£x1203 OPERATIONAL PERFORMANCE TES SECTION 06 CONTENTS Group 01- Introduction Group 04- Hydraulic Component Test Purpose 06-01-01 4-1.Pilot Primary Pressure 06-04-01 Terminology 06-01-01 4-2,Pilot Secondary Pressure 06-04-08, Preparation For Performance 4-8,Proportional Solenoid Valve Tests wee 06-01-02 Pressure ( PC Pressure) 06-04-04 4-4.Swing Parking Brake Group 02- Engine Test Releasing Pressure : 06-04-07 2-1.Engine Speed . : 06-02-01 4-5.Reducing Valve Pressure Setting 2.2.Engine Compression Pressure 06-02-03 (Pi Pressure) ........ 06-04-08 2.8.Valve Clearance Adjustment . T06-02-04 4-6.Main Pump Delivere Pressure 2-4,Nozzle Check 706-02-06 (Control Levers in Neutral) T06-04-10 2-5.Injection Timing T06-02-08 4-7.Main Relief Pressure ReliefSeting . . TO6-04-11 Group 03- Excavator Test 4-8.Overload Relief Valve 344 Travel Speed 06-03-01 Pressure Setting 06-04-15, 3-2.Track Revolution Speed 06-03-02 4-9.Main Pump Flow Test 706.04-17 3-3.Mistrack Check se. 706-039-083 4-10.Swing Motor Drainage 06-04-19 3-4,Travel Parking Function Check 06-03-04 4-11, Travel Motor Drainage 06-04-21 3-5.Swing Speed 06-03-05 3-6.Swing Function Drift Check. 06-03-06 Group 05- Basic Performance Check 3-7.Swing Motor Leakage: 06-03-07 Basic Operational Performance Check 3-8.Swing Bearing Play To6-03-08 with the Dr. EX . 06-06-01 3-9.Hydraulic Cylinder Cycle Time 06-03-09 5-1.Pressure (P) switch Check 08-05-02 3-10.Dig Function Drift Check T06-03-10 5-2.Performance Check with Control Lever 3-11.Control Lever Operating Force 7106-03-11 3-12.Control Lever Stroke 706-0312 3-13.Combined Boom Raise/Arm Roll-n Functions Check 06-03-13, 3-14,Combined Boom Raise/Swing Functions Check 06-03-14 in the Neutral Position, and at Relief Pressure eo 7106-05-03, 5-3.A sensor ( Pump Displacement Angle Sensor ) Check 7108-05-05 5-4.Single Operation Check T08-05-05 1357-06-01x1203 Combined Operation 5-5.Combined Boom Raise and Arm Roll-In Operation 6-6,Combined Bucket Roll-In Relief and Boom Raise Check 5-7.Combined Bucket Roll-In and Boom Raise Check 5-8. Combined Travel and Arm Roll-In Relief Check 5-8,Swing Check with Precision Mode (M4) Group 06- Standard Operational Performance Standard 7106-05-07 T06-05-09 T06-05-11 T06-05-12 06-05-14 T06-06-01 135T-06-02OPERATIONAL PERFORMANCE TEST / Introduction PURPOSE Performance tests are used to check: 1, OPERATIONAL PERFORMANCE OF A NEW MACHINE When ever a new machine is delivered in parts and reassembled at a customers site, it must be tested to confirm that the operational perfor- mance (Excavator Test) of the machine meets HITACHI STANDARDS. 2. OPERATIONAL PERFORMANCE OF A WORK- ING MACHINE With the passage of time, the machine's oper- ational performance deteriorates, so that the machine needs to be serviced periosically to re- store itt its original performance level. Before servicing the machine, conduct perfor- mance tests to check the extent of deteriora- tion, and to decide what kind of service needs to be done (by referring to the “Allowable Lim- its” in this manual). Working condtions 3, OPERATIONAL PERFORMANCE OF A REPAIRED MACHINE After the machine is repaired or serviced, it must be tested to confirm that its operational performance was restored by the repair andjor service work done. TERMINOLOGY 1. ‘STANDARD® Specifications applied to the brand-new ma- chine, components and parts. 2. “ALLOWABLE LIMIT" The lowest acceptable performance level. When the performance level of the machine falls be- low this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced, T06-01-01OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. 1. THE MACHINE Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. 2. TEST AREA (1) Select a hard, flat surface. (2) Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 inch), and to make a full swing with the front at- tachment extended, (9) trequired, rope off the test area and provide signboards to keep unauthorized personnel srosonovas away. 3. PRECAUTIONS (1) Before starting to test, agree upon the sig- nals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other us- ing these signals, and to follow them without fall. (2) Operate the machine carefully and always give first priority to safety. (3) While testing, always take care to avoid acci- dents due to landslides or contact with high: voltage power lines. Always confirm that there is sufficient space for full swings. (4) Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch note escaping oil. Pay special attention to this ‘when removing hydraulic pipings. 4. MAKE PRECISE MEASUREMENTS (1) Accurately calibrate test instruments in ad- vance to obtain correct data (2) Carry out tests under the exact test condi- tions prescribed for each test item. (8) Repeat the same test and confirm that the test data obtained can be procured repeatedly. Use mean values of measurements if necessary. T06-01-02OPERATIONAL PERFORMANCE TEST / Engine Test 2.1 ENGINE SPEED Measure the engine speed at each power mode (recommended testing equipment: Dr. EX) NOTE: The engine speed at each power mode must meet standard engine speed; if not, all other operational performance data will be unreliable, Itis essential to perform this test frst Preparation: (1) Warm up the machine, until the engine coolant temperature reaches 50°C (122°F) or more, and the hydraulic oil is SO°+5°C (12°F +9°F), (2) Push the P-mode switch and confirm that the fuel injection pump governor lever (2) comes into con- tact with the fast-idle stopper (1). NOTE: Never adjust stopper (1). (3) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain realtime engine speed data. (4) If Dr. EX is not available, connect engine tachome- ter (1) to fuel injection pipe (2). T06-02-01OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: (1) Start the engine. The engine will run at start idle speed. Measure engine speed with Dr. EX (or a tachometer). (2) Press work mode selector switch (2) to the gener- al purpose mode, and tum off auto-idle switch (3), (3) Measure and record the engine speed at each power mode (1) (P, E, L,I). (4) Next, push auto-idle switch (8) ON, and select the P.mode. (8) Lightly operate the bucket control lever a few times, then return the control lever to neutral; the engine will automatically enter the auto-idle speed after 4 seconds. (6) Measure and record the auto-idle speed, Evaluation: Refer to Group -06 in this section, Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-02-02OPERATIONAL PERFORMANCE TEST / Engine Test 2.2 ENGINE COMPRESSION PRESSURE 1. Measure compression pressure in the cylinders to check for a dectine in engine power. 2. Check exhaust gas color and the amount of blow-by {gas from the crankcase. Keep track of engine oll consumption. 3. Check for abnormalities in the intake system, includ- ing the air fiter. Preparation: 1. Confirm that valve clearances are correct. 2. Confirm that the batteries are charged properly. 3. Run the engine until the coolant temperature gauge reaches the operating range. 4. Stop the engine, Remove glow plugs from each cy! inder. 5. Install an adaptor and compression gauge in place of the glow plug in one cylinder. ( Be sure to sutti- ciently tighten the adaptor and compression gauge to prevent air leakage.) Measurement: 1. Tum the starter to crank the engine. Record the compression pressure of each cylinder. 2. Repeat measurement three times for each cylinder and calculate the mean values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to engine shop manual T06-02-03OPERATIONAL PERFORMANCE TEST / Engine Test 2.3. VALVE CLEARANCE ADJUSTMENT NOTE: 1. Perform the measurement when the engine is cold. 2. Bofore starting work, clean the head cover ‘mounting area to avoid contamination in the engine, Preparation : 1. Locate the top dead center (TDC) in the compres- sion stroke. Align the TOC mark on the crank pulley with the pointer located on the timing gear case as illustrat- ed. Piston No.1(or piston No.4) is now positioned at the TDC in its compression stroke, 2. Remove the head cover. 3. Move push rods for the intake and exhaust valves, fon the No.1 cylinder up and down by hand. If any clearances on the both ends of the push rods are found, piston No.1. is positioned at TDC in the compression stroke. (If the exhaust valve of cylin- der No.1 is pushed down, piston No.4 is positioned at TOC in the compression stroke, ‘07. 02.12.008 ‘Start measurement from the cylinder (No.1 or No.4) positioned at TDC in the compression stroke, Measurement: 1. Insert a thickness gauge into the clearance be- tween the rocker arm and the valve stem end to measure the valve clearance. NOTE: The cylinders are aligned from No. 1 to No. 4 in that order, as viewed from the fan side T06-02-04OPERATIONAL PERFORMANCE TEST / Engine Test 2. When the measurement is started from No.1 cylin der, perform the same measurement to all valves indicated with the mark * Q" in the table below. (When the measurement is started from No.6 cylin der, perform the measurement in the valves shown with mark "X") Cylinder No. Not | No2 | Nos No.4) Valve locations ye{efefa When the measure: Ment is. started from No.1 cylinder so cali When the measure- Tent is. started trom x |x No.6 cylinder 3, Rotate the crankshaft 360°. Align the TOC mark with the pointer. Then, contin- ue measurement of other valves in the same way. Evaluation Standard Vaive Clearance: Intake valve : 0.40 mm (0.0157 inch) Exhaust valve: 0.40 mm (0.0187 inch) Adjustment: if the measurement results are outside the standard specification, adjust the valves clearances in the same order of measurement. 1. Loosen the adjusting screw lock nuts for the rocker, arms. insert the thickness gauge set at 0.4 mm, ad- just the adjusting screws. 2. Alter adjusting, retighten the lock nuts to the speci- fication, Recheck the valve clearance alter the lock nuts are tightened. =n: 25.544.9 Nim ( 2,620.5 kgfim, 18.8 tot) ) T06-02-05OPERATIONAL PERFORMANCE TEST / Engine Test 2.4.NOZZLE CHECK NOTE: 1. Check the injection pressure and the spray pattern with a nozzle tester. 2. Before starting work, clean the nozzle holder ‘mounting area to avoid contamination in the engine. Preparation: 1. Remove the nozzle holders. Remove all nozzle holders and fuel injection pipings from the engine. 2, Attach a nozzle holder to the nozzle tester. Measurement: A CAUTION: Never touch spray directly. The fuel spray from the nozzle may pene trate the skin, resulting in serious injury. If fuel penetrates into the blood stream, it may cause blood toxication. 1. Injection pressure After attaching the nozzle holder to the nozzle test- er, strongly make several strokes of the tester to in- ject fuel. Then, while operating the tester at approx. 60 time strokes a minute, measure the fuel injection pressure, If adjustment is required, loosen the lock nuts and adjust the adjusting screws. Tum clockwise to in- crease the pressure, and counterclockwise to de- crease the pressure. 2. Spray pattern For this test, turn the pressure tester knob to by: pass the pressure gauge. Attach the nozzle holder to the nozzle tester. Strongly make several strokes of the tester and check the fuel spray pattern. NOTE: Use clean diese! ol T06-02-06OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: 1, Standard Injection Pressure: 18.1 MPa (185 kgtfom®, 2 631 psi) 2. Spray Pattern ‘@ Large-size spray should not be visible to the na- ked eye. No stray sideways sprays should be seen. ‘¢ During initial injection stage, spray size should be fine and injected intermittently ‘¢ There should be no drips found. ¢ Injection spray angle must be normal Adjustment: ‘¢ To adjust the injection pressure, loosen the lock nuts, Adjust the adjusting screw. Tum clockwise to increase the pressure, and counterclockwise to decrease the pressure. ‘© After adjusting, retighten the lock nuts. Normal ‘Abnormal T06-02-07OPERATIONAL PERFORMANCE TEST / Engine Test 2.5. INJECTION TIMING Inspection: 1. Position No.1 piston to the top dead center. Turn the crank pulley in the direction of rotation (clock- wise as seen from the front of the engine) to set a “TDC* mark on the crank pulley under the ‘point- er", located on the timing gear case. 2. Remove the timing check hole cover on the front section of the fuel injection pump, When the mark on the injection pump is set under the projection of the gear case, No.1 piston is posi tioned at the top dead center. if the mark is not set Under the projection, keep turning to adjust. 3. Tum the crank pulley at approx.30 degrees coun- terclockwise, 4, Remove the injection piping from No. cylinder. 5. Remove the delivery valve holder for No.1 cylinder from the injection pump to pull the delivery valve and the spring out. Reinstall the delivery valve hold- er. P=: 89 to 43. Nim (4 to 4.4 kgf, 28.9 to 31.8 lott) 6. While supplying fuel with the feed pump, turn the crank pulley slowly clockwise just until fuel cannot be seen from the top of the delivery valve hole. This is the position where the injection stars. 7. Check the timing mark, located on the crank pulley for what degrees the pointer indicates. Adjustment: 1. Turn the crank pulley so that the pointer comes just above the correct timing position (16 degrees be- fore the TDC) on the rank pulley. 2. Loosen the mounting nuts ofthe injection pump. 3. When advancing timing, tlt the injection pump out- ward against the cylinder block. When delaying timing, tlt the injection pump inward against the cylinder block, = ) Gear case Projection Injection pump Alignment mark Gear case Projection Injection pump Alignment mark T06-02-08OPERATIONAL PERFORMANCE TEST / Excavator Test 3.1 TRAVEL SPEED Measure the time required for the excavator to travel a 10 m (32.8 ft test track. Preparation: 1, Adjust the track sag of both tracks to be equal 2. Prepare a fat and solid test track 10 m (32.8 ft) in length, with extra length of 3 to 5 m (9.8 to 16 ft) (on both ends for machine acceleration and decel: eration 3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the ground with the arm and bucket rolled in 4. Maintain the hydraulic oil temperature at 8025 °C (12220°F) Measurement: 1. Measure both the medium and fast speeds of the machine. 2. Before starting either the medium or fast speed tests, agjust the travel mode switch to the speed to be tested, then select the following switch posi- tions: Power mode selector: P mode Work mode selector: General purpose Autonidle switch: OFF 3. Start traveling the machine in the acceleration zone with the travel levers at full stroke. 4. Measure the time required to travel 10 m (32.8 ft) 5. After measuring the forward travel speed, turn the upperstructure 180° and measure the reverse travel speed, 6. Repeat steps (4) and (6) three times in each direc- tion and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLE SHOOTING B. ‘St05m [ezeleration zone Deceteration T06-03-01A 9603OPERATIONAL PERFORMANCE TEST / Excavator Test 3.2 TRACK REVOLUTION SPEED Measure the track revolution cycle time with the track raised off ground, Preparation: 1. Adjust the track sag of both side tracks to be equal 2. On the track to be measured, mark one shoe with chalk. 3. Swing the upperstructure 80° and lower the buck- et to raise the track off ground. Keep the boom- arm angle between 90 to 110° as shown. Place blocks under machine frame. 4, Maintain the hydraulic oil temperature at 5025 °C (12249°F) Measurement: 1. Select the following switch positions: Travel mode switch: Fast Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2. Operate the travel contro! lever of the raised track in full forward and reverse. 3. Measure the time required for 3 revolutions in both directions. 4, Raise the other side of machine and repeat the procedure. 5. Repeat steps (4) and (6) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-02OPERATIONAL PERFORMANCE TEST / Excavator Test 3.3 MISTRACK CHECK Measure the deviation by the tracks from a 20 m (65.5 ft) straight line. Preparation: 1. Adjust the track sag of both tracks to be equal. 2. Provide a flat, solid test yard 20 m (65.5 ft) in length, with extra length of 3 to 5 m (9.8 to 16 ft) con both ends for machine acceleration and decel- eration 3, Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the ground with the arm and bucket rolled in 4, Maintain the hydraulic oil temperature at 50#5 °C (12288°F), Measurement: 1. Measure the amount of mistracking at fast, medi- um and slow travel speeds. 2. Before beginning each test, select the following switch posttions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 3. Start traveling the machine in the acceleration zone with the travel levers at full stroke. 4, Measure the maximum distance between a straight 20 m (68.5 ft) line and the track made by the ma- chine, 5. After measuring the tracking in forward travel, turn the upperstructure 180° and measure that in re- verse travel. 6. Repeat steps (4) and (5) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING 8. Maximum stance S105 (810 20in) extra length ‘eceleation T06-03-03OPERATIONAL PERFORMANCE TEST / Excavator Test 3.4 TRAVEL PARKING FUNCTION CHECK Measure the travel motor slip on a specified slope, Preparation: 1. The face of the test slope shall be even, with a gradient of 20%. 2, Raise the bucket 0.3 to 0.5 m (12 to 20 in) above the ground with the arm and bucket cylinders fully extended, 3. Maintain the hydraulic oll temperature at S025 °C (12229 °F). Measurement: 1. Climb the slope and place the travel levers in neu- tral 2. Stop the engine, 3. After parking the machine, make aligning marks on the side frame and a track link or shoe 4, After five minutes, measure between the marks, Evaluation: Refer to Group -06 in this section. Aligning marks Distance Remedy: Refer to T07-03 TROUBLESHOOTING B. 06-03-04OPERATIONAL PERFORMANCE TEST / Excavator Test 3.5 SWING SPEED Measure the time required to swing three complete tums, Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on ‘The same height slopes. as the boom foot 3. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. The bucket must be empty. 4. Maintain the hydraulic oil temperature at 5025 °C (12289 °F) Measurement: 1. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2. Operate swing control lever fully 3. Measure the time required to swing 3 turns in one direction, 4, Operate swing contro! lever fully in the opposite ai- rection and measure the time required for 3 tums. 5. Repeat steps (3) and (4) three times and calculate the average values Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-05OPERATIONAL PERFORMANCE TEST / Excavator Test 3.6 SWING FUNCTION DRIFT CHECK Measure the swing drift on the bearing outer circumter- fence when stopping after a 180° full-speed swing. Preparation: 1. Check the lubrication of the swing gear and swing bearing 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. “Two chalk marks 3. Position the arm cylinder with the rod 50 mm (2 inch) extended from the fully retracted position rosct-o3.cot 4, Position the bucket cylinder with the rod 50 mm (2 inch) retraced from the fully extended position, 5. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. 6. The bucket must be empty. 7. Make two chalk marks: one on the swing bearing and one directly below it on the track frame, 8 Swing the upperstructure 180°. 9. Maintain the hydraulic oil temperature at 5035 °C (12249 °F) Measurement: 1. Conduct this test in the P mode. 2. Select the following switch positions: —= Power mode selector: P mode Measure diference between marks Work mode selector: General purpose Auto-idle switch: OFF 3, Operate the swing control lever fully and return it to the neutral position when the mark on the up- perstructure aligns with that on track frame after swinging 180°. Marking on the track frame 4, Measure the distance between the two marks, 5. Align the marks again, swing 180°, then test the opposite direction. 6. Repeat steps (4) and (5) three times each and cal- culate the average values. Marking on the swing bearing Evaluation: Refer to Group -06 in this section, Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-06OPERATIONAL PERFORMANCE TEST / Excavator Test 3.7 SWING MOTOR LEAKAGE Check for upperstructure drift when suspending a load ona slop. Preparation: 1. Check the lubrication of the swing gear and swing bearing, 2, Park the machine on a smooth slope with a gradient of 26.8%, 3. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. cee WeMx1.5 where: M3=Bucket heaped capacity (m3) 1.8eSoil specific gravity 4, With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin. Apply a rated load to the bucket (bucket capacity x18), 5. Swing the upperstructure to position it 90° to the slope. Make aligning marks on the swing bearing pe- riphery and tracks frame using tape, as illustrated, 6. Maintain the hydraulic oil temperature at 505 °C (12289 °F), Measurement: 1. Maintain the engine at slow idle. After five minutes, measure the difference between the marks along the swing bearing periphery and the track frame. 2. Perform the measurement on both right and left swing directions, 3. Perform the measurement three times in each direc- tion and calculate the average values. Measure Siference between marks Evaluation: Marking 00 the track frame Refer to Group -06 in this section. Marking onthe swing bearing Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-07OPERATIONAL PERFORMANCE TEST / Excavator Test 3.8 SWING BEARING PLAY Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls, Preparation: 1. Check swing bearing mounting bolts for loosening 2. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise. 3. Install a dial gauge on the track frame as shown, Using a magnetic base. 4, Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers. 5. Position the dial gauge so that its needle point comes into contact with the bottom face of the bear- ing outer race. 6. Bucket should be empty. Measurement: 1. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. Record the dial ‘gauge reading (hy). 2. Lower the bucket to the ground and use it to raise the front idler 0.5 m (20 inch). Record the dial ‘gauge reading (ha). 3. Calculate bearing play (H) from this data (hy and he) as follows: H 2 hy Measurement: (>) The same height asthe boom feat B) pi height Evaluation: Refer to Group -06 in this section, Measurement: (hy) T06-03-08OPERATIONAL PERFORMANCE TEST / Excavator Test 3.9 HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, (standard) arm, and (standard) bucket cylinders. Preparation: 1. To measure the cycle time of the boom cylinders: With the arm rolled out and the empty bucket rolled in, lower the bucket to the ground, as shown, 2. To measure the cycle time_of the arm_ cylinder: With the empty bucket rolled in, position the arm so that itis vertical to the ground. Lower the boom un- tilthe bucket is 0.5 m (20 in) above the ground 3. To measure the cycle time of the bucket cylinder: The empty bucket should be positioned at mid- stroke between rollin and roll-out, so that the side- plate edges are vertical to the ground. 4. Maintain the hydraulic oil temperature at 50°5 °C (12289 °F), Measurement: 1. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2. To measure cylinder cycle times’ (1) Boom cylinders: Measure the time it takes to raise the boom, and the time it takes to lower the boom. To do so, position the boom at one stroke end, then move the control lever to the other stroke end as quickly as possible. (2) Arm cylinder: Measure the time it takes to rollin the arm, and the time it takes to roll out the arm. To do so, position the arm at one stroke end, then move the control le- ver to the other stroke end as quickly as possible. (3) Bucket cylinders: Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible, 3. Repeat each measurement three times and calcu- late the average values. Evaluation: Refer to Group -06 in this section, Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-09OPERATIONAL PERFORMANCE TEST / Excavator Test 3.10 DIG FUNCTION DRIFT CHECK Measure dig function drift, which can be caused by oil leakage in the control valve and boom, (standard) arm, and (standard) bucket cylinders, with the loaded bucket NOTE: When testing the aig function aritt just after oy!- inder replacement, slowly operate each oylin- der to its stroke end to purge air. Preparation: 1, Load bucket fully, In lieu of loading the bucket, weight (W) of the following specification can be used. WM 5 where: M3=Bucket heaped capacity (m3) 1.5=Soil specitic gravity 2. Position the arm cylinder with the rod 50 mm ( 2 inch) extended from the fully retracted position. 3. Position the bucket cylinder with the rod 50 mm (.2 inch) retracted from the fully extended position. 4, With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the ‘same as the boom foot pin 5. Maintain the hydraulic oil temperature at 50°+5 °C (12249 °F) Measurement: 1. Stop the engine. 2. Five minutes after the engine has been stopped, measure the changes in the positions of the bottom of the bucket, as well as the boom, arm and bucket cylinders. 3. Repeat step (2) three times and calculate the aver- age values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. Revracted aane stance tract ‘e we Retacted ‘Arm oylinder extention Boom and bucket cylinders retraction T06-03-10OPERATIONAL PERFORMANCE TEST / Excavator Test 3.11 CONTROL LEVER OPERATING FORCE Use a spring scale to measure the maximum resistance of each control lever at the middle of the grip. Preparation: Maintain the hydraulic oll temperature at 5085 °C (12289 °F). Measurement: 1. Start the engine. 2. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 3. Operate each boom, arm, bucket and swing lever at full stroke and measure the maximum operating force for each. 4, Lower the bucket to the ground to raise one track off the ground, Operate the travel lever at full stroke and measure the maximum operating force required. When finished, lower the track and then jack-up the other track. 5. Repeat steps (3) and (4) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to 107-03 TROUBLESHOOTING B. iy T06-03-11OPERATIONAL PERFORMANCE TEST / Excavator Test 3.12 CONTROL LEVER STROKE Measure each lever stroke at the lever top using a ruler. NOTE: When the lever has play, take a haif of this val- tue and add it to the measured stroke. Preparation: Maintain the hydraulic oll temperature at 50°25 °C (12289 °F) Measurement: 1. Stop the engine 2. Measure each lever stroke at the lever top from neutral to the stroke end using a ruler. 3. Repeat step (2) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-12OPERATIONAL PERFORMANCE TEST / Excavator Test 3.13 COMBINED BOOM RAISE/ARM ROLL-IN FUNCTIONS CHECK Check boom raise and arm rollin movement and speeds while operating both functions simultaneously. Preparation: 1. Start the engine and run it at fast idle. Operate the boom and arm cylinders and check to be sure that cylinder movement is smooth, with no sticking, 2. Roll out the empty (standard hoe) bucket with the (standard) atm fully rolled out so that the bucket teeth, bucket pin and arm mounting pin are on a straight line, and hold the bucket teeth distance A above ground. Distance A: 0.5 m (20 in) 3. Maintain the hydraulic oil temperature at 50°5°C (12289 °F), Measurement: 1. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-Idle Switch OFF 2. Raise the boom and roll in the arm simultaneousiy, both at full stroke. 3. When either of the two functions reaches the stroke end, release the control levers to stop both functions, then measure the height (H) of the buck- et teeth. Measure the time required to move the boom or aim to its stroke end, if required for refer- ence purposes. 4, Repeat steps (2 and 3) three times and calculate the average values. Evaluatio Refer to Group -08 in this section. Remedy: Refer to 107-03 TROUBLESHOOTING B. T06-03-13OPERATIONAL PERFORMANCE TEST / Excavator Test 3.14 COMBINED BOOM RAISE/SWING FUNCTIONS CHECK Check boom raise and swing movement and speeds while operating both functions simultaneously. Preparation: 1, Start the engine and run it at fast idle. Operate the ‘noree.cn.c08 boom raise function and check to be sure that cyl- inder movement is smooth, with no sticking, 2. With the (standard) arm fully rolled out and (stan- dard hoe) bucket fully rolled in, lower the bucket to the ground. The bucket must be empty. 3. Maintain the hydraulic oll temperature at 50°5°C (12239 °F). Measurement: 1, Select the following switch positions: Power mode selector: P mode Work mode selector : General purpose ‘eroe-02.010 Auto-Idle switch OFF 2. Raise the boom and swing simultaneously, both at full stroke, 3. When the upperstructure rotates 90°, release the control levers to stop both functions. Measure the time required to swing 90° and the height (H) of the bucket teeth, 4, Repeat steps (2) and (3) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. neraeco.on Remedy: Refer to 107-03 TROUBLESHOOTING B. T06-03-14OPERATIONAL PERFORMANCE TEST / Component Test 4.1 PILOT PRIMARY PRESSURE Preparation: 1. Stop the engine. 2. Remove the top cover of the hydraulic oil tank with, a 17 mm wrench. 3. Push the pressure release button to bleed ait. 4. Loosen and remove plug on the pilot pump delivery port and connect pressure gauge, (ST 6942) using ‘a 6 mm hexagonal head wrench. 6. Start the engine and check for oil leakage from the port. 6. Maintain the hydraulic oil temperature at 505 °C (12229°R), sresece Measurement: 1, Select the following switch positions: Power mode selector: P mode and | mode Work mode selector: General purpose Auto-idle switch: OFF 2. Measure the primary pilot pressure in both the P. mode (fast idle) and the | mode (slow idle). 3. Repeat step (2) three times and calculate the aver- age values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to 107-03 TROUBLESHOOTING B. T06-04-01OPERATIONAL PERFORMANCE TEST / Component Test Pilot Primary Pressure Adjustment Adjust pilot relief valve (1) using the following proce- dure: Pee 22 mm aE +, Remove plug (2). 2, Install the estimated necessary numbers of shims @) = 2, Titten pus 2 tothe spect ore Et. mt 24.5 Nm (25 kgf, 18 lott) 4, Check the reliet pressure of relief valve (1) 5. Repeat steps (1) to (4) when readjustment is re- aquired. Shimsthickn | Change in relief pressure ess (mm) kPa ( kalicm’ psi) 025 78 (0.8, 11.4) 05, 147 (15, 213) 1.0 204 (3.0, 42.7) 06-04-02OPERATIONAL PERFORMANCE TEST / Component Test 4.2 PILOT SECONDARY PRESSURE Preparation: 1. Stop the engine. 2. Remove the top cover of the hydraulic oll tank with a 17 mm wrench. 3. Push the pressure release button to bleed al. 4. Disconnect pilot piping (1) from the control valve section to be inspected and install pressure gauge (ST 6942) and adapter (ST 6450) assembly, as shown, using 14 and 17 mm wrenches, 5. Start the engine and check for oil leakage from the adapter. 6. Maintain the hydraulic oll temperature at 0:5 °C (12249 °F). Measurement: 1. Select the following switch positions: Power mode selector: P mode and | mode Work mode selector: General purpose Auto-idle switch: OFF 2. Measure the secondary pilot pressure in both the P. mode (fast idle) and the | mode (stow idle. 3. Repeat step (2) three times and calculate the aver- Tok6-04.008 age values. Evaluation: Reter to Group -06 in this section. Remedy: Refer to 07-03 TROUBLESHOOTING B. T06-04-03OPERATIONAL PERFORMANCE TEST / Component Test 4.3 PROPORTIONAL SOLENOID VALVE PRESSURE SETTING (PC PRESSURE) For Pc pressure Preparation: 1. Stop the engine. 2, Remove the top cover of the hydraulic oil tank with a 17 mm wrench. 3, Push the pressure release button to bieed air. 4, To measure the Pc pressure: (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain realtime Pc pressure data (2) Disconnect the Pc pressure piping between propor- tional solenoid valve and the control valve section to be inspected and install a tee (ST 6288), socket (ST 6240) and pressure gauge (ST 6942) assem: bly, as shown, using 17, 19, and 22 mm wrenches. 5, Start the engine and check for oil leakage from the tee. 6. Maintain the hydraulic oil temperature at 50:45 °C (12249 °F) Measurement: 1. Select the following switch positions: (For the boom, arm, bucket, swing travel and Auxil- iary circuits.) Power mode selector: P mode Work mode selector: General purpose ‘Auto-idle switch OFF 2. Measure the Pc pressure, using pressure gauge and Dr. EX. 8. Repeat step (2) three times and calculate the aver- age values. Evaluation Dr. EX indicated data +0.2 MPa Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-04OPERATIONAL PERFORMANCE TEST / Adjustment Pc Pressure Adjustment Adjust the proportional solenoid valves for right and left travel (1), swing (2), bucket (3), boom (4) and arm (5) circuits. IMPORTANT: Be sure not to loosen adjusting screw (8) over three turns from the wren 088 original position. Otherwise, O-ring will unseat, resulting in oil leaks. 1. Put a mark on the end face of adjusting screw (8) with white paint or a similar-substance, to record the original position. (Take care not to get paint on the thread surface.) 2. Loosen lock nut (7) and turn adjusting sorew (8) to adjust Pc pressure, 13 mm [7 4mm = 8.83 Nm (0.9 kat, 7 lott) rarsenco! Turning direction of adjusting | Counterclockwise | Clockwise Change in Pe pressure Decrease | Increase Pe pressure oil flow rate Increase | Decrease Adjusting screw turns vw | v2] 3] 4 kPa 98 | 196 | 294 | 392 ‘Adjusting screw Change in Pe pressure, kgficm? 1 2 3 4 Psi 142] 20.4 42.7 | 569 3, Check the adjustment of adjusting screw (8). N Pressure Pressure increase decrease T06-04-05OPERATIONAL PERFORMANCE TEST / Component Test For Travel Speed Selecting Pressure Preparation: 1. Stop the engine. 2. Remove the top cover of the hydraulic oil tank with a 17 mm wrench. 3, Push the pressure release button to bleed air. 4. To measure the speed selecting pressure: (1) Connect Or. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time speed selecting pressure data. (2) If Or. EX is not available, disconnect travel speed selecting pressure piping (1) between proportional solenoid valve and the center joint and install adapter (ST 6450) and pressure gauge (ST 6942) assembly, as shown, using 17 mm, 19 mm and 22 mm wrenches, 5. Start the engine and check for oil leakage from the adapter. 6. Maintain the hydraulic oil temperature at 505 °C (12249 °F) Measurement: 1. Select the following switch positions: Travel mode switch: Fast and medium or slow Power MODE selector: P mode Auto-idle switch: OFF 2, Measure the travel speed selecting pressure in the medium or slow mode. 3. Lower the bucket to the ground to raise the track off the ground. Operate the travel lever at full stroke and measure the fast speed pressure. 4, Repeat steps (2) and (3) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to 107-03 TROUBLESHOOTING 8. T06-04-06OPERATIONAL PERFORMANCE TEST / Component Test 4.4 SWING PARKING BRAKE RELEASING PRESSURE Preparation: 1. Stop the engine. 2. Remove the top cover of the hydraulic oil tank with 17 mm wrench. 3. Push the pressure release button to bleed air 4, Disconnect swing brake control pressure piping (1) between directional solenoid valve and the swing motor and install an adapter (ST 6450) and pres- sure gauge (ST 6942) assembly, as shown, using 17 mm and 19 mm wrenches. 5. Start the engine and check for oil leakage from the adapter. 6. Maintain the hydraulic oll temperature at 505 °C (12249°F). Measurement: 1. Select the following switch positions: Power mode selector: P mode Auto-idle switch: OFF 110506.04.008 2. Operate the swing function or arm roll in function and measure the swing brake control pressure with the brake disengaged. Release the control lever to return to neutral and measure the control pressure when the brake is applied. 3. Repeat step (2) three times and calculate the aver- age values. Evaluation: Refer to Group -08 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-07OPERATIONAL PERFORMANCE TEST / Component Test 4.5 REDUCING VALVE PRESSURE SET- TING (PI PRESSURE) Preparation: 1. Stop the engine. 2, Remove the top cover of the hydraulic oil tank with 17 mm wrench. 3. Push the pressure release button to bleed air. 4, To measure the Pi pressure’ (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time pressure data (2) If Dr. EX is not available, disconnect swing brake control pressure piping (1) between the reducing valve and the control valve and install an adapter (ST 6450) and pressure gauge (ST 6942) assem- bly, as shown, using 17 mm and 19 mm wrenches. 5, Start the engine and check for oil leakage from the adapter. 6. Maintain the hydraulic oil temperature at 50+5 °C (12249 °F) Measurement: 1. Select the following switch positions: Power mode selector: P mode Auto-idle switch: OFF 2, Measure the Pi pressure in the P mode. 3, Repeat step (2) three times and calculate the aver- age values, Evaluation: Refer to Group -06 in this section Remedy: Refer to 07-03 TROUBLESHOOTING 8. T06-04-08OPERATIONAL PERFORMANCE TEST / Component Test Pi Pressure Adjustment Adjust reducing valve (1) using the following procedure: mee : 22 mm 1, Remove plug (2). 2, Install the estimate mumbers of shims (2). 3, Retighten plug (2) to the specified torque. FSH 26.5 Nim (25 kgtm, 18 IbHt) 4. Check Pi pressure. Replace the reducing valve assembly if the Pi pres QC sure is outside the standard P' pressure range. Shimsthickn | Change in relief pressure ess( mm) kPa ( katfcm®, psi ) 04 302 (04, 57) T06-04-09OPERATIONAL PERFORMANCE TEST / Component Test 4.6 MAIN PUMP DELIVERY PRESSURE (CONTROL LEVERS IN NEUTRAL) Preparation: 1. Stop the engine 2. Remove the top cover of the hydraulic oil tank with 17 mm wrench. 3, Push the pressure release button to bleed air. 4. To measure the main pump pressure: (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time main pump pressure data. (2) If Dr. EX is not available, loosen and remove the plug on the main pump delivery port and connect, pressure gauge, (ST 6942) using a 6 mm_hexag- onal head wrench. 5. Start the engine and check for oil leakage from the port 6. Maintain the hydraulic oil temperature at 505 °C. Trosesotoor (12229°R), Measurement: 1. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2. Measure the main pump delivery pressure in the P mode (fast idle) 3, Repeat step (2) three times and calculate the aver- age values, Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-10OPERATIONAL PERFORMANCE TEST / Component Test 4.7 MAIN RELIEF PRESSURE RELIEF SETTING Preparation: 1. Stop the engine 2, Remove the top cover of the hydraulic oil tank with 17 mm wrench. 3. Push the pressure release button to bleed air. 4. To measure the main relief pressure: (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time main pump pressure data. (2) If Or. EX is not available, loosen and remove plug on the main pump delivery port and con- ect pressure gauge, (ST 6942) using a 6 mm hexagonal head wrench 5. Start the engine and check for oil leakage from the port 6. Maintain the hydraulic oil temperature at 50+5 °C (12249 °F). Measurement: 1. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2. Slowly operate each control lever of boom, arm and bucket functions at full stroke over relief and mea- sure the pressure. 3. In the swing function, place bucket against an im- movable object and measure the relief pressure. 4. In the travel function, lock undercarriage with an im- movable object and measure the relief pressure. 5. Repeat steps (2) to (5) three times and calculate the average values. Evaluation: Refer to Group -06 in this section NOTE: If any one of the measured pressures is lower than the others, it indicates that the reliet pres- sure setting of the overload relief valve of that circuit is lower than the main reliet valve pres- sure setting. Check the overioad relief valve of that circuit Remedy: Refer to T07-03 TROUBLESHOOTING 8. T06-04-11OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Valve Adjustment A~ Main Reliet Valve 1. Unscrew lock nut (2) on the main relief valve, 2 2. Rotate screw (3) t adjust the main relief pressure. 3. Retighien lock nut (2) ames 17 mm [so mm =: 31.5 Nim (3.2 kgm, 23 IbFft) ‘Screw turns Wa 12 34 1 Adusing sew wea | 279 | 550 | 006 | 11.2 Change in elit Pressure kgticm® | 28.5 87 85.2 | 114 psi 40s | ait |1212| 1621 ean On recess crease T06-04-12OPERATIONAL PERFORMANCE TEST / Component Test ‘Swing Relief Pressure Adjustment ‘A— Swing Reliet Valve 1, Unscrew lock nut (2) on the swing relief valve. 2, Rotate screw (1) to adjust the swing relief pressure. 3. Retighten lock nut (1) ee 17 mm FT ce mm rea 186 Nim (19 kgm, 197 bt) Screw turns ws | we | oa | 4 Adjusting srew mea | 17 | 34 | 51 | 69 justng Change in eliot pressure uation? | 17.5 | 95 | 525 | 70 psi 24g | 498 | 747 | 995 pomua —Presnee inoreaee ecrease T06-04-13OPERATIONAL PERFORMANCE TEST / Component Test Travel Relief Pressure Adjustment AX Travel Reliet Valve 1. Remove travel relief valve assembly. 2, Referring WO3-02, disassembly sleeve (1) and car- tridge. .Insert shims between poppet (3) and spring guide(4) to adjust travel relief pressure, 4, Tighten travel relief valve assembly. Ie 230 mm fat: 294 Nem (30 kgm, 217 bt) Shim 0.5 mm (0.02 inch) Unit kPa | kgficm2 | _ psi Change in relief pressure | 785 8 114 706-04-14OPERATIONAL PERFORMANCE TEST / Component Test 4.8 OVERLOAD RELIEF VALVE PRES- SURE SETTING Checking the pressure setting of the overload relief valves on the machine is not recommended for the fol- lowing reasons: (1) Raising circuit oil pressure by blocking the return circuit of the control valve and applying external force to the machine structure may cause machine damage. (2) Checking the overioad relief valve pressure setting (on the machine using a high pump flow rate is not reliable because the valves are adjusted to specifi cation with a fixed flow rate of 50 L/min, However, if required the following procedure is recom- mended to check if the overload relie! pressure setting is normal : (Same as the procedure to check the system pressure regulator relief setting.) Preparation: 1. Stop the engine. 2. Remove the top cover of the hydraulic oll tank with a 17 mm wrench. 3. Push the pressure release button to bleed air. 4, To measure the system relief pressure: (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time main pump pressure data, (2)If Dr. EX is not available, loosen and remove plug on the main pump delivery port and connect pres: sure gauge, (ST 6942) using a 6 mm hexagonal head wrench. 5, Start the engine and check for oil leakage from the port 6. Maintain the hydraulic oil temperature at 50+5 °C (1229 °F) Measurement: 1, Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idie switeh: OFF 2. Slowly operate each control lever of boom, arm and bucket functions at full stroke over relief and mea- sure the relief pressure 3. Repeat steps (2) three times and calculate the average values. Evaluation: When the measured pressure is the same as the main relief valve relief setting, the over load relief valve is functioning normally. If the measured pres- sures is lower than the main relief valve relief set- ting, the overload relief valve pressure setting of that circuit is abnormal Refer to Group -06 in this section Remedy: Refer to T07-03 TROUBLESHOOTING 8. T06-04-15A 9503| OPERATIONAL PERFORMANCE TEST / Component Test Overload Relief Valve Adjustment 1 Bucket 4 Bucket 2— Boom = 3 Am 1, Unscrew lock nut (7) on the overload relief valve, 2. Rotate screw (8) to adjust the overload reliet pres- sure. 3, Retighten lock nut (7). ome 17 mm —= =H 31.5 Nem (3.2 kgm, 23 lott} ‘Screw tums 14 2 34 1 MPa 28 5.6 84 11.2 ‘Adjusting screw cigs ea oral el a T06-04-16OPERATIONAL PERFORMANCE TEST / Component Test 4.9 MAIN PUMP FLOW TEST Measure the pressure and flow rate of the main pump using Dr. EX. If Dr. EX is not available, install a portable hydraulic tester between the main pump and the contral valve, as illustrated, Preparation: 1. Stop the engine, 2, Remove the top cover of the hydraulic oil tank with a 17 mm wrench, 3. Push the pressure release button to bleed air. Connect a vacuum pump to the oil supply port of the hydraulic oll tank. IMPORTANT: Operate the vacuum pump while connecting the portable hydraulic tester to the main pump. 1— Pressure Gauge 4= Pipe e (st 6144) (sTeaat) 2— Hydraulic Tester 5— Flange F (ST 6197) (sr 6299) 3 TestHose 6— Adapter PFI-PF3/4 (ST 6320;02 (st 6025) 4, To measure the pressure and flow rate: (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time main pump pressure data, (2) Ir. EX is not available Disconnect hose (A) . Connect flange F (5), split flange (C), bolts {D) to hose (A) Remove plug (E) and install adapter (6) Connect pipe (4), spit flange (C), bolts (D), test hose (3), (10), adapters and joints (7), (8). (9) and hydraulic tester (2). Remove plug (F) located on the delivery side of the main pump. Connect pressure gauge (1) If Dr. EX is not available, the following steps are required Steps (1) to (7), (10) and (11) are also neces- sary when using Dr. EX Adapter PFIPT1 9 Adapter PFtx1-7]8UNF (sr 6072) (st 6126) soint (ST 6330) ‘Adapter {-7UNF*PT! — 10— Test Hose (ST 6000) (st 6145) ‘Joint (ST 6320) T06-04-170 9503OPERATIONAL PERFORMANCE TEST / Component Test 5. Disconnect vacuum pump from the oil supply port 6. Loosen plug (G) on the pump housing until oi flows out to bleed air. 7. Tighten air breather cap on the hydraulic oil tank. 8 Disconnect connector ()) of differential pressure sensor (H) to increase the pump swash angle to maximum, 9. Connect engine tachometer to the fuel injection pipe 10. Fully open the loading valve of the portable hy- draulic tester. 11. Start the engine and check for cil leakage trom the port 12, Maintain the hydraulic oil temperature at 505 °C (12249 °F), Measurement: (When using a portable hydraulic tester) 1. Select the following switch positions Travel mode switch: Fast Power MODE selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2, Slowly operate the loading valve of the portable hydraulic tester to increase delivery pressure 10 14.8 MPa (120 kgf/cm?) and 19.6 MPa (200 kagflem2), and measure flow rate at each pres sure, 3. Repeat step (2) three times and calculate the average values. Evaluation: 1. Conversion Calculate flow data using pump standard speed data, employing the formula below: Qe: Calculated flow rate Q: Measuring flow rate 1: Transmission reduction rate (=1) Np: Pump standard speed (2300 min-") Ne: Measuring engine speed 2. Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-18OPERATIONAL PERFORMANCE TEST / Component Test 4.10 SWING MOTOR DRAINAGE Purpose of the measurement: To check for wear and damage inthe swing motor. A cauTI0N: Make cure the area is clear and large enough to safely swing the upperstructure, NOTE: The amount of drain ol rom the swing motor wil change depending on the ofl temperature Maintain the ol temperature within 50-15 °C (12249 °F) for correct measurement. Preparation : 1. Before measuring, swing the upperstructure a few times to warm up the inside of the swing motor. 2. Stop the engine. Push the pressure release button Tosoe.901 on the hydraulic oil tank to bleed air. 3. Disconnect drain hose (1) of the swing motor from the oll cooler return pipe. Plug the screw hole on the oil cooler return pipe. Place a container at the end of the drain hose to receive drain ol mb: 22 mm pa 59 Nim (6 kgf, 43 bt) 4, Start the engine. Select each switch position as fol lows: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF T06-04-19OPERATIONAL PERFORMANCE TEST / Component Test Measurement (1) : Measure the amount of drain oil while swinging the up- perstructure. 1, Fully retract the arm cylinder and extend the bucket cylinder. Raise the boom so that the bottom of the unloaded bucket is about 1 m (1 yd) above the ground. 2. Swing the upperstructure with a full swing control lever stroke ; after the swing speed becomes con- stant, start the measurement, 3. Measure the amount of drain oil and the time. The measuring time must be more than 45 seconds. 4. Repeat the measurement at least three times in both directions, right and left, and calculate the average values. ‘Measurement (2) : —————— Measure the amount of drain oil with the swing motor SS stalled. oa 1. Insert the bucket into the ground, as illustrated, to stall the swing motor. 2. Operate the swing control lever for more than 45 seconds. Measure the amount of drain oil and the time. 3. Repeat the measurement at least three times in both directions, right and left, and calculate the average values. Evaluation : Refer to Group -06 in this section. 1. Measure the total amount of drain il with a cali brated container. 2, Calculate the amount of drain oll per minute using oo the following equation: Q=60/txq Q: Amount of drain oil per minute ( Limin ) ti: Measuring time ( sec ) a: Total amount of drain oil (L) Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-20OPERATIONAL PERFORMANCE TEST / Component Test 4.11 TRAVEL MOTOR DRAINAGE Purpose of the measurement: ‘To check for wear and damage in the travel motor. IMPORTANT: (1)The amount of drain oil from the travel motor will change depending on the oil temperature. Maintain the oil tempera- ture within 50£50 °C (12249 °F) for correct measurement. (2) Measure travel speed and mistracking in addition to measuring the amount of drain oil, Use the data obtained from all three tests to check the travel motors. Preparation : 1, Swing the upperstructure to the side to be tested, Lower the bucket to raise the track off the ground, 2. Rotate the raised track back and forth to warm up the inside of the travel motor before measuring 3. Stop the engine. Push release button on the hy- draulic oll tank to bleed ait. 4, Disconnect drain hose (1) from the travel motor and, close the drain hose end with a plug. Connect hose {ST 6622) to the travel motor and place a container the end of the hose to receive drain oil ame: 22 mm ae 49 Nem (5 kgtim, 36 Ibft) 65, Start the engine and select each switch position as follows: Travel mode switch: Fast o7.06-05.002 Power selector: P mode Auto-idle switch: OFF T06-04-21OPERATIONAL PERFORMANCE TEST / Component Test Measurement : 1. Rotate the travel motor for more than 45 seconds. Measure the amount of drain oil and the time. 2. Repeat the measurement at least three times in both directions, back and forth, and calculate the average values. Evaluation : Refer to Group -06 in this section. ‘ier.6-08.008 1, Measure the total amount of drain oil with a cali- brated container. 2. Calculate the amount of drain oil per minute using the following equation: = 60 xq Q: Amount of drain oil per minute ( Limin ) t: Measuring time ( sec ) q: Total amount of drain oil (L) Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-22OPERATIONAL PERFORMANCE / Basic Performance Check BASIC OPERATIONAL PERFORMANCE CHECK WITH THE DR. EX. 1. Purpose : To check the machine performance using the ‘monitor function of the Dr. EX. Operational performance of the pump displace- ment solenoid valves, pressure switches (P switches) and all sensors can be checked as well NOTE: Refer to the table in section T06-06 for operational performance standards. Preparatior 1. Measurement tools required: Dr. EX, Stopwatch 2. Arrange a firm level test area spacious enough to allow the front attachment to move, the upperstructure to swing, and the machine to travel. 3. Connect the Dr. EX to the diagnostic connec- tor in the operator's cab and select the Moni- tor Data function. 4. Select the following switch positions: Powe moderselector: P mode Work mode selector: General purpose mode (M1) Maintain the hydraulic oll temperature at SOL5°C (12249° F), 5, Select sensing signals and command signals, to be measured. If the measurement resuits are outside standard values, perform troubleshooting and adjustment with the diagnostic tools (pressure gauge, har- ness lamp kits, and testers) Refer to Section T07 in this manual 3. Measurement : When measuring front attachment pertor- mance, position the cylinder piston outside the cushion range (located just before both stroke ends.). Then, push switch F1 on the Dr. EX to stabi- lize the display reading. PC pressure measured with the pressure gauge must be within 0.2 MPa (2 kaflem2, 28 psi) the PC pressure reading by the Dr. ex I the pressure gauge value exceeds this al- lowance, adjust the pump displacement sole- Noid valve, referring to Section TOS in this manual, ‘The data for some items are not always avail- able, depending on the version of the PVC. Refer to the table in section T06-06 for data items available for checking with a given PVC. version, NOTE: Only Dr. EX IC cards with a version No. atter 2.05 will display PVC version Nos. on the screen. T06-05-01OPERATIONAL PERFORMANCE / Basic Performance Check 5.1 PRESSURE (P) SWITCH CHECK Check if the P switch is functioning correctly. Operation Indication on Dr.€X ‘Boom raise Bm Travel Tr Boom lower, Arm roll-out, Bucket rol-infout or ‘Swing ‘Sw ‘Arm rollin Am When the above checks are made, the Or. EX should display data in a negative format. If a nega tive format is not displayed, the following troubles may exist. Investigate the cause using the appropri- ate diagnostic tools. 1. P switch is not connected correctly. 2. P switch failure. 3. Loose connection of P switch 4, Broken wire harness. 5. Loose connection at the junction box in the cab. 6. Loose connection between PVC and EC. NOTE: If P switches are not correctly connect- ed, the machine performance of such operations as leveling, combined opera- tion of travel and front, and auto-idle, andfor controllability will dectine. If the P switch is at fault, the Or. EX will not display an error code in the selt- diagnosing operation. T06-05-02OPERATIONAL PERFORMANCE / Basic Performance Check 5.2. PERFORMANCE CHECK WITH CONTROL LEVER IN THE NEUTRAL POSITION, AND AT RELIEF PRESSURE Preparation : Select the following switch positions: Power mode selector : P mode Work made switch : General purpose mode(M1) Maintain the hydraulic oil temperature at $0=5°C (12239°F) Before measuring the engine speed, make sure that the fuel injection pump governor lever comes into contact with the fast- idle stopper. Measurement Measure the following items. Items to be measured with the control lever in the neutral position. (A) Engine speed: N (min~') (B) Differential pressure of pump delivery cil AP (kaif om’) (C) Pump delivery oil pressure: P (kal! cm’) (D) Pump flow rate: Q (Limin) Items to be measured at reliet pressure. Rol in the arm to relief pressure. (F) Engine speed: N (min-') (G) Differential pressure of pump delivery oi: P (kglf om?) (H) Pump delivery oll pressure: P (kgff em) (1), Pump flow rate: Q (Limin) (J) Actual/set engine speed difference: AN (min~1) NOTE: (1) The displayed values on Dr. EX may vary. Try to read the median values. The engine speed change is displayed with changes of 4 ‘min (rpm) or more. (2) Diferential pressure of pump deliv. ery oil is lable to change by oil ter: perature. Be sure to maintain the hydraulic oil temperature at BOSC (12249°F) (3) To make it easier to read the pump delivery pressure, the display on the Dr. EX is designed to respond slowly to pressure change. Try to read it after it becomes stabilized. (4) When the measurement results do not meet the standard values, refer to the items shown on the following page. T06-05-03OPERATIONAL PERFORMANCE / Basic Performance Check If any of the troubles shown below are found during the check described in 5-2, investigate the causes and repair as necessary. item Problems Causes Check and Repair Methods Engine speed too slow [(A-1_ Reduced engine power (a) (A}2 Too much unloaded pump drive | Pump delivery ol pressure will torque increase. Differential pressure | (8)-1_ Faulty DP sensing signal Tn case check value does not (8) | too smal Unload valve failure. change after DP sensor replaced, check unload valve. (D)_| Flow rate too high (O)-1 Faulty A sensor sensing signal, | Adjust or replace A sensor. Check A sensor drive link. relief pressure too small Differential pressure at | (G)-1 Overload relief valve leak or setting pressure is decreased, too small and relief pressure at relief pressure too low (G) [Diferental pressure | (G)-2 Main relief valve failure (eg, stuck with foreign matter), pressure exceeds standards valve. Pump delivery (A1 P sensor failure. Faulty adjustment of main relief | after replacing P sensor, adjust Tf data stil exceeds standards adjusting screw of main relief valve. too small and relief wate Differential pressure | (Hi-2 Faulty setting of overload relief Check pressure while reliefing other cicuit actuator (Hh) HS Si in [0 le and check ressure too low (HS. Stuck spool or broken spring in| Disassemble and ched ae Unloading vaive. Unloading valve. (Hy-4 Reduced main pump flow rate. | Check flow rate with flow meter. Change main pump if failed (H)5 Oil contamination while using | Check for main pump failure. breaker Reduced pump flow |()-1 Faully sensing signal rom A | Check sensing signal from A [rate sensor. sensor. Reduced engine power. Check causes of power loss such as grade of fuel, etc. ‘Actual engine speedis [(J)-1 Reduced engine power or Check for causes of faulty much siower than set, excessively increased main _| sensing signal from A sensor or speed. pump drive torque. loss of engine power. 0 Check operation of stop motor. ‘Actual engine speeds |(J)-2 Sensing signal from A sensor | Check sensing signal from A much higher than set too hig} sensor. speed. Reference I pump delivery pressure does not reach relief pres- sure, the source of trouble may exist in the following points. Check ane by one, 1. Leaks in load sensing line. (1) Shuttle valve stuck open, due to foreign matter. Pressure oil leaks increase the differential pressure. ‘The pump flow rate is thus reduced and the unload- ing valve opens to the hydraulic oil tank. Therefore, the main pump pressure does not increase. 2, Stuck unloading valve, and faulty main relief valve, overload relief valve, or cross relief valve. Although the pump flow rate increases, the pump delivery pressure cannot reach relief pressure. T06-05-04OPERATIONAL PERFORMANCE / Basic Performance Check 5.3 A SENSOR (PUMP DISPLACE- MENT ANGLE SENSOR ) CHECK Measure the sensing signals from A sensor when the pump displacement angle is at a minimum or maximum position, When measuring at a minimum angle. Position the control lever in neutral (Differential pressure should be over 20 kgficm®) When measuring at a maximum angle. Move the control levers (for the boom raise, arm rollin, and bucket rollin) full stroke. It the measurement results do not meet the standard values, the following troubles might exist. Check each item, 1. Faulty signal due to A sensor failure. 2. Faulty signal due to loose connection of A sen- sor. 3. A sensor drive link failure in the pump. 5.4. SINGLE OPERATION CHECK Refer to Section T06-03 for check procedure. Check travel speed at medium speed Operations to be checked (A) Boom raise (B) Boom lower (C) Armrolin (D) Arm roll-out (E) Bucket rollin (F) Bucket roll-out (G) Swing (H) Travel Check items: Operation speed (sec) PC pressure (kgtlom?) Pump differential pressure AP (kgticm?) Pump delivery pressure P (kgf/em®) Pump fiow rate Q(Umin) Actual/set engine speed difference AN (min-") NOTE: (1) Measure the actuator speed using a stop watch, and use the Dr. EX to measure items other than the actuator speed. (2) When monitoring with the Dr. EX, the displayed valu can be held by pushing the Ft key. Before a oylin- der piston enters the cushion range, push the Ft key to measure ‘ts normal operating speed. (3) Do not attempt to measure with a long arm or heavy bucket attached; incorrect data will be obtained. T06-05-05OPERATIONAL PERFORMANCE | Basic Performance Check If any measurement results do not meet stan- dard values, perform troubleshooting, referring to the table in the following page to investigate the causes and repair or adjust as necessary. od aa {8) Slow speed of oom increase due to failure in oad | shuttle, Readjust or replace (Shuttle stuck open by ee oon Ela ca a cra) ood sneroere T06-05-06OPERATIONAL PERFORMANCE / Basic Performance Check COMBINED OPERATION Performance of combined operation varies depending on each PC pressure. If the proportional solenoid valve outputs a different PC pressure from the command sig- nal sent out by the PVC, the machine cannot function as it was designed to. This section describes the relevant checking proce- dures. 5.5 COMBINED BOOM RAISE AND ARM ROLL-IN OPERATION ‘Summary : Mainly check for abnormality in arm PC pressure. Preparation 1. Select the following switch positions Power mode selector : P mode Work mode selector : General purpose mode (M1) Auto-idle switch : OFF 2, Install the standard front: Standard arm and hoe bucket. 3. Check that the slow-return valve functions normally with the engine running at fast idl. 4. Maintain the hydraulic oll temperature at 5025%C (12289°F) 5. With the arm cylinder extended full stroke, position the teeth end and the arm pivot pin center in a line, as shown in fig. A Hold the bucket so that the height (H1) of the teeth tend is 0.5 m (20 in) above the surface (The bucket must be empty.) Measurement : 1, Operate the boom control lever to raise and the ‘arm control lever to rollin full stroke, at the same time, from the position shown in fig. A. Move the control levers to their stroke ends to ex- tend the boom and arm cylinders full stroke. Mea- sure the moving time of each cylinder. 2. Teeth end height measurement. Operate the boom control lever to raise and the arm control lever to roll-in full stroke, at the same time, from the position shown in fig. A. Return both levers to noutral when either the boom or the arm cylinder reaches its stroke end. Measure the teeth end height (H2), as shown in fig c. 3, Measurement by the Dr. EX. Measure the pump differential pressure, pump de- livery pressure, pump flow rate, boom PC pressure, and arm PC pressure. Push hold key (F1) at the point when the arm is perpendicular to the ground. 4. Repeat each measurement 3 times and calculate the average values, Fig. A Fig. 8 T06-05-07OPERATIONAL PERFORMANCE / Basic Performance Check Evaluatio NOTE: (1) Compare the standard values in the ta- ble in section T06-06 with the Dr. EX ‘measured values. I any measured val- ue does not meet standards, refer to the table below for corrective action. (2) Check if the arm PC pressure (at the ‘SB port ) is normal Problems Causes ‘Check and Repair Front attachment movement is unstable. 1-1 Aerated piping between solenoid valve and control valve. Loosen piping to release air. Bucket contacts ground at point B shown in fig. B, or 2-1 No. fuse broken. ‘Check using lamp kit or circuit tester. height H 2 is lower than standards. 2-2 Broken harness for solenoid valve, solenoid valve connector disconnected, or misconnected ‘Check using lamp kit or circuit tester. 2:3 Low arm PC pressure. (at $B port) Measure PC pressure. Replace or readjust solenoid valve. 2-4 Faulty variable pressure compensated valve for arm, Disassemble to clean or replace variable pressure compensated valve. 2-5 DP sensor sensing signal too igh Check that Dr. EX indicates 0.5 kgfjem® or less with engine stopped and key switch ON, ‘Arm cycle time is slow or height H 2 is higher than ‘3:1 Arm PC pressure (at SB port) too high. Measure PC pressure. Replace or readjust solenoid valve. standard. 3-2 Short stroke of arm spool. Measure arm spoo! pilot pressure or disassemble solenoid valve to check. 3-3 Failure in switch panel. Use Dr. EX to check for signal in grading mode (M3) and precision mode (M4), 3-4 Faulty arm variable pressure compensated valve. Disassemble valve to clean or replace it, T06-05-08OPERATIONAL PERFORMANCE / Basic Performance Check 5.6 COMBINED BUCKET ROLL-IN RE- LIEF AND BOOM RAISE CHECK Summary Mainly check for boom PC-pressure (SA port out- ut) abnormalities. Preparation : 1. Select the following switch positions Power mode selector : P mode Work mode selector : General purpose mode (M1) ‘Auto-idle switch : OFF 2. Install the standard front Standard hoe bucket and arm. 3. Check that the siow-return valves function normally with the engine running at fast idle. 4, Maintain the hydraulic oil temperature at 5025°C (12289°F}, 5. With the arm rolled-out and bucket rolled-in both fully, lower the bucket onto the ground. The bucket must be empty. Measurement 1, While the bucket lever moved in the rollin position, relieving, move the boom raise lever to the stroke end, 2, Measure the boom cylinder stroke time, from the bucket on the ground to the most boom raised po- sition. 3. Dr.£X measurement. Measure the pump differential pressure, pump de- livery pressure, pump flow rate, boom PC pressure, and actual/set engine speed difference. Be sure to push the hold key (F1) just before the boom reaches the cushion zone. 4. Repeat each measurement 3 times and calculate the average values Evaluatio Compare the standard values in the table in section 706-06 with the Dr. EX measured values. If any mea- sured value does not meet standards, refer to the table below for corrective action, T06-05-09OPERATIONAL PERFORMANCE / Basic Performance Check Problems Causes ‘Check and repair Front attachment movement is unstable. 1-1 Aerated pipings between solenoid valve and control valve. Loosen pipings to release air, Actual/set engine speed difference is large. ‘Adjust engine. Boom raise is slow. 3+1 Boom PC pressure(SA port output) too high, ‘Adjust or replace solenoid valve. 3-2 Faulty variable pressure compensated valve, resulting in decreased flow rate. Disassemble to clean or replace variable pressure compensated valve. 3-3 Wrongly installed (connected) solenoid valve. Boom raise is too fast 4-1 Boom PC pressure (SA port output) 100 low, or an open exists in wire harnesses, Adjust or replace solenoid valve. Repiace open wire harness. 4-2 Faulty variable pressure compensated valve, resulting in increased flow rate. Disassemble to clean or replace variable pressure compensated valve. T06-05-10