The Kobelco K909-II, K909LC-II shop manual PDF (OEM ID S5LQ0003E-02) takes both hydraulic excavators apart across 531 pages, from the travel reduction unit and swivel joint through the hydraulic pump, control valve and every cylinder. Hydraulic schematics trace oil from the pump through the control valve to the swing and travel motors, and wiring diagrams map the electrical system down to the cluster gauge and Intelligent Total Control System. Component overhaul fills more than half the book; troubleshooting sorts faults by drive, hydraulic, swing, travel and attachment system so you can pin a weak travel motor before a hose comes off. Expect each 23 x 17.6 x 2 mm shim to move the low pressure relief setting about 6 kgf/cm² (85 psi), and torque 22 x 3.0 mm tube fittings to 22 ± 2 kgf-m (158 ft-lbs). An excavator parked for want of one number costs your crew a day. Bookmarked, text-searchable, and yours to keep for this machine.
What's Inside This Kobelco K909-II, K909LC-II Manual
| System | Pages | Key Topics |
|---|---|---|
| Operation and Controls | 4-5 | How to Index Each Shop Manual Section, List of Shop Manual |
| Specification | 6-21 | Names of Components, General Dimensions, Specifications and Performance |
| Location and Weight of Components | 22-27 | Location of Components, Weight of Components, Transportation Weight |
| Maintenance Standards and Test Procedures | 28-59 | Pressure Measurement and Adjustment, Cylinder Speed, Cylinder Oil-Tightness, Swing Performance, Travel Performance |
| Troubleshooting | 60-83 | Drive System, Hydraulic System, Swing System, Travel System, Attachment System |
| Working Standards | 84-87 | Tightening Torques for Capscrews, Nuts, And Sleeves |
| Systems - Drive, Hydraulic, Swing, Travel, Attachment, Control, Upper Frame, Air, Electrical | 88-172 | Drive System, Hydraulic System, Swing System, Travel System, Attachment System, Control System, Upper Frame, Air System |
| Attachments | 173-192 | Attachment System, Backhoe Attachments, Removing/Installing Bucket and Arm, Maintenance Standards for Attachments |
| Control System | 193-206 | Engine Control System, Travel Control System, Hydraulic Control System, Solenoid Valve, Pressure Control Valve |
| Upper Frame | 207-220 | Fuel Tank, Counterweight, Cab, Upper Frame Disassembly/Mounting |
| Air System | 221-224 | Air System Operation, Compressor, Safety Valves, Air Reservoir |
| Electrical System | 225-238 | Electrical System Diagram, Cluster Gauge Lamp, Intelligent Total Control System |
| Components - Reduction Unit, Hydraulic Pump, Control Valve, Hydraulic Motor, Swivel Joint, Hydraulic Cylinder | 239-252 | Reduction Unit, Hydraulic Pump, Control Valve, Hydraulic Motor, Swivel Joint, Hydraulic Cylinder, Hydraulic Gear Pump |
| Hydraulic Pump and Regulator | 253-330 | Hydraulic Pump, Replacement Standards of Abrasive Parts, PQ Curve of Pump, Regulator |
| Hydraulic Motor (Swing) and Pilot Valve | 331-356 | Hydraulic Motor, Fault Finding of Motor Proper, Pilot Valve |
| Control Valve, Swing Control Valve and Travel Brake Valve | 357-436 | Control Valve, Pressure Adjustment for Relief Valves, Swing Control Valve, Brake Valve (Travel) |
| Hydraulic Motor (Swing) and Travel Motor | 437-470 | Hydraulic Motor, Hydraulic Motor (Travel), Parts Maintenance Standards |
| Swivel Joint | 471-482 | Usable Limit of the Parts, Inspection Procedure and Remedy |
| Hydraulic Cylinder | 483-502 | Preparation Before Disassembly, Inspection After Disassembly |
| Reduction Unit (Swing and Travel) | 503-531 | Reduction Unit, Shim Adjusting Procedure, Functional Principle |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Low pressure relief valve pressure adjustment | about 6 kgf/cm² (85 lbs/in²) per 23x17.6x2mm shim | p. 36 |
| Tightening Torque for Plug (152) | 0.85-1.15 kgf-m (6.1-8.3 ft-lbs) | p. 395 |
| Tightening torque for 10x1.5 mm tube size | 6 ± 1 kgf-m (43.3 ± 7.2 ft-lbs) | p. 87 |
| Tightening torque for 15x2.0 mm tube size | 15 ± 2 kgf-m (108 ± 14.4 ft-lbs) | p. 87 |
| Tightening torque of socketscrew (A) | 33 ± 3.0 kgf·m (238.1 ± 21 ft-lbs) | p. 100 |
| Tightening torque of socketscrew (C) | 44 ± 0.4 kgf·m (317.5 ± 3 ft-lbs) | p. 100 |
| Socket bolts fastening swing motor and swing reduction unit (LQ-1601~1788, LL-1201~1487) | 28.5 ± 3 kgf·m (205 ± 21.6 ft-lbs) | p. 141 |
| Socket bolts fastening swing motor and swing reduction unit (LQ-1789~, LL-1488~) | 18.5 ± 2 kgf·m (133 ± 14.4 ft-lbs) | p. 141 |
| Socket bolts fastening swing reduction unit and upper frame | 55 ± 6 kgf·m (396 ± 43.3 ft-lbs) | p. 141 |
| Valve plate and shoe plate hardness | HS78 min. | p. 466 |
| Gap between piston and caulked part of shoe | 0-0.1 mm | p. 467 |
| Boom Cylinder Weight | 220 kg (485 lbs) | p. 485 |
Kobelco K909-II, K909LC-II Common Problems This Manual Covers
Kobelco K909-II and K909LC-II excavator hydraulic oil temperature climbing abnormally high during a working shift
Check hydraulic oil volume and fill to the standard level, following the chart on page 63. Clean a clogged oil cooler and clear anything blocking airflow. Adjust fan belt tension or replace the belt. Verify main relief set pressure against 290 +5/0 kgf/cm² from page 33 and readjust it if low. If main relief is working very often, reduce the load.
Manual Section: Hydraulic System Troubleshooting p. 63Clogged suction strainer or air leak in pump suction line, hydraulic pump cavitating
Check hydraulic oil volume and fill to the standard level, following page 63. Make sure the oil viscosity is not too high, and replace the oil with one of proper viscosity if it is. Clean the suction strainer. Then check the pump suction line for air intrusion and retighten or replace the leaking parts.
Manual Section: Hydraulic System Troubleshooting p. 63Hydraulic oil drawn during routine service from the hydraulic tank looks cloudy
Drop a hydraulic oil sample on a hot plate, following page 63. If foam comes up, water is mixed in. Let the oil stand still, separate the water and dispose of it, or replace the hydraulic oil. If it does not foam, air is getting in. Check the suction line and return line and eliminate the source.
Manual Section: Hydraulic System Troubleshooting p. 63When operating the swing control, upper structure swing speed is low in one or both directions
Check whether the slow swing is in one direction or both, following page 65. For one direction, compare LH and RH secondary pilot pressure and clean or repair clogged or leaking pilot piping. Move the swing control valve spool by hand and repair it if it is stuck. For both directions, check external pilot pressure and clean the shuttle valve in the swing control valve.
Manual Section: Swing System Troubleshooting p. 65Upper structure swing unit drifts when the machine is parked at rest on a slope
Inspect the swing control valve return spring first and replace it if faulty, following page 67. Check swing relief pressure against the standard level, then adjust the swing relief valve pressure or replace the valve. Next, check the swing motor drain rate. If it is outside the standard value, the swing motor is broken and needs disassembly and repair.
Manual Section: Swing System Troubleshooting p. 67Travel action powerless while boom, arm and bucket functions still work normally
Check travel relief valve pressure against 350 +5/0 kgf/cm² from page 33. If it is out of spec, repair or replace the travel relief valve. Check that travel brake pressure is within the standard level, and repair or replace a defective travel brake valve, following page 70. If both pass, check the travel motor drain rate. A motor outside the standard is faulty.
Manual Section: Travel System Troubleshooting p. 70Frequently Asked Questions
What is the standard torque for a M10 bolt with no lubrication (4T) on the Kobelco K909-II?
The standard tightening torque for a M10 bolt (P=1.5) with no lubrication and 4T classification is 2.2 ± 0.20 kgf-m (15.9 ± 1.4 ft-lbs). p. 86
What is the standard cylinder speed for boom cylinder extension in H mode?
The standard cylinder speed for boom cylinder extension in H mode is 3.2 to 3.8 seconds. p. 38
What is the standard oil volume for the engine oil filter and other components on the Kobelco K909-II, K909LC-II?
The engine oil volume for the filter and other components is 4 liters (1.05 gallons). p. 20
How do I adjust the main relief valve pressure on a Kobelco K909-II, K909LC-II excavator?
On the Kobelco K909-II, first confirm the main relief pressure by relieving at the bucket and boom cylinder stroke ends (see the pressure table in the test procedures). To adjust, loosen the locknut and turn the main relief valve adjust screw: pressure rises when it is turned clockwise and falls when turned counterclockwise. A half turn of the adjust screw changes pressure by about 115 kgf/cm² (1,635 psi) (page 35). p. 35
What is the standard valve clearance for the engine on the Kobelco K909-II, K909LC-II?
The standard valve clearance for the engine (when cool) is 0.4 mm (0.016 in). p. 20
What exactly do I receive with this Kobelco K909-II Shop Manual?
Instant PDF download. You get the full 531-page searchable Shop Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print this Kobelco K909-II manual?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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