Hitachi EX8000-7 Hydraulic Excavator FCO Cummins engine Troubleshooting Technical Manual PNTTKHA90 (

PART NO.

TTKHA90-EN-00

EX8000-7 HYDRAULIC EXCAVATOR

Technical Manual Troubleshooting

TECHNICAL MANUAL

EX8000-7

TROUBLESHOOTING

Hydraulic Excavator FCO Cummins engine

BACKHOE FRONT TTKHA90-EN-00

PRINTED IN JAPAN (K) 2019, 06

Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TOKHA90-EN Technical Manual (Troubleshooting) : Vol. No.TTKHA90-EN Workshop Manual : Vol. No.WKHA90-EN

INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

The machine specification and description according to destination may be explained on this manual.

 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.):  PS Information Center Hitachi Construction Machinery Co., Ltd.  TEL: 81-29-832-7084  FAX: 81-29-831-1162  E-mail: HCM-TIC-GES@hitachi-kenki.com

 Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

Manual Composition This manual consists the Technical Manual and the Workshop Manual.

 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 removal / installation and assemble / disassemble procedures.

 Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T 1 3 5

 Workshop Manual: W 1-3-2-5 W 1 3 2 5

Technical Manual Section Number Group Number Consecutive Page Number for Each Group

IN-1

Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

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 of machine damage.

dCAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death.

d This is the safety alert symbol. When you see this

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

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.

fNOTE: Indicates supplementary technical information or knowhow.

Units Used SI Units (International System of Units) are used in this manual.

A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

mm

in

0.03937

mm

ft

0.003281

L

US gal

0.2642

L

US qt

1.057

m3

yd3

1.308

Weight

kg

lb

2.205

Force

N

kgf

0.10197

N

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

10.197

MPa

psi

145.0

kW

PS

1.360

kW

HP

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Power

-1

Flow rate

0.10197 2

IN-2

SYMBOL AND ABBREVIATION Symbol / Abbreviation TO TT T/M W, W/M FCO IDU DLU ELUF

ELUT

ELUV

MCU HMU

CSU ECM EHU

HTC LTC PFU

PMU ODR

Name

Explanation

Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual Workshop manual (Removal and Installation, Disassembly and Assembly).

Fuel Consumption/Combustion The engine maker designs to specifically optimize for the Combustion/Consumption of the diesel fuel.

Information Display Unit Information display controller. IDU displays the information from each controller on the monitor.

Data Logging Unit Data logging unit. DLU records the information from each controller.

Electric Lever Control Unit for Front Electric control lever controller for controlling the front attachment operation. ELUF controls the pilot pressure which supplies to the control valve (center pilot panel).

Electric Lever Control Unit for Travel Electric control lever controller for controlling the travel operation. ELUT controls the pilot pressure which supplies to the control valve (center pilot panel).

Electric Lever Control Unit for Front Electric control lever controller for controlling front valves.

Valve ELUV controls the pilot pressure which supplies to the control valve (front pilot panel).

Monitor Control Unit Controller for the alarm monitor and sub control. MCU judges the alarms, controls fans, and controls auto-lubrication control.

Hydraulic System Monitoring Unit Hydraulic system monitoring unit. HMU monitors the condition of the hydraulic components such as swing motor and others and the oil cooler.

Contamination Sensing Unit Contamination sensing unit. CSU senses contaminants in the drain circuits of the main pump, swing motor, and travel motor.

Engine Control Module Engine controller. ECM controls fuel injection amount according to the machine operating condition.

Engine Heat Balance Monitoring Unit Engine cooling system monitoring unit. EHU monitors the engine cooling system condition such as HTC radiator, LTC radiator, and others.

High Temperature Cooling Circuit HTC indicates the engine cooling circuit.

Low Temperature Cooling Circuit LTC indicates the supercharger cooling circuit.

Pump Flow Control Unit Pump flow rate control controller. PFU calculates the target pump displacement of each main pump and controls each pump flow rate.

Pump Monitoring Unit Pump monitoring unit. PMU monitors the drain pressure of main pump.

Operation Data Recorder Operation data recorder. ODR automatically records the data related to the detected information which has been set.

SY-1

SYMBOL AND ABBREVIATION Symbol / Abbreviation ACU

Name

Explanation

Aerial Angle Control Unit

BPU

Basic Performance Monitoring Unit

FMU

Fatigue Monitoring Unit

GSM

Global System for Mobile Communications Controller

WIU GPS CAN EDQR Valve

Wireless Interface Unit Global Positioning System Controller Area Network Electric Dual Quick Response Valve

Aerial angle control unit. ACU controls the circumference check of the machine by using the monitor.

Basic performance monitoring unit. BPU semiautomatically measures the basic performance.

Mechanical fatigue monitoring unit. FMU monitors mechanical fatigue of the structures.

Communication controller. GSM is a type of wireless communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone.

WIU outputs the machine operation data to PC via wireless LAN.

LCD C/U ENG. REG. (L) (R)

Liquid Crystal Display Control Unit Engine Regulator (Left) (Right)

CAN communication. CAN is a serial communications protocol EDQR valve receives command current according to the electric control lever stroke, flows pilot pressure oil according to this command current to the control valve, and moves the spool of the control valve.

SY-2

SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices.

SA-2644

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.  Some safety signs are occasionally used on this machine that do not use any of the designated signal words mentioned above after the safety alert symbol.

 To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. 

fNOTE: Indicates an additional explanation for a piece of information.

SA-1

SA-1223

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.  If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).  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 of the machine may impair its function and/or safety and affect machine life.  Do not modify any machine parts without authorization.

Failure to do so may deteriorate the safety, function, and/ or service life of the part. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy.  Never attempt to modify or disassemble the inlet/exhaust parts. Possibly damaging it or lowering its performance.  Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy.  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 and/ or your authorized dealer before operating or performing maintenance work on the machine.

SA-2

SA-003

SAFETY Prepare for Emergencies  Be prepared for a fire or an accident.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly.  To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual.  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.

SA-437

Wear Protective Clothing  Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and clothing for the job. Do not take any chances.  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 the machine.

SA-3

SA-438

SAFETY 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.

SA-434

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 "Inspect Machine Daily Before Starting" section in the operator’s manual.

SA-435

SA-4

SAFETY General Precautions for the Cab  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.  Do not mess up around the operator’s seat with parts, tools, soil, stones, obstacles that may fold up or turn over, cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the travel levers/pedals, pilot control shut-off lever or control levers, which may result in serious injury or death.  Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.  Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.  Keep all flammable materials and/or explosives away from the machine.  Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.  Correctly lay the floor mat specific to the machine. If another floor mat is used, it may be displaced and contact with the travel pedals during operation, resulting in serious injury or death.

SA-5

SAFETY Use Handholds and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always maintain a three-point contact with the steps and handrails.  Do not use any controls as hand-holds.  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.  Never get on and off the machine with tools in your hands.

SA-439

Adjust the Operator's Seat  A seat which is poorly adjusted for the individual operator, or the work to be undertaken, may quickly fatigue the operator leading to misoperation.  The seat should be adjusted whenever the operator of the machine changes.  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.  Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

SA-6

SA-378

SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever and/or pedal, possibly resulting in serious personal injury or death.  Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Push the engine stop switch to stop the engine.  Before leaving the machine, close all windows, doors, and access covers and lock them.

Fasten Your Seat Belt  If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.  Prior to operating the machine, thoroughly examine 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 is replaced every three years regardless of its apparent condition.  Seat belt is also provided on the trainer’s seat. Be sure the rider on the trainer’s seat properly fastens seat belt before operating the machine.

SA-7

SA-237

SAFETY 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. 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.  Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.  Ensure the cab door, windows, doors and covers are securely locked.  Check the mirrors and the monitor in the cab for problems.

If there is, replace the problem part (s) or clean the mirror, camera lens and the monitor display.

Refer to operator's manual for information on cleaning the camera lens and the monitor display.

SA-8

SA-426

SAFETY Operate Only from Operator's Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  Do not start engine by shorting across starter terminals.  Before starting the engine, confirm that all control levers are in neutral.  Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-444

Handle Starting Aids Safely Starting fluid:  Starting fluid is highly flammable.  Keep all sparks and flame away when using it.  Keep starting fluid well away from batteries and cables.  Remove container from machine if engine does not need starting fluid.  To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.  Do not incinerate or puncture a starting fluid container.

SA-293

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.

SA-032

SA-9

SAFETY 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 the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.  If the machine is equipped with a second seat and someone other than the operator is on board, the person must always stay in the second seat with the seat belt fastened.

SA-379

Precautions for Operations  Investigate the work site before starting operations.  Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine.  Keep bystanders and obstacles clear of the area of machine operation.

Keep persons other than the operator away from areas where there is danger, such as from flying objects.  Always be aware of the surroundings while operating.

When working in a small area surrounded by obstacles, take care not to hit the upperstructure against obstacles.  When loading onto trucks, bring the bucket over the truck beds from the rear side. Take care not to swing the bucket over the cab or over any person.

M178-05-007

SA-10

SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles or banks from collapsing.  Make a work plan. Use machines appropriate to the work and job site.  Reinforce ground, edges and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.  When working on an incline or on a road shoulder, employ a signal person as required.  Do not allow anyone within the range of work, swing or movement of the machine.  When the ground footing is weak, reinforce the ground before starting work.  When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.  Beware the possibility of fire when operating the machine near flammable materials such as dry grass.

SA-11

SA-380

SAFETY  Make sure the worksite has sufficient strength to firmly support the machine.

When working close to an excavation or at road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear, so that the machine can more easily evacuate if the cliff face collapses.  If working on the bottom of a cliff or a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work on the area.  Soft ground may collapse when the machine is operated on it, possibly causing the machine to tip over. When working on soft ground is required, be sure to reinforce the ground first using steel plates strong and firm enough to easily support the machine.  Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. When operating on rough terrain or on slopes:  Reduce the engine speed.  Select slow travel speed mode.  Operate the machine slowly and be cautious with machine movements.

Restriction of Attachment Installation Do not install an attachment which exceeds the specified weight for the machine structure.

SA-12

M104-05-016

SAFETY Provide Signals for Jobs Involving Multiple Machines  For jobs involving multiple 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.

SA-481

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 pedals/levers are operated facing forwards.

SA-491

SA-13

SAFETY Drive Machine Safely  Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling.

A

SA-657

 Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.  Never attempt to ascend or descend 30 degrees or steeper slopes.  Be sure to fasten the seat belt.  When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (see A on the right) above the ground.  If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.  Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.  Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.  If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control levers to neutral.

Then, restart the engine.  Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained.

A

SA-658

SA-441

WRONG

SA-590

SA-14

SAFETY  Be sure to fully pull up the stairway before traveling.  Before descending a slope, turn the travel mode switch to the SLOW position on level ground. Do not operate the travel mode switch while descending a slope. The machine may slip, possibly causing safety accident.  When descending a steep slope, avoid quick start or stop traveling in the FAST mode. Failure to do so may result in damage to the travel motors.  Use a signal person when moving, swinging or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Before moving machine, determine which way to move travel pedals/levers for the direction you want to go.

When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers.  Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction.  When traveling on a level surface, position the front with boom (1) fully raised, and arm (2) fully retracted, as illustrated, in order to apply the load as evenly as possible to all of the lower rollers.  Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if necessary.  Use wood plates in order not to damage the road surface.

Be careful of steering when operating on asphalt roads in summer.  When crossing train tracks, use wood plates in order not to damage them.  Do not make contact with electric wires or bridges.  When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller.  When traveling on rough terrain, reduce engine speed.

Select slow travel speed. Slower speed will reduce possible damage to the machine.  Avoid operations that may damage the track and undercarriage components.  During freezing weather, always clean snow and ice from track shoes before loading and unloading the machine, to prevent the machine from slipping.

Travel Motor M145-05-003

M145-05-004

1

2

M145-05-027

1

2

M145-05-022

SA-15

SAFETY Avoid Injury from Rollaway Accidents  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 the machine.  Do not park the machine on a gradient.  Lower the bucket and/or other work tools to the ground.  Turn the auto-idle switch OFF.  Run the engine at slow idle speed without load for 5 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 position.  Block both tracks and lower the bucket to the ground.

Thrust the bucket teeth into the ground if you must park on a gradient.  Position the machine to prevent rolling.  Park at a reasonable distance from other machines.

SA-391

SA-2273

SA-16

SAFETY Avoid Injury from Back-Over and Swing Accidents  If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious 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.  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.  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.  No machine motions shall be made unless signals are clearly understood by both signal person and operator.  Learn 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-383

SA-384

SA-17

SAFETY Keep People Clear from Working Area  People around the operating machine may be hit severely by the swinging front attachment or counterweight, be caught in other objects, and/or be struck by flying objects, resulting in serious injury or death.  Set up barriers and/or put a “NO ADMISSION” sign at the machine operating site and areas exposed by flying objects to prevent anyone from entering the work area.  Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

SA-386

Never Position the Bucket Over Anyone  Never lift, move, or swing the bucket above anyone or above the truck cab.

Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

SA-487

SA-18

SAFETY Avoid Undercutting  In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.  If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.

SA-488

Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT  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 gradient.  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.

SA-012

 Be careful when working on frozen ground.  Temperature increases will cause the ground to become soft and make ground travel unstable.

SA-440

SA-19

SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death.

SA-489

Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.  Before digging check the location of cables, gas lines, and water lines.  Keep the minimum distance required, by law, from cables, gas lines, and water lines.  If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.  Contact your local “diggers hot line” if available in your area , and/or the utility companies directly.

Have them mark all underground utilities.

SA-382

Operate with Caution  If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.  Take care to avoid hitting overhead obstacles with the boom or arm.

SA-389

SA-20

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 to within 3 m plus twice the line insulator length of overhead wires.  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 shock. Keep all bystanders or co-workers away from the site.

SA-381

Precautions for Lightning  Lightning may strike the machine.

If lightning comes close, immediately stop the operation, and take the following action.  When you are around the machine or operating cabless machine, evacuate to a safe place far away from the machine.  When you are in the cab, stay in the cab until lightning has passed and safety is assured. Close the cab doors and windows. Lower the bucket to the ground, and stop the engine. Put your hands on your lap to avoid contact with any metal surfaces. Never go out of the cab.

If lightning strikes the machine or near the machine, check all of the machine safety devices for any failure after lightning has passed and safety is assured. If any trouble is found, operate the machine only after repairing it.

SA-21

SA-1088

SAFETY Object Handling  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.  When using the machine for craning operations, be sure to comply with all local regulations.  Do not use damaged chains or frayed cables, 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-014

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.  Always close the windows and doors, when operating the machine.

SA-432

SA-22

SAFETY Park Machine Safely To avoid accidents:  Park machine on a firm, level surface.  Lower bucket to the ground.  Turn auto-idle switch OFF.  Run engine at slow idle speed without load for 5 minutes.  Press and hold the engine stop switch until stopping the engine completely.  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-390

Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or 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.  Keep the machine clean and free from dirt and debris such as grease.  Do not store oily rags; they can ignite and burn spontaneously.  Securely tighten the fuel and oil filler caps.

SA-018

SA-019

SA-23

SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the 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.

5. Press and hold the engine stop switch to stop the engine.

6. Relieve the pressure in the hydraulic system by moving the control levers several times.

SA-028

7. Remove the key from the key switch.

8. Attach a “Do Not Operate” tag on the control lever.

9. Pull the pilot control shut-off lever to the LOCK position.

10. Allow the engine to cool.  If a maintenance procedure must be performed with the engine running, do not leave the 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 of this 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.  When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.  Turn the battery disconnect switch to OFF before adjusting the electrical systems or performing welding on the machine.

SA-24

SA-527

SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. If the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

Warn Others of Service Work  Unexpected machine movement can cause serious injury.  Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

SS3076175

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.

SA-527

SA-25

SAFETY Stay Clear of Moving Parts  Entanglement 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.

SA-026

SA-2294

Prevent Parts from Flying  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 air release plug to release pressure.

SA-26

SA-344

SAFETY Avoid Injury from Attachment Falling Accident  Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.  To avoid possible personal injury from attachment falling accident, use a platform when replacing an attachment.  Securely store attachments such as a bucket, blade, breaker and other parts to prevent falling.  Keep children and bystanders away from attachment storage areas.

SA-034

Prevent Burns Hot spraying fluids:  After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, coolant reserve tank and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.  Avoid possible injury from hot spraying water. Do not remove the coolant reserve tank 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.

SA-039

Hot fluids and surfaces:  Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.  Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

SA-27

SAFETY 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. (See the page of “Periodic replacement of parts” in the operator’s manual.)  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.

SA-019

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.  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.  If an accident occurs, 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-031

SA-292

SA-044

SA-28

SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to 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.  Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil cooler and oil cooler flange bolts.  Do not bend or strike high-pressure lines.  Never install bent or damaged lines, pipes, or hoses.  Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance.

Check for Shorts:  Short circuits can cause fires.  Clean and tighten all electrical connections.  Check before each shift 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.  Never attempt to modify electric wirings.

SA-29

SA-019

SAFETY Clean up Flammable Materials:  Spilled fuel and oil, trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammable materials immediately. Check and clean high temperature parts such as the exhaust outlet and muffler earlier than the normal interval.  Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents.  Do not store oily cloths as they are vulnerable to catching fire.  Keep flammable materials away from open flames.  Do not ignite or crush a pressurized or sealed container.  Check and clean the machine every day and immediately remove accumulated flammable materials.

Check Engine Stop Switch:  If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check engine stop switch function before operating the machine every day: 1. Start the engine and run it at slow idle.

2. Press and hold the engine stop switch to confirm that the engine stops.  If any abnormalities are found, be sure to repair them before operating the machine.

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.  If hydraulic hoses are broken while the engine cover is open, splattered oil on the high temperature parts such as muffler may cause fire. Always close the engine cover while operating the machine.

SA-30

SAFETY Check Emergency Engine Stop Switch:  If a fire breaks out, failure to release pressurized air inside the hydraulic oil tank will escalate fire, hampering fire fighting.  Check the emergency engine stop switch function every 250 hours: 1) Start the engine and run it at slow Idle.

2) Press the emergency engine stop switch.

3) Confirm that engine stops and that pressurized air inside the hydraulic oil tank is released (a hissing sound should be heard).  If any abnormalities are found, be sure to repair them before operating the machine.

SA-31

SAFETY Evacuating in Case of Fire  A fire on the machine may result in serious injury or death.  Inspect the following things and prepare in case of fire.

1) Check if the window can be opened and closed smoothly before operating the machine so that escape through the window is possible. If any abnormalities are found, repair them.

2) Before each shift, check that the emergency escape chute is not worn and its mounting hardware is not damaged; if any abnormalities are found, replace with new genuine Hitachi parts before operating the machine.

SA-393

 Before operating the machine for the first time, all new operaters must practice evacuating with the emergency escape device at least once.  If a fire breaks out during operation, evacuate from the machine in the followig way.  Stop the engine by pushing the emergency engine stop switch if there is time.  Use a fire extinguisher if there is time.  Evacuate from the machine using the emergency escape device. (See the chapter "Emergency Escape Device for operator's manual.")  In case of emergency, if the door or window cannot be opened, break the front windowpane or rear windowpane using the emergency evacuation hammer and evacuate the machine. (Refer to the section "Emergency Exit for operator's manual".)

SA-32

SS-1510

SAFETY 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-016

Precautions for Welding and Grinding  Welding may generate gas and/or small fires.  Be sure to perform welding in a well ventilated and prepared area. Store flammable materials in a safe place before starting welding.  Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.  Turn the battery isolation switch to the OFF position before performing welding on the machine.  Grinding on the machine may create fire hazards. Store flammable materials in a safe place before starting grinding.  After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

SA-33

SA-818

SAFETY Avoid Heating Near Pressurized Fluid Lines  Flammable spray can be generated by heating near pressurized fluid 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 before engaging in welding, soldering, etc.

SA-030

Avoid Applying Heat to Lines Containing Flammable Fluids  Do not weld or flame cut pipes or tubes that contain flammable fluids.  Clean pipes and tubes thoroughly with non-flammable solvent before welding or flame cutting.

Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause explosion, possibly resulting in serious injury or death.

Strictly comply with the following items:  Do not disassemble the unit.  Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing of the unit, sealed gas must be released.

Consult your authorized dealer.

SA-34

SAFETY 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: 1. 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 materials from area. Allow fumes to disperse at least 15 minutes before welding or heating.

SA-029

Beware of Asbestos and Silica Dust and Other Contamination  Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung cancer. Inhalation of silica dust or other contaminations may cause sickness.  Depending on the work site conditions, the risk of inhaling asbestos fiber, silica dust or other contaminations may exist. Spray water to prevent asbestos fibers, silica dust or other contaminations from becoming airborne. Do not use compressed air.  When operating the machine in a work site where asbestos fibers, silica dust or other contaminations might be present, be sure to operate the machine upwind, and wear a mask rated to prevent the inhalation of asbestos, silica dust or other contaminations.  Keep bystanders out of the work site during operation.  Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts.

SA-35

SA-029

SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Do not keep tools, metals or flammable materials around the battery or inside the battery room. If a metal tool is placed across the battery terminal, sparks may be created, possibly resulting in fire and/or explosion.  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 the battery to 16 ˚C ( 60 ˚F ) first.  Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.  Loose terminals may produce sparks. Securely tighten all terminals.  Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.

SA-032

 Battery electrolyte is poisonous. If the battery should 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 Safely  If spilled onto skin, refrigerant may cause a cold contact burn.  Refer to the instructions described on the container for proper use when handling the refrigerant.  Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.  Never touch the refrigerant.

SA-405

SA-36

SAFETY Handle Chemical Products Safely  Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, battery electrolyte, coolants, paints, and adhesives.  Safety Data Sheet (SDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.  Check the SDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.  See your authorized dealer for SDS’s (available only in English) on chemical products used with your machine.

SA-2579

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, or from your authorized dealer.

SA-37

SA-226

SAFETY Never Ride Attachment Never allow anyone to ride on attachments or the load. This is an extremely dangerous practice.

Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices.

Inquire to the device manufacturer for information on electrical wave disturbance when using an electronic device near the communication terminal.

Precautions for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed in a cover which is in the right side of cab. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, could be affected and malfunction due the electrical waves emitted from the communication terminal equipment.

Any person fitted with a medical device such as the above should not use this machine, unless the medical device and the rear tray are at least 22 centimeters apart at all times. If this condition cannot be met, please contact your authorized dealer and have the person in charge stop the communication terminal equipment from functioning completely, and confirm that it is not emitting electrical waves.

Specific Absorption Rate ("SAR") (measured by 10 g per unit) of communication terminal equipments: E-GSM900 DCS-1800 WCDMA Band I WCDMA Band VIII

0.12 W/kg (897.6 MHz) 0.06 W/kg (1748.0 MHz) 0.05 W/kg (1950.0 MHz) 0.10 W/kg (892.6 MHz)

 This data was measured by having each type of communication terminal equipment, such as the communication terminal equipment used with this machine, and a human body set apart by 3 cm.  SAR is a measure of the amount of radio frequency energy absorbed by the body when using a wireless application such as a mobile phone.

SA-38

SA-2654

SAFETY In Japan: Under the Japanese Radio Act and other relevant Japanese regulations, the maximum SAR value is 2 W/kg (as of March 2010).

In EU member nation: Under the "Council Recommendation 1999/519/EC 12 July 1999", the maximum SAR value is 2 W/kg.

In US: Under the "Federal Communications Commission (FCC) Guidelines (FCC 1997)", the maximum SAR value is 1.5 W/kg.

In Canada: Under the "Canada's Radio Standards Specification (RSS) -102", the maximum SAR value is 1.5 W/kg.  Do not attempt to disassemble, repair, modification and displacement of the communication terminal, antenna and cables. Failure to do so may cause damage or fire on the machine and the communication terminal. (Before removing or installing the communication terminal, consult your authorized dealer.)  Do not pinch or forcibly pull cables, cords and connectors.

Failure to do so may cause damage or fire on the machine and the communication terminal due to short/broken circuit.

SA-39

SAFETY Precaution for WIU (Wireless Interface Unit) Communication Equipment (Optional)

2

This machine has a WIU communication equipment emitting electrical waves installed inside the cab.

1- Controller 2- Antenna There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the WIU communication equipment.

Any person affixed with a medical device such as the above should use this machine with caution.  Never attempt to disassemble, repair, modify or displace the WIU communication equipment, antennas or cables.

Failure to do so may result in damage and/or fire to the base machine or to the WIU communication equipment. (When required to remove or install the WIU communication equipment, consult your nearest Hitachi dealer.)  Do not pinch or forcibly pull cables, cords or connectors.

Failure to do so may cause short circuit or broken circuit that may result in damage and/or fire to the base machine or to the WIU communication equipment.

SA-40

1

MKEB-00-001

SAFETY Machine Fire Suppression What you should do: This machine, like other large mobile machines that operate virtually nonstop, 24 hours per day, 7 days per week, generates considerable heat in close proximity to flammable fluids and is susceptible to fire.

Fires can result in expensive repair or replacement and more importantly serious injury to the equipment operator.

It is strongly recommended that you install a Fire Suppression System (FSS) on this machine and maintain it in good working condition. This machine is equipped with a communication link to ensure seamless operation of FSS with the operation of the machine. It is essential that whichever FSS you choose is compatible with the machine communication system. Before installation of FSS, contact your authorized dealer with installation details. We will provide any required documentation to the FSS supplier for optimum configuration.

What can the local supplier of FSS should provide:  Commissioning expertise  Operator and service training  Service and performance contracts  Support for preventative maintenance  Strong spare parts availability

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.

SA-435

SA-41

SAFETY (Blank)

SA-42

SECTION AND GROUP SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction CONTENTS Group 2 Standard Group 3 Engine Test Group 4 Machine Performance Test Group 5 Component Test

TECHNICAL MANUAL (Troubleshooting)

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(C)2018 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 Cross Reference Table Group 4 Component Layout Group 5 Troubleshooting for Each Code Group 7 Air Conditioner Group 8 e-Service

(Blank)

SECTION 4

OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction

Operational Performance Tests....................................... T4-1-1 Preparation for Performance Tests................................ T4-1-2

Group 2 Standard

Operational Performance Standard Table.................. T4-2-1 Main Pump P-Q Diagram.................................................. T4-2-5 Oil Cooler Fan Motor Pump P-Q Diagram................... T4-2-6 Radiator Fan Motor Pump P-Q Diagram...................... T4-2-7 Oil Cooler Fan Motor Pump/ Radiator Fan Motor Pump I-Q Diagram.................. T4-2-8 Electric Control Lever......................................................... T4-2-9

Group 3 Engine Test

Engine Speed........................................................................ T4-3-1

Group 4 Machine Performance Test

Travel Speed.......................................................................... T4-4-1 Track Revolution Speed..................................................... T4-4-2 Mistrack Check...................................................................... T4-4-3 Travel Parking Leakage...................................................... T4-4-4 Swing Speed.......................................................................... T4-4-5 Swing Function Drift Check............................................. T4-4-6 Swing Motor Leakage........................................................ T4-4-8 Maximum Swingable Slant Angle................................T4-4-10 Swing Bearing Play............................................................T4-4-12 Hydraulic Cylinder Cycle Time.......................................T4-4-14 Cylinder Drift Check..........................................................T4-4-16 Control Lever Operating Force......................................T4-4-18 Control Lever Stroke.........................................................T4-4-19 Combined Operation of Boom Raise and Swing Function Check................................................T4-4-20

Group 5 Component Test

Primary Pilot Pressure......................................................... T4-5-1 Secondary Pilot Pressure (Solenoid Valve of EDQR Valve)................................. T4-5-2 Secondary Pilot Pressure (EDQR Valve)........................ T4-5-4 Main Relief Set Pressure.................................................... T4-5-6 Overload Relief Set Pressure..........................................T4-5-12 Main Pump Flow Rate Measurement.........................T4-5-14 Fan Motor Pump Flow Rate............................................T4-5-18 Swing Motor Drainage.....................................................T4-5-23 Travel Motor Drainage.....................................................T4-5-25

KHA90T-4-1

(Blank)

KHA90T-4-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Operational Performance Tests Use operational performance test procedure to quantitatively check all system and functions on the machine.

The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours.

Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours.

Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values.

2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.

Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine.

2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.

3. To economically operate the machine under optimal conditions.

Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders.

2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves.

Performance Standards “Performance Standard” is shown in tables to evaluate the performance test data.

Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are.

2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions.

T4-1-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Preparation for Performance Tests Observe the following rules in order to carry out performance tests accurately and safely.

THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.

TEST AREA 1. Select a hard and flat surface.

2. Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 in), and to make a full swing with the front attachment extended.

3. If required, rope off the test area and provide signboards to keep unauthorized personnel away.

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.

T105-06-01-003

MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance to obtain correct data.

2. Carry 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 produced repeatedly. Use mean values of measurements if necessary.

T105-06-01-004

T4-1-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard The standard measurement conditions are as followings unless instructed in each performance test procedure:  Engine Control Dial: Fast Idle  Auto-Idle Switch: OFF  Hydraulic Oil Temperature : 50±5 °C (122±9 °F).

Operational Performance Standard Table The standard Performance values are listed in the table below.

The detailed measurement procedures are explained in T4-3, T4-4, and T4-5. Refer to the reference page.

Performance Test Designation ENGINE SPEED Fast Idle Speed Slow Idle Speed Auto-Idle Speed TRAVEL SPEED

Unit

Performance Standard min-1

Reference Page T4-3-1

1900±50 800±50 1400±50 sec/20 m (in/65.7 ft)

T4-4-1

Fast Speed Mode 36.0±3.0 Slow Speed Mode 51.0±4.0 TRACK REVOLUTION SPEED sec/3 rev Fast Speed Mode 123±10 Slow Speed Mode 177±10 MISTRACK mm/20 m Less than 250 (9.8) (Fast/Slow Speed Mode) (in/65.7 ft) TRAVEL PARKING LEAKAGE mm (in)/5 min 0 SWING SPEED sec/3 rev 57±5.0 SWING FUNCTION DRIFT CHECK mm (in)/180° Less than 1588 (62.5) SWING MOTOR LEAKAGE mm (in)/5 min 0 MAXIMUM SWINGABLE SLANT ANGLE SWING BEARING PLAY

Remark

deg Over 6 mm (in) Less than 0.5 (0.02)

T4-2-1

T4-4-2

T4-4-3 T4-4-4 T4-4-5 T4-4-6 T4-4-8

Bucket: empty Bucket: empty Bucket: loaded Weight: 64500 kg (143000 lb) Bucket: loaded T4-4-10 Weight: 64500 kg (143000 lb) Allowable limit: 8 (0.3) T4-4-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation HYDRAULIC CYLINDER CYCLE TIME Backhoe Boom Raise Boom Lower Arm Extend Arm Retract Bucket Tilt-In Bucket Tilt-Out CYLINDER DRIFT CHECK Backhoe Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom

Unit

Performance Standard sec

Remark

Reference Page 3 43.0 m (PCSA heaped) bucket T4-4-14 Bucket: empty

9.9±0.7 5.4±0.5 9.7±0.5 8.1±1.0 6.1±0.5 5.0±0.5 mm (in)/5 min

43.0 m3 (PCSA heaped) bucket T4-4-16 Weight: 64500 kg (143000 lb) Less than 55 (2.17) Less than 55 (2.17) Less than 30 (1.18) Less than 450 (65.7)

T4-2-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation CONTROL LEVER OPERATING FORCE Front/Rear at Right Side

Unit

Performance Standard N (lbf )

Reference Page T4-4-18

5.1 to 6.4 (1.15 to 1.44)/6.1 to 7.6 (1.37 to 1.71) 5.2 to 6.5 (1.17 to 1.46)/5.9 to 7.4 (1.33 to 1.66) 5.1 to 6.4 (1.15 to 1.44)/6.1 to 7.6 (1.37 to 1.71) 5.9 to 7.4 (1.33 to 1.67)/5.2 to 6.5 (1.17 to 1.46) 21.6 to 26.3 (4.86 to 5.92)

Left/Right at Right Side

Front/Rear at Left Side

Left/Right at Left Side

Travel Control Lever CONTROL LEVER STROKE Front and Rear at Right Side Right and Left at Right Side Front and Rear at Left Side Right and Left at Left Side Travel Control Lever COMBINED OPERATION OF BOOM RAISE AND SWING FUNCTION CHECK (The time required to swing the upperstructure 90 degrees) Bucket Height: H

Remark

T4-4-19

mm (in)

55±7 (2.17±0.28) 55±7 (2.17±0.28) 55±7 (2.17±0.28) 55±7 (2.17±0.28) 138±10 (5.43±0.39) sec/90 7.9±0.7 degree

mm (in)

Over 7500 (295.3)

T4-2-3

Bucket: empty

T4-4-20

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation HYDRAULIC SYSTEM PRIMARY PILOT PRESSURE Engine: Fast Idle Speed

Unit

Performance Remark Standard

MPa (psi)

MPa (psi)

Engine: Slow Idle Speed MAIN PUMP DELIVERY PRESSURE MAIN RELIEF SET PRESSURE Each relief operation of boom raise/lower, arm roll-in/roll-out and bucket roll-in/rollout Relief operation of bucket close RELIEF PRESSURE (Relief operation of travel) RELIEF PRESSURE (Relief operation of swing) OVERLOAD RELIEF PRESSURE Boom, Arm and Bucket Bucket Close MAIN PUMP FLOW RATE OIL COOLER FAN MOTOR PUMP FLOW RATE RADIATOR FAN MOTOR PUMP FLOW RATE SWING MOTOR DRAINAGE

TRAVEL MOTOR DRAINAGE

Slow speed: With the track raised off the ground

T4-5-2 4.4±0.5 (638±73) Over 3.5 (508)

Engine: Slow Idle Speed SECONDARY PILOT PRESSURE (EDQR Valve) Engine: Fast Idle Speed

T4-5-1 4.4±0.5 (638±73) Over 3.5 (508)

Engine: Slow Idle Speed SECONDARY PILOT PRESSURE (Solenoid Valve of EDQR Valve) Engine: Fast Idle Speed

Reference Page

Control Lever:

Full Stroke

Control Lever:

Full Stroke

MPa (psi) 4.3±0.5 (624±73) Over 3.3 (479) MPa (psi) 29.4+2.0-0 (4264+290-0) MPa (psi) 29.4+2.5-0 (4264+363-0)

T4-5-4 Control Lever:

Full Stroke

Control Lever:

Full Stroke

15.7+2.3-0 (2280+334-0) MPa (psi) 29.4+2.5-0 (4264+363-0) MPa (psi) 29.4+1.5-0.5 (4264+218-73) MPa (psi) 31.4+2.3-0 (4554+334-0) 15.7+2.3-0 (2280+334-0) L/min Refer to T4-2-5 L/min Refer to T4-2-6 L/min Refer to T4-2-7 L/min Less than 3.5 With constant speed (US gal/ (0.93) min) L/min (US gal/ min) Less than 15 (3.96)

T4-2-4

T4-5-6

T4-5-12

T4-5-14 T4-5-18 T4-5-18 T4-5-23

T4-5-25

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Main Pump P-Q Diagram Points on P-Q Line (Main Pump) Delivery Pressure (P) Flow Rate (Q) MPa (psi) L/min (gpm) A 14.2 (2060) Approx. 490 (129.5) B 25.0 (3626) Approx. 278 (73.4) C 29.4 (4264) Approx. 237 (62.6)

 P-Q Control (Torque Control)  Rated Pump Speed: 1836 min-1  Pump Speed Ratio: 1.020  Hydraulic Oil Temperature: 50±5 degree C (122±9 degree F) NOTE: Refer to T4-5-14.

f

Flow Rate (Q) L/min

A

B C

Delivery Pressure (P) MPa

T4-2-5

TKFB91-04-02-001

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Oil Cooler Fan Motor Pump P-Q Diagram  P-Q Control (Torque Control)  Rated Pump Speed: 1996 min-1 (Engine: Rated)  Pump Speed Ratio: 1.109  Hydraulic Oil Temperature: 50±5 degree C (122±9 degree F) NOTE: Refer to T4-5-18.

f

Points on P-Q Line Delivery Pressure (P) MPa (psi) A 4.5 (655) B 16.3 (2360) C 21.4 (3100)

A

Flow Rate (Q) L/min (gpm) 374 (98.8) 365 (96.4) 262 (69.2)

Flow Rate (Q) L/min

B

C

Delivery Pressure (P) MPa

T4-2-6

TKHA90-04-02-001

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Radiator Fan Motor Pump P-Q Diagram  P-Q Control (Torque Control)  Rated Pump Speed: 1996 min-1 (Engine: Rated)  Pump Speed Ratio: 1.109  Hydraulic Oil Temperature: 50±5 degree C (122±9 degree F) NOTE: Refer to T4-5-18.

f

Points on P-Q Line Delivery Pressure (P) MPa (psi) A 4.9 (710) B 19.3 (2880) C 20.6 (2990)

A

Flow Rate (Q) L/min (gpm) 354 (93.5) 344 (90.9) 319 (84.3)

B

Flow Rate (Q) L/min

C

Delivery Pressure (P) MPa

T4-2-7

TKHA90-04-02-002

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Oil Cooler Fan Motor Pump/Radiator Fan Motor Pump I-Q Diagram

Points on I-Q Line Command Current Signal (I) of Pump Control Solenoid Valve mA A 381±30 B 592±40

 I-Q Control  Rated Pump Speed: 2107 min-1 (Engine: Fast Idle)  Pump Speed Ratio: 1.109  Hydraulic Oil Temperature: 50±5 degree C (122±9 degree F).

Flow Rate (Q) L/min (gpm) 374±3 (98.8±0.8) 77±5 (20.3±1.3)

Flow Rate (Q) L/min

A

B

Command Current Signal (I) mA

T4-2-8

TKFB91-04-02-004

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Electric Control Lever When moving the electric control lever, command current is sent from the controller to ELUF, ELUV and ELUT according to the control lever stroke.

Front Attachment, Swing 15 degrees

15 degrees

(-)

(-)

Y

To ELUF

Controller

(+)

X (+)

Travel, Bucket Open/Close

12.4±1 degrees 12.4±1 degrees

fNOTE: Bucket Open/Close: only Loading Shovel

Controller

To ELUT

T4-2-9

T18G-03-04-002

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Front Attachment, Swing

90±2% Short Zone Approx. 3 degrees

Output Voltage Ratio

88+4%-2%

50±1.5%

12+2%-4% 10±2% 15 degrees 15 degrees

Mechanical Control Angle

2, 11 1, 12 Short Zone Resistor for Calibration

4, 9 30±5 degrees Electrical Turning Angle

3, 10 Short Zone Resistor for Calibration

Total Resistance 2 kΩ±15 %

TKEB-04-02-001

(+) Direction on XY Axis

TKEB-04-02-002

T4-2-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Travel (Control Curve: 25±5 degree C (77±9 degree F)) Control Torque

Output Voltage Ratio V

100

N·m 16.0 15.3±2.3

80±7.5

Output Voltage Ratio

12.0

50±5 20±7.5

8.0 6.5±1.0

0

12.4±1

4.0

0

12.4±1

F

R T18M-03-04-004

0

12.4±1

12.4±1

F

R

Control Angle (degrees)

Neutral Switch

T18M-03-04-003 F-

Front Side

R-

Rear Side 0

Bucket Open/Close (only Loading Shovel) F

(Control Curve: 25±5 degree C (77±9 degree F))

R T18G-03-04-006

Control Torque

Output Voltage Ratio

N·m 16.0

V

100

80±7.5 Output Voltage Ratio

12.0 9.3±1.4 8.0

50±5 20±7.5

0 4.0

12.4±1

3.9±0.6

0

12.4±1

F 0

12.4±1

0

F

Control Angle (degrees)

R T18M-03-04-004

12.4±1

Neutral Switch

R T18L-03-04-001

F-

Front Side

R-

Rear Side

0 F

R T18G-03-04-006

T4-2-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard (Blank)

T4-2-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Engine Speed Summary: 1. Measure the engine speed by using the monitor unit or a pulse meter.

2. Measure the engine speeds in each condition.

fNOTE: Measure the engine speed before performing all other tests. If the engine speed is not adjusted correctly, all other performance data will be unreliable.

Test Conditions  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Ground Conditions: Flat and solid ground Preparation: 1. Press and hold the engine stop switch until the engine completely stops rotating. Turn the key switch to the OFF position. Remove the key from the key switch.

1

2. Disconnect the connector of engine speed sensor (1). Install a pulse meter.

3. Start the engine. Warm up the machine until the coolant temperature reaches 50 °C (122 °F) or more and the hydraulic oil temperature is 50±5 °C (122±9 °F).

1-

TKHA90-01-02-020

Engine Speed Sensor

2

TKEB-04-03-001 2-

T4-3-1

Engine Speed Sensor Connector (Main Harness End)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Measurement:

Evaluation:

1. Measure the items as shown in the table below.

Refer to Operational Performance Standard (T4-2).

2. When measuring, set the switch and test condition as shown in the table below in response to the engine speed to be measured.

Calculate the engine speed by using the following formula.

Engine Speed (min-1) = Pulse Number×60/168 (min-1) Item

Engine Control Dial

Auto-Idle Switch

Slow Idle Speed Fast Idle Speed

Slow Idle Fast Idle

OFF OFF

Auto-Idle Speed

Fast Idle

ON

T4-3-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Speed Summary: 1. Measure the time required for the machine to travel a test track and check the performance of the travel systems (from main pump to travel motor).

Preparation: 1. Adjust track sag of both tracks to dimension (a).

2. Provide a flat, solid test yard 20 m (65 ft) in length, with extra length of 2 to 3 m (6 ft 7 in to 9 ft 10 in) on both ends for machine acceleration and deceleration.

3. Empty the bucket and fully retract the arm.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

a

Measurement: 1. Measure in both fast and slow travel modes.

T145-05-03-001

2. Select the following conditions.

Travel Mode Switch

Engine Control Auto-Idle Dial Switch

Slow Mode

Fast Idle

OFF

Fast Mode

Fast Idle

OFF

a-

735 to 825 mm (2 ft 4.9 in to 2 ft 8.5 in)

3. Start traveling the machine in the acceleration zone with the travel levers to full stroke.

4. Measure the time required to travel between the start (e) and end (c).

5. After measuring the forward travel speed, turn the upperstructure 180 degrees and measure the reverse travel speed in the same way.

b

6. Repeat the measurement three times and calculate the mean values.

d

e

b TKAB-04-04-001

b-

Evaluation: Refer to Operational Performance Standard (T4-2).

c

cd-

T4-4-1

Acceleration/Deceleration Zone: 2 to 3 m (6 ft 7 in to 9 ft 10 in) End 20 m (65 ft)

e-

Start

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Track Revolution Speed Summary: 1. Measure the track revolution cycle time with the track raised off ground and check the performance of the travel systems (from main pump to travel motor).

Preparation: 1. Adjust track sag of both tracks to dimension (a). a

2. On the track to be measured, put a mark on one shoe by using a piece of chalk or cloth.

3. Raise the track to be measured off the ground as illustrated.

Securely support the raised machine dCAUTION: off the ground by using blocks.

T145-05-03-001 a-

735 to 825 mm (2 ft 4.9 in to 2 ft 8.5 in)

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Measure on both tracks at slow and fast travel modes with forward and reverse travel.

b

2. Select the following conditions.

Travel Mode Switch Slow Mode

Engine Control Auto-Idle Dial Switch Fast Idle OFF

Fast Mode

Fast Idle

TKAB-04-04-002 b-

OFF

3. Operate the travel control lever of the track to be measured to full stroke.

4. Measure the time required for three revolutions after a constant track revolution speed is obtained.

5. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (T4-2).

T4-4-2

90 to 110°

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Mistrack Check Summary: 1. Allow the machine to travel 20 m (65 ft). Measure the maximum tread deviation from the tread chord drawn between the travel start and end points and check the performance of the travel system (from main pump to travel motor).

2. If measured on a pavement surface, the tread deviation has a trend to decrease.

a

Preparation:

T145-05-03-001

1. Adjust track sag of both tracks to the nominal dimension (a).

a-

735 to 825 mm (2 ft 4.9 in to 2 ft 8.5 in)

2. Provide a flat, solid test yard 20 m (65 ft) in length, with extra length of 2 to 3 m (6 ft 7 in to 9 ft 10 in) on both ends for machine acceleration and deceleration.

3. Empty the bucket and fully retract the arm.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement:

TKAB-04-04-003

1. Measure in both fast and slow travel modes.

2. Select the following conditions.

Travel Mode Switch Slow Mode

Engine Control Auto-Idle Dial Switch Fast Idle OFF

Fast Mode

Fast Idle

OFF

3. Start traveling the machine in the acceleration zone with the travel control levers to full stroke.

4. Measure maximum distance (b) between a straight 20 m (65 ft) tread chord and the tread made by the machine.

c

5. After measuring maximum distance (b) in forward travel, turn the upperstructure 180 degrees and measure maximum distance (b) in reverse travel.

b d

6. Repeat the measurement three times and calculate the mean values. c

Evaluation: Refer to Operational Performance Standard (T4-2).

T115-07-03-005 bc-

T4-4-3

Maximum Distance Acceleration/Deceleration Zone: 2 to 3 m (6 ft 7 in to 9 ft 10 in)

d-

20 m (65 ft)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Parking Leakage Summary: Measure the parking brake function on a specified slope.

Preparation: 1. Measure on a flat slope with a gradient of 20 % (11.31 degrees).

a

2. With the arm and bucket cylinders fully extended, hold the bucket 0.5 to 1.0 m (20 to 40 in) (a) above the ground. (Empty the bucket.)

3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

TKAB-04-04-004 a-

0.5 to 1.0 m (20 to 40 in)

Measurement: 1. Climb the slope and set the travel control levers in neutral.

2. Stop the engine.

3. After the machine stops, put marks on the track link or the shoe, and the track side frame.

4. When five minutes passed, measure the distance between marks (b) on the track link or the shoe, and the track frame.

Evaluation: Refer to Operational Performance Standard (T4-2).

b TDAA-04-04-001 b-

T4-4-4

Distance measured when five minutes passed

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Speed Summary: 1. Measure the time required to swing three complete turns and check the performance of the swing system (from main pump to swing motor).

Preparation: 1. Check lubrication of the swing gear and the swing bearing.

2. Place the machine on a flat and solid ground with ample space for swinging. Do not conduct this test on a slope.

a

3. Fully retract the arm cylinder. Fully extend the bucket cylinder. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (Empty the bucket.)

TKAB-04-04-005 a-

fNOTE: In case a sufficient space for the measurement is difficult to find, carry out the measurement with the boom fully raised and the arm fully rolled-in.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

Measurement: 1. Select the following conditions.

Engine Control Dial Fast Idle

Power Mode Auto-Idle Switch HP OFF

Work Mode Digging Mode

2. Operate the swing control lever to full stroke and swing the upperstructure.

3. Measure the time required to swing three turns when the swing speed is a constant speed.

4. Check the time in both clockwise and counterclockwise directions.

5. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (T4-2).

T4-4-5

The same height as boom foot pin

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Function Drift Check Summary: 1. Measure the swing drift on the swing bearing outer circumference when stopping after a 180 degrees full-speed swing and check the performance of the swing brake valve.

2. The mechanical brake for the swing parking brake is equipped for the swing motor.

a

Preparation:

TKAB-04-04-005

1. Check lubrication of the swing gear and the swing bearing.

a-

The same height as boom foot pin

2. Place the machine on a flat and solid ground with ample space for swinging. Do not conduct this test on a slope.

3. Fully retract the arm cylinder. Fully extend the bucket cylinder. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (Empty the bucket.)

4. Put marks on the swing bearing outer circumference (upperstructure side) and the track frame.

b

5. Swing the upperstructure 180 degrees.

T105-06-03-008 b-

6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Put the marks on swing bearing outer circumference and track frame.

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

c T105-06-03-009 c-

T4-4-6

Before start the measurement, swing the upperstructure 180 degrees.

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

a

2. Operate the swing control lever to full stroke and swing the upperstructure 180 degrees. When the mark on upperstructure aligns with that on track frame, return the swing control lever to the neutral position.

3. After stopping the upperstructure, measure the arc length (swing bearing circumference) between the two marks on the swing bearing and track frame.

4. Check the arc length in both clockwise and counterclockwise directions.

b c T105-06-03-010 ab-

5. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (T4-2).

T4-4-7

Measure arc length (swing bearing circumference).

Mark on Track Frame

c-

Mark on Swing Bearing

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Motor Leakage Summary: 1. Set the machine on a specified slope and swing the upperstructure 90 degrees to the slope. Measure the upperstructure drift while suspending a load on a specified slope and check the performance of the swing parking brake.

(The mechanical brake for the swing parking brake is equipped for the swing device.)

Preparation: 1. Check lubrication of the swing gear and the swing bearing.

2. Load the bucket. (Refer to the Operational performance Standard about the loading weight.)

T105-06-03-011

3. Fully extend the bucket cylinder and fully retracted arm cylinders. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height.

4. Park the machine on a smooth slope with a gradient of 15±1 degrees.

5. Climb a slope and swing the upperstructure to position it 90 degrees to the slope. Put the marks on the swing bearing outer circumference (upperstructure side) and the track frame.

6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Stop the engine. When five minutes passed, measure the arc length (swing bearing circumference) between the two marks on the swing bearing and track frame.

a

2. Check the arc length in both clockwise and counterclockwise directions.

3. Repeat the measurement three times and calculate the mean values.

b

Evaluation:

c

Refer to Operational Performance Standard (T4-2).

T105-06-03-010 ab-

T4-4-9

Measure arc length (swing bearing circumference).

Mark on Track Frame

c-

Mark on Swing Bearing

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Maximum Swingable Slant Angle Summary: 1. With the upperstructure swung 90 degrees to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side.

Preparation: 1. Check lubrication of the swing gear and the swing bearing.

2. Load the bucket. (Refer to the Operational performance Standard about the loading weight.)

3. Fully extend bucket cylinder and fully retracted arm cylinders. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height.

4. Climb a slope and swing the upperstructure 90 degrees to the slope.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-10

T105-06-03-011

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

2. Operate the swing control lever to full stroke to swing the upperstructure to a uphill side.

3. If the machine can swing, measure the cab floor slant angle.

4. When the machine can swing, increase the slant angle. Check the slant angle in both clockwise and counterclockwise directions.

Evaluation: Refer to Operational Performance Standard (T4-2).

T4-4-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Bearing Play Summary: 1. Measure the swing bearing play and check the wear of the swing bearing races and the rollers.

Preparation:

TKHA90-04-04-001

A

1. Check the swing bearing mounting bolts for looseness.

Detail A

1, 2

2. Check lubrication of the swing bearing. Confirm that bearing rotation is smooth without noise.

3. Remove bolts, washers (4) (8 Used), nuts (5) (8 Used), washers (6) (8 Used), bolts (1) (6 used) and washers (2) (6 used). Remove scraper assemblies (3) (2used).

Wrench Size (mm) Tightening Torque (N·m [lbf·ft]) j : 46 Bolt (1) 1950 [1440] Bolt, Washer (4) m : 17 50 [37] 4. Secure dial gauge (b) on the upper surface of the track frame by using magnetic base (a).

4, 5, 6

3 TKHA90-04-04-002

5. Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers.

6. Position dial gauge (b) so that its needle point comes in contact with the bottom surface of the swing bearing outer race.

7. Empty the bucket.

fNOTE: The measured value will vary depending on

where magnetic base (a) is secured. Secure magnet base (a) as close to the round trunk as possible. a a-

Magnetic Base

b b-

a a-

T4-4-12

Magnetic Base

b b-

T105-06-03-014

Dial Gauge

T18P-04-04-002 Dial Gauge

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Measure at positions A, B, C, and D (4 places).

2. Fully extend bucket cylinder and fully retracted arm cylinders. Hold the boom so that the bucket bottom height is the same as the boom foot pin height.

Record dial gauge reading (h1) of the dial gauge.

A D

B C

3. Lower the bucket onto the ground and raise the front idler 0.5 m (20 in) off the ground by using the front attachment. Record reading (h2) of the dial gauge.

4. Calculate bearing play (H) from these data (h1 and h2) as follows:

T145-05-03-023

H=h2-h1 Evaluation: Refer to Operational Performance Standard (T4-2).

Measurement of (h1)

Measurement of (h2)

a b TKAB-04-04-006 a-

The same height as boom foot pin

b-

T4-4-13

0.5 m (20 in)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Hydraulic Cylinder Cycle Time Summary: 1. Measure the cycle time of boom, arm, and bucket cylinders, and check the performance of the front attachment system (from main pump to each cylinder).

2. Empty the bucket.

Preparation: 1. Measurement is made for the following positions.  Measurement of the cycle time of the boom cylinder: With the bucket cylinder fully extended and the arm cylinder fully retracted, lower the bucket onto the ground.

 Measurement of the cycle time of the arm cylinder: With the bucket cylinder fully extended, raise the boom so that the bucket bottom height is 0.5 m (20 in) above the ground when the arm oscillation center faces vertically to the ground. Set the arm so that the center of arm operation is vertical.

 Measurement of the cycle time of the bucket cylinder: Adjust the boom and arm cylinders so that the bucket oscillation center faces vertically to the ground.

TKAB-04-04-007

TKAB-04-04-008

2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T105-06-03-020

T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions.

Engine Control Dial Fast Idle

Auto-Idle Switch OFF

2. Measure the cylinder cycle times as follows: (Cylinder full stroke includes cylinder cushioning zone.)  Measurement of the cycle time of the boom cylinder: Operate the boom control lever to full stroke.

Measure the time to raise and lower the boom.  Measurement of the cycle time of the arm cylinder: Operate the arm control lever to full stroke. Measure the time to retract and extend the arm.  Measurement of the cycle time of the bucket cylinder: Operate the bucket control lever to full stroke.

Measure the time to tilt in and tilt out the bucket.

3. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (T4-2).

T4-4-15

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Cylinder Drift Check Summary: 1. Measure the drifted amount of cylinders, which can be caused by oil leakage in the control valve and boom, arm and bucket cylinders, with the bucket loaded.

2. When measuring the drifted amount just after cylinder replacement, slowly operate the cylinder for 10 minutes and bleed air from the cylinder.

a

Preparation:

TKAB-04-04-010

1. Load the bucket. (Refer to the Operational Performance Standard about the loading weight.)

a-

2. Fully retract the arm cylinder. Fully extend the bucket cylinder. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height.

3. Position the arm cylinder and the bucket cylinder with the rod 50 mm (2 in) away from the full stroke end position.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-16

The same height as boom foot pin

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Stop the engine.

a

b

2. When five minutes passed, measure the drifted amount in position of bottom of the bucket, as well as the boom, arm, and bucket cylinders.

b

Drifted amount of Boom, Arm, and Bucket Cylinders: Retraction a a=A-B 3. Repeat the measurement three times and calculate the mean values.

T110-06-03-002 a-

Evaluation: Refer to Operational Performance Standard (T4-2).

T4-4-17

Boom, Arm and Bucket Cylinders: Retraction

b-

Mark

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Operating Force Summary: 1. Check a play and operating condition and measure the operating force.

2. Measure the maximum operating force of the front attachment control lever.

3. Measure the lever operating force along the control lever operation at the grip center of each control lever.

Measurement:

TKEB-04-04-005

1. Stop the engine.

2. Measure the operating force of each control lever.

3. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (T4-2).

TKEB-04-04-006

T4-4-18

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Stroke Summary: 1. Check a play and operating condition and measure each control lever stroke.

2. Measure the control lever stroke at the grip center of each control lever.

3. In case the lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes.

Measurement: 1. Stop the engine.

T107-06-03-005

2. Measure each control lever stroke from neutral to the stroke end of each control lever of boom, arm, bucket, swing, and travel at the grip center.

3. Measure the chord length from neutral to the stroke end.

4. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (T4-2).

T4-4-19

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Combined Operation of Boom Raise and Swing Function Check Summary: 1. Check the boom raise and swing movement and speed while operating both functions simultaneously.

TKAB-04-04-005

2. Check if the cylinders do not hesitate while operating the cylinder with the engine running at fast idle.

Preparation: 1. Fully extend bucket cylinder and fully retracted arm cylinders. Lower the bucket onto the ground.

(Empty the bucket.)

2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

T142-05-03-009

Measurement: 1. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

2. Raise the boom and swing the upperstructure in full stroke at the same time. Measure the time required to swing the upperstructure 90 degrees and height (H) of the bucket teeth. (The bucket should be empty.)

3. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard (T4-2).

T4-4-20

T142-05-03-010

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure

Left Pump Compartment

1

Measure primary pilot pressure in the pilot circuit at each pilot filter outlet in the right and left pump compartments.

Preparation: 1. Stop the right and left engines.

Do not turn the cap of the hydraulic dCAUTION: oil tank quickly. The cap may fly off by internal pressure. Slowly loosen the cap and release any remaining pressure before removing the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank. (Refer to Operator's Manual.)

2

TKHA90-04-05-001

l : 4 mm 3. Disconnect hose (1) from adapter (2) or elbow (3).

Install tee (ST 6652) (4), adapter (ST 6069) (5), and pressure gauge (ST 6942) (6) between disconnected adapter (2) or elbow (3) and the hose.

Right Pump Compartment

j : 19 mm, 36 mm 4. Start the right and left engines. Confirm that no oil leakage is observed at the pressure gauge connection.

1

5. Maintain the hydraulic oil temperature at 50±5 degree C (122±9 degree F).

Measurement:

3

1. Measurement conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

Slow Idle

OFF

TKHA90-04-05-002

6

2. Measure the pilot pressure without load by using the pressure gauge under each condition above.

5

3. Repeat the measurement three times and calculate the mean value.

2, 3

TKHA90-04-05-003

Evaluation

1

Refer to Operational Performance Standard (T4-2).

1234-

T4-5-1

Hose Adapter Elbow Tee (ST 6652)

4 56-

Adapter (ST 6069) Pressure Gauge (ST 6942)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure (Solenoid Valve of EDQR Valve) Measurement:

Measure secondary pilot pressure applied through the pilot shut-off solenoid valve at the solenoid valve of the EDQR valve of each pilot panel.

Always make sure that the area is dCAUTION: clear and that coworkers are out of the work area before starting the measurement.

Preparation:

When measuring the boom lower secondary pilot pressure, set the machine position with the tracks raised off the ground. Take care not to allow the rear of the machine to come in contact with the ground. Take care not to allow the machine overturn as the machine becomes unbalanced.

1. Stop the right and left engines.

Do not turn the cap of the hydraulic dCAUTION: oil tank quickly. The cap may fly off by internal

pressure. Slowly loosen the cap and release any remaining pressure before removing the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank. (Refer to Operator's Manual.)

1. Measurement conditions.

l : 4 mm 3. Disconnect wire harnesses (1 to 21) according to the circuits to be measured. Remove pressure sensor (22).

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

Slow Idle

OFF

2. Operate the control lever to be measured. Measure the pilot pressure by using the pressure gauge with the control lever set to the full stroke.

Install adapter (ST 6069) (27) and pressure gauge (ST 6942) (26).

3. Repeat the measurement three times and calculate the mean value.

j : 19 mm, 24 mm 4. Start the right and left engines. Confirm that no oil leakage is observed at the pressure gauge connection.

5. Maintain the hydraulic oil temperature at 50±5 degree C (122±9 degree F).

Evaluation Refer to Operational Performance Standard (T4-2).

fNOTE: When the measured data is abnormal, measure the primary pilot pressure. When the primary pilot pressure is normal, the EDQR valve or pilot shut-off solenoid valve can be determined as faulty.

T4-5-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Center Pilot Panel

Front Pilot Panel

1, 22 2, 22 3, 22 4, 22 5, 22 6, 22 7, 22 8, 22

16, 22 17, 22 18, 22 19, 22 20, 22 21, 22

23

25

TKHA90-04-05-005

9, 22 10, 22 11, 22 12, 22 13, 22 14, 22 15, 22

24 TKHA90-04-05-004

23, 24, 25

27

26 TKFB91-04-05-015

1234567-

Valve Warmer Solenoid Valve 1 Boom Raise Priority Swing Left Swing Right Right Travel Reverse Boom Raise Arm Roll-Out

891011121314-

Bucket Roll-Out Valve Warmer Solenoid Valve 2 Boom Lower Right Travel Forward Arm Roll-In Bucket Roll-In Left Travel Forward

15161718192021-

T4-5-3

Left Travel Reverse Valve Warmer Solenoid Valve 3 Bucket Roll-In Arm Roll-In Boom Raise Arm Roll-Out Bucket Roll-Out

222324252627-

Pressure Sensor EDQR Valve (Upper) EDQR Valve (Lower) EDQR Valve (Front Pilot Panel) Pressure Gauge (ST 6942) Adapter (ST 6069)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure (EDQR Valve) Measure secondary pilot pressure at the outlet of the EDQR valve of each pilot panel.

Measurement: Always make sure that the area is dCAUTION: clear and that coworkers are out of the work area

Preparation:

before starting the measurement.

1. Stop the right and left engines.

When measuring the boom lower secondary pilot pressure, set the machine position with the tracks raised off the ground. Take care not to allow the rear of the machine to come in contact with the ground. Take care not to allow the machine overturn as the machine becomes unbalanced.

Do not turn the cap of the hydraulic dCAUTION: oil tank quickly. The cap may fly off by internal

pressure. Slowly loosen the cap and release any remaining pressure before removing the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank. (Refer to Operator's Manual.)

1. Measurement conditions.

l : 4 mm 3. Disconnect hoses (1 to 18) according to the circuits to be measured.

Remove elbow (22) from each EDQR valve (19 to 21).

Install tee (A852443) (27), adapter (ST 6272) (26), adapter (ST 6453) (25), adapter (ST 6069) (24), and pressure gauge (ST 6942) (23) between EDQR valves (19 to 21) and hoses (1 to 18).

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

Slow Idle

OFF

2. Operate the control lever to be measured. Measure the pilot pressure by using the pressure gauge with the control lever set to the full stroke.

3. Repeat the measurement three times and calculate the mean value.

j : 19 mm, 22 mm 4. Start the right and left engines. Confirm that no oil leakage is observed at the pressure gauge connection.

5. Maintain the hydraulic oil temperature at 50±5 degree C (122±9 degree F).

Evaluation Refer to Operational Performance Standard (T4-2).

fNOTE: When the measured data is abnormal, measure

the secondary pilot pressure of the solenoid valve of the EDQR valve. When the secondary pilot pressure of the solenoid valve of the EDQR valve is normal, EDQR valves (19 to 21) can be determined as faulty.

T4-5-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Center Pilot Panel

Front Pilot Panel

1, 22 2, 22 3, 22 4, 22 5, 22 6, 22 7, 22

14, 22 15, 22 16, 22 17, 22 18, 22

21 19 TKHA90-04-05-007

8, 22 9, 22 10, 22 11, 22 12, 22 13, 22

20 TKHA90-04-05-006

19, 20, 21

1 to 18 23 24 25 26

TKFB91-04-05-019

27

12345678-

Boom Raise Priority Swing Left Swing Right Right Travel Reverse Boom Raise Arm Roll-Out Bucket Roll-Out Boom Lower

910111213141516-

Right Travel Forward Arm Roll-In Bucket Roll-In Left Travel Forward Left Travel Reverse Bucket Roll-In Arm Roll-In Boom Raise

1718192021222324-

T4-5-5

Arm Roll-Out Bucket Roll-Out EDQR Valve (Upper) EDQR Valve (Lower) EDQR Valve (Front Pilot Panel) Elbow Pressure Gauge (ST 6942) Adapter (ST 6069)

25- Adapter (ST 6453) 26- Adapter (ST 6272) 27- Tee (A852443)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Set Pressure

Evaluation Refer to Operational Performance Standard (T4-2).

Measure the main relief valve set pressure at the highpressure strainers of the delivery port of each main pump in the right and left pump compartments.

fNOTE: If all circuit pressure in the circuits to be

measured are lower than the specified range, the probable cause is the set pressure decrease of the main relief valve. If only pressure of a particular circuit is lower, the probable cause is a pressure decrease except the main relief valve.

Preparation: 1. Stop the right and left engines.

Do not turn the cap of the hydraulic dCAUTION: oil tank quickly. The cap may fly off by internal

pressure. Slowly loosen the cap and release any remaining pressure before removing the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank. (Refer to Operator's Manual.)

Connection of High-Pressure Strainer Main High Connected to Pump Strainer P1 1 Control Valve 4 (Lower Center)

l : 4 mm 3. Remove plug (A) of the upper part of high-pressure strainers (1 to 8) according to the circuits to be measured. Install adapter (ST 6069) and pressure gauge (ST 6941).

P2 P3

4. Start the right and left engines. Confirm that no oil leakage is observed at the pressure gauge connection.

Control Valve 2 (Lower Left)

Boom Raise, Arm, Travel (Left)

3

Control Valve 1 (Upper Left)

Boom Raise, Bucket, Arm Roll-In, Travel (Right)

5. Maintain the hydraulic oil temperature at 50±5 degree C (122±9 degree F).

4

Control Valve 7 (Boom Left)

Boom Raise, Bucket, Arm

5

Control Valve 8 (Boom Right)

Boom Raise, Bucket, Arm

6

Control Valve 3 (Upper Center)

Swing, Boom Raise, Arm Roll-In, Bucket Roll-In

7

Control Valve 6 (Lower Right)

Travel (Left), Boom, Arm RollIn, Bucket

8

Control Valve 5 (Upper Right)

Travel (Right), Boom, Arm

P4 P5 P6 P7

Measurement: 1. Measure the main relief pressure at the fast idle engine speed.

P8

2. Slowly operate each control lever of bucket, arm, and boom. Operate each cylinder to the stroke end and relieve the pressure.

P11

 When measuring the pressure of travel, secure the tracks against an immovable object. Slowly operate the travel control lever and relieve the pressure.  When measuring the pressure of swing, secure the upperstructure so that it does not swing. Slowly operate the swing control lever and relieve the pressure.

3. Measure each relief pressure.

4. Repeat the measurement three times and calculate the mean value.

Swing, Boom Raise, Arm Roll-In, Bucket Roll-In

2

l : 6 mm j : 19 mm

Operation

P12 P13 P14 P15 P16 P17 P18

T4-5-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Left Pump Compartment

A 3

2

1 P7, P8

A 4 P1, P2

P3, P4

P5, P6 TKHA90-04-05-008

Right Pump Compartment

A 6 P13, P14 A

7

8

5

P11, P12

P15, P16

TKHA90-04-05-009

P17, P18

A-

Plug

P1P2P3P4-

Main Pump L1 Main Pump L2 Main Pump L3 Main Pump L4

P5P6P7P8-

Main Pump L5 Main Pump L6 Main Pump L7 Main Pump L8

P11- Main Pump R1 P12- Main Pump R2 P13- Main Pump R3 P14- Main Pump R4

P15- Main Pump R5 P16- Main Pump R6 P17- Main Pump R7 P18- Main Pump R8

1-

High-Pressure Strainers 1 (P1, P2) High-Pressure Strainers 2 (P3, P4)

3-

High-Pressure Strainers 3 (P5, P6) High-Pressure Strainers 4 (P7, P8)

5-

7-

2-

4-

6-

T4-5-7

High-Pressure Strainers 5 (P11, P12) High-Pressure Strainers 6 (P13, P14)

8-

High-Pressure Strainers 7 (P15, P16) High-Pressure Strainers 8 (P17, P18)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Valve Pressure Adjustment Procedure IMPORTANT: Do not customize the machine illegally.

For example: the machine performance is set over the specification.

It may cause more serious problems, such as the shorten life or the breakage of the components and machine structure.

1

Adjustment: 1. Loosen lock nut (2). j : 17 mm 2. Turn adjusting bolt (3) and adjust the set pressure. l : 6 mm 3. After the adjustment, tighten lock nut (2). j : 17 mm TKEB-04-05-009

m : 27.5 to 31.4 N·m (20.5 to 23.0 lbf·ft) 4. After the adjustment, check the set pressure.

1-

Main Relief Valve

fNOTE: Standard Change in Pressure (Reference) Adjusting Bolt (3) Turns Change in MPa Pressure (psi)

1/4

1/2

3/4

1

4.5 (653)

8.9 (1291)

13.4 (1944)

17.8 (2582)

1

2

3 TKEB-04-05-010 12-

Main Relief Valve Lock Nut

3-

Adjusting Bolt

3

2

a

b W107-02-05-129

a-

Pressure Increase

b-

Pressure Decrease

2-

Lock Nut

3-

Adjusting Bolt

T4-5-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Swing Relief Valve Pressure Adjustment Procedure IMPORTANT: Do not customize the machine illegally.

For example: the machine performance is set over the specification.

It may cause more serious problems, such as the shorten life or the breakage of the components and machine structure.

Adjustment: 1. Loosen lock nut (2). j : 41 mm 2. Turn adjusting bolt (3) and adjust the set pressure. j : 27 mm

1

3. After the adjustment, tighten lock nut (2).

1-

TKFB91-04-05-006

Swing Relief Valve

j : 41 mm

1

2

3

m : 19.5 to 29.5 N·m (14.5 to 22.0 lbf·ft) 4. After the adjustment, check the set pressure.

fNOTE: Standard Change in Pressure (Reference) Adjusting Bolt (3) Turns Change in MPa Pressure (psi)

1/4

1/2

3/4

1

2.92 (425)

5.84 (845)

8.75 (1270)

11.7 (1700)

TKEB-04-05-011 12-

Swing Relief Valve Lock Nut

3-

Adjusting Bolt

2 3

a

b TKEB-04-05-015

a-

Pressure Increase

b-

Pressure Decrease

2-

Lock Nut

3-

Adjusting Bolt

T4-5-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Travel Relief Valve Pressure Adjustment Procedure 1

IMPORTANT: Do not customize the machine illegally.

For example: the machine performance is set over the specification.

It may cause more serious problems, such as the shorten life or the breakage of the components and machine structure.

Adjustment: 1. Loosen lock nut (3).

2

2

j : 17 mm

TKEB-04-05-012

2. Turn adjusting bolt (4) and adjust the set pressure.

1-

Travel Brake Valve

2-

Travel Relief Valve

l : 6 mm

3

3. After the adjustment, tighten lock nut (3). j : 17 mm m : 34 to 44 N·m (25.0 to 32.5 lbf·ft)

4

4. After the adjustment, check the set pressure.

2

fNOTE: Standard Change in Pressure (Reference) Adjusting Bolt (4) Turns Change in MPa Pressure (psi)

1/4

1/2

3/4

1

1.96 (284)

3.92 (569)

5.88 (853)

7.85 (1139)

T145-05-04-004 23-

Travel Relief Valve Lock Nut

4-

Adjusting Bolt

4

3

a

b W107-02-05-129

a-

Pressure Increase

b-

Pressure Decrease

3-

Lock Nut

4-

Adjusting Bolt

T4-5-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test (Blank)

T4-5-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Overload Relief Set Pressure 1. When measuring the overload relief pressure, the circuit pressure must be increased by applying an external force while blocking the return circuit of the control valve. However, this measuring method is hazardous and the results obtained with this method are unreliable.

2. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate.

3. Measurement on the machine is not recommended because of above mentioned reasons. If the measurement on the machine is required, please use the measurement of the main relief set pressure as a substitute.

T4-5-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Overload Relief Valve Pressure Adjustment Procedure (Reference) IMPORTANT: Adjust the overload relief valve pressure on a test stand.

Adjustment: 1

1. Loosen lock nut (2).

1

j : 17 mm 2. Turn adjusting bolt (3) and adjust the set pressure. l : 6 mm 3. After the adjustment, tighten lock nut (2). j : 17 mm m : 27.5 to 31.4 N·m (20.5 to 23.0 lbf·ft) 4. After the adjustment, check the set pressure.

TKEB-04-05-009

fNOTE: Standard Change in Pressure (Reference) Adjusting Bolt (3) Turns Change in MPa Pressure (psi)

1/4

1/2

3/4

1

5.3 (769)

10.6 (1537)

15.9 (2306)

21.2 (3075)

1-

Overload Relief Valve

1

2

3 TKEB-04-05-010 12-

Overload Relief Valve Lock Nut

3-

Adjusting Bolt

3 2

a

b W107-02-05-129

a-

Pressure Increase

b-

Pressure Decrease

2-

Lock Nut

3-

Adjusting Bolt

T4-5-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Pump Flow Rate Measurement  P-Q Control (Torque Adjustment)

5. Install the disconnected delivery hose from the main pump with O-ring (12), split flanges (21) (2 used) and bolts (22) (4 used).

Measure the flow rate at each main pump in the right and left pump compartments.

Install a hydraulic tester to the delivery port of the main pump to be measured. Main pump performance is checked by measuring the pump flow rate.

j : 19 mm m : 90 N·m (66 lbf·ft) 6. Install a pressure gauge to the high-pressure strainer of the main pump to be measured. (Refer to T4-5-6.)

Preparation: 1. Stop the right and left engines.

7. Bleed air from the main pump.

Do not turn the cap of the hydraulic dCAUTION: oil tank quickly. The cap may fly off by internal

8. Connect a pulse meter to the engine speed sensor.

(Refer to T4-3-1.)

pressure. Slowly loosen the cap and release any remaining pressure before removing the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank. (Refer to Operator's Manual.)

9. Fully open the loading valve of hydraulic tester (ST 6299) (19).

l : 4 mm 3. Disconnect delivery hose (13) from the main pump to be measured. Connect pipe (ST 6132) (16) to the delivery port of the main pump with split flanges (14) (2 used) and socket bolts (15) (4 used) of disconnected delivery hose (13). l : 10 mm m : 90 N·m (66 lbf·ft) 4. Connect pipe (ST 6132) (16) and hydraulic tester (ST 6299) (19) with test hose (ST 6145) (17) and adapter (ST 6603) (18). Install adapter (ST 6603) (18), test hose (ST 6145) (17), and flange (ST 6140) (20) to hydraulic tester (ST 6299) (19).

10. Disconnect the solenoid valve of EDQR valve (upper) (1) and connectors (3, 4, 5, 6) of the pilot pressure sensor. Connect extension wire harness (ST 6300) (9) to disconnected connector (5) and solenoid valve (7). Connect extension wire harness (ST 6301) (10) to disconnected connector (4) and pilot pressure sensor (2).

11. In the same way as step 10, connect extension wire harnesses (ST 6300, ST 6301) (9, 10) to EDQR valve (front pilot panel) (8).

12. Start the right and left engines. Confirm that no oil leakage is observed at the hydraulic tester (ST 6299) (19) and pressure gauge connections.

Measurement: 1. Maintain the hydraulic oil temperature at 50±5 degree C (122±9 degree F).

Test Hose (ST 6145) (17) j : 41 mm

2. Measure the maximum flow rate.

m : 210 N·m (155 lbf·ft) Adapter (ST 6603) (18) j : 55 mm

3. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

m : 420 N·m (310 lbf·ft)

4. Slowly restrict the loading valve of hydraulic tester (ST 6299) (19) while relieving pressure in the boom raise circuit. Measure the flow rates and engine speed at each pressure point specified in the P-Q curve.

5. Repeat the measurement three times and calculate the mean value.

T4-5-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Evaluation

Center Pilot Panel

1. Convert the measured flow rates to those at the specified engine speed by using the following formula.

1

7

2

Qc = Ns×Q/Ne 6

Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Engine Speed: 1800 min-1 Ne : Measured Engine Speed 2. Standard Flow Rate

3 4

Refer to Operational Performance Standard (T4-2).

5

TKHA90-04-05-010 Front Pilot Panel

8

7 5

7

9

2

3

6

4 5 4

10

2 TKHA90-04-05-012

TKHA90-04-05-011

16

14 123-

4-

EDQR Valve (Upper) Pilot Pressure Sensor (Valve Warmer Solenoid Valve) Connector (Pilot Pressure Sensor (Valve Warmer Solenoid Valve)) Connector (Pilot Pressure Sensor (Boom Raise))

17

18

19

18

17

15 5-

20 21 22

12

Connector (Boom Raise Solenoid Valve) 6- Connector (Valve Warmer Solenoid Valve) 7- Solenoid Valve 8- EDQR Valve (Front Pilot Panel) 9- Extension Wire Harness (ST 6300)

10- Extension Wire Harness (ST 6301) 12- O-Ring 13- Delivery Hose 14- Split Flange 15- Socket Bolt 16- Pipe (ST 6132) 17- Test Hose (ST 6145)

T4-5-15

1819202122-

13

TKHA90-04-05-013

Adapter (ST 6603) Hydraulic Tester (ST 6299) Flange (ST 6140) Split Flange (4075853) (2 Used) Bolt (J901250) (4 Used)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Maximum Flow Rate and Minimum Flow Rate (Main Pump)

4

The main pump flow rate can be adjusted by changing the position when the servo piston reaches maximum stroke. Loosen lock nut (1) of the large chamber side of the servo piston, turn adjusting bolt (2), and adjust the maximum pump flow rate. Loosen lock nut (3) of the small chamber side of the servo piston, turn adjusting bolt (4), and adjust the minimum pump flow rate.

Lock Nut (1)

3

1

2 1

3

j : 30 mm

4

TKFB91-04-05-009

m : 240 N·m (177 lbf·ft)

1-

Adjusting Bolt (2)

2-

l : 13 mm

Lock Nut (Large Chamber Side) Adjusting Bolt (Large Chamber Side)

34-

Lock Nut (Small Chamber Side) Adjusting Bolt (Small Chamber Side)

fNOTE: Standard Change in Flow Rate (Reference)

Lock Nut (3)

Engine Speed: 1800 min-1

j : 30 mm

Adjusting Bolt Turns

m : 240 N·m (177 lbf·ft)

Change in Flow Rate (Large 9.4 L/min (2.48 US gal/min) Chamber Side) Change in Flow Rate (Small 9.4 L/min (2.48 US gal/min) Chamber Side)

Adjusting Bolt (4) l : 10 mm

1

Adjustment of Maximum Flow Rate

2

a

1/4

Q

b W107-02-05-129

a-

Flow Rate Decrease

b-

Flow Rate Increase

1-

Lock Nut (Large Chamber Side)

2-

Adjusting Bolt (Large Chamber Side)

I

Adjustment of Minimum Flow Rate

3

b

Q

4

a W107-02-05-129

a-

Flow Rate Decrease

b-

Flow Rate Increase

3-

Lock Nut (Small Chamber Side)

4-

Adjusting Bolt (Small Chamber Side)

I I: Command Current of Pump Control Solenoid Valve

T4-5-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Main Pump Flow Rate Control The main pump flow rate control is performed by command current (I) of the pump control solenoid valve.

Loosen lock nut (2), turn adjusting bolt (3), and adjust the flow rate.

Lock Nut (2) j : 17 mm m : 29 N·m (21.5 lbf·ft) Adjusting Bolt (3) l : 5 mm 1

2

3

T16J-04-04-006 1-

Spring

2-

Lock Nut

3-

Adjusting Bolt

fNOTE: Standard Change in Flow Rate (Reference)

Flow Rate Control

Engine Speed: 1800 min-1 Q

Adjusting Bolt Turns

1/4

Change in Flow Rate

44 L/min (11.63 US gal/min)

2

3 I I: Command Current of Pump Control Solenoid Valve

a

b

W107-02-05-129 a-

Flow Rate Decrease

b-

Flow Rate Increase

2-

Lock Nut

3-

Adjusting Bolt

T4-5-17

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Fan Motor Pump Flow Rate

5. Install flange (ST 6118) (14) and delivery hoses (2, 3) disconnected from the fan motor pump with O-Ring (17), split flanges (ST 6130) (15) (2 used), and bolts (ST 6379) (16) (4 used).

 P-Q Control (Torque Adjustment) Measure the flow rate at the oil cooler fan motor pump and the radiator fan motor pump in the right and left pump compartments. Install the hydraulic tester to the delivery port of the fan motor pump to be measured.

Fan motor pump performance is checked by measuring the pump flow rate.

j : 19 mm m : 90 N·m (66 lbf·ft) 6. Remove plugs (5, 6) from the delivery pressure check port of the fan motor pump to be measured.

Install pressure gauge assembly (ST 6934).

Preparation:

j : 19 mm

1. Stop the right and left engines.

m : 36 N·m (26.5 lbf·ft)

d

CAUTION: Do not turn the cap of the hydraulic oil tank quickly. The cap may fly off by internal pressure. Slowly loosen the cap and release any remaining pressure before removing the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank. (Refer to Operator's Manual.)

7. Loosen drain hoses (1, 4) of the fan motor pump to be measured and bleed air.

8. Connect a pulse meter to the engine speed sensor.

(Refer to T4-3-1.)

9. Fully open the loading valve of hydraulic tester (ST 6299) (10).

l : 4 mm 3. Disconnect delivery hoses (2, 3) from the fan motor pump to be measured. Connect pipe (ST 6144) (7) to the delivery port of the fan motor pump with split flange (19) and socket bolt (18) of the disconnected hose.

10. Start the right and left engines. Confirm that no oil leakage is observed at the hydraulic tester (ST 6299) (10) and pressure gauge connections.

Measurement: 1. Maintain the hydraulic oil temperature at 50±5 degree C (122±9 degree F).

l : 10 mm m : 90 N·m (66 lbf·ft) 4. Connect pipe (ST 6144) (7) and hydraulic tester (ST 6299) (10) with test hose (ST 6145) (8) and adapter (ST 6603) (9). Install adapter (ST 6000) (11), joint (ST 6994) (12), test hose (ST 6320) (13), and flange (ST 6118) (14) to hydraulic tester (ST 6299) (10).

2. Measure the maximum flow rate.

3. Measurement condition.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

4. Slowly restrict the loading valve of hydraulic tester (6299) (10). Measure the flow rates and engine speed at each pressure point specified in the P-Q curve. (Refer to T4-2-6, T4-2-6)

Test Hose (ST 6145) (8) j : 41 mm m : 210 N·m (155 lbf·ft)

5. Repeat the measurement three times and calculate the mean value.

Adapter (ST 6000) (11) j : 55 mm m : 420 N·m (310 lbf·ft)

T4-5-18

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Evaluation 1. Convert the measured flow rates to those at the specified engine speed by using the following formula.

2. Standard Flow Rate Refer to Operational Performance Standard (T4-2).

Qc = Ns×Q/Ne

View A

5

Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Engine Speed: 1800 min-1 Ne : Measured Engine Speed

A TKFB91-04-05-017 View B

4

B

3

2

1

TKFB91-04-05-010

6 12-

Drain Hose (for Oil Cooler Fan Motor Pump) Delivery Hose (for Oil Cooler Fan Motor Pump)

34-

Delivery Hose (for Radiator Fan Motor Pump) Drain Hose (for Radiator Fan Motor Pump)

7

19

789-

Pipe (ST 6144) Test Hose (ST 6145) Adapter G1×UNF1-7/8 (ST 6603)

8

9

56-

10

TKFB91-04-05-018

Plug (for Oil Cooler Fun Motor Pump) Plug (for Radiator Fan Motor Pump)

11

12

13

18

10- Hydraulic Tester (ST 6299) 11- Adapter R1×UNF1-7/8 (ST 6000) 12- Joint (ST 6994)

14 15 16

17

13141516-

T4-5-19

Test Hose (ST 6320) Flange (ST 6118) Split Flange (ST 6130) (2 Used) Bolt (ST 6379) (4 Used)

2, 3

TKHA90-04-05-013

17- O-Ring 18- Socket Bolt (4 Used) 19- Split Flange (2 Used)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Maximum Flow Rate and Minimum Flow Rate (Fan Motor Pump) The fan motor pump flow rate is adjusted by changing the position when the servo piston reaches maximum stroke. Loosen lock nut (1) of the large chamber side of the servo piston, turn adjusting bolt (2), and adjust the maximum pump flow rate. Loosen lock nut (3) of the small chamber side of the servo piston, turn adjusting bolt (4), and adjust the minimum pump flow rate.

Lock Nut (1)

4

1

3

2 1

3

4

j : 30 mm m : 240 N·m (177 lbf·ft)

TKFB91-04-05-012

Adjusting Bolt (2)

1-

l : 13 mm

2-

Lock Nut (3) j : 30 mm

Lock Nut (Large Chamber Side) Adjusting Bolt (Large Chamber Side)

34-

Lock Nut (Small Chamber Side) Adjusting Bolt (Small Chamber Side)

fNOTE: Standard Change in Flow Rate (Reference)

m : 240 N·m (177 lbf·ft)

Engine Speed: 1800 min-1

Adjusting Bolt (4)

Adjusting Bolt Turns

l : 10 mm

Change in Flow Rate (Large 8.0 L/min (2.11 US gal/min) Chamber Side) Change in Flow Rate (Small 8.0 L/min (2.11 US gal/min) Chamber Side)

1/4

Adjustment of Maximum Flow Rate

1

a

2

Q

b

W107-02-05-129 a-

Flow Rate Decrease

b-

Flow Rate Increase

1-

Lock Nut (Large Chamber Side)

2-

Adjusting Bolt (Large Chamber Side)

Pi

Adjustment of Minimum Flow Rate

3

4

b

Q

a

a-

Flow Rate Decrease

b-

3-

Lock Nut (Small Chamber Side)

4-

W107-02-05-129 Flow Rate Increase Adjusting Bolt (Small Chamber Side)

Pi Pi: Flow Rate Control Pressure

T4-5-20

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Fan Motor Pump Flow Rate Control The fan motor pump flow rate control is performed by command current signal (I) of the pump control solenoid valve.

Loosen lock nut (2), turn adjusting bolt (3), and adjust the flow rate.

Lock Nut (2) j : 13 mm m : 16 N·m (12 lbf·ft) Adjusting Bolt (3) l : 4 mm

1

2 3

T1J1-04-05-005 1-

Spring

2-

Lock Nut

3-

Adjusting Bolt

fNOTE: Standard Change in Flow Rate (Reference)

Flow Rate Control

Engine Speed: 1800 min-1 Q

Adjusting Bolt Turns

1/4

Change in Flow Rate

23 L/min (6.08 US gal/ min)

2

3 I I: Command Current of Pump Control Solenoid Valve

b

a

W107-02-05-129 a-

Flow Rate Decrease

b-

Flow Rate Increase

2-

Lock Nut

3-

Adjusting Bolt

T4-5-21

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Torque Constant Control (Fan Motor Pump) The torque control (fan motor pump ) is performed by own pump delivery pressure P. CAUTION: Do not turn adjusting bolts (4, 6) over one turn. After the adjustment, securely tighten lock nuts (3, 5).

1

2

3

4 5

d

6

Adjust the set force of springs (1, dCAUTION: 2) while watching the engine performance in

order not to increase the pump driving torque excessively.

1. Loosen lock nut (3), turn adjusting bolt (4), and adjust the set force of outer spring (1).

Lock Nut (3)

Adjusting Bolt (4)

j : 36 mm

j : 24 mm

TKEB-04-05-016 123-

Outer Spring Inner Spring Lock Nut (Outer Spring)

456-

Adjusting Bolt (Outer Spring) Lock Nut (Inner Spring) Adjusting Bolt (Inner Spring)

m : 160 N·m (118 lbf·ft)

fNOTE: When turning adjusting bolt (4) of outer spring

3

(1), adjusting bolt (6) of inner spring (2) turns at the same time. When adjusting only outer spring (1), adjust outer spring (1) and turn adjusting bolt (6) of inner spring (2) by the amount [adjusting bolt (4) turns × 2.17] reversely.

2. Loosen lock nut (5), turn adjusting bolt (6), and adjust the set force of inner spring (2).

Lock Nut (5)

Adjusting Bolt (6)

j : 17 mm

j : 5.5 mm

5 6

TKEB-04-05-017

fNOTE: Standard change (reference) when adjusting the spring

Flow Rate Decrease

b-

Flow Rate Increase

P-Q Control (Torque Adjustment: Outer Spring) Q

Engine Speed: 1950 min-1

Adjusting Bolt Turns Flow Rate

b

a

a-

m : 19 N·m (14 lbf·ft)

Outer Spring (Adjusting Bolt (4)) 1/4

4

Inner Spring (Adjusting Bolt (6)) 1/4

Turns

32.0 L/min (8.45 32.0 L/min (8.45 US gal/min) US gal/min) 1.57 MPa (273 psi) 3.73 MPa (315 psi)

Engine Torque

44 N·m (20.5 lbf·ft) 29 N·m (16.5 lbf·ft)

P TDAA-04-05-006 P-Q Control (Torque Adjustment: Inner Spring) Q

P TDAA-04-05-007

T4-5-22

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Swing Motor Drainage 1. Measure the amount of oil draining from the swing motor while swinging the upperstructure and check the swing motor performance.

2. Secure absolute safety for the measuring persons as well as for the surrounding while measuring.

3. The amount of drain oil from the swing motor will change significantly depending on the hydraulic oil temperature. Keep the hydraulic oil temperature.

4. Measure the swing motor drainage one by one.

Preparation: 1. Maintain the hydraulic oil temperature at 50±5 degree C (122±9 degree F). Rotate the swing motor and warm the inside of the motor.

2

1

TKHA90-04-05-014

1

TKHA90-04-05-015

2. Stop the right and left engines.

Do not turn the cap of the hydraulic dCAUTION: oil tank quickly. The cap may fly off by internal

pressure. Slowly loosen the cap and release any remaining pressure before removing the cap.

3. Loosen the cap and release any pressure from the hydraulic oil tank. (Refer to Operator's Manual.) l : 4 mm 4. Disconnect drain hose (1) of the swing motor to be measured. Install plug (1-7/16-12 UN) to return pipe (2).

2

j : 41 mm m : 210 N·m (155 lbf·ft)

1-

Preconditions for Measurement: 1. Measurement condition.

Engine Control Dial Fast Idle

Auto-Idle Switch OFF

T4-5-23

Filling Cap

2-

Return Pipe

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: Always make sure that the area is dCAUTION: clear and that coworkers are out of the swing area before starting the measurement.

Also, take care not to fall off from the machine while measuring.  Amount of Oil Drained While Swinging the Upperstructure 1. Fully retract the arm cylinder. Fully extend the bucket cylinder. Hold the boom so that the arm tip pin height (a) is the same as the boom foot pin height. Empty the bucket.

2. Start the right and left engines. Operate and hold the swing control lever in the full stroke. After the swing speed reaches a constant speed, start the draining oil measurement when the drain oil starts coming out of the drain hose end, and measure the time.

3. Repeat the measurement three times or more in both clockwise and counterclockwise directions, and calculate the mean value.

4. The measuring time should be more than 20 seconds.  Amount of Oil Drained While Relieving Swing Motor Circuit 1. Thrust the bucket teeth into the ground so that the upperstructure does not swing.

2. Start the right and left engines. Operate and hold the swing control lever in the full stroke. Start the draining oil measurement when the drain oil starts coming out of the drain hose end, and measure the time.

3. Repeat the measurement three times or more in both clockwise and counterclockwise directions, and calculate the mean value.

4. The measuring time should be more than 20 seconds.

Evaluation

a TKAB-04-04-005 a-

Refer to Operational Performance Standard (T4-2). * Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil by using a calibrated container. Then, convert the measured drain oil into the per-minute value by using the following formula. Q = 60×q/t Q : Amount of drain oil per minute (L/min) (US gal/ min) t : Measured time (seconds) q : Total amount of drain oil (L) (US gal)

T4-5-24

The same height as boom foot pin

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Travel Motor Drainage

Preconditions for Measurement: 1. Measurement condition.

1. While rotating the travel motor with the track to be measured raised off the ground, measure the amount of oil draining from the travel motor and check the travel motor performance.

Engine Control Dial Fast Idle

Auto-Idle Switch OFF

2. Secure absolute safety for the measuring persons as well as for the surrounding while measuring.

3. Judge the travel motor performance from the results including the travel speed, mistrack, and so on overall.

4. The amount of drain oil from the travel motor will change significantly depending on the hydraulic oil temperature. Keep the hydraulic oil temperature.

Preparation: 1. Adjust track sag of both tracks to dimension (a).

2. Maintain the hydraulic oil temperature at 50±5 degree C (122±9 degree F). Rotate the travel motor and warm the inside of the motor.

a

3. Stop the right and left engines.

T145-05-03-001

Do not turn the cap of the hydraulic dCAUTION: oil tank quickly. The cap may fly off by internal

a-

735 to 825 mm (28.9 to 32.5 in)

pressure. Slowly loosen the cap and release any remaining pressure before removing the cap.

4. Loosen the cap and release any pressure from the hydraulic oil tank. (Refer to Operator's Manual.)

1

2 4

l : 4 mm 5. Disconnect drain hose (1) from the travel motor to be measured. Remove adapter (3) or elbow (3).

Install plug (A885006) to pipe (4) at the hydraulic oil tank side.

3 1

Drain Hose (1) j : 36 mm m : 180 N·m (133 lbf·ft) TKHA90-04-05-016

Adapter (2), Elbow (3) j : 36 mm m : 140 N·m (103 lbf·ft)

12-

T4-5-25

Filling Cap Adapter

34-

Elbow Pipe

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement:  Amount of Oil Drained While Rotating Travel Motor 1. Start the right and left engines. Raise the track to be measured off the ground.

When the working around moving dCAUTION: parts is unavoidable, pay special attention to

a

ensure that hands, feet, and clothing do not become entangled. Securely support the raised machine off the ground by using blocks.

2. Rotate the track to be measured. Start drain oil measurement when drain oil starts coming out of the connected drain hose end, and measure the time.

TKAB-04-04-002 a-

3. Repeat the measurement three times or more in both clockwise and counterclockwise directions, and calculate the mean value.

4. The measuring time should be more than 20 seconds.

Evaluation Refer to Operational Performance Standard (T4-2). * Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil by using a calibrated container. Then, convert the measured drain oil into the per-minute value by using the following formula.

Q = 60×q/t Q : Amount of drain oil per minute (L/min) (US gal/ min) t : Measured time (seconds) q : Total amount of drain oil (L) (US gal)

T4-5-26

90 to 110 degrees

MEMO

MEMO