe]........2-4

2.3WEIGHTOFCOMPONENTS............................................................................................2-5

2.4TRANSPORTATION..........................................................................................................2-7

2.4.1OVERALLDIMENSIONSOFMACHINEONATRAILER........................................2-7

2.4.2DIMENSIONSOFATTACHMENT...........................................................................2-8

2.5SPECIFICATIONSANDPERFORMANCE.......................................................................2-10

2.5.1SPEEDANDCLIMBINGCAPABILITY.....................................................................2-10

2.5.2ENGINE....................................................................................................................2-10

2.5.3HYDRAULICCOMPONENTS..................................................................................2-10

2.5.4WEIGHT...................................................................................................................2-10

2.6TYPEOFCRAWLER.........................................................................................................2-11

2.7COMBINATIONSOFATTACHMENT................................................................................2-12

2.8ENGINESPECIFICATIONS..............................................................................................2-13

2.8.1SPECIFICATIONS....................................................................................................2-13

IssueDateofIssueApplicableMachinesRemarks

FirsteditionMay,2007SK260–8:LL12-05001~S5LQ0214E01

2.2GENERALDIMENSIONS

2.2.1SK260–8[6.02m(19ft-9in)Boom+2.98m(9ft-9in)StandardArm+1.0m3(1.3cu•yd)BucketShoe]

Dimensionsmarked*donotincludetheheightoftheshoelug.

2.2.2SK260–8[6.02m(19ft-9in)Boom+3.66m(12ft-0in)LongArm+0.81m3(1.06cu•yd)BucketShoe]

2.3WEIGHTOFCOMPONENTS

Unit;kg(lb)

ItemSK260-8

Machinecomplete26000(57320)

1.Upperframeassembly(assemblyoffollowing:)11920(26279)

1.1Upperframe2260(4982)

1.2Counterweight(semi-weighted)6020(13271)

1.3Cab270(595)

1.4Engine*610(1344)

1.5Hydraulicoiltank*170(375)

1.6Fueltank*160(350)

1.7Swingmotor(includingreductionunit)*290(639)

1.8Controlvalve*240(530)

1.9Boomcylinder*240(530)2

1.10Pin(formountingboom)130(290)

1.11Pump*120(260)

1.12Radiator(includingintercooler)*120(264)

2.Lowerframeassembly(assemblyoffollowing:)8960(19753)

2.1Lowerframe2,880(6,350)

2.2Swingbearing400(880)

2.3Travelmotor(includingreductionunit)520(1,150)2

2.4Upperroller50(110)2

2.5Lowerroller30(66)18

2.6Frontidler250(550)2

2.7Idleradjuster150(330)2

2.8Sprocket 50(110)2

2.9Swiveljoint*25(55)

2.10Tracklinkwith800mm(31.5in)shoesassembly1770(3,900)2

2.10.1Tracklinkassembly560(1150)2

3.Attachment(assemblyoffollowing/STD:) 5,120(1234)

{6.02m(19ft-9in)boom+2.98m(9ft-9in)arm+1.0m3(1.3cu•yd)bucket}

3.1Bucketassembly(STD)810(1,790)

3.2STDarmassembly(assemblyoffollowing:)1,030(2,270)

3.2.1STDarm850(1,870)

3.2.2Bucketcylinder*210(460)

3.2.3Idlerlink60(132)2

3.2.4Bucketlink100(220)

3.2.5Pin(2pcs.formountingbucketcylinder/2pcs.formountingbucket)90(200)

3.3Boomassembly(assemblyoffollowing:)2,040(4,500)

3.3.1Boom1,890(4,170)

3.3.2Armcylinder*370(815)

3.3.3Pin(Mountingarm•Mountingarmcylinder)60(132)

Unit;kg(lb) ItemSK260-8

4.Lubricantandwater(assemblyoffollowing:)590(1,300) 4.1Hydraulicoil160(350) 4.2Engineoil20(44) 4.3Fuel380(840) 4.4Water30(66)

*Dryweight.

2.4TRANSPORTATION

2.4.1OVERALLDIMENSIONSOFMACHINEONATRAILER (1)6.02m(19ft-9in)Boom+2.98m(9ft-9in)Arm+1.00m3(1.3cu•yd)Bucket

ItemSK260-8

Width800mm(31.4in)shoes3390(11ft-12in) Weight26000kg(57320lbs)

(14.6")

*marksindicateLCspecifications.

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