Kobelco SK135SR-2 SK135SRLC-2 Shop Manual S5YY0021E01 Hydraulic Excavator Service Guide

Description

Kobelco SK135SR-2 SK135SRLC-2 Shop Manual S5YY0021E01 Hydraulic Excavator Service Guide

This compiled shop manual gathers the repair, adjustment, and diagnosis material needed to keep a SK135SR-2 or SK135SRLC-2 hydraulic excavator in service. Book code S5YY0021E01 binds the specification, maintenance, system, disassembly, troubleshooting, and engine groups used on these compact-radius machines. Serial coverage printed in the applicable-machines tables is SK135SR-2 : YY06-15978~ and SK135SRLC-2 : YH06-08090~. Section issue dates on the bound books fall in November 2010, with the compiled volume carrying a 2015 Kobelco Construction Machinery copyright line.

File Details

• Manual type: Shop manual (hydraulic excavator)
• Brand / models: Kobelco SK135SR-2, SK135SRLC-2
• Document number: S5YY0021E01
• Language: English
• Page count: 1195
• File format: PDF
• Applicable serial ranges: YY06-15978~ (SK135SR-2), YH06-08090~ (SK135SRLC-2)

Machines and Powertrain Covered

The specification group identifies both undercarriage lengths. Fully equipped weight is listed as 13,800 kg (30,420 lb) for the SK135SR-2 and 14,700 kg (32,410 lb) for the SK135SRLC-2. Standard working equipment used for the dimension and weight tables is the 4.68 m (15 ft-4 in) boom, 2.38 m (7 ft-10 in) arm, and 0.50 m³ (0.65 cu-yd) bucket. Swing speed is 11.5 min⁻¹, travel is 3.4 / 5.6 km/h (1-speed / 2-speed), and gradeability is 70% (35 degrees).

The installed diesel is the MITSUBISHI D04FR-74kW: water-cooled, 4-cycle, 4-cylinder direct-injection engine with intercooler turbocharger, 102 mm bore × 130 mm stroke, 4.249 L displacement. The detailed engine specification table records compression ratio 17.8, rated output with fan 74 kW (99.2 PS) at 2,000 min⁻¹, maximum torque without fan 375 N·m (277 lb-ft) at 1,600 min⁻¹, high idle 2,220–2,260 min⁻¹, low idle 995–1,035 min⁻¹, firing order 1-3-4-2, 24 V × 5.0 kW starter, and 24 V × 50 A alternator. Engine oil quantity is given as 17.5 L full / 14.5 L low / 18.5 L total. The hydraulic package is two variable-displacement axial piston pumps plus one gear pump, an axial-piston swing motor, two variable-displacement travel motors with counterbalance valves, an 8-spool control valve, and double-acting boom, arm, and bucket cylinders.

IMAGES PREVIEW

Chapters Covered

• 1 Outline — general precautions for repairs; preparation before disassembling; safety when disassembling and assembling; hydraulic equipment handling; electrical equipment; hydraulic parts; weld repair; environmental issues; SI unit system
• 2 Specifications — name of components; general dimensions for SK135SR-2 and SK135SRLC-2; weight of components; transportation dimensions; speed and climbing capability; engine and hydraulic component lists; crawler and bucket types; attachment combinations; engine specification and characteristic curve
• 3 Attachment dimensions — boom, arm, and bucket dimensional drawings and maintenance standards; lug and boss section drawings
• 11 Tools — tightening torques for capscrews, nuts, hoses, fittings, plugs; special spanners; special tools; locking and sealing compounds; suction stopper; counterweight and upper-frame lifting jigs; engine mounting pedestals; track spring set jig
• 12 Standard maintenance time schedule
• 13 Maintenance standard and test procedure — performance inspection standard table; engine speed measurement; hydraulic pressure measurement and relief-valve adjustment; travel, swing, and attachment performance tests; swing bearing checks; mechatro controller input/output and A-B-C adjustment
• 21 Mechatro controller — unload, positive / P-Q, boom-up conflux, arm recirculation and anti-cavitation, bucket, swing-priority, travel-straight, and pressure-release controls; multi display, self diagnosis, service diagnosis, trouble history, trouble diagnosis mode, maintenance-schedule setting
• 22 Hydraulic system — circuits and components; color coding; neutral, travel, bucket, boom, swing, arm, and combined circuits; pressure draining
• 23 Electric system — circuit diagrams; instrument panel, controller, operator switches; upper, floor, engine, cab, and boom harness assemblies; lighting and travel-alarm installs
• 24 Components system — hydraulic pump and regulator; control valve; attachment and travel pilot valves; swing motor unit; travel motor (standard and L spec.); swivel joint; cylinders; electrical equipment list and specifications
• 25 Air-conditioner system — HVAC air cycle; piping; cooling circuit; unit disassembly; refrigerant charging; electric circuit; panel self diagnosis
• 26 Cab interference prevention system (option for offset specification) — outline and functions
• 31 Disassembling and assembling — chapter format and tightening-torque indication
• 32 Attachment — removing and installing boom, arm, and related pins and cylinders
• 33 Upper slewing structure — operator seat, cab, battery, guards, tanks, hydraulic pump, air cleaner, muffler, counterweight, radiator and oil cooler, engine, control valves, pilot valves, swing motor, swivel joint, upper frame; pump, valve, pilot valve, swing motor, and swivel joint overhaul
• 34 Travel system — crawler, upper and lower rollers, front idler and adjuster, sprocket, travel motor, swing bearing; travel-motor unit overhaul for standard and L-spec motors with maintenance standards
• 46 Troubleshooting by error codes — site judgment, failure classification, mechatro-controller fuses, code-by-code checks
• 47 Troubleshooting by trouble — hydraulic system, electric systems, engine-related fault charts
• 48 Troubleshooting (trouble diagnosis mode) — unload, pump, travel-straight, engine, and pilot diagnostic sequences
• 51 Engine — Mitsubishi diesel service group covering specifications, service data, overhaul timing and compression test, basic-engine disassembly/inspection/reassembly, fuel and electrical systems, ECU Q-rank replacement notes, valve clearance, break-in, and scan-tester diagnosis

Taken together, the bound books walk a technician from nameplate identification and lifting weights through circuit theory, on-machine performance tests, component overhaul, and electronic fault isolation. Outline pages spell out tank-pressure release, air-bleed sequences after pump, swing-motor, travel-motor, or cylinder work, and the rule that hydraulic equipment must not be forced apart outside the written procedure. The mechatro group explains how the controller coordinates pump load with engine speed and how the multi display stores replacement intervals (engine oil 500 Hr, fuel filter 500 Hr, hydraulic filter 1,000 Hr, hydraulic oil 5,000 Hr). Upper-structure and travel chapters give removal order, stand and sling requirements, and reassembly torque so a cab, pump, or track motor can be exchanged without guessing fastener size. The engine group, edited from the Mitsubishi supplier manual, adds compression limits, injector and common-rail cautions, and ECU rank matching so a D04FR swap does not leave the machine under- or over-fueled.

Workshop Jobs Supported by This Manual

Use the Kobelco SK135SR-2 SK135SRLC-2 Shop Manual S5YY0021E01 Hydraulic Excavator Service Guide when measuring relief pressure, setting the A-B-C pump and unload outputs after a controller or pump change, timing travel or swing cycle tests, or splitting a travel motor. Attachment dimension plates give boss and pin wear limits for the 4.68 m boom and 2.38 m or 2.84 m arms. Bucket combination tables mark which hoe capacities are standard, light-duty only, or prohibited on each arm so a 0.50 m³ standard bucket is not hung on the long arm. Crawler notes call for 600 mm grouser shoes on rock and warn that the wrong shoe can bend plates and loosen track hardware. Safety pages cover battery disconnect, blocking raised attachments, pinhole hydraulic leaks, and track-pin chip hazards before any of those jobs start.

Diagnosis is split three ways so a shop can start from a displayed code, from a customer complaint such as engine stall at lever stroke or no auto-accel, or from the built-in trouble diagnosis mode that steps through unload PSV, pump, travel-straight, and engine-speed checks. Electric diagrams locate harness assemblies including cab harness YY14E00033F1 and engine harness YY16E00005F1. Air-conditioner pages cover refrigerant charging with the engine at 1,500 min⁻¹ class speed and panel self-diagnosis lamps. Offset-specification machines receive the cab interference prevention calibration sequence after boom, arm, and offset stroke-end teaching.

How to Work From the Document

Begin in specifications to confirm which undercarriage and attachment set is on the machine, then move to tools for torque and jig call-outs before cracking a line. After any suction-side or major-component change, follow the outline air-bleed steps: loosen the pump or swing-motor drain plug at low idle until oil appears; run travel motors and cylinders ten minutes at no-load low speed; cycle digging, swing, and travel to purge the pilot circuit; set the attachment in the oil-level check pose and refill the tank. Never stroke a freshly installed cylinder to the stop on the first cycle. When welding, disconnect the battery ground. When replacing the engine ECU, match the Q-rank stamped with the engine serial plate so power output stays in the intended band.

Get the Manual and Start the Repair

With this shop manual a technician can identify the SK135SR-2 or SK135SRLC-2, weigh and lift major assemblies, test hydraulic and travel performance against the printed standard-value table, overhaul pumps, valves, swing and travel motors, trace harnesses, clear mechatro and engine ECU faults, and rebuild the Mitsubishi D04FR diesel to the supplier service data. Using the published pressures, idle bands, torque figures, and air-bleed order prevents scored pumps, unbalanced tracks, and mis-adjusted unload valves that follow guesswork. After purchase the file is delivered instantly as a PDF—no shipping wait—so it can be opened on a shop PC, tablet, or phone and printed for the bench.