Replacing the shift solenoid on a Kobelco SK200SR Crawler Excavator involves several steps and requires attention to detail to ensure the system functions correctly after the replacement. click here for more details on the download manual…..
- Kobelco SK200SR Hydraulic Excavator
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Below is a detailed guide on how to perform this task, including information on the necessary components and tools.
### Tools and Materials Needed:
1. **Tools**:
– Socket set (metric)
– Wrench set (metric)
– Screwdriver set
– Torque wrench
– Pliers
– Safety glasses
– Work gloves
– Shop rags or towels
2. **Replacement Parts**:
– New shift solenoid (specific to Kobelco SK200SR)
– O-ring or gasket (if applicable for the solenoid)
### Safety Precautions:
1. **Park the Excavator**: Ensure the excavator is on a flat surface, the engine is turned off, and the key is removed.
2. **Use Safety Gear**: Wear gloves and safety glasses to protect from potential hydraulic fluid leaks and debris.
### Step-by-Step Replacement Process:
#### Step 1: Access the Shift Solenoid
1. **Locate the Shift Solenoid**: The shift solenoid on the Kobelco SK200SR is typically located near the hydraulic control valve or transmission assembly. Refer to the operator’s manual for the exact location diagram.
2. **Remove the Engine Cover**: If the solenoid is covered by an engine cover or panel, you will need to remove it. Use the appropriate socket to unfasten any bolts holding the cover in place.
3. **Disconnect the Battery**: To prevent electrical shorts, disconnect the negative terminal of the battery.
#### Step 2: Remove the Old Shift Solenoid
1. **Identify Connections**: Locate the electrical connector and any hydraulic lines connected to the solenoid.
2. **Disconnect Electrical Connector**: Gently pull the connector from the solenoid. If it’s stuck, wiggle it slightly while pulling to release it without damaging the pins.
3. **Remove Hydraulic Lines**: If there are hydraulic lines attached, use the appropriate wrench to unscrew them. Be prepared for some hydraulic fluid to leak, so have rags handy to catch any spills.
4. **Unbolt the Solenoid**: Use the socket set to remove any bolts securing the shift solenoid to the valve body or transmission.
5. **Remove the Solenoid**: Carefully pull the old solenoid out of its mounting position.
#### Step 3: Install the New Shift Solenoid
1. **Prepare the New Solenoid**: Before installing, check the new solenoid for any damage and ensure it matches the old one.
2. **Install O-ring or Gasket**: If the new solenoid requires an O-ring or gasket, ensure it is properly seated to prevent leaks.
3. **Position the New Solenoid**: Align the new solenoid in the mounting position.
4. **Bolt the Solenoid Down**: Use the socket set to secure the solenoid with the bolts removed earlier. Ensure they are tightened to the manufacturer’s specifications using a torque wrench.
5. **Reconnect Hydraulic Lines**: If you removed hydraulic lines, Reconnect them securely. Make sure to tighten them properly to prevent leaks.
6. **Reconnect Electrical Connector**: Plug the electrical connector back into the new solenoid. Ensure it clicks into place
and is secure.
#### Step 4: Reassemble and Test
1. **Replace Engine Cover**: If you removed an engine cover or panel, reattach it and secure it with bolts.
2. **Reconnect the Battery**: Reconnect the negative terminal of the battery.
3. **Check for Leaks**: Before starting the engine, check all connections for leaks, particularly around the hydraulic lines.
4. **Start the Excavator**: Start the engine and allow it to warm up. Test the functionality of the hydraulic system and ensure the shift solenoid operates correctly.
5. **Perform a Function Test**: Operate the controls to ensure the excavator shifts properly and there are no warning lights on the dashboard.
### Conclusion
Replacing the shift solenoid on a Kobelco SK200SR Crawler Excavator requires careful attention to detail and adherence to safety protocols. By following these steps and ensuring all components are properly connected and secured, you can successfully replace the solenoid and maintain the functionality of your excavator. Always refer to the operator’s manual for specific torque settings and additional details related to your model. If you are unsure at any step, consult a professional mechanic or technician.
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