Kobelco Equipment Maintenance Manual (EN)

Table of contents

MAINTENANCE GO 2 MAIN INDEX Table of contents Page 4.1 GENERAL INFORMATION ................................................................................................................................ 4-3 4.2 GENERAL SAFETY ........................................................................................................................................... 4-3 4.3 INSPECTION & MAINTENANCE CHART ......................................................................................................... 4-7 4.4 FLUIDS & FILTERS .......................................................................................................................................... 4-10 A.

Required Fluids & Capacities................................................................................................................... 4-10 B. Required Filters ......................................................................................................................................... 4-10 C. Kobelco Fluids and Lubricants ................................................................................................................ 4-10 D. Lubricant Specifications...........................................................................................................................

4-11 4.5 PRE-START (EVERY 8 HRS) INSPECTION & MAINTENANCE..................................................................... 4-12 A. ENGINE OIL LEVEL .................................................................................................................................... 4-12 B. ENGINE COOLANT LEVEL ........................................................................................................................ 4-12 C. ENGINE FLUID LEAKS .............................................................................................................................. 4-13 D.

AIR CLEANER ............................................................................................................................................ 4-13 E. ENGINE ELECTRICAL ............................................................................................................................... 4-14 F. FUEL LEVEL ............................................................................................................................................... 4-15 G. HYDRAULIC OIL LEVEL ........................................................................................................................... 4-16 H.

HYDRAULIC FUNCTIONS ......................................................................................................................... 4-17 I. HYDRAULIC OIL LEAKS............................................................................................................................. 4-17 J. MACHINE ELECTRICAL ............................................................................................................................ 4-17 K. STEPS AND HANDRAILS.......................................................................................................................... 4-18 L.

FRAME STRUCTURE ................................................................................................................................. 4-18 M. TRACKS & COMPONENTS....................................................................................................................... 4-18 N. TRACK TENSION ....................................................................................................................................... 4-20 O. BOOM & ARM ............................................................................................................................................ 4-21 P.

CUTTING EDGE, BUCKET TEETH & SIDE CUTTERS ............................................................................. 4-21 Q. ATTACHMENT LUBRICATION .................................................................................................................. 4-22 4.6 50 HOUR (WEEKLY) & NEW MACHINE BREAK–IN INSPECTION & MAINTENANCE PROCEDURES. .... 4-24 A. ENGINE OIL AND FILTER ELEMENT ....................................................................................................... 4-24 B. WATER PUMP BEARING LUBRICATION ................................................................................................. 4-25 C.

FUEL TANK DRAIN .................................................................................................................................... 4-26 D. WATER SEPARATOR................................................................................................................................. 4-26 E. AIR INTAKE SYSTEM................................................................................................................................. 4-26 F. RADIATOR, OIL COOLER & DEBRIS SCREEN ........................................................................................ 4-27 G.

FUEL FILTERS ........................................................................................................................................... 4-28 1. Replacing Fuel Filter ............................................................................................................................ 4-28 2. Cleaning Priming Pump Strainer......................................................................................................... 4-28 3. Bleeding Air From Fuel System........................................................................................................... 4-29 H.

HYDRAULIC RETURN FILTER .................................................................................................................. 4-30 I. PILOT LINE FILTER ..................................................................................................................................... 4-31 J. BATTERIES ................................................................................................................................................. 4-32 K. FAN AND A/C BELT WEAR & TENSION ................................................................................................... 4-33 L. SLEWING RING AND SWING BEARING LUBRICATION.

........................................................................ 4-34 1. Slewing Ring ......................................................................................................................................... 4-34 2. Swing Bearing Lubrication .................................................................................................................. 4-34 M. CHECKING SLEWING RING ATTACHING BOLTS FOR PROPER TORQUE ......................................... 4-35 N. OIL LEVEL IN SWING AND TRAVEL REDUCTION UNITS ...................................................................... 4-35 O.

INSPECTING COUNTERWEIGHT ATTACHING BOLTS FOR PROPER TORQUE ................................. 4-35 4.7 120 HOUR INSPECTION & MAINTENANCE PROCEDURES. ....................................................................... 4-36 A. CONTROL LEVER JOINT LUBRICATION................................................................................................. 4-36 B. SWING MOTOR REDUCTION OIL ............................................................................................................ 4-36 C. TRAVEL MOTORS REDUCTION OIL (FOR SK210 (LC) -VI) ................................................................... 4-37 D.

Стр. 1

Table of contents

MAINTENANCE 4.8 250 HOUR (3-MONTH) INSPECTION & MAINTENANCE PROCEDURES. ................................................... 4-38 A. FAN AND A/C BELT WEAR AND TENSION.............................................................................................. 4-38 1. Fan Belts................................................................................................................................................ 4-38 2. Air Conditioning Compressor Belt ...................................................................................................... 4-38 B.

CLIMATIZER-AC UNIT FILTER INSPECTION ........................................................................................... 4-39 1. Fresh Air Filter ...................................................................................................................................... 4-39 2. Recirculate Air Filter ............................................................................................................................. 4-39 C. CHECKING THE RADIATOR CAP & HOSES............................................................................................ 4-40 4.9 500 HOUR (6-MONTH) INSPECTION & MAINTENANCE PROCEDURES. ...................................................

4-41 A. CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS (SK210(LC)-VI, SK250(LC)-VI & SK250NLC-VI) 4-41 1. SK210(LC)-VI ........................................................................................................................................ 4-41 2. SK250(LC)-VI and SK250NLC-VI......................................................................................................... 4-41 B. CHANGE OIL IN SWING REDUCTION UNIT ............................................................................................ 4-42 C. CHECKING AND CLEANING FUEL TANK AND STRAINER.................................................................... 4-42 D.

CHECKING THE AIR CONDITIONER REFRIGERANT ............................................................................. 4-43 E. FUEL SYSTEM INJECTION PRESSURE AND NOZZLE CONDITION (Atomization) ............................. 4-44 4.10 1000 HOUR (12-MONTH) INSPECTION & MAINTENANCE PROCEDURES. ............................................. 4-44 A. ENGINE VALVE CLEARANCE................................................................................................................... 4-44 B. ENGINE COMPRESSION PRESSURE ...................................................................................................... 4-44 C.

INSPECTION OF STARTER AND ALTERNATOR ...................................................................................... 4-44 D. ENGINE FUEL INJECTION TIMING .......................................................................................................... 4-44 4.11 2000 HOUR INSPECTION & MAINTENANCE PROCEDURES .................................................................... 4-45 A. ENGINE COOLANT CHANGE ................................................................................................................... 4-45 B. REMOVAL AND INSTALLATION OF RADIATOR...................................................................................... 4-47 C.

CHANGE HYDRAULIC OIL........................................................................................................................ 4-48 D. HYDRAULIC TANK BREATHER ................................................................................................................ 4-51 E. MAINTENANCE ON ROLLERS AND IDLERS........................................................................................... 4-52 4.12 PERIODICAL INSPECTION ITEMS ............................................................................................................... 4-53 A.

DUST SEALS.............................................................................................................................................. 4-53 B. ATTACHMENT ............................................................................................................................................ 4-54 1. Bucket/Arm & Link Clearance ............................................................................................................. 4-54 2. Reversing Bucket ................................................................................................................................. 4-55 3.

Removing the Bucket ........................................................................................................................... 4-56 4. Installing the Bucket............................................................................................................................. 4-56 5. Bucket Teeth and Side Cutters ............................................................................................................ 4-57 C. CHANGE SLEWING RING GREASE BATH .............................................................................................. 4-58 D.

WINDSHIELD WASHER RESERVOIR....................................................................................................... 4-58 E. FUSES......................................................................................................................................................... 4-59 F. HYDRAULIC LINES, TUBES AND HOSES ................................................................................................ 4-60 G. FOAM SEALS.............................................................................................................................................

4-61 4.13 MACHINE STORAGE..................................................................................................................................... 4-62 A. Prepare Machine......................................................................................................................................... 4-62 B. Care During Storage ................................................................................................................................. 4-62 C. Removing Machine From Storage ...........................................................................................................

4-62 4.14 INSPECTION MAINTENANCE CHECK LIST ............................................................................................... 4-63 4 4-2 SK210(LC)/SK250(LC)–VI Dynamic Acera OM, 09/00 Rev.2

Стр. 2

4.2 GENERAL SAFETY 4-

MAINTENANCE 4.1 GENERAL INFORMATION WARNING READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS CONTAINED IN THIS MANUAL BE- FORE PERFORMING ANY INSPECTION OR MAIN- TENANCE PROCEDURES ON THIS MACHINE, ITS SYSTEMS OR COMPONENTS. A. It is recommended by KOBELCO AMERICA INC., that an inspection and maintenance schedule be developed and maintained on a regular basis for this machine. Developing and maintaining such a schedule, helps to keep the machine in optimum operating condition. See Figure 4.3A. B. The information contained in this section gives the proper procedures for performing inspection and maintenance functions for this machine.

Use these procedures when performing inspection and main- tenance as they will guide the technician step by step for each procedure. Also, refer to the Inspec- tion and maintenance charts for general service interval recommendations. FIGURE 4.3A 4 SK32004002 NOTE The inspection and maintenance charts provided in this section give only general time intervals. It may be neces- sary to develope a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions. FIGURE 4.3B Dispose of Waste Properly C. Use only KOBELCO oils, fluids, lubricants, filters and replacement parts to keep machine in optimum operating condition. See Figure 4.3B.

4.2 GENERAL SAFETY A. Disposal of Hazardous Waste– FIGURE 4.3C Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly. FIGURE 4.3C SK32004003 CAUTION Dispose of all hazardous waste in accordance with govern- ment environmental regulations, laws and codes. B. Keep Machine Clean– FIGURE 4.3D Thoroughly clean machine before performing In- spection and maintenance procedures. It is easier and safer to locate problems, perform maintenance and also reduce the risk of hydraulic system con- tamination when machine is clean. FIGURE 4.3D SK32004004 SK210(LC)/SK250(LC)–VI Dynamic Acera OM, 09/00 Rev.2 4-3

Стр. 3

4.2 GENERAL SAFETY 4-

MAINTENANCE C. Hot Surfaces & Fluids– FIGURE 4.4A Use caution and wear the proper safety equipment when working around hot areas. Never change oils, engine coolant or filters immediately after a ma- chine has been stopped. Allow machine to cool down before performing maintenance procedures. D. Warm Engine Oil Engine oil should have a temperature should be between 20 ° C ~ 40 ° C (68 ° F ~ 104 ° F) before the oil is changed. If necessary run engine until the oil is warm within the recommended oil change tem- perature. SK32004005 FIGURE 4.4A E.

“Tag-Out” Machine– FIGURE 4.4B Before beginning any inspection or maintenance procedures, secure a “DO NOT OPERATE” tag to the operators console to inform the operator that the machine will be inoperable for inspection and maintenance. This tag will help prevent accidental starting of the machine. Order tag P/N: YN20T01320P1 DO NOT OPERATE 4 F. Inspect Waste Oils and Filters– FIGURE 4.4C Before disposal, inspect all waste oils, fluids and filters for debris and foreign material. It is recom- mended to cut open the oil filters to determine any abnormal wear. FIGURE 4.4B SK32004006 G.

Prevent Contamination– FIGURE 4.4D Always cap or plug lines when hydraulic compo- nents are removed to help prevent hydraulic sys- tem contamination that can be caused by dirt, dust and debris entering a line or port. CHECK FOR DEBRIS CAUTION Never allow a hydraulic line or component to become contaminated. This could cause severe system damage. Contact an authorized KOBELCO dealer to obtain the proper caps and plugs to be used on this machine. Re- fer to Specification’s Section, page 6-41, for proper part numbers. SK32004007 FIGURE 4.4C H. Seals & “O”-Rings Always replace seals and “O”-Rings with new parts. Never reuse a seal or “O”-Ring during reassembly of components.

Make sure to lubricate all new seals with the appropiate oil before installation. SK32004008 FIGURE 4.4D 4-4 SK210(LC)/SK250(LC)–VI Dynamic Acera OM, 09/00 Rev.2

Стр. 4