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Kobelco Mark IV

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KOBELt~O
KobelcoAmericaInc.

MarkIV 08/99
Page10-1
 MEASURING& ADJUSTING PRESSURES
TABLE OF CONTENTS
10.1MACHINE
PREPARATION
.......................................................................................................................... 10-3
A. Tools
& Equipment
Required............................................................................................................................ 10-3
B.Machine
Settings
&SiteConditions ........................................................................................................... 10-3
C.Machine
Preparation
Procedures ..................................................................................................... 10-3 ~ 10-4
D. MainandPortRelief Pressure Measurement AndAdjustment Notes............................................................. 10-4

10.2MAIN
PILOTCIRCUIT................................................................................................................................. 10-5
A. MainPilot ReliefValvePressure Measurement Procedures .......................................................................... 10-5
B. MainPilot ReliefValve Adjustment Procedures ........................................................................................... 10-5

10.3TRAVELCIRCUIT
......................................................................................................................................... 10-6
A. TravelMainReliefValve Pressure Measurement .......................................................................................... 10-6
B.TravelMainReliefValve Pressure Adjustment ............................................................................................. 10-6

10.4ATTACHMENT
CIRCUIT-
"HEAVYLIFT"..................................................................................................... 10-7
A. AttachmentMain Relief ValvePressureMeasurement with "HEAVY LIFT" or "PowerBoost" ModeON............ 10-7
B. AttachmentMainRelief ValvePressureAdjustmentwith "HEAVY LIFT" or "PowerBoost" ModeON.............. 10-7

10.5ATTACHMENT
CIRCUIT
- NORMAL
LIFT..................................................................................................... 10-8
A. AttachmentMain Relief Valve PressureMeasurement with "HEAVY LIFT" or "PowerBoost" ModeOFE.......... 10-8
B. AttachmentMain Relief Valve PressureAdjustmentwith "HEAVY LIFT" or "PowerBoost"ModeOFE............. 10-8

10.6SWINGCIRCUIT
.......................................................................................................................................... 10-9
A. Swing
PortReliefValve Pressure Measurement .......................................................................................... 10-9
B. Swing
PortReliefValve Pressure Adjustment .............................................................................................. 10-9
OPTIONAL TROUBLESHOOTINGPRESSURES
10.7 ATTACHMENTCYLINDERPORT RELIEF VALVES .................................. i ......................................
10-10 ~ 10-12
A. Attachment
CylinderPort Relief ValvePressure Measurement & Adjustment.................................... 10-10 ~ 10-12

10.8LOWPRESSURE
CIRCUIT
........................................................................................................................ 10-13
A. LowPressure
ReliefValvePressure Measurement .................................................................................... 10-13
B. LowPressure
ReliefValve Pressure Adjustment ........................................................................................ 10-13

10.9NEGATIVE
CONTROL
CIRCUIT
................................................................................................................. 10-14
A. Negative
Control
Pressure
Measurement .................................................................................................. 10-14
B. Negative
Control
Pressure
Adjustment ..................................................................................................... 10-14

10.10POWER SHIFT (Pf)CIRCUIT .................................................................................................................... 10-15

A. Power Shift(Pf)Pressure Measurement ................................................................................................. 10-15
B. Power Shift(Pf)Pressure Adjustment .................................................................................................... 10-15
NOTES
.............................................................................................................................................................. 10-16

10.11 PERFORMANCE INSPECTION SPECIFICATION CHARTS ANDILLUSTRATIONS ........................ 10-17 ~10- 33

A.SK115DZ
.................................................................................................................................. 10-17~ 10-18
B.SK130
...................................................................................................................................... 10-19 - 10-20
C.SK150-ED180
........................................................................................................................... 10-21 - 10-24
D. SK200-SK210........................................................................................................................... 10-24 - 10-25
E. SK220-SK250........................................................................................................................... 10-26 ~ 10-27
F. SK270....................................................................................................................................... 10-28 ~ 10-29
G. SK300-SK330 ........................................................................................................................... 10-30 - 10-31
H. SK400-SK460............................................................................................................................ 10-32 ~ 10-33

Page1 0-2 Mark

IV08/99
 MEASURING& ADJUSTING PRESSURES
10.1 MACHINEPREPARATION
A. Tools & EquipmentRequired MACHINEIN HYDRAULICOIL CHECKPOSITION
1. Two700kg/cm 2 (10,000psi) PressureGauges.
2
2. Two105kg/cm(1,500)psi) PressureGauges.
3. One70kg/cm 2 (1,000 psi) PressureGauge.
4. Two1/4 X 1/4 X 1/4 PT"Tee" adaptorfittings.
5. GeneralHandor powertools to removeand
replacehydraulic fittings and components.
FIGURE2.1
SK100 ~ SK330 ILLUSTRATED
NOTE
REMOVE
It maybe necessary
to modifyhandtools in order to reach
certain components
for adjustment.

6. Thermometer to read hydraulic oil temperature.

7. Specialtools for locking TravelMotors.

S. MachineSettings & Site Conditions

1. Attachmentin Hydraulic Oil CheckPosition.
2. Hydraulic Oil Temperature at 45°Cto 55°C
(113°Fto 131°F).
3. KPSSModeSwitch in H-Mode.
4. ThrottleControlin "Hi-Idle" position.
5. Firm,level testing site. FIGURE2.2

C° MachinePreparation Procedures P3 TEST PORT

1. Movethe machine to a firm, level testing area.
2. Operatethe attachmentcontrols until the ma-
chineis in the HydraulicOil Check position. See
Figure2.1.
3. Allow the hydraulic oil to reacha temperature
of 45°Cto 55°C(113°Fto 131°F).
4. Turn engine "OFF". i
5. Releasehydraulic tank pressureby removing
cap frompressurerelief valve and depressing
relief valve stem.SeeFigure2.2. - :.:
q
WARNING
PILOT SYSTEI~
¯ BE EXTREMELY CAUTIOUSWHILE RELEASING GEAR PUMP
HYDRAULICTANK PRESSUREOR REMOVING
FIGURE2.3
LINES ANDFITTINGS, VAPORS
ANDOIL MAYBE
EXTREMELY HOT. SK100 THROUGHSK160 SK200 THROUGHSK460
CONFIGURATION CONRGURATION
¯ WEARAPPROVED SAFETYCLOTHES, SHOES,
\
GLOVESAND HARD HAT WHENPERFORMING a2 PORT---~if"
ANY MAINTENANCEOR TEST PROCEDURES. t/
6. OpenMain PumpAccess Door and removethe
Test Port Plug (P3) from OutputPort on Pilot
2
SystemGearPumpand install 105kg/cm
(1,500 psi) PressureGauge.SeeFigure 2.3.
7. Install 700kg/cm2 (10,000psi) PressureGauges /
into al Port on pumpP1 and into a2 Port on \. --J
al PORT
pumpP2. SeeFigure 2.4.
FIGURE2.4
MarkIV 08/99
Page 10-3
 MEASURING & ADJUSTING PRESSURES
8. Start engineand verify the engineRPM’sare 9. Recordall Gaugereadings and compareto that
within specified ranges. particular machine’schart BEFORE makingany
9. Performthe primarypressuretests and adjust- adjustments.
mentsin the order they are listed below. 10. All PressureTestsare conductedwith machine
a. MainPilot Relief Pressure. in "H" Modeand enginein "HI-IDLE," unless
b,Travel MainRelief Pressures. otherwisespecified in test procedure.
c. Attachment MainRelief Pressuresin
"HEAVYLIFT " ON. NOTE
d. Attachment MainRelief Pressuresin nor- Whenadjusting, pressures are increased and decreased
mal modewith "HEAVYLIFT" OFF. as follows:
e. SwingPort Relief Pressures CLOCKWISEROTATION-Increase
10. Perform the following OPTIONAL Pressure COUNTERCLOCKWISE ROTATION- Decrease
Testsas required. (Not necessarilyas listed).
E.VERIFYING ENGINE RPM-SK150~ SK460
a. Attachment CylinderPort Relief
1. Start Engine.
Pressures.
2. Depressthe Buzzer Stop Switch 5Times.This
b. LowPressureRelief Valve Pressures.
will changethe GaugeCluster Display from
c. NegativeControl Pressures.
Clock to Engine RPM.SeeFigure A.
d. PowerShift (Pf) Pressures

D. Main andPort Relief PressuresMeasurement

and AdjustmentNotes
s_
BUZZER STOP .

1. If pressuregaugereadingsare within specifi-

cations for the particular machine beingtested,
it is not necessary to adjust Relief ValvePres-
sures.
2. During adjustmentof the two stage attachment
mainrelief valves for P1 and P2pumps,per- FIGURE A
form measurement and adjustmentof the boost
(heavylift) stageof the mainrelief valvesfirst. NOTE
Then, completethe normal main attachment The WarningBuzzer soundswhile the Engine’s RPMis
being displayed to avoid the RPMdisplay being left on
relief pressuremeasurement and adjustment.
during normalmachineoperation andaffect the other sys-
SeeFigures 2.15A& 2.18Afor "HeavyLift"
tem displays and warnings.
and "Normal"adjustmentscrewsand Iocknuts.
3. Measurement and adjustment of attachment
cylinder.port relief valves are not necessary 3. To return Gauge
Cluster Displaybackto nor-
mal, depressthe buzzerstop switch one time.
during normal pressure measurement proce-
dures. If measurement and adjustmentof an
NOTE
attachment port relief valve is required, it may
The EngineRPMDisplay can be brought backat any time
be necessaryto increase the openingpres-
by depressingthe BuzzerStop Switch one time.
sures of the attachmentmainrelief valves and
possibly the travel mainrelief valves. Mark If the poweris turned"OFF",it will be necessaryto repeat
themaccordingly for easeof readjustment. steps 1 and 2 to get the EngineRPM on the display.
4. Install propersize pressuregaugesat correct
4. Shouldthe EngineRPMdisplay show"0" while
locations.
the engineis running, checkandcorrect the
5. Confirmthat enginerpm’s are within specifica-
following areas:
tions.
6.Confirmthat enginecoolant andhydraulic oil a. RPMSensor Adjustment
are at normaloperating temperatures. b. RPMSensor Resistance Value
7. Performall testing and adjustmentprocedures c. Electrical Harnessand Connections
observingall applicablesafety requirements.
F. VERIFYINGENGINERPM-SK100~ SK130
8. PerformanceInspection StandardCharts are
on Pages2-15 through 2-22 and are organized Install an external Tachometer
to enginein order
by Model Number. to verify engineRPM.
MarkIV 08/99
Page 10-4
 MEASURING& ADJUSTING PRESSURES
10.2 MAINPILOT CIRCUIT CONFIGURATION " J ,~PPLACE
A. MainPilot Relief Valve I FORSK150
THRU
5K4601
/I THROTTLE
Pressure MeasurementProcedures
1. Performmachinepreparation proceduresas
described in 2.1 MACHINE PREPARATION.
2. Start engineandplacethrottle control in Hi-
Idle position. SeeFigure2.5.
3. Place KPSSModeSwitch in "H"-Mode. See
Figure2.5.
4. Donot operateany controls.Thenread the
pressure gauge. Recordreading and compare
to chart for specific modelbeing tested on FIGURE2.5
pages2-15 through2-22.

B. MainPilot Relief Valve Adjustment Procedures

1. Locatethe MainPilot Relief Valve mounted to
the side of the HydraulicOil Tankin the Mani-
fold Assembly¯SeeFigure 2.6.
2. Remove protective cap. SeeFigure 2.7.
Loosenthe adjusting screwIocknut. See
Figure2.8,
/
3. Adjust until specified pressureaccordingto
properchart for specific machinebeing.ad-
justed is achieved.
,,,
FIGURE2.6
NOTE
1 CompleteTurn Adjusts PressureApproximately:
2 (200 psi)
14¯4kg/cm
1/4 Turn AdjustsPressureApproximately:
2 (51.2 psi)
3.6kg/cm PROTECTIVE
CAP
4. After correct pressureis obtained,tighten ad-
justing screwIocknut, beingcareful not to over-
tighten. SeeFigure 2.8.
5. Install protectivecapandtighten. Becareful
not to overtightencap. SeeFigure2.7.
6. Verify pressureafter tightening Iocknutandcap.
FIGURE2.7

ADJUSTING .~
~-~__ -’-
SCREW --
FIGURE2.8
MarkIV 08/99 Page10-5
 MEASURING & ADJUSTING PRESSURES
SPECIAL TOOL LOCATIONFOR SPECIAL TOOL LOCATION FOR
10.3TRAVEL CIRCUIT REVERSESTALL FORWARDSTALL
A.Travel Main ReliefValve PressureMeasurement
1, Perform MachinePreparation Proceduresas ..’;
~, " .~..~
described in 2.1 MACHINE PREPARATION.
2. Start engineandinstall specialtool (refer to
page5-3 for tool dimensions)into sprocketon
eachside of machinefor stalling forwardmo- i. !
tion of TravelMotors.SeeFigure2.9.
II lt-~~.
,,/J~t ~’~,II s

FIGURE2.9
¯ MAKECERTAINSPECIALTOOLIS SEATED
CONFIGURATION
FOR SKt50 THRU SK460
AGAINSTCRAWLERFRAMEAND BETWEEN
SPROCKETTEETH. NEVERALLOWSPECIAL
TOOL TO REST AGAINSTCRAWLER FRAMECORNER CO.TROL
/ I "

;.RO
E
REINFORCEMENTS. ENGAGE TRAVELSLOWLY&
CAREFULLYUNTIL TOOLIS POSITIONEDCORRECTLY

3. Movethrottle control to "HI-IDLE" place KPSS

ModeSwitch in "H"-ModeSeeFigure 2.10.
4. Place Travel SpeedSelect switch in 2nd (J~)
speedposition. SeeFigure 2.10. />/~" /TRAVEL--I
5. OperatebothTravelcontrolstogetherto full for- SPEED
wardtravel position and hold. SeeFigure 2.11. SWITCH SWITCH
6. Recordreading from 700kg/crrF(10,000psi) FIGURE2.10
Pressure Gauges.
OPERATEBOTH
7. Repositionspecial tool in sprocketsto stall TRAVEL LEVERS
reversetravel. SeeFigure2.9. TOGETHER C ;i
FULL STROKE
8. Repeatsteps 3 and 4.
9. Operateboth travel controls togetherto full
reversetravel andhold. Seefigure 2.11.
10. Recordreading from 700kg/cm 2 (10,000psi)
Pressure Gauges.
11. Compare readings to chart for specific model
being tested on pages2-15 through2-22.

B. Travel MainRelief PressureAdjustment

1. LocateTR1and TR2on the maincontrol valve.
SeeFigure 2.12 for SK200~460 exampleand FIGURE2.11
refer to the Performance Inspection Standard I I i ,,-,.. I "~1 ~lit~w
I’~-’~
Illustration for the particular machinebeingad-
justed (Pages2-15~2-22). ’’ ’c~---~~--’~ ~ ?~"" ’~ [1 I sK300ILLUSTRATED
2. Loosenlock nuts and adjust eachTravel Main
Relief until properpressureis achieved.

NOTE
TR1-RightTravel Main Relief Valve
TR2-Left Travel MainRelief Valve
1 Rotation=Approximately115kg/cm 2 (1640 psi)
2
1/4 Rotation=Approximately58kg/cm (825 psi)

3. After adjustment,securelytighten adjustingmain

Iocknuts,beingcareful not to overtighten. FIGURE2.12

Page10-6 Mark
IV08/99
 MEASURING & ADJUSTING PRESSURES
10.4 ATTACHMENT CIRCUIT-"HEAVYLIFT" CONFIGURATION -~ I ~HROTTLE
("HEAVYLIFT IS ONSK200~ SK460ONLY) / / CONTROL
A. AttachmentMainRelief Valve Pressure -~_J J.J I-~ I I "~’~
MeasurementWith "HEAVYLIFT" Mode ON
1. Performmachinepreparation proceduresas
described in 2.1 MACHINE PREPARATION.
2. Movethrottle control to "HI-IDLE"place KPSS
ModeSwitch in "H"-ModeSeeFigure 2.13. SWITCH
3. Place"HeavyLift" Switchin the "ON"position.
SeeFigure 2.14. ~--~ "J L
4. Operatebucketin (digging) control until bucket
is completelyin, thenhold. FIGURE2.13
5. Recordreading from 700kg/cm 2 (10,000 psi)
PressureGaugeat al port on P1 Main Pump.
HEAVYLIFT
SWITCH
"ON"
° MAKE
CERTAIN
THERE
ARENOOBJECTS
IN THE
PATHOFTHEBOOM

6. OperateBoomUp Control until boomis com-

pletely up andhold.
7. Recordreading from 700kg/cm 2 (10,000psi)
PressureGaugeat a2 port on P2 Main Pump.
8. Compare readingsfrom steps 5 and 7 to proper
chart for particular machine
beingtested.

B. AttachmentMain Relief Valve Pressure FIGURE2.14

Adjustment With "HEAVYLIFT" ModeON
1. Locate MR1and MR2Attachment Main Relief SK300 ILLUSTRATED
Valveslocated on the maincontrol valve. See
Figure 2.15 for SK200 exampleandrefer to the
Performance Inspection Standardchart illus-
tration on the particular machinebeingadjusted
(Pages2-15~2-22)for properlocation of MR1
and MR2adjustment Main AttachmentRelief
Valves.
2. Loosenlock nuts and adjust each Attachment
MainRelief Valveuntil properpressureis
achieved.SeeFigure 2.15A. FIGURE2.15

NOTE
MR1-BucketIn (Digging)
HEAVY LIFT--
(POWER BOOS’r) X~ .~::
~ =~i ~ NORMAL
DJUSTMENT
SCREW’
MR2- Boom Up ADJUSTMENT ~ ~k~,~ ’NORMAL
SCREW ~
2 (1640psi)
1/2 Rotation=Approximately115kg/cm ADJUSTMENT
= LOCK NUT
2 (825 psi)
114 Rotation=Approximately58kg/cm HEAVYLIFT ---"--~ ~L-_.
(POWERBOOST) [~_____
ADJUSTMENT I~,.~
3. After adjustment,securely tighten Attachment LOCK NUT
MainRelief ValveIocknuts. Becareful not to ATTACHMENT
overtighten. I - I~ MAIN RELIEF
I ii
:l
VALVE
(MR1 OR MR2)
’ (SK200 ~SK460 ONLY)

FIGURE2.15A
MarkIV 08/99
Page10-7
 MEASURING& ADJUSTING PRESSURES
10.5 ATTACHMENT CIRCUIT- NORMALLIFT
CONFIGURATION ~1 /~-~HROTrLE
A. AttachmentMain Relief Valve Pressure FORSK150THRUSK460 J / I CONTROL
MeasurementWith "HEAVYLIFT" Mode OFF
1. Perform machinepreparation proceduresas
described in 2.1 MACHINE PREPARATION.
2. Movethrottle control to "HI-IDLE", place KPSS
ModeSwitch in "H"-ModeSeeFigure 2.16.
3. Place"HeavyLift" Switchin the "OFF"posi-
tion. SeeFigure2.17.
4. Operatebucketin control until bucketis com-
pletely in andhold.
5. Recordreading from 700kg/cm 2 (10,000 psi)
FIGURE2.16
PressureGaugeat al port on P1 Main Pump.
,~ \~ HEAVYLIFT

PATHOF THE BOOM

6. Operateboomup control until boomis com-

pletely up andhold.
7. Recordreading from 700kg/cm 2 (10,000 psi)
Pressure Gaugeat a2 port on P2 Main Pump.
8. Compare readings from steps 5 and 7 to proper
chart for particular machine
being tested.

B. AttachmentMain Relief Valve Pressure

FIGURE2.17
Adjustment With "HEAVYLIFT" ModeOFF
SK300 ILLUSTRATED
1. Locate MR1and MR2Attachment Main Relief
Valveslocated on the maincontrol valve. See
Figure 2.18 and refer to the PerformanceIn-
spectionStandardchart illustration on the
particular machinebeing adjusted (Pages
2-15~2-22)for properlocation of MR1andMR,?.
Main AttachmentRelief Valves.
2. Loosenlock nuts and adjust each Attachment
MainRelief Valveuntil properpressureis
achieved.Seefigure 2.18Afor adjustment
FIGURE2.18
points

NOTE NORMAL
ADJUSTMENT
MR1-BucketIn (Digging) NORMAL >~ SCREW
ADJUSTMENT
MR2-BoomUp (Raise) LOCK NUT
2 (1640psi)
112 Rotation=Approximately115kg/cm
2
114Rotation=Approximately58kg/cm(825 psi)

3. After adjustment,securelytighten adjustingmain

Iocknuts,beingcareful not to overtighten.
4. Place "HEAVY LIFT" Switch in "ON"position. A’R’ACHMENT-------I-
MAIN RELIEF /
5. Re-checkpressuresby operating the Bucket VALVE Iii
In and BoomUpControls and comparingPres- (MRI OR MR2)
sure Gauge readingswith properchart for the
particular machinebeing tested. FIGURE2.18A

Page 1 0-8 MarkIV 08199

 MEASURING & ADJUSTING PRESSURES
10.6 SWINGCIRCUIT
[CONFIGURATION "~
A. SwingPort Relief Valve PressureMeasurement ~""~TTH ROTTLE

1. Performmachinepreparation proceduresas /I
described in 2.1 MACHINE PREPARATION.
2. Movethrottle control to "HI-IDLE," place KPSS
ModeSwitch in "H"-ModeSeeFigure 2.19.
3. Operateboomdowncontrol until bucket teeth
penetrate soil approximately305mm (12"). See
Figure2.20.
4. Operate swingcontrol to the left andhold, stall-
2
ing swing. Recordreading from 700kg/cm
(10,000psi) PressureGauge installed to test
port a2 on P2 Main Pump. FIGURE2.19
5. Operateswingcontrol to the right andhold,
2
stalling swing. Recordreading from 700kg/cm
(10,000psi) PressureGauge installed to test
port a2 on P2 Main Pump.

B. SwingPort Relief Valve PressureAdjustment

1. Locate RV11and RV12SwingPort Relief Valve
FIGURE2.20
Adjustmentpoints located in the SwingCon-
trol ValveAssemblyon SwingMotor. SeeFig-
ure 2.21 and refer to the Performance Inspec- SK300 ILLUSTRATED
tion Standardchart illustration onthe particu-
lar machinebeing adjusted(Pages2-15-2-22),
for properlocation of RV11and RV12adjust
\
mentpoints.
2. Remove rubber protective covers and loosen
lock nuts on RV11and RV12.
3. Adjust RV11and RV12until proper pressures
are achieved. ! f--
i.
NOTE ..
RV11-Right SwingPort Relief Valve
RV12-Left SwingPort Relief Valve
1 Rotation= Approximately100kg/cm2 (1420 psi)
I RV11 J ,
2 (356 psi)
1/4 Rotation=Approximately25kg/cm .-1 R

4. After adjustment,securelytighten Port adjust-

. ...,’1
ing Iocknuts,beingcareful not to overtighten,
andinstall rubberprotective covers. I
NOTE ©
Adjustmentproceduresfor the SK120~130 require the use
of internal shimsonly. Noexternal adjustmentpoints are I
I
available.

/
FIGURE2.21

MarkIV 08/99
Page1 0-9
 MEASURING& ADJUSTING PRESSURES
10.7 A’n’ACHMENTCYLINDERPORTRELIEFS O-IDLE 2 (~i)
A. Attachment
Cylinder Port Relief PressureMea- SPEEDf~ ’~ "L’~>.~
"-..!
surement

X
¯ PRECISE ADJUSTMENTOF THE MACHINE’S
A’FrACHMENTPORTRELIEF VALVESIS
NOT POSSIBLE ON THE MACHINE.
FIGURE2.22
° SHOULDA PROBLEMBE FOUNDWITH THE
ATTACHMENTPORTRELIEF VALVES, IT IS SPECIAL TOOL LOCATION FOR SPECIAL TOOL LOCATION FOR
REVERSESTALL FORWARD STALL
RECOMMENDED TO REPLACEFAULTY ATTACH-
MENTPORTRELIEF VALVES.
SUCH ADJUSTMENTCOULD VOID WARRANTY.

NOTE
Thefollowing proceduresare providedfor referenceonly.
Ell.,
Attachment Port Relief Valvesare factory presetandshould
not be field adjusted.
FIGURE2.23
1. Performmachinepreparation proceduresas
described in 2.1 MACHINE PREPARATION.
2. Movethrottle control to "LO-IDLE,"place KPSS
ModeSwitch in "FC" or "D" -Mode.Seefigure
2.22.
3. Install specialtool (refer to page5-3)into +
sprocketon eachside of machine
travel. SeeFigure2.23.
for stalling
jl .{
4. Placetravel speedselect switchin 2nd(4p)
~p~edposi~;!on. SeeFigure 2.22.
5. Operateb6t~TravelControlstogetherto full
forwardtravel position andhold. FIGURE2.24

NOTE
Before raising pressuresat TR1,TR2, MR1and MR2,mark \’~ HEAVYLIFT
original position of reliefs to makereadjustment
cation easier.
to specifi- SW’o
.C"
6. LocateTR1and TR2Travel Main Reliefs and
adjust pressureabovespecification by
14kg/cm 2 (200 psi). SeeFigure 2.24. Secure
Iocknuts.
7. Place "HEAVY LIFT’ Switch in "ON"posi-
tion. SeeFigure2.25. FIGURE2.25
8. Operatebucketin control until bucketis com-
SK300 ILLUSTRATED
pletely in andhold.
9. Locate MR1on Main Control Valve and adjust
pressureabovespecification by 14kg/cm z (200
psi). SeeFigure2.26.
10. Operatethe boomup control until boomis
completelyup and hold.
11. Locate MR2on Main Control Valve and adjust
2
pressureabovespecification by 14kg/cm
(200psi). SeeFigure 2.26.
FIGURE2.26

Page 1 0-1 0 MarkIV 08/99

 MEASURING & ADJUSTING PRESSURES

WARNING
¯ THE FOLLOWINGADJUSTMENT PROCEDURES, " "ON"
FOR ATTACHMENT CYLINDERPORT RELIEF ~V,_ LO_IDLE
VALVES(RV5-RV10), IT IS NOTRECOMMENDED
INTHE FIELD ON MACHINE.
¯ REPLACEFAULTYATTACHMENT PORTRELIEF
VALVES

12. Placethrottle control in "LOW-IDLE"

position, FIGURE2.27
place KPSSModeSwitch to "FC" Modeand
place "HEAVY LIFT" Switch to "ON". See
Figure 2.27. SK300 ILLUSTRATED

NOTE
2 (1640 psi)
1 Rotation=Approximately115kg/cm
2 (825 psi)
114Rotation=Approximately58kg/cm

a. RV5- BOOMUP PORTRELIEF

1. OperateBoomUpControl until boom
is completelyup andhold.
2. Recordreading from Pressure Gauge
at al test port on P1 Main Pump. /
Compare reading to proper chart for
specific machinebeing tested.
3. LocateRV5on Main Control Valve,
loosen Iocknut and adjust RV5to
test benchpressure. SeeFigure 2.28.
4. SecureIocknut beingcarefull not to
overtighten.
FIGURE2.28
b. RV6- BOOMDOWNPORTRELIEF
1. OperateBoomDownControl until
boomis completely downand hold. SK300 ILLUSTRATED
2. Recordreading from Pressure Gauge
at al test port on P1 Main Pump.
Compare reading to proper chart for
specific machinebeing tested.
3. Locate RV6on Main Control Valve,
loosen Iocknut and adjust RV6to
test benchpressure. SeeFigure 2.29.
4. SecureIocknut, beingcareful not to
overtighten.

c. RV7- BUCKETIN PORTRELIEF

1. Operatebucketin control until bucket
is completelyin, then hold.
2. Recordreading from Pressure Gauge
at al test port on P1 Main Pump.
Compare reading to proper chart for
specific machinebeing tested.
3. LocateRV7on Main Control Valve,
loosen Iocknut and adjust RV7to FIGURE2.29
test benchpressure. SeeFigure 2.29.
4. SecureIocknut, being careful not to
overtighten.
MarkIV 08/99 Page 10-1 1
 MEASURING & ADJUSTING PRESSURES
SK300 ILLUSTRATED
d. RV8- BUCKETOUTPORTRELIEF
1. OperateBucketOut Control until
bucketis completelyout and hold.
2. Recordreading from Pressure Gauge
at al test port on P1 Main Pump.
Compare reading to proper chart for
specific machinebeing tested.
3. LocateRV8on MainControl Valve, :, .... J,=,
loosen Iocknut and adjust RV8to
,..
test benchpressure. SeeFigure 2.30.
4. SecureIocknut being carefull not to
overtighten.

e. RV9- ARMIN PORTRELIEF

1. Operatearmin control until armis
completelyin and hold.
2. Recordreading from PressureGauge
at a2 test port on P2 Main Pump.
Compare reading to proper chart for
specific machinebeing tested.
"’7
FIGURE2.30
3. Locate RV9on Main Control Valve,
SK300 ILLUSTRATED
loosen Iocknut and adjust RV9to
test benchpressure. SeeFigure 2.31.
4. SecureIocknut, being careful not to
overtighten.
\
f. RV10- ARMOUTPORTRELIEF
1. Operatearmout control until armis
completelyout, then hold.
2. Recordreading from Pressure Gauge
at a2 test port on P2 Main Pump.
Compare reading to proper chart for
specific machinebeing tested.
3. LocateRV10on Main Control Valve, " i,Y I! 1
loosen Iocknut and adjust RV10to
test benchpressure. SeeFigure 2.32.
4. SecureIocknut, being careful not to
overtighten.
FIGURE2.31
13. Adjust TR1, TR2, MR1and MR2back to speci-
fied settings. Referto Figures2.24 and2.26. SK300 ILLUSTRATED
Verify pressuresand that machineoperation
is correct.

FIGURE2.32

Page 1 0-1 2 MarkIV 08/99

 MEASURING& ADJUSTING PRESSURES
10.8 LOWPRESSURE CIRCUIT
A. LowPressureRelief Valve Pressure
Measurement

WARNING
¯ WHENPERFORMING
THIS TEST, DO NOT
OPERATEANY HYDRAULICCONTROLS!
¯ ANY MOVEMENTOF HYDRAULICCONTROLS
WILL CAUSEEXTENSIVE DAMAGETO GAUGES!

1. Perform machinepreparation proceduresas

described in 2.1 MACHINE PREPARATION
using 105kg/cm 2 (1500 psi) PressureGauges
FIGURE2.33
in al and a2 Test Ports on P1 and P2 Main
Pumps.
2. Movethrottle control to "HI-IDLE," place KPSS
ModeSwitch in "H"-ModeSeeFigure 2.33. DO
NOT TOUCHHYDRAULICCONTROLS.
3. Recordreading from 105kg/cm 2 (1500 psi)
PressureGauges at al and a2 test ports on
P1 and P2 Main Pumps.Reduceengine RPM
to "LO"idle.
4. Place KPSSModeSwitch in "D"-Modeand
movethrottle to "HI-IDLE".SeeFigure 2.33. DO
NOT TOUCHHYDRAULICCONTROLS.
5. Recordreading from PressureGaugesat al
and a2 test ports on PI and P2 Main Pumps.
6. Compare readingsto properchart for specific
machinebeing tested.

B. LowPressureRelief Valve Pressure

Adjustment FIGURE2.34
1. Shouldadjustmentof the LowPressureRelief
Valvesbe necessary,refer to the ShopManual
for the Specific Machinebeing adjusted.

NOTE
TheLowPressureRelief Valvesare not adjustable exter-
nally Theyare adjustedusing internal Shims.

2. TheLowPressureRelief Valvesare located in

the endsections of the MainControl Valve. See
Figure 2.34 for SK200~460 and Performance
InspectionSpecificationcharts andillustrations
for specific model.

MarkIV 08/99 Page 1 0-1 3

 MEASURING& ADJUSTING PRESSURES
10.9 NEGATIVECONTROL CIRCUIT SK300ILLUSTRATED
A. Negative Control PressureMeasurement
1. Performmachinepreparation proceduresas
described in 2.1 MACHINE PREPARATION.
2. Install one1/4 X 1/4 X 1/4 PF"TEE"fitting at
Pil port on P1 Main PumpRegulator. See
Figure2.35. Install one105kg/cm 2 (1500psi)
Pressure Gaugeonto "TEE".
3. Install one1/4 X 1/4 X 1/4 PF"TEE"fitting at
Pi2 port on P2 Main PumpRegulator. See
Figure 2.36. Install one105kg/cm 2 (1500psi)
Pressure Gaugeonto "TEE".
4. Start engine,movethrottle control to "HI-IDLE,"
FIGURE2.35
and place KPSSModeSwitch in "H"-ModeSee
Figure2.37. SK300ILLUSTRATED
5. Donot operate any Hydraulic Controls. Record j ; ;T LLTEiA
DG’UG
2 (1500 psi) Pressure
readings from 105kg/cm ’ ] ~".~,~,~1--01 BETWEEN LINE
~-~.,,<%.___.,, ’
&ELBOW
.. ,.,
Gauges at Pil and Pi2 test ports.
6. Place KPSSModeSwitch in "D"-Modeand
leavethrottle at "HI-IDLE."SeeFigure2.37.
7. Recordreading from PressureGaugesat Pil
andPi2 test ports.
8. Compare readingsto properchart for specific
machinebeing tested.

B. Negative Control PressureAdjustment

1. Shouldadjustmentof the negativecontrol
pressurebe necessary,refer to the Shop FIGURE2.36
Manualfor the specific machine
being adjusted.

NOTE
Adjustment of the low pressurerelief valves also changes
negativecontrol pressure.Thelow pressurerelief valves
are not adjustableexternally. Theyare adjustedusingin-
ternal shims.

2. Thelow pressurerelief valves are locatedin

the endsections of the maincontrol valve. See FIGURE2.37
Figure 2.38 for SK200-460 and Performance
SK300ILLUSTRATED
Inspectionspecificationcharts andillustrations
for specific model.

FIGURE2.38

Page1 0-14 Mark

IV08/99
 MEASURING& ADJUSTING PRESSURES
10.10 POWER SHIFT(Pf) CIRCUIT(SK150~SK460 ONLY) SK300 ILLUSTRATED
A. PowerShift (Pf) PressureMeasurement
1, Performmachinepreparation proceduresas
described in 2.1 MACHINE PREPARATION.
2. Install one 70kg/cm 2 (1000psi) PressureGauge
in a3 test port on powershift SolenoidValve.
\
SeeFigure 2.39. I ~, t",~-’-----
1 POWERSHIFT
NOTE
"1SO’ENO,D
VALVE
t
PowerShift (Pf) is also referred to as: The Secondary ~’--~---7f~- I t l.-. - F
Pressure of KPSSElectromagnetic Proportionate Sole-
noid ReducingValve¯

3. Placethe throttle control in the "HI-IDLE"posi-

VIEWED FROMUNDERR.H. SIDE OF REARCOUNTERWEIGHT]
tion. SeeFigure2.40.
4. Recordreadingsfrom 70kg/cm 2 (1000 psi) with
FIGURE2.39
no operationof HydraulicControlsin the fol-
lowing KPSSModeSwitch settings:
a. "H" Mode
b. "S" Mode
c. "FC" Mode
d. "D" Mode
5. Locate the KPSSReleaseSwitch behind op-
erators seat. Remove rubber grommetand
place KPSSRelease Switch in the "RELEASE"
position¯ SeeFigure2.41.
6. Place Machinein "H" Modeand record reading
from 70kg/cm2 (1000 psi) PressureGauge with-
out anyoperationof hydrauliccontrols¯
7. Place the KPSSReleaseSwitch in the "KPSS"
FIGURE2.40
position. SeeFigure2.41.
8. Place the "HEAVY LIFT" Switch in the "ON"
SWITCH
position. SeeFigure 2.40. (SK200-SK460 only) BEHIND GROMMET
9. Recordreading from PressureGauge¯Com-
pareall readingsto properchart for specific ma-
chinebeing tested.
-7 v

B. PowerShift (Pf) PressureAdjustment

Shouldit be necessaryto adjust the PowerShift
(Pf) Pressure, contact: KOBELCO Product
SupportDepartment for (Pf) PressureAdjustment
Instructions and Assistance.

MOVE GROMMET
AND MOVE SWITCH UP

FIGURE2.41

Mark
IV08/99 Page1 0-15
 NOTES

Page1 o-1 6 Mark

IV08/99
 MEASURING& ADJUSTING PRESSURESSK115DZ M/C
PERFORMANCE INSPECTION & SPECIFICATION LPU-5001~
SK115DZ

MAIN CONTROL VALVE

BOOM -q~8 q I --RV /---BUCKET ’~r-~/’~i~/-t?Lr~
=~- ---
~ RIGHTTRAVEL

x,
c, - ,s
c~, ~LE,,T.AV,L
.%_"
I1~ ~®OQ
POP1 ~ ~- Pis ~ RV10

P4 j I II I/__o~ CONF’UXSPOOL\J
~ ~1

" P2 -- ~ _
Pi2 .... ~,

~ TRAVEL PREFERENTIAL
>’ <
~UI_/ ~- DR1 NEGATIVE CONTROL ~
MR2
SPOOLASSEMBLY
~.-~ ~---
RELIEF VALVE T--~
RV9

SWING CONTROL VALVE

SWING PORT ~ ’
SWING SHOCKLESS REL, EFVALVES
RV11 & RV12
~I~
VALVES ~- R (RETURN)

- p

PiA
PA Pi
U U I__pi
A
~ PB
AM --~ BM

TRAVEL MOTOR ASSEMBLY Cl-

I CASE DRA,N~t
PORT
/ __.:-
OIL
PORT
OIL
FILL/CHECK
TRAVEL PORT
PORT
RELIEFI tn ~ ILJ o - ~1 ~t ol 2-SPEED I~_t~ II
R~V~ES4I~- \o~--i~-=~/ot .,O.A’.O.TJ~&
1t (
t-
°’c:°"\2o ~ L i
I OIL DRAIN
PORT
C2- CASE DRAIN
PORT
Mark
IV08/99 Page
1 0-17
 MEASURING& ADJUSTINGPRESSURESSK115DZ M/C
LPU-5001 ~

PRESSURE MEASURING
Adjustment CONDITION,
INSPECTION ITEM Point
READING FROM SPECIFICATION FUNCTION
Cleanlinessof HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A Take Sample
Temperatureof HydraulicOil HydraulicOil TankSurface °C- 45-55°F- 113-131 N/A AmbientTemperature
-10oc - 50oc
EngineCoolantTemperature RadiatorSurface °C- 60-90 °F- 140-194 N/A (14OF- 122OF)
STANDARDS LowIdle 850~900 RPM Throttle @"LO"-Idle
FOR .= Hi- Idle
Extemally Mounted
Tachometer
2335-2370RPM Throttle@"HI"- Idle
TESTING n"
O¢8

Auto AcceI-Decel"ON" 850-1000 RPM Throttle@"HI"- Idle

ILl LU--I
(Optional)
BB m m
PILOT CIRCUIT ~RIMARYPRESSURE 47-53 670-750 P3 En,qine
- Hi Idle
al Engine
at Hi Idle.
TRAVEL F 350-355 ¢980-505C TR1 Simultaneous LH/RH
Main Pump a2
R 350-355 4980-505C TR2 Operation
Travel Stalled.
MAIN
REUEFS
ATTACHMENT
RH al 1300-305 4270-434C MR1 BucketDigging
Main Pump
HH a2 !300-305 4270~434C MR2 BoomRaising
BUCKET ROD al 330-340 4694~4836 RV8 Bucket Dump
Main Pump
(DO NOTADJUST) HEAD a2 330-340 4694-4836 RV7 BucketDigging
BOOM ROD al 330-340 4694-4836 RV6 BoomLowering
Main Pump
(DO NOTADJUST) HEAD a2 330-340 4694-4836 RV5 BoomRaising
ARM ROD al 330~340 4694~483E RV10 ArmOut(CylinderIN)
Main Pump
PORT ArmIn (Cylinder OUT)
i(DO NOTADJUST) HEAD a2 330-340 4694~483E RV9
RELIEFS F al 360-370 ~120~5263 RV14 "H’-Mode,
Engine
at HiIdle.
RH R Simultaneous
LH/RH Travel
TRAVEL
MainPump PF1/4 al 360-370 5120~5263 RV13 En~]a~ed
(DONOTADJUS~ F a2 350-370 5120~5263 RV13 "H’-Mode,
Engine
at HiIdle.
LH R Simultaneous
LWRH Travel
a2 360~370 5120-5263 RV14 En~a£1ed
R a2 280-310 3982~440~ RV11 BucketLock, StatlSwing
SWING Main Pump
L a2 280-310 3982~440£ RV12 BucketLock, Stall Swing
U al 260-280 3982-4409 RV15 BladeUpandStall
DOZER Main Pump
D a2 260-280 3982~440£ RV16 BladeDownand Stall

LOW PRESSURE Enginein "HI" Idle al 32-47 455-668 Internal Enginein "HI" Idle
Main Pump
RELIEFS Controlsin Neutral a2 32~47 455~668 Shims Controlsin Neutral
Low
Pressure
NEGATIVE
CONTROL Enginein "HI" Idle Pil 32-47 455~668 Relief Enginein "HI" Idle
Controlsin Neutral Main Pump
PRESSURES Pi2 32-47 455-668 Valves Controlsin Neutral

TESTPORTLOCATIONS:

NOTE
:
Take Measurements with
Engine at "HI" Idle
al & a2 Test Ports Pil Test Port
unless otherwise
specified. The standard

i I tolerance shall be an
allowable range in field
measurements.

Pi2 Test Port

Page1 0-1 8 Mark

IV 08/99
 MEASURING& ADJUSTINGPRESSURES
SK130 M/C
SK130 YPU- 2001~
MAIN CONTROL VALVE

RV8
TR1

-- Cl
1_ RV6
RV7

Z4 L(~G~R2 AA~

.52-- P~

~I L_A2
L__B2
DR1
~A3
.o..-- ~j~,~,,~
NEGATIVE CONTROL
RELIEF VALVE
~,~RAVE’.E~ERENT,AL
MR2- -RV, SPOOL ASSEMBLY __~i i -’-[ ~
T
SWING CONTROL VALVE & MOTOR ASSEMBLY
P

VALVE ~ ~ ~MU ~-"~11

_~
---’’
k~.~U..,-,. u-4_[
I
PA-~ ~._~. r~SW’NG .OTOR ~’ TOPV,EW
¢,~ ~-~..~= GAUGE PORT
BOTTOMViEW .... "-- ~, ~ ’,~:~V~<%2P"--CASE
ORAIN
PORT-Or

I"~~ i s,~,c"’I¢~ ~SW,NGRE,CTION

¯ .s,.v,. ~
TRAVEL MOTOR ASSEMBLY ...... .,--s,.v,.
C1- CASE DRAIN-- ""

o,,:o.
Jill V,ttl CK
") tl I11 tll
f_fol~It-t_. ~:,o)..1:-sP-o~
Po~?~&.--I
VALVES
t t<-’ S,GNALPORT
\O\~--I~_.L._____GI.:~/OI
--7 ~) J III U’
RV13 & RV14 ~//
OIL PORT ~ ~ ~JL
II OIL DRAIN
,=~_ PORT
\o~oI .~ _-_ . c 2_ c A S#o.Di.-
Mark
IV08/99 Page1 0-19
 MEASURING
& ADJUSTINGPRESSURES
SK130 M/C
YPU - 2001 ~

PRESSURE I, djustmenl MEASURING

INSPECTIONITEM Point CONDITION,
READING FROM SPECIFICATION FUNCTION
Cleanliness
of HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A Take Sample
Temperature
of HydraulicOil HydraulicOil TankSurface°C-45-55 °F-113-131 N/A AmbientTemperature
-10°C - 50°C
EngineCoolantTemperature RadiatorSurface °C- 60-90°F-140-194 N/A (14OF- 122OF)
STANDARDS
FOR LowIdle 850-900RPM "o = Throttle @"LO"-Idle
TESTING .= Hi- Idle
Externally Mounted
Tachometer
2335-2370RPM Throttle@"HI"- Idle
IZ:
Lu tO~
Z
Auto AcceI-Decel"ON" 850 - 10O0R PM ¢D:¢ Throttle@"HI"- Idle
IU
(Optional)
II PRIMARYPRESSURE
m P3
m En,qine
- Hi Idle
PILOT CIRCUIT 47-53 670-750
350~355 4980-505C TR1 Engine
at Hi Idle.
TRAVEL F al Simultaneous LWRH
Main Pump
R a2 350-355 4980-505C TR2 Operation
Travel Stalled.
MAIN
REUEFS
ATTACHMENT
RH al 1300-305 4270-434C MR1 BucketDigging
Main Pump
HH a2 300-305 4270~434C MR2 BoomRaising
BUCKET ROD al 330-340 4694-4836 RV8 Bucket Dump
Main Pump
(DO NOTADJUST) HEAD a2 330-340 4694-4836 RV7 BucketDigging
BOOM ROD al 330-340 4694-4836 RV6 BoomLowering
Main Pump
(DONOTADJUST) HEAD a2 330-340 4694-4836 RV5 BoomRaising
ARM ROD al 330-340 4694~4836 RV10 ArmOut(CylinderIN)
Main Pump
PORT (DO NOTADJUST) HEAD a2 330-340 4694-483E RV9 ArmIn (Cylinder OUT)
RELIEFS "H"-Mode,Engineat Hi Idle.
F al 360-370 ~120-526,3 RV14
RH R Simultaneous LH/RHTravel
TRAVEL 5120-5263 RV13
Main Pump PF1/4 al 360-370 Engaged
(DO NOTADJUST) F a2 360-370 5120-5263 RV13 "H"-Mode,Engineat Hi Idle.
LH R Simultaneous LWRH Travel
a2 360-370 5120~5263 RV14 Engaged
R a2 280-310 3982-440£ RV11 BucketLock, Stall Swing
SWING Main Pump
L a2 280-310 3982-440~ RV12 BucketLock, Stall Swing

LOWPRESSURE Enginein "HI" Idle al 32-47 455-668 Internal Enginein "HI" Idle
Main Pump
RELIEFS Controlsin Neutral a2 32-47 455-668 Shims Controlsin Neutral
Low
Pressure
NEGATIVE
CONTROL Enginein "HI" Idle Pil 32-47 455~668 Relief Enginein "HI" Idle
Main Pump
PRESSURES Controlsin Neutral Pi2 32-47 455~668 Valves Controlsin Neutral

TESTPORTLOCATIONS:

NOTE :
Take Measurements with
Engine at "HI" Idle
al & a2 Test Ports Pil Test Port unless otherwise
on Main Pumps on P1 Regulator
specified. The standard
tolerance shall be an
allowable range in field
measurements.

I Pi2 / ~,~,~!’~ I

P3 Test Port Pi2 Test Port

on Pilot Gear Pump on P2 Regulator

Page 10-20 Mark

IV 08/99
 MEASURING& ADJUSTINGPRESSURES
SK150 .-- SK160 M/C
C. SK150 ~ SK160 YMU- 1501~
MAIN CONTROL VALVE
/---INDEPENDENT
TR1--1 / TRAVEL BLOCK
RV5
RV8

- D~
~’ ~’~-~
MRI~ ~ C2’ ~
XI-~ ~

el ’

Ccl~

POP1 \ Pis
RVlO
ARM RAISE \
CONFLUX SPOOL ~, ~
-- DR2 --_
RV10
C~--

f Z4 TR2

"’,~ / I = .=~;.,v:co%.-~o~~
L~t ~ ~&- ~ ~
~____~r ~_p1
B,-~~DR, REL,EFVALVE.R=_~/
RV,SPOO.ASSE.BL~ ,.,,~, PREFERENTIAL

SWING CONTROL VALVE

ix
C
,.~O
- p

AM BM PiA --
TRAVEL MOTOR ASSEMBLY
,~~~ CASE ORA,N PORT- C1--~
OIL FILL PORT
¢1

PORTRELIEF J PORT- O
~ I "~’ i! ~d
VALVES--
RV,~. I111¢t:;2~I
RV14 I~I’-~_’%/ IT~V
~/~/ O,LPORT-B~ II - OIL CHECKPORT

MarkIV 08/99
CASE DRAIN PORT- C2
il OIL DRAIN PORT

Page1 0-21
 MEASURING
& ADJUSTINGPRESSURES
SK150 ~ SK160 MIC
YMU - 1501~

MEASURING
¢~djustment CONDITION,
INSPECTION ITEM Point
READING FROM SPECIFICATION FUNCTION
Cleanlinessof HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A Take Sample
Temperatureof HydraulicOil HydraulicOil TankSurface °C- 45~55 °F- 113-131 N/A Ambient Temperature
-10°C - 50°C
Engine Coolant Temperature Radiator Surface °C- 60-9O°F- 140-194; N/A
(14OF- 122OF)
STANDARDS
FOR LowIdle 850-900 RPM Throttle @"LO"-Idle
GaugeCluster Display
TESTING Hi- Idle 2365-2400RPM Throttle @"HI"- Idle
or
"S" or "D" Mode 1950-2050 RPM Throttle @"HI"- Idle
Externally Mounted
"FC" Mode 1550-1650 RPM Throttle @"HI"- Idle
Tachometer
Auto AcceI-Decel "ON" 1000-1100 RPM Throttle @"HI"- Idle
m
PILOT CIRCUIT PRIMARYPRESSURE 47-53 670-750 PR1 ’H"-Mode~Eng/HiIdle
RH al 350-355 $980-5050 TR1 ’H’-Mode,
Engine
at Hi Idle.
TRAVEL Main Pump 3imultaneous
LWRH Operation
LH a2 350-355 $980-5050 TR2 travel
Stalled.
MAIN
RELIEFS
RH al 300-305 ~270-4340 MR1 BucketDigging
ATTAC
H M E NT Main Pump
LH a2 300-305 ~270-4340 MR2 3oomRaising
BUCKET ROD al 330-340 4700-4835 RV8 Bucket Dump
Main Pump
(DO NOTADJUST) HEAD a2 330-340 4700-4835 RV7 BucketDigging
BOOM ROD al 330-340 4700-4835 RV6 BoomLowering
Main Pump
(DO NOTADJUST) HEAD a2 330-340 4700-4835 RV5 BoomRaising
ARM ROD al 330-340 4700-4835 RVl0 ~rmOut(CylinderIN)
Main Pump
PORT (DO NOTADJUST) HEAD a2 330-340 4700-4835 RV9 ~,rmIn (CylinderOUT)
RELIEFS al 360-370 5120-5260 RV14 ’H’-Mode, Engine
atHiIdle.
RH Simultaneous
LH/RH Travel
TRAVEL !R Main Pump =F 114 al 360-370 5120-5260 RV13
(DO NOTADJUST) a2 5120-5260 RV13 "H’-Mede, Engineat Hi Idle.
LH F 360-370 SimultaneousLH/RHTravel
R a2 360-370 5120-5260 RV14 Enmmd
RH a2 ;235-295 3340-4200 RV11 BucketLock,Stall Swing
SWING Main Pump
LH a2 235-295 3340-4200 RV12 BucketLock,Stall Swing
Flow 242-256 CPU "S"Mode, Engin "HI" Idle
MODELOADING MODE Upper
VARIABLELOADING Distribution
17-18 ADJ
(OP~ON) SWITCH Lower SolenoidVaive 11.5-12.5 163.6-177.8 "g" "S"Mode, Engin "HI" Idle
INDEPENDENT RH al 32-47 455-668 Internal ’H"Mode,Engin "HI"Idle
Main Pump 455-668
LOW PRESSURE "D" MODE-OFF LH a2 32-47 Shims Controlsin Neutral
RELIEFS INDEPENDENT RH al 0-7 0-100 Internal ’D"Mode, Engin "HI" Idle
Main Pump
"D" MODE-ON LH a2 0-7 0-100 Shims Controlsin Neutral
INDEPENDENT RH PI1 32-47 455-668 Low ’H" Mode, Engin "HI" Idle
NEGATIVE Main Pump
"D"MODE-OFF LH Pi2 32-47 455-668 Pressure Controlsin Neutral
CONTROL
INDEPENDENT RH Pil 28-38 398-540 Relief ’D"Mede,Engin "HI"Idle
PRESSURES Main Pump
"D"MODE-ON LH Pi2 28-38 398-540 Valves Controlsin Neutral
PROPORTIONAL H.S.FC.D a3 13.3-16.3 0-43 Pf
Enginein "HI" Idle
SOLENOID KPSS Release Gear Pump a3 32-40 74-145 Solenoid
Controlsin Neutral
VALVE Boost Valve

TEST PORT LOCATIONS:

NOTE :
Take Measurements with
Engine at "HI" Idle
unless otherwise
al & a2 Test Ports Pil Test Port a3 Test Port
specified. The standard
tolerance shall be an

t allowable range in field

measurements.

P3 Test Port Pi2 Test Port VARIABLE LOADING

Page10-22 Mark
IV08/99
 MEASURING & ADJUSTING PRESSURES ED180
ED180 YLU - 0001 ~
MAIN CONTROLVALVE
/---INDEPENDENT
TR1--
RV8
\RV5 -~
~AVEL BLOCK
PZ Tm---~ ~...
C(@):K~-~-- Dr3 a2 / ~-~
MRI~

cl ’

C¢1

POP1 RV10
Pis
IV7 RV6
ARM RAISE ~
CONFLUX SPOOL \ ~
-- DR2 RV10
-’~/’~ r--~-~" ~ -- V1
Pil ~ ~ ,---PAIN ..... TR2
TR1
~P2
RV1O-~ ~
PZ - F ~r~

T --o0o
¯’i
Pig -J/ A2
~A3 Pop2 .... ]J ~- P1

BI-~ LDRI--REL-IE"F’IiLVi
....
LMR22| RV9 SPOOLASSEMBLY
SWING CONTROLVALVE

SWING
SHOCKLESS VALVE~ SWING SHOCKLESS
-.--

- p

L BM ’ PiA
/AM PiA --
TRAVEL MOTOR ASSEMBLY
[]
,~~~~ CASEDRA,NPO,T- C~ .
--OIL FILL PORT

-- OIL CHECK
PORT

CASE DRAIN PORT- C2~" "-~ OIL DRAIN

PORT

MarkIV 08/99
Page10-23
 MEASURING& ADJUSTINGPRESSURESED180
YLU-0001

PRESSURE Adjustmenl MEASURING

INSPECTION ITEM Point CONDITION,
READING FROM SPECIFICATION FUNCTION
Cleanlinessof HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A Take Sample
Temperatureof HydraulicOil Hydraulic Oil TankSurface°C- 45-55 °F- 113-131 N/A Ambient Temperature
-10oc - 50oc
i EngineCoolant Temperature Radiator Surface °C- 60-90 °F- 140-194 N/A (14OF- 122OF)
STANDARDS LowIdle 850-900 RPM Throttle @"LO"- Idle
Externally Mounted
FOR Hi- Idle 2335-2370 RPM Throttle @"HI"- Idle
iu Tachometer ~.=_.
TESTING z_~ S or D Mode 1950-2050 Throttle @"HI"- Idle
or
FC Mode Cluster 1550-1650 Throttle @"HI"- Idle
ul Auto AcceI-Decel"ON" 950 -1100 RPM Throttle @"HI"-Idle
Gauge ~5
~’~"]lll=liv~
, )[o]LrAI
"Je]
~,I=1~ =tr_4.1[¢1
~-_~,,,]it4=111
-_xl]--ii i II~"l rl*] i [,~ t-1
PILOT CIRCUIT PRIMARYPRESSURE Gear Pump P3 47-53 670-750 P3 En,qine- Hi Idle
Engineat Hi Idle.
F al 350-355 $980-505( TR1
TRAVEL Main Pump SimultaneousLH/RHOperation
R a2 350-355 ~980-505( TR2 TravelStalled.
MAIN
REUEFS
ATTACHMENT
RH al 300-305 $270~434£ MR1 Bucket Digging
Main Pump
HH a2 300-305 ~270-434( MR2 BoomRaising
BUCKET ROD al 1330-340 ~694-483E RV8 Bucket Dump
Main Pump
(DO NOT ADJUST HEAD a2 !330-340 ~694~483E RV7 Bucket Digging
BOOM ROD al 330-340 4694-483E RV6 BoomLowering
Main Pump
(DO NOTADJUST H EAD a2 330-340 ~694-483E RV5 BoomRaising
ARM ROD al 330-340 4694-483e RVI0 ArmOut(Cylinder IN)
Main Pump
PORT (DO
I NOTADJUST) HEAD a2 330-340 4694-483E RV9 ArmIn (Cylinder OUT)
360-370 5120~526~ RV14 "H’-Mode,
RELIEFS F al Engine
at HiIdle.
RH Simultaneous
LWRHTravel
TRAVEL al 360-370 5120-526~ RV13 E~
(DO NOTADJUST) F IMain Pump PF1/4 a2 360-370 5120-526~ RV13 "H’-Mode,Engineat Hi Idle.
LH R a2 360-370 ;120-526~ RV14 SimultaneOUS LH/RHTravel

R a2 280-310 3982-440~ RVll BucketLock, Stall Swing

SWING Main Pump
L a2 280-310 3982-440~ RV12 BucketLock, Stall Swing
U al 260-280 3982-440; RV15 Blade Upand Stall
DOZER D a2 260-280 3982-440~ RV16 Blade Downand Stall
Dozer Pump
U/D P4 25O 3550 DRV1 BladeUpand Stall
Enginein "HI" Idle al 32-47 455-668 Internal Enginein "HI" Idle
LOW PRESSURE Controlsin Neutral Main Pump a2 32-47 455-668 Shims Controlsin Neutral
RELIEFS Low
Pressure
Enginein "HI" Idle Pil 32-47 455-668 Relief Enginein "HI" Idle
Main Pump
Controlsin Neutral Pi2 32-47 455-668 Valves Controlsin Neutral
PROPORTIONAL H-S.FC.D a3 13.3-16.3 0-43 Pf Enginein "HI" Idle
SLENOID KPSS Release Gear Pump a3 32-40 74-145 Solenoid
Controlsin Neutral
VALVE Boost Valve
TEST PORT LOCATIONS:

11um
a2 P2 pump
P3 Gear Pump
NOTE :
Take Measurements
with
P4 Dozer Pump
Engine at "HI" Idle
unless otherwise
specified. The standard
tolerance shall be an
allowable range in field
measurements.

Page10-24 Mark
IV08/99
 MEASURING& ADJUSTING PRESSURESSK200 ~ 210 M/C
SK200 ~ SK210 YQU-3101 ~
MAIN CONTROL
VALVE
PAr PAl
PAb (Advance) (Advance)
PAC
P1 LOW--~
PAl PRESSURE
RELIEF
VALVE

Pil-~ P1
CUT PRESSURE
PORT

P2 LOW PRESSURE
VALVE RELIEF VALVE
ARM -- MR2
SEQUENCE--
LEFT SIDE CONFLUENT
SPOOL PBI PZ VALVE
-- PBa
Ps
(Retreat)

--TRAVELPREFERENTIAL
PBr
Cl
TR1
.(
SPOOL
TRAVEL PREFERENTIAL Piga
(Retreat) TR2 -- Pigc
VIEW A-A PRESSURE PORT
FRONT VIEW VIEW B-B
SWINGCONTROLVALVE
WI2
SWING SHOCKLESS R
VALVE

c-
PB~pi
A

PRESSURE MEASURING
PORT
TRAVELBRAKEMOTORASSEMBLY
VB

TRAVEL PORT -- TRAVEL PORT

RELIEF VALVE RELIEF VALVE
RV13 & RV14 RV13 & RV14

-- MA

MarkIV 08/99
Page1 0-25
 MEASURING
& ADJUSTINGPRESSURES
SK200 ~ 210 M/C
YQU-3101~

PRESSURE Adjustmenl MEASURING

INSPECTION ITEM Point CONDITION,
READING FROM SPECIFICATION FUNCTION
Cleanliness
of HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A TakeSample
Temperature
of HydraulicOil HydraulicOil TankSurface°C- 45-55°F- 113-131 N/A AmbientTemperature
N/A -10°C - 50°C
STANDARDS EngineCoolant Temperature RadiatorSurface °C- 60-90 °F- 140-194 (14OF- 122OF)
FOR
TESTING =E LowIdle GaugeCluster Display 850-900 RPM Throttle @"LO"-Idle
I,i
o: Hi-Idle or 2335-2370 RPM o E ._o. Throttle@"HI"- Idle
ILl Externally Mounted 1950~2050RPM I’.O ~~"~E Throttle@"HI"- Idle
Z "S" or "D" Mode
"FC" Mode Tachometer 1550-1650 RPM Throttle@"HI"- Idle
Z
ILl Auto AcceI-Decel"ON" 1000-1100 RPM Throttle@"HI"-Idle
m Okl’Ok ¢f-II[¢1=IE~] I-Je]-’ill̄[,z(;liI;l’~i i
PILOTCIRCUIT PRIMARYPRESSURE Gear Pump P3 47-53 670-750 P3 "H"-Mode T Eng/HiIdle
TRAVEL F al !350-355 4980-5050 TR1 ’H"-Mode, Engineat Hi Idle.
SimultaneousLH/RHOperation
Main Pump
R a2 350-355 4980-5050 TR2 TravelStalled.
MAIN BOOST RH al 315-330 4480-4694 MR1 BucketDigging
Main Pump
RELIEFS PRESSURE HH a2 315-330 4480-4694 MR2 BoomRaising
RH al J300.305 4270-4340 MR1 BucketDigging
ATTACHMENT MainPump
HH a2 300-305 4270-4340 MR2 BoomRaising
BUCKET ROD al 330-340 4694~4836 RV8 Bucket Dump
Main Pump
(DO NOTADJUST) HEAD a2 330-340 4694-4836 RV7 BucketDigging
BOOM ROD al 330-346 4694-4836 RV6 BoomLowering
Main Pump a2
(DO NOTADJUST) HEAD 330-340 4694-4836 RV5 BoomRaising
ARM ROD al 880-340 4694-4836 RVl0 ArmOut(CylinderIN)
Main Pump
PORT (DO NOTADJUST) HEAD a2 880-340 4694-4836 RV9 ArmIn (Cylinder OUT)
RELIEFS F al "H’-Mode,
360~370 5120-5263 RV14 Simultaneous Engineat Hi Idle.
RH LH/RH Travel
TRAVEL R al 360~370 5120-5263 RV13 En~la~ted
(DO NOTADJUST) Main Pump PFI~ "H’-Mode,Engineat Hi Idle.
F a2 360-370 5120-5263 RV13 Simultaneous LH/RHTravel
LH R a2 360-370 5120-5263 RV14 En~a~ed
R a2 280-310 3982-4409 RV11 BucketLock, Stall Swing
SWING Main Pump
L a2 280-310 3982~4409 RV12 BucketLock, Stall Swing
Flow CPU "S"Mode, Engin "HI" Idle
VARIABLELOADING LOADING MODE Upper Distribution
18.5-19.5 263-277 ADJ
MODE(OPTION) SWITCH Lower Solenoid Valve 13.5-14.5 192-206 "B" "S"Mode, Engin "HI" Idle
INDEPENDENT RH al 32-47 455-668 Internal "H" Mode, Engin "HI" Idle
Main Pump
"D"MODE-OFF LH a2 32-47 455-668 Shims Controlsin Neutral
LOW PRESSURE
INDEPENDENT RH al 0-7 0.100 Internal "D" Mode, Engin "HI" Idle
RELIEFS MainPump
"D" MODE-ON LH a2 0-7 0.100 Shims Controlsin Neutral
INDEPENDENT RH Pil 32-47 455-668 Low "H" Mode, Engin "HI" Idle
NEGATIVE MainPump
"D"MODE-OFF LH Pi2 32-47 455-668 PressureControlsin Neutral
CONTROL
INDEPENDENT RH Pil 0-7 0-100 Relief "D" Mode, Engin "HI" Idle
PRESSURES Main Pump
"D" MODE-ON LH Pi2 0-7 0-100 Valves Controlsin Neutral
PROPORTIONAL H.S-FC-D a3 0-3 0-43 Pf
Enginein "HI" Idle
SOLENOID KPSS Release Gear Pump a3 13.3-16.3 189-232 Solenoid Controlsin Neutral
VALVE Boost a3 32-40 455-569 Valve

TEST PORT LOCATIONS:

NOTE :

Take Measurements In
al & a2 Test Ports Pil Test Port a3 Test Port "H" Mode unless otherwise
specified. The standard
tolerance shall be an
PORT ~~ allowable range in field
measurements.

P3 Test Port Pi2 Test Port VARIABLE LOADING

Page10-26 Mark
IV08/99
 MEASURING& ADJUSTING PRESSURESSK220 ~ 250 M/C
SK220 ~ SK230 LLU-5101-

MAIN CONTROL VALVE

PAr PAZ
PAb (Advance) (Advance)
PAC
P1 LOW
PAl PRESSURE \
RELIEF
Pil -~ VALVE

P1
CUT PRESSURE
PORT

F 5 RIGHT SIDE

P2 LOW PRESSURE
Dr1
VALVE RELIEF VALVE
ARM -- MR2
SEQUENCE
LEFT SIDE CONFLUENT
PZ VALVE @
SPOOL
-- PBa
Ps
(Retreat)
C1
TRAVEL PREFERENTIAL ~Pigc Piga
SPOOL PBr TR1
(Retreat) PREFERENTIAL
VIEW A-A TR2
PRESSURE PORT
FRONT VIEW VIEW B-B

SWING CONTROL VALVE

P RV12 Pi

PB
PiA

.t
RV11~~
j~~-,

,~. ~. )
~ C

PA

SWING SHOCKLESS
VALVE
UU U U U

TRAVEL MOTOR ASSEMBLY

PILOT SELECTORVALVE ,, I~ PRESSURE
MD~ ~ ~ MEASURING
VA-~~L ~ PORT
MA--

D1 ( ~i’~’~-~-I
1r l i wOVL~’~OAvlvE

MEASURING
PORT
A

MarkIV 08/99
Page10-27
 MEASURING
& ADJUSTINGPRESSURES
SK220 -250 M/C
LLU-5101~

PRESSURE MEASURING
INSPECTION ITEM Point CONDITION,
READING FROM SPECIFICATION FUNCTION
Cleanlinessof HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A TakeSample
Temperatureof HydraulicOil HydraulicOil TankSurface°C- 45-55°F- 113-131 N/A AmbientTemperature
-10°C ~ 50°C
STANDARDS EngineCoolant Temperature RadiatorSurface °C- 60-90 °F- 140-194 N/A (14°F- 122°F)
FOR
TESTING ~ Low Idle 850-900 RPM Throttle @"LO"-Idle
GaugeCluster Display ~ ~ 8
~ Hi- Idle 2335-2370 RPM Throttle @"HI"- Idle
or
"S" or "D" Mode 1950-2050 RPM o~E=o~,~. Throttle@"HI"- Idle
Externally Mounted ~=~
~3 "FC" Mode Tachometer 1550-1650 RPM 0: < :~ ,~ Throttle@"HI"- Idle
Auto AcceI-Decel"ON" 1000-1100 RPM Throttle@"HI"- Idle

PILOT CIRCUIT PRIMARYPRESSURE "H"-Mode~ En,q/HiIdle

TRAVEL ¯ F al 350-355 4980-505C TR1 "H’-Mode, Engineat Hi idle¯
Main Pump SimultaneousLH/RHOperation
R a2 350-355 4980-505C TR2 Travel Stalled.
MAIN BOOST ¯ RH Main Pump al 315-330 4480~4694 MR1 BucketDigging
RELIEFS PRESSURE HH a2 315-330 4480-4694 MR2 BoomRaising
RH Main Pump al 300-305 4270-4340 MR1 BucketDigging
ATTACHMENT ¯
HH a2 300-305 4270-4340 MR2 BoomRaising
al 330-340 4694-4836 RV8 Bucket Dump
BUCKET ¯ ROD Main Pump
(DO NOTADJUST) HEAD a2 330-340 4694~4836 RV7 BucketDigging
BOOM ROD al 330-340 4694~4836 RV6 BoomLowering
(DO NOTADJUST) HEAD Main Pump a2 330-340 4694-4836 RV5 BoomRaising
ARM ROD al 330-340 4694-4836 RV10 ArmOut(Cylinder IN)
PORT (DO NOTADJUST) HEAD Main Pump a2 330~340 4694-4836 RV9 ArmIn (Cylinder OUT)
RELIEFS F al 360-370 5120-5263 RV14 "H"-Mode, Engineat Hi Idle.
RH Simultaneous LH/RHTravel
TRAVEL al 360-370 5120-5263 RV13 Engaged
(DO NOTADJUST) Main PumpPF 1/4
F a2 360-370 5120-5263 RV13 "H’-Mode, Engineat Hi Idle.
L.H SimultaneousLH/RHTravel
R a2 360-370 5120-5263 RV14 En~laged
R a2 280-310 3982-4409 RV11 BucketLock,Stall Swing
SWING Main Pump
L a2 280-310 3982-4409 RV12 BucketLock,Stall Swing
Flow 18.5~19.5! 263-277 cPu "S"Mode, Engin "HI" Idle
LOADING MODE Upper Distribution
VARIABLE LOADING ADJ
MODE(OPTION)
SWITCH LowerSeleooidValve 13.5-14.5 192-206 "B" "S"Mode, Engin "HI" Idl~
INDEPENDENT RH Main Pump al 32-47 455-668 Internal "H" Mode, Engin "HI" Idle
"D" MODE-OFF LH a2 32-47 455-668 Shims 3ontrolsin Neutral
LOW PRESSURE INDEPENDENT RH Main Pump al 0~7 0-100 Internal "D" Mode, Engin "HI" Idle
RELIEFS
"D" MODE-ON LH a2 0-7 0-100 Shims Controlsin Neutral
INDEPENDENT RH Pil 32-47 455~668 Low "H" Mode, Engin "HI" Idle
NEGATIVE "D" MODE-OFF LH Main Pump Pi2 32-47 455-668 Pressure 3ontrolsin Neutral
CONTROL
PRESSURES INDEPENDENT RH Main Pump Pil 0-7 0-100 Relief "D" Mode, Engin "HI" Idle
"D" MODE-ON LH Pi2 0-7 0-100 Valves Controlsin Neutral
PROPORTIONAL H¯ S ° FC¯ D a3 0-3 0-46 Pf Enginein "HI" Idle
SOLENOID KPSS Release Gear Pump a3 13.3-16.3 189-232 Solenoid Controlsin Neutral
VALVE Boost a3 32-40 455-569 Valve

TEST PORTLOCATIONS:

IT~-~~\~I ~

NOTE:

Take MeasurementsIn
al & a2 Test Ports Pil Test Port a3 Test Port "H" Modeunless otherwise
specified. Thestandard
I~ ~lnstall Gauge toleranceshall be an
I allowablerangein field
measurements.
{~.".’~.}~PORT .~J~-~’~’~ ’-~/-~ ~"

P3 Test Port Pi2 Test Port VARIABLE LOADING

Page10-28 Mark
IV08/99
 MEASURING& ADJUSTING PRESSURESSK270 M/C
SK270 LBU-0201~

MAIN CONTROL
VALVE
PAr PAZ P2 NEUTRAL
PAb (l~dvance)
(Advance) I CUT PRESSURE
PAC PORT
P1
PRESSURE
RELIEF CONFLUENT
VALVE

.i.\ P1
CUTPRESSURE
SPOOL
I,,To
~(

PORT

P4- @ ~
B1 o JPi3
DY
P5 RIGHT SIDE
P2 LOWPRESSURE
RELIEFVALVE
ARM-- MR2
LEFT SIDE CONFLUENT
SPOOL PZ

Ps
PB1
(Retreat)

TRAVELPREFERENTIAL Cl
SPOOL PBr
(Retreat) TRAVELPREFERENTIAL
VIEW A-A PRESSUREPORT
FRONT VIEW VIEWB-B
SWINGCONTROLVALVE
P
-R

PiA
RV11

/
~
if ~RV12 Pi

Pie
~
c
~"~
¯ PA
~,C

SWINGSHOCKLESS
VALVE
U UU U U U"

TRAVEL MOTORASSEMBLY
--iiisSSuU

D1

MEASURING
PORT
MarkIV 08/99 Page1 0-29
 MEASURING& ADJUSTING PRESSURESSK270 M/C
LBU-0201 ~

PRESSURE MEASURING
S,djustmenl CONDITION,
INSPECTION ITEM Point
READING FROM SPECIFICATION FUNCTION
Cleanliness
of HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A Take Sample
Temperature
of HydraulicOil HydraulicOit TankSurface°C- 45-55I°F- 113-131 N/A AmbientTemperature
STANDARDS -10°C - 50°C
FOR EngineCoolantTemperature RadiatorSurface °C- rF-
60-90 140-194 N/A
(14°F- 122°F)
TESTING Throttle @"LO"-Idle
=E LowIdle 850~900 RPM
GaugeCluster Display
Hi- Idle 2335-2370 RPM Throttle@"HI"- Idle
or
"S" or "D" Mode 1950-2050 RPM Throttle@"HI"-Idle
Externally Mounted
"FC" Mode 1550-1650 RPM ~.~8~
~o 2 Throttle@"HI"- Idle
Tachometer
I,LI Auto AcceI-Decel"ON" 1000-1100 RPM Throttle@"HI"- Idle

II mP3"H"-Mode~ En,q/HiIdle
PILOTCIRCUIT PRIMARYPRESSURE
F al 350-355 4980-505£ TR1 ¯Simultaneous
H’-Mode,
Engineat HiIdle.
TRAVEL Main Pump LH/RH Operation
R a2 1350-355 4980-505C TR2 Travel Stalled.
MAIN BOOST RH al 315-330 4480-4694 MR1 BucketDigging
Main Pump
RELIEFS PRESSURE HH a2 315-330 4480-4694 MR2 BoomRaising
RH al 300-305 4270-434£ MR1 BucketDigging
A’n’ACHMENT Main Pump
HH a2 300-305 4270-434£ MR2 BoomRaising
BUCKET ROD al 330-340 4694~483~ RV8 Bucket Dump
Main Pump
(DO NOTADJUST) HEAD a2 330-340 4694-4836 RV7 BucketDigging
BOOM ROD al 330-340 4694-4836 RV6 BoomLowering
Main Pump
(DONOTADJUS~ HEAD a2 330-340 4694-4836 RV5 BoomRaising
ARM ROD al 330-340 4694-4836 RV10 ArmOut(CylinderIN)
Main Pump
PORT (DO NOTADJUST) HEAD a2 330-340 4694-4836 RV9 ArmIn (Cylinder OUT)
RELIEFS F al 360-370 5120-5263 RV14 "H’-Mode, Engineat Hi Idle.
RH;R Simultaneous
LH/RH Travel
TRAVEL al 360-370 5120-5263 RV13 Enkindled
(DO NOTADJUST) Main Pump PF1/4
F a2 360-370 5120-5263 RV13 "H’-Mode, Engineat Hi Idle.
LH Simultaneous
LH/RH Travel
a2 360-370 ~120-5263 RV14 En~a~ed
R a2 280-310 3982-4409 RV11 BucketLock,Stall Swing
SWING Main Pump
L a2 280-310 3982-4409 RV12 BucketLock,Stall Swing
Flow
LOADINGMODE Upper Distribution 18.5-19.5 263-277 CPU "S"MOde,Engin "HI" Idle
VARIABLELOADING ADJ
MODE(OPTION)
SWITCH Lower Solenoid Valve 13.5-14.5 192-206 "B" "S"Mode, Engin "HI" Idle
INDEPENDENT RH Main Pump al 32-47 455-668 Internal "H" Mode, Engin "HI" Idle
"D"MODE-OFF LH a2 32-47 455-668 Shims Controlsin Neutral
LOW PRESSURE INDEPENDENT RH Main Pump al 0-7 0-100 Internal "D" Mode,Engin "HI" Idle
RELIEFS "D"MODE-ON LH a2 0-7 0-100 Shims Controlsin Neutral
INDEPENDENT RH Main Pump Pil 32-47 455-668 Low :"H" Mode, Engin "HI" Idle
NEGATIVE "D"MODE-OFF LH Pi2 32-47 455-668 PressureControlsin Neu~al
CONTROL
INDEPENDENT RH Main Pump Pil 0-7 0-100 Relief "D" Mode, Engin "HI" Idle
PRESSURES
"D" MODE-ON LH Pi2 0-7 0-100 Valves Controlsin Neutral
PROPORTIONAL H-S-FC.D a3 0-3 0-43 Pf
Engine
in "HI" Idle
SOLENOID KPSS Release Gear Pump a3 13.3-16.3 189-232 Solenoid Controlsin Neutral
VALVE Boost a3 32-40 455-569 Valve

TEST PORT LOCATIONS:

.OTE:
Take Measurements In
al & a2 Test Ports Pil Test Port a3 Test Port "H" Mode unless otherwise
specified. The standard

PORT tolerance shall be an

allowable range in field
measurements.
.it ~ --

P3 Test Port Pi2 Test Port VARIABLE LOADING

Page 10-30 Mark

IV08/99
 MEASURING& ADJUSTING PRESSURESSK300 ~ SK330 M/C
SK300 ~ SK330 YCU-0611
-
PAl
MAIN CONTROL PAr--]
PRESSUREPORT
VALVE PAb-~ t
-- Dr3
P1 LOW I
POpl--~ BOOM
PAI-~ \ PRESSURE\ r- PAa
RELIEF
p. ~\ VALVE
\ _~ SPOOL
A1--
PL1- \ ~1 ~ I P1 NEUTRAL--~ I1==.
\ \~p~CUT PRESSURE
PORT

B2 ~ --D~ POP2-~

Ba2

PS ~
VALVE
Dr1 -~
~_~ LOW PRESSURE
RELIEFVALVE
~.~ ’~-P4ARM
~J CONFLUENT
SPOOL
LEFTSIDE PBc RIGHTSIDE
TRAVELPREFERENTIAL7 ~ PAl Piga
SPOOL / / f/--- T2
L PZi!
PBr ~
@~ I-- PB.1.

~T
PAr
~__ Q(~) -Pea2
o PAa Ngb Pisd
PBr -- C1 TR1 2
Piga
- Dr3VIEW
AA TR2
Pigc
FRONT VIEW VIEWB-B
SWING CONTROL
VALVE ~ RV12
-R
F
PB

U U
SWINGSHOCKLESS
VALVE
TRAVEL MOTORASSEMBLY
PILOT SELECTOR
VALVE --PRESSURE
~ MEASURING
P VA PORT
MA--

~ OVERLOAD

D1 v’w
MEASURING
PORT

MarkIV 08/99
Page 10-31
 MEASURING
& ADJUSTINGPRESSURES
SK300 ~ SK330 M/C
YCU-0611~
PRESSURE ~,djuslment MEASURING
INSPECTIONITEM Point CONDITION,
READING FROM SPECIFICATION FUNCTION
Cleanlinessof HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A TakeSample
Temperatureof HydraulicOil Hydraulic Oil TankSurface °C- 45-55 °F-113-131 N/A AmbientTemperatura
-10°C ~ 50°C
EngineCoolantTemperature RadiatorSurface ’C- 60-90°F- 140-194 N/A (14OF_122OF)
STANDARDS
850-900 RPM ~ . Throttle@"LO"-Idle
FOR Low Idle GaugeCluster Display
TESTING uJ Hi- Idle 2065-2100 RPM ~:~ 8.< Throttle@"HI"- Idle
z or
~ "S" or"D" Mode 1670-1760 RPM ®~ 2 ® Throttle@"HI"- Idle
= n- "FC" Mode Externally Mounted ~
1370-1430RPM o. ~ ® ~. Throttle@"HI"- Idle
UJ Tachometer
Auto AcceI-Decel"ON" 1000-1100 RPM ~< Throttle@"HI"- Idle

PILOTCIRCUIT PRIMARYPRESSURE Gear Pump P3 47-53 670-750 PR1 "H"-MOde,

Eng/HiIdle
"H’-Mode,Engineat Hi Idle.
RH al 350-355 4980-5050 TR1
TRAVEL Main Pump Simultaneous LH/RH
LH a2 350-355 4980-5050 TR2 OperationTravel
Stalled.
MAIN BOOST RH - MainPump al 330-345 4695-4910 MR1 BucketDigging
REUEFS PRESSURE LH a2 330-345 4695-4910 MR2 BoomRaising
RH - MainPump al 300-305 4270-4340 MR1 BucketDigging
ATTACHMENT
LH a2 300-305 4270-4340 MR2 BoomRaising
BUCKET ROD -Main Pump al 330-340 4695-4837 RV8 Bucket Dump
(DO NOTADJUST) HEAD a2 345-355 4910-5050 RV7 BucketDigging
BoomLowering
BOOM ¯ ROD - MainPump al 330-340 4695-4837 RV6
(DO NOTADJUST) HEAD a2 345-355 4910-5050 RV5 iBoomRaising
ARM ROD al 345-355 4910-5050 RV10 !ArmOut(CylinderIN)
PORT (DO NOTADJUST) HEAD - MainPump a2 330-340 4695-4837 RV9 ~,rmIn (CylinderOUT)
RELIEFS ’H"-Mode,Engineat Hi Idle.
F al 350-360 4980-5120 RV14
RH - .~imultsneous LH/RHTravel
TRAVEL R Main Pump PF1/4 al 350-360 4980-5120 RV13 -ngaged
(DO NOTADJUST) F a2 350-360 4980-5120 RV13 "H’-Mode,Engine at Hi Idle.
LH- - Simultaneous LH/RHTravel
R a2 350-360 4980-5120 RV14 En,qa,qed

¯ RH Main Pump a2 225-325 3200-4625 RV11 BucketLock,Stall Swing

SWING
LH a2 225-325 3200-4625 RV12 BucketLock,Stall Swing
Flow 17-18 242-256 CPU "S"MOde,Engin "HI" Idle
VARIABLELOADING LOADINGMODE Upper Distribution ADJ
MODE(OPTION) SWITCH Lower Solenoid 11.5-12.5 163.6-177.8 "B" "S"Mode,Engin "HI" Idle
INDEPENDENT RH - Main Valve al 32-47 455-668 Internal ’H" Mode,Engin "HI" Idle
Pump
LOWPRESSURE "D" MODE-OFF LH a2 32-47 455-668 Shims Controlsin Neutral
REUEFS INDEPENDENT ¯ RH ¯ MainPump al 0-7 0-100 Internal ’D" Mode,Engin "HI" Idle
"D" MODE-ON LH a2 0-7 0-100 Shims Controlsin Neutral
INDEPENDENT RH Main Pump Pil 32-47 455-668 Low ’H" Mode, Engin "HI" Idle
NEGATIVE "D" MODE-OFF Pi2 32-47 455-668 Pressure Controlsin Neutral
LH
CONTROL Pil
INDEPENDENT ¯ RH ¯ MainPump 28-38 398-540 Relief ’D" Mode, Engin "HI" Idle
PRESSURES
"D" MODE-ON LH Pi2 28-38 398-540 Valves Controlsin Neutral
PROPORTIONAL H¯ S ° FC¯ D a3 0-3 0-43 Pf
Engine
in "HI" Idle
SOLENOID KPSS Release Main Pump a3 13.3-16.3 189-232 Solenoid
Controlsin Neutral
VALVE Boost a3 32-40 455-569 Valve

TESTPORTLOCATIONS:

NOTE:
TakeMeasurementsIn
al & a2 Test Ports Pil Test Port a3 Test Port "H"Modeunless
otherwise
specified.
Thestandard
tolerance
shallbean

t allowable
range
in field

P3 Test Port Pi2 Test Port

~ ~stall Gauge Here

VARIABLE LOADING
measurements.

Page10-32 Mark
IV08/99
 MEASURING& ADJUSTING PRESSURESSK400 ~ SK460 M/C
SK400 ~ SK460 YSU-0242~

MAIN CONTROL --TR1

--TR2
VALVE
-- PBL
--PZ
PBa2
=
r

PLI"
~ L

°
-- Piga

PO

LEFT SIDE

U U
SWING SHOCKLESS
VALVE

TRAVEL MOTOR
P2

~~F
TRAVEL PORT
RELIEF VALVE

G2

MarkIV 08/99 Page1 0-33

 MEASURING
& ADJUSTING
PRESSURES
SK400 ~ SK460 M/C
YSU-242~

PRESSURE Adjustment MEASURING

Point CONDmON,
READING FROM SPECIFICATION FUNCTION
Cleanlinessof HydraulicOil HydraulicOil Tank Class: NAS7-9 N/A Take Sample
Temperatureof HydraulicOil HydraulicOil TankSurface’C- 45-55 °F- 113-131 N/A AmbientTemperature
-10°C - 50°C
EngineCoolant Temperature RadiatorSurface ’C- 60-90 °F- 140-194 N/A (14OF- 122oF)
Lowldle 850-900 RPM Throttle@"LO"-Idle
GaugeCluster Display =
I, LIHi-Idle** ** 2165-2200RPM ¢o¢.- Throttle@"HI"- Idle
z=i or =’~2®
(~a. "S" or"D" Mode 1870-1930R PM o~m~E Throttle@"Hr’-Idle
Extemally Mounted
,,=,="FC" Mode 1570-1630 RPM Throttle@"Hl"-Idle
Tachometer
Auto AcceI-Decel"ON" 1000~1100 RPM Throttle@"HI"-Idle

47-53
m
670-750
m
PR1 ’H"-MOde, Eng/HiIdle
PRIMARYPRESSURE
RH al 350-355 4980-5050 TR1 ’H"-Mode, Engineat Hi Idle.
TRAVEL Main Pump 3imultaneous LH/RHOperation
LH a2 350-355 4980-5050 TR2 RavelStalled.
MAIN BOOST RH al 350-355 4980-5050 MR1 3ucketDigging
Main Pump
RELIEFS PRESSURE LH a2 350-355 4980-5050 MR2 BoomRaising
RH al 320-325 4550-4620 MR1 3ucketDigging
ATTACHMENT Main Pump
LH a2 320-325 4550-4620 MR2 3oomRaising
BUCKET ROD al 335-355 4765-5050 RV8 Bucket Dump
Main Pump
(DO NOTADJUST) HEAD a2 335-370 4765-5260 RV7 BucketDigging
BOOM ROD al 315-355 4480-5050 RV6 BoomLowering
Main Pump
(DO NOTADJUST) HEAD a2 335-370 4765-5260 RV5 BoomRaising
ARM ROD al 335-355 4765-5050 RV10 ArmOut(CylinderIN)
Main Pump
PORT (DO NOTADJUST) HEAD a2 335-355 4765-5050 RV9 ArmIn (Cylinder OUT)
350-365 4980-5190 RV14 ’H’-Mode,
RELIEFS Engine at Hi Idle.
F al
RH Simultaneous LH/RHTravel
TRAVEL R al 350-365 4980-5190 RV13 Engaged
MainPump PFI~
(DONOTADJUST) F a2 350-365 4980-5190 RV13 "H’-Mode, Engine at Hi Idle.
LH Simultaneous LH/RHTravel
R a2 350-365 4980-5190 RV14 Enqa,qed
RH a2 260-300 3700~4270 RV11 BucketLock,Stall Swing
SWING Main Pump
LH a2 260-300 3700-4270 RV12 BucketLock,Stall Swing
VARIABLELOADINGLOADINGMODE Upper Flow 18.5-19.5 260-280 CPU "S"MOde, Engin "HI" Idle
Distribution ADJ
MODE(OPTION) SWITCH Lower Solen~dValve 13.5-14.5 192.0-206.; "B" "S"Mode, Engin "HI" Idle
INDEPENDENT RH al 32-47 455-668 Intemat "H" Mode, Engin "HI" Idle
Main Pump
LOW PRESSURE "D"MODE-OFF LH a2 32-47 455-668 Shims Controlsin Neutral
RELIEFS INDEPENDENT RH al 0-7 0-100 Internal "D" Mode, Engin "HI" Idle
Main Pump
"D" MODE-ON LH a2 0~7 0-100 Shims Controlsin Neutral
INDEPENDENT RH Pil 32-47 455-668 Low "H" Mode, Engin "HI" Idle
NEGATIVE Main Pump
"D" MODE-OFF LH Pi2 32-47 455-668 Pressure Controlsin Neutral
CONTROL
INDEPENDENT RH Pil 28-38 398-540 Relief "D" Mode, Engin "HI" Idle
PRESSURES Main Pump
"D" MODE-ON LH Pi2 28-38 398~540 Valves Controlsin Neutral
PROPORTIONAL H-S.FC-D a3 0-3 0-43 Pf Engine in "HI" Idle
SOLENOID KPSS Release Main Pump a3 13.3-16.3 189-232 SolenoidI Controlsin Neutral
VALVE Boost a3 32-40 455-569 Valve

TEST PORT LOCATIONS:

I
** NOTE: on unit serial numbers
YSU-0200-0241
Hi-Idle Speed = 2,200-2,220 RPM

NOTE :

al & a2 Test Ports Pil Test Port a3 Test Port

Take Measurements In
"H" Mode unless otherwise
I~
I ~lnstall Gauge specified. The standard
tolerance shall be an
allowable range in field
measurements.

P3 Test Port Pi2 Test Port VARIABLE LOADING

Page10-34 Mark
IV08/99