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Page 9-1
TABLE OF CONTENTS
1. VERIFICATION OF ENGINE RPM .................................................................................................... 3
A.Machine Preparation Procedures .................................................................................................... 3
2. ENGINE SPEED MEASURED WITH
SERVICE DIAGNOSTICS (28 ITEM CHECK) ................................................................................. 3
3. HYDRAULIC OIL CAUTIONS ........................................................................................................... 4
A. Checking the Main Relief Setting Using Service Diagnostics ( 28 Item Check) ........................... 4
B. Tools & Equipment Required for Checking and
Adjusting of Pilot and Main Relief Valves ...................................................................................... 4
4. PILOT CIRCUIT ................................................................................................................................
A. Machine Preparation Procedures .................................................................................................
B. Pilot Relief Valve Pressure Measurement Procedures .................................................................
C. Pilot Relief Valve Adjustment Procedures ....................................................................................
5
5
5
5
Page 9-2
FIGURE 5.1
ENGINE EMERGENCY
STOP CONTROL
SAFETY LOCK
LEVER IN LOCK
POSITION
MODE
H
H-1 ACCEL. VOLT. 4.2V
POS
100%
ECU OUTPUT 0.5V
FIGURE 5.2
Work
Mode
22:00
RPM 1008
H
Buzzer
Stop
Switch
Screen
Change
Switch
Select
Switch
Note: Sk350-8
Cluster Gauge Shown
Auto Accel
Switch
FIGURE 5.3
FIGURE 5.4
Page 9-3
PILOT CIRCUIT
3. PILOT CIRCUIT
A. Machine Preparation Procedures
1. Note: Verify Engine RPM before proceeding.
2. Confirm that the machines front attachment is in the oil check position.
Verify Hyd. oil level. See Figure 7.1.
3. Release hydraulic tank pressure by depressing relief valve stem item c on
the pressure relief valve. See Figure
7.2.
4. Open Main Pump Access Door and
remove the PF1/4 test Port Plug (a5)
from Output Port on Pilot System Gear
Pump and install 105kg/cm2 (1,000 psi)
Pressure Gauge. See Figure 7.3.
SK350 ILLUSTRATED
FIGURE 7.1
YM104ReleaseHydTankPres
FIGURE 7.2
P3 TEST PORT
(Port a5 )
A3
PSV2
(PSV1)
Dr3
B3
Page 9-4
B1
a1
a2
PILOT SYSTEM
GEAR PUMP
FIGURE 7.3
Note: All test ports on pump are PF1/4 BSPP
(Never install test port that are NPT, or pump
damage will occur.
NPT
PILOT CIRCUIT
5. Place all pilot controls in neutral, read
and record the 70kgf/cm2 (1000 psi)
pressure gauge at the P3 pump, a7
pressure test port. See Figure 7.3.
Compare to chart for specific model
being tested.
C. Pilot Relief Valve Adjustment Procedures
1. With safety lock lever in the locked (up)
position. Locate the Pilot Relief Valve
mounted on the bottom of the P3 Pilot
Pump Assembly. See Figure 7.4.
2. Loosen the adjusting screw locknut
with a 24mm spanner. See Figure 7.4.
3. Adjust using a 6mm allen until specified pressure according to proper chart
for specific machine being adjusted is
achieved.
4. After correct pressure is obtained,
tighten adjusting screw locknut, tightening torque 3.0 kgfm2 (22ft.lb). See
Figure 7.4.
5. Verify pressure after tightening locknut.
D. Pilot Relief Pressure Check at low Idle
1. With safety lock lever in the locked (up)
position. Locate and place throttle potentiometer in low Idle position with
engine still idling.
2. Place all pilot controls in neutral, read
and record off the 70kgf/cm2 (1000 psi)
pressure gauge at the P3 pump, a7
pressure test port.
3. Pilot Pressure should not drop below
500 psi (35kgf/cm2)if pilot pressure
drops below pressure level pilot pump
or pilot relief valve is damage or worn,
replace or repair to correct problem.
LOCKNUT
HEX
24mm
BOTTOM VIEW
OF P3 PUMP
ADJUSTING
SCREW 6mm
FIGURE 7.4
Conversions Notes: Kg/cm 2 x 14.224 = PSI
Mpa x 145.0377 = PSI
Page 9-5
WARNING
BE EXTREMELY CAUTIOUS WHILE RELEASING
HYDRAULIC TANK PRESSURE OR REMOVING
LINES AND FITTINGS, VAPORS AND OIL MAY BE
EXTREMELY HOT.
WEAR APPROVED SAFETY CLOTHES, SHOES,
GLOVES AND HARD HAT WHEN PERFORMING
ANY MAINTENANCE OR TEST PROCEDURES.
PILOT
CONTROL
FOR BUCKET
AND BOOM
FIGURE 6.1
Note: To Change MPa to PSI multiply MPa
pressure x 145.0377 = Psi
BUZZER STOP
SWITCH
FIGURE6.2
07.V 0P
FIGURE 6.3
Mark 8 05/08 Rev. 05
WARNING
FIGURE 8.1
YM104ReleaseHydTankPres
FIGURE 8.2
P1 Pump
a1 PORT
P2 Pump
a2 PORT
FIGURE 8.3
DEPRESS THIS SIDE
TO TURN " ON "
DEPRESS THIS SIDE
TO TURN "OFF"
Note :
HEAVY LIFT
SWITCH
"ON"
FIGURE 8.4
Page 9-7
WARNING
CONFIGURATION
FOR SK210 THRU
SK485
PLACE
THROTTLE
CONTROL
IN "HI"
FIGURE 9.1
DEPRESS THIS SIDE
TO TURN " ON "
DEPRESS THIS SIDE
TO TURN "OFF"
Note :
HEAVY LIFT
SWITCH
"ON"
FIGURE 9.2
MAIN
RELIEF
MR1
FRONT OF
MACHINE
SK350-8 MAIN
CONTROL VALVE
FIGURE 9.3
HEAVY LIFT
(POWER BOOST)
ADJUSTMENT
SCREW 19mm
NOTE
Turning Heavy lift Power Boost Adjusting Screw
Clockwise One turn
Increases Pressure Approximately
108 kgf/cm2 180 (2560 psi)
HEAVY LIFT
(POWER BOOST)
ADJUSTMENT
LOCKNUT 32mm
ATTACHMENT
MAIN RELIEF
VALVE MR1
REFERENCE SK210
FIGURE 9.4
Page 9-8
WARNING
WORK
MODE
H
H
MODE
SWITCH
FIGURE 10.1
DEPRESS THIS SIDE
TO TURN " ON "
DEPRESS THIS SIDE
TO TURN "OFF"
Note :
HEAVY LIFT
SWITCH
"OFF"
FIGURE 10.2
MAIN
RELIEF
MR1
FRONT OF
MACHINE
SK350-8 MAIN
CONTROL VALVE
FIGURE 10.3
NORMAL
ADJUSTMENT
LOCKNUT 22mm
NOTE
Turning Normal Adjusting Screw Clockwise One
turn
Increases Pressure Approximately
108 kgf/cm2 180 (2560 psi)
NORMAL
ADJUSTMENT
6mm ALLEN
ATTACHMENT
MAIN RELIEF
VALVE MR1
REFERENCE SK210
FIGURE10.4
Mark 8 05/08 Rev. 05
Page 9-9
MEASURING
CONDITION,
FUNCTION
Std Value
Low er Limit Upper Limit
113
135
140
2350
950
1000
2350
2350
2150
210
2450
1050
1100
2450
2450
2250
2400
1000
1050
2400
2400
2200
Units:
f
Throttle @ "HI"- Idle
Throttle @ "LO"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Units:
High Idle
50
711
782
Low Idle
P1
Main
Heavy Lift
Relief
P2
Valve
Normal
P1
Pressure
Relief
P2
40
350
350
385
385
569
5476
5476
4978
4978
782
5618
5618
5078
5078
Pilot Pressure
Note:
Port
Relief
Valve
Pressure
for
Attachme
nts
(Values in
Parenthes
is () are
Actual
Port
Port relief valves are set at a precise flow rate and cannot be
adjusted on the machine. Port relief valves can be checked for
excessive leakage by increasing the value of main relief valve. (turn
main relief clockw ise one complete turn). Check at low idle, heavy
lift on (if Applicable). Refer to chart below for port relief valve.
Boom
Arm
Bucket
Swing
Head
MR1
4907
5760
Rod
Head
Rod
Head
Left
Right
MR1
MR1
MR1
MR1
310 (285)
310 (285)
MR1
MR1
MR1
MR1
4907
4907
4836
4907
4054
4054
4978
4978
4978
4978
5760
5476
5476
5760
4907
4907
5191
5191
5191
5191
RH Fw d
Travel
RH Rev
LH Fw d
LH Rev
psi
P3 Pump
a5 PORT
Dr1
(Dr1)
P1 Pump
a1 PORT
Dr1
(Dr1)
P2 Pump
a2 PORT
B3
a1
a2
a3
Page 9-10
113
135
140
2250
950
1000
2350
2350
2150
210
2450
1050
1100
2450
2450
2250
2400
1000
1050
2400
2400
2200
Pilot Pressure
Low Idle
P1
Main Relief Heavy Lift
P2
Valve
P1
Normal
Pressure
Relief
P2
Note:
Units:
f
Throttle @ "HI"- Idle
Throttle @ "LO"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Units:
711
711
782
569
5476
5476
4978
4978
569
5476
5476
4978
4978
782
5618
5618
5078
5078
Port relief valves are set at a precise flow rate and cannot be
adjusted on the machine. Port relief valves can be checked for
excessive leakage by increasing the value of main relief valve.
(turn main relief clockw ise one complete turn). Check at low idle,
heavy lift on (if Applicable). Refer to chart below for port relief
valve.
Function
Boom
Port Relief
Valve
Pressure
for
Attachmen
ts
MEASURING
CONDITION,
FUNCTION
Std Value
Arm
Bucket
Swing
Std Value
psi
Head
5760
4907
5760
Rod
Head
Rod
Head
Left
Right
5760
5476
5476
5760
4054
4054
4978
4978
4978
4978
4907
4907
4836
4907
4054
4054
4978
4978
4978
4978
5760
5476
5476
5760
4907
4907
5191
5191
5191
5191
RH Fw d
Travel
RH Rev
LH Fw d
LH Rev
Swing, relief
P3 Pump
a5 PORT
Dr1
(Dr1)
P1 Pump
a1 PORT
Dr1
(Dr1)
P2 Pump
a2 PORT
B3
a1
a2
a3
Page 9-11
Radiator Surface
ENGINE
RPM
STANDARDS
FOR
TESTING
SPECIFICATION
975~1025 RPM
H - Mode
1970~2030 RPM
Display change switch on
gauge cluster
S - Mode
A - Mode
Auto - Accel
COMPONENT
Gear Pump
PRIMARY PRESSURE
HEAVY LIFT
Main Pump
Normal Relief
Main Pump
MAIN
RELIEF
NOTE:
PORT
RELIEFS
a5
a1
a2
a1
a2
BOOM
(DO NOT ADJUST)
ROD
HEAD
ARM
(DO NOT ADJUST)
ROD
Main Pump
HEAD
ROD
Main Pump
HEAD
Left Main Pump
Right
BUCKET
(DO NOT ADJUST)
SWING
AUXILIARY */
All
**
Main Pump
1020~1080
MPa
PSI
Adj PSI
point Measuring Condition
P3
37.3~38.8 5400~5627
MR1
33.8~35 4900~5076
MR1
5~5.5
725~800
COMPONENT
a3
P2 pump
proportional valve
a4
Pump Regulation
a1 33.8~39.7 4902~5760
a2 33.8~37.8 4977~5474
OR8
OR7
33.3~37.8 4829~5480
33.8~39.7 4977~5760
OR1
OR2
OR5
OR6
Bucket Out
Bucket In
a1
a2
a2
a2
28.9~35 4195~5076
28.9~35 4195~5076
R Main Pump
a1
a1
33.8~35.8 4902~5192
33.8~35.8 4902~5192
F
R
a2
a2
33.8~35.8 4902~5192
33.8~35.8 4900~5192
Gauge
Cluster
P2 Pump
a2 PORT
Boom Down
Boom Up
GAUGE @
P1 pump
proportional valve
OR4
OR3
MPa
mA
No.07
0.2~0.5
2.0~3.0
330~360
630~770
Neutral
activated
No.07
0.2~0.5
2.0~3.0
330~360
630~770
Neutral
activated
SCREEN #
Service Diag.
RH
LH
P1 Pump
a1 PORT
33.8~37.8 4902~5480
33.8~39.7 4902~5760
a1
a2
Main Pump
F
TRAVEL
(DO NOT ADJUST)
SYSTEM
1970~2030
N/A
Take Sample
Ambient Temperature
-10C ~ 50C
(14F ~ 122F)
Port relief valves are set at a precise flow rate and cannot be adjusted on the machine. Port relief valves can be
checked for excessive leakage by increasing the value of main relief valve. (turn main relief clockwise one complete
turn). Check at low idle, heavy lift on (if Applicable). Refer to chart below for port relief valve.
PF 1/4
PILOT CIRCUIT
1770~1830
N/A
N/A
MEASURING
CONDITION,
FUNCTION
1970~2030
B- Mode
SYSTEM
140~194F
Low Idle
Adjustment
Point
Service
Connector
Installed
INSPECTION ITEM
NOTE :
Take Measurements
H-Mode Engine at "HI" Idle.
Levers in neutral for neutral
reading,
then activate circuit to take
activated readings
Power Shift:
*** ...All controls in neutral
** ....Front attachment stalled
* .....Both travel motors stalled
0~10 mA
0~10 mA
10~30 mA
Page 9-12
Radiator Surface
ENGINE
RPM
STANDARDS
FOR
TESTING
SPECIFICATION
970~1030 RPM
H - Mode
2070~2130 RPM
Display change switch on
gauge cluster
S - Mode
A - Mode
Auto - Accel
MAIN
RELIEF
NOTE:
PORT
RELIEFS
COMPONENT
Gear Pump
PRIMARY PRESSURE
HEAVY LIFT
Main Pump
Normal Relief
Main Pump
a5
a1
a2
a1
a2
BOOM
(DO NOT ADJUST)
ROD
HEAD
ARM
(DO NOT ADJUST)
BUCKET
(DO NOT ADJUST)
SWING
AUXILIARY */
All
**
Main Pump
1020~1080
MPa
PSI
Adj PSI
point Measuring Condition
P3
37.3~38.8 5400~5627
MR1
33.8~35 4900~5076
MR1
5~5.5
725~800
COMPONENT
a3
P2 pump
proportional valve
a4
Pump Regulation
a1 33.8~39.7 4902~5760
a2 33.8~37.8 4977~5474
OR8
OR7
a1
a2
a2
a2
OR1
OR2
OR5
OR6
Bucket
Bucket
Bucket
Bucket
33.3~37.8 4829~5480
33.8~39.7 4902~5760
27.5~32.5 3988~4713
27.5~32.5 3988~4713
Out
In
Ground,Stall Swing
Ground, Stall Swing
R Main Pump
33.8~35.8 4902~5192
33.8~35.8 4902~5192
F
R
a2
a2
33.8~35.8 4902~5192
33.8~35.8 4900~5192
Gauge
Cluster
P2 Pump
a2 PORT
Boom Down
Boom Up
a1
a1
GAUGE @
P1 pump
proportional valve
OR4
OR3
MPa
mA
No.07
0.2~0.5
2.0~3.0
330~360
Neutral
activated
630~770
No.07
0.2~0.5
2.0~3.0
330~360
630~770
Neutral
activated
SCREEN #
Service Diag.
RH
LH
P1 Pump
a1 PORT
33.8~37.8 4902~5480
33.8~39.7 4902~5760
a1
a2
Main Pump
F
TRAVEL
(DO NOT ADJUST)
SYSTEM
2070~2130
N/A
Take Sample
Ambient Temperature
-10C ~ 50C
(14F ~ 122F)
Port relief valves are set at a precise flow rate and cannot be adjusted on the machine. Port relief valves can be
checked for excessive leakage by increasing the value of main relief valve. (turn main relief clockwise one complete
turn). Check at low idle, heavy lift on (if Applicable). Refer to chart below for port relief valve.
PF 1/4
PILOT CIRCUIT
1870~1930
N/A
N/A
MEASURING
CONDITION,
FUNCTION
2070~2130
B- Mode
SYSTEM
140~194F
Low Idle
Adjustment
Point
Service
Connector
Installed
INSPECTION ITEM
NOTE :
Take Measurements
H-Mode Engine at "HI" Idle.
Levers in neutral for neutral
reading,
then activate circuit to take
activated readings
Power Shift:
*** ...All controls in neutral
** ....Front attachment stalled
* .....Both travel motors stalled
0~10 mA
0~10 mA
10~30 mA
Page 9-13
INSPECTION ITEM
113
135
140
2070
970
1020
2070
2070
1870
210
2130
1030
1080
2130
2130
1930
2100
1000
1050
2100
2100
1900
MEASURING
CONDITION,
FUNCTION
f
Throttle @ "HI"- Idle
Throttle @ "LO"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Pilot Pressure
Main
Boom
Relief
raise
Valve
Heavy Lift
Pressure
Note:
Port
Relief
Valve
Pressure
for
Attachme
nts
(Values in
Parenthes
is () are
Actual
Port
High Idle
711.15
711
782
Low Idle
P1
P2
P1
P2
569
4978
4978
5476
5476
569
4907
4907
5405
5405
782
5078
5078
5618
5618
Port relief valves are set at a precise flow rate and cannot be
adjusted on the machine. Port relief valves can be checked for
excessive leakage by increasing the value of main relief valve. (turn
main relief clockw ise one complete turn). Check at low idle, heavy
lift on (if Applicable). Refer to chart below for port relief valve.
Boom
Arm
Bucket
Swing
Head
MR1
4907
5760
Rod
Head
Rod
Head
Left
Right
MR1
MR1
MR1
MR1
4054
4054
MR1
MR1
MR1
MR1
4907
4907
4836
4907
4267
4267
4907
4907
4907
4907
5760
5476
5476
5760
4694
4694
5191
5191
5191
5191
RH Fw d
Travel
RH Rev
LH Fw d
LH Rev
P1 Pump
a1 PORT
P2 Pump
a2 PORT
psi
NOTE :
Take Measurements
H-Mode Engine at "HI" Idle.
Levers in neutral for neutral
reading,
then activate circuit to take
activated readings
Power Shift:
*** ...All controls in neutral
** ....Front attachment stalled
* .....Both travel motors stalled
0~10 mA
0~10 mA
10~30 mA
Page 9-14
INSPECTION ITEM
113
135
140
2070
970
1020
2030
2030
1830
210
2130
1030
1080
2130
2130
1930
2100
1000
1050
2100
2100
1900
MEASURING
CONDITION,
FUNCTION
f
Throttle @ "HI"- Idle
Throttle @ "LO"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Pilot Pressure
High Idle
711.15
711
782
569
4978
4978
5476
5476
569
4907
4907
5405
5405
782
5078
5078
5618
5618
Low Idle
Main
Normal
P1
Relief
Relief
P2
Valve
P1
Heavy Lift
Pressure
P2
Note:
Port
Relief
Valve
Pressure
for
Attachme
nts
(Values in
Parenthes
is () are
Actual
Port
Port relief valves are set at a precise flow rate and cannot be
adjusted on the machine. Port relief valves can be checked for
excessive leakage by increasing the value of main relief valve. (turn
main relief clockw ise one complete turn). Check at low idle, heavy
lift on (if Applicable). Refer to chart below for port relief valve.
Boom
Arm
Bucket
Swing
Head
MR1
4907
5760
Rod
Head
Rod
Head
Left
Right
MR1
MR1
MR1
MR1
4054
4054
MR1
MR1
MR1
MR1
4907
4907
4836
4907
4267
4267
4907
4907
4907
4907
5760
5476
5476
5760
4694
4694
5191
5191
5191
5191
RH Fw d
Travel
RH Rev
LH Fw d
LH Rev
P1 Pump
a1 PORT
P2 Pump
a2 PORT
psi
NOTE :
Take Measurements
H-Mode Engine at "HI" Idle.
Levers in neutral for neutral
reading,
then activate circuit to take
activated readings
Power Shift:
*** ...All controls in neutral
** ....Front attachment stalled
* .....Both travel motors stalled
0~10 mA
0~10 mA
10~30 mA
Page 9-15
Std Value
Low er Limit Upper Limit Units:
113
135
140
1820
775
825
1820
1820
1720
210
1880
825
875
1880
1880
1780
1850
800
850
1850
1850
1750
MEASURING
CONDITION,
FUNCTION
f
Throttle @ "HI"- Idle
Throttle @ "LO"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Throttle @ "HI"- Idle
Pilot Pressure
Main
Normal
Relief
Relief
Valve
Heavy Lift
Pressure
Note:
Port
Relief
Valve
Pressure
for
Attachme
nts
(Values in
Parenthes
is () are
Actual
Port
High Idle
711.15
711
782
Low Idle
P1
P2
P1
P2
569
4551
4551
4978
4978
569
4480
4480
4907
4907
782
4651
4651
5120
5120
Port relief valves are set at a precise flow rate and cannot be
adjusted on the machine. Port relief valves can be checked for
excessive leakage by increasing the value of main relief valve. (turn
main relief clockw ise one complete turn). Check at low idle, heavy
lift on (if Applicable). Refer to chart below for port relief valve.
Boom
Arm
Bucket
Swing
Head
MR1
4480
5263
Rod
Head
Rod
Head
Left
Right
MR1
MR1
MR1
MR1
3627
3627
MR1
MR1
MR1
MR1
4480
4480
4480
4480
3627
3627
4907
4907
4907
4907
5263
5049
5049
5263
4480
4480
5191
5191
5191
5191
RH Fw d
Travel
RH Rev
LH Fw d
LH Rev
psi
NOTE :
Take Measurements
H-Mode Engine at "HI" Idle.
Levers in neutral for neutral
reading,
then activate circuit to take
activated readings
P3 Pump
a3 PORT
C
Page 9-16
C
C
P1 Pump
a1 PORT
P2 Pump
a2 PORT