Kobelco SK200-SK210 Professional Shop Manual (2004) – 1000+ Pages | Crawler | Factory OEM PDF Access

KOBELCO SK200/SK210 Series Shop Manual - 2004 Edition

This professional-grade technical shop manual provides the foundational data and advanced procedural guidance required for the maintenance and overhaul of KOBELCO SK-Series Hydraulic Excavators. A critical technical insight for long-term reliability is the precise calibration of the Mechatro Controller: "A" and "B" adjustments must be performed sequentially to synchronize the governor motor with the hydraulic pump loading. Maintaining these specific clearance benchmarks and pressure settings is vital to prevent sluggish hydraulic response and ensure peak operational uptime under heavy-duty cycles.

Technical Applicability & Serial Ranges

• SK200/SK200LC-6E Series: Covers machines with Machine ID YN10-38001 and higher.
• SK210/SK210LC-6E(S) Series: Covers machines with Machine ID YQ10-05501 and higher.
• SK210NLC-6ES (Narrow Chassis): Technical configurations specifically optimized for the narrow-track regional variants.

System Architecture & Operational ROI

• Hydraulic Precision: Detailed specifications for the 6-spool control valve and variable displacement axial piston pumps ensure factory-standard cycle times.
• Engine Performance: Full technical benchmarks for the Mitsubishi 6D34-TLE2A and 6D34-TLU2D intercooled turbo-diesel engines.
• Safety & Structural Integrity: Includes rigorous maintenance standards for pin-to-bushing clearances (e.g., 2.5mm service limit for boom foot pins) to prevent structural fatigue.
• Calibration Accuracy: Step-by-step diagnostic procedures for the Mechatro system, including fault code analysis and proportional valve adjustments.

Document Metadata

• Book Code: S5YN0017E (Comprehensive Series Manual).
• Publication Date: November 2004

Technical Depth & Factory Benchmarks

• Engine Performance: Mitsubishi 6D34-TLE2A/6D34-TLU2D water-cooled, 4-cycle direct injection with intercooler turbocharger. Rated output of 150 PS (110 kW) at 2,000 rpm with a maximum torque of 428 lbf-ft at 1,500 rpm.
• Hydraulic System Pressures: Main relief valve (ATT/Travel) standard setting at 4,980 psi (350 kgf/cm²), with power boost capability up to 5,470 psi (385 kgf/cm²). Swing relief is factory set at 4,050 psi (285 kgf/cm²).
• Clearance Standards: Boom foot pin standard clearance of 0.08–0.10 inches (2.0–2.5 mm) service limit. Thrust direction shimming is required for boom foot if clearance exceeds 0.02 inches.

Maintenance & Visual Navigation Aids

• Calibration Screens: Step-by-step multidisplay diagnosis codes for service diagnosis modes No. 2 through No. 25, covering engine speed and proportional valve current (mA).
• Hydraulic Schematics: Detailed layouts of the 6-spool control valve, variable displacement axial piston pumps, and pilot primary/secondary pressure circuits.
• Dimensional Drawings: Comprehensive orthographic views of the 18'6" (5.65m) boom, 9'8" (2.94m) standard arm, and multiple bucket configurations (0.51 to 1.05 cubic yards).

Table of Contents

• Section 1: Specification Section - General dimensions, weight of components, and engine specifications.
• Section 2: Maintenance Section - Tools, tightening torques, and standard maintenance schedules.
• Section 3: System Section - Mechatro control system, hydraulic system, and electrical components.
• Section 4: Disassembly Section - Procedures for upper structure, travel system, and attachment removal.
• Section 5: Troubleshooting - Fault code analysis and mechatro system diagnosis.
• Section 6: Engine Section - Specific data for the Mitsubishi 6D34 series powerplants.
• Section 7: Optional Attachments - Installation procedures for breakers and nibblers.

Operational Limits & Specifications

• Fluid Capacities: Engine oil (Full level) at 4.8 gal (18.0 L); Coolant system at 5.3 gal (20 L).
• Tightening Torques: M16 (Strength 10.9T) non-lubricated at 250 lbf-ft (35 kgf-m). Flareless joint nuts (Tube OD 15mm) require 87 lbf-ft (12 kgf-m).
• Mechanical Tolerances: Valve clearance (Intake/Exhaust) is 0.016 inches (0.4 mm) measured cold. Fuel injection timing is set at 14° before top dead point.

FAQ

Does this manual cover specific serial number ranges for the SK210LC-6E series? Yes, this technical documentation is specifically applicable to the SK210 and SK210LC-6E(S) models starting from Machine ID YQ10-05501 and higher, as well as the SK200 and SK200LC-6E models beginning with Machine ID YN10-38001. It ensures that technicians working on these specific production runs have the correct engineering data for their chassis.

What are the primary relief valve pressure settings for the main hydraulic system? The manual specifies that the main relief valve for attachment and travel circuits is factory set at 350 kgf/cm² (4,980 psi). When the power boost function is activated, this pressure limit increases to 385 kgf/cm² (5,470 psi), providing the necessary force for extreme excavation conditions.

Does this document provide comprehensive coverage of the mechatro control system? Absolutely. Section 3 (System Section) provides an exhaustive breakdown of the mechatro control architecture, including the ITCS (Intelligent Total Control System). It details the logic behind the "A" and "B" adjustment procedures required for the governor motor and pump drive synchronization to ensure the engine and hydraulics operate in peak harmony.

What specific maintenance procedure is required for the boom foot pins to prevent structural wear? Technicians must monitor the clearance of the boom foot pins and bushings, adhering to a service limit of 2.5 mm (0.10 inches). The manual instructs that if the thrust direction clearance exceeds 0.5 mm, specific shimming must be applied to maintain structural alignment and prevent uneven loading on the attachment.

Can I instantly locate and print specific wiring diagrams or troubleshooting flowcharts for field repairs? Yes, the digital structure of this manual allows for rapid navigation to Section 5, which contains the specialized troubleshooting fault codes and electrical schematics. Technicians can instantly access and print high-resolution diagrams for the gauge cluster diagnosis modes or the engine controller (C-1) pin-out charts, facilitating immediate on-site repair without carrying a bulky physical binder.