Kobelco ED195-8 Tier 3 Excavator Dozer Service Manual

Name: Kobelco ED195-8 Tier 3 Excavator Dozer Service Manual
Brand: MidWestTech
SKU: 87693703
Price: 99.55 USD
Availability: InStock

920 pages · Publication 87693703

$99.55

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Models: ED195-8 Tier 3
Manual type: Service Manual
Pages: 920
Publication: 87693703
Condition: Brand new

Kobelco ED195-8 Tier 3 Excavator Dozer Service Manual, publication 87693703

What's inside

From the manual's own table of contents: 11 sections, 596 entries. See sample pages (PDF, 816 KB)

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ED195-8 SHOP MANUAL1 topic

Section Table of Contents

SECTION 1 - SAFETY AND GENERAL INFORMATION159 topics

SAFETY PRECAUTIONS
Generalities
Starting
Operating
Stopping
MAINTENANCE
Keep Hands and Clothes Far Off Moving Parts
Do Not Smoke
Do Not Look at The Welding Arc Without Proper Eye Protection
Transfers and Transportation
Engine
Electrical System
Hydraulic System
Tools
RECOGNIZE SAFETY INFORMATION
Environmental Protection
Follow Safety Precautions
Prepare For Emergencies
Wear Protective Clothing
Protect Against Noise
Inspect The Machine
Use Hand Holds And Steps
Adjust The Operator's Seat
Fasten Seat Belt
Move And Operate Machine Safely
Operate Only From The Driver's Seat
Do Not Carry Person On The Machine
Confirm Direction Where The Machine Is To Be Driven
Avoid Injury From Back Over And Swing Accidents
Drive Machine Safely
Avoid Overturning
Park Machine Safely
Investigate Job Site Before Operating The Machine
Protecting Against The Fall Of Rocks And Landslides
Dig With Caution
Operate With Caution
Avoid Electric Lines
Keep Personnel Clear From Working Area
Never Move The Bucket Over Any One
Do Not Operate In Tunnels
Never Undercut A High Bank
Safety Loads Moving
Avoid Excessive Digging Efforts
Pay Attention When Digging Deeply
Do Not Use The Traction Force Of The Machine For Digging
Do Not Use The Turret Swing For Digging
Do Not Use The Bucket As A Hammer
Avoid Operating The Cylinders To Full Stroke
Provide Signals For Jobs Involving A Number Of Machines
Transporting The Machine Under Safe Conditions
GENERAL MACHINE NOMENCLATURE
Main Components - Upperstructure
Main Components – Under Carriage
SPECIFICATIONS AND PERFORMANCE
Dozer Blade Specifications
Speed and Gradeability
Hydraulic Components
Hydraulic Pump
Control Valve
Pilot Valve
Swing Motor Unit
Travel Device
Cylinders
Operating Pressures
Digging Forces
Working Weight
Attachment Working Ranges
Machine and Components Weights (Dry)
TRANSPORTATION
Ground Transportation
Machine Preparation
Loading The Machine
Machine With Long Reach Attachment
Securing Machine To Trailer
Lifting Machine
Lifting Machine Without Attachment
Transportation Dimension and Weight of Attachment
Boom With Arm Cylinder
Arm With Bucket Cylinder
Arm With Bucket Cylinder and Bucket
Bucket (Standard Bucket)
Dozer Blade
ENGINE SPECIFICATIONS
Main Specifications
LIFTING CAPACITIES
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
Preparations For Disassembly
Disassembling and Assembling Hydraulic Equipment
Disassembling Hydraulic Equipment
Assembling Hydraulic Equipment
Installing Hydraulic Equipment
Bleeding Air from Hydraulic System
Floating Seal Precautions
Electrical Equipment
TORQUE CHART
Bolt Types
Specified Tightening Torque Chart
Bolt Tightening Order
Service Recommendations for Split Flange
Nut and Bolt Lockings
Lock Plate
Cotter Pin
Lock Wire
PIPING JOINT
Pipe Thread Connection / Union Joint Tightening Torque Specifications
Union Joint
O-ring Seal Joint
Screwed-In Connection
Seal Tape Application
Low Pressure Hose Clamp Tightening Torque
Connecting Hose
HOW TO USE THE MAINTENANCE STANDARDS
Standard and Cautions to be Exercised
Application
Terminology
Cautions to be Exercised at Judgment
Other Cautions to be Exercised
Preparation For Performance Tests
The Machine
Test Area
Precautions
Make Precise Measurement
PERFORMANCE INSPECTION STANDARD TABLE
MEASUREMENT OF ENGINE SPEED
Warming Up Of Engine
Engine Speed Measured Value Through Service Diagnosis
MEASUREMENT OF HYDRAULIC PRESSURE
Preparing To Measure Hydraulic Pressure
Place To Install Pressure Gauge
Pressure Adjustment Position
Pilot Relief Valve
Swing Over Load Relief
Procedure For Adjusting Relief Valve
2-Stage Main Relief Valve
Over Load Relief Valve
Over Load Relief Valve (Swing)
Over Load Relief Valve (Travel)
Dozer Relief Pressure Measurement
Dozer Relief Pressure Adjustment
MEASURING TRAVEL PERFORMANCES
Travel Speed
Deviation of Travel
Performances of Parking Brake
Drain Rate of Travel Motor
MEASURING SWING PERFORMANCES
Swing Speed
Performance of Swing Brake
Performance of Swing Parking Brake
Drain Rate of Swing Motor
MEASURING ATTACHMENT OPERATING PERFORMANCES
Operating Time of Cylinders
Oil Tightness of Cylinders
MEASURING PERFORMANCES OF SWING BEARING
ENGINE CONTROL INPUT/OUTPUT
Engine Control
Engine Control Assembly
Engine Control Equipment
Governor Motor and C–1 Controller
Speed Sensor

SECTION 2 - SYSTEMS37 topics

PREFACE
SUMMARY OF MECHATRO CONTROL SYSTEM
Mechatro Control System In General
Unload Valve Control
Positive Control and P-q Control
Boom Up Conflux Control
Arm in Recirculation and Conflux Control
Arm-in Anti-cavitation Control
Arm-out Conflux Control
Bucket Digging (Dump) Conflux Control
Bucket Digging Anti-cavitation Control
Swing Priority Control
Travel Straight Control
Pressure Release Control
N&b Switch Control (Option)
Option Conflux Control (Option)
MECHATRO CONTROLLER
Summary Of Multi Display
Warning Table
Self Diagnosis Display
Service Diagnosis Display Function
Trouble History Diagnosis
Trouble Diagnosis Mode
Set Procedure of Maintenance Schedule
Adjusting Procedure of Display
For Operator
Function for Service
Setting the Language
Setting Adjusting Mode 1
Adjusting Overload Pressure
Drain Hydraulic Pressure
Mechatro Control Equipment
C-1 Mechatro Controller
Gauge Cluster (Symbol C-2)
Relay & Fuse Box (Symbol E-1)
High Pressure Sensor : YN52S00048P1
Low Pressure Sensor : YX52S00013P1

CHAPTER 1 - MECHATRO CONTROL SYSTEM61 topics

MEAS
NO.16 PRESS.SENSOR
SUMMARY
Function and Features of Hydraulic Circuit
HYDRAULIC CIRCUITS AND COMPONENTS
Hydraulic Control System Logic
Positive Control System
Symbols and Components
HYDRAULIC CIRCUIT
Hydraulic Schematic Legends
Hydraulic Schematic Diagram
HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION
Electric Circuit Diagram
Harness Connection
ELECTRIC EQUIPMENT LIST
ELECTRICAL SCHEMATIC
Electrical Schematic Diagrams
Diagram A
Diagram B
Diagram C
Dozer Electrical Circuit
HYDRAULIC PUMP ASSEMBLY OUTLINE
General View and Hydraulic Ports
Hydraulic Circuit Diagram
Specifications
Main Pump
Gear Pump (For Pilot)
PTO Gear Case
Operation
Rotary Group
Swash Plate Group
Valve Block Group
PTO Group
REGULATOR
Construction
Positive Flow Control
Adjusting The Regulator
Adjusting The Maximum Flow
Adjusting The Minimum Flow
Adjusting The Flow Control Characteristics
Causes Of Fault Resulting From Regulator
Control Curve Of Pump
PILOT VALVE (ATT) OUTLINE
General View
PILOT VALVE (TRAVEL) OUTLINE
Outside View
Performance Characteristics
Construction and Operation
CONTROL VALVE OUTLINE
Control Valve Outside View (1/2)
Control Valve Outside View (2/2)
Control Valve Ports
Control Valve (1/6)
Control Valve (2/6)
Control Valve (3/6)
Control Valve (4/6)
Control Valve (5/6)
Control Valve (6/6)
Main Relief Valve (601)
Boom Spool (301)
Lock Valve Selector (211)

CHAPTER 5 - AIR CONDITIONING SYSTEM43 topics

BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)
Air Cycle
Auto Air Conditioner System Outline
Component and Construction
Component
Receiver Dryer
Function
Mechanism of Cooling Circuit
Characteristics of Refrigerant
Component Parts
Evaporator
Expansion Valve
Compressor
Condenser
Disassembly and Assembly
Precautions to be Exercised in Operation
Removing Inner Air Filter
Removing Selector Box
Removing Main Harness
Removing Upper Unit Case
Replacing Blower Controller
Removing Heater Core
Replacing Evaporator and Expansion Valve
Replacing Motor Actuator
CHARGING REFRIGERANT
OPERATING PROCEDURE
Procedure for the Generation of Vacuum
Procedure for the Charging of the Gas
ELECTRIC CIRCUIT
Wiring Diagram and Connectors
Connectors
Structure and Operation of Each Functional Parts and the Inspection
TROUBLESHOOTING
Self Diagnosis Function On Display Of Panel
Position of Indication for Failure
Explanation of Indication for Failure
Failure of Motor Actuator
Failures of Sensors
Communication Error of Control Amplifier and Panel
Explanation of Monitor Mode
Position of Monitor Mode Indication
Operation of Monitor Mode
Contents of Monitor Mode Display

SECTION 3 - DISASSEMBLY AND ASSEMBLY96 topics

FRONT ATTACHMENT REMOVAL AND INSTALLATION
Attachment Assembly and Name
BOOM AND ARM
Removal
Installation
Standard Dimensions for Arm and Bucket Connection
BUCKET
Replacement of Bucket
Removing the Bucket
Installing the Bucket
Bucket Play Adjustment
Bucket Teeth Replacement
Removal and Installation
Bucket Cylinder Removal
Bucket Cylinder Installation
Arm Cylinder Removal
Arm Cylinder Installation
Boom Cylinders Removal
Boom Cylinders Installation
Positioner Cylinder Removal
Positioner Cylinder Installation
Assembly and Disassembly
Bucket Cylinder
Bucket Cylinder Disassembly
Bucket Cylinder Assembly
Arm Cylinder
Arm Cylinder Disassembly
Arm Cylinder Assembly
Positioner Cylinder (Triple Articulation Version)
Positioner Cylinder Disassembly
Positioner Cylinder Assembly
Boom Cylinders
Boom Cylinders Disassembly
Boom Cylinders Assembly
Maintenance Standard: Rod
Dozer Blade Removal
Dozer Blade Installation
UPPER STRUCTURE
Preparation
Removal of Upper Structure
Removal and Installation of the Cab
Removal and Installation of Counterweight
Disconnecting Hoses of Swivel Joint Lower Side
Removal and Installation of Main Frame
Hydraulic Pump Components
Disassembly
Assembly
Maintenance Standard
Repair Standards for Cylinder, Valve Plate and Swash Plate (Shoe Plate Face)
PTO GEAR CASING
Air Pulling Out Point
Removal of Control Valve
Installation of Control Valve
Control Valve Ports (1/2)
Control Valve Ports (2/2)
Components
Assembly and Disassembly of Control Valve
Preparation For Disassembly
SWING DEVICE
DESIGNATION AND LOCATION OF UNDERCARRIAGE
CRAWLER
Removing Crawler
Position Machine
Slacken Crawler Track Assembly
Removing Track Master Link
Remove Crawler Track Assembly
Installing Crawler
Preparation Before Installing Crawler
Winding Crawler Track Assembly
Connecting Master Link
Adjusting Crawler Track Tension
Crawler Construction
Shoe and Track link Assembly
UPPER ROLLER
Upper Roller Assembly
Upper Roller Construction
LOWER ROLLER
Track Lower Roller Assembly
Lower Roller Construction
FRONT IDLER (IDLER ADJUSTER ASSEMBLY)
Front Idler Components
Front Idler Construction
Separating the Idler Wheel from the Idler Spring Adjuster
Idler Wheel Construction
Disassembling Idler Wheel
Assembling Idler Wheel
Idler Wheel Specifications
Jigs for Idler Wheel
Idler Spring Adjuster Construction
Disassembling Idler Spring Adjuster
Assembling Idler Spring adjuster
Idler Spring Adjuster Specifications
Assembling the Idler Wheel to the Idler Spring Adjuster
SPROCKET
TRAVEL MOTOR
Travel Motor Assembly

SECTION 4 - TROUBLESHOOTING73 topics

OUTLINE
Judgment of Actual Trouble at Site
Verify background of trouble occurred
How to Diagnose Trouble
Explanation of the Cause of Trouble
CHECK POINTS FOR MECHATRO SYSTEM (FOR TROUBLESHOOTING)
Solenoid Proportional Valve Block
Low Pressure Sensor
High Pressure Sensor
Attaching Position Of Components
Location of Solenoid Proportional Valve Block
Location of Low Pressure Sensors for Pilot Operation
At Sensor Block
At Main Control Valve
At Travel Pilot Valves
Location Of Solenoid Valves and High Pressure Sensor
At Solenoid Valve Block
At Main Hydraulic Pump
ACTUATOR FOR TROUBLESHOOTING MECHATRO CONTROL
Actuator Table
TROUBLESHOOTING OUTLINE FOR MECHATRO CONTROL
Outline Table
TROUBLE DIAGNOSIS
No Operation is Possible
Machine Moves Unexpectedly With Lever in Neutral
All Attachment Motions are Slow
Only The Bucket Motion is Slow
Only The Boom Raise Motion is Slow
Motions Other Than Boom Raise, Arm In and Arm Out are Slow
Only Arm in Action is Slow
Only Arm Out Operation is Slow
All Attachment Operating Power is Poor
Bucket Digging Power is Poor
Boom Raise Operating Power is Poor
Arm In Power is Poor
Machine Cannot Perform Fine Operation of Bucket Digging and Dump
Machine Can Not Perform Fine Operation of Boom Raise and Lower
Machine Can Not Perform Fine Swing Operation
Machine Can Not Perform Fine Operation of Arm In and Out
Travel Ist and 2nd Speeds Can Not Be Changed Over
Travel Independent Speed is Low
Travel Power is Poor
Machine Does Not Travel Straight
Machine Deviates in Travel Independent Motion
Machine Drifts on a Slope (Machine Can Not Be Held on a Sl0pe)
Swing Motion Does Not Work
Swing Speed is Slow
Swing Power is Poor
Swing Motion Drifts Very Large
Swing Motion Is not Held on a Slope
Abnormal Sound is Heard During Swing Operation
Electric System Table
MULTIDISPLAY SELF DIAGNOSTIC TABLE
No Motions Operate
Machine Move Unexpectedly When Lever is at Neutral
All Motions are Slow
Only Bucket Motion is Slow
Only Boom Up Speed is Slow
Machine Motions are Slow Except Boom Raise or Arm Out
Only Arm In Motion is Slow
Only Arm Out Motion is Slow
Attachment All Motion Power is Poor
Bucket Motion Power is Poor
Boom Raise Motion Power is Poor
Arm In Motion Power is Poor
Fine Operation of Bucket Digging Motion Can Not be Performed
Fine Operation of Boom Raise and Lower Motions Can Not be Performed
Fine Operation of Arm In and Out Motions is not Possible
Travel 1-2 Speeds Can Not be Changed
Machine Drifts on a Slope at Parking
Swing Motion Can Not be Held on a Slope
Fine Operation of Swing Motion Can Not be Performed
Auto Idling Stop (AIS) Does Not Function

CHAPTER 3 - TROUBLESHOOTING ELECTRICAL SYSTEM10 topics

Color
Mechatro controller error
failure
Battery relay fail
ROM data
Mechatro set error
SET ERROR
sensor fail
fail
proportional valve fail

ENGINE44 topics

F4GE - ENGINES
F4HE - ENGINES
CODING OF SOURCE ENGINES
ENGINE PROPERTIES
GENERAL ENGINE FEATURES
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY
VALVE GEAR - CYLINDER ASSEMBLY
TORQUE SPECIFICATIONS (F4GE) - ENGINES
TORQUE SPECIFICATIONS (F4HE) - ENGINES
SPECIAL TOOLS
DESCRIPTION OF MAIN ENGINE COMPONENTS
ACCESSORY EQUIPMENT DRIVE
COUNTER BALANCER - F4GE ENGINES
ENGINE LUBRICATION - F4GE ENGINES
ENGINE LUBRICATION - F4HE ENGINES
COOLING SYSTEM
AIR INDUCTION BOOST DIAGRAM
MECHANICAL INJECTION FEEDING SYSTEM - F4GE ENGINES
ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES
KKSB COLD START ADVANCE SYSTEM - F4GE ENGINES
FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION - F4GE ENGINES
HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL) - F4HE ENGINES
EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION
FUEL SUPPLY SYSTEM - F4HE ENGINES
COMMON RAIL
COMMON RAIL PRESSURE RELIEF VALVE
ELECTRO-INJECTOR
CHECKING THE FUEL SYSTEM
SPECIAL DISASSEMBLY - F4GE ENGINES
SPECIAL DISASSEMBLY - F4HE ENGINES
CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES
CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE
CAMSHAFT
REASSEMBLY
CRANKSHAFT
PISTONS
VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY
INJECTION PUMP TIMING FIRST PHASE - F4GE ENGINES
ASSEMBLING COUNTER BALANCER - F4GE ENGINES
FLYWHEEL
MOUNTING THE OIL AND WATER PUMP
CYLINDER HEAD FOR F4GE ENGINES
VALVES
MOUNTING CYLINDER HEAD

SECTION 5 - ENGINE14 topics

Engine Won’t Start
Engine Overheats
Engine Lacks Power and Runs Erratically
Engine lacks power and runs erratically (continued)
Engine Exhaust Smoke Black or Dark Grey
Engine exhaust smoke black or dark grey (continued)
Engine Exhaust Smoke Grey (Verging On White)
Engine Exhaust Smoke Light Blue
Engine Knocks Irregularly
Engine Stops
Excessive or Insufficient Oil Pressure
Excessive or Insufficient Oil Pressure continued
Excessive Fuel Consumption
Engine Won’t Stop

CHAPTER 2 - 445TA ENGINE OVERHAUL47 topics

F4GE9454H and F4GE9454J Engine
F4GE9484D Engine
F4HE9484A Engine
Engine Block
Crankshaft Oil Seals
Connecting Rods
EGR Exhaust Gas Recirculation System
Valve Control for F4GE Engines
Valve Control for F4HE Engines
Cylinder Head for F4GE9454H and F4GE9454J Engines
Cylinder Head for F4GE9484D Engines
Cylinder Head for F4HE9484A Engines
Valves and Valve Seats for F4GE engines
Valves and Valve Seats for- F4HE Engines
Engine Flywheel
Heat Exchanger
Oil Pressure Control Valve
By-Pass Valve
Oil Pump
Oil Pan (Sump)
Oil Vapor Recirculation for F4GE Engines
Oil Vapor Recirculation for- F4HE Engines with Blow-by Filter
Blow-By Recirulation
Oil Vapor Recirculation for- F4HE Engines without Blow-by Filter
LOCATION OF MAIN ELECTRICAL COMPONENTS - F4GE ENGINES
Coolant Temperature Sensor
Rotary Injection Pump
KKSB Water Temperature Sensor
Oil Pressure Sensor
Grid Heater
LOCATION OF MAIN ELECTRICAL COMPONENTS - F4HE ENGINES
EDC7UC31 Electronic Control Unit
Cabling Connector Pinout On Engine
Connector (A) Injectors Pinout Diagram
Connector (C) Sensors Pinout Diagram
Crankshaft Sensor
Camshaft Sensor
Boost Temperature - Pressure Sensor
Engine Oil Temperature - Pressure Sensor
Common Rail Fuel Pressure Sensor
Electro-injectors
Grid Heater and Control Relay
Fuel Temperature Sensor
High Pressure Pump - Pressure Regulator
STARTER MOTOR
Quick Diagnosis
ALTERNATOR

Inside this manual

Real pages from this service manual (920 pages). Open the sample pages (PDF, 815 KB)

Sample pages from the Kobelco ED195-8 Tier 3 Excavator Dozer Service Manual: Specifications, Diagram, Troubleshooting, Color page, Color page, Foldout diagram (color)

Specifications, page 81: CHAPTER 2 - SPECIFICATIONS
Diagram, page 529: CHAPTER 2 - UPPER STRUCTURE
Troubleshooting, page 683: CHAPTER 3 - TROUBLESHOOTING ELECTRICAL SYSTEM
Color page, page 71: Issued 02-2008
Color page, page 217: Issued 02-2008
Foldout diagram (color), page 234: Issued 02-2008

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 920 pages

Quantity one is the manual described above.

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Ships in 1 business day.

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