Drive, hydraulic, steering, travel and brake control systems are each worked through end to end in this 855-page Kobelco SK100W-2 shop manual PDF (OEM ID S5YE0002E) for the SK100W-2 hydraulic excavator. Hydraulic circuit diagrams trace the neutral, travel, slewing, bucket and boom circuits, while wiring diagrams lay out the electrical routing and troubleshooting charts help you narrow a fault. Steering work ends at toe-in adjustment. Axle, transmission and brake valve service follow, and brake work finishes with air bleeding. Hydraulic system set pressure is 34.3 MPa (350 kgf/cm²); torque a 15x2.0 mm nut and sleeve to 12 ± 1.2 kgf·m (88 ± 9 ft-lbs). Suspect slewing bearing wear on your machine? The maintenance standard and test procedure section covers that check, plus pilot and main circuit pressure measurement. Section bookmarks and a text layer let you find a fitting or screw size in the Work Standard tables before you place a parts order.
What's Inside This Kobelco SK100W-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Specifications | 7-21 | Name of Components, Specifications and Performance, Type of Bucket, Combination of Attachments, Working Range, Lifting Diagram, Engine Specifications |
| Location and Weight of Components | 22-27 | Location of Components, Unit Weight, Transportation Weight and Dimensions |
| Maintenance Standard and Test Procedure | 28-32 | Pilot Circuit Pressure, Main Circuit Pressure, Travel Performance, Slewing Performance, Attachment Operability, Slewing Bearing Wear |
| Operation | 33-44 | Pressure Measurement and Adjustment, Measurement of Travel Performance, Measurement of Slewing Performance |
| Work Standard | 45-50 | Tightening Torques for Capscrews and Nuts, Tightening Torques for Nuts and Sleeves, Screw Size and Tightening Tool Size |
| Systems Section Overview | 51-52 | |
| Drive System | 53-65 | Power Plant, Hydraulic Pump Removal, Coupling Installation, Radiator Installation, Engine Removal, Suction Stopper |
| Hydraulic System | 66-101 | Hydraulic Circuit Diagrams, Neutral Circuit, Travel Circuit, Slewing Circuit, Bucket Circuit, Boom Circuit |
| Steering System | 102-109 | Steering Valve, Steering Cylinder, Handle Assembly, Toe-In Adjustment, Steering Angle Adjustment |
| Travel System | 110-128 | Front Axle, Rear Axle, Transmission, Equalizer, Tire Specifications, Travel System Hydraulic Lines |
| Brake Control System | 129-140 | Wheel Brake, Parking Brake, Brake Valve, Selector Valve, Brake Oil Reservoir, Air Bleeding |
| Attachment | 141-157 | Operation of Attachment System, Attachment Pilot System, Dynamic Damper (DD) Circuit, Removal and Installation of Attachment, Maintenance Standard |
| Control System | 158-210 | Operator Control, Mechatro Control, Engine Control, Major Electrical Equipment |
| Upper Frame | 211-220 | Construction of Upper Frame, Hydraulic Tank, Removal and Installation of Counterweight, Removal and Installation of Cab, Maintenance Standard |
| Pneumatic System | 221-239 | Pneumatic System and Switch Operation, Pneumatic System Line, Outline of Pneumatic Equipment |
| Electrical System | 240-259 | Boom Working Light Harness, Engine Harness, Upper Harness, Steering Assy, Controller Assy |
| Air Conditioning System | 260-297 | Construction of Major Equipment, Disassembling and Assembling, Refrigerant Charging Method, Electric Circuit, Troubleshooting |
| Pump | 298-340 | Construction and Operation, Disassembly and Assembly, Regulator, Pump Control Curve, Hydraulic Gear Pump |
| Steering Valve | 341-445 | Pilot Relief Valve, Pilot Valve, Control Valve, Construction and Operation, Disassembly and Assembly, Troubleshooting and Measures to Be Taken, Pilot Check Valve |
| Hydraulic Motor | 446-503 | Swivel Joint, Construction and Operation, Disassembly and Assembly, Counter Balance Valve (Brake Valve), Anticavitation Valve, Maintenance Standard, Troubleshooting and Measure to Be Taken |
| Hydraulic Cylinder | 504-550 | Construction and Operation, Disassembly and Assembly, Maintenance Standard, Jig and Tools, Dozer Cylinder (Option) |
| Reduction Unit | 551-594 | Transmission, Construction and Function, Disassembly and Assembly, Maintenance Standards, Construction and Operation, Maintenance Standard, Troubleshooting and Measures to Be Taken |
| Rear Axle | 595-664 | Carrier Assy, Planetary Gearing and Hub Assy, Front Axle, Disk Brake Assy, Maintenance Standard |
| Engine | 665-855 | Group 12 Lubrication, Group 13 Fuel and Engine Control, Group 54 Electrical System |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for nuts and sleeves (Nippon A.M.C. 10x1.5 mm) | 5 ± 1 kgf·m (36 ± 7 ft-lbs) | p. 48 |
| Tightening torque for nuts and sleeves (Nippon A.M.C. 15x2.0 mm) | 12 ± 1.2 kgf·m (88 ± 9 ft-lbs) | p. 48 |
| Capscrew tightening torque (A) | 22 ± 1kgf·m | p. 63 |
| Capscrew tightening torque (B) | 22 ± 1kgf·m | p. 63 |
| Hydraulic System Set Pressure | 34.3 MPa (350 kgf/cm²) | p. 394 |
| Main Relief Valve Setting Pressure | 29.4 ± 0.5 MPa (300 ± 5 kgf/cm²) | p. 394 |
| Travel Relief Valve Setting Pressure | 31.9 ± 0.5 MPa (325 ± 5 kgf/cm²) | p. 394 |
| Engine Oil Capacity (Oil Pan) | 18 dm³ (18 L) | p. 756 |
| Engine Oil Capacity (Oil Filter) | 1.1 dm³ (1.1 L) | p. 756 |
| Transmission Oil Capacity | 12 L | p. 569 |
| Front Axle Oil Capacity | 10 L | p. 629 |
| Cylinder Head Bolt Tightening Torque | 145 N·m (15 kgf·m) + 90° ± 5° | p. 692 |
Kobelco SK100W-2 Common Problems This Manual Covers
Kobelco SK100W-2 control valve travel circuit not operating, or delayed response with lack of power
Measure travel relief valve pressure against 31.9 ± 0.5 MPa (325 ± 5 kgf/cm²) per page 394. Lower the bucket to the ground and relieve all oil pressure before disconnecting any lines (page 2). Disassemble and clean the main poppet and seat, repair sticking with an oilstone, replace a broken spring, clear the poppet orifice, then readjust and torque the locknut following page 432. Clear any clogged pilot system orifice.
Manual Section: Hydraulic System Troubleshooting p. 432Bucket, boom and arm do not operate, or operate slowly with lack of power and delayed response
Measure pilot secondary pressure first, then check main relief valve pressure against 29.4 ± 0.5 MPa (300 ± 5 kgf/cm²) from page 394, along with the port relief valves. With the bucket grounded and oil pressure relieved (page 2), disassemble the main spool, clean out foreign matter, repair sticking with an oilstone, replace a broken return spring and clear the pilot circuit per page 434. Replace spool or casing if clearance is large.
Manual Section: Hydraulic System Troubleshooting p. 434Cylinder self-weight drop is large with the control valve spool set to neutral
Measure pilot secondary pressure to confirm the spool returns fully to neutral, then check main relief, port relief and anticavitation check valve pressures following page 433. Lower attachments to the ground and relieve oil pressure before opening any lines (page 2). Clean foreign matter from casing and spool, replace any spring with permanent set, and replace spool or casing when clearance between them is large.
Manual Section: Hydraulic System Troubleshooting p. 433Slewing motor pressure does not rise, or slewing drift on a slope is too large
Check the slewing motor relief valve for a stuck plunger, broken spring, loose tightening or clogged plunger restrictor, and adjust it to specified pressure following page 385. Inspect spool and casing for sticking or large clearance, clean the pilot shuttle valve ball and seat, and repair anticavitation valve seats. Relieve all oil pressure before disconnecting any lines (page 2).
Manual Section: Slewing Motor Troubleshooting p. 385Hydraulic cylinder oil leakage from rod sliding surface with an oil ring forming on the rod
Lower the attachment to the ground, relieve oil pressure (page 2), and never check for leaks with your hands (page 3). Remove foreign matter and replace the U-packing and dust wiper following page 549. Dress rod flaws with an oilstone; if it still leaks, disassemble and recheck. Replace the rod if hard chromium plating is peeling, and replace damaged O-rings.
Manual Section: Hydraulic Cylinder Troubleshooting p. 549Steering handle too heavy, or steering cylinder improperly follows rotation of the handle
Realign the steering valve and column with the installing bolts, and tighten the six end cap socket head bolts evenly to 2.3 kgf·m following page 358. Check oil level and steering pump delivery, adjust relief valve set pressure, and bleed air from the Gerotor section. Relieve oil pressure before disconnecting lines (page 2), then replace a seized spool and sleeve or a failed steering cylinder piston seal.
Manual Section: Steering Valve Troubleshooting p. 358Frequently Asked Questions
What are the hydraulic pressure test points and specifications for the SK100W-2?
The main circuit pressure test points are at the PF1/4 plugs (a1) and (a2) of the main pump. The standard value for the main relief pressure is 125 kgf/cm² at the steering pump delivery port (PF1/4), and the pilot primary pressure standard value is 50 kgf/cm² at the a3 port. p. 31
What is the standard tightening torque for the cylinder head bolts on the 6D34-T engine in the Kobelco SK100W-2?
The cylinder head bolts must be tightened to 145 N·m (15 kgf·m) plus an additional 90° ± 5°. These bolts can be reused up to 3 times, and they must be tightened in a wet state. p. 122
What is the standard valve clearance for the 6D34-T engine on the Kobelco SK100W-2?
The standard valve clearance for both intake and exhaust valves when the engine is cold is 0.4 mm. p. 119
What is the correct oil quantity for the transmission on the SK100W-2?
The total oil volume for the transmission is 12 liters. p. 140
What is the procedure for bleeding air from the cooling system?
Remove the pressure cap and keep the coolant temperature at 90°C while the engine is idling. Keep the heater controller's adjustment lever at its maximum-temperature position to allow coolant to flow freely in the heater piping until the system is completely bled of air. p. 86
Do I get instant access to this Kobelco SK100W-2 Shop Manual?
You get a 855-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Can I print just the pages I need from this Kobelco SK100W-2 manual?
Yes. Print individual pages or full chapters for your own shop use, on letter or A4 paper.
