You have a Terex Schaeff machine on the stand with weak steering or a lift that has lost its push, and a gauge in your hand. This service manual gives you the test ports, the setting values and the adjustment points. It covers the SKL and SKS series, the HML mobile excavators and the HR compact excavators.
This is the TEREX | SCHAEFF edition 01.2006: three factory folders bound into one PDF and split into twelve groups. They run from Technical Data and Diesel Engine through Setting Instructions, the Electrical System wiring diagrams and the Maintenance inspection plans. Sheets are printed in German, English and French.
Guessing at hydraulic settings on an older Schaeff gets expensive fast. Check the data sheet and hydraulic diagram for your exact model first, so the valve or seal kit you order is right the first time.
What's Inside This Schaeff SKL, SKS, HML, HR Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 1-28 | Foreword, Safety and Accident Prevention, Tightening Torques for Piston Nuts, Pictograms, Test Ports, Drift Values |
| Technical Data (Folder 1) | 29-152 | Data Sheets for SKL 863 to HR Models, Pressure and Setting Values |
| Diesel Engine (Folder 1) | 153-234 | Deutz and Mitsubishi Engine Data, Valve Clearance, Injection Timing, Tightening Torques |
| Hydraulic System (Folder 1) | 235-464 | Hydraulic Diagrams and Legends per Model |
| Setting Instructions (Folder 1) | 465-632 | Steering and Working Hydraulic Tests at Test Ports, LS-valve, Secondary Relief Valves, Pump Stand-By Pressure, Hydrostatic Drive |
| Functioning Description (Folder 1) | 633-728 | Location of Hydraulic Components, Valve and Pump Functions |
| Electrical System (Folder 2) | 729-1090 | Fuse and Relay Box Assignment Diagrams, Wiring Diagrams per Model, Generator Charge Test |
| Maintenance (Folder 2) | 1091-1228 | Inspection Plans and Test Certificates per Model, Test Certificate HR 18 Mitsubishi Engine, HR 12 Mitsubishi Engine, Check Smooth Running of Operator Controls |
| Operation (Folder 2) | 1229-1318 | Work Before Putting Into Operation, Operator Controls and Indicator Lamps |
| Options (Folder 2) | 1319-1346 | Fast Travel Version and Other Options |
| Repair Instructions (Folder 2) | 1347-1444 | Assembly Tool Overview, Tilt Cabin |
| Technical Data (Folder 3) | 1445-1526 | Data Sheets for SKL 823 to SKL 853 and Further Models, Pressure and Setting Values, Working Cycles, Slew Drive, Lubricants |
| Diesel Engine (Folder 3) | 1527-1544 | Deutz Engine Data |
| Hydraulic System (Folder 3) | 1545-1665 | Hydraulic Diagrams per Model |
| Setting Instructions (Folder 3) | 1666-1673 | Steering Valve and Setting Values |
| Functioning Description (Folder 3) | 1674-1709 | Height-Adjustable Cabin, Steering Description and Hydraulic Diagram |
| Electrical System (Folder 3) | 1710-1895 | Fuse Assignment Diagrams and Wiring Diagrams per Model, Fuse and Diode Assignment, Fuse and Relay Box - Assignment Diagram, Lighting and Signalling System, Heater Fan |
| Maintenance (Folder 3) | 1896-1979 | Inspection Plans and Test Certificates per Model, SKL 823 Basic, SKL 877, HR 41 |
| Operation (Folder 3) | 1980-2053 | Operator Controls per Model |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Mitsubishi L3E-61KL | ||
| Valve clearance, cold, inlet and exhaust | 0.25 mm | p. 211 |
| Injection nozzle pressure | 140 bar | p. 211 |
| Compression pressure, new / lower limit | 28 bar / 22 bar | p. 211 |
| Crankshaft pulley torque (M16) | 100 to 120 Nm | p. 211 |
| Main bearing cap torque (M10) | 50 to 55 Nm | p. 211 |
| Flywheel bolts torque (M10) | 85 to 95 Nm | p. 211 |
| Cylinder head bolts torque (M10) | 75 to 85 Nm | p. 211 |
| Deutz F4M 2011 | ||
| Rated speed / minimum idle | max. 2800 rpm / 900 rpm | p. 173 |
| Firing order | 1-3-4-2 | p. 173 |
| Bore x stroke | 94 mm x 112 mm | p. 173 |
| All Models | ||
| Generator charge voltage after about 5 minutes | 13.5 - 14.5 V | p. 1079 |
| SKL 873 | ||
| Steering / LS-valve test gauge | 600 bar gauge at test port 15 | p. 535 |
Schaeff SKL, SKS, HML, HR Common Problems This Manual Covers
Weak steering or weak digging and lifting force
Check the pressures before you change parts. The Setting Instructions put a 600 bar gauge on test port 15 with the machine at service temperature and the engine at increased idle. Steering is read at the mechanical stop and set at the main relief valve under plug 16; the working hydraulics are set at LS-valve 20 on the control valve. The same sheet covers the secondary relief valves and the pump stand-by pressure.
Manual Section: Setting Instructions p. 535Machine will not start or drive, transmission symbol on the monitor
The transmission is stuck in an intermediate position, not failed. The Operation section explains that brief steering movements let the transmission engage. The same section covers the operator controls, the indicator lamps and the work to do before putting the machine into operation, so you can read the monitor correctly.
Manual Section: Operation p. 1264Battery keeps going flat
Do the generator charge test in the Electrical System group before buying a new battery. After about 5 minutes the reading should be 13.5 to 14.5 V, and never below 13 V with consumers switched on. Then check the diodes in the fuse box, using the fuse and relay assignment diagrams for your model.
Manual Section: Electrical System p. 1079Hydraulic pressure still trapped in the lines before repair work
The system has not been depressurized. The Safety and Accident Prevention part of the General group says to lower the equipment to the ground with the engine off. Then operate all hydraulic control levers before you crack a fitting. Use the per-model diagrams in the Hydraulic System group to find the line you are opening.
Manual Section: General / Safety and Accident Prevention p. 13Frequently Asked Questions
How do I check steering and LS-valve pressure on an SKL 873?
Fit a 600 bar gauge at test port 15, with the machine at service temperature and the engine at increased idle. For steering, turn to the mechanical stop and read the pressure; the main relief valve sits under plug 16. For the working hydraulics, tilt the bucket in or raise the loader arm to the mechanical stop and adjust at LS-valve 20 on the control valve. The adjustment values are in the Technical Data group or the test certificate in Maintenance. p. 535
My machine won't start or drive and the transmission symbol is showing on the monitor. What is wrong?
The transmission is usually sitting in an intermediate position. The Operation section says brief steering movements let it engage. Do that before you start pulling wiring apart or condemning the transmission. p. 1264
How do I know if the generator is actually charging?
Run the generator charge test in the Electrical System group. After about 5 minutes you should see 13.5 to 14.5 V. With consumers switched on, it must not drop below 13 V. The same test tells you to check the diodes in the fuse box, which is easy to forget. p. 1079
What are the valve clearance and head bolt torque specs for the Mitsubishi L3E-61KL engine in a Schaeff?
Set valve clearance cold to 0.25 mm on both inlet and exhaust. The M10 cylinder head bolts take 75 to 85 Nm in the tightening order shown in the Diesel Engine group. The M16 crankshaft pulley takes 100 to 120 Nm. Compression should be 28 bar new, with 22 bar as the lower limit. Nozzle pressure is 140 bar. p. 211
What speeds and firing order does the book give for the Deutz F4M 2011?
Rated speed is max. 2800 rpm and minimum idle is 900 rpm. Firing order is 1-3-4-2. The Diesel Engine group also lists valve clearance, injection timing and tightening torques for the engines covered, so you are not borrowing figures from a different engine. p. 173
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