YM91ZU0009P1NAR0-sk160 sk190

SHOP MANUAL
EXCAVATOR
SK160LC
ED190LC
YM91ZU0009P1 NA
APPLICABLE:
SK160LC . . . . . . . . YM02U0522~
Issued 12-2006 ED190LC . . . . . . . . YL02U0135~
SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 21 - MECHATRO CONTROL SYSTEM CHAPTER 21 - MECHATRO CONTROL SYSTEM
21.2 SUMMARY OF MECHATRO CONTROL SYSTEM

21.2.1 MECHATRO CONTROL SYSTEM IN GENERAL
DC06E087 Figure 21-1
YM91ZU0009P1 NA Issued 01Dec06 Cst 21-21

21.2.2 BOOM RAISE CONFLUX Boom Raise Conflux

1. Start boom raise operation, and the boom raise operation pilot pressure switches boom spool and boom conflux spool,
and inputs into low pressure sensor.
2. The voltage output by low pressure sensor is input into the Mechatro controller, and the controller processes the pilot
signal and outputs the command corresponding to input to P1, P2 pump and P2 bypass cut valve.
3. Each proportional valve puts out the secondary pressure for the pilot proportional valve according to command values
from the mechatro controller, changes the delivery rates of the P1, P2 pump and switches the P2 bypass cut valve.
4. A pure hydraulic command switches the boom main spool and the boom conflux valve. A mechatro command switches
the P1, P2 pumps and the P2 by pass cut valve. This causes the oil delivered by the P1 pump to combine with that by
the P2 pump at boom raise operation.
21-22 Issued 01Dec06 Cst YM91ZU0009P1 NA

21.2.3 ARM IN RECIRCULATION & SEQUENCE CONFLUX A. Recirculation Cut Control

1. If load increases and the load pressure of the pump rises above set pressure during arm in operation, the output
voltage of the high pressure sensor (SE-23) is put into the mechatro controller. The Mechatro Controller processes pilot
signals and puts out a command current that cuts off the variable recirculation, to the variable proportional valve.
2. The variable recirculation proportional valve puts out secondary pilot pressure according to a command current of the
mechatro controller, brings back the variable recirculation valve to the recirculation cut position and blocks the
recirculation passage.
B. Sequence Conflux Control
1. If load increases and the load pressure rises above set pressure during arm in operation, the mechatro controller
processes a pilot signal and puts out a command current to the travel straight proportional valve and the P1 bypass cut
proportional valve according to the secondary operating pilot pressure.
2. The travel straight proportional valve and the P1 bypass cut proportional valve put out the secondary pilot pressure
according to a command current of the mechatro controller and switches the travel straight valve and the P1 bypass cut
valve.
3. When the travel straight valve is changed over, the parallel passage on the P1 side connects with the parallel passage
on the P2 side. When the P1 bypass cut valve is changed over, the oil delivered by the P1 pump is combined with that
by the P2 pump by arm operation.
C. Recirculation Control
1. Start arm in operation, and arm operation pilot secondary pressure switches arm spool, and is input into the low
pressure sensor.
2. The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro controller processes
the pilot signal and puts out a command current according to the input voltage to the P2 pump proportional valve, and
the variable recirculation proportional valve.
3. Each proportional valve puts out secondary pilot pressure according to a command current from the mechatro
controller and switches the delivery rate at the P2 pump. At the same time it switches the variable recirculation valve of
the control valve.
4. The pure hydraulic command switches the arm main spool. Then a command from the mechatro controller switches
the P2 pump, and the variable recirculation valve. This cause the returned oil of the arm cylinder rod side to be
recirculated to the delivered by the P2 pump.

21.2.4 ARM IN ANTI-CAVITATION CONTROL Arm in Anti-Cavitation Control

1. If the arm in is performed, the secondary pilot pressure for the arm operation switches the arm spool and is put into the
low pressure sensor.
2. An engine speed command put out from the acceleration potentiometer is put into the mechatro controller.
3. The output voltage from the low pressure sensor is put into the mechatro controller, and processes the pilot signal and
puts out a command current according to the input voltage to the P2 pump proportional valve.
4. Also, the mechatro controller puts out a command current to the variable recirculation proportional valve according to
the input voltage from the accel potentiometer.
5. Each proportional valve puts out a secondary pilot pressure according to a command current from the mechatro
controller. This controls the variable recirculation valve to provide a spool stroke according to the engine speed and
changes the recirculation ratio. This holds down cavitation when the engine speed is low and the delivery rate of the
pumps is low.

21.2.5 ARM OUT CONFLUX Arm Out Conflux

1. Start arm out operation. and arm operation pilot pressure switches arm spool, arm conflux spool and is input into low
pressure sensor.
pilot signals and puts out command current according to the input voltage to the P1, P2 pump proportional valves and
the P1 cut proportional valve.
3. Each proportional valve puts out a secondary pilot pressure according to a command current from the Mechatro
controller, changes the delivery rate of the P1and P2 pumps and switches the P1 bypass cut valve of the control valve.
4. A pure hydraulic command switches the arm main spool and arm conflux spool. A mechatro command switches the P1,
P2 pumps and the P1 bypass cut valve. This causes the oil delivered by the P1 pump to combine with the oil delivered
by the P2 pump during arm out operation.

21.2.6 TRAVEL STRAIGHT Travel Straight

1. Start ATTs work operations (boom, arm, bucket, swing) in travel operation (right and left), and the pilot pressure
switches respective spools, and is input into respective low pressure sensors.
NOTE: Boom raise operation is explained here.
2. If mechatro controller receives the input satisfying the following combination shown in Table, the controller determines
it as travel straight, and the travel straight signal turns on.
3. After the travel straight signal has turned on, the signal is input to respective proportional valve corresponding to the
following commands:
A. Travel straight proportional valve command.
Outputs switching command corresponding to boom raise pilot pressure (Selection of the higher ATT pilot pressure
in operation).
B. P1 bypass cut valve command.
The P1 bypass cut valve does not operate if the boom raise operation is performed. During the arm and swing
operation, the higher of the remote control pressures is selected to put out a select pressure.
C. P2 bypass cut valve command.
outputs switching command corresponding to boom raise pilot pressure (Selection of the higher ATT pilot
pressures from C/V on P1 side during operation) and the pressure selected by travel right pilot pressure as high
priority.
(Reference) Operating condition where travel straight signal turns on.

ATT Operation
Boom Bucket Arm Swing
In Travel Right Operation (P1) O O - -
In Travel Left Operation (P2) - - O O

21.2.7 SWING PRIORITY CONTROL Swing Priority Control At Arm In (The forced recirculation position)
1. If swing operation is performed during arm in (or arm in is performed during swing), the secondary pilot pressure for
arm operation switches arm spool and swing spool. Respective pressure is simultaneously put into each low pressure
sensor (SE-7, SE-5).
pilot signals. The command currents according to the input voltage are put out to the following:
A. P1 pump proportional valve (PSV-P1).
B. P2 pump proportional valve (PSV-P2).
C. Travel straight proportional valve (PSV-C).
D. P1 bypass cut proportional valve (PSV-D).
E. Arm variable recirculation Valve (PSV-A).
3. Each proportional valve puts out a secondary pilot pressure according to a command current from the mechatro
controller and switches the delivery rate of the P1 and P2 pumps. At the same time, the pressure moves the P1 bypass
cut spool to full stroke position, and switches the arm variable recirculation valve to the forced recirculation position.
4. If arm in and swing operations are performed simultaneously, the secondary pilot pressure moves sub-spool of arm
spool and consequently passage in arm cylinder head is restricted. The return oil from the rod side is recirculated while
restricted, and flows into head side because of the arm variable recirculation spool is shifted to forced recirculation
position. Consequently the operation pressure of arm cylinder is risen.
5. Delivery oil of P2 pump flows into swing and arm sections of P2 side, but it flows preferentially into swing side because
the operation pressure of arm cylinder is higher than the swing side pressure.
6. On the other hand, as travel straight spool is shifted to travel straight position and P1 bypass cut spool is switched,
delivery oil of P1 pump flows into parallel circuit of P2 side and confluxes with swing circuit, and swing priority is
accelerated.
7. By this operation, delivery oil of P2 pump preferentially flows into swing side which pressure is lower than arm side.
Therefore arm working speed keeps required speed because recirculation oil is used to arm cylinder, and as P1 pump
delivery oil confluxes with swing circuit, swing priority control is more available.
8. If arm in or swing operation are performed, energized signal from mechatro controller to swing parking brake solenoid
valve (SV-1) is cut, and swing parking brake is released.

21.2.8 PRESSURE DRAINING (RELEASING) CONTROL Pressure Draining (Releasing) Control

1. Simultaneously the screen change switch and the buzzer stop switch of gauge cluster are kept pressed for more than
ten seconds, the mechatro controller judges it as Pressure Releasing Control.
2. If the mechatro controller judges it pressure releasing control, the mechatro controller performs the following regardless
of input signals (from operation pilot valve, accel potentiometer, etc.):
A. Puts out a minimum tilting angle command to the pump proportional valve.
B. Puts out command current for pressure releasing control revolution to the governor motor.
C. Puts out a command current for the pressure position switch to the travel straight proportional valve.
D. Puts out standby command current to the P1 bypass cut valve and the P2 bypass cut proportional valve.
3. A command current from the mechatro controller causes the following to occur:
A. The pump proportional valve puts out a secondary pilot pressure to the pump to minimize the tilting angle of the
pump.
B. The governor motor controls the engine revolution to a pressure releasing control revolution.
C. The travel straight proportional valve puts out a secondary pilot pressure to switch the travel straight valve to the
pressure releasing position.
D. The P1 bypass cut valve and the P2 bypass cut proportional valve put out a secondary pilot pressure to hold the P1
bypass cut valve and the P2 bypass cut valve in their standby position.
4. The mechatro controller senses the output voltage of the high pressure sensor of the main pump, judges it as pump
pressure and displays “DRAINING HYD. PRESS” or “FAIL DRAIN HYD. PRESS” on the gauge cluster.
5. Since the travel straight valve is in the pressure releasing position, the oil delivered by each pump is unloaded to the
tank passage. If the operating levers are operated and the spools switched, the pressure remaining in the actuators
may be discharged.

21.2.9 PUMP CONTROL (POSITIVE CONTROL & P-Q CONTROL) A. Positive Control
1. If any operation performed, the secondary pilot pressure switches the spools and is put into the low pressure sensors.
2. The output voltage of the low pressure sensor is put into the mechatro controller which processes pilot signals and put
out command current to the proportional valve of each pump according to the input voltage.
3. The proportional valve of each pump puts out a secondary pilot pressure according to a command current from the
mechatro controller, switches the tilting angle of the pump and controls the delivery rate of the pump.
4. This causes the delivery rate according to a lever stroke to be supplied to the actuator, thus an operating speed
according to a lever stroke is achieved.
B. P-Q Control
1. The output voltage of the high pressure sensor attached to each pump piping is put into the mechatro controller, which
processes pilot signals and computes command current according to input voltage (load pressure).
2. The lower of the command current computed by positive control and the command value (1) computed by P-Q control
is selected and put out to the proportional valve of each pump as a command current.
3. The proportional valve of each pump puts out a secondary pilot pressure according to a command current of the
mechatro controller, switches the tilting angle of the pump and controls the delivery rate of the hydraulic pressure.
4. This increases the load of the actuator, enabling the engine to keep running even if the pump is highly loaded.

21.2.10 STANDBY FLOW CONSTANT CONTROL Standby Flow Constant Control

1. An engine rotation command put out of the accel potentiometer is put into mechatro controller.
2. The mechatro controller processes pilot signals and puts out a command current to the proportional valve of each
pump so as to make the delivery rate of the pump constant when the engine speed is below an intermediate rpm.
3. The proportional valve of each pump puts out a secondary pilot pressure according to a command current of the
mechatro controller, changes the tilting angle of the pump till the engine speed arrives at an intermediate rpm.
4. If the engine speed increases an intermediate rpm, command current from the mechatro controller become constant,
with the result that the delivery rate of each pump rises linearly as the engine speed increases.
5. The result is that the motion of the lever at the start of each operation becomes the same as that when a standby flow
is available. Also, if the engine revolution is increased, the operating feeling according to each revolution is available.

CHAPTER 22 - HYDRAULIC SYSTEM CHAPTER 22 - HYDRAULIC SYSTEM
NOTES

22.3 HYDRAULIC CIRCUITS

22.3.1 SK160LC HYDRAULIC CIRCUIT
22.3.1.1 SK160LC HYDRAULIC SCHEMATIC LEGENDS
Hydraulic Pump Schematic Legend Hydraulic Schematic Legend
Item Description Item Description
a1 Test port P1 pump High Pressure 1 Main Hydraulic Pump
a2 Test port P2 pump High Pressure 2 Main Control Valve
a3 Test port P1 proportional solenoid valve (PSV1) 3 Swing Motor
a4 Test port P2 proportional solenoid valve (PSV2) 4 Travel Motor Assembly
a7 Test port Pilot Pressure 5
Boom Cylinders
A1 Delivery port P1 pump 6
A2 Delivery port P2 pump 7 Arm Cylinder
A3 Delivery port P3 pump 8 Bucket Cylinder
PSV1 Proportional solenoid valve P1 pump 9 Swivel Joint
PSV2 Proportional solenoid valve P2 pump Left Hand Pilot Valve
10
PH1 Pump high pressure port P1 Right Hand Pilot Valve
PH2 Pump high pressure port P2 11 Travel Pilot Valve
SE-9 Pressure Sensor Travel 12 Oil Cooler
SE-10 Pressure Sensor Travel 13 Pilot Filter Manifold
SE-22 High pressure sensor P1 pump 14 Accumulator
SE-23 High pressure sensor P2 pump 15 Suction Strainer
B1 Supply oil for P1 and P2 pumps 16 8 Solenoid Valves
B3 Supply oil for P3 pump 17 Return Filter
Dr1 Drain for pumps P1 and P2 18 By-pass Check Valve
Dr3 Drain for pilot pump P3 19 Tank Breather
P3 Pilot pump 20 Return Check Valve
21 Return Check Valve (Oil Cooler)
22 One Way Check Valve Assembly
23 Independent By-pass Valve
24 Independent By-pass Solenoid
25 Swing Priority Solenoid
26 Slow Return Check
30 Swing Priority / Breaker Option valve
31 Temperature Sensor

22.3.1.2 SK160LC HYDRAULIC SCHEMATIC DIAGRAM

22.3.2 ED190LC HYDRAULIC CIRCUIT

22.3.2.1 ED190LC HYDRAULIC SCHEMATIC LEGENDS
Hydraulic Pump Schematic Legend Hydraulic Schematic Legend

Item Description Item Description
a1 Test port P1 pump High Pressure 1 Main Hydraulic Pump
a2 Test port P2 pump High Pressure 2 Main Control Valve
a3 Test port P1 proportional solenoid valve (PSV1) 3 Swing Motor
a4 Test port P2 proportional solenoid valve (PSV2) 4 Travel Motor Assembly
a6 Test port P4 Dozer pump 5
Boom cYlinders
a7 Test port Pilot Pressure 6
A1 Delivery port P1 pump 7 Arm Cylinder
A2 Delivery port P2 pump 8 Bucket Cylinder
A3 Delivery port P3 pump 9 Swivel Joint
A4 Delivery port P4 pump Left Hand Pilot Valve
10
PSV1 Proportional solenoid valve P1 pump Right Hand Pilot Valve
PSV2 Proportional solenoid valve P2 pump 11 Travel Pilot Valve
PH1 Pump high pressure port P1 12 Oil Cooler
PH2 Pump high pressure port P2 13 Pilot Filter Manifold
SE-9 Pressure Sensor Travel 14 Accumulator
SE-10 Pressure Sensor Travel 15 Suction Strainer
SE-22 High pressure sensor P1 pump 16 8 Solenoid Valves
SE-23 High pressure sensor P2 pump 17 Return Filter
SE-29 Dozer Blade 18 By-pass Check Valve
SE-30 Dozer Blade 19 Tank Breather
B1 Supply oil for P1 and P2 pumps 20 Return Check Valve
B3 Supply oil for P3 pump 21 Return Check Valve (Oil Cooler)
B4 Supply oil for P4 pump 22 One Way Check Valve Assembly
Dr1 Drain for pumps P1 and P2 23 Independent By-pass Valve
Dr3 Drain for pilot pump P3 24 Independent By-pass Solenoid
P3 Pilot pump 25 Swing Priority Solenoid
D1 Dozer Control Valve 26 Slow Return Check
D2 Dozer Solenoid Valve 30 Swing Priority / Breaker Option valve
D3 Dozer Pilot Control Valve

22.3.2.2 ED190LC HYDRAULIC SCHEMATIC DIAGRAM

NOTES

CHAPTER 23 - ELECTRICAL SYSTEM CHAPTER 23 - ELECTRICAL SYSTEM
23.2 ELECTRICAL SCHEMATIC

23.2.1 SK160LC AND ED190LC ELECTRICAL SCHEMATIC DIAGRAMS
23.2.1.1 DIAGRAM A

23.2.1.2 DIAGRAM B

23.2.1.3 DIAGRAM C

23.2.1.4 DOZER ELECTRICAL CIRCUIT - ED190LC ONLY

SECTION 2 - SYSTEMS SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONER SYSTEM CHAPTER 25 - AIR CONDITIONER SYSTEM
25.7.2 WIRING DIAGRAM AND CONNECTORS
DC06F138 Figure 25-1

SECTION 2 - SYSTEMS SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONER SYSTEM CHAPTER 25 - AIR CONDITIONER SYSTEM
NOTES

SECTION 4 - TROUBLESHOOTING SECTION 4 - TROUBLESHOOTING
CHAPTER 41 - MECHATRO CONTROL CHAPTER 41 - MECHATRO CONTROL
41.3 ACTUATOR FOR TROUBLESHOOTING MECHATRO CONTROL

41.3.1 ACTUATOR TABLE
Actuator
Hydraulic
Electric
Control Valve Motor Cylinder Other
Arm Variable Recirculation Proportional Valve
Attachment power boost solenoid valve
P1 Pump Solenoid Proportional Valve
P2 Pump Solenoid Proportional Valve

Swing Parking Brake Solenoid Valve
P2 Bypass Cut Proportional Valve
Safety Lock Lever Solenoid Valve

Travel Straight Proportional Valve
Travel 1-2 Speed solenoid valve
Arm Variable Recirculation Valve

HI Pressure Sensor (P1)
HI Pressure Sensor (P2)
Low Pressure Sensor

Operating Condition
P1 Bypass Cut Valve
P2 Bypass Cut Valve
Travel Straight Valve
Boom conflux valve
Arm Conflux Valve
Travel Right Motor
Boom Lock Valve

Travel Left Motor
Bucket Cylinder
Arm Lock Valve

Boom Cylinder
Arm Cylinder
Swing Motor
Travel Right
Travel Left
Bucket
Swing
Boom
SE SE SE PSV PSV PSV PSV SV SV SV SV PSV PSV
Arm
22 23 1-10 A B C D 1 2 3 4 P1 P2
Boom up inching operation O O O O O O O O O
Boom up full lever operation O O O O O O O O O O O O O
Boom down operation O O O O O O O O
iNDEPENDENT oPERATION
Arm out inching operation O O O O O O O O

Arm out full lever operation O O O O O O O O O O O O
Arm in inching operation O O O O O O O O O O O O
Arm in full lever operation O O O O O O O O O O O O
Heavy duty arm in full lever operation O O O O O O O O O O O O O O O O O
Bucket digging O O O O O O O O
Bucket dump O O O O O O O
Swing operation O O O O O O O O
Travel LH/RH operation (1st speed) O O O O O O O O O O
Travel LH/RH operation (2nd speed) O O O O O O O O O O O

CHAPTER 41 - MECHATRO CONTROL CHAPTER 41 - MECHATRO CONTROL
41.4 TROUBLESHOOTING OUTLINE FOR MECHATRO CONTROL

41.4.1 OUTLINE TABLE
Operating Pilot Secondary Pressure Pressure Sensor Solenoid Proportional Valve

Lever
ATT High pressure Low pressure P1, P2 P2 Travel P1 Arm variable
Position ATT Travel
TRAVEL (Pump) (Pilot) pump bypass cut straight bypass cut recirculation
ATT
Bucket digging
Bucket dump
Approx. Approx.
Boom up
Control lever at full 30 kgf/cm2 24 kgf/cm2 More than More than MIN. MAX. MAX. MAX. MIN.
Boom down
stroke (430 psi) (340 psi) 4.5 V 4.5 V 750 mA 706 mA 513 mA 706 mA 200 mA
Swing left
or more or more
Swing right
Arm in
Arm out
TRAVEL Approx. Approx.
Forward 6.0 kgf/cm2 6.0 kgf/cm2 Approx. Approx. MAX.
Lever at neutral 200 mA 350 mA 200 mA 404 mA
Reverse (85 psi) (85 psi) 0.5 V 0.5 V 350 mA
or less or less
Note: Operating condition - Engine speed at high idle

42.1 TROUBLE DIAGNOSIS

42.1.1 HYDRAULIC SYSTEM
Oil Pressure
Oil Pressure
Relief Valve
Pump Control Valve Swing Motor Travel Motor Cylinder Other valve Proportional Valve Block Main Control Valve Travel Swing
Swing Parking Brake Solenoid Valve

Safety Lock Lever Solenoid Valve
Travel Straight Proportional Valve

Arm Variable Recirculation Valve
Travel 1-2 Speed Solenoid Valve
Arm Variable recirculation Valve

Boost pressure Solenoid Valve
Counter Balance Check Valve
Pilot valve (1-2 Speed Select)

Check Valve of Relief Valve
Component
Pilot Valve (Attachment)

Counter Balance Valve
Trouble
P2 Bypass Cut Valve
P1 Bypass Cut Valve

Travel Straight Spool
Boom Conflux Valve
Arm Conflux Valve
Pilot Valve (Travel)

Load Check Valve
Main Relief Valve

Pilot Relief Valve
Right Shockless
Right Shockless
Reduction Parts
Bucket Cylinder
Boom Lowering
Bucket Digging
E/G Revolution
Boom Cylinder
Left Shockless
Left Shockless
Boom Raising
Parking Brake
Parking Brake
Bucket Dump
Bucket Spool
Arm Cylinder
Swing Spool
Swing Motor
Boom Spool
Travel Spool
Swivel Joint
Pilot Pump
Lock Valve
Arm Spool
Classification
P1 Pump
P2 Pump
Arm Out
Arm In
Group No.
Motor
Device No. 1 2 3 4 5 6 7 8 9 10 11
No operation is possible. O O O O O O O
(1)
Machine operates unexpectedly even though lever is in neutral. O O O O O O O O O O O O O
All Actions O O O O O O O O
Speed is low
Bucket digging and dump O O O O O O O O O O O O

Lower O O O O O O O O O O O
(2) Boom
Raise O O O O O O O O O O O O O O O
Attachment Operation
Arm In O O O O O O O O O O O O O O O O
Arm Out O O O O O O O O O O O O O O
All motions O O O O O O O O O
Power lacks
Bucket digging O O O O O O O O O O O O
(3) Lower O O O O O O O O O O O
Boom
Raise O O O O O O O O O O O O O O
Hydraulic System
Arm In and Out O O O O O O O O O O O O O O O

Fine operation
Bucket digging and dump O O O O O O O O O O O

impossible
Lower O O O O O O O O O O O
(4) Boom
Raise O O O O O O O O O O O O O O
Arm In and Out O O O O O O O O O O O O O O
Travel Operation
(5) Travel 1, 2 speed change impossible. O O O O

(6) Travel speed is low. O O O O O O O O O O O O O O O O O O
(7) Travel power is low. O O O O O O O O O O O O O O O O O O
(8) Machine cannot travel straight or deviates in one direction. O O O O O O O O O O O O O O
(9) Machine does not stop still on a slope. O O O O O O O
(10) Swing motion does not work. O O O O O O O O O O O O
Swing Operation
(11) Swing speed is low. O O O O O O O O O O O O O O O

Swing power is poor. O O O O O O O O O O O O O O O
(12)
Swing motion drifts very large. O O O O O O
Swing motion is not held on a slope. O O O O O O O O
(13)
Abnormal sound is heard during swing motion. O O O O O O

NOTES


43.1.1 ELECTRIC SYSTEM TABLE
C1 Mechatro Controller
Operation Pressure Sensor Power Supply & Other Signal Switch & Relay
Accel motor start point indexing LS
Wiper motor prevent spark relay

Boom lowering pressure sensor
Bucket digging pressure sensor
Engine coolant temperature LS

Boom raising pressure sensor
Bucket dump pressure sensor
Hydraulic oil temperature SW

Travel right pressure sensor
Window washer motor relay

Fuel level sensor thermistor
Engine oil pressure low LS
Swing left pressure sensor
Travel left pressure sensor
P1 pump pressure sensor

Wiper motor reverse relay

Swing parking release LS
Arm out pressure sensor
P1 Opt. pressure sensor

P2 Opt. pressure sensor
Auto idle stop select SW

Swing flasher select SW
Front working light relay

Engine coolant level LS
Arm in pressure sensor
Swing pressure sensor
Electric rotation button

Overload alarm (OPT)
Independent travel LS
Component
Engine speed sensor
ATT power boost SW

Hydraulic oil level LS
Safety lock lever SW
Rear work light relay

Air filter restrictor LS
Wiper motor reverse

Accel potentiometer
Key switch ON/OFF
Wiper interlock SW
Swing flasher relay

Engine oil level LS
Alternator voltage
Travel alarm relay

Key switch Glow
Trouble
Heavy lift
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Connector No. CN11 CN12 CN13 CN14
Classification
1 4 7 10 13 16 19 22 25 28 31 1 4 7 10 13 16 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 12 16 18 19 20 21 22 23 25 26
Group No.
2 5 8 11 14 17 20 23 26 29 32 2 5 8 11 14 17 21 13 17 24 27
Pin No.
3 6 9 12 15 18 21 24 27 30 33 3 6 9 12 15 18 22 14 28
34 19 15
No motion operate. O
1
Machine moves freely where lever is in neutral. O O O O
All operate.
Speed is slow
Only bucket speed is slow.

Only boom raise speed is slow O O O O
2
Motions are slow except boom raise & arm out O O
Only arm in motion is slow. O
Only arm out motion is slow. O
operation Power is poor
All operates.
Bucket digging
3
Boom raising
Arm in
Electric System
impossible
Bucket digging, dump O O O O

Fine
4 Boom raising, lowering O O O O

Arm in, out O O O O O O
5 Travel 1-2 speeds can not be changed.
Travel Operation
6 Travel independent speed is low. O O O O O O O O

7 Travel speed is poor.
ATT travel combined and travel straight are impossible.
8
Travel deviates; zigzags O O O O O O O O O O
9 Machine drifts 0n a downhill and does not stop still on a slope.
10 Swing motion does not work O O
Option Swing Operation
11 Swing speed is slow. O

12 Swing power is poor. O
Swing can not be held on a slope. O O O
13
Swing fine operation impossible
Auto idle stop is not actuated O
14

C1 Mechatro Controller Electrical Equipment

Governor Motor & Proportional Valve & SOL Cluster Gauge Handy Checker E P SV SW SE
Arm variable recirculation proportional valve

Swing parking brake solenoid valve
Electric Nibbler open/close signal

P1 bypass cut proportional valve
Travel straight proportional valve
Arm variable recirculation valve
Travel 2-speed solenoid valve

Mechatro controller back-up
P1 pump proportional valve

Power boost solenoid valve
Mechatro controller ground
PHS TXD2/RXD2 /ground

Governor motor Phase A
Governor motor Phase B

Travel straight proportional valve
Boom lowering pressure sensor
Bucket digging pressure sensor
Engine speed pressure sensor

Component
Boom raising pressure sensor
Bucket dump pressure sensor
P2 side OPT pressure sensor

P1 side OPT pressure sensor
Orbcom & download
Travel right pressure sensor

Travel left pressure sensor

Arm out pressure sensor
Arm in pressure sensor
Orbcom power
Swing pressure sensor

Cluster gauge
ATT power boost SOL
Safety lock lever SOL

Travel 2nd speed SW
Battery relay
Safety lock lever SW

PHS control
Accel potentiometer
PHS power
Travel 2-speed SOL

Swing parking SOL
Trouble
N/A
N/A
N/A
N/A
Fuse box
Battery
Connector No. CN15 CN16 CN17
Classification
1 4 6 8 10 12 15 17 19 21 22 23 24 25 1 5 7 10 15 1 11 12 14 15 19 E E P P P P P P S S S S S S S S S S S S S S S S S S S S S
2 5 7 9 11 13 16 18 20 26 2 6 8 11 16 - 13 - 20 1 4 S S S S S S V V V V W W E E E E E E E E E E E E E E E
Group No.
Pin No. 3 14 3 9 12 10 18 21 V V V V V V 1 2 3 4 3 11 3 4 8 7 1 2 5 9 10 16 22 23 13 11 20
4 13 22
14 A B C D P1 P2
1 No motion operate. O O O O O O O
Machine moves freely where lever is in neutral. O O O O O O O O
All operate. O O O O
Speed is slow
Only bucket speed is slow. O O O O O O

Only boom raise speed is slow O O O O O O
2
Motions are slow except boom raise & arm out O O
Only arm in motion is slow. O O O O O
Only arm out motion is slow. O O O O O
operation Power is poor
All operates. O O
Bucket digging
3
Boom raising
Arm in
Electric System
impossible
Bucket digging, dump O O O O

Fine
4 Boom raising, lowering O O O O

Arm in, out O O O O O O O O
5 Travel 1-2 speeds can not be changed. O O O
Travel Operation
6 Travel independent speed is low. O O O O O O O O O O O

7 Travel speed is poor.
ATT travel combined and travel straight are impossible.
8
Travel deviates; zigzags O O O O O O O O O O
9 Machine drifts 0n a downhill and does not stop still on a slope.
10 Swing motion does not work O O
Option Swing Operation
11 Swing speed is slow. O O O

12 Swing power is poor. O O
Swing can not be held on a slope. O O O
13
Swing fine operation impossible O O
Auto idle stop is not actuated
14

Engine
System
Other Trouble Drop In Output Rotation Trouble Starting Trouble
6
4
Group No.
12
YM91ZU0009P1 NA
changed
Over heat
CHAPTER 44 - ENGINE
SECTION 4 - TROUBLESHOOTING
Idling not smooth

1 Starter does not run
Exhaust gas is black

Medium speed hunting
3 High speed not smooth
power does not shut off

E/G deficiency in output
not disappear after idling)

9 Excessive oil consumption
Issued 01Dec06
10 Excessive fuel consumption
2 Starter runs but does not start
Trouble
Maximum revolution is too high
Cst
Components
Does not reach maximum revolution
7 Knocking occurs after warming-up E/G

5 Accel potentiometer does work properly
11 Engine does not stop when key is turned off

44.1.1 TROUBLE DIAGNOSIS TABLE-ENGINE
Revolution does not change if work modes are
Engine is stop the moment the key is turned OFF, but

8 Exhaust gas is white (In cold state, white smoke does
o
Fuel not filled up or leaking
o
Oil cooler element clogged
o
o
o
o
o
Fuel system trouble (air or water entered)
o
Oil filter clogged
o
o
o
o
Air cleaner clogged
Filters
o
o
Gauze filter clogged
o
o
o
o
o
Fuel filter clogged
o
V-belt slipped
Inspection
o
Breather hose bent
o
Cooling water level
o
o
Fuel is of poor quality or leaking
o
o
Specific gravity of battery fluid

Fluid
o
o
o
o
o
Viscosity of engine oil is not suited or level not proper
o
o
o
o
o
o
Poor quality of fuel is used or heavy oil is used
o
o
o
o
o
Blow-by gas is much
o
o
o
o
Gas leaks from valve and gasket
o
o
engine oil is too much
Gas/Fluid
Service man
Visual Check
o
o
Battery fluid level

o
Fuse
o
o
Starter key
o
o
Battery relay
o
o
o
Mechatronic controller
o
o
Mechatro “A” adjustment

Machine Side
o
o
o
o
o
o
stepping motor
o
o
Accel potentiometer
o
o
Connector and electric wiring

o
Safety relay
Electrical fittings
Glow relay
o
Glow
o
Starter motor
Engine Side
Starter relay
Alternator
o
o
Feed pump function

o
o
o
o
o
o
o
Check injection timing

o
o
o
o
o
o
o
Inspect nozzle
Fuel System
o
o
o
o
o
o
o
o
Injection pump
o
o
o
o
Valve clearance
o
o
Valve spring is fatigued

Intake/
System
Exhaust
Air cleaner & muffler

o
o
o
Check if engine oil level goes into combustion chamber

o
Check relief valve

Oil strainer clogged
system
Lubrication
Fuel is mixed
o
o
o
o
o
Check thermostat
o
Oil cooler element damaged

Cooling
Engine Dealer
o
o
o
o
o
o
Compressor pressure low

o
o
o
o
Control rack movement not smooth

o
o
o
o
Governor spring fatigued

o
Crank shaft oil seal no good

o
o
Piston liner worn

o
o
o
o
o
Piston ring worn

o
o
o
Valve spring fatigued

Main structure
Internal parts stuck

o
o
Check fuel feed

o
o
o
o
Head gasket faulty

o
Flywheel gear damaged

SECTION 4 - TROUBLESHOOTING
CHAPTER 44 - ENGINE
44-3
CHAPTER 44 - ENGINE CHAPTER 44 - ENGINE
NOTES

KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. North American English
245 E NORTH AVENUE Part Number YM91ZU0009P1 NA
CAROL STREAM, IL 60188 U.S.A. Printed in U.S.A. • Bur

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SHOP MANUAL

21.2 SUMMARY OF MECHATRO CONTROL SYSTEM

DC06E087 Figure 21-1

YM91ZU0009P1 NA Issued 01Dec06 Cst 21-21

21.2.2 BOOM RAISE CONFLUX Boom Raise Conflux

DC06E088 Figure 21-2

21-22 Issued 01Dec06 Cst YM91ZU0009P1 NA

21.2.3 ARM IN RECIRCULATION & SEQUENCE CONFLUX A. Recirculation Cut Control

DC06E089 Figure 21-3

YM91ZU0009P1 NA Issued 01Dec06 Cst 21-23

21.2.4 ARM IN ANTI-CAVITATION CONTROL Arm in Anti-Cavitation Control

DC06E090 Figure 21-4

21-24 Issued 01Dec06 Cst YM91ZU0009P1 NA

21.2.5 ARM OUT CONFLUX Arm Out Conflux

DC06E091 Figure 21-5

YM91ZU0009P1 NA Issued 01Dec06 Cst 21-25

21.2.6 TRAVEL STRAIGHT Travel Straight

(Reference) Operating condition where travel straight signal turns on.

DC06E092 Figure 21-6

21-26 Issued 01Dec06 Cst YM91ZU0009P1 NA

DC06E093 Figure 21-7

YM91ZU0009P1 NA Issued 01Dec06 Cst 21-27

21.2.8 PRESSURE DRAINING (RELEASING) CONTROL Pressure Draining (Releasing) Control

DC06E094 Figure 21-8

21-28 Issued 01Dec06 Cst YM91ZU0009P1 NA

DC06E096 Figure 21-10

DC06E095 Figure 21-9

YM91ZU0009P1 NA Issued 01Dec06 Cst 21-29

21.2.10 STANDBY FLOW CONSTANT CONTROL Standby Flow Constant Control

DC06E098 Figure 21-12

DC06E097 Figure 21-11

21-30 Issued 01Dec06 Cst YM91ZU0009P1 NA

YM91ZU0009P1 NA Issued 01Dec06 Cst 22-9

22.3 HYDRAULIC CIRCUITS

22-10 Issued 01Dec06 Cst YM91ZU0009P1 NA

22.3.1.2 SK160LC HYDRAULIC SCHEMATIC DIAGRAM

DC06E058 Figure 22-1

22.3.2 ED190LC HYDRAULIC CIRCUIT

Hydraulic Pump Schematic Legend Hydraulic Schematic Legend

22-12 Issued 01Dec06 Cst YM91ZU0009P1 NA

22.3.2.2 ED190LC HYDRAULIC SCHEMATIC DIAGRAM

DC06E059 Figure 22-2

22-14 Issued 01Dec06 Cst YM91ZU0009P1 NA

23.2 ELECTRICAL SCHEMATIC

DC06E066 Figure 23-1

YM91ZU0009P1 NA Issued 01Dec06 Cst 23-7

DC06E067 Figure 23-2

23-8 Issued 01Dec06 Cst YM91ZU0009P1 NA

DC06E068 Figure 23-3

YM91ZU0009P1 NA Issued 01Dec06 Cst 23-9

23.2.1.4 DOZER ELECTRICAL CIRCUIT - ED190LC ONLY

DC06E069 Figure 23-4

23-10 Issued 01Dec06 Cst YM91ZU0009P1 NA

25.7.2 WIRING DIAGRAM AND CONNECTORS

DC06F138 Figure 25-1

YM91ZU0009P1 NA Issued 01Dec06 Cst 25-37

25-38 Issued 01Dec06 Cst YM91ZU0009P1 NA

41.3 ACTUATOR FOR TROUBLESHOOTING MECHATRO CONTROL

Arm Variable Recirculation Proportional Valve

Attachment power boost solenoid valve

P1 Pump Solenoid Proportional Valve

P2 Pump Solenoid Proportional Valve

P1 Bypass Cut Proportional Valve

Safety Lock Lever Solenoid Valve