Chapter 10 Revised

Kobelco
Dynamic
Acera
Kobelco Construction Machinery America LLC

Mechatronics
Kobelco Construction
Machinery America LLC
Dynamic Acera 11/00

Page 10-1
MECHATRONICS
TABLE OF CONTENTS
1. Layout of Electrical Components ..................................................................................... 4
A. Components related to the Upper Frame ......................................................................... 4
B. Components related to the Pump & Battery Compartments ............................................. 5
C. Pilot Low Pressure Sensors & 8 Solenoid Block .............................................................. 6
2. Solenoid / Proportional Valve Block ................................................................................. 7
A. Appearance .................................................................................................................... 7
B. Specifications ................................................................................................................. 7
C. Construction of On/Off Solenoids ..................................................................................... 8
D. Construction of Proportional Solenoids ............................................................................ 9
3. Pressure Sensors ............................................................................................................ 10
A. Appearance .................................................................................................................. 10
B. Specifications ............................................................................................................... 10
C. Resistance Checks ........................................................................................................ 11
4. Layout of Electrical Components - Engine Related ...................................................... 12
A. Components related to the Engine Block ....................................................................... 12
B. Components related to the Pumps ................................................................................. 12
C. Pump sensor line drawings and actual pictures .............................................................. 13
5. Main Pump Proportional Solenoids PSV-1; PSV-2 ....................................................... 14
A. Appearance .................................................................................................................. 14
B. Specifications ............................................................................................................... 14
6. Location of Auto Accel Service Connector .................................................................... 15
A. Location ........................................................................................................................ 15
7. Left Hand Console ........................................................................................................... 16
A. Switch Description and locations ................................................................................... 16
8. Right Hand Console ........................................................................................................ 17
B. Work Mode Switch & Buzzer Stop Locations ................................................................. 17
9. Right Side of Operator Cab ............................................................................................. 18
B. Wiper Motor Location .................................................................................................... 18
10. Floorplate Wiring Harness - Underneath Side ............................................................... 19
A. Sensor Description and locations .................................................................................. 19
B. Actual View ................................................................................................................... 19
11. Rear of Operator Cab ....................................................................................................... 20
A. Fuse Box Location ........................................................................................................ 20
B. DC-DC Converter (24Vdc~12Vdc) Location ................................................................. 20
12.Ground Cable Attachment Locations ............................................................................. 21
A. Cable Description and Locations .................................................................................. 21
13. C-1 Main Controller .......................................................................................................... 22
A. Controller Location ........................................................................................................ 22
B. Controller Breakdown .................................................................................................... 23
A. Test/Run Switch Internal Location ................................................................................... 24
B. VR1-MAX Flow Limiter Location ................................................................................... 24
Dynamic Acera 11/00

Page 10-2
MECHATRONICS
TABLE OF CONTENTS - Continued

A. Wiring Harness Connection Location ............................................................................. 25
B. Pin-Out Location on Controller ....................................................................................... 25
C. Wiring Information for Pin-Out Location on Controller ............................................... 26~31
16. Stepping Motor ( M-2 ) ...................................................................................................... 32
A. Appearance .................................................................................................................. 32
B. Coil Resistance & Information ........................................................................................ 32
C. Internal Construction ...................................................................................................... 33
D. Electrical Connector & Motor Check Information ............................................................ 33
17. Gauge Cluster (C-2) ......................................................................................................... 34
A. Appearance .................................................................................................................. 34
B. Screen Change Button Location .................................................................................... 35
C. Internal Construction ...................................................................................................... 35
D. Electrical Connector & Check Information ...................................................................... 35
E. Contrast and Dip Switch Information .............................................................................. 35
18. Service Icon Sequence .................................................................................................... 36
A. Multidisplay self diagnnostic .................................................................................... 36~39
19. Engine Speed Sensor (SE-15) ........................................................................................ 40
A. Appearance .................................................................................................................. 40
B. Resistance Checks & Adjustment .................................................................................. 40
20. Throttle Potentiometer (SE-16) ........................................................................................ 41
A. Appearance .................................................................................................................. 41
B. Resistance Checks & Adjustment .................................................................................. 41
21. Error Code History Diagnosis ......................................................................................... 42
A. How to Display .............................................................................................................. 42
B. How to Cancel Contents ................................................................................................ 42
C. Error Code History Contents .......................................................................................... 43
22. Service Diagnosis Functions .......................................................................................... 45
A. How to Display .............................................................................................................. 45
B. Service Diagnosis Check Chart SK210 ~ SK330 .................................................... 46~52
28 Item Check .................................................................................................................. 53~57
23. Procedure “A” Adjustment .............................................................................................. 58

A. Pre-Checks prior to Adjustment “A” ............................................................................... 58
B. Adjustment “A” Procedure ....................................................................................... 59~66
C. Post-Adjustment Checks ............................................................................................... 67
24. SK480 Engine Diagnostics Lamps ................................................................................. 68
A. Method of Confirming Errors .......................................................................................... 68
B. SK480 Engnie Diagnosis Lamps .................................................................................. 69
C. Location of Engine Controller .................................................................................. 70~71
D. Engine Electronics Troubleshooting Chart ............................................................... 72~73
E. Legend Electrical Schematics ....................................................................................... 74
F. Electrical Schematics .................................................................................................. 75~
Dynamic Acera 11/00

Page 10-3
MECHATRONICS
Layout of Electric components
1. Components related to Upper frame (SK210 • SK250)
Independent
Travel Valve
Swing Priority Valve
Dynamic Acera 11/00

Page 10-4
MECHATRONICS
High Pressure Negative Control

Sensors Low pressure
sensors
Independent
Proportional Travel Solenoids
Solenoid
Valves
Battery Fusible
Relay R-1 Links
Dynamic Acera 11/00

Page 10-5
MECHATRONICS
Two P1 P2 Lock
Speed Bypass Bypass Lever
Travel Cut Cut
Swing Arm
Travel Power
Parking Regen-
Priority Boost
Brake eration
Bucket Boom Swing Arm

Head Rod Right Rod
Bucket Boom Swing Arm

Rod Head Left Head
Dynamic Acera 11/00

Page 10-6
MECHATRONICS
SK210 Solenoid/Proportional valve block
1. Appearance :
On/Off
On/Off
On/Off
On/Off
2. Specifications :
Code Size Torque N·m (lbf/ft)

P1, P2, TA1 PF 3/8 74 ± 5 (54 ± 3)
A2~A8 PF 1/4 36 ± 2 (26 ± 1)
Item Specifications
Type 8KWE5G-30 / G24WR-804 B
2
Rated Pressure (P port) 0~50 kgf/cm (0~711 psi)
2
Allowable Back pressure (T port) 0~10 kgf/cm (0~140 psi)
Solenoid Rated Voltage 20.4 ~ 30 VDC
Valve Coil Resistance 34 ~ 40 Ω
Proportional Rated Voltage 20.4 ~ 30 VDC
Valve Coil Resistance 17 ~ 25 Ω
Dynamic Acera 11/00

Page 10-7
MECHATRONICS
Construction of solenoid valve
The command to activate the 2 speed travel , ATT boost, slewing P/B solenoid valve is
controlled by the mechatro controller.
The lever lock solenoid valve is activated through a limit switch with a two second delay on
the left hand control box.
➀ Travel 2nd speed, ATT boost, Lever lock solenoid valve normally closed.
Non Adjustable
Resistance 34 to 40 Ω
➁ Slewing P/B solenoid valve normally open.

With the key switch turned to the on position, the slewing parking brake solenoid valve is
activated. Because the Slewing parking brake is normally open when activated no pilot
oil can pass through the solenoid and parking brake is applied.
Non Adjustable
Dynamic Acera 11/00

Page 10-8
MECHATRONICS
SK210 Proportional valve for control valve
(PSV-A ~ PSV-D)
Proportional Solenoids x 4
Non Adjustable
Dynamic Acera 11/00

Page 10-9
MECHATRONICS
Pressure sensors
1. Appearance and
specifications
Not used on (Pos-con)

SK160 / ED190
Dynamic Acera 11/00

Page 10-10
MECHATRONICS
Checking resistance on pressure sensors :
Check the resistance between connector pin 1 100 M Ω or more is normal for all
and 2 with multimeter. sensors
Terminal Connector
No. terminal layout
1 Power supply (+)
2 Output (+)
3 Common High pressure sensor
Low pressure sensor
Back pressure sensor
Negative control sensor
Structure
Typical low pressure sensor

Dynamic Acera 11/00
Page 10-11
MECHATRONICS
Components related to engine: Relative to (SK210)
Note: See next page for Pump

Details
Dynamic Acera 11/00

Page 10-12
MECHATRONICS
Hyd. Pump Sensors & Solenoids :
SE- 26
P1 Nega-Con
SE-23
Sensor
P2 High
Pressure
Sensor
PSV-1
P1
Proportional
Solenoid
PSV-2
P2
Proportional
Solenoid
SE-22 SE- 27
P1 High P2 Nega-Con
Pressure Sensor
Sensor
Dynamic Acera 11/00

Page 10-13
MECHATRONICS
Proportional valve for main pump

(PSV-P1, PSV-P2)
Construction of proportional valve :

This valve is actuated by a command current
from the mechatronics controller.
1. Appearance Non Adjustable
Output pressure of prop. valve (reference) P 2 (kgf/cm2)

Negative Control PSV Flow Curve
250 (66) 50
Pump delivery flow rate Qd l/ min (gpm)
45
372 mA 414 mA Pump Flow
200 (52) 40
Current to
prop. valve 35
150 (39) 30
25
100 (26) 20
15
50 (13) 10
5
0 0
300 400 500 600 700 800
Input current of proportional valve (mA)
Note: Typical of SK210~480, N/A SK 160/ED190 due to Positive Control Sytem
Page 10-14
Dynamic Acera 02/03 Rev 01
MECHATRONICS
AUTO
ACCEL
SERVICE
CONNECTOR
NORMAL
Dynamic Acera 11/00

Page 10-15
MECHATRONICS
Left Hand Console :
Air Conditioner
Control Panel
Auto Indepenent Two Single Heavy

Warm- Up Travel Speed / Lift
Travel Double
Pump
Flow
(OPTION)
Dynamic Acera 11/00

Page 10-16
MECHATRONICS
Right Hand Console :
Mode
Switch
Throttle
Potentiometer
Work mode
selector switch
Buzzer
Stop
Switch
Keyswitch
24V DC
Radio
Buzzer stop
switch
Dynamic Acera 11/00

Page 10-17
MECHATRONICS
M-3
Wiper
Motor
Dynamic Acera 11/00

Page 10-18
MECHATRONICS
Floorplate Wiring Info.
Actual View : Front of Machine
SE-9 SE-10
Right Travel Left Travel
Sensor Sensor
Floorplate
Ground
Points
SE-20 SE-11
Opt. Sensor Opt. Sensor
Connector Connector
P1 Pump P2 Pump
Dynamic Acera 11/00

Page 10-19
MECHATRONICS
24V DC~ 12V DC

DC - DC
Converter
Back of Cab View ( Behind operator’s seat)
24V DC ~ 12V DC to DC-DC Converter

Dynamic Acera 11/00
Page 10-20
MECHATRONICS
4. Grounding cable attaching position (SK210)
Dynamic Acera 11/00

Page 10-21
MECHATRONICS
C-1 MAIN CONTROLLER
Dynamic Acera 11/00

Page 10-22
MECHATRONICS
C-1 MAIN CONTROLLER
Dynamic Acera 11/00

Page 10-23
MECHATRONICS
Mechatro controller (C-1)
Test
VR1 - Max. Flow Limiter- aux. Hyd. circuits
CN18 - Factory Use Only
SW2 - Test/Run Switch (see page 10-49)
RUN
Dynamic Acera 11/00

Page 10-24
MECHATRONICS
Mechatro controller (C-1)
Note: A commn mechatro controller is used for SK210 to SK330.

But the software differs, so a controller has to be ordered by machine size.
Dynamic Acera 11/00
Page 10-25
MECHATRONICS
4.5a Pin out of Connectors CN11~CN17

CN-11
In - Wire
Pin No. Component Remarks
Out Color
11-1 Boom raise press. sensor (GND) (SE-3) In BR
11-2 " (SE-3) " LgY
11-3 " (5V) (SE-3) " W
11-4 Boom lower press. sensor (5V) (SE-4) " OB
11-5 " (SE-4) " LO
11-6 " (GND) (SE-4) " BrW
11-7 Arm in press. sensor (GND) (SE-7) " BrL
11-8 " (SE-7) " PG
11-9 " (5V) (SE-7) " OL
11-10 Arm out press. sensor (5V) (SE-8) " OW
11-11 " (SE-8) " PL
11-12 " (GND) (SE-8) " Gr
11-13 Bucket digging press. sensor (GND) (SE-1) " BrR
11-14 " (SE-1) " LgR
11-15 " (5V) (SE-1) " RB
11-16 Bucket dump press. sensor (5V) (SE-2) " RL
11-17 " (SE-2) " LgW
11-18 " (GND) (SE-2) " BL
11-19 Swing right press. sensor (GND) (SE-6) " GrL
11-20 " (SE-6) " VY
11-21 " (5V) (SE-6) " YB
11-22 Swing left press. sensor (5V) (SE-5) " YG
11-23 " (SE-5) " VG
11-24 " (GND) (SE-5) " Br
11-25 Travel right press. sensor (GND) (SE-9) " BY
11-26 " (SE-9) " VY
11-27 " (5V) (SE-9) " YL
11-28 Travel left press. sensor (5V) (SE-10) " YR
11-29 " (SE-10) " Sb
11-30 " (GND) (SE-10) " BG
11-31 Accel potentio (GND) (SE-16) " BW
11-32 " (SE-16) " P
11-33 " (5V) (SE-16) " WR
11-34 Governor motor (M-2) " GB
Dynamic Acera 11/00

Page 10-26
MECHATRONICS
Cont. - Pin out of Connectors CN11~CN17
Wire color list Actual wiring

Jacket
Symbol Color Symbol Color Symbol Color Symbol Color color
B Black W White Br Brown V Violet
G Green Y Yellow Lg Light Green Stripe
L Blue P Pink Gr Gray
R Red O Orange Sb Sky Blue
Wiring color W R
Stripe (Red)
Jacket color (White) Jacket color Stripe

Indicate in order of
ground color and stripe.
CN-12
In - Wire
Out Color
12-1 P1 pump press. sensor (GND) (SE-22) In BrB
12-2 " (SE-22) " V
12-3 " (5V) (SE-22) " YL
12-4 P2 pump press. sensor (5V) (SE-23) " YR
12-5 " (SE-23) " L
12-6 " (GND) (SE-23) " BrY
12-7 P1 Nega-Con sensor (GND) (SE-26) " BY
12-8 " (SE-26) " GR
12-9 " (5V) (SE-26) " WY
12-10 P2 Nega-Con sensor (GND) (SE-27) " RG
12-11 " (SE-27) " LY
12-12 " (GND) (SE-27) " BW
12-13 Charge " WR
Release
12-14 Connector for maintenance " LO
with
12-15 Starter key ON " WL
12-16 Glow " GrB
12-17 Travel two-speed switch (SW-3) " PL
12-18 Swing parking brake release switch (SW-4) " Lg
12-19 KPSS release switch (SW-5) " PG
12-20 Engine speed sensor (SE-13) " R
12-21 " (SE-13) " W
12-22 " shield (SE-13) "
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Page 10-27
MECHATRONICS
CN-13
Pin - In- Wire
Component Remarks
No. Out Color
13-1 Opt. press. sensor P2 side (GND) (SE-11) In BL Opt.
13-2 " (SE-11) " GO "
13-3 " (5V) (SE-11) " RL "
13-4 Opt press. sensor P1 side (5V) (SE-20) " RB "
13-5 " (SE-20) " LgR "
13-6 " (GND) (SE-20) " BW "
13-7 Opt. boom rod press. sensor (GND) (SE-25) " BP "
13-8 " (SE-25) " WY "
13-9 " (5V) (SE-25) " RL "
13-10 Opt. boom head press. sensor (5V) (SE-24) " RL "
13-11 " (SE-24) " LgY "
13-12 " (GND) (SE-24) " BP "
13-13 Back press. sensor (GND) (SE-28) " GrG
13-14 " (SE-28) " Sb
13-15 " (5V) (SE-28) " RW
13-16 Opt. High-reach crane S/W (SE-41) " GY Opt.
CN-13 If clinometer equipped

Pin - In- Wire
Component Remarks
No. Out Color
Opt. F/R & RH/LH
13-7 (GND) (SE-29) In BP Opt.
clinometer potentio
13-8 " (SE-29) " WY "
13-9 " (5V) (SE-29) " RL "
13-11 " (SE-29) " LgY "
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Page 10-28
MECHATRONICS
CN-14
In - Wire
Pin - No. Component Remarks
Out Color
14-1 E/G coolant switch (SW-6) In GB
14-2 E/G Oil press. switch (SW-7) " BY
14-3 Air filter clogging switch (SW-8) " Lg
14-4 Stroke-end proximity SW (SW-32) " Br Opt.
14-5 E/G oil level SW (SW-23) " BG
14-6 E/G coolant level SW (SW-24) " GL
14-7 Hyd. oil level SW (SW-25) " RrL
14-8 Fuel sensor (SE-15) " VW
14-9 Wiper motor (Rise-up) Stop (M-3) " L
14-10 Wiper motor (Rise-up) Reverse (M-3) " G
14-11 ATT boost SW (SW-21) " GrG
14-12 Wiper motor (Arc prevention) (M-3) Out LR
14-13 Wiper motor (Forward relay) (M-3) " GB
14-14 Wiper motor (Reverse relay) (M-3) " Gr
14-15 Wash motor (M-4) " GrL
14-16 Work light relay (R-6) " BrY
14-17 Swing flasher & work light unit (R-19) " WB Opt.
14-18 Switch box assy. (5V) (C-3) " RG
14-19 " (C-3) In BrW
14-20 " (C-3) Out LgR
14-21 " (C-3) " LG
14-22 " (C-3) " VW
14-23 " (C-3) " LY
14-24 " (GND) (C-3) " GW
14-25 Serial communication to gauge cluster In/Out R
14-26 " (C-2) In/Out W
14-27 " Ground (C-2) B
14-28 " Shield (C-2)
Dynamic Acera 11/00

Page 10-29
MECHATRONICS
CN-15
In - Wire
Out Color
15-1 Governor motor Phase A (M-2) Out G
15-2 " (M-2) " B
15-3 " Shield (M-2) "
15-4 P1 by-pass cut propo. valve (PSV-D) " BP
15-5 " (PSV-D) " PW
15-6 P2 by-pass cut propo. valve (PSV-B) " BO
15-7 " (PSV-B) " GrR
15-8 Travel straight propo. valve (PSV-C) " VR
15-9 " (PSV-C) " GrB
15-10 Arm variable recirculation valve (PSV-A) " BrG
15-11 " (PSV-A) " YV
15-12 Mechatro controller back-up (C-1) In RY
15-13 " (C-1) " RY
15-14 Mechatro controller back-up (C-1) " YG
15-15 Governor motor Phase B (M-2) Out R
15-16 " (M-2) " W
15-17 P1 pump propo. valve (PSV-P1) " VR
15-18 " (PSV-P1) " GrG
15-19 P2 pump propo. valve (PSV-P2) " VW
15-20 " (PSV-P2) " GY
15-21 Travel 2-speed solenoid valve (SV-3) " LgB
15-22 Swing parking brake solenoid valve (SV-1) " V
15-23 Power boost sol. valve (SV-2) " P
15-24 Battery relay (R-1) " WG
15-25 Mechatro controller Ground (C-1) B
15-26 " (C-1) B
CN-16
In - Wire
Out Color
16-1
16-2
16-3
16-4
16-5
16-6
16-7
16-8
16-9
16-10
16-11
16-15 Press. switch (Clamp) (SW-50) λ LW Opt.

Dynamic Acera 11/00
Page 10-30
MECHATRONICS
CN-17
In - W ire
Out Color
17-1 Bucket control relay (R-10) In OL Opt.
17-2 Nibbler open relay (R-15) Out G "
17-3 Swing flasher relay (R-19) " GW "
17-4 " (R-19) " WV "
17-5 Nibbler close relay (R-16) " GL "
17-6 Travel alarm relay (R-8) " BP "
17-7 Power window controller (C-5) " YB "
17-8 Hyd. oil temp. SW (SW -37) In O
17-9 Travel alarm SW (SW -22) " WY Opt.
17-10 Swing flasher SW (SW -9) " LgY "
17-11 Lever lock SW (SW -11) Out YV
17-12 Rotary N & B In GrL Opt.
17-13 W iper intelrock SW (SW -19) " PB
17-18 Boom potentio (5V) (SE-17) In RB Opt.

17-19 " (SE-17) " L "
17-20
17-21 Arm potentio (SE-19) In V Opt.
17-22 Grounding (GND) (SE-17·19) " BG "
CN-17 Opt. Multi demolition equipped

In - W ire
Out Color
17-18 Nibbler rotation (5V) (SE-30) In RG Opt.
17-19
17-20 Nibbler rotation (SE-30) In WR Opt.
17-21
17-22 Nibbler rotation (GND) (SE-30) In BG Opt.
CN-18
In- Wire
Out Color
18-1 In/Out
18-2 Personal computer for ROM "
18-3 programming "
18-4 (GND)
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Page 10-31
MECHATRONICS
Governor motor (M2) Note:
( Stepping motor) 1. Install motor so that surface I or faces

upward.
2. 2 52° (degree) shows the operating range.
Coil Resistance
1. Appearance
5.7 Ω ± 10%
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Page 10-32
MECHATRONICS
Internal construction
Function of governor motor

➀ Control the engine speed according to
the work mode.
➁ Control the engine speed according to
the accel potentiometer
➂ Auto accel function
➃ Engine stop function
5. Governor motor
Check the resistance of each pin of limit switch and motor connector with tester
Limit switch connector
No. Lead color Terminal No. Lead color Terminal

5 White COM 1 Brown A
6 Red NO 2 Orange A
7 Yellow NC 3 Red B
4 Yellow B
How to check limit switch
Turn starter switch OFF, apply tester to pins
How to check motor
5 and 6 and turn the output shaft. And if it
is “OFF” when the resistance is ∞ Ω in the Apply tester on connector pins 1 and 2, and
range of 52 degree, and if it is “ON” when 3 and 4, and the resistance is 5.7 Ω ± 10%,
the resistance is 0 Ω or over when turning the connectors are normal.
angle is over 52 degrees, the limit is normal.
Detail of output shaft

Dynamic Acera 09/02
Page 10-33
MECHATRONICS
Gauge cluster (C-2)
1. Appearance
Work mode T5.28V / 1.4W / 2,000h
Engine coolant
temperature Fuel meter
Multidisplay
LCD
Trimmer
VR1
CN21 Connector
Screen Dip switch

change DSW
SW
Face side Back side (Cover removed)
Connector CN21
No. Name Wire color No. Name Wire color
Fuel sensor BrR 5 GND B
1 E/G coolant sensor YR 6 GND B
2 RXD (Serail communication) Receive R 7 Power Source (+24V) W
3 TXD (Serial communication) Transmi W 8 (Shield) -
3. Serial communication
Serial communication (various information) are transmitted between main controller and gauge
cluster.
TXD RXD Gauge cluster
▼
Main controller
Opt. SW panel
▼
RXD TXD (Interference prevention,

High reach crane)
(a) Main controller → Gauge cluster

➀ Switches data: Condition of mode select switches
➁ E/G revolution: E/G Speed
➂ E/G oil replacing time: E/G oil replacing time
➃ Warning: Failure of Machine (e.g., E/G oil press, E/G coolant temp.)
➄ Self diagnosis: Output signal failure of press. sensor, propo. valve, etc.
➅ Service diagnosis: Output signal failure of press. sensor, propo. valve, etc.
➆ Trouble history: Trouble data
➇ Opt. indicator: Data of UR, High reach, etc.
➈ Others: Initial adjustment data, etc.
(b) Gauge cluster → Main controller

➀ Screen change signal: Switch signal of gauge cluster
➁ Opt. switches signal: Condition of interference prevention on High reach crane
➂ Gauge data: E/G coolant and Fuel level signal
Dynamic Acera 11/00
Page 10-34
MECHATRONICS
Gauge cluster
➀ Adjustment of brightness and language of the multidisplay

(Perform when the starter switch is turned ON.)
Details of dip switch
LCD display
adjustable by
trimmer VR1
Trimmer
VR1
Dip switch
DSW
Adjusting brightness of multidisplay Back side of gauge cluster (remove cover)

Adjust brightness by turning the driver (+) inserted Select the language by setting the figure to the
trimmer VR1 clockwise and counterclockwise. required one while turning the driver (+) inserted
➁ Resistance measured between case and in dip switch DSW.
Position (Figure) Language
CN21 each terminal with 0 Japanese
500V mega tester. 1 English
3 M Ω or more
2 Thai
3 Indonesian
4 French
5 Spanish
6 Europe
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Page 10-35
MECHATRONICS
The icons in the chart below are listed in priority from the most
The following chart s aimed at familiarizing personnel
serious to least serious. EXAMPLE:If the engine oil pressure is
with the priority of the Gauge Cluster Display Icons.Pay
abnormal and Fuel level s low, the engine oil pressure Icon will
close attention to these icons as they can aid in avoid-
display and buzzer will sound. After the oil pressure is back to
ing unnecessary repairs and expense.
safe operating pressure, the low fuel Icon will display.
LCD display SERVICE FUNCTION ICON SEQUENCE BUZZER SOUNDING
NORMAL
No sounding
DISPLAY
No sounding
•For the description
ASSIST MODE of display of the
DISPLAY assist mode.
•Each display
flickers during
operation.
Supplementary Explanation :
The screen can be switched into three images by pressing the screen change switch.
•#2,#3,#5,#6,
#7,#10,#28
Buzzer sounds.
Supplementary
Explanation :
Icons #5 and #6 are

displayed and
buzzers do not stop
sounding even if
WARNING the buzzer stop
switch is pressed.
When icon 6 is
displayed,the engine
RPM will idle
immediately and the
engine will shut
down after 15
6 LOW E/G seconds.
OIL PRESS
Icon #7 is displayed
and buzzer stops
sounding when the
buzzer stop switch
is pressed.
Icons #2,#3,#10
and #28 are
displayed and
buzzers sound
intermittently and
stop sounding after
5 seconds.
Dynamic Acera 11/00

Page 10-36
MECHATRONICS
Multidisplay self diagnostics
the error of the I/Q signal of the pressure sensor and the proportional valve
1. Indication item
Connector Wire or
Wire
No. Contents Display of monitor No. ID
color
– Pin No. No.
1
MECHATRO
1 Mechatro controller error CPU CN14-25 770 R
CONTR. FAIL
Gauge cluster → I-1
RECEIVE
2 Mechatro CN14-26 582 W
ERROR
controller communication
I-2
BAT
3 Battery relay fail CN15-24 857 WG
RELAY
A-1
4 ROM data ROM DATA
CP
FAILURE
A-2
5 Mechatro set error MECHATRO
CP
SET ERROR
Boom raise pressure B-1 CN11-2 LgY
BOOM RAISE
6 SE-3
sensor fail SENSOR CN11-1 BR
Boom lower pressure B-2 CN11-5 LO

BOOM LOWER
7 SE-4
sensor fail SENSOR CN11-6 BrW
Arm in pressure B-3 CN11-8 PG

ARM OUT
8 SE-7
sensor fail SENSOR CN11-7 BrY
B-4
Arm out pressure ARM IN CN11-11 PL
9 SE-8
sensor fail SENSOR CN11-12 Gr
Bucket dig pressure B-5 CN11-14 LgR

BUCKET DIG
10 SE-1
sensor fail SENSOR CN11-13 BrR
Bucket dump pressure B-6 CN11-17 LgW

BUCKET DUMP
11 SE-2
sensor fail SENSOR CN11-18 BL
Swing (RH) pressure B-7 CN11-20 V

SWING (R)
12 SE-6
sensor fail SENSOR CN11-19 GrL
Swing (LH) pressure B-8 CN11-23 VG

SWING (L)
13 SE-5
sensor fail SENSOR CN11-24 Br
Travel (RH) pressure B-9 CN11-26 VY

TRAVEL (R)
14 SE-9
sensor fail SENSOR CN11-25 BY
Travel LH pressure B-10 CN11-29 Sb

TRAVEL (L)
15 SE-10
sensor fail SENSOR CN11-30 BG
Dynamic Acera 11/00

Page 10-37
MECHATRONICS
1. Indication item
Connector Wire or
Wire
color
– Pin No No
B-11
P1 Nega-Con pressure P1NEGA-CON CN12-8 GR
16 SE-26
sensor fail SENSOR CN12-7 BY
B-12
P2 Nega-Con pressure P2NEGA-CON CN12-11 LY
17 SE-27
sensor fail SENSOR CN12-12 BW
B-15
BACK PRESS CN13-14 Sb
18 Back pressure sensor fail SE-28
SENSOR CN13-13 GrG
Pump P1 pressure C-1 CN12-1 BrB
PUMP P1
19 sensor CN12-2 SE-22 VY
SENSOR
fail CN12-3 YL
Pump P2 pressure C-2 CN12-4 YR
PUMP P2
20 sensor CN12-5 SE-23 Sb
SENSOR
fail CN12-6 BrL
P1 By-pass cut propo- D-1
P1 BY-PASS CN15-4 BP
21 valve PSV PSV-D
PROPO-VALV CN15-5 PW
fail
P2 By-pass cut propo- D-2
P2 BY-PASS CN15-6 BO
22 valve PSV PSV-B
PROPO-VALV CN15-7 GrR
fail
D-3
Travel straight TRAVEL CN15-8 BG
23 PSV PSV-C
propo-valve fail PROPO-VALV CN15-9 BrB
Arm variable D-6
RECIRCULAT CN15-10 BrG
24 recirculation PSV PSV-A
PROPO-VALV CN15-11 YV
propo-valve fail
E-1
PUMP P1 CN15-17 VR
25 Pump P1 propo-valve fail PSV PSV-P1
PROPO-VALV CN15-18 GrG
E-2
PUMP P2 CN15-19 VW
26 Pump P2 propo-valve fail PSV PSV-P2
PROPO-VALV CN15-20 GY
F-1
27 ATT boost solenoid fail POWERBOOST CN15-23 SV-2 P
SV
SOLENOID
F-2
Swing parking brake SWING BRAKE
28 SV CN15-22 SV-1 V
solenoid valve fail SOLENOID
Travel two-speed F-3
TWO-SPEED
29 solenoid SV CN15-21 SV-3 LgB
SOLENOID
valve fail
Dynamic Acera 11/00

Page 10-38
MECHATRONICS
1. Indication item
Connector Wire or
Wire
color
– Pin No. No.
CN15-1 771 G
G-1
Governor motor current STEP MOTOR CN15-2 772 B
30
fail M CURRENT-NG CN15-15 773 R
CN15-16 774 W
G-2
Governor motor starting STEP MOTOR
31 CN11-34 544 GB
point indexing fail M S/PT. ERROR
G-3
E/G REV. CN12-20 580 R
32 Engine speed sensor fail RPM
SENSOR CN12-21 581 W
H-1 CN11-33 917 WR
ACCELERATR
33 Accel potentio motor fail POT POTENTIO CN11-32 517 P
CN11-31 967 BW
Arm variable D-6
RECIRCULAT CN15-10 BrG
34 recirculation PSV PSV-A
PROPO-VALV CN15-11 YV
propo-valve fail
D-11
Prop-Valve P1 - I-Trave PUMP P-1 CN16-1 WV
35 PSV PSV-E
fail I-TRAVEL CN16-2 GR
Prop-Valve P2 -I- Trave D-12 PUMP P-2 I- CN16-3 WL

36 PSV PSV-F
fail TRAVEL CN16-4 GR
Prop-Valve SW. Priority D-13 SWING CN16-7 WG

37 PSV PRIORITY PSV-H
fail CN16-8 G
Dynamic Acera 11/00

Page 10-39
MECHATRONICS
Engine speed sensor (SE15)
1. Appearance
2. Function :
The engine speed sensor used to detect How to adjust speed sensor
the actual engine speed is installed on Ring gear
ring gear section of engine flywheel, and
electrically counts the number of gear Speed sensor
teeth passing through in front of the
sensor. And the detection is performed Lock nut
by magnetic force, and magnets and coils
Tighten, voltage rises.
are placed in the sensor. Also, the
Loosen it, voltage drops.
engine speed which is computed by the
signal from the sensor by mechatronics ➀ Remove Sensor and inspect and clean tip
controller is indicated on the cluster with clean cloth (Note: Do not apply any
gauge display. type of cleaner such as brake clean, ether
or degreaser to RPM Sensor).
3) Voltage : ➁ Reinstall sensor into bell housing of engine
How to measure and tighten it until the end of speed sensor
comes into contact with the ring gear lightly,
1) Resistance then backout senor one and a half turns.
(Space between ring gear and sensor top
end is approx. 2.3mm.)
2.3 k Ω ± 0.2 k Ω
➂ After turning it out one and a half turns,
tighten lock nut to the torque specified
below.
Tightening torque:
AC range 24.5 to 34.3N•m {2.5 to 3.5 kgf • m}
1.4V ~ 6V
④ Start engine and verify with and external
Disconnect the connector of speed sensor, tachometer that the low idle is 850~900
and measure the voltage between pins on rpms and verfy that voltage is 1.4 VAC ~
the sensor side. When the measured 3.0 VAC at low idle and is 6 VAC or
voltage at high idling in the AC range is higher at High idle.
3V or more, it is acceptable. (The voltage
is set to 4V or more before shipment.) Note: If voltage is low turn sensor in.
If voltage is High turn sensor out.
Dynamic Acera 11/00

Page 10-40
MECHATRONICS
Potentiometer (for accel dial, SE-16)

1. Appearance
2. Function :
The accel potiometer is used to control engine governor speed via the stepping motor
mounted to the engine. The accel potiometer has 5 VDC applied to it from the main
mechatronics controller on terminal B and dependant on the position of the potiometer in the
90O the output to the main mechatronics controller will be between .4 VDC to 4.5 VDC and this
voltage change will signal the main controller to increase or decrease stepping motor position
to increase or decrease the engine rpm.
3. Testing Accel potentiometer :

Apply multimeter test leads to terminal B -
power supply (5V) of connector and
terminal R- ground and measure the
resistance.
Resistance: The resistance 2 k Ω is normal
Dynamic Acera 11/00

Page 10-41
MECHATRONICS
2. How to cancel the contents of the
Error Code History diagnosis Trouble History
The error code detected by the self diagnosis ➀ Display the trouble history mode.
of the main controller is stored in the mechatro ➁ Press the work mode switch and the
controller as a history and can displayed on buzzer stop switch for 10 seconds or more
the multidisplay. concurrently.
1. How to display ➂ When the deletion is completed, the “NO
ERROR” is displayed.
➀ Turn the Key switch ON. ➃ Turn the starter switch OFF.
➁ Press the buzzer stop switch 5 times in Note: All the stored Error Codes are
sequence within a 10 second period. permanently erased and
cannot be restored.
(See Figure 10.42a)
3. Error Code History Contents
(Example) ( See Chart on next page for Codes )
No errors NOERROR
00025H
Error detected B-1 BOOMRAISE
inthe past D-1 P1 BY-PASS
F-3 TWOSPEED Work mode
selector switch
➂ There are 20 pages of Error History and

are displayed in order from newest to
oldest.
➃ The error data (one or more) and hour the
error happened are displayed on the
gauge cluster.
• Hour meter data and 3 errors are
displayed on the screen all at one time.
• If more than three error data exist, the
data is displayed three errors per page
and the display scrolls between pages
in order every 5 seconds.
➄ To scroll the page manually, use the work
mode and the buzzer stop switch.
• Press the work mode switch for page up.
• Press the buzzer stop switch for page
down.
Note: All the error items are stored in
sequence by hourmeter, if old Buzzer stop
codes are present see below for
Figure 10.42a
procedure on how to clear
codes.
NOTE
➅ Turn the Key switch off, and the Error history To clear fault codes on the ED190 press the travel
mode is exited.
speed change switch and the buzzer stop switch
at the same time. The new rocker switch for the
Mode/Buzzer Stop switch makes it impossible to
press both switches at the same time.
Dynamic Acera 11/00

Page 10-42
MECHATRONICS
3. Error Code History Contents
Symbol Display
A-10 ROM DATA FAILURE
A Controller
A-20 MECHATRO SET ERROR
B-10 BOOM RAISE SENSOR
B-20 BOOM LOWER SENSOR
B-30 ARM OUT SENSOR
B-40 ARM IN SENSOR
B-50 BUCKET DIG SENSOR
B-60 BUCKET DUMP SENSOR
B-70 SWING (R) SENSOR
Low pressure
B B-80 SWING (L) SENSOR
sensors
B-90 TRAVEL (R) SENSOR
B-10 TRAVEL (L) SENSOR
B-11 P1NEGA-CON SENSOR
B-12 P2NEGA-CON SENSOR
B-15 BACK PRESS SENSOR
B-16 OPT P1 SENSOR
B-17 OPT P2 SENSOR
High
pressure
C-1 PUMP P1 SENSOR
C sensors
C-2 PUMP P2 SENSOR
(Hydraulic
pump)
D-1 P1 BY-PASS PROPO-VALVE

D-2 P2 BY-PASS PROPO-VALVE
D-3 TRAVEL PROPO-VALVE
Proportional D-6 RECIRCULATION PROPO-VALVE
D
Solenid Valves D-11 P1 I-TRAVEL PROPO-VALVE
D-12 P2 I-TRAVEL PROPO-VALVE
D-13 SW. PRIOR PROPO-VALVE
E-1 PUMP P1 PROPO-VALVE

E E-2 PUMP P2 PROPO-VALVE
F-1 POWERBOOST SOLENOID

Solenoid
F F-2 SWINGBRAKE SOLENOID
valve
F-3 TWO-SPEED SOLENOID
G-1 STEP MOTOR CURRENT-NG
G E/G Accessory G-2 STEP MOTOR S/PT. ERROR
G-3 E/G REV. SENSOR
H Potentiometer H-1 ACCELERATR POTENTIO
I-1 BAT. RELAY
I Relay
I-2 RECEIVE ERROR
MONITOR SYSTEM OK
Dynamic Acera 01/03

Page 10-43
Dynamic Acera 11/00
Page 10-44
MECHATRONICS
Service diagnosis Service diagnosis display

The service diagnosis can check multi items Gauge cluster
that are displayed on the gauge cluster
according to the data received from the
mechatro controller.
How to display
➀ Press the buzzer stop switch while turning
the starter switch to “ON” will activate the
service diagnostics. Start the engine and
preform the checks listed on the following
pages.
➁ The first item displayed will be Part No. of
mechatro controller and the program
version. Example: SK210
No.1
MAIN CONT. P/NO.
YN22E00037F1
PROGRAM VERSION
Screen change
VER 7.00 switch Example: SK210
➂ Each time the screen change switch on the
gauge cluster is pressed, the number
advances forward (Ex. No. 2, No. 3 ···).
➃ Each time the buzzer stop switch on the
right console is pressed, the number
descends (Ex. No. 25, No. 24 ···). Work mode
➄ For training purposes, after service selector switch
diagnosis No. 1, release the auto accel
function. For procedure, See Note below.
➅ The display disappears only when the
starter switch is turned OFF.
Note:
Factory Default
Release
➆ After completion of service diagnosis

Buzzer stop
restore the auto accel to factory default.
Dynamic Acera 11/00
Page 10-45
MECHATRONICS
Display Operation procedures SK210 SK250 SK290 SK330 Remarks

No. 1 (Screen No.)
Page 10-46
Main Cont. P/No. Refer to How to Display YN22E....... LQ22E....... LB22E....... LC22E....... Part Number and
Program Version version of software
Ver. Ver. Ver. Ver.
Ver 7.00
No. 2 (Screen No.) The set value varies Low Hi Low Hi Low Hi Low Hi
E/GSET 1000 according to the accel dial 1000 2220 1050 2320 1000 2340 1050 2430 M mode Hi Idle
MEAS 1007 position and work mode 1950 2050 2100 2050 A mode
selector operation. 2220 2320 2340 2385 B mode
E/G PRS LIVE
LIVE - Engine Running
KPSS SW M
Dead - Engine
Stopped
Control lever in neutral In auto accel operation : 1050

Auto accel. position, in 4 seconds
When engine is running : LIVE
E/G PRS. LIVE When Engine is stopped: DEAD Mode lamp in gauge
cluster changes from M
M A B (default) to A to B when
KPSS S.W.
mode switch is pushed.
Mechatronic Controller
No. 3 (Screen No.)
H-1 Low Hi
By operating the accel dial
ACCEL VOLT. 0.0 V 0.3V 4.4V For full stepping motor
from low to high, the voltage
position auto accel must
SERVICE DIAGNOSTIC CHECK CHART
Pos. 0 % varies. The step number may 0% 100%

vary a little after “A” adjustment. be in release position.
Motor Step 283 549
POS. 8% 100%
No. 4 (Screen No.) G-1Coil A 0.9 ~ 1.1 A At the moment when

0.9 ~ 1.1 A the key switch turns
STEP. MOTOR G-1Coil B
OFF, ON
G-2 Limit OFF
Dynamic Acera 11/00

Controlled by Mecha-
Dynamic Acera 11/00

No. 5 (Screen No.)
SOL. VALVE. At swing and arm in operation tronic Controller.
F-2 SWING - BRAKE
Operate swing lever in
*SV - 1 OFF
COMP. ON clockwise or counterclock-
wise, or arm-in action. OFF ON 5 sec. after swing lever neutral position
MEAS. ON
OFF ON simultaneous arm lever neutral position
RELEASE SW OFF
No. 6 (Screen No.) Instruction: OFF

SOL. VALVE. Measured: ON
F-3 1~2 TRAVEL (even if in disconnec-
Operate travel speed
*SV - 3 1st Speed 2nd Speed tion, displayed)
change switch
COMP.OFF OFF ON Voltage of connectors
MEAS. OFF OFF ON ON: 24V
SWITCH OFF OFF OFF (ON during SW actuated) OFF: 10V
P. Boost SW P. Boost Heavy Lift
Multi Solenoid Valve Block

No. 7 (Screen No.) Measure the voltage
Operate Boost / Heavy Lift Heavy Lift SW
SOL. VALVE. SW of connectors.
switch
F-1 POWER BOOST Measure resistance
*SV - 2 ON/ON ON ON of solenoid valve.
COMP. OFF ON OFF ON Perform checking
MEAS. OFF ON OFF ON changing the connec-
SWITCH OFF ON ON OFF tor positions
No. 8 (Screen No.)

RELAY
1-2 BAT. RELAY Operate Starter Switch Starter SW ON Starter SW OFF
*E-1
COMP. ON ON ON
MEAS. ON ON ON
* I.D. Number
Mechatronic Controller
KEY SWITCH ON ON OFF
Page 10-47
MECHATRONICS

No. 9 (Screen No.) Control lever at neutral Note: 0k = 0 kg/cm2
PRESS. SENSOR position
Page 10-48
0.5V / 0k Note: V = Volts
B-1 BOOM RAISE E/G speed LOW and
*SE - 3 0.5V 0k HIGH common When control lever is
E/G speed High idile in neutral position you
B-2 BOOM LOWER
Down/ Up to over relief 5.0V / 30k will have minimum val-
*SE - 4 .5V 0k
ues.
No. 10 (Screen No.) Control lever at neutral
PRESS. SENSOR As you increase the
position
B-3 ARM OUT 0.5V / 0k angle of the control
E/G speed LOW and
*SE - 8 0.5V 0k lever, the values will
HIGH common
increase proportion-
B-4 ARM IN E/G speed High idile ally.
*SE - 7 0.5V 0k In/Out to over relief 5.0V / 30k
If values do not
No. 11 (Screen No.) Control lever at neutral change while operat-
PRESS. SENSOR position ing the control lever,
B-5 BUCKET DIG E/G speed LOW and 0.5V / 0k remove connector on
*SE - 1 0.5V 0k HIGH common the failed low pres-
B-6 BUCKET DUMP E/G speed High idile sure sensor. Then in-
Low Pressure Sensor

*SE - 2 0.5V 0k In/out to over relief 5.0V / 30k stall connector on
pressure sensor which
is known to work.
B-7 SWING (R) E/G speed LOW and 0.5V / 0k
*SE - 6 0.5V 0k HIGH common If display does not
B-8 SWING (L) E/G speed High idile change:

5.0V / 30k FAILURE OF HARNESS
*SE - 5 0.5V 0k Block to hyd. stall
B-9 TRAVEL (R) E/G speed LOW and 0.5V / 0k If display changes:
FAILURE of SENSOR
*SE - 9 0.5V 0k HIGH common
B-10 TRAVEL (L) E/G speed High idile
*SE - 10 0.5V 0k Block sprocket Hyd.stall 5.0V / 30k * I.D. Number
Dynamic Acera 11/00

MECHATRONICS

No. 14 (Screen No.) Control lever at neutral Note: 0k = 0 kg/cm2
Dynamic Acera 11/00

PRESS. SENSOR position Note: V = Volts
E/G speed LOW and 0.7V / 20k
C-1 PUMP P1 HIGH common When control lever is
*SE - 22 0.7V 20k in neutral position you
E/G speed High idile
Boom up and over relief 3.3V / 350k will have minimum val-
C-2 PUMP P2 ues.
*SE - 23 0.7V 20k E/G speed High idle
High Press. Sensor

plus boost 3.5V / 400k As you increase the
angle of the control
No. 15 (Screen No.) lever, the values will
PRESS. SENSOR Without N & B Piping 0.0V / 0k increase proportion-
B-16 P1 OPT. ally.
*SE - 20 0.5V 0k With N & B Piping 0.5V / 0k
WIth N & B piping when If values do not
B-17 P2 OPT. control pedal is de- change while operat-
*SE-11 0.5V 0k pressed fully 5.0V / 30k ing the control lever,
remove connector on
No. 16 (Screen No.) Control lever neutral the failed low pres-
PRESS. SENSOR position, E/G speed LOW 2.2V / 21k sure sensor. Then in-
B-11 P1 NEGA-CON stall connector on
*SE - 26 2.2V 21k Control lever neutral pressure sensor which
position, E/G speed HIGH 3.0V / 31k is known to work.
B-12 P2 NEG-CON
*SE - 27 2.2V 21k Control lever at full stroke, 0.5V / 4k
If display does not
Low Press. Sensor

E/G speed HIGH or less
change:
No. 19 (Screen No.) Control lever neutral FAILURE OF HARNESS
PRESS. SENSOR position, E/G speed LOW 0.7V / 2k
B-15 BACK RESS.
Control lever neutral
position, E/G speed HIGH 0.8V / 2k If display changes:
*SE - 28 0.5V 3k FAILURE of SENSOR
Control lever at full stroke,
E/G speed HIGH 1.9V /3k * I.D. Number
Page 10-49
MECHATRONICS
No. 20 (Screen No.) Control lever neutral Note: 0k = 0 kg/cm2
PROP VALVE position, E/G speed LOW 350mA / 6k
Page 10-50
Note: V = Volts
D-1 P1 BY-PASS and HIGH common
*PSV - D When control lever is
Engine speed High idle in neutral position you
COMP. 350 mA 6k position, with arm out 647mA / 25k will have minimum val-
MEAS. 345 mA 6k operation over relief. ues.
No. 21 (Screen No.) Control lever neutral As you increase the

PROP VALVE position, E/G speed LOW 350mA / 6k angle of the control
D-2 P2 BY-PASS and HIGH common lever, the values will
*PSV - B increase proportion-
Engine speed High idle ally.
COMP. 350 mA 6k position, with boom raise 647mA / 25k
If values do not
MEAS. 345mA 6k operation over relief.
change while operat-
ing the control lever,
No. 22 (Screen No.) Control lever neutral remove connector on
PROP VALVE position, E/G speed LOW 350mA / 6k the failed low pres-
D-3 S-TRAVEL and HIGH common sure sensor. Then in-
*PSV - C stall connector on
pressure sensor which
Engine speed High idle is known to work.
COMP. 350 mA 6k
Multi proportional Solenoid Valve 17.5 ± 1 Ω

position, with arm in 647mA / 25k
MEAS. 345mA 6k operation over relief.
If display does not

No. 23 (Screen No.) change:
Control lever neutral
PROP VALVE FAILURE OF HARNESS
position, E/G speed LOW 750mA / 30k
D-6A-RECIRCULATE and HIGH common
*PSV - A
If display changes:
COMP. 350 mA 6k Engine speed High idle FAILURE of SENSOR
MEAS. 345mA 6k position, with arm in 200mA / 0k
operation over relief.
* I.D. Number
Dynamic Acera 11/00

MECHATRONICS
Note: 0k = 0 kg/cm2
Dynamic Acera 11/00

No. 24 (Screen No.) Control lever neutral
PROP VALVE position, E/G speed LOW 700 mA/27k 720 mA/28k 700 mA/27k 700 mA/27k Note: V = Volts
E-1 P1 PUMP idle.
*PSV - 1 When control lever is
Control lever neutral in neutral position you
position, E/G speed HIGH 750 mA/30k 770 mA/31k 770 mA/32k 770 mA/32k will have minimum val-
COMP 750 mA 30k
idle. ues.
MEAS 745 mA 30 k
POWERSHIFT 0mA E/G speed HIGH idle, With
RH track off ground,(cycle 350 mA/6k As you increase the
time position) travel motor angle of the control
rotating. lever, the values will
increase proportion-
No. 25 (Screen No.) Control lever neutral ally.
PROP VALVE position, E/G speed LOW 700 mA/27k 720 mA/28k 700 mA/27k 700 mA/27k If values do not
E-2 P2 PUMP idle. change while operat-
*PSV - 2 ing the control lever,
Control lever neutral remove connector on
position, E/G speed HIGH 750 mA/30k 770 mA/31k 770 mA/32k 770 mA/32k
COMP 750 mA 30k the failed low pres-
idle.
MEAS 745 mA 30 k sure sensor. Then in-
POWERSHIFT 0mA E/G speed HIGH idle, With stall connector on
Pump Proportional Valve 17.5 ± 1 Ω

LH track off ground,(cycle 350 mA/6k pressure sensor which
time position) travel motor is known to work.
rotating.
No. 32 (Screen No.) Control lever neutral If display does not

PROPO-VALVE position, E/G speed LOW change:
D-11 P1 I - TRAVEL or HIGH idle . FAILURE OF HARNESS
*PSV - E
Independent Travel 700mA/30K
Switch ON
COMP 350 mA 6k If display changes:
MEAS 331 mA 6k FAILURE of SENSOR
Independent Travel 350mA / 6k
Switch OFF
* I.D. Number
Page 10-51
MECHATRONICS
Page 10-52
No. 33 (Screen No.) Control lever neutral Note: 0k = 0 kg/cm2
PROPO-VALVE position, E/G speed LOW Note: V = Volts
D-12 P2 I - TRAVEL or HIGH idle irrelevant.
*PSV - F
Switch ON 700mA/30K
34 ± 2 Ω
COMP 350 mA 0k
Switch OFF
Solenoid Valve
MEAS 331 mA 0k 350mA / 6k
As you increase the

No. 39 (Screen No.) ! Caution ! angle of the control
MECHATRO ADJT. RUN= RUN
It is strictly prohibited to lever, the values will
CONTROL SW RUN increase proportion-
move the Switch from RUN
CONTROL VOL 100% to TEST when the
TEST = TEST
ally.
PROG SW OFF Keyswitch is in the “ON”
position.

RELEASE SWITCH position, E/G speed LOW
or HIGH idle irrelevant.
KPSS OFF
Mechatronic Switches
Switch ON
If display does not
SWING BRAKE OFF change:
Switch OFF FAILURE OF HARNESS

PROPO-VALVE position, E/G speed LOW
D-13 SW. PRIORITY or HIGH idle irrelevant.
*PSV - H If display changes:
Arm In & Swing 670mA /25k FAILURE of SENSOR
COMP 360 mA 0 k
17.5 ± 1 Ω
Prop. Valve
MEAS 351 mA 0 k Swing Only 350mA / 6k
* I.D. Number
Dynamic Acera 11/00

28 ITEM CHECK LIST
MODEL No. SERIAL NUMBER
Hours.
No. 1
Main Cont. P/no.
Program Version
VER. No.
No. 2 M Mode M Mode A Mode A Mode

Low Idle High Idle Low Idle High Idle
E/GSET RPM
MEAS.
Auto Accel.
E/G PRS.
KPSS SW.
No. 3
H-1 Low High
ACCEL VOLT. V
POS. %
MOTOR STEP
POS.
No. 4
STEP. MOTOR G-1 Coil A A
G-1 Coil B A
G-2 Limit
No. 5
SOL. VALVE At swing and arm in operation.
F-2 SWING - BRAKE
COMP. COMP.
MEAS. MEAS.
RELEASE SW.
Dynamic Acera 11/00

Page 10-53
28 ITEM CHECK LIST
No. 6 REMARKS
SOL. VALVE 1 St Speed 2nd Speed
F-3 1/2 TRAVEL
COMP.
MEAS.
SWITCH
No. 7
SOL. VALVE P. Boost Switch P. Boost Heavy Lift Operate Att. Boost switch.
F-1 POWER BOOST & Heavy Lift Switch Switch Operate heavy lift Switch.
COMP.
MEAS.
SWITCH
No. 8
RELAY With Key On
1-2 BAT. RELAY
COMP.
MEAS.
KEY SWITCH
No. 9 With control lever in neutral

PRESS. SENSOR Controls in neutral position you will have mini-
B-1 BOOM RAISE (Over relief) High Idle mum values.
V Kg V Kg
As you increase the angle of
B-2 BOOM LOWER control lever the valuse will
V Kg V Kg increase proportionally.
No. 10
PRESS.SENSOR Controls in neutral
B-3 ARM OUT (Over relief) High Idle If values do not change while
V Kg V Kg operation the control lever ,
remove connector on the
B-4 ARM IN (Over relief) failed low pressure sensor.
V Kg V Kg
No. 11
PRESS. SENSOR Controls in neutral
B-5 BUCKET DIG (Over relief) High Idle Then install connector pres-
V Kg V Kg sure sensor which is known
to work.
B-4 BUCKET DUMP (Over relief)
V Kg V Kg
Dynamic Acera 11/00

Page 10-54
28 ITEM CHECK LIST
No. 12 Controls in neutral REMARKS

PRESS. SENSOR High Idle Place bucket in ground. With
B-7 SWING ( R ) (Over relief) throttle at high Idle, swing
V Kg V Kg left check pressure, then
swing right check pressure.
B-8 SWING ( L ) ( Over Relief)
V Kg V Kg
No. 13 Controls in neutral Engine speed high idle block

PRESS. SENSOR High Idle sprocket Hyd. Stall.
B-9 TRAVEL ( R ) (Over relief)
V Kg V Kg
B-10 TRAVEL ( L ) (Over relief)
V Kg V Kg
No. 14 Boom Over Relief Neutral:

PRESS. SENSOR Neutral High Idle Controls at neutral position
C-1 PUMP P1 E/G speed measure Low
V Kg V Kg and High Idle.
Boom Over Relief:
C-2 PUMP P2 E/G speed high Idle boom
V Kg V Kg up and over relief.
No. 15 Controls in neutral

PRESS. SENSOR Neutral High Idle With N&B piping:
B-16 P1 OPT. With control pedal de-
V Kg V Kg pressed fully E/G Hi Idle.
B-17 P2 OPT.
V Kg V Kg
No. 16 Not Available on SK160 ED190

PRESS. SENSOR Controls in neutral Neutral:
B-11 P1 NEGA-CON Neutral Hi Idle High Idle Control lever neutral position,
V Kg V Kg Boom Over Relief:
Control lever at full stroke, E/G
P2 NEGA-CON speed Hi.
V Kg V Kg
No. 19
Control lever neutral posi-
PRESS. SENSOR
tion, E/G speed Hi.
B-15 BACK PRESS.
V Kg
Dynamic Acera 11/00

Page 10-55
28 ITEM CHECK LIST
No. 20 REMARKS
PROP VALVE
D-1 P1 BY PASS Neutral Hi Idle Arm Over Relief Engine speed high idle
COMP. mA Kg mA Kg position, with arm out op-
MEAS. mA Kg mA Kg eration over relief.
No. 21 Engine speed high idle

PROP VALVE position, with boom raise
D-2 P2 BY PASS Neutral Hi Idle Boom Over Relief operation over relief.
COMP. mA Kg mA Kg
MEAS. mA Kg mA Kg
No. 22 Engine speed high idle

PROP VALVE position, with arm in opera-
D-3 S-TRAVEL Neutral Hi Idle Boom Over Relief tion over relief.
COMP. mA Kg
MEAS. mA Kg
No. 23
PROP VALVE
D-6 A-RECIRCULATE Arm In Over Relief
COMP. mA Kg
MEAS. mA Kg
No. 24 Track Moving Over Engine speed high idle

PROP VALVE Relief position, with RH track off
E-P1 PUMP Neutral ground travel motor rotat-
COMP. mA Kg mA Kg ing.
MEAS. mA Kg mA Kg
Powershift Powershift
No. 25 Track Moving Over

PROP VALVE Relief Engine speed high idle posi-
E-P2 PUMP Neutral tion, with LH track off ground
COMP. mA Kg mA Kg travel motor rotating.
MEAS. mA Kg mA Kg
Powershift mA Powershift ma
Dynamic Acera 11/00

Page 10-56
28 ITEM CHECK LIST
REMARKS
No. 32
PROP VALVE Control lever neutral posi-
D-11 P1 I - TRAVEL tion, E/G speed low or high
COMP. mA Kg idle.
MEAS. mA Kg Independent travel switch
ON.
No. 33
PROP VALVE
D-12 P2 I - TRAVEL
Switch on Control lever neutral position,
COMP. mA Kg E/G speed low or high idle.
MEAS. mA Kg
Switch off
COMP. mA Kg
MEAS. mA Kg
No. 39
Do not change switch with
MECHATRO ADJT.
key in the on position
CONTROL SW
CONTROL VOL
PROG SW
No. 40
RELEASE SWITCHES
KPSS
SWING BRAKE
No. 42 SWING & ARM IN

PROP-VALVE
D-13 SW PRIORITY SWING ONLY
COMP mA Kg mA Kg
MEAS mA Kg mA Kg
Dynamic Acera 11/00

Page 10-57
PRE-CHECKS PRIOR TO PREFORMING ADJUSTMENT “A”
NOTE
With key in the “ON” position and engine not
running, Gauge cluster display must read
“MONITOR SYSTEM OK”. If any warning Icons
are visible in gauge cluster display, preform the Screen Change
proper maintenance or repairs to correct the Switch
problem. Then proceed to Adjustment “A”. See Monitor
Figure 10.29 A. System Ok
A. Emergency Stop Control, and Manual

Throttle Cable
1. Check the operation of Emergency
Stop control, confirm that cable moves
freely both in and out, and does not FIGURE 10.29 A
bind.
2. Emergency stop cable must be pushed Water
in to obtain proper engine Temperature
performance. Gauge
3. Confirm that the Manual Throttle
Control Cable is disconnected and
Screen Change
tagged properly for operator. RPM 2300
Switch
B. Verify engine RPM ( Push Switch
Once )
1. If possible start engine, run excavator
hydraulic system until water temperature
is at normal operating range.
2. Verify engine RPM in “M” mode, “A”
mode, and in “B”mode by pushing
screen change switch once. Record
engine RPM readings for later
verification. See Figure 10.29 B. FIGURE 10.29 B
C. RPM Sensor Test Resistance value

Proper adjustment of the RPM sensor is 2.3k Ω ± 0.2 k Ω
critical to a successful Adjustment “A”
Procedure. With engine running press
screen change switch one time, will RPM
appear on screen?
1. If screen shows 0 RPM check the
following:
a. With engine OFF (not running)
disconnect the RPM sensor from the
machine electrical harness. Check the
Voltage must be
resistance value of RPM sensor. Value
4 V or more.
must be 2.3k V 6 0.2 k V .
b. Connect the speed sensor, to a multi
meter. With engine running at low idle,
measure the voltage AC. voltage must
be 4 V or more. See Figure 10.29 C. FIGURE 10.29 C
Dynamic Acera 11/00
Page 10-58
ADJUSTMENT “A” PROCEDURE
Adjustment “A”- Mechatronic Controller

SK210 ~ SK250
A. Conditions to use Adjustment “A”
Adjustment “A” procedure must be
preformed when one or more of the following
components have been removed, repaired,
adjusted or replaced. FIGURE 10.30 A
1. Mechatronics Controller (CPU)
2. Stepping Motor Assembly ENGINE EMERGENCY
STOP CONTROL
3. Linkage between Stepping Motor and
Engine Fuel Pump Assembly. SAFETY LOCK
4. Engine or Injection pump LEVER IN LOCK
5. When the ROM DATA FAILURE is POSITION
displayed on the multidisplay.
6. When the ROM DATA FAILURE and
or MECHATRO SET ERROR are
displayed alternately on the
multidisplay.
FIGURE 10.30 B
7. Incorrect High or Low idle Rpm.
Maintenance Connector
B. Tools & Equipment Required for Check
and adjusting of Adjustment “A” Factory Default
14 mm spaner wrench Release
13 mm spaner wrench
10 mm spaner wrench
5 mm allen wrench Manual Throttle
0.1mm (.004“) Feeler gauge Control
1. General hand tools to remove and re-
place stepping motor linkage and com-
ponents.
2. Thermometer to read hydraulic oil tem-
perature.
C. Machine Settings and Site condition
1. Attachment in the Hydraulic Oil Check
Position. See Figure 10.30 A.
2. Engine Emergency Stop Knob pushed FIGURE 10.30 C
completely “IN”. See Figure 10.30 B.
3. Maintenance Connector placed in the
“Release Condition”. See Figure 10.30
C.
4. Manual Throttle Control Cable is
disconnected and tagged properly for
operator.
5. With safety lock in the lock (up) position, Pilot control
See Figure 10.30 B. for Bucket
and Boom
6. Firm level test site.
FIGURE 10.30 D
Dynamic Acera 11/00

Page 10-59
D. Verification of Engine Low RPM

1. With safety lock in the lock (up)
position, See Figure 10.30 B.
a. Place the maintenance connector in
the release position. See Figure
10.30 C.
b. Turn key switch to start position and
start engine. See Figure 10.31 A. Pilot control
c. Place throttle potentiometer to low idle for Bucket
position. See Figure 10.31 A. and Boom
d. Locate the screen change switch,

depress the switch once to select RPM.
See Figure 10.31 B. FIGURE 10.31 A
e. Verify engine Rpm.
f. Press screen change switch two times
to retun screen to Monitor System Ok.
See Figure 10.31 B.
E. Verification of auto accel RPM

1. With safety lock in the lock (up)
Screen Change
position, See Figure 10.31 C.
Switch
2. Maintance Connector in the factory RPM 0
default position. See Figure 10.30 C.
a. Turn key switch to start position and
start engine. See Figure10.31 A
b. Place throttle potentiometer to high
idle position. See Figure 10.31 A.
c. Locate the screen change switch,
depress the switch once to select
FIGURE 10.31 B
RPM. See Figure 10.31 B.
d. Place Safety lock lever in the unlock
(down) position.See Figure 10.31 C. SAFETY LOCK
ENGINE EMERGENCY LEVER IN LOCKED
e. Fully activate pilot control for bucket STOP CABLE POSITION
dig then release pilot control, wait
three seconds and check engine
RPM. See Figure 10.31 A.
FIGURE 10.31 C
Dynamic Acera 11/00

Page 10-60
F. Removal of CPU Access Panel OPERATOR
CONTROL
1. Pull up on the top bail for seat adjustment SEAT
STAND
and move seat fully forward. See Figure
10.32 A.
2. Pull reclining adjustment lever up and
move seat back forward. See Figure
10.32 B.
3. Release the 4 top screws from rear panel
top cover (behind the operator’s seat)
by turning 90 degrees. See
Figure 10.32 C.
NOTE
Screws are quick release type not threaded FIGURE 10.32 A
type.
4. Press the panel locks to release panel,

tilt the cover towards the operators seat
to obtain access to the speaker wires,
remove wires. See Figure 10.32 C.
5. With speaker wires removed carefully
remove CPU access panel from cab
LEVER FOR SEAT
and place in safe area. See Figure
RECLINING
10.32 C
Remove Wires FIGURE 10.32 B

from Both TOP SCREWS
Speaker’s
CPU PANEL
PANEL LOCKS
FIGURE 10.32 D
LOWER PANEL
G. Removal of Rod linkage and Lever from

Stepping Motor.
1. Move to the engine compartment and ENGINE SPEED CONTROL
locate the injection pump and stepping FIGURE 10.32 C

motor. See Figure 10.32 E.
Dimension B
2. With a 13 and 14 mm spanner wrench Splined Lever
loosen the ball joint end jam nuts on the
rod linkage of the stepping motor, be sure
to use a holding wrench on the opposite
side of the nut to avoid linkage damage.
NOTE
Threads are R.H and LH on opposite ends. FIGURE 10.32 E
Dynamic Acera 11/00
Page 10-61
3. Using a 5 mm allen wrench wrench remove
the splined lever from stepping motor
shaft. See Figure 10.56D. Remove
Splined Lever
Here
4. Place a holding wrench on the shoulder
side of the ball joint. Loosen nut and
remove it and lock washer from the ball
joint end connected to the Fuel Rack lever.
This allows the complete linkage to be
removed now. See Figure 10.56 F.
FIGURE 10.56 D
NOTE
If a holding wrench is not used while removing
this linkage damage to the stepping motor Place
can occur. holding
wrench
5. Set the linkage aside for now here Loosen
locknut
6. Return to cab and :
a. Place Safety lock lever in the lock
(UP) position.See Figure 10.31 C. FIGURE 10.56 E
b.Place throttle potentiometer to LOW
idle position. See Figure 10.31 A. Remove Ball
c. Turn key switch to start position and Ball joint end
start engine. See Figure10.31A Here
d. Locate the screen change switch,
depress the switch once to select
RPM. See Figure 10.31 B.
7. Return to engine compartment and

carefully manually move Fuel Rack lever
over to the High Idle Stop Bolt. FIGURE 10.56 F
CAUTION
Make certain to use proper safety procedures in and around
running engine; wear proper work clothing, use safety
glasses and utilize all proper safety devices.
8. Verify on the Cluster Gauge or with an Screen Change

external photo tach what the max. Switch
achievable high engine rpm against the RPM 0
high stop. See Figure 10.56 G.
9. Verify High Stop bolt rpms against

Machine Performance specs in this
training manual. If rpms are within tolerance
continue onward with this procedure, if not
stop and repair engine or fuel rack to allow
FIGURE 10.56 G
proper engine rpm.
Dynamic Acera 11/00
Page 10-62
10. Return to cab and shut engine off and Dimension B

Splined Lever
return keyswitch to the off position.
11. Loosen the left and right hand thread jam

nuts on rod linkage and inspect the heads
of linkage for excessive wear.
12. Set the rod length to the specific dimension

per machine model number listed below. Dimension B
See Figure 10.33 A.
NOTE Jam Nut’s

Dimension B is the starting dimension of fuel Typical of SK210 other models may differ.
injection rod assembly. Final dimension of rod FIGURE 10.33 A
will be determined when rod and lever is
installed on engine and engine stop gap is set.
Dimension B: See Figure 10.33 A

170 mm ( 6.69”) SK160 ~ SK190
288 mm (11.34”) SK210
304 mm (11.97”) SK250
198 mm ( 7.80”) SK290 ~ SK330
Note: MM=Millimeters, ” = Inches
NOTE
Dimension “B”is only a starting point, NOT THE
FINAL DIMENSION. The final length or the rod
will be determened in the next step.
Adjustment “A” Procedure

1. Remove the key from key switch. See FIGURE 10.33 B
Figure 10.33 B.
2. Locate the CPU behind operators seat.

Remove grommet located on the top of
CPU. Carefully move the test run switch
to test position. See Figure 10.33 C.
3. Insert key in key switch, turn key to the “ON”

position, do not start engine. Gauge
Cluster must display “Monitor System
Ok” . If not preform maintenance or repairs
to correct problem. Proceed to next Step.
4. Turn accel dial to the low idle position. See

Figure 10.33 B.
FIGURE 10.33 C
Dynamic Acera 11/00
Page 10-63
5. Press the buzzer stop switch for 5 to 10

seconds and release. Step 1 will not apear
until buzzer stop switch is released. See
Figure 10.34 D.
STEP 2
CPU GAP (STOP)
FIGURE 10-34 D
6. When STEP 1 is displayed on the gauge
cluster, wait until STEP 2 is displayed on FIGURE 10.34 A
gauge cluster. See Figure 10.34 A.
Fuel Rack Lever Splined Lever
7. After verification that CPU STEP 2 GAP
STOP is displayed on the gauge cluster,
you will notice that the controller has moved
the stepping motor to the LOW STOP
position.
See Figure 10.34 A.
8. While holding the fuel rack lever against

the low stop bolt reinstall the linkage
assembly between the stepping motor and
injection pump. See Figure 10.34 B. Example SK210
Note: If the splined shaft lever will not align FIGURE 10.34 B
while other ball joint end is inserted into
the fuel lever remove that end from the fuel
rack, retain position move splined lever
one spline forward or backward on the
stepper motor shaft to allow splines to
align. Then adjust the intermediate rod so
the ball joint end can not be installed on
the fuel lever.
Warning: Make sure to insert the ball joint end

of the rod linkage in the proper bolt hole of
the fuel lever bracket - Do Not install in the
slot for the manual override cable. See
Figure 10.34 B & 10.34 C Example SK290
FIGURE 10.34 C
Dynamic Acera 11/00

Page 10-64
NOTE
Dimension “B”is only a starting point, NOT THE Shaft
FINAL DIMENSION. The final length of the rod Protrusion =
3mm (.125”)
will be determened in the next step.
9. Confirm that the spline on the stepping

motor is protruding approximately 3mm
(.125”) past the lever assembly. Secure
the lever to stepping motor with the 5mm
allen wrench.
See Figure 10.59 A.
10. With a feeler gauge inserted between the

fuel shut off stop bolt and the fuel injection FIGURE 10.59 A
pump lever adjust the clearance to 0.1mm
(.004 “). See Figure 10.59 B.
Fuel Stop Bolt
11. Once clearance has been reached with Feeler Gauge
only slight resistance on the feeler gauge
tighten both rod linkage jam nuts with 13
and 14 mm wrenches. Do not over tighten
max. torque is 1.84 kgf•m, (13.27 ft•lbs)
See Figure 10.34 C.
12. Recheck all linkage fastners and make

sure everything is tight. also make sure ball
joint linkage ends are equally aligned and
not twisted. Afterwards return to the
operator’s cab for the next step.
Note: Remove all tools and wrenches in and FIGURE 10.59 B
around engine compartment to prepare for
the starting of the engine in the next Holding Wrench Tighten Jam Nut
process. here Here
FIGURE 10.59 C
Dynamic Acera 11/00

Page 10-65
13. Press buzz start switch once and CPU
STEP 3 Start E/G will appear in gauge
Cluster. You will notice that the controller
will move the stepping motor to a position
higher than the normal RPM starting range.
See Figure 10.35 A.
CPU STEP 3
14. Start engine and wait until engine reaches Start E/G
normal operating temperature range.
Note: Hydraulics system maybe
functioned to warm engine and hydraulic
system up.
FIGURE 10.35 A
15. With engine running, press the buzzer stop
switch once, the gauge cluster will read
CPU STEP 4 MEMORY. The controller
will take control of the stepping motor and
bring the engine from:
a. Mid range.
b. Below Low Idle.
c. High Idle.
CPU Step 4
d. Low Idle. Memory
See Figure 10.35 B.
NOTE
Required time for computer to memorize total
engine steps is about 3 minutes.
16. CPU STEP 4 MEMORY will take

FIGURE 10.35 B
approximately three minutes to cycle the
stepping motor and record the data in the
controller.
Note
17. After completion of the above, the gauge “Finished CPU
cluster display will read the following: (****)RPM”
CPU FINISHED **** RPM (****) will represents the
represent the highest RPM which was read highestRPM
by the controller during Step 4. whichwas recorded
See Figure 10.35 C. by the controller FINISH
during Step 4. CPU **** RPM
Please refer to the Measuring & Adjusting
Pressures chapter in this manual for the proper
RPM reading for your machine by Model and
Serial Number.
NOTE
The finished RPM in step 4 may show higher
FIGURE 10.35 C
than Actual High Idle RPM.
Dynamic Acera 11/00

Page 10-66
E. After completion of “A “ Adjustment

Service diagnosis display
1. Turn key switch to Off position, stop engine
Gauge cluster
and allow the battery relay to shut off
(approximately 4 seconds).
2. Return the CPU controller adjustment

switch from the TEST to RUN position.
Reinstall protective grommet in the
controller cover.
3. If not already changed, change

maintenance connector from the Factory
Default to accel release position. Start
the engine, raise the engine speed to
the high idle RPM.
Change back to factory when finished
See 10.36 A.
4. Press the screen change switch once to

bring up RPM. Verify engine speed Screen change
changes on the multidisplay in Example: SK210
switch
accordance with the set values which is
listed in the Measuring & Adjusting
Pressures chapter of this manual
5. If all engine RPM’s are correct reinstall

the CPU access cover and return
operators seat to the original position.
Work Mode
Maintenance Connector
Factory Default
Release
Buzzer Stop
FIGURE 10-36 A
Dynamic Acera 11/00
Page 10-67
SK480 ENGINE DIAGNOSIS LAMPS
METHOD OF CONFIRMING ERRORS:
Troubles can be confirmed with two error

lamps located on the operator’s left console.
See Figure 4.
FIGURE 4
Troubles codes will flash on lamps one at a

time a total of three times and then repeat if
multiple codes are present. See Table 1.
Dynamic Acera 11/00

Page 10-68
SK480 Engine diagnosis lamps
(Red and Amber) – FIGURE 2.16A, 2.16B
Two diagnosis lamps are installed on the left side
control panel as indicated in the figure. These lamps
will indicate any abnormality in the engine. Refer to
the following tables for normal and abnormal condi-
tion of the engine:
Normal engine condition
NOTE 1
During normal conditions, both lamps will illuminate as soon
as the key switch is turned to the “ON” postion, and will FIGURE 2.16A
stay illuminated until the engine is started. Lamps will turn
Off, and will stay Off after starting the engine. NOTE 3
The code is indicated by a 2 figure number: the code’s
first figure lights on for 1.2 seconds and off for 1.2 sec-
Abnormal engine condition onds, and the code’s second figure lights on for 0.4 sec-
onds and off for 0.4 second, as shown inFig. 2.16B. Ev-
ery code is displayed three times repeatedly, and where
there is no more code, the display will return to the first
code.
Therefore, in the case where codes 12 and 13 are present:
12 12 12 13 13 13
NOTE: This example shows failure code 12

Light indicator for the Light indicators for the
NOTE 2 code’s first figure (1) code’s second figure (2)
There exists two different abnormal conditions:
» The red and/or amber lamps will illuminate and flash the Lamp “ON”
engine failure code(s) (See Figure 2.16B for details on
flashing codes). Engine not running mode.
Lamp “OFF”
» The red and/or amber lamps will illuminate and flash the
engine failure code(s) (See Figure 2.16B for details on
flashing codes). Engine running mode. 2.4 sec. 2.4 sec.
* * * *
If abnormal conditions appear on engine, refer to 1.2 sec. 0.4 sec.

Page 10-71~10-72 Engine Electronics Troubleshooting
chart Engine Failure Codes. Contact your closest FIGURE 2.16B
Kobelco’s Service Department for assistance and re-
pairs if required.
NOTE 4
If one of the engine diagnosis lamps (Red or amber) does
not illuminate as soon as the key switch is set to the ON
position, check for defective light bulb.
Dynamic Acera 11/00

Page 10-69
Location of Engine Controller:
Engine Fuel
System Controller
Dynamic Acera 11/00

Page 10-70
Location of Memory Clear & Diagnostic Connectors
Memory Clear Diagnostic
Dynamic Acera 11/00

Page 10-71
SK480 ENGINE ELECTRONICS TROUBLESHOOTING
DIAGNOSIS FAILURE DIAGNOSIS

CONDITION OBSERVATIONS
CODE LOCATION LAMP
01 Normal --- --- Engine is operable
Engine not operable.

07 Engine overrun Eng. Speed Eng. overrun condition Red Use emergency shut
down function to stop it.
Engine not operable.

Engine reverse Reverse rotation of the
45 Red Use emergency shut
rotation engine. down function to stop it.
ECU power is OFF. Use

emergency shut down
function to stop it. Engine
Governor servo Difference of ECU command will run in backup mode
11 Red and the amber lamp
system value and feedback value.
indicatorwillbe
illuminated. Operable
only for repairs.
ECU power is OFF. Use

emergency shut down
function to stop it. Engine
will run in backup mode
22 Rack sensor 0.5V Rack sensor 4.4V Red and the amber lamp
indicatorwillbe
illuminated. Ope r a b l e
o n l y f o r repairs.
0.5V Rack sensor 4.4V.
ECU power is Off.

Engine runs at constant
Electronic timer Difference of ECU command fuel injection and will run
17 Amber in backup mode (amber
control system value and feedback value.
lamp on). Operable only
for repairs.
»D i s c o n n e c t i o n n o t
detected. Operable only
for repairs.
»E C U p o w e r i s O f f .
»Disconnection detected.
23 Timer control valve Amber Engine runs at constant
»Short-circuit detected. fuel injection and will run
in backup mode (amber
lamp on). Operable only
for repairs.

fuel injection and will run
in backup mode (amber
14 Timing sensor Cross checking to NE sensor. Amber lamp on). Return of
timing sensor pulse.
Operable only for
repairs.

fuel injection and will run
Cross checking to timing in backup mode (amber
15 NE sensor Amber lamp on). Operable only
sensor.
for repairs. Return of NE
sensor pulse.
Dynamic Acera 11/00

Page 10-72
SK480 ENGINE ELECTRONICS TROUBLESHOOTING
DIAGNOSIS FAILURE DIAGNOSIS

CONDITION OBSERVATIONS
CODE LOCATION LAMP
Use emergency shut
down function to stop it.
Speed sensor in When key switch is ON, both Key switch is Off or
14 + 15 Red return of either of both
both directions speed sensors have no pulse.
sensors. Engine not
operable.
Engine operable. Control

done with Accel sensor
24 Accel sensor 1 0.2V Accel sensor 1 4.8V --
2. Engine is operable.
0.2V Accel sensor1 4.8V.
Control done with Accel

sensor 1. Engine is
16 Accel sensor 2 0.2V Accel sensor 2 4.8V -- operable. 0.2V Accel
sensor2 4.8V.
Engine controlled by
Accel switch (Accel SW
Simultaneous Off: 100%, Accel SW
ON: 0%). Operable only
24 + 16 failure of sensors 1 0.2V Accel sensors 1&2 4.8V Amber for repairs in backup
and 2 mode (amber lamp On).
0.2V Accel sensors
1&2 4.8V.
Engine operable
Accel openning 30%, Accel
65 Accel SW -- (Normal). Accel opens
SW On. 30%, Accel SW Off.
Operable only for

repairs in backup mode
(amber lamp On). 0.5V
32 Boost sensor 0.5V Boost sensor 4.8V Amber Boost sensor 4.8V.
Set boost pressure to 0
Kpa (Relative pressure).
Engine is operable.
Coolant temp. 4.9V.
Coolant temp. Set coolant temp. to
21 Coolant temp. sensor 4.9V -- 80° C (When engine is
sensor
started, temp. is set to -
20° C).
Engine is operable. Set

Atmospheric atmospheric press. to
19 1.89V Atm. press. sensor 5.0V -- 101 KPa. 1.89V Atm.
pressure sensor
press. sensor 5.0V.
Engine is operable. Set

Q-regulation
34 0.1V Q-reg. resistance 4.6V -- injection correction
resistance value to lower limit.
»Disconnection not
detected.
»Disconnection detected. »ECU power is off. Air
78 Heater relay Amber heating control stops.
»Short-circuit detected.
Engine may not start in
cold conditions.
»Micron checking error. Engine not operable.

33 Systeme error »CPU mutual checking error. Red ECU power Off. Use
emergency shut down
»Interrupt processing error. function to stop engine.
Dynamic Acera 11/00
Page 10-73
Dynamic Acera 11/00
Page 10-74
SK160 SCHEMATICS
SK160 LC-VI ELECTRICAL SCHEMATIC Page
A. ELECTRIC CIRCUIT DIAGRAM (A)..............................................................................................................1E-1
C-1: Top section of CPU
C-2: Cluster gauge
SW-1: Key switch
SW-3: Two speed selector switch
SW-4: Swing parking release switch
SW-5: KPSS release switch
SW-21: Power boost switch
SW-35: Heavy lift switch
E-1: Fuse box
E-2: Alternator
E-3: Hour meter
E-4: Resistor for KPSS release
M-1: Starter motor
M-2: Stepping motor
R-1: Battery relay
R-2: Starter relay
R-3: Glow relay
R-4: Safety relay
SE-1~SE-10: Low pressure sensors for pilot control system
SE-11 & SE-20: Low pressure sensors - pilot control system for optional attachments
SE-13: Engine RPM sensor
SE-14: Coolant thermo sensor
SE-15: Fuel sensor
SE-16: Throttle control pressure sensor
SE-22 & SE-23: High pressure sensors for P1 & P2
SE-26 & SE-27: Negative control pressure sensors
SE-28: Back pressure sensor
SV-1: Swing parking brake solenoid
SV-2: Power Boost solenoid
SV-3: Two speed selector solenoid
PSV-A: Arm variable recirculation proportional solenoid
PSV-B: P2 By pass cut proportional solenoid
PSV-C: Travel priority proportional solenoid
PSV-D: P1 By pass cut proportional solenoid
PSV-E: P1 Independent travel proportional solenoid
PSV-F: P2 Independent travel proportional solenoid
PSV-H: Swing priority proportional solenoid
PSV-P1: Pump P1 proportional solenoid
B. ELECTRIC CIRCUIT DIAGRAM (B)..............................................................................................................1E-2
C-1: Middle section of CPU
C-3: Switch box assembly
SW-2: Mode, buzzer stop switch
SW-6: Engine water temperatur switch
SW-7: Engine oil pressure switch
SW-8: Air filter restriction switch
SW-10: Horn switch
SW-12: Over load alarm selector switch
SW-11: Lever lock switch
SW-13: Air conditioner switch
SW-15: Conflux/single selector switch
SW-19: Wiper intermitent switch
SW-20: Wiper, washer, light switch
SW-23: Engine oil level switch
SW-24: Engine coolant level switch
SW-25: Hydraulic fluid level switch
SW-37: Hydraulic oil temperature switch
SW-38: Warm up switch
SW-39: Overload detector switch
E-5: Horn high
E-6: Horn low
E-10: Receiver Drier
E-14: Cigarette lighter
M-3: Wiper motor
M-4: Washer motor
R-5: Horn relay
R-7: Wiper relay assy
R-20: Timer relay
SV-4: Operating lever lock solenoid
L-5: Room light
SK160LC–VI Dynamic Acera OM, 01/01 Rev. 1

SK160 SCHEMATICS
Page
C. ELECTRIC CIRCUIT DIAGRAM (C)..............................................................................................................1E-3
C-1: Bottom section of CPU
SCHEMATIC NOMENCLATURE
SW-9: Swing flasher switch
SW-16: Engine room light switch
SW-26: Cab working light switch
SYMBOL COLOR Example of wire color:
SW-40: Rotary light switch W L
B Black
SW-47: Extra&breaker switch
E-8: Speaker left G Green
E-7: Radio AM&FM Stripe color (Blue)
E-9: Speaker right L Blue
E-13: Travel alarm
E-22: AC-DC converter R Red Base color (White)
E-23: 12V socket connection
M-11: Fuel supply pump W White
R-6: Work light relay Abreviations:
R-8: Travel alarm relay Y Yellow BZ: Buzzer
R-9: Cab working light relay 1
R-11: Cab working light relay 2 P Pink SV: Solenoid valve
R-19: Flasher relay SW: Switch
SV-11: Extra&breaker solenoid
O Orange
SE: Sensor
L-1: Boom working light left
Br Brown M: Motor
L-2: Frame working light right
L-3: Swing flasher left & rear working light Lg Light Green R: Relay
L-4: Swing flasher right & rear working light
L: Light
L-6: Boom working light right Gr Gray
L-7: Cab working light front 1 PSV: Proportional solenoid valve
L-8: Cab working light front 2 Sb Sky blue D: Diode
L-10: Rotary light
L-11: Engine room light V Violet E: Electrical fitting
L-15: Cab working light front 3
L-17: Back light
L-18: Cab working light back
D. HYDRAULIC CIRCUIT DIAGRAM (Neutral) ...............................................................................................1H-1
HYDRAULIC SCHEMATIC LEGEND
ITEM # DESCRIPTION
1 Main Hydraulic Pump
2 Main Control Valve
3 Swing Motor
4 Travel Motor Assy.
5
Boon Cylinders
6
7 Arm Cylinder
8 Bucket Cylinder
9 Swivel Joint
10 Left and Right Hand Pilot Control Valve
11 Travel Pilot Valve
12 Pattern Changer Valve (Optional)
13 Pilot Filter Manifold
14 Accumulator
15 Suction Strainer
16 8 Solenoid Block
17 Return Filter
18 Oil Cooler
19 Tank Breather Valve
20 Return Check Valve
22 Check Valve with Fixed Restriction
23 Independent Travel Bypass Valve
24 Independent Travel Valve Solenoids
25 Arm Out Check Valve with Restriction
26 Swing Priority Solenoid
30 Swing Priority/Breaker Option Valve
9 CONVERTER BACK UP
SK-160 ELECTRIC CIRCUIT DIAGRAM (A) 917
517
WR(5V)
P
11-33
C-1:MECHATRO CONTROLLER
SE-16:ACCEL POTENTIO 11-32
967 BW(GND)
CONTROLLER
CONTROLLER
CONTROLLER
KAI APPLICABLE YM02U0101~
ROOM LIGHT
4 CONVERTER
11-31
MECHATRO
MECHATRO
CIGARETTE
PRESS.SENSOR 900 RB (5V)
BACK UP
3 LIGHTER
11-15
771 G A PHASE
10 KEY SW.
LgR
2 RELAY
500 15-1
5 HORN
SE-1:BUCKET DIGGING 11-14
950 BrR (GND) 772 B
11-13 15-2
773 R B PHASE M M-2:GOVERNOR MOTOR
15-15
1A
1B
901 RL (5V)
8
7
11-16 774 W
RY
1.25
WG
15-16
WV
WY
WV
501 LgW
YG
RY
OL
YB
YL
E-1:FUSE BOX SE-2:BUCKET DUMP 11-17 SHIELD
951 BL (GND) 15-3
11-18 544 GB B
11-34
10A
20A
20A
10A
10A
20A
902 W (5V)
5A
5A
5A
11-3
51 2W 52 5R 502 LgY N L E
50 1.25L SE-3:BOOM RAISING 11-2 TIO A AS
53 5Y 952 BR (GND) SI RM LE
PO NO RE
TERMINAL
11-1
SW-4:SWING PARKING RELEASE SW.
20A
20A
10A
20A
20A
20A
20A
MECHATRO 903 OB (5V)
5A
5A
5A
11-4
CONTROLLER 503 LO
SE-4:BOOM LOWERING 11-5 545 Lg
C-1 C-1 12-18 1
BrW (GND)
1.25
1.25
1.25
1.25
953
1.25
1.25
1.25
720 PB B
WG
RW
WR
WB
RG
WL
YR
RB
15-26 15-25 11-6
RL
2 SV-1:SWING PARKING BRAKE SOL.
W
701 V
904 OL (5V) 15-22 3
TUNER (RADIO) 11
12
13
WIPER,WASHER 14
SOLENOID 15
WORKING LIGHT(F) 16
OPT WORKING 17
AIR CON 18
AIR CON 19
RESERVE 20
4 3 11-9
SE-7:ARM IN 504 PG
POWER WINDOW
FLASHER,WORKING
CLUSTER GAUGE
11-8 702 LgB B
LIGHT (R),ALARM 954 BrL (GND) 15-21 SV-3:TWO-SPEED SELECT SOL.
11-7
905 OW (5V) 703 P B
11-10 15-23 SV-2:POWER BOOST SOL.
LIGHT
SE-8:ARM OUT 505 PL
11-11
955 Gr (GND)
B1 A1 11-12
740 BO
60A 60A 15-6
51 G 906 YB (5V) PSV-B:P2 BY-PASS CUT PROPORTIONAL SOL.
11-21 741 GrR
SE-6:SWING RIGHT 15-7
E2 B BATTERY BATTERY 506 VY
11-20
51 R B A 60B 60B 60B 956 GrL (GND) 742 VR
11-19 15-8
E3 B L B PSV-C:TRAVEL PRIORITY PROPORTIONAL SOL.
907 YG (5V) 743 GrB
SHIELD 15-9
11-22
B2 700 WG SE-5:SWING LEFT 507 VG 11-23
ION
POSITPREHEATIN
G D-9 957 Br (GND) 744 BP
15-4
TERMINAL
SW-1:KEY SW. 60 WL 59 W 11-24 PSV-D:P1 BY-PASS CUT PROPORTIONAL SOL.

O A O S
R-1:BATTERY RELAY 745 PW
T 15-5
F C N A
D-1
R 908 YL (5V)
F C T 11-27
10 1.25WV SE-9:TRAVEL RIGHT 508 VY 746 BrG
10 B 11-26 15-10
PSV-A:ARM VARIABLE RECIRCULATION
ACC R-3:GLOW RELAY 958 BY (GND) 747 YV
60B
11-25 15-11 PROPORTIONAL SOL.

D-2
POSITION
GLOW
NORMAL
RELEASE
M 33 2OB 34 5W
61 GrB
G1 546 PG
TERMINAL
58 P 12-19
G2 909 YR (5V)
ST 63 WY M-1: 11-28
SE-10:TRAVEL LEFT 509 Sb SW-5:KPSS MODE RELEASE SW.
STARTER MOTOR B M E D-4 11-29 E-4:RESISTOR
M
959 BG (GND)
66 5L
11-30 B
WB 1
15 756 BrY
R-2: 2
STARTER RELAY B S S
E-2:ALTERNATOR 3
749 GrG
SW 64 LW B 5B 15-18 4
S E B E 748 VR 757 RY
915 YL (5V) 15-17 5 PSV-P1:PUMP P1 PROPORTIONAL SOL.
D-3 12-3
59 W 66 L 515 V 6 B
R R 12-2
30 GY SE-22:PUMP P1 7
P P 965 BrB (GND) 758 BrB
12-1 8
L 65 WR L
751 GY 9
15-20 10
R-4:SAFETY RELAY 916 YR (5V) 759 RL
12-4 750 VW 11
15-19 PSV-P2:PUMP P2 PROPORTIONAL SOL.
SE-23:PUMP P2 516 L
E-3:HOUR METER 12-5 12
B 966 BrY (GND)
65 WR 12-6
H -M
914 RL (5V) 752 WV

C-2:CLUSTER GAUGE 13-3 16-1
514 GO 753 GR PSV-E: INDEPENDENT TRAVEL
SE-11:P2 Optional 13-2 16-2
W 21-7 964 BL (GND) PROPORTIONAL SOL.
SE-14: 13 ENG.WATER 13-1
COOLANT THERMO SENSOR TEMP INDICATOR 913 RB (5V)
600 YR 21-3 12-9
SE-20:P1 Optional 513 LgR
12-8 754 WL
553 VW C-1 963 BW(GND) 16-3
5 12-7
14-8 755 GR PSV-F: INDEPENDENT TRAVEL
SE-15: B FUEL METER 16-4
601 BrR 21-4 PROPORTIONAL SOL.
FUEL SENSOR 15-24
CHARGE 65 WR
12-13
KEY ON 60 WL 12-15
85 1.25WB
8 GLOW 61 GrB
R-6: 12-16 738 WG
16-7
WORK LIGHT RELAY LCD BACK LIGHT PSV-H:SWING PRIORITY
B 540 LG 739 G
SW-36:INDEPENDENT TRAVEL SW. 13-16 16-8 PROPOTIONAL SOL.
B 541 PL
B SW-3:TWO-SPEED SELECT SW. 12-17
21-6 B 542 GrG
A M B SW-21:POWER BOOST SW. 14-11
RY
B 543 GO 15-12 1A
SW-35:HEAVY LIFT SW. 17-9 E2 B (GND)
LCD 15-25 3
RY
580 R 15-13 1B
12-20
SE-13:ENG.REVOLUTION SENSOR 20 C-1:MECHATRO CONTROLLER(RESISTOR)
581 W
12-21
SHIELD
12-22
15-26 E3 (GND) B
4
21-2 770 R
14-25 15-14 YG
7
21-1 582 W
14-26
21-8 980 B
14-27
SHIELD
14-28
TO 1E-2
YM03Z00001P3 SK160LC –VI Dynamic Acera OM, 01/01 Rev. 1 1E---1
KAI SK-160 ELECTRIC CIRCUIT DIAGRAM (B) C-3: SW.BOX ASSY

FROM 1E-1 32-8 SW-38: WARM-UP SW.
562 O APPLICABLE YM02U0101~
547 GB
SW-6:ENG.WATER TEMP.SW. 14-1
32-9 564 LY 982 BG SW-15:
17
548 GY CONFLUX/SINGLE SELECT SW.
SW-7:ENG.OIL PRESS.SW. 14-2 C-3 OPTION
B 549 Lg SW-46:
SW-8:AIR FILTER RESTRICTION SW. 14-3 32-12 561 GR
COUNTER REMOVAL SW.
B OPTION
550 BG
SW-23:ENG.OIL LEVEL SW. 14-5
32-14 569 LO
15 SW-29: NIBBLER OPEN SW
B 551 GL
SW-24:ENG.COOLANT LEVEL SW. 14-6 32-15 570 YB
16 SW-30: NIBBLER CLOSE SW
B 552 BrL
SW-25:HYD.FLUID LEVEL SW. 14-7 32-3 572 GrG 6
930 RG (5V) 31-6 MODE SW-2: SW.ASSY(MODE,BUZZER STOP)
330 14-18
C-1 1 RY 31-4 32-4 573 V 4
20 704 LgR BUZZER
15-13 14-20 3 STOP
705 LG 31-3
SE-15:FUEL SENSOR 553 VW 14-21 85 WB 2 1 B
C-2 5 14-8 706 VW 31-2 R-6 8
14-22
B 707 LY 31-1
MAINTENANCE CONNECTOR 520 LO 14-23
12-14
(Auto-Acceleration connector) 556 BrW 31-5
14-19 32-5 574 PL 6
981 GW(GND) 31-8 WIPER SW-20: SW.ASSY(WIPER,WASHER,LIGHT)
B 563 O 14-24 5
SW-37:HYD.FLUID TEMP.SW. 17-8 32-6 575 LgB WASHER
SW-15 32-7 576 LB 4
982 BG (GND) 31-7 LIGHT
17 3
2 1 B
Europe Only R-7:WIPER RELAY ASSY

WY
2
B 583 VW 540 LG
13-16
2
SW-39: OVER LOAD SW-12: OVER LOAD PREVENT
DETECTOR SWITCH ALARM SELECTOR SW. SPARK WIPER MOTOR RELAY
RELAY
3 80 GrR
1.25RB 1
14
708 LR 6 M-3:WIPER MOTOR
14-12 R-5:HORN RELAY
709 GB 7 M 5 WG 83 GO B
14-13 5 E-5:HORN HIGH
WIPER MOTOR 84 WR B B
REVERSING RELAY E-6:HORN LOW
B 10 B
4 81 GrB SW-10:HORN SW.
710 Gr 8
14-14
KAI Option
L-5:ROOM LIGHT
R-10
Breaker Relay WINDOW WASHER MOTOR RELAY M-4:WASHER MOTOR 9 YB
9
21
5 82 GO B
M
711 GrL 9
14-15
3 YL B
3 E-14:CIGARETTE LIGHTER
557 L STOP
14-9
D-11 558 G REVERSE
220 LW 14-10
22
R-12
ClockWise
Relay
C-4
R-15 AIR CON.
20 E-10:RECEIVER DRIER E-11:AIR COMPRESSOR CLUTCH
Nibbler
Open Relay PB 559 LW
17-13 SW-19:WIPER INTERLOCK SW. R-6 7 85 WB 150 BP 155 BR
18 1.25WG 1.25B SW-13:AIR CONDITIONER SW.

18
19 RL 151 R
19 24V 24V
R-20:TIMER RELAY 152 G
TXD RXD
153 W
RXD TXD
15 WB 87 YV E D 86 OW B 154 B
15 GND
SHIELD
SW-11: SV-4:
SAFETY LEVER LOCK SW. OPERATING LEVER LOCK SOL.
COOLING
A B UNIT
TIMER
17-11
1E---2
TO 1E-3 YM03Z00001P3 SK160LC –VI Dynamic Acera OM, 01/01 Rev. 1
KAI SK-160 ELECTRIC CIRCUIT DIAGRAM (C) FROM 1E-2 R-6:WORK LIGHT RELAY
WB
L-6:BOOM WORKING LIGHT RIGHT
ANT. E-7:TUNER AM&FM
1.25RW 85 1.25WB WB
16 L-1:BOOM WORKING LIGHT LEFT 98 LW
WY 1(+) E-8:SPEAKER LEFT
2 WB B 7(-) 99 Br
7 C-4 L-2:FRAME WORKING LIGHT RIGHT
713 BrY
APPLICABLE YM02U0101~ 14-16 FM/AM
100 LR
8 SW-2, SW-20, and C-2 YR 2(+) E-9:SPEAKER RIGHT
11 4 101 OB
8(-)
YB B
9 11 9
R-19:FLASHER RELAY L-3:SWING FLASHER & WORKING LIGHT UNIT LEFT BACK UP
RG 401 GR R
12
R Standard for KAI
714 WB
14-17
402 YG Y E-22:DC-DC CONVERTER
OL 96 WG
715 GW 4 1GN 12V E-23:12V SOCKET
17-3
YB 97 YV
403 Br Br B 9 24V
MEM
B
GND
716 WV Standard for Europe
17-4
B 560 LgY
SW-9:SWING FLASHER SW. 17-10
401 GR
R
R E-7:TUNER AM&FM
ANT.
98 LW
402 YG 1(+) E-8:SPEAKER LEFT
7(-) 99 Br
Y
FM/AM
100 LR
96 WG 2(+) E-9:SPEAKER RIGHT
403 Br B 4 101 OB
8(-)
Br 97 RY BACK UP B
11 9
L-4:SWING FLASHER & WORKING LIGHT UNIT RIGHT
SWING FLASHER & WORKING LIGHT

KAI Option: HAND CONTROL FOR BREAKER
17- 6 Standard for Europe
SV-5:
R-10: Breaker Relay Breaker Sol. R-8: Travel Alarm E-13: TRAVEL ALARM
R-9:OPT.WORK LIGHT RELAY
WB 223 YG B 1.25 RG 88 PG
15
12 1.25WL 90 RY RY B
LW 262 LY WY B 17 L-7:CAB WORKING LIGHT FRONT 1
21
B 2 WY 89 BrL B
SW-43: 717 BP
RY B L-8:CAB WORKING LIGHT FRONT 2
Clockwise SW
SW-26:
611 LG OPT.WORK LIGHT SW. RY B
14-14 L-15:CAB WORKING LIGHT FRONT 3
1.25WL 92 RW RW B
L-16:CAB WORKING LIGHT FRONT 4
KAI Option: HAND CONTROL FOR ROTATION WY 89
YG RW B L-18:CAB WORKING LIGHT BACK
214 SV-6:
R-12: Clockwise Relay Clockwise Sol. R-11:CAB WORKING LIGHT RELAY 2
RW B
LW 216 O B L-17:BACK LIGHT
22
89 BrL
B
SW-33:
D-5 Clockwise SW
SW-40:ROTARY LIGHT SW. L-10:ROTARY LIGHT
610 GrL WL 91 Y B
17-12 17
215 GR Optional for KAI
SV-7:
D-6 Counterclockwise Sol. STD for Europe
218 P B
219 GY B
R-13:Counterclockwise SW-34:
M-11:FUEL SUPPLY PUMP
Relay Counterclockwise SW
KAI Option: HAND CONTROL FOR NIBBLER OPEN/CLOSE 10A

WV B
8 M
20 R-15:
NIBBLER OPEN RELAY
Optional
SW-29: NIBBLER OPEN SW. 240 LW B
569 LO 982 BG WY
15 17 2 SW-16:ENG.ROOM LIGHT SW. L-11:ENG.ROOM LIGHT
SV-9:
NIBBLER OPEN SOL.
750 G YB B
17-2 9
SW-30: NIBBLER CLOSE SW. R-16:
NIBBLER CLOSE RELAY
570 YB 982 BG Optional
16 17 241 LO B
SV-10: SW-47:EXTRA & BREAKER SW. SV-11:EXTRA SOL

NIBBLER CLOSE SOL. WB 94 RL B
751 GL 15
17-5
Optional
YM03Z00001P3 SK160LC –VI Dynamic Acera OM, 01/01 Rev. 1 1E---3
SK210 ~ SK250 SCHEMATICS
SK210(LC)-VI, SK250LC-VI & SK250NLC-VI ELECTRICAL AND HYDRAULIC SCHEMATICS Page
C-1: Top section of CPU
C-2: Cluster gauge
SW-1: Key switch
SW-3: Two speed selector switch
SW-4: Swing parking release switch
SW-5: KPSS release switch
SW-21: Power boost switch
SW-35: Heavy lift switch
E-1: Fuse box
E-2: Alternator
E-3: Hour meter
E-4: Resistor for KPSS release
M-1: Starter motor
M-2: Stepping motor
R-1: Battery relay
R-2: Starter relay
R-3: Glow relay
R-4: Safety relay
SE-1~SE-10: Low pressure sensors for pilot control system
SE-11 & SE-20: Low pressure sensors - pilot control system for optional attachments
SE-13: Engine RPM sensor
SE-14: Coolant thermo sensor
SE-15: Fuel sensor
SE-16: Throttle control pressure sensor
SE-22 & SE-23: High pressure sensors for P1 & P2
SE-26 & SE-27: Negative control pressure sensors
SE-28: Back pressure sensor
SV-1: Swing parking brake solenoid
SV-2: Power Boost solenoid
SV-3: Two speed selector solenoid
PSV-A: Arm variable recirculation proportional solenoid
PSV-B: P2 By pass cut proportional solenoid
PSV-C: Travel priority proportional solenoid
PSV-D: P1 By pass cut proportional solenoid
PSV-E: P1 Independent travel proportional solenoid
PSV-F: P2 Independent travel proportional solenoid
PSV-H: Swing priority proportional solenoid
PSV-P1: Pump P1 proportional solenoid
C-1: Middle section of CPU
C-3: Switch box assembly
SW-2: Mode, buzzer stop switch
SW-6: Engine water temperatur switch
SW-7: Engine oil pressure switch
SW-8: Air filter restriction switch
SW-10: Horn switch
SW-12: Over load alarm selector switch
SW-11: Lever lock switch
SW-13: Air conditioner switch
SW-15: Conflux/single selector switch
SW-19: Wiper intermitent switch
SW-20: Wiper, washer, light switch
SW-23: Engine oil level switch
SW-24: Engine coolant level switch
SW-25: Hydraulic fluid level switch
SW-37: Hydraulic oil temperature switch
SW-38: Warm up switch
SW-39: Overload detector switch
E-5: Horn high
E-6: Horn low
E-10: Receiver Drier
E-14: Cigarette lighter
M-3: Wiper motor
M-4: Washer motor
R-5: Horn relay
R-7: Wiper relay assy
R-20: Timer relay
SV-4: Operating lever lock solenoid
L-5: Room light
SK210~SK250 SCHEMATICS
Page
C-1: Bottom section of CPU
SW-9: Swing flasher switch
SW-16: Engine room light switch
SW-26: Cab working light switch
SYMBOL COLOR Example of wire color:
SW-40: Rotary light switch W L
B Black
SW-47: Extra&breaker switch
E-8: Speaker left G Green
E-7: Radio AM&FM Stripe color (Blue)
E-9: Speaker right L Blue
E-13: Travel alarm
E-22: AC-DC converter R Red Base color (White)
E-23: 12V socket connection
M-11: Fuel supply pump W White
R-6: Work light relay Abreviations:
R-8: Travel alarm relay Y Yellow BZ: Buzzer
R-9: Cab working light relay 1
R-11: Cab working light relay 2 P Pink SV: Solenoid valve
R-19: Flasher relay SW: Switch
SV-11: Extra&breaker solenoid
O Orange
SE: Sensor
L-1: Boom working light left
Br Brown M: Motor
L-2: Frame working light right
L-3: Swing flasher left & rear working light Lg Light Green R: Relay
L-4: Swing flasher right & rear working light
L: Light
L-6: Boom working light right Gr Gray
L-7: Cab working light front 1 PSV: Proportional solenoid valve
L-8: Cab working light front 2 Sb Sky blue D: Diode
L-10: Rotary light
L-11: Engine room light V Violet E: Electrical fitting
L-17: Back light
L-18: Cab working light back
D. HYDRAULIC CIRCUIT DIAGRAM (Neutral) ...............................................................................................1H-1
HYDRAULIC SCHEMATIC LEGEND
ITEM # DESCRIPTION
1 Main Hydraulic Pump
2 Main Control Valve
3 Swing Motor
4 Travel Motor Assy.
5
Boon Cylinders
6
7 Arm Cylinder
8 Bucket Cylinder
9 Swivel Joint
10 Left and Right Hand Pilot Control Valve
11 Travel Pilot Valve
12 Pattern Changer Valve (Optional)
13 Pilot Filter Manifold
14 Accumulator
15 Suction Strainer
16 8 Solenoid Block
17 Return Filter
18 Oil Cooler
19 Tank Breather Valve
22 Check Valve with Fixed Restriction
23 Independent Travel Bypass Valve
24 Independent Travel Valve Solenoids
25 Arm Out Check Valve with Restriction
26 Swing Priority Solenoid
30 Swing Priority/Breaker Option Valve
9 CONVERTER BACK UP
SK210 ELECTRIC CIRCUIT DIAGRAM (A) 917
517
WR(5V)
P
11-33
967 BW(GND)
CONTROLLER
CONTROLLER
CONTROLLER
KAI APPLICABLE YN07-30001~
ROOM LIGHT
4 CONVERTER
11-31
MECHATRO
MECHATRO
CIGARETTE
900 RB (5V)
YQ07-03501~ PRESS.SENSOR
BACK UP
3 LIGHTER
11-15
771 G A PHASE
10 KEY SW.
LgR
2 RELAY
500 15-1
5 HORN
SE-1:BUCKET DIGGING 11-14
LQ08-04501~ 950 BrR (GND) 15-2
772 B
11-13
LL08-03001~ 15-15
773 R B PHASE M M-2:GOVERNOR MOTOR
1A
1B
901 RL (5V)
8
7
11-16 774 W
RY
1.25
WG
15-16
WV
WY
WV
501 LgW
YG
RY
OL
YB
YL
E-1:FUSE BOX SE-2:BUCKET DUMP 11-17 SHIELD
951 BL (GND) 15-3
11-18 544 GB B
11-34
10A
20A
20A
10A
10A
20A
902 W (5V)
5A
5A
5A
11-3
51 2W 52 5R 502 LgY N L E
50 1.25L SE-3:BOOM RAISING 11-2 TIO A AS
53 5Y 952 BR (GND) SI RM LE
PO NO RE
TERMINAL
11-1
SW-4:SWING PARKING RELEASE SW.
20A
20A
10A
20A
20A
20A
20A
MECHATRO 903 OB (5V)
5A
5A
5A
11-4
CONTROLLER 503 LO
SE-4:BOOM LOWERING 11-5 545 Lg
C-1 C-1 12-18 1
BrW (GND)
1.25
1.25
1.25
953
1.25
1.25
1.25
1.25
720 PB B
WG
RW
WR
WB
RG
WL
RB
15-26 15-25 YR 11-6
RL
2 SV-1:SWING PARKING BRAKE SOL.
W
701 V
904 OL (5V) 15-22 3
12
13
WIPER,WASHER 14
SOLENOID 15
WORKING LIGHT(F) 16
OPT WORKING 17
AIR CON 18
AIR CON 19
RESERVE 20
TUNER (RADIO) 11
4 3 11-9
SE-7:ARM IN 504 PG
POWER WINDOW
FLASHER,WORKING
CLUSTER GAUGE
11-8 702 LgB B
LIGHT (R),ALARM 954 BrL (GND) 15-21 SV-3:TWO-SPEED SELECT SOL.
11-7
905 OW (5V) 703 P B
11-10 15-23 SV-2:POWER BOOST SOL.
LIGHT
SE-8:ARM OUT 505 PL
11-11
955 Gr (GND)
B1 A1 11-12
906 YB (5V)
11-21 740 BO
60A 60A SE-6:SWING RIGHT 506 VY 15-6
51 G 11-20 PSV-B:P2 BY-PASS CUT PROPORTIONAL SOL.
741 GrR
956 GrL (GND) 15-7
E2 B BATTERY BATTERY 11-19
51 R B A 60B 60B 60B 907 YG (5V)
11-22 742 VR
SE-5:SWING LEFT 507 VG 15-8
E3 B L B 11-23 PSV-C:TRAVEL PRIORITY PROPORTIONAL SOL.
743 GrB
SHIELD 957 Br (GND) 15-9
11-24
B2 700 WG
ION G 908 YL (5V) 744 BP
POSITPREHEATIN D-9 11-27 15-4
TERMINAL
SW-1:KEY SW. 60 WL 59 W SE-9:TRAVEL RIGHT 508 VY PSV-D:P1 BY-PASS CUT PROPORTIONAL SOL.
O A O S
R-1:BATTERY RELAY 11-26 745 PW
T
958 BY (GND) 15-5
F C N A
D-1 11-25
R
F C T 909 YR (5V)
10 1.25WV 11-28 746 BrG
10 B SE-10:TRAVEL LEFT 15-10
509 Sb PSV-A:ARM VARIABLE RECIRCULATION
ACC R-3:GLOW RELAY 11-29 747 YV
60B
15-11 PROPORTIONAL SOL.

D-2 959 BG (GND)
POSITION
GLOW
NORMAL
11-30
RELEASE
M 33 2OB 34 5W
61 GrB
G1 910 WY(5V) 546 PG
12-9
TERMINAL
58 P 12-19
G2 SE-26:P1 NEGA-CON. 510 GR
63 WY 12-8
ST M-1: 960 BY (GND) SW-5:KPSS MODE RELEASE SW.
STARTER MOTOR B M E D-4 12-7 E-4:RESISTOR
M
66 5L
911 RG(5V) B
12-10 WB 1
SE-27:P2 NEGA-CON. 511 LY 15 756 BrY
R-2: 12-11 2
STARTER RELAY B S S 961 BW(GND)
E-2:ALTERNATOR 12-12 3
749 GrG
SW 64 LW B 5B 912 RW(5V) 15-18 4
S E B E 13-15 748 VR 757 RY
SE-28:BACK PRESS. 512 Sb 15-17 5 PSV-P1:PUMP P1 PROPORTIONAL SOL.
D-3 13-14
59 W 66 L 6 B
R R 962 GrG (GND)
30 GY 13-13 7
P P 758 BrB
915 YL (5V) 8
L 65 WR L
12-3
515 V 9
SE-22:PUMP P1 12-2 751 GY
965 BrB (GND) 15-20 10
R-4:SAFETY RELAY 12-1 759 RL
750 VW 11
916 YR (5V) 15-19 PSV-P2:PUMP P2 PROPORTIONAL SOL.
E-3:HOUR METER 12-4 12
SE-23:PUMP P2 516 L
65 WR B 12-5
H -M 966 BrY (GND)
12-6
913 RB (5V) 752 WV

C-2:CLUSTER GAUGE 13-4 16-1
513 LgR 753 GR PSV-E: INDEPENDENT TRAVEL
SE-20:P1 OPT. 13-5 16-2
W 21-7 963 BW(GND) PROPORTIONAL SOL.
SE-14: 13 ENG.WATER 13-6
COOLANT THERMO SENSOR TEMP INDICATOR 914 RL (5V)
600 YR 21-3 13-3
SE-11:P2 OPT. 514 GO
13-2 754 WL
553 VW C-1 964 BL (GND) 16-3
5 13-1
601 BrR 21-4 PROPORTIONAL SOL.
FUEL SENSOR 15-24
CHARGE 65 WR
12-13
KEY ON 60 WL 12-15
85 1.25WB
8 GLOW 61 GrB
R-6: 12-16 738 WG
16-7
WORK LIGHT RELAY LCD BACK LIGHT PSV-H:SWING PRIORITY
B 540 LG 739 G
SW-36:INDEPENDENT TRAVEL SW. 13-16 16-8 PROPOTIONAL SOL.
B 541 PL
B SW-3:TWO-SPEED SELECT SW. 12-17
21-6 B 542 GrG
A M B SW-21:POWER BOOST SW. 14-11
RY
B 543 GO 15-12 1A
SW-35:HEAVY LIFT SW. 17-9 E2 B (GND)
LCD 15-25 3
RY
580 R 15-13 1B
12-20
SE-13:ENG.REVOLUTION SENSOR 20 C-1:MECHATRO CONTROLLER(RESISTOR)
581 W
12-21
SHIELD
12-22
15-26 E3 (GND) B
4
21-2 770 R
14-25 15-14 YG
7
21-1 582 W
14-26
21-8 980 B
14-27
SHIELD
14-28
TO 1E-2
YN03Z00028P1 SK210(LC)/SK250(LC) –VI Dynamic Acera OM, 09/00 Rev. 2 1E---1
C-3: SW.BOX ASSY
KAI SK210 ELECTRIC CIRCUIT DIAGRAM (B) 32-8 SW-38: WARM-UP SW.
FROM 1E-1 562 O
APPLICABLE YN07-30001~
SW-6:ENG.WATER TEMP.SW.
547 GB
14-1
32-9 564 LY 982 BG
17
SW-15:
CONFLUX/SINGLE SELECT SW.
YQ07-03501~
C-3 OPTION LQ08-04501~
548 GY
SW-7:ENG.OIL PRESS.SW. 14-2
32-12 561 GR SW-46: LL08-03001~
B 549 Lg COUNTER REMOVAL SW.
SW-8:AIR FILTER RESTRICTION SW. 14-3 OPTION
B 32-14 569 LO
550 BG 15 SW-29: NIBBLER OPEN SW
SW-23:ENG.OIL LEVEL SW. 14-5
32-15 570 YB
B 16 SW-30: NIBBLER CLOSE SW
551 GL
SW-24:ENG.COOLANT LEVEL SW. 14-6
32-3 572 GrG 6
B 930 RG (5V) 31-6 MODE SW-2: SW.ASSY(MODE,BUZZER STOP)
552 BrL 14-18
SW-25:HYD.FLUID LEVEL SW. 14-7 32-4 573 V 4
704 LgR 31-4 BUZZER
330 14-20
C-1 RY 3 STOP
20
1 705 LG 31-3
15-13 14-21 85 WB 2 1 B
706 VW 31-2 R-6 8
SE-15:FUEL SENSOR 553 VW 14-22
C-2 5 14-8 707 LY 31-1
14-23
B 556 BrW 31-5
MAINTENANCE CONNECTOR 520 LO 14-19 32-5 574 PL 6
12-14 WIPER
(Auto-Acceleration connector) 981 GW(GND) 31-8 SW-20: SW.ASSY(WIPER,WASHER,LIGHT)
14-24 5
32-6 575 LgB WASHER
B 563 O SW-15 4
SW-37:HYD.FLUID TEMP.SW. 17-8 31-7 32-7 576 LB
982 BG (GND) LIGHT
17 3
2 1 B
Europe Only R-7:WIPER RELAY ASSY

WY
B 583 VW 540 LG 2
13-16
SW-39: OVER LOAD SW-12: OVER LOAD 2
PREVENT
DETECTOR SWITCH ALARM SELECTOR SW. SPARK WIPER MOTOR RELAY
RELAY
3 80 GrR
1.25RB 1
14
708 LR 6 M-3:WIPER MOTOR
14-12 R-5:HORN RELAY
709 GB 7 M 5 WG 83 GO B
14-13 5 E-5:HORN HIGH
WIPER MOTOR 84 WR B B
REVERSING RELAY E-6:HORN LOW
B 10 B
4 81 GrB SW-10:HORN SW.
710 Gr 8
14-14
KAI Option L-5:ROOM LIGHT
R-10 WINDOW WASHER MOTOR RELAY M-4:WASHER MOTOR 9 YB
Breaker Relay 9
5 82 GO B
M
21
711 GrL 9
14-15
3 YL B
3 E-14:CIGARETTE LIGHTER
557 L STOP
14-9
558 G REVERSE
D-11 14-10
220 LW
22
R-12
ClockWise
Relay
C-4
AIR CON. E-10:RECEIVER DRIER E-11:AIR COMPRESSOR CLUTCH
R-15
20 Nibbler PB 559 LW
Open Relay 17-13 SW-19:WIPER INTERLOCK SW. R-6 7 85 WB 150 BP 155 BR
18 1.25WG 1.25B SW-13:AIR CONDITIONER SW.

18
19 RL 151 R
19 24V 24V
R-20:TIMER RELAY 152 G
TXD RXD
153 W
RXD TXD
15 WB 87 YV E D 86 OW B 154 B
15 GND
SHIELD
SW-11: SV-4:
SAFETY LEVER LOCK SW. OPERATING LEVER LOCK SOL.
COOLING
A B UNIT
TIMER
17-11
TO 1E-3
1E---2 YN03Z00028P1 SK210(LC)/SK250(LC) –VI Dynamic Acera OM, 09/00 Rev. 2
KAI SK210 ELECTRIC CIRCUIT DIAGRAM (C) FROM 1E-2 R-6:WORK LIGHT RELAY
WB
L-6:BOOM WORKING LIGHT RIGHT
1.25RW 85 1.25WB WB
16 L-1:BOOM WORKING LIGHT LEFT
WY
2 WB B
7 C-4 L-2:FRAME WORKING LIGHT RIGHT
713 BrY
APPLICABLE YN07-30001~ 14-16
YQ07-03501~ 8 SW-2, SW-20, and C-2
LQ08-04501~ E-22:DC-DC CONVERTER

LL08-03001~ R-19:FLASHER RELAY L-3:SWING FLASHER & WORKING LIGHT UNIT LEFT
OL 96 WG
RG 401 GR R 4 1GN 12V E-23:12V SOCKET
12 YB
9 24V 97 YV
R MEM
714 WB B
14-17 GND
402 YG Y
17-3 715 GW
403 Br Br B
ANT. E-7:TUNER AM&FM
98 LW
716 WV 1(+)
17-4 Br E-8:SPEAKER LEFT
7(-) 99
B 560 LgY
SW-9:SWING FLASHER SW. 17-10 FM/AM
401 GR 100 LR
96 WG 2(+) E-9:SPEAKER RIGHT
R 4 101 OB
R 8(-)
97 RY BACK UP B
11 9
402 YG
Y
403 Br B
Br
L-4:SWING FLASHER & WORKING LIGHT UNIT RIGHT

17- 6 Standard for Europe
SV-5:
R-10: Breaker Relay Breaker Sol. R-8: Travel Alarm E-13: TRAVEL ALARM
R-9:OPT.WORK LIGHT RELAY
WB 223 YG B
15 1.25 RG 88 PG
16 1.25WL 90 RY RY B
LW 262 LY B 17 L-7:CAB WORKING LIGHT FRONT 1
21 WY
B 2 WY BrL B
SW-43: 89
717 BP
Clockwise SW RY B L-8:CAB WORKING LIGHT FRONT 2
SW-26:
611 LG OPT.WORK LIGHT SW. RY B
14-14 L-15:CAB WORKING LIGHT FRONT 3
KAI Option: HAND CONTROL FOR ROTATION 1.25WL 92 RW RW B

L-16:CAB WORKING LIGHT FRONT 4
YG WY 89
214 SV-6: RW B L-18:CAB WORKING LIGHT BACK
R-12: Clockwise Relay Clockwise Sol.
R-11:CAB WORKING LIGHT RELAY 2
LW 216 O B
22 RW B
BrL L-17:BACK LIGHT
89
B
SW-33:
D-5 Clockwise SW
SW-40:ROTARY LIGHT SW. L-10:ROTARY LIGHT

610 GrL
17-12
GR WL 91 Y B
215 17
SV-7:
D-6 Optional for KAI
Counterclockwise Sol.
218 P B STD for Europe
219 GY B
R-13:Counterclockwise SW-34:
Relay Counterclockwise SW
M-11:FUEL SUPPLY PUMP
10A
WV B
KAI Option: HAND CONTROL FOR NIBBLER OPEN/CLOSE 8 M
20 R-15: Optional
NIBBLER OPEN RELAY
SW-29: NIBBLER OPEN SW. 240 LW B
569 LO 982 BG WY SW-16:ENG.ROOM LIGHT SW. L-11:ENG.ROOM LIGHT
15 17 2
SV-9: YB B
NIBBLER OPEN SOL. 9
17-2 750 G
SW-30: NIBBLER CLOSE SW. R-16:

Optional
NIBBLER CLOSE RELAY
570 YB 982 BG
16 17 241 LO B
SW-47:EXTRA & BREAKER SW. SV-11:EXTRA SOL
SV-10: WB 94 RL B
15
NIBBLER CLOSE SOL.
751 GL
17-5
Optional
YN03Z00028P1 SK210(LC)/SK250(LC) –VI Dynamic Acera OM, 09/00 Rev. 2 1E---3

SK480 SCHEMATICS
Table of contents Page
ELECTRICAL CIRCUIT DIAGRAMS:
D. ELECTRIC CIRCUIT DIAGRAM (D)..............................................................................................................1E-4
Example of wire color:
SYMBOL COLOR
W L
B Black
G Green
Stripe color (Blue)
L Blue
R Red Base color (White)

W White Abreviations: BZ: Buzzer
Y Yellow SV: Solenoid valve
P Pink SW: Switch
O Orange
SE: Sensor
M: Motor
Br Brown
R: Relay
Lg Light Green
L: Light
Gr Gray
PSV: Proportional solenoid valve
Sb Sky blue D: Diode
V Violet E: Electrical fitting
HYDRAULIC CIRCUIT DIAGRAM.............................................................................................................................1H-1

8 BACK-UP HR-METER
C-6: ENG. CONTROLLER
9 TUNER BACKUP
TUNER (RADIO)
SK480 ELECTRIC CIRCUIT DIAGRAM (A) SW-44: DIAG DISPLAY SW.
4 CONTROLLER
SW-45: MEMORY RESET SW.
CONTROLLER
3B CONTROLLER
CPU BACK UP
CONTROLLER
CONTROLLER
ROOM LIGHT
CIGARETTE
301 Sb B
MECHATRO
MECHATRO
6-71
LIGHTER
328 GrR
ENGINE
3A ENGINE
ENGINE
10 KEY SW.
KAI APPLICABLE YS06U0101 ~ 6-82 302 BrW
2 RELAY
6 HORN
6-37
E-18: Q-ADJ. RESISTOR
1A
1B
7
5
303 BrG
RY
1.25
WG
WV
WY
6-46
YG
RY
YR
G
YB
YL
R
R
Y
E-1: FUSE BOX 3B 6-93
Y
4 16
15A
10A
20A
15A
10A
20A
5A
5A
5A
5A
G 304 GB
51 2W 3A 6-92 6-56 7 ENGINE
CONTROLLER
52 5R E4 (GND) B 305 GL 1
22 6-99 6-58 CHECK
50 1.25L B CONNECTOR
E5 (GND) B
6-100 4
53 5Y 23
B
54 2R
5
55 1.25WP
SHIELD
20A
20A
10A
20A
20A
20A
20A
10A
5A
5A
B
1.25
1.25
1.25
1.25
1.25
1.25
1.25
WG
RW
6-87
WR
WB
RG
WL
RB
OL
RL
W
B 306 R
12
CLUSTER GAUGE 13
WIPER,WASHER 14
15
WORKING LIGHT(F) 16
OPT WORKING 17
AIR CON 18
AIR CON 19
SPARE 20
CONVERTER 11
6-42 6-4 SE-30: ENG.RPM
307 W SENSOR FOR ELECT.
FLASHER,WORKING
LEVER LOCK
6-15
GOVERNOR
SOLENOID
LIGHT (R),ALARM
23 22 SHIELD
LIGHT
SHIELD
6-54
MECHATRO 308 G
6-34
CONTROLLER
309 B
C-1 6-52
C-1 310 R
15-26 R VB
15-25 55 1.25WP 6-33
67 BG
4 3 6-1 311 W W
6-51 POWER GND
54 G
312 LW L
E4 B 6-35 PMW
6-60
60A 60A
54 R 313 BW G
6-43 BUF VIST
E5 W BATTERY BATTERY KEY ON 60 WL 314 YV
60B 60B 60B 6-61 Y
SHIELD 6-36 VCC
B
315 BrY Br
ENGINE START 63 WY 6-53 SIGNAL GND
GOVERNOR
51 G 6-65
700 WG
E2 B 316 BP B
6-9 PULL DOWN
51 R L-14: DIAG LAMP (Red)
R-1: BATTERY RELAY
E3 W 329 LgR 317 V V
6-22 LIMP HOME
SHIELD R21: HEATER 6-91
4 RELAY R
VB
ION G 64 LW
POSITPREHEATIN D-9
TERMINAL
60 WL 59 W W
O A O S 330 Lg POWER GND
4
58 P
T 6-40 318 LY
60B
F C N A 6-44 L PMW
R D-1
F C T
10 1.25WV L-14: DIAG LAMP (Amber) Br
10 B 315 BrY SIGNAL GND
ACC R-3: HEATER RELAY 331 YB Y
66 2OB HEATER 6-45 VCC
M 34 5W
61 GrB ACCEL1 (SIG)
G1 33 2OB 6-73 SHIELD
G2
SENSOR
319 B W
TIMING
ST 63 WY 6-17 GND
M-1: B M E D-4 ACCEL1
SW-1: KEY SW. M 320 W R SIGNAL
STARTER MOTOR (GND) 6-5
66 5L
6-83
781 LR
S Y
4
R-2: R
(PUMP)(RET)
E-2: ALTERNATOR
ADV-RTD
STARTER RELAY 64 LW B 321 BO B
5B C-1: MECHATRO CONTROLLER 6-26
TCV
S E
780 LG
B E
D-3 RW
59 W 66 L 322 BR BW
R R 6-25
30 GY
P P 16-13 323 YR YL
L 65 WR L
6-75 WATER
16-14 TEMP.
R-4: SAFETY RELAY 324 BrL Y SENSOR
6-27
6-6 325 L (5V) YR
E-3: HOUR METER BOOST
326 OL (SIG) LW
6-18 SENSOR
65 WR B ACCEL2 (SIG) 327 GrL (GND) GW
H -M 6-50 6-28
8 ACCEL2 (GND)
6-84
15-24
CHARGE 65 WR
12-13
KEY ON 60 WL
12-15
PREHEATING 61 GrB
12-16
RY 15-12
1A
E2 B (GND)
3 15-25
RY
1B 15-13
C-1: MECHATRO CONTROLLER 19
E3 (GND) B 15-26
4
YG 15-14
8
TO 1E-2
LS03Z00003P1 SK480(LC) –VI Dynamic Acera OM, 10/00 Rev. 0 1E---1
FROM 1E-1
SK480 ELECTRIC CIRCUIT DIAGRAM (B)
KAI APPLICABLE YS06U0101~
917 WR(5V)
11-33
517 P
967 BW(GND)
11-31
900 RB (5V)
11-15 SW-4: SWING PARKING RELEASE SW.
SE-1:BUCKET DIGGING 500 LgR
11-14
950 BrR (GND) N L E
11-13 TIO A AS
O SI ORMELE
901 RL (5V) P N R
TERMINAL
11-16
501 LgW
SE-2:BUCKET DUMP 11-17
951 BL (GND) SV-1: SWING PARKING BRAKE SOL.
11-18 545 Lg
12-18 1
720 PB B
902 W (5V) 2
11-3 701 V
502 LgY 15-22 3
SE-3:BOOM RAISING 11-2
952 BR (GND)
11-1
903 OB (5V) SV-3: TWO-SPEED SELECT SOL.
11-4
503 LO 702 LgB B
SE-4:BOOM LOWERING 11-5 15-21
953 BrW (GND)
11-6
904 OL (5V) SV-2: POWER BOOST SOL.
11-9 703 P B
SE-7:ARM IN 504 PG 15-23
11-8
954 BrL (GND)
11-7
905 OW (5V)
11-10 740 BO
SE-8:ARM OUT 505 PL 15-6
11-11 PSV-B: P2 BY-PASS CUT PROPORTIONAL SOL.
955 Gr (GND) 741 GrR
15-7
11-12
906 YB (5V)
11-21 742 VR
SE-6:SWING RIGHT 506 VY 15-8
11-20 PSV-C: TRAVEL PRIORITY PROPORTIONAL SOL.
743 GrB
956 GrL (GND) 15-9
11-19
907 YG (5V)
11-22 744 BP
15-4
SE-5:SWING LEFT 507 VG 11-23 PSV-D: P1 BY-PASS CUT PROPORTIONAL SOL.
745 PW
957 Br (GND) 15-5
11-24
908 YL (5V) 746 BrG
LOW PRESS.SENSORS 11-27 15-10
SE-9:TRAVEL RIGHT 508 VY PSV-A: ARM VARIABLE RECIRCULATION
11-26 747 YV PROPORTIONAL SOL.
958 BY (GND) 15-11
11-25
909 YR (5V)
POSITION
NORMAL
RELEASE
11-28
SE-10:TRAVEL LEFT 509 Sb
11-29 546 PG
TERMINAL
959 12-19
BG (GND)
11-30
910 WY(5V) SW-5: KPSS MODE RELEASE SW.
12-9 E-4: RESISTOR
SE-26:P1 NEGA-CON. 510 GR B
12-8
960 BY (GND) WB 1
12-7 15 756 BrY
2
911 RG(5V) 3
12-10 749 GrG
SE-27:P2 NEGA-CON. 511 LY 15-18 4
12-11 757 RY
748 VR 5
961 BW(GND) 15-17 PSV-P1: PUMP P1 PROPORTIONAL SOL.
12-12
6 B
912 RW(5V)
13-15 7
SE-28:BACK PRESS. 512 Sb 758 BrB
13-14 8
962 GrG (GND) 9
13-13 751 GY
15-20 10
915 YL (5V) 759 RL
12-3 750 VW 11
515 V 15-19 PSV-P2: PUMP P2 PROPORTIONAL SOL.
SE-22:PUMP P1 12-2 12
965 BrB (GND)
12-1
916 YR (5V)
12-4
C-2: CLUSTER GAUGE 516 L 752 WV
SE-23:PUMP P2 12-5 16-1
966 BrY (GND) 753 GR PSV-E: INDEPENDENT TRAVEL
W 12-6 16-2 PROPORTIONAL SOL.
21-7
SE-14: 13 ENG.WATER
COOLANT THERMO SENSOR TEMP INDICATOR 913 RB (5V)
600 YR 21-3 13-4
513 LgR
SE-20:P1 OPT. 13-5 754 WL
553 VW C-1 963 BW(GND) 16-3
5 13-6
601 BrR 21-4 914 RL (5V) PROPORTIONAL SOL.
FUEL SENSOR 13-3
SE-11:P2 OPT. 514 GO
13-2
964 BL (GND) 13-1
85 1.25WB
8
R-6: 738 WG
B 540 LG 16-7
WORK LIGHT RELAY LCD BACK LIGHT SW-36: INDEPENDENT TRAVEL SW. 13-16 PSV-H: SWING PRIORITY
739 G
16-8 PROPOTIONAL SOL.
B 543 GO
B SW-35: HEAVY LIFT SW. 17-9
A M B 21-6 B 541 PL
SW-3: TWO-SPEED SELECT SW. 12-17
B 542 GrG
SW-21: POWER BOOST SW. 14-11
LCD
580 R
12-20
SE-13: ENG.REVOLUTION SENSOR
FOR MECHATRONIC CONTROLLER 581 W
12-21
SHIELD
12-22
21-2 770 R
14-25
21-1 582 W
14-26
21-8 980 B
14-27
SHIELD
14-28
TO 1E-3
LS03Z00003P1 SK480(LC) –VI Dynamic Acera OM, 10/00 Rev. 0 1E---2
SK480 ELECTRIC CIRCUIT DIAGRAM (C)
FROM 1E-2 C-3: SW.BOX ASSY
32-8 562 O SW-38: WARM-UP SW. KAI APPLICABLE YS06U0101~

547 GB
SW-6: ENG.WATER TEMP.SW. 14-1
32-9 564 LY 982 BG SW-15:
548 GY 17
SW-7: ENG.OIL PRESS.SW. 14-2 CONFLUX/SINGLE SELECT SW.
C-3 OPTION
B 549 Lg
SW-8: AIR FILTER RESTRICTION SW. 14-3 SW-46:
32-12 561 GR
B COUNTER REMOVAL SW.
550 BG OPTION
SW-23: ENG.OIL LEVEL SW. 14-5
32-14 569 LO
B 551 GL 15 SW-29: NIBBLER OPEN SW
SW-24: ENG.COOLANT LEVEL SW. 14-6
32-15 570 YB
16 SW-30: NIBBLER CLOSE SW
B 552 BrL
SW-25: HYD.FLUID LEVEL SW. 14-7
330 32-3 572 GrG 6
930 RG (5V) 31-6 MODE SW-2: SW.ASSY(MODE,BUZZER STOP)
C-1 1 RY 14-18
15-13 19 31-4 32-4 573 V 4
704 LgR BUZZER
14-20 3 STOP
SE-15: FUEL SENSOR 553 VW 705 LG 31-3
C-2 5 14-8 14-21
31-2 85 WB 2 1 B
706 VW R-6 8
B 14-22
MAINTENANCE CONNECTOR 520 LO 707 LY 31-1
12-14 14-23
(Auto-Acceleration connector)
556 BrW 31-5
14-19 32-5 574 PL 6
B 563 O 981 GW(GND) 31-8 WIPER SW-20: SW.ASSY(WIPER,WASHER,LIGHT)
SW-37: HYD.FLUID TEMP.SW. 17-8 14-24 5
32-6 575 LgB WASHER
SW-15 32-7 576 LB 4
982 BG (GND) 31-7 LIGHT
17 3
2 1 B
SW-42: ENG.OIL FILTER SW B

(BY-PASS ALARM). 566 LW
16-15
R-7: WIPER RELAY ASSY

WY
2
PREVENT 2
SPARK WIPER MOTOR RELAY
RELAY
3 80 GrR
1.25RB 1
14
Europe Only 708 LR 6 M-3: WIPER MOTOR
14-12 R-5: HORN RELAY
B 583 VW 540 LG 7 M 5 WG 83 GO B
13-16 14-13 5 E-5: HORN HIGH
WIPER MOTOR
709 GB 84 WR B B
SW-39: OVER LOAD SW-12: OVER LOAD REVERSING RELAY E-6: HORN LOW
DETECTOR SWITCH ALARM SELECTOR SW. B 10 B
4 81 GrB SW-10: HORN SW.
710 Gr 8
14-14
KAI Option L-5: ROOM LIGHT
WINDOW WASHER MOTOR RELAY M-4: WASHER MOTOR
R-10: 9 YB
Breaker Relay 5 82 GO B 9
M
21 711 GrL 9
14-15
3 YL B
3 E-14: CIGARETTE LIGHTER
557 L STOP
14-9
558 G REVERSE
D-11 14-10
220 LW
22
R-12:
ClockWise
Relay
C-4:
AIR CON. E-10: RECEIVER DRIER E-11: AIR COMPRESSOR CLUTCH
R-15:
20 Nibbler PB 559 LW
Open Relay 17-13 SW-19: WIPER INTERLOCK SW. R-6 7 85 WB 150 BP 155 BR
18 1.25WG 1.25B SW-13: AIR CONDITIONER SW.

18
19 RL 151 R
19 24V 24V
R-20: TIMER RELAY 152 G
TXD RXD
153 W
RXD TXD
15 WB 87 YV E D 86 OW B 154 B
15 GND
SHIELD
SW-11:
SAFETY LEVER LOCK SW. SV-4:
OPERATING LEVER LOCK SOL. COOLING
A B UNIT
TIMER
17-11
TO 1E-4
LS03Z00003P1 SK480(LC) –VI Dynamic Acera OM, 10/00 Rev. 0
1E---3 1E---3
C-1: MECHATRO CONTROLLER
KAI SK480 ELECTRIC CIRCUIT DIAGRAM (D) FROM 1E-3 R-6: WORK LIGHT RELAY
WB
L-6: BOOM WORKING LIGHT RIGHT
1.25RW 85 1.25WB WB
16 L-1: BOOM WORKING LIGHT LEFT
WY
2 WB B
7 C-4 L-2: FRAME WORKING LIGHT RIGHT E-7: TUNER AM&FM
ANT.
APPLICABLE YS06U0101~
98 LW
14-16 713 BrY 8 SW-2, SW-20, and C-2 1(+)
Br E-8: SPEAKER LEFT
7(-) 99
FM/AM
100 LR
R-19: FLASHER RELAY L-3: SWING FLASHER & WORKING LIGHT UNIT LEFT YR 2(+) E-9: SPEAKER RIGHT
11 4 101 OB
8(-)
RG 401 GR R YB B
12 9 11 9
BACK UP
R
714 WB
14-17 402 YG Y
Standard for KAI
17-3 715 GW
E-22: DC-DC CONVERTER
403 Br Br B
716 WV OL 96 WG
17-4 4 1GN 12V E-23:12V SOCKET
YB 97 YV
9 24V
B 560 LgY MEM
17-10 B
401 GR GND
SW-9: SWING FLASHER SW.
R Standard for Europe
R
402 YG
Y E-7: TUNER AM&FM
ANT.
98 LW
B 1(+) E-8: SPEAKER LEFT
403 Br 99 Br
7(-)
Br FM/AM
100 LR
96 WG 2(+) E-9: SPEAKER RIGHT
L-4: SWING FLASHER & WORKING LIGHT UNIT RIGHT 4 101 OB
8(-)
97 RY BACK UP B
11 9
SV-5: 17- 6
R-10: BREAKER RELAY BREAKER SOL.
B R-8: Travel Alarm E-13: TRAVEL ALARM
WB 223 YG
15 1.25 RG 88 PG
16
LW 262 LY B
21 WY
B 2 Standard for Europe
SW-43:
Clockwise SW 717 BP
R-9: OPT.WORK LIGHT RELAY
611 LG 1.25WL 90 RY RY B
14-14 17 L-7: CAB WORKING LIGHT FRONT 1
WY 89 BrL B
KAI Option: HAND CONTROL FOR ROTATION RY B L-8: CAB WORKING LIGHT FRONT 2
YG SV-6: SW-26:
214 CLOCKWISE SOL. OPT.WORK LIGHT SW. RY B
R-12: Clockwise Relay L-15: CAB WORKING LIGHT FRONT 3
B
LW 216 O
22 1.25WL 92 RW RW B
BrL L-16: CAB WORKING LIGHT FRONT 4
89
WY 89
B
SW-33: RW B L-18: CAB WORKING LIGHT BACK
D-5 CLOCKWISE SW.
RW B
610 GrL R-11: CAB WORKING LIGHT RELAY 2 L-17: BACK LIGHT
17-12
215 GR SV-7: CCW SOLENOID
D-6 B
M-11: FUEL SUPPLY PUMP
218 P
219 GY B 10A
WV M B
R-13: COUNTER CLOCKWISE 8
SW-34:
RELAY COUNTERCLOCKWISE SW
Optional
SW-40: ROTARY LIGHT SW. L-10: ROTARY LIGHT

KAI Option: HAND CONTROL FOR NIBBLER OPEN/CLOSE
R-15: WL 91 Y B
20 17
NIBBLER OPEN RELAY Optional for KAI
240 STD for Europe

SW-29: NIBBLER OPEN SW. LW B
569 LO 982 BG WY
15 17 2
SW-16: ENG.ROOM LIGHT SW. L-11: ENG.ROOM LIGHT
SV-9:
17-2 750 G NIBBLER OPEN SOL. YB B
9
R-16:
SW-30: NIBBLER CLOSE SW.
NIBBLER CLOSE RELAY
570 YB 982 BG
16 17 241 LO B Optional
SW-47: EXTRA & BREAKER SW. SV-11: EXTRA SOL

WB 94 RL B
SV-10: 15
751 GL NIBBLER CLOSE SOL.
17-5
Optional
LS03Z0000P1 SK480(LC)–VI Dynamic Acera OM, 10/00 Rev. 0 1E---4

Chapter 10 Revised

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Kobelco

Kobelco Construction Machinery America LLC

Dynamic Acera 11/00

Dynamic Acera 11/00

TABLE OF CONTENTS - Continued

28 Item Check .................................................................................................................. 53~57

23. Procedure “A” Adjustment .............................................................................................. 58

Dynamic Acera 11/00

Swing Priority Valve

Dynamic Acera 11/00

High Pressure Negative Control

Dynamic Acera 11/00

Bucket Boom Swing Arm

Bucket Boom Swing Arm

Dynamic Acera 11/00

SK210 Solenoid/Proportional valve block

Code Size Torque N·m (lbf/ft)

Dynamic Acera 11/00

Construction of solenoid valve

➁ Slewing P/B solenoid valve normally open.

Dynamic Acera 11/00

Dynamic Acera 11/00

Not used on (Pos-con)

Dynamic Acera 11/00

Checking resistance on pressure sensors :

Typical low pressure sensor

Components related to engine: Relative to (SK210)

Note: See next page for Pump

Dynamic Acera 11/00

Hyd. Pump Sensors & Solenoids :

Dynamic Acera 11/00

Proportional valve for main pump

Construction of proportional valve :

1. Appearance Non Adjustable

Output pressure of prop. valve (reference) P 2 (kgf/cm2)

Note: Typical of SK210~480, N/A SK 160/ED190 due to Positive Control Sytem

Dynamic Acera 11/00

Left Hand Console :

Auto Indepenent Two Single Heavy

Dynamic Acera 11/00

Right Hand Console :

Dynamic Acera 11/00

Dynamic Acera 11/00

Floorplate Wiring Info.

Actual View : Front of Machine

Dynamic Acera 11/00

24V DC~ 12V DC

Back of Cab View ( Behind operator’s seat)

24V DC ~ 12V DC to DC-DC Converter

Dynamic Acera 11/00

C-1 MAIN CONTROLLER

Dynamic Acera 11/00

C-1 MAIN CONTROLLER

Dynamic Acera 11/00

Mechatro controller (C-1)

Dynamic Acera 11/00

Mechatro controller (C-1)

Note: A commn mechatro controller is used for SK210 to SK330.

4.5a Pin out of Connectors CN11~CN17