Hướng dẫn sửa chữa máy múc Kobelco SK480 SK500DLC 8Hướng dẫn sửa chữa máy múc Kobelco SK480 SK500DLC 8Hướng dẫn sửa chữa máy múc Kobelco SK480 SK500DLC 8Hướng dẫn sửa chữa máy múc Kobelco SK480 SK500DLC 8Hướng dẫn sửa chữa máy múc Kobelco SK480 SK500DLC 8Hướng dẫn sửa chữa máy múc Kobelco SK480 SK500DLC 8Hướng dẫn sửa chữa máy múc Kobelco SK480 SK500DLC 8Hướng dẫn sửa chữa máy múc Kobelco SK480 SK500DLC 8Printed in Japan 2009 09 (KE) SHOP MANUAL APPLICABLE Book Code No DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM S5LS6111E01 SK480DLC 8 SK500DLC 8 YS10 01501~ 61 61 DEMOLITION MACHINE WITH COMMON.
DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM SHOP MANUAL APPLICABLE Book Code No SK480DLC-8 / SK500DLC-8 YS10-01501~ S5LS6111E01 Printed in Japan 2009.09 (KE) ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM TABLE OF CONTENTS 61.1 FOREWORD ……………………………………………………………………………………………………61-3 61.2 GENERAL VIEW ………………………………………………………………………………………………61-7 61.3 ATTACHMENT …………………………………………………………………………………………………61-39 61.4 MAINTENANCE STANDARD AND TEST PROCEDURE …………………………………………………61-45 61.5 MECHATRO CONTROL SYSTEM ……………………………………………………………………………61-73 61.6 HYDRAULIC SYSTEM …………………………………………………………………………………………61-138 61.7 ELECTRICAL SYSTEM ……………………………………………………………………………………… 61-169 61.8 COMPONENTS …………………………………………………………………………………………………61-219 61.9 DISASSEMBLING & ASSEMBLING …………………………………………………………………………61-246 61.10 DISASSEMBLING & ASSEMBLING OF ATTACHMENT ………………………………………………61-248 61.11 DISASSEMBLY AND ASSEMBLY OF UPPER SLEWING STRUCTURE ……………………………61-289 61.12 DISASSEMBLING & ASSEMBLING OF TRAVEL SYSTEM……………………………………………61-293 61.13 TROUBLESHOOTING …………………………………………………………………………………………61-298 61.14 SAFETY EQUIPMENTS ………………………………………………………………………………………61-302 61.15 AUTOMATIC LUBRICATION EQUIPMENT ………………………………………………………………61-307 Book Code No S5LS6111E01 61-1 61 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ Issue Data of Issue First Edition August, 2009 Applicable Machines SK480DLC-8/SK500DLC-8 : YS10-01501~ 61-2 Remarks S5LS6111E01 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.1 FOREWORD This separate volume describes the specifications, functions, construction, and operation of following attachments which are equipped with the demolition machine with common use type main boom ・ 3-Piece demolition ultra long attachment (LMN) ・ Separate boom The explanations, values, and illustrations in this manual were prepared based on the latest information available at that time Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual Some illustrated pictures may be different from your machine, as technical improvement is continuous; manuals are periodically updated to reflect these changes For further information about this machine, please contact our dealer/distributor For ordering parts and service, inform an authorized Manufacturer distributor of your machine's Serial Number.Owing to the policy of continual improvement, changes may be made by Manufacturer to any of its products without any obligation on the part of Manufacturer 61 61-3 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.1.1 CHANGED MAJOR PARTS FROM STANDARD MACHINE (1) Hydraulic main pump Main pump is PTO type and equips 4th gear pump This gear pump is used for crusher rotation (2) Main control valve One optional valve was added to P1 side Two relief valves for optional valve were added to P2 side The relief valves of P2 side were used for crusher The setting pressure of over load relief valve was set at the factory in advance Switch the mode to "B" to use breaker, and selector valve is switched to the circuit for breaker And hydraulic oil returns to tank (3) Mechatro-controller Internal software was changed (4) Undercarriage adopts Long Crawler, but it is different according to the machine model ・ SK480DLC-8: Mechanical VLC (Retractable crawler) Rigid LC (Fixed crawler) ・ SK500DLC-8: Hydraulic VLC (Hydraulic retractable crawler) (5) Classification of appearance according to attachments ・ Demolition machine with ultra long attachment: Basic arm spec Long arm spec ・ Separate boom: Basic jib cylinder spec Large diameter jib cylinder spec (6) Classification of connector for attachment ・ Stop valve spec (7) Counterweight Replace the counterweight to the one piece weighted counterweight SK500DLC-8: New stack type counterweight is designed (Transportability improvement) (8) Replace two control lever grips to the grips with switch for rotation of crusher 61-4 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.1.2 CHANGED PIPING PARTS FROM STANDARD MACHINE (1) Foot pedal type pilot valves were added to front of floor plate And these pedals are used for operation of jib cylinder and crusher (2) Regarding the hydraulic components, compare the components according to hydraulic circuit and model numbers (3) Switching of LMN/BH is conducted by replacement of connector When L.M.N attachment is equipped, make sure to select the switch of L.M.N side If you select the BH side when you use L.M.N, the arm moves reversely In addition, the working range limitation alarm does not sound, it is very dangerous To match the operation of arm, replace the LMN/BH connector (4) Add 3-face guard and skylight window wiper to the cab (5) To prevent tip-over, add potentio meters to main boom, front boom, and inter boom (6) Add auto grease lubricator (7) Add one-way call device unit Regarding the electric circuit, refer to electric system section (8) In case of SK500DLC-8, add the devices and apparatus of retractable crawler unit 61-5 61 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.1.3 OUTLINE FOR MACHINE 61.1.3.1 SPECIFIED WORK The works in the following specification are allowed to use this machine A In specification for long attachment (L.M.N) Demolition work C In specification for backhoe used for demolition work Demolition work B In specification for separate boom Demolition work Light digging work Light digging work Loading work Loading work For the working details, refer to Section Machine Operation 61.1.3.2 FRONT/REAR AND RIGHT/LEFT OF MACHINE The terms Right-hand, Left-hand, Front, and Rear are used in this Manual to indicate this sides as they are seen from the operator's seat when the cab is over the track idler wheels 61.1.3.3 RUNNING-IN PERIOD This machine is shipped after sufficient adjustment and inspection The lowering of function is made earlier by unreasonable operation at the beginning and consequently the lifetime is made shorter Operate the machine in the following steps of running-in until every part of machine moves smoothly Perform running-in using care especially the following points ・ Do not work with heavy load and high speed ・ Avoid abrupt start, abrupt speed up, unnecessary sudden stop and turn Full loading operation without running-in could cause seizure and flaws, and might exert bad influence on the lifetime of machine Do not neglect the running-in operation 61-6 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.2 GENERAL VIEW 61.2.1 COMPONENTS 61.2.1.1 ATTACHMENTS A 3-PIECE DEMOLITION TYPE B 3-PIECE DEMOLITION TYPE (LONG ARM SPEC.) 61 C SEPARATE BOOM TYPE 61-7 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ D BACKHOE TYPE 61-8 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.15.3 LUBRICATION CONTROLLER Lubrication controller is installed to left wall of the inside of cab And this controller has the following functions Switching of "Auto start" and "Manual start" Setting of "Lubrication interval", "Lubricating time", and "Limitation of lubrication frequency" Initialization of this machine is described on the page 2-11 Indicator Power (LED) Drive (LED) Alarm (LED) Set (LED) Level key Item key Start/Set key Reset/Escape key 10 Fuse (Blade type 10A) In the condition of pressure holding, the controller indicates "0" on the indicator (1) In case of auto lubrication, smaller amount of grease is fed than manual lubrication, but this does not affect performance In the event of failure of the auto lubrication system, it is possible to lubricate manually from the grease nipples located on each distributor Only when the following mode settings are changed, use the "LEVEL" key or "ITEM" key Contact our dealer/distributor when you change "LEVEL" or "ITEM" Lubrication interval Lubricating time Limitation of lubrication frequency When controller is normal, the lamp in the lower right of the indicator flickers after the engine starts 61-308 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.15.4 PARTS NAMES AND FUNCTIONS Indicator Power (LED) Drive (LED) Alarm (LED) Set (LED) Level key Item key Start/Set key Reset/Escape key 10 Fuse (Blade type 10A) Indicator At function is set: Symbol of set item and Level code are indicated Lubrication interval is accumulated Small lamp is flickering At pressurized Rotate clockwise At pressure holding Rotation stops At depressurized Rotate counterclockwise When the lubricating frequency becomes less than nine times Remaining frequencies are indicated (Countdown starts) When abnormality is occurred "E" and "Error code" are indicated Power (LED): When applying current, lamp lights (Pilot lamp) Drive (LED): When pump is working Lamp flickers At pressure holding Lamp flickers slowly At depressurized Lamp flickers quickly Alarm (LED): When abnormality is occurred Lamp flickers Set (LED): When each item is set Lamp flickers Level key: Represented by (6) key hereafter Item key: Represented by (7) key hereafter At function is set Switching key to step to select "LEVEL (Setting item)" At function is set To select "ITEM" Press select keys (6), (7) simultaneously, the mode is changed to setting mode Start/Set key: Represented by "SET" hereafter At function is set "SET" key, after set the "Level code No." by each item"SET" At manual drive When press the Start/Set key, one cycle operation is driven In this case, the operating interval during counting is once canceled, and the new counting starts again after the pump stops automatically Reset/Escape key: Represented by "ESC" key hereafter At function is set After all items are set, releasing key of computer setting mode At abnormality is occurred Alarm releasing key Cartridge Press "ESC" key for seconds or more, the memory of lubrication frequency is reset 61-309 61 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.15.5 SETTING ITEM AND SETTING PROCEDURE To actuate the centralized lubricating system by controller, there are next procedures A AUTOMATIC OPERATION (CONTROLLED WITH TIMER) The lubricator starts and stops lubrication automatically with controller built-in timer If you need the change of set value, contact our dealer/distributor B MANUAL OPERATION The lubricator starts and stops lubrication manually with controller start switch When manual operation is selected, press the start key And one cycle lubrication is performed regardless of the counting time (1) Contents of set items According to the working condition of excavator, ambient temperature, and kind of grease, you can select the next items This machine is set the right table as an initial setting (2) Set items and level codes numbers Do not use the columns which were lined diagonally The code numbers can be entered into each item 61-310 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ (3) Setting procedure ・ In case of setting Before setting, put the controller into "Setting mode" by pressing required keys In this situation, the setting can be entered ・ In case of completion of setting Release the controller from "Setting mode" by pressing required keys And the system returns to usual operation mode which is the situation of lubrication interval counting time Start engine, and turn power on Press (level) key and (item) key simultaneously, and the set mode is selected And the setting LED is flickering (See right diagram.) When the (Item) key is pressed, the setting items (a, b, and c) on the controller are changed in turn as shown in the right diagram 61 61-311 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ (4) How to set (Exercise) Install the initial setting value for the Ultra Long Attachment Demolition Machine See the right table and decide the level codes, and enter the values of lubrication interval, lubrication time, and lubrication limit frequency is 1.5 hour, 15 minutes, and 150 times Press "LEVEL" key and "ITEM" key simultaneously Select and set the required item by pressing "ITEM" key In case of the exercise, press "ITEM" key until "a" is appeared While "a" flickers, press "LEVEL" key and "a" to "0" to "a" to "0" flicker by turns Then, code number (number portion) is moved up for every pressing "ITEM" key It changes as follows "a" to "0" to "a" to "1" "a" to "2" to "a" to "9" For exercise, input "2" in the level code No of the Table to set 1.5 hour When "a" to "2" flickers, press "SET" key Now 1.5 hour has been set to "a" And "b" to "0" to "b" to "0" flickers for next setting item So, for exercise, input "6" in the Table to set 15 minutes When "b" to "6" to "b" to "6" flickers, press "SET" key For the following setting, since the "c" to "0" flickers, input code "5" in the Table when "c" to "5" flickers When "c" to "5" to "c" to "5" flickers, press "SET" key, and "a" and "2" are flickered alternately After setting every item for "a" "b" "c" Press "ESC" key for seconds or more to release the setting mode Immediately after pressing "ESC" key, the counting of lubrication interval is started, and the flicker at a part of indication segment proves the execution of counting After setting, the set value is stored even if the power is off If the cartridge is replaced with new one, press the "ESC" key for seconds or more When release your finger from key, figure "0" flickers several times on the indicator, and it shows the reset of lubrication frequency 61-312 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.15.6 NORMAL OPERATION DISPLAY LIST The condition of the lubrication system can be known by segments LED of the control panel and the display contents of LED This list is useful to judge whether the operation is normal or abnormal after the initial setting and the installation A NORMAL OPERATION UNDER NORMAL OPERATION 61 61-313 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ B ERROR LIST kinds of the lubrication system error are shown by alarm LED, and the error contents and the display are indicated by error code However, the power LED does not light up when the fuse is blown 61.15.7 AUTOMATIC LUBRICATING POINTS Automatic lubrication points are shown below Excluding these lubrication points, lubricate the other points with conventional grease gun according to the instruction on page 5-13 in this manual Lubricate the marked points (Bucket, link, and crusher area) with grease gun Lubricate the bucket area every 50 hours and lubricate the crusher area every hours In the event of malfunction of automatic lubricating system, use the grease gun and lubricate the grease from the grease nipples located on each distributor 61-314 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ A DEMOLITION BACKHOE No Lubricating points Q'ty No Lubricating points Q'ty Boom foot (Right) Boom cylinder rod (Left) Boom foot (Left) Arm cylinder head Boom cylinder head (Right) Boom point Boom cylinder head (Left) Arm cylinder rod Boom cylinder rod (Right) 10 Boom cylinder head 61 61-315 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ B 3-PIECE DEMOLITION MACHINE No Lubricating points Q'ty No Lubricating points Q'ty Boom foot (Right) Inter boom foot (Right) Boom foot (Left) 10 Inter boom foot (Left) Boom cylinder head (Right) 11 Arm cylinder head Boom cylinder head (Left) 12 Arm foot (Right) Boom cylinder rod (Right) 13 Arm foot (Left) Boom cylinder rod (Left) 14 Arm cylinder rod Jib cylinder head 15 Bucket cylinder head Jib cylinder rod 61-316 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ C SEPARATE BOOM MACHINE No Lubricating points Q'ty No Lubricating points Q'ty Boom foot (Right) Main boom top pin Boom foot (Left) Arm cylinder head Boom cylinder head (Right) 10 Jib cylinder head Boom cylinder head (Left) 11 Arm cylinder rod Boom cylinder rod (Right) 12 Front boom top pin Boom cylinder rod (Left) 13 Bucket cylinder head Jib cylinder rod 61 61-317 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.15.8 REPLACEMENT OF CARTRIDGE A INDICATION OF REPLACING TIME The total greasing amount of every section for time of this auto lubricating system is set about 4cc by the distributor, and the lubricating frequency until the cartridge, 1000cc, is emptied is memorized 200 times by the controller When the remaining greasing times reduces to 10 times or less, the indicator of controller counts down like 9, 8, 3, 2, and when reaches to "0" the error code "E"-"0" goes on and off alternately on the indicator to tell the replacement If the error code "E"-"0" should be missed, the cartridge can afford to lubricate further and when reaching to the following greasing time the grease is automatically lubricated Replace the cartridge within the given time the error code "E"-"0" is indicated The operation the error code "E"-"0" is left indicated might cause inadequate lubricating pressure and so on because the cartridge is emptied B REPLACING PROCEDURE Turn cartridge cover counterclockwise slightly and remove cover At this time, take care that the built in spring for pressure is jumped out of the cover Remove spring and spring retainer giving Remove empty cartridge and install the new attention to the spring retainer direction cartridge After the grease is pushed out a little, screw the cartridge into the inlet securely to prevent the entering of the air Install the spring and the spring retainer paying attention to the spring retainer direction and tighten the cartridge cover securely After replacement of cartridge, keep RESET/ESC switch pushing for seconds or more and the memory of lubricating frequency is reset 61-318 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ Before installing new cartridge, remove inner lid (cap) of cartridge Prevent air and dust from entering into grease Be sure to use recommended grease See the table at the previous page 61.15.9 AIR BLEEDING FROM GREASE PUMP Remove the air-bleed plug located on the side of pump using mm Allen wrench Press the switch marked START/SET, and start pump, then continue the running of pump until the containing air-bubbles grease is completely removed Check that the only pure grease comes out continuously from air bleeding hole Stop the pump and install the air-bleed plug in original position 61 Do not reuse the used cartridge refilled with new grease, to avoid the trouble of grease pump Use the genuine cartridge of parts number 2421Z512 61-319 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.15.10 ・ CAUTIONS IN LOW AND HIGH TEMPERATURE CONDITIONS In low temperature condition The grease in cartridge is abruptly contracted in the event of sudden temperature drop In this case, the grease volume discharged by distributor can not cover the shortage due to contraction of grease volume There is a case that one operation might not be enough to discharge grease to pins In this case, try to operate it several times manually and it is lubricated ・ In high temperature condition The grease in piping from distributor to pins is expanded in the event of the increase of temperature, and the discharge to pins by one operation is a little increased But the greasing volume is stabilized with repetition of operation ・ Adjustment of grease discharge The grease discharge is adjusted before shipping and set to the proper condition by each distributor, but if the adjustment is required, remove vinyl cap of distributor and turn adjusting screw with Allen wrench (3mm) The one rotation of adjusting screw in clockwise reduces about 0.1cc of discharged grease volume 61.15.11 MAINTENANCE AND CHECK The maintenance and checking of the automatic lubrication system must be carried out every weeks according to the items shown in the Table below Checking items Does controller work normally Is the power lamp lit during engine operation? Is error not indicated? Is the pump area free from leak of grease? Is the distributor valve free from leak of grease? Is grease fed to each pin surely? It is less than the ordinary amount of grease, but does grease come out by bit? Are attaching bolts of controller, pump and distributor free from loosening? Are attaching bolts of hose, tube and so on free from loosening? 61-320 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.15.12 GREASING PROCEDURE AT THE TIME OF REMOVAL OF ATTACHMENT When pin on the greasing section is removed to remove attachment, lubricate grease until the grease comes out of the boss end 61 61-321 ［61 DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.15.13 TROUBLESHOOTING When this lubrication system fails, the corresponding error code on the controller display flickers Check the system for the cause of failure and take a corrective action 61-322 ... 51,300kg [52 ,80 0kg] 51,700kg [53,200kg] 50,000kg [51,600kg] Machine weight (Without attachment) 40,300kg [41 ,80 0kg] 40,300kg [41 ,80 0kg] 40,300kg [41 ,80 0kg] 40,300kg [41 ,80 0kg] 40,300kg [41 ,80 0kg] Machine... DEMOLITION MACHINE WITH COMMON USE TYPE MAIN BOOM］ 61.2 .8 ENGINE SPECIFICATION 61.2 .8. 1 SPECIFICATIONS Applicable machine SK460 -8, SK 480 LC -8 Engine model HINO P11C-UP Water-cooled, cycle cylinder... 2,990(Most retracted) 3,490(Most extended) 2, 980 (Most retracted) 3, 480 (Most extended) B 4.5M Main boom + 3.98M Insert boom + 4. 485 M Front boom + 2.3M Inter boom + 5 .85 M Arm + KR1100TPR Nibbler/Crusher