Kobelco 115DZSR Bucket Dump Sensor: Troubleshooting and Solutions

[MikePhua]

The Kobelco 115DZSR is a compact yet powerful excavator widely used in construction and other heavy industries. Its high efficiency and versatile capabilities make it an ideal choice for various digging, lifting, and moving tasks. However, like any complex machine, the Kobelco 115DZSR may experience issues with its sensors and electronics. One such issue that operators may encounter is a faulty bucket dump sensor.
In this article, we will discuss the common problems associated with the bucket dump sensor on the Kobelco 115DZSR, how to troubleshoot the issue, and provide solutions to fix it. Additionally, we will explore some preventive maintenance tips that can help avoid sensor problems and ensure the continued smooth operation of your excavator.
What is the Bucket Dump Sensor and Its Role in the Kobelco 115DZSR?
The bucket dump sensor is an integral component of the excavator's hydraulic system. It is designed to monitor the position of the bucket during operation, especially when dumping materials. This sensor ensures that the bucket is correctly aligned and in the proper position to release its contents safely and efficiently.
In modern excavators like the Kobelco 115DZSR, sensors like these are connected to the machine's electronic control unit (ECU), which processes the sensor's data and adjusts the hydraulic functions accordingly. When the bucket dump sensor works correctly, the machine can control the dumping action with precision, preventing spillage or damage to the load. It also helps to prevent over-rotation or misalignment, which could lead to inefficient operation or potential damage to the hydraulic system.
Common Issues with the Bucket Dump Sensor

1. Sensor Malfunction or Failure:
   Over time, sensors can wear out or become damaged due to regular use or harsh working conditions. A common sign of a malfunctioning bucket dump sensor is inaccurate readings or erratic behavior during the dumping process. The sensor might fail to properly detect the bucket's position, causing issues with load release.
   
2. Wiring Issues:
   The sensor relies on electrical connections to send signals to the ECU. If there are issues with the wiring — such as frayed wires, loose connections, or corrosion — the sensor may not function correctly. A break or short in the wiring can interrupt communication between the sensor and the control unit, leading to the malfunction of the dumping mechanism.
   
3. Contamination or Physical Damage:
   The bucket dump sensor is located in a vulnerable area of the machine, and it can become exposed to dirt, debris, or harsh weather conditions. Over time, contaminants like dirt and dust can build up on the sensor, causing it to provide false readings. Additionally, the sensor might be physically damaged due to impacts or wear from the surrounding environment.
   
4. Incorrect Calibration:
   The bucket dump sensor may lose its calibration over time or after a major repair. If the sensor is not calibrated correctly, it can lead to misalignment or improper functioning during the bucket’s dumping action. In such cases, recalibrating the sensor is necessary to restore proper performance.
   
5. Faulty ECU or Software Issues:
   In some cases, the issue may not lie with the sensor itself but with the ECU or the software that interprets the sensor data. A malfunctioning ECU or a software glitch can cause incorrect signals to be sent or misread, affecting the sensor's performance and operation.
   

Diagnosing and Troubleshooting the Bucket Dump Sensor Issue

1. Check for Warning Lights or Error Codes:
   Many modern excavators, including the Kobelco 115DZSR, come equipped with onboard diagnostic systems that can detect sensor problems. If there is a malfunction with the bucket dump sensor, the machine may display a warning light on the dashboard or show an error code. Refer to the machine's operator manual to interpret these codes and narrow down the problem.
   
2. Inspect the Sensor and Wiring:
   Visually inspect the bucket dump sensor for any signs of physical damage or contamination. Look for dirt buildup, cracks, or bent components. Check the wiring connections leading to the sensor, ensuring there are no loose, frayed, or corroded wires. If any issues are found with the wiring, repair or replace the damaged sections as needed.
   
3. Test the Sensor:
   Use a multimeter to test the sensor's output signal. By measuring the voltage and comparing it to the manufacturer’s specifications, you can determine whether the sensor is functioning properly. If the sensor is producing an abnormal or inconsistent signal, it may need to be replaced.
   
4. Check the ECU and Software:
   If the sensor appears to be in good condition, but the problem persists, the issue may be related to the machine's ECU or software. In this case, consult the machine’s service manual for diagnostic procedures or consult a qualified technician who can perform a thorough ECU diagnostic test to rule out software issues.
   

Solutions to Fix the Bucket Dump Sensor Issue

1. Replacing the Sensor:
   If the sensor is found to be malfunctioning or damaged, the only solution is to replace it. Always ensure that you use the correct replacement sensor designed for the Kobelco 115DZSR to ensure compatibility. After replacing the sensor, recalibrate it according to the manufacturer’s specifications.
   
2. Repairing or Replacing Damaged Wiring:
   If the issue is related to the wiring, the damaged sections should be repaired or replaced. Ensure that all connections are tight and secure, and use high-quality wiring and connectors designed for heavy equipment. If there is corrosion, clean the connectors and replace any affected parts.
   
3. Cleaning the Sensor:
   If the problem is due to dirt or debris buildup on the sensor, carefully clean the sensor using a non-abrasive cloth. Ensure that the sensor is not physically damaged during cleaning. Regular cleaning of the sensor can help prevent future issues caused by contamination.
   
4. Recalibrating the Sensor:
   If the sensor is still in good condition but has lost its calibration, you will need to recalibrate it. Refer to the machine’s manual for specific calibration instructions. In some cases, this may involve adjusting the sensor’s alignment or resetting the electronic control unit to factory settings.
   
5. ECU Repair or Replacement:
   If the ECU is found to be faulty, it may need to be repaired or replaced. An experienced technician should handle this, as working with the ECU requires specific knowledge of the machine's electronic systems.
   

Preventive Maintenance to Avoid Future Bucket Dump Sensor Issues

1. Regularly Inspect the Sensor:
   Schedule routine inspections of the bucket dump sensor to identify any early signs of damage or wear. Checking the sensor regularly can help you address minor issues before they develop into more serious problems.
   
2. Keep the Sensor Area Clean:
   Make sure that the sensor is kept clean and free from dirt, debris, and other contaminants. Consider installing protective covers or shields to protect the sensor from exposure to the elements.
   
3. Monitor Fluid and Hydraulic Systems:
   Regularly check the hydraulic systems that power the bucket’s dumping action. Ensure that the fluid is at the correct level and that the system is functioning properly. Poor hydraulic performance can sometimes affect the sensor's operation, so maintaining the entire hydraulic system is essential.
   
4. Use the Correct Calibration Procedures:
   When performing maintenance or after major repairs, always ensure that the sensor is properly calibrated to the manufacturer's specifications. Proper calibration ensures that the sensor will function accurately and reliably.
   

Conclusion: Ensuring Optimal Performance of the Kobelco 115DZSR
A malfunctioning bucket dump sensor can significantly impact the performance of the Kobelco 115DZSR excavator, especially when it comes to efficient and safe dumping. By understanding the common causes of sensor issues and following the recommended troubleshooting steps, operators can quickly identify and resolve problems. Regular maintenance, cleaning, and calibration of the bucket dump sensor, along with a proactive approach to repairs, will ensure that your Kobelco 115DZSR remains in optimal working condition and continues to deliver high performance for years to come.