KOBELCO Arm Shock Countermeasure

APPLICABLE No.
SK200-6E YN10-38001~41732
SK200LC-6E YQ10-05501~05981
READ, UNDERSTAND AND FOLLOW ALL SAFETY

PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS
MANUAL BEFORE OPERATING THE MACHINE.
Book Code No. S2YN00019ZE02

Printed in Japan 2007.07 (K·E)
Copyright © 2017 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S2YN00019ZE02] [1228CsCsspWbYs]
FOREWORD
GENERAL
• This manual contains procedures to aid the operator gain peak performance through effective, economical machine
operation and maintenance for the KOBELCO SK200-6E and SK200LC-6E Hydraulic Excavators.
• Before operating the machine, operators must thoroughly read and understand all safety, Operation and Maintenance
instructions found in this manual. Failure to follow the instructions given in this manual may lead to serious injury to
persons and or equipment failure.
• Operators and persons working with this machine should continually study this manual until proper safety, Operation
and Maintenance procedures are completely understood.
• This manual describes the basic operating techniques. Skill is gained as the operator utilizes these techniques and
perfects them with an actual machine.
• Some illustrated pictures may be different from your machine, as technical improvement is continuous, manuals are
periodically updated to reflect these changes.
• This manual may not contain attachments and optional equipment that are available in your area. Please contact an
authorized KOBELCO Distributor for any optional attachments required.
• Materials and specifications are subject to change without notice.
PERIODIC INSPECTIONS
• After delivery of a machine, the Authorized KOBELCO Distributor will make periodic service inspections. These inspec-
tions will be free of charge to the owner of the machine and will be at time intervals set by KOBELCO. Contact an
authorized KOBELCO Distributor for any service related questions not explained in this manual.
NOTICE
• The contents of this manual may not reflect the specifications of the machine delivered. Contact an authorized KOBELCO
Distributor to obtain assistance in specifications for machines equipped with options not contained in this manual.
• Owing to the policy of continual improvement, changes may be made by KOBELCO CONSTRUCTION MACHINERY
CO., LTD, to any of its products without any obligation on the part of KOBELCO CONSTRUCTION MACHINERY CO.,
LTD.
• The letter “E” of 6E in the machine model expresses that the engine mounted on this machine is approved by the new
regulation established after the emission rate became more severe. Therefore the last letter “E” in the machine model,
represents the “Emission” or “Ecology”.
TABLE OF CONTENTS
Section I – SAFETY PRECAUTIONS ......................................................................................................... 1-0 ~ 1-21
Section II – MACHINE FAMILIARIZATION .................................................................................................. 2-0 ~ 2-33
Section III – BASIC MACHINE OPERATION ................................................................................................ 3-0 ~ 3-25
Section IV – MAINTENANCE ........................................................................................................................ 4-0 ~ 4-61
Section V – TRANSPORTATION .................................................................................................................. 5-0 ~ 5-8
Section VI – SPECIFICATIONS ..................................................................................................................... 6-0 ~ 6-9
Section VII – TROUBLESHOOTING .............................................................................................................. 7-0 ~ 7-3
Section VIII – OPTIONAL EQUIPMENT .......................................................................................................... 8-0 ~ 8-19
All rights reserved. Any use of editorial or pictorial content is strictly prohibited without express written permission from KOBELCO CONSTRUCTION MACHINERY CO., LTD.
Section I – SAFETY PRECAUTIONS
Table of Contents
GENERAL SAFETY INFORMATION ........................................................................................................... 1-1
SAFETY PRECAUTIONS ............................................................................................................................. 1-1 ~ 1-3
PRE-START SAFETY ................................................................................................................................... 1-4 ~ 1-6
SAFETY DURING OPERATION ................................................................................................................... 1-6 ~ 1-9
INSPECTION & MAINTENANCE SAFETY .................................................................................................. 1-9 ~ 1-11
BATTERY SAFETY ...................................................................................................................................... 1-12 ~ 1-13
WARNING LABELS & DECALS .................................................................................................................. 1-14 ~ 1-19
PROHIBITED MACHINE OPERATION ........................................................................................................ 1-20 ~ 1-21
END OF WORK SHIFT SAFETY .................................................................................................................. 1-21
READ, UNDERSTAND AND FOLLOW ALL SAFETY PRECAUTIONS AND PROCEDURES FOUND IN THIS
MANUAL BEFORE ATTEMPTING ANY OPERATION, INSPECTION OR MAINTENANCE OF THIS MACHINE,
ATTACHMENT OR SYSTEMS. KOBELCO CANNOT ANTICIPATE EVERY POSSIBLE CIRCUMSTANCE THAT
MIGHT INVOLVE A POTENTIAL HAZARD. THE WARNINGS IN THIS PUBLICATION AND ON THE PRODUCT
ARE THEREFORE NOT ALL INCLUSIVE. IF A TOOL, PROCEDURE, WORK METHOD OR OPERATING TECH-
NIQUE NOT SPECIFICALLY RECOMMENDED BY KOBELCO IS USED, YOU MUST SATISFY YOURSELF THAT
IT IS SAFE FOR YOU AND OTHERS. YOU SHOULD ALSO ENSURE THAT THE PRODUCT WILL NOT BE
DAMAGED OR MADE UNSAFE BY THE OPERATION, LUBRICATION, MAINTENANCE AND/OR REPAIR PRO-
CEDURES YOU CHOOSE.
1—0
1.1 GENERAL SAFETY INFORMATION c. CAUTION – Indicates a potentially hazardous situ-
ation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against
possible damage to the machine and its compo-
DO NOT OPERATE OR PERFORM ANY MAINTE- nents and is represented as follows:
NANCE ON THIS MACHINE UNTIL ALL INSTRUC-
TIONS FOUND IN THIS MANUAL HAVE BEEN
THOROUGHLY READ AND UNDERSTOOD.
IMPROPER OPERATION OR MAINTENANCE OF 4. It is very difficult to forecast every danger that may
THIS MACHINE MAY CAUSE ACCIDENTS AND occur during operation. However, safety can be en-
COULD RESULT IN SERIOUS INJURY OR DEATH. sured by fully understanding proper operating proce-
ALWAYS KEEP THIS MANUAL IN THE OPERATOR’S dures for this machine according to methods recom-
SEAT POCKET. mended by KOBELCO.
IF IT IS MISSING OR DAMAGED, PLACE AN OR-
DER WITH AN AUTHORIZED KOBELCO DISTRIBU- 5. While operating the machine, be sure to perform work
TOR FOR A REPLACEMENT. with great care, so as not to damage the machine, or
IF YOU HAVE ANY QUESTIONS, PLEASE CONSULT allow accidents to occur.
AN AUTHORIZED KOBELCO DISTRIBUTOR.
6. Continue studying this manual until all safety, opera-
1. Most accidents, which occur during operation, are due tion and Maintenance procedures are completely un-
to neglect of precautionary measures and safety rules. derstood by all persons working with the machine.
Sufficient care should be taken to avoid these accidents.
Erroneous operation, lubrication or maintenance ser-
vices are very dangerous and may cause injury or 1.2 SAFETY PRECAUTIONS
death of personnel. Therefore all precautionary mea-
sures, NOTES, DANGERS, WARNINGS and CAU-
TIONS contained in this manual and on the machine
should be read and understood by all personnel be- THE PROPER AND SAFE LUBRICATION AND MAIN-
fore starting any work with or on the machine. TENANCE FOR THIS MACHINE, RECOMMENDED
BY KOBELCO, IS OUTLINED IN THE OPERATOR’S
2. Operation, inspection, and maintenance should be MANUAL FOR THIS MACHINE.
carefully carried out, and safety must be given the first
IMPROPER PERFORMANCE OF LUBRICATION OR
priority. Messages of safety are indicated with marks.
MAINTENANCE PROCEDURES ARE DANGEROUS
The safety information contained in this manual is in-
AND COULD RESULT IN INJURY OR DEATH. READ
tended only to supplement safety codes, insurance
AND UNDERSTAND THE OPERATOR’S MANUAL
requirements, local laws, rules and regulations.
BEFORE PERFORMING ANY LUBRICATION OR
MAINTENANCE.
3. Messages of safety appear in this manual and on the
machine. All messages of safety are identified by the
The serviceman or mechanic may be unfamiliar with
words “DANGER”, “WARNING” and “CAUTION”.
many of the systems on this machine. This makes it
a. DANGER – Indicates an imminently hazardous important to use caution when performing service
situation which, if not avoided, will result in death work. A knowledge of the system and or components
or serious injury and is represented as follows: is important before the removal or disassembly of any
component.
Because of the size of some of the machine compo-

b. WARNING – Indicates a potentially hazardous situ- nents, the serviceman or mechanic should check the
ation which, if not avoided, could result in death or weights noted in this manual. Use proper lifting pro-
serious injury and is represented as follows: cedures when removing any components. Weight of
components table is shown in Page 6-3 of SECTION
VI – SPECIFICATIONS.
1—1
THE FOLLOWING IS A LIST OF BASIC PRECAUTIONS 8. Use steps and grab handles when mounting or dis-
THAT MUST ALWAYS BE OBSERVED. mounting a machine. Clean any mud, grease, oil or
debris from steps, walkways or work platforms before
1. Read and understand all warning plates and decals using. Always face the machine when using steps,
on the machine before operating, maintaining or re- ladders and walkways. When it is not possible to use
pairing this machine. the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair opera-
2. Always wear protective glasses and protective shoes tions.
when working around machines. In particular, wear
protective glasses when using hammers, punches or 9. To avoid back injury, use a hoist when lifting compo-
drifts on any part of the machine or attachments. Use nents which weigh 23 kg (50 lb) or more. Make sure
welders gloves, hood/goggles, apron and the protec- all chains, hooks, slings, etc., are in good condition
tive clothing appropriate to the welding job being per- and are the correct capacity. Be sure hooks are posi-
formed. Do not wear loose fitting or torn clothing. tioned correctly. Lifting eyes are not to be side loaded
Remove all rings from fingers, loose jewelry, confine during a lifting operation.
long hair and loose clothing before working on this
machinery. 10. To avoid burns, be alert for hot parts on machines
which have just been stopped and hot fluids in lines,
3. Disconnect the battery and hang a “Do Not Operate” tubes and compartments.
tag in the Operator’s compartment. Remove ignition
keys. 11. Be careful when removing cover plates. Gradually back
off the last two bolts or nuts located at opposite ends
4. If possible, make all repairs with the machine parked of the cover or device and carefully pry cover loose to
on a level, hard surface. Block the machine so it does relieve any spring or other pressure, before removing
not roll while working on or under the machine. Hang the last two bolts or nuts completely.
a “Do Not Operate” tag in the Operator’s compartment.
12. Be careful when removing filler caps, breathers and
5. Do not work on any machine that is supported only by plugs on the machine. Hold a rag over the cap or plug
lift, jacks or a hoist. Always use blocks or jack stands, to prevent being sprayed or splashed by liquids under
capable of supporting the machine, before perform- pressure. The danger is even greater if the machine
ing any disassembly. has just been stopped because fluids can be hot.
13. Always use the proper tools that are in good condition
and that are suited for the job at hand. Be sure you
DO NOT OPERATE THIS MACHINE UNLESS YOU
understand how to use them before performing any
HAVE READ AND UNDERSTAND THE INSTRUC-
service work.
TIONS IN THE OPERATOR’S MANUAL. IMPROPER
MACHINE OPERATION IS DANGEROUS AND
14. Reinstall all fasteners with the same part number. Do
COULD RESULT IN INJURY OR DEATH.
not use a lesser quality fastener if replacements are
necessary.
6. Relieve all pressure in air, oil or water systems before
any lines, fittings or related items are disconnected or 15. Repairs which require welding should be performed
removed. Always make sure all raised components only with the benefit of the appropriate reference in-
are blocked correctly and be alert for possible pres- formation and by personnel adequately trained and
sure when disconnecting any device from a system knowledgeable in welding procedures. Determine type
that utilizes pressure. of metal being welded and select correct welding pro-
cedure and electrodes, rods or wire to provide a weld
7. Lower the bucket, blade or other attachments to the metal strength equivalent at least to that of the parent
ground before performing any work on the machine. If metal. Make sure to disconnect battery before any
this cannot be done, make sure the bucket, blade or welding procedures are attempted.
other attachment is blocked correctly to prevent it from
dropping unexpectedly.
1—2
16. Do not damage wiring during removal operations. 23. Caution should be used to avoid breathing dust that
Reinstall the wiring so it is not damaged nor will be may be generated when handling components con-
damaged in operation of the machine by contacting taining asbestos fibers. If this dust is inhaled, it can be
sharp corners, or by rubbing against some object or hazardous to your health. Components in KOBELCO
hot surface. Do not connect wiring to a line containing products that may contain asbestos fibers are brake
fluid. pads, brake band and lining assemblies, clutch plates
and some gaskets. The asbestos used in these com-
17. Be sure all protective devices including guards and ponents is usually bound in a resin or sealed in some
shields are properly installed and functioning correctly way. Normal handling is not hazardous as long as air-
before starting a repair. If a guard or shield must be borne dust which contains asbestos is not generated.
removed to perform the repair work, use extra caution
and replace the guard or shield after repair is com-
plete. IF DUST WHICH MAY CONTAIN ASBESTOS IS
PRESENT, THERE ARE SEVERAL COMMON SENSE
18. The maintenance and repair work while holding the GUIDELINES THAT SHOULD BE FOLLOWED.
bucket raised is dangerous due to the possibility of a
falling attachment.
a . Never use compressed air for cleaning.
Do not fail to lower the attachment and place the bucket
to the ground before starting the work. b . Avoid brushing or grinding of asbestos containing
materials.
19. Loose or damaged fuel, lubricant and hydraulic lines, c . For clean up, use wet methods or a vacuum
tubes and hoses can cause fires. Do not bend or strike equipped with a high efficiency particulate air
high pressure lines or install ones which have been (HEPA) filter.
bent or damaged. Inspect lines, tubes and hoses care-
fully. Do not check for leaks with your hands. Very small d . Use exhaust ventilation on permanent machining
(pin hole) leaks can result in a high velocity oil stream jobs.
that will be invisible close to the hose. This oil can e . Wear an approved respirator if there is no other
penetrate the skin and cause personal injury. Use card- way to control the dust.
board, wood or metal to locate pin hole leaks.
f . Comply with applicable rules and regulations for
the work place.
20. Tighten connections to the correct torque. Make sure
that all heat shields, clamps and guards are installed g . Follow environmental rules and regulations for dis-
correctly to avoid excessive heat, vibration or rubbing posal of asbestos.
against other parts during operation. Shields that pro- h . Avoid areas where asbestos particles may be in
tect against oil spray onto hot exhaust components in the air.
event of a line, tube or seal failure must be installed
correctly.
21. Do not operate a machine if any rotating part is dam-

aged or contacts any other part during operation.
Any high speed rotating component that has been
damaged or altered should be checked for balance
before reusing.
22. Be careful when servicing or separating the tracks.

Chips can fly when removing or installing a track pin.
Wear safety glasses and long sleeve protective cloth-
ing. Tracks can unroll very quickly when separated.
Keep away from front and rear of machine. The ma-
chine can move unexpectedly when both tracks are
disengaged from the sprockets. Block the machine to
prevent it from moving.
1—3
1.3 PRE-START SAFETY G ER
Many failures that occur during machine operation DAN CAUT
OF Bucke ION
EAR t can co
P CL AREA
d am ag nt
or servicing result from neglecting fundamental safety E E machi
e ca act and
ne equi
b w
h en
K NG
CAUTIO
N
some pped
SWI
FOR
attach with
precautions. The following safety precautions are INTER
FERE
C h ec k
ments
.
betwee cl ea ra
given to prevent such failures, but they are only a OP cab be
n bu
cket
n ce
M A E R AT
Exerc
forre
WARNING
op
ise ca eration.
and
part of what you must follow. Read, understand and operat re w

MA INTE ION
PREVENT ingBATTERY hen
a buck EXPLOSION
et near
• Batteries give off hydrogen gasses that can
follow all safety precautions found in this manual and NU NA explode and cause personal injury.
SK AL NC 2432
• Keep sparks, openP3 flames
380 and cigarettes away
E
on the machine thoroughly before operating the SK 200-6 from batteries.
• Keep metallic articles away from batteries.
200 E • Keep all ventilation caps tightly secured.
machine. Ap LC • Never check charge by placing metal articles
pl
ica
ble -6E across battery terminals.
m • Leave battery box open to improve ventilation
OBSERVE ALL SAFETY PRECAUTIONS

A. OBSERVE SAFETY PRECAUTIONS
Follow all safety rules, precautions, and operating
procedures. If there are other personnel and flag-
men working in the area, have them observe the
specified signs.
B. WEAR PROTECTIVE CLOTHING

Wear well fitting safety shoes, hard hat, and work- WEAR PROTECTIVE CLOTHING
ing clothes, and put on protective glasses, face
shield, ear protection and gloves. When necessary,
STORAGE
wear reflective vest. AREA
C. READ AND UNDERSTAND THE OPERATOR’S

MANUAL
Before operating the machine, read and understand
this operator’s manual thoroughly in order to use
the machine effectively and safely. READ MANUAL / KEEP IN MACHINE CAB
D. KEEP OPERATOR’S MANUAL IN MACHINE CAB

Keep this manual in the specified storage area lo-
cated behind the operator’s seat for quick reference.
Should the operator’s manual become lost or dam-
aged, contact an authorized KOBELCO distributor
to order the operator’s manual.
E. HOW TO HANDLE LIFE HAMMER

A life hammer is provided on the right side of cab. HOW TO HANDLE LIFE HAMMER
In case of emergency, take the life hammer, break
the cab glass, and escape from the cab.
In addition, the life hammer is equipped with a cut-
ter on the lever side to cut the seat belt, etc.
F. PREPARE FOR EMERGENCIES

Have a fire extinguisher and first aid kit ready for
emergencies. Know how to operate the fire extin-
guisher and know where the first aid kit is located
for easy access in case of emergency.
PREPARE FOR EMERGENCIES
1—4
G. ENSURE SAFETY AT THE WORK SITE
Know the work area! Before operating the ma-
chine, carefully survey and record the land and
worksite features to prevent the machine from fall-
ing or the soil from caving in.
H. PERFORM PRE-START INSPECTION

Before starting the machine, perform a PRE-START
inspection of the machine. If any problems are
found, repair or replace defective components im- WORKSITE SAFETY – KNOW THE AREA
mediately. DO NOT OPERATE THE MACHINE until
all problem areas are properly repaired.
Always keep the windshield, working lamps, and
mirrors clean for good visibility.
I . ENGAGE SAFETY LOCK LEVER BEFORE LEAV-

ING MACHINE
Before leaving the operator’s seat, move the safety
lock lever to the “LOCKED” (Up) position.
This will not allow operation of any hydraulic c o n - PRE-START INSPECTION OF MACHINE
trols should they be accidentally moved. If the le-
LOCKED
ver is not set to the “LOCKED” position and hydraulic (UP) POSITION
controls are touched accidentally, the machine may
move suddenly resulting in serious injury.
Also before leaving the machine, lower the bucket
to the ground, place the safety lock lever in the
“LOCKED” (Up) position, stop the engine and re-
move the starter switch key.
UNLOCKED
(DOWN) POSITION
J. SIGNS, SIGNALS & FLAGMEN SAFETY LOCK LEVER

Install signs on soft shoulders and ground areas,
have a flagman direct the operation if necessary.
The operator should note marks and follow signals
from the flagman. All personnel should know the
meaning of the signs, marks, and signals. Only one
flagman should give the signs and signals.
K. KEEP FIRE AWAY FROM FUEL AND OIL

Oil, antifreeze, and especially fuel are highly flam-
mable. Never use fire near the machine. KEEP FIRE AWAY FROM FUEL & OIL
Securely tighten all fuel and oil caps. Keep fuel and
oil in the designated storage areas. Promptly clean
up any all spills and dispose of waste properly.
L. USE CAUTION NEAR NOISE

If noise is high during operation, hearing loss may
result. Approved hearing protection should be used
if personnel will be exposed to high noise levels for
a long period of time. USE CAUTION NEAR NOISE
1—5
M. MOUNTING & DISMOUNTING MACHINE
KEEP STEP CLEAN AND
When getting on and off the machine, always main- IN GOOD CONDITION
tain three point contact by using the handrails and
step. Inspect and clean handrails, step, and mount-
ing parts. Remove slippery materials, such as lu-
bricants, and mud. Always place the cab door en-
trance parallel to the tracks before stopping the en-
gine for dismounting.
N. AVOID HOT SURFACES & AREAS USE GRIP BARS

Immediately after the machine is operated, the tem- AND STEP
perature and pressure of the engine coolant, en-
gine oil, and hydraulic oil are very high. Burns may MOUNTING/DISMOUNTING MACHINE
result if caps are removed, or oil, water, or filters
are changed under these conditions. Wait until the
temperature goes down, before attempting to check
fluids or change filters.
O. USE THE PROPER OPTIONAL ATTACHMENT

Use only optional attachments designed for and
approved by KOBELCO. Read, understand and
HOT SURFACES
follow all instructions in the manual accompanying
the optional attachment. Use of any optional attach-
ment not approved by KOBELCO in writing, can
cause serious injury to personnel, damage to the
machine and its components and shorten the life of
the machine. Contact an authorized KOBELCO dis-
tributor for optional attachments available for the
machine.
P. PREVENT FIRES USE PROPER ATTACHMENT

Leaking or spilled fuel, lubricants and hydraulic oil
are fire hazards. Clean and properly dispose of spills
as they occur. Repair or replace all leaking compo-
nents to prevent fire. Also, clean the machine regu-
larly removing all debris to help prevent fires, pay
particular attention to removal of leaves, sticks,
paper etc. Keep fire extinguisher in an accessible
area and know how to use the fire extinguisher
should a fire occur.
PREVENT FIRES– CLEAN UP SPILLS
1.4 SAFETY DURING OPERATION
A. STARTING ENGINE
Sit in the operator’s seat.
Sound the horn before starting the engine to alert
people the machine is being started. Make sure no
one is near the machine.
Do not short circuit the starter circuit or battery to
start the machine. This may cause serious injury or
cause damage the electrical system.
SOUND HORN BEFORE STARTING
1—6
B. PASSENGERS
This equipment is not intended or designed for the
transportation of persons. Never allow persons to
ride on the machine. Serious injury or death can
result from allowing passengers on or in the ma-
chine.
C. TRAVEL
Make certain of the location of the travel motors
before operating travel controls. Sound horn before
moving the machine to inform persons that the ma-
chine is travelling. Position the attachment as shown NO PASSENGERS
in illustration before beginning travel.
Move the machine at slow speeds. Do not turn sud-
denly on rough terrain. Avoid travelling over ob-
stacles. Should it become necessary to travel over
an obstacle, keep the attachment low to the ground
and travel at extremely slow speed.
D. SWING
Make certain the swing area of machine is clear of
all persons and obstacles before operating swing
controls. Sound horn before swinging machine. If
necessary, have a flagman signal operator during TRAVEL MOTORS AT REAR OF MACHINE
operation to help prevent injury to persons or dam-
age to obstacles and equipment. KNOW TRAVEL MOTOR POSITION
E. BOOM, ARM & ATTACHMENTS

Give the work you are doing your undivided atten-
tion. Make certain the attachment being used is
suited for the job at hand. Make certain of obstacles
in the work area and operate the machine within
those limits. If necessary have a flagman signal the
operator to prevent injury to persons or damage to
the machine or obstacles in the work area. ZL11M04116
ALWAYS PLACE ATTACHMENTS ON THE

SWING SAFETY/USE SWING FLASHERS
GROUND AND RAISE THE SAFETY LOCK LE-
VER BEFORE LEAVING THE CAB.
F. OPERATING ON INCLINES OR SLOPES

Operation of this machine on an incline or slope
may cause the machine to become unstable or
unbalanced. Work up and down inclines or slopes
never across. Never swing or turn machine around
on slopes. Build a level area for the machine to op-
erate. Operate controls carefully to prevent sudden
movements which may cause the machine to slide
or tip over. Use a flagman to direct the operator.
BUILD BANKING FOR SLOPE OPERATION
1—7
G. WORKING AROUND UTILITIES
If it is suspected that utility lines such as gas, wa-
ter, phone or electrical power are in the work area,
contact the local utility authority for line location BE-
FORE beginning work in the area. Use extreme
caution around electrical power lines.
Keep a sufficient distance away from electrical lines
during operation. See chart below for minimum dis-
tances.
LINE VOLTAGE Minimum Distance - M (FEET)

0 ~ 50,000 3.0M (10) OR MORE
50,000 ~ 200,000 4.5M (15) OR MORE
200,000 ~ 350,000 6.0M (20) OR MORE
350,000 ~ 500,000 7.5M (25) OR MORE KEEP A SAFE DISTANCE FROM UTILITIES
500,000 ~ 750,000 10.5M (35) OR MORE
750,000 ~ 1,000,000 13.5M (45) OR MORE
H. LIFTING
This machine is an excavator. Use extreme cau-
tion when lifting or moving heavy loads. Use proper
lifting equipment rated at a capacity to handle the
load. NEVER USE BUCKET TEETH TO LIFT OR
MOVE HEAVY LOADS.
I . FROZEN OR SNOW COVERED WORK SITES

Use extreme caution when operating the machine
on frozen or snow covered work sites. Operate all
USE PROPER LIFTING DEVICES
controls slowly and cautiously to prevent sudden
movements that may cause the machine to unex-
pectedly shift, slide or move. Even on the slightest
slope, when snow is present or work area is frozen
can allow a machine to unexpectedly move.
Snow on shoulders or snow drifts can be much
deeper than expected. The machine can easily be-
come buried under such conditions. Use extreme
caution while operating the machine around or in
snow.
USE EXTREME CAUTION ON FROZEN OR SNOW
J. FILLED OR UNSTABLE GROUND

Be certain the condition of the work site is stable
and capable of supporting the machine during op-
eration. Do not operate attachment too close to the
machine. Operation of the machine on shoulders
or filled areas could cause the machine to become
unstable presenting a work hazard.
Position the travel motors to the rear of the ma-
chine, allowing for quick reversal, should the work
area become unstable.
WORK ON STABLE GROUND
1—8
K. RESTRICTED WORK AREAS
In work sites with limited height and swing areas
such as tunnels, bridges, around electrical power
lines, other utilities, or inside structures, use extreme
caution in keeping the machine and its attachment
a safe distance away to prevent personal injury and/
or equipment or structure damage. Use a flagman
to direct the operator.
L. PARKING THE MACHINE

Always park the machine on a firm, level surface.
If no firm level surface is available, block the tracks
and lower attachment to the ground to help prevent BE AWARE OF OBSTACLES
machine movement.
Should the machine be parked on a roadway, move
the machine to the shoulder to allow passing of traf-
fic. Also post reflective warning signs and markers
at a distance from the machine to safely warn mo-
torists. Refer to local code and regulations regard-
ing the posting of work area warnings and mark- 120°
CHOCK
ers. TRACKS
M. STABILIZE ATTACHMENTS
Stabilize all attachments removed from the machine
to prevent the attachment falling over.
N. SEATBELT PARKING SAFETY

The fastening of seatbelt is strictly obliged by the
possibility of hard blow inside of cab, being hurled
out of the cab, or being crushed under the machine
when the machine has tipped over. It may cause
severe personal injury or death.
RELEASE
BUTTON (RED)
• MAKE SURE THAT THE BRACKET AND BELT ARE
FREE FROM DAMAGES BEFORE FASTENING
SEATBELT. DEFECTIVE ONES MUST BE RE-
PLACED WITH NEW ONES. BUCKLE
• BEFORE STARTING MACHINE, TAKE A SEAT AND
DON’T FAIL TO FASTEN SEATBELT. FASTEN SEATBELT
1.5 INSPECTION & MAINTENANCE SAFETY

A. “TAG-OUT” MACHINE
Before performing any inspection or maintenance
procedures to the machine, fill out and post to the
operator’s controls a “DO NOT OPERATE” tag to
warn persons not to start the machine. Also inform
the supervisor and all operators that the machine
is under inspection or maintenance and they will
be informed when the machine is ready for normal
operation.
STABILIZE ATTACHMENTS WHEN REMOVED
1—9
B. TOOLS & EQUIPMENT
Use the proper tools and equipment for the task at
hand. Know the proper use of the tools and equip-
ment before starting any inspection or maintenance
procedures.
C. PERSONAL EQUIPMENT
Wear well fitting work clothes, hard hat, safety shoes
and gloves. Confine long hair, loose clothing and
remove all jewelry before attempting any inspec-
USE PROPER TOOLS
tion or maintenance procedures to this machine or
attachments.
LOCKED
(UP) POSITION
D. STOP THE ENGINE
BE CERTAIN TO TURN ENGINE OFF AND
PLACE THE SAFETY LOCK LEVER IN THE
“LOCKED” (UP) POSITION before attempting any
inspection or maintenance procedures to the ma-
chine. Failure to stop engine could result in serious
bodily injury or death.
E. SET THE ATTACHMENT

Always set the machine in the hydraulic oil check STOP ENGINE/ENGAGE SAFETY LOCK LEVER
position on firm level ground before attempting any
inspection or maintenance procedures to the ma-
chine. If it is not possible to put the machine in this
position, secure the boom, arm and attachment to
help prevent sudden movement. ALWAYS PLACE
ATTACHMENTS ON THE GROUND AND RAISE
THE SAFETY LOCK LEVER BEFORE LEAVING
THE CAB.
HYDRAULIC OIL CHECK POSITION
F. CLEAN THE MACHINE
Keep the machine clean and free of debris, excess
or spilled lubricants, fuel and fluids. Use approved
solvents, detergents and water to clean the machine
and its components on a regular basis.
Be careful not to allow water to reach electrical com-
ponents. Serious damage can occur to the electri-
cal system by allowing water to reach the electrical
components. Never clean inside of cab, or electri-
cal components with pressurized water or steam.
KEEP MACHINE CLEAN
G. PRESSURIZED FLUIDS & LUBRICANTS DEPRESS RUBBER CAP

Always release pressure from hydraulic reservoir, TO RELEASE PRESSURE
engine coolant, fuel system and all systems con-

taining pressure before removing any caps or com-
ponents. BE CAUTIOUS OF HOT FLUIDS AND
GASSES FROM SYSTEMS ON MACHINES THAT
HAVE JUST BEEN STOPPED. ALLOW SUFFI-
CIENT TIME FOR SYSTEMS TO COOL BEFORE
PERFORMING ANY INSPECTION OR MAINTE-
NANCE PROCEDURES.
RELEASE HYDRAULIC TANK PRESSURE
1 — 10
H. SUPPORT THE MACHINE
If it becomes necessary to raise the machine for
inspection or maintenance, always support the
machine by positioning the machine as shown in
the illustration and use safety supports or blocks, 90~110°
with a sufficient capacity rating to support the ma-
chine, under the tracks. NEVER INSPECT OR PER- SUPPORT
FORM MAINTENANCE PROCEDURES UNDER
A RAISED MACHINE THAT IS NOT SUFFI-
CIENTLY SUPPORTED.
SUPPORT THE MACHINE
I. REFUELING
Move the machine to a well ventilated area for refu-
eling. Use only specified fuel as described in the
MAINTENANCE section of this operator’s manual.
Immediately clean up all spilled fuel and dispose of
it properly. After refueling is complete, securely
tighten fuel cap.
J. HYDRAULIC PRESSURE
REFUELING
Under normal conditions, all circuits of the hydrau-
lic system are under extreme pressure. When in-
specting for leaks, use a small piece of cardboard,
wood or metal to locate leaks. SMALL (PINHOLE)
LEAKS CAN BE DANGEROUS IF CONTACT
WITH SKIN OR EYES IS MADE. Wear approved
safety glasses or face shield, gloves, hard hat,
safety shoes and work clothes during all inspection
and maintenance procedures.
CHECKING FOR HIGH PRESSURE LEAKS
K. TRACK SHOE TENSION
The grease used to adjust the track shoe tension is
under extreme pressure in the cylinder. Use extreme
caution when adjusting track shoe tension. KEEP
FACE, HANDS AND LEGS AWAY FROM THE
GREASE NIPPLE AREA. Carefully and slowly
loosen the grease nipple when lessening track shoe
tension. Never loosen grease nipple more than one
complete turn.
USE CAUTION WHEN ADJUSTING TRACKS

L. ELECTRICAL SYSTEM
Before performing any inspection or maintenance
to the electrical system, or performing any welding
procedures, disconnect the negative (–) cables from
the battery terminals. Not disconnecting the nega- DISCONNECT BATTERY
tive (–) cable could cause extensive damage to the NEGATIVE (-) CABLE WHEN
INSPECTING ELECTRICAL
electrical system. OR WELDING
ELECTRICAL SYSTEM PRECAUTION
1 — 11
M. USE APPROVED WORK LIGHTS
Use only approved work lights when performing
inspection and maintenance procedures to prevent
possible fire or explosion. Certain types of work
lights should not be used due to the possibility of
ignition of certain flammable gasses and fluids from
the machine.
N. DISPOSE OF WASTE PROPERLY

USE PROPER LIGHTING
Dispose of oils, fuel, coolant, solvents, filters, bat-
teries etc. according to federal, state and local codes
and regulations regarding hazardous waste dis-
posal. Contact local authorities for proper disposal
methods of such materials.
1.6 BATTERY SAFETY
A. WEAR PROPER PROTECTIVE CLOTHES

Wear long sleeve shirt, gloves and approved safety
glasses or face shield when working with or around
batteries. Battery electrolyte (acid) will cause se-
vere burns if allowed to make contact with clothing,
skin or eyes.
Should electrolyte (acid) come in contact with
WEAR PROTECTIVE CLOTHES
clothes, skin or eyes, immediately remove effected
clothing, flush area with clean water for 15 minutes
and get prompt medical attention.
B. KEEP AWAY FROM FIRE OR FLAMES

Never allow batteries in the vicinity of fire or flames
and do not smoke when working with batteries.
Explosive hydrogen gas is produced by the elec-
trolyte (acid) in the batteries. Always work with bat- KEEP AWAY FROM FIRE OR FLAMES
teries in a well ventilated area.
NEGATIVE (-) CABLE

C. CHARGING BATTERY
Charge battery off of and away from machine in a
well ventilated area. When charging battery, remove
cell covers to allow gasses to escape.
Avoid breathing gasses from battery. Wear ap-
POSITIVE (+) CABLE
proved safety equipment when working with bat-
teries.
MAKE CERTAIN OF THE POSITIVE (+) AND

NEGATIVE (-) TERMINALS
1 — 12
D. USING BOOSTER CABLES
Wear proper safety equipment when working with
batteries. IMPROPER BOOSTER CABLE CONNECTIONS CAN
CAUSE AN EXPLOSION RESULTING IN PERSONAL
If using another machine or vehicle to boost batter-
INJURY.
ies, make certain the machine or vehicle DOES NOT
CONNECT BOOSTER CABLES USING FOLLOWING
touch the disabled machine.
PROCEDURE.
Make certain of the positive (+) and negative (–) 1. CONNECT BOOSTER CABLE TO POSITIVE (+)
terminals on the booster battery and the disabled BATTERY TERMINAL OF DISCHARGED BAT-
machine before connecting booster cables. TERY. CONNECT OTHER END OF BOOSTER
CABLE TO POSITIVE BATTERY TERMINAL OF
Connect the positive (+) cable first, then connect NORMAL BATTERY.
negative (–).
2. CONNECT OTHER BOOSTER CABLE TO NEGA-
When disconnecting, disconnect the negative (–) TIVE (–) BATTERY TERMINAL OF NORMAL BAT-
cable first, then disconnect the positive (+) cable. TERY. CONNECT OTHER END OF BOOSTER
CABLE TO UPPER FRAME OF TROUBLED MA-
Refer to BASIC MACHINE OPERATION section of CHINE.
this manual for proper procedures for use of booster
3. START ENGINE AND REMOVE BOOSTER CABLES
cables.
IN REVERSE ORDER.
1 — 13
1.7 WARNING LABELS & DECALS (SOUTH-
EAST ASIA) SUPPLEMENTARY EXPLANATION
Warning labels and decals are affixed to the machine The content of pictograph in ISO warning labels is de-
to remind operators and personnel specific safety scribed on the foot of a label in detail, so read it with good
precautions in certain areas of the machine. The fol- understanding.
lowing are illustrated examples of all warning labels
and decals along with their locations.
1. SWING-DANGER 2. PRESSURIZED HOT OIL-WARNING

Located on each side of the rear counterweight. Located on each hydraulic tank.
Part Number - ZL11M04124 (2-REQ'D) Part Number - YN20T01355P1
YN20T01355P1
ZL11M04124
Pressurized hot oil can

cause burns.
Depress cap slowly with
engine off to relieve
hydraulic tank pressure.
3. PRESSURIZED HOT OIL & 4. DO NOT CLIMB-WARNING 5. STOP ENGINE-WARNING

COOLANT-WARNING Located on fuel tank. Located on engine radiator.
Located on top of engine radiator. Part Number - ZL11N02604 Part Number - ZL11N05204
Part Number - ZL11N00404
ZL11N00404 ZL11N02604 ZL11N05204
1 — 14
6. HANDLING BATTERY-DANGER AND WARNING
Located on battery cover.
Part Number - YN20T01356P1 Improper booster cable connections
can cause an explosion resulting in
personal injury.
Connect booster cables using following

procedure.
1. Connect booster cable to positive (+)
battery terminal of discharged battery.
Connect other end of booster cable to
positive battery terminal of normal
battery.
2. Connect other booster cable to
negative(–) battery terminal of normal
battery. Connect other end of booster
cable to upper frame of troubled machine.
3. Start engine and remove booster
cables in reverse order.
CONNECTING A BOOSTER CABLE (RED)
NORMAL BATTERY
YN20T01356P1
DISCHARGED BATTERY
TO THE UPPER FRAME OF A
(BLACK) TROUBLED MACHINE
AVOID ACID BURNS

• Electrolyte is an acid and can cause injury
or blindness if it contacts with skin or eyes.
• Wear eye protection and protective clothing
when handling or servicing batteries.
• If electrolyte contacts skin or eyes, flush 7. BOOSTER CABLE-WARNING
affected areas immediately with clean water Located on battery cover.
and seek medical attention.
Part Number - ZL11N01104
DANGER EXPLOSIVE GASES

Cigarettes, flames or sparks could cause battery to explode. Always
shield eyes and face from battery. Do not charge or use booster cables
or adjust post connections without proper instruction and training.
KEEP VENT CAPS TIGHT AND LEVEL

POISON CAUSES SEVERE BURNS
Contains sulfuric acid. Avoid contact with skin, eyes or clothing. In
event of accident flush with water and call a physician immediately.
KEEP OUT OF REACH OF CHILDREN
ZL11N01104
PREVENT BATTERY EXPLOSION

• Batteries give off hydrogen gasses that can
explode and cause personal injury.
• Keep sparks, open flames and cigarettes away
from batteries.
• Keep all ventilation caps tightly secured. Electric hazard may cause injury
• Never check charge by placing metal articles when mishandling the cable.
across battery terminals. Read operator manual for safe
• Leave battery box open to improve ventilation
when charging. and proper handling.
1 — 15
8. HOT PARTS-CAUTION 9. STOP ENGINE-WARNING 10. DO NOT CLIMB UPON ENGINE
Located on engine bonnet. Located on engine radiator. COVER-WARNING
Part Number - ZL11N00504 (2-REQ'D) Part Number - ZL11N05104 Located on engine bonnet.
Part Number - ZL11M02708 (2-REQ'D)
ZL11M02708
ZL11N00504 ZL11N05104
11. BUCKET TO CAB CONTACT-CAUTION 12. SAFETY LOCK LEVER-WARNING

Located inside cab R.H. Located on control stand.
Part Number - YN20T01350P1 Part Number - ZL11N04204
YN20T01350P1 ZL11N04204
Bucket can contact and Machine may move suddenly and cause serious
damage cab when personal injury if a control lever is accidentally
CAUTION machine equipped with touched be sure the safety lock lever is disengaged
FOR
INTERFERE some attachments. and in the locked position before exiting the cab.
Check clearance
between bucket and
cab before operation.
Exercise care when
operating a bucket near
cab.
1 — 16
13. LIFTING FRONT WINDOW-WARNING 14. NIBBLER & BREAKER OPERATION-CAUTION
Located inside cab front window. Located on left hand operator console.
Part Number - ZL11M06008 Part Number - YN20T01354P1
ZL11M06008 YN20T01354P1
15. SWING PARKING BRAKE RELEASE SWITCH

-CAUTION
Located on rear cover. Do not set this switch to nibbler combined flow
Part Number - YN20T01353P1 operation position when using breaker.
16. KEEP CLEAR WORKING AREA-DANGER

Located on arm.
Part Number - ZL11M07508 (2-REQ'D)
YN20T01353P1
The swing parking brake release switch

are installed on the rear side this cover.
Swing parking brake release switch

• While operating swing aciton,
when the parking brake can not
be released, set the toggle
switch to "RELEASE" position,
and the parking brake is
released. Usually, this toggle
switch should be set to
"NORMAL" position and contact ZL11M07508
our service shop immediately.
17. READ OPERATOR'S MANUAL 18. ELECTRICAL POWER LINES 19. ADJUSTING TRACK
-WARNING -WARNING TENSION-WARNING
Located inside cab R.H. Located inside cab R.H. Located inside cab R.H.
Part Number - ZL11N00104 Part Number - ZL11N01304 Part Number - ZL11N07704
ZL11N00104 ZL11N01304 ZL11N07704
1 — 17
20. DO NOT PINCH YOUR HAND(S)-CAUTION 21. POWER BOOST SWITCH-WARNING
Located on operator seat support. Located inside cab R.H.
Part Number - ZL11M03708 Part Number - YN20T01351P1
ZL11M03708
Be careful not to pinch

your hand(s) when
YN20T01351P1
operating the lever.
Releasing power boost switch while

lifting a load can cause unexpected
lowering of load,resulting in severe
POWER BOOST SWITCH
injury or death.
Never use power boost switch for
lifting a load.
22. DO NOT PINCH YOUR HAND(S)-CAUTION 23. ENGINE CONTROL CABLE – WARNING
Located inside cab R.H. Located inside cab R.H.
Part Number - ZL11N03704 Part Number - YN20T01319P1
ZL11N03704 YN20T01319P1
Be careful not to pinch

your hand(s) when
operating the lever.
1 — 18
24. ENGINE AUTO IDLING STOP-NOTICE 25. ENGINE AUTO IDLING STOP-WARNING
Located inside cab R.H. Located inside cab R.H.
Part Number - YN20T01696P1 Part Number - YN20T01685P1
YN20T01696P1
When an auto idling stop

switch is ON, after raising
a safety lock lever, engine
stops after fixed time
progress.
YN20T01685P1
When you do the work which has

fear, such as fall of a load,
when engine stops, please be sure
to turn OFF an auto idling stop
switch.
The auto idling stop function for

cutting down generating of the useless
fuel consumption and an exhaust gas at
the time of a stop in this machine is
carried. When you use it, be careful of
the following things.
· When you start the engine again after an
auto idling stop, please be sure to start
after once returning a key switch at
ACC or OFF and also returning a throttle
potentiometer to Lo. But the engine cannot
be again started until a buzzer stops,
after engine stops.
· When you leave from a cab for a long
time, please be sure to turn OFF
a starter switch.
· When the engine coolant temperature error
are displayed with the LCD or lamp, it
does not operate, even if the auto idling
stop switch is turned on ON.
Please read the operator's manual.
1 — 19
1.8 PROHIBITED MACHINE OPERATION
The following examples of machine abuse and mis-
use should never be attempted by even the most
experienced operator. Such abuse and misuse of this
machine and its attachments can result in serious
bodily injury, death, severe equipment damage and
shortened service life of the machine. Under no cir-
cumstance should any of these operations be at-
tempted. Use common sense and follow proper op-
eration procedures found in this operator’s manual
while operating this equipment.
A. DO NOT USE TRACTIVE FORCE OF THE MA- DO NOT USE TRACTIVE FORCE
CHINE FOR LOADING THE BUCKET ATTACH-
MENT
Doing so will exert excessive force on the machine
structure, front end attachments and could cause
severe equipment damage. Use tracks for normal
travel operations only.
B. DO NOT USE SLEWING FORCE OF THE MA-

CHINE FOR OPERATIONS
Doing so will exert excessive force to the machine
structure, front end attachments and shorten life of
the swinging system of the machine. Also, serious
injury or death could result from such operations.
DO NOT USE SLEWING FORCE
C. DO NOT PERFORM “HAMMERING” OPERA-

TIONS WITH THE BUCKET.
Performing operations such as hammering and pil-
ing will cause extensive damage to the machine
and its components. These types of operations can
also result in serious injury or death.
DO NOT HAMMER WITH ATTACHMENT
D. DO NOT USE THIS MACHINE FOR ANYTHING

OTHER THAN ITS INTENDED PURPOSE.
This machine is designed and manufactured for
digging and loading operations only. Any other use
can exert excessive force to the machine, its com-
ponents, its systems and result in serious bodily
injury or death to the operators and other person-
nel working in the vicinity of or with the machine.
USE ONLY FOR INTENDED PURPOSE
1 — 20
E. DO NOT OPERATE BUCKET AND ARM CYLIN-
ALLOWANCES
DERS TO STROKE END REPEATEDLY
Extending the bucket and arm cylinders to stroke
end to clean debris from the bucket, will cause im-
pact to the bucket cylinder causing cylinder dam-
age. Use high pressure water or manually remove
stubborn material from the bucket.
F. DO NOT OVER EXERT THE MACHINE’S CA-

PACITIES.
Know the limitations of the machine and its attach-
ments and operate the machine within those speci-
fications. Do not exceed lift charts. Never tip or raise DO NOT OPERATE CYLINDER TO STROKE END
the machine to obtain power to move material. This
could cause extensive damage to the machine and
its components as well as result in serious bodily
injury or death.
1.9 END OF WORK SHIFT SAFETY

Perform all of the following procedures after each
shift is complete to insure the machine it in optimal
operating condition for the next shift or job site.
A. Move the machine to a firm, level surface.
B. Lower attachment to the ground. DO NOT OVER EXERT THE MACHINE
C. Refill fuel tank to full mark to reduce air volume

and condensation (moisture). This will decrease
the possibility of freezing in the fuel tank, rusting
due to moisture and other problems associated
with start up and operation.
D. Close and secure all windows in place to prevent

water or moisture reaching the electrical compo-
nents of the machine.
E. Thoroughly clean and inspect the machine. Per-

form lubrication maintenance and repair or replace
any problem areas found before restarting the
machine. END OF WORK SHIFT SAFETY
F. If operating the machine in cold climates, it may

be necessary to remove the batteries from the
machine and store in a warm well ventilated area.
Install the batteries in the machine before next
start up. This will help prevent premature battery
deterioration.
G. Remove key from key switch and lock all doors

and access panels.
1 — 21
Section II – MACHINE FAMILIARIZATION
Table of Contents
FAMILIARIZATION ....................................................................................................................................... 2-1
GENERAL MACHINE NOMENCLATURE ................................................................................................... 2-1
OPERATOR CAB NOMENCLATURE .......................................................................................................... 2-2
COMPONENT & CONTROLS NOMENCLATURE ....................................................................................... 2-3 ~ 2-16
Right Hand Operator Console .............................................................................................................. 2-3 ~ 2-7
Left Hand Operator Console ................................................................................................................. 2-7 ~ 2-14
Air Conditioner ....................................................................................................................................... 2-7 ~ 2-11
Rear Panel And Others .......................................................................................................................... 2-15 ~ 2-16
Operating Levers And Controls ............................................................................................................ 2-17 ~ 2-19
Gauge Cluster ........................................................................................................................................ 2-20 ~ 2-26
Operator Cab And Operator Seat ......................................................................................................... 2-27 ~ 2-31
Seat Belt .................................................................................................................................................. 2-32
Machine Access Panels And Doors ..................................................................................................... 2-32 ~ 2-33

PRECAUTIONS AND PROCEDURES FOUND IN
THIS MANUAL BEFORE ATTEMPTING ANY OPERA-
TION, INSPECTION OR MAINTENANCE OF THIS
MACHINE, ATTACHMENT OR SYSTEMS.
2—0
2.1 FAMILIARIZATION 2.2 GENERAL MACHINE NOMENCLATURE
All operators, service mechanics and personnel re- The nomenclature drawing below (Figure 2.1), points
sponsible for operation, inspection and maintenance out locations of major components of the KOBELCO
of the machine should become thoroughly familiar SK200-6E and SK200LC-6E hydraulic excavator.
with the controls and components and their functions Study these areas and locate these components on
before working with or on this equipment. the machine. Specific information regarding these
Study the information in this section to become fa- components are explained on the following pages of
miliar with the controls and components of this ma- this section.
chine.
ARM
ARM CYLINDER
BOOM
BUCKET
CYLINDER
SWIVEL JOINT
SWING MOTOR
BATTERIES
IDLER HANDRAIL
FUEL TANK
LINK
MAIN CONTROL VALVE
BUCKET BOOM CYLINDER
LINK HYDRAULIC OIL TANK
OPERATOR MITSUBISHI
CAB 6D34-TLE2A
ENGINE
BUCKET PUMP ACCESS

DOOR
HYDRAULIC
PUMP
TRACK SHOE ASSEMBLY
(600 mm STANDARD)
TRACK IDLER (1 EACH SIDE) COUNTER
WEIGHT
TRACK SPRING (1 EACH SIDE)

ENGINE
LOWER ROLLER (7 EACH SIDE) RADIATOR
(8 EACH SIDE)-LC
UPPER ROLLER (2 EACH SIDE) OIL COOLER
TRACK GUIDE
ENGINE COOLANT RESERVOIR
RADIATOR ACCESS DOOR
ENGINE AIR CLEANER
TRAVEL MOTOR
FIGURE 2.1
2—1
2.3 OPERATOR CAB NOMENCLATURE
The operator cab nomenclature (Figure 2.2), points Study these areas and locate these components on
out locations of operator controls of the KOBELCO the machine. Specific information regarding these
SK200-6E and SK200LC-6E hydraulic excavator op- components are explained on the following pages of
erator cab. section VI.
LEFT TRAVEL LEVER RIGHT TRAVEL LEVER

LEFT TRAVEL PEDAL RIGHT TRAVEL PEDAL
LEFT FOOT REST RIGHT FOOT REST GAUGE CLUSTER
RIGHT HAND
LEFT HAND OPERATOR OPERATOR CONTROL
CONTROL LEVER LEVER (POWER
(HORN SWITCH) BOOST SWITCH)
24V CIGARETTE
SAFETY LOCK LEVER LIGHTER
(FOR HYDRAULICS)
ASH-TRAY
ENGINE EMERGENCY
STOP CONTROL
LEFT SIDE SWITCH THROTTLE

PANEL POTENTIOMETER
SWING FLASHER
SWITCH
AIR-CONDITIONER
PANEL
KEY SWITCH
ARM REST
OPERATORS SEAT ENGINE MANUAL

(3 WAY ADJUSTABLE) CONTROL CABLE
(For back up mode)
SWING PARKING BRAKE HEAD REST

RELEASE SWITCH (ADJUSTABLE)
FIGURE 2.2
2—2
2.4 COMPONENT & CONTROLS NOMENCLA-
TURE KEY SWITCH POSITIONS
The following information provides a brief descrip-
tion and function of the components and controls of
the KOBELCO SK200-6E and SK200LC-6E hydraulic ex-
cavator.
All personnel associated with this machine should
read and understand this information BEFORE be-
ginning any work with or on this equipment.
A. RIGHT HAND OPERATOR CONSOLE

1. Key Switch – FIGURE 2.3
The key switch is located on the right hand opera-
tor console and has 5 operating functions.
“HEAT” .... This position is used for starting the
engine in cold climates. See section III.
“OFF” ...... When key is turned to this position, the
engine stops and electrical power to the
machine’s electrical systems is stopped FIGURE 2.3
after approximately 4 seconds.
“ACC” ...... With key in the “ACC” position only the
cigarette lighter, tuner and horn will have
power. (1)
“ON” ........ When key is in the ON position, electri-
cal power is supplied to all the machine’s
electrical systems.
“START” .. When key is turned to this position elec-
trical power is supplied to the starter so-
lenoid causing the starter to start the en-
gine. After engine starts key should be
released to go back to the “ON” position.
2. KPSS Mode Switch (1) – FIGURE 2.4
The KPSS mode switch is located on the gauge
cluster switch panel and has 3 operating functions.
After starting the engine, the mode
switch is turned to mode default.
Select an effective work mode comply-
ing with the working condition and work-
ing target from 3 modes.
Each time the work mode switch is FIGURE 2.4
pressed, the work mode indicator lamp is
switched to , and in order.
a. A (assist) mode
The mode is set meeting to the operator’s
work condition.
The controller makes a distinction between Digging mode Leveling mode
works, digging, leveling, spreading, slope fin-
ishing, tamping etc. automatically, and dis-
plays the distinction results on the multi dis-
play per second. And the power correspond- Spreading mode Tamping mode Standby mode
ing to the load is output, the engine speed is
controlled to a constant speed, and conse-
quently the noise is lowered.
2—3
b. M (manual) mode
FLOW L
This mode catches the movement of RATE min Displayed
flow rate
control lever sensitively and is suitable
(b)
for the heavy load digging work giving
priority to the work load at high speed.
c. B (breaker) mode
When the attachments in option like
breaker, etc. are used, the operator can
(2) (3) (1)
adjust the max. flow rate.
a. Flow rate display

• After turning the key switch “ON” (the engine
does not start) set it to B (Breaker) mode (a) by
pressing mode select switch (1).
• Keep pressed the screen change switch (2) on
the gauge cluster, after 3 to 10 seconds the mode
is switched to the adjust mode. FIGURE 2.5
The flow rate stored last time is displayed, but in

case of the initial display, Maximum flow rate is
displayed as standard value.
• Press the mode switch (1), and the displayed
flow rate (b) is increased, and press the buzzer
stop switch (3), and the displayed flow rate (b)
is reduced.
• In operating switches (1), (3) the addition or re-
duction starts 2 seconds later and displays in
graduation of 10 L/min, release the switches
when the required flow rate is obtained.
The flow rate can be adjusted in the maximum
up to minimum range.
(a)
• Pressing the screen change switch (2) again,
the adjusted flow rate value is stored, and the
adjust mode is dismissed.
3. Buzzer Stop Switch (3) – FIGURE 2.6

When the engine coolant temperature is DISPLAYED
too high, or various sensors of mechatro FLOW RATE
controller (self-diagnosis) fail, the alarm (b)
sounds intermittently. To stop sounding, FLOW L
press the buzzer stop button. RATE min
NOTE
The buzzer sounding because of the preheat complete
(2)
operation and because of engine oil low pressure warn-
ing, can be stopped only by turning the key switch OFF.
(3) (1)
FIGURE 2.6
2—4
4. Screen Change Switch (4) – FIGURE 2.7
Each time the screen change switch on
the gauge cluster is pressed, the engine
rpm and the accumulated time since last
replacement of engine oil, fuel filter, hy-
draulic oil filter, hydraulic oil are dis-
played in order.
After the engine starts, is dis-
played for 5 seconds, then 14 : 20
(4)
(switched to the clock display automati-
cally), and each time the screen change
switch is pressed, the display is switched
256Hr AFT
to (Engine rpm)
1515 RPM
E/G OIL CH
256Hr AFT 256Hr AFT 256Hr AFT

FUEL FIL CH HYD FIL CH HYD OIL CH
14 : 20
in order.
5. Wiper & Washer Switch (5), (6) – FIGURE 2.8

Press this switch, and the front window FIGURE 2.7
wiper starts moving.
a. Press it once ............ Wiper moves intermittently

b. Press it again ........... Wiper moves continuously
c. Press it once more ... Wiper stops moving
Press this switch, and washer fluid is

sprayed on the front window while it is
pushed. Wiper acts in the same time (5)
(7) (6)
automatically.
The washer fluid reservoir is located
behind the cab, in the air cleaner com-
partment.
Make certain the washer reservoir has washer fluid

before operating washer.
FIGURE 2.8
6. Working Lights Select Switch (7) – FIGURE 2-8

Press switch, and frame, boom and rear
working lights light up, and when the
switch is ON the back-up lamp also lights
up.
a. Press switch once, and the frame and boom work-
ing lights light up.
b. Press it one more time, and rear working light also
light up.
c. Press it again, the frame, boom and rear working
lights go out.
2—5
7. Auto Accel Switch (8) – FIGURE 2.9
When this switch is activated (ON) the
auto-accel system activates.
The auto-accel reduces the engine
speed to the idle level reducing fuel con-
sumption and noise under the following
conditions:
1. The accel dial position is set over the
idle level. (8)
2. The control lever and/or pedal are not
operated for 4 seconds or more.
When the control lever and/or pedal are
operated, the engine speed rises back
to the accel dial set level gradually, ac-
cording to the respective operating pilot
valve stroke.
Anytime this switch is deactivated (OFF)
the engine speed rises to the accel dial FIGURE 2.9
set level, independently by other opera-
tions.
WHEN LOADING OR UNLOADING MACHINE ON

TRAILER, TURN THE AUTO ACCEL SWITCH OFF.
IF IT IS OPERATED KEEPING THE ACCEL SWITCH
ON, THE ENGINE SPEED CHANGES SUDDENLY.
8. Throttle Potentiometer – FIGURE 2.10

The throttle potentiometer is located on the right
hand operator console and controls engine RPM.
When the throttle potentiometer is rotated to any
position it increases or decreases engine rpm and
maintains engine at the programed RPM for that
particular position on the dial. THROTTLE
POTENTIOMETER
(CONTROL)
FIGURE 2.10
2—6
9. 24 Volt Cigarette Lighter – FIGURE 2.11
The cigarette lighter is located on the right wall of
cab. To use the cigarette lighter the key switch must
be in the ON position. Push the lighter in and wait
approximately 30 seconds for it to “POP” out. Pull
lighter from the socket to use. Replace lighter back
into its socket after use.
Do not use the cigarette lighter as a power source for

12 Volt accessories. It is 24 Volt outlet.
FIGURE 2.11
10. Swing Flasher Switch – FIGURE 2.12

The swing flasher switch is located on the right hand
PRESS HERE
operator console. The swing flasher is a 2 position FOR "ON"
rocker switch which is used to turn on the swing
PRESS HERE
flashers. FOR "OFF"
“ON” ...... Push the symbol side of switch down to
turn swing flashers ON.
“OFF” .... Push the empty side of switch down to
turn swing flashers OFF.
FIGURE 2.12
B. LEFT HAND OPERATOR CONSOLE
1. Air Conditioner – FIGURE 2.13 and 2.14

The climate control-AC provides a comfortable in-
door environment and adjustable control of cab tem-
perature. It removes moisture from humid air and
reducing window glass frosting.
The climate control-AC is installed behind operator’s (C) (A)

seat and sends cold air or hot air into cab.
(A)
Air outlet selector
Select a preferable blowout direction moving grille
by hand. (B)
(A), (B), (C), (D) ........ Air outlet (D)
FIGURE 2.13
2—7
I . Control Panel Description
AIR OUTLET MODE FRESH AND RECIRCULATE LCD COMPRESSOR AUTO CONTROL
SELECTOR SWITCH AIR SELECTOR SWITCH DISPLAY SWITCH SWITCH
DEFROSTER TEMPERATURE FAN SPEED MAIN POWER

SWITCH SETTING SWITCH SELECTOR SWITCH SWITCH
(°C °F SELECTOR SWITCH)
FIGURE 2.14
SUPPLEMENTARY EXPLANATION
The LCD display indicates temperature, air outlet mode,
compressor ON - OFF, AUTO, recirculate and fresh air
and fan speed.
Each switch, FAN mark of blower, and TEMP mark are
illuminated green at night.
II. Fundamental use – FIGURE 2.15

Before turning air-conditioner on, close doors of cab FRESH AND RECIRCULATE COMPRESSOR AUTO
and windows to achieve the best performance. AIR SELECTOR SWITCH SWITCH CONTROL
SWITCH
1. Press control switch “AUTO” to control air capacity
and blower outlet automatically, and set the tem-
perature in the range from 18.5°C (65.3°F) to 31.5°C
(88.7°F).
The outlet temperature, outlet opening and fan
speed are adjusted automatically so that indoor tem- FAN SPEED
SELECTOR SWITCH
perature of cab comes closer to the set tempera-
ture.
FIGURE 2.15
2. Select proper mode manually through recirculate
and fresh air capacity selector switch and compres-
sor switch ON - OFF.
3. Select preferable fan speed manually through fan

speed selector switch when fan speed, selected
through auto control, is not preferable.
The indicator lamp of “AUTO” in LCD display goes
out. Press “AUTO” switch to return to automatic cli-
mate control.
2—8
III. Control Panel Functions
1. Main power switch and display – FIGURE 2.16 LCD

DISPLAY
a. LCD display is illuminated when the climate con-
trol-AC is operating.
When the climate control-AC is stopped, LCD
will be turned off.
b. Press main power switch, and all functions for
the climate control-AC switch ON or OFF.
Each time when this switch is pressed, the func- MAIN POWER
SWITCH
tion switches ON and OFF. When switched ON,
the climate control-AC starts operating at the
point set before switching OFF (when it is set to FIGURE 2.16
AUTO, in auto mode; if NORMAL is selected,
then in normal mode).
NOTE
The key switch will switch air-conditioner OFF, but the
operating condition just before switching off may not be
restored when the key switch is turned ON again.
2. Auto Control Switch and Display - FIGURE 2.17

a. Press the main power switch to activate the cli- LCD AUTO
mate control-AC and the LCD display will illumi- DISPLAY CONTROL
SWITCH
nate.
b. Press control switch AUTO, and fan speed and
air outlet are automatically controlled, and
“AUTO” indicator lamp on LCD display is illumi-
nated.
c. When the main power switch is OFF, the sys-
MAIN POWER
tem will retain the previous setting in memory. SWITCH
Therefore, when the main power switch is
pressed again, the climate control AC will come
on in the auto control mode. In the auto mode, FIGURE 2.17
the fan speed and air outlet openings are oper-
ated automatically.
3. Temperature Setting Switch and Display - FIG-

URE 2.18 LCD
DISPLAY
a. The set temperature is indicated in digits on LCD
display. Temperature set range is 18.5°C (65.3°F)
to 31.5°C (88.7°F).
b. Press the two temperature set switches simul-
taneously for 5 seconds to change the display
from Centigrade ( ° C) to Fahrenheit ( ° F) or
viceversa in the LCD display
TEMPERATURE
(Eg.) 25°C 77°F or 77°F 25°C SETTING SWITCH
(° C °F SELECTOR SWITCH)
c. Press temperature set switch DOWN or UP to
change the set temperature. FIGURE 2.18
The temperature goes up or down by 0.5°C (0.9°F)
in graduation.
The set temperature may be raised or lowered
by continued pressing of the switch.
2—9
d. The set temperature 18.5°C (65.3°F) is the low-
est cooling temperature, and 31.5°C (88.7°F) is
the highest heating temperature.
Control beyond either of these limits is not pos-
sible.
4. Air outlet mode selector switch and display –

FIGURE 2.19
a. Air outlet position is indicated by the arrow on AIR OUTLET MODE LCD DISPLAY
LCD display. SELECTOR SWITCH
b. Press air outlet mode switch in the condition

where auto display light is on, and the display
mode is fixed., “AUTO” indicator lamp on LCD
display goes out, and “AUTO” control of air out-
let opening is released.
Press it again, and the level is changed to
VENT BI-LEVEL FOOT FACE.
FIGURE 2.19
LCD DISPLAY
Air outlet opening Vent Bi-level Foot Face

Air outlet direction Upper half of body Upper half of body, foot Foot, front glass Upper half of body (Front)
5. Defroster switch and display – FIGURE 2.20

FRESH AND LCD
a. Press defroster switch, defroster indicator lamp RECIRCULATE AIR DISPLAY
will be displayed. SELECTOR SWITCH
b. Press air outlet mode selector switch, and it re-

turns to air outlet mode just before pressing de-
froster switch.
c. Press defroster switch in the condition where
AUTO display is lighting up, “AUTO” indicator
lamp on LCD display goes out and the auto con- DEFROSTER AIR OUTLET MODE
trol of air outlet opening is released. SWITCH SELECTOR SWITCH
FIGURE 2.20
6. Recirculate and fresh air selector switch and
display – FIGURE 2.20
a. Suction (fresh air intake) mode is indicated on
LCD display
b. Each time recirculate and fresh air capacity se-
lector switch is pressed, the mode is switched
to air recirculate or fresh air intake.
2 — 10
7. Compressor switch and display – FIGURE 2.21
Press compressor switch in the condition where LCD FAN COMPRESSOR
DISPLAY SPEED SWITCH
mark on LCD display is unlit, compressor starts DISPLAY
operating and indicator lamp of mark on LCD dis-
play goes on.
Press it again, and compressor turns off, and indi-
cator lamp of mark on LCD display goes out.
FAN SPEED
SELECTOR SWITCH
FIGURE 2.21
8. Fan speed selector switch and display – FIG-

URE 2.22 LCD
When it is set to MANUAL mode, fan speed on LCD DISPLAY
display is as follows.
FAN SPEED LOW MEDIUM HIGH MAX.
DISPLAY FAN SPEED FIGURE 2.22
LCD 1 LAMP IS LIT UP. LOW
LCD 2 LAMPS ARE LIT UP. MEDIUM
LCD 3 LAMPS ARE LIT UP. HIGH
LCD 4 LAMPS ARE LIT UP. MAX
Press UP or DOWN of fan speed selector switch,

and auto control of fan speed is released, and
“AUTO” indicator lamp on LCD display goes out.
2. Horn Switch – FIGURE 2.23

The horn switch is a momentary push grey button lo-
cated on the operator’s left control lever, see Figure
2.23 for better reference.
NOTE
Always sound horn before starting engine to alert person-
nel that the machine is going to be operated.
FIGURE 2.23
2 — 11
3. Auto warm up selector switch (Middle east OPT.) –
FIGURE 2.24
Place the ignition switch to the “on position” (Do not
start the engine yet). Turn on the warm up switch lo-
cated on the left panel and then start the engine. PRESS HERE
FOR "OFF"
a. Warming up of engine
The “WARMING UP” is displayed on the multi dis-
play after operating the engine for 3 minutes at auto
accel speed (1050 rpm.) when the accel dial set
value is the value for deceleration or lower, the en-
gine speed returns to the speed set by the accel
dial.)
b. Warming of hydraulic oil

After performing the operation of pump max. flow
rate at the engine speed (1,050 rpm) for 3 minutes
pump max. flow rate at the engine speed (1,600
rpm) for 5 minutes pump max. flow rate and
control valve full open at the engine speed (1,600 FIGURE 2.24
rpm) for 5 minutes max. flow rate at the engine
auto accel speed (1,050 rpm) for 10 minutes,
“WARMING UP” is displayed on the multidisplay.
c. Warming up complete
After an elapse of about 26 minutes of warming of hy-
draulic oil, or when the hydraulic oil temperature switch
turns OFF, the WARMING UP indication(“WARMING
UP”) on the multidisplay disappears, and concurrently
buzzer sounds for 5 seconds. Turn the auto warm up
switch OFF.
NOTE
While warming up the engine, operate the pilot lever and
the warming up is forcibly disconnected.
Turn the auto warm up switch OFF, and the warming up is
forcibly stopped. While warming the hydraulic oil, operate
the lever and the warming is stopped temporarily, and af-
ter an elapse of 10 seconds of the neutral condition the
warming operation restarts.
2 — 12
4. Auto idling stop select switch – FIGURE 2.24A
ZPlease symbol mark corresponding to this switch to
PRESS HERE
turn “ON”, and the engine in operation stops automati- FOR "ON"
cally after a constant elapse of time with safety lock
lever (1) remaining locked. Consequently the fuel con- PRESS HERE
FOR "OFF"
sumption is reduced.
And, press the switch no symbol mark is given, and the
auto idling stop function canceled.
NOTE
1. Put safety lock lever to “Locked Position”, and the rota-
tion changes to the decel rotation about 4 seconds later.
2. Buzzer sounds before 5 seconds from engine stop and
for 10 seconds after engine stop.
After auto idling stop, to restart engine;

a. Make sure that the buzzer stops sounding.
FIGURE 2.24A
b. Set throttle potentiometer to low idling position.
c. Return starter switch to “ACC” or “OFF” once and
restart the engine.
(1)
WHEN YOU DO THE WORK WHICH HAS FEAR,

SUCH AS FALL OF A LOAD, WHEN ENGINE STOPS,
PLEASE BE SURE TO TURN OFF AN AUTO IDLING
STOP SWITCH.
Don’t restart the engine while the buzzer is sounding FIGURE 2.24B
after the engine stops through auto idling stop switch.
The engine starter motor may be damaged.
Where being apart from the machine, be sure to switch In the following cases, the auto idling stop switch can’t
the key “OFF”. The discharge of battery may occur. be functioned regardless of the idling stop select switch
position.
• When the warning of “HIGH E/G COOL TEMP” is given
on LCD or by means of lamp,
When the following functions are applied to it, turn the • When auto warm-up (Middle East opt.) is being oper-
auto idling stop select switch “OFF”. ated.
While keeping the safety lock lever on “LOCKED PO-
SITION”.
• When required warm up the engine;
• When required to operate the air-con continuously;
• When keeping the working light on;
2 — 13
5. Over load alarm select switch – FIGURE 2.25
The over load alarm select switch is located on the
PRESS HERE
right hand control console. The over load alarm switch FOR "ON"
is a 2 position rocker switch and used for lifting opera-
tions. PRESS HERE
FOR "OFF"
“ON” ...... Push the symbol side of switch down to turn IA
T AS
over load alarm ON when performing lifting AS
operations. T HE
U
E SO
“OFF” .... Push the empty side of switch down to Sturn
over load alarm OFF when performingTU
NO other
operations.
FIGURE 2.25
6. Cab working lights select switch – FIGURE 2.26

The cab working lights select switch is located on the
PRESS HERE
left hand control console. The cab working light switch FOR "ON"
is a 2 position rocker switch and is used to turn work-
ing light “ON” and “OFF”. PRESS HERE
FOR "OFF"
“ON” ...... Push the symbol side of switch down to turn
working light ON.
“OFF” .... Push the empty side of switch down to turn
working light OFF.
FIGURE 2.26
7. Rotary light switch – FIGURE 2.27

This switch is located to the rear on the left hand con-
trol console. Its basic function is to turn the rotary light PRESS HERE
FOR "ON"
“ON” and “OFF”.
PRESS HERE
Depress this side to turn rotary light “ON”. FOR "OFF"
Depress empty side of switch to turn rotary A SIA
light “OFF”. ST
H EA
UT
E SO
T US
NO
FIGURE 2.27
2 — 14
C. REAR PANEL AND OTHERS
1. Swing Parking Brake Release Switch – FIGURE

2.28
After removing 4 cover set screws on the rear side
of operator seat, release the locks (5 places) of cover
section, and remove the upper and lower covers.
Swing parking brake is usually locked. The swing
parking brake is released in swing and arm-in op-
eration. When it cannot be unlocked due to trouble,
turn toggle switch to “Release lock” (unlock), and the
parking brake is released. Then, move machine to
safe area immediately and contact our representa-
tive or service shop.
And return to toggle switch to “NORMAL” position in
REAR PANEL
normal condition.
SET SCREW
FIGURE 2.28
2. Fuse Box – FIGURE 2.29

The fuse box is located behind the operator’s seat.
It contains all necessary fuses for the electrical cir-
cuits of the machine. Should it become necessary to
inspect or change a fuse, remove the fuse box cover
by gently pulling each end away from the box. Should
a fuse require replacement, use a replacement fuse
of the same type and amperage.
Turn key switch to “OFF” and wait approximately 4
seconds for all electrical power to stop before re-
moving or replacing a bad or blown fuse. The fuse
cover incorporates a fuse puller to remove fuses.
Refer to the maintenance section of this manual for COVER FUSE BOX
a detailed diagram and description of fuse box.
FIGURE 2.29
3. Hour Meter – FIGURE 2.30

This indicates the total time the engine
has run. Even if the excavator is not mov-
ing, the meter continues to count as long
as the engine is running.
HOUR METER
FIGURE 2.30
2 — 15
4. 12 Volt Power Supply – FIGURE 2.31
The 12 Volt power supply is located beside the right
side switch panel.
For use of common auto accessories such as a fan
or other accessories requiring 12 Volt (DC) power,
pull cover away from 12 Volt power supply and in-
sert 12 Volt male socket into power supply. Replace A SIA
cover after use. A ST
T HE
OU
S ES
TU
NO
Do not use the cigarette lighter as a power source for
12 Volt accessories. It is 24 Volt outlet. Plugging a 12
Volt accessory into a 24 Volt connector may result in
shorting and/or fire.
FIGURE 2.31
MAXIMUM CONTINUOUS OUTPUT – 2.5 Amps
5. Power Boost Switch – FIGURE 2.32

Located on the right hand control lever, this switch
should only be used for increased break out force
during digging.
NOTE
Use of it is prohibited where an arm longer than the stan-
dard is installed.
FIGURE 2.32
6. Holder – FIGURE 2.33

LOCK BUTTON
This cup holder is located the right front of operator.
Place a canned or a bottled drink.
Press lock button ...... cover open
COVER
FIGURE 2.33
2 — 16
D. OPERATING LEVERS AND CONTROLS
ENGINE EMERGENCY
1. Engine Emergency Stop Control – FIGURE 2.34 STOP CONTROL
The engine emergency stop control located at the
lower right hand side of operator seat. It is used only
in an emergency situation to stop the engine quickly.
It has 2 operating positions.
“IN” ........ Releases the fuel stop lever on the gover-
nor to allow normal starting of the engine.
“OUT” .... Activates the fuel stop lever on the engine
governor to immediately stop the engine.
FIGURE 2.34
Do not suddenly stop the engine when operating at

high RPM. Doing so may damage turbo or engine.
2. Engine Control Cable – FIGURE 2.35

When the “CPU MECHATRO CONT. FAIL.” or “(M)
STEP MOTOR S/PT. ERROR are displayed on the
gauge cluster, and the engine can not be controlled
regularly, carry out the following procedure to con-
tinue the work.
ENGINE CONTROL
a. Stop the engine. CABLE
(For back up mode)
b. Loosen lock nuts of two screws for back up mode
of the hydraulic pump, and after loosening the screw (1)
fully tighten the lock nut.
c. Start the engine and pull the knob fully, the knob
can be fixed at the position it has been released,
maintaining the high idling condition.
Turn the knob right, and the lock is released en-
abling the knob to return.
(1)
NOTE FIGURE 2.35

After completion of work, contact our dealer immediately
for inspection and maintenance.
NOTE
At shipping of machine, the engine control cable is not con-
nected to lever of governor.
Connect the engine cable according to following procedure.
1. Connect the yoke side of control cable to lever of gover-
nor.
2. Start engine, and pull the control cable fully, and confirm
that the function of back up mode actuates correctly.
2 — 17
3. Safety Lock Lever – FIGURE 2.36
SAFETY LOCK
The safety lock lever is located on the front outside LEVER IN
of the left hand operator console and is red in color. LOCKED
(UP) POSITION
The safety lock lever is used to lock out the hydrau-
lic controls disallowing the use of any hydraulic func-
tion. The safety lock lever has 2 operating positions.
“UP” .......... When placed in the up position the safety
lock lever stops all hydraulic controls from
functioning and allows the operator to
enter and exit the operator seat.
“DOWN” .... When placed in the down position, the
safety lock lever allows all operating func-
tions of the hydraulic controls to resume
and also locks the left hand operating
console in operating position.
ALWAYS PLACE THE SAFETY LOCK LEVER IN THE

LOCKED (UP) POSITION BEFORE LEAVING THE
SAFETY LOCK LEVER
OPERATOR CAB.
IN UNLOCKED
NEVER LEAVE THE MACHINE UNATTENDED WITH (DOWN) POSITION
ENGINE RUNNING OR LEVER IN THE DOWN PO-
SITION. FIGURE 2.36
4. Left Hand Operator Control Lever – FIGURE 2.37 L.H. CONTROL LEVER ARM OUT
(ISO PATTERN)
Hydraulic controls are designed for and set to ISO op-

erating pattern for optimum machine performance and SWING LEFT
safety. Changing the control pattern will effect the per-

formance of the machine. SWING RIGHT
The left hand operator control lever is located at the

top front of the L.H. operator console. Its purpose is
to allow the operator to control operations of the swing ARM IN
and arm. Operating speed of function is variable from
stop to full stroke depending on how far lever is op-
erated. The left hand operator control lever has 4
basic operational functions.
“FORWARD” ....... Variable speed arm out. FIGURE 2.37

“BACKWARD” .... Variable speed arm in.
“LEFT” ................. Variable speed left swing.
“RIGHT” ............... Variable speed right swing.
“CENTER” ........... Neutral position.
2 — 18
5. Right Hand Operator Control Lever – FIGURE 2.38
BOOM DOWN R.H. CONTROL LEVER
The right hand operator control lever is located at (ISO PATTERN)
the top front of the R.H. operator console. Its pur-
pose is to allow the operator to control operations of
the boom and bucket. Operating speed of function is
variable from stop to full stroke depending on how
BUCKET OUT
far lever is operated. The right hand operator control
has 4 basic operational functions. BUCKET IN
“FORWARD” ....... Variable speed boom down.

“BACKWARD” .... Variable speed boom up.
“LEFT” ................. Variable speed bucket in (digging). BOOM UP
“RIGHT” ............... Variable speed bucket out (dump).

FIGURE 2.38
6. Left and Right Travel Lever & Pedal – FIGURE 2.39

The travel lever & pedal are located in front of op- LEFT HAND RIGHT HAND
TRAVEL LEVER TRAVEL LEVER
erator seat. They are used to move the left or right
track of the machine either forward or backward. LEFT HAND RIGHT HAND
TRAVEL PEDAL TRAVEL PEDAL
These controls have 2 basic operational functions.
“FORWARD” ....... Variable speed forward track

movement.
FOOT FOOT
“BACKWARD” .... Variable speed reverse track
REST REST
movement.
These operations are with travel motors at the rear

of the machine. If travel motors are positioned in front
of the machine the functions of the travel levers will
be opposite.
FIGURE 2.39
2 — 19
E . GAUGE CLUSTER
The monitor displays information sent from sensors positioned at various places on the excavator, making it possible
to monitor the excavator’s operating working conditions.
KPSS WORK MODE LAMP
WATER TEMPERATURE GAUGE

FUEL LEVEL GAUGE
LCD DISPLAY
6 LOW E/G
OIL PRESS LCD DISPLAY
BUZZER STOP SWITCH

KPSS WORK MODE SWITCH
WASHER SWITCH
SCREEN CHANGE SWITCH
WIPER SWITCH
AUTO ACCEL WORKING LIGHTS LED LAMP

SWITCH SELECT SWITCH
FIGURE 2.40
1. Fuel Level Gauge 3. KPSS Work Mode Lamp

This indicates the amount of re- Press the work mode selector
maining fuel. switch in order, and , or
F : Full tank is about 340 Liter (90 mode is selected and the se-
gal). lected work mode display green
lamp goes on.
E : The remaining fuel oil is about After the engine starts, the mode
54 Liter (14 gal). is always set to the A mode.
2. Water Temperature Gauge SUPPLEMENTARY EXPLANATION

This indicates the temperature of For guideline of work mode selector switch, see pages 2-
the engine coolant water, and op- 3 ~ 2-4.
erates when the starter switch is
turned to the “ON” position.
The temperature is normal in the
white range. If the needle enters
the red range, let the engine idle
until the water cools down and the
needle moves back into the white
range.
2 — 20
4. L.C.D. Display – FIGURE 2.41 a . Normal Displays
The L.C.D. display is illustrated below and will display The seven status are appear on the display by press-
the icons listed on this page. Study these icons and ing the screen change switch ( ).
their definitions so that possible problems will be quickly Utilize this function checking total cumulative time of
recognized and repairs made in a timely fashion. inspection and maintenance.
1. System status icon

LCD This icon is display after key switch is
(2) DISPLAY
6 LOW E/G turned “ON” and all machine systems
OIL PRESS
and components are checked by CPU
and found to be in good working or-
der. It remains displayed for 5 seconds.
(1) (3)
2. Clock display
This icon is displayed after 1 system
14 : 20 status icon disappears, current time
FIGURE 2.41 is displayed.
NOTE SUPPLEMENTARY EXPLANATION

The languages on gauge cluster can be switched by the 1. When the time is displayed, press the display selector switch
following procedure. And languages displayed on the ( ) for 5 to 10 seconds and the switch is changed to the
gauge cluster are as follows. ON, and release it, and the time can be adjusted.
“J” ................. Japanese 2. Press the mode switch ( ) and the value increases,
“E” ................ English and press buzzer stop switch ( ) and the value
“EA” .............. English (For North America) decreases.
“T” ................ Thai 3. Press the working light switch ( ) and the adjusting
“I” .................. Indonesian items are switched to Y01 M03 D3 H13
“F” ................ French m25 (This indicates 13:25 on March 3, 2001.) in order.
“S” ................ Spanish
4. Press the display selector switch ( ) the time ad-
“EU” .............. Pictorial symbol (For EU)
justment mode is terminated at the time when the ad-
“G” ................ German
justed value is stored.
“C” ................ Chinese
3. Engine R.P.M icon

• Switching procedure – FIGURE 2.41 The engine speed (output) corre-
2250RPM sponding to the throttle potentio
1. While keeping screen change switch (1) pressed,
meter position is displayed.
turn the key switch “ON”.
2. The gauge cluster displays the initially set language. 4. Engine lubrication cumulative time
“J” ... Japanese (This is displayed without fail). For instance, 256 hours has elapsed
since the change of engine oil.
3. Press buzzer stop switch (2) or mode change switch This indication shows the total cumu-
(3) and select and display the desired language. lative time since the engine oil has
4. Press screen change switch (1), and the setting is been changed.
completed.
5. Fuel filter cumulative time
5. Turning the starter switch to “HEAT” position can This indication shows the total cumu-
identify the set language. lative time on since the engine fuel
filter has been changed.
6. Hydraulic oil filter cumulative time

This indications shows the total cu-
mulative time since the hydraulic fil-
ter has been changed.
2 — 21
7. Hydraulic oil cumulative time 4. Engine pre-heat complete icon
This indication shows the total cumu- 5 This icon is displayed when the PRE-
FINISH
lative time since the hydraulic oil has PREHEAT HEAT is completed.
been changed. If the buzzer sounds and can’t be
stopped, turn key switch to the OFF
position and wait for 4 sec’s until the
SUPPLEMENTARY EXPLANATION electrical system is turned off. Then
For the correcting method of accumulated time for engine start engine. Continuous preheat af-
oil, fuel filter, hydraulic oil filter, hydraulic oil, etc., see page ter this icon is displayed could cause
2-25. And while correcting the time, press the mode switch damage to the engine.
and buzzer stop switch for 5 seconds simultaneously, and
all items are cleared. NOTE
Do not operate the preheat position of the key switch for
more than 20 seconds at one time.
b . Warning Displays
5. Engine oil pressure icon
WARNING DISPLAYS
6 LOW E/G
This icon will display and the buzzer
The buzzer will sound the instant #2, #4, #5, #6, #8 and
OIL PRESS will sound should the engine oil pres-
#17 warning icons are displayed.
sure drop below safe operating pres-
sure. If this icon is on display and
1. I.T.C.S controller-CPU icon buzzer is sounding, stop the engine
1 MECHATRO
This icon will display when a problem immediately and check engine oil
CPU
CONT. FAIL exists in the I.T.C.S. (Intelligent Total level. Fill engine to proper level with
Control System). Turn key switch approved engine oil. In case of en-
“OFF” and back to “ON” to try and re- gine LOW OIL PRESSURE, the en-
set CPU programming. Should this gine will automatically go to “LO”
icon remain on display, stop operation, Idle RPM.
stop engine call KOBELCO service This icon will display only if alterna-
technician for temporary CPU bypass tor is charging.
procedures or refer to page 2-17.
6. Engine coolant temperature icon
2. Swing parking brake release icon 7 HIGH E/G
This icon will display and the buzzer
2
Turn the “Swing parking brake re- COOL TEMP will sound should the engine coolant
SWINGBRAKE
DISENGAGED lease switch” on the rear side of temperature rise above safe operat-
operator’s seat to the “RELEASE” ing temperature. Should this icon dis-
position, and this warning is display and buzzer sound, reduce engine
played. While this warning is dis- RPM to idle and stop operation until
played, the swing parking brake does engine coolant temperature reaches
not actuates. So this switch should safe operating temperature range.
be used only in the event of emer-
gency. Call KOBELCO distributor for 7. Engine air cleaner icon
assistance. 9
This icon will display the engine air
REST'D AIR
CLEANER cleaner element(s) (FILTERS) be-
3. Engine pre-heating icon come too dirty to allow proper air flow
4 E/G
This symbol is displayed when key to the engine. Should this icon dis-
PREHEAT switch is turned to heat position and play stop engine immediately and
the engine preheat circuit is acti- clean or replace engine air cleaner
vated. element(s) as required.
This display goes out at completion This icon will display only if alterna-
of pre-heating, at which time 5
tor is charging.
is displayed.
2 — 22
8. Over load alarm icon (EU only) 14. Attachment boost pressure icon
10
The icon will display and the buzzer 19 This icon will display when the power
ATTACHMENT POWER
OVER LOAD will sound if the boom cylinder circuit BOOST ON boost switch is depressed. This icon
pressure exceeds the set, specified is displayed only when this system is
A
ASI
pressure. If this Thappens, the opera- activated during operation.
E A S
tor should
UT Hbe aware that he is oper-
E
atingSOthe machine in a range of low 15. Heavy lift pressure icon
S
T Umachine stability. The operator A
N O This icon will displayASIwhen the heavy
20 HEAVY LIFT
E A ST
should reduce the attachment reach lift switch H in the “ON” position. This
Tis
in order to increase machine stabil- S OU
E
icon
S is displayed only when this sys-
TU
ity for safer operation. NO tem is activated during operation.
9. Battery charging system icon 16. Auto warning up icon (Middle east OPT.)
This icon will display the electrical
WARMING UP This icon is displayed to indicate the
11 CHARGING 21
PROBLEM charging system not function prop-
warming up operation of the engine
erly. Should this icon display has
and hydraulic oil when the engine
electrical charging system repaired
rotates in decel condition after the key
immediately. Icon displays only when
engine is running with normal oil switch is turned on and the auto
pressure and a problem occurs in the warming up selector switch on the left
charging system. console is set to “ON” position.
Turn the auto warming up select
10. Fuel level icon switch, hydraulic oil temperature
12 LOW
This icon will display should the fuel switch and the key switch OFF, and
FUEL LEVEL level in fuel tank reaches 54 liters the warming up operation stops forc-
(14 Gal.) or less. Should this icon dis-
ibly and the display disappears.
play refill fuel tank immediately us-
ing approved fuel oil. 17. Auto warming up finish icon (Middle east OPT.)
28 FINISH This icon is displayed when the
11. Hydraulic oil level icon
This icon will display should the hy- warming up of the engine or hydrau-
13 LOW HYD
draulic oil level in hydraulic oil reser- lic oil is finished or the warming up is
OIL LEVEL
voir fall below safe operating level. stopped forcibly by operating the le-
Should this icon display before start- ver or turning the auto warm-up
ing engine, position the machine in switch OFF forcibly, and concurrently
hydraulic oil check position and check the buzzer sounds continuously for
sight gauge for oil level. Full hydrau- about 5 seconds.
lic reservoir to proper level using ap-
proved hydraulic oil. This icon will not 18. Replace engine oil icon
display with engine running and a 29 CHANGE
This icon will display at every 500
loss of hydraulic oil is experienced. E/G OIL hours of machine operation to remind
operator of scheduled engine oil
12. Engine coolant level icon change. The recommended oil change
14
This icon will display should the en- interval for MITSUBISHI engines is
LOW E/G
COOL LEVEL gine coolant level fall below safe op- every 500 hours of operation.
erating level. Should this icon display
When this icon is displayed, and a
before starting the engine, check and
second time to reset the oil change
fill coolant level in the radiator and
coolant reservoir. Icon will not display interval to zero. Make sure to
if alternator is charging and a sud- recalibrate the engine oil change in-
den loss of coolant is experienced. terval as indicated in page 2-25.
13. Engine oil level icon

15 LOW E/G
This icon is displayed when the en- SUPPLEMENTARY EXPLANATION
OIL LEVEL gine oil level of the engine oil pan is For the correcting procedure of the accumulated time of
low. Check the engine oil level im-
engine fueling, see page 2-25.
mediately and make up the shortage
of the engine oil.
2 — 23
19. Display of starting number of engine auto idling stop
NO.1
MAIN CONT P/N
STARTER CHG
PROGRAM VER
Indicates the appeal of starter change
VER 4.00
Recommended This indication flickers for 10 seconds

number of on the multi-display each time the
engine starting
starter key is switched ON after the
starting number of starter motor for
auto idling stop function is raised to
the set value.
Replace the starter motor.
The limit number of durable starting times of starter motor
varies according to the model of machine.
2 — 24
5. How to Calibrate the Engine Oil Change Interval
The accumulated time for fuel filter, hydraulic oil filter, hy-
draulic oil, etc. can be corrected by the procedure for cor-
rection of the accumulated time for engine oil supply after
the adjusting items have been displayed.
While correcting the time, press the mode switch and
buzzer stop switch for 5 seconds simultaneously, and all
LCD
items are cleared.
DISPLAY 256Hr AFT
E/G OIL CH
MODE
SWITCH
SCREEN
CHANGE
SWITCH
BUZZER STOP SWITCH
(Eg.) The procedure for correction of the accumulated time for engine oil supply.
PROCEDURE OPERATING PROCEDURE DISPLAY ON MULTIDISPLAY
(Normal) Clock is displayed
A Turn the starter switch on. Clock is displayed
14 : 20
after 5 seconds
E/G speed is displayed
Press the gauge cluster screen change switch Press once
B 14 : 20 2250 RPM
once, and the E/G speed (rpm) is sidplayed.
Clock is displayed
E/G speed is displayed
Press once more, and the engine oil supply Press once more
C 2250 RPM
100Hr AFT
cumulative time screen is displayed. E/G OIL CH
Press the screen change switch for 5 to 10 100Hr AFT 256Hr AFT 100Hr AFT
D seconds and release the hand, it returns to the E/G OIL CH FUEL FIL CH E/G OIL CH
correction mode.
Press the work mode selector switch and the 100Hr AFT Cumulative time 101Hr AFT
E E/G OIL CH E/G OIL CH
cumulative time increases. (once 1 Hr) increases
Press the buzzer stop switch, the cumulative time 100Hr AFT The cumulative 99Hr AFT
F E/G OIL CH E/G OIL CH
decreases. (once 1 Hr) time decreases
Press the gauge cluster screen change switch 99Hr AFT Complete the 256Hr AFT
G once the correcting time is stored, and exits from E/G OIL CH correction FUEL FIL CH
the correction mode and is displayed and
256Hr AFT
FUEL FIL CH
the correction is completed.
NOTE : 1. Press the screen change switch once after the procedure D, and the condition is stored and the correction is
completed.
2. To correct the each accumulated time of fuel filter, hydraulic oil filter and hydraulic oil, press the screen
change switch and display the accumulated time screen for the items required to correct, then repeat the
procedure D to G.
3. The engine oil change time is warned on the multidisplay by 500 hours, but no buzzer sounds.
4. For the fuel filter, hydraulic oil filter and hydraulic oil, press the screen change switch, and the “ ” is
displayed, but no warning and no buzzer are given.
5. The time is displayed with 4 digits for hydraulic oil, and 3 digits for others.
2 — 25
The following chart is aimed at familiarizing personnel with EXAMPLE:
the priority of the gauge cluster display icons. Pay close If the engine oil pressure is abnormal and fuel level is low,
attention to these icons as they can aid in avoiding un- the engine oil pressure icon will display and buzzer will
necessary repairs and expense. sound. After the oil pressure is back to safe operating pres-
The icon in the chart below are listed in priority from the sure, the low fuel icon will display.
most serious to least serious.
LCD DISPLAY SERVICE FUNCTION ICON SEQUENCE BUZZER SOUNDING
14 : 20
Press it once
Key S/W after E/G starts. Press once
OFF
14 : 20 1515 RPM
NO SOUNDING
Press once Press once
NORMAL 1920Hr AFT 256Hr AFT
DISPLAY HYD OIL CH E/G OIL CH Use to ensure the time of the
Press once Press once replacement for the inspection,
service, etc.
256Hr AFT 256Hr AFT
HYD FIL CH Press once FUEL FIL CH
Supplementary Explanation:
The screen can be switched into seven images by pressing the
screen change switch.
NO SOUNDING
ASSIST • For the description of display

Digging mode Leveling mode
MODE of the assist mode, refer to
DISPLAY Page 3-10.
Each display flickers during
discrimination.
Spreading mode Tamping mode Standard mode
1 MECHATRO 9 REST'D AIR 19 POWER • #2, #5, #6, #7, #28

CPU buzzer sounds.
CONT. FAIL CLEANER BOOST ON
2 11 21
Supplementary Explanation:
SWINGBRAKE CHARGING WARMING UP
Icons #5 and #6 are displayed
DISENGAGED PROBLEM
and buzzers do not stop
4 12 (Middle east OPT.) sounding even if the buzzer
E/G LOW
stop switch is pressed.
PREHEAT FUEL LEVEL 28 FINISH
Icon #7 is displayed and buzzer
5 FINISH 13 LOW HYD stops sounding when the
WARNING (Middle east OPT.)
PREHEAT OIL LEVEL buzzer stop switch is pressed.
29 CHANGE Icons #2 and #28 are displayed
6 LOW E/G 14 LOW E/G E/G OIL and buzzers sound intermittently
OIL PRESS COOL LEVEL and stop sounding after 5 seconds.
NO.1
MAIN CONT P/N
7 HIGH E/G 15 LOW E/G STARTER CHG No. 1 flickers on the multi-display
PROGRAM VER
COOL TEMP OIL LEVEL VER 4.00 each time the starter key is
switched ON after the number
of starting number of starter
motor is raised to the set value.
2 — 26
F. OPERATOR CAB AND OPERATOR SEAT
1. Locking/Unlocking Cab Door USE KEY SWITCH KEY TO

Use the key switch key to lock or unlock cab door. LOCK & UNLOCK CAB DOOR
Insert key into door lock and turn clockwise to un-
lock or turn counterclockwise to lock cab door. See
Figure 2.42.
FIGURE 2.42
2. Cab Door Latch

CAB DOOR LATCH
a . The cab door can be latched in an open position
by opening door until it is locked open by the door
latch located on the cab. See Figure 2.43.
FIGURE 2.43
b . Release door latch by pushing release lever down PUSHING LEVER

to release door from latch. See Figure 2.44. DOWN TO
RELEASE DOOR
FIGURE 2.44
c . Pull release lever near side, and door opens from

the inside of cab. See Figure 2.45.
PULL RELEASE LEVER
FIGURE 2.45
2 — 27
3. Housing of Front Window (Upper) LEVER (1 EACH SIDE)
• To open
The front window (upper) can be stored in the ceiling.
The front window (upper) must be stored securely by

setting it in the rear side of cab ceiling. And then don’t
fail to turn the levers on both sides rearward to tighten
securely. If the levers are not securely tightened, this
HANDLE
might introduce the danger of slipping down of front
window, causing accident resulting in injury or death. FRONT INSIDE OF CAB
And also, if the levers are not securely tightened, the FIGURE 2.46
wiper interlock does not work, and when the wiper motor
is turned ON, the wiper may be damaged because the
wiper bumps into the cab frame.
a . Place machine on flat ground.

b . Pull levers placed on the right and left corners on
the upper side of front window near side by hand,
and the lock is released. Figure 2.46.
c . Raise the front window (upper) with handles placed
on the center section of upper side and the lower LEVER
section of left side of the front window, move it to
the rear most of rail on the rear of ceiling, and turn REAR INSIDE OF CAB
and secure the levers rearward (upward) fully to FIGURE 2.47

tighten. Figure 2.47.
• To close
a . To close the front window (upper), pull and loosen
the levers near side (downward), grip the handles
on the center section of upper side and the lower
section of left side, and lower it slowly while lifting
the rear side a little.
b . After returning the front window (upper) to the origi-
nal position, turn levers upward to secure the front
window.
Close the front window while bringing it down slowly.

Then care should be taken not to put hand in the win-
dow.
2 — 28
4. Removing & Storing Lower Front Window
HOLDER
a . After placing upper front window in ceiling, hold
lower front window by hands and remove it from
window frame.
b . Store the removed lower front window in holder HOLDER
on the rear side of cab securely.
c . To store it, insert the right and left sides of glass in

holder, and support it with holder on the lower sec-
tion of window frame. See Figure 2.48.
HOLDER
FIGURE 2.48
5. Opening and closing door glass
a . Open cab door glass (upper) sliding it to front side LOCK

after unlocking it.
LOCK
b . Close the door glass sliding it to LOCK position,
then lock it. See Figure 2.49.
FIGURE 2.49
6. Opening and Closing Sunroof LOCK (1 EACH SIDE)

Pull locks on right and left sides inward, and sunroof
opens through the aid of gas spring.
Close sunroof pulling locks inward, and lock it.
Also the roof can be left slightly open to ventilate air
in cab by placing lock section on section. See Fig-
ure 2.50.
(B)
(A)
FIGURE 2.50
7. Cab Dome Light OFF
a . Turn cab dome Light “ON” by pushing the dome

light switch downward.
b . Turn “OFF” by pushing switch all the way up. See ON

USE THIS SWITCH
Figure 2.51. TO TURN DOME
LIGHT "ON" AND
c . Place dome light switch in the “CENTER” position "OFF"
and the light will be operated by the door switch.
When door is opened the light will come “ON” and
when the door is closed the light will turn “OFF”.
FIGURE 2.51
2 — 29
8. Storage Compartment
The operator and parts manual storage compartment
MANUAL STORAGE
is a pouch located on the back of the operator’s seat.
Keep the operator and parts manual for this machine
in this location at all times for quick, easy reference.
See Figure 2.52.
FIGURE 2.52
9. Operator Seat Adjustments

ROTATE TO SET
The operator seat incorporates several adjustment OPERATOR WEIGHT
mechanisms to insure operator comfort, ease of op-
eration and operator safety. The adjustment areas
are as follows:
a . Operator weight adjustment – FIGURE 2.53

Rotate the adjustment knob until weight close to
the operator’s weight is at the top end of the dial.
FIGURE 2.53
b . Seat height adjustment – FIGURE 2.54

1. Pull height adjustment lever up to raise or lower
rear of seat.
2. Push height adjustment lever down to raise or
lower front of seat.
PULL UP TO ADJUST REAR OF SEAT

PUSH DOWN TO ADJUST FRONT OF SEAT
FIGURE 2.54
c . Seat reclining adjustment – FIGURE 2.55

1. Pull reclining adjustment lever up to set desired
reclining angle.
2. Release reclining adjustment lever to lock seat
in position.
PULL UP TO ADJUST
SEAT RECLINING
POSITION
FIGURE 2.55
2 — 30
d . Seat front to back adjustment – FIGURE 2.56 USE BOTTOM BAIL TO USE TOP BAIL TO
Pull up on seat adjustment bail and move seat ADJUST CONTROL ADJUST OPERATOR
STAND SEAT ONLY
forward or backward to desired position.
FIGURE 2.56
e . Arm rest adjustment – FIGURE 2.57

Lower arm rest and with finger, turn adjustment TURN WHEEL TO
ADJUST ARM REST
wheel until arm rest is in desired position. (1 EACH ARM REST)
FIGURE 2.57
f . Head rest adjustment – FIGURE 2.58

MANUALLY ADJUST HEAD REST HEIGHT
1. Move head rest forward or backward to desired AND RECLINING TO DESIRED POSITION
reclining angle.
2. Raise or lower head rest to desired height.
FIGURE 2.58
2 — 31
G. SEAT BELT – FIGURE 2.59
1. Sit on the operator’s seat and adjust the seat posi-

tion so that the operator’s back closely contacts with
the seat back.
2. Sit on the seat, and draw out the belt. RED BUTTON
NOTE
If the belt is stopped drawn out halfway, the belt is locked
at the stopped position. Return it once to draw it out again. BUCKLE
3. When the seat belt is used, draw it out moderately FIGURE 2.59
long and insert it in the buckle until rattling sound is
heard.
Release hands, and the length is automatically ad-
justed and the belt is locked.
4. After locking, the belt can be extended or shortened

in about 25 mm (1 in) range so as not to fasten the
body tightly.
5. Press the red button of the buckle, and the belt is

unfastened.
ALWAYS WEAR SEAT BELT WHILE SITTING IN

OPERATOR SEAT.
ALWAYS CHECK CONDITION OF SEAT BELT AND
SEAT BELT MOUNTING HARDWARE TO MAKE
CERTAIN SEAT BELT IS IN GOOD CONDITION AND
PROPERLY SECURE.
H. MACHINE ACCESS PANELS & DOORS

ENGINE COOLANT
1. Engine Coolant Tank & Engine Air Cleaner Ac- TANK ACCESS DOOR
cess Doors – FIGURE 2.60

Located on the L.H. side of the machine the engine
coolant tank access door allows access to the en-
gine coolant tank. It also holds the engine air cleaner
access door closed.
Use the key switch key to lock and unlock the en-
gine coolant tank access door. RADIATOR SUB TANK
ENGINE AIR CLEANER ACCESS DOOR
ACCESS DOOR
FIGURE 2.60
2 — 32
2. Main Pump Access Door – FIGURE 2.61
MAIN PUMP ACCESS DOOR
Locate on the right side of the machine this door al-
lows access to the main pump.
FIGURE 2.61
3. Battery Box Access Cover – FIGURE 2.62

Located on the right front of the upper frame this cover
allows access to the batteries and battery relay. This
access cover is also locked and unlocked by key BATTERY ACCESS
COVER
switch key.
Use stay to leave the cover open.
FIGURE 2.62
4. Fuel cap – FIGURE 2.63

Stop engine and remove cap on fuel tank, then make FUEL CAP
it up with fuel.
FIGURE 2.63
5. Engine Bonnet – FIGURE 2.64

ENGINE BONNET
Open engine bonnet with key switch after stopping
engine.
Use stay to support it.
FIGURE 2.64
2 — 33
Section III – BASIC MACHINE OPERATION
Table of Contents
PRE-START CHECK .................................................................................................................................... 3-1
STARTING & STOPPING MACHINE ENGINE ABOVE 0°C (32°F) ............................................................. 3-1
Starting Engine ...................................................................................................................................... 3-1
Stopping Engine .................................................................................................................................... 3-2
Emergency Engine Shut Down ............................................................................................................. 3-2
STARTING & STOPPING MACHINE ENGINE BELOW 0°C (32°F) ............................................................. 3-2
Starting Engine ...................................................................................................................................... 3-2
Stopping Engine .................................................................................................................................... 3-3
Emergency Engine Shut Down ............................................................................................................. 3-3
STARTING MACHINE ENGINE WITH BOOSTER CABLES ....................................................................... 3-4 ~ 3-5
Connecting Booster Cables .................................................................................................................. 3-4
Starting Boosting Machine Engine ...................................................................................................... 3-5
Starting Disabled Machine Engine ....................................................................................................... 3-5
Disconnecting Booster Cables ............................................................................................................. 3-5
MACHINE WARM-UP ................................................................................................................................... 3-6
Auto Warm Up ........................................................................................................................................ 3-6
Manual Warm Up .................................................................................................................................... 3-7
CONTROLS DECAL ..................................................................................................................................... 3-8
Operating Pattern ................................................................................................................................... 3-8
Operating Pattern Decal ........................................................................................................................ 3-8
BASIC OPERATION OF HYDRAULIC CONTROLS ................................................................................... 3-9 ~ 3-16
Safety Lock Lever .................................................................................................................................. 3-9
KPSS (KOBELCO Power Sensing System) Work Mode Switch ........................................................ 3-10
Machine Travel Controls ....................................................................................................................... 3-11 ~ 3-13
Machine Attachment & Swing Controls ............................................................................................... 3-14 ~ 3-15
Using Power Boost ................................................................................................................................ 3-15
Using Auto-accel .................................................................................................................................... 3-16
Towing the Machine ............................................................................................................................... 3-16
PRACTICES TO IMPROVE EFFICIENCY ................................................................................................... 3-17 ~ 3-18
MACHINE OPERATION IN ADVERSE WEATHER ..................................................................................... 3-19
FLAGMAN HAND SIGNALS ........................................................................................................................ 3-20 ~ 3-25

3—0
3.1 PRE-START CHECK
Perform pre-start inspection and maintenance pro-
cedures before starting the machine. Refer to the
maintenance section of this manual for specific in-
structions.
3.2 STARTING & STOPPING MACHINE ENGINE

WITH TEMPERATURE ABOVE 0˚C (32˚F)
A. STARTING ENGINE
THROTTLE IN KEY SWITCH IN
1. Move throttle control to “LO” position. See Figure 3.1. "LO" POSITION "ON" POSITION
2. Insert key into key switch and turn to the “ON” posi-
FIGURE 3.1
tion. See Figure 3.1.
3. Sound horn to warn personnel that the machine is
being started. See Figure 3.2. SOUND
HORN
4. Turn key to the “START” position and release as soon
as engine starts. Key will automatically return to the
“ON” position.
Release key after 20 seconds of cranking if engine does

not start.
Wait at least 2 minutes before attempting to start en-
gine again to allow starter motor to cool.
FIGURE 3.2
NOTE
If engine fails to start after 3 attempts, inspect fuel system
and correct any problems found.
When cranking engine, the absence of “Blue” or “White”
smoke from the exhaust indicates no fuel is reaching the
engine cylinders. When you do the work which has fear, such as fall
of a load, when engine stops, please be sure to turn
OFF an auto idling stop switch.
The auto idling stop function for cutting down generat-

ing of the useless fuel consumption and an exhaust
gas at the time of a stop in this machine is carried. When
you use it, be careful of the following things.
· When you start the engine again after an auto idling
stop, please be sure to start after once returning a
key switch at ACC or OFF and also returning a throttle
potentiometer to Lo. But the engine cannot be again
started until a buzzer stops, after engine stops.
· When you leave from a cab for a long time, please be
sure to turn OFF a starter switch.
· When the engine coolant temperature error are dis-
played with the LCD or lamp, it does not operate, even
if the auto idling stop switch is turned on ON.
3—1
B. STOPPING ENGINE – NORMAL CONDITIONS
MACHINE ON FIRM, ATTACHMENT IN
1. Move machine to a firm, level area and place the LEVEL SURFACE HYDRAULIC OIL
attachment in the hydraulic oil check position. See CHECK POSITION
Figure 3.3.
2. Move throttle control to “LO” position. See Figure 3.1.
Allow engine to idle for 5 minutes.
3. Turn key switch to “OFF”.
C. EMERGENCY ENGINE SHUT DOWN FIGURE 3.3

In only cases of emergency should this method be used.
1. Turn key switch to the “OFF” position.
2. Pull out the engine emergency stop control located
on the lower right side of control stand. See Figure
EMERGENCY
3.4. ENGINE STOP
CONTROL
3. Before restarting engine, push emergency engine
stop control in.
3.3 STARTING & STOPPING MACHINE ENGINE

WITH TEMPERATURE BELOW 0˚C (32˚F)
FIGURE 3.4
A. STARTING ENGINE
2. Turn the key switch to “HEAT” and preheat for 20
seconds to make start-up easier. See Figure 3.6.
3. Sound horn to warn personnel that the machine is
being started. See Figure 3.7.
4. Turn key to the “START” position and release as soon
as engine starts. Key will automatically return to the THROTTLE IN KEY SWITCH IN
"LO" POSITION "ON" POSITION
“ON” position.
FIGURE 3.5
KEY IN "HEAT" POSITION

Release key after 20 seconds of cranking if engine does FOR 20 SECONDS
not start.
Wait at least 2 minutes before attempting to start en- 4 E/G
gine again to allow starter motor to cool. PREHEAT
NOTE
• In the cold weather, use the auto warm up switch described FIGURE 3.6
on page 2-12 of Section II, and warm the engine and hy-
draulic oil. (Middle east OPT.)
SOUND
• If engine fails to start after 3 attempts, inspect fuel system HORN
and correct any problems found.
• When cranking engine, the absence of “Blue” or “White”
smoke from the exhaust indicates no fuel is reaching the
engine cylinders.
FIGURE 3.7
3—2
When you do the work which has fear, such as fall

of a load, when engine stops, please be sure to turn
OFF an auto idling stop switch.
The auto idling stop function for cutting down generat-

ing of the useless fuel consumption and an exhaust
gas at the time of a stop in this machine is carried. When
you use it, be careful of the following things.
· When you start the engine again after an auto idling
stop, please be sure to start after once returning a
key switch at ACC or OFF and also returning a throttle
potentiometer to Lo. But the engine cannot be again
started until a buzzer stops, after engine stops.
· When you leave from a cab for a long time, please be
sure to turn OFF a starter switch.
· When the engine coolant temperature error are dis-
played with the LCD or lamp, it does not operate, even
if the auto idling stop switch is turned on ON.
B. STOPPING ENGINE– NORMAL CONDITIONS

MACHINE ON FIRM, ATTACHMENT IN
1. Move machine to a firm, level area and place the LEVEL SURFACE HYDRAULIC OIL
attachment in the hydraulic oil check position. See CHECK POSITION
Figure 3.8.
Allow engine to idle for 5 minutes.
3. Turn key switch to “OFF”.
FIGURE 3.8
C. EMERGENCY ENGINE SHUT DOWN
In only cases of emergency should this method be used.
1. Turn key switch to the “OFF” position.
2. Pull out the engine emergency stop control located
on the lower right side of control stand. See Figure
3.9.
EMERGENCY
3. Before attempting to restart the engine, push emer- ENGINE STOP
CONTROL
gency engine stop control in.
FIGURE 3.9
3—3
3.4 STARTING MACHINE ENGINE WITH
KEY SWITCH POSITIONS
BOOSTER CABLES
A. CONNECTING BOOSTER CABLES
1. Move vehicle or machine to be used for boosting as
close to the battery box of the disabled machine as
possible.
DO NOT ALLOW THE VEHICLE OR MACHINE USED

FOR BOOSTING TO TOUCH METAL TO METAL
WITH THE DISABLED MACHINE. THIS COULD
SHORT CIRCUIT ELECTRICAL SYSTEMS AND
CAUSE EXTENSIVE DAMAGE TO THE CPU AND
OTHER COMPONENTS.
FIGURE 3.10
Use only vehicles or machines with 24 V DC electrical

system for boost starting this machine.
2. Make certain key switch of disabled machine is in

NEGATIVE (-) CABLE
the “OFF” position before proceeding with booster
cable connection. See Figure 3.10.
POSITIVE (+) CABLE
WEAR HARD HAT, APPROVED SAFETY GLASSES

OR FACE SHIELD, GLOVES AND OTHER SAFETY
EQUIPMENT WHEN WORKING WITH BATTERIES.
3. Locate and connect one end of the booster cable to

the positive (+) terminal on the battery of the dis-
abled machine. See Figure 3.11. FIGURE 3.11
4. Connect other end of positive booster cable to posi-
tive (+) terminal of battery being used for boosting.
5. Locate and connect second cable to the negative (-)
terminal of the battery being used for boosting. CABLE CONNECTING ORDER
6. Connect other end of negative (-) cable to the upper

frame of disabled machine as far away from battery
as possible. See Figure 3.12.
12V 12V 12V 12V

THE NEGATIVE CABLE, WHEN CONNECTED TO
NORMAL DISCHARGED
THE UPPER FRAME OF DISABLED MACHINE, MAY BATTERIES BATTERIES
ARC CAUSING SPARKS. SPARKS COMING IN CON-
TACT WITH BATTERIES, COULD TRIGGER AN EX-
PLOSION. UPPER FRAME OF
NEVER CONNECT NEGATIVE CABLE TO NEGA- DISABLED MACHINE
TIVE (-) TERMINAL OF DISABLED BATTERY. FIGURE 3.12
3—4
B. STARTING BOOSTING MACHINE ENGINE
CABLE DISCONNECTING ORDER
1. Start engine of boosting machine in normal manner
according to climate conditions. Refer to pages 3-1
& 3-2 for specific starting instructions.
2. Allow five minutes or more to provide partial charge
to the discharged batteries.
12V 12V 12V 12V
C. STARTING DISABLED MACHINE ENGINE
NORMAL DISCHARGED
Start engine of disabled machine in normal manner BATTERIES BATTERIES
according to climate conditions. Refer to pages 3-1 &
3-2 for specific starting instructions.
UPPER FRAME OF
DISABLED MACHINE
FIGURE 3.13
D. DISCONNECTING BOOSTER CABLES

1. After disabled machine engine is running, discon-
nect the negative (-) cable from disabled machine
upper frame. See Figure 3.14.
2. Disconnect negative (-) cable from battery used for
boosting.
3. Disconnect positive (+) cable from battery used for
boosting.
4. Disconnect positive (+) cable from terminal of dis-
DISCONNECT NEGATIVE (-) CABLE
abled machine. See Figure 3.14. FROM DISABLED MACHINE
FIGURE 3.14
When using booster cables remember;

1. Connect positive (+) cable first.
2. Disconnect negative (–) cable first from frame of dis-
abled machine.
3—5
3.5 MACHINE WARM UP (MIDDLE EAST OPT.)
A. AUTO WARM UP – FIGURE3.15

Place the ignition switch to the “on position” (do not
start the engine). Turn on the warm up switch located PRESS HERE
FOR "OFF"
on the left panel and then start the engine.
1. Warming Up of Engine
The “WARMING UP” is displayed on the multi dis-
play after operating the engine for 3 minutes at auto
accel speed (1,050 rpm). When the accel dial set
value is the value for deceleration or lower, the en-
gine speed returns to the speed set by the accel dial.
2. Warming of Hydraulic Oil

The warm up of hydraulic oil is performed as follows:
operation of pump max. flow rate at the engine speed
(1,050 rpm) for 3 minutes pump max. flow rate
(control value closed) at the engine speed (1,600
rpm) for 5 minutes pump max. flow rate and con- FIGURE 3.15
trol valve fully open at the engine speed (1,600 rpm)
for 5 minutes max. flow rate at the engine auto
accel speed (1,050 rpm) for 10 minutes, “WARM-
ING UP” is displayed on the multidisplay.
In operating the machine with cold hydraulic oil, the
3. Warming Up Complete operator may experience slow or unexpected move-
After an elapsed time of about 26 minutes of warm- ment of functions.
ing of hydraulic oil, or when the hydraulic oil tem- Damage to the hydraulic components may result due
perature switch turns OFF, the WARMING UP indi- to the cold oil not providing adequate lubrication.
cation (“WARMING UP”) on the multidisplay disap-
pears and concurrently buzzer sounds for 5 seconds.
Turn the auto warm up switch OFF.
NOTE
1. If a pilot control lever is activated while the warm up
system is active, the warm up is disconnected. The
warm up system will restart after 20 sec. of neutral
condition in the pilot control system.
2. If the auto warm up switch is pressed to the OFF posi-
tion, the warm up system is disconnected.
3. In climates below -18°C (0°F) it may be necessary to
use a coolant heater, fuel heater, engine heater jacket
and/or additional battery power to aid in starting the
engine.
Auto warm-up should be utilized anytime machine is

started in climate temperatures below 10°C (50°F) to
stabilize machine control response. Cold oil can cause
erratic machine operation.
3—6
B. MANUAL WARM UP
ALLOW THE ENGINE TO RUN FOR 5 MINUTES
1. Warming Up of Engine IN LOW IDLE BEFORE WARM UP
a. Allow the engine to run for 5 minutes under no load

conditions with throttle control at “LO” idle position.
See Figure 3.16.
b. During warm up, visually and audibly inspect en-
gine for abnormal conditions such as unusual ex-
haust color, excessive vibrations and excessive or
unusual noises.
c. Should problem areas be noticed, stop engine, lo-
cate and repair problem areas before restarting or
operating the machine.
NOTE
In warming up the engine, turn auto idling stop select switch
OFF.
2. Warming of Hydraulic Oil

a. Move throttle control to “HI” idle position.
b. Perform bucket dig operation and hold over relief
for 10 to 15 seconds, then operate bucket dump FIGURE 3.16
and hold over relief for 10 to 15 seconds. Repeat
this operation for 5 to 10 minutes to help oil to reach
operating temperature. See Figure 3.17. OPERATE BUCKET DIG AND DUMP OVER RELIEF
FOR 10 ~ 15 SEC. REPEATEDLY FOR 5 ~ 10 MIN.
c. Move throttle control to mid position and operate
the boom and arm controls for 5 to 10 minutes each.
See Figure 3.17.
While operating the machine with cold hydraulic oil,

the operator may experience slow or unexpected move-
ment of functions.
Damage to the hydraulic components may result due
to the cold oil not providing adequate lubrication. OPERATE THE BOOM, AND ARM FOR
5 ~ 10 MINUTES EACH
Auto warm-up should be utilized anytime machine is

started in climate temperatures below 10°C (50°F) to
stabilize machine control response. Cold oil can cause
erratic machine operation.
Check clearance between

bucket and cab before opera-
CAUTION tion. Slowly cycle bucket, check
FOR
INTERFERE for interference with arm and
cab, particularly if a lifting eye
is welded on bucket bottom.
Exercise care when operating
the bucket near the cab. FIGURE 3.17
3—7
3.6 CONTROLS DECAL B. OPERATING PATTERN DECAL
Figure 3.18 is a representation of the “CONTROLS”
A. OPERATING PATTERN decal located on the right side window inside the op-
The operating and travel controls of this machine are erator cab. Study this decal and understand the direc-
factory set to ISO standard operating patterns for opti- tions each control can be operated and the functions
mum performance of the machine and its systems. associated with each movement of particular control.
Detailed instructions for each control and its functions
are explained on the following pages of this section.
CHECK AND MAKE SURE THAT OPERAION’S PAT- Should this decal become damaged or missing, install
TERN CONTROL MATCHES THE DECAL PRO- new decal KOBELCO Part Number YT20T01072P1.
VIDED INSIDE THE RIGHT SIDE WINDOW.
HYDRAULIC CONTROL LEVERS
LEFT RIGHT
LEFT CONTROL LEVER TRAVEL TRAVEL RIGHT CONTROL LEVER
LEVER LEVER
AND AND
PEDAL PEDAL
NOTE
Travel motors are positioned
behind the operator's cab.
FIGURE 3.18
3—8
3.7 BASIC OPERATION OF HYDRAULIC CON-
TROLS
The following instructions are aimed at providing an
operator with the basic function of each hydraulic
control. Use of these instructions, and practice with
a machine, will allow a given operator to become
more efficient in the operation of this equipment.
Each operator must read, understand and follow
these basic instructions along with all safety precau-
tions found in this manual and on the machine be-
fore operating this equipment.
TRAVEL MOTORS AT REAR OF MACHINE
NORMAL POSITIONING OF THE MACHINE FOR FIGURE 3.19

THE PURPOSE OF DETERMINING FRONT, REAR,
FORWARD AND REVERSE ARE WITH THE TRAVEL
MOTORS LOCATED BEHIND THE OPERATOR’S
CAB. SEE FIGURE 3.19.
ALWAYS KNOW THE LOCATION OF TRAVEL MO-
TORS BEFORE OPERATING ANY HYDRAULIC
CONTROLS.
A. SAFETY LOCK LEVER – FIGURE 3.20

1. Unlocked Position
Before any hydraulic operation is possible the safety lock
lever must be placed in the “UNLOCKED” (DOWN) posi-
tion. Placing the safety lock lever in the UNLOCKED
(DOWN) position also positions the L.H. operators con-
sole in its operating position.
2. Locked Position
Before leaving the operator cab, place the safety lock SAFETY LOCK LEVER
IN UNLOCKED
lever in the “LOCKED” position by pulling lever up. (DOWN) POSITION
With safety lock lever in the “LOCKED” (UP) posi-
tion, no hydraulic operation is possible and allows
SAFETY LOCK
easy access in and out of the operator seat. LEVER IN
LOCKED
(UP) POSITION
ALWAYS PLACE THE SAFETY LOCK LEVER IN THE

“LOCKED” (UP) POSITION BEFORE LEAVING CAB
TO PREVENT ANY OPERATION OF HYDRAULIC
CONTROLS.
FAILURE TO PLACE SAFETY LOCK LEVER IN THE
LOCKED (UP) POSITION COULD RESULT IN SERI-
OUS INJURY OR DEATH AS WELL AS SERIOUS FIGURE 3.20
DAMAGE TO THE MACHINE AND ITS COMPO-
NENTS.
3—9
B. KPSS (KOBELCO POWER SENSING SYSTEM) MODE SWITCH – FIGURE 3.21
Press the work mode selector switch in order, and , or mode can be selected.
Select the effective work mode according to the work condition and working target from the table shown below.
For the selected work mode, refer to the table shown below.
L.C.D. DISPLAY
KPSS WORK
MODE SWITCH
FIGURE 3.21
KPSS WORK MODE SELECTION TABLE

CONTROL MODE DISTINCTION REMARKS
A (assist) mode Digging

Ditch digging • Since the mode is set appropriately according to the
Trench box operator's work, the digging, slope finishing, tamping
digging and spreading works are automatically discriminated
and set by the controller without turning the switch.
Leveling • While outputting the power equivalent to the load,

Slope finishing the engine speed is kept constant and the noise is
reduced.
• The distinction results are displayed on the

Spreading multidisplay. (Updated every 5 seconds)
• The display appears several seconds later. And the

display may not always satisfy your intention.
Tamping But it does not indicate a failure.
This mode catches the movement of control lever

Indicator
M (manual) mode sensively, and is suitable to carry out the heavy load
lamp lights on
work giving priority to the work load at high speed.
When an attachment, like breaker, etc., is required, the
Indicator lamp
B (breaker) mode max. flow rate is adjustable. All other modes get full
lights on
flow regardless of the flow setting for breaker mode.
3 — 10
C. MACHINE TRAVEL CONTROLS
FORWARD TRAVEL
This machine incorporates several travel controls for
the convenience of the operator. Each track can be
operated independently to turn the machine or simul-
taneously to spinturn the machine or to travel straight.
1. Operating Both Travel Levers Together
a. Push both travel levers or press the pedals toward

front of machine and machine will travel “FOR-
WARD”. See Figure 3.22.
b. Pull both travel levers or press the pedals toward

operator seat and machine will travel “REVERSE”.
FIGURE 3.22
See Figure 3.23.
c. Return both travel levers to “NEUTRAL” (center)

position and machine will stop. Parking brakes are
REVERSE TRAVEL
automatically applied when travel levers are in neu-
tral position.
NOTE
The distance travel levers are pushed or pulled determines
travel speed of the machine.
EXAMPLE: Travel levers are pulled or pushed to full stroke
- machine will travel at top speed.
Travel levers are pulled or pushed to mid po-
sition - machine will travel at 1/2 speed.
FIGURE 3.23
2. Use of Travel Speed Select Switch
a. For fast travel speed, depress and release the travel PRESS HERE FOR
speed select switch once before operating the travel "FAST" & "SLOW"
controls. See Figure 3.24.
This puts the travel motors in “FAST” ( ) travel
speed and the lamp for “FAST” ( ) on the gauge TRAVEL SPEED
cluster display, will come on. SELECT SWITCH
b. To return to “SLOW” ( ) travel speed, depress

and release travel speed select switch once. See
Figure 3.23.
Use “FAST” ( ) travel speed on firm, level surfaces

only.
Do not travel continuously for more than two hours.
Stop for a period of 10 min. at low idle speed before FIGURE 3.24
resuming travel.
3 — 11
3. Turning Machine
LEFT FORWARD
TRAVEL
a. Push the L.H. travel lever toward front of machine
to turn machine RIGHT in forward motion. See Fig-
ure 3.25.
b. Pull the L.H. travel lever back toward operator seat

to turn machine to the LEFT in reverse motion.
c. Push the R.H. travel Lever toward front of machine

to turn machine to the LEFT in forward motion. See
Figure 3.26.
d. Pull R.H. travel lever toward operator seat to turn FIGURE 3.25
machine to the RIGHT in reverse motion.
RIGHT FORWARD
4. Counter Rotating Machines TRAVEL
a. Pull L.H. travel lever BACK and push R.H. travel

lever FORWARD to counter rotate machine to the
LEFT. See Figure 3.27.
b. Pull R.H. travel lever BACK and push L.H. travel

lever FORWARD to counter rotate machine to the
RIGHT. See Figure 3.28.
NOTE
All the functions explained with use of travel levers can FIGURE 3.26
also be performed using the travel pedals.
COUNTER ROTATING
TO THE LEFT
1. Depending on shoe type and ground conditions this

machine has a maximum climbing ability of 35° (70%)
maximum, limited by engine lubrication.
2. When approaching or descending a slope, operate
the travel slowly.
3. For braking, slowly return travel levers or pedals to
the neutral (center) position. Brakes are engaged
automatically. FIGURE 3.27
4. The travel operation for 2 hours or more may cause

COUNTER ROTATING
the failure of travel motor due to the rise of operat-
TO THE RIGHT
ing temperature. Don’t travel it for 2 hours or more.
5. In extremely cold conditions, below -20°C (-4°F), the
travel lever or pedal action may be “heavier” than
normal. This is normal due to the viscosity of the
hydraulic oil in frigid climates.
FIGURE 3.28
3 — 12
5.Travel Safety
a. Make certain travel motor location is known before
performing any travel operation.
b. Travel on firm, level surfaces as much as possible.
WATER
c. When traveling on rough terrain, travel in SLOW ( ) DEPTH
speed with engine at a low idle.
d. Travel with the travel motors in back of the machine
for long distance travel.
e. When traveling or operating machine on snow or
icy surfaces, clean track shoes frequently to pre- BED MUST BE
vent clogging. This will help keep the machine from FIRM & STABLE
sliding unexpectedly.
MODEL MAXIMUM WATER DEPTH
f . Keep a safe distance from stationary objects and SK200-6E
720 mm (2´-4˝)
electrical power lines. SK200LC-6E
g. Be aware of load capacities of bridges and road
shoulders. Reinforce if necessary. FIGURE 3.29
h. Use decking or plating to protect road surfaces as

much as possible. Be careful when turning or spin-
ning machine on asphalt pavement.
i . Do not allow large or heavy objects to strike travel
motors.
j . Do not travel over large objects such as boulders
rocks etc.
k. If necessary to travel or operate machine in a river
or other water, the bed must be firm and water cur-
rent slow. Water must not be deeper than indicated
in the chart in Figure 3.29.
NOTE
If the machine is operated while the slewing bearing is
submerged in water, then the slewing bearing, slewing
pinion, and the swivel joint may wear out prematurely. Im-
mediate replacement of grease in grease bath and over-
haul of the slewing bearing is required. See maintenance
section.
l . On soft ground or mud the machine can sink. Stay

constantly aware of undercarriage position.
3 — 13
D. MACHINE ATTACHMENT & SWING CONTROLS
The following instructions are to be used with hoe bucket
attachment only. If other attachments are being used,
consult the operator’s manual for the particular attach-
ment.

PRECAUTIONS DURING ALL OPERATIONS OF
THIS MACHINE AND ITS ATTACHMENT(S).
1. Boom Operation – FIGURE 3.30 PULL BACK- PUSH FORWARD-

Operation of the boom is performed by pushing and BOOM UP BOOM DOWN
pulling the R.H. control lever forward and backward.
Boom speed is determined by how far the lever is
activated.
a. Pulling R.H. control lever BACK raises boom.
b. Pushing R.H. control levelr FORWARD lowers
boom.
c. Returning R.H. control lever to the neutral (center)
position stops operation of the boom.
FIGURE 3.30
2. Arm Operation – FIGURE 3.31 PULL BACK- PUSH FORWARD-
Operation of the arm is performed by pushing or ARM IN ARM OUT
pulling the L.H. control lever forward and backward.
Arm speed is determined by how far the lever is ac-
tivated.
a. Pushing the L.H. control lever FORWARD moves
the arm out.
b. Pulling the L.H. control lever BACK moves the arm
in.
c. Returning the L.H. control lever to the neutral (cen-
FIGURE 3.31
ter) position, stops operation of the arm.
3. Bucket Operation – FIGURE 3.32 PULL LEFT- PUSH RIGHT-

Operation of the bucket is performed by moving the BUCKET IN (DIGGING) BUCKET OUT (DUMPING)
R.H. control lever to the right or left.
a. Moving the R.H. control lever to the LEFT operates
the bucket IN (digging).
b. Moving the R.H. control lever to the RIGHT oper-
ates the bucket OUT (dumping).
BE CAREFUL WHEN OPERATING CERTAIN AT- FIGURE 3.32

TACHMENTS CLOSE TO THE CAB.
CERTAIN ATTACHMENTS CAN HIT AND DAMAGE
CAB.
STOP ATTACHMENT A SAFE DISTANCE AWAY
FROM CAB TO AVOID DAMAGE OR INJURY.
3 — 14
4. Swing Operation - FIGURE 3.33
PUSH LEFT TO SWING LEFT
NOTE
Use swing flashers during swing operations.
Swing operation is performed by moving the L.H.

control lever to the right and left. Swing speed is
determined by the amount the lever is moved.
a. Moving the L.H. control lever to the LEFT swings
the machine to the left.
b. Moving the L.H. control lever to the RIGHT swings
the machine to the right.
c. Returning control to the neutral (center) position PULL RIGHT TO SWING RIGHT
stops swing.
MAKE CERTAIN AREA IS CLEAR OF OBSTACLES

AND PERSONS BEFORE BEGINNING SWING OP-
ERATION OF THE MACHINE. SOUND HORN BE-
FORE BEGINNING SWING OPERATIONS
FIGURE 3.33
E . USING POWER BOOST

DEPRESS WITH
The KOBELCO power boost switch is located on top THUMB TO TURN "ON"
of the R.H. operator control. It is a momentary switch
which is activated by depressing with the thumb. This
system is designed for use during bucket digging op-
erations when extra “Break-Out” power is required to
allow the bucket to break through a dig.
1. Operate the bucket in (digging) control. While bucket

is digging, depress the power boost switch with right
thumb. See Figure 3.34. This will increase bucket
digging power by approximately 15%.
NOTE
If the power boost switch is left depressed while perform- FIGURE 3.34
ing other hydraulic operations the operator will experience
slower operation of the hydraulic functions. While power
boost switch is depressed the power boost icon ( ) will
be displayed on the gauge cluster display.
3 — 15
F . USING AUTO ACCELERATION – FIGURE 3.35
Press the symbol mark on this switch to switch ON 14 : 20
(LED is illuminated). If the remote control pressure of
the operating pedal (in option) does not actuate for 4
seconds, when the accel dial is placed on the decel
position (1,050 rpm) or higher, the auto accel actuates
automatically resulting in the decel speed, conse-
quently the fuel consumption and noise are reduced.
By operating the control lever and the operating pedal,
the engine speed rises to the speed equivalent to the
accel dial set position gradually corresponding to the AUTO ACCEL SWITCH
motion of control lever or pedal.
And, when operating at decel speed, press the no sym-
bol side to switch OFF, the engine speed rises to the
speed equivalent to the accel dial set position.
HI
LO
THROTTLE
POTENTIOMETER
FIGURE 3.35
G. TOWING THE MACHINE – FIGURE 3.36 & 3.37

Where you can not get the machine out of soft soil,
place wire slings as shown on the right and pull it by
an other machine. Always place wire slings around the
frame section and put pads on each corner to prevent
the wire slings from being damaged.
NOTE
Do not pull the machine utilizing the holes provided for
pulling lightweight objects.
Otherwise the holes may break.
FIGURE 3.36
FIGURE 3.37
3 — 16
3.8 PRACTICES TO IMPROVE EFFICIENCY
USE ARM IN ACTION
AS MUCH AS POSSIBLE
A. USE ARM IN ACTION – FIGURE 3.38
Operate the bucket at shallow depths and use the arm
in action to fill the bucket. Setting the bucket too deep
will decrease the machine’s efficiency.
FIGURE 3.38
B. OPERATE BOOM SMOOTHLY – FIGURE 3.39

Always begin and end boom operation slowly with OPERATE BOOM SMOOTHLY
DURING ALL BOOM OPERATIONS
smooth, careful movement of the control lever. Do not
perform sudden starts and stops of the boom as this
creates unnecessary stress on the machine and its
components.
FIGURE 3.39
C. BUCKET TEETH DIRECTION – FIGURE 3.40

ALWAYS POINT BUCKET TEETH
Always point bucket teeth in the direction the machine IN DIRECTION OF DIGGING
will be digging to reduce digging resistance and the
possibility of bucket teeth damage.
FIGURE 3.40
D. MAXIMUM DIGGING FORCE POSITION – FIGURE

MAXIMUM DIGGING FORCE IS OBTAINED
3.41 WITH BOOM AND ARM AT 90°~110° EACH OTHER
The attachment will provide maximum digging force
when the arm and boom are at 90° ~ 110° of each other.
90°~110°
FIGURE 3.41
3 — 17
E . CLEANING SAND & SOIL FROM BUCKET – FIGURE
3.42
Operate arm to a near level position and bring the
bucket to a dumping position. If sand and soil do not
fall out, move the bucket lever right and left a few times.
Avoid shaking out soil using shocks at the end of the

bucket cylinder stroke.
OPERATE BUCKET IN & OUT WITH
ARM OUT TO DISLODGE MATERIAL FROM BUCKET
F . STOP SWING MOTION EARLY – FIGURE 3.43
To stop slewing action, release the swing lever before FIGURE 3.42
you get to your final point of digging or dumping.
RELEASE SWING BEFORE REACHING DESIRED

G. BACK FILLING & LEVELING – FIGURE 3.44 DIGGING POSITION
For back filling and leveling work after digging, move
the bucket back and forth horizontally.
NOTE
Do not push or pull material with the bucket like a bull-
dozer when using the machine to level material.
1. In leveling ground toward machine, pull the arm gen-

tly, lift the boom a little and when the arm has passed
the vertical point, lower the boom gently and ma- FIGURE 3.43
nipulate the machine so the bucket moves horizon-
tally.
USE ARM TO MOVE BUCKET HORIZONTALLY
2. For leveling ground away from machine, reverse op- FOR LEVELING
eration in step 1 above.
3. ln the above operation, bucket motion may be used
together with the boom. By controlling the action of
the boom work lever, you can dig a slope- like, slope
facing operation.
4. Never travel with attachment touching the ground.
Severe structural damage could occur.
H. OPERATING THE SHOVEL – FIGURE 3.45 FIGURE 3.44

Digging with the shovel differs slightly from digging with
backhoe.
GRADE AT 2°~ 3° SLOPE FOR DRAINAGE
1. Using the arm cylinder, scrape the ground.
2. Scrape the ground at 2°~ 3° to improve draining in
areas near the groundwater level.
3. Be careful not to bump the reversed bucket into the cab.
4. The excavating power during shovel operations is
2°~ 3 °
less than that during backhoe operations.
5. If machine bucket is equipped with a lifting eye, check
to make sure that the eye will clear arm with bucket
cylinder in full extended (full dump) position.
FIGURE 3.45
3 — 18
I . MACHINE OPERATION IN ADVERSE WEATHER
CONDITIONS
1. Operation in Extreme Cold Do not allow dirt and debris to accumulate in the radia-
tor fins, oil cooler fins or debris screen.
a. Follow procedures on page 3-2 as starting en-
gine may be difficult due to extremely cold tem-
peratures. c. Keep all belts properly tensioned.
b. Use an engine oil, hydraulic oil and diesel fuel d. Make certain that the engine coolant mixture is
designed for use in cold climates. See mainte- sufficient to keep the machine safe.
nance section, page 4-8 for reference. Also, keep e. If the machine becomes overheated, idle the ma-
battery fully charged. chine to help cool the engine, turn engine “OFF”
c. Make certain to perform machine warm-up pro- and check coolant level. After filling to proper level
cedures as described on page 3-6 and 3-7 to pre- the machine continues to over heat, stop engine,
vent premature wear or damage to pumps, mo- allow to cool, drain and flush entire cooling sys-
tors and other components. tem and refill with the proper mixture of fresh,
clean coolant.
NOTE f . Check the battery electrolyte (acid) level fre-
In extremely frigid climates, covering the radiator is a
quently and fill as necessary with distilled water.
method to aid the machine warm-up. IF NECESSARY TO
MAINTAIN OPERATING TEMPERATURES, COVER g. Keep a close watch on the gauge cluster for warn-
THE OUTER EDGES OF THE RADIATOR, LEAVING AN ing icons during operation. Avoid unnecessary low
OPENING IN THE CENTER PART OF THE COVER - speed running of the engine during operation.
THUS AVOIDING FAN OVERLOADING. Keep a close During slow, or no work periods, place throttle
watch on the gauge cluster for warning icons during op- potentiometer in “LO” idle position.
eration. It may be necessary to use a coolant heater, fuel 3. Operation in High Altitudes
heater, engine heater jacket, and/or additional battery
power to aid engine starting. a. Due to low atmospheric pressure at high altitudes,
a decrease in engine power will be experienced.
Be aware of this fact when placing machine un-
d. Make certain that the engine coolant mixture is
der heavy load in high altitude climates.
sufficient to keep the machine safe. Take into con-
sideration wind chill factors when mixing coolant b. Keep close watch on the engine temperature
ratios. gauge to avoid overheating of the engine.
4. Operation in Sandy and Dusty Areas
NOTE
Mix coolant to a protection temperature of 5˚C (9˚F) lower a. Check the engine air cleaner elements frequently
than the machine will experience during operation, stor- in sandy or dusty conditions.
age or transport. b. When air cleaner restriction lamp is lit, change
filters immediately regardless of time intervals.
e. Keep battery terminals free of ice and snow. Ice c. Service fuel filter, water separator, and all hydrau-
and snow could cause the terminals to short cir- lic filters frequently.
cuit and cause extensive damage to the machine
systems. Check the battery electrolyte (acid) level 5. Operation at Seashore or Salty Climate
frequently and fill as necessary with distilled wa- a. Thoroughly wash machine daily to help avoid cor-
ter. If the machine will be left outside overnight, it rosion of machined areas, electrical components
is recommended to remove the batteries and store and cylinder rods.
in a warm area.
b. Frequently check all mounting hardware for proper
2. Operation in Extreme Heat tightness. Torque to proper value to aid in pre-
a. Use an engine oil, hydraulic oil and fuel oil de- venting salt from entering the machine systems.
signed for use in hot climates. Also, keep battery 6. Operation in Humid Climate
fully charged.
a. In climates with high humidity, thoroughly wash
b. Clean radiator, oil cooler and debris screen often
the machine daily and coat all bare surfaces with
to prevent damage or overheating of the machine.
an oil based lubricant to help prevent corrosion.
3 — 19
3.9 FLAGMAN HAND SIGNALS
The following is a compilation of the hand signals to
be used when a flagman is required for excavator
operation. All personnel associated with the opera-
tion of the excavator should know these signals and
their meaning before attempting to operate this ma-
chine.
A. RAISE LOAD VERTICALLY

Face machine operator, raise right forearm vertical, with
index finger pointing up and move hand in a small cir-
cular motion. See Figure 3.46.
FIGURE 3.46
B. LOWER LOAD VERTICALLY

Face machine operator, extend right arm down, point
index finger down and move hand in a small circular
motion. See Figure 3.47.
FIGURE 3.47
C. MOVE LOAD IN HORIZONTALLY

Face machine operator, extend right arm toward op-
erator with hand facing operator and move hand in di-
rection of movement required. See Figure 3.48.
FIGURE 3.48
D. MOVE LOAD OUT HORIZONTALLY

Face machine operator, extend right arm toward op-
erator with back of hand facing operator and move hand
in direction of movement required. See Figure 3.49.
FIGURE 3.49
3 — 20
E . RAISE BOOM
Face machine operator, extend right arm out horizon-
tally from shoulder, make a fist with thumb up. See
Figure 3.50.
FIGURE 3.50
F . LOWER BOOM
tally from shoulder, make a fist with thumb down. See
Figure 3.51.
FIGURE 3.51
G. SWING LEFT
tally from shoulder, make a fist with index finger point-
ing in swing direction. See Figure 3.52.
FIGURE 3.52
H. SWING RIGHT
Face machine operator, extend left arm out horizon-
tally from shoulder, make a fist with index finger point-
ing in swing direction. See Figure 3.53.
FIGURE 3.53
3 — 21
I . ARM IN
Face machine operator, bend at elbows with arms fac-
ing operator, make fists and point thumbs in toward
each other. See Figure 3.54.
FIGURE 3.54
J . ARM OUT
Face machine operator, bend at elbows with arms fac-
ing operator, make fists and point thumbs out away
from each other. See Figure 3.55.
FIGURE 3.55
K. COUNTER ROTATE LEFT
Face machine operator, place right hand on top of hard
hat, bend left arm at elbow to the right, make a fist with
left hand with index finger pointing out and rotate hand
in a reverse circular motion. See Figure 3.56.
FIGURE 3.56
L . COUNTER ROTATE RIGHT
Face machine operator, place left hand on top of hard
hat, bend right arm at elbow to the left, make a fist with
right hand with index finger pointing out and rotate hand
in a forward circular motion. See Figure 3.57.
FIGURE 3.57
3 — 22
M. TRAVEL FORWARD
Face machine operator, bend both elbows in,
make fists and rotate fists one over the other in a re-
verse circular motion. See Figure 3.58.
FIGURE 3.58
N. TRAVEL REVERSE
Face machine operator, bend both elbows in,
make fists and rotate fists one over the other in a for-
ward circular motion. See Figure 3.59.
FIGURE 3.59
O. CLOSE BUCKET (BUCKET IN OR DIG)

Face machine operator, hold left hand in,closed and
stationary, hold right hand in, make a fist with index
finger pointing toward left hand and move right hand in
a small reverse circular motion. See Figure 3.60.
FIGURE 3.60
P . OPEN BUCKET (BUCKET OUT OR DUMP)

Face machine operator, hold left hand in,open and sta-
tionary, hold right hand in, make a fist with index finger
pointing toward left hand and move right hand in a small
forward circular motion. See Figure 3.61.
FIGURE 3.61
3 — 23
Q. TURN LEFT
Face machine operator, raise right forearm up, make
fist with right hand and hold stationary, bend left arm
in, make fist with left hand and rotate left fist in a small
reverse circular motion. See Figure 3.62.
FIGURE 3.62
R. TURN RIGHT
Face machine operator, raise left forearm up, make
fist with left hand and hold stationary, bend right arm
in, make fist with right hand and rotate right fist in a
small forward circular motion. See Figure 3.63.
FIGURE 3.63
S . MOVE THIS MUCH

Face machine operator, raise both forearms up, hands
open and facing each other , move hands in laterally
indicating how far to go. See Figure 3.64.
FIGURE 3.64
T . MOVE SLOWLY
Face machine operator, raise left arm out horizontally
toward right shoulder with hand open and facing down,
point right index finger up toward open left hand and
rotate right hand in a reverse circular motion. (Raise
load slowly is illustrated.) See Figure 3.65.
FIGURE 3.65
3 — 24
U. STOP
Face machine operator, raise left arm out horizontally
from shoulder with hand open and facing down, move
arm in a horizontal motion back and forth. See Figure
3.66.
FIGURE 3.66
V . EMERGENCY STOP
Face machine operator, raise both arms out horizon-
tally from shoulders with hands open and facing down,
move arms in a horizontal motion back and forth. See
Figure 3.67.
FIGURE 3.67
W. STOP ENGINE
Face machine operator, right arm at side, draw left
thumb or index finger across throat. See Figure 3.68.
FIGURE 3.68
3 — 25
Section IV – MAINTENANCE
Table of Contents
GENERAL INFORMATION .......................................................................................................................... 4-1
GENERAL SAFETY ..................................................................................................................................... 4-1 ~ 4-4
INSPECTION AND MAINTENANCE CHART .............................................................................................. 4-5 ~ 4-7
FLUIDS AND FILTERS ................................................................................................................................. 4-8 ~ 4-9
Required Fluids And Quantities ........................................................................................................... 4-8
Required Filters ...................................................................................................................................... 4-8
KOBELCO Fluids And Lubricants ........................................................................................................ 4-8
Lubricant Specifications ....................................................................................................................... 4-9
PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE ........................................................... 4-10 ~ 4-21
Engine Oil Level ..................................................................................................................................... 4-10
Engine Coolant Level ............................................................................................................................ 4-10
Engine Fluid Leaks ................................................................................................................................ 4-11
Fan Belt Wear And Tension ................................................................................................................... 4-11
Air Cleaner .............................................................................................................................................. 4-12
Engine Electrical .................................................................................................................................... 4-13
Fuel Level ............................................................................................................................................... 4-14
Hydraulic Oil Level ................................................................................................................................. 4-15
Hydraulic Functions .............................................................................................................................. 4-16
Hydraulic Oil Leaks ................................................................................................................................ 4-16
Machine Electrical .................................................................................................................................. 4-16
Step And Handrails ................................................................................................................................ 4-17
Frame Structure ..................................................................................................................................... 4-17
Tracks And Components ....................................................................................................................... 4-17 ~ 4-18
Track Tension ......................................................................................................................................... 4-19
Boom And Arm ....................................................................................................................................... 4-20
Cutting Edge, Bucket Teeth And Side Cutters .................................................................................... 4-20
50 HOUR (WEEKLY) & NEW MACHINE BREAK-IN INSPECTION & MAINTENANCE ................................ 4-21 ~ 4-28
Engine Oil And Filter Element ............................................................................................................... 4-21
Engine Oil ............................................................................................................................................... 4-22
Fuel Tank Drain ...................................................................................................................................... 4-23
Water Separator ..................................................................................................................................... 4-23
Air Intake System ................................................................................................................................... 4-23
Radiator, Oil Cooler And Debris Screen .............................................................................................. 4-24
Hydraulic Return Filters ........................................................................................................................ 4-25
Batteries .................................................................................................................................................. 4-26 ~ 4-27
Attachment Lubrication ......................................................................................................................... 4-28
4—0—1
120 HOUR INSPECTION & MAINTENANCE .................................................................................................. 4-29 ~ 4-30

Swing Motor Reduction Oil ................................................................................................................... 4-29
Travel Motors Reduction Oil ................................................................................................................. 4-30
250 HOUR (3-MONTH) INSPECTION & MAINTENANCE ........................................................................... 4-31 ~ 4-32
Belt tensioner (Fan & Air Conditioner) ................................................................................................. 4-31
Air Conditioner Filters ........................................................................................................................... 4-32
Inspecting Counterweight Attaching Bolts for Loosening ................................................................ 4-32
500 HOUR INSPECTION & MAINTENANCE .............................................................................................. 4-33 ~ 4-36
Fuel Filter ................................................................................................................................................ 4-33
Clean Fuel Pre-Filter .............................................................................................................................. 4-33
Bleeding Air from the Fuel System ...................................................................................................... 4-34
Greasing the Slewing Ring ................................................................................................................... 4-35
Checking Slewing Ring Fitting Bolts for Loosening .......................................................................... 4-35
Water Pump Bearing Lubrication ......................................................................................................... 4-35
Checking the Air Conditioner Refrigerant ........................................................................................... 4-36
Fuel System Injection Pressure And Nozzle Condition (Atomization) .............................................. 4-36
1000 HOUR (12-MONTH) INSPECTION & MAINTENANCE ....................................................................... 4-37
Engine Valve Clearance ......................................................................................................................... 4-37
Engine Compression Pressure ............................................................................................................. 4-37
Inspection of Starter and Alternator ..................................................................................................... 4-37
Engine Fuel Injection Timing ................................................................................................................ 4-37
2000 HOUR INSPECTION & MAINTENANCE ............................................................................................ 4-38 ~ 4-54
Change Engine Coolant ........................................................................................................................ 4-38 ~ 4-39
Removal And Installation of Engine Radiator ..................................................................................... 4-40
Change Hydraulic Oil ............................................................................................................................. 4-41 ~ 4-43
Hydraulic Tank Breather ........................................................................................................................ 4-44
Change Oil in Travel Motor Reduction Units ....................................................................................... 4-45
Pilot Line Filter ....................................................................................................................................... 4-46
Change Oil in Swing Reduction Units .................................................................................................. 4-47
Attachment & Dust Seals ...................................................................................................................... 4-48 ~ 4-53
Windshields Washer .............................................................................................................................. 4-53
Change Grease in Swing Ring Grease Bath ........................................................................................ 4-54
MISCELLANEOUS ....................................................................................................................................... 4-55 ~ 4-59
Fuses ....................................................................................................................................................... 4-55
Periodical Inspection Items .................................................................................................................. 4-56 ~ 4-58
Machine Storage .................................................................................................................................... 4-59
Inspection Maintenance Check List ..................................................................................................... 4-60
4—0—2
4.1 GENERAL INFORMATION

PRECAUTIONS CONTAINED IN THIS MANUAL BE-
FORE PERFORMING ANY INSPECTION OR MAIN-
TENANCE PROCEDURES TO THIS MACHINE, ITS
SYSTEMS OR COMPONENTS.
A. It is recommended by KOBELCO CONSTRUCTION

MACHINERY CO., LTD. that an inspection and main-
tenance schedule be developed and maintained on a FIGURE 4.1
regular basis for this machine. Developing and main-
taining such a schedule, helps to keep the machine in
optimum operating condition. See Figure 4.1.
B. The information contained in this section gives the

proper procedures for performing inspection and main-
tenance functions for this machine. Use these proce-
dures when performing inspection and maintenance
as they will guide the technician step by step for each
procedure. Also, refer to the inspection and mainte-
nance charts for general service interval recommen-
dations.
NOTE FIGURE 4.2

The inspection and maintenance charts provided give only
general time intervals. It may be necessary to develope a
custom schedule to perform machine maintenance at more
frequent intervals based on the work conditions.
C. Use only KOBELCO oils, fluids, lubricants, filters and

replacement parts to keep machine in optimum oper-
ating condition. See Figure 4.2.
4.2 GENERAL SAFETY

A. DISPOSAL OF HAZARDOUS WASTE – FIGURE 4.3
Dispose of waste oils, fluids, lubricants, filters and other FIGURE 4.3
hazardous waste properly.
Dispose of all hazardous waste in accordance with

government environmental regulations, laws and
codes.
B. KEEP MACHINE CLEAN – FIGURE 4.4

Thoroughly clean machine before performing inspec-
tion and maintenance procedures. It is easier and safer
locate problems, perform maintenance and also re-
duces the risk of hydraulic system contamination when
machine is clean. FIGURE 4.4
4—1
C. HOT SURFACES & FLUIDS – FIGURE 4.5
Use caution and wear the proper safety equipment
when working around hot areas. Never change oils,
engine coolant or filters immediately after a machine
has been stopped. Allow machine to cool before per-
forming maintenance procedures.
D. WARM ENGINE OIL

Engine oil should have a temperature of between 20°C
~ 40°C (68°F ~ 104°F) before the oil is changed. If nec-
FIGURE 4.5
essary run engine until the oil is warm within the rec-
ommended oil change temperature.
E . “TAG-OUT” MACHINE – FIGURE 4.6

Before beginning any inspection or maintenance pro-
cedures, secure a “DO NOT OPERATE” tag to the
operator’s console to inform the operator that the ma-
chine will be inoperable for inspection and mainte-
nance. This tag will help prevent accidental starting of
the machine. Order tag P/No. : YN20T01320P1.
F . INSPECT WASTE OILS AND FILTERS – FIGURE 4.7 FIGURE 4.6

Before disposal, inspect all waste oils, fluids and filters
for debris and foreign material.
It is recommended to cut open the oil filters to deter-
mine any abnormal wear.
CHECK FOR
G. PREVENT CONTAMINATION – FIGURE 4.8 DEBRIS
Always cap or plug lines when hydraulic components

are removed to help prevent hydraulic system contami-
nation that can be caused by dirt, dust and debris en-
tering a line or port.
FIGURE 4.7
Never allow a hydraulic line or component to become
contaminated. This could cause severe system dam-
age. Contact an authorized KOBELCO distributor to
obtain the proper caps and plugs to be used on this
machine.
H. SEALS AND “O”-RINGS

Always replace seals and “O”-rings with new parts.
Never reuse a seal or “O”-ring during reassembly of
components. Make sure to lubricate all new seals with
the appropriate oil before installation.
FIGURE 4.8
4—2
I . STOP ENGINE
Never attempt any MAINTENANCE with engine run-
ning. Always stop the engine and allow machine to cool.
J . WEAR SAFETY EQUIPMENT – FIGURE 4.9

Wear hard hat, safety goggles or face shield, work
gloves, safety shoes and well fitting work clothes when
performing inspection and maintenance procedures on
this machine.
FIGURE 4.9
K. CLEANING PARTS
Use only approved cleaning solvents and proper equip- DEPRESS RUBBER CAP
ment to clean parts. TO RELEASE PRESSURE
NEVER USE GASOLINE, DIESEL FUEL OR OTHER

FLAMMABLE SOLVENTS TO CLEAN PARTS.
ALWAYS CLEAN PARTS IN A WELL VENTILATED
AREA.
L . HYDRAULIC TANK PRESSURE FIGURE 4.10

Always release the internal pressure of the hydraulic
tank before performing inspection or maintenance pro-
cedures.
1. Push rubber cap “DOWN” to release air pressure in

the reservoir. See Figure 4.10.
Gasses from hydraulic tank may be hot.

Wear safety equipment.
KEY SWITCH IN
"OFF" POSITION
FIGURE 4.11
M. WELDING SAFETY
1. Turn key switch to “OFF” position. Wait 4 seconds

for electrical power to disconnect. See Figure 4.11.
2. Remove negative (-) cable from battery terminal. See

Figure 4.12.
3. Attach welder ground cable with 1 m (3´-3˝) away

from component being welded.
4. Make certain welder ground is not located at a seal

or bearing.
5. Make certain that no bearings nor seals separates

the welder ground and the weld area. FIGURE 4.12
4—3
N. RELEASING INNER PRESSURE IN HYDRAULIC
SYSTEM
NEVER CHANGE OILS OR FILTERS ON A MACHINE

THAT HAS JUST FINISHED WORKING. ALLOW
MACHINE TO COOL FIRST UNTIL OILS AND FLU-
IDS ARE WARM NOT HOT.
RELEASE HYDRAULIC TANK PRESSURE BEFORE
WORKING WITH ANY HYDRAULIC COMPONENT.
1. Select the hard and flat area and place the machine FIGURE 4.13
in the position shown in Figure 4.13.
2. Stop the engine. DEPRESS RUBBER CAP

TO RELEASE PRESSURE
3. Immediately after the engine stops, shift the R.H. and

L.H. travel control levers shift forward and backward,
operate the R.H. and L.H. control levers in full stroke
several times, and release the internal pressure re-
maining in the hydraulic system.
4. Press valve with rubber cap on the upper surface of

hydraulic tank several times(5 or 7 times) and re-
lease the pressure in the hydraulic tank. See Figure FIGURE 4.14
4.14.
5. Make sure that the pressure in the hydraulic tank is

released completely, and after that carry out the in-
spection and maintenance of hydraulic tank.
4—4
4.3 INSPECTION AND MAINTENANCE CHART
Follow the chart below for recommended intervals
of regular inspection and maintenance procedures. READ, UNDERSTAND AND FOLLOW ALL SAFETY
PRECAUTIONS FOUND IN THIS MANUAL BEFORE
PERFORMING INSPECTION & MAINTENANCE.
MAINTENANCE TO COMPONENT INTERVAL (HOURS ON HOURMETER) REF.

SYSTEM
PERFORM LOCATION 8 50 120 250 500 1,000 2,000 PAGE #
CHECK OIL LEVEL ON SIDE OF ENGINE 4-10
CHECK COOLANT LEVEL RESERVOIR 4-10
CHECK FOR FLUID LEAKS COMPLETE ENGINE 4-11
CHECK BELT TENSION FRONT OF ENGINE 4-11
FUEL TANK
CHECK FUEL LEVEL 4-14
GAUGE CLUSTER
CHECK AIR CLEANER AIR CLEANER 4-12
CHECK ENGINE ELECTRICAL COMPLETE ENGINE 4-13
DRAIN WATER FROM FUEL FUEL TANK BOTTOM 4-23
CHANGE ENGINE OIL OIL PAN 4-22
CHANGE OIL FILTER L.H. SIDE OF ENGINE 4-21
CHANGE FUEL FILTER L.H. SIDE OF ENGINE 4-33
FUEL PRE-FILTER R.H. SIDE OF ENGINE 4-33
DRAIN WATER SEPARATOR R.H. SIDE OF ENGINE 4-23
ENGINE CHECK AIR INTAKE SYSTEM HOSES & CLAMPS 4-23
CHECK FAN ASSEMBLY FRONT OF ENGINE
CHECK BELT TENSIONER FRONT OF ENGINE 4-31
CLEAN RADIATOR RADIATOR 4-24
BETWEEN RADIATOR
CLEAN DEBRIS SCREEN 4-24
AND OIL COOLER
CHANGE ENGINE COOLANT RADIATOR & ENGINE 4-38~4-39
CHANGE AIR CLEANER
AIR CLEANER 4-12~4-13
ELEMENTS
ADJUST VALVE CLEARANCE ENGINE TOP 4-37
CHECK ENGINE COMPRESSION ENGINE 4-37
CHECK INJECTION PRESSURE ENGINE 4-36
CHECK INJECTION TIMING ENGINE 4-37
LUBRICATE WATER PUMP ENGINE 4-35
CHECK STARTER AND ALTERNATOR ENGINE 4-37
PILOT LINE FILTER HYDRAULIC TANK 4-46
HYDRAULIC OIL LEVEL SIDE OF HYD TANK 4-15
CHECK HYD FUNCTIONS OPERATOR'S CONTROLS 4-16
CHECK FOR OIL LEAKS HYDRAULIC SYSTEM 4-16
CHECK HOSES/LINES HYDRAULIC SYSTEM 4-16
HYDRAULIC CLEAN SUCTION SCREEN HYDRAULIC TANK 4-41~4-43
CHANGE RETURN FILTERS HYDRAULIC TANK 4-25
CHANGE HYDRAULIC TANK

HYDRAULIC TANK 4-44
BREATHER
CHANGE HYDRAULIC OIL HYDRAULIC TANK 4-41~4-43
CLEAN HYDRAULIC TANK HYDRAULIC TANK 4-41~4-43
••• Regular inspection & maintenance required.
••• Break-in (after first 50 hours) inspection & maintenance required.
4—5

SYSTEM
INSPECT ALL WIRING COMPLETE MACHINE 4-16
ELECTRICAL BATTERY ELECTROLYTE BATTERIES 4-27
BATTERY SERVICE BATTERIES 4-26~4-27
HYD. FUNCTION OPERATION OPERATOR'S CONTROLS 4-16
CHECK SWITCHES CONTROL PANELS 4-16
CHECK SWING BRAKE OPERATOR'S CONTROLS
CHECK WARNING LIGHTS CAB/FRAME/BOOM 4-16
CHECK GAUGES GAUGE CLUSTER 4-16
CHECK HORN HORN SWITCH 4-16
CHECK GAUGE CLUSTER GAUGE CLUSTER 4-16
CHECK SWING REDUCTION
UPPER FRAME 4-29
OIL LEVEL & FILL
CHECK BOLTS/TORQUE SLEWING RING 4-35
UPPER
CHECK SLEWING RING & SIGHT WINDOW ON
FRAME
PINION GEAR CENTER SECTION
CHECK SLEWING RING SEAL SLEWING RING
CHECK SWIVEL JOINT SEALS SWIVEL JOINT
DRAIN WATER FROM LOWER FRAME
4-54
SLEWING RING GREASE BATH CAVITY DRAIN PORT
GREASE SLEWING RING SLEWING RING 4-35
CHANGE GREASE IN REMOVE UPPER
4-54
SLEWING RING GREASE BATH FRAME
CHANGE SWING REDUCTION
SWING MOTOR 4-47
UNIT OIL
CHECK BOLTS/TORQUE COUNTERWEIGHT 4-32
CHECK FOR OIL LEAKS COMPLETE SYSTEM 4-16
CHECK LINES FOR DAMAGE FRAME CAVITY 4-16
CHECK STEPS & HANDRAILS FRAME RAILS 4-17
CHECK FRAME STRUCTURE ENTIRE FRAME 4-17
CHECK TRACKS & LINKS TRACKS 4-17~4-18
CHECK SPROCKET WEAR FRONT OF TRACKS 4-18
LOWER CHECK IDLER WEAR REAR OF TRACKS 4-18
FRAME CHECK ROLLER WEAR TRACKS 4-18
CHECK TRACK TENSION RAISE TRACKS 4-19
ADJUST TRACK TENSION FRAME RAILS 4-19
CHECK TRAVEL REDUCTION
TRAVEL MOTORS 4-30
UNIT OIL LEVEL & FILL
CHANGE TRAVEL
TRAVEL MOTORS 4-45
REDUCTION UNIT OIL
CHECK BOLTS/HARDWARE ENTIRE MACHINE
CHECK BOOM & ARM
BOOM & ARM 4-20
STRUCTURE
CHECK BUCKET TEETH &
ATTACHMENT BUCKET 4-20
SIDE CUTTERS
GREASE BOOM PINS BOOM 4-28
GREASE ARM PINS ARM 4-28
GREASE BUCKET PINS ARM & BUCKET 4-28

4—6

SYSTEM
CHECK A/C REFRIGERANT CLIMATE CONTROL-A/C 4-35
CHECK A/C COMPRESSOR
ENGINE 4-11, 4-31
BELT & ADJUST
CHECK A/C CONDENSER RADIATOR
4-24
AND CLEAN COMPARTMENT
ACCESSORIES CHECK A/C FRESH AIR FILTER CAB 4-32
CHECK A/C RECIRCULATE
CAB 4-32
AIR FILTER
CHECK WIPER WASHER AIR CLEANER
4-53
FLUID LEVEL COMPARTMENT
CLIMATE CONTROL-
CHECK BOLTS/TORQUE
A/C SYSTEM
4—7
4.4 FLUIDS AND FILTERS
The following charts list all the necessary lubricants, oils, greases, fuels, coolants and filters required for the KOBELCO
SK200-6E and SK200LC-6E hydraulic excavators. Also a chart is provided giving specific information for the proper
lubricants, oils, greases, fuels and coolants to be used in certain climates. Contact KOBELCO distributor to order
the required filters, fluids and lubricants.
A. REQUIRED FLUIDS AND QUANTITIES B. REQUIRED FILTERS

TYPE OF QUANTITIES LOCATION
LOCATION OF USE SYSTEM PART NUMBER
FLUID REQUIRED OF FILTER USE
156 Liters RETURN FILTER ELEMENT
HYDRAULIC TANK YN52V01008R100
(41 GAL) KIT (STD & BREAKER)
HYDRAULIC TANK SUCTION
246 Liters YW50V00004F3
HYDRAULIC SYSTEM STRAINER
(65 GAL) HYDRAULIC
TANK BREATHER
ENGINE OIL PAN 18 Liters YN57V00002S010
FILTER ELEMENT
(H LEVEL) (4.8 GAL)
PILOT LINE FILTER
ENGINE OIL PAN 15.5 Liters YN50V01001S005
ELEMENT
(L LEVEL) (4.1 GAL) ENGINE OIL FILTER
*ME088532
30cc X 4 CARTRIDGE
UPPER ROLLER
(1.8cu.in X 4) AIR CLEANER
ENGINE OIL ENGINE YN11P01013P1
160cc X 14 INNER ELEMENT
(10cu.in) X 14 AIR CLEANER
LOWER ROLLER YN11P00001S002
160cc X 16 OUTER ELEMENT
(10cu.in) X 16···LC ENGINE FUEL FILTER
*ME015254
200cc X 2 CARTRIDGE
IDLER ENGINE FEED PUMP
(12cu.in X 2) FUEL 2446U287S4
GAUZE FILTER
SWING MOTOR 7.5 Liter
REDUCTION UNIT (2.0 GAL) ENGINE FEED PUMP
GEAR OIL GAUZE FILTER
TRAVEL MOTOR 5.5 Liter X 2 AIR-CON FILTER
REDUCTION UNIT (1.5 GAL X 2) YN50V01006P1
OPERATOR (OUTER)
OPERATING "U" JOINT CAB AIR-CON FILTER
LEVER JOINT EACH SIDE YT20M00004S050
(INNER)
* AVAILABLE FROM AN AUTHORIZED MMC DEALER ONLY.
ATTACHMENT PINS 16 PLACES
EP GREASE
1 PLACE
SLEWING RING GEAR C. KOBELCO (BRAND) FLUIDS AND LUBRICANTS
90˚ X 4
TRACK TENSION 2 PLACES PART NUMBER DESCRIPTION
ADJUSTMENT AS REQ'D KSP1000-1001 ENGINE OIL-SAE 15W/40 (1 GALLON)
WITH LITHIUM KSP1000-1005 ENGINE OIL-SAE 15W/40 (5 GALLON)
SWING GEAR 8.3 kg KSP1000-1055 ENGINE OIL-SAE 15W/40 (55 GALLON)
BASE MoS2
SUMP (BATH) (18.3 lbs) KSP1000-2005 HYDRAULIC OIL-AW 46 (5 GALLON)
GREASE
KSP1000-2055 HYDRAULIC OIL-AW 46 (55 GALLON)
9.5 Liters
RADIATOR KSP1000-4014 GREASE EP/2-14 OUNCE
ENGINE (2.5 GAL)
KSP1000-4035 GREASE EP/2-35 POUNDS
COOLANT COOLING SYSTEM 19 Liters KSP1000-120 GREASE EP/2-120 POUNDS
TOTAL VOLUME (5 GAL) KSP1000-3035 GEAR OIL 80W90-5 GALLONS
340 Liters
DIESEL FUEL FUEL TANK
(90 GAL)
4—8
D. LUBRICANT SPECIFICATIONS
The following information is designed to allow usage of the proper oils, greases, fuels and coolants in various cli-
mates and certain working conditions.
LUBRICANT CLIMATE ZONE

HYDRAULIC OIL FRIGID FRIGID FRIGID~WARM WARM VERY HOT
(ANTI-WEAR, ANTIOXIDANT -30˚C~15˚C -20˚C~30˚C -25˚C~40˚C -5˚C~40˚C 5˚C~55˚C
AND NON-FOAMING) (-22˚F~59˚F) (-4˚F~86˚F) (-13˚F~104˚F) (23˚F~104˚F) (41˚F~131˚F)
*Note:Machines are shipped from factory
with ISO VG68 hydraulic oil ISO VG22 ISO VG32 ISO VG32S ISO VG46 ISO VG68*

ENGINE OIL* FRIGID WARM VERY HOT
A.P.I. CLASSIFICATION FOR "SERVICE CD" -30˚C~30˚C -5˚C~40˚C 30˚C and Above
*ALL ENGINES SHIPPED FROM FACTORY (-22˚F~86˚F) (23˚F~104˚F) (86˚F and Above)
WITH SAE30 OR SAE15W40 OIL
ACCORDING TO AMBIENT
TEMPERATURE IN ENGINE OIL PAN. SAE10W30 SAE15W40 SAE15W50

FRIGID WARM VERY HOT
-15˚C~-25˚C -5˚C~-15˚C -5˚C and Above
FUEL (5˚F~-13˚F) (23˚F~5˚F) (23˚F and Above)
WINTERIZED
ASTM D975 No.1 ASTM D975 No.2 ASTM D975 No.2
LUBRICANT
FOR ROLLERS AND IDLERS ON ALL MODELS.
ENGINE OIL A.P.I. Classification for "Service CD"-SAE30
(FOR GENERAL PURPOSE LUBRICATION)
LUBRICANT FOR SWING MOTOR REDUCTION UNIT AND TRAVEL MOTOR REDUCTION
UNITS ON THE FOLLOWING MODELS : SK200-6E, SK200LC-6E
GEAR OIL EXTREME PRESSURE GEAR OIL #90
GRADE GL-4 BY A.P.I. CLASSIFICATION
LUBRICANT GENERAL LUBRICATION SWING GEAR SUMP (BATH)

EXTREME PRESSURE MULTIPURPOSE
N.L.G.I. No.2 LITHIUM BASE WITH
GREASE GREASE No.2
MoS2 GREASE
EP TYPE GREASE
LUBRICANT ANTIFREEZE (LLC)

-34˚C (-29.2˚F)
ENGINE COOLANT MIXTURE RATIO SHOULD PROSPECT TO 5˚C (9˚F) LOWER THAN THE
(50% MIXTURE) COLDEST TEMPERATURE THE MACHINE WILL EXPERIENCE. TAKE INTO
CONSIDERATION WIND CHILL FACTORS.
NOTE: USE OF BIO-DEGRADABLE OILS

When you use Bio-degradable Oil (BIO OIL), refer to the following information.
1. There are two types of BIO OIL available; vegetable-based and synthetic-based. You are recommended to use the
synthetic-based type, because the vegetable-based oil has a maximum usage temperature of 80˚C (176˚F). Because
of this, the degradation of vegetable-based oil occurs more rapidly, and caused reduced service life.
2. Do not mix either type of BIO OIL with the original factory-filled mineral oil, in the case that you do use BIO OIL, it is
required to flush the hydraulic system that was filled with BIO OIL oil three times.
3. If you use BIO OIL, slewing and propel parking brake performance will be reduced, because of the lower friction factor
of BIO OIL compared to that of mineral oil.
4. For further information about recommended Bio-degradable oil, please contact KOBELCO distributor.
4—9
4.5 PRE-START(EVERY 8 HOURS) INSPEC-
TION & MAINTENANCE ENGINE OIL DIPSTICK
ON SIDE OF ENGINE
The following procedures are to be performed every
8 hours or daily, before the machine is started.
BE CAUTIOUS OF HOT FLUIDS AND SURFACES.

WEAR GOGGLES, SAFETY SHOES, HARD HAT,
WORK CLOTHES AND WORK GLOVES TO PER-
FORM INSPECTION AND MAINTENANCE ON THIS ENGINE OIL
FILLER CAP
MACHINE.
H
A. ENGINE OIL LEVEL L

BETWEEN
1. Raise engine bonnet. LOW & HIGH
IS 2.5 LITER
2. Locate and pull engine dipstick. Clean it with a clean,
dry, lint free cloth. Reinsert into engine. Pull out and
visually inspect the engine oil level on dipstick. See FIGURE 4.15
Figure 4.15.
3. If necessary to add oil, remove oil filler cap and fill

engine oil to proper level. See Figure 4.15 and refer ENGINE COOLANT
to page 4-9 for oil specifications. RESERVOIR PROPER
LEVEL
NOTE
After adding oil, check oil level again, replace oil filler cap,
replace dipstick and close engine cover.
FULL
B. ENGINE COOLANT LEVEL

LOW
1. Open engine access cover and inspect coolant level
in engine coolant reservoir. See Figure 4.16. FIGURE 4.16
2. Proper coolant level is between “FULL” and “LOW”
marks. See Figure 4.16.
3. If necessary to add coolant, remove reservoir cap

and fill to proper level with fresh coolant. See Figure RADIATOR CAP
4.16 and refer to page 4-9 for proper coolant specifi-
cations.
4. If no coolant is in reservoir, check coolant level in

radiator. Fill radiator with proper coolant mixture and
replace cap. See Figure 4.17. Then fill reservoir to
proper level.
DO NOT REMOVE WHEN ENGINE IS HOT
NEVER REMOVE RADIATOR CAP WHEN ENGINE FIGURE 4.17

IS HOT. ALLOW ENGINE TO COOL BEFORE RE-
MOVING RADIATOR CAP.
4 — 10
C. ENGINE FLUID LEAKS
USE CARDBOARD TO CHECK
FOR PRESSURE LEAKS
1. Inspect complete engine for signs of fluid leaks.
2. When inspecting around pressure lines and hoses

use a stiff piece of cardboard. See Figure 4.18.
Never use hands to check for leaks. High pressure fluid

leaks will penetrate the skin and cause severe injury.
FIGURE 4.18
D. FAN BELT WEAR AND TENSION

Inspect belt tensioner assembly on a new machine af- ALTERNATOR IDLE PULLEY
ter the first 50 hours of operation. Then at every 250
hours of engine operation.
1. Measure belt tension on longest span of belt. Belt

deflection should be 8mm ~ 15mm. Force : approx.
98N (22lbf, 10kgf)
BELT DEFLECTION
Fan belt 10 mm ~ 15 mm (0.4˝ ~ 0.6˝)
Air conditioner 7 mm ~ 10 mm (0.3˝ ~ 0.4˝)
2. Loosen mounting bolt and adjusting nut, and adjust

tension of belt. See Figure 4.20.
CRANK PULLEY COMPRESSOR
FIGURE 4.19
3. Loosen adjusting bolt, adjust fan belt to the speci-
fied tension, and tighten mounting bolt and adjusting
ADJUSTING BOLT MOUNTING BOLT
nut. See Figure 4.20. 8.4 ± 1.0 kgf·m
(61 ± 7 lbf·ft)
4. After adjustment, rotate engine at low idling for about
5 minutes, then check the tension of belt.
5. Adjust the tension of belt of air conditioner turning

adjusting bolt of idle pulley. Figure 4.20.
NOTE
When moving the alternator, try not to damage the stater
coil section between the front and rear brackets or the ADJUSTING NUT
bolts. 7.7 ± 1.5 kgf·m Force : approx.
(56 ± 11 lbf·ft)
98N (22lbf, 10kgf)
FIGURE 4.20
4 — 11
E . AIR CLEANER
9 REST'D AIR
CLEANER
Wear protective glasses or goggles when using com-

pressed air.
NOTE
Filter elements should not be changed until the engine air
FIGURE 4.21
cleaner icon appears on the gauge cluster display. See
Figure 4.21.
1. Open engine air cleaner access door with starter

switch key. See Figure 4.22
ENGINE AIR CLEANER

ACCESS DOOR
FIGURE 4.22
2. Release clamp from the air cleaner cover. See Fig-

ure 4.23.
RELEASE CLAMP
AND COVER
FIGURE 4.23
3. Remove the air cleaner outer element from the hous-

REMOVE AIR CLEANER
ing. See Figure 4.24. OUTER ELEMENT
FIGURE 4.24
4 — 12
4. Remove the air cleaner inner element from the hous-
ing. See Figure 4.25.
5. Cover air intake port of the housing (to prevent entry

of dust).
6. To clean the outer element, blow compressed air {less

than 7 kgf/cm2 (100 psi)} up and down along the folds GEAR OIL CAN
of the filter element interior to remove clogged dust INNER ELEMENT
or other contaminates. See Figure 4.26.
7. After cleaning, use a light to check the inside of the

element for tearing, pinholes, or packing damage.
Replace with a new element if necessary. FIGURE 4.25
Carefully hold the o-ring water inside cause engine fail-

ure.
8. Remove the cover attached to protect it from dust.
9. Assemble elements in the reverse order of disas-

sembling.
NOTE
For machines equipped with W (double) element and the
inner element must be replaced together with the outer
element. Don’t fail to replace the inner element with new FIGURE 4.26
one. See Figure 4.24 and 4-25.
F . ENGINE ELECTRICAL
NEGATIVE (-) CABLE
1. Visually and manually inspect all engine electrical
wiring, connectors and components for signs of dam-
age and malfunction. See Figure 4.27.
2. Repair or replace all damaged or malfunctioning wir-

POSITIVE (+) CABLE
ing, connectors and components before resuming
operation of the machine.
OPERATING THE MACHINE WITH DAMAGED OR

FIGURE 4.27
MALFUNCTIONING ELECTRICAL COMPONENTS
CAN CAUSE SERIOUS DAMAGE TO THE MACHINE
AND SERIOUS INJURY TO PERSONNEL. REPAIR
OR REPLACE FAULTY COMPONENTS IMMEDI-
ATELY.
4 — 13
G. FUEL LEVEL
1. Turn “ON” the key switch key and the fuel level gauge
in the cluster gauge will indicate the fuel tank level.
See Figure 4.28.
2. To refuel the machine, use the key switch key to re-

move the fuel tank cap. Do not remove the fuel screen
for fueling. Refill fuel tank to full mark to reduce air
volume (condensation). Failure to do so could cre-
ate problems such as rusting and fuel freezing, as
well as other associated problems.
a. Filling tank using auxiliary fuel pump (EU spec.)

1. Open battery access cover, remove the filter end
FIGURE 4.28
of the fuel pump suction hose from its storage
housing and insert the fuel suction hose into fuel
supply reservoir. See Figure 4.29.
2. Locate the auxillary fuel pump switch inside the
storage box access door. Place the switch in the
“ON” position. See Figure 4.30. Place pump switch
in the “OFF” position when fuel tank is full. FUELAPUMP
I
AS
SUCTION HOSE
A ST
NOTE
T HE
Delivery rate of the auxiliary fuel pump is 35 liters per OU
S
minute (9.2 U.S. Gal per minute). U SE
T
NO below
• Do not pump petrol on products with flashpoints
37°C (98.6°F).
• Do not run dry for more than 30 seconds.
3. After removing fuel delivery hose from fuel sup- FIGURE 4.29
ply reservoir, coil hose and place filter into its stor-
age housing. Replace fuel strainer and fuel filler
cap.
NOTE
• The suction head of fuel pump is approx. 2 m (6.7 feet)
locate the fuel drum as near as possible to the machine. A SIA
A ST
• After the switch is turned ON, if the fuel pump does not THE
U
actuate, check the fuse in the fuse box for possible dam-SO
S E
age. The fuse is 15 A (tubular fuse).
O TU
N
FUEL PUMP
SWITCH
FIGURE 4.30
4 — 14
H. HYDRAULIC OIL LEVEL
1. Place the machine in the oil check position on a firm
surface as shown in Figure 4.31.
FIGURE 4.31
2. Right hand hydraulic oil tank side cover and view the
hydraulic oil level in the sight glass on side of hy-
draulic oil tank. See Figure 4.32.
FOR SAFE OPERATION ON INCLINES, THE HY-

DRAULIC OIL LEVEL MUST BE MAINTAINED BE- UPPER LIMIT
TWEEN “PROPER LEVEL” AND “UPPER LIMIT”
PROPER LEVEL
MARK.
LOW (ADD OIL)
FIGURE 4.32
3. Use the following instructions to add hydraulic oil :

DEPRESS RUBBER CAP
a. Release hydraulic tank pressure. See Figure 4.33. TO RELEASE PRESSURE
Gasses from hydraulic tank may be hot. Wear safety

equipment.
b. Remove the six mounting bolts from the hydraulic

suction screen cover plate. See Figure 4.34.
c. Add hydraulic oil through the suction screen, filling

FIGURE 4.33
hydraulic tank to the proper level. See Figure 4.34.
d. Before replacing filter cover, replace “O”-ring. Or-

der KOBELCO part number ZD11G20000. See Fig-
ure 4.34.
SLOWLY REMOVE
e. Place new “O”-ring in seat. Place cover over open- BOLTS & COVER
ing and install mounting bolts with lockwashers. REPLACE "O"-RING
PART No. ZD11G20000
f . Torque mounting bolts to proper value. Refer to
torque specifications table.
CLEAN UP ALL SPILLED OIL TO PREVENT FIRES.

ADD CLEAN OIL
DISPOSE OF HAZARDOUS WASTE ACCORDING
TO ENVIRONMENTAL LAWS AND REGULATIONS.
FIGURE 4.34
4 — 15
I . HYDRAULIC FUNCTIONS
CHECK ALL CONTROLS
FOR PROPER FUNCTION
1. Check all hydraulic controls for proper function be-
fore operating the machine. See Figure 4.35.
NEVER OPERATE THE MACHINE WITH A FAULTY

CONTROL OR FUNCTION. MAKE ALL NECESSARY
REPAIRS BEFORE ALLOWING ANY OPERATION.
J . HYDRAULIC OIL LEAKS FIGURE 4.35
1. Check complete hydraulic system for leaks. Use a

small piece of cardboard when checking areas with USE CARDBOARD TO CHECK
FOR PRESSURE LEAKS
high pressure. See Figure 4.36.
Never use hands to check for leaks. High pressure fluid

leaks will penetrate the skin and cause severe injury.
2. Check all hoses and lines for signs of damage.
3. Repair or replace damaged hoses and lines before

allowing any operation.
FIGURE 4.36
CLEAN UP ALL SPILLED OIL TO PREVENT FIRES.

CHECK AND REPLACE
DISPOSE OF HAZARDOUS WASTE ACCORDING ANY BROKEN WIRES
TO ENVIRONMENTAL LAWS AND REGULATIONS.
K. MACHINE ELECTRICAL
1. Check all switches for proper operation.

CHECK ALL GAUGES AND LCD DISPLAY
2. Visually check all wiring and connectors for signs of
damage, corrosion etc..
3. Repair or replace all damaged or faulty electrical

components before allowing any operation of the
machine.
4. Check all gauges and LCD display on the gauge clus-

ter panel for proper operation. See Figure 4.37.
DAMAGED OR FAULTY ELECTRICAL COMPO-

NENTS CAN CAUSE SEVERE DAMAGE TO THE
MACHINE AND CAUSE SERIOUS PERSONAL IN-
JURY OR DEATH.
FIGURE 4.37
4 — 16
L . STEPS AND HANDRAILS
KEEP STEP CLEAN AND
IN GOOD CONDITION
1. Carefully inspect all mounting steps and handrails
on the machine to make sure they are clean and in
safe working condition. See Figure 4.38.
2. Repair or replace all areas before allowing any op-

eration of the machine.
USE GRIP BARS

Use steps, and handrails when mounting and dismount- AND STEP RAILS
ing the machine. Keep steps, handrails and step rails
clean and in safe working condition. FIGURE 4.38
M. FRAME STRUCTURE
1. Carefully inspect the entire frame structure for signs

of damage, broken welds etc..
DISCONNECT BATTERY
NEGATIVE (-) CABLE WHEN
2. Repair or replace all frame components found to be INSPECTING ELECTRICAL
damaged before allowing any operation of the ma- OR WELDING
chine.
3. In cases where welding repair is required, consult

KOBELCO distributor for proper procedures concern-
FIGURE 4.39
ing weld repairs. Use only certified welding person-
nel familiar with structural welding methods to per-
form repairs requiring welding.
DISCONNECT BATTERIES BEFORE WELDING ON CHECK FOR BEND

THIS MACHINE. SEE FIGURE 4.39. CONNECT
WELDER GROUND CABLE 1M (3´-3˝) AWAY FROM
AREA TO BE WELDED.
CHECK SHOE WEAR
N. TRACKS AND COMPONENTS
1. Track shoes FIGURE 4.40
a. Visually inspect track shoes for signs of excessive

wear or damage. See Figure 4.40.
b. Have all repair or replacement work done by

KOBELCO distributor.
c. Check tightness of shoe attaching bolts and nuts. TORQUE

BOLTS
If loose, torque to 87 ± 5 kgf·m (628 ± 36 lbf·ft).
See Figure 4.41.
FIGURE 4.41
4 — 17
2. Track links
a. Inspect links for signs of excessive wear or dam-

age. See Figure 4.42.
b. Have all repair or replacement work done by INSPECT TRACK LINK

KOBELCO distributor. ASSEMBLIES
FIGURE 4.42
3. Sprockets
INSPECT THESE BOLTS
a. Inspect sprockets for excessive wear and damage.

See Figure 4.43.
b. Should the sprockets require service, contact

c. Check and make sure all sprocket bolts are prop-

erly tightened.
INSPECT THESE SURFACES
FIGURE 4.43
4. Idlers
a. Inspect idlers for excessive wear and damage. See

Figure 4.44.
b. Should the idlers require service, contact KOBELCO

distributor.
FIGURE 4.44
5. Rollers
LOWER ROLLER UPPER ROLLER
a. Inspect rollers for excessive wear and damage. See INSPECT THESE SURFACES
Figure 4.45.
b. Should the rollers require service, contact KOBELCO

distributor.
FIGURE 4.45
4 — 18
O. TRACK TENSION
MACHINE
POSITION
1. Operate swing, arm, bucket and boom controls until
machine is set up as shown in Figure 4.46.
SUPPORT LOWER FRAME WITH SUITABLE BLOCKS.
2. In center of track, measure the distance between the

bottom of frame rails and surface of shoe. See Fig-
ure 4.47.
FIGURE 4.46
3. Perform steps 1 and 2 on right track.
4. To increase track tension, set machine as shown in

Figure 4.46 and with grease gun inject extreme pres-
sure No.2 grease into idler adjustment grease nipple
until proper tension is reached. See Figure 4.48. Per-
form this procedure on both tracks.
NOTE 320 ~ 350 mm

After injecting grease, operate the travel control forward (12.6"~13.8")
and reverse for the track being adjusted. This will balance
the tension between the idler and the sprocket. Then re-
measure as shown in Figure 4.47.
5. To decrease track tension, set machine up as shown FIGURE 4.47

in Figure 4.46.
6. Carefully loosen the adjusting grease nipple to allow

grease to escape. See Figure 4.48.
GREASE IN TRACK TENSIONING MECHANISM IS

UNDER EXTREME PRESSURE AND CAN PEN-
ETRATE SKIN CAUSING SEVERE INJURY. KEEP
FACE AND BODY AWAY FROM GREASE NIPPLE TRACK ADJUSTING
AREA. NEVER LOOSEN GREASE NIPPLE MORE GREASE NIPPLE
THAN ONE COMPLETE TURN. IF GREASE DOES
NOT RELEASE AFTER ONE TURN OF THE NIPPLE,
CALL AN AUTHORIZED KOBELCO SERVICE
DEALER FOR ASSISTANCE.
FIGURE 4.48
7. Tighten grease nipple, measure track tension as

shown in Figure 4.48.
8. If necessary, perform steps 5 through 7 on other track.
4 — 19
P . BOOM AND ARM
1. Inspect boom and arm structures for signs of exces-

sive wear and damage. See Figure 4.49.
2. Should repair or replacement be necessary, contact

INSPECT BOOM &

ARM FOR DAMAGE
FIGURE 4.49
DISCONNECT BATTERIES BEFORE WELDING ON

THIS MACHINE. SEE FIGURE 4.50. CONNECT
WELDER GROUND CABLE 1M (3´-3˝) AWAY FROM DISCONNECT BATTERY
NEGATIVE (-) CABLE WHEN
AREA TO BE WELDED.
INSPECTING ELECTRICAL
OR WELDING
FIGURE 4.50
Q. CUTTING EDGE, BUCKET TEETH & SIDE CUTTERS
1. Inspect bucket teeth and side cutters for signs of

excessive wear and damage. See Figure 4.51. INSPECT TEETH AND SIDE
CUTTERS FOR DAMAGE
2. Should repair or replacement be required, follow
bucket manufacturers recommendations.
Wear goggles, safety shoes, hard hat, work clothes

and work gloves to perform inspection and maintenance
on this machine.
FIGURE 4.51
3. Should repair or replacement be required, contact

KOBELCO distributor for proper advice.
4 — 20
4.6 50 HOUR (WEEKLY) & NEW MACHINE
BREAK-IN INSPECTION & MAINTENANCE
PROCEDURES
Change the engine oil and filter on a new machine REMOVE BOLTS AND
LOWER COVER
after the first 50 hours of operation. Then change
the engine oil at every 500 hours of operation.
NOTE
One new oil filter is shipped with the machine in the sup-
port kit. This is to be used at the 50 hour oil & filter change.
LOOSEN BOLTS TO
A. ENGINE OIL AND FILTER ELEMENT LOWER COVER
1. Move the machine to a firm, level surface and run

engine for 5 minutes to warm the oil. FIGURE 4.52
DO NOT CHANGE OIL ON A MACHINE THAT HAS

JUST STOPPED WORKING. THE OIL WILL BE EX-
TREMELY HOT. ALLOW THE ENGINE TO COOL
UNTIL OIL IS JUST WARM BEFORE CHANGING.
NOTE
• Check the waste oil. If there are metal chips or powder ENGINE OIL FILTER
mixed in the oil, contact KOBELCO distributor. REMOVAL
• The oil filter can not be reused because it is cartridge type.

FILTER WRENCH
2. Remove the four mounting bolts from the engine

lower cover plates. See Figure 4.52. EXTENSION BAR
3. Place the oil container under the filter.

RATCHET HANDLE
4. Remove the oil filter by turning counterclockwise. See
Figure 4.53.
FIGURE 4.53
5. To install the oil filter, apply a thin coat of engine oil
to the gasket of the oil filter, and then secure the
filter by tightening prescribed number of rotations
after the gasket comes in contact with the oil filter APPLY CLEAN ENGINE OIL
head. See Figure 4.54.
6. When replacing the element only, and not the en-
gine oil, the amount of oil to be added is shown be-
low.
Partially fill filter with oil before installing.
Oil volume ...... Approx. 1.1 Lit (0.29 GAL)
7. Start engine, operate it at idling operation for sev-
eral minutes. Then check filter fitting section for oil
leakage.
FIGURE 4.54
8. Install cover just below the engine to the regular po-
sition.
4 — 21
B. ENGINE OIL
1. Move the machine to a firm, level surface and run

LOOSEN BOLTS
engine for 5 minutes to warm the oil. TO LOWER COVER
DO NOT CHANGE OIL ON A MACHINE THAT HAS

JUST STOPPED WORKING. THE OIL WILL BE EX-
TREMELY HOT. ALLOW THE ENGINE TO COOL
UNTIL OIL IS JUST WARM BEFORE CHANGING.
REMOVE BOLTS AND
LOWER COVER
2. Remove the six retaining bolts from the oil pan ac-
cess cover on the bottom, rear center of machine.
See Figure 4.55. FIGURE 4.55
3. Raise engine bonnet and remove oil filler cap. See

Figure 4.56. ENGINE OIL DIPSTICK
ON SIDE OF ENGINE
4. Place a 20 liter (5.3 Gal) capacity container under oil
pan. Remove engine oil drain plug. See Figure 4.57.
5. Install engine oil drain plug.
6. Refer to page 4-9 for the proper oil to use and fill
engine oil to proper level.
• Total oil volume to be replaced
SK200LC-6E, SK200LC-6E : 18 liters (4.8 Gal) ENGINE OIL
FILLER CAP
7. Install oil filler cap. Clean up all spilled oil. FIGURE 4.56
8. Start engine, run for 5 minutes. While running, check
for oil leaks.
9. Should any oil leaks be found, repair immediately

and refill with proper oil.
10. Check oil level and close cover.
Dispose of all hazardous waste in accordance with ENGINE OIL

DRAIN PLUG
government environmental regulation.
FIGURE 4.57
4 — 22
C. FUEL TANK DRAIN
1. Locate and open fuel tank drain valve on bottom of

fuel tank. See Figure 4.58.
2. Allow all water and sediment to drain from fuel tank

into a waste container, then close the drain valve.
FIGURE 4.58
D. WATER SEPARATOR
The water separator isolates water that mixes in with AIR PLUG
the fuel. The case is equipped with a float. When wa-
ter accumulates, the float rises. When the float rises to
WATER SEPARATOR
the level line, drain the water. See Figure 4.59.
1. Loosen the drain plug and air plug to drain the water.
2. When the float comes down to the bottom, close the

drain plug. LEVEL LINE
3. Tightening the drain plug and air plug. FLOAT (RED)
4. Check that fuel is not leaking.

DRAIN PLUG
Drain water whenever the float rises to the level line,
regardless of inspection time. FIGURE 4.59
Clean up all spilled fuel to avoid a fire.

Dispose of all hazardous waste in accordance with
govemment environmental regulation, laws and codes.
E . AIR INTAKE SYSTEM

HOSE & CLAMPS FROM AIR CLEANER
Inspect all hoses and clamps of the air intake system
on a new machine after the first 50 hours of operation.
Then at every 500 hours of engine operation.
1. Inspect all hoses for damage and tighten all hose

clamps. See Figure 4.60.
2. Replace any hose found to be damaged before al-

lowing any operation of the machine.
FIGURE 4.60
4 — 23
F . RADIATOR, OIL COOLER AND DEBRIS SCREEN
ENGINE COOLANT
1. Clean radiator after every 50 hours of operation us- TANK ACCESS DOOR
ing pressurized water.
2. Open engine air cleaner access door and engine bon-

net for cleaning the radiator and oil cooler. See Fig-
ure 4.61.
RADIATOR SUB TANK

ENGINE AIR CLEANER ACCESS DOOR
ACCESS DOOR
FIGURE 4.61
3. Open engine bonnet and remove the wing bolts re-
ENGINE BONNET
taining the debris screen. See Figure 4.62. Carefully
remove debris screen and clean with pressurized
water.
ENGINE RADIATOR
ACCESS DOOR
FIGURE 4.62
4. Remove wash out access cover from bottom of ma-
chine. See Figure 4.64.
5. Rinse all dirt and debris from engine compartment.

OIL COOLER
Reinstall debris screen and wash out access cover.
Be careful not to bend or damage cooling fins of the

A/C CONDENSER
radiator or oil cooler. Replace debris screen if damage
is found. Repair damaged cooling fins of radiator and
oil cooler.
FIGURE 4.63
DEBRIS SCREEN
NOTE WASH OUT COVER
To remove or install the screen, remove three wing bolts
on the upper section of radiator, and pull out the screen
on the front side then pull the rear screen frontward and
remove. After cleaning it, install it by the reverse proce-
dure.
REMOVE BOLTS
FIGURE 4.64
4 — 24
G. HYDRAULIC RETURN FILTERS
DEPRESS RUBBER CAP
Change the hydraulic tank return filter on a new ma- TO RELEASE PRESSURE
chine after the first 50 hours of engine operation then
change every 1,000 hours.
NOTE
One new hydraulic return filter is shipped with the ma-
chine in the support kit. This is to be used at the 50 hours
filter change.
Move machine to firm leveled ground and place attach-
ment in oil level check position.
FIGURE 4.65A
1. Release hydraulic tank pressure. See Figure 4.65A.
SLOWLY REMOVE
BOLTS & COVER

THAT HAS JUST FINISHED WORKING. ALLOW MA-
CHINE TO COOL FIRST UNTIL OILS AND FLUIDS
ARE WARM NOT HOT. RELEASE HYDRAULIC
TANK PRESSURE BEFORE WORKING WITH ANY
HYDRAULIC COMPONENT.
2. Remove the six mounting bolts (1) and spring washer

(2) from the hydraulic return cover (3). See Figure
4.67A. FIGURE 4.66A
(4) (1)
Slowly remove the mounting bolts. The filter cover plate
(2)
is under spring tension.
(3)
3. Remove “O”-ring (5) and spring (4). See Figure 4.67A. (B)
4. Disassemble element assy (A) while turning the

(C) (5)
handle.
ELEMENT
Disassembling parts ...... (B), (C), (D), (E), (F) ASSY (5)
(D)
(A)
5. Replace “O”-ring (C) of check valve (B). (C)
6. Replace packing (F) of plate (E). (E)

(F) (D)
7. Replace element, and assemble element assy (A)
disassembled in procedure (4) again.
8. Attach element in reverse procedure of the (3) and (F)

(4) above-mentioned. ELEMENT KIT P/No.
YN52V01008R100
9. Install cover (3). FIGURE 4.67A

Tightening torque : 46.1 ± 4.9 N·m {4.7 ± 0.5 kgf·m}
10. Start engine, put the machine on hydraulic oil level SUPPLEMENTARY EXPLANATION
check position while moving each operating lever, Long-life return filter is used.
and check hydraulic oil level. Place an order of return filter element kit,
P/No. YN52V01008R100.
4 — 25
H. BATTERIES
Perform complete battery service on a new machine
after the first 50 hours of engine operation.
Then, check electrolyte (acid) every 50 hours.
1. WEAR SAFETY CLOTHES, GOGGLES OR FACE

SHIELD, GLOVES AND SAFETY SHOES WHEN
WORKING WITH BATTERIES.
2. WORK IN A WELL VENTILATED AREA.
3. BATTERY ELECTROLYTE (ACID) IS CORROSIVE.
IF IT COMES IN CONTACT WITH SKIN, EYES OR
CLOTHING, FLUSH WITH LARGE AMOUNTS OF
WATER AND SEEK IMMEDIATE MEDICAL AT-
FIGURE 4.68
TENTION. SEE FIGURE 4.68.
4. BATTERY ELECTROLYTE (ACID) PRODUCES
HYDROGEN GAS THAT IS HIGHLY EXPLOSIVE.
DO NOT ALLOW NEAR SPARKS, FIRE OR
FLAMES AND DO NOT SMOKE WHEN WORK-
ING WITH BATTERIES. SEE FIGURE 4.70.
1. Open battery box access cover. See Figure 4.69.

BATTERY ACCESS
2. Remove battery cell caps and visually inspect elec-
COVER
trolyte (acid) level. Proper level is 10~15 mm (0.4˝ ~
0.6˝) above cell plates. See Figure 4.70.
3. If necessary, fill each cell to proper level with dis-

tilled water only.
4. Remove cables from terminals and clean with hot

water. Coat each terminal with a thin layer of petro-
leum jelly. Clean cables in the same manner and re-
install onto battery.
FIGURE 4.69
5. If cables are found to be in poor condition, replace
with new parts immediately.
ELECTROLYTE LEVEL
NEGATIVE (-) CABLE
10 ~ 15MM
(0.4" ~ 0.6")
PREVENT BATTERY EXPLOSION
• Batteries give off hydrogen gasses that can ex- CELL
plode and cause personal injury. PLATES
• Keep sparks, open flames and cigarettes away

from batteries.
• Keep all ventilation caps tightly secured. REMOVE CELL CAPS
• Never check charge by placing metal articles

across battery terminals. FIGURE 4.70
• Leave battery box open to improve ventilation

when charging.
4 — 26
6. Use a hydrometer to check the specific gravity of
each cell. Compare readings to the chart below.
NOTE
Use hydrometer according to its manufacturer’s instruc- DISCONNECT BATTERY
tions. NEGATIVE (-) CABLE WHEN
. INSPECTING ELECTRICAL
OR WELDING
AMBIENT TEMPERATURE
CHARGE % 20˚C 0˚C -10˚C
(68˚F) (32˚F) (14˚F)
FIGURE 4.71
100 % 1.26 1.27 1.28
90 % 1.24 1.25 1.26
80 % 1.22 1.23 1.24
75 % 1.21 1.22 1.23
7. When disconnecting batteries, remove the negative

(–) cable first. When connecting batteries, connect
the negative (–) cable last. See Figure 4.71.
8. When the battery requires charging;
a. Disconnect battery cables from terminals.
b. Remove all cell caps.
c. Check for proper electrolyte (acid) level.
d. Connect charger leads to the proper battery termi-

nals.
Make certain not to cross positive and negative termi-

nals when connecting charger.
e. Stop charge if battery overheats.
f . Periodically check the specific gravity of the bat-

teries with a hydrometer. Stop charging batteries
when 100% charged.
NOTE
Battery life can be shortened by over discharging of the
battery. Replace any battery that will not hold charge or is
difficult to charge.
4 — 27
I . ATTACHMENT LUBRICATION
Lubricate attachment pins every 500 hours of engine
operation. Use extreme pressure multi-purpose grease
No. 2 EP type grease. Lubricate all points until grease
oozes.
NOTE
If attachment is sank in water, it is recommended to lubri-
cate it every 8 hours.
BOOM CYLINDER
HEAD PINS
1. Boom cylinder head pins. See Figure 4.72.
FIGURE 4.72
2. Boom foot pin. See Figure 4.73.
BOOM CYLINDER
3. Boom cylinder rod pins. See Figure 4.73. ROD ENDS
ARM CYLINDER
4. Arm cylinder head pin. See Figure 4.73. HEAD END
BOOM FOOT PIN
BOOM FOOT PIN EACH END
(CENTER)
CENTRALIZED GREASE NIPPLES ON BOOM
FIGURE 4.73
5. Arm cylinder rod pin. See Figure 4.74.

ARM TO
BOOM PIN
6. Arm to boom pin. See Figure 4.74.
7. Bucket cylinder head pin. See Figure 4.74.
ARM
BUCKET
CYLINDER
CYLINDER
ROD END
HEAD PIN
FIGURE 4.74
8. Bucket link pins. See Figure 4.75.

IDLER LINK TO
ARM PIN
9. Idler link to arm pin and arm to bucket pin. See Fig-
ARM TO
ure 4.75. BUCKET PIN
10. Bucket cylinder rod pin. See Figure 4.75. BUCKET

CYLINDER
ROD END
TOP BUCKET BOTTOM BUCKET

LINK PIN LINK PIN
FIGURE 4.75
4 — 28
4.7 120 HOUR INSPECTION & MAINTENANCE
PROCEDURE
FILL PLUG
A. SWING MOTOR REDUCTION OIL DIPSTICK
Check the oil level of the swing motor reduction unit
on a new machine after the first 50 hours of engine
operation. Then check every 120 hours.
1. Locate the dipstick on the side of the swing motor.

See Figure 4.76. Pull dipstick, wipe clean and rein-
sert all the way in.
2. Pull dipstick and read oil level.
3. If necessary to add oil, remove plug from oil fill port FIGURE 4.76
and fill to full level with proper oil. See Figure 4.76
and refer to page 4-9 for oil specifications.
Reduction unit may be under pressure.

Remove plug slowly.
4. To drain oil from swing motor reduction unit;
a. Locate drain port under rear of machine. See Fig-

ure 4.77.
b. Place a 20 liter (5.3 gallon) container under drain DRAIN PORT
port and remove plug allowing oil to drain into con- FIGURE 4.77
tainer.
Total Oil Volume
MODEL VOLUME
SK200-6E
7.5 Liter (2.0 Gal)
SK200LC-6E
c. Replace plug and tighten securely after all oil is

drained.
d. Fill through fill port using proper oil. See Figure

4.76 and refer to page 4-9 for oil specifications.

MACHINE TO COOL FIRST UNTIL OILS AND
FLUIDS ARE WARM NOT HOT.
4 — 29
B. TRAVEL MOTORS REDUCTION OIL
FILL / LEVEL
Inspect oil level of travel motor reduction unit on a new PLUG
machine after the first 50 hours of engine operation.
Then check every 120 hours.
1. Move machine to a firm, level surface. Operate travel

until “FILL / LEVEL” plugs on travel motors are at
about 9:00 o’clock. See Figure 4.78.
2. Stop engine and remove the travel motor reduction

unit oil level plug. See Figure 4.78. If oil just seeps
from the port, oil level is correct.
DRAIN PLUG
FIGURE 4.78
Reduction unit may be under pressure.

Remove plug slowly.
3. To add oil, remove the oil FILL / LEVEL plug and add
extreme pressure gear oil #90 grade GL-4 until oil
just begins to flow from level plug.
NOTE
Capacity of each travel motor reduction unit is 5.5 liters
(1.5 Gallons).
4. Replace all plugs and tighten securely.
4 — 30
4.8 250 HOUR (3-MONTH) INSPECTION &
ALTERNATOR
MAINTENANCE PROCEDURE
NOTE
Perform all pre-start (every 8 hour and 50 hour) inspec-
tion & maintenance procedures along with the following
IDLE PULLEY
120 hour inspection and maintenance procedures.
A. FAN AND A/C BELT WEAR AND TENSION

Inspect belts and tensioner assembly on a new ma-
chine after the first 50 hours of operation. Then at ev-
ery 250 hours of engine operation.
Measure belt tension on longest span of belt. Apply a
10 kgf (22 lbf) on the belts as indicated in Figure 4.79
and measure the belt deflection. Compare to the fol-
lowing table:
CRANK PULLEY COMPRESSOR
BELT DEFLECTION
FIGURE 4.79
Fan belt 10 mm ~ 15 mm (0.4˝ ~ 0.6˝)
Air conditioner 7 mm ~ 10 mm (0.3˝ ~ 0.4˝) ADJUSTING BOLT MOUNTING BOLT
8.4 ± 1.0 kgf·m
(61 ± 7 lbf·ft)
1. Fan Belts
Check fan belts for excessive wear and cracks and
replace them if needed. When replacing a twin type
V-belt, replace them both. If only one belt is re-
placed, it may fail due to the excessive loading. To
adjust the fan belts, proceed as follows:
a. Loosen mounting bolt and adjusting nut on the al-
ternator. See Figure 4.80.
ADJUSTING NUT
b. Loosen or tighten adjusting bolt to adjust fan belt
to the specified tension, and tighten mounting bolt
and adjusting nut properly. See Figure 4.80.
FIGURE 4.80
TIGHTENING TORQUES
ADJUSTING BOLT
Mounting capscrew .... 8.4 ± 1.0 kgf-m (61 ± 7 lbf·ft) ALTERNATOR
Adjusting nut .............. 7.7 ± 1.5 kgf-m (56± 11 lbf·ft)
c. After adjustment, start engine and run it at low idle

for about 5 minutes. Then recheck belt tension.
2. Air Conditioning Compressor Belt IDLE PULLEY

Check belt for excessive wear and cracks and re-
place if needed. To adjust the A/C compressor belt,
proceed as follows:
Force : approx.
a. Loosen the idler pulley nut. See Figure 4.81.
98N (22lbf, 10kgf)
b. Loosen or tighten adjusting bolt.
c. Tighten idler pulley nut to 4.0 ~ 5.5 kgf-m (29 ~ 40
lbf·ft).
d. After adjustment, start engine and run it at low idle
for about 5 minutes with A/C turned on. Then re- CRANK PULLEY COMPRESSOR
check belt tension. FIGURE 4.81
4 — 31
B. AIR CONDITIONER FILTERS
SCREW SCREW REAR COVER SCREW
Cleaning recirculate and fresh air filters.
Recirculate air filter ... Every 500 hours
Fresh air filter ............ Every 250 hours
1. Cleaning Fresh Air Filter

a. Remove 4 machine screws of rear cover on the
rear side of operator seat, release the lock, and LOCK
remove the rear cover. See Figure 4.82. LOCK
b. Remove the fresh air filter.
NOTE
Water washing is not allowed to clean air filter because it REAR COVER
is paper filter. FIGURE 4.82
c. Cleaning about 10 times is allowed, or replace it

with new one every two years.
RECIRCULATE AIR
2. Cleaning Recirculate Air Filter FILTER
FRESH AIR
a. Raise recirculate air filter slightly, and pull it out. FILTER
b. Clean it with water or compressed air blow.
COVER
NOTE
Washing with organic solvent (gasoline, trichlene, thinner,
etc.) is strictly prohibited.
c. When frequently clogged, or damage is serious,

replace it with new one. MACHINE FRONT
d. After drying, set outside and recirculate air filters
and install cover. FIGURE 4.83
C. INSPECTING COUNTERWEIGHT ATTACHING BOLTS

FOR LOOSENING – FIGURE 4.84
Check bolts and nuts for proper torque. See Figure
4.84.
Striking counterweight against obstruction may cause

loosening of bolts. Check bolts for loosening after 50 COUNTERWEIGHT
hours the first time, and every 250 hours after that. ATTACHING BOLT
Unit : kgf·m (lbf·ft)

TORQUE SPECIFICATION FIGURE 4.84
MODEL
(Apply Loctite #262)
SK200-6E
130 ± 13 (939 ± 94)
SK200LC-6E
4 — 32
PROCEDURES
NOTE
Perform all pre-start (every 8 hour and 50 hour) inspec-
tion & maintenance procedures along with the following APPLY CLEAN FUEL
250 hour inspection and maintenance procedures.
REMOVAL
A. FUEL FILTER
FILTER WRENCH
CLEAN UP ALL SPILLED FUEL.

FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL
CAN CAUSE FIRES.
EXTENSION BAR
1. Put the oil pan under the filter cartridge.
2. Set filter wrench, extension bar and ratchet handle RATCHET HANDLE
supplied with the machine and remove the fuel filter
turning it counterclockwise. See Figure 4.85. FIGURE 4.85
NOTE
The fuel filter is cartridge type, and so cannot be reused.
3. Clean the filter base and apply clean fuel on the gas-
ket section of new fuel filter lightly.
4. Push it in until the filter gasket of fuel filter comes

into contact with the filter base by hand, and tighten
it with filter wrench 3/4 to 1 turn.
5. Start the engine and idle it several minutes, then

make sure that there is no leakage of fuel.
B. CLEAN FUEL PRE-FILTER
1. Remove it by turning it counterclockwise, using a fil-

ter wrench. See Figure 4.86.
2. When installing element assy tighten it 3/4 to 1 turn

when gasket contacted with sealing surface.
3. Start the engine and check to see that there is no oil

leakage from the sealing surface.
CLEAN UP ALL SPILLED FUEL.

FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL FIGURE 4.86
CAN CAUSE FIRES.
4 — 33
C. BLEEDING AIR FROM THE FUEL SYSTEM
AIR PLUG
CLEAN UP ALL SPILLED FUEL. FUEL FILTER

FUEL OIL IS HIGHLY FLAMMABLE. SPILLED FUEL
CAN CAUSE FIRES.
If air contaminates the fuel system, the engine may

become hard to start or it malfunction. Bleed the air PRIMING PUMP
whenever the fuel tank is empty, the water separator
is drained, or the fuel filter element is replaced. See
Figure 4.87. KNOB
AIR PLUG
1. Loosen the knob of the priming pump.
2. Loosen the air plug of the fuel filter.
3. Moving the knob up and down by hand, supply fuel

until air bubbles stop issuing from the air plug.
NOTE
Cover the air plug with a cloth before performing this op-
eration. AIR PLUG
4. Tighten the air plug when the air bubbles stop issu-
ing from it.
5. Move the knob up and down a few times, then set it

in the down position and screw it in to secure it.
NOTE
Wipe away all spilled fuel before starting up the engine.
After engine has started, check for fuel leaks.
6. The air in the injection pump will automatically be

forced out when the engine starts.
TO UPPER RIGHT
FIGURE 4.87
4 — 34
D. GREASING THE SLEWING RING GREASING SWING
BEARING
1. EXTREME-PRESSURE.
1. Locate the grease nipple at the front of the slewing MULTIPURPOSE GREASE.
N.L.G. I No.2 LITHIUM BASE
GREASE EP TYPE.
ring. See Figure 4.88. 2. ADD GREASE EVERY 500 HOURS.

3. ROTATE UPPER FRAME ADDING
GREASE EVERY 90° (TOTAL 4X)
2432P2689
2. Using grease gun filled with general purpose EP

grease (refer to page 4-9), lubricate slewing ring with
several shots from grease gun.
3. Swing machine 90° right, and repeat step 2. See la-
bel on frame.
4. Continue to swing machine at 90° increments and SLEWING RING
lubricating slewing ring until ring has been completely GREASE NIPPLE
greased.
FIGURE 4.88
E . CHECKING SLEWING RING FITTING BOLTS FOR

BALL
LOOSENING
Check that bolts securing slewing ring are not loos-
ened. SLEWING RING
If loosened, remove bolts once, apply Loctite #262 or
equivalent, and tighten them again.
BOLTS
Unit : kgf·m (lbf·ft)
Model Location Torque Specification
SK200-6E Inner Race 57.5 ± 5.8 (415 ± 42)
SK200LC-6E Outer Race 40.0 ± 4.0 (289 ± 29) LOWER FRAME
Alternately tighten bolts facing each other in order. See FIGURE 4.89
Figure 4.89.
NOTE
Since the tightening of slewing ring requires special tools,
contact KOBELCO distributor for assistance.
F . WATER PUMP BEARING LUBRICATION

Lubricate the water pump bearing on a new machine
after the first 50 hours of engine operation. Then check
and lubricate every 500 hours.
1. Open the engine bonnet, lock it open, and locate
grease nipple for the water pump bearing, in front of
the engine. See Figure 4.90.
2. Wipe all dust and mud off the grease nipple.
3. Use N.L.G.I. No. 2 (Lithium soap) wheel bearing
grease to lubricate the bearing.
4. Close engine bonnet.
FIGURE 4.90
NOTE
Do not over grease the water pump bearing. It only re-
quires about one shot of a manual grease gun, which is
equivalent to aprox. 6.1 cc. NEVER USE A PNEUMATIC
GREASE GUN.
4 — 35
G. CHECKING THE AIR CONDITIONER REFRIGERANT
AIR CAPACITY COMPRESSOR
SELECTOR SWITCH SWITCH
1. Start the engine. Set the engine speed to the middle
speed position.
2. Set the machine to the conditions shown below when

checking the refrigerant. See Figure 4.91.
• Air conditioner switch ........ ON
• Fan switch ...................... HI position (Maximum )
TEMPERATURE MAIN POWER
• Temp. adjustment switch ... Lower temp position ( ) SETTING SWITCH SWITCH
(˚C ˚F SELECTOR SWITCH)
• Door / Window ............... Close
• Compressor switch ........ ON (The lamp lit up) FIGURE 4.91
3. Follow the procedure below and check the refriger-

ant volume by looking through the sight glass (in- Refrigerant volume Description
spection window) on the upper part of the receiver
(A) Proper
dryer.
a. Figure (A) shows that the refrigerant volume is
After the air conditioner is turned ON, little
proper. See Figure 4.92. bubbles appear. The refrigerant becomes
transparent, then turns a light milky white.
b. Figure (B) shows that the refrigerant is over
(B) Overcharged
charged. This will make both high and low pres-
sure extreme and exert a bad influence on the pres-
sure switch operation and the air conditioning sys- After the air conditioner is turned ON, no
tem. See Figure 4.91. bubbles appear.
(C) Insufficient
c. Figure (C) shows that the refrigerant is insufficient.
Have the refrigerant recharged at your KOBELCO
distributor. See Figure 4.91. After the air conditioner is turned ON,
bubbles appear continuously.
NOTE FIGURE 4.92
• New refrigerant (HFC-R134a), whose characteristics are Bubbles : Refrigerant gas is mixed with
different from conventional CFC-12, is used in this ma- refrigerant fluid.
chine. Do not mix HFC-R134a with CFC-12.
No Bubbles : Whole refrigerant becomes fluid
• Keep the air conditioner ready for use all year round. and transparent.
Operate the air conditioner at least once every week for
several minutes to rotate the compressor regardless of Cloudy : Refrigerant is separated from oil.
the season. This will prevent the refrigerant gas from The fluid becomes a light milky
leaking from the compressor sealing. white.
H. FUEL SYSTEM INJECTION PRESSURE AND NOZZLE

CONDITION (ATOMIZATION)
Perform this inspection and adjustment every 500 hours
of engine operation. Contact KOBELCO distributor for
assistance.
Initial injection pressure : 220 kgf/cm2 (3,128 psi)
4 — 36
4.10 1000 HOUR (12-MONTH) INSPECTION &
MAINTENANCE PROCEDURES
A. ENGINE VALVE CLEARANCE

Check and adjust the engine valve clearance every 1000
hours of engine operation. Contact your KOBELCO dis-
tributor for assistance.
Adjust exhaust and intake valves at 0.4 mm

(0.016˝) (With cold engine)
B. ENGINE COMPRESSION PRESSURE

Check engine compression every 1000 hours of en-
gine operation. Contact your KOBELCO distributor for
assistance.
Compression pressure : 2.6 MPa (377 psi)

at 200 rpm at engine temperature between
75 ~ 85°C (167 ~ 185°F)
C. INSPECTION OF STARTER AND ALTERNATOR

Check starter and alternator every 1000 hours of en-
gine operation. Contact your KOBELCO distributor. It
is necessary to disassemble these components for
proper cleaning and inspection.
D. ENGINE FUEL INJECTION TIMING

Check engine fuel injection timing every 1000 hours of
engine operation. Contact your KOBELCO distributor
for assistance.
Injection timing : 14° BTDC
4 — 37
PROCEDURES
REMOVE CAP SLOWLY
Perform all other inspection & maintenance proce-
dures as previously described in this section.
A. CHANGE ENGINE COOLANT - 2000 HOURS

FORM INSPECTION AND MAINTENANCE ON THIS
ALLOW ENGINE TO COOL BEFORE OPENING
MACHINE. ALLOW ENGINE TO COOL BEFORE
CHANGING FLUIDS. FIGURE 4.93
DEBRIS SCREEN
1. Raise engine bonnet and slowly remove radiator cap. WASH OUT COVER
See Figure 4.93.
2. Locate coolant drain access cover under L.H. rear

of machine. See Figure 4.94. Remove the four re-
taining bolts.
3. Locate radiator drain valve, place a 20 liter (5.3Gal)

capacity container under drain tube and turn drain
valve counterclockwise to open. See Figure 4.95.
4. After drainage, close drain valve and drain plug, and

feed water in it. REMOVE BOLTS
5. Open drain valve and drain plug. And clean it with FIGURE 4.94
flowing water for 10 minutes in low idling state.
Be careful that water hose is not disconnected from
water feeding port of radiator while cleaning and flow-
ing water.
6. After cleaning, stop engine, and also stop water feed-

ing. Then after draining water, close drain valve and
drain plug.
7. After draining, clean it with radiator flush. Clean it

following instruction manual for flush in use. ENGINE DRAIN PLUG RADIATOR DRAIN VALVE
8. After cleaning, open drain valve and drain plug, then FIGURE 4.95
close them after completely draining water, and fill it
with water close to the water supply port.
NOTE
Expected minimum temperature Long life coolant

NOTE -14.5˚C (5.9˚F) 30% mixed
Never spill the coolant on the ground that can cause the
-34˚C (-29.2˚F) 50% mixed
environmental pollution.
Change contaminated and foamy coolant with new one
as soon as possible.
Cooling water other than long life coolant should be
changed two times a year, in spring and autumn.
4 — 38
9. Fill radiator with water, open drain valve and drain
plug, and clean it flowing water with engine in a low
idling state until clean water is flowing out.
Adjust water feeding and draining so as to keep ra-
diator in full condition.
10. After clean water has drained out, stop engine and
close drain valve and drain plug. See Figure 4.95.
Fill with "long life coolant" in appropriate concentra-
tion. ENGINE DRAIN PLUG RADIATOR DRAIN VALVE
Refer to pages 4-9.
FIGURE 4.96
11. Run engine at low idling for 5 minutes and high idling
for 5 minutes to bleed air contaminated in coolant
(with cap of radiator removed).
12. Drain coolant in reservoir, clean inside of reservoir ENGINE COOLANT

RESERVOIR PROPER
and fill it up with long life coolant in appropriate con-
LEVEL
centration to mid point of FULL and LOW. See Fig-
ure 4.97.
13. Stop engine, fill it with water to the top of radiator

about 3 minutes later, and tighten cap. FULL
14. Return engine bonnet and access door to the closed

position respectively.
LOW
FIGURE 4.97
NOTE
Total cooling system volume is approximately 19 liters (5.0
Gal).
4 — 39
B. REMOVAL AND INSTALLATION OF ENGINE RADIA-
RADIATOR
TOR – SEE FIGURE 4.98 (3) OIL COOLER
The radiator removal and installation procedure is de-
scribed below.
(1)
1. Remove one under cover on the lower side of radia-
tor.
(3)
2. Open cap and radiator drain cock and pour the cool-
(2)
ing water into container.
3. Loosen four wing bolts (1) and remove insect proof

net in front of the radiator.
4. Loosen four capscrews (M10) (2) and remove pads

SHROUD
(3) on the RH and LH sides of radiator shoulder.
5. Remove four securing capscrews (M10) (4) on the (6)

upper of radiator.
6. Remove two securing capscrews (M10) (5) on the

lower side of radiator.
(4)
7. After making sure that the cooling water is completely
gone out, loosen hose band (6) of radiator and re- INSECT PROOF NET
move it on radiator side only. (5)
8. Shift the radiator to the oil cooler side, and hang it

paying attention not to damage the insulation.
Radiator weight : 29 kg (64 lbs) (6)
PULL UP
9. After cleaning, install it by the reverse procedure.

SHIFT IT TO THE OIL COOLER SIDE

MACHINE. ALLOW ENGINE TO COOL BEFORE
FIGURE 4.98
CHANGING FLUIDS.
4 — 40
C. CHANGE HYDRAULIC OIL
NOTE
The following procedures are to be used for normal chang-
ing of the hydraulic oil only.
If necessary to change the hydraulic oil viscosity, change

hydraulic oil due to hydraulic component failure or chang-
ing main pump, contact KOBELCO distributor for assis- FIGURE 4.99
tance.
DEPRESS RUBBER CAP
TO RELEASE PRESSURE

MACHINE. ALLOW HYDRAULIC OIL TO COOL HYDRAULIC TANK
BEFORE CHANGING.
FIGURE 4.100
1. Move the machine to a firm, level surface with the SLOWLY REMOVE
BOLTS & COVER
attachment in the hydraulic oil check position. See
Figure 4.99.
NOTE
If machine is cold, warm the hydraulic oil by operating
attachment controls before placing machine in the hydrau-
lic oil check position.
2. Release hydraulic tank pressure. See Figure 4.100. FIGURE 4.101
BOLT
3. Slowly remove the six retaining bolts from the suc-
tion strainer cover plate. See Figure 4.101. SPRING COVER
WASHER
4. Remove “O”-ring, and suction strainer from hydrau- O-RING
lic tank. See Figure 4.102.
SUCTION
STRAINER
NOTE
Never spill the hydraulic oil on the ground, that can cause
the environmental pollution.
FIGURE 4.102
4 — 41
5. Install special suction stopper, part number
24100P978F2, over suction tube insidehydraulic HYDRAULIC
TANK
tank. See Figure 4.103.
6. Place a 156 liter (41 Gal) capacity container under

drain plug. Remove plug and allow all oil from hy-
draulic tank to drain into container. SUCTION STOPPER
ASSEMBLY
PART No. 24100P978F2
SUCTION
TUBE
FIGURE 4.103
7. Remove the hydraulic drain plug on bottom of hy-

draulic tank. See Figure 4.106.
8. After all oil has drained, carefully and thoroughly clean

inside of hydraulic tank.
9. Replace drain plug and tighten securely.
10. Remove suction stopper and clean outside of suc-

DRAIN PLUG
tion tube with a clean, dry cloth.
11. Carefully inspect suction strainer for damage. If any

damage is found, replace strainer with new part. FIGURE 4.106
Order part number YN50V00002S001.
12. Install strainer assembly onto suction tube.
˝)
7.2
(2
m
m
2
69
FIGURE 4.107
4 — 42
13. Install new “O”-ring, part number ZD11G20000, in
cover plate mounting surface groove and install suc- BOLT
tion strainer cover plate onto hydraulic tank. Make COVER

SPRING
certain plate boss is inside suction strainer holder. WASHER
See Figure 4.108.
O-RING
14. Torque retaining bolts to proper value. Refer to speci-

fications section. SUCTION
STRAINER
15. Fill hydraulic tank to proper level with fresh, clean
hydraulic oil through hydraulic return filter. See Fig-
ure 4.108.
Use same viscosity oil in hydraulic tank as was drained.

Refer to page 4-9 for oil specifications.
NOTE
This machine was shipped from the factory with ISO VG68
viscosity hydraulic oil in hydraulic system. FIGURE 4.108
4 — 43
D.HYDRAULIC TANK BREATHER
DEPRESS RUBBER CAP
TO RELEASE PRESSURE
1. Release hydraulic tank pressure. See Figure 4.109.
HYDRAULIC TANK
FIGURE 4.109
2. Remove rubber cap and nut. See Figure 4.110.

RUBBER CAP
3. Remove breather housing. See Figure 4.110.
NUT
FILTER
BREATHER
HOUSING
FIGURE 4.110
4. Remove old filter, clean mounting surfaces and in-

REMOVE FILTER
stall new filter. See Figure 4.111. Order part num-
ber YN57V00002S010.
5. Install breather housing.
6. Install retaining nut and tighten securely.

Torque : 1.0 ~ 1.4 kgf·m (7.2 ~ 10 lbf·ft)
7. Install rubber cap part number YN57V00002S012.
FIGURE 4.111
4 — 44
E . CHANGE OIL IN TRAVEL MOTOR REDUCTION UNITS
Change the travel reduction units oil on a new ma- FILL / LEVEL
PLUG
chine after the first 500 hours of engine operation then
change every 2000 hours.

DRAIN PLUG
1. Move machine to a firm, level surface. Operate travel
until “FILL/LEVEL” plugs on travel motors are at about FIGURE 4.112
9:00 o’clock. See Figure 4.112.
2. Stop engine and remove the travel motor reduction

unit “DRAIN” Plug. See Figure 4.112.
3. To add oil, remove the oil fill plug and add extreme
pressure gear oil #90 grade GL-4 until oil just begins
to flow from level plug.
4. To drain oil, remove “FILL/LEVEL” plug and drain

plug. Allow oil to drain into a 12 liter (3 Gal) capacity
container. Replace drain plug, remove level plug and
fill through fill port using extreme pressure gear oil
#90 grade GL-4.
NOTE
Capacity of each travel motor reduction unit is 5.5 liters
(1.5 Gallons).
5. Replace all plugs and tighten securely.
4 — 45
F . PILOT LINE FILTER
When cleaning or replacing the filter, move the control
lever several times and release the internal pressure
in the pilot line completely.
Prepare an oil pan.
ELEMENT
THAT HAS JUST FINISHED WORKING. ALLOW MA- O-RING
CHINE TO COOL FIRST UNTIL OILS AND FLUIDS
ARE WARM NOT HOT. CASE
RELEASE HYDRAULIC TANK PRESSURE BEFORE

WORKING WITH ANY HYDRAULIC COMPONENT. FIGURE 4.113
1. Open the main pump access door and locate the

pilot manifold mounted to the side of the hydraulic
Tank. See Figure 4.113.
2. Loosen the manifold block case with spanner 24 mm

(0.94˝).
3. Clean the removed parts and fit new element and

O-ring in the case.
4. After the case is installed on the filter base, tighten it

with spanner 24 mm (0.94˝).
Tightening torque : 2.5 to 3.5 kgf·m (18 to 25 lbf·ft)
5. Lock the main pump access door.
4 — 46
G. CHANGE OIL IN SWING REDUCTION UNIT
Change the swing reduction unit oil on a new machine
after the first 500 hours of engine operation then change FILL PLUG
every 2000 hours. DIPSTICK

1. Remove the drain plug on the rear lower side of the

swing reduction unit to drain oil to the container. See FIGURE 4.114
Figure 4.115.
2. Clean the drain plug seal it with teflon tape, and in-
stall.
3. Remove the oil filler plug and fill with extreme pres-
sure gear oil #90 grade GL-4.
4. Using the dipstick, confirm that the extreme pres-

sure gear oil #90 grade GL-4 levels is within the des-
ignated range. See Figure 4.114.
DRAIN PORT
5. Clean the fill plug and install.
FIGURE 4.115
NOTE
Capacity of each swing reduction unit is 7.5 liters (2 Gal-
lons).
4 — 47
H. ATTACHMENT & DUST SEALS
STABILIZE BUCKET ON GROUND
1. Bucket Clearance
a. Inspect bucket clearance frequently for wear. If

clearance between bucket and bucket link and/or
between arm and bucket is greater than 1.2 mm
(0.05˝) adjust clearance according to following in-
structions.
Set the safety lock lever to the locked position and stop
the engine when adjusting the clearance of the bucket. FIGURE 4.116
BUCKET CLEARANCE
STANDARD CLEARANCE OF THE BUCKET ADJUSTING MECHANISM
(A) 1.2 mm (0.05˝) or less
b. Lower the bucket onto the ground to stabilize, as

shown in the right figure. See Figure 4.116.
c. Move the o-ring (1) from its normal position to the

bucket boss. See Figure 4.118.
d. Slightly swing in the left direction to slightly push

the arm end to the bucket left side (where no clear-
ance adjusting mechanism is equipped). FIGURE 4.117
e. Set the safety lock lever to the locked position; then (1)
stop the engine.
f . Measure the clearance (A) between the arm and

bucket boss. If the measurement value is 1.2 mm
(0.05˝) or more, adjust the clearance.
g. Five shims (3) 1.0 mm (0.04˝) on the average are

inserted in the three capscrews (2) at the clear-
ance adjusting part. Loosen every capscrews (2)
and remove shims (3) corresponding the clearance.
BUCKET BOSS
See Figure 4.119.
FIGURE 4.118
h. Tighten the capscrews equally to the specified tight-
ening torque.
Tightening torque : 28 ± 2.9 kgf·m {203 ± 21 lbf·ft}
(2) (3) (1)
(A)
i . Return the o-ring to the normal position.
FIGURE 4.119
4 — 48
2. Reversing Backhoe Bucket
a. Move the machine to a firm, level surface and rest
the bucket on the ground, making certain the bucket
is stable. See Figure 4.120.
FIGURE 4.120
b. Roll “O”-rings onto bucket boss. See Figure 4.121.

FLEXIBLE RING
AND PINS
c. Remove flexible ring and pin, and also remove

bucket pin and link pin. See Figure 4.122. ROLL "O"-RINGS ONTO
BUCKET BOSS
d. Clean pins and pin hole, and apply grease on it.
FIGURE 4.121
e. Carefully remove main pins mounting arm and
bucket link to bucket
f . Rotate bucket 180° or move machine, install arm

and bucket link in their respective positions. See
Figure 4.123.
NOTE FLEXIBLE RING

Make certain “O”-rings are on bucket boss for reinstalla- AND PIN
tion.
FIGURE 4.122
g. Roll “O”-rings into grooves between bucket/arm and

bucket/bucket link. BUCKET LINK HERE
h. Align each pin holes, insert bucket pin, and fit flex-
ible ring and pin.
NOTE ARM HERE

Inspect “O”-rings for damage or excessive wear. If worn
or damaged replace with new parts to protect seals, pins
and surfaces from dirt and debris which can cause pre-
mature failure.
“O”-ring part number (4 Required) 2445Z1136.
FIGURE 4.123
4 — 49
3. Removing the Bucket
a. Move the machine to a firm level surface and place
the bucket on the ground, making certain that the
bucket is stable. See Figure 4.124.
FIGURE 4.124
b. Roll “O”-rings onto the bucket bosses. See Figure

4.125. FLEXIBLE RING
AND PINS
c. Remove flexible ring and pins. See Figure 4.125.
ROLL "O"-RINGS ONTO

BUCKET BOSS
FIGURE 4.125
d. Carefully remove main pins mounting arm and

SLIDE OUT PINS
bucket link to bucket. You may have to start the
engine and slightly operate the boom and arm to
remove load from pins. See Figure 4.126. Be care-
ful not to damage dust seals.
4. Installing the Bucket FIGURE 4.126

a. Make certain that the bucket is stable on firm level
ground. INSTALL BUCKET
LINK FIRST
b. Install “O”-rings onto the bucket bosses.
c. Clean pins and pin holes, and apply grease on pin

and holes surfaces.
d. Move the bucket cylinder to match the bucket pin

holes with the bucket link hole. Insert pin. Be care-
ful not to damage seals. See Figure 4.127.
FIGURE 4.127
4 — 50
e. Operate the boom and arm (1) to match the bucket
(1)
(2) pin holes with the arm hole connection. Insert
pin (3) carefully to avoid damaging the seals. See
Figure 4.128.
(3)
(2) (2)
FIGURE 4.128
f . Install flexible ring and pins. See Figure 4.129.

FLEXIBLE RING
g. Roll “O”-rings onto the grooves between bucket/ AND PINS
arm, and bucket/bucket link. See Figure 4.129.
h. Apply sufficient grease to the bucket pin connec-

tions.
ROLL "O"-RINGS ONTO

BUCKET BOSS
FIGURE 4.129
4 — 51
5. Bucket Teeth and Side Cutters
Frequently, check bucket tooth points and side cut-
ters for wear and looseness. The life of the bucket WEAR GOGGLES, SAFETY SHOES, HARD HAT,
teeth and side cutters can not be determined by WORK CLOTHES AND WORK GLOVES TO PER-
working hours, but rather by application and operat- FORM INSPECTION AND MAINTENANCE ON THIS
ing conditions. MACHINE.
a. Parts description, see Figure 4.130:
(1) adapter nose, (2) tooth point, (3) rubber lock
pin, (4) locking pin, (5) side cutter, (6) capscrew,
(7) nut.
(6)
NOTE (1)
(5)
Contact your KOBELCO dealer for assistance in regards (7)
to parts for the specific bucket installed on your machine. (4)
(3)
(2)
b. Replace the bucket teeth when their cutting edge
and/or when hole for retaining pin on tooth are ex- FIGURE 4.130
cessively worn.
b.1 Place a wood block under the bucket teeth
support lip, as indicated in Figure 4.131, and DO NOT STRIKE TEETH WITH
HAMMER. THIS CAN CAUSE
remove all sand and soil adhered to the teeth CHIPS TO FLY CAUSING IN-
pin connection areas. JURY.
b.2 Use a hammer and a punching tool to hammer

out the locking pin. Be careful not to damage
the rubber lock.
b.3 Inspect the lock pin (4) and rubber lock (3). BLOCK
Replace them if the lock pin (4) is too short or
the rubber lock (3) is in poor condition.
FIGURE 4.131
b.4 Clean the surface of the adapter nose (1) with
putty knife.
b.5 Fit the tooth point (2) onto the adapter nose
(1).
b.6 Push the rubber lock pin (3) into the hole of the
adapter nose (1).
b.7 Hammer the locking pin (4) until it is aligned
with the point surface. CUT BOLT HEADS
c. Replacing the side cutters

c.1 Remove all sand and soil adhered around the FIGURE 4.132
side cutters capscrews.
c.2 Use a torch and cut off the capscrews, then
remove the side cutters. See Figure 4.132.
c.3 Clean the mounting surface and install a new
side cutter with new capscrews and nuts. See
Figure 4.133.
c.4 Torque the capscrew with nuts to 100 ± 5 kgf·m
(722 ± 36 lbf·ft).
c.5 Spot weld the nuts. FIGURE 4.133
4 — 52
6. Dust Seals
ATTACHMENT LUBRICATION POSITION
a. The attachment incorporates several dust seals
that should be periodically checked for damage and (8) (7)
excessive wear. See Figure 4.134. (1)
b. If excessive wear or damage is found remove seal (8) (2)
and replace with new parts.
(5) (5) (6)
NOTE
Order the following part numbers for replacement seals: (9) (3) (9)
1. Boom Foot ........................ 244TR220D6 (2 Req’d) (4)
2. Arm to Boom .................... 2445R220D6 (2 Req’d) FIGURE 4.134
3. Arm to Idler Link .............. 2445R220D3 (2 Req’d)
4. Bucket Cylinder to
Bucket Link ....................... 2445R220D4 (4 Req’d) LIP OUT
5. Arm to Bucket .................. 2445R220D4 (4 Req’d)
6. Boom Cylinder Head ........ 2445R138D8 (2 Req’d)
7. Boom Cylinder Rod ......... 2438U941S3 (2 Req’d) BOSS
8. Arm Cylinder Head
and Rod ............................. 2438U1106S26 (4 Req’d)
9. Bucket Cylinder Head
and Rod ................................. 2438U1109S28 (4 Req’d)
c. Install replacement seals as shown in Figure 4.135.
d. Make certain pin surface and tapered end are

smooth and free from all burrs or imperfections.
Rough pin surfaces can cause damage to the new
seals.
BUSHING
SEAL
FIGURE 4.135
I . WINDSHIELD WASHER RESERVOIR

OPEN ENGINE AIR CLEANER ACCESS DOOR
Fill the windshield washer fluid reservoir as required
using approved windshield washing fluid. WINDSHIELD WASHER
RESERVOIR CAP
1. Open engine air cleaner access door to locate
washer fluid reservoir. See Figure 4.136.
2. Pull cap off and fill with proper windshield washing

fluid.
3. Replace cap and reposition engine air cleaner ac-

cess door.
FIGURE 4.136
4 — 53
J . CHANGE GREASE IN SLEWING RING GREASE BATH
1. Drain water by removing drain plate located in lower

frame cavity. See Figure 4.137.
If the slewing ring ever becomes submerged in water,

it is mandatory that the sump bath grease be changed.
SUMP BATH
DRAIN PLATE
FIGURE 4.137
2. To replace the slewing bath grease it is necessary to re-

CLEAN & FILL
move the upper frame. Contact KOBELCO destributor to WITH MoS2 GREASE
do it. See Figure 4.138.
SUMP BATH GREASE QUANTITIES CHART

SK200-6E
GREASE TYPE
SK200LC-6E
8.3 kg
N.L.G.I.LITHIUM BASE W/MoS2
(18.3 lb)
FIGURE 4.138
4 — 54
4.12 MISCELLANEOUS
A. FUSES
Follow the procedures below to replace “blown” or faulty
fuses.
1. Move seat and seat base completely forward.
2. Remove fuse box cover from fuse box. See Figure

4.139.
3. Locate and remove faulty fuse. Replace fuse with

FUSE BOX
same amperage fuse as removed.
FIGURE 4.139
NEVER REPLACE A FAULTY FUSE WITH A HIGHER 1 2 3 4 5 6 7 8 9 10

AMP FUSE. NEVER USE A “JUMPER” IN PLACE
OF A FUSE. NEVER SPLICE ACCESSORIES DI-
RECTLY INTO FUSE TERMINALS.
4. Refer to fuse box cover or Figure 4.140 for fuse am-

perage and their functions.
NOTE
When ordering replacement fuses, order the following part 11 12 13 14 15 16 17 18 19 20
numbers: No. AMPS FUNCTION
10 AMP – Part number 2479R655S8 1 20A Mechatro Controller (CPU)
20 AMP – Part number 2479R655S9 2 10A Wiper, Washer Relay
3 10A Cigarette Lighter 24V
4 10A DC-DC Converter
5 10A Horn
6 NONE None
7 10A Mechatro Controller (Back up)
8 20A Fuel Supply Pump
9 10A Dome Lamp, Converter (Back up)
10 20A Starter Switch
11 10A Auto Grease
12 20A Swing Flasher
13 10A Gauge Cluster
14 20A Wiper, Washer
15 10A Solenoid Valve (Lever Lock)
16 20A Working Light (Front)
17 20A Working Light (CAB)
18 20A Air Conditioner
19 10A Controller (A/C)
20 20A Spare 24V
FIGURE 4.140
4 — 55
B. PERIODICAL INSPECTION ITEMS
Since there is no definite time table for the replace- HEATER HOSE
ment of hydraulic lines, tubes and hoses, inspect the
following periodically for tightness and signs of dam-
age. Replace all damaged lines, tubes and hoses with
new parts. Refer to the parts manual for correct part
numbers when ordering.
DO NOT BEND, STRIKE OR DAMAGE HIGH PRESSURE

LINES.
DO NOT INSTALL BENT OR DAMAGED LINES, TUBES
OR HOSES. FIGURE 4.141
REPLACE ALL DAMAGED LINES, TUBES AND HOSES
IMMEDIATELY.
TIGHTEN ALL LOOSE FITTINGS AND CONNECTIONS
TO THE PROPER TORQUE VALUE.
CLEAN UP ALL FUEL AND OIL SPILLS IMMEDIATELY
TO HELP PREVENT FIRES.
NEVER USE HANDS TO CHECK FOR LEAKS CARE-
FULLY INSPECT ALL LINES, TUBES AND HOSES FOR:
1. FITTINGS & CONNECTIONS DAMAGED OR LEAK-
ING.
BOOM HOSES
2. OUTER COVERING OF HOSES WORN, CUT OR
DAMAGED EXPOSING WIRE REINFORCEMENT.
3. HOSE SWELLING OR “BALLOONING”.
4. EVIDENCE OF HOSE BEING KINKED OR COL-
FIGURE 4.142
LAPSED.
5. STEEL PROTECTIVE COVERING WORN OR DAM-
AGED.
ARM HOSES
6. LOOSE FITTINGS AND CONNECTIONS.
MAKE CERTAIN ALL CLAMPS, GUARDS AND HEAT
SHIELDS ARE IN PLACE AND SECURE. THIS WILL
HELP PREVENT VIBRATION, EXCESSIVE WEAR OF
COMPONENTS AND EXCESSIVE HEAT DURING OP-
ERATION.
1. Heater Hoses
Inspect the heater hoses between heater and en-
gine for signs of damage and wear. See Figure 4.141.
2. Boom Hoses & Tubes FIGURE 4.143

Inspect boom head and rod hoses and tubes for dam-
age, wear and loose connections. See Figure 4.142.
3. Arm Hoses & Tubes

Inspect arm head and rod hoses and tubes for dam-
age, wear and loose connections. See Figure 4.143.
4. Bucket Hoses & Tubes

BUCKET HOSES
Inspect bucket head and rod hoses and tubes for AND LINES
damage, wear and loose connections. See Figure
4.144.
5. Fuel Lines and Hoses

Inspect fuel lines and hoses for damage, wear and
loose connections. Repair or replace fuel lines and
hoses before operating the machine. FIGURE 4.144
4 — 56
6. Hydraulic Suction Tubes & Hoses
USE CARDBOARD TO CHECK
Inspect all hydraulic tubes and hoses for damage, FOR PRESSURE LEAKS
wear and loose connections. See Figure 4.145.
FIGURE 4.145
7. Radiator Hoses & Cap

Inspect the radiator hoses for signs of damage or
deterioration. Replace hoses if found to be in bad
condition. Inspect the radiator cap seal for signs of
damage and deterioration and replace with new part
if found to be in bad condition. See Figure 4.146.
RADIATOR HOSES
AND LINES
FIGURE 4.146
8. Foam Seals
Inspect the foam rubber seals around the radiator,
oil cooler and on the engine cover. Make certain they
are in place and secure to prevent overheating of
the engine. See Figure 4.147.
FOAM SEALS
FIGURE 4.147
9. Fuel Filler Strainer

Inspect the fuel filler strainer beneath fuel filler cap
FUEL FILLER
for damage, dirt and debris. Make certain the strainer STRAINER
is clean and in place before fueling the machine. See
Figure 4.148. If the strainer is damaged, replace with
a new part. Order part number YN50V00017P1.
FIGURE 4.148
4 — 57
10. Fuel Lines and Hoses
Inspect fuel lines and hoses for damage, wear and
loose connections. Repair or replace fuel lines and
hoses before operating the machine.
See Figure 4.149.
CHECK FUEL LINES
FIGURE 4.149
11. Rear View Mirrors

Inspect the rear view mirrors. Make certain both sides
rear view mirrors are in place, properly adjusted,
clean, and in good condition. Secure them tight to
prevent them from breaking. See Figure 4.150.
MAKE SURE REAR VIEW MIRRORS ARE

CLEAN AND IN GOOD CONDITION
FIGURE 4.150
4 — 58
C. MACHINE STORAGE 3. Completely fill fuel tank with fresh, clean fuel to aid
Perform the following procedure to prepare the main preventing condensation of moisture inside the fuel
chine for long term storage. tank.
1. Perform all inspection and maintenance procedures 4. Move machine to an indoor location for storage.
as previously described in this section.
5. Operate bucket and arm completely “IN” extending
2. Thoroughly clean the machine, inspect for damaged cylinders. Then lower boom until attachment is rest-
or worn parts and components and replace or repair ing on the floor. See Figure 4.151.
all damaged or worn parts.
6. Coat cylinder rods with a heavy coat of grease to
prevent corrosion during storage.
7. Remove batteries and store in a well ventilated, warm

Protect CPU and all electrical components from water area.
and steam when cleaning the machine.
POSITION MACHINE AS SHOWN INSIDE A STORAGE BUILDING
HEAVILY GREASE ALL CYLINDER

RODS TO PREVENT CORROSION
FIGURE 4.151
D. CARE DURING STORAGE E. REMOVING MACHINE FROM STORAGE

Every 30 days during storage, it will be necessary to
start and run the machine to circulate the fluids through 1. Perform all Inspection and maintenance procedures
the systems. Before starting clean cylinder rods and as described in this section before bringing machine
after running re-grease cylinder rods. out of storage for normal operation.
2. Remove drain plugs from travel motor and swing gear

NOTE reduction units to drain off any moisture which may
Run and operate machine for approximately 1 hour to al- have accumulated during storage.
low all fluids to circulate well and reach normal operating
temperatures. 3. Carefully and closely inspect all hydraulic hoses af-
ter long periods of storage for signs of deterioration.
Replace all hoses showing these signs.
4 — 59
INSPECTION MAINTENANCE CHECK LIST
MACHINE MODEL : SK SERIAL No. : MACHINE HOURS :
ITEM OK MAINT. PERFORMED ITEM OK MAINT. PERFORMED

ENGINE OIL LEVEL HYD. FUNCTION OPERATION
ENGINE COOLANT LEVEL CHECK SWITCHES
CHECK FOR FLUID LEAKS CHECK TRAVEL ALARM
CHECK BELT TENSION CHECK SWING BRAKE
CHECK FUEL LEVEL CHECK WARNING LIGHTS
DRAIN WATER SEPARATOR CHECK BUZZER
CHECK AIR CLEANER CHECK GAUGES
CHECK ENGINE ELECTRICAL CHECK HORN
DRAIN WATER FROM FUEL CHECK DISPLAY MONITOR
CLEAN RPE-FILTER BOWL SWING REDUCTION OIL
CHANGE ENGINE OIL SLEWING RING GEAR
CHANGE OIL FILTER GREASE BATH LEVEL
CHANGE FUEL FILTER SLEWING RING PINION
CHANGE WATER SEPARATOR SLEWING RING SEAL
CHANGE COOLANT FILTER SWIVEL JOINT SEALS
CHECK AIR INTAKE SYSTEM DRAIN WATER FROM BATH
CHECK FAN ASSEMBLY GREASE SLEWING RING
CHECK BELT TENSIONER CHANGE GREASE BATH
CHECK VIBRATION DAMPER CHECK BOLTS/HARDWARE
CLEAN RADIATOR CHECK FOR OIL LEAKS
CLEAN DEBRIS SCREEN CHECK LINES FOR DAMAGE
CHANGE ENGINE COOLANT CHECK STEPS
AIR CLEANER ELEMENTS CHECK FRAME STRUCTURE
ADJUST VALVE CLEARANCE CHECK TRACKS & LINKS
CHANGE ETHER CYLINDER CHECK SPROCKET WEAR
HYDRAULIC OIL LEVEL CHECK IDLER WEAR
CHECK HYD FUNCTIONS CHECK ROLLER WEAR
CHECK FOR OIL LEAKS CHECK TRACK TENSION
CHECK HOSES/LINES ADJUST TRACK TENSION
CLEAN SUCTION SCREEN TRAVEL REDUCTION OIL
CHANGE RETURN FILTER CHECK BOOM & ARM
PILOT MANIFOLD FILTER BUCKET TEETH
CHANGE HYDRAULIC OIL SIDE CUTTERS
CLEAN HYDRAULIC TANK GREASE BOOM PINS
INSPECT ALL WIRING GREASE ARM PINS
BATTERY ELECTROLYTE GREASE BUCKET PINS
BATTERY SERVICE CHECK COOLANT ADDITIVE
These item include non-equipped parts by the

machine specification.
MECHANIC:
SIGNATURE: DATE:
4 — 60
Section V – TRANSPORTATION
Table of Contents
GROUND TRANSPORTATION .................................................................................................................... 5-1 ~ 5-3
Machine Preparation .............................................................................................................................. 5-1
Loading the Machine ............................................................................................................................. 5-1
Securing Machine to Trailer .................................................................................................................. 5-3
LIFTING MACHINE ...................................................................................................................................... 5-4
LIFTING MACHINE WITHOUT ATTACHMENT ........................................................................................... 5-5
SHIPPING DIMENSIONS ............................................................................................................................. 5-6 ~ 5-8
Machine With Standard Attachments ................................................................................................... 5-6
Boom With Arm Cylinder – Figure 5.11 ................................................................................................ 5-7
Arm With Bucket Cylinder and Bucket – Figure 5.12 ......................................................................... 5-7
Arm With Bucket Cylinder – Figure 5.13 .............................................................................................. 5-7
Bucket - Figure 5.14 ............................................................................................................................... 5-8
5—0
5.1 GROUND TRANSPORTATION
3. Obtain any permits required from proper government
A. MACHINE PREPARATION agencies for transport of machine.
1. Know the total weight, length, width and height of 4. Use only a trailer with a rated capacity sufficient to
the machine being transported. See Figure 5.1. transport the machine.
2. Know route to be traveled. Investigate bridges, over- 5. Make certain trailer has ramps or a ramp is available
passes, trusses and traffic flow on route. for loading and unloading the machine.
9,440mm (31´-0˝) 2,290mm (7´-6˝)

{2,440mm (8´-0˝)}
3,070mm (10´-1˝)
(2´-4˝) 3,770mm (12´-4˝)
150mm (5.9˝)
80mm
700mm
(3.1˝)
{230mm (9.1˝)}
NOTE : { } indicate LC specifications.

Dimensions and weights are with 2.94 m (9´-8˝) arm,
0.80 m3 (1.05 cu yd) bucket and 5.65 m (18´-6˝) boom.
MACHINE WEIGHT
MODEL 600mm SHOE
SK200-6E 20,000 kg (44,090 lb)
SK200LC-6E 20,400 kg (44,970 lb)
FIGURE 5.1
5—1
B. LOADING THE MACHINE
TRAVEL SPEED
SELECT SWITCH THROTTLE CONTROL
NEVER ATTEMPT TO LOAD OR UNLOAD MACHINE
HI
LO
WITHOUT RAMPS.
NEVER USE ATTACHMENT AS AN AID IN LOAD-
ING OR UNLOADING THE MACHINE.
1. Apply parking brakes on tractor and trailer and chock

FIGURE 5.2
trailer wheels before attempting to load or unload
machine.
2. Lower ramps of trailer.
3. Place travel speed select switch in 1st ( ) speed
position and move throttle control to the “LO” idle
position. See Figure 5.2.
4. Slowly travel machine up trailer ramps and over rear
axles of trailer. See Figure 5.3.
15° or less
TO PREVENT THE ARM AND BUCKET CYLINDER

(S) FROM ANY DAMAGE, YOU ARE ADVISED TO
FOLLOW THE FOLLOWING INSTRUCTIONS.
DO NOT HAVE THE ARM AND/OR BUCKET CYLIN-
DER FULLY EXTENDED TO A "RAMP OVER CEN-
TER" SITUATION. THIS ALLOWS SUDDEN AND
ABRUPT CONTACT OF THE ARM OR BUCKET TO A
TRAILER DECK, RAMP OR THE GROUND.
THIS CAN RESULT IN INTERNAL MECHANICAL
CONTACT, WHICH CAN STRETCH THE CYLINDER
ROD(S).
FIGURE 5.3
5. Slowly travel machine completely onto trailer until in

proper transport position.
6. Slowly swing machine 180° until attachment is to- SAFETY LOCK
ward rear of trailer. LEVER IN
LOCKED
7. Slowly lower boom until attachment rests on trailer (UP) POSITION
bed.
8. Place safety lock lever in the up “LOCKED” position.
See Figure 5.4.
9. Turn machine “OFF”, remove key and lock all doors,
filler caps and access panels.
FIGURE 5.4
Place a cover over the exhaust pipe of the machine
and secure to avoid water entering the engine.
5—2
C. SECURING MACHINE TO TRAILER
SECURE
FRONT & REAR
1. Using cable or wire rope of sufficient capacity to se- OF EACH TRACK
cure front and rear of each track to trailer. See Fig-
ure 5.5. Chock the tracks, use the lower frame front
and rear brackets to secure machine to trailer. Also,
make sure to secure front and rear of each track.
2. Securely fasten all loose parts, as well as removed

parts to trailer or transporting platform.
3. Secure all loose components to trailer.
SECURE
ATTACHMENT
FIGURE 5.5
5—3
5.2 LIFTING MACHINE
The following procedures are for lifting the machine,
as built by KOBELCO CONSTRUCTION MACHIN-
ERY CO., LTD. These procedure do not take into ALWAYS USE PROPER LIFTING EQUIPMENT AND
account modifications made to the machine that af- DEVICES.
fect machine weight or center of gravity. USE OF IMPROPER LIFTING EQUIPMENT COULD
1. Locate lifting locations at the front and rear of each ALLOW THE LOAD TO SHIFT OR FALL CAUSING
crawler frame. See Figure 5.6 to 5.7. SEVERE DAMAGE, SERIOUS INJURY OR DEATH.
2. Attach cables or wire rope with a capacity rating suf-
ficient to lift the machine, at lifting locations.
DO NOT USE COUNTERWEIGHT LIFTING EYES TO

Place a hardwood or steel block between cables and LIFT WHOLE MACHINE.
crawler frame to prevent damage to the tracks from LIFTING EYES CAN FALL UNDER THIS LOAD RE-
cables during lifting. See Figure 5.6 to 5.7. SULTING IN PERSONAL INJURY.
REFER TO OPERATOR’S MANUAL FOR PROPER
3. Bring loose ends of cables together at machine cen- WAY OF LIFTING MACHINE.
ter of gravity and attach to an overhead lifting device
with a rated lifting capacity sufficient to lift the ma-
chine. See Figure 5.6 to 5.7.
TOOLS
NOTE
It may be necessary to place reinforced spreader bars ITEM SIZE Q'TY
between lifting cables to prevent damage to the machine CABLE (A) Ø 33.5 X 15.0 m 1
during lifting. See Figure 5.6 to 5.7. CABLE (B) Ø 33.5 X 14.9 m 1
SPREADER BARS (C) 4.0 m 2
4. Slowly lift and move machine to desired location.
WEIGHT : 20,000 kg (44,090 lb) (A) (B)

ARM : 2.94 m (9´-8˝) (C)
2,000mm
SHOE : 600 mm (23.6˝)

(6´-7˝)
(1 (45 ° °)
MODEL : SK200-6E 2 °) °) ) (45
(11 4,000mm
CENTER OF GRAVITY (13´-1˝)
3,400mm (11´-2˝)
670mm 75mm 645mm

(26.4˝) (3˝) PLACE BLOCK (25.4˝)
BETWEEN EACH NOTE :
CABLE AND FRAME Lifting machine with wider track shoes
will tend to shift the center of gravity
DO NOT USE THE COUNTERWEIGHT slightly forward, toward the center of
LIFTING EYES TO LIFT MACHINE. the slewing ring.
FIGURE 5.6
5—4
TOOLS
ITEM SIZE Q'TY
CABLE (A) Ø 33.5 X 15.2 m 1
CABLE (B) Ø 33.5 X 15.1 m 1
WEIGHT : 20,400 kg (44,970 lb) (A) (B)

ARM : 2.94 m (9´-8˝) (C)
2,000mm
SHOE : 600 mm (23.6˝)
(6´-7˝)
(45 ° °
MODEL : SK200LC-6E
(13
° °) ) (45 )
) (12 4,000mm
CENTER OF GRAVITY (13´-1˝)
3,400mm (11´-2˝)
695mm 75mm 635mm
(27.4˝) (3˝) PLACE BLOCK (25˝)
BETWEEN EACH NOTE :
CABLE AND FRAME Lifting machine with wider track shoes
will tend to shift the center of gravity
FIGURE 5.7
5.3 LIFTING MACHINE (WITHOUT ATTACHMENT) TOOLS

Lift up machine without attachment is the procedure ITEM SIZE Q'TY
described below. See Figure 5.8 to 5.9. CABLE (A) Ø 33.5 X 15.4 m 1
CABLE (B) Ø 33.5 X 14.7 m 1
WEIGHT : 16,300 kg (35,930 lb) (A) (B)

SHOE : 600 mm (23.6˝) (C)
2,000mm
(6´-7˝)
MODEL : SK200-6E (45 ° °

) (45 )
(1
9 °) 4,000mm
CENTER OF GRAVITY °
(3 ) (13´-1˝)
3,400mm (11´-2˝)
670mm 765mm 645mm

(26.4˝) (30.1˝) (25.4˝)
NOTE :
Lifting machine with wider track shoes
PLACE BLOCK will tend to shift the center of gravity
DO NOT USE THE COUNTERWEIGHT BETWEEN EACH slightly forward, toward the center of
LIFTING EYES TO LIFT MACHINE. CABLE AND FRAME the slewing ring.
FIGURE 5.8
5—5
TOOLS
ITEM SIZE Q'TY
CABLE (A) Ø 33.5 X 15.6 m 1
CABLE (B) Ø 33.5 X 14.9 m 1
WEIGHT : 16,800 kg (37,040 lb) (A) (B)

SHOE : 600 mm (23.6˝) (C)
2,000mm
(6´-7˝)
MODEL : SK200LC-6E (45 ° °
) (45 )
CENTER OF GRAVITY (2
0° 4,000mm
) °
(5 ) (13´-1˝)
3,400mm (11´-2˝)
695mm 750mm 635mm
(27.4˝) (29.5˝) (25˝)
NOTE :
PLACE BLOCK Lifting machine with wider track shoes
BETWEEN EACH will tend to shift the center of gravity
CABLE AND FRAME
FIGURE 5.9
5.4 SHIPPING DIMENSIONS

A. SK200-6E AND SK200LC-6E These dimensions consider the following:
a. Machine With Standard Attachments a.1. Standard boom .... 5.65 m (18´-6˝)
Refer to Figure 5.10 for reference in regards to the a.2. Standard arm ....... 2.94 m (9´-8˝)
machine basic dimensions, as manufactured by a.3. Bucket .................. 0.80 m3 (1.05 cu yd)
KOBELCO, with standard attachments:
a.4. Standard shoe ..... 600 mm (23.6˝)
* Marked dimensions do not include height of shoe lug.
9,410mm (30´-10˝)
2,730mm (8´-11˝)
*1,060mm (3´-6˝)
2,930mm (9´-7˝)
2,910mm (9´-7˝)
*450mm (17.7˝)
4,170mm (13´-8˝) 600mm (23.6˝)

4,450mm (14´-7˝)-LC
4,820mm (15´-10˝) 2,800mm (9´-2˝)
4,960mm (16´-3˝)-LC 2,990mm (9´-10˝)-LC
FIGURE 5.10
5—6
B. BOOM WITH ARM CYLINDER – FIGURE 5.11
Boom mm (ft-in) 5,650 (18´-6˝)
5,850 X 1,570 X 770

L X H XW mm (ft-in)
(19´-2˝ X 5´-2˝ X 2´-6˝)
Weight w/
kg (lb) 1,620 (3,570)
Arm Cylinder
H
L
FIGURE 5.11
C. ARM WITH BUCKET CYLINDER AND BUCKET – FIGURE 5.12
Arm 2.4 m (7´-10˝) Arm 2.94 m (9´-8˝) Arm 3.5 m (11´-6˝)

Combination
Bucket 0.93 m3 (1.22 cu yd) Bucket 0.80 m3 (1.05 cu yd) Bucket 0.70 m3 (0.92 cu yd)
4,720 X 895 X 1,330 5,250 X 895 X 1,160 5,800 X 895 X 1,080
L X H XW mm (ft-in)
(15´-6˝ X 2´-11˝ X 4´-4˝) (17´-3˝ X 2´-11˝ X 3´-10˝) (19´-0˝ X 2´-11˝ X 3´-7˝)
Weight w/
kg (lb) 1,570 (3,460) 1,650 (3,640) 1,760 (3,880)
Bucket Cylinder
H
FIGURE 5.12
D. ARM WITH BUCKET CYLINDER – FIGURE 5.13
Arm 2.4 m (7´-10˝) 2.94 m (9´-8˝) 3.5 m (11´-6˝)

3,360 X 800 X 540 3,900 X 800 X 540 4,500 X 800 X 540
L X H XW mm (ft-in)
(11´-0˝ X 2´-7˝ X 1´-9˝) (12´-10˝ X 2´-7˝ X 1´-9˝) (14´-9˝ X 2´-7˝ X 1´-9˝)
Weight w/
kg (lb) 910 (2,010) 990 (2,180) 1,120 (2,470)
Bucket Cylinder
H
FIGURE 5.13
5—7
E . BUCKET – FIGURE 5.14
Standard bucket is 0.80 m3 (1.05 cu yd)
(A) Length is 1,370 mm (4´-6˝)
(B)
(B) Height is 1,260 mm (4´-2˝)
(C) Width without side cutters is 1,050 mm (3´-5˝)
(D) Width with side cutter is 1,160 mm (3´-10˝)
(E) Bucket weight is 650 kg (1,430 lb)
(A)
(C)
(D)
FIGURE 5.14
5—8
Section VI – SPECIFICATIONS
Table of Contents
GENERAL SPECIFICATIONS ...................................................................................................................... 6-1 ~ 6-4
Machine Dimensions ............................................................................................................................. 6-1
Working Ranges ..................................................................................................................................... 6-1
Boom ....................................................................................................................................................... 6-2
Arm .......................................................................................................................................................... 6-2
Bucket ..................................................................................................................................................... 6-2
Shoes ...................................................................................................................................................... 6-2
Performance Specifications .................................................................................................................. 6-3
Travel speed ...................................................................................................................................... 6-3
Swing speed ...................................................................................................................................... 6-3
Gradeability ....................................................................................................................................... 6-3
Engine ................................................................................................................................................ 6-3
Hydraulic Components ..................................................................................................................... 6-3
Machine and Components Weights ..................................................................................................... 6-3
Lifting Capacities ................................................................................................................................... 6-4
OPTIONAL ATTACHMENTS SPECIFICATIONS ......................................................................................... 6-5
Working Ranges ..................................................................................................................................... 6-5
Bucket and Arm Combinations ............................................................................................................. 6-6
TORQUE SPECIFICATIONS ........................................................................................................................ 6-7
Capscrews and Nuts .............................................................................................................................. 6-7
Nuts and Sleeves ................................................................................................................................... 6-7
Flare Type Fitting Joints ........................................................................................................................ 6-7
Nylon Tube Fitting Joints ...................................................................................................................... 6-7
ORS Joints .............................................................................................................................................. 6-7
Torque Values for Most Common Bolts ............................................................................................... 6-8
MISCELLANEOUS INFORMATION ............................................................................................................. 6-9
Temperature Table ................................................................................................................................. 6-9
Special Pipe Wrenches .......................................................................................................................... 6-9
Weight of Materials Table ...................................................................................................................... 6-9
Caps and Plugs for Tubes and Hose Fitting ........................................................................................ 6-9

6—0
6.1 GENERAL SPECIFICATIONS A. MACHINE DIMENSIONS – FIGURE 6.1
The specifications found in this section are given on These dimensions consider the following:
the standard SK200-6E and SK200LC-6E hydraulic a. Standard boom ........ 5.65 meter (18´-6˝)
excavator as manufactured by KOBELCO CON-
STRUCTION MACHINERY CO., LTD. No modifica- b. Standard arm ........... 2.94 meter (9´-8˝)
tions or options are taken into consideration in re- c. Bucket ...................... 0.80 m3 (1.05 cu yd)
gard to these specifications. d. Standard shoe .......... 600 mm (23.6˝)
* Marked dimensions do not include height of shoe lug.
9,410mm (30´-10˝)
2,730mm (8´-11˝)
*1,060mm (3´-6˝)
2,930mm (9´-7˝)
2,910mm (9´-7˝)
*450mm (17.7˝)
4,170mm (13´-8˝) 600mm (23.6˝)
4,450mm (14´-7˝)-LC
4,820mm (15´-10˝) 2,800mm (9´-2˝)
4,960mm (16´-3˝)-LC 2,990mm (9´-10˝)-LC
FIGURE 6.1
B. WORKING RANGES – FIGURE 6.2 A

Standard attachment working ranges : B
a. BOOM ............................. 5.65 m (18´-6˝) H
b. ARM ................................ 2.94 m (9´-8˝)

c. BUCKET
SAE heaped .................... 0.80 m3 (1.05 cu yd)
Struck .............................. 0.59 m3 (0.77 cu yd)
Width with side cutters .... 1,160 mm (3´-10˝)
D
E
Width w/o side cutters ..... 1,050 mm (3´-5˝)

Weight ............................. 650 kg (1,430 lb)
ITEM FUNCTION mm SAE

F
A Maximum digging reach 9,900 32´- 6˝

B Maximum digging reach at ground 9,750 32´- 0˝
C Maximum digging depth 6,700 22´- 0˝
D Maximum digging height 9,600 31´- 6˝
E Maximum dumping clearance 6,790 22´- 3˝
F Minimum dumping clearance 2,330 7´- 8˝
G
C
G Max. vertical wall digging depth 6,040 19´- 10˝

H Minimum swing radius 3,560 11´- 8˝
FIGURE 6.2
6—1
C. BOOM – FIGURE 6.3
Standard boom is 5.65 m (18´-6˝)
C
A: Length is 5.65 m (18´-6˝)
Center line to center line of pins.
ARM CYLINDER
B: Height is 1,182 mm (3´-11˝) BOSS
From center line of boom end to center line of arm
cylinder boss.
B
C: Width is 674 mm (26.5˝) GROUND LEVEL
From edge to edge of boom foot.

A
Weight : Approximately 1,240 kg (2,730 lb)
FIGURE 6.3
D. ARM – FIGURE 6.4

Standard arm is 2.94 m (9´-8˝)
A: Length is 2.94 m (9´-8˝)
B
Center line to center line of pins.
B: Width is 325 mm (12.8˝)
From edge to edge of arm end.
Weight : Approximately 610 kg (1,340 lb)
FIGURE 6.4
E . BUCKET – FIGURE 6.5

Standard bucket is 0.80 m3 (1.05 cu yd)
A: Length is 1.37 m (4´-6˝)
B
B: Height is 1.26 m (4´-2˝)

C: Width without side cutters is 1,050 mm (3´-5˝)
D: Width with side cutters is 1,160 mm (3´-10˝)
E: Bucket weight is 650 kg (1,430 lb)
A
C
D
FIGURE 6.5
F . SHOES – FIGURE 6.6
1. Standard shoes for the SK200LC-6E and SK200LC-6E

are 600 mm (23.6˝) triple grouser.
2. Quantity of shoes ;
SK200-6E .............. 46 per track
TRIPLE
SK200LC-6E ......... 49 per track GROUSER
SHOE
FIGURE 6.6
6—2
G. PERFORMANCE SPECIFICATIONS H. MACHINE AND COMPONENT WEIGHTS
The following performance specifications are based on The following weight specifications are based on the
the standard machine with standard attachment. standard machine with standard attachment.
1. Travel speed, swing speed & gradeability 1. Component weights Unit : kg (lb)
DESCRIPTION SPECIFICATION COMPONENT SK200-6E SK200LC-6E
6.0 km per hr (3.7 mph) in mode. COMPLETE MACHINE (STANDARD) 20,000 (44,100) 20,400 (44,970)
TRAVEL SPEED
4.0 km per hr (2.5 mph) in mode. UPPER FRAME ASSEMBLY 9,900 (21,800) 9,900 (21,800)
SWING SPEED 11 RPM IN M-Mode / "HI" idle. Counterweight 4,620 (10,190) 4,620 (10,190)
GRADEABILITY 70 % (35°) Cab 260 (570) 260 (570)
Boom Cylinder* 177 (390) X 2 177 (390) X 2
Engine* 480 (1,060) 480 (1,060)
Radiator & Oil Cooler 70 (154) 70 (154)
2. Engine
Major engine specifications Pump Assembly 127 (280) 127 (280)
Control valve 165 (360) 165 (360)
Engine maker Mitsubishi
Fuel Tank* 93 (205) 93 (205)
Model 6D34-TLE2A
Hydraulic Tank* 156 (340) 156 (340)
4-cycle, water cooled, direct injection
Type Swing Motor & Reduction Unit 235 (520) 235 (520)
with intercooler turbocharger, diesel
Number of cylinders-Bore X Stroke 6-104 mm X 115 mm (4.09˝ X 4.53˝) LOWER FRAME ASSEMBLY 6,800 (15,000) 7,200 (15,900)
Displacement 5,861 liter (358 cu in.) Slewing ring 245 (540) 245 (540)
Compression ratio 18.2 Travel Motor & Reductin Unit 250 (550) X 2 250 (550) X 2
Output rating 110 kW / 2,000 min-1 Idler Assembly 106 (230) X 2 106 (230) X 2
Maximum torque 580 N •m / 1,500 min-1 Lower Roller Assembly 35 (77) X 14 35 (77) X 16
Ignition order 1 - 5 - 3 - 6 - 2 - 4 clockwise rotation Upper Roller Assembly 22 (48) X 4 22 (48) X 4
Injection timing 14° Before Top Dead Point Track Tension Assembly 101 (220) X 2 101 (220) X 2
Intake valve clearance cold 0.4 mm (0.0157˝) Sprocket 54 (120) X 2 54 (120) X 2
Exhaust valve clearance cold 0.4 mm (0. 0157˝) Swivel Joint 30 (66) 30 (66)
Electrical system D.C. 24V Track Link w/600mm (23.6˝) Shoes 1,260 (2,780) X 2 1,350 (2,980) X 2
Starting motor 24 V – 5.0 kW Track Link 510 (1,120) X 2 540 (1,190) X 2
24 V – 35 A ATTACHMENT (STANDARD) 3,300 (7,280) 3,300 (7,280)
Applicable No. YN10-38001~41290
YQ10-05501~05896 Bucket Assembly [0.80m3 (1.05cu yd)] 650 (1,430) 650 (1,430)
Alternator
24 V – 50 A Arm Assembly [2.94m (9´-8˝)] 990 (2,180) 990 (2,180)
Applicable No. YN10-41291~41732
YQ10-05897~05981 Arm [2.94m (9´-8˝)] 610 (1,340) 610 (1,340)
Batteries 2 - 12 V Bucket cylinder* 148 (326) 148 (326)
Engine dry weight* 480 kg (1,060 lb) Idler link 21 (46) X 2 21 (46) X 2
Wax type thermostat Bucket link 90 (198) 90 (190)
Thermostat
(bottom by-pass type) Pin (2pcs for mtg bucket cyl. & bucket) 65 (140) 65 (140)
Ø600 (Ø24˝) suction type, Boom Assembly 1,620 (3,570) 1,620 (3,570)
Cooling fan drive method
belt drive, pulley ratio : 1.00
Boom 1,330 (2,930) 1,330 (2,930)
Air cleaner Dry type with safety elements
Arm cylinder* 250 (550) 250 (550)
*Less flywheel and electrics.
Pin (mounting the arm) 27 (59) 27 (59)
FLUIDS 535 (1,180) 535 (1,180)
Hyd Oil 215 (470) 215 (470)
3. Hydraulic components
Eng Oil 20 (44) 20 (44)
COMPONENT TYPE Fuel 280 (620) 280 (620)
Tandem, variable displacement, Water 20 (44) 20 (44)
Hydraulic Pumps
axial piston with pilot gear pump. *Dry weight
Swing Motor Axial piston
Travel Motor Axial piston
Control Valves 6 spool multiple control
Cylinders (all) Double acting USE ONLY LIFTING DEVICES AND EQUIPMENT WITH
Return Filter Safety valve containing filter type RATED CAPACITIES SUFFICIENT TO LIFT THE SPECIFIC
Oil Cooler Air cooled COMPONENT(S) BEING REMOVED OR INSTALLED.
6—3
I . LIFTING CAPACITIES
1. Conditions of Calculation
a. The lifting load shows the lower value either 87% of hydraulic lifting capacity or 75% of tipping load.
b. The load point is on the bucket supporting point, and the bucket position is a closed position.
c. The values in the upper rows show the lifting capacity of a machine facing sideways, and values in the lower rows
show a mchine facing longitudinally.
d. Unit : ton, Crawler : 600 mm (23.6 in), iron : crawler
e. Set hydraulic pressure : 350 kg/cm2 (4,980 psi)
Unit : ton
11M
10
9
3.3
3.3
4.0
4.6 7
2.9 4.0
4.0 4.7 6
2.9 3.9
4.7 5.0 5
2.2 2.9 3.8 5.2 7.3

3.6 4.6 5.5 6.1 7.3 4
2.1 2.8 3.6 4.9 7.0 9.1

3.5 4.5 5.9 7.1 9.0 9.1 3
2.1 2.7 3.5 4.7 6.6

3.5 4.4 5.7 7.7 10.5 2
1.9
3.0
2.1 2.6 3.4 4.5 6.3
3.5 4.3 5.6 7.5 11.0 1
2.0 2.5 3.3 4.3 6.1 4.6

3.4 4.2 5.4 7.3 10.8 4.6
0
2.5 3.2 4.3 6.1 7.2 4.2
4.2 5.4 7.3 10.7 7.2 4.2 1
2.5 3.2 4.3 6.1 10.0 7.1

4.2 5.4 7.2 10.8 10.3 7.1 2
3.2 4.3 6.1 10.1 10.3

5.4 7.3 10.8 13.8 10.3 3
3.3 4.4 6.3 10.3 14.3

5.5 7.4 9.4 11.9 14.3 4
6.5 9.0
7.1 9.0 5
6.2
6.2
6
7M
12M 11 10 9 8 7 6 5 4 3 2 1
6—4
6.2 OPTIONAL ATTACHMENTS SPECIFICA- A
TIONS B
The following working ranges specifications are based H
on the standard machine with optional attachments.
A. WORKING RANGES – FIGURE 6.7

1. Attachment with :
a. BOOM ............................. 5.65 m (18´-6˝)
b. ARM ................................ 3.5 m (11´-6˝)
D
E
c. BUCKET
SAE heaped .................... 0.70 m3 (0.92 cu yd)
Struck .............................. 0.52 m3 (0.68 cu yd)
F
Width w/o side cutters ..... 980 mm (3´-3˝)
Weight ............................. 630 kg (1,390 lb)

B Maximum digging reach at ground 10,150 33´- 4˝ G
C

D Maximum digging height 9,520 31´- 3˝
FIGURE 6.7
2. Attachment with :
a. BOOM ............................. 5.65 m (18´-6˝)
b. ARM ................................ 2.4 m (7´-10˝)
c. BUCKET
SAE heaped .................... 0.93 m3 (1.22 cu yd)
Struck .............................. 0.67 m3 (0.88 cu yd)
Width w/o side cutters ..... 1,230 mm (4´-0˝)
Weight ............................. 710 kg (1,570 lb)

B Maximum digging reach at ground 9,250 30´- 4˝
D Maximum digging height 9,380 30´-9˝
6—5
B. BUCKET AND ARM COMBINATIONS
BUCKET m3 (cu yd) ARM

SAE (JIS) JIS, SAE 2.4 m 2.94 m 3.5 m
(HEAPED) (STRUCK) (7´-10˝) (9´-8˝) (11´-6˝) •••• Normal working
0.51 (0.67) 0.39 (0.51)
•••• Standard
• • • • Light duty only
0.70 (0.92) 0.52 (0.68)
• • • • Do not use this combination
0.80 (1.05) 0.59 (0.77)
0.93 (1.22) 0.67 (0.88)
6.3 TORQUE SPECIFICATIONS

The following torque specifications are provided for use when actual torque value of a fastener is not known.
A. CAPSCREWS AND NUTS

1. Metric coarse thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper
torque values.
Torque Value Unit : kgf·m (lbf·ft)
Classification 4.8 T 7T 10.9 T
NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION
M6 P=1 0.45 ± 0.05 (3.2 ± 0.4) 0.38 ± 0.04 (2.7 ± 0.3) 0.98 ± 0.1 (7.1 ± 0.7) 0.83 ± 0.08 (6.0 ± 0.6) 1.77 ± 0.18 (12.8 ± 1.3) 1.5 ± 0.15 (10.8 ± 1.1)
M8 P=1.25 1.09 ± 0.11 (7.9 ± 0.8) 0.92 ± 0.09 (6.6 ± 0.7) 2.4 ± 0.2 (17.3 ± 1.4) 2.0 ± 0.2 (14.4 ± 1.4) 4.3 ± 0.4 (31.0 ± 2.9) 3.6 ± 0.4 (26.0 ± 2.9)
M10 P=1.5 2.2 ± 0.2 (15.9 ± 1.4) 1.83 ± 0.18 (13.2 ± 1.3) 4.7 ± 0.5 (33.9 ± 3.6) 4.0 ± 0.4 (28.9 ± 2.9) 8.5 ± 0.9 (61.3 ± 6.5) 7.2 ± 0.7 (52.0 ± 5.1)
M12 P=1.75 3.7 ± 0.4 (26.7 ± 2.9) 3.2 ± 0.3 (23.1 ± 2.2) 8.1 ± 0.8 (58.5 ± 5.8) 6.8 ± 0.7 (49.1 ± 5.1) 14.6 ± 1.5 (105 ± 10.8) 12.3 ± 1.2 (88.8 ± 8.7)
M14 P=2 5.9 ± 0.6 (42.6 ± 4.3) 5.0 ± 0.5 (36.1 ± 3.6) 12.8 ± 1.3 (92.5 ± 9.4) 10.8 ± 1.1 (78.0 ± 7.9) 23 ± 2 (166 ± 14) 19.5 ± 1.9 (140 ± 14)
M16 P=2 9.0 ± 0.9 (64.9 ± 6.5) 7.6 ± 0.7 (54.8 ± 5.1) 19.5 ± 2.0 (140 ± 14.4) 16.4 ± 1.6 (118 ± 11.5) 35 ± 4 (252 ± 28.9) 29 ± 3 (209 ± 21.6)
M18 P=2.5 12.4 ± 1.2 (89.6 ± 8.7) 10.5 ± 1.0 (75.8 ± 7.2) 27 ± 3 (195 ± 22) 23 ± 2 (166 ± 14) 49 ± 5 (354 ± 36) 41 ± 4 (296 ± 29)
M20 P=2.5 17.5 ± 1.7 (126 ± 12.3) 14.7 ± 1.4 (106 ± 10.1) 38 ± 4 (274 ± 29) 32 ± 3 (231 ± 22) 68 ± 7 (491 ± 51) 57 ± 6 (412 ± 43)
M22 P=2.5 23 ± 2 (166 ± 14) 19.6 ± 2.0 (142 ± 14) 51 ± 5 (368 ± 36) 43 ± 4 (310 ± 29) 92 ± 9 (663 ± 65) 77 ± 7 (555 ± 58)
M24 P=3 30 ± 3 (217 ± 22) 24 ± 3 (173 ± 22) 65 ± 7 (469 ± 51) 53 ± 5 (383 ± 36) 118 ± 12 (852 ± 87) 96 ± 10 (693 ± 72)
M27 P=3 44 ± 4 (318 ± 29) 36 ± 3 (260 ± 22) 96 ± 10 (693 ± 72) 78 ± 8 (563 ± 58) 173 ± 17 (1250 ± 120) 140 ± 14 (1010 ± 100)
M30 P=3.5 60 ± 6 (433 ± 43) 50 ± 5 (361 ± 36) 131 ± 13 (946 ± 94) 110 ± 11 (794 ± 79) 235 ± 24 (1700 ± 170) 198 ± 20 (1430 ± 140)
M33 P=3.5 81 ± 8 (585 ± 58) 68 ± 7 (491 ± 51) 176 ± 18 (1270 ± 130) 148 ± 15 (1070 ± 110) 317 ± 32 (2290 ± 200) 266 ± 27 (1920 ± 200)
M36 P=4 105 ± 10 (758 ± 72) 88 ± 9 (636 ± 65) 227 ± 23 (1640 ± 170) 190 ± 19 (1370 ± 140) 409 ± 41 (2960 ± 300) 343 ± 34 (2480 ± 250)
2. Metric fine thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque
values.
Torque Value Unit : kgf·m (lbf·ft)
Classification 4.8 T 7T 10.9 T
NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION
M8 P=1.0 1.15 ± 0.11 (8.3 ± 0.8) 0.97 ± 0.1 (7.0 ± 0.7) 2.5 ± 0.2 (18.0 ± 1.4) 2.1 ± 0.2 (15.2 ± 1.4) 4.5 ± 0.4 (32.5 ± 2.9) 3.8 ± 0.4 (27.4 ± 2.9)
M10 P=1.25 2.3 ± 0.2 (16.6 ± 1.4) 1.91 ± 0.19 (13.8 ± 1.4) 4.9 ± 0.5 (35.4 ± 3.6) 4.2 ± 0.4 (30.3 ± 2.9) 8.9 ± 0.9 (64.2 ± 6.5) 7.5 ± 0.7 (54.2 ± 5.1)
M12 P=1.25 4.0 ± 0.4 (28.9 ± 2.9) 3.4 ± 0.3 (24.5 ± 2.2) 8.7 ± 0.9 (62.8 ± 6.5) 7.3 ± 0.7 (52.7 ± 5.1) 15.7 ± 1.6 (113 ± 13) 13.2 ± 1.3 (95.3 ± 9.4)
M16 P=1.5 9.4 ± 0.9 (67.9 ± 6.5) 7.9 ± 0.8 (57.0 ± 5.8) 20 ± 2 (144 ± 14) 17.2 ± 1.7 (124 ± 12) 37 ± 4 (267 ± 29) 31 ± 3 (224 ± 22)
M20 P=1.5 19 ± 9 (137 ± 14) 15.8 ± 1.6 (114 ± 14) 41 ± 4 (296 ± 29) 34 ± 3 (246 ± 22) 74 ± 7 (535 ± 51) 62 ± 6 (448 ± 43)
M24 P=2 32 ± 3 (231 ± 22) 27 ± 3 (195 ± 22) 70 ± 7 (506 ± 51) 58 ± 6 (419 ± 43) 126 ± 12 (910 ± 87) 105 ± 10 (758 ± 72)
M30 P=2 65 ± 6 (469 ± 43) 54 ± 5 (390 ± 36) 142 ± 14 (1030 ± 100) 118 ± 12 (852 ± 87) 255 ± 26 (1840 ± 190) 212 ± 21 (1530 ± 150)
M36 P=3 109 ± 11 (787 ± 79) 91 ± 9 (657 ± 65) 238 ± 23 (1720 ± 170) 198 ± 20 (1430 ± 140) 428 ± 43 (3090 ± 310) 357 ± 36 (2580 ± 260)
6—6
B. NUTS AND SLEEVES
B
SLEEVE NUT
O.D. (Ø) O.D. (Ø)
TUBE SIZE OPPOSING FLATS

MANUFACTURER'S WORKING PRESSURE TORQUE VALUE
O.D. X THICKNESS mm
NAME kgf/cm2 (psi) kgf·m (lbf·ft)
mm (in) Dimension B
10 X 1.5 (0.394 X 0.059) 19 4.5 ± 0.5 (33 ± 4)
15 X 2.0 (0.591 X 0.079) 27 15 ± 2 (108 ± 14)
350 (4,980)
NIPPON A.M.C 18 X 2.5 (0.709 X 0.098) 32 18 ± 2 (130 ± 14)
Travel line only
22 X 3.0 (0.866 X 0.118) 36 22 ± 2 (159 ± 14)
28 X 4.0 (1.10 X 0.157) 41 28 ± 3 (203 ± 22)
350 (4,980)
IHARA KOATSU 35 X 5.0 (1.38 X 0.20) 55 35 ± 4.5 (253 ± 33)
Travel line only
C. FLARE TYPE FITTING JOINTS D. N2 (NYLON) TUBE FITTING JOINTS

Overtightening of flare type (Union nut type) metal joints
may cause damage to nuts, seat surfaces and prevent 1. Clean tube and make certain tube end is trimmed
optimum sealing resulting in oil leaks. smooth.
1. Pipe Threads 2. Insert tube into fitting until tube end is securely seated
Unit : kgf·m (lbf·ft) in fitting body.
NOMINAL SIZE TORQUE VALUE
3. Tighten the nut by hand.
1 / 4˝ 2.5 ± 0.3 (18.1 ± 1.8)
3 / 8˝ 5 ± 0.5 (36.2 ± 3.6) 4. Use a spanner wrench, securely tighten nut by turn-
1 / 2˝ 6 ± 0.6 (43.4 ± 4.3) ing 1-1/4 turns.
3 / 4˝ 12 ± 1.2 (86.8 ± 8.7) PLASTIC SLEEVE
1˝ 14 ± 1.4 (101 ± 10)

1-1 / 4˝ 17 ± 1.7 (123 ± 12)
1-1 / 2˝ 21 ± 2.1 (152 ± 15)
2˝ 42 ± 4.2 (304 ± 30)
BODY NUT NYLON

TUBE
E. ORS JOINTS (O-RING SEALING TYPE)
OPPOSING FLATS TORQUE VALUE WORKING PRESSURE

NOMINAL SIZE
mm kgf·m (lbf·ft) kgf/cm2 (psi)
1-14 UNS 30 • 32 14 ± 1.4 (101 ± 10) 350 (4,980)
Hose mouth ring
1-3/16 12 UN 36 • 41 18 ± 1.8 (130 ± 13) 385 (5,475)
and coupling
1-7/16 12 UN 41 • 46 21 ± 2.1 (152 ± 15) (Power Boost)
CONNECTOR O-RING NIPPLE
NUT
6—7
F. TORQUE VALUES FOR MOST COMMON BOLTS
Follow the table below and tighten or retighten every capscrew and nut. Check for any loose or missing capscrews or
nuts before daily operation and during periodical inspections. Retighten or supply new parts for missing ones as
required.
Size Q'ty Location Tightening torque kgf•m (lbf·ft)

M5 5 • Sending unit mounting (fuel tank) • 0.2 ± 0.02 (1.4 ± 0.1)
M6 6 • A/C Condenser mounting • 0.45 ± 0.1 (3.2 ± 0.7)
4 • Muffler mounting (Nut-Upper) • 1.1 ± 0.1 (7.9 ± 0.7)
M8 4 • Muffler mounting (Nut-Lower) • 0.9 ± 0.09 (6.5 ± 0.7)
4 • A/C compressor mounting • 2.7 ± 0.3 (20 ± 2.2)
6 • Swivel joint dust cover mounting • 1.5 ± 0.2 (10.8 ± 1.4)
2 • Slewing grease bath inspection cover mounting • 3.0 ± 0.3 (21.7 ± 2.2)
16 • Floor plate rubber mouting • 4.7 ± 0.5 (34 ± 3.6)
4 • Air cleaner mounting • 4.0 ± 0.4 (29 ± 2.9) Apply Loctite #262
M10 12 • Power take-up bracket mounting • 4.0 ± 0.4 (30 ± 2.9) Apply Loctite #262
12 • Hydraulic oil tank cover mounting • 4.7 ± 0.5 (34 ± 4.0)
2 • Lower frame grease cover mounting • 1.1 ± 0.1 (7.9 ± 0.7)
3 • Stepping motor mounting • 2.0 ± 0.2 (14 ± 1.4) Apply Loctite #242
16 • Engine mounting • 6.6 ± 0.6 (48 ± 4.3) Apply Loctite #262
3 • Swivel joint mounting • 11 ± 1.0 (80 ± 7) Apply Loctite #262
M12 8 • Cab mounting • 11 ± 1.5 (80 ± 11)
4 • Radiator mounting • 12.3 ± 1.2 (89 ± 9) Apply Loctite #262
4 • Fuel tank mounting • 22 ± 2.0 (159 ± 14) Apply Loctite #262
4 • Floor plate rubber mounting nut • 19 ± 2.0 (137 ± 14)
M16 4 • Hydraulic tank mounting • 22 ± 2.0 (159 ± 14) Apply Loctite #262
6 • Power take-up coupling mounting • 22 ± 2.0 (159 ± 14)
4 • Idler and idle adjuster connection • 28.5 ± 3.0 (206 ± 22) Apply Loctite #262
4 • Engine mounting • 23.0 ± 2.2 (166 ± 16) Apply Loctite #272
8 (24-LC) • Track guide mounting • 40.5 ± 4.0 (293 ± 29) Apply Loctite #262
M18
44 • Sprocket mounting • 40.5 ± 4.0 (293 ± 29) Apply Loctite #262
56 (64-LC) • Lower roller mounting • 40.5 ± 4.0 (293 ± 29) Apply Loctite #262
4 • Upper roller mounting • 55.0 ± 5.5 (398 ± 40) Apply Loctite #262
4 • Hydraulic pump mounting • 44.0 ± 4.0 (318 ± 29) Apply Loctite #262
184 (196-LC) • Shoe bolt mounting • 87.0 ± 5.0 (629 ± 36) Apply SAE 30 CD
M20 33 • Slewing bearing outer race mounting • 40.0 ± 4.0 (289 ± 29) Apply Loctite #262
36 • Slewing bearing inner race mounting • 57.5 ± 5.7 (416 ± 41) Apply Loctite #262
12 • Swing reduction unit mounting • 55 ± 5.5 (398 ± 40) Apply Loctite #262
34 • Travel motor mounting • 55 ± 5.5 (398 ± 40) Apply Loctite #262
M24 8 • Side cutter mounting • 100 ± 5.0 (723 ± 36)
M27 4 • Counterweight mounting • 130 ± 13 (940 ± 94) Apply Loctite #262
5/8-18 2 • Idler adjuster grease nipple mounting •6±1 (43 ± 7)
UNF
6—8
6.4 MISCELLANEOUS INFORMATION D. CAPS AND PLUGS FOR TUBES AND HOSE FITTINGS
A. TEMPERATURE TABLE C
˚C ˚F ˚C ˚F ˚C ˚F ˚C ˚F ˚C ˚F ˚C ˚F Tube & Hose Plugs

-10 14 55 131 120 248 185 365 250 482 315 599
-5 23 60 140 125 257 190 374 255 491 320 608
0 32 65 149 130 266 195 383 260 500 325 617
70 158 135 275 200 392 265 509 330 626 B
5 41
10 50 75 167 140 284 205 401 270 518 335 635
15 59 80 176 145 293 210 410 275 527 340 644 A
20 68 85 185 150 302 215 419 280 536 345 653
25 77 90 194 155 311 220 428 285 245 350 662
30 86 95 203 160 320 225 437 290 554 355 671
35 95 100 212 165 329 230 446 295 563 360 680
TUBE "A" INTERNAL "B" NUT "C" EXTERNAL
40 104 105 221 170 338 235 455 300 572 365 689 DIA. (For hose end) (Use with "A") (For tube end)
45 113 110 230 175 347 240 464 305 581 370 698
10 mm ZF83P10000 ZF93N10000 ZF83H10000
50 122 115 239 180 356 245 473 310 590 375 707
15 mm ZF83P15000 ZF93N15000 ZF83H15000
Example of how to convert 45˚C to ˚F:
18 mm ZF83P18000 ZF93N18000 ZF83H18000
˚F = 1.8 X ˚C + 32 ˚F = 1.8 X 45 + 32 = 81 + 32 = 113˚F
22 mm ZF83P22000 ZF93N22000 ZF83H22000
Example of how to convert 122˚F to ˚C
˚C = 0.56 (˚F - 32) ˚C = 0.56 (122 - 32) = 0.56 X 90 = 50˚C 28 mm ZF83P28000 ZF93N28000 ZF83H28000
35 mm ZF83P35000 ZF93N35000 ZF83H35000
B. SPECIAL PIPE WRENCHES
A
B
G C Male PF Plugs
"D"
"C"
D
F E Unit : mm (in) "B"
TUBE PART
A B C D E F G
DIA. No.
15 27 70 22 12.7 8 40 16
2421T160 "A"
(0.591) (1.06) (2.76) (0.87) (0.50) (0.32) (1.57) (0.63)
Dia. (ø)
18 32 70 22 12.7 11 42 19
2421T138
(0.709) (1.26) (2.76) (0.87) (0.50) (0.43) (1.65) (0.75)
22 36 70 22 12.7 11.5 48 23
2421T130
(0.866) (1.42) (2.76) (0.87) (0.50) (0.44) (1.89) (0.91)
28 41 109 22 12.7 14.5 60 29 60˚
2421T115
(1.10) (1.614) (4.29) (0.87) (0.50) (0.57) (2.36) (1.14)
35 55 90 45 20 20.5 81 41 Unit : mm
2421T314
(1.38) (2.17) (3.54) (1.77) (0.79) (0.81) (3.19) (1.61) PLUG PART "A" "B" "C" "D"
SIZE NUMBER O.D. (Ø) LENGTH LENGTH FLATS
C. WEIGHT OF MATERIALS TABLE PF 1/4 2444Z2728D1 13.5 16.5 24.5 14
lb/yd3 kg/m3 Material (loose weight) PF 3/8 2444Z2728D2 16.6 17.5 25.5 17
700 420 Wood chips
PF 1/2 2444Z2728D3 20.6 20.0 31.0 22
750 440 Peat, dry
950 560 Cinders PF 3/4 2444Z2728D4 26.2 21.5 34.0 27
1170 690 Peat, wet PF 1 2444Z2728D5 33.3 23.5 36.0 36
1600 950 Topsoil
1780 1050 Coal
2100 1250 Calcite
2100 1250 Earth, loam Female PF caps
2250 1330 Shale
SIZE PART NUMBER
2400 1420 Sand, dry
2500 1480 Clay, dry PF 1/4 2444Z2729D1
2550 1510 Earth, dry PF 3/8 2444Z2729D2
2600 1540 Limestone, broken or crushed PF 1/2 2444Z2729D3
Thread Screw
2700 1600 Earth, wet
PF 3/4 2444Z2729D4
2800 1660 Clay, wet
2800 1660 Rock, granite, blasted & broken PF 1 2444Z2729D5
2850 1690 Sand, moist PF 1 1/4 2444Z2729D6
2900 1720 Sand and gravel, dry
3100 1840 Sand, wet
3400 2020 Sand and gravel, wet
6—9
Section VII – TROUBLESHOOTING
Table of Contents
GENERAL TROUBLESHOOTING ............................................................................................................... 7-1 ~ 7-3

7—0
7.1 GENERAL TROUBLESHOOTING
This troubleshooting information covers the compo- replacement of components or adjustment of valves
nents and systems as described in this operator’s be required, contact KOBELCO distributor for assis-
manual. Should in depth troubleshooting, repair or tance.
SYS PROBLEM PROBABLE CAUSE POSSIBLE REMEDY

a . Low hydraulic oil level a. Fill oil to specified level
a. Tighten suction pipe hose
b. Air leaking into the suction pipe
1. All operating speeds clamp or replace hose
are slow or power is c . Hydraulic pump damaged a. Repair or replace
lost d. Pilot gear pump damaged a. Repair or replace
e . Main relief valve is not adjusted correctly a. Adjust or replace
f . Pilot relief valve is not adjusted correctly a. Adjust or replace
a . Cylinder seal is damaged a. Repair or replace
2. A specific cylinder b. Control valve or overload valve functions incorrectly a. Repair or replace/Bleed
functions improperly or there are signs of air in the cylinder air from cylinder
or loses power c . Pilot valve is damaged a. Repair or replace
d. Pilot valve piping is loose a. Retighten
3. The cylinder position a . Cylinder seal is scored a. Repair or replace
will not hold with b. Control valve or overload valve is damaged a. Repair or replace
OPERATING
operating lever in c. Overload valve is not operating a. Repair or replace

neutral d. Pilot valve is damaged a. Repair or replace
a . Brake valve is not working a. Repair or replace
b. Hydraulic motor (swing) is not working or swing gear
a. Repair or replace
4. Machine does not is damaged
swing c . Swing bearing is damaged a. Repair or replace
d. Pilot valve is not working a. Repair or replace
e . Swing reduction unit is damaged a. Repair or replace
a . Brake valve is not working a. Repair or replace
b. Control valve is not working a. Repair or replace
5. Swing speed is slow
c . Hydraulic motor (swing) is not working a. Repair or replace
d. Hydraulic pump is not working a. Repair or replace
6. Abnormal sound a . Insufficient lubrication of swing gear and bearings a. Grease
occurs when swinging b. Low oil level in the swing reduction unit a. Refill with proper oil
7. "With swing stopped, a . Brake valve malfunctions a. Repair or replace
the machine drifts b. Set pressure of brake valve is incorrect a. Adjust or replace
and is hard to control" c . Brake lining is worn a. Repair or replace
a . Too much track tension a. Adjust track tension
1. Machine does not b. Dirty track links and shoes a. Clean tracks
travel smoothly c . Brake valve is not working a. Repair or replace
d. Travel reduction unit is damaged a. Repair or replace
a . Hydraulic pump is damaged a. Repair or replace
b. Poor engine performance a. Repair or replace
TRAVEL
c . Main relief valve pressure is set incorrectly a. Adjust or replace

2. Traveling power is
d. Low hydraulic oil level a. Fill to proper level
insufficient
e . Hydraulic motor (travel) is not working a. Repair or replace
f . Brake valve is not working a. Repair or replace
g. Seal in swivel joint is scored or oil is leaking a. Repair or replace
a . Unequal tensions on tracks a. Adjust tension
3. Machine does not
b. Set pressures of main relief valves unbalanced a. Adjust.
travel in a straight
line c . Performances of hydraulic travel motor has
a. Repair or replace
deteriorated
7—1

a . Oil cooler core clogged a. Clean
HYDRAULIC
b. Engine fan belt slipping a. Adjust or replace

1. Temperature rise in
c . Low hydraulic oil level a. Refill to specified level
the hydraulic oil
tank. a. Replace with correct,
d. Wrong type hydraulic oil used
new oil
e . Hydraulic pump is not working a. Repair or replace
1. Engine oil pressure is a . Engine oil level low a. Fill to specified level
too low. (Buzzer sounds b. Oil leaking a. Repair & fill to proper level
GAUGE CLUSTER DISPLAY
and icon displays) c . Wrong oil viscosity a. Replace with proper oil
a . Low coolant a. Fill to proper level
b. Coolant leaking a. Repair & fill to proper level
2. Abnormal rise in the c . Loose radiator cap a. Tighten
coolant temperature
d. Radiator core clogged a. Clean cooling system
(Buzzer sounds and
icon displays) e . V-belt loose or damaged a. Tighten to proper tension
f . Rust or scale in coolant a. Flush system / fill to level
g. Faulty thermostat a. Replace
a . Clogged air cleaner a. Replace elements
3. Air cleaner clogged
b. Hoses from air cleaner to turbo clogged a. Clean, repair or replace
a . Battery disconnected a. Connect
1. Starter does not turn b. Battery discharged a. Charge
or turns slowly which
c . Battery terminals disconnected, loose, or corroded a. Clean and connect
does not start the
engine d. Ground cable disconnected a. Connect
e . Engine oil viscosity too thick (Cold weather) a. Change to proper oil
a . Insufficient fuel a. Refuel
b. Improper starting procedure a. Refer to pages 3-1~3-2
2. Starter turns but c . Air in fuel line a. Bleed
engine does not start d. Clogged fuel filter a. Replace element
e . Clogged air cleaner a. Replace elements
f . Air heater circuit malfunctioning a. Check circuit
a . Low idling RPM a. KOBELCO serviceman
3. Engine tends to stop b. Fuel filter clogged a. Replace element
at low speed c . Air cleaner clogged a. Replace element
ENGINE
d. Improper valve clearance a. KOBELCO serviceman

a . Fuel filter clogged a. Replace element
b. Air cleaner clogged a. Replace elements
4. No power c . Improper valve clearance a. KOBELCO serviceman
d. Loose clamps on the air inlet hose (with turbo charger) a. Tighten clamps
e . Cracked air inlet hose (with turbo charger) a. Replace hose
a . Insufficient coolant a. Refill coolant
b. Clogged radiator a. Clean cooling components
5. Engine overheats
c . V-belt to loose or damaged a. Adjust or replace belt
d. Faulty thermostat a. Replace
6. Engine exhaust is a . Air cleaner clogged a. Replace elements
black b. Improper valve clearance a. KOBELCO serviceman
a . Fuel leak a. KOBELCO serviceman
7. Poor fuel b. Air cleaner clogged a. Replace elements
consumption c . Loose clamps on suction hose (with turbo charger) a. Tighten clamps
d. Cracked suction hose (with turbo charger) a. Replace w/new hose
7—2

a . Improper oil a. Replace with correct oil
8. Excessive oil b. Oil leak a. KOBELCO serviceman
consumption c . Improper oil replacement intervals a. Change at correct interval
d. Improper warming-up operation a. Refer to page 3-6
ENGINE
a . Low oil volume a. Fill to specified level

9. Engine oil pressure
b. Oil leak a. KOBELCO serviceman
does not rise
c . Improper oil viscosity a. Replace with proper oil
a . Battery terminals disconnected loose, or corroded a. Clean & tighten terminals
b. Low battery electrolyte a. Fill cells w/distilled water
10. Battery dies often
c . V-belt loose or damaged a. Adjust or replace belt
d. Defective battery a. Replace battery
7—3
Section VIII – OPTIONAL EQUIPMENT
Table of Contents
HYDRAULIC BREAKER .............................................................................................................................. 8-1 ~ 8-4
SAFETY PRECAUTIONS ............................................................................................................................. 8-5 ~ 8-6
MAINTENANCE FOR NIBBLER / BREAKER ............................................................................................. 8-7
REINFORCEMENT OF ATTACHMENT ....................................................................................................... 8-7
HANDLING THE LONG RANGE ATTACHMENT ........................................................................................ 8-8 ~ 8-12
AUTO GREASE LUBRICATOR ................................................................................................................... 8-13 ~ 8-19

8—0
8.1 HYDRAULIC BREAKER
A. SELECTION OF THE HYDRAULIC BREAKER
When mounting the breaker on the hydraulic excavator, it is necessary to match stability, hydraulic pressure, and the
oil level for each breaker. To select hydraulic breakers, contact your KOBELCO distributor.
B. BEFORE OPERATING THE HYDRAULIC BREAKER

Consult your KOBELCO distributor for the piping or enforcement of the arm when installing the hydraulic breaker.
REPLACE THE HYDRAULIC RETURN FILTER ACCORDING TO THE REPLACEMENT SCHEDULE TABLE
LISTED ON PAGE 9-7. Thoroughly read the hydraulic breaker operation manual and SAFETY PRECAUTIONS from
this section, as well as the safety precaution’s section on this manual to avoid damaging the machine or hydraulic
breaker during operation. SELECT THE APPROPRIATE HYDRAULIC FLOW FOR THE BREAKER BY FOLLOW-
ING THE INSTRUCTIONS DETAILED IN PAGE 8.2.
C. HYDRAULIC OIL LEVEL CHECK AND CONTAMINATION PREVENTION

When the hydraulic breaker is not installed on the machine, attach the blank plugs to the tube end on the arm top end
and the hose end on the hydraulic breaker side to prevent dust and water from entering into the piping.
Before starting operation, check the capscrews on the tube fixing clamps for looseness, and the connections of the
tubes and hoses for oil leakage.
D. BASIC OPERATION

PRECAUTIONS AND OPERATION PROCEDURES
FOUND IN THIS MANUAL BEFORE OPERATING
THE MACHINE OR ANY ATTACHMENT.
SAFETY LOCK LEVER

1. Start machine and place the safety lock lever in the IN UNLOCKED
“UNLOCKED” (Down) position. See Figure 8.1. (DOWN) POSITION
2. Move throttle control to the “HI” idle position.

FIGURE 8.1
3. Using boom, arm and bucket controls set the breaker
or nibbler to desired position.
4. Release control pedal lock rod. See Figure 8.2. PUSH LOCK ROD
FORWARD
5. Make certain breaker or nibbler is in desired position TO RELEASE
and against material to be broken.

6. Place right foot on pedal and depress with toe to ac-
tivate breaker or nibbler. See Figure 8.2. PULL LOCK ROD
BACKWARD
7. Operate breaker or nibbler for one minute then re- TO LOCK PEDAL
lease pedal.
DEPRESS PEDAL
WITH TOE TO
ACTIVATE
OPERATION OF BREAKER OR NIBBLER LONGER FIGURE 8.2

THAN ONE MINUTE INTERVALS COULD CAUSE
PREMATURE WEAR OR DAMAGE TO THE ATTACH-
MENT AND THE MACHINE.
IF MATERIAL IS NOT BREAKING, REPOSITION
BREAKER OR NIBBLER AND REPEAT OPERATION NEVER LEAVE THE OPERATOR CAB WITH ENGINE
IN ONE MINUTE INTERVALS. RUNNING.
8—1
E . BREAKER AND NIBBLER SELECTOR SWITCH
This machine is provided with breaker or nibbler single
circuit and nibbler and breaker Bi direction flow circuit.
To use breaker or nibbler, select circuit appropriate to
the specification through switch on the side of driver’s
seat. See Figure 8.3.
1. Switch Position
Specification Switch Position Circuit
Breaker Single flow
Nibbler
Nibbler Bi direction flow
Never turn switch on (Bi direction flow) to operate

breaker. It may cause damage of machine.
FIGURE 8.3
F . SELECTION OF B (BREAKER) MODE – SEE FIG-

URE 8.4 AND 8.5
In case the attachments in option like breaker, etc. are
used, the flow rate can be altered to optimum value
automatically.
Adjust the max. flow rate by the following procedure.
Each time the work mode is pressed, the work mode
indicator lamp is switched to · or in order.
1. Adjusting Max. Flow Rate

Turn the screen change switch of gauge cluster ON
within 3 to 10 seconds after turning the starter switch
ON (E/G does not start) and the mode switch to B FIGURE 8.4
(breaker) mode, and the mode is switched to adjust
mode.
2. Flow Rate Display KPSS WORK MODE LAMP
The last stored flow rate is indicated on the display,

but the max. flow rate is initially displayed as a refer-
ence.
Each time the mode switch is pressed the displayed
value of flow rate increases, and each time the buzzer
stop switch is pressed the displayed value decreases.
Since the increasing and decreasing action starts in
FLOW L KPSS
2 seconds after pressing either of switches and is RATE min
WORK
indicated by graduation of 10 L/min, release the hand MODE
immediately after the desired value of flow rate is SWITCH
displayed.
The flow rate can be adjusted within the range of
max. flow rate and min. flow rate.
Turn the screen change switch ON again, and the
maximum value of flow rate is stored and the adjust SCREEN CHANGE SWITCH
mode is canceled. FIGURE 8.5
8—2
G. CONTROL PEDAL
1. Hydraulic Breaker Single Circuit

Release pedal lock on the right front side of driver’s
seat to operate pedal. See Figure 8.6.
Precaution for pedal operation.

The operation varies in the specifications, so before
operating, read the operator’s manual carefully.
Foot pedal depressing section Operating condition

Depress toe section Breaker starts operation
Pedal in neutral position Breaker stops operating PUSH LOCK ROD
FORWARD
TO RELEASE
2. Nibbler and Breaker Combined (Conflux) Circuit
Release pedal lock on the right front side of driver’s PULL LOCK ROD
DEPRESS PEDAL
seat to operate pedal. See Figure 8.6. WITH TOE TO
BACKWARD
TO LOCK PEDAL
ACTIVATE
Hydraulic breaker
Depress heel section Breaker starts operation
Pedal in neutral position Breaker stops operating FIGURE 8.6
Nibbler
Depress toe section Nibbler close
Depress heel section Nibbler open
NEVER LEAVE THE OPERATOR CAB WITH ENGINE

RUNNING.
8—3
H. SETTING SELECTOR VALVE – FIGURE 8.7
For machines provided in nibbler and breaker specifi- (A)
cation, the selector valve installed on the main control
valve is required to be switched to the position corre-
sponding to the specification.
NOTE
• Inappropriate switching of selector valve may cause
decrease of work efficiency and operating speed due to
inferior operation, and also cause damage of machine. FIGURE 8.7
Securely switch selector valve. IN SERVICE OF BREAKER
• Be sure to switch selector valve 1 or 2 times a month TO HYD. TANK
periodically.
STAMP
1. Tools Used
TO ATT.
SELECTOR CIRCUIT TOOLS
VALVE
SOCKET BOLT
MAIN Spanner (24 mm) TO C/V
(A)
(Circuit) Allen Wrench (5 mm)
FIGURE 8.8
2. Setting Procedure – FIGURE 8.8 ~ 8.9 IN SERVICE OF NIBBLER

TO HYD. TANK
a. Use a allen wrench to loosen and remove the
socket bolt. STAMP
b. Use a wrench to turn the selector valve to the proper
position.
c. After the valve is in the proper position, tighten the TO ATT.
socket bolt.
SOCKET BOLT
d. Markings of the selector valve are shown below. TO C/V
B : Breaker
FIGURE 8.9
N : Bi direction flow of nibbler
I . SETTING STOP VALVE – FIGURE 8.10

Stop valve on arm top end is used to stop hydraulic oil
flowing.
Free : Hydraulic oil flows.
Stop : Hydraulic oil stops flowing.
Before removing attachment, set stop valve to “STOP” (B)
position.
1. Tools Used
STOP CIRCUIT TOOLS

VALVE mm
24
MAIN
(B) Spanner (24 mm)
(Arm)
FREE STOP
FIGURE 8.10
8—4
8.2 SAFETY PRECAUTIONS
The following safety precautions should be used in
conjunction with all other safety precautions found
in this manual.

PRECAUTIONS AND OPERATING PROCEDURES
FOUND IN THIS MANUAL BEFORE OPERATING
THE MACHINE OR ANY ATTACHMENT.
FIGURE 8.11
A. USE FOR INTENDED PURPOSE – FIGURE 8.11

Use the attachment only for its intended purpose. If
not used in accordance with the manufactures instruc-
tions, the excessive pressure exerted on the boom,
arm and frame structure of the machine will cause pre-
mature failure of the components.
B. PASSENGERS
Never allow passengers on the attachment or machine. INSTALL GUARD
AND CLOSE WINDOWS
C. PROTECTIVE EQUIPMENT – FIGURE 8.12 FIGURE 8.12

Install protective guards on the machine and close the
all window to protect the operator from flying debris.
Also the operator and all personnel in the vicinity of
the machine should wear protective gear such as safety
shoes, hard hat, gloves and face shield or goggles.
D. CYLINDERS – FIGURE 8.13

Do not operate boom, arm or bucket cylinders to stroke
ends when using a breaker attachment. Doing this can
cause undue stress on the cylinder rods and result in
damage.
FIGURE 8.13
E . AVOID CONTINUOUS OPERATION – FIGURE 8.14

Operate the breaker or nibbler in one minute intervals.
Operation for longer than one minute at a time can
Within
cause high oil temperatures and damage the accumu- One Minute
lators, cylinder seals and possibly pump damage.
FIGURE 8.14
8—5
F . HOSE SURGE – FIGURE 8.15
Should the hydraulic hoses begin to surge or vibrate
abnormally during operation of a breaker or nibbler,
immediately stop operation and contact KOBELCO
distributor for assistance. This problem often is a re-
sult in damaged accumulators and can also result in
valve failure.
FIGURE 8.15
G. DO NOT USE DROPPING FORCE – FIGURE 8.16
Never use the dropping force of the attachment to break
or drive objects. This will cause extensive damage to
the attachment and machine structure.
FIGURE 8.16
H. DO NOT USE SWING FORCE – FIGURE 8.17
Never use the swing force of the machine for pushing
or sliding objects. This will cause premature failure of
the attachment and other machine components.
FIGURE 8.17
I . DO NOT LIFT – FIGURE 8.18
Never use an optional attachment to lift or transport
objects or material. Doing so can cause extensive dam-
age to the attachment, the machine structures and
cause injury or death.
FIGURE 8.18
J . WORKING RANGES – FIGURE 8.19 UNACCEPTABLE WORK RANGE
Never operate an optional attachment over the sides
of the machine. Only operate over the front or rear of
the tracks.
ACCEPTABLE ACCEPTABLE
WORK RANGE WORK RANGE
UNACCEPTABLE WORK RANGE
FIGURE 8.19
8—6
8.3 MAINTENANCE FOR NIBBLER/BREAKER DEPRESS RUBBER CAP
It is necessary to perform the following maintenance TO RELEASE PRESSURE
schedule in regard to hydraulic oil and filters along
with normal inspection and maintenance as described
in Section IV of this manual for the nibbler / breaker
optional attachment.
FIGURE 8.20
REPLACEMENT SCHEDULE
1ST 2ND REGULAR
COMPONENT LOCATION
MAINTENANCE MAINTENANCE MAINTENANCE
CHANGE HYDRAULIC OIL HYDRAULIC TANK EVERY 600 HOURS
RETURN FILTER ELEMENT KIT

FOR STD & NIBBLER/BREAKER HYDRAULIC TANK 50 HOURS 250 HOURS EVERY 250 HOURS
(P/No. YN52V01008R100)
8.4 REINFORCEMENT OF ATTACHMENT

The use of machine with breaker and nibbler may
cause damage of attachment. So contact your
KOBELCO distributor to reinforce arm.
8—7
8.5 HANDLING THE LONG RANGE ATTACHMENT
A machine with a long-range attachment can reach long distances and effectively dredge and clean mud and
sludge accumulated at the bottom of rivers. However, the machine must be handled carefully.
Failure to correctly use the attachment may damage it and cause a personnel accident.
A. CAUTION ON OPERATION
1. The long-range attachment is made only for light

operations. Do not use the long-range attachment
for civil engineering work such as excavation.
2. Operate the machine smoothly to perform stable and safe

swing motion as the boom and the arm are very long.
3. If the machine is stopped suddenly to stop swinging,

it swings the attachment greatly and experts unrea-
sonable force upon the attachment, which may do
damage to the machine. Try to operate the machine
smoothly exercising full care. After the swing motions PRECAUTIONS WHEN SWINGING
quite stops, place the bucket on the ground.
4. Do not perform digging and swing motions on a slope.
5. Comparing the boom and arm with those on the stan-

dard machine, this has larger inertia force. Avoid the
boom and arm operation requiring the motion so that
respective cylinder is fully stroked.
6. The large length of the boom and the arm increases

the maximum digging height and the reach. There-
fore, exercise full care of interference with the upper
front of the machine and interference with other things
when swinging the machine.
7. Do not lift or drive the machine with the bucket on DO NOT MACHINE LIFT UP
the ground. It is dangerous because force is added
to the pin near the bucket.
8. Don’t attach the bucket other than that specified for

the long-range attachments. The attachment of TRANSPORTING STAY
bucket larger than the specified one may cause the
instability and the turnover of the machine resulting D
EN
in the damage of boom, arm, etc. O KE
S TR
9. When the long-range attachment is attached, the use

of attachment boost is strictly prohibited.
This machine is designed as special pur-

pose machine, A mode is therefore used PRECAUTIONS TRANSPORTING THE MACHINE
as standard for the control mode appropri-
ate to the specification for each machine.
When being used as special purpose ma-
chine, the application other than A mode NOTE
may cause abnormal operation, so be sure Attach the stay after retracting the arm cylinder to approxi-
to apply A mode. mately 5 mm from the arm cylinder stroke end.
8—8
B. LONG RANGE ATTACHMENT MACHINE DIMENSIONS
3,050mm (10´-0˝)-50FT 12,540mm (41´-2˝)-50FT / 10,770mm (35´-4˝)-40FT

2,990mm (9´-10˝)-40FT
C. WEIGHT
Unit : kg (lb)
Model SK200-6E SK200LC-6E
Types
Item 40 FT 50 FT 40 FT 50 FT
Shoes 800 mm (31.5˝)
Fully equipped weight 22,290 (49,140) 22,520 (49,650) 22,770 (50,200) 23,000 (50,700)
Upper frame machinery + 4,870 (10,740) +
Heavy counterweight 5,800 (12,790)
Lower frame machinery 7,650 (16,870) 8,130 (17,920)
Attachment 3,970 (8,750) 4,200 (9,260) 3,970 (8,750) 4,200 (9,260)
D. GROUND PRESSURE
Unit : kPa {kgf/cm2}
Model SK200-6E SK200LC-6E
Types
Item 40 FT 50 FT 40 FT 50 FT
Ground pressure (800 mm) 37 {0.38} 38 {0.39} 35 {0.36} 36 {0.36}
8—9
E . OVERALL SPECIFICATIONS OF BOOM
Boom 7.0 m (23´-0˝) Boom 8.75 m (28´-8˝) Boom

7.20 X 1.55 X 0.67 8.95 X 1.39 X 0.67
L X H XW m (ft-in)
(23´-7˝ X 5´-1˝ X 2´-2˝) (29´-4˝ X 4´-7˝ X 2´-2˝)
Weight w/Arm cylinder kg (lb) 2,010 (4,430) 2,230 (4,920)
H
L
F . OVERALL SPECIFICATIONS OF ARM
Arm 4.93 m (16´-2˝) Arm 6.35 m (20´-10˝) Arm

5.90 X 0.93 X 0.41 7.31 X 0.89 X 0.41
L X H XW m (ft-in)
(19´-4˝ X 3´-1˝ X 1´-4˝) (24´-0˝ X 2´-11˝ X 1´-4˝)
Weight w/Bucket cylinder kg (lb) 1,140 (2,510) 1,220 (2,690)
H
L
G. OVERALL SPECIFICATIONS OF BUCKET
Bucket 0.45 m3 (0.59 cu yd) 0.70 m3 (0.92 cu yd)

1.17 X 1.08 X 0.91 1.17 X 1.08 X 1.29
L X H XW m (ft-in)
(3´-10˝ X 3´-7˝ X 3´) (3´-10˝ X 3´-7˝ X 4´-3˝)
Weight kg (lb) 370 (820) 480 (1,060)
H
8 — 10
H. WORKING RANGES (40FT)
A
A'
G
C
D
H
E
K
F
J
B
1. Long Range Working Ranges : ITEM FUNCTION mm SAE

a. Boom ....... 7.00 m (23´-0˝) A Max. digging reach 12,850 42´-2˝
b. Arm ......... 4.93 m (16´-2˝) A' Max. digging reach at ground 12,730 41´-9˝
B Max. digging depth 9,500 31´-2˝
c. Bucket .... SAE heaped 0.70 m3 (0.92 cu yd)
Struck 0.50 m3 (0.66 cu yd) C Max. digging height 11,350 37´-3˝
Width with side cutters - 1,290 mm (4´-3˝) D Max dumping clearance 9,000 29´-6˝
Width w/o side cutters - 1,190 mm (3´-11˝) E Min. dumping clearance 1,700 5´-7˝
Weight - 480 kg (1,060 lb) F Max. vertical wall digging depth 8,450 27´-9˝
G Min. swing radius 4,340 14´-3˝
H Height at minimum swing radius 8,680 28´-6˝
J Digging depth for 8´ level bottom 9,380 30´-9˝
K Horizontal dig. stroke at ground level 9,000 29´-6˝
8 — 11
I . WORKING RANGES (50FT)
A
A'
G
C
D
H
E
K
F
J
B
1. Long Range Working Ranges : ITEM FUNCTION mm SAE

a. Boom ....... 8.75 m (28´-8˝) A Max. digging reach 15,820 51´-11˝
b. Arm ......... 6.35 m (20´-10˝) A' Max. digging reach at ground 15,720 51´-7˝
B Max. digging depth 12,010 39´-5˝
c. Bucket .... SAE heaped 0.45 m3 (0.59 cu yd)
Struck 0.35 m3 (0.46 cu yd) C Max. digging height 13,660 44´-10˝
Width with side cutters - 910 mm (3´-0˝) D Max dumping clearance 11,300 37´-1˝
Width w/o side cutters - 810 mm (2´-8˝) E Min. dumping clearance 1,930 6´-4˝
Weight - 370 kg (820 lb) F Max. vertical wall digging depth 11,030 36´-2˝
G Min. swing radius 4,840 15´-11˝
H Height at minimum swing radius 10,370 34´-0˝
J Digging depth for 8´ level bottom 11,910 39´-1˝
K Horizontal dig. stroke at ground level 11,610 38´-1˝
8 — 12
8.6 AUTO GREASE LUBRICATOR 3. Controller Indicator
After definite time of operation of electric pump, the
8.6.1 SETTING set value of pressure indicator is in the pressure
hold state of 245 kgf/cm2 (3,480 psi), and the indi-
A. CONTROLLER INDICATION AND SETTING KEY
cation of controller returns to “zero”.
BLADE
TYPE 4. The LED of Indicator Flickers
FUSE
While counting a operation interval, the LED on a
Table 1.
LED RESET /
Represented by key hereafter.
ESC
START /
SET
INDICATOR Level selection
LEVEL
Item selection
ITEM
TABLE 1
Item Set Value Contents
Greasing Greasing interval during
4.0 hour
interval auto operation
FIGURE 8.22 Greasing Pump operating time per
5 minutes
time greasing
B. SETTING ITEMS AND SET VALUES Greasing Greasing frequency carried
The three items shown in Table 1 can be set through frequency 200 times out by the time the 1000 cc
limit cartridge grease is consumed
controller.
The set values are varied conforming to the size and
operating condition, and the initial setting of this con- NOTE
troller is shown in Table 1. All attachment has to be lubricated every 8 hours for the
first 50 hours of operation.
C. OPERATING PROCEDURE AND THE DESCRIP-
TION
5. Engine Key Off
1. Starting Engine When the grease pump is operated, stop it imme-
Starting engine flickers indicator lamps on the lu- diately and release the pressure.
bricating controller for several seconds.
After the CPU housing a controller has restored, D. CHECKING GREASING OPERATION OF DISTRIB-
the LED of indicator flickers (begins counting of UTING VALVE
greasing interval) and lamps other than power lamp Press start key (Manual) of controller to start pump
go out. operating, and when greasing or the pressure release
has been performed, make sure that indicator of dis-
2. Switching Operation from Auto Mode to Manual tributing valve is actuated.
Mode
HOW TO CHECK
There are two switching methods as shown below. GREASE SUPPLY ADJUST SCREW
CAP
Auto start Auto stop
INDICATOR
Manual start Auto stop
INSPECTION DOOR
When the auto start is selected, the controller starts
operating on reaching the set time of greasing in-
terval. A B
When Manual operation is selected, press key of
controller. One cycle operation is performed regard-
less of the counting. In this case, the operating in- FIGURE 8.23
terval during counting is once canceled, and the Cross sectional view of one section distributing valve.
new counting starts again after the electric motor
1. Remove cap.
pump stops automatically.
8 — 13
2. Check the operation of indicator through inspec- 4. For exercise, input 5 in Table 2 to set 4 hour.
tion door. When flickers, press “SET” key. Now
When applying grease ........ Indicator moves in A 8 hour has been set to and
direction. flickers for next setting item. So, for
exercise, input 3 in Table 2 to set 5 minutes.
When releasing pressure .... Indicator moves in B
When flickers,
direction.
press key.
• Indicator returns to the original point immediately
after the pressure release is completed. 5. For the following setting, since the flick-
ers, input code 6 in Table 2 when flick-
E. CARES WHEN ATT PINS ARE PULLED OUT ers.
When pins on the grease applied part are pulled out
to remove attachments, etc., grease should be ap- 6. After setting every items for (a) (b) (c).
plied through grease nipple until the grease is come Press key to switch off the set mode.
out from the boss end after attaching the pins. Immediately after pressing key, the counting
DISTRIBUTING GREASE of greasing interval is started, and the flicker at a
VALVE NIPPLE part of indication segment proves the execution of
counting.
After setting, the set value is stored even if the power
is off.
For replacing value in each item, operate key

and key to select and set the item required to
change, and don’t fail to press key after
completion of setting.
FIGURE 8.24
Press key
F. SETTING PROCEDURE OF SET VALUE
Select code No. corresponding to the setting item in Press key Press key
Table 2 “Setting Table” to input the set value.
1. Start engine, and turn power on.

SYMBOL SYMBOL
2. Press (level) key and (item) key simulta- Greasing interval
neously, and the set mode is selected.
Greasing time
3. Setting items on the indicator of controller are changed Greasing limit frequency
as shown in the right diagram.
REPLACING SETTING ITEMS
G. HOW TO SET (EXERCISE)
When the set values of greasing interval, greasing TABLE 2 SETTING TABLE
time, and greasing limit frequency are 4 hour, 5 min- Code Greasing interval Greasing time Greasing limit
No. (Hr) (a) (min) (b) frequency (c)
utes, and 200 times.
0
1. Press key and key simultaneously. 1 1 2 25
2. Select and set the required item by pressing key. 2 1.5 3 50

In case of the exercise, press key until is 3 2 5 75
appeared. 4 3 7 100
3. While flickers, press key and 5 4 10 150

flicker by turns. 6 5 15
Then, code No. (figure portion) is moved up for ev- 7 6 20 250
ery pressing. It changes as follows.
8 8 25
9
8 — 14
8.6.2 INITIAL GREASE APPLYING PROCEDURE
After completion of grease piping, apply grease as
follows.
PUMP ASSY
A. APPLY GREASE IN EVERY PIPING FROM THE

PUMP ASSY TO THE DISTRIBUTING VALVE
1. Disconnect elbow from the connector on the lower

ELBOW
part of the pump assy. See Figure 8.25.
2. Attach socket (ZG21U06002) and grease nipple to

the elbow. See Figure 8.26. FIGURE 8.25
3. Remove blank plug (PT3/8) on the top end of the
arm distributing valve. See Figure 8.27.
4. Apply grease through grease nipple attached with APPLY GREASE

para. 2 mentioned above, until dust, etc. are com- GREASE
pletely removed through the hole from which the NIPPLE
SOCKET
blank plug is disconnected. ZG21U06002
(PT1/8 X PT3/8)
5. Apply grease in the connector of the pump assy
and the elbow in para. 1 mentioned above.
TO
B. APPLY GREASE FROM THE DISTRIBUTING DISTRIBUTOR
VALVE TO EACH PIN ELBOW HOSE

Fill grease through respective grease nipple (A)
supplementary attached on the distributing valves on FIGURE 8.26
the right front of the swing frame, boom and arm until
dust is removed from boss and pin completely.
• Apply grease after connection of main pipe from the

lower part of the pump assy to the arm top end. DISTRIBUTOR
TO ARM
Connect them after applying grease by respective
pipe to respective distributing valve, or air leaves in
the connector, causing the abnormal operation.
• Take care that dust, mud, etc. don’t enter in the pip-
ing. GREASE
NIPPLE (A)
BLANK PLUG (PT 3/8)
FIGURE 8.27 DISTRIBUTOR
8 — 15
8.6.3 CHANGING THE CARTRIDGE GREASE WITH
INTERMEDIATE COVER
NEW ONE – FIGURE 8.28
M35 P4.8
1. Cartridge Changing Interval

The cartridge grease capacity is 1 liter. The change
of grease is not necessary for about 1.5 months
78
96
(hour meter 200 Hr or equivalent).
2. Grease Change Signal

CAP
When the grease change is required, the error code 96
192
E 0 on the controller flickers alternately.
In addition, when the counter of greasing reaches GREASE CARTRIDGE
to the counter just before 10 times required for the
grease change, the counter will count down like 9 Type MY Reservoir DL-2
8 7... However, when the cartridge is re- Capacity 1,000 cc
placed, the controller is required to be reset. Grease in use Unilub DL-No.2
Manufacturer KYODO YUSHI Co. Ltd.
FIGURE 8.28
Press RESET / ESC key for 5 seconds of more just
after the cartridge grease has been changed, and the
greasing counter is reset and the counter returns to
the set value.
3. Cartridge Replacing Method

The recommended grease should be used.
• Part No. 2421Z512
When the above cartridge grease is used on electric

pump, screw in it after removing the intermediate cover.
4. Air Bleeding of Grease Tank
8.6.4 SETTING OF COUNTER FOR GREASE DIS- VINYL CAP ADJUSTING SCREW
CHARGE – FIGURE 8.29
Setting the counter for the grease to be discharged. INSPECTION
DOOR
Remove vinyl caps of each distributing valve, turn
the allen wrench (3 mm with opposing flats), and
set the counter of the grease quantity to be dis-
charged.
The discharge of each distributor is about 0.4 cc in the

initial condition where the adjusting screw is not turned.
And, the discharge quantity can be reduced about 0.1 FIGURE 8.29 DISTRIBUTOR
cc by one right rotation of the adjusting screw. (1 mm
stroke by one turn)
8 — 16
8.6.5 INDICATION
A. NORMAL OPERATION DISPLAY LIST

The condition of the lubrication system can be known by 7 segments LED of the control panel and the display
contents of LED. This list is useful to judge whether the operation is normal or abnormal after the initial setting and
the installation.
TABLE 3 1) Just after E/G start

Normal Operation Under Usual Operation
ON
Phenomenon LED 7 Segments
Items Display Display
"DRIVE" LED
1) In operation of pump Clockwise OFF
lamp lights
(Under lubrication) flickered.
up. FLICKERS
2) Under holding of "DRIVE" CLOCKWISE
Under pressure (After LED lamp 2) After 2 minutes from the starting
Flickering stops.
lubrication approx. 3 minutes is flickering.
from E/G start) (slow)
ON
"DRIVE" LED
3) Under releasing of Counterclockwise
is flickering. FLICKERING
pressure flickered.
(Quick) (SLOW)
After 0 display OFF
just after E/G
starting.
Under Note) Impossible to access the mode
counting Power LED is set in this condition.
4) In normal operation
(IN period of lights up. 3) Under releasing of pressure
operation) (Charging of piston chamber)
LED is flickering ON
or the figure
flickering.
Under "SET" LED is Following each FLICKERING
5) Setting mode (QUICK)
setting flickering. setting mode.
OFF
* When the number of remaining lubricating times is 10 or less, the FLICKERS
figure (9 to 0) flickers, and is counted down by completion of COUNTER CLOCKWISE
FOR SEVERAL SECONDS
lubrication.
4) Under counting in normal operation
ON
OFF
FLICKERS
Note) Possible to access the mode

set in this condition.
5) Under setting mode
ON
OFF
FLICKERS
FLICKERING
8 — 17
B. ERROR LIST
4 kinds of the lubrication system error (See Table 4) are shown by alarm LED, and the error contents and the
display (Table 4) are indicated by error code. However, the power LED does not light up when the fuse is blown.
TABLE 4
Error Phenomenon Error Code
The pressure does not go
Pump Pressurizing
up within the lubricating
Error Flickers alternately
time.
ON
Pressure Releasing The pressure is remained
Error after releasing the pressure. Flickers alternately
The pressure detection LS

Pressure Detection
is actuated before the lubri-
Error Flickers alternately
cation system is started. OFF
When the number of the

lubrication times is 10 times
Tank Empty or less equivalent to the limit
number of times, the counting Flickers alternately
is down like 9 8 7 .
8 — 18
8.6.6 TROUBLESHOOTING
When this lubrication system fails, the corresponding error code on the controller display flickers.
Check the system for the cause of failure and take a corrective action.
TABLE 5
Error Code Error Item Cause Corrective Action
1. Operate the pump to discharge the
1. Air contaminated in main pipe grease through the pipe end, and then
release air.
2. Discharge grease through air escape
2. Air entered in the pump
Pump pressurizing section on the pump and release air.
error
3. Insufficient screwing in of cartridge 3. Tighten the cartridge securely.
4. Check and tighten each connection of
4. Grease leakage of main pipe
main pipe including hoses.
5. The cartridge of grease is empty 5. Change of cartridge grease.
1. Disassemble the pressure release
1. Failure of pressure release system
section carefully and check for possible
Pressure release housed in pump.
failure and clean it.
error
2. Failure of pressure detecting unit 2. Check the limit switch on the pressure
housed in pump. detecting section for possible failure.
1. Failure of pressure detecting unit 1. Check the limit switch for possible
housed in pump. failure.
Pressure detection
error 2. Disassemble the pressure release
2. Failure of pressure release system
section carefully and check for possible
housed in pump.
failure and clean it.
1. When the number of lubrication 1. Change the grease cartridge with new
times reaches to the limit time. one.
Tank empty
2. Change the grease cartridge with 2. Press ESC key on the controller for 5
new one under counting. seconds or more to reset.
8 — 19

KOBELCO Arm Shock Countermeasure

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Droits d'auteur :

KOBELCO Arm Shock Countermeasure

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Droits d'auteur :

APPLICABLE No.

READ, UNDERSTAND AND FOLLOW ALL SAFETY

Book Code No. S2YN00019ZE02

Because of the size of some of the machine compo-

21. Do not operate a machine if any rotating part is dam-

22. Be careful when servicing or separating the tracks.

part of what you must follow. Read, understand and operat re w

OBSERVE ALL SAFETY PRECAUTIONS

B. WEAR PROTECTIVE CLOTHING

C. READ AND UNDERSTAND THE OPERATOR’S

D. KEEP OPERATOR’S MANUAL IN MACHINE CAB

E. HOW TO HANDLE LIFE HAMMER

F. PREPARE FOR EMERGENCIES

H. PERFORM PRE-START INSPECTION

I . ENGAGE SAFETY LOCK LEVER BEFORE LEAV-

J. SIGNS, SIGNALS & FLAGMEN SAFETY LOCK LEVER

K. KEEP FIRE AWAY FROM FUEL AND OIL

L. USE CAUTION NEAR NOISE

N. AVOID HOT SURFACES & AREAS USE GRIP BARS

O. USE THE PROPER OPTIONAL ATTACHMENT

P. PREVENT FIRES USE PROPER ATTACHMENT

SOUND HORN BEFORE STARTING

E. BOOM, ARM & ATTACHMENTS

ALWAYS PLACE ATTACHMENTS ON THE

F. OPERATING ON INCLINES OR SLOPES

LINE VOLTAGE Minimum Distance - M (FEET)

I . FROZEN OR SNOW COVERED WORK SITES

USE EXTREME CAUTION ON FROZEN OR SNOW

J. FILLED OR UNSTABLE GROUND

L. PARKING THE MACHINE

N. SEATBELT PARKING SAFETY

1.5 INSPECTION & MAINTENANCE SAFETY

E. SET THE ATTACHMENT

G. PRESSURIZED FLUIDS & LUBRICANTS DEPRESS RUBBER CAP

engine coolant, fuel system and all systems con-

USE CAUTION WHEN ADJUSTING TRACKS

ELECTRICAL SYSTEM PRECAUTION

N. DISPOSE OF WASTE PROPERLY

1.6 BATTERY SAFETY

A. WEAR PROPER PROTECTIVE CLOTHES

B. KEEP AWAY FROM FIRE OR FLAMES

NEGATIVE (-) CABLE

MAKE CERTAIN OF THE POSITIVE (+) AND

1. SWING-DANGER 2. PRESSURIZED HOT OIL-WARNING

Pressurized hot oil can

3. PRESSURIZED HOT OIL & 4. DO NOT CLIMB-WARNING 5. STOP ENGINE-WARNING

ZL11N00404 ZL11N02604 ZL11N05204

Connect booster cables using following

AVOID ACID BURNS

DANGER EXPLOSIVE GASES

KEEP VENT CAPS TIGHT AND LEVEL

PREVENT BATTERY EXPLOSION

11. BUCKET TO CAB CONTACT-CAUTION 12. SAFETY LOCK LEVER-WARNING

15. SWING PARKING BRAKE RELEASE SWITCH

16. KEEP CLEAR WORKING AREA-DANGER

The swing parking brake release switch

Swing parking brake release switch

our service shop immediately.

ZL11N00104 ZL11N01304 ZL11N07704

Be careful not to pinch

Releasing power boost switch while

Be careful not to pinch

When an auto idling stop

When you do the work which has

The auto idling stop function for

B. DO NOT USE SLEWING FORCE OF THE MA-

C. DO NOT PERFORM “HAMMERING” OPERA-