This shop manual covers the Mechatro control system in depth. It explains the mechatro controller and boom raise conflux. It also covers the self diagnosis and service diagnosis displays on the gauge cluster. The rest of the book covers hydraulic circuits by spec, electric harness drawings, the Isuzu BB-4BG1T engine, the travel system and attachment teardown.
A torque from memory or a pressure from the wrong model can crack a part or hurt someone. This book gives you Kobelco's tightening torque tables and its own procedures for measuring engine speed and hydraulic pressure.
It covers the SK115SR-1E, SK135SR-1E, SK135SRLC-1E and SK135SRL-1E, and some specs change between them. The SK115SR-1E runs a 24 V / 30 A alternator and the SK135 machines run 24 V / 50 A. Confirm your model so you order the right part the first time.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Outline | 6-11 | General Precautions for Making Repairs, International Unit Conversion System |
| Specification | 12-33 | Names of Components, General Dimensions, Weights of Components, Specifications and Performance, Types of Crawler and Bucket, Combinations of Attachment |
| Attachment Dimension | 34-51 | Boom, Arm and Bucket Dimensional Drawings and Maintenance Standards |
| Tools | 52-68 | Tightening Torques for Capscrews, Nuts and Sleeves, Screw Sizes, Plugs, Special Spanner for Tube, Special Tools, Screw Locking and Sealing Compounds, Lifting Jigs and Boom Foot Pin Pulling Tools |
| Standard Maintenance Time Schedule | 69-80 | Standard Maintenance and Replacement Times by Component Group, Attachment, Cab & Guard, Swing Frame, Standard Working Time Table |
| Maintenance Standard and Test Procedure | 81-104 | Performance Inspection Standard Table, Measurement of Engine Speed and Hydraulic Pressure, Travel, Swing and Attachment Performance Tests, Swing Bearing, Parking Brake Checks |
| Mechatro Control System | 105-124 | Mechatro Control System Summary, Boom Raise Conflux, Mechatro Controller, Self Diagnosis and Service Diagnosis Displays on the Gauge Cluster |
| Hydraulic System | 125-200 | Hydraulic Circuits and Components by Spec (EU STD, Dozer, Boom and Arm Safety, Extra, N&B), Color Coding Standard, Neutral and Travel Circuits, Hose Clipping Drawings |
| Electric System | 201-244 | Electric Circuit Diagram, Electrical Equipment List, Harness List and Harness Drawings |
| Components System | 245-380 | Hydraulic Pump and Regulator, Pilot Valves (ATT and Travel), Control Valve, Swing Motor Unit, Travel Motor, Swivel Joint, Hydraulic Cylinder, Dozer Control Valve, List and Specification of Electric Equipment |
| Air-Conditioner System | 381-416 | Construction and Piping, A/C Controller Wiring Diagram and Connectors, Troubleshooting |
| Disassembling and Assembling: Explanation | 417-419 | How the Disassembly Chapters Are Laid Out, Indication of Tightening Torques |
| Attachment | 420-454 | Removing and Installing Bucket, Arm and Boom, Cylinder Disassembly and Assembly |
| Upper Structure | 455-604 | Removing and Installing the Cab, Operator Seat, Battery, Counterweight, Guards, Air Cleaner, Muffler, Fuel Tank, Pump, Radiator and Oil Cooler, Control Valves, Pilot Valves, Swing Motor, Swivel Joint, Upper Frame; Disassembly of Pump, Control Valve and Pilot Valve |
| Travel System | 605-741 | Crawler, Upper and Lower Rollers, Front Idler, Travel Motor Removal, Installation and Disassembly |
| Troubleshooting: Mechatro Control | 742-750 | Outline, Actuator Table, Troubleshooting Outline for the Mechatro System |
| Troubleshooting: Hydraulic | 751-777 | Trouble Diagnosis Table and Hydraulic Troubleshooting, No Operation Is Possible, All Attachment Motions Are Slow, Only the Bucket Motion Is Slow, Only the Boom Raise Motion Is Slow, Only Arm Out Operation Is Slow, Boom Up Operating Power Is Poor, Arm in Power Is Poor |
| Troubleshooting: Electric | 778-798 | Trouble Diagnosis Table, Self Diagnosis Table, Service Diagnosis Table, Electrical Troubleshooting Flowcharts |
| Troubleshooting: Engine | 799-808 | Engine Trouble Diagnosis Table and Troubleshooting Flowcharts, Starter Does Not Run, Starter Turns But Engine Is Hard to Start, E/G Output Is Insufficient, Overheat, E/G Does Not Stop |
| Engine | 809-963 | Isuzu Engine: General, Engine Proper, Lubrication and Cooling Systems, Troubleshooting, Special Tools, Repair Standard, Turbocharger, Starter, Alternator |
| Installation Procedures for Optional Attachment | 964-1022 | Mounting the Breaker and Nibbler: Additional Parts, Modification Items, Piping and Electrical Installation |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine model | Isuzu BB-4BG1T | p. 25 |
| Engine type | Water-cooled, 4-cycle direct injection, turbocharged | p. 25 |
| Cylinders - bore x stroke | 4 - 105 mm x 125 mm (4.13 in x 4.92 in) | p. 25 |
| Total displacement | 4,329 cc (264 cu·in) | p. 25 |
| Rated output / rotation speed | 62.5 kW (85 PS) / 2,050 rpm (SK135SR-1E, SK135SRLC-1E, SK135SRL-1E) / 58.8 kW (80 PS) / 2,050 rpm (SK115SR-1E) | p. 25 |
| Maximum torque / rotation speed | 32.4 kgf·m (235 lbf·ft) / 1,600 rpm (SK135SR-1E, SK135SRLC-1E, SK135SRL-1E) / 30.0 kgf·m (217 lbf·ft) / 1,600 rpm (SK115SR-1E) | p. 25 |
| Starter | 24 V / 4.5 kW | p. 25 |
| Alternator | 24 V / 50 A (SK135SR-1E, SK135SRLC-1E, SK135SRL-1E) / 24 V / 30 A (SK115SR-1E) | p. 25 |
| Swing speed | 11.7 rpm (SK135SR-1E, SK135SRLC-1E, SK135SRL-1E) / 11.4 rpm (SK115SR-1E) | p. 25 |
| Travel speed (1-speed / 2-speed) | 2.8 / 5.1 km/h (1.7 / 3.2 mph) (SK135SR-1E, SK135SRLC-1E, SK135SRL-1E) / 3.5 / 6.0 km/h (2.2 / 3.7 mph) (SK115SR-1E) | p. 25 |
| Gradeability | 70% (35°) | p. 25 |
| Fully equipped weight | 13,700 kg (30,200 lbs) (SK135SR-1E) / 13,900 kg (30,640 lbs) (SK135SRLC-1E) / 15,700 kg (34,610 lbs) (SK135SRL-1E) / 11,900 kg (26,230 lbs) (SK115SR-1E) | p. 25 |
