Kobelco SK150(LC)IV ED180(LC) Hydraulic Excavator Shop Manual - PDF DOWNLOAD

SHOP MANUAL HYDRAULIC EXCAVATOR

SK150(LC)IV ED180(LC)

Applicable: SK150(LC)IV YMU1001~ Applicable: ED180(LC) YLU001~ S5YMU/YL01E-01

04/02

MEASURING & ADJUSTING PRESSURES 1.2 MAIN PILOT CIRCUIT A. Main Pilot Relief Valve Pressure Measurement Procedures 1. Perform machine preparation procedures as described in 1.1 MACHINE PREPARATION. 2. Start engine and place throttle control in HiIdle position. See Figure 2.5.

3. Place KPSS Mode Switch in "H"-Mode. See Figure 2.5.

4. Do not operate any controls. Then read the pressure gauge. Record reading and compare to chart for specific model being tested on pages 15 through 18.

FIGURE 2.5

B. Main Pilot Relief Valve Adjustment Procedures 1. Locate the Main Pilot Relief Valve mounted to the side of the Hydraulic Oil Tank in the Manifold Assembly. See Figure 2.6.

2. Remove protective cap. See Figure 2.7.

Loosen the adjusting screw locknut. See Figure 2.8.

3. Adjust until specified pressure according to proper chart for specific machine being adjusted is achieved.

MAIN PILOT RELIEF VALVE

NOTE 1 Complete Turn Adjusts Pressure Approximately: 14.4kg/cm2 (200 psi) 1 /4 Turn Adjusts Pressure Approximately: 3.6kg/cm2 (51.2 psi)

FIGURE 2.6

PROTECTIVE CAP

4. After correct pressure is obtained, tighten adjusting screw locknut, being careful not to overtighten. See Figure 2.8.

5. Install protective cap and tighten. Be careful not to overtighten cap. See Figure 2.7.

6. Verify pressure after tightening locknut and cap.

FIGURE 2.7

LOCKNUT

ADJUSTING SCREW

FIGURE 2.8 SK150LC IV / ED180 SM REV 1, 5/02

5

CYLINDERS & MOTOR CYCLE TIMES TRAVEL MOTORS TRAVEL MOTOR TEST CONTINUED

SK150 ILLUSTRATED

CAUTION

REMOVE LINE AT TEE INSTALL CAP ON TEE. LINE TO BUCKET

•Thoroughly clean all hydraulic lines and fittings before removal. Do not allow any dirt or debris to enter the open lines or fittings.

• Thoroughly clean the bucket that the oil is to be drained into.

10. After cleaning away all dirt and debris, remove hydraulic line routed from "Tee" on top of Swing Motor to center port on Swivel Joint at swing motor "Tee". See Figure 5.10.

11. Install one hydraulic fitting cap onto "Tee". See Figure 5.10. Torque to proper value.

12. Place loose end of line into a clean 38 liter (10 gal.) capacity bucket.

13. Start engine, raise boom a little and place throttle control in the "High" idle position.

14. With special tool installed in each travel motor sprocket, operate the left travel control at full stroke forward for one minute. Measure the amount of oil in bucket and record.

TEE

SWING MOTOR

FIGURE 5.10 SPECIAL TOOL INSTALLED FOR FORWARD STALL

NOTE If it seems the flow of oil will be high, perform the test for 15 seconds and multiply amount of oil by 4 to compare to chart.

EXAMPLE: 19liters(5 U.S. Gal) X 4= 76liters(20 Gal)

SPROCKET

15. Repeat step 14 with right control at full stroke forward for one minute. Record amount of oil in bucket.

16. Remove special tool and place into sprocket to stall reverse movement. See Figure 5.11.

17. Repeat steps 14 and 15 with control to reverse movement.

18. Compare readings for each travel motor to Travel Motor Oil Case Drain Specification Chart.

19. If readings are greater than values in chart, refer to shop manual for additional instructions.

20. Remove hydraulic fitting cap. Install hydraulic lines back to the original fitting and torque to the proper value.

21. Check Hydraulic Oil level. Refer to Operators Manual for hydraulic oil level check procedures.

FIGURE 5.11 TRAVEL MOTOR OIL CASE DRAIN SPECIFICATIONS MODEL SK115

FORWARD/REVERSE TRAVEL STANDARD- 6(1.6)

SK115

MAXIMUM- 15(4.0)

SK130

STANDARD- 6(1.6)

SK130

MAXIMUM- 15(4.0)

SK150

STANDARD- 6(1.6)

SK160

MAXIMUM- 15(4.0)

SK200

STANDARD- 8(2.1)

SK210

MAXIMUM- 20(5.3)

SK220

STANDARD- 8(2.1)

SK250

MAXIMUM- 20(5.3)

SK270

STANDARD- 10(2.6)

CAUTION

SK270

MAXIMUM- 20(5.3)

SK300

STANDARD- 10(2.6)

•Fill Hydraulic tank to proper level using only approved new hydraulic oil as listed in the List of Oils, Greases, Filters and Elements Chart on Page 1-8 of this manual.

SK330

MAXIMUM- 20(5.3)

SK400

STANDARD- 15(4.0)

SK150LC IV / ED180 SM REV 1, 5/02

SK460

37

MAXIMUM- 30 (9.5) Unit: Liters per Minute (Gallons per Minute)

Book Code No.

KCMA-S5

YLU18

01E

SK150

YMU / YL02

Travel System TABLE OF CONTENTS 1. Crawler 1.1 Dismantling and Mounting Procedure .............................. 1 1.2 Construction ................................................ 4 2.3 Disassembly and Reassembly ....................... 5 1.4 Tools and Jigs ............................................... 6 2. Upper Roller 2.1 Dismantling and Mounting Procedure .............................. 7 2.2 Construction ................................................ 8 2.3 Disassembly and Reassembly ....................... 8 2.4 Maintanance Standard ............................... 11 2.5 Tools and Jigs ............................................ 11 3. Lower Roller 3.1 Dismantling and Mounting Procedure ............................ 12 3.2 Construction .............................................. 13 3.3 Disassembly and Reassembly ..................... 13 3.4 Maintanance Standard ............................... 16 3.5 Tools and Jigs ............................................ 17 4. Front Idler 4.1 Dismantling and Mounting Procedure ............................ 18 4.2 Construction .............................................. 19 4.3 Disassembly and Reassembly ..................... 19 4.4 Maintanance Standard ............................... 21 4.5 Tools and Jigs ............................................ 22

5. Idler Adjuster 5.1 Dismantling and Mounting Procedure ............................ 23 5.2 Construction .............................................. 23 5.3 Disassembly and Reassembly ..................... 24 5.4 Maintance Standard ................................... 26 5.5 Tools and Jigs ............................................ 27 6. Sprocket 6.1 Dismantling and Mounting Procedure ............................ 27 6.2 Maintenance Standard ............................... 28 6.3 Tools and Jigs ............................................ 28 7. Travel Reduction Gear 7.1 Dismantling and Mounting Procedure ............................ 29 7.2 Maintance Standard ................................... 30 7.3 Tools and Jigs ............................................ 30 8. Swing Joint 8.1 Dismantling and Mounting Procedure ............................ 31 8.2 Maintenance Standard ............................... 31 9. Swing Bearing 9.1 Dismantling and Mounting Procedure ............................ 32 9.2 Construction .............................................. 33 9.3 Dissassembly and Reassembly ................... 34 9.4 Maintanance Standard ............................... 34 9.5 Tools and Jigs ............................................ 34

©2002 KOBELCO CONSTRUCTION MACHINERY AMERICA LLC, Calhoun, Georgia / Stafford, Texas USA. All rights reserved. Any use of editorial or pictorial content is strictly prohibited without express written permission from KCMA, Calhoun, Georgia / Stafford, Texas USA. Printed in U.S.A.

18

Applicable Machines YMUIO01---

Revision First edition

Dateof Issue January,1995

Remarks S5YMUlSO1E

K

Return to Contents

Book Code No.

KCMA-S5

YLU18

01E

SK150

YMU / YL02

Travel System TABLE OF CONTENTS 1. Crawler 1.1 Dismantling and Mounting Procedure .............................. 1 1.2 Construction ................................................ 4 Maintenanceand Standard.............

12.3 Disassembly Reassembly ....................... 5 1.4 Tools and Jigs ............................................... 6 2. Upper Roller 2.1 Dismantling and Mounting Procedure .............................. 7 2.2 Construction ................................................ 8 2.3 Disassembly and Reassembly ....................... 8 2.4 Maintanance Standard ............................... 11 2.5 Tools and Jigs ............................................ 11 3. Lower Roller 3.1 Dismantling and Mounting Procedure ............................ 12 3.2 Construction .............................................. 13 3.3 Disassembly and Reassembly ..................... 13 3.4 Maintanance Standard ............................... 16 3.5 Tools and Jigs ............................................ 17 4. Front Idler 4.1 Dismantling and Mounting Procedure ............................ 18 4.2 Construction .............................................. 19 4.3 Disassembly and Reassembly ..................... 19 4.4 Maintanance Standard ............................... 21 4.5 Tools and Jigs ............................................ 22

5. Idler Adjuster 5.1 Dismantling and Mounting Procedure ............................ 23 5.2 Construction .............................................. 23 5.3 Disassembly and Reassembly ..................... 24 5.4 Maintance Standard ................................... 26 5.5 Tools and Jigs ............................................ 27 6. Sprocket 6.1 Dismantling and Mounting Procedure ............................ 27 6.2 Maintenance Standard ............................... 28 6.3 Tools and Jigs ............................................ 28 7. Travel Reduction Gear 7.1 Dismantling and Mounting Procedure ............................ 29 7.2 Maintance Standard ................................... 30 7.3 Tools and Jigs ............................................ 30 8. Swing Joint 8.1 Dismantling and Mounting Procedure ............................ 31 8.2 Maintenance Standard ............................... 31 9. Swing Bearing 9.1 Dismantling and Mounting Procedure ............................ 32 9.2 Construction .............................................. 33 9.3 Dissassembly and Reassembly ................... 34 9.4 Maintanance Standard ............................... 34 9.5 Tools and Jigs ............................................ 34

©2002 KOBELCO CONSTRUCTION MACHINERY AMERICA LLC, Calhoun, Georgia / Stafford, Texas USA. All rights reserved. Any use of editorial or pictorial content is strictly prohibited without express written permission from KCMA, Calhoun, Georgia / Stafford, Texas USA. Printed in U.S.A.

18

Applicable Machines YMUIO01---

Revision First edition

Dateof Issue January,1995

Remarks S5YMUlSO1E

K

6.3 MAINTENANCE STANDARD

FIG. 6-4 TABLE 6.1 PITCH

SPECIFICATIONS

202.8 mm (7.984IN)

ROLLER DIA. 698mm O.D. OF SPROKET (27.480IN.)

NUMBER OF TEETH

21

PITCH DIA. WIDTH OF SPROKET TEETH

688.03 80mm (3.150in)

6.4 TOOLS AND JIGS (1) TIGHTENING TOOLS NAME SOCKET

OPPOSING FLATS 27mm

I-28

SPROCKET TOOTH PROFILE DETAIL

I-29 SK150LC/IV ED180 REV 1, 05/02

1. REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT 1.1 CONSTRUCTION OF TRAVEL MOTOR 35

12 13 3 7 5

37

39 24

6

28

Tightening torque kgfym( ftylbs)

36

20

☆：Apply Locktite #242 Opposing flats mm

No.

NAME

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

CASING REAR COVER CYLINDER BLOCK SHOE RETAINER FRICTION PLATE BRAKE PISTON SEPARATOR PLATE VALVE PLATE SHAFT COUPLING SHOE PLATE BALL JOINT SPRING RETAINER PISTON ASSY D RING (SMALL) D RING (LARGE) CHECK VALVE SNAP RING SNAP RING TILTING PISTON BALL PIVOT PISTON SEAL M6 ORIFICE；∅0.6 OIL SEAL SPRING SPRING(CYLINDER) SPRING(BRAKE) BEARING BEARING

33

21 23 29

32 17

9

26 38

18

40

39 View Z

41 10 2

19

30 8

25 22 44

1

11 50

4 27 42 45 48 47

15 16 49

43

42

14 46

Tightening torque

Y

kgfym( ftylbs)

Opposing flats mm

1 1 1 1 3 1 4 1 1 1 1 1 1 9 1 1 3 1 1 1 1 2 1 2 1 3 9 2 1 1

23.5 (170)

14

1.4 (10)☆ 1.5 (11) 3.0 (22)

5 6

11 (80)

32

5.5 (40)

22

Q T

31 32 33 ― 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

5.5 (40)

2.8 (20) 10 (72)

No.

10

NAME

Q T Y

SOCKET BOLT；M16×45 8 SHIM 1~2 PARALLEL PIN；∅6×12 1 ─── ― PLUG；NPT1/16 1 PLUG；NPT1/16(Meck : TB) 10 PLUG 1 PLUG；PF1/8 3 PLUG；PF1/4 2 ORING；1B P8 5 ORING；1B P11 4 ORING；1B P14 2 ORING；190.17×2.62 1 2 OVER LOAD RELIEF VALVE；M27 SPOOL 1 PLUG；PF3/8 1 SPRING RETAINER 1 PIN 1 SPRING 1 CONNECTOR 1 SPOOL ASSY 1 COVER 2 SPRING 2 SPRING RETAINER 2 RESTRICTOR VALVE 2 SPRING 2 PLUG 2 ORING；42.52×2.62 2 ORING；1B P9 2 SOCKET BOLT；M12×35 8

58 54

44-3

44-2

44-1

44-4 44-12 44-13 44-9 44-8 44-12 44-10 44-11 44-6

44-7

44-5

60 53

52 57

41

59 51 55 56 31 VIEW Z (Shows part of the cross-sectional view) Fig.1-1 Construction of travel motor SK150LC/IV ED180 REV 1, 05/02

Tightening torque kgfym( ftylbs)

Opposing flats mm

11 (80)

32

16 (120)

35

No.

NAME

44-1 44-2 44-3 44-4 44-5 44-6 44-7

SOCKET VALVE VALVE SEAT CONNECTING PISTON PLUG PILOT BODY PISTON

Note) Quantities are worth one overload relief valve.

Tightening Opposing torque flats No. NAME Q TY Q TY kgfym( ftylbs)

1 1 1 1 1 1 1

mm

44-8 44-9 44-10 44-11 44-12 44-13

SHIM ADJUSTMENT SPRING O RING；1B P7 BACK UP RING O RING；1B G25 BACK UP RING

1 1 1 2 2 1 I-1

1.2 CONSTRUCTION OF REDUCTION UNIT

24

15

16

14 13

12

18

25

20

4 7 3 5 10 6

Clearance:-0.08 to+0.02mm (-0.0031 to+0.0008in) Adjust it with only one shim.

9

(0.043˝ )

(0.016˝ ～0.094˝ )

8

Storage this unit in condition that the axis is horizon.

1 2 11 26

17

21

22

19

23

Fig.1-2 Construction of reduction unit Apply Locktite #242 Tightening torque

kgfym( ftylbs)

Ⅱ－2

Opposing flats mm

No.

NAME

Q T Y

Tightening torque

kgfym( ftylbs)

Opposing flats mm

No.

NAME

Q T Y

1 2 3 4 5

COVER CARRIER 1 CARRIER PIN 1 NEEDLE BEARING THRUST WASHER 1

1 1 3 3 6

14 15 16 17 18

PLANETARY GEAR 2 SPRING PIN；∅6×36 THRUST WASHER 2 RING GEAR HOUSING

3 3 6 1 1

6 7 8 9 10

PLANETARY GEAR 1 SPRING PIN；∅4×22 THRUST PLATE SUN GEAR 1 SUN GEAR 2

3 3 1 1 1

19 20 21 22 23

BEARING SHIM LOCK WASHER SUPPORT RING FLOATING SEAL

2 1 2 1 1

11 12 13

CARRIER 2 CARRIER PIN 2 NEEDLE BEARING

1 3 3

24 25 26

SOCKET BOLT；M10×25

8.0 (58)☆ 28.0 (200)☆ 1.0 (7.2) SEAL TAPE

8 14 14

SOCKET BOLT；M16×80 SOCKET PLUG；PT3/4

15 19 2

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Return to Contents

Book Code No.

YMU/YL21

KCMALLC -S5

01E

YMU/YL21

SK 150LC IV ED180 ATTACHMENT DISASSEMBLY DIMENSION ATTACHMENT TABLE OF CONTENTS 1.

BUCKET 1.1 Dismantling and Mounting Procedure ............................................... 1 1.2 Construction .................................................................................... 2 1.3 Maintanance Standard ..................................................................... 2 2. ARM 2.1 Dismantling and Mounting Procedure ............................................... 4 2.2 Construction .................................................................................... 5 2.3 Maintanance Standard ..................................................................... 5 3. BOOM 3.1 Preparation for Dismantling and Mounting ........................................ 8 3.2 Dismantling and Mounting Procedure ............................................... 8 3.3 Construction .................................................................................... 9 3.4 Maintanance Standard ................................................................... 10 4.

Hydraulic Cylinder 4.1 Dismantling and Mounting Hydraulic Cylinder ..................................... 12

© 2 0 02 KO B E LCO C O N S T RU C T I O N M AC H I N E RY A M E R I C A L LC . Calhoun, Georgia / Stafford, Texas USA. All rights reserved. Any use of editorial or pictorial content is strictly prohibited without express written permission from KCMA LLC, Calhoun, Georgia / Stafford, Texas USA. Printed in U.S.A.

Applicable Machines YMU1001~ YLU0001~

Revision

Date of Issue

First Edition

MAY, 2002

Remarks KCMA-S5YMU/YL01/01E

Edited and Compiled by KCMA LLC

Return to Contents

Book Code No.

KCMA LLC-S5

YMU/YL22

01E

SK150LC-IV ED180 MECHATRO CONTROL SYSTEM

YMU/YL22

TABLE OF CONTENTS 1.

OPERATING CONTROLS 1.1 Operating Switched of Control Board ............................................... 1 1.2 Display Function ............................................................................... 6 1.3 Control Lever Operation ................................................................. 10 1.4 Engine Control ................................................................................ 11

2.

MECHATRONIC CONTROL 2.1 KPSS Controller (C-1) .................................................................. 12 2.2 Cluster Gauge Controller (C-2) ....................................................... 15

3.

MAIN ELECTRIC EQUIPMENT 3.1 Summery of Main Electric Equipment .............................................. 20

©2001 KOBELCO CONSTRUCTION MACHINERY AMERICA LLC Calhoun, Georgia / Stafford, Texas USA. All rights reserved. Any use of editorial or pictorial content is strictly prohibited without express written permission from KCMA, Calhoun, Georgia / Stafford, Texas USA. Printed in U.S.A.

Dynamic Acera 07/01 Rev. 01

Applicable Machines YMU1001~ YLU0001~

This Page Intensionally left Blank

This Page Intentionally left Blank

ELECTRIC CIRCUIT DIAGRAM LUOOO1

ELECTRIC CIRCUIT DIAGRAM LUOOO1

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

ED180PM REV.1 08/01

411-49-1

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

411-49-2

ED180PM REV.1 08/01

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

ITEM PART NUMBER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 37 38 39 40 41 42 43 45 46 47 49 50 51 52 55 ED180PM REV.1 08/01

DESCRIPTION

QTY

24100J20706F1

WIRING ASSY, ELEC (~4/9/99)

F1

-

-

24100J20706F2

WIRING ASSY, ELEC (4/9/99 ~ 10/29/99)

-

F2

-

24100J20706F3

WIRING ASSY, ELEC (10/29/99~)

-

-

F3

2479U2108 2479R1470F1 2479U1009F1 2479U1009F2 YM13EU1001D1 YM13EU1002D1 YM13EU1003D1 YN13EU1004D1 YN13EU1005D1 2479U2110 2479U2127 2479U2124 2479Z2427 2479Z2296 ZN18C04003 ZW26X04000 ZN18C06005 ZW26X06000 ZW16K06000 ZS18C08025 ZS18C08030 ZN18C08007 ZW26X08000 ZW16K08000 ZS18C10014 ZN18C10008 ZW26X10000 ZW16X10000 ZW26X12000 ZS18C12020 ZN18C12010 2432Z290 2432R233D2 2432R233D3 2420Z699 2420Z1188 ZS18C06030 YM72EU1001P1 2420T6788 YN24SU1002P1 24100R499 2479U2123 2479U1979 LQ13EU1002D1 LQ13EU1003D1 ZS18C08045 2479U2003 2479R1470F4 2479U2062 2479U2147

HARNESS (Left side) RELAY, BATTERY HORN, LOW (E-4) HORN, HIGH (E-3) CABLE, BATTERY (L=700mm) CABLE, BATTERY (L=320mm) CABLE (L=370mm) CABLE CABLE HARNESS (Dozer Pilot Valve) HARNESS (Right side) HARNESS (Dozer Rew ork) HARNESS (Ground) HARNESS (Boom Work Light) NUT (M4) WASHER, LOCK (M4) NUT (M6) WASHER, LOCK (M6) WASHER (M6) CAPSCREW (M8X25mm) CAPSCREW (M8X30mm) NUT (M8) WASHER, LOCK (M8) WASHER (M8) CAPSCREW (M10X14mm) NUT (M10) WASHER, LOCK (M10) WASHER (M10) WASHER, LOCK (M12) CAPSCREW (M12X20mm) NUT (M12) CLIP CLIP CLIP GROMMET GROMMET CAPSCREW (M6X30mm) COVER SEMS-BOLT (M10X25mm) RELAY, STARTER CONNECTOR HARNESS (Below Floor) HARNESS (Side-L) CABLE (Heater Relay) CABLE (Heater Relay) CAPSCREW (M8X45mm) HARNESS (Below Floor) RELAY, BATTERY (Heater Relay) HARNESS (Side-R) HARNESS (Reserve Pow er)

1 1 1 1 1 1 1 1 1 1 1 1 2 2 3 3 5 3 2 5 10 8 1 1 2 2 2 1 1 8 2 1 6 2 2 1 2 1 1 1 1 1 2 1 1 1 1

1 1 1 1 1 1 1 1 1 1 2 2 3 3 5 3 2 5 10 8 1 1 2 2 2 1 1 8 2 1 6 2 2 1 2 1 1 1 1 2 1 1 -

1 1 1 1 1 1 1 1 1 1 1 1 2 2 3 3 5 3 2 5 10 8 1 1 2 2 2 1 1 8 2 1 6 2 2 1 2 1 1 1 1 1 2 1 -

411-49-3

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U1979

411-49-4

ED180PM REV.1 08/01

WIRING ASSEMBLY, ELECTRIC 24100J20706F2

2479U1979

ED180PM REV.1 08/01

411-49-5

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2003

411-49-6

ED180PM REV.1 08/01

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2003

ED180PM REV.1 08/01

411-49-7

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2062

411-49-8

ED180PM REV.1 08/01

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2062

ED180PM REV.1 08/01

411-49-9

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2108

411-49-10

ED180PM REV.1 08/01

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2110

ED180PM REV.1 08/01

411-49-11

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2123

411-49-12

ED180PM REV.1 08/01

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2123

ED180PM REV.1 08/01

411-49-13

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2124

411-49-14

ED180PM REV.1 08/01

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

2479U2147

ED180PM REV.1 08/01

411-49-15

WIRING ASSEMBLY, ELECTRIC 24100J20706F1,F2,F3

411-49-16

ED180PM REV.1 08/01

ED180PM REV.1 08/01

WIRING ASSEMBLY, ELECTRIC 24100J20706F1, F2, F3

2479U2127

411-49-17

ED180PM REV.1 08/01

WIRING ASSEMBLY, ELECTRIC 24100J20706F1, F2, F3

2479U2127

ED180PM REV.1 08/01

411-49-18

ED180PM REV.1 08/01

INSTRUMENT PANEL HARNESS ASSEMBLY 24100J20748F3

2479U2169

ED180PM REV.1 08/01

415-49-2

INSTRUMENT PANEL HARNESS ASSEMBLY 24100J20748F3

2479U2169

415-49-3

ED180PM REV.1 08/01

INSTRUMENT PANEL HARNESS ASSEMBLY 24100J20748F3

2479U2169

ED180PM REV.1 08/01

415-49-4

INSTRUMENT PANEL HARNESS ASSEMBLY 24100J20748F3

2479U2109

415-49-4

ED180PM REV.1 08/01

INSTRUMENT PANEL HARNESS ASSEMBLY 24100J20922F1

2479U2122

ED180PM REV.1 08/01

416-49-2

INSTRUMENT PANEL HARNESS ASSEMBLY 24100J20922F1

2479U2122

416-49-3

ED180PM REV.1 08/01

INSTRUMENT PANEL HARNESS ASSEMBLY 24100J20922F1

2479U2122

ED180PM REV.1 08/01

416-49-4

INSTRUMENT PANEL HARNESS ASSEMBLY 24100J20922F1

2479U2122 416-49-5

ED180PM REV.1 08/01

This Page Intentionally left Blank

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SHOP MANUAL S K 1 5 0 L C - IV ED180 COMPONENTS

TABLE OF CONTENTS 1. Hydraulic Pump ....................................................................................

2. Control Valve .......................................................................................

12 13

3. Other Valves .........................................................................................

14

4. Hydraulic Motor ...................................................................................

15 16

5. Swivel Joint ..........................................................................................

6. Hydraulic Cylinder ................................................................................

7. Reduction Unit ......................................................................................

8. Engine ..................................................................................................

©2002 KOBELCO CONSTRUCTION MACHINERY AMERICA LLC, Calhoun, Georgia / Stafford, Texas USA. All rights reserved. Any use of editorial or pictorial content is strictly prohibited without express written permission from KCMA, Calhoun, Georgia / Stafford, Texas USA. Printed in U.S.A.

17 21 50

YMU

Index No.

12

List

of Shop Manual COMPONENTS Section

Book Code No. Title

Distribution

HYDRAULIC PUMP

$5120409E~ 1995-01

REGULATOR

$5120421EO 1995-01

HYDRAULIC GEAR PUMP

$5120451E 1995-01

CONTROL VALVE (SWING)

$5130668E~ 1995-01

PILOT VALVE (TH40K)

$5130715E 1995-01

PILOT VALVE (TRAVEL)

$5130772E(~) 1995-01

CONTROL VALVE

$5130795E 1995-01

HOLDING VALVE (BOOM SAFETY) HOLDING VALVE (BOOM LOCK)

$5140696E 1995-01 $5140712E(~) 1995-01

MANIFOLD BLOCK

$5140732EO 1995-01 $5150435E~) 1995-01

15

HYDRAULIC MOTOR (SWING) HYDRAULIC MOTOR (TRAVEL)

$5150455EO 1995-01

16

SWIVEL JOINT

$5160117E(~ 1995-01

17

HYDRAULIC CYLINDER

$5170185EO 1995-01

21

REDUCTION UNIT (SWING)

$5210372E~ 1995-01

5O

ENGINE

$5500044E 1995-01

13

14

Applicable Machines

YMUIO01~

Year-Month

Return to Contents

Bookcode No.

KCMA LLC

120409E

KOBELCO SHOP

MANUAL

SK150LC -IV

HYDRAULIC PUMP TABLE OF CONTENTS

1. SPECIFICATION 1.1 General View .....................................

1.2 Specification ......................................

2. CONSTRUCTION AND FUNCTION 2.1 Construction ......................... .............

2.2 Function .........................................

3. DISASSEMBLY AND ASSEMBLY 3.1 Tools .............................................

3.2 Preparation before Disassembly ...................

3.3 Disassembly ......................................

3.4 Preparation before Assembly ......................

3.5 Assembly .........................................

4. CARTRIDGE TYPE ELECTROMAGNETIC PROPORTIONATE REDUCING VALVE ¯ ¯ 5. MAINTENANCE STANDARDS 5.1 Replacement Standards for Abrasive Parts .........

5.2 Repair Standards for Cylinder Valve Plate and Swash Plate ............

5.3 Tightening Torque ................................

6. TROUBLESHOOTING 6.1 Locating Causes of Troubles ......................

6.2 Troubleshooting ..................................

1 1 2 3 5 5 6 9 9 13 14 15 15 16 16

KOBELCO CONSTRUCTION MACHINERY(U.SA.) INC.

PREFACE The pump is of variable-displacement axial piston type with a swash plate. The pumps may be used either in a single or double (tandem) form.

The basic section of the pump regulator may be enclosed in the pump. Alternatively, it may be mounted outside the pump. This arrangement enables the pump to be applied to a variety of control duties.

Models

Applicable Machines

Models

Notes

Markl]]

YM-O0101~

Spec. 1

MarkIV

YMUIO01 ~

Spec. 2

Applicable

Machines

Notes

i

II

Revision

Dateof Issue

First edition

February,

1993

First revision

January,1995 ,i

Remarks $5120409E $5120409E~)

K

This Page Intensionally left Blank

Return to Contents

SHOP

Book

code

NO.s5

12042~E®

MANUAL REGULATOR (KR36-9C) TABLE OF CONTENTS

1.

SPECIFICATION 1.1 General View .......................................

1.2 Specification ........................................

2. CONSTRUCTION AND FUNCTION 2.1 Construction ................................ ¯ ....... ? ....................

2.2 Functional Explanation ........ ....

2.3 Adjusting the Regulator ........................

2.4 Fault Finding and Remedies on the Regulator .......

3. DISASSEMBLY AND ASSEMBLY (REGULATOR SECTION) 3.1 Tools ...............................................

3.2 Preparation Before Disassembly .....................

3.3 Disassembly ........................................

3.4 Preparation Before Assembly ........................

3.5 Assembly ...........................................

4. PUMP CONTROLCURVES ...........................

1 1 2 6 9 11 13 14 14 18 18 26

KOBELCO CONSTRUCTION MACHINERY(U.S,A.) INC.

PREFACE The regulator controls the delivery rate (tilting angle) of the variable displacement hydraulic pump according to loaded condition and pilot pressure levels that varies with operating lever strokes. It has four control functions, horsepower control, power shift control, flow control and maximumflow cut control.

Models

Applicable Machines

Notes

Markm

YM-O0101-

Spec.1

MarkIV

YMUIO01~

Spec. 2

Revision

Models

Applicable Machines

Date of Issue

First edition

February,

1993

First revision

January, 1995

No~s

Remarks $5120421E $5120421E~)

K

This Page Intensionally left Blank

PREFACE The hydraulic pumptakes in hydraulic oil, pressurizes it and sends it out to components.

The pumpis a small-capacity gear pump and is utilized as a hydraulic source for the pilot hydraulic piping.

Models

Applicable

MarkN

YNU0201~

MarkIV MarkIV

YQU2001 ~ ~ LQU0101

MarklV

! LLU1201~

MarkIV

YWUIO01-

MarklV

LPUIO01 ~

i MarkIV

YPUI001~

MarkIV

YMUI001~

MarkIV

YCU0301 ~

MarklV

LCUO001 ~

Machines

Models

Notes

Applicable

Machines I

Notes |

.|

I

I

I III

Revision

Date of Issue January,

First edition

I

1995

Remarks I1

$5120451E

II ,|

K

Return to Contents

13 0668E®

KOBELCO SHOP

MANUAL SWING CONTROLVALVE TABLE OF CONTENTS 1.

SPECIFICATION 1.1 General View .....................................

1.2 Specification ......................................

2, CONSTRUCTION AND FUNCTION 2,1 Construction ......................................

2,2 Function .........................................

3. DISASSEMBLY AND ASSEMBLY 3,1 General Precautions ...............................

3.2 Tools .............................................

3.3 Disassembly ......................................

3.4 After Disassembly ................................

3.5 Assembly .........................................

4. MAINTENANCE STANDARDS 4.1 Inspecting Parts ..................................

4.2 Tightening Torque ................................

4,3 Adjusting Relief Valve ............................

5. TROUBLESHOOTING ...............................

1 1 2 4 8 8 9 10 11 15 16 16 17

KOBELCO CONSTRUCTION MACHINERY(U.SJL) INC.

.

PREFACE

I

t i 1

The swing control valve KSC series is direct-connected to the swing motor and controls smoothly the swing body having large inertia force according to external pilot pressure signals. The valve is provided with such functions as control of rotating direction, acceleration/deceleration, anti-cavitation, hold of a stop position and prevention of swingreaction.

I t t

Models

Applicable Machines

Markl]I

YQU-00401~

Mark(If

YM-00101~

MarkIV

YNU0201 ~

MarkIV

YQU2001-

MarkIV

YMUIO01 ~

Notes

Models

Applicable

Machines

Notes

Revision

Date of Issue

First edition

October, 1990

$5130668E

K

First revision

February, 1993

$5130668E~

K

January,

$5130668E~)

Second revision

1995

Remarks

This Page Intentionally left Blank

Return to Contents

KOBELCO SHOP

MANUAL PILOT VALVE (TH40K) TABLE OF CONTENTS

i.

SPECIFICATION I.I General View .....................................

1.2 Specification ......................................

1.3 Performance Characteristics .......................

2. CONSTRUCTION AND FUNCTION 2.1 Construction ...................................

2.2 Function .........................................

3. DISASSEMBLY AND ASSEMBLY 3.1 Tools .............................................

3.2 Reminders on Disassembly and Assembly ..........

3.3 Disassembly ......................................

3.4 Assembly .........................................

4. MAINTENANCE STANDARDS 4.1 Parts Replacement Standard ......................

4.2 Tightening Torque ................................

5. TROUBLESHOOTING ...............................

I 1 i ...

2 3 4 4 4 5 7 7 7

KOBELCO CONSTRUCTION MACHINERY(U.SJL) INC.

i I

PREFACE The pilot valve is a remote control valve of’ pressure reducing type that contains multiple pressure reducing valves in its casing to control secondary pressures.

The output pressure varies in proportion to the tilting of a control lever.

The secondary pilot pressure of the high pressure selector valve becomes an auto accel signal.

Models

Applicable Machines

MarkN

YNU0201-

MarkN

YQU2001~

MarkW

LQUOI01~

Mark N

LLUI201~

MarkIV

YMUIO01-

MarkN

YCU0301~

MarkIV

LCUO001"-.

Mark IV i i ,

YSJO001~

Notes

Models

Applicable Machines

Notes

i i

J i l i ii

Revision First edition

I II

Date of Issue

Remarks

I

January, 1995 i i

SS130715E ii

K

i |

This Page Intensionally left Blank

Return to Contents

KOBELCO SHOP

MANUAL CONTROLVALVE TABLE OF CONTENTS

1. SPECIFICATIONS I.I ExternalViews...................................

1 1.2 Specification ......................................

1 2. CONSTRUCTION AND OPERATION 2.1 Construction ......................................

2 2.2 Operation........................................

6 3. DISASSEMBLY AND REASSEMBLY 3.1 GeneralPrecautions ..............................

22 3.2 Tools.............................................

22 3.3 Disassembly ......................................

22 3.4 Reassembly .......................................

30 4. MAINTENANCE STANDARDS 4.1 Inspection of Components.........................

34 5. TROUBLESHOOTING 5.1 Control Valve ....................................

35 5.2 Relief Valve ......................................

37

KOIBELCO CONSTRUCTION MACHINERY(U.~A.) INC.

*~llk~qlRl.~mn,,~mm

~wlllm~wmtm,,,..mNu,.,,3m~J,,lmll~..~llml~,.ENij

PREFACE This is a composite valve that holds the circuit pressure within safe ranges by means of relief valves, changeover valves, conflux valves and sequence valves, in addition to changing the control directions of the operating part (actuators) as circuits are changed over.

Models MarkIV

Applicable Machines YMUIO01

~otes

Models

Applicable Machines

Notes

Spec.1

Revision First edition

Date of Issue January,

1995

Remarks $5130795E

K

This Page Intensionally left Blank

Models

Applicable Machines

No~s

MarkIll

YQU-O0401-

Spec.1

Mark]l]

LLU-00301~

Spec.2

Mark[]]

YM-00101--

Spec.I

Mark IV

YNU0201~

Spec. 2

MarkIV

YQU2001~

Spec.2

MarkIV

LQU0101--

Spec.I

Mark IV

LLUI201~

MarkIV

YMU1001-

Models

Applicable

Machines

No~s

Spec. I i |

Spec.1 i ¯

I

II

Revision

Date of I~ue

First edition

October, 1990

$5150435E

K

First revision

February, 1993

S5150435£~

K

Second revision

January, 1995

$5150435E~)

K

Remarks

I

This Page Intensionally left Blank

PREFACE The swivel joint is installed in the center part of the upper machinery and continuously maintains the connection of the fluid circuit regardless of the swing angle.

Major parts of this swivel joint consist of body and stem which are able to rotate "~ is~pr/vidII,l~ed.,IIwit~~h p/rt~ for thenumber of fluid circuit onitiiI~IiiJ .

--.p. ’ e,l~aCh

Models

Applicable Machines

Notes

Models

Applicable Machines

Notes

Spec. 1

MarkN

LPUI001-

SI~C. 2

Spec. 1

MarkN

YPUIO01--

SI~. 2

LLU0301 ~

Spec.I

MarklV

YMUI001~

Spec. 2

!Mark[]

LCUO001 -

Spec.1

Mark IV

YCU0301 -

Spec.2

, Mark[]

YCUO001-

Spec. I

MarklV

LCU0001 ~

Spec. 2

MarkIV

YNU0201 ~

Spec.2

MarklV

YQU2001~

Spec. 2

MarklV

LQU0101-

Spec. 2

MarkP¢

LLUI201 ~

8pec.2

MarkIV

YWUI001--

8pec. 2

Mark[]

YPU0301~

MarkIll

YQU0401 ~

MarkHI

’1

,m

Revision

Date of Issue

First edition

October, 1990

SSI60117E

K

First revision

July, 1992

S516OlITE(i)

K

Second revision

January, 1995

S5160117E~)

K

I

Remarks II

This Page Intentionally left Blank

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This Page Intentionally left Blank

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Hydraulic Pump (Dozer)

DISPLACEMENT AND PRESSURE Displacement Rated Revolution rpm Working Pressure Max. flow Max. input horsepower

27.4 cm3/Rev. 2200 250 kgf/cm2(3550 psi) 61.6 liter/min. (16.27 gal/min) 33

SAE INVOLUTE SPLINE DATA No. of teeth Diameterical Pitch Pressure Angle Major Dia. Minor Dia. Over Pin Dia. Pin Dia.

13 16/32 30 deg.

21.80/21.68mm 18.83MM 24.772/24.659mm 3.048mm

MANUFACTURER=SHIMAZU SEISAKU SHO. Part Number = YB10V00003F1

H-1-2

REMOTE CONTROL LINES (DOZER) ITEM DESCRIPTION 1 SOLENOID VALVE 2 PLATE 3 SENSOR PRESS. 4 SWITCH PRESS 5 HOSE 6 HOSE 7 HOSE 8 HOSE 9 HOSE 10 HOSE 11 HOSE 12 HOSE 13 HOSE 14 HOSE 15 HOSE 16 ELBOW 17 TEE 18 TEE 19 TEE 20 CONNECTOR 21 CONNECTOR 22 CONNECTOR 23 ELBOW 24 BALL 25 ELBOW 26 CONNECTOR 27 ELBOW 28 PLUG 29 TEE 30 CONNECTOR 31 CONNECTOR 32 TEE 33 CAPSCREW 34 LOCK WASHER 35 CAPSCREW 36 LOCK WASHER 37 ELBOW 38 ELBOW 39 ELBOW 40 ELBOW 41 HOSE 42 CAPSCREW 43 WASHER 44 CLAMP 45 VALVE PILOT 46 CAPSCREW 47 LOCK WASHER 48 CONNECTOR 49 CONNECTOR

H-2-1

REMOTE CONTROL LINES (DOZER)

H-2-2

KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. Part Number North American English 245 E NORTH AVENUE Printed in U.S.A. CAROL STREAM, IL 60188 U.S.A

S5YMU/YL01E-01 NA 07/02 Bur