Pda Mechatro - Handbook 070226

MECHATRO HANDBOOK
SK200-8/SK210D-8 YN11-45001
SK210(D)LC-8 YQ11-06001
SK250-8/SK260D-8 LQ12-06001
SK260(D)LC-8 LL12-05001
SK330-8/SK350D-8 LC10-07001
SK350(D)LC-8 YC10-03501
Contents
OPERATOR CAB CONTROLS P1P2
SELF DIAGNOSIS FUNCTION (ERROR CODE) P3P6
TROUBLE HISTORYDIAGNOSIS
P7
MAINTENANCE SCREEN DISPLAYS
SERVICE DIAGNOSIS FUNCTION P8P12
SERVICE DIAGNOSIS DATA LIST P13P20
ABC ADJUSTMENT PROCEDURE P20P23
ADJUSTMENT FUNCTION FOR OPERATOR
P24
N&B FLOW RATE ADJUSTMENT PROCEDURE
ADJUSTMENT FUNCTION FOR SERVICE P25
(ADJUSTING MODE 1)
TROUBLE DIAGNOSIS MODE P26P31
ELECTRICAL PARTS ARRANGEMENT P32
ELECTRICAL PARTS ARRANGEMENT P33P34
FOR ENGINE
SUMMARY OF MECHATRO CONTROL P35P36
MULTIDISPLAY OPERATION CHART P37P38
Technical Service Group, Customer Support Department
Book Code No.:---------------
OPERATOR CAB CONTROLS
GAUGE CLUSTER
(MULTI-DISPLAY)
Switch Panel Starter Key Switch
Throttle Potentiometer
Swing Parking Brake

Release Switch
Potentiometer For
Emergency Mode
ECU
Mechatro Controller
Fuse & Relay & Download connector BOX
(1)
DETAIL OF GAUGE CLUSTER
1Display Indications
KPSS Work Mode Indication
H for heavy duty work
S for standard work and
loading operations
A for crusher (nibbler)
B for breaker
Travel-Speed Indication
-HIGH (2nd) Speed
-LOW (1st) Speed
Auto Accel ON/OFF Indication
Auto Idle Stop ON/OFF Indication
Wiper Status Indication
-wiper moves intermittently
-wiper moves continuously
Failure IndicationNEW!
Icon is displayed when trouble
occurred
2Switchs
Screen Change Switch
Buzzer Stop Switch
KPSS Work Mode Select Switch
Washer() Switch
Wiper Switch
Travel Speed Select Switch
Auto Accel Switch
Select Switch NEW!
Use it when you decide
"Item or value of the adjustment".
(2)
SELF DIAGNOSIS FUNCTION (ERROR CODE)
This funcion identifies abnormality of control input / output signal like pressure,
proportional solenoid valve current, etc. during machine operation . The failed
items are displayed on multi display of gauge cluster by the ERROR CODE.
Explain of ERROR CODE

Alphabet : Decide system failure occured.
Last 2nd and 3rd digits : Specifies failed section.
Last 1 digit : Specifies failure type.
22:00
B013
B 01 3 S
A B C D E F G H I K P R
last Cont. Low High Propo Propo E/G Poten- com-
Sol. Battery E/G Relay
2,3 memo- press. press. valve valve rev. tiom- muni-
valve Relay ECU output
digits ry sensor sensor (C/V) (pump) sensor eter cation
Wiper arc
E/G ATT
Boom P1 P1 P1 Battery preven-
01 adjust power Accel
raise pump unload pump Relay tion
data boost
relay
Wiper
Torque motor
Boom P2 P2 P2 Swing Boom
02 adjust forward
lower pump unload pump P/B deg.
data rotation
relay
Wiper
Unload Travel motor
Arm Boom Travel For Arm
03 adjust speed reverse
out head straight KPSS deg.
refer to page 5 - 6.
data change rotation

relay
Boom
N&B For Washer
raise Arm Boom
04 sele- KPSS motor
adjust in rod
ctor &ECU relay
data
Arm-in Buc- Bucket
05 adjust ket stroke
data dig limit
Arm-out Buc-
Arm-2
06 adjust ket
spool
data dump
07 Swing
08
Travel Fuel
09
R) sensor
Travel
10
L)
Note: Worning error codes (the head is W) are described to page 6.
(3)
Selector CAN
11 position Communi-
detect cation
Swing
13 flasher
relay ( R )
Swing
14 flasher
relay ( L )
Travel
15
alarm relay
P1 AIS
16
OPT relay
refer to page 5 - 6.
P2 E/G stop
17
OPT relay
Lever
18
lock relay
Adjust data
21 safety relay
sector1
Adjust data
22
sector2
Hour meter
23
sector1
Hour meter
24
sector2
Propo valve
25
adjust data
Cluster
31 Communi-
cation
last 1
digits
Larger Larger
than than
0
normal normal
range range
Tran-
sistor
CAN
1 ON fault
error
/Ground
shortage
Transis- Transis-
Wrong Wrong Over
2 tor ON tor ON
output output run
failure failure
Tran-
sistor
Dis- Dis- Dis- Dis- Dis- Dis-
ON fault Time
3 connec- connec- connec- connec- connec- connec-
/Dis- over
tion tion tion tion tion tion
conne-
ction
Contact
point
Short- Short- Short- Short-
4 melted
age age age age
or
adhered
Illegal
5
value
(4)
( )
ERROR CODE OF ENGINE

Output
Error
Presumed cause of breakdown Engine power down Limitation
code
Level
P0088 Excessive common rail pressure Low output 2
Excessive common rail pressure,
P0088 Low output 2
supply pump excess forced feed
P0108 Boost pressure sensor malfunction (HI) Insufficient engine power 2
P0117 Coolant temperature sensor malfunction (LOW) Insufficient engine power 2
P0118 Coolant temperature sensor malfunction (HI) Insufficient engine power 2
P0182 Fuel temperature sensor malfunction (LOW) 1
P0183 Fuel temperature sensor malfunction (HI) 1
P0191 Common rail pressure sensor malfunction Insufficient engine power 2
P0192 Common rail pressure sensor malfunction (LOW) Insufficient engine power 2
P0193 Common rail pressure sensor malfunction (HI) Insufficient engine power 2
P0200 ECU charge circuit high input Low output 3
P0201 Injector circuit malfunction-cyliner 1 Low output 2
P0217 Engine over heat Low output 2
P0219 Engine over run 1
P0234 Turbo charger over boost Insufficient engine power 3
P0237 Boost pressure sensor malfunction (LOW) Low output 2
P0263 Cylinder 1 contribution / balance fault 1
Engine does not start
P0335 Engine speed main sensor circuit malfunction 1
/ Engine stopped.
P0340 Engine speed sub sensor circuit malfunction 1
P0404 EGR valve 1 stick Other problem 2
P0405 EGR lift sensor 1 circuit low input Other problem 2
P0406 EGR lift sensor 1 circuit hight input Other problem 2
P0407 EGR lift sensor 2 circuit low input 2
P0408 EGR lift sensor 2 circuit hight input 2
EGR solenoid 1 malfunction
P0489 Other problem 2
(Open circuit, ground line short)
P0490 Other problem 2
(Power source line short)
Preheat circuit malfunction
P0540 Difficult to start engine. 1
(Open / GND short circuit)
P0540 Preheat circuit malfunction (+B short circuit) Difficult to start engine. 1
P0605 Flash ROM error Low output 2
Engine does not start
P0606 CPU malfunction (Hard detection) 0
/ Engine stopped.
P0607 Monitoring IC malfunction in CPU Low output 2
Note:The error code of a blue character is displayed only with SK330. (For six cylinders)
Note:Output Limitation Level 0:Engine Stop 1:No Load Limitation 2: to 75% 3: to 50%
(5)
( )
Load
Error
Presumed cause of breakdown Problem Limitation
code
Level
P0611 ECU charge circuit low input Low output 3
P0617 Starter switch malfunction 1
Supply pump SCV Malfunction
P0628 Low output 3
(Full discharge mode)
Supply pump SCV Malfunction Engine does not start
P0629 3
(Power source line short) / Engine stopped.
P0686 Main relay malfunction 1
P1211 Injector common 1 grand short Low output 3
P1212 Injector common 1 open circuit Low output 3
P1214 Injector common 2 grand short Low output 3
P1215 Injector common 2 open circuit Low output 3
P1401 EGR valve 2 stick 2
P1402 2
(Open circuit, ground line short)
P1403 2
(Power source line short)
P1601 Injector correction data conformity error Low output 1
Insufficient engine power
P2120 Accelerator sensor 1 and 2 malfunction 1
(Low idle 800rpm fixing)
P2122 Accelerator sensor 1 malfunction (LOW) 1
P2123 Accelerator sensor 1 malfunction (HI) 1
P2127 Accelerator sensor 2 malfunction (LOW) 1
P2128 Accelerator sensor 2 malfunction (HI) 1
Atmospheric pressure sensor
P2228 Insufficient engine power 2
malfunction (LOW)
Atmospheric pressure sensor
P2229 Insufficient engine power 2
malfunction (HI)
P2635 Supply pump abnormal pressure record 3
P2635 Supply pump SCV sticking Low output 3
P2635 Supply pump malfunction Low output 3
U1001 Interruption of CAN communication (Machine) -
Note:The error code of a blue character is displayed only with SK330. (For six cylinders)
Note:Output Limitation Level 0:Engine Stop 1:No Load Limitation 2: to 75% 3: to 50%
ERROR CODE OF WARNING

Code Content Detail
W001 Swing P/B release
W004 Coolant level
W005 Low engine oil pressure These error codes are displayed
Other W006 High engine water temperature only in the trouble history display.
W008 Clogged air filter (When these trouble occurred, it is
W009 N&B selector switch error displayed on the screen as not the
W010 Drain water separator error code but a warning display. )
Preheating error
W011
(The energizing time to Grow plug is long. )
)
(6)
(3)
TROUBLE HISTORY DIAGNOSIS

Procedure Example of screen
How to display
1) Turn starter key switch ON.
2)Press buzzer stop switch for 10 seconds continuously
10,530Hr F023
5 times and the trouble history screen is displayed. 8,500Hr P1211
3)Press washer switch (), item moves upward.
Press wiper switch (), item moves downward. 3,000Hr G033
4)Turn starter switch OFF, trouble history data display
1,500Hr C013
is disappeared.
How to delete trouble history data.
1)Display trouble history screen.

2)Press work mode change swtich and buzzer stop
switch simultaneously for 10 seconds or more. NO ERROR
3)Trouble history data is deleted, and display indicates
"NO ERROR".
4)Turn starter switch OFF.
MAINTENANCE INTERVAL DISPLAYS

How to display
Press screen change switch on the switch panel

once, clock display changes to the display 450Hr
of remaining time for coming engine oil change. ENGINE OIL
The display changes whenever the display switch
is pressed.
ENGINE OIL>Fuel Filter>HYD. Filter>HYD. OIL
H
How to adjust interval
1)Press select switch once and the maintanance
interval display reverses.
2)Press washer switch (), time is increased.
390Hr
Press wiper switch (), time is decreased. ENGINE OIL
If you want to adjust to the initial set time,
) press buzzer stop switch once.
3)Press select switch once and the set time is saved.
FLOWCHART
Maintenance Time Displays Maintenance Time Adjustment
Engine Oil
Engine Oil /
Maintenance Time Adj.
Time Adj.
Fuel Filter
Fuel Filter (by 10 hours. )
Main Maintenance Time Adj.
Screen Default
HYD. Oil Filter
HYD. Oil Filter
Maintenance Time Adj. Select
HYD. Oil HYD. Oil Cancel
7
Maintenance Time Adj.
(7)
SERVICE DIAGNOSIS FUNCTION
How to display
Turn starter key switch ON keeping buzzed No.1MAIN CONT.P/N
stop switch pressed. YN22E000193F1
Washer switch :Screen gains by 1 in order. PROGRAM VERSION
Wiper switch :Screen loses by 1 in order. 1-VER4.00
Auto idling switch :Service Diag. No. advances 2-VER0.00
from No.1 to No.3. (1>2>3>1...)
Travel speed select switch:Service Diag. No. SERVICE DIAG 1
advances from No.3 to No.1. (3>2>1>3...)
About the switch of the mode of the service diagnosis.
There are three modes in the service diagnosis in this model.
1)Service diagnosis mode 1: Screen No.1-30.

Information of each part kind (sensor and proportion valve etc) is displayed.
2)Service diagnosis mode 2: Screen No.1 and No.31-40.

Information of the sensor and the proportion valve etc. that relates to each
operation (boom and swing etc) is displayed.
Note: The value of the current of the proportion valve of service diagnosis mode 2
is set value in the mechatronics controller. Please refer to diagnosis mode 1
(screen No.8 and 9) for the measured value.
3)Service diagnosis mode 3: Screen No.1 and screen No.41-50.

Hour-meter and machine information of the engine adjustment value etc.
are displayed.
FLOWCHART
Service Diagnosis
+ Key ON
/ :Screen No. Change
Service Diagnosis Service Diagnosis Service Diagnosis

Mode 1 Mode 2 Mode 3
No.130 No.1, 3140 No.1, 4150
(8)
SERVICE DIADNOSIS MODE1 DISPLAYS
No. Displays Contents No. Displays Contents
1 NO.1 6 NO.6 PRESS.SENSOR
MAIN CONT.P/N B-7 SWING
YN22E00001F1 P/No.indication 3.5V 2.6M Sensor vol. / Press. converted value
PROGRAM VERSION B-9 TRAVEL(R)
1-VER 12.34 Program version indication 3.5V 2.6M Sensor vol. / Press.converted value
2-VER 00.00 MERIT controller program version B-10 TRAVEL(L)
3.5V 2.6M Sensor vol. / Press. converted value
SERVICE DIAG1 Service diagnosis mode B-16 P1 OPT.
B-17 P2OPT.
B-18 DOZER
B-19 DOZER
2 NO.2 ENG 7 NO.7 PSENSOR PROPO-V

G-3 SPEED SET 2205 No load setting rpm C-1 PUMP P1
MEAS1 2201 Actual rpm 1 3.5V 32.6M Sensor vol. / Press. converted value
MEAS2 2201 Actual rpm 2(Engine controller) C-2 PUMP P2
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 32.6M Sensor vol. / Press. converted value
WATER TEMP 100 OFF Coolant temperature sensor C-3 BOOM-HEAD
MODE HM Work mode 3.5V 32.6M Sensor vol. / Press. converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage C-4 BOOM-ROD
POS. 100 Voltage % indication 3.5V 32.6M Sensor vol. / Press. converted value
ECU OUTPUT 0.5V Accel output voltage to engine PROPO-VALVE
controller E-3 OPT RELIEF1
COMP. 600mA 14.5M Set value in comp. / Press. converted value
MEAS. 600mA 14.5M Measured value / Press. converted value
E-4 OPT RELIEF2
COMP. 600mA 14.5M Set value in comp. / Press. converted value
MEAS. 600mA 14.5M Measured value / Press. converted value
3 NO.3 SOL.VALVE 8 NO.8 PROPO-VALVE

F-1POWER BOOST D-1 PI UN-LOAD(BP-CUT)
COMP. OFF Set value in computer COMP. 600mA 4.5M Set value in computer / Press. converted value
MEAS. OFF Measured value MEAS. 600mA 4.5M Measured value / Press. converted value
SWITCH OFF Switch D-2 P2 UN-LOAD(BP-CUT)
F-2 SWING-BRAKE COMP. 600mA 4.5M Set value in computer / Press. converted value
COMP. OFF Set value in computer MEAS. 600mA 4.5M Measured value / Press. converted value
MEAS. OFF Measured value D-3 S-TRAVEL
RELEASE SW OFF Switch COMP. 600mA 4.5M Set value in computer/ Press. converted value
F-3 1/2-TRAVEL MEAS. 600mA 4.5M Measured value / Press. converted value
COMP. OFF Set value in computer D-6 ARM IN-2-SPEED
MEAS. OFF Measured value COMP. 600mA 4.5M Set value in computer / Press. converted value
SWITCH OFF Switch MEAS. 600mA 4.5M Measured value / Press. converted value
4 NO.4 RELAY 9 NO.9 PROPO-VALVE

E-1 P1 PUMP
K-1 AIS RELAY 2 OFF lndicated value COMP. 600mA 4.5M Set value in comp. / Press. converted value
K-2 SAFETY RLY OFF lndicated value MEAS. 600mA 4.5M Measured value / Press. converted value
K-3 ENG STOP OFF lndicated value POWER SHIFT 100mA Power shift
KEY SWITCH OFF Key switch FLOW RATE 100L Flow rate of pump P1
START SWITCH OFF Starter switch E-2 P2PUMP
CHARGE LIVE Alternator COMP. 600mA 4.5M Set value in comp. / Press. converted value
K-4 LOCK LEVER OFF lndicated value MEAS. 600mA 4.5M Measured value / Press. converted value
SWITCH OFF Switch POWER SHIFT 100mA Power shift
FLOW RATE 100L Flow rate of pump P2
5 NO.5 PRESS.SENSOR 10 N0.10 SENSOR,SWITCH

B-1 BOOM RAISE H-9 FUEL LEVEL
3.5V 2.6M Sensor vol. / Press. converted value 4.5V 90 Fuel level
B-2 BOOM LOWER H-10 HYD.OILTEMP
3.5V 2.6M Sensor vol. / Press. converted value 4.5V 30 Hydraulic oil temperature
B-3 ARM OUT GLOW OFF Glow switch
3.5V 2.6M Sensor vol. / Press. converted value AIR FILTER LIVE Air filter clogging
B-4 ARM IN WATER SEPA. LIVE Water separator clogging
3.5V 2.6M Sensor vol. / Press. converted value ENG OIL FILTER LIVE Engine oil filter clogging
B-5 BUCKET DIG FRONT WINDOW OFF Front window open/close switch
3.5V 2.6M Sensor vol. / Press. converted value DOUBLE FLOW ON Conflux/Single flow select switch
B-6 BUCKET DUMP KPSS SW OFF KPSS switch
3.5V 2.6M Sensor vol. / Press. converted value HEATER OFF Command from air heater
ENGOILLEVEL LIVE Engine oil level
COOLANT LEVEL LIVE Coolant level
(9)
Note:The displayed value is example of the SK200-8. (H mode, engine LOW, and no operation)
11 NO.11 SOL.VALVE 16 NO.16 PRESS.SENSOR
F-4 OPTSELECT B-11
COMP. OFF Set value in computer 3.5V 12.6M Sensor vol. /Press. converted value
MEAS. OFF Measured value(Feed back value) B-12
3.5V 12.6M Sensor vol. /Press. converted value
SPOOL POS. NIB Spool position B-13
SELECT SWITCH NIB Mode of selector valve 3.5V 12.6M Sensor vol. /Press. converted value
F-5 FAN PUMP B-14
COMP. OFF Set value in computer 3.5V 12.6M Sensor vol. /Press. converted value
MEAS. OFF Measured value B-15
F-6 3.5V 12.6M Sensor vol. /Press. converted value
COMP. OFF Set value in computer B-20
MEAS. OFF Measured value 3.5V 12.6M Sensor vol. /Press. converted value
12 NO.12 POTENTIO.
H-2 BOOM
Sensor sent value / Angle converted value
3.5V 137
H-3 ARM Sensor sent value / Angle converted value
3.5V 137
Digital input / output detail

Function Signal level
18 NO.18 DIGITAL INPUT EARTH / OPEN
DI1 OFF ON/OFF indication Cab slow up and down +24V / OPEN
DI2 OFF ON/OFF indication Key switch (ON) +24V / OPEN
DI3 OFF ON/OFF indication Key switch (GLOW) +24V / OPEN
DI4 OFF ON/OFF indication Spare EARTH / OPEN
DI5 OFF ON/OFF indication Swing P/B release +24V / OPEN
DI6 OFF ON/OFF indication See E/G start EARTH / OPEN
DI7 OFF ON/OFF indication Mechatro High reach (hoisting at fixed position) EARTH / OPEN
DI8 OFF ON/OFF indication controller Water separetor EARTH / OPEN
DI9 OFF ON/OFF indication connector E/G oil filter EARTH / OPEN
DI10 OFF ON/OFF indication Air filter EARTH / OPEN
DI11 OFF ON/OFF indication Stroke end check EARTH / OPEN
DI13 OFF ON/OFF indication E/G coolant level EARTH / OPEN
19 NO.19 DIGITAL INPUT

DI16 OFF ON/OFF indication Wiper rise up EARTH / OPEN
DI17 OFF ON/OFF indication Wiper reverse EARTH / OPEN
DI18 OFF ON/OFF indication ATT boost EARTH / OPEN
DI19 OFF ON/OFF indication Nibbler open check SW EARTH / OPEN
DI20 OFF ON/OFF indication ECU main relay EARTH / OPEN
DI21 OFF ON/OFF indication Elevator cab up check +24V / OPEN
DI22 OFF ON/OFF indication Spare +24V / OPEN
DI23 OFF ON/OFF indication Lever lock +24V / OPEN
DI24 OFF ON/OFF indication Hand control rotation / clamp open or close EARTH / OPEN
DI25 OFF ON/OFF indication Front window open or close EARTH / OPEN
DI26 OFF ON/OFF indication Hand control breaker EARTH / OPEN
DI27 OFF ON/OFF indication Conflux / single select EARTH / OPEN
20 NO.20 DIGITAL INPUT

DI29 OFF ON/OFF indication Overload select EARTH / OPEN
DI30 OFF ON/OFF indication High reach (hoist at travel) EARTH / OPEN
DI31 OFF ON/OFF indication
DI32 OFF ON/OFF indication Hand control nibbler EARTH / OPEN
DI33 OFF ON/OFF indication Charge ~12V / 12V~
DI36 OFF ON/OFF indication Heavy lift EARTH / OPEN
DI38 OFF ON/OFF indication Quick coupler EARTH / OPEN
DI39 OFF ON/OFF indication Extra pressure EARTH / OPEN
DI42 OFF ON/OFF indication
( 10 )
Note: The displayed value is example of the SK200-8. (H mode, engine LOW, and no operation)
No. Displays Contents Function Signal level
21 NO.21 DIGITALOUTPUT
DO1 COMP. OFF Set value in computer Wiper arc prevention EARTH / OPEN
MEAS. OFF Measured value
DO2 COMP. OFF Set value in computer Wiper normal moving EARTH / OPEN
DO3 COMP. OFF Set value in computer Wiper reserve moving EARTH / OPEN
DO4 COMP. OFF Set value in computer Washer motor EARTH / OPEN
DO5 COMP. OFF Set value in computer Bucket move limitation EARTH / OPEN
DO6 COMP. OFF Set value in computer Reserved EARTH / OPEN
DO7 COMP. OFF Set value in computer Travel 1,2 speed select valve +24V / OPEN
22 N0.22 DIGITALOUTPUT
DO8 COMP. OFF Set value in computer Swing P/B select valve +24V / OPEN
DO9 COMP. OFF Set value in computer Travel 1,2 speed select valve +24V / OPEN
DO10 COMP. OFF Set value in computer Cab up and down switching valve EARTH / OPEN
DO11 COMP. OFF Set value in computer Attachment boost select valve +24V / OPEN
DO12 COMP. OFF Set value in computer Rotary light (RH) EARTH / OPEN
DO13 COMP. OFF Set value in computer Swing flasher (RH) EARTH / OPEN
DO14 COMP. OFF Set value in computer Swing flasher (LH) EARTH / OPEN
DO15 COMP. OFF Set value in computer Travel alarm EARTH / OPEN
DO16 COMP. OFF Set value in computer Auto idle stop relay EARTH / OPEN
DO17 COMP. OFF Set value in computer Engine stop EARTH / OPEN
DO18 COMP. OFF Set value in computer Lever lock EARTH / OPEN
DO19 COMP. OFF Set value in computer Extra pressure release EARTH / OPEN
DO20 COMP. OFF Set value in computer Spare EARTH / OPEN
DO21 COMP. OFF Set value in computer Safety relay EARTH / OPEN
DO22 COMP. OFF Set value in computer Spare EARTH / OPEN
DO23 COMP. OFF Set value in computer Rotary light (yellow) EARTH / OPEN
DO24 COMP. OFF Set value in computer Rotary light (green) EARTH / OPEN
DO25 COMP. OFF Set value in computer
25 NO.25 WIPER SYSTEM 28 NO.28 ENGCONT.

WIPER SW OFF Wper switch TRANS.COUNT. 100 Counted number of transmission error
RISE UP SW OFF Wper rise-up switch RECEIVE COUNT. 100 Counted number of reception error
REVERSE SW OFF wper reverse rotation switch DIAG STATUS 9 Diagnosis status
PREVENT ARC OFF Wper motor ark prevention reay NUMBER OF DIAG 100 Numbers of error
CW MOTOR RLY OFF Wper normalrotation relay BOOST PRESS. 100 Boost pressure
CCW MOTOR RLY OFF Wper reverse rotation relay BOOST TEMP. -100 Boost temperature
WASHER SW OFF Washer switch BAROM ETRIC P. 100 Atmospheric pressure
MOTOR RELAY OFF Washer motor relay FUEL TEMR -100 Fuel temperature
FUEL CONS. 200 Fuel consumption
27 NO.27 MERIT SYSTEM
INTAKE TEMP. -100 lntake air temperature
ENG PRESS. 300 Engine oil pressure
COMMUNICATION OFF Status of communication in MERIT controller
GLOW OFF Glow output from ECU
4
ENG STOP OFF Engine stop command from ECU
TORQUE 1000 Calculated torque of ECU
0412051200
( 11 )
1 NO.1 33 N0.33 BUCKET
MAIN CONT.P/N C-1 P1-PRES 13.9M Pump pressure sensor
YN22E00001FI P/No.indication C-2 P2-PRES 13.9M Pump pressure sensor
PROGRAMVERSION E-1 P1-PSV 600mA Command current
1-VER 12.34 Program version indication E-2 P2-PSV 600mA Command current
2-VER 00.00 MERIT controller program version D-1 P1-UL BPC 600mA Command current
D-2 P2-UL BPC 600mA Command current
SERVICE DIAG 2 Service diagnosis mode D-3 S-TRAVEL 600mA Command current
B-5 BUCKET DIG 1.9M Bucket digging pressure sensor
B-6 BUCKET DUMP 1.9M Bucket dump pressure sensor
G-3 ENG SPEED 2205 Engine actual speed
POWER SHIFT 100mA Power shift current
31 NO.31 BOOM 34 N0.34 TRAVEL

C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressuresensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressuresensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
D-1 P1-UL BPC 600mA Command current D-1 P1-UL BPC 600mA Command current
D-2 P2-ULBPC 600mA Command current D-2 P2-ULBPC 600mA Command current
B-1 BOOM RAISE 1.9M Boom up pressure sensor D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL R 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVELL 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot pressure at travel straight (P1 side)
Pi-P2 13.9M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current
32 NO.32 ARM,SWING 35 NO.35 OPT

C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
D-1 P1-ULBPC 600mA Command current D-1 P1-ULBPC 600mA Command current
D-2 P2-UL BPC 600mA Command current D-2 P2-UL BPC 600mA Command current
D-3 S-TRAVEL 600mA Command current D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARMOUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL(Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux / Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current

1 NO.1 43 NO.43 MACHINE-INFORM.
MAIN CONT.P/N HOUR METER 3550 Hour meter of controller
YN22E00001F1 P/No.indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATlON 3300 All accumulated operating time
1-VER 12.34 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 00.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operatingtime
SERVICE DIAG 3 Service diagnosis mode CRANE 100 All accumulated high-reach crane opeating time
STARTER 1200 All accumulated starter operating time
41 NO.41 ADJUSTMENT 1 44 NO.44 MACHINE-INFORM.

ENG PUMP PRESS.
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution( )
PUMP LEVEL1 24% 22% Total / In the ast 10 hours
ACT1 515mA Current at pump adjustment LEVEL2 50% 50% Total / In the ast 10 hours
15mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the ast 10 hours
PUMP P 35.0M Pressure at pump adjustment LEVEL4 1% 3% Total / In the ast 10 hours
ESS N 2040 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution( )
P2 600mA P2 unload corrective current LEVEL1 24% 22% Total / In the ast 10 hours
BOOM 137137 Angle adjustment LEVEL2 50% 50% Total / In the ast 10 hours
ARM 137137 Angle adjustment LEVEL3 25% 25% Total / In the ast 10 hours
OFFSET 137137 Angle adjustment LEVEL4 1% 3% Total / In the ast 10 hours
INTER-B 137137 Angle adjustment
( 12 )
( )
SERVICE DIAGNOSIS DATA LIST

The value indicated in the following tables is a normal value of service diagnosis
mode 2 (screen No.31-35) at each operation. Please compare the values, and
do the trouble shoot of the machine.
The value of the current of the proportional valve displayed on the screen of
service diagnosis mode 2 is set value in the mechatronics controller.
Please compare it with the actual measurement value of mode 1(screen No.8 and 9).
Note:
- The values in following display are reference values with standard attachment
attached machine.
-The value of pressure sensor is calculated taking variation into accounts. When
compared to performance check reference criteria , measure it with the aid of
calibrated measuring instrument.
- The current of proportional valve is not the measured value, but command value.
The measured value should be confirmed by the value in the displayed value
for each proportional valve.
- The current value of pump proportional valve is reference value because it varies
according to pump pressure and adjusted torque value.
- The value in display during operation shows the value in steady state, rather than,
at start of operation.
- Check on machine after sufficiently warning up machine.
- The value in display may differ according to software version. Contact our dealer/
distributor.
Operation No.1No operation

H mode Hi idle SK200-8 SK250-8 SK330-8
No.32ARM, SWING
C-1 P1-PRESS. 0.2~1.5M 0.2~1.5M 0.2~2.0M
C-2 P2-PRESS. 0.2~1.5M 0.2~1.5M 0.2~2.0M
E-1 P1-PSV 350mA 350mA 350mA
E-2 P2-PSV 350mA 350mA 350mA
D-1 P1-UL(BPC) 750mA 750mA 750mA
D-3 S-TRAVEL 350mA 350mA 350mA
D-6 ARM IN-2 750mA 750mA 750mA
B-3 ARM OUT 0.0M 0.0M 0.0M
B-4 ARM IN 0.0M 0.0M 0.0M
B-1 BOOM-RAISE 0.0M 0.0M 0.0M
B-7 SWING 0.0M 0.0M 0.0M
G-3 ENG-SPEED 1970~2030rpm 2070~2130rpm 2070~2130rpm
POWER SHIFT 0mA 0mA 0mA
( 13 )
( )
Operation No.2 No operation

S mode Hi idle SK200-8 SK250-8 SK330-8
No.32ARM, SWING
C-1 P1-PRESS. 0.2~1.5M 0.2~1.5M 0.2~2.0M
C-2 P2-PRESS. 0.2~1.5M 0.2~1.5M 0.2~2.0M
E-1 P1-PSV 350mA 350mA 350mA
E-2 P2-PSV 350mA 350mA 350mA
. D-2 P2-UL(BPC) 750mA 750mA 750mA
B-3 ARM OUT 0.0M 0.0M 0.0M
B-4 ARM IN 0.0M 0.0M 0.0M
B-7 SWING 0.0M 0.0M 0.0M
Operation No.3Boom up in full lever operation & relief

No.31BOOM
C-1 P1-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
C-2 P2-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
E-1 P1-PSV 415~525mA 415~525mA 470~585mA
E-2 P2-PSV 415~525mA 415~525mA 470~585mA
B-1 BOOM RAISE 3.0M 3.0M 3.0M
B-2 BOOM LOWER 0.0M 0.0M 0.0M
Operation No.4Boom up in full lever operation & in operation

No.31BOOM
C-1 P1-PRESS. 11.0~16.0M 12.0~17.0M 13.0~18.0M
C-2 P2-PRESS. 11.0~16.0M 12.0~17.0M 13.0~18.0M
E-1 P1-PSV 560~750mA 560~750mA 630~770mA
E-2 P2-PSV 560~750mA 560~750mA 630~725mA
( 14 )
Operation No.5Boom down in full lever & in operation
No.31BOOM
C-1 P1-PRESS. 12.5~16.0M 10.5~14.0M 5.0~9.0M
C-2 P2-PRESS. 0.2~1.5M 0.7~2.0M 0.2~2.0M
E-1 P1-PSV 600~617mA 585~605mA 600~620mA
E-2 P2-PSV 350mA 350mA 350mA
D-1 P1-UL(BPC) 427~477mA 435~485mA 427~477mA
Operation No.6Arm-in in full lever &relief

No.32ARM, SWING
C-1 P1-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
C-2 P2-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
E-1 P1-PSV 415~525mA 415~525mA 470~585mA
E-2 P2-PSV 415~525mA 415~525mA 470~585mA
B-3 ARM OUT 0.0M 0.0M 0.0M
B-4 ARM IN 3.0M 3.0M 3.0M
B-7 SWING 0.0M 0.0M 0.0M
Operation No.7Arm-in in full lever & in operation

No.32ARMSWING
C-1 P1-PRESS. 12.5-16.5M 12.5-16.5M 9.0-13.0M
C-2 P2-PRESS. 12.5-16.5M 12.5-16.5M 9.0-13.0M
E-1 P1-PSV 550~750mA 550~750mA 750~770mA
E-2 P2-PSV 550~750mA 550~750mA 750~770mA
B-3 ARM OUT 0.0M 0.0M 0.0M
B-4 ARM IN 3.0M 3.0M 3.0M
B-7 SWING 0.0M 0.0M 0.0M
( 15 )
Operation No.8Arm-out in full lever operation & relief
No.32ARM, SWING
C-1 P1-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
C-2 P2-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
E-1 P1-PSV 415~525mA 415~525mA 470~585mA
E-2 P2-PSV 415~525mA 415~525mA 470~585mA
B-3 ARM OUT 3.0M 3.0M 3.0M
B-4 ARM IN 0.0M 0.0M 0.0M
B-7 SWING 0.0M 0.0M 0.0M
Measure the values after a laps of 5 minutes or after release of low temperature mode
Operation No.9Arm-out in full lever & in operation

No.32ARM, SWING
C-1 P1-PRESS. 15.0~22.0M 15.0~22.0M 15.0~22.0M
C-2 P2-PRESS. 15.0~22.0M 15.0~22.0M 15.0~22.0M
E-1 P1-PSV 488~677mA 488~677mA 570~680mA
E-2 P2-PSV 488~677mA 488~677mA 570~680mA
B-3 ARM OUT 3.0M 3.0M 3.0M
B-4 ARM IN 0.0M 0.0M 0.0M
B-7 SWING 0.0M 0.0M 0.0M
Measure the values after a laps of 5 minutes or after release of low temperature mode
16
Operation No.10Swing in full lever & relief
No.32ARM, SWING
C-1 P1-PRESS. 0.2~1.5M 0.5~1.8M 0.2~2.0M
C-2 P2-PRESS. 28.0~35.8M 28.0~35.8M 28.0~35.8M
E-1 P1-PSV 350mA 350mA 350mA
E-2 P2-PSV 528~750mA 528~750mA 615~770mA
B-3 ARM OUT 0.0M 0.0M 0.0M
B-4 ARM IN 0.0M 0.0M 0.0M
B-7 SWING 3.0M 3.0M 3.0M
Operation No.11Swing in full lever operation & in operation

No.32ARM, SWING
C-1 P1-PRESS. 0.2~1.5M 0.5~1.8M 0.2~2.0M
C-2 P2-PRESS. 10.0~15.0M 10.0~15.0M 10.0~15.0M
E-1 P1-PSV 350mA 350mA 350mA
E-2 P2-PSV 750mA 645mA 770mA
B-3 ARM OUT 0.0M 0.0M 0.0M
B-4 ARM IN 0.0M 0.0M 0.0M
B-7 SWING 3.0M 3.0M 3.0M
Operation No.12Bucket digging in full lever & relief

No.33BUCKET
C-1 P1-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
C-2 P2-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
E-1 P1-PSV 415~525mA 415~525mA 470~585mA
E-2 P2-PSV 415~525mA 415~525mA 470~585mA
B-5 BUCKET DIG 3.0M 3.0M 3.0M
B-6 BUCKET DUMP 0.0M 0.0M 0.0M
17
Operation No.13Bucket digging in full lever operation & in operation
No.33BUCKET
C-1 P1-PRESS. 4.0-8.0M 3.5-7.5M 7.0-11.0M
C-2 P2-PRESS. 4.0-8.0M 3.5-7.5M 7.0-11.0M
E-1 P1-PSV 650~750mA 650~750mA 670~770mA
E-2 P2-PSV 540~563mA 510~533mA 600~620mA
Operation No.14Bucket dump in full lever operation & relief

No.33BUCKET
C-1 P1-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
C-2 P2-PRESS. 33.0~35.8M 33.0~35.8M 33.0~35.8M
E-1 P1-PSV 415~525mA 415~525mA 470~585mA
E-2 P2-PSV 415~435mA 415~435mA 470~585mA
Operation No.15Bucket dump in full lever operation & in operation

No.33BUCKET
C-1 P1-PRESS. 6.0~15.0M 8.0~17.0M 15.0~24.0M
C-2 P2-PRESS. 6.0~15.0M 8.0~17.0M 15.0~24.0M
E-1 P1-PSV 577~750mA 577~750mA 550~770mA
E-2 P2-PSV 415~435mA 425~445mA 550~770mA
18
Operation No.16P2 side option in full lever operation & relief
A modeHi idle SK200-8 SK250-8 SK330-8
No.35OPTION
C-1 P1-PRESS. 22.5~26.0M 22.5~26.0M 22.5~26.0M
C-2 P2-PRESS. 22.5~26.0M 22.5~26.0M 22.5~26.0M
E-1 P1-PSV 459~584mA 459~584mA 530~665mA
E-2 P2-PSV 459~584mA 459~584mA 530~665mA
E-3 OPT RELIEF 0mA 0mA 0mA
B-16 P1 OPT 0.0M 0.0M 0.0M
B-17 P2 OPT 2.0~2.6M 2.0~2.6M 2.0~2.6M
F-4 OPT SELECT NIB NIB NIB
DOUBLE FLOW SW. ON ON ON
*Confluence Switch is ON. Relief set pressure value of shipping.
Operation No.17P2 side option in full lever operation & relief

B modeHi idle SK200-8 SK250-8 SK330-8
No.35OPTION
C-1 P1-PRESS. 0.2~1.5M 0.5~1.8M 0.2~2.0M
C-2 P2-PRESS. 22.5~26.0M 22.5~26.0M 22.5~26.0M
E-1 P1-PSV 500mA 500mA 350mA
E-2 P2-PSV 665~750mA 665~750mA 770mA
E-3 OPT RELIEF 0mA 0mA 0mA
B-16 P1 OPT 0.0M 0.0M 0.0M
B-17 P2 OPT 2.0~2.6M 2.0~2.6M 2.0~2.6M
F-4 OPT SELECT BRK BRK BRK
DOUBLE FLOW SW. OFF OFF OFF
*Confluence Switch is ON. Relief set pressure value of shipping.
19

Operation No.18TRAVEL (R) (when idling travel full lever position)

H modeHi idle SK200-8 SK250-8 SK330-8
No.33BUCKET
C-1 P1-PRESS. 5.0~12.0M 4.5~11.5M 7.0~13.0M
C-2 P2-PRESS. 0.2~1.5M 0.2~1.5M 0.2~2.0M
E-1 P1-PSV 750mA 750mA 770mA
E-2 P2-PSV 350mA 350mA 350mA
B-9 TRAVEL R 2.0~2.5M 2.0~2.5M 2.0~2.5M
B-10 TRAVEL L 0.0M 0.0M 0.0M
Pi-P1 0.0M 0.0M 0.0M
Pi-P2 0.0M 0.0M 0.0M
Operation No.19TRAVEL (L) (when idling travel full lever position)

H modeHi idle SK200-8 SK250-8 SK330-8
No.33BUCKET
C-1 P1-PRESS. 0.2~1.5M 0.2~1.5M 0.2~2.0M
C-2 P2-PRESS. 5.0~12.0M 4.5~11.5M 7.0~13.0M
E-1 P1-PSV 350mA 350mA 350mA
E-2 P2-PSV 750mA 750mA 770mA
B-9 TRAVEL R 0.0M 0.0M 0.0M
B-10 TRAVEL L 2.0~2.5M 2.0~2.5M 2.0~2.5M
Pi-P1 0.0M 0.0M 0.0M
Pi-P2 0.0M 0.0M 0.0M
ABC ADJUSTMENT PROCEDURE

Preparation
1)Execute warm-up.
(Not only the engine but also the temperature of the HYD. oil must rise it. )
2)The attachment is grounded, and the engine is stopped, and the key
switch is turned off.
3)Execute Calibration of Injectors.
(The procedure of Calibration of Injectors is described to page 25 of
service adjustment 1 in the paragraph. )
4)Stop engine, and turn starter key switch OFF.
(20)

Notes
1)In the state that the load hangs to the engine, it is not likely to be able to
adjust it normally.
- The air conditioner must make to turning off and execute the adjustment.
- Turn off the dynamo and execute the adjustment in the lifting magnet
machine.
2)When the breakdown etc. occur, it is not likely to be able to adjust
it normally. First of all, please execute the adjustment after normally
maintaining the machine.
WARNING Execute the adjustment with the attachment grounded.
ENGINE ADJUSTMENT (A-ADJUSTMENT)

Procedure Example of Screen
1)Turn starter key switch ON keeping the work mode
selector switch on the gauge cluster pressed, and
hold it for 510 seconds, and then release it.
(If the engine is started, the following indication is not
22:00
displayed. Therefore do not start the engine.)
H
2) Keep buzzer stop switch on gauge cluster pressed
for 5 seconds and release it and the screen for sele- ADJUST
cting adjustment is displayed. When adjustment data
is not entered in mechatro controller, "READY" is indi- READY
cated. If the adjustment operation is once performed,
"FIN" is indicated. *when you want to do only FEED
C adjustment,do page sending on this screen,
display "UNLOAD", and push the select switch.
3) Press select switch on gauge cluster to display
"START ENG".
START ENG
ENGINE SPEED 0rpm
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and
PUMP PRESSURE
"STEP" (acceleration command voltage) are indicated.
C-1 0.0M C-2 0.0M
STEP 140
4) After starting engine, press select switch on gauge

cluster, and "MEMORY ENG" is displayed, the engine
speed is automatically increased, and the adjustment of MEMORY ENG
engine is performed. (When trying to limit engine speed, ENGINE SPEED 1000rpm
press select switch on gauge cluster at the speed as it is, PUMP PRESSURE
and the adjustment of engine is terminated. The torque C-1 1.0M C-2 1.0M
adjustment and unloading adjustment required later are STEP 140
not performed, and default value is written.)
21
5)When normal HIGH idling speed is detected,the adj-
ustment is completed. And "FINISH ENG" is displayed
FINISH ENG
ENGINE SPEED 2000rpm
(Press the buzzer stop switch on gauge cluster while
PUMP PRESSURE
this display is appeared, and the adjustment of engine
C-1 2.0M C-2 2.0M
is completed. The torque adjustment and unloading
STEP 400
adjustment required later are not performed, and
default value is written.)
PUMP ADJUSTMENT (B-ADJUSTMENT)

1) The adjustment automatically shifts from engine to MEMORY PUMP
pump, the speed shifts from LOW idling to HIGH idling. ENGINE SPEED
And the unloading proportional valve actuate, accordingly
2000rpm
the loading of pump is increased. PUMP PRESSURE
The "ENGINE SPEED",P1, P2 "PUMP PRESSURE" and
C-1 2.0M C-2 2.0M
P1, P2 pump"PROPO-VALVE" current (command valve) PROPO-VALVE
are indicated. E-1 300mA E-2 300mA
2) After detection of the engine rated speed, the MEMORY PUMP

adjustment of pump is automatically completed. ENGINE SPEED
And "FINISH PUMP" is displayed.
2000rpm
(Press the buzzer stop switch on gauge cluster while PUMP PRESSURE
display is appeared and the adjustment is completed.
C-1 35.0M C-2 35.0M
The unloading adjustment required later is not performed, PROPO-VALVE
and default value is written.) E-1 300mA E-2 300mA
UNLOAD ADJUSTMENT (C-ADJUSTMENT)

1) The adjustment shifts from pump to unloading,and the
MEMORY UNLOAD
unloading valve actuates, accordingly the pump pressure
ENGINE SPEED
is detected. And "MEMORY UNLOAD" is displayed.
2000rpm
The "ENGINE SPEED",P1, P2 "PUMP PRESSURE" and
PUMP PRESSURE
P1, P2 "PROPO-VALVE" voltage (command value) are
C-1 2.0M C-2 2.0M
indicated.
PROPO-VALVE
E-1 300mA E-2 300mA
2) When the unloading valve operates to the specified
value, the adjustment of unloading proportional valve is FINISH UNLOAD
automatically terminated. And "FINISH UNLOAD" is ENGINE SPEED
displayed.The speed is shifted to the speed correspo- 2000rpm
nding to acceleration potentiometer. The adjusting current PUMP PRESSURE
value is indicated on the display of current of P1, P2 C-1 2.0M C-2 2.0M
unloading proportional valves. The adjusting range is PROPO-VALVE
usually 520~635mA. Stop engine.(The adjust data D-1 300mA D-2 300mA
automatically stored.)
22
When the adjustment can not be performed
1)When "ERROE ENG" is displayed.
judging condition: The read engine speed is 50 rpm lower than the last value.
Cause and investigation item
Cause Investigation item
1)Reading error of the Check that it is free from wrong reading of
engine speed sensor. speed due to engine vibration.
2)Abnormal engine speed Check that it is free from abnormal increase
by the pump load. of pump pressure during adjustment of engine
though adjustment screen.
3)Error of accelerator Measure the acceleration command voltage output
command voltage from mechatro controller to engine controller.
Check that signal is regularly input to the engine
controller by actual measurement of voltage or
with failure diagnosis tool of engine controller.
2)When "ERROE PUMP" is displayed.
judging condition 1:P1 and P2 pump average pressure at the time when the
adjustments completed is 25 MPa or less.
judging condition 2:The adjustment does not complete although the pump
proportional valve current reaches to the specified value.
1)The pressure does not Check that the relief valve operates normally.
increase. Check that the hydraulic circuit is free from
leak of pressure
Check that the pressure sensor functions normally.
2)The actual flow rate does not Check that the pump proportional valve operates
increase normally.
Check that the pump regulator operates normally.
3)When "ERROR UNLOAD" is displayed.
judging condition1 :The pump press. doesn't increase up to the pressure
in the range of the specified adjustment.
Or the increase pressure is held as it.
judging condition2 :Pressure sensor of either P1 pump or P2pump is failed.

1)Pressure does not increase. Check that the relief valve operates normally.
Check that the hydraulic circuit is free from
leak of pressure
Check that the pressure sensor functions normally.
23
ADJUSTMENT FUNCTION FOR OPERATOR
Adjustment items Content
AUTO IDOL STOP Switch ON/OFF .
AUTO WARM-UP Switch ON/OFF .
SWING FLASHER Switch ON/OFF .
CLOCK ADJUSTMENT Time adjustment.
ADJ CONTRAST Contrast adjustment.

In main screen , press select switch and display
the right screen.
In this condition , press FEED / and move
cursor to "SWITCH STATUS" or "CLOCK/CON-
SWITCH STATUS
TRAST".Select the desired item and then CLOCK/CONTRAST
press select switch.
SWITCH STATUS > Select Auto idle stop ON/OFF.
Select swing alarm ON/OFF.
Select Auto warm-up ON/OFF.
CLOCK/CONTRAST>Clock adjustment.
Contrast adjustment
The adjustment item is displayed in the upper
art of the screen.
Select the adjustment item with washer () or AUTO IDLE STOP
wiper () switch. And, select the desired item
and then press select switch.
OFF
Adjustment value or ON/OFF indication reverse FEED
in black and the right screen is displayed.
Select the desired setting value or ON/OFF and
then press select switch and the flow rate is set
to the desired value.
N&B FLOW RATE ADJUSTMENT PROCEDURE

The mode that wants to adjust flow rate is
displayed with MODE switch.
BBreaker ModeANibbler Mode
FLOW
RATE
150 L /min
A
Press select switch in A/B mode.
Value of flow rate reverses in black and the
right screen is displayed.
In this condition, press FEED / and the FLOW
flow rate value increases or decreases.
RATE 150 L /min
Select the desired setting value and then press
select switch and the flow rate is set to the
desired value.
24
ADJUSTMENT FUNCTION FOR SERVICE
(ADJUSTING MODE 1)
Following items are provided for adjustment of service function.
Adjustment items Content
RISE-UP WIPER ON/OFF of wiper function.
AUTO IDOL STOP Auto idle stop time adjust.
P1-OPT SENSOR ACTIVE ON/OFF of self diagnosis for
P2-OPT SENSOR ACTIVE P1/P2 option pressure sensor.
SWING ALARM ON/OFF of swing alarm.
LEFT PEDAL ACTIVE When use pedal to rotate > ON. To jib > OFF.
1:No option. 2:flow rate ADJ. active.
SELECT OPT SYSTEM
3:relief pressure ADJ. active.
ENG SPEED DISPLAY ON/OFF of engine rpm display
Adjustment the type of the engine speed of auto
AUTO ACCEL.
deceleration run up abruptly.
START MODE Change of start mode
CANCEL LOW TEMP MODE LOW temperature mode release.
Function for the engine adjustment.
CHECK INJECTOR (When you exchange injector or supply pump or
ECU , use this function.)
DRAIN HYD. PRESS For pressure release
WARNING Ground the attachment before the pressure release mode

is done. The attachment falls and it is very dangerous.
1) Turn starter switch on keeping buzzed stop No.1MAIN CONT.P/N
switch pressed. YN22E000193F1
PROGRAM VERSION
1-VER4.00
2-VER0.00
SERVICE DIAG 1
2) Press select switch three times while pressing
buzzer stop switch. LANGUAGE/LOGO
After it, select "ADJUSTING MODE 1" .
ADJUSTING MODE1
( Move the cursor to the desired position with PRESET BY FACTORY
washer "" or wiper "" switch, and press the
select switch.)
It continues to the next page.

25
3) Select the adjustment item with washer () or
wiper () switch. And, select the desired item
and then press select switch. CHECK INJECTOR
OFF
* right picture : for CHECK INJECTOR. FEED
4) Adjustment value or ON/OFF indication reverse

in black and the right screen is displayed.
Select the desired setting value or ON/OFF and
CHECK INJECTOR
then press select switch. ON
OFFON
* right picture : for CHECK INJECTOR.
TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for
the trouble which can not be detected by self diagnosis function.(ex.:spool stick )
Diag. Mode 1Used to diagnose unload, pump, travel straight, engine systems.
Diag. Mode 2Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional
valve are automatically actuated, the sensor detects the machine condition and the
mechatro controller identifies the normal condition or failed condition of the system.
PROCEDURE
CAUTION: Before executing this mode,execute warm-up and ABC adjustment.
Procedure example of screen
1) Turn starter switch on keeping buzzed stop
switch pressed. LANGUAGE/LOGO
ADJUSTING MODE1
After if, press select switch three times while
pressing buzzer stop switch.
PRESET BY FACTORY
2) Select "FAULT DIAG MODE" .

( Move the cursor to the desired position with FAULT DIAG MODE
washer "" or wiper "" switch, and press the
select switch.)
26
3) Select "MODE1" or "MODE2" with washer ()
or wiper () switch. And, select the desired item DIAG MODE 1
and then press select switch.
DIAG MODE 2
Notes
1. When the trouble diagnosis mode is operating, lower the attachment
and put the bucket onthe ground. If the machine failed ;the unexpected
touch to the lever may move the attachment and it causes injury or death.
Because the bucket-grounded/bucket-not-grounded can not be automatically
identified, do not fail to start operating the trouble diagnosis mode after
making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor,
proportional value and select value for possible abnormally. Check that the
commands of proportional valve and select valve do not largely differ from the
actually measured values though the service diagnosis. The preliminary inves-
al tigation of electric system makes the time saving and high precision diagnosis
possible.
3. For the diagnosis results and the corrective actions to be taken, usually occu-
rred troubles are taken as an example. When multiple troubles are occurred at
the same time, there is a case no accordance of diagnosis obtained. In this
case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diag-
nosis and warning does not appear. If necessary, examine the presence or
absence of trouble referring to the trouble history.
27
CASE OF DIAG MODE 1
START ENG LOWER BOOM RELEASE
SENSOR CHECK
TO GROUND LOCK LEVER
CHECK
For the diagnosing items, see Table1.

When required to stop in diagnosis
operation, press the buzzer stop switch
and the operation is stopped compellingly.
DIAG MODE 1 1 P1 UNLOAD DIAG MODE 1 ENGINE STOP
START END
STOP
About 15 minutes are required for the diagnosis.

The suspected trouble sections are displayed on order
of possibility. The suspected in maximum are displayed.
When desired to see other suspected trouble sections,
press feed "" button. For diagnosis results and
corrective actions to be taken, see Table-2.
The data at the time of judgement can
When failed, be confilmed with the select switch.
ENG SPEED 1000rpm
DIAG MODE1 RESULT1 1 P1 UNLOAD PRESSURE C-1 00.3M
P1 UNLOAD PSV NG C-2 00.0M
P2 UNLOAD SPOOL NG NG PROPO-VALVE
E-1 350mA
DATAEND FEED DATAEND FEED E-2 005mA
When not failed, The other judgments can be

confirmed with the feed button.
ENG SPEED 1000rpm

DIAG MODE 1 1 P1 UNLOAD PRESSURE C-1 00.0M
C-2 00.0M
OK OK PROPO-VALVE
E-1 350mA
DATAEND DATAEND FEED E-2 005mA
28
Table1 Failure diagnosis Mode-1/Diagnosis item
No. Display Contents of diagnosis
1 1 P1 UNLOAD ls normal pressure generated in the condition that the flow rate at
P1 side is minimum and the unloading valve is in the emergency
position?
2 2 P1 UNLOAD ls normal pressure generated in the condition that the minimum

flow rate is relieved at P1 side?
3 3 P1 UNLOAD ls normal pressure generated in the condition that the unload valve
is fully opened, and P1 side flow rate is minimum?
is in emergency position. and P2 side flow rate is minimum?
5 2 P2 UNLOAD ls normal pressure generated in the condition that the minimum

flow rate is relieved at P2 side?
is fully opened, and P2 side flow rate is minimum?
7 1 P1 PUMP ls normal pressure generated in the condition that the flow rate at
P1 side is emergency and the unloading valve is in the emergency
position?
8 2 P1 PUMP ls normal pressure generated in the condition that the unload valve
n is emergency, and P1 side flow rate is minimum?
is in emergency position, and P1 side flow rate is maximum?
10 1 P2 PUMP ls normal pressure generated in the condition that the flow rate at
P2 side is emergency and the unloading valve is in the emergency
position ?
is emergency, and P2 side flow rate is minimum?
is in emergency position. and P2 side flow rate is maximum?
13 1 TRAVEL-S ls normal pressure generated in the condition that P1 side flow rate
is minimum. Unload valve is emergency position and travel straight
is stroked fully?
14 2 TRAVEL-S ls normal pressure generated in the condition that P2 side flow rate
is minimum. Unload valve is emergency position and travel straight
is stroked fully?
15 1 P1 ENGINE ls rated engine speed obtained in the condition that P1 side flow
rate increases little by little when P1 side flow rate is relieved?
16 2 P2 ENGINE ls rated engine speed obtained in the condition that P2 side flow
rate increases little by little when P2 side flow rate is relieved?
29
Table-2 Failure diagnosis Mode-1/Diagnosis and Remedy
Diagnosis(Display) Possible cause Remedy
SENSOR CHECK Disconnection of pressure sensor, Check each pressure sensor by
NG short circuit, Abnormal out put service diagnosis and replace it if
P1 UN-LOAD PSV secondary pressure is excessive Check P1 unload proportional valve
NG high against the command and replace it if necessary
secondary pressure is excessive
low against the command
P1 UN-LOAD SPOOL stuck at full-stroke side Check P1 unload spool and replace it if
NG stuck at neutral side necessary
P2 UN-LOAD PSV secondary pressure is excessive Check P2 unload proportional valve
NG high against the command and replace it if necessary
P2 UN-LOAD SPOOL stuck at full-stroke side Check P2 unload spool and replace it if
NG stuck at neutral side necessary
P1 B-P CUT NG stuck at closing side Check P1 by-pass cut valve and
stuck at neutral side replace it if necessary
P2 B-P CUT NG stuck at closing side Check P2 by-pass cut valve and
stuck at neutral side replace it if necessary
P1 PUMP PSV NG secondary pressure is excessive Check P1 pump proportional valve and
high against the command replace it if necessary
P1 PUMP NG Delivery rate is excessive large against Check P1 pump regulator and replace
the command it if necessary. Check P1 pump and
Delivery rate is excessive small against replace it if necessary.
the command
P2 PUMP PSV NG secondary pressure is excessive high Check P2 pump proportional valve and
against the command replace it if necessary
secondary pressure is excessive low
against the command
P2 PUMP NG Delivery rate is excessive large against Check P2 pump regulator and replace
the command it if necessary. Check P2 pump and
Delivery rate is excessive small against replace it if necessary.
the command
S-TRAVEL PSV NG Secondary pressure is excessive high Check travel straight proportional valve
against the command and replace it if necessary
Secondary pressure is excessive low
against the command
S-TRAVEL SPOOL Stuck at full-stroke side Check travel straight spool and replace
NG Stuck at neutral side it if necessary
PUMP 1 PRESS. Pressure is recognized lower than it is Check P1 high pressure sensor and
SENSOR NG replace it if necessary
PUMP 2 PRESS. Pressure is recognized lower than it is Check P2 high pressure sensor and
SENSOR NG replace it if necessary
MAIN RELIEF NG Set pressure decreases Check main relief valve and replace it if
Set pressure increases necessary
ENGINE NG Output is lowered Check engine and replace it if
necessary
E/G R SENSOR NG Characteristics is misaligned Check engine speed sensor and
replace it if necessary
30
CASE OF DIAG MODE 1
SENSOR CHECK START ENG LOWER BOOM DIAG MODE 2
TO GROUND
CHECK START
In the normal condition,

OK is displayed when the
At control lever Example: control lever is moved to
is neutral. Cace of boom up stroke end.
BOOMUP BOOMUP
OK
Pressure0.0Mpa Pressure1.5Mpa Pressure3.0Mpa
INSPECTIONABLE OPERATION
Boom up Arm in Bucket digging
Boom down Arm out Bucket dump
P1 side option P2 side option swing Travel
Notes
1. When the trouble diagnosis mode is operating, lower the attachment
and put the bucket on the ground. If the machine failed ;the unexpected
touch to the lever may move the attachment and it causes injury or death.
Because the bucket-grounded/bucket-not-grounded can not be automatically
identified, do not fail to start operating the trouble diagnosis mode after
making sure of the bucket-grounded condition.
Place the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2" pump pressure is unloaded with unload valve
in order not to actuate attachment. When trouble diagnosis is performed,
if the pump pressure is generated, the engine stops and "UNLOAD PSV NG"
is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diag-
nosis and warning does not appear. If necessary, examine the presence or
absence of trouble referring to the trouble history.
31

ELECTRICAL PARTS ARRANGEMENT
PSV-P1pump P1
PSV-Aarm two- speed inverse proportional sol.
proportional sol.
PSV-P2pump P2
PSV-DP1 unload
proportional sol.
proportional sol.
PSV-Ctravel priority
proportional sol.
PSV-BP2 unload
proportional sol.
SE-23press sensor
P2pump
SE-22press sensor
SV-2power boost sol.
P1pump
SV-3two-speed select sol.
SV-1swing parking
brake sol.
SV-4operatiog lever
lock sol.
SE-9press sensor
travel right
SE-10press sensor SE-5press sensor

travel left swing
SE-4 SE-3
boom lowering boom raising
SE-8press sensor
arm out
SE-1press sensor SE-1
bucket digging bucket digging
SE-2press sensor
bucket dump
boom raising arm out
SE-4press sensor SE-2 arm in
arm in boom lowering bucket dump
SENSOR TOWER TYPE MULTI CONTROL VALVE TYPE

32
ELECTRICAL PARTS ARRANGEMENT FOR ENGINE
(JO5E-TA for 20t, JO5E-TB for 25t)
water temperature
sensor
Oil pressure
warning switch Right side view
28 Engine speed
sub sensor
Engine speed
main sensor
Supply pump
SCV
EGR valve
(lift sensor / solenoid) Upper view
Injector connector Boost pressure sensor
Fuel temperature
sensor
Engine speed sensor

(for shobel)
Commom rail
pressure sensor
Left side view
33
ELECTRICAL PARTS ARRANGEMENT FOR ENGINE
(JO5E-TA for 20t, JO5E-TB for 25t)
water Engine speed
temperature main sensor
sensor
Upper view
Commom rail
Oil pressure Right side view
pressure
warning
sensor
switch
Boost pressure sensor

EGR valve
Injector connector (lift sensor / solenoid)
Supply pump
SCV
Fuel temperature
sensor
Engine speed
sub sensor
Left side view
Engine speed sensor
(for shobel)
34

SUMMARY OF MECHATRO CONTROL SYSTEM
35
36

MULTIDISPLAY OPERATION CHART

Normal Indication Adjustment Function for Operator
Operator Setting : Enter to Setting

Normal Display
/ : Adjust
Switch Status
: Set
: Cancel
Auto Warm-up(ON/OFF)
Swing Flasher(ON/OFF)
Auto Idle Stop(ON/OFF)
Clock / Contrast / : Select Item

/ : Adjust
Adjust Clock
(Cancel)
(Set)
(Y M D H M)
Adjust Contrast
(Cancel)
(Set)
(11111 - 99999)
Maintenance Interval Maintenace Schedule Adjustment

Engine Oil Engine Oil Schedule Adjust /
: Adjust Time
: Default
Fuel Filter Fuel Filter Schedule Adjust
: Set
: Cancel
Hydraulic Filter Hyd. Filter Schedule Adjust
Hydraulic Oil Hyd. Oil Schedule Adjust
(A/B mode Flow Rate)
(Engine Rev.) A/B mode Flow Rate Adjustment
B mode - Flow Rate / : Adjust Flow

B mode Flow Adj.
: Set
A mode Flow Adj. : Cancel
A mode - Flow Rate
37

Diagnosis Function Adjustment Function for Service
Trouble History Mechatro (A-B-C) Adjustment

Press 5 times + Key SW ON, Hold pressing 5 - 10 sec
Press 5 - 10 sec, and release
/ : Page Feed / Back
+ : Erase History
Press 10 sec or more Adjust Engine (A) Adjust
In Adj.
E/G Rev. Limit Set
Service Diagnosis /
Adjust Unload After Adj.

+ Key SW ON
Skip B-C Adjust
Service Diag. Mode 1 Pump (B) Adjust

(No.1 - 30) After Adj.
Skip C Adjust
Service Diag. Mode 2
(No.1, 31 - 40) Unload Valve (C) Adjust
Key SW OFF : Memory
Service Diag. Mode 3

No.1, 41 - 50
In Screen No.1
Hold + 3 times
/ : Page Feed / Back To Screen No.1 Factory / Service Adjustment

Change Language
Fault Diagnosis Language/Logo / : Change
: Set : Cancel
Fault Diag. Mode
Adjusting Mode 1
/ : Item Feed / Adj.
Adj. Mode 1
: Back / Cancel
Diag. Mode 1 : Select / Set
Rise-up Wiper (ON/OFF)

Diagnose Drain Hy d. Press. (ON/OFF)
Check Injector (ON/OFF)
After Preset by Factory Cancel Low Temp. Mode (ON/OFF)
Diag. Mode 2 Finish
Start Mode (S, H, B, A, X)
Auto Accel (6 - 18)
E/G Speed Display (ON/OFF)
Select Opt. Sy stem (1, 2, 3)
Diagnosis Result Lef t Pedal Activ e (ON/OFF)
: Show Detail Swing Alarm (ON/OFF)
P2 Opt. Sensor Activ e (ON/OFF)
/ : Page Feed P1 Opt. Sensor Activ e (ON/OFF)
Auto Idle Stop (60 - 999)
38

KOBELCO CONSTRACTION MACHINARY CO., LTD.

Pda Mechatro - Handbook 070226

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MECHATRO HANDBOOK

Switch Panel Starter Key Switch

Swing Parking Brake

Fuse & Relay & Download connector BOX

Explain of ERROR CODE

data change rotation

ERROR CODE OF ENGINE

ERROR CODE OF WARNING

TROUBLE HISTORY DIAGNOSIS

1)Display trouble history screen.

MAINTENANCE INTERVAL DISPLAYS

Press screen change switch on the switch panel

About the switch of the mode of the service diagnosis.

There are three modes in the service diagnosis in this model.

1)Service diagnosis mode 1: Screen No.1-30.

2)Service diagnosis mode 2: Screen No.1 and No.31-40.

3)Service diagnosis mode 3: Screen No.1 and screen No.41-50.

Service Diagnosis Service Diagnosis Service Diagnosis

2 NO.2 ENG 7 NO.7 PSENSOR PROPO-V

3 NO.3 SOL.VALVE 8 NO.8 PROPO-VALVE

4 NO.4 RELAY 9 NO.9 PROPO-VALVE

5 NO.5 PRESS.SENSOR 10 N0.10 SENSOR,SWITCH

Digital input / output detail

19 NO.19 DIGITAL INPUT

20 NO.20 DIGITAL INPUT

25 NO.25 WIPER SYSTEM 28 NO.28 ENGCONT.

31 NO.31 BOOM 34 N0.34 TRAVEL

32 NO.32 ARM,SWING 35 NO.35 OPT

SERVICE DIADNOSIS MODE3 DISPLAYS

41 NO.41 ADJUSTMENT 1 44 NO.44 MACHINE-INFORM.

SERVICE DIAGNOSIS DATA LIST

Operation No.1No operation

Operation No.2 No operation

Operation No.3Boom up in full lever operation & relief

Operation No.4Boom up in full lever operation & in operation

Operation No.6Arm-in in full lever &relief

Operation No.7Arm-in in full lever & in operation

Operation No.9Arm-out in full lever & in operation

Operation No.11Swing in full lever operation & in operation

Operation No.12Bucket digging in full lever & relief

Operation No.14Bucket dump in full lever operation & relief

Operation No.15Bucket dump in full lever operation & in operation

Operation No.17P2 side option in full lever operation & relief

Operation No.18TRAVEL (R) (when idling travel full lever position)

Operation No.19TRAVEL (L) (when idling travel full lever position)

ABC ADJUSTMENT PROCEDURE

WARNING Execute the adjustment with the attachment grounded.

ENGINE ADJUSTMENT (A-ADJUSTMENT)

4) After starting engine, press select switch on gauge

PUMP ADJUSTMENT (B-ADJUSTMENT)

2) After detection of the engine rated speed, the MEMORY PUMP

UNLOAD ADJUSTMENT (C-ADJUSTMENT)

Cause and investigation item

Procedure Example of Screen

N&B FLOW RATE ADJUSTMENT PROCEDURE

WARNING Ground the attachment before the pressure release mode

It continues to the next page.

4) Adjustment value or ON/OFF indication reverse

TROUBLE DIAGNOSIS MODE

2) Select "FAULT DIAG MODE" .

For the diagnosing items, see Table1.

DIAG MODE 1 1 P1 UNLOAD DIAG MODE 1 ENGINE STOP

About 15 minutes are required for the diagnosis.