2001–2011 Kobelco SK30SR-2 & SK35SR-2 Hydraulic Excavator Service Manual Set (P/N A0A5063-2 T9610)

This service manual set combines the Kobelco shop manual for the 2001–2011 SK30SR-2 and SK35SR-2 mini excavators, Book Code S5PW0002E, with the included Yanmar TNE-series engine service manual. Kobelco sections include December 2002 revisions and cover canopy/cab machines in US, EU, and Oceania configurations.

• Hydraulic repair: Pump, BCV35 control valve, pilot valves, slewing motor, and swivel joint disassembly, inspection, reassembly, and air-bleeding guidance.

• Travel and undercarriage: Travel motor and reduction-unit overhaul, parking-brake and two-speed functions, crawler replacement, and roller, idler, sprocket, and slewing-bearing service.

• Attachments: Boom, arm, bucket, dozer, swing bracket, and hydraulic cylinder removal and installation, with seal work and pin/bushing maintenance standards.

• Electrical diagnosis: Wiring diagrams, connector views, harness connection tables, and troubleshooting for starting, instruments, travel-speed selection, and optional deceleration.

• Engine service: Yanmar 3TNE82A disassembly and reassembly, compression testing, injection checks, timing adjustment, and internal wear measurements.

• Performance testing: Hydraulic pressure checks, travel and slewing tests, cylinder speed and drift measurements, slew-bearing play, and crawler-tension inspection.

The material suits experienced equipment mechanics equipped for hydraulic testing and component lifting. Hydraulic component disassembly calls for specialist knowledge or parts-service training.

Hydraulic Circuits and Component Repair

The hydraulic chapters explain pump control, pilot operation, and control-valve functions. Hydraulic Circuit Diagram sheets distinguish regional configurations, while the Travel/Dozer Combined Operating Circuit shows how shared functions interact.

Control-valve reassembly requires hydraulic equipment for relief-setting, leakage, and flow-resistance tests. Faulty relief-valve assemblies are generally specified for replacement.

The air-bleeding notes warn that operating pumps or motors without proper filling and bleeding can damage the equipment. Hydraulic teardown also involves residual pressure and heavy assemblies; follow the manual’s pressure-release and support precautions.

Attachment Standards and Travel-Drive Assembly

Boom dimensional drawings, swing bracket dimensional drawings, and pin/bushing tables distinguish standard dimensions, repair values, and serviceability limits. Separate serial-specific tables help identify the applicable fit before replacement pins or bushings are selected.

Travel-drive overhaul includes the hydraulic motor, parking brake, two-speed mechanism, and spur/differential reduction unit. The tapered-roller-bearing clearance procedure applies after specified drive components are replaced; overlooking it can cause motor malfunction and shorten service life.

Electrical Fault Tracing

The Electric Circuit Diagram sheets and Instrument Panel Harness drawings provide wire codes, connector details, and regional harness arrangements. Separate electrical sections distinguish the earlier machines from the later PW10/PX11 builds.

Fault charts address a starter that will not rotate, an engine that cranks without starting, instrument failures, loss of control functions, and travel-speed or deceleration faults. The charts link symptoms to circuit tests and component checks.

Yanmar Engine Repair and Included Limits

The engine section pairs the 3TNE82A-YBC installation with SK30SR-2 and 3TNE82A-YBD with SK35SR-2. Engine performance curves accompany the excavator-specific specifications.

The included TNE manual adds cylinder-head, valve-train, piston, connecting-rod, crankshaft, gear-train, and trochoid-pump inspection and repair content. Its broader engine-family tables require the matching 3TNE82A column.

The separate Yanmar Chapter 10 torque tables and referenced end-of-manual engine exploded drawings are not included in this PDF. Cylinder-head tightening data is present in the reassembly section.

Torque References and Maintenance Labor

Capscrew and nut tables cover M6–M36 fasteners, with lubricated and unlubricated values. Other references address hose joints, sleeve-type fittings, cylinder-seal jigs, and counterweight lifting equipment.

Standard maintenance times assume trained technicians, an equipped shop, and a well-maintained standard machine. Diagnosis, machining, welding, transport, and administrative time are excluded from the listed allowances.

A Preview of Engine Settings and Slew-Bearing Limits

These examples represent a small selection of the engine and chassis service data in the manuals.

For both excavator engines, Kobelco specifies cold intake and exhaust valve clearance of 0.2 mm (0.008 in). The engine-oil specification lists a maximum volume of 3.9 liters.

Slew-bearing inspection separates the standard play of 1.4 ± 0.4 mm from the 2.6 mm repair value, with a dedicated measurement procedure.

PDF Search, Circuit Detail and Publication Breakdown

Search and circuit detail: PDF text search and embedded bookmarks are not available. Small wiring codes, connector-pin labels, and dense hydraulic circuit details require zooming.

One printable English-language PDF download contains 644 pages across the two publications:

All covers, contents, safety and revision pages, the engine-section introduction, and the Yanmar back cover are already included in these totals.