Document number S5RO0002E NA on the cover marks this as the maker's own factory book: the 331-page Kobelco SK024, SK027, SK032 shop manual PDF for all three compact hydraulic excavators. Hydraulic schematics trace oil from the pump through the control valve's main relief, port relief and anti-cavitation valves, and wiring diagrams map the electrical circuits that feed the solenoid valves. Travel motors get separate disassembly chapters, since the 027 runs a different unit than the 024 and 032, and troubleshooting fills roughly the last sixth of the book, sorted by overall machine, travel, slewing and boom faults. Check boom and arm pressure on the 024 against 200 kgf/cm², and keep engine oil at or below the 4.7 L upper limit on the pan. Out on site with a stalled machine, you have no one to ask. Bookmarked and text-searchable, the PDF travels on your laptop or tablet to wherever the excavator is parked.
What's Inside This Kobelco SK024, SK027, SK032 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 14-27 | General Precautions, Precautions for Disassembly and Assembly, Precautions for Removing and Installing Hydraulic Units |
| Specifications | 28-81 | Specification Diagrams, Lifting Capacities, Specification Tables |
| Machine Configuration | 82-140 | Drive System, Slew System, Travel System, Upper Frame |
| Hydraulic Pump | 141-154 | Pump Construction, Pump Operation, Disassembly and Assembly, Inspecting and Adjusting, Troubleshooting |
| Control Valve | 155-174 | Valve Construction, Main Relief Valve, Port Relief Valve, Anti-Cavitation Valve, Solenoid Valve, Troubleshooting |
| Cylinder | 175-198 | Boom Cylinder, Arm Cylinder, Bucket Cylinder, Dozer Blade Cylinder, Swing Cylinder, Disassembly and Assembly |
| Travel Motor (SK024, SK032) | 199-226 | Reduction Gear, Counterbalance Valve, 2-Speed Control Valve, Disassembly and Assembly, Inspecting and Adjusting |
| Travel Motor (SK027) | 227-244 | Hydraulic Motor, Reduction Gear, Counterbalance Valve, 2-Speed Control Valve, Disassembly and Assembly |
| Slew Motor | 245-268 | Hydraulic Motor, Reduction Gear, Brake Valve, Disassembly and Assembly, Inspecting and Adjusting |
| Swivel Joint | 269-278 | Swivel Joint Construction, Disassembly and Assembly, Inspecting and Adjusting, Troubleshooting |
| Troubleshooting | 279-331 | Overall Machine, Machine Travel, Slewing, Boom |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic Hose Fittings Union Nut (PF) 1/8 Torque | 1.0 ± 0.5 kgf-m (7.3 ± 3.5 ft-lb) | p. 24 |
| Hydraulic Hose Fittings Union Nut (PF) 1/4 Torque | 2.5 ± 0.5 kgf-m (18.1 ± 3.5 ft-lb) | p. 24 |
| Boom Hydraulic Oil Pressure | 200 kgf/cm² | p. 72 |
| Arm Hydraulic Oil Pressure | 200 kgf/cm² | p. 72 |
| Engine Oil Pan Upper Limit | 4.7L | p. 55 |
| Engine Oil Pan Lower Limit | 2.9L | p. 72 |
| Bore (dimension A) replacement limit | 37.49 mm | p. 151 |
| Shaft diameter | 17.968 mm | p. 152 |
| Overall Displacement 1st gear (SK024) | 798 cc/rev. | p. 202 |
| Overall Displacement 2nd gear (SK024) | 420 cc/rev. | p. 202 |
| Hydraulic Hose Fitting Union Nut (PF) 1/8 Torque | 1.0 ± 0.5 kgf-m | p. 24 |
| Hydraulic Hose Fitting Taper Threads (PT) 1/8 Torque | 1.2 ± 0.12 kgf-m | p. 24 |
Kobelco SK024, SK027, SK032 Common Problems This Manual Covers
Kobelco SK024, SK027, SK032 engine runs but boom, arm, bucket, travel and slew functions all inoperable
Check the hydraulic fluid level first, top up with the same brand already in the machine, then repressurize the tank as shown on page 285. If the level is fine, relieve all pressure in the system before disconnecting any lines (page 10). Then pull the pump discharge hose, plug it, and crank on the starter with the throttle at engine stop. If the pump puts out no fluid, the pump or coupling is faulty.
Manual Section: Overall Machine Troubleshooting p. 284Hydraulic functions operate but have no power, with pump making unusual noise
Check the suction piping for air leaks by coating suspect joints with grease or oil and watching for air being drawn in. Then check the suction filter for clogging and pressurize the hydraulic tank (page 287). Gauge the relief valve at the test port. If pressure does not rise with a 1/4 turn of the setting screw, the relief valve is faulty.
Manual Section: Overall Machine Troubleshooting p. 287Right or left track will not travel while other hydraulic actuators operate normally
Measure the travel spool stroke against 6.0 mm. Replace the housing block if the spool sticks or is scratched, and check for a loose return spring bolt (page 290). Relieve pressure before breaking any lines (page 10), then gauge the swivel joint hose at the counter balance valve for 200 ±10 kgf/cm². Pull the counter balance plunger: it should move 10 mm smoothly under your finger (page 291).
Manual Section: Machine Travel Troubleshooting p. 290Travel speed drops on one side and the machine tracks in curves
Check crawler belt tension and clear out any foreign objects first. Swap the pump's left and right discharge hoses; if the curve reverses, the pump is faulty (page 293). Relieve pressure before disconnecting hoses (page 10). Measure travel motor drainage at 50 to 60 °C and rated RPM. It should be 600 cc/min or less at low speed and 1,000 cc/min or less at high speed (page 294).
Manual Section: Machine Travel Troubleshooting p. 294Boom, arm and bucket do not operate while the machine is traveling
Check the fuse for the solenoid valve circuit. Move the travel levers, set the limit switch On, and test for current at the solenoid valve with the engine off (page 298). Press lightly on top of the solenoid valve; your finger should drop slightly when it works. Gauge the linear travel valve ports while the machine travels and look for a 5.5 kgf/cm² differential. Take safety precautions, because these readings are taken with the machine moving.
Manual Section: Machine Travel Troubleshooting p. 298Machine does not slew and slew pressure reads low or will not rise
Check spool operation first and repair or replace the housing block if it is faulty (page 299). Measure slew pressure. If it is low, adjust the relief valve on the slew brake valve to set pressure. If it will not rise, repair or replace the brake valve. If pressure is normal, inspect the slew motor, then the slew reduction gear and the slew bearing.
Manual Section: Slewing Troubleshooting p. 299Frequently Asked Questions
What are the hydraulic pressure test procedures for the Kobelco SK024, SK027, and SK032?
To test hydraulic pressure, mount a pressure gauge on the pressure detection port, operate the desired hydraulic circuit, and measure the relief pressure. The engine must be at rated R.P.M. with a hydraulic oil temperature between 50°C and 60°C. For the boom, arm, and dozer blade, the relief valve is normal if the reading conforms to 200 +10/0 kgf/cm². p. 74
Why does the Kobelco SK024/SK027/SK032 have weak or slow hydraulics?
Weak or slow hydraulics can be caused by low hydraulic fluid levels, a clogged suction filter, or a faulty hydraulic pump. If the pump generates unusual noises, check for faulty suction lines or air bubbles in the tank. Refer to the troubleshooting flow charts on pages 284 and 286 for specific diagnostic steps. p. 286
What are the replacement specs for the hydraulic return and suction filters on the Kobelco SK024, SK027, SK032?
The manual specifies that the suction filter is a 150 mesh type. If excessive wear is discovered during disassembly, be sure to replace both the hydraulic fluid filters and return filters. p. 130
What is the torque spec for the engine mount damping rubber nuts on the Kobelco SK024, SK027, SK032?
When installing the engine, the torque specification for the damping rubber nuts is 9.9 kgfm. p. 93
What is the procedure for bleeding air from the hydraulic cylinder?
Always bleed cylinders after removing or mounting them. Start the engine and let it idle for 5 minutes, then extend and retract the cylinder four or five times at low speed, ensuring you do not allow any relief. Finally, repeat the procedure with the engine at full speed, this time allowing relief at the end of the stroke. p. 194
How will I receive this Kobelco SK024 Shop Manual?
A single searchable PDF file of 331 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Can I print a copy of this Kobelco SK024 Shop Manual for the shop?
Yes. Print the pages or sections you need for your own shop use. Any standard printer works.
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