Kobelco SK295-8 Tier 3 Crawler Excavator Service Manual

Name: Kobelco SK295-8 Tier 3 Crawler Excavator Service Manual
Brand: MidWestTech
SKU: 87694088
Price: 89.65 USD
Availability: InStock

838 pages · Publication 87694088

$89.65

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Models: SK295-8 Tier 3
Manual type: Service Manual
Pages: 838
Publication: 87694088
Condition: Brand new

Kobelco SK295-8 Tier 3 Crawler Excavator Service Manual, publication 87694088

What's inside

From the manual's own table of contents: 9 sections, 481 entries. See sample pages (PDF, 751 KB)

Search the contents

SK295-8 SHOP MANUAL1 topic

Section Table of Contents

SECTION 1 - SAFETY AND GENERAL INFORMATION140 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
MAIN COMPONENTS
Main Components – Upper Structure
Main Components – Under Carriage
Main Components – Front Attachment
Hydraulic Components
Hydraulic Pump
Control Valve
Pilot Valve
Swing Motor Unit
Travel Device
Cylinders
Excavator Performance
Engine Data
Digging Data
Transporting Dimensions
Bucket Applications as a Function of the Arms SK295-8
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 JOINTS
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)
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 Equipment
Speed Sensor
Work Mode Select Switch
Adjustment of Mechatro Controller Output
Purpose of the Adjustment
In Cases Where the Adjustment of Mechatro Controller Is Required
Preparation

CHAPTER 5 - ATTACHMENT DIMENSIONS15 topics

BOOM
Boom Dimensional Drawings
Boom Maintenance Standards
Clearance of Pin and Bushing on Boom Section
Clearance in Thrust Direction on the Boom Cylinder Installation Section
Clearance In Thrust Direction on the Boom Foot Installation Section
Arm Dimensional Drawing - Standard Arm 3.2 Meter (10 Ft 6 In)
Arm Dimensional Drawing - Short Arm 4.0 Meter (13 Ft 1 In)
Arm Maintenance Standards
Clearance of Pin and Bushing on Arm Section
Clearance in Thrust Direction on Arm and Arm Cylinder Installation Section
Clearance in Thrust Direction on Idler and Bucket Links Installation Section
BUCKET
Bucket Installation
Bucket Specifications

SECTION 2 - SYSTEMS38 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
Adjustment of Optional Hammer/Nibler
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 SYSTEM125 topics

COMMUNICATION OFF
Washer motor relay
SUMMARY
HYDRAULIC CIRCUITS AND COMPONENTS
Hydraulic Circuit Diagram
N&B Hydraulic Circuit (Option)
N&B Hydraulic Circuit Diagram
Holding Valve For Boom and Arm (Option)
Holding Valve For Boom And Arm Hydraulic Circuit Diagram
Color Coding Standard For Hydraulic Circuits
Neutral Circuit
Operation of Bypass Cut Valve and Unloading Valve Housed in Control Valve
Safety Lock Lever and Pilot Circuit
Pump Positive Flow Control
Pump P-q Curve Control Operation
Neutral Circuit: Positive Control Function At Safety Lock Lever Down (Unlocked Position)
Travel Circuit
Travel Forward Pilot Simultaneous Operation Circuit
2-speed Travel Solenoid Command Circuit and Auto 1st Speed Return Function
Travel Main Circuit
Travel Motor Function
Travel Circuit: Travel 2nd Speed, Rh & Lh Simultaneous Operation
Bucket Circuit
Pilot Circuit For Bucket Digging
Auto Acceleration Operation
Flow Control in the Work Mode
Bucket Digging and Travel Priority Confluence (Conflux) Main Circuit
Bucket Spool Stroke Limiter
Control)
Boom Circuit
Boom Raise Pilot Circuit
Boom Up 2 Pumps Conflux Main Circuit in C/V
Boom Circuit: Boom Up Operation, Confluence Function
Boom Down Pilot Circuit
Prevention Of Natural Fall By Lock Valve And Actuation At Lowering
Constant Recirculation Function of Boom Down Main Circuit
Boom Circuit: Boom Down Operation and Prevention of Natural Boom Falling
Swing Circuit
Pilot Circuit for Left Swing
Swing Auto Parking Brake
Swing Main Circuit
Swing Motor Circuit
Swing Circuit: Swing Operation (LH)
Arm Circuit
Arm In, Light-load Operating Pilot Circuit
Arm-in, Light-load Variable Normal Recirculation, Internal Conflux Main Circuit
Arm Circuit: Arm In (Light Load) Operation, Arm Variable Recirculation and Cavitation Function
Arm In, Heavy Load Operating Pilot Circuit
Arm In, Heavy Load Operating Recirculation Cut Main Circuit
Arm Circuit: Arm In (Heavy Load) Operation, Arm Confluence And Recirculation Cut Function
Arm Out Pilot Circuit
Arm Out 2 Pumps Conflux Main Circuit
ELECTRICAL SYSTEM MAIN COMPONENTS
Electrical System (Overall System)
Cab Control
Electrical Components
Cluster Gauge
Control Lever, Safety Lever
Cluster Gauge Wiring Harness
Mechatro Controller and Fuses & Relay Box
Fuse & Relay box
Fuses
Relays
Batteries, Batteries Relay, Fuses Link
Hydraulic System Electrical Components (1/2)
Hydraulic System Electrical Components (2/2)
Engine Electrical Components
Electrical Components (Lights, Horns)
ELECTRICAL SYSTEM DIAGRAMS
Electrical System Diagram Reading Key (No. 1)
Electrical System Diagram (No. 1)
Electrical System Diagram Reading Key (No. 2)
Electrical System Diagram (No. 2)
Electrical System Diagram Reading Key (No. 3)
Electrical System Diagram (No. 3)
Electrical System Diaram Reading Key (No. 4)
Electrical System Diagram (No. 4)
Electrical System Diagram Reading Key (No. 5)
Electrical System Diagram (No. 5)
WIRING HARNESS
Cluster Guage Wiring Harness Assemby Reading Key
Cluster Gauge Wiring Harness Assembly Diagram
Platform Wirng Harness Assembly Reading Key
Platform Wiring Harness Assembly Diagram
Upper Frame Wiring Harness Assembly Reading Key
Upper Frame Wiring Harness Assembly Diagram
HYDRAULIC PUMP ASSEMBLY OUTLINE
General View and Hydraulic Ports
Specifications
Main Pump
Gear Pump (For Pilot)
PTO Gear Case
Operation
Rotary Group
Swash Plate Group
Valve Block Group
PTO Group
REGULATOR
Construction
Adjusting the Regulator
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)
Over Load Relief Valve (602, 603)
Lock Valve Selector (211)
Bypass Cut Valve (605)
Swing Shuttle Valve Cover (204)
Boost Check Valve (517)
In Neutral Position

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 ASSEMBLY67 topics

FRONT ATTACHMENT
Removal
Installation
Maintenance to be Performed When Required
Replacement Of Bucket
Removing the Bucket
Installing the Bucket
Bucket Play Adjustment
Bucket Teeth Replacement
Cylinders Removal and Installation
Bucket Cylinder Removal
Bucket Cylinder Installation
Arm Cylinder Removal
Arm Cylinder Installation
Boom Cylinders Removal
Boom Cylinders Installation
CYLINDER DISASSEMBLY AND ASSEMBLY
Bucket Cylinder
Bucket Cylinder Disassembly
Bucket Cylinder Assembly
Arm Cylinder
Arm Cylinder Disassembly
Arm Cylinder Assembly
Boom Cylinders
Boom Cylinders Disassembly
Boom Cylinders Assembly
Maintenance Standard: Rod
UPPER STRUCTURE
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
Disassembly and Assembly of Hydraulic Pump Device
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)
Control Valve Diagrams
Components
Assembly and Disassembly of Control Valve
Preparation For Disassembly
Disassembling P1 Unload Spool
Disassembling the Travel Spool (Left Travel and Right Travel)
Disassembling the Boom Conflux Spool
SWING BEARING
Tool Table
SWIVEL JOINT
Inspection After Assembly
TRACKS
Link Pin and Track Bushing
Master Pin
Master Bushing
Grouser Shoe
TRACK ADJUSTER (WITH FRONT IDLER)
DISASSEMBLY AND ASSEMBLY TRACK ADJUSTER
FRONT IDLER ASSEMBLY
Front Idler
Axle and Bushing
UPPER ROLLER
LOWER ROLLER

SECTION 4 - TROUBLESHOOTING10 topics

TROUBLESHOOTING OUTLINE
Judgment Of Actual Thing At Site
Get To The Site As Quickly As Possible
Verify Background Of Trouble Occurred
How To Diagnose Trouble
Explanation Of The Cause Of Trouble
Classification Of Failure And Troubleshooting
The Blown Fuse of Mechatro Controller
TROUBLESHOOTING BY ERROR CODE
Error Codes

CHAPTER 2 - TROUBLESHOOTING BY TROUBLE33 topics

TROUBLESHOOTING BY TROUBLE
All Controls Do Not Function/Slow
Engine Down/Stalled
Move at Lever Neutral Position
Poor Fine Operability
Slow Boom Up, Insufficient Power
Slow Boom Down, Insufficient Power For Lifting Up Body
Slow Arm In, Insufficient Power
Slow Independent Arm Out (In The Air)
Slow Bucket Digging
Slow Bucket Dump
Swing Operation Not Functioned/Slow
Noise During Swing Operation
Swing on a Slope Drifts When Control Lever is in Neutral Position
Swing Drifts When Swing Operation is Stopped
Slow Travel Speed/Weak
Travel Deviation
Travel 1st/2nd Speed Not Changed
Travel Parking on a Slope is Not Held
Travel Does Not Run Straightly When Both Crawlers and Attachment Operated Simultaneously
Slow Breaker (Crusher) Operation, Weak Power
Option Selector Valve Malfunction: Not Switched To Breaker Circuit
Option Selector Valve Malfunction: Not Switched To Nibbler Circuit
Electric Systems
Wiring Checking Procedure
Trouble
Engine Does Not Stop
CPU Data Communication Error is Displayed on Multi Display
Auto Accel Does Not Actuate
Wiper Does Not Function
How To Use and Flow Chart
Table 1 - Failure Diagnosis Mode-1/ Diagnosis Item
Table 2 - Failure Diagnosis Mode-1/ Diagnosis and Remedy

Inside this manual

Real pages from this service manual (838 pages). Open the sample pages (PDF, 750 KB)

Sample pages from the Kobelco SK295-8 Tier 3 Crawler Excavator Service Manual: Specifications, Diagram, Troubleshooting, Color page, Color page, Foldout diagram (color)

Specifications, page 132: CHAPTER 5 - ATTACHMENT DIMENSIONS
Diagram, page 216: Issued 02-2008
Troubleshooting, page 780: CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES
Color page, page 458: Issued 08-2007
Color page, page 520: Issued 08-2007
Foldout diagram (color), page 222: 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, 838 pages

Quantity one is the manual described above.

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