2000–2002 Kobelco SK200SR / SK200SRLC Hydraulic Excavator Shop Manual (P/N S5YB0001E(3))

This Kobelco shop manual covers the 2000–2002 SK200SR and SK200SRLC hydraulic excavators equipped with the Isuzu AA-4BG1 TC engine. Book Code S5YB0001E(3) includes chapter revisions through May 2002, with specifications, repair procedures and troubleshooting for standard and long-carriage configurations.

• Hydraulic repair: Main pump and regulator overhaul, control and pilot valve service, swing motor repair, swivel joint rebuilding and pressure-testing procedures.

• Cylinder service: Boom, arm and bucket cylinder disassembly, seal installation, inspection and leak testing, with separate procedures for the documented serial-number change.

• Travel and undercarriage: Travel motor and planetary reduction repair, crawler removal, roller and idler service, sprocket inspection and swing bearing replacement.

• Mechatro and electrical diagnosis: Controller “A” adjustment, self-diagnosis, service displays, trouble history, wiring diagrams and harness connection drawings.

• Engine repair: Internal disassembly, cylinder head and liner inspection, crankshaft measurements, reassembly, injection nozzle service, cooling-system repair and turbocharger inspection.

• Air conditioning: R134a system construction, unit removal, evaporator and actuator replacement, evacuation, refrigerant charging and electrical troubleshooting.

This manual suits experienced excavator technicians equipped for hydraulic pressure testing, precision measurement and heavy component handling.

Hydraulic Systems and Cylinder Changes

Separate EU, KAI and OCEANIA circuit layouts identify differences in control valves, pressure-release arrangements and optional equipment. The hydraulic chapter explains travel-straight control, boom conflux, arm recirculation and swing priority, connecting component operation with the symptoms covered in the troubleshooting charts.

Cylinder selection: The earlier cylinder sections apply to YB01-01001~ and LA01-01001~01098; revised sections apply from LA01-01099~. Their construction drawings, component references and assembly procedures help identify the correct cylinder design before selecting seals or planning a rebuild.

Pump, valve and motor chapters include inspection limits and component-specific troubleshooting. The manual also warns that inadequate oil filling or omitted air bleeding after hydraulic component work can damage the equipment.

Mechatro Controls and Electrical Fault Tracing

Self-diagnosis tables link fault displays to connector pins, wire numbers and wire colors. Service diagnosis separates commanded and measured values, while trouble-history displays associate stored faults with operating hours.

The controller “A” adjustment section covers controller or governor motor replacement. Its preparation notes explain that an extended emergency-stop knob prevents correct engine-speed setting.

The Electric Circuit Diagram and Harness Connection Drawing support tracing faults through the controller, sensors, proportional valves and cab wiring. Regional equipment lists identify the corresponding harness and electrical assembly differences.

Engine Overhaul and Fuel-System Scope

The integrated engine chapter is adapted from Isuzu service material for this machine’s 4BG1 installation. It covers cylinder head, valve train, pistons, liners, connecting rods and crankshaft inspection, followed by reassembly and engine tuning. Lubrication and cooling chapters include oil pump, oil cooler, water pump and thermostat work.

Injection equipment: Nozzle testing and injection-timing procedures are included. Injection-pump adjustment and repair are assigned to an authorized injection-equipment service outlet; the calibration sheets are examples, not universal settings for this excavator.

Undercarriage, Attachments and Workshop References

Travel reduction procedures cover planetary carriers, bearings, seals and post-assembly inspection. Crawler, roller, idler and sprocket sections provide wear criteria, while the upper-structure chapter covers removal of the cab, counterweight, engine and swing frame.

Lifting diagrams, the Boom Dimensional Drawing and engine characteristic curves supplement attachment dimensions and crawler-shoe data. Standard maintenance labor times, tightening tables, unit-conversion logarithmic charts and tool references—including suction stopper assembly 24100P978F2—support workshop preparation.

Breaker hydraulic circuits are included, but the separately indexed YB63 breaker/nibbler installation chapter is not included in this PDF.

Observe the manual’s precautions for protective equipment, hydraulic pressure release and secure support of raised components.

Cab Air-Conditioning Service

The R134a chapter includes refrigerant-circuit diagrams, connector identification and diagnostic charts for blower, temperature-control and actuator faults. It specifies SP20 compressor oil and explains how moisture contamination and incorrect refrigerant charging affect system operation.

Examples of Engine Settings and Final-Drive Lubrication

For the AA-4BG1 TC installation, the engine specification table lists injection timing at 9° before top dead center. Intake and exhaust valve clearance is 0.4 mm (0.016 in.) with the engine cold.

The travel reduction unit specification lists a lubricant capacity of 5.5 L (1.5 gal) and SAE #90 (GL-4) gear oil, separately from the hydraulic motor specifications.

PDF Access, Diagram Detail and Page Breakdown

Search, navigation and diagrams: PDF text search is unavailable, and there are no embedded PDF bookmarks. Small wire labels and connector codes in the large-format circuit drawings require magnification.

The download is one printable English PDF with 917 pages: four opening pages, 714 pages of excavator specifications, systems, repair and troubleshooting, and the integrated 199-page engine section. The total includes the cover, two safety pages, master index, chapter title pages and revision sheets.