All 782 pages of this Fiat Kobelco E40.2SR, E50.2SR shop manual PDF (OEM #604.13.368) focus on one job: bringing your short-radius hydraulic excavator back to factory spec. You get complete hydraulic circuit diagrams, electrical schematics with harness connection charts, and troubleshooting trees that walk hydraulic, electrical, and engine faults down to the failed part. Inside: teardown and reassembly procedures for the attachments, upper slewing structure, travel system, and the engine itself, backed by torque tables for capscrews, joints, hoses, and sleeve-type tube fittings. Set the piston pump working pressure at 23.0 MPa (3340 psi), then torque the relief valve nut to 19.6 N-m before you button it up. No more chasing a pressure fault with borrowed numbers. Bookmarked with a live text layer, so you can jump to any section or search a spec right from your phone at the machine.
What's Inside This Fiat Kobelco E40.2SR, E50.2SR Manual
| System | Pages | Key Topics |
|---|---|---|
| E40.2Sr - E50.2Sr | 1-4 | Specifications, Maintenance Standards, Hydraulic System, Electrical System, Engine Specifications, Attachment Dimensions |
| Safety Precautions | 5-8 | General Safety Information, Warning Plates, Lubrication and Maintenance, Welding Repair, Hydraulic Lines and Hoses, Track Servicing |
| Outline | 11-20 | General Precautions for Repairs, International Unit Conversion System |
| Specifications | 21-38 | Components Name, Machine Dimensions, Specifications and Performance, Machine & Components Weight (Dry), Transportation, Type of Crawler Shoes, Type of Bucket, Engine Specifications |
| Attachment Dimensions | 39-62 | Boom, Arm, Bucket, Dozer, Swing |
| Tools | 63-74 | Torque Specifications for Capscrews & Nuts, Screw and Tool Sizes, Torque Specifications for Joints and Hoses, Torque Specifications for Sleeve Type Tube Fittings |
| Standard Maintenance Time Table | 75-86 | Standard Working Time Table for the Maintenance for Excavator |
| Maintenance Standards and Test Procedures | 87-108 | How to Use Maintenance Standards and Precautions, Performance Inspection Standard Table, Measuring Engine Speed, Measuring Hydraulic Oil Pressure, Measuring Travel Performances |
| Hydraulic System | 109-122 | Summary, Hydraulic Circuits and Component Models, Hydraulic Circuit Operation |
| Electrical System | 123-152 | How to Read Circuit Diagram and Harness Connection, Electrical Equipment & Harness |
| Components System | 153-246 | Hydraulic Components, Electrical Equipment |
| General Disassembly and Assembly | 247-252 | Contents of General Disassembly and Assembly, Specification of Tightening Torque |
| Attachments | 253-286 | Attachment Assembly and Name, Bucket, Arm, Boom, Swing, Dozer, Cylinder Disassembly and Assembly |
| Upper Slewing Structure | 287-420 | Canopy/Cab, Guards and Floor Plate, Counterweight, Hydraulic Pump, Control Valve, Solenoid Valve, Fuel and Hydraulic Oil Tanks, Generator, Starter, Radiator, Engine, Pilot Valve, Slewing Motor, Swivel Joint, Upper Frame |
| Travel System | 421-504 | Name of Travel System Parts, Crawler, Upper and Lower Rollers, Front Idler, Idler Adjuster, Sprocket, Travel Motor, Slewing Bearing, Maintenance Standards, Tools and Jigs |
| Troubleshooting (Hydraulic System) | 505-518 | General Precautions, Trouble Diagnosis: Hydraulic, Troubleshooting |
| Troubleshooting (Electrical System) | 519-530 | Trouble Diagnosis: Electric System, Troubleshooting |
| Troubleshooting (Engine) | 531-546 | Trouble Diagnosis: Engine, Troubleshooting, Electrical Equipment |
| Engine | 547-762 | General, Inspection and Adjustment, Troubleshooting, Disassembly, Inspection and Reassembly of Engines, Lubrication System, Cooling System, Fuel Injection Pump/Governor |
| Supporting Data | 763-782 | Hydraulic Circuit Diagram, Electric Circuit Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Joints for piping (O-ring sealing type) tightening torque | 17±2 N•m to 255±9.8 N•m | p. 69 |
| Hydraulic hose (30° flare type) tightening torque | 15±2.0 N•m to 137±15 N•m | p. 69 |
| Working pressure (Piston pump P1 + P2) | 23.0 MPa (3340 psi) | p. 158 |
| Working pressure (Gear pump P3) | 20.0 MPa (2900 psi) | p. 158 |
| Thermo switch continuity temperature | 107~113 °C | p. 607 |
| Engine Output Rating | 30.4 kW | p. 28 |
| Slewing Speed | 8.8 min-1 | p. 28 |
| Cooling Water Capacity (Max) | 6.0 L | p. 36 |
| Fuel Injection Pressure | 19.6 MPa | p. 36 |
| Main Relief Valve Pressure | 23.0 MPa | p. 93 |
| Engine Oil Volume (Max / Effective) | 7.4 / 4.0 L | p. 36 |
| Valve Clearance (intake & exhaust, cold) | 0.2 mm | p. 36 |
Fiat Kobelco E40.2SR, E50.2SR Common Problems This Manual Covers
Fiat Kobelco E40.2SR hydraulic system slow and weak under load, boom and arm barely lift
Check the hydraulic oil level first, then tee a pressure gauge into the pump outlet and stall each circuit. Main relief should hold 23.0 MPa; the measuring procedure starts on page 93. If pressure tests low, work the pump and attachment diagnosis charts beginning on page 505 before condemning the pump.
Manual Section: Troubleshooting (Hydraulic System) p. 505Engine cranks strong but will not fire, or starts hard and stalls under load
The 4TNV88-XYB is a mechanically governed swirl-chamber Yanmar with no engine ECU, so work it by measurement, not by code reading. Bleed the fuel system and change the cartridge paper fuel filter, then check compression against 3.4 ± 0.1 MPa (500 ± 14 psi) at 250 rpm and nozzle opening pressure against 19.6 MPa, both listed in the engine specifications on page 36. Injection timing is 15.5 ± 1° b.T.D.C. Follow the engine trouble-diagnosis charts starting on page 531.
Manual Section: Troubleshooting (Engine) p. 531Hydraulic pump noisy and jerky at operating temperature, cylinders shudder and cavitate on fast movements
Check the tank oil level and inspect the suction hose for cracks that pull in air; a hissing pump at idle confirms ingress. Tighten O-ring sealing pipe joints to specification, 17±2 N·m up to 255±9.8 N·m depending on size per the torque tables on page 69, then bleed the pump.
Manual Section: Troubleshooting (Hydraulic System) p. 505Travel motors weak on one side, machine pulls left or right when tracking straight
Swap the travel pilot lines side to side to determine whether the fault follows the motor or the control valve. Measure travel speed in both directions; each piston pump should deliver 57.1 L/min at 2400 rpm. If one motor lags, strip and inspect it per the travel system section starting on page 421.
Manual Section: Travel System p. 421Slewing sluggish with abnormal noise from swing motor, upper structure drifts on slopes
Check slewing speed against the 8.8 min-1 specification on page 28 with the engine at full throttle. If rotation drags or grinds, drain the reduction gear oil and look for metal, then inspect the swing motor per the upper slewing structure section starting on page 287. Replace worn rotating group parts as a set.
Manual Section: Upper Slewing Structure p. 287Engine overheats and coolant warning comes on during heavy digging in hot weather
Check the coolant level cold; total system capacity is 6.0 L, listed on page 36. Clean packed debris from the radiator core, then test the thermo switch, which should show continuity at 107 to 113 °C per page 607. Prove the cap and thermostat before blaming the water pump.
Manual Section: Engine p. 547Frequently Asked Questions
What are the torque specifications for hydraulic line fittings on a Fiat Kobelco E40.2SR/E50.2SR?
Use the machine-wide torque table in the Tools section, pages 69-70. For PF joints of the O-ring sealing type: 1/8 = 17±2 N•m (12±1 lbf•ft), 1/4 = 36±2 N•m (27±1 lbf•ft), 3/8 = 74±5 N•m (54±4 lbf•ft). For 30° flare type hydraulic hose fittings: 1/4 = 29±4.9 N•m (22±4 lbf•ft), 3/8 = 49±4.9 N•m (36±4 lbf•ft). Individual component sections repeat their own fitting torques, so where a procedure prints a figure beside the step, follow that one. p. 69
What are the cylinder head bolt torque specs for the Fiat Kobelco E40.2SR/E50.2SR?
The E40.2SR and E50.2SR are fitted with the Yanmar 4TNV88-XYB, so use the TNV84-88 column of the head bolt table on page 636: tighten in two steps, 41.1~46.9 N•m (4.2~4.8 kgf•m) first, then 85.3~91.1 N•m (8.7~9.3 kgf•m), in the reverse of the loosening order, with oil on the threads and seats. The neighbouring TNV82A, 4TNV94L/98 and 4TNV106(T) columns belong to other engines in the same Yanmar family, so do not use them on this machine. p. 636
What is the valve clearance for the Fiat Kobelco E40.2SR/E50.2SR engine?
For the Yanmar 4TNV88-XYB, both intake and exhaust valve clearance is 0.2 mm (0.008 in) measured cold, per the engine specifications on page 36. Adjust it with a 0.2 mm thickness gauge between the rocker arm and the valve cap, following the procedure on page 597. p. 36
What is the engine oil capacity of the Fiat Kobelco E40.2SR/E50.2SR?
The Yanmar 4TNV88-XYB takes 7.4 litres (1.96 gal) maximum with an effective capacity of 4.0 litres (1.06 gal), listed in the engine specifications on page 36. On the same page, cooling water capacity is 6.0 litres for the whole system and 2.7 litres for the engine alone. p. 36
What is the correct V-belt tension for the Fiat Kobelco E40.2SR/E50.2SR?
Press the V-belt with your thumb at approximately 98 N (10 kgf) in the middle of the belt span. Measured at position A the deflection should be 10~14 mm for a used belt and 8~12 mm for a new one; at position B, 7~10 mm used and 5~8 mm new; at position C, 9~13 mm used and 7~11 mm new (page 582). A belt only counts as new until it has run five minutes on the engine; after that, re-check it against the used-belt figures. p. 582
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