Kobelco SK135SR-1E Excavator Factory Shop Manual 2002–2003 (P/N S5YY0004E2)
993 Pages • 54.51 MB • Instant, Printable PDF
Kobelco Models Covered & Key Technical Specifications
Models: SK115SR-1E, SK135SR-1E, SK135SRLC-1E, SK135SRL-1E
Sub-models / Variants: LC and L configurations; -1E model series; optional dozer blade
Model Years: 2002–2003
Manual Publication Dates: First edition: February 2002; first revision: December 2003
Serial Numbers: YV02-01701–, YY02-03001–, YH02-01301–, LK02-01041–, YV03-02194–, YY03-04464–, YH03-02077–, LK03-01107– (each number denotes the start of an applicable serial range)
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Engine: Isuzu BB-4BG1T, 4-cylinder, turbocharged diesel, 4,329 cc displacement
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Power Output: 58.8 kW (80 PS) for SK115SR-1E; 62.5 kW (85 PS) for SK135 models; both at 2,050 RPM
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Max Torque: 30.0 kgf·m (217 lbf·ft) for SK115SR-1E; 32.4 kgf·m (235 lbf·ft) for SK135 models; both at 1,600 RPM
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Main Relief Pressure — Travel and Attachment Circuit: 330 kgf/cm² for SK115SR-1E; 350 kgf/cm² for SK135SR-1E and SK135SRLC-1E
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Main Relief Pressure — Dozer/Extra Control Valve: 210 kgf/cm² (2,990 psi)
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A1/B1 Port Relief Pressure — Dozer/Extra Control Valve: 280 kgf/cm² (3,980 psi)
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Fuel Tank Capacity: 168 liters (44 US gal)
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Swing Speed: 11.4 RPM for SK115SR-1E; 11.7 RPM for SK135 models
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Travel Speeds — SK115SR-1E: 1st speed: 3.5 km/h; 2nd speed: 6.0 km/h
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Travel Speeds — SK135 Models: 1st speed: 2.8 km/h; 2nd speed: 5.1 km/h
Kobelco Manual Features & Content Preview
- 993-page PDF scan of the Kobelco shop manual, Book Code No. S5YY0004E2, with machine specifications, repair procedures, troubleshooting and optional-attachment installation documentation.
- Engine repair coverage for the Isuzu BB-4BG1T extends to cylinder-head work, liner replacement, crankshaft inspection and engine reassembly.
- Hydraulic teardown instructions cover the main pump and regulator, control and pilot valves, swing motor and swivel joint, with inspection and adjustment standards.
- Mechatro C-1 controller documentation includes self-diagnosis, service readings, stored fault history and the “A” adjustment associated with controller or governor-motor replacement.
- Undercarriage repair covers steel and rubber crawlers, rollers and idlers, plus separate standard/LC and L-type travel-motor procedures.
- Factory wiring diagrams, harness connection drawings and electrical test data support fault tracing between sensors, proportional valves, the controller and gauge cluster.
The procedures suit technicians familiar with excavator systems and equipped to test and adjust hydraulic assemblies after repair.
Model Coverage and Serial Changes
The core chapters carry February 2002 first-edition and December 2003 revision dates. Coverage identifies these earlier and modified machine configurations, including standard and applicable dozer-blade equipment:
| Model | Earlier configuration, starting at | Modified configuration, starting at |
|---|---|---|
| SK115SR-1E | YV02-01701 | YV03-02194 |
| SK135SR-1E | YY02-03001 | YY03-04464 |
| SK135SRLC-1E | YH02-01301 | YH03-02077 |
| SK135SRL-1E | LK02-01041 | LK03-01107 |
The revisions separate controller and harness assemblies by build. Hydraulic diagrams also distinguish the earlier add-on breaker return filter from the updated standard return filter on later machines.
Hydraulic, Travel and Upper-Structure Repair
Hydraulic pressure-testing and relief-valve adjustment procedures distinguish the main, pilot, swing and dozer circuits. Shop mechanics can use the provided reference values for cylinder operating times and swing speeds to verify hydraulic performance against original factory standards.
Upper-structure procedures cover counterweight removal, hydraulic-tank service, radiator/oil-cooler removal and engine removal and installation. The control-valve section warns that excessive vise pressure can distort the boom and arm spools.
Travel-motor rebuilding includes bearing-preload and axial-clearance adjustment. The L-type section has its own distance-piece and thrust-bearing selection procedures and performance-verification tests.
The R134a air-conditioning section covers evacuation, refrigerant charging, leak checks and component diagnosis, supported by a dedicated wiring diagram.
Engine Service and Shop Reference Data
Fuel-system coverage includes injection timing and injection-nozzle inspection and adjustment. Internal injection-pump repair is referred to separate manufacturer service literature. Starter repair and testing are included, along with separate alternator sections for the SK115's 30-amp unit and the SK135's 50-amp unit.
Technical shop data focuses on precise tolerance charts, capscrew torque specifications, and fluid pressure thresholds. Wear limits, fluid capacities and standard labor-time tables support inspection and repair planning. Boom and special-bucket dimensional drawings, lug-section views and pin/bushing clearance charts support attachment checks. Engine characteristic curves provide additional performance references.
Special-tool documentation identifies the boom foot pin pulling tool assembly YX01T00002F1, together with lifting jigs and track-spring fixtures.
Breaker and Nibbler Conversion Coverage
The included 57-page conversion publication, S5YY6304E, dates from May 2002. Its applications are the earlier serial groups for SK115SR-1E, SK135SR-1E and SK135SRLC-1E listed above.
The conversion procedures distinguish KCME, Oceania and Asia configurations. They address control-valve changes, hydraulic piping and instrument-panel modifications, plus idler-link reinforcement, flushing and single/conflux-flow selection. The piping notes explain how incorrect breaker return routing can transmit pressure pulsations to the oil cooler and damage the machine. Breaker-specific installation requirements are referred to the attachment manufacturer.
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