1997–1999 Kobelco SK25SR / SK30SR / SK35SR Excavator Shop Manual Set (P/N S5PW0001E2)

Kobelco publication S5PW0001E2 covers the 1997–1999 SK25SR, SK30SR and SK35SR mini excavators, with the main shop documentation first issued in May 1997 and revised through April 1999. This manual set also includes breaker/nibbler mounting instructions and Yanmar TNE engine service information.

• Hydraulic testing: Main and pilot circuit pressure tests, cylinder cycle-time checks, travel deviation measurements, natural drift tests and slew bearing play measurements.

• Hydraulic component repair: Pump, control valve, pilot valve, swivel joint and hydraulic cylinder disassembly, inspection and reassembly, with component-specific maintenance standards.

• Travel and slew units: Motor and reduction-unit repair, counterbalance valves, optional parking brakes, crawler replacement, roller service and track adjuster inspection.

• Engine service: Compression testing, valve adjustment, injection timing, internal component measurement, engine disassembly and reassembly, fuel injection pump repair and governor service.

• Electrical documentation: Wiring diagrams, harness layouts, connector views and connection tables for starting, charging, engine controls, relays and cab equipment.

• Attachments and structure: Bucket, arm, boom and dozer blade removal and installation, pin and bushing wear data, shim clearances, component weights and lifting diagrams.

• Breaker and nibbler conversion: Control valve and pedal installation, auxiliary piping, selector-valve arrangements, attachment reinforcement and flushing procedures.

Suited to technicians familiar with hydraulic excavator systems and equipped for pressure testing, precision measurement and supported component lifting.

Hydraulic Circuits and Component Repair

The hydraulic system section explains travel, boom, arm, bucket, swing and slew operation, including compound travel/boom movements and the travel straight circuit. Main piping diagrams and pilot piping diagrams connect the operating explanations to the machine’s hydraulic layout.

Separate pump chapters distinguish the AP2D units used on the SK25SR and SK35SR from the SK30SR pump. Control valve documentation covers main and port relief valves, anti-cavitation valves and spool operation. Symptom-based troubleshooting links weak travel, poor slew power and attachment faults to the relevant checks, supporting fault isolation before major components are replaced.

Hydraulic cylinder chapters include seal work, inspection limits and post-assembly testing. Their repair cautions explain how contamination or an unsupported piston rod can damage cylinder surfaces, bushings and seals.

Undercarriage and Attachment Work

Travel motor documentation extends into the integrated reduction units and brake valves, with separate configurations for optional parking brakes. The SK30SR orbit-type slew motor has its own service chapter rather than sharing the axial-piston motor procedures.

Attachment sections provide pin and bushing inspection data and shim-adjusted clearances. Upper structure work covers the cab, counterweight, tanks, radiator, engine installation and power-takeoff coupling. Component weight tables support lifting preparation; working standards provide fastener and hydraulic-connection torque tables, special tube-spanner information and unit conversion charts.

Electrical Circuits and Harness Identification

The Electric Circuit Diagram is supported by main and engine harness drawings, connector pin arrangements, wire-color information and relay connection data. Serial-specific layouts help match the electrical documentation to the installed harness before tracing starting, charging or control faults. Cab heater, wiper/washer and work-light circuits are included.

Yanmar Engine Inspection and Overhaul

The engine section provides cylinder head, block, piston, connecting rod, camshaft and crankshaft inspection, together with disassembly and reassembly procedures. Compression ratios, valve clearances, idle-speed data and engine performance curves supplement the repair material.

Fuel-system coverage includes injector testing, injection timing, direct-injection pump work and governor service. The Yanmar reference covers several TNE configurations; the Kobelco application table identifies the engine installations relevant to these excavators.

Operation and routine preventive maintenance are referred to the separate operator’s manual.

Breaker and Nibbler Installation Limits

The mounting supplement distinguishes breaker return piping from the reversible circuit used for a nibbler. It covers carry-over operation, selector-valve arrangements, upper-frame modifications and model-specific boom and arm piping.

Its cautions identify machine and oil-cooler damage from incorrect breaker return routing, and arm damage where required reinforcement is omitted. The documented conversion excludes arms longer than the standard arm.

Pressurized hydraulics and suspended assemblies require the manual’s pressure-release and lifting precautions.

Examples of Crawler Tension and Cylinder Wear Data

For all three models, the crawler-tension tables specify standard droop of 60–70 mm for rubber tracks and 118–128 mm for steel tracks. The test section defines the measurement position and the rubber-track joint orientation.

The shared SK25SR/SK35SR cylinder chapter gives a rod-to-bushing clearance replacement threshold above 0.25 mm. That chapter excludes the SK35SR swing cylinder, which is covered separately.

PDF Search, Diagram Detail and Included Publications

Search and diagram detail: PDF text search and embedded bookmarks are unavailable. Small wiring numbers, connector labels and wire-color codes require zooming.

Supplied as one printable English PDF with 805 pages:

All covers, revision pages and the final publisher page are already included in these page counts.