Download Complete Service Repair Manual for Kobelco SK260-8 Tier 3 Hydraulic Excavator.
This Factory Service Repair Manual offers all the service and repair information about Kobelco SK260-8 Tier 3 Hydraulic Excavator. The information on this manual covered everything you need to know when you want to repair or service Kobelco SK260-8 Tier 3 Hydraulic Excavator.
S5YN0118E01 NA Issued 01May 07
Applicable: SK260-8. . . . . . . . . LL12-05001~
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Manual Contents:
0.1 GENERAL SAFETY INFORMATION……………………………………………………………………….. 0-2
0.2 SAFETY PRECAUTIONS ………………………………………………………………………………………. 0-3
1-OUTLINE
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
2-SPECIFICATIONS
2.1 NAME OF COMPONENTS……………………………………………………………………………………2-3
2.2 GENERAL DIMENSIONS ……………………………………………………………………………………..2-4
2.2.1 SK260–8 [6.02m (19ft-9in) Boom+2.98m (9ft-9in) Standard Arm+1.0m3
(1.3cu•yd) Bucket Shoe] ……………………………………………………………………………….2-4
2.2.2 SK260–8 [6.02m (19t-9in) Boom+3.66m (12ft-0in) Long Arm+0.81m3
(1.06cu•yd) Bucket Shoe] ……………………………………………………………………………..2-4
2.3 WEIGHT OF COMPONENTS………………………………………………………………………………..2-5
2.4 TRANSPORTATION…………………………………………………………………………………………….2-7
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ………………………………….2-7
2.4.2 DIMENSIONS OF ATTACHMENT………………………………………………………………….2-8
2.5 SPECIFICATIONS AND PERFORMANCE………………………………………………………………2-10
2.5.1 SPEED AND CLIMBING CAPABILITY ……………………………………………………………2-10
2.5.2 ENGINE ……………………………………………………………………………………………………..2-10
2.5.3 HYDRAULIC COMPONENTS ……………………………………………………………………….2-10
2.5.4 WEIGHT……………………………………………………………………………………………………..2-10
2.6 TYPE OF CRAWLER……………………………………………………………………………………………2-11
2.7 COMBINATIONS OF ATTACHMENT……………………………………………………………………..2-12
2.8 ENGINE SPECIFICATIONS ………………………………………………………………………………….2-13
2.8.1 SPECIFICATIONS……………………………………………………………………………………….2-13
3-ATTACHMENT DIMENSIONS
3.1 BOOM………………………………………………………………………………………………………………..3-3
3.1.1 BOOM DIMENSIONAL DRAWING…………………………………………………………………3-3
3.1.2 BOOM MAINTENANCE STANDARD……………………………………………………………..3-4
3.2 ARM …………………………………………………………………………………………………………………..3-6
3.2.1 ARM DIMENSIONAL DRAWING……………………………………………………………………3-6
3.2.2 ARM MAINTENANCE STANDARD………………………………………………………………..3-7
3.3 BUCKET AND PIN……………………………………………………………………………………………….3-10
3.3.1 BUCKET AND PIN DIMENSIONAL DRAWING………………………………………………..3-10
3.3.2 BUCKET AND PIN DIMENSIONAL TABLE……………………………………………………..3-11
MAINTENANCE SECTION
11-TOOLS
11.1 STANDARD TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS………………11-3
11.2 SCREW SIZE…………………………………………………………………………………………………….11-5
11.2.1 CAPSCREW (BOLT) ………………………………………………………………………………….11-5
11.2.2 CAPSCREW (SOCKET BOLT)…………………………………………………………………….11-5
11.2.3 SOCKET SET SCREW……………………………………………………………………………….11-5
11.3 TORQUE SPECIFICATIONS FOR HOSE AND FITTINGS………………………………………11-6
11.3.1 JOINT (O-RING TYPE)……………………………………………………………………………….11-6
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ……………………………………………………….11-6
11.3.3 JOINT (ORS TYPE) ……………………………………………………………………………………11-6
11.3.4 SPLIT FLANGE………………………………………………………………………………………….11-6
11.4 TORQUE SPECIFICATIONS FOR NUTS AND SLEEVES ………………………………………11-7
11.5 PLUG ……………………………………………………………………………………………………………….11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ………………………………………………………….11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT ………………………………………………………..11-9
11.6 SPECIAL SPANNER FOR TUBE …………………………………………………………………………11-11
11.7 SPECIAL TOOLS……………………………………………………………………………………………….11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND……11-14
11.9 SUCTION STOPPER………………………………………………………………………………………….11-15
11.9.1 COMPONENTS …………………………………………………………………………………………11-15
11.9.2 DIMENSION………………………………………………………………………………………………11-15
11.9.3 APPLICABLE MODEL ………………………………………………………………………………..11-15
11.10 COUNTER WEIGHT LIFTING JIG……………………………………………………………………….11-16
111.10 UPPER FRAME LIFTING JIG…………………………………………………………………………….11-17
11.11 ENGINE TURNOVER STAND……………………………………………………………………………..11-18
11.13 TRACK SPRING SET JIG……………………………………………………………………………………11-19
12-STANDARD MAINTENANCE TIMETABLE
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR….12-4
13-MAINTENANCE STANDARD AND TEST PROCEDURE
13.1 HOW TO USE THE MAINTENANCE STANDARD………………………………………………….13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE……………………………………………..13-4
13.3 MEASUREMENT OF ENGINE SPEED …………………………………………………………………13-6
13.3.1 MEASUREMENT OF ENGINE SPEED…………………………………………………………13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE…………………………………………………….13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE …………………………………13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE……………………………………………………13-7
13.4.3 PRESSURE ADJUSTMENT POSITION………………………………………………………..13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE………………………………………….13-10
13.5 MEASURING TRAVEL PERFORMANCES……………………………………………………………13-12
13.5.1 TRAVEL SPEED………………………………………………………………………………………..13-12
13.5.2 DEVIATION OF TRAVEL…………………………………………………………………………….13-12
13.5.3 PERFORMANCES OF PARKING BRAKE …………………………………………………….13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR……………………………………………………………..13-14
13.6 MEASURING SWING PERFORMANCES……………………………………………………………..13-15
13.6.1 SWING SPEED………………………………………………………………………………………….13-15
13.6.2 PERFORMANCE OF SWING BRAKE…………………………………………………………..13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE …………………………………………..13-16
13.6.4 DRAIN RATE OF SWING MOTOR……………………………………………………………….13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ………………………………13-18
13.7.1 OPERATING TIME OF CYLINDERS…………………………………………………………….13-18
13.7.2 CYLINDER LEAK CHECK…………………………………………………………………………..13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING…………………………………………13-20
13.9 MECHATRO CONTROLLER……………………………………………………………………………….13-21
13.9.1 ENGINE CONTROL INPUT / OUTPUT…………………………………………………………13-21
13.9.2 ENGINE CONTROL……………………………………………………………………………………13-22
13.9.3 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT
(A-B-C ADJUSTMENT)……………………………………………………………………………….13-24
13.9.4 OPERATIONS IN THE EVENT OF A MECHATRO CONTROLLER FAILURE……13-29
SYSTEM SECTION
21-MECHATRO CONTROL SYSTEM
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM…………………………………………………21-4
21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL …………………………………………..21-4
21.1.2 UNLOAD VALVE CONTROL……………………………………………………………………….21-6
21.1.3 POSITIVE CONTROL & P-Q CONTROL ………………………………………………………21-7
21.1.4 BOOM UP CONFLUX CONTROL ………………………………………………………………..21-9
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL………………………………………21-10
21.1.6 ARM-IN ANTI-CAVITATION CONTROL………………………………………………………..21-12
21.1.7 ARM-OUT CONFLUX CONTROL ………………………………………………………………..21-13
21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL ……………………………………….21-14
21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL ……………………………………….21-15
21.1.10 SWING PRIORITY CONTROL …………………………………………………………………….21-17
21.1.11 TRAVEL STRAIGHT CONTROL ………………………………………………………………….21-18
21.1.12 TRAVEL INDEPENDENT CONTROL……………………………………………………………21-20
21.1.12 PRESSURE RELEASE CONTROL………………………………………………………………21-22
21.1.13 N&B SWITCH CONTROL (OPTION)…………………………………………………………….21-23
21.1.14 OPTION CONFLUX CONTROL (OPTION) ……………………………………………………21-24
21.2 MECHATRO CONTROLLER……………………………………………………………………………….21-25
21.2.1 SUMMARY OF MULTI DISPLAY………………………………………………………………….21-25
21.2.2 SELF DIAGNOSIS DISPLAY……………………………………………………………………….21-30
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION ……………………………………………….21-31
21.2.4 TROUBLE HISTORY DIAGNOSIS ……………………………………………………………….21-42
21.2.5 TROUBLE DIAGNOSIS MODE ……………………………………………………………………21-43
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE …………………………………….21-43
21.2.7 ADJUSTING PROCEDURE OF DISPLAY …………………………………………………….21-44
21.2.8 MECHATRO CONTROL EQUIPMENT …………………………………………………………21-47
22-HYDRAULIC SYSTEM
22.1 SUMMARY………………………………………………………………………………………………..22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS………………………………………………22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS………………………….22-8
22.4 NEUTRAL CIRCUIT……………………………………………………………………………………22-8
22.5 TRAVEL CIRCUIT ……………………………………………………………………………………..22-10
22.6 BUCKET CIRCUIT……………………………………………………………………………………..22-12
22.7 BOOM CIRCUIT ………………………………………………………………………………………..22-14
22.8 SWING CIRCUIT ……………………………………………………………………………………….22-18
22.9 ARM CIRCUIT …………………………………………………………………………………………..22-20
22.10 COMBINED CIRCUIT …………………………………………………………………………………22-26
22.11 PRESSURE DRAINING (RELEASING) CIRCUIT …………………………………………..22-32
23-ELECTRICAL SYSTEM
23.1 ELECTRIC CIRCUIT DIAGRAM…………………………………………………………………………..23-3
23.2 ELECTRICAL EQUIPMENT LIST…………………………………………………………………………23-8
23.3 HARNESS…………………………………………………………………………………………………………23-10
23.3.1 HARNESS LIST …………………………………………………………………………………………23-10
23.3.2 INSTRUMENT PANEL ASSY………………………………………………………………………23-11
23.3.3 TUNER INSTALL……………………………………………………………………………………….23-12
23.3.4 UPPER ELECTRIC ASSY …………………………………………………………………………..23-13
23.3.5 UPPER FRAME HARNESS ASSY……………………………………………………………….23-14
23.3.6 UPPER FLOOR PLATE HARNESS ASSY…………………………………………………….23-20
23.3.7 CAB HARNESS ASSY………………………………………………………………………………..23-25
23.3.8 BOOM HARNESS ASSY…………………………………………………………………………….23-28
23.3.9 INSTALLING BOOM LIGHT ………………………………………………………………………..23-28
23.3.10 INSTALLING DECK LIGHT …………………………………………………………………………23-29
23.3.11 TRAVEL ALARM ASSY………………………………………………………………………………23-29
23.3.12 FLASHER LAMP INSTALL………………………………………………………………………….23-35
24-COMPONENTS SYSTEM
24.1 HYDRAULIC COMPONENTS………………………………………………………………………………24-3
24.1.1 HYDRAULIC PUMP, REGULATOR ……………………………………………………………..24-3
24.1.2 CONTROL VALVE……………………………………………………………………………………..24-21
24.1.3 PILOT VALVE (ATT)…………………………………………………………………………………..24-59
24.1.4 PILOT VALVE (TRAVEL)…………………………………………………………………………….24-63
24.1.5 SWING MOTOR ………………………………………………………………………………………..24-65
24.1.6 TRAVEL MOTOR……………………………………………………………………………………….24-76
24.1.7 SWIVEL JOINT………………………………………………………………………………………….24-93
24.1.8 CYLINDER………………………………………………………………………………………………..24-95
24.2 ELECTRIC EQUIPMENT…………………………………………………………………………………….24-100
24.2.1 ELECTRIC EQUIPMENT LIST …………………………………………………………………….24-100
24.2.2 SPECIFICATION OF ELECTRIC EQUIPMENT ……………………………………………..24-104
25-AIR CONDITIONER SYSTEM
25.1 BASIC AIR CONDITIONER SYSTEM (HVAC AIR CONDITIONER)………………………….25-3
25.1.1AIR CYCLE ……………………………………………………………………………………………………….25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE …………………………………………….25-4
25.2 COMPONENT AND CONSTRUCTION …………………………………………………………………25-5
25.2.1 COMPONENT……………………………………………………………………………………………25-5
25.2.2 CONSTRUCTION………………………………………………………………………………………25-6
25.3 PIPING……………………………………………………………………………………………………………..25-9
25.3.1 AIR CONDITIONER……………………………………………………………………………………25-9
25.3.2 RECEIVER DRYER ASSY ………………………………………………………………………….25-11
25.4 FUNCTION………………………………………………………………………………………………………..25-12
25.4.1 MECHANISM OF COOLING CIRCUIT………………………………………………………….25-12
25.4.2 COOLING CIRCUIT……………………………………………………………………………………25-14
25.4.3 COMPONENT PARTS………………………………………………………………………………..25-15
25.5 DISASSEMBLY AND ASSEMBLY………………………………………………………………………..25-19
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION……………………………………25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ………………………………………………….25-20
25.6 CHARGING REFRIGERANT……………………………………………………………………………….25-24
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION……………………………………25-24
25.6.2 OPERATING PROCEDURE………………………………………………………………………..25-25
25.6.3 CHARGING PROCEDURE………………………………………………………………………….25-26
25.7 ELECTRIC CIRCUIT…………………………………………………………………………………………..25-32
25.7.1 WIRING DIAGRAM AND CONNECTORS……………………………………………………..25-32
25.7.2 STRUCTURE AND OPERATION OF EACH PART AND INSPECTION…………….25-34
25.8 TROUBLESHOOTING………………………………………………………………………………………..25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ……………………………………….25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. …………………………………………………25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. ………………………………………….25-44
25.9.3 EXPLANATION OF MONITOR MODE………………………………………………………….25-46
DISASSEMBLING SECTION
31-DISASSEMBLY AND ASSEMBLING
31.1 DISASSEMBLY & ASSEMBLY OVERVIEW…………………………………………………………..31-3
31.1.1 GENERAL INFORMATION………………………………………………………………………….31-3
31.1.2 TORQUE SPECIFICATIONS……………………………………………………………………….31-3
32-ATTACHMENT
32.1 REMOVING AND INSTALLING ……………………………………………………………………………32-3
32.1.1 ATTACHMENT ASSEMBLY………………………………………………………………………..32-3
32.1.2 BUCKET …………………………………………………………………………………………………..32-3
32.1.3 ARM…………………………………………………………………………………………………………32-6
32.1.4 BOOM………………………………………………………………………………………………………32-9
32.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………32-13
32.2.1 CYLINDER………………………………………………………………………………………………..32-13
33-UPPER STRUCTURE
33.1 REMOVING AND INSTALLING……………………………………………………………………………33-3
33.1.1 OPERATOR SEAT …………………………………………………………………………………….33-3
33.1.2 CAB………………………………………………………………………………………………………….33-4
33.1.3 BATTERY …………………………………………………………………………………………………33-6
33.1.4 GUARD…………………………………………………………………………………………………….33-7
33.1.5 UNDER COVER ………………………………………………………………………………………..33-13
33.1.6 FUEL TANK ………………………………………………………………………………………………33-14
33.1.7 HYDRAULIC TANK…………………………………………………………………………………….33-16
33.1.8 HYDRAULIC PUMP……………………………………………………………………………………33-20
33.1.9 AIR CLEANER…………………………………………………………………………………………..33-25
33.1.10 MUFFLER…………………………………………………………………………………………………33-26
33.1.11 COUNTERWEIGHT……………………………………………………………………………………33-28
33.1.12 RADIATOR & OIL COOLER………………………………………………………………………..33-29
33.1.13 ENGINE ……………………………………………………………………………………………………33-35
33.1.14 CONSOLE COVER…………………………………………………………………………………….33-38
33.1.15 CONTROL VALVE……………………………………………………………………………………..33-39
33.1.16 PILOT VALVE (FOR ATT) …………………………………………………………………………..33-42
33.1.17 PILOT VALVE (FOR TRAVEL) …………………………………………………………………….33-43
33.1.18 SWING MOTOR ………………………………………………………………………………………..33-46
33.1.19 SWIVEL JOINT………………………………………………………………………………………….33-48
33.1.20 UPPER FRAME…………………………………………………………………………………………33-51
33.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………33-54
33.2.1 HYDRAULIC PUMP • REGULATOR …………………………………………………………….33-54
33.2.2 CONTROL VALVE……………………………………………………………………………………..33-80
33.2.3 PILOT VALVE (ATT)…………………………………………………………………………………..33-111
33.2.4 PILOT VALVE (FOR TRAVEL) …………………………………………………………………….33-121
33.2.5 SWIVEL JOINT………………………………………………………………………………………….33-130
33.2.5 SWIVEL JOINT………………………………………………………………………………………….33-163
34-TRAVEL SYSTEM
34.1 REMOVING AND INSTALLING……………………………………………………………………………34-3
34.1.1 TRAVEL SYSTEM…………………………………………………………………………………….34-3
34.1.2 CRAWLER………………………………………………………………………………………………..34-3
34.1.3 UPPER ROLLER ……………………………………………………………………………………….34-7
34.1.4 LOWER ROLLER ………………………………………………………………………………………34-13
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) …………………………………………………..34-21
34.1.6 SPROCKET ………………………………………………………………………………………………34-30
34.1.7 TRAVEL MOTOR………………………………………………………………………………………34-33
34.1.8 SWING BEARING………………………………………………………………………………………34-35
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT………………………………….34-38
34.2.1 CONSTRUCTION OF TRAVEL MOTOR……………………………………………………….34-38
TROUBLESHOOTING SECTION
46-TROUBLESHOOTING (BY ERROR CODES)
46.1 EVALUATION OF ACTUAL PROBLEM AT THE SITE…………………………………………….46-3
46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING………………………………….46-4
46.3 MECHATRO CONTROLLER BLOWN FUSE ………………………………………………………..46-4
46.4 TROUBLESHOOTING BY ERROR CODE…………………………………………………………….46-4
47-TROUBLESHOOTING (BY SYMPTOM)
47.1 HYDRAULIC SYSTEM………………………………………………………………………………………..47-3
47.2 ELECTRIC SYSTEMS ………………………………………………………………………………………..47-27
47.2.1 WIRING CHECKING PROCEDURE……………………………………………………………..47-27
47.2.2 TROUBLE…………………………………………………………………………………………………47-30
47.3 ENGINE RELATED TROUBLESHOOTING……………………………………………………………47-33
48-TROUBLESHOOTING (BY DIAGNOSIS MODE)
48.1 TROUBLE DIAGNOSIS MODE ……………………………………………………………………………48-3
ENGINE SECTION
51-ENGINE
CHAPTER 1 – DIAGNOSTICS ………………………………………………………………………………….. 1-1
CHAPTER 2 – 6.7 L T/A ENGINE OVERHAUL………………………………………………………………2-1
CHAPTER 3 – CHARGING AND START-UP…………………………………………………………………3-1
This manual can be used by anyone from a first time owner/amateur to a professional technician.Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings.Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
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