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Kobelco 120 Series Background
The Kobelco 120 series hydraulic excavators, including models like the SK120 and SK120-III, were introduced in the 1990s and early 2000s as part of Kobelco’s mid-size lineup. These machines were designed for versatility in utility work, forestry, and small-scale construction. Powered by reliable Isuzu diesel engines, typically the 4BG1 or 4JJ1, the SK120 offered around 85–95 horsepower and an operating weight of approximately 12 metric tons. With a two-speed travel system and robust hydraulic output, the 120 series became a popular choice in North America and Southeast Asia.
Kobelco Construction Machinery, founded in 1930 in Japan, has long been known for its innovation in hydraulic systems and fuel efficiency. By the early 2000s, Kobelco had sold tens of thousands of SK120 units globally, with strong dealer support and a reputation for long-term durability.
Sudden Hydraulic Failure and Electrical Symptoms
When a Kobelco 120 excavator suddenly loses all hydraulic function and power to the key switch, the issue often lies in a combination of electrical and mechanical faults. In one reported case, the machine operated normally for two hours before abruptly shutting down while lifting a tree top. The engine stopped, hydraulics ceased, and the key switch lost power—suggesting a systemic failure rather than isolated component damage.
Primary Suspects and Diagnostic Path
In 2019, a forestry operator in Tennessee experienced a similar failure on his SK120-III while clearing storm debris. The machine shut down mid-lift and refused to restart. After bypassing the ignition circuit with a jumper wire, the engine fired up, but hydraulics remained dead. A technician traced the issue to a failed pilot lockout relay hidden behind the fuse panel. Replacing the relay restored full function, and the machine returned to service the same day.
Final Thoughts
Sudden hydraulic failure in a Kobelco 120 excavator is often a compound issue involving both electrical and mechanical systems. By methodically checking power delivery, lockout circuits, and pump integrity, operators can isolate the fault and restore functionality. Given the machine’s robust design and widespread use, understanding its interlock systems is essential for efficient troubleshooting and long-term reliability.
The Kobelco 120 series hydraulic excavators, including models like the SK120 and SK120-III, were introduced in the 1990s and early 2000s as part of Kobelco’s mid-size lineup. These machines were designed for versatility in utility work, forestry, and small-scale construction. Powered by reliable Isuzu diesel engines, typically the 4BG1 or 4JJ1, the SK120 offered around 85–95 horsepower and an operating weight of approximately 12 metric tons. With a two-speed travel system and robust hydraulic output, the 120 series became a popular choice in North America and Southeast Asia.
Kobelco Construction Machinery, founded in 1930 in Japan, has long been known for its innovation in hydraulic systems and fuel efficiency. By the early 2000s, Kobelco had sold tens of thousands of SK120 units globally, with strong dealer support and a reputation for long-term durability.
Sudden Hydraulic Failure and Electrical Symptoms
When a Kobelco 120 excavator suddenly loses all hydraulic function and power to the key switch, the issue often lies in a combination of electrical and mechanical faults. In one reported case, the machine operated normally for two hours before abruptly shutting down while lifting a tree top. The engine stopped, hydraulics ceased, and the key switch lost power—suggesting a systemic failure rather than isolated component damage.
Primary Suspects and Diagnostic Path
- Pilot Lockout Circuit: This safety system prevents hydraulic activation unless certain conditions are met. If the pilot lockout solenoid loses power or the circuit is interrupted, the machine will not respond to joystick inputs.
- Hydraulic Pump Coupling: A failed coupling between the engine and hydraulic pump can cause the pump to stop turning, resulting in total hydraulic loss. This mechanical failure may occur suddenly, especially under load.
- Limit Switch and Relays: The pilot lockout often interfaces with a limit switch and one or more relays. If a relay fails or the switch wiring is damaged, the system may cut power to the solenoid and key switch.
- Battery and Fuse Box: A weak or disconnected battery ground can cause intermittent power loss. In one case, applying a jumper wire directly to the starter solenoid restored engine function, confirming a power delivery issue.
- Check Battery Voltage and Grounds: Ensure both batteries are charged and all ground connections are clean and tight.
- Inspect Fuse Box: Look for blown fuses, especially those linked to the pilot lockout and ignition circuits.
- Test Lockout Solenoid: Apply direct power to the solenoid to verify operation. If it clicks and restores hydraulics, the issue is upstream.
- Trace Wiring from Limit Switch: Follow the wires to the relay and ECM. Look for corrosion, pinched wires, or disconnected plugs.
- Verify Hydraulic Pump Rotation: Remove the inspection cover and confirm the pump shaft is turning with the engine. If not, the coupling may be broken.
- Pilot Lockout: A safety feature that disables hydraulic functions unless specific conditions are met.
- Limit Switch: An electrical switch that detects position or status, often used in safety interlocks.
- Hydraulic Pump Coupling: A mechanical link between the engine and hydraulic pump, transmitting rotational force.
In 2019, a forestry operator in Tennessee experienced a similar failure on his SK120-III while clearing storm debris. The machine shut down mid-lift and refused to restart. After bypassing the ignition circuit with a jumper wire, the engine fired up, but hydraulics remained dead. A technician traced the issue to a failed pilot lockout relay hidden behind the fuse panel. Replacing the relay restored full function, and the machine returned to service the same day.
Final Thoughts
Sudden hydraulic failure in a Kobelco 120 excavator is often a compound issue involving both electrical and mechanical systems. By methodically checking power delivery, lockout circuits, and pump integrity, operators can isolate the fault and restore functionality. Given the machine’s robust design and widespread use, understanding its interlock systems is essential for efficient troubleshooting and long-term reliability.
