Rebuilding the transmission on a Kobelco SK30SR or SK35SR excavator requires a comprehensive understanding of the machine’s hydraulic and mechanical systems. click here for more details on the download manual…..
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Here is a detailed guide to help you with the process. Note that this is a high-level overview; consult the service manual for specific torque specifications and detailed procedures.
### Tools and Equipment Needed:
1. **Wrenches and Sockets** – Metric sizes to match the bolts.
2. **Torque Wrench** – For precise torque specifications.
3. **Pry Bar** – For gently separating components.
4. **Transmission Jack** – To safely support and remove the transmission.
5. **Fluid Draining Pan** – To collect hydraulic fluid.
6. **Cleaning Supplies** – Including rags, brushes, and solvents.
7. **Gasket Scraper** – To remove old gasket material.
8. **Replacement Parts** – Gaskets, seals, bearings, and any damaged components.
9. **Hydraulic Oil** – For refilling the system post-rebuild.
10. **Service Manual** – For reference on specifications and procedures.
### Step-by-Step Rebuild Process:
#### Step 1: Preparation
– **Safety First**: Ensure that the excavator is on stable ground, and engage the parking brake. Shut down the engine and disconnect the battery.
– **Fluid Drainage**: Place a pan under the transmission and remove the drain plug to allow the hydraulic fluid to drain completely.
#### Step 2: Remove the Transmission
1. **Access Points**: Open the engine cover and any necessary panels to access the transmission.
2. **Disconnect Components**:
– Disconnect the hydraulic lines leading to the transmission. Make sure to cap or plug these lines to prevent contamination.
– Remove the electrical connectors from the transmission (if applicable).
3. **Unbolt the Transmission**: Use the appropriate wrenches to remove the bolts securing the transmission to the engine and the frame.
4. **Use a transmission Jack**: Carefully lower the transmission using a transmission jack. Ensure that it is supported securely as you remove it from the excavator.
#### Step 3: Disassembly
1. **Remove the transmission Case**: Unbolt the transmission case using the appropriate socket sizes. Carefully separate the case from the internal components.
2. **Inspect Internal Components**: As you disassemble, take note of the arrangement of gears, bearings, and seals. This is crucial for reassembly.
3. **Document Wear and Damage**: Inspect gears, clutches, and bearings for wear. Take photos or notes on any damaged components that need replacing.
#### Step 4: Cleaning
– **Clean All Components**: Using solvents and brushes, thoroughly clean all parts, including the case, gears, and other components. Remove old gasket material from surfaces to ensure a proper seal on reassembly.
#### Step 5: Replace Worn Components
1. **Install New Bearings and Seals**: Replace any worn bearings and seals. Ensure that they are installed correctly and lubricated if necessary.
2. **Replace Clutch Packs**: If the clutch packs are worn, replace them according to the specifications outlined in the service manual.
#### Step 6: Reassemble the Transmission
1. **Install Gears**: Carefully place the cleaned and inspected gears back into the transmission case in the correct order.
2. **Install New Gaskets**: Place new gaskets on the mating surfaces to prevent leaks.
3. **Reattach the transmission Case**: secure the transmission case using the specified torque settings from the service manual.
#### Step 7: Reinstallation
1. **Mount the Transmission**: Use the transmission jack to lift the transmission back into place in the excavator. Align it with the engine
and frame.
2. **Reconnect Components**: Reattach the hydraulic lines and electrical connectors. Ensure that everything is secure and properly connected.
3. **Bolt Down the Transmission**: tighten the bolts to the specified torque settings.
#### Step 8: Refill Hydraulic Fluid
– **Add New Hydraulic Fluid**: Fill the transmission with the appropriate hydraulic fluid as specified in the service manual. Check the fluid level as per the manufacturer’s guidelines.
#### Step 9: Testing
1. **Reconnect the Battery**: Reconnect the battery and start the engine.
2. **Check for Leaks**: Inspect around the transmission for any signs of leaking fluid.
3. **Test Operations**: Operate the excavator in a safe area to ensure that the transmission is functioning correctly. Pay attention to any unusual noises or performance issues.
### Final Considerations:
Rebuilding a transmission is a complex task that requires mechanical expertise. If at any point you feel unsure, consult with a professional or seek assistance from a qualified technician. Always refer to the specific service manual for the Kobelco SK30SR or SK35SR for detailed specifications and diagrams relevant to your rebuild project.
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