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    S5YY0007E GB

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    Oscar Losada

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    © All Rights Reserved
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    HYDRAULIC EXCAVATOR SK115SR-1es SHOP MANUAL model SK135SRL-05 INDEX 1 |SPECIFICATION SECTION MAINTENANCE SECTION SYSTEM SECTION DISASSEMBLY SECTION TROUBLESHOOTING ENGINE SECTION INSTALLATION PROCEDURES. FOR OPTIONAL ATTACHMENT NIO;Q|HR]O }p g 5 g ir A 4 Pa 5 pines onc KOBELCO Book code No. SSYYO007E SAFETY Peed ‘The proper and safe lubrication and maintenance for this machine, recommended by KOBELCO are outlined in the OPERATION & MAINTENANCE GUIDE for this machine. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE GUIDE before performing any lubrication or maintenance. ‘The serviceman or mechanic may be unfamiliar with many of the systems on this machine, This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component. Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed. 1. Read and understand all Warning plates and decals on the machine before operating, lubricating or repairing this product, 2, Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when Pounding on any part of the machine or its attachments with a hammer or sledge. Use welders gloves, hood / goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery. 3, Disconnect battery and discharge any capacitors before starting to work on machine. Hang “Do Not Operate” tag in the Operator's Cab. 4, Ifpossible, make all repairs with the machine parked on a level, hard surface. Block machine 0 it does not roll while working on or under machine, 5. Do not work on any machine that is eupported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any disassembly. Do not operate this machine unless you have read and understand the instructions in the OPERATORS MANUAL. Improper machine operation is dangerous and could result in injury or death. 6, Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. 7. Lower the bucket, blade, ripper or other attachment to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, blade, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly. 8. Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform’ safe repair operations. 9, To avoid back injury, use a hoist when lifting components which weigh 23 kg (60 Ibs) or more. Make sure all chains, hooks, slings, etc., are in good condition and are in the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation, 10. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and components. 11. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely. 12, Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure, ‘The danger is even greater if the machine has just been stopped because fluids can be hot. 13. 14. 16. 16. uv. 18. 19. Always use toola that are in good condition ‘and be sure you understand how to use them before performing any service work. Reinstall_all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledge- able in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. Always disconnect battery during welding operations to protect sensitive electric equipment. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. Loose or damaged fuel, Iubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high-pressure lines or install ones, which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pinhole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pinhole leaks. ‘Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other pari during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly. 20. Do not operate a machine if any rotating part ia damaged or contacts any other part during operation. Any high speed-rotating component ‘that has been damaged or altered should be checked for balance before reusing. 21. On track-type machines, be careful when servicing or separating tracks. Chips can fly when removing or installing a track pin. Wear safety glasses and long sleeve shirts. Track can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks are disengaged from the sprockets. Block the machine to prevent it from moving. 22, Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this, dust is inhaled, it can be hazardous to your health. Components in KOBELCO products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch. plates and some gaskets. The asbestos used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust, which contains asbestos, is not generated. If dust, which may contain asbestos, is present, there are several common sense guidelines that should be followed. a, Never use compressed air for cleaning. b. Avoid brushing or grinding of asbestos containing materials. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. d. Use exhaust ventilation on permanent machining jobs. e. Wear an approved respirator if there is no other way to control the dust. £ Comply with applicable rules and regulations for the work place. g. Follow environmental rules and regulations for disposal of asbestos. h. Avoid areas where asbestos particles may be in the air. SKIISSR-AES SK135SR(L0)-1Es Index of Shop Manual SK135SRL-1ES Book Code No. Index on Distribution Year—Month No ‘SSYYO107E 3 2004.09 OUTLINE 0 ‘S5YYO207E 2004-09 SPECIFICATION ) ‘S5YYO307E i 7 "2004-09 pag = ATTACHMENT DIMENSION ) SBYYI107E 2004-09 ed ‘SSYV1207E ‘STANDARD MAINTENANCE 2004-09 ‘TIME SCHEDULE SSYY1307E MAINTENANCE STANDARD AND 2004-09, ‘TEST PROCEDURE ‘SSYY2107E MECHATRO CONTROL 2004.09 SYSTEM ‘S5YY2207E 200109 HYDRAULIC SYSTEM ‘SSYY2907E a 2004-09, ELECTRICAL SYSTEM ‘SSYY2407E : "2004-09 COMPONENTS SYSTEM SMe AIR-CONDITIONER SYSTEM SSYYS107E 7 DISASSEMBLING AND 2004-09 4 ASSEMBLING ‘SSYY3207E FY 2004.09 HB ATTACHMENT ‘SSYY307E 3 200809 3 UPPER STRUCTURE fr ‘S8YYS407E 5 E P B0OLoe 4 ‘TRAVEL SYSTEM ‘SBYY4107E g r 2004-09 2 MECHATRO CONTROL 6 ‘S8YY4207E 8 P 00408 g HYDRAULIC ‘S8YY4307E 3 F 300409 FA ELECTRICAL ‘S5YVa407E Fs . ; aa 2004-09 Fs ENGINE SSYY5107E ry ‘SSYY6307E MOUNTING THE BREAKER 2004-09 AND NIBBLER & BREAKER Wea Yio4-ba00|~ APPLICABLE MACHINES KOBELCO ess ¥YO1 ove scusen. SHOP MANUAL skisssRucs ED rs OUTLINE a TABLE OF CONTENTS, 1, GENERAL PRECAUTIONS FOR MAKING REPAIRS peered 2. INTERNATIONAL UNIT CONVERSION SYSTEM eats KOBELCO CONSTRUCTION MACHINERY CO.,LTD. Applicable Machines SK115SR-4ES SK135SR-1ES SK135SRL-1ES YV04-03001~ YY04-06001~ SK135SRLC-1Es8 YH04-03001~ LKO4- Revision First edition Date of Iesue September, 2004 1. GENERAL PRECAUTIONS FOR MAKING REPAIRS an) 1.1 PREPARATION BEFORE Ea DISASSEMBLING (QD) Knowledge of operating procedure Read Operator's Manual carefully to understand the operating procedure. (2) Cleaning machines Clean machines of soil, mud, and dust before carrying into the repair shop. Carrying a soiled machine into the repair shop, causes making less efficient work and damage of parts, and interferes with rust prevention and dust protection while reassembling, (8) Inspecting machines Confirm the disassembling section before starting work, determine the disassembly procedure taking the conditions in work shop into account, and request to procure necessary parts in advance, () Recording Record the following items to keep contact and prevent malfunction from recurring. 1) Inspecting date, place 2) Model name, Applicable machine No., Records on hour meter 3) Trouble condition, place, cause 4) Visible oil leakage, water leakage and damage 5) Clogging of filters, etc., oil level, oil quality, oil contamination and looseness which can be inspected, 6) Examine the problems on the basis of operation rate with the last inspection date and records on hour meter. (®) Arrangement and cleaning in repair shop 1) Tools required for repair work. 2) Specify places to put the disassembled parts on in advance. 8) Prepare oil pans for leaking oil, ete. 1.2 SAFETY WHEN Sune ASSEMBLING (1) Safety 1) Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves, 2) Suspend warning tag “Don't operate” from lever, and begin preliminaries before getting down to work. 3) Before starting inspection and maintenance which contain the danger of being caught in machine, stop the engine. 4) Confirm the position of first-aid box and fire extinguisher, and also where to make contact: for emergency measure and ambulance to prepare for accidents and fire. 8) Choose a hard, flat and safe place, and put attachment on the ground without fail. 6) Use crane, etc. to remove parts of heavy weight (20kg [44 Ibs] or more). 7) Use proper tools, and change or repair defective tools. 8) Machine and attachment required to work in the lifting condition should be supported with supports or blocks securely. = b[aI ASSEMBLING HYDRAULIC EQUIPMENT (Removing hydraulic equipment asey 1) Before removing pipes, elease the pressure of hhydraulie oil tank, or open the cover on the return side to tank, and take out the filter. 2) Put the cil in the removed pipes in reservoir taking care it is not spilled on the ground. 3) Pipes with plugs or caps to prevent oil leaking, entry of dust, ete 4) Clean the outside surface of equipment, etc before disassembling, and drain hydraulic oil and gear oil before putting them on. working bench. @ Disassembling hydraulic equipment 1) Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsiblity on the manufacture’s side, disassembly, assembly and conversion without permission are strictly prohibited, 2) fit is unavoidably necessary to disassemble and convert, it should be carried out by experts or personnel authorized through service training. 3) Make match mark on parte for xeassembling. 4) Before disassembling, read Disassembling Instruction upplied with equipment in advance, and determine if the disassembly and assembly aro permitted o: not 5) For parte which are required to use jig and tools, don't fail to use the specified jig and tools. 6) For parts which can not be removed in the specified produre, never force removzl. First check for the cause. 1.8 DISASSEMBLING AND 8) @ Q 2) 3) a » 2) 3) 4 5) 6) 8) 9) © D 2) ‘The removed parts should be put in order and tagged so as to install on proper places without confusion. For common parts, pay attention to the quantity and places, Inspecting parts Check that the disassembled parts are free from adherence, interference and non- uniform working face. Measure the wear of parts and clearance, and record the measured values. If an abnormality is detected, repair or replace the parts. Reassembling hydraulic equipment Before cleaning, turn the fun on or open doors to ventilate air. Before assembly, clean parts roughly first, and then completely. Remove with oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. Replace the removed O ring, back-up rings and oil seal with new ones, and apply grease oil on them before assembling Removes stain and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them. Before assembling, remove rust preventives on new parts, Use special tools to fit bearings, bushing and oil seal Assemble parts matching to the marks. After completion, check that there is no omission of parts. Installing hydraulic equipment Confirm hydraulic oil and lubrication oil. Air release is required in the following cases ; Change of hydraulic oil Replacement of parts on suction pipe side Removing and attching hydraulic pump Removing and attching swing motor Removing and attching travel motor ‘Removing and attching hydraulic cylinder mo peee If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. 8) For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is oozed out. After completion of air bleed, tighten plug securely. 4) For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed. AL Por cylinder, don’ t move it to the stroke end at beginning. 5) Air in pilot circuit can be bled out by only operating digging, swing and traveling motions thoroughly. 6) Check hydraulic oil level. Move attachments to hydraulic oil check position, and check hydraulic oil level of tank. Refill oil if the oil level is lower than the minimum level, How to check oil level of hydraulic oll tank (iene LEVEL GAUG: oN = 1.4 ELECTRICAL EQUIPMENT (@) The disassembly of electrical equipment is not allowed. (2) Handle equipment with care so as not to drop it or bump it. (8) Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire, (4) Check that connector is connected and locked completely. (5) Switch key off connecting connector (©) Switch key off before touching terminals of starter and alternator. (1) Remove battery grounding terminal before beginning work close to battery and battory relay with tools, (8) Wash machine with care so as not to splash water on electrical equipment and connector, before removing and (9) When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting. AL Battery electrolyte is dangerous. ‘The battery electrolyte is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes, skin and clothes. When the electrolyte has adhered on them, take an emergency measure immediately and see a doctor for medical advice ¢ When it has adhered on skin Wash with soap and water When it has got in eyes Wash in water for 10 minutes or ore immediately. o When it has spilled out in large quantity Use sodium neutralize, water o When it was swallowed ; Drink milk or water o When it has adhered on clothes; Wash it immediately. a 4.5 HYDRAULIC PARTS: 1) Oring © Check that O ring is free from flaw and has elasticity before fitting. © Even if the size of O ring is equal, the ‘usage differs, for example in dynamic and static sections, the rubber hardness also differs according to the pressure force, and also the quality differs depending on the materials to be seated. So, choose proper O ring. @ Fit O ring co as to be free from distortion and bend. © Floating seal should be put in pairs 2) Flexible hose (F hose) © Even if the connector and length of hhose are the came, the parts differ according to the withstanding pressure. Use proper parts. bicarbonate to or wash away with Tighten it to the specified torque, and check that it is free from distortion, over tension, interference, and oil leakage. 4.6 WELD REPAIR (2) The weld repair should be carried out by authorized personnel in the specified procedure after disconnecting the grounding cable of battery. If the grounding cable is not disconnected, the electrical equipment may be damaged (2) Remove parts which may cause flame due to the entry of spark beforehand. (8) Repair attachments which are damaged, giving particular attention to the plated section of piston rod to protect it from sparks, and don't fail to cover the section with fire clothes, 1.7 ENVIRONMENTAL ISSUES (Q) Engine should be started and operated in the place where air can be sufficiently ventilated, (2) Industrial waste disposal The following parts follows the regulation, Waste oil, waste container Battery (B) Asbestos parts Breathing dust that may be generated when handling components containing asbestos fibors raises danger of getting lung cancer. Don't raise dust by compressed air and breath it Parts to be handled with care : Brake parts, gasket, etc. (@ Precautions for handling hydraulic oil Hydraulic oil may cause inflammation of eyes. Wear goggles to protect eyes on handling it © When it has got in eyes ; Wash eyes with water until the stimulus is gone. © When breathed dust ; Immediately 900 a doctor for medical advice. © When it has adhered on skin ; Wash with soap and water. (6) Others For spare parts, grease KOBELCO genuine ones. and oil, use 2. INTERNATIONAL UNIT CONVERSION SYSTEM Introduction Although this manual uses the JIS unit system. If you need SI unit, refer to following international system of units. Given hereinunder are an excerpt of the units that are related to this manual : 1. Etymology of SI Units French : Le Systéme International d’ Unités English: International System of Units 2, Construction of SI Unit System (4) Derived Units bearing Peculiar Designations Table 2-4 QUANTITIES | DESIGNATION. Frequency [Herta SIGN | DERIVED UNIT Work, Quantity of heat Motive power, Table 26 (Basie Units Table 2-1 QUANTITIES | DESIGNATION [sign Length [Meter m Mass [Kilogram kg ‘Time 'Second 5 Current Ampere A ‘Thermodynamic [Kelvin K temperature Gram molecule {Mol mol Luminous intensity |Candela cd (2) Supplementary Units Table 2-2 QUANTITIES | DESIGNATION [sien Plane angle [Radian rad Solid angle \Steradian sx E Basic units co oa [Table 2-1 Quantity of. [Supplement- ] [Derived units of electricity _ — face r stants HHorr nits | rfoescwnie Potential Volt lal paae unit ‘Table 2-2 ‘Table 2-8 Voltage, | awiay system Electromotive Derived |Derived units force | eee [units \bearing peculiar Quantity of [Farad eesinatons siatic Table 2-4 electricity : Capacitance | Prefixes of SI Electric {Ohm (auth power of 10, where nis anintgral resistance [Celcius degree| lor degree () Prefixes of SI Table 25 PREF POWER, cy 10° 10° 10 10 10" 10 10" 1078 107" 1077 © Unit Conversion Table (8) Derived Units of Basic Units Table 2-6 Table 2-3 QUANTITIES] JIS ‘SI___| REMARKS “QUANTITIES DESIGNATION [sign Mass Ike Ike ‘Area [Square meter mi Foree lket 10N 9.807N Volume |Cubie meter m? Torque ligtm — |10Nem | 9.807Nem Velocity IMeter per second mis Pressure —{kgflem* |0.1MPa_| 0.098MPa. Acceleration [Meter per second / second | mis* Motive power [PS lo.7355kW Density [Kilogram per cubic meter kg/m? Revolution Irpm min“! __| r/min _ #1 %1 Unite that are allowed to use KOBELCO 0 Y020e SKisssnan SHOP MANUAL Sk135SRL"1:3 Cornel SPECIFICATION ae TABLE OF CONTENTS 1. NAME OF COMPONENTS 1 2. GENERAL DIMENSION wr--srensmennnnninnnnnnnanns 2 3, WEIGHT OF COMPONEI ae 3 4, TRANSPORTATION DIMENSION AND WEIGHT ~~ “4 5. SPECIFICATIONS AND PERFORMANCE «esse 2 6. TYPE OF CRAWLER “4 a UYPE OF BUCK Ti eee eee eee eng 8 COMBINATIONS OF ATTACHMENT +--+ Ww 9, ENGINE SPECIBICATION ss -eessnnnnnnnnnnennnnees 18, KOBELCO CONSTRUCTION MACHINERY CO.,LTD. Applicable Machines SK115SR-1ES YV04-03001~ SK135SR-1ES YY04-06001~ SK135SRLC-1Es YH04-03001~ SK135SRL-1es LKO4- al Revision Date of Issue Remarks First edition | September, 2004 | SsY¥o207B or 4. NAME OF COMPONENTS \cKET CYLINDER, BATTERIES HYDRAULIC OIL TANK ‘TRACK SHOE ASSENBLY. (600 mm STANDARD) suzy LOWER ROLLER (6 EACH SIDE) ENN ENGINE UPPER ROLLER (1 EACH SIDE} ‘COUNTERWEIGHT ENGINE AIR CLEANER ENGINE RADIATOR ENGINE COOLANT RESERVOIR ‘TRAVEL MOTOR 2. GENERAL DIMENSION 2.1 SKIGSSR MOLE: 4.6m (15' 1”) Boom+2.45m (8” ) Arm+0.5m* (0.85cu-yd) Bucket+800mm (23.6") Shoe 2.4400 (7-11 { 910mm (3°) 2.740mn (70°) ml ara 488mm ( 2.810mm (9-3) pana 2 [io = I 3.570mm (11-8) (e00mm (23.6 B.7é0ram (172-S}LO 2.580 (826°) 7,360mm(24"-2) “744omm (24-5 FCC “Marked dimensions do not include height of shoe lug. 2.2 BKISSSALIES 4.6m (15' 1") Boom+2.45m (8°) Arm+0.Sm* (0.650u-yd) Bucket+700mm (28°) Shoe 1425mm_,, 2,440 (7-11 bes) | 2,940mn (9°-8 ‘abSmm 23.5") x = =F) = puma) siboaniiPs Ten) tee 5 “Matted mensions not etude hight shoe ug 2.3 BRTSSREg 4,26m (14°) Boom+2.2m (73°) Arm+0.45m* (0.59cu.yd) Bucket+600mm (23.6") Shoe 988mm 73 2,590mm (810" 6,880mm (22'-7" “Marked dimensions do not include height of shos lug 2 8. WEIGHT OF COMPONENTS Unit : kg (Ibs) al Modell sxissRes ake, SKISSRES Machine complete 13,700(30,200) | 13,900(30,640) | 17,900(26,230) [15,700(34,610)] 1. Upper frame assy (including the following :) 7,830(16,160) - 6,080(18,400) 4.1 Counterweight 3,490(7,690) - 2,340(5,160) Counterweight (Add-on) 600(1,320) - - 12 Cab 210(460) - - 13 Engine 5 369(810) - even) ff 1.4 Hydraulic oll tank 3% 91(200) - + 1.5 Fueltank 53(116) - - 1.6 Slewing motor (including reduction unit) 110(240) - + 1.7 Control vaive 122(270) - 114(251) 1.8 Boom cylinder 3 107(235)X2 - 84(295)x2 4.9 Pin (pcs. for mounting boom) 37(82) - - 1.10 Pump 3% 95(210) + - 1.11 Radiator # 77(170) = 65(143) 2. Lower frame assy (including the following :) 4,450(8,810) 4,850(10,250) | 4,140(8,130) [6,750(14,880)) 2.41 Slewing bearing 149(830) a a 2.2 Travel motor (including reduction unit) 144(820)X2 - - 2.3 Upper roller 8(18)x2 a(t8)x4 (18) x2 2.4 Lower roller 27(60)X12 27(60)X14 27(80)X12 2.5 Frontidler 70(150)x2 - - 2.8 Track tension adjuster 57(125)X2 - - 2.7 Sprocket 36(79)X2 - + 2.8 Swivel joint 30(66) + - 2.9 Track link with 700mm (28in) shoes assy Track link with 600mm (24in) shoes assy Track link with 500mm (20in) shoes assy 870(1,920) x2} 730(1,610) XI 1,340 (2,950))x2 915(2,020) X2| 760(1,670)X2 680(1,500)X2 2.9.1 Track link assy 290(640)X2 300(680)2 270(590)X2 [485(1,040))2 2.10 Dozer blade (OPT) 470(1,040) - + 2.11 Dozer blade cylinder (OPT) 57(125)X2 = + 3. Attachment 1,920(4,280) - 1,680(8,700) 3.1 Bucket assy 380(640) - 340(750) 3.2 Arm assy (including the following :) 580(1,280) - 480(1,080) 321 Am 374(820) - 300(660) 3.2.2 ° Bucket cylinder % 90(198) - 87(190) 3.23 — Idler link 12(26) x2 - - 3.2.4 Bucket link 43(95) - 35(77) 3.2.5 — Attachement pin 36(79) - 24(52) 3.3 Boom assy (Including the following :) 1940(2,070) + 850(1,870) 3.3.1 Boom 740(1,630) - 680(1,500) 3.3.2 Atm cylinder 3% 149(830) - 128(280) 3.3.3 Pin (Mounting arm + Mounting arm cylinder) 29(64) = 27(59) 4. Lubricant and water (including the following :) 310(680) = = 44 Hydraulic oil 138(804) - - 42 Engine oll 11124) - - 4.3 Fuel + water 139(310) + 18(40) NOTE: Numerical values marked # nda the dry weigt 8 4. TRANSPORTATION DIMENSION AND WEIGHT (SK135SRLc}1es BKTS5SALAE: Model] e re Sk135SR4Es sxrassricrs | @ OVERALL DIMENSIONS OF A STD COMPLETE MACHINE ON A TRAILER SK195SRL1Es, ‘Shoe & Width _mmitsin) 600mm (24”) 2,590 (8' 6") Weight kg(los) 18,700 (80,200) 13,900 (30,600) [800mm (32") 2,790 (8 2") 16,000 (35,300) * LosPES. “LSPEC, @ OVERALL DIMENSION: IS OF WITHOUT ARM AND BUCKET Type] A: Shoe wih] C:Cengin | H=Hagat |W: Wid Weight Combination nm (fn om (f-in) | __rom (fin) cg (ibs) [STD] 600(24") | 6,510 (21 4") | 2,740(8 12°) [12,720 (28,000) Met sBucket [EC] e00@e") | ess0(er7) | 2.0400 8) [12,920 (28,500) ic 800 (32°) _| 6,620 (21 9°) 1 t 14,920 (32,900) “"LSPEC, @ OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET Type] A: Shoe width] L:Length | H:Aeight ) W:Width Weight Combination mm (jin) | nm (fin) | mm fin) | _mm (ftin kg (lbs) Wt [STD| _600(247) | 8570(11 97) | 2,740 (8 127) | 2,590 (8 6°) [11,780 (26,000) ithout : a “ — Irmend Bucker [EC _[ 60024") [3,740 (12"s") | 2,940 (676) | 2.840 (84) [17,880 (26,400) L 800 (32) _| 3,800 (12°6") | 1 t [13,980 (80,800) *LSPEC. @ OVERALL DIMENSIONS OF BOOM re Tyee| 4.6m (15ft-1in) Boom Length> WL YES | (eeo) 0.43 1,100 | 1,000 400, 0870.79] ey | wey | we | 5 | | ves | com 050 1.480 | 400 ozooea)| C5 | — | iss | 5. | wo | ves | on SKISSRAES Hoe bucket coy | 8 Outer wat mm (0) [Numero] W WO |APEIADEY] Weg mmteary [mcuya)| WEG [WmasGe| tooth [sce cuter| shovel | ko (oe) orroay| @i | — | of) | 2 | wo | ves | a oases | gi | | a sw | ves | a, anos) 2% |g, | Ls | wes | ae 027 | 800 | 700 320 9870-48) | oss | @7) | ea | * | * | YES | com STD 0.39 950, 850 | 350 0.45(0.59) | (0.51) (oe (29°) 4 u Mee (770) 035 | 1,000 | 900 370 0510-67) | (os) | o's’) | ert) | & | W I YES | 0) 16 8. COMBINATIONS OF ATTACHMENT ‘SKISSSAUC-1ES | [SKISSSAL1ES) Hoe bucket oases |” Sruck Applicable Am miearye) | meleurys)| 2im@itjam | 245m@)Am | _298m('8)Am 0.24031) | G59) ° ° ° 0.31(0.41) nS O° | ° ° 0.38(0.50) os ° ° | ° | 0.45(0.59) faa ° ° a STD | 038 a 0.500.685) | (0.50) 2 | ° a 0.87(0.78) | ina ° A x 0,70(0.29 | (Gee) A x x Hoe bucket oan ‘Struck ‘Applicable Arm ] meena | mecuya)| Tame Am eam (7S )Am | atm IOV Am 0.17(0.22) (ox ° ° ° 0.28(0.20) | 95) | ° | © ° 0.30(0.39) nes fe} ° ° 0:37(0.48) | 34) ° ° ° STD 0.39 0.45(0.59) | (0.51) ° ° i 0510.67) | fea | ° A x | NOTE © Standard combination © General operation : Excavation or loading of sand, gravel, and clay 4. Light operation : Mainly loading or loose gravel (e.9., cultivation or loading of sand or gravel) X Prohibited combination : There are problems from the view points of strength and stability, A © Use the attachments recommended by KOBELCO. Reinforcement of arm allows to use it as ribbler and breaker. ‘The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibility © When bucket marked by 4 has been attached or nibbler has been attached on long arm, the specified stability may not be obtained. So add weight 600kg (1,920 Ibs) in add-on type as: required 7 ee If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and bucket may occur. 9. 9.1. SPECIFICATIONS ENGINE SPECIFICATION Model SK135SRL0)-1E8, SK135SRL-1Es| SK115SR-1Es Engine model ISUZU BB—4BG1T ISUZU BB—4BG1T Diesel, 4-cycle water-cooled, in- Diesel, 4-cycle water- ‘Type Tine, direct injection, turbo cooled, in-line, direct charger injection, turbo charger Bunmber of pylinder— mm (in)| 4X 1054.18) 126(4.92) - Total displacement ee (eu"in) 4,820(264) - Compression ratio 18.0 - Rated output kW (PS) at rpm 62.5 (85) at 2,050 58.8 (80) at 2,050 ee kgf Qbfeft) at rpm 82.4 (235) at 1,600 30.0 (217) at 1,600 High idling rpm 2,310+20 - Low idling rpm | 1,000+ 20 - Injection valve ket/em*(psi)| 185(2,630) - gpenang preeure etlom(p , rmostat action ; Starubull open CR) 82 / 95(180 / 203) - Firing order 1-8-4-2 - prea are aa kgflem (psi) at rpm 81(440) at 200 - Lubrication oil pressure —_— — Fuel injection timing 9° +1° before top dead point = Valve clearance | Open Close Valve clearance Intake valve | PERRO | Meeting” | A agra” 0.4mm (0.016") | 57° before bottom | 15° after top Exhaust valve | in cold condition dead point dead point Starter capacity Vxkw 24X45 - Gigperator capacity vxA 24X50 24x80 (0 @1.7in) suction type | 2650 (21.7in) suction type Cooling fan drive method 8 fans, V-belt drive, pulley | 6 fans, V-belt drive, pulley ratio Crank / Fan= 0.89 ratio Crank / Fan= 0.98 Engine oll quantity «i (Oneae onbt e(gal)] Max. 19(6.4), Min. 112.9) = Dry weight kg (lbs) 368(811) _ Fuel consumption yeWeh (giPS-h)| 22424 7% (164::7%) = Allowable inclination Front / Rear and Right / Left : 35° Dimension (.XWXE) = 900% 690%665 860% 670% 850 84.4in X27 in X 34.1in) (33,91 X 26. 4in X 38.5in) Rotating direction 18 Counterelockwise seeing from flywheel side [SKT35SR-1Es] [SK1S5SAL0-1e5] [SKTSSSRL-1E5| 9.2 ENGINE CHARACTERISTIC CURVE (ISUZU 8 Condition to be measured : With fan and generator Without muffler and air cleaner -4BG1T) | I | 319:520,0Nim fAbouttéoomin” |] (N™) xem) T [ors LOkgfsm /Aboutt600min~*)[] 980733) t | LTT 10 SHAFT TORQUE. (31) SHAFT ! ToRQUE - | (29) es) caw) | CET a0 al —— en ooo |.BkKW/2050min 4 ) | - I (80)-7 60 I SHAFT 605 output ‘ol ' | 40) 1 20) | 5 | (204 1 2350-20min k Ly (e/kWeh) (giPS+b) | ] 2507 (010) L y | sco L190) FUEL 260-790) consumeTion 224.0 7%IRWch [2OSOMIn Lt yg p27 rare | | (150) SFC Lok ++ 220-1130) | | | FUEL CONSUMPTION RATE ! co 200 1000) 1500 2000 2500 ENGINE SPEED (min™') Fuel consumption volume Fuel consumption volume = Fuel consumption rate yi Load factor (a) = Euelconsumption rate pg xt pad factor (@) (0.885 1000 or 885% 1000 = 224ghw-h 69 skwX @ = —164/PS-h_yespsx @ 0.835 1000 0.886% 1000 =16.7 ¢ -thh =16.7@ +¢/h a : Standard load factor (0.70~0.80) Fuel consumption in regular operation oad factor : 0.70~0.80) 1.7~18.40hh 19 SKTTESRAES 9.3 ENGINE CHARACTERISTIC CURVE (ISUZU _BB—48G1T) Condition to be measured : With fan and generator Without muffler and air cleaner ‘300—20.0Nem /AboutT60Omin* |) (Nm) (sef-m) (30.62,0kgf.m /About1600min™) wel (33) on (81) SHAFT peel oe es { 9) @s) aw) 270 80) , Len (200). | 58-757 kW /2050min 7 {| (79.8-+2.5PS/2050min™) | Leal | TINT T (07 6 [SHAFT OUTPUT | _ shart 0) a oureur wll 404 Cot 20 iF i 1 Es I oo T | [ aaevonn I | Cr TT T L LI I LTT I (g/kW-h) (g/PS-h) o> T 2807. 10 B45 Te OBO oo FUEL y 260: CONSUMPTION — jt + Litt} far 1 ae joo T T | 2207+ (130) 1 ij 2002 1000 1500 2000 2500 ENGINE SPEED (min™) Fuel consumption volume Fuel consumption volume Fuel consumption rate_ x ps xLoad factor («) = Fuclconsumption rate jew%Lond factor (a) = 0.835% 1000 a 0.835% 1000 = 22dghw iby 58 Tew x @ = _164gIPS*h_ x o9 apsx a 0.835 x 1000 835 X 1000 =15.7 a *€/b =15.7 @ ehh @ :Standard load factor (0.70~0.80) Fuel consumption in regular operation (load factor : 0.70~0.80) 11,0~12.6@/b KOBELCO ss¥ Y¥ OSo7e sistssenn SHOP MANUAL Sk135SRL-1:3 YYO — ATTACHMENT DIMENSION —— TABLE OF CONTENTS 1. BOOM 1.1 Boom dimensional drawing + 1 1.2 Boom maintenance standard ~~ “2 2. ARM 2.1 Arm dimensional drawing rrr 4 2.2 Arm maintenance standard “r+ n-nnnmnnnnnennannnnnnne 5 3. BUCKET 8.1 Hoe bucket 3.2. Special bucket «r= 8.3 Detail dimensional drawing of lug section ~~~ sens UY 8.4 Detail dimensional drawing of boss section 2 4, DOZER 4.1 Dozer dimensional drawing == 4 4.2 Dozer maintenance standard ~~~ z z 15 KOBELCO CONSTRUCTION MACHINERY CO., LTD. Applicable Machines SK115SR-4ES SK135SR-1ES SK135SRLC-1Es SK135SRL-1ES YV04-03001 ~ YY04-06001~ YH04-03001~ Lko4- ce Revision. Date of lesue Remarks First edition | September, 2004 | SsYY0307E x — 14 BOOM DIMENSIONAL DRAWING SECTION 88 1. BOOM SECTION CC Fig. 1-1 Boom dimensional drawing ‘Table 1-1 Unit: mm (fein) Ne NAME SRI | a ‘A [Boom length 4,600(15'1") | 4,260 (13°12”) B [Boom foot width 574('10.6")| 674.0106") C [Boom end inner width 274(0.8") | 282 0.13") D [Boom end outer width 386 (1’32") | 376 1'2.8") _E Height of boom cylinder rod pin 9616'1.8") |_919(9°0.2") Gl F [Height of arm cylinder (head side) pin [Distance between pins of boss H [Distance between pins of bracket \Arm cylinder (head side) inner width [Outer width of bracket on the arm cylinder (rod side) mounting section [Boom foot pin dia. (Boom cylinder (rod side) pin dia. [Pin dia, of arm end, \Arm cylinder (head side) pin dia. | Leste @7") | 1,037.5 5") (R2,024 (6'8”) _|R1,960 (6'5”) |R2,308(7°7") — |R2,129.5 (6°12") 108 (4.25”) 108 (4.25) 400,0'8.7") | _400(0'8.7")_ O70 (2.76") 70 (2.76") 280 (3.15") | 275 (2.95") } 7002.76") | 702.76") 270 (2.76") O70 (2.76") 1.2 BOOM MAINTENANCE STANDARD (1) Clearance of pin and bushing on boom ection 1) BRIS5SRCO.ms, SKISSSRL ans Fig. 1-2 Clearance of pin and bushing on boom section Table 1-2 (1/2) Unit : mm (in) Standard value Clearance Sym ‘Bushing “bol| Tem Pin partNo. | Pin | Pin dia. | ™S}!8 |Standard| Repairable] Service| Remedy dia. | tolerance tolerance] value | _level__| limit T 3] +081 | +0207 ‘A |Boom foot | Y¥o2B01014P1 ag |nonsn) ants 270 | 0.0012) | 0.00639) 40.0063) | oh 2.7559) 0030 0i80 p |Boomevlinder| yo po1017P1 0.0012) 0.007) | (Head side) 7 cPaogsy | More than [Replace ©) 02m | More than | 2.9 [Replace on 70s) +0180 | =0180 | 2. | oa [Puatine ° Tey |¥¥O2B01016P1 |q755 4) COG) [Oty | “Soo” » Rod side) )__|¢0.003| goon) ‘Arm oylinder 70 | 0.0012) noo") D A 'YY02B01063P1 eon 755] 0 | “0.070 ead side) 7585) ® coat, 2) SRUISSRa Table 1-2 2/2) Unit : mm (in) = Standard value Clearance “bol| Hem Pin partNo. [Pin | Pin dia. | 54 [Standard] Repairable|Service| Remedy | dia. |tolerance|ioierance| value | level _| limit 0) 2a | +0261 © | 0.009») ¢0.0105) ‘A |Boom foot | YY02B01014P1 Beat eco iai| eo. 270 | (0.0012) | 0.0062)| (0.0068) | Boom lind 2.7560\— 70050 iB p [Boom evlinder| oopor017P1 0.0012) or ead ie) | A UME | soreten| ay fRepac 12 lbushing Boom eylinder| coon |\«oaor] Goon 08 lerpin © yvo2Bo1023P1 |.,275,) 9) |ContD| Soom. gases) 0 | 0.100} =0070 God side) E289) | a'aos| e002) 0.050 1.180 Arm cylinder ovo | eo.0n12) | ooo D ‘Yvo2Bo1069P1 lead sido) a7ss0] 0 ‘S007 Glond side) | ems} ot 0.0025) (2) Clearance in thrust direction on the boom ee ey — ce cylinder installation section SECTION DD SECTION AA SECTION 8B Fig. 1-8 Clearance in thrust direction on the boom cylinder installation section SkissSRaG ws, SKISSRE I SKLSRAES Table 1.3 Unit :mm Gn) ~ ‘Shim adjusting clearance [Length under Sec- i paacaeal (Total of both sides) pnt | ned tem smedy tion! ‘Sym Standard [Repairable|Service| bol] $#° | value | level | limit [No-]/enethy |Boom 574 (22.6)| 0.6 (0.02) 10 16 716 1 A [Boom foot TGoperframe | “" |ssi@z.9) orless | 0.08 | 0.06)|*"| es.) B ‘Boom cylinder |Boom cylinder Le 90 (8.54) | 0.6~1.0 2.0 25 22 180, (ead side) [Upper frame 04.70) (0.02~0.04)| 0,08) | 0.10) |®*| 7.09) loping c |Boom cylinder |Boom cylinder | L3 | 80 (3.15) | 0.6~2.0 2.5 8.0 | 3 | 597 [adjustment (od side) [Boom L3'[ 400 05.7)(0.02~0.08)| (0.10) | (0.12)| €3 | 3.5) D |Arm cylinder |Boom cylinder 4 100 (3.94)| 0.6~1.0 2.0 25 eh 212 (Head side) |Boom 108 (4.25)|(0.02~0.04)} (0.08) | (0.10) (8.35) ‘However the mark 3 shows the length specified in the figure because it has no neck length, 2.1 ARM DIMENSIONAL DRAWING 2. ARM APOINT. B POINT SECTION AA P a3 4 al Q te Ty 2 M SECTION 8B VEw 1 Fig. 21 Arm dimensional drawing Table 2-1 Unit :mm (f-in) STS SESS TERS as SES Le a ag] sro [sm Nase Pag] emo | om Zao | 2480 | — 00 ma | 20 [ara ane wey Lee] ey [2 [pemtoevetionton wisn | wat ae Tes =| |e 1p [Distanse between pins 580¢__| 52) |nese.s) Rage | Boe win oar) a0") efhoes and bracket neva |@25.°}] 47) tos [p18 Inpoint | gos 1 facet innse wit aa aa 280 -| | or op if otbos for eae | © [Bracke soe width a ao De|ED ottoss coe) | |_| P fltertini dimension fancy ea et oo ee | Daf oreo eres 2 feta ink dimension a fae [Distance between oFtoas and [1600] | “RII a a a B lorscet ow) Gur) | lester 078) oso") ese es 2a |_| _ 26 F [Distance beeen thon andon | Gem, ai [Pana fan foes eit berwenn pin howrand | as65 | | a es S horns aso") ay | Pindin ee") HE oie leaiaes lcicheberweenpine AP | cos”) | ass} 244 | Pin ee) ¥ Jetbeee and bracket 50 ]e707)) eer") aig eal Breint | war") 24 Pin in err) 0 Te a 1 [hom op end with with shina | wre) | | wary [as|Pindia exe) | ~ | 7 X [Boss wiaen em l— lem 2.2 ARM MAINTENANCE STANDARD. (2) Clearance of pin and bushing see.) Fig. 22 Clearance of pin and bushing on arm section 1) SRIGSSRaams, SKISSSRL- TES ‘Table 2-2 (1/2) Unit : mm Gn) Sym Standard value Clearance Pal Item Pin part No. [Pin | Pindia. | Bushingié |Standard|Repairable] Service [Remedy 2 ia |tolerance| toierane | value | level | Limit. | 4 [asm point | ue, | ae | ee | ryiapoizasp1 | 265 mon |_cindban_| ciaseto p [Bucket link 2.8501) caiman, | ett |@ucket connection) aia lidier link oat Ce ao ion (LP12B01028P1 cae :p [Bucket link ® Eon Ele ink eomnection) 260 | tmz» |_ coor 120) 20 [penne — i nashin [Bucket cylinder |7712B10?9P1 | asa (0.48) | @.08) Pushing ead side) ® [Bucket cylinder |yy >po1046P1 city |(Botiom side) Geist | Co |Arm cylinder ® coms) Pal oreay [rvozpo1ossP1 | | 2.7859) | Coven | came G [Arm foot [-Pozpoxor2p2 7089) some, | came | corm i icon | aos | 2) SRITSSR1BS ‘Table 2-2 (2/2) Unit: mm (in) A Standard value Clearance eal Item PinpartNo. “Pin | Pin dia. [Bushing [Standard|Repairable] Service [Remedy dia, | tolerance | “wirance | value | evel | limit A (Arm point | nero | Cities | he : IYV12B01067P 1 hom? | Seas — Sie [Bucket link Sec: a Bate aee (Total of both sides) pinneck _|% tion [No] SS SAS] Standard [Repsiale/Serdza |, Taesescn|stiuase) © piss | tus | value sel | at us is 7 32 ‘Arm point = = 1a Se a | Bucket ga [a rz | | sao | a5 Link side (ees (0.05) as.) | asa) B | Bucket link Le = 2 Bucket, gan | ate Idlerlink [Arm ean | ea | os cox | 10 | 20 © (dom connection) [Link ade ——|L% =] orless | coon | (0.08 | *3 2 E]link [Bucket link sdel | Gad aoae | xsi0 | B 1p | = [somnestion| ler ink side St) ste | ae | | >| 29 | & [Bucket [Rod side ool |‘ (0.05) = $ | cyinder a} Se coon E & | connection| Bucket link aide | ean | _— 5 Bucket Bottom side eo | wave | ass | 2 E |cylinder U5 Se = £51 79 | (Botzom side) [Arm age | =| 652° | 20 | os |] 7 | 20 ‘Arm cylinder [Rod side pel so | = | ons | 8° ) 9] sears | Laso | - | (Rod side) Arm az | (8.35) } G [Arm foot ‘Arm [uz] dom | es [oso | 10 | 20 | o,| was | Boom ur] ay La | artes | 09 | oom | 7] asa) Note: The mark % shows the length from the under head to the center of pin hole. 3. BUCKET 3.1 HOE BUCKET (1) Hoe bucket dimensional drawing G GW) 1 Aon t Nt oh Led | |i c F Fig. 3-1 Hoe bucket dimensional drawing Table 3-1 No. NAME, Noy NAME ‘A [Distance between pin and bracket B [Distance between bucket pin and tooth end C {Inner width of bucket top end D Jnner width of lug E |Inner width of bracket | 1 |Outer width of bushing G [Outer width of bucket bottom H [Bucket outer width of front side I [Pitch between teeth Io [Pitch between teeth F |Outer width of side cutter a2 [Pin dia. (2) Hoe bucket dimensional table 1) BRIS6SRWO.ims, SKI35SRLa Table 3-2 (1/2) Unit :mm (ft-in) ‘Type Hoe bucket cormity| feet 24m | ostm | 088m | 045m | 057m | 070m! Gera | OBlewya) | OALeuyd) | O50euya) | O.59euyd) | (O.TEeuya) | O.S2oua) Assy No. Yvexpo000sr2 _|rvexBo0022"2|rv6:00021P2}yverRoo020F2/vy61B00081F2|rvoxBo0018r2 fyve1po0oa2Fe A | suse) | — = = = = = B [Ri2250°) = = = = = = C_|_ sezes9) | a2 62")| s62@2.1) o02@51)| 772G04")| 9627.9) [u268) D | suaze) | — = = = = = E 252 9.92") S =| = - | + F_| 10003") | 593@3.8")| 700(27.6")| 800(615°)| _910,85.8°)|1,10077) — G | teec@or) | 3890617) 439797) s30@12")| 649 @567)| 830630") | 9800897) H_| 900547) | s00a07")| soo sey] ro a76")| sIGLe L000) La50e's") 1_[_ 1935 cra2")] ser c7ae7)] 997 @.99°)| 1o1c7.se)| 226 @98")) 218.5:@.00")| 256001") To | 1935 ¢7.627)| 167.36")|_287(0.88")| 191(7.52")| 228 @98")| 2185(6.60")| 266 00.17) ai | caeis) | = = = ee ee a | oes) | — = = = = 5 ‘Table 8-2 (2/2) Unit : mm (ft-in) ‘Type Hoe bucket pon Or] % a a 0.30m° 0.37m* 051m" | (osdeuya) | C-22euyd | (0.800) | (0.38euyd) | 0.A8euyd) | (0.67euyd) ‘Assy No. | YVe1B0000382 | yveLBoo005P2 | YV61BOO0I0F2 | Yv61BO0009R2 | Yv61B0q008F2 | Yv61BOOOUTF2 A_| steaasy| = = = = B zeny kiseu ren) = = : C_| s122.07)[ a200005")| _462,082")| 5020221") | 662(26.17) |_ 8721045") D_ | aaaoey| — | = = = al EB | ase) = = = = F [| s0@74)| — 600 (23.6")| 700 (27.6") | 8001.5") | 1,01066°4") G | 6s5@707)| 54c39")| 33508.27)| 495.0717) | 595@117) | 745.298") H_| s50@a5")| 45007.7°)| _500,49.7°)| 60028.) |_700@7.67) | 910005.8") T | sae@sey| — = - 3927.56) | _ 198 (7.72") To | 241 @.49°)| 1725 6.79") @738")| 287 088") | 1910.52") | 196 0.72") a | ees) — = |-ESSr= = a2 | so0ese)| — = a = 3.2. SPECIAL BUCKET (D Special bucket dimensional drawing 1) Bucket with ejector : & “ Hi 0,0 co aor 2) Slope finishing bucket 8) Dismantle Spec. bucket G bles Fig. 3-3 Special bucket dimensional drawing No] A [Distance between pin and bracket _D [Inner width of ug c B |Distance between bucket pin and tooth end ‘Table 3-3 ‘NAME B’ [Distance between bucket pin and bucket end C [Inner width of bucket top end E [Inner width of bracket F |Outer width of side cutter G |Outer width of bucket bottom H [Bucket inner width of front side I [Pitch between teeth To [Pitch between teeth J {Finishing plate depth at [Pin dia. a2 [Pin dia. 2) Special bucket dimension Table 3-4 Unit : mm (ft-in) Model SK186SRO)18S, SK135SRL-1ES SKUSSRAES Type | pemande Bucket Slope Bucket Slope Spec. bucket_| with ejector__| finishing bucket | with ejector_| finishing bucket TSOO GOO TSOOXBOO Capasity| ¢g@. 20" 0.21m* wur’x35.4") 0.21m* (6'3°x95.4") 8) (0.65eu-yd) (0.27ewva) (O.2Tew-yd) 0.40m' (0.68cuya) | (0.52euyd) Part No.| YY6IBO0003F1 | LP61B00027FI | LPGIBOOOZIF1 | YWe1BO0021F2 | YW61B00017F1 A 370 (14.6") 3754.8") | R370 (14.6) 3754.8") | R375 04.8") B | R125 4) = R928 (86.5") = R878 (84.6) By = 1,072 (6°6") = 1,073 (86") = ¢€ 862 (83.9") 434 07.1") = 434 07.1") = D_ | __s24(12.8") = 824 12.8") = 290 1.4") E 250 (0.92 2660.57) | 262 9.92") 280 9.06") 218 (8.58°) F 1,000 (8’8") = = = = G | 7399.17) 400.05.77) | 1.800671") 4005.77) | 1,600 673") H | _900(05.47) 419 06.5") = 419 06.5") = T 198.5 (7.62") = | = = = To 198.5 (7.62) |__172.5 (6.79" = 172.5 6.79") = J = = 900 (85.47) = 900 (85.47) a 280 (8.18") 280 (3.15") 80 (8.15") 275 2.95") 275 2.95") a 265 (2.567) 265 2.56") 265 (2.567) 60(2.36) | 602.36") 10 3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION Td eet BOSS (SKta5SF:6) | 2avBP26832 i BOSSISKITESR:1E0) | 2a18P26881 a SHIMt=1 Insert No.18 pin unti the BOSS (SKIS5SF-1e8) surface becomes level. SECTION AA ‘YverBot00sPs BOSS (SK115SR 165) DETAIL 1 Ywe1B01002P1 Fig. 8-4 Dimension of lug section 1) SK135SRLO-1s, SK135SRL-1Es Table 3-5 (1/2) ‘Unit : mm (ft-in) | al ] | E 8 o Z g|4 g a type ot [O88 Irae wo.ot | € | 2 lela) alele]3 ot bucket =lsie/2)2)4)21a)2l2 bucket ‘ bucket 2 3 = & = & en : hn’ (cud) SS; eS) e) 2) es} ea) eb) el ele elie el 2 le 212 Els a)s]>)e,Frfo|s)s[M|N stm) 0.30 (0.95 |vsipononrs | 0.24 (0.31) |yyeipoon2aF3| | | ae 580-2) fryeimo00et2) ges | 22 | os | ow | ous} i, | 2 | ous | os | ue ‘oe bucket | 9.38 (0.50) |yyexBo0020F2 0.866") | (3.15") | (0.3947}| 6.75") 0.866") } 6.48") | G.42") | (4.68°) 0.45 (0.59) }yye1Bo0os1F2| | | | 0.37 078) rvexsooar2 | 0.70 (282 |yvanBo0ser Spec. bucket) 2-50 (0-68) | ¥v61B00008F «2 55-) | gsery| «.16") |(0294") M4 |o.s66")| 6.43") |az") | ano") Bucket with] ‘280 | | Bushs] 93 2m | nemmosrr oe | Slope [BuO co / we Finishing eurease) rotor eS oa bucket |0.52.0.68) |_| - u 2) SK115SR.1Eg ‘Table 3-5 (2-2) ‘Unit : mm (ft-in) L 2 o i aja 4 £ pacity Z g a aie Type of eee e[PartNo.of | 3 |S fale gel eed ero eee jecale a uckee [OF UCKEE sucker pag erat tase creel eeceltacte ec aeecatliare | aa! i (aya) 2] eo 2) E)a)tlayeyel? Ela |e ]s)]s [a] el lala] A B D E F G H a M N SID) 0.45 (0.59) |rverpoonar2 0.17 (0.22) yworpo0acsr2 Hoe buerer[028(030)]rvexs00n0r2| e260 | 2 | ons | o10 | ov | ya, | 22 | ore | am | or 0:30 0.89) vexs0ura| 22°) | 8667] a7 Joaae| esr) jose") | sos) |.are) | aarry 0.37 (0.48) | ywerB0%008F2 0.51 (0.67) | ywe wo0n0rF| Backer wil a aime Che |o21 0.29 frwerpocera a hae Slope | 160052700 finishing | esx |yweunoonrey or ma mn bucket 0.40 (0.52), eae eee 12 3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION oS 4 | - nN 2C|2D za\ OB 15 DETAIL F Fig. 3-4 Dimension of boss section Table 3-6 Unit : mm (ft-in) Capac ‘Type ot PartNo, | PartNo of bucket ous Par [otic | axe |ea}ow| ec joo} |r jec| Hu] 1 (st) 50 (0) | yveunoconsr2 joa oar | rvexsmcozar2 | ow bucket (°84(0417)| Wouoooetrs & oso: sor foteimcnr|anorasa| 8) 28 eneesna] owes) i» | o« | ou | w | 2s a eae ioce yvernemnaneS | aon | are Jawseurn| ase | re] aa Jesor| osu] ose, = lost os) | yreumooisre % ln70,a92") | yveupooo22r2 ig [Dismantle 2 Spec. [osocoss) | yvexno000ar1 & [isk @ [Basket WA gar) [ueeamoora © lector w | » 3 [slope | 1ancano fremowors| tf rf ot fot fo oe td % Isnishing | wuss. «| Lpe1po0oa1F1 ere ee Poucket ~ _|osznc6") reaader [ase oss) | tresBooootr: (sm) Joss aa2") | xvens0000nr2 ercor- |yvermeaneers|qaspaess) 2° | 284 Jessseos|oxss| ao | as | ou | ae | 2s 1g ioe bucket [ozs c0s0-) | expooorar= 66207 | at |asrssmm | ase | caer | a7 |oser| stn | osoen a 0.00639") | ywersoaoner2 g or (04s) | yweuboon08r2 a oi csr") | ywe1B00007F2 © [Bucket wit = 5 Bucket wy oy wary frwommoneatr2| neowent + | 41 + 11 |] @l a be bg Slope | Taxa 0380 | asm fanning | eras | ywernoo0r7P1 bucket _Jounease) 18 4. DOZER 4.1 DOZER DIMENSIONAL DRAWING Fig. 4-1 Dozer dimensional drawing ‘Unit : mm (ft-in) Table 4-1 [SKI35SRLO.1ms| SKI16SRans DOZER ASSY ‘Y¥51B0000SF1 | YY5LBOOOOIFL No] ‘NAME DIMENSION | DIMENSION A ‘A [Blade width 2,590 66") = B |Biade height | 590 @3.2") - jstance from dozer attaching pin center oa Ge © lowes odes ond ‘taching pin center to R1,729 (6°8") | R1,638 64") D |Inner width of dozer attaching bracket, 672 26.5") a IE Width of dozer attaching bracke' |__ 128 66.04") = [Distance from dozer attaching pin center to | ea omer apo renner pay Cay) - g [Attaching bracket inner width on dozer cylinder] gp ¢g gp) | re Ihead side 1 [Dozer attaching pin dia. 260 (2.36") - a2 |Attaching pin dia. on dozer cylinder head side 260 (2.36") - “4 4.2 DOZER MAINTENANCE STANDARD 7=6.7£0.7 (4825.1) Y TI | ‘TeTightening torque : kefm (bit) 12x 120 71.2 M2120 12120 TH 7412 T=117212 (8548.7) (58.7) MEW _B MEW_A SECTION CC Fig. 4-2 Dozer maintenance standard (Q) Clearance of pin and bushing co Table 4-2 Unit : mm Gin) sym Standard value Clearance rT ‘in part No. | Pin | Pin dia, | Bushing ‘epairable| Service Sri} Item | Pin part No. | Pin | Pin di a. |Clenrance|ePaiable| Remedy dia, | tolerance | tolerance evel | limit ‘a, Dozer eylinder =0.06 | +0.200 | +0.820 | T 1 \Rod side) 5 (~0.0024)]+-0.0079)](+0.0125) [Dozer eylinder| *X51B1006P 1 =012 | 0 | +0.060 | Ineo |(Head side) 60 |(—0.0047)| __0)__|(+0.0024)] 1.2 (0.05) | 2.0 jp vR ine (2.36) =0.150 | F0.230 | +0.440 | or more | (0.08) [pr rye® - (~0.0089) |(+-0.0091)|(+0.0173) C [Dozer foot | 2419P1556D5 oro tae oe ee osan | |__(0.0083)|(+0.0051)|(-+0.0210) (2) Clearance in thrust direction on the dozer cylinder attaching section ‘Table 4-3 Unit: mm Gn) 5 ‘Shim adjusting clearance Length under sy pace Total of both sides) in nek Ei Item { Remedy “bol sym Standard [Repairable Service Foot |S |“ vaine | level | limit [No-Heneth [Dozer eylinder|Rod side 90 (8.54) | | A 200 | A |(®od side) [Lower frame] [92 (.62) fT 180 p [Doe index|tiead side |, [9018.54] 1.0~20 | 2.000.08)| 3.0 [2,| C09) |snim (Head side) Dozer 92 (3.62) |(0.04~0.08)) or more | (0.12) jadjustment [Dozer |g [2286.04 218 © [Dozer foot Ls e3| ou * [ower frame) ° [1506.91)] 58) 15 KOBELCO en gs VY 1 ove SKissshan SHOP MANUAL SK135SRLc — TOOLS — TABLE OF CONTENTS 1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS 1 2, SCREW SIZE 2 8. TIGHTENING TORQUES FOR NUTS AND SLEEVES 8 4. PLUG .. nnn 4 5. SPECIAL SPANNER FOR TUBE 7 6. SPECIAL TOOLS 8 7. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND 10 8, SUCTION STOPPER u 9. COUNTER WEIGHT LIFTING JIG 12 10. BOOM FOOT PIN PULLING TOOLS winnie nnn 1B. uu. TING JIG Mu 12, ENGINE MOUNTING PEDESTAL 16 13. TRACK SPRING SET JIG .ssnnsnnnnennnmnnnnnennsnnneee 1B KOBELCO CONSTRUCTION MACHINERY CO., LTD. Applicable Machines SK115SR-4Es YV04-03001~ SK135SR-1Es — YY04-06001~ SK135SRLc-1es YHO04-03001~ SK135SRL-1Es — LK04- oe Date of Iaeue Remarks First edition September, 2004 SsYY107E, 1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ‘Tables 1-1 and 1-2 indicate tightening torques Insufficient tightening may lead to a loosening or applicable to cases where no special note is given. loss of bolts. Always tighten bolts to proper Overtightening of bolts may result in a twist-off torques. and a fracture under load. Table 1-1 Tightening torque for coarse thread metric screws (not plated) unit : kgfam (bff) eT 4.8T 1T 10.9T Sizn ‘Use| No lubrication | Oil lubrication | No lubrication | Oil lubrication | No lubrication | Oil lubrication je | 098004 | O98=01 | 0.83=0.08 Ms 2.70.3) 0.92E0.09 MB (6.70.7) T3=0.18 | M10 £ T Th6E15 M2 11011 W28E13 M14 3x9) =2.0 mae 19.5=2.0 aed M18 |_a7ox14 (30029) - S23 BTEG M20_P=2.5 | (130412) 270+39) | (23022) (410+ 43) 7 | 8ee 19.6220) 515 1324 8 Moz _P=2.5| To+i9 | Gso+14 | 7036 | @10+29) | (660-58) ; BOES BES O27 Es TI8E 12 ‘9610 M24 _P=8 (22022) | (17022) (470£51) (38036) (69072) 7 96=10 7B=8 TAOS 14, M27_P=3 69072) _| (66058) (2000 100)_ Tsl=1s—|~ W011 T9820 M30_P=3.6 (s50+94) | (80080) | (1700:£170) | (1400: 140) TIGE18 | 148515 |“ BlT#82 |” 266427 M33_P=3.6 | (490+51)__| (13002130) | (1100110) | (23002230) | (1900-200) B29 B27E23 | 190F19 | 40941 M36_P=4 (76072) (640465) _| (1600170) | (1400140) | (3000300) Table 1-2 ‘Tightening torques for fine threads metric screws (not plated) unit : kefom (Ibe) aT T aT 1097 Sie [No lubrication | Oil lubrication | No lubrication | Oil lubrication | No lubrication | Oil lubrication TI0=0.11 25L02 45204 | 38204 M8 P=L (8.30.8) 181) (383) (278) ZSEOR 89E09 | 7520.7 Mio P5125) 71) | 545) “| 40=04 TSE 15 Ml2_P=1.25] (2943) | (95:9) 5 | osE0s é | 3 Mié P=1.5 (43012) M20_P=Lb Riazi bo22) = 3826 M24_P=2 51051) | (42:43) | (1087) 5AEb Tagel4 ~~ TEL 36 M30_P=2 ao-e48) (39036) _| (2000100) |_(850:87)_| (1800-190) (4800: 150 : BTE9 RET 190E19 | Ie8E16 | S4lEG4 |“ 2B4-ED8 M33_P=2_ | (63065) (520: 51) (1400140) | (1100120) | (25002250) | (2100-200) [gpa 238423 | I9BE20 | 49843 | STE M36_P=3 (790 80) 680585) (1700170) | (1400140) | (3100310) | (2600+ 260) (Q) Capascrew 2. SCREW SIZE a 2 2) Socket bolt B Table 2-1 Table 2-2 Table 2-3 Nominal |B mm Nominal | Bim Nominal | B mm cee and on oa @ | Re caurmanen| tue @ |® M6 | 10 1/4-20UNC ll M6 5 Ms 13 5/16-18UNC} 13 Ms 6 M10 17, 3/8-16UNC 14 M10 8 19 7/16-14UNC, 16 M12 10 (22) ig M14 12 24 24 M16 14 7) 3/4-10UNC 29 (M18) 14 a0 “B9tINC | a3 ‘wo | a7 isunc | 8 Mae [19 11/8-7UN 43 M30 22 11/4-7UN, 4s M36 27 11/2-6UN_ 57 Maz 32, M48 36 3. TIGHTENING TORQUES FOR NUTS AND SLEEVES Table 3 indicates standard tightening torques sleeves in flareless joint may develop oil leaks applicable to cases where no particular note is through pipe connections. given. Always tighten nuts and sleeves to proper torques. Overtightening or undertightening of nuts and Table 3-1 F Working pressure Pe Opposing | Tightening torque Manufacturer's ODX thickness x Rome | _kef/em* (psi) ‘mm Gn) [flats IEX)| _kgfm dbf) 10X15 fs (0.394% 0.059) s 15%2.0 aaa| (0.591.0.079) . 300 TBX25 a 1BELS Nippon AMC «a270) co709x0.008 | © vo8=13) 22x30 a 22222 (0.866 0.118) (15916) 28X40 yi 28228 | | a.10x0.157) (20020) : 300 355.0 - eae Thara Koatu 3 5 eee 4270) (2.38X0.197) G (380233) Table 8-2 SLEEVE NUT ‘Tube size Parts No, ‘Tube size |nor? pa : Parts Ne @a Thara Koatu_| Nippon AM.C. @a B Thara Koatu_| Nippon A.M.C. 6 | 2F98806000 = 6 | 14 | Zr9sno6o00 = ZF93808000_| 2 8 7 ‘ZE93N08000 = ___10 | ZF98s10000 | ZA98810000 10 | 19 | ZF9sN10000 | ZA98N10000 12_|_2F93812000 = 12 | 22 | ZF9sN12000 = is_{ ZP93S1s000 | ZA93S15000 15 | 27 | ZF9sNi6000 | ZA93N15000 18 | ZF93818000 | 2493818000 as | 82 | ZF9sN18000 | ZA9SNI8000 22 | ZFe3s22000 | 2493822000 22 | 36 2P93N22000 | ZA93N22000 28 | Zr9ss28000 | 2493828000 28 | 41 __ | ZF9sN28000 | ZA93N28000 82_| Zr93ssz000 | = az_| 50 | ZF9aNa2000 = 35 | 293835000 | ZA93S35000 35 | 5 __ | ZF93N35000 | ZA93N35000 3s | ZF93S38000 = 38 | 60 ‘ZF93N38000 = 4. PLUG (1) Plug for hydraulic pipe joint 1) Cap nut pebbled “Appliable]| “ oft, (Cap nutpartsNo| T screw If 4 d 8 | amssHo8000 | Mi4xu.s] 17 | 17 \ y # 10 _|_zrssHi0000_[Mmiexi.s| 17 | 19 H Dall = \ 12 zr8sH12000 | Misx1.5| 19 | 22 Zo 15__| _zrsarii5000_| 22x11. Sra 18 ‘ZF83H18000_| M26x1. zs T screw \H 22 ‘Z83H22000_| M30X1.5 28 | Z83H28000_| M36X1.5 ‘Table 4-2 ‘oni | Pru parts No orDa 6 ZFS3P06000 8 ZE83P08000 10 ZE83P 10000 12 o_ 16 ZESSP15000 oe / \, 18 ZE83P18000 joint body/ Nees 22 ZES3P22000 28 | Z8sP28000 3) Nut Table 43 ~ “Applicable ofbe, | Nutparts No. | d screw oe 6 | ZF9sNo6000 | MIgx158] 14 8 ‘ZFesNoB000 | MI4x1.5| 17 10 | ZFesNi0000 | Miexi5| 19 Ww ZF9SNi2000 | MI8xI.5| 22 16 ZE9BN15000_| M22%1. 27 18 ZP9sN18000_| M26x1. 32 22 | ZF93N22000_| M30x1. 36 28 [| ZF9aN28000 [Ms6x1s| 41 32 zresNs2000 | M42x1.5| 50 35 ZFOBN35000 | M45X1.5| 66 38__| ZresNssooo |Masxis] 60 (2) Plug for hydraulic equipment, 1) PF screw ‘Table 4-4 EE, [Ptug parts No.| B mm | OPAEPErS [Norminal PFi/4 | ze72xo4000 |_19 | zDi2P01100 [1B Pil PF sis_| Zi72x06000 | 22 | ZDi2P01400 | 1B P14 PF1/2_| ZE72x08000 |_27_| ZD12P01800 | 1B P18 PF si_| zm72x12000 | 36 | ZDi2P02400 [1B P24 PF1__| Zo72x16000 | 41 | ZD12P02900 [1B P20 2) PT screw Pee screw B addy | Plus parts No.|B mm PT vs | Zes2T02000 | 5 { pri | ZEs2Tos000 | 6 ox PTsis_| Zs2To6000 | 8 PT 12 | ZE82T08000 | 10 PT a/4_| Zms2712000 | 14 PTi__| ZeszTi6000 [17 PT i W4| Zbs2T20000 | 22 PT i wa] ZeszT2«000 | 22 (8) Plug for () flare hose Table 4-6 PF screw PF Tp . obit, | Plug parts No. [B mm Gr PF 14 | 244422728D1 | 14 3 nt cn PF gis | 244472728D2 | 17 PF 1/2 | 2444z2728D3 | 22 Qeresing pp aia | s4sazo728D4 | 27 PF1__| 244aza728p5 | 36 Table 4-7 abt, | Pugparts No.|E mm| F mm PF v4 | 2aaazar20p1 | 14 | 19 PF sig | 24aazo720D2| 17 |_22 PF 12 | e44aza720p3 [23 | 27 Pr ala | 2aaaze720D4| 27 | 36 PFi | 24aaz2720D5| 36 | 41 PF i wal 244az2720D6| 40 | 50 (4) Plug for ORS joints Male onING g Table 4-8 Applicable On Oring parts Norminal posing Screw size A] hose lus 's No. 7 OD_| PMEPeHSNS lnseaHED| No, O ring At 1-14UNS. @21.7_| YN01HO01001P1) 27 2ZD12A01600|1B A16 18/16-12UN| @27.2_|YNO1HO1002P1 36 2D12A01800/1B Al8& 17/16-12UN|_@34.0_|YN01HO1003P1 41 ZD12A02100|1B A21 Female Table 4-9 Applicable on Screw size A) tube lug parts No, | PPOSPE Z ] ew size on Plug parts Ni lnats(HEX) LiduNs | 921.7 YNOIHO1004P1| 32 13/16-12UN|_©27.2 YNOIHO1005Pi| 36 17/16-12UN]_@34.0 [yNoIHO1006Pi| 41 5. SPECIAL SPANNER FOR TUBE Table 5-1 Applicable tube diameter | Part No 7 Drawing of a special spanner mm (in) | 10.276) 00.515) a 2421T160 27 oss 7} PART-No. ona (0.591) HEXS? 1 \woasn 10 12.7793( 0.600 288% ) | 702.76 IL 18 19] a : a PART.No| be20.860) (0.709) | 24217138 (0.748)| | 520.566) HEX82 512.7283 (0.500 “388 | |__10@76) | tansy 22 19] 4 | 3 2a) —SPSdoarrno, |o200.800) (0.860) 24217129 30 (0.748), 520868) HEX30 312.7233 (0.500 7848 80.8 70.276) | eT) 22 . 3 3 aif t coe 24217130 36 | age NPART-NG e866 | HEXS6 012.7533(0.500 *388 ) ee 109 (4.29) | SEED) 28 2 a 5 2g PART. 2.0.86) 19 2421T115, 41 aig -PART-No.-{} p20. 866) a 7783 ( 0.500 “388 109 4.20) 28 | 31] ott ears PART-NOL [ssc 10) | (24217231 46 (1.22) oa uExaé 219.05 £34( 0.750 “2382 800.15 10042 32 F al *pART No oe) 24217232 | 60 aay "ART -No! s50.38) a HEX! oo 219.05 °84(0.750 28885 6. SPECIAL TOOLS ‘Table 6-1 No} Tools name | Tools No. Sketch Applicable Ic ‘Allen wrench |Z1T22A10000 Pump suction Nominal B : 14 Commercial tool length (L1) — cut length = Required length 401.57) — 10(0.39°) = 80(1.18°) |Allen wrench |Z7T22414000 Pump install Nominal B: 14) \Commercial tool length (L1) — cut length = Required length] 862.20°) — 1100.49") = 45(.7) Cut a Spanner 271282000) ~ eatiaei Swing 8 | Nominal $ : 82 motor A,B port (Commercial tol outer width (D) ~ ext length= Required loath 732.87) — 1900.51) = 60@.36) J Additional M10x22 |For _ Pius ZB72X12000 threading slinging PFSI4 for M10 eve bolt the ewing motor PRaid O ring Bye bolt 7891001000 aa IMioxis jor stinging 5 | commercial a equivalent " & Flare hose ‘Table 6-2 No.| Tools name | Tools No. | Sketch Applicable ] z MB Bye bolt Plug ZF83P22000 Nominal ‘nube dia. 2 «6 | Reference Reference nut [Flare hose Eye bolt —_|Z2S9100800 aX Nut Z¥93N22000 ' MBx18 ' WW “Additional \ ‘threading for | MB Eye bolt MB Bye bolt Max18 ‘Additional Plug YNo1Ho1001P1) treading, 7 | Nominal Flare hose 1-14UNS |Bye bolt | 2891C00800 1 i | sxe MB Bye bo Additional Plug YNo1Ho1002P1) “reading, Ghee Flare hose 1 8/16-12UN i Eye bolt —_|Z891C00800 | 5 For slinging the Eye bolt | 891000800 swing motor Msx15 for & commercial |Flare hose equivalent 4 T 4 Lema T 10 [Pins | zB72X08000 Adina! MB>20 ror stinging the PFI2 wreading for nae MS Bye bolt aren prin ‘O-RING 7. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND () For general Table 7-1 { Manufacturer Service Features Loctite Three-bond #242 1360K | Low strength aaa #262 1974 _| Middle strength #71 1305 High strength ‘Sealing a ° Gare #515 121 Sealing (2) For specific location Table 7-2 No| Use | Manufacturer Name Bquivalent Applicable | (Manufacture ; Loctite) #1901 Anti-seizure Cylinder |#1215 eray #5699 | Swing motor ‘Three-bond #1211 white #53010 ‘Swing motor | #13038 #211 ‘Main pump Seatiog (Manufacturer ; Three-bond) . #222 #1344N |Main pump ssiesne | Loctite | #277 #1807N Pilot valve (Manufacture ; Three-bond) Loctite Parmatex 98D #1121 ‘Hydraulic oi] tank : Hose Sumitomo Loctite #515 Qhemical | Cyano Bond PO |sree-pond #1215 For swing bearing : Seal Shell Shell Alvania EP2 | New Molyknock Grease 2 Swing bearing grease [petroleum |bath 10 8. SUCTION STOPPER 8.1 COMPONENTS No.| NAME PARTS No. [QTY SUCTION STOPPER ASSY|24100P978F2 | 1 Rea 1 |ROD 24207466001} 1 |zniecosoo7 | 1 7 2araTaizsp2| 1 aszows | 1 2Nut 3 Cover FH f 4 Oring 82 DIMENSION Fig. 81 Components of suction stopper 118 (4.45) Ms NUT [28(0.818") 600 (23.6") 28(1.10") |= Soar fRosaowr } ms | 200° re [eR oi f * [eR oi f 25) ROD COVER (0.08% fig. 82 Dimension of suction stopper 83 APPLICABLE MODEL “Applicable | | AE ‘model wlglalé a | e|2|2|2/2/2|2 . siale|2/Hl ell ele |2) Ble BLS RAILS] ee LS | saroorarar2 || of of ol olofololololofololo 9, COUNTER WEIGHT LIFTING JIG (@) Use two eye bolts M36(ZS91C03600) or commercial equivalent for the standard ‘counterweight lifting gear. 1 (2) Use two commercial eye bolts M20 for the lifting gear for the additional weight (onapsack type). 2 10. BOOM FOOT PIN PULLING TOOLS Fig. 10-1 Slide hammer for boom foot pin ‘Tools accessories assy YXO1TOOO02F1 Table 10-1 No] Tool name] Tools No. Sketch Applicable {Roa YXO1TOLOO2P1 Boom foot pin pulling 1 o (0830716 Boom foot, 2 |Hammer | YR02B01286P1 pin pulling | 3 | 30 | rooe.say | 30 | 18) 16016307 13 11. UPPER FRAME LIFTING JIG 6 6") Nh 6) i ' t | q 1 tit > ! 3 } ' 5 j : SHEL] t e i a8 1 3 > —{[] fa \l oy a Ry 0 G35) ‘ ef Es eset Es 40 12 ‘25 dsr Bary SET % mae = “3 SECTION AA Qty: deet Material : POK400(8841) Fig. 11-1 Upper frame lifting jig 4 12. ENGINE MOUNTING PEDESTAL Note) Hold the oil pan 0) 21 275. ral section of engine. a) (oair) 10.87 foaa) “- Material : Plywood or wooden plate Fig. 12-1 Engine stand 13. TRACK SPRING SET JIG ‘M30 Retainer nut Stand 360 Hydraulic jack Base Fig. 18-1 ‘Track spring set jig 16 KOBELCO ss Y 1 Qove SK115SR-1«s SHOP MANUAL Sk135SRLc8 — STANDARD MAINTENANCE ——QQQE TIME SCHEDULE TABLE OF CONTENTS 1. STANDARD MAINTENANCE TIME [EDULE FOR EXCAVATOR swvvvennntnnsenine Lo ors 168 2, STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE sre 247 KOBELCO CONSTRUCTION MACHINERY CO., LTD. Applicable Machines SK115SR-1ES YV04-03001~ SK135SR-41ES YY04-06001~ SK135SRLC-1ES YH04-03001~ SK135SRL-1ES — LKO4- ad PREFACE Q) Working condition Workers : More than one, worker shall be Let class service technician (having five years or more of field experience and having received training in the operation). 2) Equipment digs, tools, apparatuses and testers used in field service work shall be available commercially. The maintenance plant, shall be equipped with a service shop, a ctane and inspection apparatuses a) Bfeessary for speci self mepection activities 8) Place ‘A flat land where work may be performed and to which a service car or a truck crane is accessible (2) Range of standard maintenance time hrect maintenance time+Preparation time 2) Direct maintenance time : Net time actually spent for maintenance 3) Spare time ‘ime needed, to move machines for service, prepare safety operations, discuss work, and process the needs of the body. (Q) Etrs time (not included inthe standard service time) Repair time Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and anti 2) Roms excluded from service time because of uncertainty in time Recriving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults, diagnosis, and inspection. 3) Indirect tine ‘Time for Held work, preparation of necessary parte before leaving for work, return for field work, Waiting time beeaust of aser" s convenience in the feld, paper werk afer feturning to shop, an Bepatacion of ils cial time’: Work at early morning, at midnight and on holidays aze to be caloulated separately. separate calculation: The operating time for service cars, trucks with a crane and crane trucks. ‘Applicable machine for estimation of standard maintenance time Standard machine . A'well maintained and controlled machine with a standard combination of attachments which is used in @ general environment Revision Date of Issue Remarks First edition | September, 2004 | SSYY1207E x weBoe 4 es 1. STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR (1) Standard maintenance time schedule 1) Units of working time : 6 minutes=0.1 hour 2) Calculating method of standard maintenance time : ‘Maintenance tim ‘orking time X the number of workers (working time=Maintenance time the number of workers) 8) When more than one operation is going on Add each standard service time. A pure time (readily started) is given except covers easily removed by hand. Assy works include the following works marked with lack dot « 4)O/H :Basically the installing and removing operations are included. 5) Abbreviations in the table. (2) Classification of working code No ‘Group Remarks 01 [Attachment 01 JAttachment [Indicates installing, 03 |Svinghame removing, replacement 04 | Travel system _|and overhaul. 06 | Electric indicates the installing, equipments removing and replacement of single items, 09 [B/G relation |Indicates overhaul of the single engine. (Materials prepared by manufacturer ) (@) Conditions for standard service time of the engine 1) Toole designated by E/G maker are used 2) Genuine parts are changed AIC; Airconditioner F hose ; Flexible hose 3)_Correct working procedures are observed. ASSY ; Assembly O/H ; Over haul + The time required for works specified ATT ; Attachment SOL; Solenoid in this Chapter showe the total time BRG ; Bearing SW ; Switch for maintenance. CN ;Controlvalve V_ ; Valve Cyl; Cylinder EIG ; Engine Unit : Hour 3 Work tobe ag Group Location done | Unit Remark a |e a le 00) Bucket relation i 2 Reference fr bucket 01] Bucket ASSY [Detachvattach] pe. Include adjustment op 2) baer esting and detain pectin Proparation | 1 pe a |e (3) « Bucket attaching pin [Detachiatzacd} 1 [Include omission of in a] e 4) « Backer drive pin [Detachiattach| 1 a] ie 05) « Bucket sling and movement Preparation | 1 pe orf ie 06] Bucket ingle) OR | ie. frecaiemmcinesnadectinn | 20 | + | 07) + toot Replace | 1p os | E | op] + side curser Replace | 1p wo} & | os] Bushing Replace _|_1pe os Le & (10) ie elation Rafeence fr am = [uf am assy DDetachrattach| 1 pe zo | = 3 Santos a Preparation | 1 pe. os | o + Bucket cylinder rod pia |Detachiattach} po. | Include omission ofpin a |e + Bucket eyindar head pin IDotach/attach| 1 pe. |Ineluds omission of pin ale + Bucket cylinder assy IDetachiattach| 1 pe. ofc sm eylinde rod pin |Detachlattach) 3 pe. Include omission of pin ote ‘+ Boom top pin [Detach/attach| 1 pe. |include detent of pin, or fe + Arm ling and movement [Decaeh/attach|_1 pe oi fie 30) Boom relation Reference for boom 31) Boom ASSY [Detactvattack| 7 pe m0 | = 32] too ashing nd ean pon Proparation | 1 pe Joa ]e 33} « Boom cylinder temporary singing Preparation | 2pes Jo2 | © 34] + Boom cylinder sod pin [Dotachfattach| 1 Include omission oftwo pins. | 02 | 1-1 7 Worst be i Group Location done | Unit Remark g 26] + Boom cylinder pining [Detach/auach] Ope | | © 30), + Arm & bucket piping DDetacbattach| 1 pe. | « 37] + Boom asey tomporary singing [Dotachettach| 1 pe « 38]. + Boom fot pin DDetachettach| 1 include omission opin on] e 39], «Boom assy slinging [Detachattach| 1 pe a] e | solarmerlindeestaching and detaching (Detacvactach| 1p: a] eo A] a) -Armeptinder piping [Detachitiach| 1 pe aa} e S| 42|. «som cplindor head pin [Detachiatach| 1 | Include omission of pin a] & S| 43) + Aemeylinder singing Detachaitech) 1 pe . 40} Boom eylinder attaching and detaching [Detachiatach) 2 pea, © 5 | si}. + Boom eytinder piping DDetachiacsach| 2 « 42} + Boom exlinder head pin [Detachattac| 2 ps. « 5a] Boom eylinder slinging [Detachattach| 2 « 60] Bucket eylinder on . si] + Pinbushing Replace | 1 include ses |e 10} arm eslinder ont ao | + ti] +Pin bushing Replace Include sea ao} + 80 Boom eylinder om | 2 oo] + si[_+Pin bushing replace | 1eot_[fncude sat wie 10| Cat eelation [7a Roteronce tor eat [uu] ca assy [Detachiatiach| | 12], «Front lower glass, oor mat }Decachatiac| rye } 13}, + Rear cover mounting bolts |Detachattach 5 places Jo2 |< 14} Seat roar cover fDetachvattach| 1 pe. + 15} + Aircon duet [Detachattach) 2 a 16| + Couper for gauge cluster (let) [Detachattach) 1 « 1] + Geb slinging [Detachiattach| paces © 20] Guar zeation 6 Taronce for guard 21) Cover (t) [Dewachiavach| pe. | o2 | + 22]. «Cover 1) slinging [Detaclottach| 1 pe. or) 6 E| 25] ranct assy [Detachiatach] 1 pe a} e & | 24f cover assy 6) IDetackvateneh] 1 pe oa] & | 25) Bonnet assy () [Detachattach| 1 pe 02 | 6 2 | 26] + Bonnot assy slinging [Detachatiach| 1 pe a1 |e S| arf cuara bDetachieiach) 1 pe. | a] © 3 | 23} Guard assy jDetachlatiach| pe. | or] © © | 29] cover ao) DDetachiattach| 1 pe. a] eo 30] Guard (24) IDetachisxach| 1 pe oa fe 21 Cover an) [Detachisxach| 1 pe. a] e 22} Guard 08)18) [Detachiatach| 1 pe. ote 43} Guard asay 26,85) Inetachatzach| 1 pe a] eo 34] Guard assy 7) [Detachiatsach) 1 pe }oz | + } 88) Bracket assy (16) Ibetachiattach| 1 pe on |e 36} Cover assy (73) [Detachiaezach] 1 pe or] e sifBracket assy (12) [Detachittach| 1 pe on fe sePBracket assy @27) [Detachiattach) 1 pe oz | © sofBracket assy (15) JDetachatiacs| 1 pe Joz |e 40) Bracket asey_( IDetachateach| 1 pe rte [30] cover solation | etorence for undercover 3] Cover (2) [Detachittach| ale 2] Cover Iberacbiatach| pe. | ole Work tobe ee Groxp Lectin oe | nie Remark é T Potachataai] 10 Nake | eiachiatiach| 1p, or} eo é eiachaviach| 1p, a i Detaciatach| 1 po oa |e S| stoma PDecacictch| pe aa | © S |_ 55} cover) etacatich| 1p. mes x [00] counter eign ron Thea ° 61} Counter weight ASSY [Detach/attach| o4 |e 6a) «Counter weight iting ig eiaciac oa} eo | 60] Counter msighttemporry slinging | Preparation Joa | + 64)» Counter weight mounting bolt [Detach/attach| pore 65|_+Coumr wight singing DDetachanh ajo al Conta slain 0] EG consol ASST PDeacvatach| pe | Ince ajanimene ao al «Emergency stp ob contro eabe _|_Replase_| 16 or |e 10] Take lation © Retrene fr Ar eae 1) fir cleaner ASST [Demctvavacs| Tp Te] = 13) soe @) eiactattach| 1 ale 13) ow @) foechatach) 1 a | + Biemen Replace | a [7 20f exhaust relation 9. Reference for muffler 2] utr ASS Dractvatach| 2p ue | «Uo Peracvattasi| 1p, a} © 23), Clamp ASSY izes) 1p. a} eo aul casket Replace | pe als » [__20| Radiator relation [ 1A, Reference for Radiator E | a1) Racntr assy [Deeevatach] pe w]e E| sd) somant aL Replace. | 1pe. ale Ba). 6 concentration ofcniant Measuring | 19 oa | © B| 34] eacconienser [ostacivatach| 192 oa | © =| ef esuy footacwatach| 1s | BS] ao] bracket etacvattch| 1 oa | + oi] «Sab tak peiacvttach} 1p, oa | ae] +Fan guns eiscivaict| 1 pe a |e as) Water hose nator IG) petscratah) 2 02 | © 40) + Radiator mounting tole removing [Detaclattach| 2 pe oa | © 4a) Undercover Ioetacivatac| 1 pe oa} 42) Hiya tank suction topper attach detache, oa | © 43| | +Hydraulic oil piping coupling [Detachiactach| 1 pe. os | 44) +Hydraulic oil piping |Detach/attach} 1 pe. Jor pe 45), Waterhoes 1G — radio) petacnatac} 3 o2 | © 46|_sRadiator iting o brsting Deracatach 2 pe. vale al Pct ration i Reena i] Fuel tank ASST Detacatac pe mee Fel Replae|1 oo |e

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