PRE-CHECKS PRIOR TO PREFORMING MINOR CHANGE ADJUSTMENT

“A&B”

NOTE
Check Serial number or machine and verify that B

this is a Minor Change Machine and this is the

correct procedure for the machine you are
working on. Before minor change machines only Screen Change
Switch
have one switch located on the cluster gauge.
See Figure 10.29 A. (this is Minor Change) Monitor
System Ok

A. Emergency Stop ControlCable

1. Check the operation of Emergency
Stop control, confirm that cable moves
freely both in and out, and does not
bind. FIGURE 10.29 A
2. Emergency stop cable must be pushed
in to obtain proper engine Water
performance. Temperature
B
Gauge
B. Verify engine RPM
1. If possible start engine, run excavator Screen Change
hydraulic system until water temperature Switch
is at normal operating range. ( Push Switch
Once )
2. Verify engine RPM in “M” mode, “A” RPM 2300
mode, and in “B”mode by pushing
screen change switch once. Then push
the mode switch to change modes
record engine RPM readings for later
verification. See Figure 10.29 B.
C. RPM Sensor Test
FIGURE 10.29 B
Proper adjustment of the RPM sensor is
critical to a successful Adjustment “A”
Resistance value
Procedure. With engine running press 2.3k Ω ± 0.2 k Ω
screen change switch one time, will RPM
appear on screen?
1. If screen shows 0 RPM check the
following:
a. With engine OFF (not running)
disconnect the RPM sensor from the
machine electrical harness. Check the
resistance value of RPM sensor. Value
must be 2.3k Ω ± 0.2 k Ω.
b. Connect the speed sensor, to a multi Voltage must be
meter. With engine running at low idle, 3 V or more.
measure the voltage AC. voltage must
be 4 V or more. See Figure 10.29 C.

FIGURE 10.29 C
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 MINOR CHANGE ADJUSTMENT “A&B” PROCEDURE

Adjustment “A”- Mechatronic Controller

SK210 ~ SK290 - Minor Change
A. Conditions to use Adjustment “A”
Adjustment “A” procedure must be
preformed when one or more of the following
components have been removed, repaired,
adjusted or replaced. FIGURE 10.30 A
1. Mechatronics Controller (CPU)
2. Stepping Motor Assembly ENGINE EMERGENCY
STOP CONTROL
3. Linkage between Stepping Motor and
Engine Fuel Pump Assembly. SAFETY LOCK
4. Engine or Injection pump LEVER IN LOCK
5. When the ROM DATA FAILURE is POSITION
displayed on the multidisplay.
6. When the ROM DATA FAILURE and
or MECHATRO SET ERROR are
displayed alternately on the
multidisplay.
FIGURE 10.30 B
7. Incorrect High or Low idle Rpm.
B. Tools & Equipment Required for Check Auto
and adjusting of Adjustment “A” Accel B
14 mm spaner wrench Button
13 mm spaner wrench
10 mm spaner wrench
5 mm allen wrench
0.1mm (.004“) Feeler gauge
1- Metric or Inch Tape Measure to measure
Monitor System
linkage
1- Thermometer to read hydraulic oil tem- OK
perature.
General hand tools to remove and replace
stepping motor linkage and components.

C. Machine Settings and Site condition

1. Attachment in the Hydraulic Oil Check
Position. See Figure 10.30 A. FIGURE 10.30 C
2. Engine Emergency Stop Knob pushed
completely “IN”. See Figure 10.30 B.
3. Throttle potentiometer placed in the low
idle position. See Figure 10.30 D.
4. With safety lock in the lock (up) position,
See Figure 10.30 B.
5. Firm level safe test site.
6. A/C switch in “OFF” position.

FIGURE 10.30 D
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 MINOR CHANGE ADJUSTMENT “A&B” PROCEDURE

D. Verification of Engine Low RPM

1. With safety lock in the lock (up)
position, See Figure 10.30 B.
a. Press the auto accel switch once to
disable auto accel. See Figure 10.30
B.
b. Turn key switch to start position and
start engine. See Figure 10.31 A. Right Hand
c. Place throttle potentiometer to low idle Console
position. See Figure 10.31 A.
d. Locate the screen change switch,
depress the switch once to select RPM.
See Figure 10.31 B. FIGURE 10.31 A
e. Verify engine Rpm. Buzzer
f. Press screen change switch to return Stop
screen to Monitor System Ok. Switch B
See Figure 10.31 B.

E. Verification of High Idle RPM

1. With safety lock in the lock (up) YQ102AutoAccelON
position, See Figure 10.31 C.
2. Maintance Connector in the release RPM 0000
position. See Figure 10.30 C.
a. Turn key switch to start position and
start engine. See Figure10.31 A Auto Accel
b. Place throttle potentiometer to high Switch
idle position. See Figure 10.31 A.
c. Locate the screen change switch,
depress the switch once to select
RPM. See Figure 10.31 B. FIGURE 10.31 B
d. Press screen change switch two
times to return screen to Monitor
System Ok. SAFETY LOCK
See Figure 10.31 B. ENGINE EMERGENCY LEVER IN LOCKED
STOP CABLE POSITION
e. Return machine to low idle and shut
keyswitch to the off position.

FIGURE 10.31 C

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 MINOR CHANGE ADJUSTMENT “A&B” PROCEDURE

F. Removal of Rod linkage and Lever from

Stepping Motor. Dimension B
Splined Lever
1. Move to the engine compartment and
locate the injection pump and stepping
motor. See Figure 10.32 E.
2. With a 13 and 14 mm spanner wrench
loosen the ball joint end jam nuts on the
rod linkage of the stepping motor, be sure
to use a holding wrench on the opposite FIGURE 10.32 E
side of the nut to avoid linkage damage.

NOTE Remove
Threads are R.H and LH on opposite ends. Splined Lever
Here

3. Using a 5 mm allen wrench wrench remove

the splined lever from stepping motor
shaft. Note the position of the lever on the
stepping motor shaft so the lever can be
reinstalled closely to the same position as
when removed. See Figure 10.56D. FIGURE 10.56 D

NOTE
Not all machine have the lever on Place
thestepping motor installed in the same holding
direction, besure remember the direction wrench
of the lever before removal and reinstall here Loosen
in the same direction. locknut

4. Place a holding wrench on the shoulder FIGURE 10.56 E

side of the ball joint. Loosen nut and
remove it and lock washer from the ball
Remove Ball
joint end connected to the Fuel Rack lever.
Ball joint end
This allows the complete linkage to be
Here
removed now. See Figure 10.56 F.

NOTE
If a holding wrench is not used while removing
this linkage damage to the stepping motor
FIGURE 10.56 F
can occur.

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 MINOR CHANGE ADJUSTMENT “A&B” PROCEDURE

Verification of Fuel Rack Capabilities: Grasp Fuel

Lever
6. Return to cab and : Here
a. Place Safety lock lever in the lock
(UP) position.See Figure 10.31 C.
b. Place throttle potentiometer to
LOW idle position. See Figure
10.31 A.
c. Turn key switch to start position and
start engine. See Figure10.31A FIGURE 10.56 G
d. Locate the screen change switch,
depress the switch once to select
RPM. See Figure 10.56J.

7. Return to engine compartment and

carefully manually move Fuel Rack lever
over to the High Idle Stop Bolt.
See Figure 10.56H

8. Verify on the Cluster Gauge or with an

external photo tach what the max.
achievable high engine rpm against the
high stop. See Figure 10.56 J.& Figure FIGURE 10.56 H
10.56I.

9. Verify High Stop bolt rpms against

Machine Performance specs in this
training manual. If rpms are within tolerance
continue onward with this procedure, if not
stop and repair engine or fuel rack to allow
proper engine rpm. High
Stop
10. Return to cab and shut engine off and Bolt
return keyswitch to the off position.
FIGURE 10.56 I

CAUTION B

Make certain to use proper safety procedures in and around

running engine; wear proper work clothing, use safety Screen Change
glasses and utilize all proper safety devices. Switch

RPM 0

FIGURE 10.56 J
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 MINOR CHANGE ADJUSTMENT “A&B” PROCEDURE

11. Loosen the left and right hand thread jam Dimension B
Splined Lever
nuts on rod linkage and inspect the heads
of linkage for excessive wear.

12. Set the rod length to the specific dimension

per machine model number listed below.
See Figure 10.33 A.

NOTE Dimension B
Dimension B is the starting dimension of fuel
injection rod assembly. Final dimension of rod
will be determined when rod and lever is Jam Nut’s
installed on engine and engine stop gap is set. Typical of SK210 other models may differ.

FIGURE 10.33 A
Dimension B: Minor Change ONLY

186 mm ( 7.32”) SK160 ~ SK190

288~304 mm (11.34~11.96”) SK210
165 mm (6.49”) SK250
210~213 mm ( 8.26~8.38”) SK290
Note: MM=Millimeters, ” = Inches

NOTE
Dimension “B”is only a starting point, NOT THE
FINAL DIMENSION. The final length or the rod
will be determened in the next step.

Adjustment “A” Procedure

1. Place key in key switch, press the Mode

Switch on the cluster gauge and continue FIGURE 10.33 B
to hold while turning key to the “ON”
position the Gauge Cluster will display
“Monitor System Ok”, continue to hold the Mode B
Mode Switch till the clock (time) is Switch
displayed on the cluster gauge. Once the
clock is displayed release the Mode
Switch. Do not start engine. IF Gauge
Cluster will not display “Monitor System
Ok” preform maintenance or repairs to Monitor System
correct problem. See Figure 10.33 C. OK
2. Turn accel dial to the low idle position.
See Figure 10.33 B.
Note:
Pressing the mode switch and turning the
keyswitch on does not cause anything to show
on the display. FIGURE 10.33 C
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 MINOR CHANGE ADJUSTMENT “A&B” PROCEDURE

5. Press the buzzer stop switch for 5 to 10 Buzzer

seconds and release. Step 1 will not apear Stop
until buzzer stop switch is released. See Switch
Figure 10.34 A.

Buzzer B
Step 1
Stop
Switch
YQ102AutoAccelSwitch

STEP 2
CPUGAP(STOP)

YQ102AutoAccelON

FIGURE 10-34 D
6. When STEP 1 is displayed on the gauge
cluster, wait until STEP 2 is displayed on
gauge cluster. See Figure 10.34 D.
FIGURE 10.34 A
7. After verification that CPU STEP 2 GAP
STOP is displayed on the gauge cluster,
you will notice that the controller has moved Fuel Rack Lever Splined Lever
the stepping motor to the LOW STOP
position. This is computer controlled, no
need to adjust this point.

Reinstalling Linkage:

8. Reach and grasp the fuel rack lever and

pull it down against the low stop bolt. While
holding the fuel rack lever against the low
stop bolt reinstall the linkage assembly
Example SK210
between the stepping motor and injection
pump. See Figure 10.34 B.
FIGURE 10.34 B
Note: If the splined shaft lever will not align
while other ball joint end is inserted into Lever MUST be
the fuel lever remove that end from the fuel against stop bolt
rack, retain position move splined lever
one spline forward or backward on the
stepper motor shaft to allow splines to
align. Then adjust the intermediate rod so
the ball joint end can be installed on the
fuel lever.
Warning: Make sure to insert the ball joint end
of the rod linkage in the proper bolt hole of
the fuel lever bracket - Do Not install in the
slot for the emergency stop cable. See
Figure 10.34 B & 10.34 C FIGURE 10.34 C

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 MINOR CHANGE ADJUSTMENT “A&B” PROCEDURE

NOTE
Dimension “B”is only a starting point, NOT THE Shaft
Protrusion =
FINAL DIMENSION. The final length of the rod 1mm (.039”)
will be determened in the next step.

9. Confirm that the spline on the stepping

motor is protruding approximately 1mm
(0.039”) past the lever assembly. Secure
the lever to stepping motor with the 5mm
allen wrench.
See Figure 10.59 A.

10. With a feeler gauge inserted between the

fuel shut off stop bolt and the fuel injection FIGURE 10.59 A
pump lever adjust the clearance to 0.1mm
(.004 “). See Figure 10.59 B.
Fuel Stop Bolt
11. Once clearance has been reached with Feeler Gauge
only slight resistance on the feeler gauge
tighten both rod linkage jam nuts with 13
and 14 mm wrenches. Do not over tighten
max. torque is 1.84 kgf•m, (13.27 ft•lbs)
See Figure 10.34 C.

12. Recheck all linkage fastners and make

sure everything is tight. also make sure ball
joint linkage ends are equally aligned and
not twisted. Afterwards return to the
operator’s cab for the next step.
Note: Remove all tools and wrenches in and FIGURE 10.59 B
around engine compartment to prepare for
the starting of the engine in the next Holding Wrench Tighten Jam Nut
process. here Here

13. Press buzz stop switch once and CPU

STEP 3 Start E/G will appear in gauge
Cluster. You will notice that the controller
will move the stepping motor to a position
higher than the normal RPM starting range.
See Figure 10.35 A.

14. Start engine and wait until engine reaches

normal operating temperature range.
Note: Hydraulics system maybe
functioned to warm engine and hydraulic
FIGURE 10.59 C
system up.
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 MINOR CHANGE ADJUSTMENT “A&B” PROCEDURE
15. With engine running, press the buzzer stop
switch once, the gauge cluster will read Buzzer
B

CPU STEP 4 MEMORY. The controller Stop

will take control of the stepping motor and Switch
bring the engine from:
a. Mid range.
b. Below Low Idle. CPU STEP 3
c. High Idle. Start E/G
d. Low Idle.
See Figure 10.35 B.

NOTE
Required time for computer to memorize total FIGURE 10.35 A
engine steps is about 3 minutes.

16. CPU STEP 4 MEMORY will take

approximately three minutes to cycle the B

stepping motor and record the data in the

controller.
17. After completion of the above, the gauge
cluster display will read the following: CPU Step 4
CPU FINISHED **** RPM (****) will Memory
represent the highest RPM which was read
by the controller during Step 4.
See Figure 10.35 C.

PROCEDURE “B”:

18. After Step 4 finishes do not stop the FIGURE 10.35 B

engine. Step 5 (Procedure”B”) will
automatically start thru the computer
control. The throttle will move to high idle
and the computer will load the engine thru Note
the pump PSV solenoids and record a stall “Finished CPU B

rpm. (****)RPM”
19. After completion of step 5, the gauge represents the
cluster display will read CPU Finished 0 end of Step 4.
You must allow
RPM, then the display will change back to
the completion of CPU Step 5
the clock display. the procedure is now
STEP 5 before Memory
complete. the procedure
20. Turn keyswitch to the off position and allow is Complete.
system to shut down.

Note:
Please refer to the Measuring & Adjusting
Pressures chapter in this manual for the
proper RPM reading for your machine by FIGURE 10.35 C
Model and Serial Number.

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