APPLICABLE:
SK260-8 ......... LL12-05001~ Issued 01May 07
S5YN0118E01 NA
SK260-8
TIER 3
EXCAVATOR
SHOP MANUAL
SK260-8 TABLE OF CONTENTS
SPECIFICATIONS SECTION
0-SAFETY
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+1.0m
3
(1.3cu•yd) Bucket Shoe] ........................................................................................... 2-4
2.2.2 SK260–8 [6.02m (19t-9in) Boom+3.66m (12ft-0in) Long Arm+0.81m
3
(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
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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
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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
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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
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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
0. SAFETY
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Kobelco SK260-8 Service Manual
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Description
The Kobelco SK260-8 Excavators Repair Manual is a comprehensive guide for maintaining and repairing your excavator. Whether you're a professional mechanic or a do-it-yourself enthusiast, this workshop manual provides all the necessary information to keep your machine in top-notch condition.
Inside this manual, you'll find detailed instructions for the removal, installation, disassembly, and assembly of various components. Every aspect of your excavator, from the engine to the hydraulic system, is covered. The manual also includes electrical wiring diagrams and hydraulic schematic diagrams to assist in troubleshooting any electrical or hydraulic issues.
Additionally, this repair manual features diagnostic procedures to help quickly identify and resolve problems. It also provides specifications and torque values for all components, ensuring precise repairs and maintenance.
Models included in this repair manual:
- Kobelco SK260-8 Excavator
