Replacing the pressure plate on a Kobelco EX235S excavator involves several steps and requires a good understanding of the machine’s components and systems. click here for more details on the download manual…..
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Below is a detailed guide that outlines the steps to replace the pressure plate, along with descriptions of the components involved.
### Components Involved
1. **Pressure Plate**: Part of the clutch assembly; it applies pressure to the clutch disc, allowing for engagement and disengagement of the engine from the transmission.
2. **Clutch Disc**: Located between the pressure plate and flywheel, it transmits power from the engine to the transmission.
3. **Flywheel**: Attached to the engine, it provides a smooth surface for the clutch disc and helps in maintaining engine momentum.
4. **Release Bearing**: This bearing allows the clutch to engage and disengage by pushing against the pressure plate.
5. **Clutch Fork**: A lever that mechanically engages and disengages the release bearing from the pressure plate.
6. **Bell Housing**: The outer casing that houses the transmission and clutch assembly.
7. **Fasteners**: Various bolts and nuts that secure the pressure plate to the flywheel.
8. **Torque Wrench**: An essential tool to ensure that fasteners are tightened to the manufacturer’s specifications.
### Tools Required
– Socket set (metric)
– Wrenches
– Torque wrench
– Screwdrivers
– Clutch alignment tool (optional but recommended)
– Jack and Jack stands
– Safety glasses and gloves
– Shop manual (for reference)
### Step-by-Step Procedure
1. **Safety Precautions**:
– Ensure the excavator is on a level surface.
– Engage the parking brake.
– Disconnect the battery to avoid electrical shorts.
2. **Remove the Cabin Cover**:
– Depending on the specific design, you may need to remove the cabin cover or access panels to reach the clutch assembly.
3. **Drain the Transmission Fluid**:
– Place a drain pan under the transmission and remove the drain plug to allow the fluid to drain out.
4. **Remove the Transmission**:
– Disconnect any components that might obstruct the removal of the transmission, such as the driveshaft and any electrical connections.
– Support the transmission with a Jack and carefully remove the bolts securing it to the engine. Slide the transmission back to disengage it from the engine.
5. **Access the Clutch Assembly**:
– Once the transmission is removed, you will have access to the clutch assembly. Remove any protective covers or shields.
6. **Remove the Pressure Plate**:
– Use a socket wrench to remove the bolts securing the pressure plate to the flywheel. Keep track of the bolt locations, as they may be of different lengths.
– Carefully disengage the pressure plate from the flywheel and remove it. Be cautious of the release bearing, which may be attached.
7. **Inspect the Components**:
– Check the clutch disc for wear. If it is worn or damaged, consider replacing it along with the pressure plate.
– Inspect the flywheel for scoring or cracks. If damaged, it may require resurfacing or replacement.
8. **Install the New Pressure Plate**:
– Position the new pressure plate onto the flywheel. Ensure that the alignment is correct.
– If you have a clutch alignment tool, use it to center the disc while you secure the pressure plate.
– Hand-tighten the bolts first, then use a torque wrench to tighten them to the manufacturer’s specifications (refer to the shop manual for the exact torque values).
9. **Reassemble the Clutch Assembly**:
– Reattach the release bearing to the clutch fork if it was removed.
– Ensure that the clutch fork is properly positioned.
10. **Reinstall the Transmission**:
– Carefully position the transmission back onto the engine. Align it properly
and slide it forward until it engages with the engine.
– Reinstall the bolts securing the transmission to the engine and torque them to the specifications.
11. **Reconnect Components**:
– Reconnect the driveshaft and any electrical connections that were disconnected earlier.
– Replace the transmission fluid and install the drain plug.
12. **Reassemble the Cabin Cover**:
– If you removed any panels or covers from the cabin, reinstall them at this stage.
13. **Reconnect the Battery**:
– Reconnect the battery terminals and ensure they are secure.
14. **Test the System**:
– start the excavator and engage the clutch to ensure proper operation. Listen for unusual noises and check for any leaks.
### Conclusion
Replacing the pressure plate on a Kobelco EX235S requires attention to detail and a good understanding of the machinery. Always refer to the manufacturer’s service manual for specific instructions and torque specifications. If you are not confident in your mechanical abilities, consider seeking help from a qualified technician. Safety should always be your top priority when working on heavy machinery.
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