Kobelco K904-II / K905-II Hydraulic Excavator Shop Manual

Kobelco K904-II / K905-II Hydraulic Excavator Service Manual

This factory service manual provides comprehensive technical instructions for safe inspection, maintenance, troubleshooting, and repair of Kobelco K904-II and K905-II hydraulic excavators. All content below is derived strictly from the manual’s Table of Contents, covering specifications, maintenance standards and test procedures, system operation, removal and installation workflows, and detailed component overhaul procedures.

Model Covers:

Kobelco K904-II Hydraulic Excavator (S.N. YW-0101-)
Kobelco K904-II Hydraulic Excavator (S.N. LX-1501-)
Kobelco K905-II Hydraulic Excavator (S.N. LP-2401-)
Kobelco K905-II Hydraulic Excavator (S.N. YP-1001-)

Note: Applies exclusively to K904-II and K905-II machines within the specified serial ranges. Includes machine specifications, attachment combinations, lifting capacities, maintenance standards with pressure measurement and performance testing, system troubleshooting, work standards with tightening torques, and full disassembly and assembly procedures for hydraulic and mechanical components.

File Format: PDF

Size: 26.03 MB

No. of Pages: 498

Language: English

Quality: Readable text, low-quality images

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

📑 Included Sections:

General Specifications & Machine Data

• Names of components and general dimensions
• Specifications and performance characteristics
• Shoe types and attachment combinations
• Working ranges of attachments and lifting capacities
• Engine specifications
• Component locations and weights
• Transportation and lifting weights for machine, boom, arm, and bucket

Maintenance Standards & Test Procedures

• General maintenance standards for different serial groups
• Pressure measurement and adjustment procedures
• High- and low-pressure gauge locations
• Drive and relief valve adjustment methods
• Cylinder speed and oil-tightness checks
• Swing and travel performance measurements
• Oil drain checks from motors
• Swing bearing play inspection
• Performance inspection standards and measuring conditions

Troubleshooting

• Machine general troubleshooting guidance
• Drive system troubleshooting
• Hydraulic system troubleshooting
• Swing and travel system troubleshooting
• Attachment system troubleshooting
• Control system troubleshooting
• Electrical system troubleshooting

Work Standards

• Tightening torques for cap screws and nuts
• Tightening torques for nuts and sleeves

Drive System

• Power plant and pump connection overview
• Removal and installation of hydraulic pump
• Removal and installation of coupling
• Removal and installation of engine and radiator
• Maintenance standards for pump connection and engine mounting

Hydraulic System

• Hydraulic system diagrams and components
• Functional descriptions of travel, boom, arm, bucket, and swing circuits
• Negative control and neutral circuit explanations

Swing System

• Swing operation and pilot piping functions
• Swing bearing and grease bath
• Removal and installation of swing control valve
• Removal and installation of swing motor
• Removal and installation of swing reduction unit
• Removal and installation of swing bearing
• Maintenance standards for swing system

Travel System

• Construction of lower machinery
• Travel system function and pilot piping
• Track links, rollers, idler, and track spring
• Removal and installation of travel motor and sprocket
• Maintenance standards for undercarriage components

Attachments

• Attachment system construction and functions
• Drive and pilot piping connections
• Removing and installing bucket, arm, and boom
• Maintenance standards for pin and bushing clearances
• Adjusting clearances between boom, arm, and bucket

Control System

• Engine control construction, function, and throttle adjustment
• Travel control system outline
• Hydraulic control system: solenoid and pressure control valves
• Maintenance standards for control levers and ports tightening torque

Upper Frame

• Upper frame construction
• Fuel tank construction and removal/installation
• Counterweight removal and installation
• Cab removal and installation
• Upper frame dismantling and mounting
• Maintenance standards and tightening torques

Electrical System

• Electrical system diagrams
• Cluster gauge lamp indications
• Intelligent total control system

Hydraulic & Mechanical Components

• Hydraulic gear pump: specifications, construction, disassembly/assembly, troubleshooting
• Main hydraulic pump: specifications, overhaul, maintenance standards, troubleshooting
• Regulator: construction, adjustment, disassembly/assembly, pump control curves
• Pilot valve (TH40K): specifications, overhaul, maintenance standards
• Main control valve and swing control valve: construction, pressure adjustment, troubleshooting
• Swing hydraulic motors for K905-II and K904-II: specifications, overhaul, maintenance standards
• Travel hydraulic motor: construction, overhaul, maintenance standards, troubleshooting
• Swivel joint: construction, overhaul, inspection, troubleshooting
• Hydraulic cylinders: specifications, disassembly/assembly, oil leak limits, tools and jigs
• Swing reduction units for K905-II and K904-II: construction, overhaul, maintenance standards

This Kobelco K904-II / K905-II Service Manual is an essential factory reference for accurate diagnostics, maintenance, system servicing, and complete component overhaul of these hydraulic excavators.