Kobelco SK260-8 Tier 3 Hydraulic Excavator Service Repair Manual (LL12-05001~)

1 GENERAL SAFETY INFORMATION 0-2
02 SAFETY PRECAUTIONS

0-3
1-OUTLINE
11 GENERAL PRECAUTIONS FOR MAKING REPAIRS 1-3
111 PREPARATION BEFORE DISASSEMBLING

1-3
112 SAFETY WHEN DISASSEMBLING AND ASSEMBLING1-3
113 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT 1-3
114 ELECTRICAL EQUIPMENT

1-4
115 HYDRAULIC PARTS 1-5
116 WELD REPAIR 1-5
1

17 ENVIRONMENTAL ISSUES1-5
12 INTERNATIONAL UNIT SYSTEM

1-6
2-SPECIFICATIONS
21 NAME OF COMPONENTS2-3
22 GENERAL DIMENSIONS

2-4
221 SK2608 [602m (19ft-9in) Boom+298m (9ft-9in) Standard Arm+10m3
(13cuyd) Bucket Shoe] 2-4
2

22 SK2608 [602m (19t-9in) Boom+366m (12ft-0in) Long Arm+081m3
(106cuyd) Bucket Shoe] 2-4
23 WEIGHT OF COMPONENTS

2-5
24 TRANSPORTATION2-7
241 OVERALL DIMENSIONS OF MACHINE ON A TRAILER

2-7
242 DIMENSIONS OF ATTACHMENT2-8
25 SPECIFICATIONS AND PERFORMANCE2-10
2

51 SPEED AND CLIMBING CAPABILITY 2-10
252 ENGINE

2-10
253 HYDRAULIC COMPONENTS 2-10
254 WEIGHT

2-10
26 TYPE OF CRAWLER2-11
27 COMBINATIONS OF ATTACHMENT

2-12
28 ENGINE SPECIFICATIONS 2-13
281 SPECIFICATIONS

2-13
3-ATTACHMENT DIMENSIONS
31 BOOM3-3
311 BOOM DIMENSIONAL DRAWING3-3
3

12 BOOM MAINTENANCE STANDARD3-4
32 ARM

3-6
321 ARM DIMENSIONAL DRAWING3-6
322 ARM MAINTENANCE STANDARD

3-7
33 BUCKET AND PIN3-10
331 BUCKET AND PIN DIMENSIONAL DRAWING

3-10
332 BUCKET AND PIN DIMENSIONAL TABLE3-11
MAINTENANCE SECTION
11-TOOLS
111 STANDARD TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS11-3
11

2 SCREW SIZE11-5
1121 CAPSCREW (BOLT)

11-5
1122 CAPSCREW (SOCKET BOLT)11-5
1123 SOCKET SET SCREW

11-5
113 TORQUE SPECIFICATIONS FOR HOSE AND FITTINGS11-6
1131 JOINT (O-RING TYPE)

11-6
1132 HYDRAULIC HOSE (30 FLARE TYPE) 11-6
1133 JOINT (ORS TYPE) 11-6
11

34 SPLIT FLANGE11-6
114 TORQUE SPECIFICATIONS FOR NUTS AND SLEEVES 11-7
11

5 PLUG 11-8
1151 PLUG FOR HYDRAULIC PIPE JOINT

11-8
1152 PLUG FOR HYDRAULIC EQUIPMENT 11-9
116 SPECIAL SPANNER FOR TUBE 11-11
11

7 SPECIAL TOOLS11-12
118 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND11-14
11

9 SUCTION STOPPER11-15
1191 COMPONENTS 11-15
11

92 DIMENSION11-15
1193 APPLICABLE MODEL

11-15
1110 COUNTER WEIGHT LIFTING JIG11-16
11110 UPPER FRAME LIFTING JIG

11-17
1111 ENGINE TURNOVER STAND11-18
1113 TRACK SPRING SET JIG11-19
12-STANDARD MAINTENANCE TIMETABLE
12

1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR12-4
13-MAINTENANCE STANDARD AND TEST PROCEDURE
131 HOW TO USE THE MAINTENANCE STANDARD

13-3
132 PERFORMANCE INSPECTION STANDARD TABLE13-4
133 MEASUREMENT OF ENGINE SPEED 13-6
13

31 MEASUREMENT OF ENGINE SPEED13-6
134 MEASUREMENT OF HYDRAULIC PRESSURE13-7
13

41 PREPARING TO MEASURE HYDRAULIC PRESSURE 13-7
1342 PLACE TO INSTALL PRESSURE GAUGE13-7
1343 PRESSURE ADJUSTMENT POSITION

13-8
1344 PROCEDURE FOR ADJUSTING RELIEF VALVE13-10
135 MEASURING TRAVEL PERFORMANCES13-12
13

51 TRAVEL SPEED13-12
1352 DEVIATION OF TRAVEL

13-12
1353 PERFORMANCES OF PARKING BRAKE 13-13
1354 DRAIN RATE OF TRAVEL MOTOR

13-14
136 MEASURING SWING PERFORMANCES13-15
1361 SWING SPEED

13-15
1362 PERFORMANCE OF SWING BRAKE13-15
1363 PERFORMANCE OF SWING PARKING BRAKE 13-16
13

64 DRAIN RATE OF SWING MOTOR13-17
137 MEASURING ATTACHMENT OPERATING PERFORMANCES 13-18
1371 OPERATING TIME OF CYLINDERS

13-18
1372 CYLINDER LEAK CHECK13-19
138 MEASURING PERFORMANCES OF SWING BEARING13-20
13

9 MECHATRO CONTROLLER13-21
1391 ENGINE CONTROL INPUT / OUTPUT13-21
13

92 ENGINE CONTROL13-22
1393 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT
(A-B-C ADJUSTMENT)

13-24
1394 OPERATIONS IN THE EVENT OF A MECHATRO CONTROLLER FAILURE13-29
SYSTEM SECTION
21-MECHATRO CONTROL SYSTEM
211 SUMMARY OF MECHATRO CONTROL SYSTEM21-4
21

11 MECHATRO CONTROL SYSTEM IN GENERAL 21-4
2112 UNLOAD VALVE CONTROL21-6
21

13 POSITIVE CONTROL & P-Q CONTROL 21-7
2114 BOOM UP CONFLUX CONTROL 21-9
21

15 ARM IN RECIRCULATION & CONFLUX CONTROL21-10
2116 ARM-IN ANTI-CAVITATION CONTROL21-12
211

7 ARM-OUT CONFLUX CONTROL 21-13
2118 BUCKET DIGGING (DUMP) CONFLUX CONTROL 21-14
2119 BUCKET DIGGING ANTI-CAVITATION CONTROL

21-15
21110 SWING PRIORITY CONTROL 21-17
21111 TRAVEL STRAIGHT CONTROL

21-18
21112 TRAVEL INDEPENDENT CONTROL21-20
21112 PRESSURE RELEASE CONTROL21-22
21

113 N&B SWITCH CONTROL (OPTION)21-23
21114 OPTION CONFLUX CONTROL (OPTION) 21-24
21

2 MECHATRO CONTROLLER21-25
2121 SUMMARY OF MULTI DISPLAY

21-25
2122 SELF DIAGNOSIS DISPLAY21-30
2123 SERVICE DIAGNOSIS DISPLAY FUNCTION

21-31
2124 TROUBLE HISTORY DIAGNOSIS 21-42
2125 TROUBLE DIAGNOSIS MODE 21-43
21

26 SET PROCEDURE OF MAINTENANCE SCHEDULE 21-43
2127 ADJUSTING PROCEDURE OF DISPLAY 21-44
2128 MECHATRO CONTROL EQUIPMENT 21-47
22-HYDRAULIC SYSTEM
22

1 SUMMARY22-3
222 HYDRAULIC CIRCUITS AND COMPONENTS22-4
22

3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS22-8
224 NEUTRAL CIRCUIT22-8
22

5 TRAVEL CIRCUIT 22-10
226 BUCKET CIRCUIT

22-12
227 BOOM CIRCUIT 22-14
228 SWING CIRCUIT

22-18
229 ARM CIRCUIT 22-20
2210 COMBINED CIRCUIT 22-26
22

11 PRESSURE DRAINING (RELEASING) CIRCUIT 22-32
23-ELECTRICAL SYSTEM
231 ELECTRIC CIRCUIT DIAGRAM

23-3
232 ELECTRICAL EQUIPMENT LIST23-8
233 HARNESS23-10
23

31 HARNESS LIST 23-10
2332 INSTRUMENT PANEL ASSY23-11
23

33 TUNER INSTALL23-12
2334 UPPER ELECTRIC ASSY

23-13
2335 UPPER FRAME HARNESS ASSY23-14
2336 UPPER FLOOR PLATE HARNESS ASSY

23-20
2337 CAB HARNESS ASSY23-25
2338 BOOM HARNESS ASSY

23-28
2339 INSTALLING BOOM LIGHT 23-28
23310 INSTALLING DECK LIGHT 23-29
23

311 TRAVEL ALARM ASSY23-29
23312 FLASHER LAMP INSTALL

23-35
24-COMPONENTS SYSTEM
241 HYDRAULIC COMPONENTS24-3
2411 HYDRAULIC PUMP REGULATOR

24-3
2412 CONTROL VALVE24-21
2413 PILOT VALVE (ATT)

24-59
2414 PILOT VALVE (TRAVEL)24-63
2415 SWING MOTOR

24-65
2416 TRAVEL MOTOR24-76
2417 SWIVEL JOINT

24-93
2418 CYLINDER24-95
242 ELECTRIC EQUIPMENT

24-100
2421 ELECTRIC EQUIPMENT LIST 24-100
2422 SPECIFICATION OF ELECTRIC EQUIPMENT

24-104
25-AIR CONDITIONER SYSTEM
251 BASIC AIR CONDITIONER SYSTEM (HVAC AIR CONDITIONER)25-3
2511AIR CYCLE

25-3
2512 AUTO AIR CONDITIONER SYSTEM OUTLINE 25-4
252 COMPONENT AND CONSTRUCTION 25-5
25

21 COMPONENT25-5
2522 CONSTRUCTION25-6
25

3 PIPING25-9
2531 AIR CONDITIONER25-9
25

32 RECEIVER DRYER ASSY 25-11
254 FUNCTION

25-12
2541 MECHANISM OF COOLING CIRCUIT25-12
2542 COOLING CIRCUIT25-14
25

43 COMPONENT PARTS25-15
255 DISASSEMBLY AND ASSEMBLY

25-19
2551 PRECAUTIONS TO BE EXERCISED IN OPERATION25-19
2552 DISASSEMBLY AND ASSEMBLY OF UNIT 25-20
25

6 CHARGING REFRIGERANT25-24
2561 PRECAUTIONS TO BE EXERCISED IN OPERATION25-24
25

62 OPERATING PROCEDURE25-25
2563 CHARGING PROCEDURE

25-26
257 ELECTRIC CIRCUIT25-32
2571 WIRING DIAGRAM AND CONNECTORS

25-32
2572 STRUCTURE AND OPERATION OF EACH PART AND INSPECTION25-34
258 TROUBLESHOOTING25-37
25

9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL 25-44
2591 POSITION OF INDICATION FOR FAILURE 25-44
259

2 EXPLANATION OF INDICATION FOR FAILURE 25-44
2593 EXPLANATION OF MONITOR MODE25-46
DISASSEMBLING SECTION
31-DISASSEMBLY AND ASSEMBLING
31

1 DISASSEMBLY & ASSEMBLY OVERVIEW31-3
3111 GENERAL INFORMATION

31-3
3112 TORQUE SPECIFICATIONS31-3
32-ATTACHMENT
321 REMOVING AND INSTALLING 32-3
32

11 ATTACHMENT ASSEMBLY32-3
3212 BUCKET

32-3
3213 ARM32-6
3214 BOOM32-9
32

2 DISASSEMBLING AND ASSEMBLING32-13
3221 CYLINDER

32-13
33-UPPER STRUCTURE
331 REMOVING AND INSTALLING33-3
3311 OPERATOR SEAT

33-3
3312 CAB33-4
3313 BATTERY 33-6
33

14 GUARD33-7
3315 UNDER COVER

33-13
3316 FUEL TANK 33-14
3317 HYDRAULIC TANK

33-16
3318 HYDRAULIC PUMP33-20
3319 AIR CLEANER

33-25
33110 MUFFLER33-26
33111 COUNTERWEIGHT33-28
33

112 RADIATOR & OIL COOLER33-29
33113 ENGINE 33-35
33

114 CONSOLE COVER33-38
33115 CONTROL VALVE

33-39
33116 PILOT VALVE (FOR ATT) 33-42
33117 PILOT VALVE (FOR TRAVEL)

33-43
33118 SWING MOTOR 33-46
33119 SWIVEL JOINT

33-48
33120 UPPER FRAME33-51
332 DISASSEMBLING AND ASSEMBLING33-54
33

21 HYDRAULIC PUMP REGULATOR 33-54
3322 CONTROL VALVE

33-80
3323 PILOT VALVE (ATT)33-111
3324 PILOT VALVE (FOR TRAVEL)

33-121
3325 SWIVEL JOINT33-130
3325 SWIVEL JOINT

33-163
34-TRAVEL SYSTEM
341 REMOVING AND INSTALLING34-3
3411 TRAVEL SYSTEM

34-3
3412 CRAWLER34-3
3413 UPPER ROLLER

34-7
3414 LOWER ROLLER 34-13
3415 FRONT IDLER (IDLER ADJUSTER ASSY)

34-21
3416 SPROCKET 34-30
3417 TRAVEL MOTOR34-33
34

18 SWING BEARING34-35
342 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT34-38
34

21 CONSTRUCTION OF TRAVEL MOTOR34-38
TROUBLESHOOTING SECTION
46-TROUBLESHOOTING (BY ERROR CODES)
461 EVALUATION OF ACTUAL PROBLEM AT THE SITE

46-3
462 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING46-4
463 MECHATRO CONTROLLER BLOWN FUSE 46-4
46

4 TROUBLESHOOTING BY ERROR CODE46-4
47-TROUBLESHOOTING (BY SYMPTOM)
471 HYDRAULIC SYSTEM

47-3
472 ELECTRIC SYSTEMS 47-27
4721 WIRING CHECKING PROCEDURE

47-27
4722 TROUBLE47-30
473 ENGINE RELATED TROUBLESHOOTING47-33
48-TROUBLESHOOTING (BY DIAGNOSIS MODE)
48

1 TROUBLE DIAGNOSIS MODE 48-3
ENGINE SECTION
51-ENGINE
CHAPTER 1 DIAGNOSTICS

1-1
CHAPTER 2 67 L T/A ENGINE OVERHAUL2-1
CHAPTER 3 CHARGING AND START-UP3-1