1996 Kobelco Super Mark V SK60V SK100V SK100LV SK120V SK120LCV SK200V SK200LCV SK220V SK220LCV Hydraulic Excavator Serviceman Handbook (P/N S7LO0023E)

Kobelco’s Super Mark V Serviceman Handbook, book code S7LO0023E, published March 1996, covers SK60V, SK100V, SK100LV, SK120V, SK120LCV, SK200V, SK200LCV, SK220V, and SK220LCV hydraulic excavators in Standard and Long Crawler configurations. It documents specifications, performance inspections, adjustments, and troubleshooting; full component-overhaul procedures are outside its scope.

Text search and diagram navigation: Text search is unavailable. Five PDF bookmarks lead to selected performance, pump-control, Mechatro, hydraulic, and electrical sections. Small wiring labels require zooming; some boxed line numbers remain difficult to distinguish.

• Hydraulic testing: Pressure-check locations, main, pilot, and port relief-valve adjustments, power-boost checks, and pump control curves support model-specific performance inspections.

• Travel and swing: Travel-speed and deviation checks, motor drain-rate measurements, parking-brake tests, swing performance, and bearing axial-play measurements establish inspection baselines.

• Mechatro diagnosis: Service displays, self-diagnosis codes, failure history, sensor and solenoid checks, and Mechatro “A” adjustment data support controller and governor diagnosis.

• Attachment inspection: Cylinder operating times, oil-tightness tolerances, pin and bushing clearances, and resinous shim tables document attachment performance and wear.

• Electrical circuits: Model-specific wiring diagrams, cluster-gauge connector pinouts, controller connections, and diagnostic tables link circuit identification with fault investigation.

• Maintenance reference: Lubricant and coolant capacities, filter-element part numbers, undercarriage wear standards, and pipe-joint torque tables support routine service and repair assessment.

Suited to technicians familiar with excavator hydraulics and electrical diagnosis, with access to pressure gauges, a hydraulic oil analyzer, and a dial indicator.

Hydraulic Performance and Measurement Procedures

Performance tables distinguish standard values, repair reference values, and service limits. You will find baseline data for travel speeds, swing torque, and cylinder operating times, with model-specific measuring conditions.

Pressure-check illustrations identify measuring points, while relief-valve tables relate adjuster turns to pressure changes. Pump pressure-flow curves distinguish travel and attachment operation; hydraulic circuit diagrams show connections among the pumps, control valve, travel and swing motors, and arm recirculation circuits.

The travel-motor drain-rate procedure warns that incorrect stopper loading against the rotation direction can break the illustrated rib. During testing, always adhere to the stated system pressure limits to prevent hydraulic failure or severe physical injury.

Mechatro Diagnostics and Electrical Repair

The Mechatro chapter applies to SK100V/SK100LV, SK120V/SK120LCV, SK200V/SK200LCV, and SK220V/SK220LCV. SK60V has separate performance and electrical information.

Diagnostic tables connect displayed faults with connector numbers, harness lines and colors, machine symptoms, checking methods, and fail-safe behavior. This helps distinguish a pressure-sensor problem from a harness fault before selecting replacement parts.

Failure history functions and Mechatro “A” adjustment coverage include governor linkage settings, engine-speed learning, and adjustment errors. Cluster-gauge connector drawings and electric circuit diagrams provide additional reference for tracing the relevant connections.

Engine Data and Service Capacities

You get engine oil volumes, compression pressures, valve-clearance specifications, injection timing, and thermostat data for the Isuzu and Mitsubishi power plants. Engine characteristic curves accompany the specification tables.

Lubrication and coolant capacity tables are organized by model. Oil and grease recommendations, filter-element part numbers, and replacement intervals provide the corresponding maintenance reference.

Attachments, Wear Limits, and Lifting Charts

Maintenance standards cover track links, idlers, sprockets, rollers, and track-adjuster components. Pin and bushing tables, sectional drawings, thrust clearances, and resinous shim data provide dimensional references for attachment repair assessment.

Machine dimensions and component weights accompany attachment working-range diagrams and lifting-capacity charts. Coverage includes standard, long, short, and extension-arm configurations, plus 50-foot and 60-foot long-range attachments for SK220V/SK220LCV; the charts include configuration-specific restrictions on power-boost use.

Pipe Joints and Special Tools

Pipe-joint torque tables cover flare, grip, and O-ring seal connections. The handbook warns that tightening an ORS joint with its O-ring outside the groove can damage the ring and cause leakage.

Special tube spanner applications identify tools 2421T160, 2421T138, 2421T130, 2421T115, and 2421T314. A dimensioned solenoid-valve box-wrench drawing and conversion tables complete the workshop reference.

PDF Format and Page Breakdown

This printable PDF is in English, with Japanese and English labels in electrical drawings. The 198-page PDF comprises 193 technical and reference pages, one contents page, two covers, and two blank pages; all are included in the total.