MECHATRONICS

Table of contents
Page
3.1 LAYOUT OF ELECTRIC COMPONENTS .......................................................................................................... 3-2
A. Parts related to upper frame ........................................................................................................................ 3-2
B. Harness grounding locations ...................................................................................................................... 3-3
C. Parts related to operator’s cab .................................................................................................................... 3-4
D. Parts related to frame ................................................................................................................................... 3-7
E. Parts related to engine ................................................................................................................................. 3-8
F. Mechatronic controller connectors .............................................................................................................. 3-9
3.2 LOCATION OF SOLENOID BLOCK AND SENSOR BLOCK ......................................................................... 3-10
A. Solenoid block ............................................................................................................................................ 3-11
B. Pump proportional solenoid valves (PSV-P1 and PSV-P2) ..................................................................... 3-12
3
C. Pressure sensors ........................................................................................................................................ 3-13
3.3 GOVERNOR MOTOR (M-2) ............................................................................................................................. 3-15
3.4 ENGINE SPEED SENSOR (SE-15) .................................................................................................................. 3-17
3.5 ACCEL POTENTIOMETER (SE-16) ................................................................................................................. 3-18
3.6 REAR CONTROL PANEL ................................................................................................................................ 3-19
3.7 OUTLINE OF MECHATRONIC CONTROL SYSTEM ...................................................................................... 3-26
3.8 MACHINE OPERATION ................................................................................................................................... 3-27
3.9 MULITDISPLAY SELF DIAGNOSIS ................................................................................................................. 3-28
3.10 TROUBLE HYSTORY DIAGNOSIS ............................................................................................................... 3-30
3.11 MECHATRONIC CONTROLLER “A” AND “B” ADJUSTMENT ................................................................... 3-31
3.12 SERVICE DIAGNOSIS ................................................................................................................................... 3-34
3.13 GENERAL TROUBLESHOOTING .................................................................................................................. 3-38

Dynamic Acera MC Training, 11/02 Rev. 0

3-1
 MECHATRONICS

3.1 LAYOUT OF ELECTRIC COMPONENTS

A. Parts related to upper frame

M-8 : Greasing motor (Opt.)

L-9 :
Boom work light (Opt.) E-6 : Buttery ground
Horn (Low tone)
E-5 :
To ATT Horn (High tone) R-1 : Battery relay
harness

3
SE-15 :
Fuel sensor

L-2 :
To inst-panel harness
Deck light
M-4 :
Washer motor

SW-25 :
SW-8 : Hyd. oil level
Air filter clogging switch
switch
8
CO
FRO OL VA

7
NTR

6
MP

B 5
TO VE SID

ILO E
VAL
CO

T
LV
NTR E

7
A 8 SE-13 :
OL

Engine speed
sensor
SE-5 :
Swing pressure
sensor
SE-22 :
SW-24 : P1 pump
Engine coolant pressure
level switch sensor

SE-23 :
P2 pump
pressure
sensor
E-10 :
Receiver dryer E-13 :
for A/C Travel alarm
PSV-P2 : (Opt.)
M-1 : P2 pump
Starter motor propo. valve
L-3 : SW-23 :
Swing flasher & Engine oil level L-4 :
Rear work light (L.H) (Opt.) swich To engine sub PSV-P1 : Swing flange &
harness P1 pump Rear work light (R.H)
propo. valve (Opt.)

A: Solenoid block
B: The sensor block for KCMA machines is the same as before minor changed machine, but only one
sensor is used for the swing system and it is located at main control valve

Dynamic Acera MC Training, 11/02 Rev. 0

3-2
 MECHATRONICS
B. Harness grounding locations F
Lever lock SOL
Note :
B are connected with E by harness ATT boost SOL

C is attached to upper frame Travel 1, 2 Speed SOL

D is attached to floor plate Swing parking SOL

E to H are connected with controller box Air filter clogging SW

J is attached to E/G Washer motor

K is connected whth E/G E/G coolant level SW
Governor motor
E/G oil level SW
Swing flasher & Rear work light (L.H)
GND between
Hyd. oil temp. SW (Opt.)
Upper frame and I
Floor B
GND of travel 1, 2
speed SW at under Fuel sensor
C
floor plate Work light

H
D
A
Horn (High)
Horn (Low)
3
Battery Battery relay
GND between Cab and
GND. Travel alarm (Opt.)
Controller (In control box)
Boom cylinder work light
Swing flasher & Rear work light (R.H)

E
In control box
Wiper inter lock SW
Mechatro controller
ATT boost SW
Horn SW
Tuner
R.H rotation SW (Opt.)
L.H rotation SW (Opt.)
Travel alarm SW
Opt. work light SW (Opt.)
Lever lock delay timer
8
CO

Safety relay
FRO OL VA

7
NTR

6
MP

Auto greasing contoroller (Opt.) 5

TO VE SID

ILO E
VAL

Wiper relay assy

CO

T
LV
NTR E

7
Air-con amplifier 8
OL

Cab work light R.H (Opt.)

Cab work light L.H (Opt.)
24V power source
Roof wipermotor
Machine management system (Opt.)

G
Cab GND. at rear right of Cab
Gauge cluster
Hour meter
Swing flasher SW. (Opt.)
Power window SW. (Opt.)
Cigar lighter
Wiper motor
Flasher relay

J K
Alternator GND. Engine GND.
Dynamic Acera MC Training, 11/02 Rev. 0
3-3
 MECHATRONICS
C. Parts related to operator’s cab C2: MONITOR

SW-21: POWER BOOST

SW-10: HORN SWITCH SWITCH

SW-11: SAFETY LOCK LEVER

(FOR HYDRAULICS)

E-14: 24V CIGARETTE

LIGHTER

SE-16: THROTTLE
SW-35: HEAVY LIFT SWITCH
POTENTIOMETER
SW-5: TWO PUMP FLOW
SELECTOR SWITCH SW-1: KEY SWITCH
SW-36: INDEPENDENT
3 TRAVEL SWITCH
OPTIONAL SWITCHES
C-4: AIR-CONDITIONER FOR EUROPEAN
FAN

EXCAVATORS
TEMP

SW-9: SWING FLASHER

MODE
R/F

DEF

SWITCH

SW-38: WARM-UP SWITCH

E-7: RADIO (FM/AM)
Locally-procured parts
in European machines

CabRelatedParts1
E-23: 12V POWER SUPPLY
(180 WATT)

To inst-panel harness
Bracket for connector

Connect to cab ground

C-5 :
Power window
controller (Opt.)
To cab harness
R-19:
Flasher relay

Detail of cab rear right corner

Dynamic Acera MC Training, 11/02 Rev. 0

3-4
 MECHATRONICS

Sensors for travel and optional valves

SE-20

SE-10

SE-9
SE-11

Dynamic Acera MC Training, 11/02 Rev. 0

3-5
 MECHATRONICS

Cab harness
E-4 : Fuse box To inst-panel
left harness

Note : Fuse box is attached

to harness.
R-6 : Work light relay
R-5 : Horn relay

3 E-9 : Speaker R.H

R-9 : Work light relay (Opt)
R-10 : Bucket restriction relay (Opt.)
R-8 : Travel alarm relay (Opt.)
M-5 : Power window motor (Opt.)
R-13 : L.H rotation relay (Opt.)
J/B (15P X 5) R-12 : R.H rotation relay (Opt.)
E-8 : Speaker L.H
J/B (15P X 4)

Harness for long range ATT

E-15 : Resister
Harness for high-reach

Cab work light L.H

T skylight wiper (Opt.)
C-6 : Auto greasing
To mechatro controller To controller

To inst-panel left
To cab
harness R-7 :
Wiper relay assy.
SW-4 :
View I Swing parking brake
C-1 : Mechatro controller release switch

R-4 :
Safety relay

9 pin connector for

IT (ORBCOMM) & Down load 13 pin connector
connector View II for PHS (Not used)
To cab
harness

R-20 : Timer
Dynamic Acera MC Training, 11/02 Rev. 0
3-6
 MECHATRONICS

D. Parts related to frame

E-10 :
Receiver dryer

L-2 : SW-24 :
Deck work light R.H Engine coolant
R-1 : SE-15 : level switch
Battery relay Fuel sensor

View II 3

SV-1 :
Swing parking SOL
SV-3 :
Travel 1, 2 speed SOL
PSV-A :
Arm variable recirculation
Upper harness
PSV-D :
P1 by-pass cut propo. valve
Starter cable
PSV-C :
Travel Straight Valve SOL
View I
PSV-B :
P2 by-pass cut propo. valve
SV-2 :
ATT boost SOL
SV-4 :
Lever lock SOL

Detail A (Proportional valve block)

SE-1
SE-1. BUCKET (H)
CONTROL VALVE

SE-2
TO CONTROL

SE-2. BUCKET (R)

FROM PILOT

VALVE SIDE

SE-3 SE-3. BOOM (H)

SE-4 SE-4. BOOM (R)
SE-5. SWING (L/R) is
located at C/V
SE-7. ARM (H)
SE-7
SE-8. ARM (R)
SE-8

Dynamic Acera MC Training, 11/02 Rev. 0

3-7
 MECHATRONICS
E. Parts related to engine

III II

M-1 : Engine ground

Starter motor

R-3 :
I Glow relay Starter motor cable

3 SW-23 :
E-2 : Engine oil level
Alternator switch

E-11 :
A/C compressor
SE-14 :
Engine coolant SW-6 :
temperature sensor Engine coolant
temperature switch
Upper harness

PSV-P2 :
P2 pump propo. valve SE-22 :
Pressure sensor : P1 pump
To pressure sensor

Engine side

PSV-P1 :
P1 pump propo. valve SE-23 :
Pressure sensor : P2 pump
View II (Pump)
View III

SE-13 :
Upper harness Engine speed sensor

SW-7 :
Engine oil pressure switch

E-2 : Alternator

View I
Dynamic Acera MC Training, 11/02 Rev. 0
3-8
 MECHATRONICS
F. Mechatronic controller connectors

CN11 CN12 CN13 CN14

1 2 4 1 2 1
2 6 1 2 8
10

16

26

34

27 22 18 16 12 28 22

C
T O
Y
P
.
P
E
N
M
.
N
O TTR
N C O
O O L
Z -5 L
8
6 L
C 1E
0
0 - R
6
0
2 6
3 2 O
7
6 E
2 0 -BS
D 0 H
A
T 0 1 INK
E 1 0
1 0 1 O
9
9
F
Y
7 9 1
E .1
-0 2
1
5
9

2 2
13 2 8 1 11 1
1

26 16 9 22 12
14

CN15 CN16 CN17

Dynamic Acera MC Training, 11/02 Rev. 0

3-9
 MECHATRONICS

3.2 LOCATION OF SOLENOID BLOCK AND SEN-

SOR BLOCK

Solenoid valve block

Cold temperature sensor

Pilot control
low pressure
sensor block

Dynamic Acera MC Training, 11/02 Rev. 0

3-10
 MECHATRONICS

A. Solenoid block

Swing parking brake

Attachment Boost
Travel 1/2 speed

P1 by pass cut

P2 by pass cut
Straight travel
Arm variable
recirculation

Lever lock
T Port
3
P2 Port P1 Port

A8 A7 A6 A5 A4 A3 A2 A1
ON/OFF Proportional ON/OFF
Solenoids Solenoid Solenoids
Type:

8KWE5G-30/G24WR-804 B
Rated Press at P port:
0~50 Kgf/cm2




(0~711 psi)
Allowable back press:

0~10 Kgf/cm 2
PSV-A

PSV-D

PSV-C

PSV-B

(0~140 psi)

SV-3

SV-4
SV-1

SV-3

Solenoid valve: rated voltage 20.4~30 VDC

coil resitance 34~40
Proportional valve: rated volts 20.4~30 VDC


coil resistance 17~25

A8 A7 A6 A5 A4 A3 A2 A1

Seal nut M6
Test condition Torque to 0.5 + 0.05 Kgf-m
> Pressure: 50 Kgf/cm2 I: 700 mA DO NOT ADJUST
+2.0 2
> Flow rate at A port: 0 L/min 26.8 -1.5 Kgf/cm

Dither condition on machine

Secondary Pilot Pressure P (Kgf/cm2)

> Frequency: 100 Hz

> Amplitude at 300 mA: 300 mA 28.8

Upper
Limit 25.3
Pressure setting condition
at power boost

I: 400 mA
2
8.8 +0.5 Kgf/cm
With Hysteresis
2 Lower
8.8 +1,.5
-0.5 Kgf/cm limit

10.3

8.3
P3 A T

Solenoid Valve Input Current (mA)

Resistance: 17 to 25

Dynamic Acera MC Training, 11/02 Rev. 0

3-11
 MECHATRONICS

B. Pump proportional solenoid valves (PSV-P1

and PSV-P2)

This valve is actuated by current

sent by the Mechatronic Controler (CPU) DO NOT ADJUST

3
Resistance: 17 to 25

(725.2 psi)

Secondary pressure of proportional solenoid valve – MPa (psi)

(580.2 psi)

(435.1 psi)
210 L/min
(55 Gal/min) (391.6 psi)
Pump Deliver Flow Rate
L/min (Gal/min)

(290.1 psi)

(145 psi)

Input current of proportional solenoid valve (mA)

Dynamic Acera MC Training, 11/02 Rev. 0

3-12
 MECHATRONICS

C. Pressure sensors

Terminal Connector
1 Power supply (+)
2 Output (+)
3 Common

3
3
2 1

Low pressure sensors for attachment and travel (SE-1~SE-10)

1 – Power supply (+) Pressure range 0 ~ 30 Kgf/cm 2 (427 psi)

2 – Output (+)
3 – Common (–) Voltage range 5 + 0.5 V DC

Voltage

3
4.5V
1
O-ring 2

PF 1/4
0.5V
A View A orifice ø: 3.3 mm 2
30 Kgf/cm (427 psi)

High pressure sensor (SE-22, SE-23)

Pressure range 0 ~ 500 Kgf/cm 2 (7712 psi)

1 – Power supply (+) Voltage range 5 + 0.5 V DC

2 – Output (+)
3 – Common (–)
Voltage

3
4.5V
2 1 3.3V
O-ring
PF 3/8
0.5V
A View A orifice ø: 3.3 mm
350 500 Kgf/cm 2 (7712 psi)
(4978 psi)

Dynamic Acera MC Training, 11/02 Rev. 0

3-13
 MECHATRONICS

Checking resistance on pressure sensors:

Check the resistance between connector pins 1 and 2

with a multimeter.

100 M or more is normal

Terminal Connector
for all pressure sensors
3 1 Power Supply (+)
High pressure sensors and
2 Output (+)
2 1 Low pressure sensors
3 Common
3

Structure

O-ring Body Diaphragm Electronic circuit

Typical low pressure sensor

Dynamic Acera MC Training, 11/02 Rev. 0

3-14
 MECHATRONICS

3.3 GOVERNOR MOTOR (M-2)

Note:
1. Install motor so that surface
or
faces upward
2. 2 52º shows the operating range.

+ 2º
2 52

Connection diagram:
Brown Red
(A) (B)

Orange Yellow
(A) (B)

Motor connection Coil resistance:

5,7 + 10%
Limit switch connection

Appearance of stepping motor

Dynamic Acera MC Training, 11/02 Rev. 0

3-15
 MECHATRONICS

Internal construction

Oil Seal Reduction unit

Motor
Output shaft

3
Cam

Limit switch
Function of governor motor
> Control de engine speed according
to the work mode.
> Control de engine speed according
to the accel potentiometer
> Auto accel function
> Engine stop function

Check the resitance of each pin of limit

switch and motor connector with tester

Limit switch connector Stepping motor connector

5 6
1 2 No. Lead color Terminal
No. Lead color Terminal
5 White Common 1 Brown A
7 6 Red NO 2 Orange A
7 Amarillo NC 3 4 3 Red B
NO: Normally open 4 Yellow B
NC: Normally closed

How to check limit switch

OFF
Turn ignition key switch OFF, disconnect the 52º How to check motor
stepping motor and connect tester to pins ON ON Make sure the ignition key switch is in the OFF
5 and 6, and turn the output shaft. position. Disconnect the stepping motor and
connect tester to pins 1/2, and 3/4.
Limit switch is normal when:
> The resistance should be 5.7 + 10%
> The resistance is infinitive (∞) within the range of
52º, limit switch is open. Front view of
> The resistance is ≥ zero (0) over the 52˚ range, motor shaft
the limit switch is closed.

Dynamic Acera MC Training, 11/02 Rev. 0

3-16
 MECHATRONICS
3.4 ENGINE SPEED SENSOR (SE-15)

Opposing flat 22
M16X1.5
Grounding (B)

Signal (Y)
Opposing flat 19

3
1. Function:

The engine speed sensor is used to detect the actual

engine speed. It is installed on the flywheel housing Speed
and electrically counts the number of gear teeth passing sensor
through in front of the sensor. The signal is picked up by
a magnetic force and a coil placed inside the sensor.
The engine speed is computed by the mechatronic
controller and indicated on the monitor display.
Flywheel
Lock nut
2. How to measure:
2.3 mm
a. Resistance

2.3 kΩ +/- 0.2 kΩ

b. Voltage 3. How to adjust the speed sensor:

a. Remove the speed sensor for inspection and clean it

(do not apply any type of cleaner such as brake cleaner,
V 1.4 VAC ~ 6 VAC ether, or degreaser to the speed sensor).
b. With the engine stopped, install the sensor into the engine
flywheel housing and tighten, lightly by hand, until the tip of
the speed sensor makes contact with the flywheel. Then
Disconnect the speed sensor. Measure the voltage across backout sensor 1.5 turns. The gap between the speed
the pins located inside the connector with the engine in sensor tip and the flywheel should be 2.3 mm.
high idle. The voltage should be ≥ 3 VAC. The voltage is c. Tighten the speed sensor lock nut to 24.5 to 34.3 Nm
set to 4 VAC or more from factory. (9.2 ~ 25.3 Lbs-ft)
d. Start the engine and verify with an external tachometer
that the engine speed is 850 ~ 900 rpm. Also verify that the
speed sensor voltage is within specifications.
Note: if needed, turn the sensor in to increase the voltage.

Dynamic Acera MC Training, 11/02 Rev. 0

3-17
 MECHATRONICS

3.5 ACCEL POTENTIOMETER (SE-16)

Detents Bracket
Potentiometer
Dial
AVX 0.5 sq. or equivalent

5V GND

R B
A
OUTPUT

3 Y

0˚
Voltage between 2 and 1
R
3
Voltage 5V

4.6V Y
2
90˚

B
0.4V 1
0V
90˚
View A

1. Function:
The accel potentiometer is used to control the engine governor speed via the stepping motor, which is mounted to the
engine. The accel potentiometer is powered by 5 VDC from the main mechatronic controller on terminal B. The position
of the potentiometer dial between 0 and 90˚ indicates the acceleration of the engine. The voltage (between 0.4 to 4.6)
will signal the main controller to increase or decrease the stepping motor position to increase or decrease the engine
rpm.

3. Testing the accel potentiometer:

Disconnect the potentiometer and measure the voltage across the
terminals B and Y. The power supply should be 5 V. 5V GND
Measure the resistance between terminals R and B. The resistance
should be 2kΩ. R B
OUTPUT

Dynamic Acera MC Training, 11/02 Rev. 0

3-18
MECHATRONICS

Dynamic Acera MC Training, 11/02 Rev. 0

3-42
YQ08U0969~ CONTROLLER GROUP

3-19 SK210LC-6E DA mc PM, REV.0 09/02

 CONTROLLER GROUP YQ08U0969~

NOTE:
SEE PAGE 266
FOR HARNESS
ROUTING

SK210LC-6E DA mc PM, REV.0 09/02

3-20
 CONTROLLER GROUP YQ08U0969~

YN14E01073P1

SK210LC-6E DA PM, REV.0 11/02

3-21
YQ08U0969~ CONTROLLER GROUP

YN14E01073P1

3-22 SK210LC-6E DA PM, REV.0 11/02

 CONTROLLER GROUP YQ08U0969~

YN14E01073P1
SK210LC-6E DA PM, REV.0 11/02
3-23
YQ08U0969~ CONTROLLER GROUP

YN14E01073P1

3-24 SK210LC-6E DA PM, REV.0 11/02

 CONTROLLER GROUP YQ08U0969~

ITEM PART NUMBER DESCRIPTION QTY

CONTROLLER ASSY

YN22E00162F1 CONTROLLER GROUP

A1 YN22E01147P2 BOX 1
A2 YN22E01141P1 PLATE 1
A4 YN22E00146F1 CONTROLLER (C-1) 1 (Mechatronic)
A5 YT24E00001F1 RELAY ASSY(Wiper) (R-7) 1
A6 EN24S00008P1 RELAY (Travel Alarm:R-8; 3
Horn:R-5; Work Light:R-6)
A7 YX50E00002F1 SWITCH (Sw ing Parking 1
Release) (SW-4)
A8 YN22E01139P1 PLATE 1
A9 ZM66C05016 SEMS-BOLT (M5X16mm) 2
A10 ZM61C06030 SEMS-BOLT (M6X20mm) 4
A11 YN22M01014P1 LABEL 1
A12 ZM61C06016 SEMS-BOLT (M6X16mm) 8
A13 2420Z699 GROMMET 1
A14 YN14E00040F2 HARNESS ASSY, CAB 1
A14-2 ZS18C06016 CAPSCREW (M6X16mm) 2
A14-3 ZM61C06020 SEMS-BOLT (M6X20mm) 8
A14-4 YN03E01001D5 CLIP 11
A14-5 ZW26X06000 LOCK WASHER (M6) 2
A14-6 ZW16X06000 WASHER (M6) 2
A14-7 YN14E01073P1 HARNESS 1
A14-7B YN73E00015F1 BOX ASSY, FUSE (E-4) 1
A14-7Ba YN73E00001S001 BASE 1
A14-7Bb YN73E00001S002 COVER 1
A14-7Bc YN73E01020P1 LABEL 1
A14-7Bd 2479R655S8 FUSE, 10AMP 11
A14-7Be 2479R655S9 FUSE, 20AMP 9

YN22E00145F1 CONTROLLER INSTAL

B1 YN22E01121P1 SUPPORT 1
B2 YN22E01145P1 SUPPORT 1
B3 YN22E01149P2 BRACKET 1
B4 YN25S00001P1 TIMER (R-20) 1
B5 ZM66C06025 SEMS-BOLT (M6X25mm) 1
B6 ZM32C10025 BOLT (M10X25mm) 5
B7 ZM22C10030 SEMS-BOLT (M10X30mm) 6
B8 ZM66C06016 SEMS-BOLT (M6X16mm) 4
B9 YN24E00010F1 RELAY ASSY 1
B9-1 YN24E01007P1 PLATE 1
B9-2 ZM61C06016 SEMS-BOLT (M6X16mm) 1
B9-3 YN77S00017P1 CONVERTER, DC-DC (E-22) 1 (24v-12v)
B9-4 YY24S00001P1 RELAY, FLASHER (R-19) 1
B9-5 ZM61C05016 SEMS-BOLT (M5X16mm) 2

MITSUBISHI COMPONENT(S)

A3 VAME077148 RELAY, SAFETY (R-4) 1

SK210LC-6E DA mc PM, REV.0 11/02

3-25
MECHATRONICS

Dynamic Acera MC Training, 11/02 Rev. 0

3-42
 MECHATRONICS

Dynamic Acera MC Training, 11/02 Rev. 0

3-25
 MECHATRONICS

3.7 OUTLINE OF MECHATRONIC CONTROL SYSTEM

Boom cylinder
Electric Controller Boom raise conflux
In / Out signal

PL1

Pcd
PB1
Hydraulic Pilot secondary pressure

Pis
Proportional valve secondary pressure 7 5 Reverse Reverse 2 3
Pilot primary pressure Arm cylinder
Arm out conflux

Boom conflux
Main circuit

P2 by-pass Arm variable

Arm conflux P1 by-pass

cut valve recirculation

cut valve
Travel straight
Arm in conflux

valve

valve

Travel right
LH RH LH RH

Travel left

Bucket
Swing

Boom
Arm
Pilot valve Pilot valve
Bucket cylinder

valve
for ATT for Travel

P2
P1
SE-9

PA1
Pca
8 6 Forward Forward 1 4

PTd
Low pressure SE-10
(C-2) sensor SE-4
Gauge cluster 4
A.M.B selective display
SE-3 Swing parking brake
Rotary multi (Lever less) C/V

Lower portion....Switch assy. 3

Screen change switch
Buzzer stop switch SE-2
2
Mode switch
Washer switch SE-1 Travel speed
1
wiper switch
Output voltage

Work light switch SE-8

8
Decel switch
Command voltage ¥current
(Serial communication)

SE-7
7
Command voltage ¥current

Accel 6
(Serial communication)

potentio System outline Feature Purpose

(SE-16) SE-5 To control P1 pump with (A) To be power curve as
5
Control P1,P2 pump 1 proportional valve an ideal curve
Output voltage

with proportional valve.

High pressure
SE-22 To control P2 pump with (B) To supply flow rate
sensor
2 proportional valve appropriate to every
A1 A2SE-23 operation
Mechatro controller Engine A3 Control travel straight valve
(C-1) Governor motor 3 To switch softly

Arm variable recirculation

(M-2) E/G speed sensor
To control a with proportional valve

P1 by-pass cut valve

P2 by-pass cut valve

(SE-13) part of control Control cut valve with

Travel 1, 2 speed
4 To switch softly

Travel straight
Swing P/B valve with proportional proportional valve

Lever lock
ATT boost
Propotional / valve. Control arm variable recircuation Control arm speed
PSV-P1 solenoid valve 5
: E/G speed sensor valve with proportional valve as required
P1 pump Proportional valve block Control main spool Control ATT boost with solenoid
: Governor motor PSV-P2 6
with oil pressure. proportional valve
: High pressure sensor P2 pump Proportional valve
(for P1 and P2 2pcs) Control swing P/B open/
7
SV-1 SV-3 PSV-A PSV-D PSV-C PSV-B SV-2 SV-4 close with solenoid valve
: Low pressure sensor
(ATT : 7pcs, Travel : 2pcs)
Safety lock
: Potentiometer lever
SW-11
24 volt
Proportional command current
Note : Pressure sensor SE-5 is attached to swing section of control valve
Dynamic Acera MC Training, 11/02 Rev. 0
3-26
 MECHATRONICS
3.8 MACHINE OPERATION
Electric Hydraulic

P2 bypass cut propo. valve

P1 bypass cut propo. valve

Pump Control valve Motor Cylinder

Swing P / B solenoid valve

P1 ind. travel propo. valve

P2 ind. travel propo. valve

Arm variable recirculation

Lever lock solenoid valve

ATT boost solenoid valve
P1 pump propo. valve

P2 pump propo. valve

High pressure sensor
Low pressure sensor

Travel straight valve

Actuator

Travel 1-2speed

Arm variable recirculation

solenoid valve
propo. valve

P1 bypass cut valve

P2 bypass cut valve

Straight travel valve

Boom holding valve

Boom conflux valve

Swing priority valve

P1 ind. travel valve

P2 ind. travel valve

Arm holding valve

Arm conflux valve

Travel right motor

Travel left motor

Nibbler/breaker
Swing motor
Travel right

Travel left
P2 Pump
P1 pump
SE1 SE22 PSV PSV A6 A3 A4 A5

Bucket

Bucket
Swing
Boom

Boom
A8 A7 A2 A1
PSV PSV PSV PSV PSV PSV

Arm

Arm
Opeating condition

•
SE10 SE23 P1 P2 A SV-1 SV-3 SV-2 SV-4
3 B C D E F

Travel fwd left/right operation (slow)

Travel fwd left/right operation (fast)

Boom up inching operation

Boom up full lever operation (no load)

Boom up and arm in operation

Boom up with HL and swing

Travel fwd, boom up with HL and swing
Arm out inching operation

Arm out full lever operation

Arm out full lever and swing
Arm in inching operation
Arm in full lever operation (light digging)

Arm in heavy digging (two pumps)

Arm in and swing (heavy digging)

Bucket in (dig) inching operation

Bucket in (heavy dig) full lever operation

Bucket out (dump) inching operation
Bucket out (dump) full lever operation

Swing operation

Nibbler/Breaker one pump flow

Nibbler/Breaker two pump flow

Neutral
Ind. Travel

Travel fwd left/right operation

Boom up with HL and swing
Travel fwd, boom up and swing

Hydraulic system pressure draining

Note : 1. In Boom, arm and bucket digging operation, ATT function through solenoid valve only when ATT boost switch is pressed.
2. ATT boost function does not actuate at P2 side option nibbler operated.
3. Press screen change switch and buzzer stop switch at the same time for 5 seconds or more, the pressure release can be performed form actuator corresponding to pressure releasing.
Dynamic Acera MC Training, 11/02 Rev. 0
3-27
 ACTUATOR (20)PSV-D (21)PSV-B (22)PSV-C (23)PSV-A (32)PSV-E (33)PSV-F
(24)PSV-P1 (25)PSV-P2
P1-ByPassCut P2-ByPassCut Travel Straight ArmRegen P1 IndTravel P2 IndTravel
FUNCTION
350/347 mA 350/348 mA
200/221 mA 200/220 mA 350/350 mA 404/405 mA 200/218 mA 200/215 mA
Operator's Control in neutral 91/88 psi 91/90 psi
0/0 psi 0/0 psi 100/100 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

492/489 mA 495/492 mA
560/560 mA 560/560 mA 350/350 mA 404/405 mA 200/218 mA 200/215 mA
Travel Fwd/Back (Slow) 216/216 psi 495/493 psi
284/284 psi 284/284 psi 100/100 psi 148/148 psi 0/0 psi 0/0 psi
PS 15~4 mA PS 15~4 mA

492/489 mA 495/492 mA
560/560 mA 560/560 mA 350/350 mA 404/405 mA 200/218 mA 200/215 mA
Travel Fwd/Back (Fast) 216/216 psi 495/493 psi
284/284 psi 284/284 psi 100/100 psi 148/148 psi 0/0 psi 0/0 psi
PS 50 to 3 mA PS 50 to 3 mA

410/408 mA 350/347 mA
404/402 mA 565/565 mA 350/348 mA 404/405 mA 200/218 mA 200/215 mA
Boom up inching 142/139 psi 91/88 psi
148/146 psi 289/289 psi 100/99 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

397 mA 560mA 340mA 612mA 456mA 480mA 200/218 mA 200/215 mA

Boom up/Arm in inching 141 psi 280psi 92psi 330psi 180psi 207psi 0/0 psi 0/0 psi

695mA 695mA 501mA 472mA 473mA 477mA 200/218 mA 200/215 mA

Boom up/Arm in inching (stall) 403psi 403psi 232psi 200psi 200psi 203psi 0/0 psi 0/0 psi

680/680 mA
680/680 mA
404/402 mA 706/700 mA 350/348 mA 404/405 mA 200/218 mA 200/215 mA
Boom up full lever (no load) 380/380 psi
148/146 psi 413/406 psi 100/99 psi 148/148 psi 80/380 psi 0/0 psi 0/0 psi
PS 30~2 mA
PS 30~2 mA

476/471 mA 476/473 mA
404/402 mA 706/700 mA 350/348 mA 404/405 mA 200/218 mA 200/215 mA
Boom up full lever (stall) 200/197 psi 200/199 psi
148/146 psi 413/406 psi 100/99 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

469/466 mA 469/467 mA
196/191 psi 196/194 psi
PS 0 mA PS 0 mA
Note: Note:
404/402 mA 706/700 mA 350/348 mA 404/405 mA Increased Increased 200/218 mA 200/215 mA
Boom up full lever (stall-HL) 148/146 psi 413/406 psi 100/99 psi 148/148 psi value of PS to value of PS to 0/0 psi 0/0 psi
max=30: max=30:
435/430 mA 435/432 mA
165/162 psi 165/162 psi
PS 0 mA PS 0 mA

600/595 mA 690/690 mA
404/402 mA 706/700 mA 350/348 mA 538/539 mA
305/305 psi 307/305 psi
148/146 psi 413/406 psi 100/99 psi 265/265 psi
When stalling: When stalling: 200/218 mA 200/215 mA
Boom up/Arm in full lever When stalling: When stalling: When stalling: When stalling:
476/471 mA 476/473 mA 0/0 psi 0/0 psi
706/704 mA 706/700 mA 513/512 mA 200/220 mA
202/197 psi 202/199 psi
413/410 psi 413/406 psi 244/242 psi 0/0 psi
PS 0 mA PS 0 mA

472/470 mA 472/471 mA
706/691 mA 706/692 mA 513/514 mA 200/214 mA 200/218 mA 200/215 mA
Boom up/Arm in (stall) 201/199 psi 202/200 psi
413/400 psi 413/400 psi 244/244 psi 0/0 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

404/402 mA 706/700 mA 350/348 mA 404/405 mA 600/595 mA 590/589 mA 200/218 mA 200/215 mA

Boom up-HL/Swing 148/146 psi 413/406 psi 100/99 psi 148/148 psi 305/305 psi 300/300 psi 0/0 psi 0/0 psi

485/480 mA 485/480 mA
560/560 mA 560/560 mA 650/650 mA 404/405 mA 200/218 mA 200/215 mA
Travel Fwd/Boom up-HL/Swing 210/201 psi 210/201 psi
284/284 psi 284/284 psi 361/361 psi 148/148 psi 0/0 psi 0/0 psi
PS 3~7 mA PS 3~5 mA

350/347 mA
404/402 mA 404/405 mA 350/348 mA 404/405 mA 400/395 mA 200/218 mA 200/215 mA
Arm out inching 91/88 psi
148/146 psi 148/149 psi 100/99 psi 148/148 psi 129/125 psi 0/0 psi 0/0 psi
PS 0mA

590/590 mA 590/590 mA
706/704 mA 404/406 mA 350/348 mA 404/405 mA 200/218 mA 200/215 mA
Arm out full lever (no load) 300/300 psi 300/300 psi
413/412 psi 148/149 psi 100/99 psi 148/148 psi 0/0 psi 0/0 psi
PS 5~40 PS 5~40

477/471 mA 477/473 mA
706/704 mA 404/406 mA 350/348 mA 404/405 mA 200/218 mA 200/215 mA
Arm out full lever (Stall) 202/197 psi 202/199 psi

3-27
413/412 psi 148/149 psi 100/99 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

3-28
555/550 mA 690/690 mA

(B)
706/704 mA 404/406 mA 350/348 mA 404/405 mA 200/218 mA 200/215 mA
Arm out/Swing full lever 273/270 psi 307/305 psi
413/412 psi 148/149 psi 100/99 psi 148/148 psi 0/0 psi 0/0 psi
PS 0~40 mA PS 0~40 mA

350/346 mA 400/395 mA
404/402 mA 404/405 mA 350/348 mA 706/700 mA 200/218 mA 200/215 mA
Arm in inching 91/87 psi 136/136 psi
MECHATRONICS

148/145 psi 148/148 psi 100/99 psi 413/407 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

350/346 mA 750/739 mA
404/402 mA 404/405 mA 350/348 mA 538/539 mA 200/218 mA 200/215 mA
Arm in (light digging) full lever 91/87 psi 442/434 psi
148/145 psi 148/148 psi 100/99 psi 265/267 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

475/471 mA 477/473 mA
706/705 mA 404/405 mA 513/511 mA 200/221 mA 200/218 mA 200/215 mA
Arm in (stall-heavy dig) full lever 199/197 psi 203/199 psi
413/410 psi 148/148 psi 244/242 psi 0/0 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

488/485 mA 489/484 mA
706/699 mA 404/405 mA 647/646 mA 623/620 mA 200/218 mA 200/215 mA
Arm in/Swing (heavy digging) 213/210 psi 213/210 psi
413/406 psi 148/148 psi 361/360 psi 339/336 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

400/397 mA 350/347 mA
404/402 mA 404/405 mA 350/348 mA 404/405 mA 200/218 mA 200/215 mA
Bucket in (Dig) inching 135/132 psi 91/88 psi
148/145 psi 148/148 psi 100/99 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

640/634 mA 540/540 mA
404/402 mA 706/700 mA 647/645 mA 404/405 mA 200/218 mA 200/215 mA
Bucket in (Dig) full lever 338/339 psi 265/265 psi
148/145 psi 413/409 psi 361/360 psi 148/148 psi 0/0 psi 0/0 psi
PS 0~22 mA PS 0~25 mA

475/471 mA 475/482 mA
404/402 mA 706/700 mA 647/646 mA 404/405 mA 200/218 mA 200/215 mA
Bucket in (Dig) full lever (Stall) 200/197 psi 200/199 psi
148/145 psi 413/409 psi 361/360 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

410/407 mA 350/347 mA
404/402 mA 404/407 mA 350/348 mA 404/405 mA 200/218 mA 200/215 mA
Bucket out (Dump) inching 135/132 psi 91/88 psi
148/145 psi 148/149 psi 100/99 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

650/648 mA 422/418 mA
404/402 mA 706/700 mA 647/646 mA 404/402 mA 200/218 mA 200/215 mA
Bucket out (Dump) full lever 348/346 psi 154/151 psi
148/145 psi 413/407 psi 361/360 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

475/475 mA 422/418 mA
404/402 mA 706/700 mA 647/646 mA 404/402 mA 200/218 mA 200/215 mA
Bucket out (Dump) full lever-Stall 203/202 psi 154/152 psi
148/145 psi 413/407 psi 361/360 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

350/346 mA 623/621 mA
404/402 mA 404/405 mA 350/348 mA 404/402 mA 200/218 mA 200/215 mA
Swing operation 91/87 psi 331/329 psi
148/145 psi 148/148 psi 100/99 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

350/346 mA 350/347 mA
404/402 mA 706/701 mA 350/348 mA 404/402 mA 200/218 mA 200/215 mA
Nibbler/Breaker (1 pump) 91/87 psi 91/88 psi
148/145 psi 413/409 psi 100/99 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

350/346 mA 350/347 mA
OPERATION OF PROPORTIONAL SOLENOID VALVES BY THE MECHATRONIC CONTROL SYSTEM DURING DIFFERENT FUNCTIONS

706/698 mA 706/701 mA 513/513 mA 404/402 mA 200/218 mA 200/215 mA

Nibbler/Breaker (2 pump) 91/87 psi 91/88 psi
413/406 psi 413/409 psi 244/244 psi 148/148 psi 0/0 psi 0/0 psi
PS 0 mA PS 0 mA

350/345 mA 350/346 mA
706/698 mA 706/700 mA 668/666 mA 404/402 mA 481/475 mA 481/472 mA
Neutral 91/87 psi 91/88 psi
413/406 psi 413/407 psi 380/377 psi 148/148 psi 206/202 psi 206/199 psi
PS 0 mA PS 0 mA

350/345 mA 620/615 mA
706/698 mA 706/700 mA 668/666 mA 404/403 mA 481/476 mA 665/654 mA
Travel Fwd L/R 91/87 psi 325/323 psi
413/406 psi 413/407 psi 380/377 psi 148/145 psi 206/202 368/360 psi
Ind. PS 1 mA PS 1 mA
Travel 677/677 mA 350/346 mA
706/698 mA 706/700 mA 668/666 mA 404/403 mA 665/658 mA 481/472 mA
Boom Up-HL/Swing 375/376 psi 91/88 psi
413/405 psi 413/407 psi 380/377 psi 148/145 psi 368/361 psi 206/199 psi
PS 0 mA PS 0 mA

499/498 mA 499/497 mA
706/698 mA 706/700 mA 668/666 mA 404/403 mA 665/658 mA 665/654 mA
Travel Fwd+Boomup&Swing 222/222 psi 222/220 psi
413/405 psi 413/407 psi 380/377 psi 148/145 psi 368/361 psi 368/360 psi
PS 0 mA PS 0 mA
Dynamic Acera MC Training, 11/02 Rev. 0

350/345 mA 350/346 mA
404/404 mA 404/405 mA 350/348 mA 404/403 mA 438/437 mA 438/433 mA
Hydraulic System Pressure Drainining 91/87 psi 91/88 psi
148/148 psi 148/148 psi 100/99 psi 148/145 psi 168/167 psi 168/164 psi
PS 0 mA PS 0 mA
3
 MECHATRONICS

Dynamic Acera MC Training, 11/02 Rev. 0

3-25
 MECHATRONICS
3.9 MULTIDISPLAY SELF DIAGNOSIS
The error of the control I/O signal of the pressure sensor and the proportional valve, etc. is detected and the error item is
displayed on the monitor.
1. Indication item
No. Contents Display of monitor Connector No. Wire Wire
Pin No. No. Color
1
MECHATRO
1 Mechatro controller error CPU CONTR.FAIL CN16-1 770 R

Gauge cluster Mechatro I-1

RECEIVE
2 controller communication CN16-2 582 W
ERROR
failure
I-2
BAT
3 Battery relay fail CN15-24 700 WG
RELAY
3
A-1
ROM DATA
4 ROM data CPU FAILURE

A-2
MECHATRO
5 Mechatro set error CPU SET ERROR

B-1
Boom raise pressure BOOM RAISE CN11-2 502 LgY
6 SE
sensor fail SENSOR CN11-1 952 BR

B-2
Boom lower pressure BOOM LOWER CN11-5 503 LO
7 SE
sensor fail SENSOR CN11-6 953 BrW

B-3
ARM IN CN11-8 504 PG
8 Arm in pressure sensor fail SE
SENSOR CN11-7 954 BrL

B-4
ARM OUT CN11-11 505 PL
9 Arm out pressure sensor fail SE
SENSOR CN11-12 955 Gr

B-5
Bucket dig pressure sensor BUCKET DIG CN11-14 500 LgR
10 SE
fail SENSOR CN11-13 950 BrR

B-6
Bucket dump pressure sensor BUCKET DUMP CN11-17 501 LgW
11 SE
fail SENSOR CN11-18 951 BL

B-7
SWING CN11-20 507 VG
12 Swing pressure sensor Fail SE
SENSOR CN11-19 957 Br

B-9
Travel (R.H) Pressure sensor TRAVEL (R) CN11-26 508 VY
13 SE
fail SENSOR CN11-25 958 BY

B-10
Travel (L.H) Pressure sensor TRAVEL (L) CN11-29 509 Sb
14 SE
fail SENSOR CN11-30 959 BG

C-1 CN12-4 915 YL

PUMP P1
15 Pump P1 pressure sensor fail SE CN12-5 515 V
SENSOR
CN12-6 965 BrB
C-2 CN12-9 916 YR
PUMP P2
16 Pump P2 pressure sensor fail SE CN12-8 516 L
SENSOR
CN12-7 966 BrY

Dynamic Acera MC Training, 11/02 Rev. 0

3-28
 MECHATRONICS
No. Contents Display of monitor Connector No. Wire Wire
Pin No. No. Color
D-1
P1 By-pass cut propo-valve P1 BY-PASS CN15-4 744 BP
17
fail PSV PROPO-VALVE CN15-5 745 PW

D-2
P2 By-pass cut propo-valve P2 BY-PASS CN15-6 740 BO
18
fail PSV PROPO-VALVE CN15-7 741 GrR

D-3
Travel straight TRAVEL CN15-8 742 VR
19
propo-valve fail PSV PROPO-VALV CN15-9 743 GrB

D-6
Arm variable recirculation RECIRCULAT CN15-10 746 BrG
20
propo-valve fail PSV PROPO-VALV CN15-11 747 YV

E-1
PUMP P1 CN15-17 748 VR
21 P1 pump propo. valve fail PSV PROPO-VALV
3 E-2
CN15-18 749 GrG

PUMP P2 CN15-19 750 VW

22 P2 pump propo. valve fail PSV PROPO-VALV CN15-20 751 GY

F-1
POWERBOOST
23 ATT boost solenoid fail SV SOLENOID
CN15-23 703 P

F-2
Swing parking brake solenoid SWING BRAKE
24
valve fail SV SOLENOID
CN15-22 701 V

F-3
Travel two-speed solenoid TWO-SPEED
25
valve fail SV SOLENOID
CN15-21 702 LgB

G-1 CN-15-1 771 G

STEP MOTOR CN-15-2 772 B
26 Gover nor motor current fail M CURRENT-NG CN-15-15 773 R
CN-15-16 774 W
G-2
Governor motor starting STEP MOTOR
27
point indexing fail M S/PT. ERROR
CN-13-1 544 BG

G-3
E/G REV. CN-12-20 580 R
28 Engine speed sensor fail RPM SENSOR CN-12-21 581 W

H-1 CN-12-1 917 BW

ACCELERATR
29 Accel potentio meter fail POT POTENTIO
CN-12-2 517 P
CN-12-3 967 WR
32
Hydraulic pressure release DRAINING
30 PR – – –
stand by HYD. PRESS

33
Hydraulic pressure release FAIL DRAIN
31 PR – – –
fail HYD. PRESS

Prop-Valve P1 I-Travel D-11

35 PUMP P-1 CN-17-15

WV
fail PSV-E I-TRAVEL CN-17-16

GR

Prop-Valve P2 I-Travel D-12

36 PUMP P-2 CN-17-17

WL
fail PSV-F I-TRAVEL CN-17-18

GR
Note : 1. Refer to electric diagram about number of connector, number of pin, wire number and wire color.

2. When the pressure release operation (Hidden mode) is performed, this condition is indicated on multi-


display.
2. In/Output flow

Input Serial communication

Pressure sensor, Governor motor, Control Gauge cluster
Proportional valve, Solenoid valve (Buzzer alarm)
and Battery relay

Dynamic Acera MC Training, 11/02 Rev. 0

3-29
 MECHATRONICS
3.10 TROUBLE HISTORY DIAGNOSIS 5. To scroll the page, use the work mode and the
The error item detected by the self diagnosis is stored buzzer stop switch.
in the mechatro controller as a history and is displayed • Press the work mode switch, page up.
on the multidisplay. • Press the buzzer stop switch, page down.
Note : All the error items are stored by
1. How to display hourmeter, when the hourmeter is dif-
1. Turn the starter switch ON. fered, press the work mode and the
2. Press the buzzer stop switch 5 times in sequence buzzer stop switch, and displays all items
for 10 seconds. and make sure that they are right.
(Example)
6. Turn the starter switch off, and the display is dis-
No errors NO ERROR
appeared.
00025H
Error detected in the
past
B-1 Boom raise
D-1 P1 BY-PASS
2. How to cancel the contents of the trouble history 3
1. Display the trouble history mode.
F-3 TWO SPEED
2. Press the work mode switch and the buzzer stop
switch for 10 seconds or more concurrentry.
3. Trouble history are displayed in order of the old
3. When the deletion is completed, the “ NO ERROR ”
one.
is displayed.
4. Transmits the error data (one or many) and hour
4. Turn the starter switch OFF.
meter to the gauge cluster.
Note : All the stored item are erased.
• Hour meter and 3 error data are displayed in
It is impossible to erase data partially
the screen.
• If three error data or more exist, display the data
three by three in order for every 5 seconds.

3. Trouble history contents

Symbol Display Symbol Display

Controller A-1
ROM DATA FAILURE Proportional
A
relation A-2
MECHATRO SET ERROR valve E-1
PUMP P1 PROPO VALVE
E
B-1
BOOM RAISE SENSOR (Hydraulic E-2
PUMP P2 PROPO VALVE
B-2
BOOM LOWER SENSOR pump)
B-3
ARM OUT SENSOR F-1
POWERBOOST SOLENOID
Solenoid
B-4
ARM IN SENSOR F F-2
SWINGBRAKE SOLENOID
valve
Low B-5
BUCKET DIG SENSOR F-3
TWO-SPEED SOLENOID
B pressure B-6
BUCKET DUMP SENSOR G-1
CURRENT-NG
sensor B-7
SWING (R) SENSOR G-2
S/PT.ERROR
E/G
B-9
TRAVEL (R)SENSOR G G-3
E/G REV
Accessory
B-10
TRAVEL (L) SENSOR G-4
E/G COOL
G-5
E/G OIL PRS
Potentio
H H-1
ACCELERATR POTENTIO
High relation
pressure C-1
PUMP P1 SENSOR H-4
AIR CLEANER RESTRICT
C sensor
(Hydraulic C-2
PUMP P2 SENSPR
I I-1
RECEIVE ERROR
pump)
I-2
BAT.RELAY
Proportional D-1
P1 BYPASS PROPO VALVE
valve D-2
P2 BYPASS PROPO VALVE
NO ERROR
D
(Control D-3
TRAVEL PROPO VALVE Note : G-4 and G-5 are newly added
valve) D-6
RECIRCULAT PROPO VALVE
D-11 PSV P1 I-TRAVEL
D-12 PSV P2 I-TRAVEL

Dynamic Acera MC Training, 11/02 Rev. 0

3-30
 MECHATRONICS
3.11 MECHATRO CONTROLLER “A” and “B” ADJUSTMENT
1. When the mechatro controller requires adjustment,
After replacement of the following parts, if following display appears on the multidisplay, the adjustment of the mechatro
controller is performed. Gauge cluster

When the mechatro controller is required to adjust,

A M B
1. When the mechatro controller is replaced,
2. When the governor motor is replaced,
3. When the ROM DATA FAILURE is displayed on the multidisplay,
4. When the ROM DATA FAILURE and MECHATRO SET ERROR
are displayed alternately on the multidisplay, OK Work mode
select switch
Buzzer stop
2. Preparation switch

3 1. Warm up the engine.

2. Turn the air-con switch off.
3. Turn the starter switch off to stop the engine.
Note : Make sure that the knob for the engine emergency stop pushed in.If the adjustment is done while the
knob is pulled out, the engine speed can not be set correctly.

3. Adjustment
A adjustment
Procedure Multidisplay Movement of governor motor
1
While keeping the work mode selector switch

on the cluster gauge pressed, turn the starter

switch ON, hold it in this condition for 5 to 10

seconds, and release it.
10 : 05

2
The governor motor returns it to the starting A

point, and it stops at the point corresponding

to the accel dial set position.
10 : 05

Stop at the position set by accel dial

3
Keep the buzzer stop switch on the gauge A
STEP 1 S

cluster pressed for 5 to 10 seconds and CPU
START

release it, and STEP 1 is displayed on the

multidisplay, then wait until the next display CPU step 1 start

STEP 2 appears.
Automatically run
to engine stop
STEP 2
CPU position (S)
GAP (STOP)

4
After verification of the STEP 2 display, go to

S

the engine room and adjust the rod Assy

standard length to Bmm in order to have the

clearance "A 0.1mm" between the governor Stop at S position

lever and the engine stop set bolt. STEP 2
CPU

If governor motor was replaced, indicate GAP (STOP) [TOOLS]

STEP 2 display and insert rod assy. • Spanner 13 mm X 14mm

• Dimension B: • Spanner 6 mm

186 mm
(SK160LC-6E), • Thickness gauge

288~304 mm
(SK210LC-6E),

165 mm
(SK250LC-6E),

210~213 mm
(SK290LC-6E),

Dynamic Acera MC Training, 11/02 Rev. 0

3-31
 MECHATRONICS
Procedure Multidisplay Movement of governor motor
5. Press the buzzer stop switch once, and wait until S A

the STEP 3 is displayed.

STEP 3
CPU
START (E/G)
Automatically run to the engine
available position A

6.
After verification of STEP 3 display, starts A

the engine.

Then, it is unaffected by the actual accel dial STEP 3

position. CPU
START E/G

Stop at A position

7.
Press the buzzer stop switch once, and the

STEP 4 is displayed and the
Lo A
Hi
3

controller returns from the A position of governor

to the low idling position once, and then reads

the engine rpm to the high idling automatically. STEP 4

(Required time : about 2 minutes.) CPU Move from A position to Lo idling
MEMORY
position, and self-travels from Lo
position to high idling (H) position

8. After completion of the read out, wait until the Hi

"CPU FINISH 2220RPM" is displayed on the

multidisplay. After the "CPU FINISH 2220RPM"

is displayed, the controller returns to the actual

dial initial optional position automatically. FINISH (Approx.
CPU A

Note : If the "CPU FINISH 2220RPM" is not 2220RPM 5seconds) Hi



displayed, the adjustment has failed.



Turn the starter switch off, and per-



form the adjustment again.

B adjustment
9. When the screen "CPU FINISH 2220RPM" is

displayed after adjustment of engine, the "CPU STEP 5
CPU

STEP 5 MEMORY" is displayed automatically, MEMORY

the engine speed changes into high idling and

the pump is loaded, and then "CPU FINISH FINISH

ORPM" is displayed after 1 minute in high CPU
ORPM

idling condition and adjustment is terminated.

Note :
1. The B adjustment is carried out by mechatro controller after completion of A adjustment automatically.
2. The temperature control of hydraulic oil is necessary to adjust it to the correct output, so special atten-
tion must be paid to the hydraulic oil temperature.
3. When the adjustment failed, start it from A adjustment after checking the relief pressure.
4. Usually the A adjustment and B adjustment must be carried out sequentially.

4. Adjustment End (Rechecking E/G speed)

1) Place starter switch to “START” position, and rise the engine speed to the high idling.
2) Press screen change switch on gauge cluster once, press engine speed display and auto accel release switch,
and the auto accel function is released.
3) By switching the work mode selector switch on gauge cluster, the mode display changes, then check that the
engine speed indicated on multi display changes.
4) Press auto accel release switch on gauge cluster to have auto accel, and check the decel speed.
5) Press screen change switch on gauge cluster 4 times to have “Time Display” and stop the engine.

Dynamic Acera MC Training, 11/02 Rev. 0

3-32
 MECHATRONICS
5. When the mechatro controller can not be adjusted,
1. The CPU STEP 4 MEMORY to CPU CONDITION ERROR is displayed, making the adjustment impossible.
A. (Display condition) - While reading the engine speed, in the condition of the engine revolution, 850 rpm or
higher, for the engine rpm before and after the steps of the governor, the revolution at rear
step is 10 rpm lower than that before step.
(Cause) - The engine speed sensor has failed to read the engine speed.
(Corrective action) After measurement and adjustment of the voltage of speed sensor, carry out the "A"
-
adjustment. (Disconnect the sensor connector and measure
the voltage.) Specified value
3V (AC) or more at high idling condition (Voltage available for Voltage 1.4 to 6V (AC)
controller to read) [4V (AC) or more at high idling condition set Resistance 2.3 ± 0.2 Ω
in the factory].
B. (Display condition) - Where the abnormal rotation (step out) in high idling condition.

3 (Cause)
(Corrective action)
- Governor motor link rod connection error. (Corrective action)
{Link rod length : 288~304 mm (SK200-6E), 336~348 mm (SK230-6E), }
- If it is stepped out even after the adjustment, press the buzzer stop once just before
the stepping out as an emergency measure, and the speed changes to the high
idling position temporarily and the CPU FINISH 2200RPM is displayed.
- Minor changed machine is added spring to link mechanism.
2. The CPU CONDITION ERROR , CPU MECHATRO CONT FAIL and CPU ROM DATE are displayed by turn,
making the adjustment impossible.
(Display condition) • When the engine speed is 300 rpm or lower, or 3,000 rpm or higher,
.............. The CPU MECHATRO CONT FAIL is displayed
• When the engine speed is 0 rpm,
.............. The CPU ROM DATA is displayed.
(Cause) • The engine sensor has failed to read the engine speed.
• The harness of the engine speed sensor is broken.
(Corrective action) • After measurement and adjustment of the voltage of speed sensor, carry out “A” adjust-
ment.
3V (AC) or more in high idling condition.
3. The CPU ROM DATE FAILURE is displayed.
A. (Display condition) • When the mechatro controller fails,
(Cause) • There is the suspicion of breakage inside of the mechatro controller.
(Corrective action) • If the failure is not recovered after the adjustment, replace the mechatro controller with
new one.
B. (Display condition) • After the mechatro controller is replaced,
(Cause) • The mechatro controller is not adjusted yet.
(Corrective action) • Adjust the mechatro controller.

4. The display does not go from the STEP 1 CPU START to STEP 2 CPU GAP (STOP) .
(Display condition) • The limit switch signal (grounding) in the governor motor is not input to the mechatro
controller.
(Cause) • Failure of the limit switch in the governor motor.
• Insufficient contact of connector on the governor motor or breakage of the harness.
(Corrective action) • Check that the limit switch of the governor motor goes on or off.
• Check connector and harness for possible damage, and adjust it if necessary.

5. Others
The engine oil pressure is displayed on the gauge cluster, and the engine stops. It may be caused by the failure of the
engine oil pressure switch and short-circuit of the harness.

Dynamic Acera MC Training, 11/02 Rev. 0

3-33
 MECHATRONICS
3.12 SERVICE DIAGNOSIS
The present service diagnosis in 23 items is displayed on the multidisplay according to the data received from the
mechatro controller. Gauge cluster
How to display
A M B
1. Keep the buzzer stop switch pressing, turn the starter switch “ON” and
starts the engine.
2. Place safety lock lever to unlocked (down) position.
3. The 1st item Parts No. of Mechatro controller and program version are
displayed. OK Buzzer stop
4. Each time the screen change switch on the gauge cluster is pressed, switch
the number runs like No. 2, No. 3,…in order.
5. Each time the buzzer stop switch on the switch panel is pressed, the
number returns like No. 25, No.24 …in order.
6. If mode indication is not in remarks column, diagnose by M mode.
3
Auto accel release switch
7. The display disappears only when the starter switch is turned OFF.
Screen change switch
Note : 1. The scrolling of service diagnosis to see variation by the work mode with the work mode selector
switch may cause the change of the mode, so use the screen change switch on the gauge cluster
for scrolling.
2. Press the auto accel release switch according to the check item.
3. When starter switch is pressed, the start-up mode is “ M ” but the change of start-up mode is
possible.

Service diagnosis display

No. Display Operation procedure SK210LC-6E SK250LC-6E Remarks
No.1 (Screen No.)
Main cont P/No. Main cont P/No.
YN22E00123F1 YN22E00146F1
Program version Program version
VER 08.00 VER 02.00
No.2 The set value varies Low Hi Low Hi
M mode at Hi position
E/G SET
1000 according to the accel 1000 2220 1000 2300
dial position and work 1950 2100 A mode
MEAS
1019 mode selector operation. 2220 2300 B mode
Aut accel Auto accel function active : 1050 System starts in "M"
Mechatro controller

Engine running : LIVE. mode by default.

E/G PRS.
LIVE A and B mode can be
When engine is stopped : DEAD
selected after ignition
Mode select
M Press the work mode At M mode : M, At A mode : A.
selector switch At B mode : B, indicator illuminates. key is turned to ON.

No.3
H-1 Low Hi Low Hi
ACCEL VOLT.
0.3V Voltage value varies while 0.3~0.4V 4.4~4.5V


POS.
0% turning throttle potentiome- 0% 100%
ter from Low to Hi.
MOTOR STEP
312 312 500
The step number varies a


POS.
0% little after A adjustment. 0% 100%
No.4
STEP. MOTOR
At the moment when the starter switch
G-1 COIL A

1.5A
turns OFF, ON
G-1 COIL B

1.5A
G-2 LIMIT

OFF

Dynamic Acera MC Training, 11/02 Rev. 0

3-34
 MECHATRONICS
No. Display Operation procedure SK210LC-6E SK250LC-6E Remarks

No.5 *SV–1 At swing and arm in operation •
COMP.

SOL. VALVE Operate swing lever in OFF
ON 5sec. after swing lever
Instructed by m

echatro
F-2 SWING-BRAKE
neutral position
controller
left or right or arm-in


COMP.
ON action. OFF
ON simultaneous arm lever •
MEAS.

Error is displayed by
Control valve solenoid valve 34±2Ω

MEAS.
ON Operate swing brake
neutral position
Feed back

RELEASE SW switch. ON, at swing brake release side.
COMP.
OFF
MEAS.
ON
No.6 *SV–3 (Even if in disconnec-
SOL. VALVE tion, displayed.)
F-3 1/2-TRAVEL Operate travel speed 1st speed 2nd speed Voltage of connectors


COMP.
OFF change switch. OFF ON
Measure the voltage


MEAS.
OFF OFF ON
of connectors.


SWITCH
OFF OFF OFF (ON while SW is active)
Measure resistance

3 No.7
SOL. VALVE
*SV–2
Operate ATT boost switch.
ATT boost SW/Heavy Lift Switch
Not operated
of solenoid valve.

SW is ON and control Perform checking

changing the connector
lever is operated
F-1 POWER BOOST Boom up positions each other
Operation


COMP.
OFF Arm in OFF ON
only


MEAS.
OFF Bucket dig OFF ON


SWITCH
OFF OFF ON

No.8
Mechatro controller

*E–1
RELAY Starter SW ON Starter SW OFF
I-2 BAT. RELAY
Operate starter switch


COMP.
ON ON ON


MEAS.
ON ON ON


KEY SWITCH
ON ON OFF

No.9 In neutral, values are

Control levers in neutral minimum. Values go up
PRESS. SENSOR 0.5V


0P
E/G speed Low/Hi proportionally with con-
B-1 BOOM RAISE trol lever movement.
*SE–3
0.5V
0P If it is not varied, change
B-2 BOOM LOWER E/G speed High idle the connector position,
4.7~5.0V

435P
*SE–4
0.5V
0P Boom over relief and check it again.

After changing the

No.10 position,
PRESS. SENSOR Control levers in neutral 0.5V

0P
B-3 ARM OUT E/G speed Low/Hi If the display changes
*SE–8
0.5V
0P failure of sensor.
B-4 ARM IN E/G speed High idle
4.7~5.0V

435P If the display does not
*SE–7
0.5V
0P Arm over relief
change
failure of harness.
Low pressure sensor

No.11 Control lever at neutral

PRESS. SENSOR position 0.5V

0P
B-5 BUCKET DIG E/G speed Low/Hi
*SE–1
0.5V
0P
B-6 BUCKET DUMP E/G speed High idle
4.7~5.0V

435P
*SE–2
0.5V
0P Bucket over relief
B-7 varies propor-
Control lever at neutral
*

tionally with control
No.12 lever movement.
PRESS. SENSOR position 0.5V

0P B-8 does not vary.
B-7 SWING (R) E/G speed Low/Hi *

*SE–5
0.5V
0P E/G speed High idle
B-8 SWING (L) Attachment blocked and 4.7~5.0V

435P


0.0V
0P swing over relief.

No.13 Control lever at neutral

PRESS. SENSOR position 0.5V

0P
B-9 TRAVEL (R) E/G speed Low/Hi
*SE–9
0.5V
0P E/G speed High idle
B-10 TRAVEL (L) Travel locked and travel 3.7~4.2V

406P
*SE–10
0.5V
0P function over relief

Dynamic Acera MC Training, 11/02 Rev. 0

3-35
 MECHATRONICS
No. Display Operation procedure SK210LC-6E SK250LC-6E Remarks
No.14 Control lever at neutral Neutral position, or
PRESS. SENSOR operating it at full
position COMP: 0.5~0.6V
188P
High pressure sensor

C-1 PUMP P1 stroke if it is varied, it's

E/G speed Low/Hi MEAS: 0.5V
87P acceptable.
*SE–22
0.6V
203P
C-2 PUMP P2 E/G speed High idle, 3.7~3.8V
6030P If it is not varied, change
*SE–23
0.5V
87P Boom over relief the connector position,
and check it.

E/G speed High idle 3.7~4.1V
6554P After changing the

Boom up over relief+ position,
Power Boost/Heavy Lift
If the display changes
No.15 failure of sensor.
Without N&B Piping 0.0V
0P
Low pressure sensor

PRESS. SENSOR
If the display does not
B-16 P1 OPT.
*SE–20
0.5V
0P With N&B Piping 0.5V
0P
change
failure of harness.
3
B-17 P2 OPT
*SE–11
0.5V
0P With N&B Piping
When control pedal is 3.7~4.2V
406P
depressed fully
No.20 Control lever at neutral COMP: 200mA
0P •
COMP.
PROPO-VALVE position, E/G speed Low MEAS: 217mA
0P
Instructed by m

echatro
D-1 P1 BY-PASS
controller
and High common •
MEAS.


COMP.
200mA 0P

Error is displayed by


MEAS.
217mA 0P E/G speed High idle COMP: 706mA
413P

Feed back
*PSV–D position, arm out MEAS: 702mA
409P
function over relief When the measured
No.21 value varies according
Control lever at neutral COMP: 200mA
0P to the variation of the
PROPO-VALVE position, E/G speed Low MEAS: 216mA
0P indication, it is acceptable.
Control valve proportional valve 17.5±1Ω

D-2 P2 BY-PASS and High common

COMP.
200mA 0P Measure the current on

MEAS.
216mA 0P E/G speed High idle COMP: 706mA
413P the connections of
*PSV–B boom up over relief MEAS: 697mA
405P connector with clamp
meter.

No.22 Control lever at neutral COMP: 350mA
100P Proportional valve

PROPO-VALVE position, E/G speed Low MEAS: 348mA
99P
D-3 S-TRAVEL Measure the resistance.
and High common


COMP.
350mA 100P
Checking after replacing


MEAS.
348mA 99P E/G speed High idle COMP: 513mA
244P the connector position is
*PSV–C Arm in function over relief MEAS: 516mA
247P possible.

No.23 Control lever at neutral COMP: 404mA
148P

PROPO-VALVE position, E/G speed Low MEAS: 407mA
149P
D-6 A-RECIRCULATE and High common


COMP.
404mA 148P


MEAS.
407mA 149P E/G speed High idle COMP: 200mA
0P
*PSV–A Arm in function MEAS: 417mA
0P
over relief

Dynamic Acera MC Training, 11/02 Rev. 0

3-36
 MECHATRONICS

No. Display Operation procedure SK210;C-6E SK250LC-6E Remarks

No.24 Control lever at neutral •
COMP
COMP: 417mA
149P
Instructed by mechatro
PROPO-VALVE position, MEAS: 415mA
148P
controller
E-1 P1 PUMP E/G speed Low idle •
MEAS
COMP.

417mA 149P
Error is displayed by
MEAS.

415mA 148P Control lever at neutral
COMP: 350mA
91P
Feed back
POWER SHIFT
0mA position,
MEAS: 349mA
90P
*PSV–1 E/G speed High idle When the measured
Pump propo.valve 17.5±1Ω

value varies according

E/G speed High idle
COMP: 750mA
442P to the variation of the
and RH travel function MEAS: 735mA
430P indication, it is acceptable.
activated
Measure the current on
No.25 Control lever at neutral the connections of
PROPO-VALVE position, COMP: 417mA
149P
connector with clamp
E-2 P2 PUMP MEAS: 414mA
148P
E/G speed Low idle meter.

3 COMP.


MEAS.


430mA 1.1M
420mA 1.1M
POWER SHIFT
0mA
Control lever at neutral
position, COMP: 350mA
91P
For proportional valve,
measure the resistance.
MEAS: 345mA
87P
*PSV–2 E/G speed High idle
Checking after replacing
E/G speed High idle COMP: 750mA
442P the connector position is
and LH travel function MEAS: 738mA
432P possible.
activated

No.32 Control lever at neutral

PROPO-VALVE position,
D–11 P1 I–TRAVEL E/G speed Low/Hi idle
COMP.

481mA 206P
MEAS.

475mA 200P
Independent travel propo.valve 34±2Ω

Independent travel COMP: 481mA
206P

*PSV–E switch ON MEAS: 475mA
200P

Independent travel COMP: 200mA
0P

switch OFF MEAS: 217mA
0P

No.33 Control lever at neutral

PROPO-VALVE position,
D–12 P2 I–TRAVEL E/G speed Low/Hi idle
COMP.

481mA 206P
MEAS.

473mA 199P Independent travel COMP: 481mA
206P
*PSV–F switch ON MEAS: 473mA
199P

Independent travel COMP: 200mA
0P

switch OFF MEAS: 217mA
0P

No.39
Mechatro controller

MECHATRO ADJT.
CONT. SW
TEST Fixed indication at RUN
CONT. SW
100% Fixed indication at 50%
PROG. SW
OFF Fixed indication at OFF

No.40
RELEASE SW.
KPSS

OFF Fixed indication at OFF
SWING BRAKE
OFF ON : When swing parking brake


released

*Screens No. 9-15 The pressure sensors show only the reference value of the indicator voltage.
Screens No. 20-25 The proportional valves show only the reference value of indicator current.
Screens No. 20-25 For the proportional valves, if the difference between the indicated value and the measured
value is 20% or less, the proportional valve is in good condition.
Note : No. 39 Mechatro adjustment
1. For the internal switch RUN, it is fixed at RUN position because the RUN and TEST switch is cancelled.
2. For the internal trimmer 50%, the service diagnosis can not be functioned during downloading, therefore it is fixed at 50%
position. (Without trimmer function)
3. For program switch OFF, it is fixed OFF position because the downloading cable is removed when executing the service
diagnosis.
Dynamic Acera MC Training, 11/02 Rev. 0
3-37
 MECHATRONICS
3.13 GENERAL TROUBLESHOOTING
This troubleshooting information covers the components of components or adjustment of valves be required, con-
and systems as described in this operators manual. tact an authorized KOBELCO Service dealer for assis-
Should in depth troubleshooting, repair or replacement tance.
SYSTEM PROBLEM PROBABLE CAUSE POSIBLE REMEDY

a. Low hydraulic oil level a. Level hydraulic oil

a. Tighten suction hose clamps

b. Air leaking into suction hose
or replace suction hose

c. Hydraulic pump damaged a. Repair or replace

1. All operating speeds are slow or
power is lost. d. Pilot pump damaged a. Repair or replace

e. Main relief valve is not adjusted properly a. Adjust or replace

f. Pilot relief valve is not adjusted properly a. Adjust or replace

g. Air inside pilot system

a. Cylinder seals are damaged

a. Bleed air from pilot system

a. Repair or replace
3
b. Control valve or overload valve functions a. Repair or replace
2. A sepecific cylinder functions incorrectly or air inside cylinder b. Bleed air from cylinders
improperly or loses power.
c. Pilot valve is damaged a. Repair or replace

d. Pilot valve piping is loose a. Tighten conecitons

a. Cylinder seal is scored a. Repair or replace

b. Control valve or overload valve is damaged a. Repair or replace

OPERATION

3. The cylinder position will not hold

with operating lever in neutral. c. Overload valve is defective a. Repair or replace

d. Pilot valve is damaged a. Repair or replace

a. Brake valve is not working a. Repair or replace

b. Swing motor not working or swing gear is

a. Repair or replace
damaged
4. Machine does not swing.
c. Swing bearing is damaged a. Repair or replace

d. Pilot valve is not working a. Repair or replace

e. Swing reduction unit is damaged a. Repair or replace

a. Brake valve is defective a. Repair or replace

b. Control valve is not working a. Repair or replace

5. Swing speed is slow. c. Swing motor not working a. Repair or replace

d. Swing pilot pressure sensor defective a. Repair or replace

e. Possible problem in regulator or hyd. pump a. Repair or replace

a. Poor lubrication of swing gear and bearings a. Lubricate as needed

6. Abnormal sound while swinging.
b. Low oil level in swing reduction unit a. Level oil in reduction unit

a. Brake valve malfunctions a. Repair or replace

7. Upper structor continues revolving
b. Brake valve pressure is incorrect a. Adjust or replace
after stopping swinging operation.
c. Brake lining is worn a. Repair or replace

a. Too much track tension a. Adjust track tension to specs

b. Dirty track links and shoes a. Clean track links and shoes
1. Machine does not travel smoothly.
c. Brake valve malfunctions a. Repair or replace

d. Travel reduction unit is defective a. Repair or replace

TRAVEL

a. Hydraulic pump is defective a. Repair or replace

b. Travel motor is defective a. Repair or replace

c. Brake valve is defective a. Repair or replace

2. Traveling power is insufficient d. Low hydraulic oil level a. Level hydraulic oil

e. Poor engine performance a. Repair or replace

f. Main relief valve adjusted incorrectly a. Repair or replace

g. Swivel valve is leaking a. Repair or replace

Dynamic Acera MC Training, 11/02 Rev. 0

3-38
 MECHATRONICS
SYSTEM PROBLEM PROBABLE CAUSE POSIBLE REMEDY

a. Unequal tension on tracks a. Adjust tension to specs

b. Main relief valve not adjusted correctly a. Adjust or replace

TRAVEL

c. Wear in travel motor(s) a. Repair or replace

3. Machine does not d. Internal leakage of regulator or main
travel in a straight line a. Repair or replace
pump, or in travel motor brake valve

e. Problem in straight travel valve or its

a. Repair or replace
proportional solenoid valve (PSV-C)

f. Problem in pilot pressure sensor a. Repair or replace

a. Hyd. oil cooler obstructed a. Clean as needed

b. Engine fan belt slipping a. Adjust or replace

3 c. Low hyd. oil level a. Level oil to specs.
HYDRAULIC

d. Hyd. oil viscosity incorrect or oil is

a. Change hydraulic oil
1. Excessive high deteriorated
temperature on hyd. oil
e. Check valve in hyd. return line is
a. Repair or replace
blocked open

f. Obstruction in hyd. return filter a. Replace filter

g. Foam seals around coolers are not in

b. Repair or replace
place or deteriorated

1. Engine oil pressure is a. Engine oil level low or deteriorated a. Repair or replace
too low; buzzer sounds,
b. Engine oil leaking a. Repair
and icon displays; and
engine shuts down. c. Wrong oil viscosity a. Change oil to specs

a. Low coolant level a. Level to specs

b. Inappropriate coolant mixture a. Repair mixture or replace

MONITOR DISPLAY

c. Coolant leakage a. Repair

2. Abnormal high d. Radiator cap malfunctioning a. Repair or replace
temperature in engine,
buzzer sounds and icon e. Obstructed radiator a. Clean radiator and/or system
displays.
f. Engine fan belt slipping or deteriorated a. Adjust or replace

g. Foam seals around coolers are not in

a. Repair or replace
place or deteriorated

h. Thermostat is malfunctioning a. Replace

a. Obstructed elements a. Clean or replace

3. Clogged air filter,
buzzer sounds and icon b. Obstruction in air intake duct system a. Repair or replace
displays
c. System sensor is malfunctioning a. Repair or replace

a. Batteries disconnected or low charge a. Repair or replace

b. Battery terminals disconnected, loose,

a. Clean and/or connect terminals
or corroded.
ENGINE

c. Defective ground cable a. Repair or replace

1. Starter does not turn or
turns slowly; engine does d. Problem in battery relay a. Repair or replace
not start
e. Problem in fuses a. Repair or replace

f. Engine oil viscosity too high (Cold

a. Change oil to specs
weather)

g. Problem in starter relay or starter motor a. Repair or replace

Dynamic Acera MC Training, 11/02 Rev. 0

3-39
 MECHATRONICS
SYSTEM PROBLEM PROBABLE CAUSE POSIBLE REMEDY

a. Low fuel level a. Refuel as needed

b. Engine emergency stop is activated a. Repair

c. Improper starting procedure (cold a. See Section 03 (Operation and

weather) Maintenance Manual)
2. Starter motor turns, but
d. Air inside fuel system a. Repair and bleed air out
engine does not start
e. Obstructed fuel filter a. Reeplace element

f. Obstructed strainer in priming pump a. Clean or replace bolt

a. Repair system or replace

g. Engine pre-heat system malfunctions
heating element

a. Consult with Kobelco's dealer

a. Excessively low idle RPM
technician

3. Engine tends to stop at b. Obstructed fuel filter a. Replace filter element

3
low speed c. Obstructed air filter a. Clean or replace element(s)

a. Consult with Kobelco's dealer

d. Improper valve clearance
technician

a. Obstructed air filter a. Clean or replace element(s)

b. Obstructed fuel filter a. Replace filter element

a. Consult with Kobelco's dealer

4. Low power c. Improper valve clearance
technician

d. Loose clamps in turbo air inlet hose a. Tighten clamps or replace hose

e. Obstruction in exhaust system a. Repair or replace

ENGINE

a. Obstruction in air filter a. Clean or replace filter element

a. Consult with Kobelco's dealer

5. Engine exhaust is b. Improper valve clearance
technician
excessively black
a. Consult with Kobelco's dealer
c. Excessive fuel in combustion chamber
technician

a. Fuel is leaking a. Repair

6. Excessive fuel b. Obstruction in air filter a. Clean or replace element

consumption
c. Turbo air inlet hose is loose or
a. Tighten or replace hose
deteriorated

a. Inappropriate oil viscosity a. Change oil

a. Change oil - Reduce

7. Excessive oil b. Oil is deteriorated
maintenance schedule
consumption
a. See Section 03 (Operation and
c. Improper warm-up operation
Maintenance Manual)

a. Engine oil level is low a. Level to specs

8. Engine oil pressure b. Engine oil leaking a. Repair

does not rise
c. Inappropriate oil viscosity or oil is
a. Change oil
deteriorated

a. Battery terminals are loose, corroded or

a. Clean and tighten conections
disconnected

b. Ground cable is loose, teriorated or

a. Repair or replace
9. Battery charge is damaged
regularly weak.
c. Low level of battery electrolyte a. Level cells with distilled water

d. Alternator belt is loose or deteriorated a. Adjust or replace belts

e. Defective battery a. Replace

Dynamic Acera MC Training, 11/02 Rev. 0

3-40