PDF Assembly Manual Kobelco 80CS-2 Acera Hydraulic Excavator - 10 MB
This specialized manual offers detailed procedures for the disassembly and assembly of the Kobelco 80CS-2 Acera Hydraulic Excavator.
It is an essential resource for major overhauls and component replacements.
The guide provides step-by-step instructions, torque specifications, and tool requirements to ensure every task is performed to factory standards.
Ideal for experienced mechanics undertaking complex repairs.
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--- Page 1 ---
31. DISASSEMBLING AND ASSEMBLING
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
31.1 DISASSEMBLY & ASSEMBLY OF THE WHOLE MACHINE ............................ 31-3
31.1.1 DISASSEMBLY & ASSEMBLY .................................................................. 31-3
31.1.2 INDICATION OF TIGHTENING TORQUE ................................................. 31-3
31
Book Code No. S5YN3129E01
31-1
--- Page 3 ---
32. ATTACHMENTS
32.1.3 ARM
32.1.3.1 REMOVING ARM
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket cylinder
and bring the arm down on the ground.
Position to remove arm
(2) Disconnecting piping of bucket cylinder
Release pressure of hydraulic tank, place oil pan to
prepare for oil leaking, and disconnect pipes.
When the removal of bucket cylinder is not
required, skip to procedure (6).
Disconnecting piping of bucket cylinder
Plug both end of disconnected pipes.
Plug:
Tools section 11.5.2-(4)
(3) Removing bucket cylinder rod pin (H)
1. Loosen nut (8), remove capscrew M12X100 (7), and push out pin (H).
Tools: Spanner: 19mm
2. Retract cylinder rod.
Insert resin shim into bucket link side.
SHIM RESIN SHIM
After adjustment of shim, the total gap
should be within 0.6~1.0 mm (0.02~0.04 in).
SHIM
7
(H)=6
13
32
DUST SEAL 8
SECTION DD
SHIM RESIN SHIM
Insert resin shim into bucket link side.
Detail of bucket cylinder rod pin (H)
32-7
--- Page 4 ---
32. ATTACHMENTS
32.1.6 DOZER
32.1.6.1 REMOVAL
(1) Put a support of appropriate height under the
R Q C2, C3
mounting side of dozer body, and make the dozer
C1
at a stable condition not to exert any load to the pin
(P).
(2) Disconnect the hydraulic hoses and apply a plug to
the connecting portions.
Tools : Spanner : 22 mm
(3) Apply a nylon sling to the dozer cylinder (C1), and
lift it up slightly not to exert any load to the pin (Q)
of rod side. SUPPORT P B2, B3
(4) Remove the capscrew (C2) and nuts (C3) those are Removing / Installing Dozer
preventing the pin (Q) from coming out. Remove
the pin (Q), and support the cylinder (C1) with wood
block, etc.
Tools : Spanner : 19mm
(5) Remove the capscrew (B2) and nuts (B3) that are
preventing the dozer body fixing pin (Q) from
coming out, and remove the two pins (P).
Tools : Spanner : 19mm
(6) Gradually move the machine to backward to
remove the dozer.
Weight of dozer assembly : 450kg (992 lbs)
(7) If necessary, remove the dozer cylinder by means
of removing the pin (R) of head side.
Weight of dozer cylinder : 58 kg (128 lbs)
32.1.6.2 INSTALLATION
The installation is carried out with the reverse order of the removal paying attention for the following.
(1) Referring to the Section "ATTACHMENT
DIMENSIONS" of Specifications, replace the worn-
out bushings and dust seals to new ones.
(2) Before installing pin (P), (Q) and (R), apply grease
to their shaft area.
(3) Referring to right Fig., install the nuts for capscrew
to prevent the pin from coming out. NUT
0.5~1.0
Tools : Spanner : 19mm (0.02"~0.04")
STOPPER
CAPSCREW
Tightening Procedures for Nuts
32
32-17
--- Page 5 ---
32. ATTACHMENTS
32.2.1.4 INSTALL
β’ Cylinder tube assembly
β’ Piston rod assembly
β’ Rod cover assembly
β’ Piston assembly
32.2.1.4.1 ASSEMBLING CYLINDER TUBE ASSEMBLY, PISTON ROD ASSEMBLY
(1) Apply hydraulic oil on the head in which pin bushing Push with a press
is inserted and on the pin bushing hole of rod.
(2) Press pin bushing (26) into cylinder tube (1) and
piston rod (2), using a press. 26
(3) Insert wiper ring (27) in both sides.
OIL HOLE LOCATION
PLATE
PISTON ROD WIPER RING
PIN BUSHING
Pressing in pin bushing (rod & tube)
32.2.1.4.2 ASSEMBLING ROD COVER ASSEMBLY
(1) Press fit bushing (4) in rod cover (3) applying plate Push with a press straight down
on the section. After press-fitting, check that the
bushing is not projected from the end surface (A).
(See right Fig.)
PLATE
A
3 4
32
Pressing in bushing
32-27
--- Page 6 ---
32. ATTACHMENTS
32.2.1.8 TOOL AND JIGS LIST
(1) Seal ring fitting jig ( I )
Material : Mild steel
Unit: mm(in)
Applicable
D0 D1 (D2) D3 L0 (L1) L2
cylinder
Boom 111 (4.3701) 110 (4.3307) 86 (3.39) 96 (3.78) 100 (3.94) 72 (2.83) 24 (0.9449)
Arm 96 (3.7795) 95 (3.7401) 71 (2.80) 81 (3.19) 100 (3.94) 72 (2.83) 23 (0.9055)
Bucket 81 (3.1890) 80 (3.1496) 56 (2.20) 66 (2.60) 100 (3.94) 72 (2.83) 20 (0.7874)
Dozer 131 (5.1575) 130 (4.1181) 111 (4.37) 116 (4.57) 99 (3.90) 66 (2.60) 28 (1.1024)
Swing 106 (4.1732) 105 (4.1339) 81 (3.19) 91 (3.58) 100 (3.94) 72 (2.83) 23 (0.9055)
32
32-37
--- Page 7 ---
32. ATTACHMENTS
Items Phenomenon Related parts Abnormalities Measures and corrective actions
1) Remove air.
a) If cylinder is not equipped with air bleed port ;
Release air by extending and retracting it at low
speed several times.
b) If cylinder is equipped with air bleed port ;
Unload so that the internal pressure is not raised,
The operation is Air is remained in
Air loosen air breather and release air completely.
unstable. cylinder.
(Reference)
When cylinder has stopped in an emergency,
cylinder may be extended and contracted
slightly. This phenomenon is caused by the
pressure of hydraulic oil, and easily occurs on
the cylinder of which the stroke is longer.
Great shock
4 when changed The space between 1) Measure dimension of pin and pin bushing, if it
Pin bushing
from / to fitting section and pin exceeds the specified dimension, replace it with
Pin
extension to / bushing is too large. new one.
from retraction.
Insufficient
Noise Lubrication 1) Lubricate.
lubrication
when cylinder is
Pin bushing Scuffing on engaged
worked. 1) Replace it with new one, and lubricate.
Pin section
Hydraulic oil is expanded and contracted with change of temperature and pressure.
Consequently the cylinder is also extended and retracted, so care must be taken in
order not to mistake this for internal leakage. Check it for internal oil leakage in the
constant temperature and pressure conditions.
32
32-47
--- Page 8 ---
33. UPPER SLEWING STRUCTURE
33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (A2) against battery (B1), and tighten capscrew (A3). 33
Tools: Socket: 17mm
Tightening torque : 10.8N-m (8.0 lbf-ft)
(2) Installing grounding cable
Install grounding cable (4) last. Especially care must be taken that the grounding face is free from painting, rust,
etc.
Tools: Spanner: 13mm
33-9
--- Page 9 ---
33. UPPER SLEWING STRUCTURE
(7) Remove hydraulic tank attaching bolt
)
Remove 4 capscrews (A1) M16X50. )
Tools: Socket: 24mm 33
(8) Slinging hydraulic oil tank
Place a wire sling, using the lifting plate on top of
)!
the tank.
Tank weight: Approximately : 62kg (137 lbs)
)
(9) Remove shim (A3). )
)!
Removing hydraulic tank
Record the shim locations.
33-19
--- Page 10 ---
33. UPPER SLEWING STRUCTURE
33.1.12 RADIATOR & OIL COOLER
33.1.12.1 PREPARATION FOR REMOVAL 33
(1) Remove counterweight.
#
(2) Bleed air from the hydraulic tank and install the
suction stopper. (See 33.1.12 RADIATOR & OIL
COOLER)
(3) Remove cover of suction strainer, and adjust oil
quantity so that oil level becomes lower than the
return tube level.
(4) Remove air cleaner hose
Refer to 33.1.9 AIR CLEANER
1. Loosen 2 clips (11).
2. Pulling out hose (5).
Tools: Flat-blade screwdriver
Removing hose (5)
(5) Removing under cover installed on lower side of
6-PLACES
radiator. 3, 7
1. Remove 6 sems-bolts (7) M12X25.
2. Remove cover (3).
Tools: Socket: 19mm
Removing under cover (3)
(6) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose 5
for draining water.
10
[Water capacity of radiator : 4.6L (1.2gal)]
(7) Remove hose from radiator sub tank (6).
1. 6
Remove clip of radiator cap side and disconnect
hose (17).
29
2. Remove 2 sems-bolts (29) M8X20.
3. Remove radiator sub tank (6) and guard (5).
Tools: Socket: 13mm 17
Removing hose of sub tank (1)
Do not loosen the joints of the hoses related to the air-conditioner. Otherwise the refrigerant leaks.
33-29
--- Page 11 ---
33. UPPER SLEWING STRUCTURE
33.1.15 CONTROL VALVE
33.1.15.1 PREPARATION FOR REMOVING 33
(1) Remove panel assembly (2-1) (See 33.1.4.2 Fig. "Removing cover assembly (2-1)")
(2) Remove cover assembly (2-5) (See 33.1.4.2 Fig. "Removing panel assembly (2-4)")
(3) Release air in hydraulic oil tank, open cover of suction element of hydraulic oil, and lower the level.
(See 33.1.8.1 Fig. "Hydraulic oil tank")
Mark each hose with a port name before removing it.
33.1.15.2 REMOVAL
(1) Removing hoses for each piping
Attach tag on hose, and write port name on it, then remove hoses.
Ports Functions Ports on right sides (on machine) Ports Functions
A8 Option (Head) UPPER SIDE B8 Option (Rod)
A7 Arm out B7 Arm in
Dr3 Drain B6 Bucket digging
A6 Bucket dump Dr2 Drain
A5 Boom down B5 Boom up
REAR FRONT
A4 Dozer down B4 Dozer up
A3 Travel left (Forward) B3 Travel left (Reverse)
A2 Travel right(Forward) B2 Travel right (Reverse)
A1 Swing (Right) BOTTOM SIDE B1 Swing (Left)
Ports Functions Ports on rear sides (on machine) Ports Functions
LEFT SIDE UPPER SIDE RIGHT SIDE a8 Option (Head)
a7 Arm out
P3 Pump
Pi2
a6 Bucket dump
a5 Boom down
Pr Back press. a4 Dozer down
CompensatonPump
a3 Travel left
a2 Travel right
a1 Swing (Right)
P Pump BOTTOM SIDE Ps LS press. detection
33-39
--- Page 12 ---
33. UPPER SLEWING STRUCTURE
33.1.20 UPPER FRAME
33.1.20.1 PREPARATION FOR REMOVING 33
(1) Remove attachment (See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove swivel joint (See 33.1.19 SWIVEL JOINT)
33.1.20.2 REMOVAL
(1) Lifting up upper frame temporarily
Attach an upper-frame hoisting jig to attaching
holes of counterweight. Attach 2 chain blocks to
WIRE ROPE
holes of boom foot pin and use these four points 16X2.5m
and hoist upper-frame.
Wire ropes ; CHAIN BLOCK
16 dia. X 2.5m, 1 pc.
16 dia. X 1.5m, 2 pcs.
Chain blocks ; For 1 ton, 2 pcs.
LIFTING JIG
Lifting up upper frame temporarily
(2) Marking match marks on swing bearing
MATCH MARK
Put match marks on upper frame and swing
bearing.
Matching mark on swing bearing and upper frame
(3) Removing upper frame attaching bolts
Remove 23 capscrews (B31) M16X85 and a
reamer bolt (B30) used to install swing bearing and
upper frame.
Tools: Socket: 24 mm
(4) Slinging upper frame
Sling according to Fig "Lifting up upper frame
temporarily", and remove upper frame and put it on
a stand.
Weight: Approximately. 5 tons (11,000 lbs)
Removing upper frame attaching bolts
33-49
--- Page 13 ---
33. UPPER SLEWING STRUCTURE
(3) Disassembling regulator
1. Loosen and remove cap SP (25) (Opposing flats
22
41) and remove springs (30) (31) and spring
retainer (32). Using a magnet, remove rod (39) and
23 33
25
piston B (40) together.
Loosen 4 socket head bolts (49), remove regulator
cover (47), piston U (48), and O-ring (44). And then 30
remove regulator cover H (45), piston H (46), and
O-ring (44). 31
And remove piston (42) and spring (43).
32
39
38
48
40
44 43
47
42
44
49 45
46
Disassembly of regulator (1/2)
Do not loosen nut (23) when not required.
(It might change the power setting.)
2. Remove O-rings (24) (79) from regulator casing
36
(38).
Using a pliers, remove snap ring (74), and using
tapped hole (M5), remove plug (75).
Remove link (77) and then remove sleeve (36).
74
75
79
38
24
3 PLACES
77
Disassembly of regulator (2/2)
33-59
--- Page 15 ---
33. UPPER SLEWING STRUCTURE
(8) Shim adjusting method
After disassembly and adjustment, if the shim SHIM ADJUSTING COLLAR 1
thickness adjustment is required by replacement of (SEE (9) ASSEMBLY JIG)
parts, carry out the adjustment by the following SHIM ADJUSTING COLLAR 2
33
procedure. Prepare shim adjusting collar 1, collar 2 for (SEE (9) ASSEMBLY JIG)
assembly jig in advance, and install collar 2 on the
SOCKET BOLTS 3 PCS.
outer ring of taper roller bearing (5) and collar 1 on (M10 X 35)
housing (4) in the condition where the procedure in
Item 9) "Assembling piston pump main body" is 57
completed. 5
Place seal retainer (52) on it and tighten 3 socket bolts
M10X35 to the specified torque 1.5 N-m (1.1 lbf-ft). 4
Measure the space between collar 1 and seal retainer
(52) with thickness gauge, and determine
"Shim thickness = 1.9 - measured space value (mm)".
Remove collars for adjustment and install shim (3)
equivalent to the determined thickness on the outer
ring of taper roller bearing (5). Shim adjusting method
(9) Assembly jig
1. Rod PW assembly jig
Spring
Spring rate : 0.3
CAP OPPOSING FLATS 17,
Wire diameter : 1.4
DEPTH 7.5
Free length of spring : 60
Total number of coils : 5.25
Outer diameter : 17
Above mentioned specification spring or equivalent
is required.
2. Taper roller bearing press-fitting jig
3. Oil seal press-fitting jig
33-69
--- Page 16 ---
33. UPPER SLEWING STRUCTURE
After a long period of operation, the poppet does not come off in some cases because of the edge on the seat 33
surface of sleeve. Do not disassemble it by force.
c. Remove cap (12) and remove spacer (13), spring
11 10 9 8 7 6 5
(14), and check valve (15).
d. Knock sleeve (9) out by lightly tapping it to the left,
using a pipe of ΓΈ4mm (0.157in) bore diameter and
ΓΈ10mm (0.394in) OD.
15 14 13 12
Removing sleeve (9)
(6) Disassembling of recirculation valve (Boom, Bucket)
1. Remove cap (1), and remove spring (2) and check 1 2 3
valve (3).
Tools: Allen wrench: 27mm
Tightening torqu : 80 N-m (59 lbf-ft)
Disassembling of recirculation valve
(Boom, Bucket)
3
2
(7) Disassembling of pressure compensation valve (Dozer, Boom, Bucket)
1. Remove cap (1), and remove spool assembly (2)
1 2 3 4
and spring (3).
Tools: Allen wrench: 27mm
Tightening torqu : 80 N-m (59 lbf-ft)
2. Hold spool assembly in the holder, hold it further in
a vise, and remove cap, spring (6), and check valve
(7).
Tools: Allen wrench: 5mm TAPPED HOLE: M5
Tightening torqu : 20 N-m (14.8 lbf-ft) (DOZER, BOOM) BKT
Disassembling of pressure compensation valve
(Dozer, Boom, Bucket)
33-79
--- Page 17 ---
33. UPPER SLEWING STRUCTURE
33.2.3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it with
kerosine. 501 33
P port: PF1/4
1 to 4 and T port: PF3/8
(2) Fix pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).
Removing boot (501)
(3) Remove adjusting nut (312) applying spanners to
adjusting nut (312) and circular plate (302).
Tools: Spanner: 22mm, 32mm 312
302
Removing adjusting nut (312)
(4) Remove circular plate (302)
Tools: Spanner: 32mm 302
Removing circular plate (302)
Circular plate is removed
Installing Jig A
33-89
--- Page 18 ---
33. UPPER SLEWING STRUCTURE
33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
33
"# $ !!
! !
* + + + ,+
% &
+ - +& ,
'
'
()
. +& *
33-99
--- Page 19 ---
33. UPPER SLEWING STRUCTURE
5. Lift up and remove cover (39).
33
39
Removing cover
6. Remove snap ring (5) with plier.
7. Remove inner race of needle bearing (6).
6
Removing bearing (6) inner race
8. Remove the O-ring (9).
9
Removing O-ring (9)
9. Remove the balance plate (10).
10
Removing balance plate
33-109
--- Page 20 ---
33. UPPER SLEWING STRUCTURE
b. Drive the spring pin (20)
33
Drive spring pin facing the split to gear side.
Beware of the direction
of spring pin.
GEAR SIDE
Caulk two point with a punch.
20
15
Driving spring pin (20)
8. Carefully mesh the holder 2 assembly (15) in the
internal teeth of the ring gear (10), and the spline of
the pinion shaft (1) with its mating part. In this
condition, insert the holder 2 assembly (15) while 15
turning it.
9. Carefully mesh spur gear 4 (11) in the spur gear 5
(18).
11
Inserting holder 2 assembly (15)
10.Installing the holder 1 assembly (13)
a.
Carefully mesh the holder 1 assembly (13) in the
internal teeth of the ring gear (10), and holder 1
(13) in the teeth of sun gear (12). In this condition,
insert the holder 1 assembly (13) while turning it
slowly.
b.
13
Place sun gear (12) in while engaging with planet
gear of holder 1 assembly (13) slowly.
11. Turn the holder 1 assembly (13) with your hand to
confirm that the pinion shaft rotates smoothly.
Inserting holder 1 assembly (13)
33-119
--- Page 21 ---
33. UPPER SLEWING STRUCTURE
33.2.6.3.3 TROUBLESHOOTING
Trouble Cause Remedy
33
1.
External leakage of hydraulic oil Defective O-ring & seal Replace all seals.
2. 1) 1)
Internal leakage of hydraulic oil Defective slipper seal Replace all seals.
2) 2)
Sliding face worn excessively Replace assembly.
3. 1) 1)
Swivel stem seized Stem and body seized Grind and hone.
Replace assembly, if stem and body are too
loose and causing oil leakage.