Diagnose, rebuild and adjust the Kobelco 140SR ACERA short-radius crawler excavator with the factory service manual, book S5YY0012E02. It runs from the Mechatro controller and hydraulic circuits to the travel motor, the air conditioner and the bound-in Mitsubishi D04FR-TAA engine manual.
Pulling the travel motor or splitting off the upper structure? The Disassembly and Assembly section covers attachments, the upper structure and the travel system. Troubleshooting lists error codes, diagnosis mode and faults by symptom. The standard hydraulic circuit diagram and electric circuit diagrams let you trace each one.
The engine data is all there: 4.249 L inline four, Bosch common rail with a CP1H pump, 24V 5kW starter and 24V 50A alternator (pages 943 to 945). Check those against what is bolted to your machine and you order the right part number the first time.
What's Inside This Kobelco 140SR ACERA Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety and General Information | 1-55 | General Precautions for Repairs, Specifications, Attachment Dimensions |
| Maintenance | 56-127 | Tools, Standard Maintenance Time Table, Maintenance Standards and Test Procedures |
| Mechatro Control System | 128-198 | Mechatro Controller, Self Diagnosis Display, Trouble History |
| Hydraulic System | 199-234 | Hydraulic Circuits and Components, Standard Hydraulic Circuit Diagram, Nibbler and Breaker, Boom and Arm Safety and Offset Option Circuits |
| Electric System | 235-281 | Electric Circuit Diagrams, Mechatro Controller C-1 Sheets, Electrical Equipment |
| Components System | 282-399 | Hydraulic Components, Pumps, Control Valve, Swing and Travel Motors |
| Air Conditioning System | 400-449 | HVAC Air Conditioner, Wiring Diagram and Connectors |
| Cab Interference Prevention System | 450-474 | |
| Attachments | 475-515 | Attachment Disassembly and Assembly |
| Upper Structure | 516-693 | Upper Structure Disassembly and Assembly |
| Travel System | 694-794 | Travel System Disassembly and Assembly, Travel Motor, Travel Troubleshooting Table |
| Troubleshooting | 795-912 | Troubleshooting by Error Codes, By Trouble, Diagnosis Mode |
| Engine | 913-1144 | Mitsubishi D04FR-TAA Engine Service Manual: Main Specifications, Common Rail Fuel System, Diagnosis Codes, Disassembly and Reassembly |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine model | D04FR-TAA (Mitsubishi) | p. 943 |
| Cylinders | 4 cylinder in-line | p. 943 |
| Bore x stroke | 102 x 130 mm (4.02 x 5.12 in) | p. 943 |
| Displacement | 4.249 L (259 cu in) | p. 943 |
| Compression ratio | 17.8 | p. 943 |
| Firing order | 1-3-4-2 | p. 943 |
| Fuel system | Common rail fuel injection system, CP1H | p. 943 |
| Dry weight (engine) | Approx. 395 kg (870.8 lb) | p. 943 |
| Engine oil capacity (engine total) | approx. 17.5 L (4.62 US gal) | p. 944 |
| Coolant capacity (engine water jacket) | 6 L (1.6 US gal) approx. | p. 944 |
| Thermostat valve opening temperature | 71 ± 2°C (160 ± 3.6°F) | p. 944 |
| ECU model | EDC16UC40 | p. 944 |
| Starter output | 24V - 5kW | p. 945 |
| Alternator output | 24V - 50A | p. 945 |
| Air heater capacity | 2.1kW | p. 945 |
Kobelco 140SR ACERA Common Problems This Manual Covers
Slow travel on one or both tracks
Start in the Troubleshooting section. Page 883 has you check the travel right and left pressure sensors through the service diagnosis data list, then inspect the remote control valve. Only once both check out is it worth pulling the travel motor for inspection.
Manual Section: Troubleshooting - Troubleshooting by trouble p. 883Machine slides down on a slope
The travel system troubleshooting table on page 790 covers a machine that slides down on a slope. Block the machine so it cannot roll before working on or under it (page 7). If the GM travel motor was rebuilt recently, page 779 warns that a spool not inserted correctly causes internal leaks and performance deterioration.
Manual Section: Disassembly and Assembly - Travel System troubleshooting p. 790Intermittent fault that will not repeat in the shop
Pull the Mechatro trouble history first using the buzzer stop switch sequence on page 180. Page 802 says to cancel the data in the history, then reproduce the failed situation. A fresh entry logged during that run shows you what actually tripped, without old codes getting in the way.
Manual Section: Mechatro Control System - trouble history p. 802Sensor reading wrong or dropping out
The Electric System section carries the Mechatro controller C-1 connector sheets. Page 166 says to take connector and pin numbers from C-1, and wire numbers and colors from the electric circuit diagram or harness. Meter the circuit pin to pin before you order a new sensor.
Manual Section: Electric System - Mechatro controller C-1 connector sheets p. 166Frequently Asked Questions
How do I bring up the trouble history on the Mechatro controller?
Turn the starter switch ON, then press the buzzer stop switch for 10 seconds, five times in a row. The trouble history screen comes up, as shown on page 180. To delete it, hold the work mode change switch and buzzer stop switch together for 10 seconds or more until NO ERROR shows. p. 180
How do I erase engine diagnosis codes after a repair?
Engine codes are kept apart from the Mechatro trouble history. Per page 1116, select ERASE FAULT CODES from the FAULT CODES menu and press ENTER. Clear the Mechatro history with the switch sequence on page 180. Only clear codes once the fault is fixed, so you can tell if it comes back. p. 1116
My 140SR travels slow. Where do I start?
Page 883 sends you to the right and left travel pressure sensors first. Read them through the service diagnosis data list, then check the remote control valve. That tells you whether it is a sensor reading or a pilot-side problem before you pull the travel motor. p. 883
What is the engine oil capacity and thermostat spec on the D04FR-TAA engine in the Kobelco 140SR ACERA?
Total engine oil capacity is approx. 17.5 L (4.62 US gal), on page 944. The thermostat opens at 71 +/- 2 C, also on page 944. Page 943 covers the base engine: 4.249 L, 102 x 130 mm bore and stroke, firing order 1-3-4-2. p. 944
Where do I find connector pin numbers when chasing a sensor fault?
Page 166 points you to section C-1, the Mechatro controller connector sheets, for connector and pin numbers. Wire numbers and colors come from the electric circuit diagram or the harness itself. With both in hand you can meter a sensor circuit end to end instead of guessing. p. 166
