SERVICE MANUAL

HYDRAULIC EXCAVATOR
SK400 IV
SK400LC IV

Applicable: SK400 IV YSJ00001~

Applicable: SK400LC IV YSU0001~
S5YSU0002E-01 03/95
 A WARNING
SAFETY
A WARNING A WARNING ,
The proper and safe lubrication and maintenance Do not operate this machine unless you have
for this machine, recommended by KOBELCO are read and understand the instructions in the
outlined in the OPERATION Br MAINTENANCE OPERATORS MANUAL Improper machine operation
GUIDE for this machine. is dangerous and could result in injury or death.

Improper performance of lubrication or mainte- 6. Relieve all pressure in air, oil or water
nance procedures is dangerous and could result in systems before any lines, fittings or related
injury or death. Read and understand the items are disconnected or removed. Always
OPERATION Br MAINTENANCE GUIDE before make sure all raised components are blocked
performing any lubrication or maintenance. correctly and be alert for possible pressure

The serviceman or mechanic mao

-----
. unfamiliar
when disconnecting any device from a system
that utilizes pressure.
with many of the systems on thi, l.chine. This
makes it important to use ,tion when 7. Lower the bucket, blade, ripper or other
performing service work. A at :!dge of the attachments to the ground before performing
system and or components is important before the any work on the machine. If this cannot be
removal or disaasembly of any component. done, make sure the bucket, blade, ripper or
other attachments is blocked correctly to
Because of the size of some of the machine prevent it from dropping unexpectedly.
components, the serviceman or mechanic should
check the weights noted in this Manual. Use 8. Use steps and grab handles when mounting or
proper lifting procedures when removing any dismounting a machine. Clean any mud or
components. debris from steps, walkways or work platforms
before using. Always face machine when using
Following is a list of basic precautions that steps, ladders and walkways. When it is not
should always be observed. possible to use the designed, access system,
provide ladders, scaffolds, or work platforms to
1. Read and understand all W&ming plates and perform safe repair operations.
labels on the machine before operating,
lubricating or repairing this product. 9. To avoid back injury, use a hoist when lifting
components which weigh 23 kg (50 lbs) or
2. Always wear protective glasses and protective more. Make S11ft all chains, hooks, slings, etc.,
shoes when working around machines. In are in good condition and are in the correct
particular, wear protective glasses when capacity. Be sure hooks are positioned
pounding on any part of the machine or its correctly. Lifting, eyes are not to be side
attachments with a hammer or sledge. Use loaded during a lifting operation.
welders gloves, hood/goggles, apron and other
protective clothing appropriate to the welding 10. To avoid burns, be alert for hot parts on
job being performed. Do not wear loose-fitting machines which have just been stopped and
or tom clothing. Remove all rings from rmgers hot fluids in lines, tubes and compartments.
when working on machinery.
11. Be careful when removing cover plates.
3. Disconnect battery and discharge any Gradually back off' the last two bolts or nuts
capacitors before starting to work on machine. located at opposite ends of the cover or device
Hang "Do Not Operate" tag in the Operator's and pry cover loose to relieve any spring or
Compartment. other pressure, before removing the last two
4. If possible, make all repairs with the machine bolts or nuts completely.
parked on a level, hard surface. Block machine
so it does not roll while working on or under 12. Be careful when removing filler caps, breathers
machine. and plugs on the machine. Hold a rag over
the cap or plug to prevent being sprayed or
5. Do not work on any machine that is supported splashed by liquids under pressure. The danger
only by lift jacks or a hoist. Always use blocks is even greater if the machine has just been
or jack stands to support the machine before stopped because fluids can be hot.
performing any disaasembly.
 A WARNING

13. Always use tools that are in good condition 20. Do not operate a machine if any rotating part
. and be sure you understand how to use them is damaged or contacts any other part during
before performing any service work. operation. Any high speed rotating component
that has been damaged or altered should be
14. Reinstall all capscrews with same part checked for balance before reusing.
number. Do not use a lesser quality capscrew
if replacements are necessary. 21. On track-type machines, be careful when
servicing or separating tracks. Chips can fly
15. Repairs which require welding should be when removing or installing a track pin.
performed only with the benefit of the Wear safety glasses and long sleeve shirts.
appropriate reference information and by Track can unroll very quickly when separated.
personnel adequately trained and knowledge- Keep away from front and rear of machine.
able in welding procedures. Determine type of The machine can move unexpectedly when
metal being welded and select correct welding both tracks are disengaged from the sprockets.
procedure and electrodes, rods or wire to Block the machine to prevent it from moving.
provide a weld metal strength equivalent at
least to that of parent metal. Always 22. Caution should be used to avoid breathing
disconnect battery during welding operations dust that may be generated when handling
to protect sensitive electric equipment. components containing asbestos fibers. If this
dust is inhaled, it can be hazardous to your
16. Do not damage wiring during removal health. Components in KOBELCO products
operations. Reinstall the wiring so it is not that may contain asbestos fibers are brake
damaged nor will it be damaged in operation pads, brake band and lining assemblies, clutch
by contacting sharp corners, or by rubbing plates and some gaskets. The asbestos used in
against some object or hot surface. Do not these components is usually bound in a resin
connect wiring to a line containing fluid. or sealed in some way. Normal handling is
not hazardous as long as airborne dust which
17. Be sure all protective devices including guards contains asbestos is not generated.
and shields are properly installed and
functioning correctly before starting a repair. If dust which may contain asbestos is present,
If a guard or shield must be removed to there are several common sense guidelines that
perform the repair work, use extra caution. should be followed.

18. Loose or damaged fuel, lubricant and hydraulic a. Never use compressed air for cleaning.
lines, tubes and hoses can cause fires. Do not b. Avoid brushing or grinding of asbestos
bend or strike high pressure lines or install containing materials.
ones which have been bent or damaged. c. For clean up, use wet methods or a
Inspect lines, tubes and hoses carefully. Do vacuum equipped with a high efficiency
not check for leaks with your hands. Pin hole particulate air (HEPA) filter.
(very small) leaks can result in a high d. Use exhaust ventilation on permanent
velocity oil stream that will be invisible close machining jobs.
to the hose. This oil can penetrate the skin e. Wear an approved respirator if there is no
and cause personal injury. Use cardboard or other way to control the dust.
paper to locate pin hole leaks. . £. Comply with applicable rules and
regulations for the work place.
19. Tighten connections to the correct torque. g. Follow environmental rules and regulations
Make sure that all heat shields, clamps and for disposal of asbestos.
guards are installed correctly to avoid h. Avoid areas where asbestos particles may
excessive heat, vibration or rubbing against be in the air.
other parts during operation. Shields that
protect against oil spray, onto hot exhaust
components in event of a line, tube or seal
failure must be installed correctly.
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SHOP
MANUAL model YSU · YSJ
TABLE OF CONTENTS

1. SPECIFICATION YSU01
2. OPERATION AND CONTROLS (Refer to Operators Manual)

3. LOCATION AND WEIGHT OF COMPONENTS YSU03

4. MAINTENANCE STANDARDS AND
TEST PROCEDURES ................................ . YSU04
5.

6. PREVENTIVE MAINTENANCE (Refer to Operators Manual)

7. WORKING STANDARDS YSU07

8. STANDARD MAN-HOUR TABLE YSU08

ORow to Index each Shop Manual Section

The GENERAL of this shop manual consists of 8
headings as shown above. Each section can be
easily referred to by indexes appended to the
margin of the page as indicated on the right.
Please use the indexes for speedy reference.

KOBELCO GENERAL
 YSU
YSJ List of Shop Manual GENERAL Section

Index Book Code No.

Title
No. Distribution Year - Month

S5YSU0102E
YSUOl SPECIFICATION 1995-03
YSJK95S0010M
- OPERATION Refer to Operators manual

LOCATION AND WEIGHT S5YSU0302E

YSU03 1995-03
OF COMPONENTS
MAINTENANCE STANDARDS S5YSU0402E
YSU04 1995-03
AND TEST PROCEDURES
PREVENTIVE YSJK95S0010M
- MAINTENANCE Refer to Operators manual

S5YSU0702E
YSU07 WORKING STANDARDS 1995-03

Applicable Machines YSJOO01-

 Book code N°'
55 YS U01 02E
KOBELCO
SHOP MANUAL YSU · YSJ
YSU01
SPECIFICATION
TABLE OF CONTENTS

1. LOCATION OF COMPONENTS ........ 00 . . . . . .. .. ... . 1

2. GENERAL DIMENSIONS . . . . .. .. . . .. .. . .. .. .. .. . .. . .. 2
3. SPECIFICATIONS AND PERFORMANCE . .. . . . .. . . . . . 3
4. TYPE OF SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. TYPE AND COMBINATION OF ATTACHMENTS ..... 4
6. WORKING RANGES OF ATTACHMENTS 00......... .. 5
7. LIFTING-UP ABILITY DIAGRAM ............ .... .... . 7
8. ENGINE SPECIFICATIONS 00 . . . . . . . . . . 0 0 . . . . • .. .. .. .. 12

KOBELCO CONSTRUCTION MACHINERY(U.S.A.) INC.

Applicable Machines
YSJ0001-
LSU0001-

Revision Date of Issue Remarks

First edition March, 1995 S5YSUOI02E K
 1. LOCATION OF COMPONENTS

FRONT

RIGHT
~---------------.BOOM
~---------.ARM CYLINDER
r------~ BOOM CYLINDER
r-------.CONTROLBOARD
,..-----.OPERATOR SEAT
,----.SWIVEL JOINT
~--4I SWING MOTOR
CONTROL VALVE

.SWING FLASHER, REAR---~

WORKING LIGHT
.HYDRAULIC PUMP------,
.GUARD----------
.HYDRAULlC-------,
TANK

.BUCKET
.BUCKET LINK
.IDLER LINK
" - - - - .BUCKET
CYLINDER
'-----'---.ARM
.FRONT IDLER
.LOWER ROLLER--...J
.TRACK SPRING - - - -
COUNTER WEIGHT
.UPPER ROLLER:-----
.MUFFLER
.CAB----------~
.SWING RING GEAR _ _ _ _ _ _ _......J '----.ENGINE
'-----.RADIATOR,OIL COOLER
.AIR C L E A N E R - - - - - - - - - - '
L..-.--.REDUCTION UNIT FOR TRAVEL UNIT
'-------------.TRACK ASSEMBLY

1
 2. GENERAL DIMENSIONS

__ -----------A------------~

Unit: m (ft)
3.0 3.45 3.95 4.9
Arm length (9-10) (11-4) (13-0) (16-1 )
11.79 11.73 11.78 11.81
A Overall length
(38-5) (38-6) (38-8) (38-7)
3.58 3.43 3.55 4.12
B Overall height (to top of boom)
(11-10) (11-3) (1 1-8) (13-9)
Overall width [900mm (35.4in) Shoe) 3.65 3.65 3.65 3.65
C-l
(12-0) (12-0) (12-0) (12-0)
3.55 3.55 3.55 3.55
C-2 Overall width [800mm (31.5in) Shoe)
(11-8) (11-8) (11-8) (11-8)
3.35 3.35 3.35 3.35
C-3 Overall width [600mm (23.6in) Shoe)
(11-0) (11-0) (11-0) (11-0)
0 Overall height (to top of cab) 3.21 3.21 3.21 3.21
(10-6) (10-6) (10-6) (10-6)
E Ground clearance of rear end* 1.325 1.325 1.325 1.325
(4-4) (4-4) (4-4) (4-4)
F 490mm 490mm 490mm 490mm
Ground clearance*
(19.3in) (19.3in) (19.3in) (19.3in)
G Tail swing radius 3.40 3.46 3.40 3.40
(11-2) (11-4) (11-2) (11-2)
4.37 4.37 4.37 4.37
H Tumbler distance
(14-4) (14-4) (14-4) (14-4)
I Overall length of crawler 5.46 5.46 5.46 5.46
(17-11) (17-11) (17-11) (17-11)
2.75 2.75 2.75 2.75
J Track gauge
(9-0) (9-0) (9-0) (9-0)
K-l 900mm 900mm 900mm 900mm
Shoe width
(35.4in) (35.4in) (35.4in) (35.4in)
.
K-2 Shoe width 800mm 800mm 800mm 800mm
(32in) (32in) (32in) (32in)
GOOmm 600mm 600mm GOOmm
K-3 Shoe width
(24in) (24in) (24in) (24in)
3.25 3.25 3.25 3.25
l Overall width of upper structure
(10-8) (10-8) (10-8) (10-8)
NOTE: FIgure of asterISk (*) apply to value wIthout shoe lug.

2
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 3. SPECIFICATIONS AND PERFORMANCE

• SPEED AND CLIMBING ABILITY

Item Model YSJ
Swing speed 9.0rpm
Travel speed 5.5 / 3.Skm / h (3.4/2.2 mph)
Gradeability 35° (70%)

• ENGINE
Model Mitsubishi 6D22-TC
~~ter-c~o~e(! ,,:-cyc~H ~~rect
injection type diesel engine With
Type Intercoo e , turbo-c arger
Number of cylinder-BoreXStroke 6-130mm(S.11 in) X 140mm(S.S1 in)
Total displacement 11,149c.c. (680cuin)
JISD 1005 NET 300 HP / 2,OOOrpm
Rated output
SAE J 1349 NET 300 HP 12,OOOrpm / 224KW I 2.000rpm
power Irevolution
DIN 6270 NET 296 HP 11,400rpm
JISD 1005 NET 121 kgf·m / 1,200rpm
Maximum
SAE J 1349 NET 8751b·ft / 1,200rpm
torque/revolution
DIN 6270 NET 121 kgf·m 11,200rpm

• HYDRAULIC COMPONENTS
Hydraulic pump DOUble-pump variable displacement, axial piston + gear pump
Hydraulic motor (swing) Axial piston motor
Hydraulic motor (travel) Axial piston motor
Control valve 6 -spool multiple control valve + 1-spool control valve (swing)
Cylinders (boom, arm, and bucket) Double acting cylinder
Return filter Safety valve containing filter type
Oil cooler Air-cooled type

Unit: kg (lbs)
~el LSU YSJ
Item
42,900 44,300 45,100 43,600 45,100 45,800
Fully-equipped weight (94,500) (97,700) (99,400) (96,100) (99,400) (100,900)
19,500
Upper machinery (43,000) lIE lIE oIIIi lIE oIIIi

Lower machinery
600 (24·)
15,600
(34,400) -- -- 16,300
(35,900) -- --
with grouser
shoe
800 (3r) -- 17,100
(37,700) -- -- 17,800
(39,200) --
900 (36·) -- -- 17,800
(39,200) -- -- 18,500
(40,700)
7.0m (23ft) Boom+3.4Sm (llfi-4in) 7,800 lIE
lIE oIIIi oIIIi lIE
Arm + 1.8m 3 (2.35 cuyd) Bucket (17,200)

3
 4. TYPE OF SHOES
Width of track Overall width of
Shape Model shoe [mm(ft-in)) crawler [mm(ft-in))
Grouser(equal height) 600 (24-) 3,3S0 ( 11' )
LSU
SOO{3r) 3,S50 (1 1 'S-) 0.63 (S.96)
50 link
900 (36-) 3,650(12') 0.57 (S.10)
600 (24-) 3,350 (11' ) 0.77 (10.9S)
YSJ
SOO(3r) 3,550 (11'S-) 0.60 (S.53)
53 link
YNK-6-7 900 (36-) 3,6S0(12') 0.54 (7.6S)
NOTE; The SOOmm (32-) shoes is applied for general civil work, while the 900mm (36-) one is used for
50ft ground operation. Do not use them in rough operations, such as gravel and rock digging.

5. TYPES AND COMBINATIONS OF ATTACHMENTS

SAE,JIS Outside width of bucket
HOE BUCKET Heaped mm (ftin) No. of Equipped Possibility Weight
with side of
ca~acity Without side teeth
m (tuyd) With side cutter cutter cutter turnover kg (Ibs)
1.3S{1.77) 1,230(4'0-) 1,100(3'T) 4 Yes Yes 1,210(2,670)
1.60(2.09) 1,380(4'6-) 1,2S0(4'n 4 Yes Yes 1,2S0 (2,820)
1.S0(2.35) 1,520(5'0-) 1,39S(4'T) 5 Yes Yes 1,3S0 (3,040)
*1.S0{2.3S) 1,535(5'1-) 1,440(4 '9-) 4 Yes Yes 1,400(3,100)
YNK-6-8
2,10(2.7S) 1,690(5'7-) 1,540(5"n 5 Yes Yes 1,460 (3,220)
* mark indicates one for
heavy digging work . 2.30(3.00) 1,820(6'0·) 1,690(S'T) 5 Yes Yes 1,530 (3,400)

• COMBINATIONS OF ATTACHMENTS
Bucket Applicable arm
SAE·JIS heaped JIS·SAE struck 3.0m 3.45m 3.95m 4.9m
Type capacity capacity (9ft-lOin) (11ft-4in) (13ft-Oin) (16ft-lin)
m3(cuyd) m3(cuyd) arm arm arm arm
US (1.77) 1.05 (1.37) 0 0 0 @

Hoe bucket 1.60 (2.09) 1.20 (1.57) 0 0 @ Ll

1.S0 (2.35) 1.40 (1.83) 0 @ 0 X
* Mark indicates
one for heaV\l * 1.S0 (2.35) 1.40 (1.83) 0 0 0 X
digging work 2.10 (2.75) 1.60 (2.09) @ Ll X X

2.30 (3.00) 1.70 (2.22) Ll X X X

NOTE ; @ Standard combinations
o General operation; Digging and loading of sand, gravels and clay-mixed soil
l:; Light operation; Operations mainly consisting of loading of loose sand and soil
(for instance, operations in paddy fields and loading of sand and gravels)
X Not usable; Do not operate in such combinations as guarantee does not cover them.

A. CAUTION
• If a bucket other than a hoe bucket is used to execute face shovel operation, it will cause damage
to the arm and the bucket•
• The combinations other than those mentioned in the above table cannot be used in principle. For
further details, contact KOBELCO.

4
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