SPECIAL PROCEDURES Back2mainTableofContents

Table of contents
Page
10.1 GENERAL ....................................................................................................................................................... 10-2
10.2 RELEASING TRAVEL MOTOR BRAKES ...................................................................................................... 10-2
A. Tools & Equipment Required ...................................................................................................................... 10-2
B. Procedures ................................................................................................................................................... 10-2
10.3 LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS ................................................ 10-6
10.4 RELEASING SWING BRAKE ........................................................................................................................ 10-7
A. Tools & Equipment Required ..................................................................................................................... 10-8
B. Procedures .................................................................................................................................................. 10-8
10.5 BLEEDING THE PILOT SYSTEM ................................................................................................................ 10-10
A. Tools & Equipment Required .................................................................................................................... 10-10
B. Bleeding Procedure ................................................................................................................................... 10-10

WARNING
READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS MANUAL
BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE, ATTACHMENT
OR SYSTEMS. KOBELCO CANNOT ANTICIPATE EVERY POSSIBLE CIRCUMSTANCE THAT MIGHT INVOLVE A
POTENTIAL HAZARD. THE WARNINGS IN THIS PUBLICATION AND ON THE PRODUCT ARE THEREFORE NOT
ALL INCLUSIVE. IF A TOOL, PROCEDURE, WORK METHOD OR OPERATING TECHNIQUE NOT SPECIFICALLY
RECOMMENDED BY KOBELCO IS USED, YOU MUST SATISFY YOURSELF THAT IT IS SAFE FOR YOU AND
OTHERS. YOU SHOULD ALSO ENSURE THAT THE PRODUCT WILL NOT BE DAMAGED OR MADE UNSAFE BY
THE OPERATION, LUBRICATION, MAINTENANCE AND/OR REPAIR PROCEDURES YOU CHOOSE.

10
SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0
10-1
 SPECIAL PROCEDURES
10.1 GENERAL
The SK210LC-6E and the SK250LC-6E machines CAUTION
incorporate automatically applied spring brake sys- USE SAFETY PROTECTION SUCH AS: HARD HAT,
tems in the travel motors and swing motors. These WORKING GLOVES, SAFETY SHOES AND SAFETY
systems will automatically engage the brakes when GLASSES WHEN NEEDED TO PERFORM THIS JOB.
the engine is stopped, making it possible to move
the machine. This section contains the required pro-
cedures for releasing the travel motor brakes, the
swing motor brake and lowering the attachments to
the ground should sudden engine failure be experi-
enced.

WARNING
SK32001002
READ, UNDERSTAND AND FOLLOW ALL SAFETY
PRECAUTIONS AND PROCEDURES FOUND IN THIS
MANUAL BEFORE ATTEMPTING ANY OPERATION,
INSPECTION, MAINTENANCE OR REPAIRS OF THIS
MACHINE, ATTACHMENT OR ANY OR ITS SYSTEMS. CAUTION
AVOID OIL SPILLS. USE CONTAINERS, RAGS, AND/
WARNING OR PAPER TOWELS TO CONTAIN ANY OIL LEAK-
THE PROCEDURES FOUND IN THIS SECTION AGE. DISPOSE ALL WASTE OILS, FLUIDS, LUBRI-
SHOULD BE PERFORMED BY A WELL TRAINED CANTS AND OTHER HAZARDOUS WASTE PROP-
EXPERIENCED SERVICE TECHNICIAN WHO IS FA- ERLY, ACCORDING TO GOVERNMENT REGULA-
MILIAR WITH THE KOBELCO SK290LC-6E & TIONS.
SK250LC-6E EXCAVATORS.

10.2 RELEASING TRAVEL MOTOR BRAKES ATTACHMENT ON

A. Tools & Equipment Required GROUND
1. Four (4) chock blocks
2. One (1) 14 mm Allen type socket wrench for
SK210(LC)-VI, or 12 mm Allen type socket
wrench for SK250(LC)-VI.
3. One (1) 8 mm Allen type socket wrench.
4. Two (2) 6 liter (1.6) Gal capacity drain pans.
5. Two (2) M10-1.5 X 30 mm lifting eyes.
6. Two (2) M12-1.75 X 20 mm lifting eyes. YQ109TracksBloqued

7. Overhead lifting device capable of lifting and CHOCK BLOCKS

holding 45 Kg (100 lbs).
8. Torque wrench 10~16 Kgf-m (72~116 ft-lb)
capacity or better. WARNING
9. Thread sealant (for drain and check/fill plugs), MAKE CERTAIN CHOCK BLOCKS ARE SECURE
and loctite # 515 for cover bolts. AT FRONT AND REAR OF EACH TRACK BEFORE
10. Rubber or soft face mallet. ATTEMPTING TO RELEASE BRAKES. NEVER
STAND IN THE PATH OF THE TRACKS WHEN RE-
B. Procedures
LEASING BRAKES.
1. Place chock blocks at front and rear of each
track to prevent machine from moving when FIGURE 10.1
brakes are released. See Figure 10.1.
2. Lower attachment to ground. See "10.3 Low-
ering Attachment" in this Section for proper

10 procedures.

SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0

10-2
 SPECIAL PROCEDURES
3. Turn key switch “OFF” and remove key. See Fig-
ure 10.2.
4. Remove check/fill plug from each travel motor
using the 14 mm socket head wrench on
SK210LC-6E, and 12 mm socket on SK250LC-
6E. See Figure 10.3.

CAUTION REMOVE KEY

YQ102KeyOff
REDUCTION UNIT MAY BE UNDER PRESSURE. RE-
MOVE PLUG SLOWLY. FIGURE 10.2

5. Place a clean 6 liter (1.6 Gallon) capacity drain FILL / LEVEL

pan under each travel motor drain plug and re- PLUG

move drain plug using the 14 mm socket head

wrench. See Figure 9.4.

NOTE
If the reduction unit drain plug is not at its lowest point
(6:00 o’clock) for draining, just drain as much oil as pos-
sible through the plug orifices, then: DRAIN PLUG
• Remove the reduction unit cover plate mounting bolts,
as indicated in Figure 10.5. Leave a couple of bolts FIGURE 10.3
half way installed on the top side of the cover to hold it
from coming completely out. Remove drain plug

• Remove the two bolts from the bossed areas and in-
stall the two (2) M10-1.5 X 30 mm lifting eyes into each
one of these holes, as shown in the figure below.

6 Liter (1.6 Gal) capacity container

FIGURE 10.4

• Attach the overhead lifting device to the lifting eyes

and remove most of the slack from the chain or cable.
• Use a rubber mallet to strike the edge of the cover
plate gently to help releasing it from the housing, until
oil starts draining.

Remove cover plate

mounting bolts

FIGURE 10.5
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SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0
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 SPECIAL PROCEDURES
6. After all of the gear oil has drained, cover the
drain pans to prevent contamination and move
them to an area away from the machine. CAUTION
7. Remove the bolts holding the Reduction Unit
Protect your hands from pinching areas at all times when
cover and remove the cover. Be careful not to
removing or installing planetary gears.
damage the cover plate seal or its surface lip.

Carrier # 2

Sun Gear # 2
Carrier # 1
Thrust Plate

Sun Gear # 1

FIGURE 10.6

8. Use Fig. 10.6 as reference to identify the
internal parts of the travel reduction unit
assembly.
9. Use the tip of a screw driver and remove the
thrust washer as indicated in Fig. 10.7.
10. Install the M10 eye bolt onto the number one
carrier assembly and use the crane hook on
the eye bolt to pull out the carrier as indicated
in Fig. 10.8, and remove most of the slack
from the cable or chain. Work the carrier by
hand to remove it.

FIGURE 10.7
FIGURE 10.8

10
SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0
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 SPECIAL PROCEDURES
11. Remove the sun gear # 1. See Fig. 10.9.
FIGURE 10.9
If the sun gear can not be removed due to the
loaded condition, remove it together with the
number one carrier. Then remove the sun
gears # 2, and # 1 respectively, as shown in
Fig. 10.10.
Remove Sun Gear # 2 Remove Sun Gear # 1
FIGURE 10.10
12. Make sure the gear coupling for Sun Gear # 1,
and Sun Gear # 2 are properly installed. See
Figure 10.11.
FIGURE 10.11
SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0
10-5
13. Reinstall the number 1 carrier assembly (DO
NOT INSTALL SUN GEAR # 1) into reduction
unit and remove the special eye bolt. Make sure
to use plenty of grease on the thrust plate to
hold it on place during assembling.
14. Install cover plate onto reduction unit housing
and tighten all bolts securely.
15. Install drain plug and refill reduction unit with
drained oil.
16. Install fill/level plug.
17. Repeat steps 4~16 on the opposite travel re-
duction unit to prepare machine for towing.
18. After all repairs are made, reinstall sun gear #
1 on both reduction units in reverse order and
make sure to use fresh gear oil. Refer to Main-
tenance Section, pages 4-10 and 4-11 for proper
oil and capacities.
TORQUE SPECIFICATIONS FOR BOTH MODELS
Apply loctite 515 on cover bolts and torque to:
7.5 kgf•m (54 ft.lbs.)
Use teflon tape on plugs and torque to:
16 kgf•m (116 ft.lbs.)
CAUTION
AVOID OIL SPILLS. USE CONTAINERS, RAGS, AND/
OR PAPER TOWELS TO CONTAIN ANY OIL LEAK-
AGE. DISPOSE ALL WASTE OILS, FLUIDS, LUBRI-
CANTS AND OTHER HAZARDOUS WASTE PROP-
ERLY, ACCORDING TO GOVERNMENT REGULA-
TIONS.
10
 SPECIAL PROCEDURES
10.3 LOWERING ATTACHMENT WHEN SUDDEN EN-
GINE FAILURE OCCURS
Should sudden engine failure occur, follow the instruc-
tions below to place the attachment on the ground.

NOTE
Rotation of the engine with the starter motor is neces-
sary in order to lower the attachment to the ground. If
rotation of the engine is not possible, contact an au-
thorized KOBELCO service technician for service and YQ102EmergShutDown

FIGURE 10.12
assistance.

WARNING
MAKE CERTAIN THE AREA AROUND THE MACHINE
IS CLEAR OF PEOPLE AND OBJECTS BEFORE AT-
TEMPTING THESE PROCEDURES.

1. Locate the engine emergency stop control at the

lower R.H. corner of the seat base and pull control
out. See Figure 10.12.
2. Place the safety lock lever in the “UNLOCKED” YQ102SafetyLeverDown

(Down) position. See Figure 10.13. FIGURE 10.13

3. Sound horn to alert people in the area of machine
movement. BOOM DOWN WHILE ROTATING THE ENGINE.
4. Turn the ignition key to the “START” position to use
YM103Boomdown
starter motor to rotate the engine.

CAUTION
Only operate the Starter Motor in 20 second intervals
and allow 3 ~ 5 minutes between intervals to allow the
starter motor to cool.

5. While engine is rotating, slowly and carefully move

the R.H. control lever forward (boom down) and
lower boom completely to ground. See Figure
10.14.
6. After Boom is completely down, leave the ignition
key in the ON position, operate the arm, bucket FIGURE 10.14
and swing controls to release hydraulic pressure YQ101ReleasePress
in these circuits. Turn ignition key off.
7. Locate hydraulic tank air breather on top of hydrau-
lic tank. Remove cap and depress stem until all
internal hydraulic tank pressure is released. See
Figure 10.15.

WARNING
USE CAUTION WHEN REMOVING OR REPAIRING

10 HYDRAULIC COMPONENTS AS HYDRAULIC PRES-

SURE MAY EXIST OR BE TRAPPED IN CIRCUITS. FIGURE 10.15

SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0

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 SPECIAL PROCEDURES
10.4 RELEASING SWING BRAKE
WARNING
MAKE CERTAIN THAT THE ATTACHMENT IS ON THE
GROUND TO HELP PREVENT SUDDEN ROTATION
OF THE UPPER STRUCTURE BEFORE ATTEMPTING
TO RELEASE THE SWING BRAKE. REFER TO PAGE
10-6 FOR ATTACHMENT LOWERING PROCEDURES.

Kobelco highly recommends the use of a hydraulic hand

pump to release the swing brake manually when the en- Remove hoses, tubes
gines fails to start. Refer the Figure 10.16B to use the and fittings from cover
proper fitting connector on PG port. Remove the hose
and install the proper connector on PG port. Install the
FIGURE 10.16A
hydraulic hand pump and apply hydraulic pressure as
follows: TOP VIEW L SWING MOTOR
B98B99SwingMotorSpecs

SK210LC-6E 29 Kgf/cm2 (413 psi)

PB
SK250LC-6E 26 Kgf/cm2 (370 psi)
DB
B
CAUTION PG
IP

IN HIGHLY CONTAMINATED ENVIRONMENTS

IT IS RECOMMENDED TO REMOVE THE A
WHOLE SWING MOTOR ASSEMBLY, IF A HY-
M
DRAULIC HAND PUMP IS NOT AVAILABLE.
SIDE VIEW PA
REFER TO THE SHOP MANUAL FOR SPECIAL Swing PB PA
2-M12 depth 24
INSTRUCTIONS OR CONTACT YOUR KO- shockless
Lifting cap. 220 Kg (2 bolts)
valve M
BELCO DEALER'S SERVICE DEPARTMENT DB Relief
FOR ASSISTANCE. WHEN THE SWING MO- valve
TOR IS REMOVED, MAKE SURE TO USE CAPS A,B
AND PLUGS ON HOSES, TUBES AND FIT-
TINGS TO PROTECT THE HYDRAULIC SYS-
TEM FROM ANY CONTAMINATION. ALSO, A PG
COVER MUST BE USED TO PROTECT THE
SLEWING GEAR COMPARTMENT. IF THIS AP-
IP
PROACH IS TAKEN, AND THE SLEWING
GEAR GREASE BATH BECOMES CONTAMI-
NATED, MAKE SURE TO FLUSH AND CLEAN
THE SLEWING GEAR COMPARTMENT. RE-
Rotation direction (Viewed from shaft end)
FER TO PAGE 4-11 AND 4-12 FOR PROPER Oil inlet A ....... Clockwise (CW)
GREASE AND COMPONENT CAPACITY. Oil inlet B ....... Counterclockwise (CCW)
Torque
Code Name Size Model
N-m (Kgf-m)
If a hydraulic hand pump is not available, and the A, B Main port 2-PF 3/4
167 (17)
contamination can be controlled easily, then pro- M Make-up port
PF 3/4 SK210LC-6E

PF 1 216 (22) SK250LC-6E

ceed to the next page for specific instructions on
PF 3/8 74 (7.5) SK210LC/SK250LC-6E
a different alternative to release the swing park- DB Drain port
PF 1/2 98 (10) SK330LC-6E

ing brake. PA, PB Gauge port

PF 1/4 36 (3.7)
PG Brake release port

CAUTION L Gear oil level port PT 1/2 65 (6.6)

USE SAFETY PROTECTION SUCH AS: HARD HAT, IP Gear oil level port PT 3/4 98 (10)

WORKING GLOVES, SAFETY SHOES AND SAFETY

GLASSES WHEN NEEDED TO PERFORM THIS JOB.
FIGURE 10.16B 10
SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0
10-7
 SPECIAL PROCEDURES
A. Tools & Equipment Required REMOVE ALL
1. Handtools required for removal of hydraulic tubes, hoses HOSES FROM TOP
and fittings. COVER
2. Plugs and caps for tubes, hoses and fittings.
3. 12 mm Allen type socket head wrench.
4. 5 mm Allen type socket head wrench.
5. Two (2) M12-1.75 X 24 mm Lifting Eye. Remove Swing
6. Overhead lifting device capable of lifting and holding 100 Shockless valves
kg (220 lbs).
7. Plenty of clean, dry shop rags and/or paper towels.
8. 17 mm Allen type socket head wrench.
9. 45 kgf-m (325 ft-lb) torque wrench.
B. Procedures
1. Lower attachment to ground and block them to
avoid sudden movement. Refer to previous
page for proper procedures in lowering the at-
tachment.
FIGURE 10.17
2. Remove all hoses and tubes from the swing
motor top plate and swing shock valves to gain
access to the top plate mountounting bolts. See
Figure 10.17.
INSTALL PROPER
3. Install the proper plugs and caps onto hoses, CAPS AND PLUGS
tubes and fittings to avoid the possibility of con- ON HOSES, TUBES
tamination entering the hydraulic system. See AND FITTINGS TO
HELP PREVENT
Figure 10.18. CONTAMINATION
ENTERING THE
CAUTION SYSTEM

Use only plugs and caps designed to properly seal the

SK23509014
specific hose, tube or fitting they are to be installed on.
FIGURE 10.18
4. Remove two plugs, as indicated in Fig. 10.19, Remove the two plugs
install 2XM12-1.75X24 mm eye bolts, and place and install lifting eyes
(M12-1.75X24 mm)
a reference mark between top cover and hous-
ing.

NOTE
Place a large quantity of clean, dry shop rags around the swing
motor to help catch any overflow of hydraulic oil from the re-
moval of the Top Plate.

5. Carefully loosen the four (4) top plate mounting

bolts with the 17 mm socket head wrench. See
MARK COVER AND HOUSING AND LOOSEN COVER BOLTS
Figure 10.19.
6. Remove two (2) top plate mounting bolts from
corners opposite of each other. FIGURE 10.19
7. Attach overhead lifting device to the lifting eyes
and remove most of the slack from the cable or
chain.
8. Carefully remove the remaining two (2) bolts
from the top mounting plate.
CAREFULLY
REMOVE SWING
NOTE
MOTOR COVER
The top plate will raise from spring pressure as the last two (2)
bolts are removes. Some movement of the upper frame may be
experienced as the spring tension is released.

9. Using the overhead lifting device, carefully lift

the swing motor top cover with swing shock
10 valve assembly and away from the swing mo-
tor, see Fig. 10.20. FIGURE 10.20

SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0

10-8
 SPECIAL PROCEDURES
13. After the machine upper structure is positioned for
CAUTION towing, remove cover again and reinstall the swing
brake springs, see Fig. 10.23.
Do not allow any dirt or debris to enter the swing motor
or settle on the top plate.
FIGURE 10.23
10. Carefully remove all brake springs and place
in a container filled with fresh, clean hydraulic
oil. Then, seal the container to prevent contami-
nation. See Figure 10.20.

FIGURE 10.20

14. Repeat steps 11~13 to lock the upper frame into po-
sition for proper transportation. Make sure to use
grease to hold the distributor plate on top cover be-
fore installing, see Fig. 10.24.

DOWEL PINS
11. Align the holes of the distributor plate in the
swing motor until they are located toward the
front and back of the swing motor housing.
See Figure 10.21. Use grease to hold the
distributor plate on the top cover, aligned with
dowel pins, before installing. GREASE

DOWEL PINS

FIGURE 10.24

GREASE

FIGURE 10.21
12.Carefully place the top plate over the swing
motor and align the dowel pins of the top plate CAUTION
with the holes in the distributor plate. See Fig-
Make certain the top plate dowel pins and the distributor plate
ure 10.22. Slowly lower the top plate into po-
holes mesh together.
sition on the swing motor and install, by hand,
the four (4) top plate mounting bolts.
CAUTION
AVOID OIL SPILLS. USE CONTAINERS, RAGS, AND/
OR PAPER TOWELS TO CONTAIN ANY OIL LEAK-
AGE. DISPOSE ALL WASTE OILS, FLUIDS, LUBRI-
FIGURE 10.22 CANTS AND OTHER HAZARDOUS WASTE PROP-
ERLY, ACCORDING TO GOVERNMENT REGULA-
TIONS. 10
SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0
10-9
 SPECIAL PROCEDURES
10.5 BLEEDING THE PILOT SYSTEM 4. Make sure the throttle control is positioned in low
idle and sound horn before starting.
WARNING YQ102SoundHorn

AVOID OIL SPILLS. USE CONTAINERS, RAGS, AND/

OR ABSORBENT TOWELS TO CONTAIN ANY OIL
LEAKAGE. DISPOSE ALL WASTE OILS, FLUIDS,
LUBRICANTS AND OTHER HAZARDOUS WASTES YQ109Throttlenlowidle

PROPERLY. 5. Start the engine and let run at low

Whenever the hydraulic system is opened for repairs, pi-
lot line change, etc., it is highly recommend that you bleed
the pilot system to prevent erratic or delayed operation of
the machine normal functions.
A. Tools & Equipment Required
1. A set of 1/2” drive metric sockets and wrenches in-
cluding sizes 13 ~ 22 mm.
2. A 1/2” drive ratchet.
3. Sufficient rags and paper towels.
B. Bleeding Procedure
1. Make sure the machine to firm level ground and the
attachments are positioned on the ground in the oil
level check position as indicated in the figure.
idle for about 10 minutes.
WARNING
Use a rag or paper towels on the pilot connec-
tions to protect yourself from spraying during
bleeding.
6. Use the figure below as reference. With the engine
running at low idle, loosen the pilot lines from the
top side of the spools in the Control Valve, one at
the time, and operate the function for the spool be-
ing bled to bleed the air out of the pilot system. Make
sure to bleed each one of the spools indicated in the
figure. Tighten hose connections to 50 N-m (37 Ft-
lbs) after bleeding each line.

PCb
Pis PAb

YQ104oilLevelcheck PAc
YQ101ReleasePress PAr

2. Release hydraulic
tank pressure. PAa

PB1

PAL
PAs

WARNING
Use safety protection such as:
hard hat, working gloves, safety 7. Make sure hydraulic oil level is within specifications,
and clean up any oil spilled. Check all connections,
shoes and safety glasses when
repair any leakage and reinstall control valve top
needed to perform this job. cover.

3. Use a 19 mm wrench and remove the main control

valve cover.
USE CLEAN OIL

UPPER LIMIT
Remove cover
PROPER LEVEL

10 LOW (ADD OIL)

YQ110Addhydoil

SK210LC/SK250LC–6E Dynamic Acera OM, 11/02 Rev. 0

10-10