I bought the machine as is and runs well but nothing moves or operates. Checked pilot pump and is set to 750 psi as per manual also checked main pump solenoid and replaced with new ones. No codes on screen all fuses good fluid full. Nothing moves or even tries. Took main pump to off had inspected said it looked new and no issues but wasn't able to bench test. Engine starts and runs great but wont move please any ideas?
Try turning the machine 45 degrees to the track frame and remove the bottom underside panels of the cab. Thes panels expose the travel lever control blocks, pilot hoses and the solenoid manifold assembly. Each solenoid on the solenoid manifold should have a small white tag on its harness connector with a label name in black. The tag you are looking for should be labeled "SV4" for the SK135SR lever lock solenoid. Check this solenoid for power when the lever lock arm is down and check the main fuse block in the cab, fuse number "15" "Solenoid" 10A rating. Kind regards
Awesome thanks for the info I will check tomorrow!
I checked the SV4 and it has 24 volt power with key on and safety lever down. All fuses show good and 24v power. No codes on screen or alarms. Any other ideas? Thanks, Bryan
To help diagnose further will require the use of your screen monitor which is hopefully working and displaying clearly. Please see attached information for setting up the screen display in service mode. Once you have this set up on the display and the machine is running, go to screen number 9 and record the values that are on the screen for B-1 Boom Raise, then lower the lever lock arm down and proceed to try and raise the boom all the way up with the pilot control lever at maximum stroke. Hold the lever in this position and record the values on the screen. Now advance to screen number 24 "Propo valve e1-pump p1" and repeat this process with the boom up function. record the values and then do the same again for screen number 25. When you get time report back with the values and we can go from there. Kind regards
Thanks I just checked it with the machine running. B-1 0.4v B-2 0.4v On screen 9 Comp 350ma MEAS 356ma On screen 25 Boom doesn't move as no hydraulics work. Volts nor pressure change when i moved the controls. Thank you for your help! Bryan
Not a problem, happy to help. Please revisit solenoid SV4 and check the coils resistance. The coil has a small slotted screw and a lock nut. Take a depth measurement of the screws protrusion from the coil then loosen the small lock nut and wind the screw all the way in gently until it starts to come to a stop, count the number of turns as you go for reference to reset it should you need to. This adjustment will override the coils operation and the machine should have pilot supply to the hand controls all the time. This should only be done as a test and should not be left like this for safety reasons. Do not attempt to exit or enter the cab while the machines engine is running while conducting this test. Kind regards
Electronic or mechanical hydraulic linkage to the solenoid valves?
See highlighted in yellow for resistance value and screw adjustment. Kind regards
I wasn't able to measure the resistance I need to get my meter however I did gently bottom out the screw and still no change. Not even a slight movement unfortunately. Thank You, Bryan
Thank you for doing those checks, this would suggest there is no pilot pressure being supplied to the block. If possible are you able to test the pilot pressure again at the pilot pump and also at the solenoid block? the pilot pump has a test point plug that should be 1/4 bspp but the solenoid block may require a test tee fitting installed inline with the hose connection "P1" that will need to be 3/8 inverted bspp. If you verify that the pilot pump has pilot pressure but the solenoid block has no pilot pressure to the"p1" port then something is interrupting the pilot flow or a hose connection is incorrect. Kind regards
I was able to pressure test the main line that connects to the side of the valve block next to SV4. After running the engine and lowering the safety lever in the cab there was no pressure at any point. I think we're getting closer for sure. Is there any check valves or pressure safety cut off between the pump and valve block? Thank you, Bryan
No, other than the pilot filter (item 13) there should not be any other device that interrupts the pilot flow to the lever lock manifold and the main pump regulators. There should always be pilot pressure input to the solenoid manifold and pump regulators when the engine is running regardless of the lever lock position. See diagrams attached. Kind regards
Ok thanks so much for the diagram thats great information. I will locate the filter and check the line to and from and let you know what I find. Im glad the great mystery of my machine is almost over!! Thank you, Bryan
As Mr.KOBE STEEL said above. There are a lot of FILTER in PILOT PIPING. You should check all of them. Some filters are also installed right at the connectors or elbows.
Hello again I wanted to reach out to you with an update on the machine. I was unable to work on it for a long time but recently did some more diagnosing by following the pilot pressure from the pump to the valve block under the cab and found a blocked screen. Now i have pilot pressure and the boom rases and moves but slow. The left track moves but the right one does not. There is no swivel of the machine of either direction. I did verify pilot pressure to P1 and P2 pump solenoids which are new. One solenoid is getting 24 volts the other only 6. After jumping 24 volts to each solenoid with pilot pressure no change in movements power or speed. Any ideas would be great I will be continuing by tracking pilot pressure to swing motor. Thank You, Bryan
Also Is 700PSI enough pilot pressure?
Hi Bryan 700 psi should be your max pilot pressure reading at the rated high engine speed. Now that you have cleared the blockage in the pilot manifold fitting and you are getting some functions to work you should operate the functions again and record the electrical sensor values from the diagnostic service display on the monitor. You need to read and record the values at full lever movements and report back if possible. Please do not apply 24V to any of the proportional solenoids for any length of time as these may burn out if they exceed the max current ratings for too long. as an example for your diagnostics readings for slew operation, operate and hold the slew to full left joystick position and record the values for screen display page numbers 12, 14, 24, 25 ( see attachment "service monitor" in previous post) repeat these steps for slew right and record. Now for the right track, raise the right track off the ground and operate full right track lever forward and record the values on the screen page numbers 13,14,24,25 and repeat for reverse travel lever operation. repeat and record for as many functions as you can and remember to include pages 14,24,25 with each function. This will help build a better picture of what is going on with your machine Finally, go to the pump regulators and remove the 2 pilot hose fittings. These 2 fittings may each have a gauze filter inside so try cleaning these and checking these are not also blocked. As always keep safety first and give yourself plenty of space for testing in case something decides to unexpectedly spring back into action during your tests! hope this helps Best regards
Thanks for the information! I did start at the 2 main pumps and found the screens where clogged. Cleaned them out and started engine with 24 volt to solenoids on main pumps and the engine quickly struggled and stalled. After testing each pump seperately the pump that stalls the engine is the one closest to the engine. As long as I move the controls while running it will not stall. Wandering if the return line from that pump is clogged or a relief valve stuck? Was able to swing left and right but only if the right joystick is pulled back at the same time. And unfortunately, no matter what i did the left track would not move at all. Tomorrow I will test the and record values as suggested. I was hoping the clogged screens would fix the problem. Thank You, Bryan
Tested and results as follows: 12 B-7 .6v-4.9v 1P-30P B-8 .6v-4.9v 1P-30P 14 C1 .7V-.7v 36-36p C2 .4v P2 0p 24 E1 P1 350MA 6P 350-356MA Power Shift 0 25 E-2 P2 350MA 6P 351-356MA Power Shift 0 13 0.38v 0-25p 0.37v 0-24p 9 0-4.8v 0-30p Both Direction 10 .5v-4.9v 0-30p Both Direction 11 .5v-4.8v 0-30p Both Direction If I had to guess 14 looks like a problem but I have no idea what it is. I hope this helps! Thank you, Bryan
Hi Bryan Thank you for the information. Sorry to be a pain but I just need some additional test readings done before I can comment on the results you have. Could you please do the following tests. (Test 1) run the machine to full engine rpm, all controls in neutral and record the values on screen numbers 14, 15, 20, 21, 24, 25 (Test 2 ) run the machine to full engine rpm, Raise the left track if possible, operate the travel left lever to full forward (or reverse) and record the values on screen numbers 13,14, 15, 20, 21, 24, 25 Try using my template below to help, Best regards ---------------- TEST 1 --------------------- No.14 C-1 __.__ V __K C-2 __.__ V __K No.15 B-16 __.__ V __K B-17 __.__ V __K No.20 D-1 Comp ___mA __K Meas ___mA __K No.21 D-2 Comp ___mA __K Meas ___mA __K No.24 E-1 Comp ___mA __K Meas ___mA __K POWERSHIFT ___mA No.25 E-2 Comp ___mA __K Meas ___mA __K POWERSHIFT ___mA ---------------- TEST 2 --------------------- No.13 B-9 __.__ V __K B-10 __.__ V __K No.14 C-1 __.__ V __K C-2 __.__ V __K No.15 B-16 __.__ V __K B-17 __.__ V __K No.20 D-1 Comp ___mA __K Meas ___mA __K No.21 D-2 Comp ___mA __K Meas ___mA __K No.24 E-1 Comp ___mA __K Meas ___mA __K POWERSHIFT ___mA No.25 E-2 Comp ___mA __K Meas ___mA __K POWERSHIFT ___mA
Hey finally got the test done here are the results. Test 1 No 14 C1 4.9 v 450k C2 0.4 v 0P No 15 B16 0.0 v 0 k B17 0.0 v 0 k No 20 D1 Comp 350 ma 6 pk Meas 356 ma 6 pk No 24 E1 Comp 350 Ma 6 pk Meas 356 ma 6 pk Power shift 0 Test 2 No 13 B9 3.8v 24p B10 3.8v 24p No 14 C1 4.0v 450p No15 B16 0 0 B17 0 0 No 20 350 MA 6p 357 MA 6p No 21 D2 P2 Comp 350-629 MA 20p Meas 357-610 MA 20p No 24 350-350 6p 351-351 6p No 25 E2 P2 350 MA 6P 356 MA 6P
I wander when the inside pump is activated, and it stalls the engine there is some sort of recirculation valve that is closed? Just a thought. Thanks Bryan
Hi Bryan Thank you for the test results. There are some unusual readings you are getting from the machine. Test 1 If we take a look at test 1, with no functions being operated we can see that P1 pump ( engine flywheel side) is fully loaded well past its typical maximum main pressure relief setting. The pump is not being commanded to go above its minimum pump flow setting so it should not be showing such a high pressure reading in neutral. The pump will not last long in this condition and will quickly increase the hydraulic oil temperature. The engine will also labor heavily while nothing is being used. This condition will need to be diagnosed first and rectified as the pressure reading is well above the maximum allowable limit. Test 2 Travel lever pilot sensors have detected your travel lever movements but the mechatronic controller is not giving any output signal to the pump solenoids to increase the pumps displacements? in addition to this the pumps pressure sensor for the flywheel side pump is still reading well outside its normal range and the other pump I'm not sure as you had missed recording its value. It is concerning that the electronic controller is not outputting any value to the pumps solenoids when commanded. This means the pump will stay in minimum flow with the functions being extremely slow or non responsive. Conclusion From here I would suggest that you diagnose the pump pressures with test points and 600 bar pressure gauges at the pump. Unfortunaly the test point/sensors locations are not the easiest to get too with the counter weight on. you will need to check and verify if pump P1 is reading a high pressure in neutral or if it is the high pressure sensor giving a faulty reading. If the sensor is reading correctly you will need to do pressure tests on the control valve to verify if a bypass cut valve or travel straight valve is being activated when it shouldn't be. At this point I would assume you have a possible issue with the machines mechatronic controller and a possible issue with the main control valve or pressure sensor Hope this helps Best regards
Good morning, I have this same machine, 2003 model. Similar symptoms, but slow to respond to joystick inputs. Where is the pilot pump filter located? Hopefully Bryan has fixed his machine. Thank you !