2004 Kobelco SK200(LC)-6E, SK210(LC)-6E(S) & SK210NLC-6ES Excavator Shop Manual (Book Code S5YN0017E)

This Kobelco Construction Machinery publication (Book Code No. S5YN0017E, first edition November 2004) covers SK200(LC)-6E, SK210(LC)-6E(S), and SK210NLC-6ES excavators equipped with Mitsubishi 6D34 diesel engines. Applicable serial ranges begin at YN10-38001 and YQ10-05501.

Supplied as a 973-page PDF in English, combining excavator service sections, Mitsubishi engine documentation, and optional-attachment installation procedures.

• Hydraulic repair: Main pump and regulator disassembly, control-valve servicing, pilot relief adjustment, pressure testing, and troubleshooting of proportional valves and solenoid valves.

• Mechatro control: Controller "A" and "B" adjustments, engine governor setup, self-diagnosis displays, service readings, and stored trouble history.

• Upper structure and travel: Removal and installation of swing and travel motor units, the swivel joint, crawler components, and swing bearing.

• Engine repair: Cylinder-head and valve work, timing gears, pistons and liners, crankshaft inspection, lubrication-system service, and engine troubleshooting.

• Attachments: Boom, arm, bucket, and hydraulic-cylinder disassembly and assembly, clearance checks, and breaker or nibbler/breaker conversion procedures.

• Air-conditioning: R134a system diagnosis, unit removal, refrigerant charging, electrical checks, and troubleshooting for cooling, blower, and compressor-clutch faults.

This manual suits experienced excavator technicians with hydraulic test equipment and lifting facilities; its hydraulic-disassembly guidance calls for experts or personnel authorized through service training.

Mechatro Diagnosis and Electrical Circuits

Electrical system sections detail connector pinouts and sensor values for the Mechatro control unit. Separate electric circuit diagrams and harness connection drawings distinguish Asia/Oceania and KCME configurations.

The hydraulic and electrical troubleshooting charts address slow attachment movement, weak digging power, travel-speed faults, and swing-brake problems. Service-diagnosis readings link these symptoms to sensor inputs and valve commands, helping narrow the fault before major components are removed.

Hydraulic Pump and Component Repair

The pump chapters distinguish assemblies with and without a PTO unit. Internal repair coverage extends to the regulator, PTO gear casing, main control valve, swing reduction unit, and swivel-joint seals, with component-specific wear limits and inspection criteria.

Hydraulic circuit diagrams and pressure-measurement views identify the relevant test points. The pump instructions warn that forcing apart the servo piston and tilting pin can score these parts.

Undercarriage and Attachment Service

Front idler, track links, upper rollers, and lower rollers have removal, assembly, and maintenance-standard coverage. Travel-motor and reduction-unit procedures include bearing-shim selection; idler-adjuster work uses the documented track spring-setting jig.

Boom dimensional drawings, bucket dimensional drawings, and pin-and-bushing clearance charts support attachment inspection. Swing-bearing checks include axial-play measurement.

Before high-pressure hydraulic tests or track disassembly, follow the manual's guidance on pressure relief, supporting raised components, and handling heavy assemblies.

Mitsubishi Engine Service and TL Supplement

Engine characteristic curves, fuel-injection timing procedures, cooling-system maintenance, thermostat checks, turbocharger inspection, and starter/alternator service accompany the internal engine chapters. Tool references include socket wrench MH061560 for cylinder-head bolts.

The 6D34-TL supplement distinguishes injection-pump and nozzle specifications, the boost-compensated governor, intercooler arrangements, and fan, V-belt, and alternator changes. These differences help technicians select the applicable service data for the 6D34-TLE2A and 6D34-TLU2D builds.

Injection-pump maintenance is referred to a Zexel service station. The turbocharger cartridge is treated as a replacement assembly.

Air-Conditioner and Optional Attachments

The air-conditioner section covers the evaporator, expansion valve, receiver dryer, and motor actuators. It also explains how insufficient compressor oil can cause seizure and gives oil allowances for component replacement.

The optional-attachment booklet (Book Code S5YN6303E) lists SK200(LC)-6E and SK210(LC)-6E(S). Country-specific conversion parts, hydraulic routing, electrical connections, and attachment reinforcement are covered; breaker selection also requires consultation with the breaker manufacturer.

Workshop Specifications and Labor Planning

Torque values for standard cap screws and hydraulic fittings are organized in tables alongside component-specific service standards. The standard maintenance time schedules cover excavator and engine work, supporting labor estimates while identifying exclusions such as diagnosis, machining, welding, and field-service overhead.

PDF Contents and Navigation

The total includes 720 pages of excavator documentation, two engine-section introductory pages, the 12-page TL supplement (Pub. No. 97821-05100), the 179-page 6D34-T manual (Pub. No. 97821-05001), and the 60-page optional-attachment section. Covers, indexes, the four opening pages, and one intentionally blank page are already included in these counts.

PDF text search and embedded bookmarks are not available. Small wiring labels require zooming.