Technical Manual (Troubleshooting) EX300-3C Excavator HITACHI KM-140E-0 TT140E-01INTRODUCTION TO THE READER ¢ This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. Be sure to thoroughly read this manual for correct, product information and service procedures. If you have any questions or comments, at if you found any errors regarding the contents of this, manual. please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.) Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162 ADDITIONAL REFERENCES © Please refer to the materials listed below in addition to this manual +The Operator's Manual + The Parts Catalog + Operation Manual of the Engine Parts Catalog of the Engine + Hitachi Training Material MANUAL COMPOSITION ¢ This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual. + Information included in the Technical Manual (Operational Principle): technical information needed for redetivery and delivery, operation and activation of all devices and systems. “Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures. + Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removaljinstallation and PAGE NUMBER Each page has a number, located on the center lower part of the page, and each number contains the following information: T.01-03-05 Example: ‘—> Group Number —— Section Number -T: Technical Manual Ly consecutive Page Number for Each Group W: Workshop Manual IN-O1INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury or machine damage. Ai Tris is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts. ¢ A caution: incicated a potentially hazardous situation which could, if not avoided, result in personal injury or death. ¢ IMPORTANT: indicates a situation which, if not conformed to the instructions, could result in damage to the machine. ¢ NOTE: indicates supplementary technical information or know-how. UNITS USED © SI Units (International System of Units) are used in this manual MKSA system units and English units are also indicated in parentheses just behind SI units. Example: 24.5 MPa ( 250 kgffcm?, 3 560 psi) A table for conversion from SI units to other system units is shown below for reference purposes. To Convert Matiply To Convert Maliply Quantity | From Into By | uantty | From Into By mm in 0038.37 MPa | kaon} 10.187 Length rm. in 0.003267] "esse MPa. ps | Ta8.9 t US gal | 0.2642 KW Pi 1.360, Volume L US at 4.057, Power kW, HP 1341 a ve? 7-308 || Temperature | *C oF [Gxt 6090 Weight ka ib 2.205 I veiocity kenfh mph O.6214 Foe N ka 0.101 97 rnin rpm 1.0. N ‘of 0,204.8 — | Flow rate Umin [US gpm [0.2642 Tm Kgtm—| 1.019 7 mijrev | ecjrev | 1.0 Torque Nem ibrft 0.7375 IN-02SAFETY RECOGNIZE SAFETY INFORMATION © This is the SAFETY ALERT SYMBOL. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. UNDERSTAND SIGNAL WORDS © On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION ~ are used with the safety alert symbol. “DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury, CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. © CAUTION also calls attention to safety messages in this manual. # To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indi- cates a situation which, if not avoided, could result in damage to the machine. © NOTE indicates an additional explanation for an ele- ment of information. A DANGER A WARNING A CAUTION IMPORTANT NOTE SA-1SAFETY FOLLOW SAFETY INSTRUCTIONS © Carefully read and follow all safety signs on the machine and all safety messages in this manual. © Safety signs should be installed, maintained and replaced when necessary. It a safety sign or this manual is damaged or missing, replace it with new one. @ Learn how to operate the machine and its controls correctly and safely. ‘® Allow only trained, qualified, authorized personnel to operate the machine. ‘© Keep your machine in proper working condition, Unauthorized modifications to the machine may impair the function andjor safety and affect machine lite, © The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor before operating or performing maintenance work on the machine. PREPARE FOR EMERGENCIES Be prepared ifa fire starts or if an accident occurs. Keep a first aid kit and fre extinguisher on hand ‘Thoroughly read and understand the label attached ‘on the fire extinguisher to use it propery. Establish emergency procedure guidelines to cope with fires and accidents. « Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone. ~ Pe | O SA-2SAFETY WEAR PROTECTIVE CLOTHING © Wear close fitting clothing and safety equipment appropriate to the job. You may need: Aboard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or fiter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. 38 «3D Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. © Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. INSPECT MACHINE © Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. In the walk-around inspection be sure to cover all points described in the "PRE-START INSPECTION" chapter in the operator's manual. SA-3SAFETY USE HANDHOLDS AND STEPS ‘© Falling is one of the major causes of personal injury. When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. Do not use any controls as handholds. Never jump on or off the machine. Never mount or dismount a moving machine. - Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. | lL gy | ADJUST THE OPERATOR’S SEAT © A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. The seat should be adjusted whenever changing the ‘operator for the machine. The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back If not, move the seat forward or backward, and check again. SA-4SAFETY FASTEN YOUR SEAT BELT © If the machine should overtum, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overuniny macho, rung in sonoue ty ot MeL death. Prior to operating the machine, thoroughly examine my webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. ‘We recommend that the seat belt be replaced every three years regardless of its apparent condition. MOVE AND OPERATE MACHINE SAFELY Bystanders can be run over. Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. SA-5SAFETY OPERATE ONLY FROM OPERATOR'S SEAT Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death, e + Start the engine only from the operator's seat. NEVER start the engine while standing on the track or on ground. Do not start engine by shorting across starter terminals, Before starting the engine, confirm that all control levers are in neutral JUMP STARTING ‘© Battery gas can explode, resulting in serious injury. If the engine must be jump started, be sure to follow the instructions shown in the "OPERATING THE ENGINE" chapter in the operator's manual. The operator must be in the operator's seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. Never use a frozen battery. Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine, KEEP RIDERS OFF MACHINE © Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. + Only allow the operator on the machine. Keep riders off - Riders also obstruct the operator's view, resulting in the machine being operated in an unsafe manner. SA6SAFETY PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES © For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person's directions. CONFIRM DIRECTION OF MACHINE TO BE DRIVEN @ Incorrect travel pedal/lever operation may result in serious injury or death Before driving the machine, confirm the position of the undercarriage in relation to the operator's position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedalsflevers are operated to the front. SA-7SAFETY DRIVE MACHINE SAFELY ‘© Before moving the machine, confirm which way to move travel pedalsjlevers for the corresponding direction you wish to go. Pushing down on the front of the travel pedals or a pushing the levers forward moves the machine towards the idlers. (Refer to the Steering the Machine Using Pedals/Levers section in the ‘operator's manual for correct travel operation.) ¢ Traveling on a grade may cause the machine to slip seas or to overturn, possibly resulting in serious injury or death. When traveling up or down a grade, keep the bucket in the direction of travel, approximately 200 to 300 mm (approximately 8 to 12 in) @ above the ground. if machine starts to skid or becomes unstable, lower the bucket immediately Traveling across the face of a slope may cause the machine to skid or to turnover. When traveling ascending/descending) on a slope, be sure to point the tracks uphilldownhil Turning on an incline may cause the machine to tip over. If turning on an incline is absolutely unavoidable, do so at a place where the slope is gentle and the surface is firm SA-8SAFETY AVOID INJURY FROM ROLLAWAY ACCI- DENTS ‘© Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: + Select level ground when possible to park machine. Do not park the machine on a grade. Lower the bucket andjor other work tools to the ground. Turn the auto-idle switch off Run the engine at slow idle speed without load for § minutes to cool down the engine. Stop the engine and remove the key from the key switch. Pull the pilot control shut-off lever to LOCK positon. Block both tracks and lower the bucket to the ground, Thrust the bucket teeth into the ground if you must park on a grade. Position the machine to prevent rolling. Park a reasonable distance from other machines. S SA-9SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS 5 If any person is present near the machine when aad backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious 7 injury or death. To avoid back-over and swing accidents: Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR, caoes Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. Sd USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal Person. sasue No machine motions shall be made unless signals are clearly understood by both signalman and operator. Leam the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling, Keep windows, mirrors, and lights clean and in good condition. + Dust, heavy rain, fog, etc., can reduce visibility. As Visibility decreases, reduce speed and use proper lighting. Read and understand all operating instructions in the operator's manual. SA-10SAFETY AVOID TIPPING © The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: © Be extra careful before operating on a grade. Prepare machine operating area flat. + Keep the bucket low to the ground and close to the machine. Reduce operating speeds to avoid tipping or slipping. ‘Avoid changing direction when traveling on grades. NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable. Reduce swing speed as necessary when swinging loads. ‘© Be careful when working on frozen ground. Temperature increases will cause the ground to become soft and make ground travel unstable. SA-11SAFETY AVOID POWER LINES © Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. When operating near an electric line, NEVER move any part of the machine or load closer than 3 m (10 ‘t) plus twice the line insulator length. Check and comply with any local regulations that may apply. “Wet ground will expand the area that could cause any person on it to be affected by electric shook. Keep all bystanders or co-workers away from the site, cxpenracnera ¥// OBJECT HANDLING @ Ifa lifted load should fall, any person nearby may be struck by the falling load or may be crushed under- Neath it, resulting in serious injury or death. «When using the machine for craning operations, be sure to comply with al local regulations. Do not use damaged chains or frayed cables, sa- bles, slings, or ropes. Before craning, position the upperstructure with the travel motors at the rear. Move the load slowly and carefully. Never move it suddenly. + Keep all persons well away from the load. Never move a load over a person's head. Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. SA-12SAFETY PROTECT AGAINST FLYING DEBRIS ¢ If flying debris hit eyes or any other part of the body, serious injury may result. Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. Keep bystanders away from the working area before striking any object. PARK MACHINE SAFELY To avoid accidents: Park machine on a level surface. Lower bucket to the ground. = Tum auto-idle switch off. + Run engine at slow idle speed without load for 5 minutes. + Turn key switch to OFF to stop engine. Remove the key from the key switch. + Pull the pilot control shut-off lever to the LOCK position. + Close windows, roof vent, and cab door. Lock all access doors and compartments. SA-13SAFETY HANDLE FLUIDS SAFELY — AVOID FIRES ¢ Handle fuel with care; it is highly flammable. If fuel ignites, an explosion andjor a fire may occur, possibly resulting in serious injury or death. Do not refuel the machine while smoking or when ‘near open flame or sparks Always stop the engine before refueling the machine. Fill the fuel tank outdoors. © All fuels, most lubricants, and some coolants are flammable. + Store flammable fluids well away from fire hazards. Do not incinerate or puncture pressurized containers. Do not store oily rags; they can ignite and burn spontaneously. SA-14SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: Understand service procedures before doing work. Keep work area clean and dry. Do not spray water or steam inside cab. “Never lubricate or service the machine while it is ‘moving. Keep hands, feet and clothing away from power- driven parts. + Before servicing the machine: 1) Park the machine on a level surface. 2) Lower the bucket to the ground. 3) Turn the auto-idle switch off 4) Run the engine at slow idle speed without load for 5 minutes. Tum the key switch to OFF to stop engine. Relieve the pressure in the hydraulic system by ‘moving the control levers several times. Remove the key from the switch. ‘Attach a ‘Do Not Operate” tag on the control lever. Pull the pilot control shut-off lever to the LOCK position, Allow the engine to cool. 5) 6) 7) 8) 9) 10) Ifa maintenance procedure must be performed with the engine running, do not leave machine unattended. If the machine must be raised, maintain a 90 to 110° angle between the boom and arm. Securely support any machine elements that must be raised for service work, Never work under a machine raised by the boom, Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the "MAINTENANCE" chapter in the operator's manual. Keep all parts in good condition and properly installed. “Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. Disconnect battery ground cable (—) before making adjustments to electrical systems or before welding on the machine. 2 x sasor SA-15SAFETY WARN OTHERS OF SERVICE WORK @ Unexpected machine movement can cause serious injury Before performing any work on the machine, attach DO a “Do Not Operate" tag on the contro! lever. NOT OPERATE SUPPORT MACHINE PROPERLY @ Never attempt to work on the machine without securing the machine first. Always lower the attachment to the ground before you work on the machine. + If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, ‘or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. sasar STAY CLEAR OF MOVING PARTS. © Entanglements in moving parts can cause serious injury, To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. on SA-16SAFETY PREVENT PARTS FROM FLYING OFF ‘© Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. As pieces may fly off, be sure to keep body and face away from valve. ‘© Travel reduction gears are under pressure. As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot. Wait for gear oil to cool, then gradually loosen the air release plug to release pressure. STORE ATTACHMENTS SAFELY ‘@ Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas, SA-17SAFETY PREVENT BURNS Hot spraying fluids: © After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. ‘Skin contact with escaping hot water or steam can cause severe burns. To prevent possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces: @ Engine oil, gear oil and hydraulic oll also become hot during operation. The engine, hoses, lines and other parts become hot aswell. Wait for the oil and components to cool before starting any maintenance or inspection work REPLACE RUBBER HOSES PERIODICALLY ¢ Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone, + Periodically replace the rubber hoses. © Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death, SZ SA-18SAFETY AVOID HIGH-PRESSURE FLUIDS ‘© Fluids such as diesel fuel or hydraulic oil under Pressure can penetrate the skin or eyes causing serious injury, blindness or death. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Relieve the pressure by moving the control levers several times. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids, Wear a face shield or goggles for eye protection, It an accident ocours, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result SA-19SAFETY PREVENT FIRES Check for Oil Leaks: © Fuel, hydraulic oil and lubricant leaks can lead to fires. Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts for oil leaks. Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil- cooler flange botts. Do not bend or strike high-pressure lines. Never install bent or damaged lines, pipes, or hoses. Check for Shorts: © Short circuits can cause fires. Clean and tighten all electrical connections. Check before each shitt or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires. Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal ‘caps. + DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: @ Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. Check Key Switch: © If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting Always check key switch function before operating the machine every day: 1) Start the engine and run it at slow idle. 2) Turn the key switch to the OFF position to confirm that the engine stops. It any abnormalities are found, be sure to repair them before operating the machine, (f sao SA-20SAFETY Check Heat Shields: ‘© Damaged or missing heat shields may lead to fires. Damaged or missing heat shields must be repaired or replaced before operating the machine. EVACUATING IN CASE OF FIRE © If a fire breaks out, evacuate the machine in the following way: + Stop the engine by tuming the key switch to the OFF position if there is time. Use a fire extinguisher if there is time. Exit the machine. BEWARE OF EXHAUST FUMES © Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. SA-21SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES © Flammable spray can be generated by heating near pressurized fuid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials when engaging in welding, soldering, etc, AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS Do not weld or flame cut pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or fiame cutting them. REMOVE PAINT BEFORE WELDING OR HEATING ¢ Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. + Avoid potentially toxic fumes and dust. Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: 4) If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2) If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. SA-22SAFETY PREVENT BATTERY EXPLOSIONS © Battery gas can explode. Keep sparks, lighted matches, and flame away from the top of battery. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode, Warm battery to 16 °C (60 °F). © Battery electrolyte is poisonous. If the battery should saan explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. Be sure to wear eye protection when checking electrolyte specific gravity. SERVICE AIR CONDITIONING SYSTEM 4 1 spied onto shin, regerant may cause a cold | contact burn. Refer to the freon container for proper use when ‘servicing the air conditioning system, “Use a recovery and recycling system to avoid venting freon into the atmosphere. Never let the freon stream make contact with the skin, SA-23SAFETY DISPOSE OF WASTE PROPERLY © Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. “Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, ‘or into any water source. Air conditioning refrigerants escaping into the air can damage the Earth's atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants, Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, of from your authorized dealer. sane BEFORE RETURNING THE MACHINE TO THE CUSTOMER After maintenance or repair work is complete, confirm that: The machine is functioning properly, especially the safety systems, -Worn or damaged parts have been repaired or replaced shane SA-24EX300-3C EXCAVATORS TECHNICAL MANUAL (Troubleshooting) SECTION AND GROUP CONTENTS Group 01 Group 02 Group 03 Group 04 Group 05 SECTION 06- OPERATIONAL PERFORMANCE TEST Introduction Engine Test Excavator Test Component Test Standard Diagnosing Procedure SECTION 07- TROUBLESHOOTING Group 01 Group 02 Troubleshooting A Group 03 Group 04 Group 05 Troubleshooting B Troubleshooting C Harness Test All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT ©1996 Hitachi Construction Machinery Co.,Ltd Tokyo, Japan All rights reservedSECTION 06 Operational Performance Test Group 01- Introduction Purpose . Terminology Preparation for Performance Test Group 02- Engine Test Engine Speed ........ Engine Compression Pressure Valve Clearance Adjustment Nozzle Check Injection Timing Group 03- Excavator Test Travel Speed Track Revolution Speed Mistrack Check Travel Parking Function Check . Swing Speed... : ‘Swing Function Drift Check ‘Swing Motor Leakage ‘Swing Bearing Play Hydraulic Cylinder Cycle Time Dig Function Drift Check Control Lever Operating Force Contro! Lever Stroke Combined Boom Raise / Swing Function Check CONTENTS 06-01-01 Group 04- Component Test 06-01-01 Pilot Primary Pressure Pilot Secondary Pressure, Travel 06-01-02 Pilot Pressure Sensor Output Travel Speed Selecting Pressure (Pressure SA) 06-02-01 Pump Torque Control Pressure 08-02-03 (Pressure SB) 06-02-04 M3 and M4 Work Mode Control 06-02-06 Pressure (Pressure SC) 06-02-08 Pump Displacement Angle Control Pressure (Solenoid Valve-3) Main Relief Pressure Shift 06-03-01 Pressure (Pressure PR) 06-03-02 ‘Swing Parking Brake Release 06-03-03 Pressure (Pressure SH) 06-03-04 Pump Control Valve Pressure 06-03-05 Main Relief Pressure Setting 06-03-08 Overload Relief Valve 06-03-07 Pressure Setting 06-03-08 Main Pump Flow Test T06-03-09 ‘Swing Motor Drainage 06-03-10 Travel Motor Drainage 06-03-11 06-03-12 Group 05- Standard Operational Performance 06-03-13 ‘Standard T06-04-01 06-04-03 T06-04-04 06-04-05 7106-04-06 T06-04-08 T06-04-09 06-04-10 06-04-11 06-04-12 T06-04-14 7106-04-15 7106-04-19 7106-04-21 06-05-01 1407-06-011407-06-02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 customer's site, it must be tested to confirm that the operational performance (Excavator Test) of the machine meets HITACHI STANDARDS. 2, OPERATIONAL PERFORMANCE OF A WORKING MACHINE With the passage of time, the machine's operational performance deteriorates, so that the machine needs to be serviced periodically to restore it to its original performance level. Before servicing the machine, conduct performance tests to check the extent of deterioration, and to decide what kind of service needs to be done (by referring to the “Allowable Limits” in this manual). 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 and/or service work done. TERMINOLOGY 1. “STANDARD’ Specifications applied to the brand-new machine, components and parts. 2. “ALLOWABLE LIMIT” The lowest acceptable performance level. When the performance level of the machine falls below 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. 4. 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 attachment extended. (8) If required, rope off the test area and provide signboards to keep unauthorized personnel away. 3. PRECAUTIONS (1) Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail, (2) Operate the machine carefully and always give first priority to safety. (3) While testing, always take care to avoid accidents 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 escaping oil. Pay special attention to this when removing hydraulic pipings. 4, MAKE PRECISE MEASUREMENTS (1) Accurately calibrate test instruments in advance to obtain correct data. (2) Carty out tests under the exact test conditions prescribed for each test item. (3) Repeat the same test and confirm that the test data obtained can be procured repeatedly. Use mean vaiues 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 oll is 50° 5°C (122°F£9°F). (2) Push the P-mode switch and confirm that the fuel injection pump governor lever (2) comes into contact with the fast-idle stopper (1). NOTE: Never adjust stopper (1). i ie <= ue Ase = (3) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time engine speed data (4) If Dr. EX is not available, connect engine tachometer (3) to fuel injection pipe (4). 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 general purpose mode, and turn off auto-idle switch (3). (8) Measure and record the engine speed at each power mode (1) (P, EL, I). (4) Next, push auto-idle switch (3) ON, and select the P-mode. (6) 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 -05 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 decline in engine power. 2. Check exhaust gas color and the amount of blow-by gas from the crankcase. Keep track of engine cil consumption. 3. Check for abnormalities in the intake system, including 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 cylinder. 5. Install an adaptor and compression gauge in place of the glow plug in one cylinder. ( Be sure to sufficiently 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 -05 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 cola. 2, Before starting work, clean the head cover ‘mounting area to avoid contamination in the engine. Preparation : 1. Locate the top dead center (TDG) in the ‘compression stroke. Align the TOC mark on the crank pulley with the pointer located on the timing gear case as iilustrated. Piston No.1(or piston No.6) is now positioned at the TDC in its compression stroke. Pointer 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 cylinder No.1 is pushed down, piston No.6 is positioned at TDC in the compression stroke. Ti90e-12.008 Start measurement from the cylinder (No.1 or No.6) positioned at TDC in the compression stroke. ‘To Mark Measurement: 1. Insert a thickness gauge into the clearance between the rocker arm and the valve stem end to measure the valve clearance. NOTE: The cylinders are aligned from No. 1 to No. 6 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 cylinder, perform the same measurement to all valves indicated with the mark * ©" in the table below. (When the measurement is started from No. cylinder, perform the measurement in the valves shown with mark *x".) Cylinder No. Not | No2 | Nod | No4 | NoS | Noo Valve locations PPE IPE, TSE; iP ey yey ise When 2 ne measurement is started from No.1 O}° ee O}° When the measurement Is * x x x started from No.6 3. Rotate the crankshaft 360°. Align the TDC mark with the pointer. Then, continue measurement of other valves in the same way. Evaluati Standard Valve Clearance: Intake valve : 0.40 mm (0.0187 inch) Exhaust valve: 0.40 mm (0.0157 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, adjust the adjusting screws. 2. After adjusting, retighten the lock nuts to the specification. Recheck the valve clearance after the lock nuts are tightened. — 25.524.9 Nm ( 2620.5 kgtm, 18.8 Itt) ) 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: AA cauTION: Never touch spray directly. The fuel spray from the nozzle may penetrate the skin, resulting in serious injury. If fuel penetrates to the blood stream, it may cause blood toxication. 1. Injection pressure After attaching the nozzle holder to the nozzle tester, strongly make several strokes of the tester to inject 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. Turn clockwise to increase the pressure, and counterclockwise to decrease the pressure. 2. Spray pattern For this test, turn the pressure tester knob to bypass 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 diesel oil T06-02-06OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: 1, Standard Injection Pressure: 19.6 MPa (200 kgf/cm? 2 844 psi ) Normat 2. Spray Pattern Large-size spray should not be visible to the naked 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. sre202.11.095 Adjustment: ‘# To adjust the injection pressure, loosen the lock nuts. Adjust the adjusting screw. Turn clockwise to increase the pressure, and counterclockwise to decrease the pressure. 7 Atter adjusting, retighten the lock nuts. 0706.02.09" 06-02-07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 (clockwise as seen from the front of the engine) to set a “TC" mark on the crank pulley under the “pointer’, located on the timing gear case. 2. When the mark on the injection pump coupling is set under the mark of the timer, No.1 piston is positioned at the top dead center. If the mark is not set under the mark of the timer, keep turning to adjust. 3.Turn the crank pulley at approx.30 degrees counterclockwise. 4, Remove the injection piping from No.1 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 holder. Pt: 108 to 118 Nem (11 to 12. kgm, 80 to 86.8 Ibfft) 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 starts. 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 (18 degrees before the TDC) on the crank pulley. 2. Loosen the mounting bolts of the injection pump coupling. 3. When advancing timing, tun timer outward against, the cylinder block. When delaying timing, turn the timer inward against the cylinder biock T06-02-08OPERATIONAL PERFORMANCE TEST / Excavator Test 3.1 TRAVEL SPEED Measure the time required for the excavator to travel a 10 m (82.8 tt) test track. Preparation: 1 2. ‘Adjust the track sag of both tracks to be equal. Prepare a flat and solid test track 10 m (32.8 ft) in length, with extra length of 3 to 5 m (9.8 to 16 tt) on both ends for machine acceleration and deceleration. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the ground with the arm and bucket rolled in. Maintain the hydraulic oil temperature at 50:5 °C (12249°F) . Measurement: Measure both the medium and fast speeds of the machine. Before starting either the medium or fast speed tests, adjust the travel mode switch to the speed to be tested, then select the following switch positions: Power mode selector: P mode Work mode selector: General purpose ‘Auto-idle switch: OFF Start traveling the machine in the acceleration zone with the travel levers at full stroke. Measure the time required to travel 10 m (82.8 ft). ‘After measuring the forward travel speed, turn the upperstructure 180° and measure the reverse travel speed. Repeat steps (4) and (5) three times in each direction and calculate the average values. Evaluation: Refer to Group -05 in this section Remedy: Refer to T07-03 TROUBLE SHOOTING B. Tom ‘Acceleration zone 3t05m Deceleration T06-03-01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 90° and lower the bucket 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 50#5 °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-idie switch: OFF 2. Operate the travel control 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 (5) three times and calculate the average values. Evaluation: Refer to Group -08 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, 1) 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) fon both ends for machine acceleration and deceleration, 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 5025 °C (12289°F). Measurement: 1. Measure the amount of mistracking at fast, medium and slow travel speeds. 2, Before beginning each test, select the following switch positions: 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 (65.5 ft) line and the track made by the machine. 5. After measuring the tracking in forward travel, turn the upperstructure 180° and measure that in reverse travel. Repeat steps (4) and (5) three times and calculate the average values. Evaluation: Refer to Group -05 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. Bt05m (@81020in) extra length fo ‘deceleration 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 oil temperature at 50+5 °C (12229 °F), Measurement: 1. Climb the slope and place the travel levers in neutral Stop the engine, Alter parking the machine, make aligning marks on the side frame and a track link or shoe. 4, Alter five minutes, measure between the marks. 2. 3. Evaluation: Refer to Group -08 in this section. Aigning marks Distance Remedy: Refer to T07-03 TROUBLESHOOTING B. TO6-03-04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 slopes. 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 control lever fully in the opposite di- rection and measure the time required for 3 turns. 5. Repeat steps (3) and (4) three times and calculate the average values. Evaluation: Refer to Group -08 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 circumfer- ence 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. 3, Position the arm cylinder with the rod 50 mm (2 inch) extended from the fully retracted position 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 oll temperature at 50#5 °C (12289 °F) Measurement: 1. Conduct this test in the P mode. 2. Select the following switch positions: Power mode selector: P mode 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 Upperstructure aligns with that on track frame after swinging 180°. 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. Evaluation: Refer to Group -05 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. “Two chalk marks —_= Measure dtference between marks Marking on the track frame Marking on the swing bearing 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 siope 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. WeMoxt.5 where: M®=Bucket heaped capacity (m3) 1.5-Soil 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 * 1.5), 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 5025 °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. Evaluation: Refer to Group -08 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. Measure diference between marks Marking on track frame Marking on swing bearing 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 bearing 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 (ho). 3. Calculate bearing play (H) from this data (hy and hz) as follows: Hehe — hy Measurement: (;) ay remo mee as boom foot Evaluation: Refer to Group -05 in this section Measurement: (h) 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 it is vertical to the ground. Lower the boom until the 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 roll-in and roll-out, so that the sideplate edges are vertical to the ground. 4, Maintain the hydraulic oil temperature at 50°25 °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) Armoylinder: Measure the time it takes to roll in 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 lever to the other stroke end as quickly as possible. (8) 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 calculate the average values. | Evaluation: Refer to Group -08 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 dig function drift just after cylinder replacement, slowly operate each oylinder 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. WeM9t.5 where: ‘M®=Bucket heaped capacity (m9) 1.5-Soil specific 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 rolied 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°25 °C (12289 °F). Measurement: 4. 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 oylinders. 3. Repeat step (2) three times and calculate the average values. Evaluation: Refer to Group -05 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. Extended distance Rovracted distance ‘Arm cylinder 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. Preparati Maintain the hydraulic oll temperature at 5025 °C (12249 °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 ‘orosancot jack-up the other track. 5. Repeat steps (3) and (4) three times and calculate the average values. Evaluation: Refer to Group -05 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. TO06-03-11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 half of this value and add it to the measured stroke. Preparatioi Maintain the hydraulic oil temperature at 50°+5 °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 caloulate the average values. Evaluation: Refer to Group -05 in this section, Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-12OPERATIONAL PERFORMANCE TEST / Excavator Test 3.13 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 or 2503.008 boom raise function and check to be sure that cylinder movement is smooth, with no sticking. 2. With the (standard) arm fully rolled out and (standard hoe) bucket fully rolled in, lower the bucket to the ground. The bucket must be empty. 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 7.05-03.010 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 -05 in this section. or06-03.011 Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-13OPERATIONAL PERFORMANCE TEST / Excavator Test T06-03-14OPERATIONAL PERFORMANCE TEST / Component Test 4.1 PILOT PRIMARY PRESSURE Preparation: 1. Stop the engine. 2, Remove the breather cap at the hydraulic oll supply port of the hydraulic oil tank to release air pressure remaining in the tank. rr 3. Disconnect the hose at the pilot filter outlet port. Install pressure gauge (ST 6942) between the filter, 4mm and the hose. Bet 527 mm, 24 mm Adaptor: sT 6477, Nipple: ‘ST 6069, Pressure Gauge: ST 6942 4, Start the engine. Check for oil leakage from the connecting port of the gauge. 5, Maintain hydraulic oil temperature at 50 + 5 C (122 #9 °F) Measurement: 1, Measure in both the P mode (fast idle) and | mode (slow idle). 2. Select the following switch positions: Engine speed | POWEEMOS® | autoidle switch Fast idle P mode of Slow idle Tmode off 3. Measure pilot pressure in each mode under no load. 4, Repeat the measurement three times and calculate the average values. Evaluation: Refer to the Operational Performance Test / ‘Standard table in Group -05 in this section. Pressure Ga insiating Poston Plot Fiter T06-04-01