Kobelco SK200-8 SK210LC-8 Shop Manual S5YN0029E04 Hydraulic Excavator Repair Guide

Description

Kobelco SK200-8 SK210LC-8 Shop Manual S5YN0029E04 Hydraulic Excavator Repair Guide

This compiled shop manual is written for technicians working on the SK200-8 and SK210LC-8 hydraulic excavators in the SE Asia and Oceania specification. Book code S5YN0029E04 binds the specification, maintenance, system, disassembly, troubleshooting, and engine books into one service volume. Serial coverage printed in the index is SK200-8 YN12-56001~ and SK210LC-8 YQ12-08001~. Dimension sheets further split the fleet at YN12-60614~/YQ12-08818~, so confirm the machine serial before using a drawing or weight line.

File Details

• Manual type: Shop manual (compiled specification, maintenance, system, disassembly, troubleshooting, and engine books)
• Brand / models: Kobelco SK200-8, SK210LC-8
• Language: English
• Page count: 1264
• File format: PDF
• Book code: S5YN0029E04
• Market shown on index: SE Asia & Oceania
• Component book dates shown: December 2008 first issues, with later revisions including November 2011 (specifications) and July 2010 (engine book S5YN5129E03 / HINO KSS-SMJ5-E004E)

Machines, Attachments, and Serial Breaks

The Kobelco SK200-8 SK210LC-8 Shop Manual S5YN0029E04 Hydraulic Excavator Repair Guide documents both the standard undercarriage and the LC (long crawler) machine. Fully equipped weights in the specification book are 20,400 kg (45,000 lbs) for SK200-8 SE Asia, 20,500 kg (45,200 lbs) for SK200-8 Oceania, and 20,900 kg (46,100 lbs) for SK210LC-8. Component weight tables break the machine into upper frame assembly, lower frame assembly, attachment, and fluids so lifting and transport planning can use published dry and wet figures.

Standard working equipment is the 5.65 m (18 ft-6 in) boom with a 2.94 m (9 ft-8 in) standard arm and 0.80 m³ (1.05 cu-yd) bucket. Alternate combinations in the same book are the 2.4 m (7 ft-10 in) short arm with 0.93 m³ (1.22 cu-yd) bucket and the 3.5 m (11 ft-6 in) long arm with 0.70 m³ (0.92 cu-yd) bucket. Hoe-bucket tables list heaped capacities from 0.51 m³ to 0.93 m³, struck capacities, tooth count, side-cutter width, and region-specific bucket weights (Oceania standard 0.80 m³ bucket 640 kg; SE Asia side-pin 0.80 m³ bucket 730 kg). Combination charts mark standard, general, light-duty, and prohibited pairings for breaker and nibbler as well as buckets.

Crawler shoes are listed at 600 mm (23.6 in), 700 mm (27.6 in), and 800 mm (31.5 in) grouser widths, with overall crawler widths and ground pressures for STD and LC. The specification note directs 600 mm shoes on rock and gravel ground to avoid shoe bend, loose shoe bolts, and track-assembly damage. Trailer-load drawings give overall transport dimensions and regional shipping weights for the standard boom-arm-bucket set.

Engine and Machine Performance Data

Both models use the HINO J05E-TA: a water-cooled, 4-cycle, 4-cylinder direct-injection diesel with intercooler turbocharger. Printed figures include 4 × 112 mm bore × 130 mm stroke, 5.123 L displacement, compression ratio 18.0, rated output 114 kW (155 PS) at 2,000 min⁻¹, and maximum torque 572 N·m (422 lbf-ft) at 1,600 min⁻¹. High idle is 1,970 to 2,030 min⁻¹ and low idle 970 to 1,030 min⁻¹. Valve clearances (cold) are 0.3 mm intake and 0.45 mm exhaust, firing order 1-3-4-2, injection starting pressure 3.2 MPa, and compression pressure 3.4 to 3.7 MPa at 280 min⁻¹. Starter rating is 24 V / 5.0 kW; alternator rating in the machine specification table is 24 V / 1.2 kW. Engine oil quantity is given as full 18.0 L, low 15.0 L, total 20.5 L. The characteristic curve page also states regular-operation fuel use of 20.7 to 23.7 L/h at load factor 0.70 to 0.80.

Travel and swing figures shared by SK200-8 and SK210LC-8 are swing speed 12.5 min⁻¹, travel 3.6 / 6.0 km/h (1-speed / 2-speed), and gradeability 70% (35 degrees). Hydraulic hardware is summarized as two variable-displacement axial piston pumps plus one gear pump, one axial-piston swing motor, two variable-displacement axial-piston travel motors with counterbalance valves, one 8-spool control valve, double-acting boom/arm/bucket cylinders, and an air-cooled oil cooler.

Chapters Covered

• 1 Outline — general repair precautions; preparation before disassembly; safety; hydraulic equipment removal/assembly and air bleed; electrical handling; O-rings and hoses; weld repair; environmental notes; SI unit conversion
• 2 Specifications — component names; general dimensions by boom/arm/bucket and serial group; component weights; transportation dimensions; speed and climbing; engine and hydraulic component summaries; crawler and bucket types; attachment combinations; HINO J05E-TA specification and characteristic curve
• 3 Attachment dimensions — boom, arm, and bucket dimensional drawings and maintenance standards; lug and boss section drawings
• 11 Tools — capscrew/nut and hose/fitting torques; plugs; special spanner; special tools; locking/sealing compounds; suction stopper; counterweight, upper-frame, engine-mount, and track-spring jigs
• 12 Standard maintenance time table — excavator maintenance working-time table; engine maintenance service standard time list
• 13 Maintenance standard and test procedure — performance inspection standard values; engine-speed measurement; hydraulic-pressure measurement and relief-valve adjustment; travel, swing, attachment, and swing-bearing performance tests; mechatro A-B-C controller adjustment and emergency-mode operation
• 21 Mechatro controller — unload, positive/P-Q, boom-up conflux, arm recirculation and anti-cavitation, bucket conflux, swing priority, travel-straight, and pressure-release control; multi-display, self-diagnosis, service diagnosis, trouble history, diagnosis mode, maintenance-schedule set, display adjustment
• 22 Hydraulic system — circuits and components; color coding; neutral, travel, bucket, boom, swing, arm, and combined circuits; pressure draining
• 23 Electrical system — circuit diagrams; equipment and harness lists; instrument panel, controllers, operator controls; upper, engine, floor-plate, cab, and boom harnesses; lighting and travel-alarm installs
• 24 Components system — hydraulic pump-regulator, control valve, attachment and travel pilot valves, swing motor, Oceania and S.E. Asia travel motors, swivel joint, cylinders; electrical equipment list and specifications
• 25 Air-conditioner system — HVAC air cycle and auto system; components, piping, cooling circuit; unit disassembly; refrigerant charging; wiring; troubleshooting and panel self-diagnosis
• 31 Disassembling and assembling — chapter format and tightening-torque indication
• 32 Attachments — remove/install of attachment assembly, bucket, arm, and boom; cylinder disassembly
• 33 Upper slewing structure — remove/install of seat, cab, battery, guards, covers, fuel and hydraulic tanks, pump, air cleaner, muffler, counterweight, radiator and oil cooler, engine, console, multi-control valve (Oceania), control valve, pilot valves, swing motor, swivel joint, upper frame; overhaul of pump-regulator, control valve, pilot valves, swing motor, and swivel joint
• 34 Travel system — crawler, upper and lower rollers, front idler/adjuster, sprocket, travel motor, swing bearing; Oceania travel-motor unit; S.E. Asia travel-motor construction, tools, disassembly, maintenance standard, and troubleshooting
• 46 Troubleshooting by error codes — site judgment, failure classification, mechatro-controller fuse, code-by-code checks
• 47 Troubleshooting by trouble — hydraulic-system symptoms; electrical wiring checks and troubles; engine-related troubleshooting charts
• 48 Troubleshooting (trouble diagnosis mode) — onboard diagnosis-mode procedures
• 51 Engine — HINO diesel engine workshop manual J05E-TA (book S5YN5129E03 / KSS-SMJ5-E004E, 2010.7): engine body, fuel system, electrical, mechanical overhaul, turbocharger, failure diagnosis by status, and engine ECU diagnostic trouble codes

Taken together, the volume is a bench and field reference for measuring the machine against published standards, tracing oil and current through the published circuits, pulling and rebuilding the major assemblies, and diagnosing both machine mechatro codes and HINO engine DTCs. It is not a parts catalog; order numbers must still be confirmed in the parts manual for the applicable machine, as the shop text itself notes.

Shop Tests, Controller Work, and Diagnostics

Chapter 13 is the performance gate for a rebuilt or complained machine. It covers how to use the maintenance standards, the standard-value table, engine-speed measurement after warmup to 60–90 °C at the radiator upper tank, hydraulic-pressure gauge points and relief-valve adjustment, travel speed and deviation, parking-brake drift, travel-motor drain rate, swing speed and swing-brake/parking-brake checks, swing-motor drain, cylinder operating times and oil tightness, and swing-bearing play. Mechatro A-B-C adjustment is written as three linked procedures: engine (“A”) matching of acceleration-command voltage to engine speed, pump (“B”) matching, and unload-valve current (typical adjusting range 520 to 635 mA). Failure of that work is itself an error path (example code A015: engine A-adjustment not done or failed).

The mechatro book explains why a lever move changes pump flow: unload-valve control, positive control and P-Q control, boom-up conflux, arm-in recirculation and anti-cavitation, arm-out and bucket conflux, swing priority, travel-straight, and pressure-release control. Gauge-cluster functions include self-diagnosis, service-diagnosis screens (engine speed, pump pressures, pilot sensors, proportional-valve currents), trouble history, and the maintenance reminder set. Default reminder intervals printed in the controller section are engine oil 500 Hr, fuel filter 500 Hr, hydraulic filter 1,000 Hr, and hydraulic oil 2,000 Hr (ASIA). Work modes start in “S” after engine start and switch S → H. Auto-accel, emergency acceleration when engine control is lost, and pressure-release display behavior are all described so a technician can tell a control problem from a pump problem.

Error-code troubleshooting walks blown mechatro fuses and individual codes such as sensor-range faults after key-on, engine-speed sensor overrange or disconnect, communication loss with the engine controller, engine forcible-stop relay faults, and common-rail pressure errors. Symptom troubleshooting then covers hydraulic complaints (no function, engine stall under load, drift at lever neutral, poor fine control, slow boom-up) and electrical complaints (engine will not stop, CPU data communication error, auto-accel will not drop or raise speed). Engine-related charts cross-check fuel, air, oil, turbo, and battery causes against starting and power complaints before the dedicated HINO workshop book is opened.

Hydraulics, Electrics, and Overhaul Practice

Hydraulic-system chapters map neutral, travel, bucket, boom, swing, arm, and combined circuits and show how to drain residual pressure before opening lines. Component-system text then goes inside the pump-regulator, 8-spool control valve, attachment and travel pilot valves, swing motor, region-specific travel motors, swivel joint, and cylinders. Upper-structure and travel disassembly chapters give remove/install sequences with tool sizes and torque callouts, then full overhaul of the same units. Travel-system work includes crawler separation warnings, roller and idler oil fills (examples: upper roller 30 cc, lower roller 160 cc, idler 200 cc of engine oil API CD #30), sprocket, swing bearing, and separate Oceania versus S.E. Asia travel-motor overhaul paths.

IMAGES PREVIEW

Outline and safety pages require pressure release, blocked attachments, battery disconnect with a “Do Not Operate” tag, correct slings for parts of 20 kg or 23 kg and above (both figures appear in different safety lists), new O-rings and oil seals, and air bleed after oil change or after pump, swing-motor, travel-motor, or cylinder R&I. Pump and swing-motor bleed is by loosening the upper drain plug at low idle until oil appears; travel motors and cylinders are bled by no-load low-speed operation for 10 minutes or more. Electrical rules forbid opening sealed electrical units, require key-off before connectors, and give sulfuric-acid first aid for battery fluid. The HVAC section covers auto air-conditioner construction, refrigerant charge precautions, wiring, and panel self-diagnosis rather than leaving cab climate as an afterthought.

HINO J05E-TA Engine Workshop Section

Section 51 reprints the HINO diesel engine workshop manual for J05E-TA. It covers engine removal and installation from the vehicle, compression testing, cylinder head and block mechanical work, timing gears and flywheel, fuel filter and supply-pump service (including ECU learning-value update after supply-pump replacement), injector QR-code entry after injector replacement, sensors and starter/alternator, turbocharger, oil pump and cooler, and failure diagnosis by engine status. Engine ECU DTC procedures include P0335/P0336 main speed sensor, P0340/P0341 sub speed sensor, P0217 overheat, P0219 overrun, common-rail pressure codes, injector and supply-pump codes, and ECU internal faults, using the Hino-DX tool and signal-check harness where specified. That section is written as a single-engine workshop book based on the HINO MOTOR manual, so chassis R&I steps still come from chapters 33 and 13 of this same SK200-8 / SK210LC-8 shop compilation.

Use This Manual on the Job

The Kobelco SK200-8 SK210LC-8 Shop Manual S5YN0029E04 Hydraulic Excavator Repair Guide supports measuring travel, swing, and cylinder performance against the printed standard-value tables; setting relief valves; performing A-B-C mechatro adjustments; tracing hydraulic and electrical faults by circuit and by error code; removing and overhauling the pump, control valve, swing and travel motors, cylinders, and undercarriage; servicing the cab HVAC; and overhauling or diagnosing the HINO J05E-TA. Using the torque, clearance, idle, pressure, and bleed values in this book keeps a repair from damaging a pump, scoring a cylinder, or leaving the controller on default maps. After purchase the file is delivered as an instant PDF download—no shipping wait—so it can be opened on a shop computer, tablet, or phone and printed for the bench or the machine.