PDF Disassembling & Assembling Manual Kobelco SK210-9 Hydraulic Excavator - 7 MB
This specialized manual provides step-by-step procedures for the complete disassembly and assembly of the Kobelco SK210-9 Hydraulic Excavator.
It is an invaluable resource for major overhauls, rebuilds, and component replacements.
The guide includes torque specifications, special tool requirements, and detailed illustrations to ensure every task is performed correctly.
For technicians undertaking significant repairs, this manual is absolutely essential.
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--- Page 31 ---
46. TROUBLE SHOOTING (BY ERROR CODES)
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER
If the fuse of the mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
a. Blown fuse 5A of mechatro controller:
"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller
program is not executed.
b. Blown fuse 20A of mechatro controller:
The controller functions normally but the power supply applied when the controller drives the solenoid, etc.
stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021
46
46-5
--- Page 32 ---
46. TROUBLE SHOOTING (BY ERROR CODES)
Table 46-13
Error code B024
Trouble Boom down pressure sensor's power source is shortcut.
Judging condition The input voltage from boom down pressure sensor is 4.7V or more.
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the event (Current when all operation is in neutral.)
of failure Only on independent operation of boom-up, set output of P1 unload proportional valve to
750mA.
Returned in normal
It returns automatically in normal condition.
condition
Screen No. 5 B-2 BOOM LOWER
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch
SE-4 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom down When B024 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.
Table 46-14
Error code B032
Trouble Arm-in pressure sensor outputs error
After starter switch ON and engine does not start yet. And the input voltage from the sensor
Judging condition
after starter switch ON is in the range of 1.4V or more to less than 4.7V.
46
Symptom The arm-out operability becomes poor.
Control in the event
Normal control
of failure
Returned in normal Not returned automatically under normal condition. Switch the power OFF once and turns on
condition it again.
Screen No. 5 B-3 ARM OUT
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch
SE-8 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between arm-out When B032 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.
46-15
--- Page 33 ---
46. TROUBLE SHOOTING (BY ERROR CODES)
Table 46-30
Error code B093
Trouble Travel right pressure sensor's wiring is disconnected.
Judging condition The input voltage from Travel right pressure sensor is 0.1V or less.
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the event (Current when all operation is in neutral.)
of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves
to 750mA.
Returned in normal
It returns automatically in normal condition.
condition
Screen No. 6 B-9 TRAVEL (R)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Travel right pressure sensor When B093 is cancelled and other error occurs by turning starter switch
SE-9 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between travel right When B093 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.
Table 46-31
Error code B094
Trouble Travel right pressure sensor's power source is shortcut.
Judging condition The input voltage from Travel right pressure sensor is 4.7V or more.
Symptom The Travel right operability becomes poor. 46
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the event (Current when all operation is in neutral.)
of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves
to 750mA.
Returned in normal
It returns automatically in normal condition.
condition
Screen No. 6 B-9 TRAVEL (R)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Travel right pressure sensor When B094 is cancelled and other error occurs by turning starter switch
SE-9 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between travel right When B094 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.
46-25
--- Page 34 ---
46. TROUBLE SHOOTING (BY ERROR CODES)
Table 46-45
Error code C014
Trouble P1 pump pressure sensor's power source is shortcut.
Judging condition The input voltage from P1 pump pressure sensor is 4.7V or more.
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the event
Set P1 pump pressure to 25MPa and control pump.
of failure
Returned in normal
It returns automatically in normal condition.
condition
Screen No. 6 C-1 PUMP P1
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch
SE-22 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 pump When C014 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.
Table 46-46
Error code C022
Trouble P2 pump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P2
Judging condition pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The P2 pump operability becomes poor. 46
Control in the event
Normal control
of failure
Returned in normal Not returned automatically under normal condition. Switch the power OFF once and turns on
condition it again.
Screen No. 7 C-2 PUMP P2
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch
SE-23 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P2 pump When C022 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.
46-35
--- Page 35 ---
46. TROUBLE SHOOTING (BY ERROR CODES)
Table 46-64
Error code E013
Trouble P1 pump proportional valve's wiring is disconnected.
The feed-back value from proportional valve is 100mA or less.
Judging condition
(If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the event
Normal control
of failure
Returned in normal Not returned automatically under normal condition. Switch the power OFF once and turns on
condition it again.
Screen No. 6 E-1 PUMP P1
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch
PSV-P1 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 -Wiring between P1 pump When E013 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 -Mechatro controller Check that the error is corrected after replacement of controller.
46
46-45
--- Page 36 ---
46. TROUBLE SHOOTING (BY ERROR CODES)
Table 46-81
Error code G042
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging condition Engine rpm input is 3000rpm or more. (Only trouble history)
Symptom Operate without problem.
Control in the event
Normal control
of failure
Returned in normal
It returns automatically in normal condition.
condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service diagnosis
Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 - Wiring between engine speed Check wiring for possible failure according to the wiring checking
sensor and controller procedure and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 -Wiring between ECU engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
pressure sensor and controller Especially check wiring for false disconnection and noise included.
4 -Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
5 -Engine controller Check that the error is corrected after replacement of controller.
46
46-55
--- Page 37 ---
47. TROUBLESHOOTING (BY TROUBLE)
No. Sections Contents/normal value Corrective action, others
12 Actual measuring Carry out service -No.9 In case where the reading
current value of P1/ diagnosis. E-1 P1 pump is largely differed from the
P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling
13 Secondary Measure the pump Check that pump proportional Replace proportional valve
pressure of pump proportional valve valve secondary pressure is
proportional valve secondary pressure 2.7MPa or more in right (left) travel
directly in idling full lever and high idling operation
operation. (Ports a3, Right travel: P1 pump proportional
a4) valve
Left travel: P2 pump proportional
valve
14 Main relief Carry out service -See Service Diagnosis Data List Measure the relief
pressure diagnosis Operation No.3 Boom up full lever pressure actually
& relief
15 Check set Check that P1 and Reset or replace
pressure P2 pump pressures
are 32MPa or more
in boom up full lever,
high idling and H
mode operation.
16 Pump regulator Visual check When removing, free from Replace
abnormal resistance against
sliding.
Free from abnormal damage, etc
on outside surface
Spring free from breakage,
damage, etc.
17 Pump Visual check When removing, inside parts Replace
(cylinder block, piston, valve plate,
shaft, etc.) are free from abnormal
resistance against sliding,
abnormal damage, etc.
47
47-5
--- Page 38 ---
47. TROUBLESHOOTING (BY TROUBLE)
No. Sections Contents/normal value Corrective action, others
17 Arm 2 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
P1, P2 pressure is sliding for damage)
high or low. Free from abnormal damage, etc
on outside surface
Spring is free from breakage.
18 Check arm 2 spool Disassembly and Free from abnormal resistance Replace spool assembly
and recirculation investigation against sliding
<Trouble> Spring is free from breakage.
Arm in power is
poor.
19 Check lock valve Visual check Free from abnormal resistance Replace
poppet against sliding (Check on the casing side
<Trouble> Free from abnormal damage, etc for damage)
Both P1, P2 on outside surface
pressures are high.
47
47-15
--- Page 39 ---
47. TROUBLESHOOTING (BY TROUBLE)
(13)Swing drifts on a slope while swing control lever is in neutral position
No. Sections Contents/normal value Corrective action, others
1 Swing pressure Carry out service -Engine stop & starter key ON Check and replace
sensor diagnosis All pilot low pressure sensors are pressure sensor
within range of 0 to 0.1MPa.
2 Remote control Check targeted Check that spool is free from Replace
valve remote control valve abnormal damage and spring is
free from breakage
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF Check parking brake
release switch
4 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 In operation: 4MPa or more
port
5 Swing motor Visual check Disassemble and inspect Replace
(Brake valve/ abnormal wear and scuffing
friction plate)
6 Parking brake Visual check Piston and friction plate do not Replace
have abnormal resistance against
sliding
Free from spring damage
(14)Swing drifts at stopping
No. Sections Contents/normal value Corrective action, others
1 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice. No damage
Pilot pressure is on spool cover (long side) and
low shuttle.
2 Swing pressure Carry out service -Engine stop & starter key ON Replace pressure sensor
sensor diagnosis All pilot low pressure sensors are
within range of 0 to 0.1MPa.
3 Swing relief valve Check set pressure -See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever
Relief pressure is and relief
low.
4 Anti-reaction valve Visual check Free from dirt entering Clean or replace 47
Sliding part should be free from
foreign matter entering, abnormal
damage and wear.
5 Remote control Check targeted Check that spool is free from Replace
valve remote control valve abnormal damage and spring is
free from breakage
6 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against
sliding.
Free from abnormal damage, etc
on outside surface (brake plate
etc)
47-25