KOBELCO 230SRLC-3 TIER 4 HYDRAULIC EXCAVATOR and HINO J05E-TJ DIESEL ENGINE SERVICE MANUAL

Kobelco 230SRLC-3 Tier 4 Hydraulic Excavator & Hino J05E-TJ Diesel Engine Service Manual

This comprehensive service manual provides complete factory procedures for the Kobelco 230SRLC-3 Tier 4 hydraulic excavator and the Hino J05E-TJ diesel engine. All technical content below is derived strictly from the Table of Contents, covering safety precautions, specifications, hydraulic and electric systems, mechatro control, machine disassembly and assembly, attachments, troubleshooting by error codes and symptoms, and full engine workshop overhaul procedures.

Model Covers:

Kobelco 230SRLC-3 Tier 4 Hydraulic Excavator
Hino J05E-TJ Diesel Engine

Note: Includes general repair precautions, international unit standards, detailed machine dimensions and weights, attachment standards, tightening torques, maintenance time tables, hydraulic pressure testing, mechatro controller diagnostics, DPF handling, complete hydraulic and electric circuit coverage, air-conditioner servicing, full machine disassembly/assembly, and extensive engine workshop procedures with diagnostic codes.

File Format: PDF

Size: 79.36 MB

No. of Pages: 1457

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Included Sections:

Outline & Safety Precautions

• General precautions for making repairs and preparations before disassembly
• Safety during disassemling and assembling operations
• Handling of hydraulic equipment, electrical equipment, and hydraulic parts
• Weld repair practices and environmental considerations
• International unit system standards

Specifications & Machine Data

• Component names and general dimensions
• Weights of components and transportation dimensions
• Machine specifications and performance characteristics
• Engine and hydraulic component specifications
• Crawler types, bucket types, and attachment combinations
• Engine specification and characteristic curve (Hino J05E-TJ)

Attachment Dimensions

• Boom dimensional drawings and maintenance standards
• Arm dimensional drawings and maintenance standards
• Bucket drawings, dimensional tables, lug and boss section drawings

Tools & Tightening Torques

• Tightening torques for cap screws, nuts, hoses, and fittings
• Screw sizes and plug specifications
• Special spanners and special tools
• Application of locking and sealing compounds
• Lifting jigs for counterweight, upper frame, engine pedestal, and track spring set

Standard Maintenance Time Table

• Standard working time tables for excavator maintenance
• Engine maintenance service standard times
• Measuring methods, working conditions, and time constituents

Maintenance Standards & Test Procedures

• Performance inspection standards and standard value tables
• Engine speed measurement procedures
• Hydraulic pressure measurement and relief valve adjustment
• Travel, swing, and attachment operating performance measurements
• Swing bearing inspection and performance checks
• Mechatro controller input/output and adjustment procedures
• DPF handling, inspection, and maintenance standards

Mechatro Control System

• System summary and overall control concepts
• Unload valve, positive control, P-Q control, and conflux control functions
• Arm, boom, bucket, swing, and travel straight control logic
• Pressure release and option control systems
• Mechatro controller display, self-diagnosis, service diagnosis, and adjustment

Hydraulic System

• Hydraulic circuit summaries and components
• Neutral, travel, boom, arm, bucket, and swing circuits
• Combined circuits and pressure releasing circuits
• Color coding standards for hydraulic circuits

Electric System

• Electric circuit diagrams and equipment lists
• Harness layouts and installation locations
• Instrument panel, controller, operator controls, and lighting systems
• Upper, cab, boom, and option harness assemblies
• Alarm systems and angle sensor installation

Components System

• Hydraulic components: pump, control valve, pilot valves, motors, swivel joint, cylinders
• Electrical equipment lists and specifications

Air-Conditioner System

• System outline, components, and construction
• Piping, cooling circuit mechanisms, and functions
• Disassembly, assembly, and refrigerant charging procedures
• Electric circuits, troubleshooting, and self-diagnosis

Disassembling & Assembling Procedures

• General explanation of disassembly and assembly chapters
• Tightening torque indications for components

Attachments

• Removing and installing attachment assemblies
• Bucket, arm, and boom procedures
• Cylinder disassembly and assembly

Upper Slewing Structure

• Removal and installation of cab, counterweight, tanks, pump, engine, valves, motors, and upper frame
• Disassembly and assembly of hydraulic pump, control valves, pilot valves, swing motor, and swivel joint

Travel System

• Removal and installation of crawler, rollers, idler, sprocket, travel motor, and swing bearing
• Travel motor construction, disassembly, maintenance standards, and troubleshooting

Troubleshooting

• Troubleshooting by error codes and blown fuse checks
• Hydraulic, electric, and engine-related troubleshooting by symptoms

Hino J05E-TJ Diesel Engine Workshop

• General precautions, tightening standards, and failure diagnosis methods
• Standard values and tightening torques for all engine systems
• Special tools and parts to be prepared
• Engine mounting/dismounting and compression inspection
• Fuel system: filters, supply pump, injectors, and common rail
• Emission control: EGR system inspection and replacement
• Electrical system: starter, alternator, ECU replacement
• Intake, mechanical systems, valve clearance adjustment
• Exhaust system and DPR cleaner service
• Cooling system: fan, thermostat, coolant pump
• Lubrication: oil cooler, pump, strainer, oil pan
• Starting and charging systems overhaul
• Turbocharger inspection and replacement
• Engine failure diagnosis and ECU diagnostic trouble codes

This service manual is an essential factory reference for accurate inspection, diagnostics, maintenance, and complete overhaul of the Kobelco 230SRLC-3 Tier 4 excavator and the Hino J05E-TJ diesel engine.